PowerLink Operational Manualopen-Set

FOREWORD
This manual contains information for the correct operation and maintenance of
your Powerlink generator sets which with 501K, 701HC, PLC-5110, PLC-5220,
PLC-5310 and PLC-55X control panels. It also includes important safety
information, installation instruction and troubleshooting guidelines.
Keep this manual with the equipment. If the equipment is traded or sold, give
the manual to the set owner.
This manual does not cover diesel engine and alternator maintenance
procedures. Consult the engine and the alternator operation and maintenance
manuals.
To make certain that your expectations are matched, we ask that you
read carefully through the instruction book before starting and operating
the generating sets.
Sincerely
POWERLINK MACHINE COMPANY
Generating Set Data

Generating Set Model................................ Product No..........................
Power (kva)................................
Engine Model...............................
Power (kva)................................ ...

Cotrol Panel Type.........................
Customer Information
Name..................................................................................
Address..............................................................................
City/ State...........................................................................
Zip Code...............................................................................
Email Address........................................................................
2006POWERLINK MACHINE COMPANY

Powerlink reserves the right to make changes
TABLE OF CONTENTS
Section
Page
FOREWORD
SECTION 1 GENERAL SAFETY INFORMATION ............................................................... 1
CLARIFICATION OF NOTATION USED WITHIN THIS PUBLICATION..........................................1
SAFETY INSTRUCTIONS FOR INSTALLATION,
OPERATION & MAINTENANCE.......................................................................................................2
SYMBOL MEANINGS ON THE GENERATING SETS .....................................................................5
SECTION 2
RECEIVING & INSTALLATION ......................................................................... 7
SECTION 3
INTRODUCTION .................................................................................... 8
3.1 INTRODUTION & OVERVIEW ....................................................................................................8

3.2 MOUNTING FOUNDATION & MOUNTING................................................................................8
3.3 EXHAUST SYSTEM..................................................................................................................13
3.4 FUEL SYSTEM..........................................................................................................................15
3.5 COOLING SYSTEM ..................................................................................................................17
3.6 VENTILATION SYSTEM ...........................................................................................................24
3.7 SOUNDPROOFING ..................................................................................................................26
3.8 TRANSFER SWITCH ................................................................................................................27
3.9 BATTERY STARTING SYSTEM...............................................................................................28
3.10 STARTING...............................................................................................................................30
SECTION 4 CONTROLPANEL INTRODUCTION ......................................................................33

4.1 CONTROL PANELS INTRODUCTION.....................................................................................33
4.2 CONTROL PANELS FUNCTION ..............................................................................................38
4.3 CONTROL PANELS INTRODUCTION (FOR PLC 5110, 56052205310 SERIES) ..........39
4.4 CONTROL PANELS INTRODUCTION (FOR PLC-5310 SERIES) ..........................................47
SECTION 5 OPERATION ............................................................................................................53

5.1STARTING..................................................................................................................................53
5.2 OPERATIONFOR DSE-501K701HC SERIES ...............................................................56
5.3 OPERATIONFOR PLC-5110560 SERIES .....................................................................57
5.4 OPERATION FOR PLC-5310 SERIES .............................................................................63
5.5 OPERATION FOR PLC-5220 SERIES .............................................................................74
5.6 OPERATION FOR PLC-55X SERIES...............................................................................83
SECTION 6
FAULT FINDING .................................................................................... 99
APPENDIX TYPICAL WIRING DIAGRAM

1 501K CONTROL PANEL TYPICAL WIRING DIAGRAM...........................................................101
2 701HC CONTROL PANEL TYPICAL WIRING DIAGRAM ........................................................102
3 5110PLC CONTROL PANEL TYPICAL WIRING DIAGRAM ....................................................103
4 560PLC CONTROL PANEL TYPICAL WIRING DIAGRAM ......................................................104
7 550/555PLC CONTROL PANEL TYPICAL WIRING DIAGRAM .................................................... 107
8 5510PLC CONTROL PANEL TYPICAL WIRING DIAGRAM ......................................................... 108
Installation Operation & Maintenance

Manual for Generating Sets
SECTION 1 GENERAL SAFETY INFORMATION

All users of mechanical and electrical equipment will realize the importance of safety and the
health of operators and others involved with such equipment. It is essential that sensible
precautions are taken in this regard whenever generating sets are supplied and installed.
In addition, there is considerable legislation in existence regarding this. It is impossible to
specify it in detail for each country due to the complex nature and continual changes occurring,
but users are advised to check up on special requirements pertaining to their own country.
Read this chapter very carefully. It concerns your safety. How safety information is presented in
the instruction book and on the product is described here. You will also find an overall picture of
the basic safety which marked on the generating sets for operation of the generating sets.
CLARIFICATION OF NOTATION USED

WITHIN THIS PUBLICATION.
Incorrect operation can lead to injuries and/or property damage. It is therefore important to read
through the instruction book very carefully before you installate, start or operate the generating
sets and maintenance or service work.
Highlights an essential element of a procedure to
ensure
correctness.
CAUTION!
Indicates a procedure or practice which, if not strictly
observed, could result in damage or destruction of
equipment.
WARNING!
Indicates a procedure or practice, which could result
in injury to personnel or loss of life if not followed
correctly.
Powerlink owns the copyright to this manual, which
cannot be copied, reproduced or disclosed to a third
party without prior written permission.

SAFETY INSTRUCTIONS FOR INSTALLATION,

OPERATION & MAINTENANCE
GENERAL
A)
B)
C)
D)
E)
F)
G)
Check that all necessary or available guards are correctly fitted.

Check generating set is securely mounted.
Check all mechanical connections are satisfactory.
Check all electrical connections are correct, safely insulated and suitably earthed.
Check service and maintenance persons are competent and adequately trained.
Keep generating set clean and generator house tidy.
Always disconnect starter battery before commencing maintenance operations.
TRANSPORTING
Always shutdown engine before transporting.
Never transport generator with air intake doors open.
Tighten fuel tank cap securely.
Drain fuel when transporting generator over long distances or bad roads.
Always tie-down the generator during transportation by securing the generator.
If generator is mounted on a trailer, make sure trailer complies with all local and state safety
transportation laws. See the page for basic towing procedures.
FUEL & OIL

A)
B)
C)
Rectify any fuel or lubricating oil leaks immediately observed.

Clean up any fuel or lubrication oil spillages immediately.
Avoid contact with fuel or lubricating oils. Wash fully if contact made. Persons with allergies
should wear protective gloves.
STARTING BATTERIES
D)
E)
F)
G)
H)
Handle batteries with care and in accordance with the recommendations given. When
preparing for use wear protective clothing, in particular guard the eyes.
Lead acid batteries contain dilute sulphuric acid. Wash well with water if spilt and contact
made with eyes wash well and obtain medical attention.
Alkaline batteries contain alkaline which is corrosive and can cause burns. Wash well with
water if spilt, cover any burns and obtain medical attention.
Keep battery areas well ventilated as they produce explosive gases. Avoid sparks, flames
and smoking near batteries. Break circuits before connecting or disconnecting or
disconnecting and ensure connections are sound.
If mixing acid and water it is essential to dilute acid by adding to water and stirring well.
Never add water to the acid. Wear protective clothing.

ELECTRIC POWER
A)
B)
Only qualified electricians should be allowed to work on electrical equipment. All

connections should be insulated and wiring boxes and panels should be fully protected.
Operators should be trained for trained for treatment of electrical shocks.
Emergencies
Always know the location of the nearest fire extinguisher and first aid kit. Know the location of
the nearest telephone.
Also know the phone numbers of the nearest ambulance, doctor and fire department.
Maintenance Safety
NEVER lubricate components or attempt service on a running machine.
Always allow the machine a proper amount of time to cool before servicing.
Keep the machinery in proper running condition.
Fix damage to the machine immediately and always replace broken parts.
Dispose of hazardous waste properly. Examples of potentially hazardous waste are used motor
oil, coolant, fuel, and fuel filters.
DO NOT use plastic containers to dispose of hazardous waste.
DO NOT pour waste, oil, coolant or fuel directly onto the ground, down a drain or into any water
source
Loading and Unloading (Crane)
Before lifting, make sure the generator's lifting hook is secure and that there is no apparent
damage to the generator itself (loose screws, nuts and bolts). If any part is loose or damaged,
please take corrective action before lifting.
Always drain fuel prior to lifting.
Always make sure crane or lifting device has been properly secured to the hook of guard frame
on generator.
NEVER lift the machine while the engine is running.
Use adequate lifting cable (wire or rope) of sufficient strength.
When lifting the generator, always use the balanced center-point suspension hook and lift
straight upwards.
NEVER allow any person or animal to stand underneath the machine while lifting.
When loading the generator on a truck, be sure to use the front and back frame bars as a
means to secure the generator during transport.
NOTE:
When the generator is not in use, close the rain doors to keep the internal area clean and
protected from rodents.

DIESEL ENGINE
Improper practices, carelessness, or ignoring the warnings can cause burns, curs, mutilation,
asphyxiation or other personal injury or death.
Read and understand all of the safety precautions and warnings before performing any repair.
This list contains the general safety precautions that must be followed to provide personal
safety .
Special safety precautions are included in the procedures when they apply.
1
Work in an area surrounding the product that is dry, well lit, ventilated, free from clutter,
loose tools, parts, ignition sources and hazardous substances. Be aware of hazardous
conditions that can exist.
Always wear protective glasses and protective shoes when working.
Rotating parts can cause cuts, mutilation or strangulation.
Do not wear loose-fitting or torn clothing .Remove all jewelry when working.
Disconnect the battery (negative [-]cable first) and discharge any capacitors before
beginning any repair work. Disconnect the air starting motor if equipped to prevent
accidental engine starting, Put a Do Not Operate tag in the operators compartment or
on the controls.
Use ONLY the proper engine barring techniques for manually rotating the engine. Do not
attempt to rotate the crankshaft by pulling or prying on the fan .This practice can cause
serious personal injury, property damage, or damage to the fan blade(s) causing
premature fan failure.
If an engine has been operating and the coolant is hot, allow the engine to cool before
slowly loosening the filler cap to relieve the pressure from the cooling system.
Always use blocks or proper stands to support the product before performing any service
work. Do not work on anything that is supported ONLY by lifting jacks or a hoist.
Relieve all pressure in the air, oil, fuel, and cooling systems before any lines, fittings, or
related items are removed or disconnected. Be alert for possible pressure when
disconnecting any device from a system that utilizes pressure. Do not check for pressure
leaks with your hand .High pressure oil or fuel can cause personal injury.
10 To reduce the possibility of suffocation and frostbite, wear protective clothing and ONLY
disconnect liquid refrigerant ( Freon ) lines in a well ventilated area .To protect the
environment ,liquid refrigerant systems must be properly emptied and filled using
equipment that prevents the release of refrigerant gas (fluorocarbons) into the lifting
atmosphere. Federal law requires capturing and recycling refrigerant.
11 To reduce the possibility of personal injury, use a hoist or get assistance when lifting
components that weigh 23 kg [50 lb ] or more. Make sure all lifting devices such as chains,
hooks or slings are in good condition and are of the correct capacity .Make sure hooks
are positioned correctly. Always use a spreader bar when necessary. The lifting hooks
must not be side loaded.
12 Corrosion inhibitor, a component of SCA and lubricating oil, contains alkali. Do not get the
substance in eyes .Avoid prolonged or repeated contact with skin. Do not swallow
4

internally .In case of contact , immediately wash skin with soap and water, In case of
contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes
IMMEDIATELY CALL A PHYSICIAN . KEEP OUT OF REACH OF CHILDREN.
13 Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with
caution. Follow the manufacturers instructions to provide complete safety when using
these materials. KEEP OUT OF REACH OF CHILDREN.
14 To reduce the possibility of burns, be alert for hot parts on products that have just been
turned off, and hot fluids in lines , tubes , and compartments.
15 Always use tools that are in good condition .Make sure you understand how to use the
tools before performing any service work .Use ONLY genuine Cummins or Cummins
ReConr replacement parts.
16 Always use the same fastener part number (or equivalent) when replacing fasteners. Do
not use a fastener of lesser quality if replacements are necessary.
17 Do not perform any repair when fatigued or after consuming alcohol or drugs that can
impair your functioning.
18 Some state an federal agencies in the United States of America have determined that
used engine oil can be carcinogenic and can cause reproductive toxicity. Avoid inhalation
of vapors, ingestion, and prolonged contact with used engine oil.
19 Liquified petroleum gas is heavier than air and can accumulate near the floor, in sumps ,
and low-lying areas.
20 Natural gas is lighter than air and can accumulate under hood and awnings.
21 To reduce the possibility of suffocation and frostbite, wear protective clothing and ONLY
disconnect natural gas and liquefied petroleum gas lines in a well ventilated area.
22 Coolant is toxic. If not reused, dispose of in accordance with local environmental
regulations.
SYMBOL MEANINGS ON THE GENERATING SETS

To reduce the risk of electrical shock, injury or death caused by explosion of fuel or moving parts,
and to ensure the safe operation of this unit, the following symbols have been placed throughout
the manual. Where these symbols appear, servicing must be performed only by qualified
personnel.
DANGEROUS VOLTAGE
This symbol indicates a dangerous voltage exists in this area of the product. Use
caution whenever working in the area to prevent electrical shock.
ATTENTION
This symbol indicates important installation, operation or maintenance instructions.
Always follow these instructions closely.
CAUTION HAND INJURED
This symbol indicates the need for following approved procedures for handling
electrostatic-sensitive components.
5

NO MATCHES OR OPEN FLAMES

This symbol indicate a fire or explosive hazard exists in this area of the product. Use
caution whenever working in the area to prevent the possible combustion of fuel or
vapors.
NO LIFTING & MECHANICAL OR MOVING PARTS HAZARD
These symbols indicate the presence of a mechanical or moving parts hazard in this
area of the product. Use caution whenever working in the area to prevent possible
injury to the operator or service personnel.
MAINTENANCE MARK & LEAK HAZARD
This symbol indicates a leak hazard exists in this area of the product. Use caution
whenever working in the area to prevent and correct any leaks detected.
CAUTION HAND INJURED

This symbol indicates the presence of high temperatures which result from the
operation of the system. To prevent burns, do not touch these areas while the system
is in operation or immediately after it has been turned off.
REFER THE MANUAL

This symbol is used in certain cases on our products and refer to important
information in the instruction book and the manual when you operating the generator
sets or when you have some trouble.
BE CAREFUL OPEN
This symbol indicates this area of the product must be carefully opened.
LIFTING POINT
This symbol indicates here is the place you can lift the product and transport it.
EMERGENCY STOPPING
This symbol indicates this is the button for stopping the generator sets emergently
when there is dangerous or you have some trouble.

SECTION 2
GENERATORS INTRODUCTION
Generator introduction is a power plant equipment which provide electric power for oneself
internal-combustion engine provide powerdrive alternator generate electricity.
Contemporaneity generator is made up of engine, alternator and control system and so on
mostly parts. internal-combustion is power equipment, it drive the generator run, alternator
generate electricity, control system control and monitor generators running. Particularly, whole
generator include three phase AC dynamotor, control box, radiator, joint-axes, fuel trunk,
common base and otherwise.
Brief describe standard fittings as follow
14
10
4
1
2
11
3
8
12
13
6
5
9
Water tank and radiator
Air Switch
Heat Shield Protection
Anti Vibration-mounting
Engine
10
Warring and notes
Air cleaner
11
Control panel box
Generators base and daily

oil trunk
12
Alternator brand and notes
Alternator
13
Storage Battery
Control panel
14
Battery Charger

SECTION 3
INSTALLATION
3.1 INTRODUCTION & OVERVIEW

This section of the manual provides installation instructions for Powerlink's Industrial generator
sets (gensets). This manual will contain the following information:
1. Mounting Recommendations This section provides mounting recommendations for
fastening the generator set to a mounting skid (base), allowing the proper space requirements
for normal operation, and service requirements.
2. Mechanical Connections This section provides the location of connection points for fuel,
exhaust, ventilation, and cooling. The contents of this section as follow:
3. Electrical Connections This section provides the location of electrical connection points
for the control, generator, and starting system.
4. Transfer Switch It provides the location of electrical connection points for Transfer switch.
5. Initial Start-Up This section provides information to test the complete system to ensure
proper installation, satisfactory performance, and safe operation. Refer to the Operation manual
for troubleshooting information.
6. Installation Checklist This section provides reference checks upon completion of
installation.
7. Installation Checklist This section provides the location of electrical connection points for
battery starting system.
3.2 Mounting Foundation & Mounting

Room Size
Open frame generators must be protected from the environment while having good ventilation
and cooling. Here are some considerations for planning a generator room or enclosure:
Never use the Genset room for storage.
The room must be large enough to contain the Genset and all the accessories, such as
batteries and their charging system, transfer switch and other controls, and elements of the
cooling and fuel systems.
2 feet minimum (preferably 4 feet), must be allowed on the two sides and the front of the
engine for service access. Allow clearance between hot parts of the system (exhaust) and
structural members of the building.
On the generator end of the engine, allow a space equal to the length of the generator
(generator length only, not the entire Genset).
Certain safety and building codes may require the Genset room not to be used to house any
other mechanical or electrical equipment.

Room Location
Often a separate building located on the site away from the main building is the most simple and
cost effective. Major considerations when housing the Genset in a separate building are:
Maintain the building at a satisfactory temperature year round (to meet applicable codes).
Assure the Genset is not located so far from the emergency loads that reliability is
compromised.
The floors load carrying capacity must be checked and must exceed the weight of the Genset
and its associated equipment.
Typical Mount Design for Stationary Genset Applications
Number of mount locations depends on genset size/weight.

Consult Mount Suppliers or Powerlink Application Engineering for further details.
Utility Power
During periods when the generator is not running, utility power must be provided to power
critical components. Battery chargers, block heaters, space heaters and other devices must
have power to maintain the generator set components and allow fast easy starting.

