PCC 3201 Service Manual

Service Manual
Generator Set
with PowerCommandR 3201 Controller
DFEG
DFEH
DFEJ
DFEK
DQCA
DQCB
DQCC
English 03-2008 960−0521 (Issue 3)

Table of Contents
SECTION TITLE PAGE

IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
1 INTRODUCTION
About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
How To Obtain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2 CONTROL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Control Panel Power On/Off Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Control Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Reading Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Menu Display and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Language/Units Selection Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Engine Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Alternator Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Control Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
History/About Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Parallel Data Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Power Transfer Main/Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Utility (PWR TRAN) Submenus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Status (PWR TRAN) Submenus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Transfer Control (PWR TRAN) Submenu) . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Genset (PWR TRAN) Submenus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
3 CONTROL CALIBRATION AND ADJUSTMENT
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Modifying Setup/Adjust Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Setup Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Governing/Volt Reg Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Customer Faults Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Calibration Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Isolated Bus/Utility Submenus (Paralleling Application) . . . . . . . . . . . . . . 3-7
Isolated Bus Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Utility Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
i
SECTION TITLE PAGE
3 CONTROL CALIBRATION AND ADJUSTMENT (CONT.)
Power Transfer Control Main Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Utility Sensors Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Genset Sensors Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Timers Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Test/Exercise Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Adjust Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Control Box Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Run Relays (K11, K12, K13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Alarm Relay (K16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Magnetic Speed Pickup Unit (MPU) Installation . . . . . . . . . . . . . . . . . . . . 3-26
4 SERVICING THE GENERATOR
Testing the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Generator/PCC Control Isolation Procedure . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Exciter Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Exciter Rectifier Bridge (Rotating Rectifier Assembly) . . . . . . . . . . . . . . . . 4-4
Exciter Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Main Rotor (Generator Field) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Main Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Test the PMG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Generator Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Generator Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Generator Mount Pre-Load Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Aligning Generator with Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
5 ENCLOSURE FUEL TANK SYSTEM (DFEG-EK)
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Fuel Transfer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
External Fuel Fill Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
External Alarm Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Rupture Basin Leak Detect Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
6 ENCLOSURE FUEL TANK SYSTEM (DQCA-CC)
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Fuel Transfer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
External/Internal Alarm Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Rupture Basin Leak Detect Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
7 WIRING DIAGRAMS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
ii
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS − This manual contains EXHAUST GASES ARE DEADLY
important instructions that should be followed during
installation and maintenance of the generator set and • Provide an adequate exhaust system to properly
batteries. expel discharged gases away from enclosed or
sheltered areas and areas where individuals are
Before operating the generator set (genset), read the likely to congregate. Visually and audibly inspect
Operator’s Manual and become familiar with it and the the exhaust daily for leaks per the maintenance
equipment. Safe and efficient operation can be schedule. Make sure that exhaust manifolds are se-
achieved only if the equipment is properly operated cured and not warped. Do not use exhaust gases to
and maintained. Many accidents are caused by failure heat a compartment.
to follow fundamental rules and precautions.
• Be sure the unit is well ventilated.
The following symbols, found throughout this manual,