Mounting the Generator Set

Generator sets are mounted on a steel skid that provides proper support. Vibration isolators are
recommended between the skid and the
foundation to provide stable operation and
avoid installation damage. Bolting the generator
set directly to the floor or foundation can result
in excessive noise and vibration, and possible
damage to the genset and floor foundation.
Mount the generator set on a substantial and
level base such as a concrete pad. Use 3/4 inch
anchored mounting bolts to secure the vibration
isolators to the skid using flat or bevel washers
and hexagonal nut for each bolt. (See Figure
XX left.)
The isolators should be located as shown on
the genset outline drawing.
Engine Mounting Guidelines

Mount Requirements:
Must support weight of engine/generator assembly (engine + generator + frame +
accessories)
Must limit the static bending moment at the rear face of the block (engine data sheet)
Must provide vibration and noise isolation
Weight of assembly:
Refer to engine data sheet for engine
Refer to Generator set assembler for package weight
Foundation:
Concrete pad minimum 6 above existing floor and extend 12 beyond Genset base
Concrete, floor, or roof must be designed to support at least 2.0 times Genset weight
Must be Flat to prevent genset base deflection
Type J or L bolts need to be used to anchor the Genset base/isolators to concrete.
Vibration Isolators:
Must be used to reduce noise and vibration transmitted to the foundation or building.
Engine speed, assembly size and weight must be considered when designing mounts
Suggest visit to www.lordmpd.com, www.aeroflex.com for mount information.
Check local building codes for specific mounting requirements.
If ground freezing is possible, the foundation must extend below the frost line.
10

Genset Location Considerations
Both Indoor and Outdoor issues to consider:
Generator set mounting
Location of switchgear
Branch circuits for coolant heaters, battery charger, etc.
Security from flooding, fire, icing, and vandalism.
Containment of spilled or leaked fuel and coolant.
Possible simultaneous damage to normal and emergency services.
Service access for general maintenance and inspections.
Access and working space for major work such as overhauls or component removal/
replacement.
Typical Outdoor Considerations:

Airborne noise and noise treatment - check local codes
Types of housings - container, drop over, sound attenuation features
Service access - housing design and placement close to other equipment or structures
Property line distances - check local codes
Engine exhaust - away from buildings and building openings
Grounding - electrodes or grounding rings may be required
Lightning protection
Security fences and site barriers
Typical Indoor Considerations:

Dedicated generator room - airflow required for genset and other equipment
Room requires fire rating - check local codes for fire resistance requirements
Working space - check local codes, space for genset repairs
Genset cooling system design - genset or remote mounted, required air flow through room
Room fresh air ventilation - remote cooling systems will require room fans
Engine exhaust - may require insulation to contain room heat, routed away from buildings
Fuel storage and piping - check local codes, accessibility for refueling
Temporary load bank connection - recommended for exercising
Access for installation, service and maintenance - large access doors for equipment
Rooftop installations - building structural design for vibration, weight, fuel delivery
Access to Set
Whenever choosing a generator site location, always allow room for service personnel and
operators to gain the proper access to the unit. Always provide adequate lighting around the
unit.
For convenience in general servicing such as radiator, fan belt, and oil filter maintenance, the
surface of the mounting base should be at least 6 inches (152mm) above the floor.
11

Vibration Isolators
Installation and Adjustment Procedure
1. Place the vibration isolators on the genset support structure. The isolators should be
shimmed or grouted to ensure that all of the
isolator bases are within 0.25 inch (6 mm)
elevation of each other. The surface the isolator
bases rest on must also be flat and level. (See
Figure XX to the left and below.)
2. Loosen the snubber lock nuts so that the top
plate of the isolator is free to move vertically and
horizontally. Be sure the top plate is correctly
aligned with the base and springs.
3. Place the genset onto the isolators while
aligning the skid's mounting with the threaded
isolator hole. The top plates will move down and
approach the base of the isolator as the weight of
the generator is applied.
4. Once the genset is in position, the isolators
may require adjusting so that the set is level. The
isolators are adjusted by inserting the leveling bolt
through the skid and into the isolator (the leveling
bolt's locking nut should be threaded up towards
the bolt head). The leveling bolt will adjust the
clearance between the top plate and the isolator
base. A nominal clearance of 0.25 inch (6 mm) or
greater is desired. This will provide sufficient
clearance for the rocking that occur during
start-up and shutdown. If the 0.25 inch clearance is not present, turn the leveling bolt until the
desired clearance is achieved.
Set mounted radiator-cooled generator sets:
Make sure radiator skid and engine/ alternator
skid are level with each other after adjusting
isolators. Improper fan belt alignment may occur
is the unit is not level.
5. Adjust the leveling bolts until the set is level
and sufficient clearance still remains. The
clearance on all isolators should be roughly equal.
Once all isolators have been set, lock the leveling
bolt in place with the lock nut.
6. The snubber nuts must remain loose and
therefore provide better isolation between the
genset and support structure.
12

3.3 Exhaust System

The exhaust system must minimize exhaust restriction. Exhaust restriction must be correct to
ensure proper engine operation. Refer to product specifications for correct exhaust pressure
(inches Hg). The exhaust system should be as short and have as few bends as possible.
Engine exhaust must be directed away from occupied buildings, windows and doorways.
For aesthetic reasons, consider exhaust placement in relation to the building. Over a period of
time, exhaust gas carbon deposits will tend to accumulate on any nearby wall or structure.
Attention must also be given to exhaust noise in selecting placement of the exhaust system.
Level Of Attenuation
In general, manufacturers offer three grades of silencers: industrial, residential, and critical.
Check the attenuation curves for the silencer to assure the desired level of silencing is met.
MultiEngine Installations
Caution: Do not connect multiengine exhaust systems together. Each engine must have
its own exhaust system for proper operation.
Exhaust gases from an operating engine will migrate back through a nonoperating engine and
cause a hydraulic lock. This may interfere with starting of the second engine. The migrating
gases will also tend to turn the turbos which are not being provided lubrication if the engine is
not running. Do not use check valves in the exhaust system because they can .stick.
Exhaust System Installation

Proper exhaust system installation will ensure safe working conditions and maximum engine
efficiency. Always pipe exhaust gases to the outside of any enclosure. Locate the exhaust
outlets away from any air inlets to avoid gases re-entering the enclosure. Exhaust installations
are subject to various detrimental conditions such as extreme heat, infrequent operation, and
light loads.
Once the exhaust system has been installed, it is important to regularly inspect the exhaust
system both visually and audibly to see that the entire system remains fume tight and safe for
operation.
WARNING:
Inhalation of exhaust gases can result in sever personal injury or death.
Use extreme care during installation to provide a tight exhaust system. Terminate exhaust pipe
away from enclosed or sheltered areas, windows, doors, and vents.
Use an approved thimble where exhaust pipes pass through wall or partitions. Insulated
wall/roof thimbles are used where exhaust pipes pass through a combustible roof or wall. This
should include structures, such as wood framing or insulated steel decking, etc. Uninsulated
wall/roof thimbles are used where exhaust pipes pass through a noncombustible wall or roof,
such as concrete. Refer to NFPA 37, Section 6-3 "Stationary Combustion Engines and GAs
13

Turbines" for accepted design practices. Build according to the code requirements in effect at
the installation site.
WARNING:
Do not use exhaust heat to warm a room, compartment, or storage area.
Weight applied to the engine manifold can result in turbocharger damage. Support the
muffler and exhaust piping so no weight or stress is applied to the engine exhaust
elbow.
Rain caps are available for the discharge end of
the vertical exhaust pipes. The rain cap clamps
onto the end of the pipe and opens from the
exhaust discharge force from the generator set.
When the generator set is stopped, the rain cap
automatically closes, protecting the exhaust
system from rain, snow, etc.
When installing the exhaust system, use a section
of flexible exhaust pipe between the engine and
remainder of the exhaust system. Support
exhaust system to minimize weight applied to
engine exhaust outlet elbow/turbocharger
connection.
When installing the exhaust system, avoid sharp
bends by using sweeping, long radius elbows and
provide adequate support for muffler and tail pipe.
Pitch a horizontal run of exhaust pipe
DOWNWARD to allow any moisture
condensation to drain away from the engine. If an
exhaust pipe must be turned upward, install a
condensation trap at the
point where the rise begins.See Figure XX Left.
Shield or insulate exhaust lines if there is any
possibility of personal contact. Allow at least twelve
inches (12" or 305 mm) of clearance if the pipes pass
close to a combustible wall or partition.
WARNING:
Exhaust pipes are very hot and they can
cause severe personal injury or death
from direct contact or from fire hazard.
Shield or insulate exhaust pipes if there is
danger of personal contact or when routed through
walls or near other combustible materials.
14

Wind Barrier
Wind blowing against air exhaust or intake openings of the Genset room must be considered,
especially where the radiator and fan are located on the engine. Wind blowing against an
exhaust opening creates restriction to the fan. Wind blowing against intake openings can blow
open gravity louvers causing low temperature and moisture problems in bad weather. A turning
vane may be required to prevent exhaust air recirculation between the exhaust louvers and the
barrier surface. This will route the exhaust upward into the atmosphere.
Rain Protection
Moisture entering the engine through an exhaust system can cause extensive damage. Exhaust
outlets must have a rain cap or be horizontal to prevent such damage. See Figure below.
3.4 Fuel System

The fuel system must provide adequate and continuous quantities of clean fuel to the Generator
Set. Bulk fuel is stored in large tanks, usually outside the building, and fuel is transferred to a
smaller tank (day tank) located near the engine.
MECHANICAL CONNECTIONS
After considering all applicable laws and finding a suitable location site for the generator set, the
installer should consider the mechanical connections that will be necessary to make during
installation. The four (4) systems that will require mechanical connections are the following:
Fuel system
Exhaust system
Ventilation system
Cooling system
Fuel System Installation

Proper installation of the fuel system is essential in obtaining proper genset performance, safe
working conditions, and preventing property and environmental damage.
It is important to have a clean installation, making every effort to prevent entrance of moisture,
dirt, or contaminants of any kind. Clean all fuel system components before installing.
Use only compatible metal fuel lines to avoid electrolysis when fuel lines must be buried. Buried
fuel lines must be protected from corrosion. Use a flexible section of tubing between the engine
and fuel supply line to provide vibration isolation.
15

Refer to the generator set manual for outline drawings and detailed information.
WARNING:
Never use galvanized or copper fuel lines, fittings, or fuel tanks. Condensation in
the tank and lines combines with the sulfur in diesel fuel to produce sulfuric acid.
The molecular structure of the copper or galvanized lines or tanks reacts with the
acid and contaminates the fuel.
Supply Tank Lower than Engine Installation

If a supply tank is lower than the engine, the day tank is installed near the generator set and
within the engine fuel pump lift capability, but below the fuel injection system. Install an auxiliary
fuel pump as close as possible to the supply tank to pump fuel from the supply tank to the day
tank. A float switch in the day tank controls operation of the auxiliary fuel pump.
The supply tank top must be below the day tank top to prevent siphoning from the fuel supply to
the day tank. Provide a return line from the engine injection system return connection to the day
tank (near the top). Provide a day tank overflow line to supply tank in case the float switch fails
to shut off the fuel transfer pump.
WARNING:
Failure to provide an overflow line to the supply tank from the day tank can cause
spilled fuel, safety hazards, and damage to equipment.
16

Supply Tank Higher than Engine Installation
If a supply tank is higher than the engine, the day tank is installed near the generator set, but
below the fuel injection system. Fuel lines should at least be as large as the fuel pump inlet. The
engine fuel return line must enter the day tank. Include a shutoff valve in the fuel line between
the fuel supply tank and the day tank to stop fuel flow when the generator set is off.
Supply Tank
Locate the supply fuel tank as close as possible to the generator set and within the five (5') foot
(1.5 m) lift capacity of the engine fuel pump. Install a fuel tank that has sufficient capacity to
keep the genset operating continuously at full load for at least 36 hours. Refer to the generator
set manual for detailed fuel consumption data.
WARNING:
Fuel leaks create fire and explosion hazards which can result in severe personal injury
or death. Always use flexible tubing between engine and fuel supply to avoid line
failure and leaks due to vibration. The fuel system must meet applicable codes.
If the main fuel tank is installed below the lift capabilities of the standard engine fuel pump, a
transfer tank (referred to as a day tank) and auxiliary pump will also be required.
If an overhead main fuel tank is installed, a transfer tank and float valve will be required to
prevent fuel head pressures from being placed on the fuel system components.
For critical start applications, where generator sets are paralleled or must satisfy emergency
start-time requirements, it is recommended that a fuel tank or reservoir be located such that the
lowest possible fuel level is not less than six (6") inches (150 mm) above the fuel pump inlet.
This will prevent air from accumulating in the fuel line while the set is in standby, eliminating the
period during start-up when it has to be purged.
Day Tank (if used)

Fuel day tanks are used when the standard engine fuel pump does not have the capacity to
draw the fuel from the supply tank; or the supply tank is overhead and presents problems of
high fuel head pressure for the system.
Engine fuel Connections

Identification tags are attached to the fuel supply line and fuel return line connections by the
factory. Flexible lines for connecting between the engine and stationary fuel line are supplied as
standard equipment.
WARNING:
Fuel leaks and spills can cause environmental contamination. Make sure the area
surrounding the fuel tanks and lines will prevent fuel from entering soil, sewers, and
water.
3.5 Cooling System

Cooling System Checklist
17

A. Has noise been considered?
B. Has system piping been properly sized?
C. Has system been properly protected from freeze up and corrosion?
D. Have standby equipment heaters been specified?
E. Have all electrically driven devices been connected to load side of EPS connection points?
F. Have system drain valves and air eliminators been installed?
The system consists of the cooling medium which is generally a solution of water and ethylene
glycol, a method of rejecting engine produced heat, and a means to transport cooling medium
between the engine and heat rejection system. The first determination is the type of cooling
system to use radiator cooling or heat exchanger cooling.
Radiator Set Requirements

Radiator set cooling air is drawn past the rear of the set by a pusher fan that blows air through
the radiator (See Figure XX next page). Locate the air inlet to the rear of the genset. Make the
inlet vent opening 1-1/2 to 2 times larger than the radiator area to ensure proper cooling.
Locate the cooling air outlet (as close as possible) directly in front of the radiator. The outlet
opening must be at least as large as the radiator area. Length and shape of the air outlet duct
should offer minimum restriction to airflow.
The radiator has an air discharge duct adapter flange. Attach a canvas or sheet metal duct to
the flange and the air outlet opening using screws and nuts so duct can be removed for
maintenance purposes. The duct prevents circulation of heated air. Before installing the duct,
remove the radiator core guard.
Engine Mounted Radiator Cooling

The most simple is the engine mounted radiator shown in Figure 2-5. The radiator, water
circulating pump, fan and fan drive are mounted to the Generator Set base rails by the factory.
This method of engine cooling is the most economical, but may require large ventilation vents
and ducts. An added advantage of this arrangement is that the cooling air removes radiated
heat from the engine, generator, and other equipment located in the emergency power system
room.
The only remaining design work with the engine mounted radiator is arranging a method of
providing air to the room, and exhausting it from the radiator. (See Figure XX Duct air
installation below).
18

Engine Mounted Radiator Cooling (With Wind/Noise Barrier)
Engine Mounted Radiator Cooled System With Wind/Noise Barrier
The ideal setup for cooling air would be to arrange the inlet or inlets such that relatively clean,
cool, dry air is drawn across the electrical switchgear, generator, and engine. The air is then
drawn into the radiator fan, and is blown through the radiator and exhausted by duct work
outside the building. Air inlets must be sized to minimize air restriction and provide the quantity
of air required by the radiator fan, engine combustion air, and any other air exhausts which
might be used in the room. On engine mounted radiator cooled systems, the engine mounted
fan will handle 0.25 of water column. This is combined intake and exhaust restriction.
The room air intakes must be located so as to minimize drawing exhaust fumes and other
outside contaminants into the room. Be very cautious about the location of the engine exhausts
in relation to room air intakes. Also, when locating the inlet and outlet, the consultant should
consider prevailing winds and noise. Motor operated louvers or properly designed and sized
gravity louvers should be used on the air intake and exhaust to minimize static pressure drop.
19

In cold climates, the high volume of outside air drawn into the Genset room
can quickly reduce temperatures in the room to freezing. Any water piping or
other equipment susceptible to freeze damage should be properly insulated or located
elsewhere.
Remote Mounted Radiator Cooling (optional)

The radiator can be mounted remotely (not mounted directly at the engine). The remote/close
system uses the same radiator type except it is mounted in another room or outside the
building,
but within close proximity to the Genset (See Figure XX Remote Radiator Cooled Installation).
The remote radiator may be mounted either vertically or horizontally. In general, the radiator will
have an electric fan to provide cooling air and may be able to utilize the engine mounted coolant
pump to provide coolant flow.
Figure XX Remote Radiator Cooled System Installation

20

The piping system friction and head loss between engine and radiator must be calculated and
not exceed the capacity of the engine pump. If the maximum coolant friction head loss external
to the engine is exceeded, a hot well system must be used. Before designing the piping system
using an auxiliary pump and hot well, the consultant should look very closely at increasing the
systems pipe size.
Electric motorized Power Exhaust louvers should be connected to the standby Genset and
controlled to open whenever the Genset is running. Operable outlet louvers should be
temperature actuated on remote radiator or heat exchanger cooled units. Louvers have
resistance to air flow. Openings with louvers should be twice the area of an unobstructed
opening to provide proper air flow. At times duct work is necessary to provide cooling air for the
room.
Duct work must be sized and installed according to SMACNA Standards.
The electric fan and auxiliary pump, if used, must be connected to the emergency power
system.
Radiator and cooling fan must be sized to provide the cooling capacity required at an
acceptable sound level, driven fan. As a result, the consultant must provide a means of
supplying air to the room, and exhausting it. The air movement must be provided by an
electrically driven fan. This fan may be located in the air inlet or exhaust opening. If the fan is
located on the exhaust side, care must be taken to not create a high negative pressure in the
room and starve the engine of combustion air.
Heat Exchanger (optional)

The optional heat exchanger uses a shell and tube type heat exchanger instead of the standard
radiator and fan (see Figure XX). Engine jacket and LTA coolant circulates through the shell
side of the two heat exchangers while the cooling water is pumped through the tubes. Engine
coolant and raw water do not mix. This type of cooling separation is necessary because raw
water can contain scale forming lime or other impurities.
21

This system can reduce set enclosure airflow requirements and noise levels. Proper operation
depends on a constant supply of raw water for heat removal. Adjust the flow to maintain the
proper engine jacket water coolant temperature and the LTA coolant temperature. The engine
coolant side of the system can be protected from freezing; the rqw water side cannot be
protected.
The heat exchanger cooling system can be used with a cooling tower. These systems are
complex, and consists of circulating pumps, heat exchanger for engine coolant, and cooling
tower for heat rejection. The system design requires that several pieces of equipment be sized
and installed. Overall, this system is more expensive than other methods of engine cooling.
Hot Well Installations

The following diagram shows a typical installation of a hot well cooling system.
Figure XX. Hot Well Installation
One final consideration on the water side is the Maximum Static Head. This is the maximum
height allowable from the engine crank center line to the highest point in the coolant system.
The maximum static head is specified on generator specification sheets. If this number must be
exceeded, a hot well tank system must be used.
The design of hot well tanks and piping systems is somewhat complex. Your authorized
Powerlink Distributor has experience in the design and installation of hot well systems. Consult
your Powerlink Distributor if the static head of the coolant system in your Genset application
exceeds this criteria and requires a hot well system.
Cooling System Design

Remote Radiator Cooling
Remote Radiator Airflow generally assumed there will be no external restrictions to airflow. If
this is not true, restriction must be considered in sizing and selection of a cooling fan and drive
22

motor. Typical examples of restrictions include landscaping, nearby buildings, air turbulence
created by buildings or other structures, and sight or noise .screens.. See Figure Remote
Radiator Fan Motor. Remote radiator cooling systems require the use of an electrically driven
fan. This fan must be connected to the emergency power source. Size of the motor is
determined by the fan size and fan speed.
1. To specify a radiator to cool the coolant you will need to determine the amount of heat
rejected to the coolant. This is listed on the Engine Data Sheet as Heat Rejected to Coolant in
BTU/min. for engines using dry or water cooled type exhaust manifolds, as applicable.
2. Determine the minimum water flow required at the engine, and the maximum top tank
temperature. Using this information, determine the heat rejection capacity required of the
radiator. Radiator systems should be sized with approximately 15% greater capacity than the
engines maximum full load heat rejection to allow for overload and cooling system
deterioration. Whether water flow is produced by an engine mounted or auxiliary pump, total
piping system friction loss must be calculated. To do this, Genset location, remote radiator
location and friction loss within the radiator, and piping system must be estimated.
3. Pressure drop through the radiator must be obtained from radiator manufacturer.
4. If total piping system pressure exceeds the allowable Maximum Coolant Friction Head
External to the engine as listed on the Engine Data Sheet, the coolant piping size should be
increased and/or a radiator with less restriction must be used.
5. Pressure drop in pipelines and friction of water tables may be found in most mechanical
handbooks such as. Cummins Engine Data handbook.
Other Considerations
1. Deaeration of the coolant. This can be accomplished through the use of the system
deaerators in very large systems, or simply ensuring the radiator top tank or surge tank is at
the highest point in the piping system. Unvented piping systems can create air pockets which
reduce coolant flow and can lead to engine overheating. Powerlink furnished radiators are
equipped with deaerating top tanks.
2. Flexible hoses must be installed at all engine connections and to the radiator to isolate
vibration and allow for thermal expansion.
3. Drain valves must be installed at the lowest point of the cooling system to facilitate system
cleaning and flushing.
4. Water treatment and antifreeze must be added to system coolant. Powerlink recommends
50/50 ethylene glycol and coolant treatment for all engines.
5. Thermostatically controlled engine coolant heaters are optional to be installed on all standby
Gensets. These will increase starting reliability under cold conditions, and improve the
startup load handling ability.
6. According the NFPA 110, priority level 1 equipment jacket water heaters shall maintain
coolant at a minimum of 90 F (32 C). In outdoor installations where temperatures will be
23

expected to drop below 32 F (0 C), a battery heater should be employed to keep the
batteries at a minimum of 50 F (10 C), and will shut off at 90 F (32 C). All heaters will shut
off when the engine is operating. Adequate antifreeze protection will be provided and ether
starting aids will not be permitted.
7. The consultant should also consider oil sump heaters if conditions warrant.
3.6 Ventilation System

Sufficient ventilation is essential for all generating sets. Air inlet and outlet systems should be
positioned to provide a direct cooling flow past both the engine and alternator. A generous flow
of fresh inlet air as cool as possible must be provided for by vents, ducts or windows at low
level.
Outlet systems should normally be adjacent to the engine end of the set and inline with the
radiator fitted. These should preferably be close and a canvas plenum connecting to the outlet is
ideal.
Any inlet or outlet ducts should be protected with mesh or louvers and allowance for any
obstruction by these should be made. Outlets
should be at least as the radiator cross sections.
Inlet ducts should preferably be 50% larger than
outlets.
Ventilation and Cooling

Generator Sets create considerable heat that
must be removed by proper ventilation. Outdoor
installations rely on natural air circulation but
indoor installations need properly sized and
positioned vents for adequate air flow.
Vents and Ducts

For indoor installations, locate vents so incoming
air passes through the immediate area of the
installation before exhausting. Install the air outlet
higher than the air inlet to allow for convection air
movement. Size the vents and ducts so they are
large enough to allow the required flow rate of air.
The "free area" of ducts must be as large as the
exposed area of the radiator.
Wind will restrict free airflow if it blows directly into the air outlet vent. Locate the outlet vent so
the effects of wind are eliminated (See Figure XX wind barrier and see Figure XX wind barrier
installation).
For outdoor installations, weather and silenced housings are available for the generator.
24

Louvers
Louvers are automatic ventilation doors that open when the engine engages and close while not
in use. Louvers protect the genset and equipment room from the outside environment. Their
operation of opening and closing should be controlled by operation of the genset. In cooler
climates movable or discharge louvers are used.
These louvers allow the air to be recirculated back to the equipment room. This enables the
equipment room to be heated while the genset engine is still cold, increasing the engine
efficiency.
Air System Checklist

A. Air inlet faces the direction of prevailing winds.
B. Air outlet does not face noise sensitive areas without noise attenuating devices.
C. All heat loads have been taken into consideration in sizing air flow.
D. Gravity louvers face inward for air intake and outward for discharge.
E. Where electrically operated ventilation devices are used, power must be present under all
operating situations. Be certain these devices are on the emergency circuit.
The room in which the Generator Set is to be installed must have adequate air flow through it to
provide combustion air, and remove heat radiated from the engine, exhaust system and
generator. See Figure next page for air flow calculations.
25

Notes:
1 These calculations assume room ambient of 100F (38C)
2 Increase V by 10% for each 2,500 ft (762m) above sea level
3 Increase V by 10% if uninsulated mufflers are inside room
4 Engine data sheet specifies .Radiated heat to ambient. In BTU/min. This value is dry type ad
water cooled exhaust manifolds.
5. Generator efficiency is 88 to 95% for Gensets 50kW to 1200kW. 1kW loss = 56.88 BTU/min.
3.7 Soundproofing
The best quality / price ratio is achieved when soundproofing is part of the initial design of the
room. On the other hand if soundproofing is added to an existing room, it will inevitably be more
expansive and not as good. Two techniques should be used to soundproof the genset room.
Insulation
Its purpose is to prevent sound travelling through the walls by providing mass and adequate
thickness.
Absorption
Sound energy is absorbed by specialist materials and reduces reverberation. For a
soundproofed room the openings have to be larger and carefully designed to provide adequate
ventilation without allowing excessive noise to pass through the openings. A properly designed
soundproofed door is also needed.
General
- Building structure: cast concrete or concrete blocks, min. 20 cm thick.
- Anti-vibration mounts under the generating set, when installed close to sensitive areas.
- Walls and ceiling may be lined with absorbent materials such as rockwool.
- Selection of one or more suitable exhaust mufflers.
- When required soundproof doors should be fitted to reach the required sound level.
- Noise attenuators mounted in the air inlet and outlet openings. EXAMPLES: Measures to be
taken.
- Basic noise level of genset : 105 to 11O dBA 1m.
Non sensitive areas

Generating set soundproofing by means of a canopy bringing the noise down to 85dBA at 1 m
(useful for low and medium powered sets), or Room soundproofing: noise attenuator on air inlet,
about lm long, soundproofed access door, 30dB exhaust muffler. Outside noise level : 75 dBA
about 1m.
Noise sensitive areas (in town, close to houses)

Noise reduction depends on the distance between the noise source and the sensitive areas 6dB
on average every time you double the distance: 1m (0); 2m (-3dB); 4m (-12dB); 8m (-18dB).
This calculation done, the following elements must be specified:
26

- From 60 to 70 dBA at about 1m
- Walls and ceiling made of 20 cm concrete blocks or cast concrete,
- Noise attenuators about 1.80 m long,
- High efficiency soundproof door,
- 40 and 19dB mufflers in series
- From 40 to 60dBA at about 1m
Noise attenuators (about 2.50 m) with baffles in ventilation shafts if possible.
- Inside walls and ceiling lined with absorbent material.
- Soundproof door and airlock.
- Floating slab beneath the generating set (vibration).
- 40 and 30dB mufflers in series. Sometimes 40dB and 19dB
mufflers are sufficient. or generating set soundproofed by means of a canopy, in which case, the
sound traps are smaller and the airlock unnecessary.
When lower noise levels are required a special study must be
carried out.
SOUND LEVEL REGULATIONS
Please refer to appropriate regulations in your area.
3.8 Transfer Switch

Transfer Switch Transfer Switch Checklist
A. Locate transfer switch in a clean, dry place, near the emergency load. B. Provide a circuit
breaker between the Genset and the transfer switch. C. Put a flexible connection between the
conduit and Genset. D. Observe applicable codes in wiringin the transfer switch and Genset.
The transfer switch connects the Genset to the emergency power system. The emergency
power system may include several Gensets and several transfer switches. Typically, the Genset
is wired to the emergency power system through a transfer switch as shown in Figure xx Typical
Emergency Power System Installations.
Figure xx Typical Emergency Power System Installations

27

Multiple Gensets can be arranged either in parallel or separately connected to dedicated
emergency loads. Figure xx Typical Emergency Power System Installations also shows a
typical arrangement of two Gensets in parallel with transfer switches for loads that have
different levels of priority. A typical multiple Genset installation is shown for NFPA 110 Level 1
and Level 2 emergency power circuits and a priority control to select the appropriate transfer
switch. Wattmeters should be installed on each Genset so load sharing can be checked. The
control system should include an automatic paralleling control. Paralleling identical Gensets is
not difficult, but paralleling dissimilar sets can cause load sharing problems. When designing an
installation that includes the paralleling of dissimilar generators, contract your nearby Powerlink
Distributor.
Transfer Switch Location

The transfer switch location is important and key considerations are:
1. Locate the transfer switch as close to the emergency load as practical to avoid interruptions
of the emergency power system due to natural or manmade disasters, or to equipment
failures. Consider several small transfer switches instead of one large one to increase
reliability.
2. Locate the transfer switch in a clean, dry, well ventilated location, away from excessive heat.
When the ambient air is above 104 F (40 C), fuses and circuit breakers must be derated.
Allow adequate working space around the transfer switch.
3. A circuit breaker (or fuses) should be installed in the line between the generator and the
transfer switch. Baldor Gensets are available with properly sized circuit breaker built into the
generator control. The circuit breaker can be separately mounted. In the case of very large
circuit breakers, a separate floor mounted circuit breaker is easier to wire up than a wall
mounted breaker.
4. Install power and control wires in separate solid conduit with flexible sections at the Genset.
The flexible sections prevent vibration from damaging the conduit. All power conduits from the
Genset must contain all three phases.
5. Never install control wires in the same conduit as power conductors.
6. Conduit, wire, circuit protective device sizes, insulation etc. must conform to applicable local
and national codes and regulations.
7. Be certain to seal around conduits that penetrate the walls of the Genset room to reduce the
amount of noise that is transmitted to the surrounding areas of the building and maintain site
fire code rating.
3.9 Battery Starting System

This section describes the battery starting system (nominal 12 volt rating of the battery supply)
for the engine, battery charger, and precautions to take if the ambient temperature is expected
to be below 70 F (20C).
WARNING:
If batteries are not mounted in the battery rack supplied with the Genset, protect
batteries from vibration and do not locate them near a source of flame or spark. A
battery presents a risk of fire and explosion because they generate hydrogen gas. Hydrogen
gas is extremely explosive. Never jump start a battery, smoke in the area around the battery or
cause any spark to occur in the area around the battery.
28

Battery Location
Locate batteries as close as possible to the Genset to minimize starting circuit resistance, see
Figure xx Battery Starting System right. High starting
circuit resistance substantially reduces starting
cranking ability. The Genset data sheet lists the
maximum allowable cranking system resistance. Mount
batteries on a level rack away from dirt and liquids.
Allow space for servicing (checking water level and
level of charge). Powerlink Gensets can be ordered
with battery racks already installed. Cold ambient
temperature at the battery location substantially
reduces the battery output.
Figure xx Battery Starting System
Battery Size
The ability to start the engine depends upon battery capacity, ambient temperature and coolant
and oil temperatures. The Engine/Generator Set Data Sheet lists minimum recommended
battery capacity at various ambient temperatures. The recommended battery capacities are
listed in the Electric Systems section of the Engine Data Sheet, cold cranking amps (CCA) at 0
F (18 C).
Battery capacities decrease as ambient temperatures decrease so it is important to specify
batteries with the appropriate CCA rating at a temperature no higher than the minimum ambient
temperature for the application. Powerlink requires thermostatically controlled coolant heaters
on all after cooled standby Gensets. After cooling is called out on the Engine Data Sheet under
General Engine. Data section as aspiration. Oil pan immersion heaters are recommended for
standby Gensets housed outside where ambient temperatures may drop below 0 F (18 C).
Coolant heaters and oil pan immersion heaters are available from Powerlink as factory installed
options.
Battery Charger
An engine mounted alternator to charge the batteries during operation is an available option.
Standby Gensets require a solid state battery charger that is connected to utility power so the
battery is charged continuously while the Genset is not running. The battery charger should be
connected to the emergency circuit. The batteries on prime power Gensets are charged by the
engine mounted alternator, if equipped.
Harmonic wave forms from solid state battery charges and belt driven alternators can cause the
electronic governor on the engine to act erratically. To avoid this, the output of the battery
charger or the belt driven alternator must be connected directly to the battery or to the battery
terminals on the starter. Make control connections to the Genset control using a conduit with a
flexible section at the Genset to avoid damage due to Genset vibrations.
Battery Cables
The wire size (wire gauge) of the cables connecting the starter to the batteries must be large
enough to ensure the resistance of the cranking circuit is less than the Maximum Allowable
29

Resistance of the Cranking Circuit as shown on the EngineGenerator Set Data Sheet. The
total cranking circuit resistance includes the resistance of the cables from the starting motor to
the battery and the resistance of all relays, solenoids, switches, and connections. The
resistance of various sizes of cables is shown in Figure xx Typical Battery Cable Calculations
(next page). For purposes of calculating cranking circuit resistance to select cable size, the
resistance of each connection can be taken as 00001 ohms and the resistance of each relay,
solenoid, and switch can be taken as 0002 ohms. Figure 2-10 illustrates an example of a typical
cranking circuit resistance calculation.
Figure xx Typical Battery Cable Calculations
3.10 STARTING
Starting an engine is easy when it succeeds, but may cause untold problems when
unsuccessful. The operation of highly complex equipment may depend on the reliability of the
genset particularly in applications such as hospitals, factory processes and building protection
systems.
That is why there are many starting processes and devices on a generating set to ensure
reliable starting every time. We make a distinction between a manual start procedure and an
emergency start procedure, which is triggered by the failure of the mains supply (generally in
automatic mode three 5 second cranks are provided).
The starting system design depends on the engine temperature. For a start in very cold
temperatures it is sometimes necessary to use starting aids, such as heating the intake air,
heating the fuel, injecting ether into the air intake. As well as these the engine coolant is heated,
and in very cold conditions also the oil is kept warm.
Generating sets can be provided with three types of start systems
- Electric Starting : This is the most widely used system and consists of a 12V or 24V starter
30

motor supplied by one or more lead acid, or in exceptional cases, alkaline batteries.
The starter motor rotates the ring gear of the engine flywheel moving on receiving the signal
from an electric contact.
Once the diesel engine has started and the flywheel has run up to its required speed, the starter
motor pinion disengages automatically from the ring gear. The batteries are recharged
automatically by an alternator or static charger.
- Pneumatic Starting : Pneumatic starting relies on an air starter that is operated by a flow of
compressed air from one or two compressed air bottles and an air compresser. The engine is
started in the same way as for electric starting.
The air bottles and air compresser are located as near as possible to the generating set.
- Mechanical Starting : Several mechanical starting system exist, i.e. spring, crank, inertia etc.
All of these are only used with low power generating sets.
The three systems above can be coupled to each other in the following way:
- electric/ pneumatic starting
- electric/ mechanical starting.
- Generating Set Starting :
CHECK BEFORE START
Before generator start, please check following thing;
1. Generator normally consume 0.25%-1% of foil wastage lubricating oil.
2. check lubricating oil and coolant water capacity,
Warning
When putting foil into trunk, do not smoking nearby or using fire.
3. check oil capacity,
4. check engine cooling fan and rap degree of tightness,
5. check all ripe, ensure not leaking out,
6. check battery pole ,ensure no cauterization,
Warning
When packing up battery, do not smoking nearby or using fire, hydrogen which battery produce
will blow up. Dont mistake battery pole,
7. Check battery liquid, if necessary, put into pure water. If battery is new , please add
beforehand mixed b attery liquid
8. Check control panel and generators, please ensure aforesaid parts clean. These dust
maybe damnous, etc, tip-and-run accident.
9. Check air cleaner, if emphraxis, please change a new.
10. Ensure surroundings of generators clean, coolant aeration unhindered.
11. Check fuel system ,coolant system and lubricating oil system ,
12. If exhaust system have exhaust water device, please letting termly.
13. Ensure alternators output switch is off.
31

Formulas
32

SECTION 4
4.1
CONTROL PANEL INTRODUCTION
CONTROL PANEL INTRODUCTION
Control Panel For Special Genset

Model
Gensets
cummins Range
701k plc5110 plc5220 plc5310 plc55x plc55xx
Volvo Range
Perkins Range
No
John Deere Range

Standard
Option
701 KEY MANUAL START SYSTEM

The Model 701 is a Manual Engine Control Module designed to control the engine via a key
switch and pushbuttons on the front panel. The module is used to start and stop the engine and
indicate fault conditions,
automatically shutting down
the engine and indicating
the engine failure by LED,
giving true, firstup fault
annunciation.
PLC-5110 CONTROL SYSTEM

The PLC-5110 control system is used to automatically start and stop the generator via remote
control signal, configurable three position includes manual, auto and stop position.
Stop: stop generator / failure
Manual: only green manual button to start generator
Auto /remote control: under working condition when it is energize, auto start generator if
receiving remote control signal.
33

PlC-5220 Automatic Mains Failure Control System

The PLC-5220 is an Automatic Mains Failure Control Module. It is used to monitor a mains
supply and automatically start and stop the engine. It indicates the operational status and fault
conditions, automatically shutting down the engine and indicating engine failure by means of an
LCD display, and flashing LED on the front panel.
The PLC-5220 mold can monitor city-electricity function. When the city-electricity get high
voltage/ low voltage or the high frequency/ low frequency, it can start automatically the
generator, and can send signal to ATS, to cut or add the generators load quickly.
34

PLC5310 ELECTRONIC ENGINE

COMPATIBLE AUTO-START MODULE
The Model 5310 is an Autostart Control Module. The module is used to automatically start a
generator set upon application of a remote signal or by manual control. The module also
provides indication of operational status and fault conditions automatically shutting down the
genset and indicating failures by means of an LCD display.
PLC-555 Automatic Mains Failure Control Module

The module 555 is an Automatic Mains Failure Control Module, and the module is used to
monitor a mains supply . It indicates
The DSE 555 module also monitors the engine, indicating the operational status and fault
conditions; automatically shutting down the engine and giving a true first up fault condition of an
engine failure.
PLC-555 control system link to PC via optional RS232 port or 485 port provides Modem via
either PSTN line or GSM network, comprehensive remote communication via WINDOWS by
LINK500 software .
SPECIFICATIONS
The PLC-555 Automatic Mains Failure Control Module possesses all of the basic function,
please refer to the table (cf. table page 16)
35

LCD Display
User Configurable
LED's with insert pocket
Deep Sea Electronics plc

Model 555
Up and Down
Scroll Buttons
Common Alarm Indicator
Information Page Indicator

Event Log Page Indicator
Operator Configuration
Mode Indicator
Page Select Button
Alarm Mute Button
AUTO
Stop/Reset Button
Mains Instruments Page Indicator
Test Mode Button
Generator Instruments Page Indicator
Start Button
Auto Mode Button

Engine Instruments Page Indicator
Manual Mode Button
Alarm Page Indicator
PLC-5510 Automatic Mains Failure Control Module

The Model 5510 is an Automatic Engine Control Module. The module is used to automatically
start and stop the engine, indicating the operational status and fault conditions by means of an
LCD display and a flashing LED on the front panel.
36

ADDITIONAL SPECIFICATIONS
SYNCHRONISING AND LOAD SHARING
Optionally, the PLC-550 and PLC-5510 controller can be configured to synchronise, volts match
and parallel with the mains supply. This facility can be used to supply a fixed amount of power to
the load and/or mains supply or share load with other 5510 or 550 enabled generator systems.
Synchroscope with auto sync control.
Volts and Frequency matching
Phase angle and Phase rotation indication.
Dead bus sensing
Multi-set load demand operation
KW and Kva load sharing with multiple generators.
Direct communication from the module to the governor and AVR.
KW export when in parallel with the mains supply.
INDICATION OF SYNCHRONISING AND LOAD SHARING

For Example as PLC-5510 Control Panel
37

4.2 SPECIFICATION OF CONTROL PANELS

PLC701K
PLC5110
PLC5220
PLC5310
PLC550
PLC5510
current
Frequency
Wire voltage
Phrase voltage
Genset KVAr
Genset KW
Generator output capacity
Output KWh
Output KW
KW factor
Mains wire Volts
Mains phrase Volts
Mains frequency
Oil pressure
Cooling fluid temperature

Battery voltage
Engine rotating speed

Engine hours run
Under / Over Mains Volts
Under / Over Mains Frequency
External Remote control start output

( load / un-load )
Configurable relay outputs
Synchronization auto / synchronization
output
All function telecom remote control
Engine instrumentation monitor
Alternator instrumentation monitor

Configurable input trip point by 9 users
4 user output trip point
Control LCD brightness in low
brightness environment
PIN password
RS232/485 Interface
All function control button on panel
including user adjustable language
Multi-language function
Alternator Under / Over Volts
Alternator Under / Over Frequency
Under / Over Speed
Low Oil Pressure
High Engine Temp
High/Low Battery Volts
Over-current
Electrical Trip
Reverse Power Electrical Trip
Phase Sequence Electrical Trip
Earth Fault Shutdown
Adjustable start periodic/times
Periodic maintenance alarm
Warning/Shutdown
Monitor FUNCTION
Engine figure
indication
measurements
PLC MODEL
38

4.3 CONTROL PANEL INTRODUCTION

(FOR PLC 5110, 560, 5220, 5310SERIES)
TYPICAL LED/LCD DISPLAY (FOR PLC 5110, 560, 5220 SERIES)
LED SCREEN
INSTRUMENTS
The LCD displays the various engine parameters such as
ENGINE SPEED, OIL PRESSURE, HOURS RUN, etc Each
instrument is displayed with the appropriate units of measure In
this example, the values being displayed are Generator phase to
phase AC voltages V
ALARM ICONS
The LCD also displays the exact nature of any alarm condition that
may have occurred such as LOW OIL PRESSURE using
appropriate icons. This allows very specific alarm conditions to be
brought to the operators attention. Refer to the Protections
section of this manual for details of the alarms.
USER DEFINED INDICATIONS
The LCD displays the user-defined indications when configured

and active. The icons will illuminate and point to the appropriate
text insert label. These indications can be used to indicate internal
states (i.e. Engine Running, Safety On, etc).
USER DEFINED ALARMS
The LCD displays the user-defined alarms when configured and

active. The icons will illuminate and point to the appropriate text
insert label. These alarms can be used to indicate the operation of
external alarms (i.e. Low Fuel Level, Low Coolant level etc) or to
indicate internal alarms (i.e. Fail to Stop, MPU fault, etc).
LCD DISPLAY AREAS

Instrument Values
Units of Measure& Display Information
Alarm Icons
User Definable Alarms/Indicators
39

The Engine Hours Run counter will only display the accumulated hours to the nearest
12 Minutes (0.2Hr). The accumulated time will be recorded in HH:MM however.
-If the DC supply to the module is interrupted the hours run counter will not
remember any undisplayed minutes accumulated since the last 12 Minute display update.i.e.
10 Hours 38 Minutes accumulated before DC supply is removed.(10.6 Hours displayed) would
become 10 Hours 36Minutes on restoration of DC supply.(10.6 Hours still displayed).
This will only occur in the event of a total DC supply break and will NOT occur if the module is
simply switched to the Stop/Reset position.
TYPICAL LED/LCD DISPLAY (FOR PLC 5310 SERIES ONLY)

TYPICAL STATUS DISPLAY
Waiting in auto
Indicates that the module is in Automatic. The unit will respond to an

active remote start.
Starting remote
Cranking attempt 1
Indicates that the module is in automatic and that a start sequence

has been initiated, with an active remote start. The module is
attempting to crank the generator.
Running in auto
Generator on load
L-N 230V 240A 50Hz
L-L 400V 133kW
Indicates that the module is in Automatic, and that the generator is

running on load. This default screen also indicates the average line
to neutral voltage, highest of the 3 phase currents, generator
frequency, average line to line voltage and total kilo Watts.
TYPICAL INSTRUMENT DISPLAY

Coolant
temperature
60 C 140F
Oil pressure
6 Bar 87 PSI
600 kPa
Generator Amps
L1 L2 L3
238 241 241
The display of coolant temperature in both degrees centigrade and

Fahrenheit.
The display of engine oil pressure in Bar, Pounds Per Square
Inchand kilo Pascal.
The display of all three generator line currents.
TYPICAL ALARM DISPLAY

Alarm
Warning
Low oil pressure
Alarm
Shutdown
Low oil pressure
Alarm
Warning
Low battery Volts
40
The module is warning that the engine oil pressure has fallen
below a pre set level. The generator is not shutdown.
The oil pressure has fallen below a second pre set value and has
shutdown the generator.
The module is warning that the battery volts is below a pre set
value.

TYPICAL EVENT DISPLAY
Event log 21:15:00
On the 10th September 2003 at 21:15 the unit detected that the oil
10th September 2003
pressure was below the pre-set trip level, and has shutdown the
Low oil pressure
generator.
Shutdown
Event log 20:10:00
8th September 2003
Emergency stop
Shutdown
Event log 08:46:00
7th September 2003
Over Volts
Shutdown
On the 8th September 2003 at 20:10. The emergency stop button

was pressed and the generator was shutdown.
On the 7th September 2003 at 08:46 the unit detected that the
generator out put volts exceeded pre-set trip level, and has
shutdown the generator.
VIEWING THE INSTRUMENTS

VIEWING THE INSTRUMENTS (FOR PLC 5110, 5220, 560 SERIES)
It is possible to manually scroll to display the different instruments by repeatedly operating the
scroll button. Once selected the instrument will remain on the LCD display until the user selects
a different instrument or after a period of inactivity the module will revert to the initial display
(Hz/RPM).
Page order:
refer to the table next page.
VIEWING THE INSTRUMENTS (FOR PLC 5310 SERIES ONLY)
It is possible to manually scroll to display the different pages of information by repeatedly
operating the next page button.
Page order:
refer to the table next page.
It is possible to manually scroll to display the different instruments by repeatedly operating the
next page button . Once selected the instrument will remain on the LCD display until the user
selects a different instrument or after a period of inactivity for the duration of the configurable
Page Timer, the module will revert to the default display.
Alternatively, to auto scroll through all instruments on the currently selected page, press and
hold the scroll button.
To disable auto scroll, press and hold the scroll button, or select another page with the page
select button.
When auto scroll is disabled, the display will automatically return to the Status/Alarms page if no
buttons are pressed for the duration of the configurable Page Timer. If an alarm becomes active
while viewing instruments, the Status/Alarms page will be automatically displayed to
draw the operators attention to the alarm condition.
41

Instrument Page Order
(For PLC5110, 560)
Frequency / RPM
AC Voltage Line-Neutral
AC Voltage Line-Line
AC Line Current
Oil Pressure
Coolant temperature
Engine Hours Run
DC Battery Voltage
Instrument Page Order/ Content

(For PLC5310)
Instrument Page Order (For PLC

5220)
Status display
Instrument display
Alarms display
Event log
Generator RPM / Frequency (Hz)

Generator AC Voltage Line-Neutral
Generator AC Voltage Line-Line
Oil Pressure
Coolant temperature
Fuel level (%)
Engine Hours Run
DC Battery Voltage
AC Line Current
Total kW
Total VA
AC phase angle (cos )
Mains (Utility) Frequency (Hz)
Mains (Utility) AC Voltage
Line-Neutral
Mains (Utility) AC Voltage Line-Line
Engine speed
Oil Pressure
Coolant temperature
Engine Hours Run
Number of starts
DC Battery Voltage
Generator
AC
Voltage
Line-Neutral
Generator AC Voltage Line-Line
AC Line Current
Generator Output
Fuel level (%)
VIEWING THE EVENT LOG

(FOR PLC 5220 AND 5310 SERIES)
The model 5220 remote start module maintains a log of the last 15 shutdown alarms and mains
fail/returns to enable the operator or engineer to view the past alarms history. Only shutdown
and electrical trip alarms are logged; warning alarms are not logged. Once the log is full (15
shutdown alarms), any subsequent shutdown alarms will overwrite the oldest entry in the log.
Hence the log will always contain the 15 most recent shutdown alarms. The alarm is logged,
along with the date and time of the event in the format shown in this example.
To view the event log, press the log button
. The LCD display will flash the log symbol
to confirm that the event log has been entered.

In this example, the oil can symbol represents an oil pressure shutdown, backed up by the
flashing shutdown symbol in the LCD display. The value displayed means that the oil pressure
st
shutdown occurred on November 1 2002 at 8:17.

Press down
to view the next most recent shutdown alarm:
In this example, the hand/button symbol represents an emergency stop shutdown, backed up
by the flashing shutdown symbol in the LCD display. The value displayed means that the
st
emergency stop button was pressed on November 1 2002 at 11:50.

Mains Failure is logged using a flashing
symbol. Mains
Return is logged by illuminating the mains available LED.

Continuing to press down will cycle through the past alarms until
all 15 logged alarms have been viewed, after which the most
recent alarm will again be showed and the cycle will begin again.
To exit the event log and return to viewing the instruments, press the log button.
42

Manually Selecting an Instrument(FOR PLC 5110, 5220, 560 SERIES)
Initial display (Hz/RPM)
Pressing the DOWN button the

LCD
will
then
show
(Generator
L-N voltages)
LCD will then show (Generator
L-L voltages)
Pressing the button
again will scroll through each individual instrument eventually
returning to the original instrument displayed.
Once selected the instrument will remain on the LCD display until the user selects a
different instrument or after a period of inactivity the module will revert to the initial display.
Manually Selecting an Instrument (FOR PLC 5310 SERIES ONLY)

Default display
Running in auto
Generator on load
L-N 230V 240A 50Hz
L-L 400V 133kW
Pressing the DOWN
Engine speed
button the LCD will then
1500 RPM
show Engine speed
50 Hz
Pressing the DOWN
Oil pressure
button the LCD will then
6 Bar 87 PSI
show Oil pressure
600 Kpa
Pressing the button again will scroll through each individual instrument eventually returning to
the original instrument displayed.
Once selected the instrument will remain on the LCD display until the user selects a
different instrument or after a period of inactivity for the duration of the configurable Page Timer,
the module will revert to the initial display.
CANBUS ERROR MESSAGES (FOR PLC 5310 SERIES ONLY)

On J1939 enabled 53xx controllers connected to a suitable J1939 CanBus ECU, alarm status
messages are transmitted to the 53xx controller and displayed on the alarms page.
Alarm
AlarmAlarm
CAN ECU error
Exhaust hi
temp
Here the ECU code is interpreted by the module,

which displays the warning as text. An error is like a
warning, and does not shutdown the generator.
The display will alternate between the text display
and the manufacturers error codes
Alarm
CAN ECU error
SPNnnnnn
FMInnnnn
43

Alarm
Alarm
A CAN ECU fail is a shutdown and the module
CAN ECU fail stops the generator.
CAN ECU fail
Fuel pressure The display will alternate between the text SPNnnnnn
low
FMInnnnn
display and the manufacturers error codes
Alarm
Where the module does not recognise the ECU error / fail code the SPN
CAN ECU
and FMI codes are displayed. These codes then have to be cross
error
referenced with engine manufactures literature to determine the exact
SPNnnnnn
problem.
FMInnnnn
For details on these code meanings, refer to the ECU instructions provided by the
engine manufacturer, or contact the engine manufacturer for further assistance.
CANBUS MESSAGES (FOR PLC 5220 SERIES ONLY)

On J1939 enabled 52xx controllers connected to a CanBus ECU, alarm status messages are
transmitted to the 52xx controller and displayed on the CanBus message instrumentation page.
Can alarm message Suspect Parameter
Number (SPN) = 102 Failure Mode
Indicator (FMI) = 16
SPN 110 Engine coolant temperature
Examples of SPN / FMI numbers, taken FMI 0 Out of range
from the Volvo Penta TAD12 manual are : FMI 3 Above normal
FMI 4 Below normal
For details on these code meanings, refer to the ECU instructions provided by the
engine manufacturer.
When using 52xx configuration and instrumentation PC software, hovering the
mouse cursor over the SPN/FMI numbers will display the J1939 messages where appropriate.
LCD INDICATORS
COMMON ALARM LCD indicators
These indicate when an alarm condition is present. The
Alarm icons or LEDs will detail the exact nature of the alarm.
(warning) or (shutdown)
USER CONFIGURABLE LCD INDICATORS
These LCDs can be configured by the user to indicate any
on of the different functions based around the following:WARNINGS and SHUTDOWNS - Specific indication of a
particular warning or shutdown condition, backed up by
LCD indication (!)- Such as Low Oil Pressure Shutdown,
Low Coolant level, etc.
STATUS INDICATIONS - Indication of specific functions or
sequences derived from the modules operating state - Such
as Safety On, Pre-heating, Generator Available, etc.
44

USER CONFIGURABLE INDICATORS (FOR PLC 5310 SERIES ONLY)

These LEDs can be configured by the user to indicate any one of 100+
different functions based around the following:Indications - Monitoring of a digital input and indicating associated
functioning users equipment - Such as Battery Charger On or
Louvers Open, etc.
WARNINGS And SHUTDOWNS
Specific indication of a particular
warning or shutdown condition, backed up by LCD indication - Such
as Low Oil Pressure Shutdown, Low Coolant level, etc.
Status Indications - Indication of specific functions or sequences
derived from the modules operating state - Such as Safety On, Preheating,
Panel Locked, Generator Available, etc.
ICONS and LED IDENTIFICATION

Symbol
Meaning
Stop/Reset
Description
Stop the generator and reset any alarm conditions. Refer to
Section 1 of this Manual.
Start
Start the generator (if in an appropriate mode).
Auto
The controller will automatically start the generator when

given a remote start command.
Manual
The controller will start the generator under manual control.

(Separate Start command may be necessary)
Common Alarm
Mains Failure Simulation
(Test)
An alarm condition has been detected.

(Warning = Steady, Shutdown = Flashing)
On AMF modules this is used to simulate a mains failure
event. (On load test)
Alarm Mute
Silences the audible warning device.
Lamp Test
Causes all indicating LEDs to illuminate to test for correct

operation
Engine Instruments
Instruments page for engine details such as Oil pressure,

Engine temperature.
G enerator Instruments
Instruments page for generator details such as frequency

and voltage
Mains Instruments
Instruments page for mains supply details such as frequency

and voltage.
Event Log
Details recorded history of generator operation.
45

BUTTONS & CONTROLS
Stop / Reset
This button places the module into its Stop/reset mode. This will clear any
alarm conditions for which the triggering criteria have been removed. If the
engine is running and this position is selected, the module will automatically
instruct the changeover device to un-load the generator (Close Generator
becomes inactive (if used)). The fuel supply will be removed and engine will
be brought to a standstill. Should a remote start signal be present while
operating in this mode, a remote start will not occur.
Manual
This mode is used to allow manual control of the generator functions. Once in
Manual mode the module will respond to the start (I) button and start the
engine and run off load. If the engine is running off-load in the Manual mode
and a remote start signal becomes present, the module will automatically
instruct the changeover device to place the generator on load (Close
Generator) becomes active (if used)). Should the remote start signal then
be removed the generator will remain on load until either the STOP/RESET
or AUTO positions is selected.
Auto
This button places the module into its Automatic mode. This mode allows
the module to control the function of the generator automatically. The module
will monitor the remote start input and once a start condition is signalled the
set will be automatically started and placed on load (Close Generator)
becomes active (if used)). If the starting signal is removed the module will
automatically transfer the load from the generator and shut the set down
observing the stop delay timer and cooling timer as necessary. The module
will then await the next start event. For further details please see the more
detailed description of Auto Operation earlier in this manual.
AUTO
Test
This button places the module into its Test mode. This mode allows the
operator to perform an on load test of the system. Once in Test mode the
module will respond to the start I button and start the engine, and run on load
(Close Generator) becomes active (if used)). The generator will continue to
run on load until Auto mode is selected. Then, If the starting signal is removed
the module will automatically transfer the load from the generator and shut the
set down observing the stop delay timer and cooling timer as necessary. The
module will then await the next start event.
For further details please see the more detailed description of Test Operation
earlier in this manual.
Start
This button is only active in MANUAL or TEST mode. Pressing this button in
manual or test mode will start the engine and run off load (manual) or on load
(test).
Mute / Lamp Test
This button silences the audible alarm if it is sounding and illuminates all of
the LEDs. If there is no audible alarm this button will only illuminate all the
LEDs.
46

4.4 CONTROL PANEL INSTRUCTION (FOR PLC 550SERIES)

LCD DISPLAY
INFORMATION PAGE
The LCD display normally indicates the status of the generator such as
GENERATOR AT REST, PRE-HEATING, GENERATOR AVAILABLE,
etc. This is the default display and is always automatically returned to after a
pre-set period of operator inactivity.
ALARM PAGE
The LCD also displays the exact nature of any alarm condition which have
occurred such as SHUTDOWN LOW OIL PRESSURE. This allows very
specific alarm conditions to be brought to the operators attention. Refer to
the Protections section of this manual for details of how to interact with the
alarm page.
ENGINE INSTRUMENTS PAGE
The LCD displays the various engine parameters such as ENGINE SPEED,
OIL PRESSURE, HOURS RUN, etc.
GENERATOR INSTRUMENT PAGE
The LCD displays the various generator output values such as
GENERATOR VOLTAGE, GENERATOR CURRENT, etc.
If the
enhanced instrumentation option is fitted the LCD will also display the values
of GENERATOR KW, GENERATOR pF, GENERATOR KVAr, etc.
MAINS INSTRUMENT PAGE

The LCD displays the various mains supply values such as MAINS
VOLTAGE, MAINS FREQUENCY, etc.
EVENT LOG PAGE
In the event of a shutdown alarm occurring the triggering alarm will be
recorded in the Event Log Memory. The Memory will record the last 25 such
shutdowns. Subsequent alarms will then over-write the oldest previous
alarm. This feature allows service engineers arriving on site a detailed look
at the recent history of the gen-set or plant.
47

VIEWING THE INSTRUMENT AND EVENT LOG PAGES

To view a particular instrument operate the Page
button to move to the required page. Each press of the
button will move the page indicator LED along. The
LCD will also indicate the page title.
i.e. To view the Engine Coolant temperature move to the Engine Instruments Page.
The LCD will display the page title and then will automatically commence scrolling down the
various instrument . These will automatically scroll round, on reaching the last instrument the
LCD display will then jump back to the page title and resume scrolling down the page. This
sequence will be repeated until either the user moves off the page or after a period of inactivity
the module will revert to the Information Page
It is also possible to manually scroll to display the different instruments, once selected the
instrument will remain on the LCD display until the user selects a different instrument or page, or
after a period of inactivity the module will revert to the Information Page.
NOTE:-This description of operation is also true for the other instrument pages and for
viewing the records in the event log.
Manually Selecting an Instrument

Initial Display
>>>>>
LCD will then show
ENGINE INSTRUMENTS
ENGINE SPEED
1503 RPM
Pressing the DOWN button again

the LCD will then show
ENG OIL PRESSURE

2.5Bar 56psi

COOLANT TEMP
78deg C
105deg f

BATTERY VOLTAGE
24.5 V

CHARGE ALT VOLTAGE

27.5 V
Pressing the UP button the LCD will

then showetc, etc, etc.
BATTERY VOLTAGE
24.5 V
If the DOWN button is pressed while the LCD display is showing ENGINE RUN TIME then the
display will jump round to the top of the page and display the page title; ENGINE
INSTRUMENTS. Pressing the DOWN button again will then display; ENGINE SPEED
48

OPERATOR CONFIGURATION MODE
This configuration mode allows the operator limited customising of the way the module
operates.
Operation
Detail
To enter the Operator configuration mode press both
the UP and DOWN scroll buttons together.
+
The module will enter Operator Configuration mode
and the Operator configuration mode indicator will
illuminate above the PAGE button.
The LCD will then display:
CONFIGURATION
To view the different configuration functions press the
PAGE button.
LANGUAGE
ENGLISH
Pressing the UP or DOWN Button will then change the

selected language.
The LCD will then display the new language:
Repeat until the required language is displayed.
or
LANGUAGE
FRENCH
LANGUAGE
GERMAN
To view the next function press the PAGE button.

CONTRAST
Pressing the UP or DOWN Button will move the sliding
bar UP (Darker) or DOWN (Lighter) - set this to the
or
desired position.
When correct, to view the next function press the PAGE
button.
This is the duration each instrument will be displayed for
during the automatic scrolling. Use the UP and DOWN
buttons to set this to the required value.
button.
Digital inputs configured as indications can be viewed on
the LCD by pressing the UP or DOWN button when the
Information Page is active. To disable this function
set to NO by pressing the UP or DOWN button.
AUTO SCROLL TIME

3.0 Seconds
or
INDICATIONS ON LCD
YES
or
49

button.
To exit the Operator configuration mode with-out
storing any changes made press the UP or DOWN
button.
If you wish to save the changes you have made to the
configuration press the PAGE button.
ABANDON CHANGES AND

EXIT
or

SAVE CHANGES AND EXIT
To exit the Operator configuration mode and store
the changes you have made press the UP or DOWN
or
button.
The module will then return to the Information Page display and the Operator Configuration
Mode Indicator will extinguish.
LED INDICATORS
COMMON ALARM LED
This LED indicates when an alarm condition is present.
The Alarms Page on the LCD will detail the exact nature
of the alarm.
OFF - no alarm active.
FLASHING - A shutdown alarm is present, but has
not been muted.
STEADY - A warning alarm is present or a shutdown
alarm which has been muted is present.
USER CONFIGURABLE LEDs
These LED can be configured by the user to indicate any
one of 100+ different functions based around the
following: INDICATIONS - Monitoring of a digital input and
indicating associated functioning users equipment Such as Battery Charger On or Louvers Open, etc.
WARNINGS and SHUTDOWNS - Specific indication
of a particular warning or shutdown condition, backed
up by LCD indication - Such as Low Oil Pressure
Shutdown, Low Coolant level, etc.
STATUS INDICATIONS - Indication of specific
functions or sequences derived from the modules
operating state - Such as Safety On, Pre-heating,
Panel Locked, Generator Available, etc.
50

CONTROL PUSH-BUTTONS
STOP/RESET
This push-button places the module into its Stop/reset mode. This will clear
any alarm conditions for which the triggering criteria have been removed. If
the engine is running and this push-button is operated, the module will
automatically instruct the change-over device to un-load the generator (Load
transfer becomes in-active (if used)). The fuel supply will be removed and
engine will be brought to a standstill. Should a remote start signal be
present while operating in the mode, a remote start will not occur.
MANUAL
This push-button is used to allow manual control of the generator functions.
Entering this mode from any other mode will initially not cause any change of
operating state, but allows further push-buttons to be used to control the
generator operation. For example once in Manual mode it is possible to
manually start the engine by using the START push-button. If the engine is
running off-load in the Manual mode and a remote start signal becomes
present, the module will automatically instruct the change-over device to
place the generator on load (Load transfer becomes active (if used)).
Should the remote start signal then be removed the generator will remain on
load until either the STOP/RESET or AUTO push-buttons are operated.
START
This push-button is used to manually start the engine. The module must first
be placed in the MANUAL mode of operation. The START button should
then be operated. The engine will then automatically attempt to start. Should
it fail on the first attempt it will re-try until either the engine fires or the pre-set
number of attempts have been made.
To stop the engine the
STOP/RESET button should be operated. It is also possible to configure
the modules such that the start push-button must be held to maintain engine
cranking.
NOTE:-Different modes of operation are possible - Please refer to

your configuration source for details.
AUTO
This push-button places the module into its Automatic mode. This mode
allows the module to control the function of the generator automatically. The
module will monitor the remote start input and once a start condition is
signalled the set will be automatically started and placed on load (Load
transfer becomes active (if used)). If the starting signal is removed the
module will automatically transfer the load from the generator and shut the set
down observing the stop delay timer and cooling timer as necessary. The
module will then await the next start event. For further details please see the
more detailed description of Auto Operation earlier in this manual.
AUTO
51

TEST
This push-button places the module into its Test mode. This mode is used
to test the function and timing of the generator start and load sequence. The
mode is initiated by pressing the Start Button and the set will be
automatically started and placed on load. The set will run on load
continuously. To test the off-loading and stopping sequence return the set to
the Auto mode, the module will automatically transfer the load from the
generator and shut the set down observing the stop delay timer and cooling
timer as necessary. The module will then await the next start event. For
further details please see the more detailed description of Test Operation
earlier in this manual.
ALARM MUTE
This push-button is used to silence the internal alarm sounder and also any
external sounder devices fed from the audible alarm output. Any further
alarm conditions will re-active the sounder. Once the alarm has been muted
and investigated it may then be cleared.
Refer to the Protections section of this manual for details.
When the Alarm Mute is operated a Lamp test function will also be
implemented and all LED indicators will be illuminated.
ICONS AND LED IDENTIFICATION DESCRIPTION

Symbol
Meaning
Description
Stop/Reset
Stop the generator and reset any alarm conditions.

Refer to Section 1 of this Manual.
Start
Start the generator (if in an appropriate mode).
Auto
The controller will automatically start the generator

when given a remote start command.
Manual
The controller will start the generator under manual

control. (Separate Start command may be necessary)
Common Alarm
An alarm condition has been detected.

(Warning = Steady, Shutdown = Flashing)
Mains Failure
Simulation (Test)
On AMF modules this is used to simulate a mains

failure event. (On load test)
Alarm Mute
Lamp Test
Engine Instruments
Generator
Instruments
Mains Instruments
Event Log
52
Silences the audible warning device.

Causes all indicating LEDs to illuminate to test
correct operation
Instruments page for engine details such as
pressure, Engine temperature.
Instruments page for generator details such
frequency and voltage
Instruments page for mains supply details such
frequency and voltage.
Details recorded history of generator operation.
for
Oil
as
as

SECTION 5 OPERATION
The following description details the sequences followed by a module containing the standard
'factory configuration'. Always refer to your configuration source for the exact sequences and
timers observed by any particular module in the field.
5.1 STARTING
Starting an engine is easy when it succeeds, but may cause untold problems when
unsuccessful. The operation of highly complex equipment may depend on the reliability of the
genset particularly in applications such as hospitals, factory processes and building protection
systems.
That is why there are many starting processes and devices on a generating set to ensure
reliable starting every time. We make a distinction between a manual start procedure and an
emergency start procedure, which is triggered by the failure of the mains supply (generally in
automatic mode three 5 second cranks are provided).
The starting system design depends on the engine temperature. For a start in very cold
temperatures it is sometimes necessary to use starting aids, such as heating the intake air,
heating the fuel, injecting ether into the air intake. As well as these the engine coolant is heated,
and in very cold conditions also the oil is kept warm.
Generating sets can be provided with three types of start systems
- Electric Starting : This is the most widely used system and consists of a 12V or 24V starter
motor supplied by one or more lead acid, or in exceptional cases, alkaline batteries.
The starter motor rotates the ring gear of the engine flywheel moving on receiving the signal
from an electric contact.
Once the diesel engine has started and the flywheel has run up to its required speed, the starter
motor pinion disengages automatically from the ring gear. The batteries are recharged
automatically by an alternator or static charger.
- Pneumatic Starting : Pneumatic starting relies on an air starter that is operated by a flow of
compressed air from one or two compressed air bottles and an air compresser. The engine is
started in the same way as for electric starting.
The air bottles and air compresser are located as near as possible to the generating set.
- Mechanical Starting : Several mechanical starting system exist, i.e. spring, crank, inertia etc.
All of these are only used with low power generating sets.
The three systems above can be coupled to each other in the following way:
- electric/ pneumatic starting
- electric/ mechanical starting.
53

Generating Set Starting :
CHECK BEFORE START
Before generator start, please check following thing;
14. Generator normally consume 0.25%-1% of foil wastage lubricating oil.
15. check lubricating oil and coolant water capacity,
Warning
When putting foil into trunk, do not smoking nearby or using fire.
16. check oil capacity,
17. check engine cooling fan and rap degree of tightness,
18. check all ripe, ensure not leaking out,
19. check battery pole ,ensure no cauterization,
Warning
When packing up battery, do not smoking nearby or using fire, hydrogen which battery
produce will blow up. Dont mistake battery pole,
20. Check battery liquid, if necessary, put into pure water. If battery is new , please add
beforehand mixed b attery liquid
21. Check control panel and generators, please ensure aforesaid parts clean. These dust
maybe damnous, etc, tip-and-run accident.
22. Check air cleaner, if emphraxis, please change a new.
23. Ensure surroundings of generators clean, coolant aeration unhindered.
24. Check fuel system ,coolant system and lubricating oil system ,
25. If exhaust system have exhaust water device, please letting termly.
Ensure alternators output switch is off.
COMMISSIONING (FOR DSE-501K, 701HC SERIES)

Before the system is started, it is recommended that the following checks are
made:1. The unit is adequately cooled and all the wiring to the module is of a standard and rating
compatible with the system.
2. The unit DC supply is fused and connected direct to the battery and of correct polarity.
3. The Emergency Stop input is wired to an external normally closed switch connected to DC
positive.
NOTE:- If Emergency Stop feature is not required link this input to the DC Positive.
4. To check the start cycle take appropriate measures to prevent the engine from starting
(disable the operation of the fuel solenoid). After a visual inspection to ensure it is safe to
proceed, connect the battery supply. Turn the key switch to RUN. The unit starts to preheat if
selected.
5. Press and hold the START push-button for a short time, starter will engage and operate for
the duration that the button is operated for. After the safety on timer has expired the module will
generate an alarm and the COMMON ALARM LED will be illuminated (if fitted). Turn to OFF
to reset the unit.
54

6. Restore the engine to operational status (reconnect the fuel solenoid), again select RUN
and operate the START push-button and this time the engine should start and the starter
motor should disengage automatically. If not then check that the engine is fully operational (fuel
available, etc.) and that the fuel solenoid is operating. The engine should now run up to
operating speed. If not, and an alarm is present, check the alarm condition for validity, then
check input wiring. The engine should continue to run for an indefinite period.
7. Select OFF on the front panel, the engine will then shutdown.
8. All internal timers and selections should now be adjusted to the customers specifications or to
the engine and alternator manufacturers recommendations.
9. If despite repeated checking of the connections between the DSE P511 and the customers
system, satisfactory operation cannot be achieved, then the customer is requested to contact
the factory for further advice.
COMMISSIONING (FOR OTHER CONTROL PANEL SERIES)

10.1.1 PRE-COMMISSIONING
Before the system is started, it is recommended that the following checks are made:10.1. The unit is adequately cooled and all the wiring to the module is of a standard and rating
compatible with the system.
10.2. The unit DC supply is fused and connected to the battery and that it is of the correct
polarity.
10.3. The Emergency Stop input is wired to an external normally closed switch connected to DC
positive.
NOTE:- If Emergency Stop feature is not required link this input to the DC Positive. The module
will not operate unless either the Emergency Stop is fitted correctly OR Pin 3 is connected to DC
positive (+ve)
10.4. To check the start cycle operation take appropriate measures to prevent the engine from
starting (disable the operation of the fuel solenoid). After a visual inspection to ensure it is safe
to proceed, connect the battery supply. Select MANUAL, the unit start sequence will
commence.
10.5. The starter will engage and operate for the pre-set crank period. After the starter motor
has attempted to start the engine for the pre-set number of attempts the LCD will display Failed
to start. Select the STOP/RESET position to reset the unit.
10.6. Restore the engine to operational status (reconnect the fuel solenoid), again select
MANUAL, this time the engine should start and the starter motor should disengage
automatically. If not then check that the engine is fully operational (fuel available, etc.) and that
the fuel solenoid is operating. The engine should now run up to operating speed. If not, and an
alarm is present, check the alarm condition for validity, then check input wiring. The engine
should continue to run for an indefinite period. It will be possible at this time to view the engine
and alternator parameters - refer to the Description of Controls section of this manual.
10.7. Select AUTO on the front panel, the engine will run for the pre-set cooling down period,
then stop. The generator should stay in the standby mode. If not check that there is not a signal
55

present on the Remote start input.
10.8. Initiate an automatic start by supplying the remote start signal. The start sequence will
commence and the engine will run up to operational speed. Once the generator is available a
load transfer will take place, the Generator will accept the load. If not, check the wiring to the
Generator Contactor Coil (if used). Check the Warming timer has timed out.
10.9. Remove the remote start signal, the return sequence will start. After the pre-set time
period, the load will be removed from the generator. The generator will then run for the pre-set
cooling down period, then shutdown into its standby mode.
10.10.Set the modules internal clock/calendar to ensure correct operation of the scheduler and
event logging functions. For details of this procedure see section entitled Front Panel
Configuration Editing the date and time.
10.11. If, despite repeated checking of the connections between the 5310 and the customers
system, satisfactory operation cannot be achieved, then the customer is requested to contact
the factory for further advice.
5.2
OPERATION (FOR DSE-501K, 701HC SERIES)
To start the generator turn the key switch to the hand position, which will power up the unit.
If at this time the auxiliary input is active the led will be illuminated, preventing the start of the
generator.
Pressing the pre-heat button will energise the pre-heat output. Releasing the button will
de-energise the output.
Pressing the start button will energise the Fuel Solenoid output, then the Starter Motor output.
The button should be pressed for the duration of the crank period.
When the engine fires, the starter motor is disengaged and locked out at 20 Hz measured from
the Alternator output.
After the starter motor has disengaged, the Safety On timer is activated (which is fixed at 12
seconds), allowing Oil Pressure, High Engine Temperature and Charge Fail to stabilise without
triggering the fault.
Turning the key to STOP de-energises the FUEL SOLENOID, bringing the generator to a stop.
NOTE: - The safety on time (used for delayed alarms) is pre set to 12 seconds and can not be
changed.
NOTE: - If the generator has not started when the start button has been released or the
generator fails once it is running, the key switch must be turned to STOP and then back to
before another start can be invoked.
NOTE: - If pre-heat is required during cranking, the pre-heat button should be pressed at the
56

same time as the start button.
NOTE: - The 701HC start button is represented by
WARNINGS
Warnings are used to warn the operator of an impending fault
BATTERY CHARGE FAILURE, if the module does not detect a voltage from the warning light
terminal on the auxiliary charge alternator, the icon will illuminate.
SHUTDOWNS
Shutdowns are latching and stop the Generator. The alarm must be cleared, and the fault
removed to reset the module. In the event of a shutdown the appropriate icon will be illuminated
Auxiliary Input, if the auxiliary input is energised an immediate shutdown will occur. The icon
will illuminate.
NOTE: - If the Auxiliary input is used to shutdown the engine, the fault must be cleared
before the unit can be reset and the generator restarted.
LOW OIL PRESSURE, if the module detects that the engine oil pressure has fallen below the
low oil pressure switch setting, after the Safety On timer has expired, a shutdown will occur.
The icon will illuminate.
HIGH ENGINE TEMPERATURE if the module detects that the engine coolant temperature has
exceeded the high engine temperature switch setting, after the Safety On timer has expired, a
shutdown will occur.
OVERSPEED, if the engine speed exceeds the pre-set trip (14% above the nominal frequency)
a shutdown is initiated. Overspeed is not delayed, it is an immediate shutdown.
NOTE: - During the start-up sequence the overspeed trip level is extended to 24% above the
normal frequency for the duration of the safety timer to allow an extra trip level margin. This is
used to prevent nuisance tripping on start-up.
NOTE: - The safety on time (used for delayed alarms) is pre set to 12 seconds and can not be
changed.
5.3 OPERATION (FOR PLC 5110, 560 SERIES)

AUTOMATIC MODE OF OPERATION
This mode is activated by pressing the pushbutton. An LED indicator beside the button confirms
this action.
When a Remote Start signal is applied to the remote start input, the following sequence is
initiated: The Remote Start Active indicator illuminates (if configured).
57

To allow for false signals the Start Delay timer is initiated. After this delay, if the pre-heat output
option is selected then the pre-heat timer is initiated, and the corresponding auxiliary output (if
configured) will energise.
If the Remote Start signal is removed during the Start Delay timer, the unit
will return to a stand-by state. After the above delays the Fuel Solenoid is energised, then
one second later, the Starter Motor is engaged. The engine is cranked for a pre-set time period.
If the engine fails to fire during this cranking attempt then the starter motor is disengaged for the
pre-set rest period. Should this sequence continue beyond the set number of attempts, the start
sequence will be terminated and Fail to Start
accompanied by a flashing shutdown symbol.
fault will be displayed
When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency
from the Alternator output. Alternatively a Magnetic Pickup mounted on the flywheel housing
can be used for speed detection (This is selected using the front panel editor).
After the starter motor has disengaged, the Safety On timer is activated, allowing Oil Pressure,
High Engine, Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to
stabilise without triggering the fault.
Once the engine is running, the Warm Up timer, if selected is initiated, allowing the engine to
stabilise before accepting the load.
If an auxiliary output has been selected to give a load transfer signal, this would then activate.
A load transfer will not be initiated until the Oil Pressure has risen. Thus
preventing excessive wear on the engine.
On removal of the Remote Start signal, the Stop delay timer is initiated, once it has timed out,
the load Transfer signal is de-energised, removing the load. The Cooling timer is then initiated,
allowing the engine a cooling down period off load before shutting down. Once the Cooling
timer expires the Fuel Solenoid is de-energised, bringing the generator to a stop.
Should the Remote Start signal be re-activated during the cooling down period, the set will
return on load.
MANUAL OPERATION
To initiate a start sequence in MANUAL, press the pushbutton. When the controller is in the
manual mode (indicated by an LED indicator beside the button), pressing the START (I) button
will initiate the start sequence.
There is no Start Delay in this mode of operation.
If the pre-heat output option is selected this timer is then initiated, and the auxiliary output
selected is energised.
58

After the above delay the Fuel Solenoid is energised, then the Starter Motor is engaged.
The engine is cranked for a pre-set time period. If the engine fails to fire during this cranking
attempt then the starter motor is disengaged for the pre-set rest period. Should this sequence
continue beyond the set number of attempts, the start sequence will be terminated and Fail to
Start
indicator.
fault will be displayed accompanied by a flashing shutdown
can be used for speed detection (This is selected using the front panel editor). Rising oil
pressure can also be used to disconnect the starter motor, however it cannot be used for
underspeed or overspeed detection.
High Engine Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to
stabilise before it can be loaded.
The generator will run off load, unless a Remote Start signal is applied, and if Load Transfer
has been selected as a control source, the appropriate auxiliary output selected will activate.
If the Remote Start signal is removed, the generator will continue to run On load until the Auto
mode is selected.
The Remote Stop Delay Timer will time out, the load is then disconnected. The generator will
then run off load allowing the engine a cooling down period.
Selecting STOP (O) de-energises the FUEL SOLENOID, bringing the generator to a stop.
PROTECTIONS
The module will indicate that an alarm has occurred in several ways;
The Common alarm LED will illuminate
(Warning = Red steady, Shutdown = Red
Flashing)
If appropriate, the LCD display or LED indicators will
display the appropriate alarm icon i.e. for battery
charging failure :
59

If no alarms are present the LCD
will extinguish any alarm icons.
In the event of a warning alarm the LCD will display the appropriate icon. If a shutdown then
occurs the module will display the appropriate icon. The original warning alarm icon will remain
displayed.
Example:-
Charge alternator warning (all symbols

steady)
Followed by.
Charge alternator warning indicator still
present, common alarm indicator has changed
to a shutdown symbol and is now flashing.
Also present is the flashing overspeed LED.
Overspeed and Shutdown alarm Icons are displayed flashing. The original warning will remain
displayed as long at the triggering conditions remain. Any subsequent warnings or shutdowns
that occur will be displayed steady, therefore only the first-up shutdown will appear flashing.
Warnings are non-critical alarm conditions and do not affect the operation of
the generator system, they serve to draw the operators attention to an
undesirable condition.
In the event of a warning alarm the LCD will display:-
terminal on the auxiliary charge alternator the icon will illuminate.
FAIL TO STOP, If the module detects the engine is still running when the Fail to stop timer
expires, then the module will display:-
Fail to Stop could indicate a faulty oil pressure sender - If engine is at rest
check oil sender wiring and configuration.
AUXILIARY INPUTS, if an auxiliary input has been configured as a warning the appropriate
LCD segment will be displayed:
60

SHUTDOWNS
removed to reset the module.
In the event of a shutdown alarm the LCD will display:The appropriate icon will also be displayed flashing
The alarm condition must be rectified before a reset will take place. If the alarm
condition remains it will not be possible to reset the unit (The exception to this is the Low Oil
Pressure alarm and similar delayed alarms, as the oil pressure will be low with the engine at
rest). Any subsequent warnings or shutdowns that occur will be displayed steady, therefore only
the first-up shutdown will appear flashing.
FAIL TO START, if the engine does not fire after the pre-set number of attempts has been
made a shutdown will be initiated.
will illuminate.
The icon
EMERGENCY STOP, removal of the +ve DC Supply from the Emergency Stop input initiates
the following sequence, firstly it will initiate a controlled shutdown of the Generator and prevent
any attempt to restart the Generator until the Emergency Stop push-button has been reset.
Secondly it removes the +ve DC supply from boththe Fuel Solenoid and Starter Solenoid. The
icon
will illuminate
The Emergency Stop +Ve signal must be present otherwise the unit will
shutdown.
low oil pressure trip setting level after the Safety On timer has expired, a shutdown will occur.
exceeded the high engine temperature trip setting level after the Safety On timer has expired, a
The icon
will illuminate.
OVERSPEED, if the engine speed exceeds the pre-set trip a shutdown is initiated.
The icon will illuminate. Overspeed is not delayed,
it is an immediate shutdown.
During the start-up sequence the overspeed trip logic will allow for a small amount of
overshoot. This temporarily raises the overspeed trip point during the safety delay timer. This is
used to prevent nuisance tripping on start-up.
UNDERSPEED, if the engine speed falls below the pre-set trip after the Safety On timer has
61

expired, a shutdown is initiated.
The icon
will illuminate.
OIL PRESSURE SENDER OPEN CIRCUIT, if the module detects a loss of signal from the oil
pressure sender (open circuit) a shutdown is initiated. The LCD will indicate:
(Steady) (And ----- on the engine oil pressure instrument). Sender failure is not delayed, it is an
immediate shutdown.
AUXILIARY INPUTS, if an auxiliary input has been configured as a shutdown the appropriate
LCD segment will be displayed:
LOSS OF SPEED SIGNAL, if the speed sensing signal is lost during cranking, a shutdown is
initiated.
The icon will illuminate. (Steady) (And ----- on the engine RPM instrument).
This will only occur if the speed sensing signal is lost during cranking or during the
safety on timer. If the signal is lost during normal operation the Generator will shutdown with an
Under-speed alarm.
ELECTRICAL TRIPS
Electrical trips are latching and stop the Generator but in a controlled manner. On initiation of
the electrical trip condition the module will de-energise the Load Transfer Output to remove
the load from the generator. Once this has occurred the module will start the Cooling timer and
allow the engine to cool, off-load before shutting down the engine. The alarm must be accepted
and cleared, and the fault removed to reset the module.
In the event of a shutdown alarm the LCD will display:The COMMON ALARM LED will also illuminate (Red steady) and the generator will be
removed from the load. Once the cooling timer has expired the COMMON ALARM LED will
flash (Red).
AUXILIARY INPUTS, if an auxiliary input has been configured as an electrical trip the
appropriate LCD segment will be displayed: The COMMON ALARM LED will illuminate (red
Steady) until the engine is shutdown (red flashing).
SPECIAL ALARM CONDITIONS
The microprocessor has a watchdog facility which continually monitors the operation of the
module. Should an error occur and the microprocessor is still functioning, an alarm will be
indicated by the LCD back-light flashing and the common alarm LED being illuminated RED.
If the module is being configured and does not receive the correct information via the 808
interface the watchdog will halt the module operation and signal a corrupt user configuration by
flashing the LCD back-light and illuminating the common alarm LED GREEN (steady).
Attempting to re-send the configuration should rectify the alarm unless a problem exists with the
configuration transfer (such as a broken cable, etc).
62

TO STOP YOUR GENERATOR:
To Stop your Generator:
Turn the circuit breaker off.
Turn the engine switch off.
Turn the fuel valve off.
5.4 OPERATION (FOR PLC-5310 SERIES)

AUTOMATIC MODE OF OPERATION (FOR PLC 5310 SERIES)
: If a digital input configured to panel loc k is active, changing module m odes will not
be possible. Viewing the instruments
and
is NOT affected by panel lock. If pane l lock
is active the Panel lock indicator (if configured) illuminates.
This mode is activated by pressing the
button confirms this action
pushbutton. An LED indicator beside the
If the Remote Start input (if configured) is active the relevant indicator (if configured) illuminates
To allow for false remote start signals, the Start Delay timer is initiated. After this delay, if the
pre-heat output option is selected then the pre-heat timer is initiated, and the corresponding
auxiliary output (if configured) will energise.
If the Remote Start signal is remove d during the Start Delay timer, the unit will re turn
to a stand-by state.
After the above delays the Fuel Solenoid (or enable ECU output if configured) is energised, then
one second later, the Starter Motor is engaged.
If the Remote Start signal is remove d during the Start Delay timer, the unit will re turn
to a stand-by state.
After the above delays the Fuel Solenoid (or enable ECU output if configured) is energised, then
one secondlater, the Starter Motor is engaged.
If the unit has been configured for J1939, compatible ECU's will receive the start
comma nd via J1939.
Start fault will be displayed.
63

can be used for speed detection (This is selected by PC using the 52/53xx series configuration
software). Rising oil pressure can also be used to disconnect the starter motor, however it
cannot be used for underspeed or overspeed detection.
If the unit has been configured for J193 9, spe ed sensing is via J193 9.
stabilise before accepting the load.
If an auxiliary output has been selected to give a load transfer signal, this would then activate
A load transfer will not be initiated until the Oil Pressure has risen. Thus preventing
excessive wear on the engine.
On removal of the Remote Start signal, the Stop delay timer is initiated, once it has timed out,
the load Transfer signal is de-energised, removing the load. The Cooling timer is then initiated,
allowing the engine a cooling down period off load bef ore shutting down. Once the Cooling
timer expires the Fuel Solenoid is de-energised, bringing the generator to a stop.
Should the Remote Start signal be re-activated during the cooling down period, the set will
return on load
stabilise without triggering the fault
MANUAL OPERATION (FOR PLC 5310 SERIES)

If a digital input configured to panel lock is active, changing module modes will not be
possible. Viewing the instruments
and
event logs is NOT affected by pane l lock. If
panel lock is active the Panel lock indicator (if configured) illuminates.
To initiate a start sequence in MANUAL, press the
pushbutton. When the controller is in
the manual mode (indicated by an LED indicator beside the button), pressing the START (I)
button will initiate the start sequence.
There is no Start Delay in this mode of operation.
selected is energized.
After the above delay the Fuel Solenoid (or ECU output if configured) is energised, then one
second later, the Starter Motor is engaged.
If the unit has been configured for J1939, compatible ECU's will receive the start.
comma nd via J1939.
64

Start will be displayed.
can be used for speed detection (This is selected by PC using the 52/53xx series configuration
If the unit has been configured for J193 9, spe ed sensing is via J193 9.
Once the engine is running, the Warm Up timer, if selected, is initiated, allowing the engine to
The generator will run off load, unless the Remote Start on load signal is applied or, if Close
generator has been selected as a control source, the appropriate auxiliary output will then
activate.
The generator will continue to run On load, until the Auto mode is selected.
If Auto mode is selected, and the remote start on load signal is not active, then the Stop Delay
Timer begins, after which, the load is disconnected. The generator will then run off load allowing
the engine a cooling down period.
PROTECTIONS
When an alarm is present the Audible Alarm will sound and the Common alarm LED if
configured will illuminate.
The audible alarm can be silenced by pressing the Mute button
The LCD display will jump from the Information page to display the Alarm Page
Alarm
Warning
Low oil pressure
The type of alarm. Shutdown or warning

The nature of alarm, eg Low oil pressure.
The LCD will display multiple alarms E.g. High Engine Temperature shutdown, Emergency
Stop and Low Coolant Warning alarms have been triggered. These will automatically scroll
round in the order that they occurred.
65

Running in Auto
Generator on load
L-N 230V 240A
50Hz
L-L 400V 133kW
If no alarms are present the

LCD will display this default
page.
In the event of a warning alarm the LCD will display the appropriate text. If a shutdown then
occurs the module will again display the appropriate text.
Example:Alarm
Shutdown
High engine
temperature
Followed by.
Alarm
Shutdown
Emergency stop
Followed by.
Alarm
Warning
Low coolant level
The unit will scroll through all active alarms in a continuous loop.
Alarm
Shutdown
High engine
temperature
WARNINGS
Warnings are non-critical alarm conditions and do not affect the operation of the generator
system, they serve to draw the operators attention to an undesirable condition.
In the event of an alarm the LCD will jump to the alarms page, and scroll through all active
warnings and shutdowns.
BATTERY CHARGE FAILURE, will be displayed if the module does not detect a voltage from
the warning light terminal on the auxiliary charge alternator.
Alarm
Warning
Charge fail
BATTERY LOW VOLTAGE, will be displayed if the module detects that the plant DC supply
has fallen below the low volts setting level. The Battery Low Voltage alarm is delayed by the
66

Low DC Volts Delay timer.
Alarm
Warning
Low battery volts
BATTERY HIGH VOLTAGE, will be displayed if the module detects that the plant DC supply
has risen above thehigh volts setting level. The Battery High Voltage alarm is delayed by the
High DC Volts Delay timer.
Alarm
Warning
High battery volts
FAIL TO STOP, will be displayed if the module detects the engine is still running when the Fail
to stop timerexpires.
Alarm
Fail to stop
Fail to Stop could indicate a faulty oil pressure sender - If engine is at rest check oil
sender wiring and configuration.
AUXILIARY INPUTS, auxiliary inputs can be user configured and will display the message as
written by the user.
Example
Alarm
Warning
Bearing temp high
LOW FUEL LEVEL, will be displayed if the fuel level detected by the fuel level sender falls
below the low fuel level setting.
Alarm
Warning
Low fuel level
ANALOGUE PRE-ALARMS
The following alarms are termed pre-alarms as they pre warn the operator of a potentially more
serious alarm condition. For instance, if the engine temperature rises past the pre alarm level, a
warning condition will occur to notify the operator. If the temperature falls below this level, then
the alarm ceases, and the set will continue to run as normal. However if the temperature
continues to rise until the coolant temperature trip point is reached, the warning is escalated and
67

a high coolant temperature shutdown is initiated.
low oil pressure prealarm setting level after the Safety On timer has expired, a warning will
occur. Alarm Warning Low Oil Pressure will be displayed.
Alarm
Warning
Low oil pressure
exceeded the high engine temperature pre-alarm setting level after the Safety On timer has
expired, a warning will occur. Alarm Warning High Coolant Temperature will be displayed.
Alarm
Warning
High temperature
LOW ENGINE TEMPERATURE if the module detects that the engine coolant temperature has
fallen below the engine temperature pre-alarm setting level after the Safety On timer has
expired, a warning will occur. Alarm Warning Low Coolant Temp will be displayed.a
Alarm
Warning
Low Coolant Temp
OVERSPEED, if the engine speed exceeds the pre-alarm trip a warning is initiated. Alarm
Warning Overspeed will be displayed. It is an immediate warning.
Alarm
Warning
Overspeed
UNDERSPEED, if the engine speed falls below the pre-set pre-alarm after the Safety On timer
has expired, a warning is initiated. Alarm Warning Underspeed will be displayed.
Alarm
Warning
Underspeed
GENERATOR HIGH FREQUENCY if the module detects a generator output frequency in
excess of the pre-set pre-alarm, a warning is initiated. Alarm Warning High frequency will be
displayed, it is an immediate warning.
Alarm
Warning
Over frequency
GENERATOR LOW FREQUENCY if the module detects a generator output frequency below
the pre-set pre-alarm after the Safety On timer has expired, a warning is initiated. Alarm
68

Warning Low Frequency will be displayed
Alarm
Warning
Under frequency
GENERATOR HIGH VOLTAGE if the module detects a generator output voltage in excess of
the pre-set prealarm,a warning is initiated. Alarm Warning High voltage will be displayed, it is an
immediate warning
Alarm
Warning
AC Overvolts
GENERATOR LOW VOLTAGE if the module detects a generator output voltage below the
pre-set pre-alarm after the Safety On timer has expired, a warning is initiated. Alarm Warning
Low Voltage will be displayed.
Alarm
Warning
AC Undervolts
CAN ECU ERROR If the module is configured for J1939 instruments and receives an error
message from the engine control unit, Can ECU error is shown on the modules display and a
warning alarm is generated.
Example
Alarm
Can ECU error
Exhaust high
temperature
The display will alternate

between the text display and
the manufacturers error codes
Can ECU error
Alarm
SPNnnnnnnn
FMInnnnnnn
HIGH CURRENT WARNING ALARM

GENERATOR HIGH CURRENT, if the module detects a generator output current in excess of
the pre-set trip a warning is initiated. Alarm Warning High Current will be displayed. If this high
current condition continues for an excess period of time, then the alarm is escalated to a
shutdown condition. For further details of the high current alarm, please see High Current
Shutdown Alarm.
Alarm
Warning
High current
69

SHUTDOWNS
The alarm condition must be rectified before a reset will take place. If the alarm
rest).
made a shutdown will be initiated. Alarm Shutdown Fail To Start will be displayed.
Alarm
Shutdown
Failed to start
Secondly it removes the +ve DC supply from both the Fuel Solenoid and Starter Solenoid.
Alarm Shutdown Emergency Stop will be displayed.
Alarm
Shutdown
Emergency stop
The Emergency Stop +Ve signal must be present otherwise the unit will shutdown.
Alarm Shutdown Low Oil Pressure will be displayed.
Alarm
Shutdown
Low oil pressure
shutdown will occur. Alarm Shutdown High Engine Temperature will be displayed.
Alarm
Shutdown
High temperature
OVERSPEED, if the engine speed exceeds the pre-set trip a shutdown is initiated. Alarm
Shutdown Overspeed will be displayed. Overspeed is not delayed, it is an immediate
shutdown.
Alarm
70

Shutdown
Overspeed
During the start-up sequence the overspeed trip logic can be configured to allow an
extra trip level margin. This is used to prevent nuisance tripping on start-up - Refer to the 53xx
series configuration software manual under heading Overspeed Overshoot for details.
expired, a shutdown is initiated. Alarm Shutdown Underspeed will be displayed.
Alarm
Shutdown
Underspeed
excess of the pre-set trip a shutdown is initiated. Alarm Shutdown High Frequency will be
displayed, it is an immediate shutdown.
Alarm
Shutdown
Over frequency
GENERATOR LOW FREQUENCY, if the module detects a generator output frequency below
the pre-set trip after the Safety On timer has expired, a shutdown is initiated. Alarm Shutdown
Low Frequency will be displayed.
Alarm
Shutdown
Under frequency
the pre-set trip a shutdown is initiated. Alarm Shutdown High Volts will be displayed, it is an
immediate shutdown.
Alarm
Shutdown
AC Overvolts
below the pre-set trip after the Safety On timer has expired, a shutdown is initiated. Alarm
Shutdown Low Volts will be displayed.
Alarm
Shutdown
AC Undervolts
pressure sender (open circuit) a shutdown is initiated. Alarm Shutdown Sender Fault will be
71

displayed. Sender failure is not delayed, it is an immediate shutdown.
Alarm
Shutdown
Oil pressure
sender fault
message will be displayed as configured by the user.
Alarm
Shutdown
Bearing temp high
LOSS OF SPEED SIGNAL, if the speed sensing signal is lost during cranking, a shutdown is
initiated. Alarm Shutdown Loss Of Speed Signal will be displayed.
Alarm
Shutdown
Loss of speed signal
NOTE:- This will only occur if the speed sensing signal is lost during cranking or during
the safety on timer. If the signal is lost during normal operation the Generator will
shutdown with an Under-speed alarm
.
CAN DATA FAIL If the module is configured for J1939 operation and does not detect data on
the engine CANbus data link, a shutdown will occur and Can data fail is shown on the modules
display.
Alarm
Shutdown
Can data fail
CAN ECU FAIL If the module is configured for J1939 instruments and receives a fail
message from the engine control unit, the engine is shutdown and Can ECU fail is shown on
the modules display.
Example
Alarm
Can ECU fail
Fuel pressure low
The display will

alternate between the
text display and the
manufacturers error
codes
Alarm
Can ECU fail
SPNnnnnnnn
FMInnnnnnn
If the CAN message is a manufacturers specific code, it may not be displayed as text.
If this is the case the display will show the generic manufacturers code, which must be cross
referenced with the engine manufacturers literature. . Please contact the engine manufacturer
72

for further assistance.
HIGH CURRENT SHUTDOWN ALARM

the pre-set trip a warning is initiated. This warning will continue for a period of time depending
upon the level of overload that the generator is subjected to, and the configuration setting for
Generator High Current in the 52/53xx series configuration software.
Alarm
Shutdown
High current trip
For instance the factory default settings for Generator High Current allow for a loading of the
generator to 110% for one hour. That is to say if the generator load level exceeds the trip point
by 10%, a warning alarm will occur while the overload condition exists. If the load level does not
drop to normal levels within one hour, the set is stopped, the 5310 module displaying either
shutdown alarm or electrical trip alarm depending upon module configuration.
NOTE:- Higher overload levels will result in a faster acting shutdown condition. For instance
with the factory default configuration, an overload level twice that of the trip level ( typically
200%) will result in a Generator High Current shutdown condition after 36 seconds. For details
of the relationship between the overload and the shutdown time, please see the Appendix
section of this manual.
ELECTRICAL TRIPS
the electrical trip condition the module will de-energise the Close Generator Output to remove
allow the engine to cool off-load before shutting down the engine. The alarm must be accepted
appropriate message will be displayed as configured by the user.
Example
Alarm
Electrical trip
Phase rotation
GENERATOR HIGH CURRENT. If the module detects a generator output current in excess of
the pre-set trip a warning is initiated. If this high current condition continues for an excess period
of time, then the alarm is escalated to either a shutdown or electrical trip condition (depending
upon module configuration). For further details of the high current alarm, please see High
Current Shutdown Alarm.
Alarm
Electrical trip
High current
73

5.5 OPERATION (FOR PLC-5220 SERIES)

The following description details the sequences followed by a module containing the standard
factory configuration. Always refer to your configuration source for the exact sequences and
timers observed by any particular module in the field.
AUTOMATIC MODE OF OPERATION

NOTE:- If a digital input configured to panel lock is active, the LCD will display the
icon. When in panel lock, changing module modes will not be possible. Viewing the instruments
and event logs and event logs
This mode is activated by pressing the
button confirms this action.
is NOT affected by panel lock.

pushbutton. An LED indicator beside the
Should the mains (utility) supply fall outside the configurable limits for longer than the period of
the mains transient delay timer, the mains (utility) failure indicator will illuminate and the mains
(utility) available GREEN indicator LED extinguishes. Additionally, while in AUTO mode, the
remote start input (if configured) is monitored. If active, the Remote Start Active indicator (if
configured) illuminates.
To allow for short term mains supply transient conditions or false remote start signals, the Start
Delay timer is initiated. After this delay, if the pre-heat output option is selected then the pre-heat
timer is initiated, and the corresponding auxiliary output (if configured) will energise.
NOTE:- If the mains supply returns within limits, ( or the Remote Start signal is
removed if the start sequence was initiated by remote start) during the Start Delay timer,
the unit will return to a stand-by state.
After the above delays the Fuel Solenoid is energised, then one second later, the Starter
Motor is engaged.
Start
symbol.
can be used for speed detection (This is selected by PC using the 5200 series configuration
74

Once the engine is running, the Warm Up timer, if selected is initiated, allowing the engine
to stabilise before accepting the load.
If an auxiliary output has been selected to give a load transfer signal, this would then activate.
NOTE:-A load transfer will not be initiated until the Oil Pressure has risen. Thus
preventing excessive wear on the engine.
On the return of the mains supply, (or removal of the Remote Start signal if the set was started
by remote signal) , the Stop delay timer is initiated, once it has timed out, the load Transfer
signal is de-energised, removing the load. The Cooling timer is then initiated, allowing the
engine a cooling down period off load before shutting down. Once the Cooling timer expires the
Fuel Solenoid is de-energised, bringing the generator to a stop.
Should the mains supply fall outside limits again (or the Remote Start signal be re-activated)
during the cooling down period, the set will return on load.
MANUAL OPERATION
icon. When in panel lock, changing module modes will not be possible. Viewing the
instruments
and event logs
To initiate a start sequence in MANUAL, press the

pushbutton. When the controller is in the
manual mode (indicated by an LED indicator beside the button), pressing the START (I) button
will initiate the start sequence.
NOTE:- There is no Start Delay in this mode of operation.
selected is energised. After the above delay the Fuel Solenoid is energised, then the Starter
Motor is engaged. The engine is cranked for a pre-set time period. If the engine fails to fire
during this cranking attempt then the starter motor is disengaged for the pre-set rest period.
Should this sequence continue beyond the set number of attempts, the start sequence will be
terminated and Fail to Start
shutdown
fault will be displayed accompanied by a flashing
indicator.
can be used for speed detection (This is selected by PC using the 5200 series configuration
75

After the starter motor has disengaged, the Safety On timer is activated, allowing Oil
Pressure, High Engine Temperature, Under-speed, Charge Fail and any delayed Auxiliary
fault inputs to stabilise without triggering the fault.
Once the engine is running, the Warm Up timer, if selected, is initiated, allowing the engine
to stabilise before it can be loaded.
The generator will run off load, unless the mains supply fails or a Remote Start on load signal
is applied. If Close generator has been selected as a control source, the appropriate auxiliary
output will then activate.
The generator will continue to run On load regardless of the state of the mains supply or remote
start input until the Auto mode is selected. If Auto mode is selected, and the mains supply is
healthy with the remote start on load signal not active, then the Remote Stop Delay Timer
begins, after which, the load is disconnected. The generator will then run off load allowing the
engine a cooling down period.
TEST OPERATION
NOTE:- If a digital input configured to panel lock is active, the LCD will display the icon. When in
panel lock, changing module modes will not be possible. Viewing the instruments and event
logs is NOT affected by panel lock.
icon. When in panel lock, changing module modes will not be possible. Viewing the
instruments
and event logs
To initiate a start sequence in TEST, press the

pushbutton. When the controller is in the
test mode (indicated by an LED indicator beside the button), pressing the START (I) button will
initiate the start sequence.
selected is energised. After the above delay the Fuel Solenoid is energised, then the Starter
Motor is engaged. The engine is cranked for a pre-set time period. If the engine fails to fire
during this cranking attempt then the starter motor is disengaged for the pre-set rest period.
Should this sequence continue beyond the set number of attempts, the start sequence will be
terminated and Fail to Start
indicator.
76

can be used for speed detection (This is
selected by PC using the 5200 series configuration software). Rising oil pressure can also be
used to disconnect the starter motor, however it cannot be used for underspeed or overspeed
detection.
Once the engine is running, the Warm Up timer, if selected, is initiated, allowing the engine to
The generator will continue to run On load regardless of the state of the mains supply or remote
start input until the Auto mode is selected.
If Auto mode is selected, and the mains supply is healthy with the remote start on load signal
not active, then the Remote Stop Delay Timer begins, after which, the load is disconnected.
The generator will then run off load allowing the engine a cooling down period.
Selecting STOP (O) removes the Close Generator output (if configured) and de-energises the
FUEL SOLENOID, bringing the generator to a stop.
PROTECTIONS
The LCD display will indicate a common
alarm either :
(warning),
(shutdown)
or
(electrical trip)
If appropriate, the LCD display or LED
indicators will display the appropriate alarm
icon i.e. for battery charging failure :
NOTE:- Alarm icons in the LED display area are hid until lit. This means that the display
area appears totally clear, and free from clutter. The advantage of this is that when an alarm
does occur, the respective LED icon will illuminate on the otherwise blank fascia. This makes
alarm identification much clearer.
NOTE:- Alarm icons in the LED display area are hid until lit. This means that the display area
appears totally clear, and free from clutter. The advantage of this is that when an alarm does
occur, the respective LED icon will illuminate on the otherwise blank fascia. This makes alarm
identification much clearer.
77

If no alarms are present the LCD will extinguish any alarm icons.
In the event of a warning alarm the LCD will display the appropriate icon. If a shutdown then
occurs the module will display the appropriate icon. The original warning alarm icon will remain
displayed.
Example:-
Followed by.
Low battery volts warning indicator still present, common alarm indicator has changed to a
shutdown symbol and is now flashing.
Also present is the flashing underspeed LED.
Underspeed and Shutdown alarm Icons are displayed flashing. The original warning will remain
displayed as long at the triggering conditions remain. Any subsequent warnings or shutdowns
that occur will be displayed steady, therefore only the first-up shutdown will appear flashing.
WARNINGS
In the event of a warning alarm the LCD will display:BATTERY CHARGE FAILURE, if the module does not detect a voltage from the warning light
icon will illuminate.
terminal on the auxiliary charge alternator the
BATTERY LOW VOLTAGE, if the module detects that the plant DC supply has fallen below the
low volts setting level, the module will display:The Battery Low Voltage alarm is delayed by the Low DC Volts Delay timer.
BATTERY HIGH VOLTAGE, if the module detects that the plant DC supply has risen above the
high volts setting level, the module will display:The Battery High Voltage alarm is delayed by the High DC Volts Delay timer.
FAIL TO STOP, If the module detects the engine is still running when the Fail to stop timer
78

expires, then the module will display:NOTE:- Fail to Stop could indicate a faulty oil pressure sender - If engine is at rest check oil sender wiring
and configuration.
LCD segment will be displayed:LOW FUEL LEVEL. If the fuel level detected by the fuel level sender falls below the low fuel
level setting, a warning will occur.
The
ANALOGUE PRE-ALARMS
The following alarms are termed pre-alarms as they pre warn the operator of a potentially more
serious alarm condition. For instance, if the engine temperature rises past the pre alarm level, a
warning condition will occur to notify the operator. If the temperature falls below this level, then
the alarm ceases, and the set will continue to run as normal. However if the temperature
continues to rise until the coolant temperature trip point is reached, the warning is escalated and
a high coolant temperature shutdown is initiated.
During a pre-alarm condition, the warning symbol
is displayed on the LCD display, along
with the appropriate icon:
low oil pressure pre-alarm setting level after the Safety On timer has expired, a warning will
occur.
The
exceeded the high engine temperature pre-alarm setting level after the Safety On timer has
expired, a warning will occur.
The
OVERSPEED, if the engine speed exceeds the pre-alarm trip a warning is initiated.
The
Overspeed is not delayed, it is an immediate warning.
UNDERSPEED, if the engine speed falls below the pre-set pre-alarm after the Safety On timer
has expired, a warning is initiated.
The
excess of the pre-set pre-alarm, a warning is initiated.
The
Generator High Frequency is not delayed, it is an immediate warning.

79

the pre-set pre-alarm after the Safety On timer has expired, a warning is initiated.
The
the pre-set trip a shutdown is initiated.
The
High voltage is not delayed, it is an immediate shutdown.
below the pre-set pre-alarm after the Safety On timer has expired, a warning is initiated.
The
CAN ECU ERROR If the module is configured for J1939 operation and receives an error
message from the engine control unit, Can ECU fail is shown on the modules display and a
warning alarm is generated. Usually, an associated alarm code is also displayed, detailing the
exact alarm detected. For details on these code meanings, refer to the ECU instructions
provided by the engine manufacturer.
HIGH CURRENT WARNING ALARM

the pre-set trip a warning is initiated.
The
If this high current condition continues for an excess period of time, then the alarm is escalated
to a shutdown condition. For further details of the high current alarm, please see High Current
Shutdown Alarm.
SHUTDOWNS
In the event of a shutdown alarm the LCD will display:(flashing).
The appropriate icon will also be displayed flashing
NOTE:- The alarm condition must be rectified before a reset will take place. If the alarm
rest). Any subsequent warnings or shutdowns that occur will be displayed steady, therefore only
the first-up shutdown will appear flashing.
made a shutdown will be initiated.
The
80

Secondly it removes the +ve DC supply from both the Fuel Solenoid and Starter Solenoid.
The
NOTE:- The Emergency Stop +Ve signal must be present otherwise the unit will
shutdown.
The
The
OVERSPEED, if the engine speed exceeds the pre-set trip a shutdown is initiated.
The
Overspeed is not delayed, it is an immediate shutdown.
NOTE:-During the start-up sequence the overspeed trip logic can be configured to allow an
extra trip level margin. This is used to prevent nuisance tripping on start-up - Refer to the 5200
series configuration software manual under heading Overspeed Overshoot for details.
expired, a shutdown is initiated.
The

excess of the pre-set trip a shutdown is initiated.
The
Generator High Frequency is not delayed, it is an immediate shutdown.

the pre-set trip after the Safety On timer has expired, a shutdown is initiated.
The
the pre-set trip a shutdown is initiated.
The
High voltage is not delayed, it is an immediate shutdown.
below the pre-set trip after the Safety On timer has expired, a shutdown is initiated.
The
pressure sender (open circuit) a shutdown is initiated. The LCD will indicate:(Steady) (And ----- on the engine oil pressure instrument). Sender failure is not delayed,
81

LCD segment will be displayed:LOSS OF SPEED SIGNAL, if the speed sensing signal is lost during cranking, a shutdown is
initiated.
The
icon will illuminate. (Steady) (And ----- on the engine RPM instrument).
NOTE:- This will only occur if the speed sensing signal is lost during cranking or during the safety on timer. If
the signal is lost during normal operation the Generator will shutdown with an Under-speed alarm.
CAN DATA FAIL If the module is configured for J1939 operation and does not detect
data on the engine CANbus datalink, a shutdown will occur and Can data fail is shown on the
modules display
CAN ECU FAIL If the module is configured for J1939 operation and receives a fail
message from the engine control unit, the engine is shutdown and Can ECU fail is shown on
the modules display. Usually, an associated failure code is also displayed, detailing the exact
failure detected. For details on these code meanings, refer to the ECU instructions provided by
the engine manufacturer.
HIGH CURRENT SHUTDOWN ALARM

the pre-set trip a warning is initiated. This warning will continue for a period of time depending
upon the level of overload that the generator is subjected to, and the configuration setting for
Generator High Current in the 5200 series configuration software.
For instance the factory default settings for Generator High Current allow for a loading of the
generator to 110% for one hour. That is to say if the generator load level exceeds the trip point
by 10%, a warning alarm will occur while the overload condition exists. If the load level does not
drop to normal levels within one hour, the set is stopped, the 5220 module displaying either
shutdown alarm or electrical trip alarm depending upon module configuration.
Additionally, the
NOTE:- Higher overload levels will result in a faster acting shutdown condition. For instance
with the factory default configuration, an overload level twice that of the trip level ( typically
200%) will result in a Generator High Current shutdown condition after 36 seconds.
For details of the relationship between the overload and the shutdown time, please see the
Appendix section of this manual.
ELECTRICAL TRIPS
the electrical trip condition the module will de-energise the Close Generator Output to remove
allow the engine to cool off-load before shutting down the engine. The alarm must be accepted
82

In the event of an electrical trip alarm the
timer the warning symbol
icon will illuminate. Additionally, During the cooling
is displayed followed by the flashing shutdown symbol
when the cooling timer has expired.

appropriate LCD segment will be displayed:GENERATOR HIGH CURRENT. If the module detects a generator output current in excess of
the pre-set trip a warning is initiated.
The
If this high current condition continues for an excess period of time, then the alarm is escalated
to either a shutdown or electrical trip condition (depending upon module configuration). For
further details of the high current alarm, please see High Current Shutdown Alarm.
5.6 OPERATION (FOR PLC-55X SERIES)

NORMAL MANUAL OPERATION
Operation
To initiate a start sequence, press the Manual
push-button.
Detail
The LED above the button will illuminate and the LCD MANUAL MODE
display will briefly indicate:
Operation
Detail
The LED above the button will illuminate and the LCD GENERATOR AT REST
display will then indicate:
Then, press and hold the START push-button, once
the module has commenced the start sequence the
button may then be released.
(However, it is
possible to configure the module such the start-button
must be held pressed to maintain engine cranking
until disconnect speed is reached - Refer to your
configuration Source)
The LED above the button will illuminate and the LCD START
display will briefly indicate:
If the pre-heat output option is configured, the PRE-HEATING
Pre-heat timer is then initiated, and the auxiliary 00:09
output selected is energised.
After the pre-heat timer has expired the module will PRE-HEATING
de-energise the pre-heat output and commence 00:00
engine starting; the following sequence occurs.
83

The Fuel Solenoid is energised, then after a 1 FUEL ON
second delay the Starter Motor is engaged
The engine is cranked for the duration of the crank CRANKING ATTEMPT.1
00:08
timer
can be used for terminating cranking, along with options of Charge alternator voltage and oil
pressure.
If a Magnetic Pick-up is utilised it is also possible to configure the module so that if the starter
motor fails to engage on the first attempt, the starter relay will be de-energised and the a second
attempt to engage will be made. For further details on this function please refer to the P810 for
Windows configuration manual.
Operation
Should the engine not fire on the first attempt and the
crank timer expires, the module will rest the starter for
the duration of the crank rest timer.
Once this has expired the module will once again
attempt to start the engine.
Detail
CRANK
REST.
1
00:04
CRANKING ATTEMPT 2
00:07
This will be repeated until either the engine fires or the pre-set number of attempts to start have
been completed
Operation
Detail
In this instance the module will indicate a Fail to SHUTDOWN
start alarm.
FAILED TO START
NOTE:- Should a Fail to start alarm occur
the module must be placed into STOP/RESET
mode by pressing the STOP/RESET
PUSHBUTTON. Determine why the engine
failed to fire before making any further attempts to start.
If the engine start is successful, the following sequence occurs:-
Operation
Detail
After the starter motor has disengaged, the Safety WAITING FOR SAFETY ON
On timer is activated.
00:08
This timer allows Oil Pressure, High Engine Temperature, Underspeed, Undervolts, Charge Fail
and any delayed Auxiliary fault inputs to stabilise without triggering the fault.
Operation
84
Detail

Once the engine is running and the Safety on GENERATOR
timer has expired, full fault protection is made IN MANUAL
available.
Pressing the STOP/RESET PUSHBUTTON will
de-energise the Fuel Solenoid and bring the
engine to rest.
AVAILABLE
The LCD screen will acknowledge the button STOP/RESET

press
While the engine runs down the module will start STOPPING
00:24
its Fail to stop timer.
If the engine is still running when the Fail to stop SHUTDOWN
FAIL TO STOP
Timer expires the module will alarm.
NOTE: The Load Transfer Output will not normally become active during a Manual start.
However, if the Remote Start input is activated once the engine is running then the Load
Transfer Output will be activated and remain active until the engine is stopped.
AUTOMATIC OPERATION ((FOR PLC 5110, 5220, 560 SERIES) Mains Failure/
REMOTE)
Operation
If the module is placed in AUTO mode by
pressing the AUTO PUSHBUTTON, it will
monitor the auxiliary inputs for a REMOTE
START signal. In addition the module will
monitor the incoming AC mains supply.
Detail
AUTO
The LCD display will briefly indicate
AUTO MODE
The LCD display will then indicate
GENERATOR AT REST
Should the REMOTE START signal be detected, or the Mains supply become outside of
acceptable limits, the following sequence will occur
The module will start its Start Delay timer,
this is used to ensure that the start event is START DELAY
really required and not just a momentary 00:09
transient signal.
Once this timer has expired the module will continue with its normal start sequence as detailed
below. Should the remote start signal be removed or the mains return to within limits during
either the start delay timer or pre-heat timer, the module will terminate its start sequence and
return to its standby AUTO state until such time as a start is signalled again.
85

Operation
If the pre-heat output option is configured,
then the pre-heat timer is then initiated, and
the auxiliary output selected is energised.
After the pre-heat timer has expired the
module will de-energise the pre-heat output
and commence engine starting; the following
sequence occurs.
Detail
PRE-HEATING
00:09
PRE-HEATING
00:00
The Fuel Solenoid is energised, then after a FUEL ON

1 second delay the Starter Motor is engaged
The engine is cranked for the duration of the CRANKING ATTEMPT.1
00:06
crank timer
can be used for terminating cranking, along with options of Charge alternator voltage and oil
pressure.
If a Magnetic Pick-up is utilised it is also possible to configure the module so that if the starter
motor fails to engage on the first attempt, the starter relay will be de-energised and the a second
attempt to engage will be made. For further details on this function please refer to the P810
For Windows configuration manual.
Operation
Detail
Should the engine not fire on the first attempt and CRANK REST.
the crank timer expires, the module will rest the 00:04
starter for the duration of the crank rest timer.
Once this has expired the module will once again CRANKING ATTEMPT 2
00:07
attempt to start the engine.
This will be repeated until either the engine fires or the pre-set number of attempts to start have
been completed
Operation
Detail
In this instance the module will indicate a Fail to SHUTDOWN
start alarm.
FAIL TO START
NOTE:- Should a Fail to start alarm occur the module must
be placed into STOP/RESET mode by pressing the
STOP/RESET PUSHBUTTON. Determine why the engine
failed to fire before making any further attempts to start.
If the engine start is successful, the following sequence occurs:Operation

Detail
After the starter motor has disengaged, the Safety WAITING FOR SAFETY
On timer is activated.
ON
00:09
86

This timer allows Oil Pressure, High Engine Temperature, Underspeed, Undervolts, Charge Fail
and any delayed Auxiliary fault inputs to stabilise without triggering the fault. Once the engine
is running and the safety on timer has expired, full fault protection is made available.
Operation
Detail
Once the generator is running at the correct speed WARMING UP
and up to voltage the Warm-up timer is then
initiated
00:08
Should the remote start signal be removed or the mains return to within limits during either of
the cranking or warm-up timers, the module will terminate its normal auto start sequence will
initialise its Cooling Timer and eventually return to its standby AUTO state until such time as a
start is signalled again.
Operation
Detail
After the warm-up timer has expired the module will GENERATOR AVAILABLE
open the mains contactor relay.
IN AUTO
After a short transfer delay to allow the mains GENERATOR AVAILABLE
contactor to open the generator contactor will
close.
The generator in now up and running and is selected to supply the load.
Operation
Detail
Should the remote start signal be removed, or the GENERATOR AVAILABLE
mains return the module will first initiate a return
00:06
timer to ensure that it is safe to stop the generator.
Should the remote start input become active again or the mains fall outside of acceptable limits
again within this time the module will continue to run the generator on load and ignore the
fluctuating remote start signal or mains supply until such time as it remains in-active for the
duration of the stop delay timer.
Once the return timer has expired, the module will de-energise the Load Transfer output.
Operation
Detail
The module will then commence its cooling timer, COOLING DOWN
this allows the engine to run off load to ensure that
it has adequately cooled before being brought to a
standstill.
Once the cooling timer has expired the module will STOPPING
de-energise the fuel solenoid and the engine will
be brought to rest.
2:34
00:27
If the engine is still running when the Fail to stop SHUTDOWN

Timer expires the module will alarm.
FAIL TO STOP
Should the engine come to rest within the time GENERATOR AT REST
allow by the fail to stop timer the screen will revert
to
87

Note:- It is possible that the module has been configured to perform regular exercise runs
automatically. This may be used to exercise the engine periodically in standby applications or to
assist in peak-lopping arrangements. Therefore even though the remote start input is not active
and the mains supply is healthy, it is possible that if the system is in the Auto mode the engine
may start unexpectedly if a scheduled run is configured to occur.
WARNING!:- Before commencing work on the generating set it is important to take steps to
ensure that a scheduled run cannot start the engine unexpected. The system should at a
minimum be taken out of the Auto mode and Stop selected. Depending on the nature of the
work to be performed - further steps to ensure safety while working may be necessary.
PROTECTIONS
The Audible Alarm will sound.
This can be
silenced by pressing the Mute button
The Common alarm LED will illuminate(Warning =
Steady, Shutdown = Flashing [steady when
Muted])
The LCD display will jump from the Information
page to display the Alarm Page and the LED above
the page icon will illuminate
ALARM
SHUTDOWN
LOW OIL PRESSURE
The LCD will the display

Followed by the appropriate alarm text
If no alarms are present the LCD will display the following message and will then return to the
Information Display page;
NO ALARM PRESENT
The LCD will display multiple alarms E.g. High Engine Temperature shutdown, Emergency
Stop and Low Coolant Warning alarms have been triggered. These will automatically scroll
round in the order that they occurred;
ALARM
SHUTDOWN
HIGH ENGINE TEMP
SHUTDOWN
EMERGENCY STOP
WARNING
LOW COOLANT LEVEL
It is also possible to manually scroll to display the different alarms
88

Initial display
>>>>>
Pressing the DOWN button the LCD
will then show
Pressing the UP button the LCD will
then showetc, etc, etc.
ALARM
SHUTDOWN
HIGH ENGINE TEMP
SHUTDOWN
EMERGENCY STOP
WARNING
LOW COOLANT LEVEL
ALARM
WARNING
LOW COOLANT LEVEL
ALARMS
If the module is operating in the normal INFORMATION PAGE display any alarm condition will
automatically be displayed.
Jumps to >>>
i
If the user is viewing instrumentation, e.g.
Then the alarm page will not automatically be displayed and must be viewed by the operator.
To view an alarm operate the page button to move to the Alarm
page.
To clear an alarm the original triggering conditions must be

removed before the alarm can be reset. Alarms are reset by
pressing the Stop/Reset pushbutton.
WARNINGS
terminal on the auxiliary charge alternator, the module will display WARNING CHARGE ALT
FAILURE on the LCD. The COMMON ALARM LED will also illuminate.
BATTERY LOW VOLTAGE, if the module detects that the plant DC supply has fallen below the
low volts setting level , the module will display WARNING LOW BATTERY VOLTAGE on the
LCD. The COMMON ALARM LED will also illuminate.
BATTERY HIGH VOLTAGE, if the module detects that the plant DC supply has risen above the
high volts setting level , the module will display WARNING HIGH BATTERY VOLTAGE on the
89

LCD.
The COMMON ALARM LED will also illuminate.
OIL PRESSURE SENDER/SWITCH, the module can be configured to only attempt to crank the
engine if the Oil Pressure is initially low, (engine at rest, not running). The module will display
FAIL TO STOP on the LCD. The COMMON ALARM LED will also illuminate.
low oil pressure pre-alarm level after the Safety On timer has expired, a warning alarm will
occur. The LCD will indicate WARNING LOW OIL PRESSURE and the COMMON ALARM
LED will illuminate.
HIGH ENGINE TEMPERATURE, if the module detects that the engine coolant temperature has
exceeded the high engine temperature pre-alarm level after the Safety On timer has expired, a
warning alarm will occur. The LCD will indicate WARNING HI COOLANT TEMP. and the
COMMON ALARM LED will illuminate.
OVERSPEED, if the engine speed exceeds the pre-alarm level a warning is initiated. The LCD
will
indicate WARNING OVERSPEED and the COMMON ALARM LED will illuminate.
UNDERSPEED, if the engine speed falls below the pre-alarm level after the Safety On timer has
expired, a warning alarm is initiated. The LCD will indicate WARNING UNDERSPEED and the
GENERATOR HIGH FREQUENCY, if the module detects a generator output frequency in
excess of the pre-alarm level a warning is initiated. The LCD will indicate WARNING GEN
HIGH FREQUENCY and the COMMON ALARM LED will illuminate.
the pre-alarm level after the Safety On timer has expired, a warning is initiated. The LCD will
indicate WARNING GEN LOW FREQUENCY and the COMMON ALARM LED will illuminate.
GENERATOR HIGH VOLTAGE, if the module detects a generator output voltage in excess of
the pre-alarm level a warning is initiated. The LCD will indicate WARNING GEN HIGH
VOLTAGE WARNING and the COMMON ALARM LED will illuminate.
GENERATOR LOW VOLTAGE, if the module detects a generator output voltage below the
pre-alarm level after the Safety On timer has expired, a warning is initiated. The LCD will
indicate WARNING GEN LOW VOLTAGE WARNING and the COMMON ALARM LED will
illuminate.
, if the module detects a generator phase rotation
MAINS PHASE SEQUENCE WRONG
error a warning is initiated. The LCD will indicate MAINS PHASE SEQ WRONG and the
MAINTENANCE DUE ALARM, if the engine exceed the allowed running hours or time between
periodic maintenance a warning is initiated. The LCD will indicate MAINTENANCE NOW DUE
and the COMMON ALARM LED will illuminate. To clear the alarm a MAINTENANCE RESET
90

must be performed (refer to config source or P810 for Windows software manual for more
detail)
LCD message will be displayed and the COMMON ALARM LED will illuminate.
SHUTDOWNS
Shutdowns are latching and stop the Generator. The alarm must be accepted and cleared, and
the fault removed to reset the module.
NOTE:- The alarm condition must be rectified before a reset will take place. If the alarm
Pressure alarm and the like, as the oil pressure will be low with the engine at rest).
FAIL TO START, if the engine does not fire after the pre-set number of attempts has been made
a shutdown will be initiated. The LCD will indicate SHUTDOWN FAIL TO START and the
COMMON ALARM and LED will flash.
Secondly it removes the +ve DC supply from both the Fuel Solenoid and Starter Solenoid. The
LCD will indicate SHUTDOWN EMERGENCY STOP and the COMMON ALARM LED will
flash.
NOTE:- The Emergency Stop +Ve signal must be present otherwise the unit will shutdown
The LCD will indicate SHUTDOWN LOW OIL PRESSURE and the COMMON ALARM LED
will flash.
HIGH ENGINE TEMPERATURE, if the module detects that the engine coolant temperature has
shutdown will occur. The LCD will indicate SHUTDOWN HIGH COOLANT TEMP and the
COMMON ALARM LED will flash.
OVERSPEED, if the engine speed exceeds the pre-set trip a shutdown is initiated. The LCD will
indicate SHUTDOWN OVERSPEED and the COMMON ALARM LED will flash. Overspeed is
not delayed, it is an immediate shutdown.
NOTE:-However during the start-up sequence the overspeed trip logic can be configured to
allow an
extra trip level margin, this is used to prevent nuisance tripping on start-up - Refer to the P810
for Window Configuration Manual under heading Overspeed Overshoot for details.
91

expired, a shutdown is initiated. The LCD will indicate SHUTDOWN UNDERSPEED and the
GENERATOR HIGH FREQUENCY, if the module detects a generator output frequency in
excess of the pre-set trip a shutdown is initiated. The LCD will indicate SHUTDOWN GEN
HIGH FREQUENCY and the COMMON ALARM LED will flash. High frequency is not delayed,
the pre-set trip after the Safety On timer has expired, a shutdown is initiated. The LCD will
indicate GEN LOW FREQUENCY and the COMMON ALARM LED will flash.
GENERATOR HIGH VOLTAGE, if the module detects a generator output voltage in excess of
the pre-set trip a shutdown is initiated. The LCD will indicate GEN HIGH VOLTAGE and the
COMMON ALARM LED will flash. High voltage is not delayed, it is an immediate shutdown.
GENERATOR LOW VOLTAGE, if the module detects a generator output voltage below the
pre-set trip after the Safety On timer has expired, a shutdown is initiated. The LCD will indicate
GEN LOW VOLTAGE and the COMMON ALARM LED will flash.
pressure sender (open circuit) a shutdown is initiated. The LCD will indicate OIL PRESS
SENDER FAULT and the COMMON ALARM LED will flash. Sender failure is not delayed, it is
an immediate shutdown.
, if the module detects a generator earth fault current in
GENERATOR EARTH FAULT
excess of the pre-set trip a shutdown is initiated. The LCD will indicate GEN EARTH FAULT
and the COMMON ALARM LED will flash.
GENERATOR PHASE SEQUENCE WRONG
rotation error
, if the module detects a generator phase
a shutdown is initiated. The LCD will indicate GEN PHASE SEQ WRONG and the COMMON
ALARM LED will flash.
AUXILIARY INPUTS, if an auxiliary input has been configured as a Shutdown the appropriate
LCD message will be displayed and the COMMON ALARM LED will flash.
= Enhanced Instrumentation Versions only.
ELECTRICAL TRIPS
the electrical trip condition the module will de-energise the Load Transfer Output to remove the
load from the generator. Once this has occurred the module will start the Cooling timer and
allow the engine to cool, off-load before shutting down the engine. The alarm must be accepted
92

GENERATOR REVERSE POWER
, if the module detects a generator reverse power current
in
excess of the pre-set trip a shutdown is initiated. The LCD will indicate GEN REVERSE
POWER and the COMMON ALARM LED will flash.
GENERATOR OVER CURRENT, if the module detects a generator output current in excess of
the pre-set trip a shutdown is initiated. The LCD will indicate GEN OVER CURRENT and the
GENERATOR SHORT CIRCUIT, if the module detects a generator fault current in excess of the
pre-set trip a shutdown is initiated. The LCD will indicate GEN SHORT CIRCUIT and the
AUXILIARY INPUTS, if an auxiliary input has been configured as an Electrical Trip the
appropriate LCD message will be displayed and the COMMON ALARM LED will illuminate.
= Enhanced Instrumentation Versions only.
PRE-ALARMS AND OPTIONS

During module configuration it is possible to select pre-alarm levels for all of the above
shutdowns and electrical trips to give a warning that the trip value is being approached. This
allows the operator to take steps to prevent the shutdown from ultimately occurring by rectifying
the triggering condition.
If the module is fitted with the optional RS232 communication board, then the following alarm is
available:MODEM POWER FAULT, if the module detects a modem supply current in excess of 350mA
warning is initiated. The LCD will indicate MODEM POWER FAULT and the COMMON
ALARM LED will illuminate. The power supply to the modem will be removed until the alarm is
reset.
If the module is fitted with the option of Check Sync or Auto Sync , then the following alarm is
available:FAILED TO SYNCHRONISE, if the module cannot synchronise within the timer allowed by the
Synchronising timer a warning is initiated. The LCD will indicate FAILED TO SYNC and the
SYNCHRONISING NOTES
CHECK SYNC VERSIONS
A special version of the module provides the function of Check Sync relay and Synchroscope
display. The module will control the operation of the load switching device to allow parallel
operation with the mains supply only when the two supplies are in Sync. These functions can
93

be used to provide manual Peak lopping/ Peak shaving and short duration no-break or
bump-less transfers back to the mains supply following a mains failure.
AUTO SYNC VERSIONS
A special version of the module provides the function of Automatic synchronising. The module
features all the functions associated with the Check sync version and in addition it provides
control signals to the Engine Governor and the Alternator AVR to control the speed and voltage
output from the generating set.
These functions can be used to provide peak lopping/ peak shaving (without load share control)
and true no-break or bump-less transfers back to the mains supply following a mains failure.
The Auto-sync 55x module provides the ability to control the generator by adjusting the speed
(frequency) and voltage being output. Several method of providing this control are available.
The following pages give typical examples of interfacing with the engine governor and alternator
AVR.
Refer to the P810 software manual for further details.
NOTE:- To verify if your particular 55x module has any of the above special features fitted
please refer to page 26 for the Power Up LCD display information.
1) GOVERNOR AND AVR CONTROL USING INTERNAL RELAYS DIRECTLY.
This scheme uses the 55x modules own internal relays to control the speed and voltage output.
It is only possible to use this system of control if the Governor or AVR in question supports
speed up/speed down and volts up/volts down via control input.
CAUTION!:- It is essential to use only the modules own internal relays for this type of control
(Auxiliary outputs 1-4). Use of the 157 relay expansion module outputs to do the same could
result in instability due to the much slower response of the 157 expansion modules control
relays.
TYPICAL CONNECTIONS
(See Note 1)
Interposing
Relay
555 Module
Governor
Aux 1
Speed Up
+Ve
Aux 2
(See Note 1)
Interposing
Relay
(See Note 1)
Interposing
Relay
Speed Down
Aux 3
Aux 4
Actuator
AVR
Volts Up
(See Note 1)
Interposing
Relay
Volts Down
To Alternator
94

Note 1:- Interposing relay should connect to recommended polarity and voltage for
Governor/AVR input. Refer to Governor or AVR manufacturer for details.
MODULE CONFIGURATION SETTING FOR 555 AUXILIARY RELAYS
Aux 1
Aux 2
Aux 3
Aux 4
Energise
Energise
Energise
Energise
Speed Raise Relay

Speed Lower Relay
Voltage Raise Relay
Voltage Lower Relay
2) GOVERNOR AND AVR CONTROL USING INTERNAL RELAYS TO DRIVE

MOTORISED/ELECTRONIC POTENTIOMETER.
This scheme uses the 55x modules own internal relays to control the speed and voltage output
via an external motorised or electronic potentiometer. It is only possible to use this system of
control if the Governor or AVR in question supports speed or voltage control via an external
potentiometer.
CAUTION!:- It is essential to use only the modules own internal relays for this type of
control (Auxiliary outputs 1-4). Use of the 157 relay expansion module outputs to do the same
could result in instability due to the much slower response of the 157 expansion modules control
relays.
TYPICAL CONNECTIONS
(See Note 1)
Interposing
Relay
555 Module
Potentiometer
Governor
(See Note 2)
Aux 1
Resistance Up
+Ve
Aux 2
(See Note 1)
Interposing
Relay
(See Note 1)
Interposing
Relay
Resistance Down
Speed Trim
Aux 3
Aux 4
Actuator
Potentiometer
(See Note 2)
AVR
Resistance Up
(See Note 1)
Interposing
Relay
Resistance Down
Volts Trim
To Alternator
Note 1:- Interposing relay should connect to recommended polarity and voltage for
potentiometer input. Refer to potentiometer manufacturer for details.
Note 2:- The Potentiometer output should be a suitable resistance as recommended by the
Governor/AVR manufacturer.
95

Aux 1
Aux 2
Aux 3
Aux 4
Energise
Energise
Energise
Energise
Speed Raise Relay

Speed Lower Relay
Voltage Raise Relay
Voltage Lower Relay
3) GOVERNOR AND AVR CONTROL USING P122 DIGITAL RESISTANCE MODULES

This scheme uses the 55x modules to control the speed and voltage output via the P122
(Governor and AVR) digital resistance boxes. This devices gives a simple modular approach
to solving the problem of interfacing to the Governor and AVR. This also negates the need to
fit interposing relays and motorised potentiometers and have the additional benefit of leaving
the modules own internal relays available for other functions. It is only possible to use this
system of control if the Governor or AVR in question supports speed or voltage control via an
external potentiometer.
CAUTION!:- When used in conjunction with the P122 Digital Resistance Modules, only
P157 Relay Expansion modules with Part Number 81xxxxx MUST be used. The digital
resistance requires a different set of data commands to operate and the 55x module will change
the data output by the 808 port to suit the P122 when selected. The older P157 relay modules
(Part No. 80xxxxx) will only function if the P122 module is not configured for use by the 555.
CAUTION!:- When used in conjunction with the P122 Digital Resistance Modules, only
P548 Relay Expansion modules with Part Number 81xxxxx MUST be used. The digital
resistance requires a different set of data commands to operate and the 55x module will change
the data output by the 808 port to suit the P122 when selected. The older P548 relay modules
(Part No. 80xxxxx) will only function if the P122 module is not configured for use by the 555.
TYPICAL CONNECTIONS
555 Module
Aux 1
+Ve
P122 Digital
Resistance
Governor
AVR
Governor
Speed Trim
Aux 2
To Interface/Exp.
Aux 3
To Controller
Aux 4
Actuator
P122 Digital
Resistance
AVR
AVR
Governor
Volts Trim
To Interface/Exp.
P808 Port on 555
To Controller
To Alternator
96

CAUTION :
The P122 digital resistance output should be a suitable resistance as recommended by the
Governor/AVR manufacturer. This should be specified on ordering from DSE.
The P122 digital resistance has a selector switch for AVR or Governor connection, this should
be set to the correct position, otherwise auto-sync control will not be possible. Refer to the
diagram above.
AUTO-SYNC CONTROL WILL NOT BE POSSIBLE.
REFER TO THE DIAGRAM ABOVE.
4) DIRECT GOVERNOR CONTROL AND AVR CONTROL USING P122 DIGITAL

RESISTANCE MODULES
This scheme uses a mixture of the possible control options from the 55x
modules to control the speed and voltage output via the P122 (Governor and
AVR) digital resistance boxes. This method gives a cost effective solution to
interfacing to the Governor and AVR. It is only possible to use this system of control if the
Governor supports speed up/down inputs and the AVR in question supports voltage control via
an external potentiometer.
When used in conjunction with the P122 Digital Resistance Modules, only
P157 Relay Expansion modules with Part Number 81xxxxx MUST be used.
The digital resistance requires a different set of data commands to operate
and the 55x module will change the data output by the 808 port to suit the P122 when selected.
The older P157 relay modules (Part No. 80xxxxx) will only function if the P122 module is not
configured for use by the 555.
When used in conjunction with the P122 Digital Resistance Modules, only P548 Relay
Expansion modules with Part Number 81xxxxx MUST be used. The digital resistance requires
a different set of data commands to operate and the 55x module will change the data output by
the 808 port to suit the P122 when selected. The older P548 relay modules (Part No. 80xxxxx)
will only function if the P122 module is not configured for use by the 555.
TYPICAL CONNECTIONS
(See Note 1)
Interposing
Relay
555 Module
Governor
Aux 1
Speed Up
+Ve
Aux 2
(See Note 1)
Interposing
Relay
Speed Down
Aux 3
Aux 4
Actuator
P122 Digital
Resistance
AVR
AVR
Governor
Volts Trim
To Interface/Exp.
P808 Port on 555
To Controller
To Alternator
97

The P122 digital resistance output should be a suitable resistance as
recommended by the AVR manufacturer. This should be specified on
ordering from DSE. The P122 digital resistance selector switch for AVR or Governor
connection, should be set to the correct position. Refer to the diagram above.
Interposing relay should connect to recommended polarity and voltage for
Governor input. Refer to Governor manufacturer for details.

Aux 1
Aux 2
Energise
Energise
Speed Raise Relay

Speed Lower Relay
SYNCHROSCOPE OPERATION (IF FITTED)

Display
Hz +2.9
Hz +0.9
Hz -0.2
Hz -0.2
98
V +0.2
V +0.2
V +0.2
V +0.2
Detail
Initial stage of Synchronising display will only show the
difference between the Mains Supply and the Generator
Output. Here the display is showing a frequency
mis-match of +2.9Hz - The gen-set frequency is too
high and should be reduced (indicated by the arrow).
The voltage is +0.2 volts high, but is within the limits set
for synchronising.
Once the difference between the Mains supply and the
Generator output has been reduced the Synchroscope
display will become active. The moving bar will roll
from left to right or right to left depending on the
mis-match between the Mains supply and the generator
output. The area in the centre of the scope indicates
the set limits for synchronising to occur.
Synchronising will only occur when both the Frequency
and the voltage differences are within acceptable limits Indicated by Tick marks on the top of the display.
Then the moving bar display will show the phase
difference. The engine speed should be adjusted until
the moving bar enters the centre of the scope.
Once the Mains and the generator are synchronised the
moving bar will be in the centre of the scope and the bar
will be locked into the synchronising window. While
the bar is locked the module will initiate a breaker close
to load the generator onto the Mains.
Should
synchronism be broken the moving bar will pass out of
the synchronising window and the locked indication will
clear.

SECTION 6
FAULT FINDING
Unit is inoperative
Check the battery and wiring to the unit. Check the DC supply.
Check the DC fuse
Unit shuts down
Check DC supply voltage is not above 35 Volts or below 9Volts

Check the operating temperature is not above 55 C. Check the DC
fuse.
Unit locks out

Emergency Stop
on
If an Emergency Stop Switch is not fitted, ensure that a positive is

connected to the Emergency Stop input. Check emergency stop
switch is functioning correctly. Check Wiring is not open circuit.
Ensure that Magnetic pick-up screen is only connected at one end, if

Intermittent Magnetic
connected at both ends, this enables the screen to act as an aerial
Pick-up sensor fault
and will pick up random voltages.
Check engine oil pressure. Check oil pressure switch/sender and
Low oil Pressure fault
wiring. Check configured polarity (if applicable) is correct (i.e.
operates after engine
Normally Open or Normally Closed) or that sender is compatible
has fired
with the Module and is correctly configured.
High
engine
Check engine temperature. Check switch/sender and wiring. Check
temperature
fault
configured polarity (if applicable) is correct (i.e. Normally Open or
operates after engine
Normally Closed).
has fired
Shutdown
operates
fault Check relevant switch and wiring of fault indicated on LCD display.
Check configuration of input
Warning fault operates
Check relevant switch and wiring of fault indicated on LCD display.

Check configuration of input.
Fail
to
Start
is
Check wiring of fuel solenoid. Check fuel. Check battery supply.
activated after preset
Check attery supply is present on the Fuel output of the module.
number of attempts to
Check the speed sensing signal is present.
start
Continuous starting of
Check that there is no signal present on the Remote Start input.
generator when in
Check configured polarity is correct
AUTO
Generator fails to start Check Start Delay timer has timed out. If remote start fault, check
on receipt of Remote signal is on Remote Start input. Confirm input is configured to be
Start signal
used as Remote Start.
99

Pre-heat inoperative
Check wiring to engine heater plugs. Check battery supply. Check

battery supply is present on the Pre-heat output of module. Check
pre-heat has been selected in your configuration.
Starter
inoperative
Check wiring to starter solenoid. Check battery supply. Check

battery supply is present on the Starter output of module. Ensure
that the Emergency Stop input is at +Ve
motor
Engine
runs
but Check Warm up timer has timed out. Ensure generator load inhibit
generator will not take signal is not present on the module inputs. Check connections to the
load
switching device.
NOTE: The above fault finding is provided as a guide check-list only. As it is possible for the
module to be configured to provide a wide range of different features always refer to the source
of your module configuration if in doubt.
100
REMARK
Please contact us if theres any question.

Powerlink Machine Company Limited
Dongguan Factory Address: Yangwu Industrial Park, Dalingshan Town,
Dongguan City, Guangdong Province, China
Tel: +860769 85615178
Fax: +860769 83359743
Shanghai Factory Address: No.666 Minshen Road,
Songjiang industrial Park, Shanghai provinceChina
TEL086-021-57684476 FAX086-021-57684471
E-mail: [email protected]
Http: //www.powerlinkgenerators.cn

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FOREWORD

Generating Set Data

Power (kva)................................ ...

2006POWERLINK MACHINE COMPANY

RECEIVING & INSTALLATION ......................................................................... 7

3.1 INTRODUTION & OVERVIEW ....................................................................................................8

SECTION 4 CONTROLPANEL INTRODUCTION ......................................................................33

SECTION 5 OPERATION ............................................................................................................53

FAULT FINDING .................................................................................... 99

APPENDIX TYPICAL WIRING DIAGRAM

Installation Operation & Maintenance

SECTION 1 GENERAL SAFETY INFORMATION

CLARIFICATION OF NOTATION USED

Installation Operation & Maintenance

SAFETY INSTRUCTIONS FOR INSTALLATION,

Check that all necessary or available guards are correctly fitted.

FUEL & OIL

Rectify any fuel or lubricating oil leaks immediately observed.

Installation Operation & Maintenance

Only qualified electricians should be allowed to work on electrical equipment. All

Installation Operation & Maintenance

Always wear protective glasses and protective shoes when working.

Rotating parts can cause cuts, mutilation or strangulation.

Installation Operation & Maintenance

SYMBOL MEANINGS ON THE GENERATING SETS

Installation Operation & Maintenance

NO MATCHES OR OPEN FLAMES

CAUTION HAND INJURED

REFER THE MANUAL

Installation Operation & Maintenance

Water tank and radiator

Heat Shield Protection

Warring and notes

Control panel box

Generators base and daily

Alternator brand and notes

Installation Operation & Maintenance

3.1 INTRODUCTION & OVERVIEW

3.2 Mounting Foundation & Mounting

Installation Operation & Maintenance

Typical Mount Design for Stationary Genset Applications

Number of mount locations depends on genset size/weight.

Installation Operation & Maintenance

Mounting the Generator Set

Engine Mounting Guidelines

Installation Operation & Maintenance

Typical Outdoor Considerations:

Typical Indoor Considerations:

Installation Operation & Maintenance

Installation Operation & Maintenance

3.3 Exhaust System

Exhaust System Installation

Installation Operation & Maintenance

Installation Operation & Maintenance

3.4 Fuel System

Fuel System Installation

Installation Operation & Maintenance

Supply Tank Lower than Engine Installation

Installation Operation & Maintenance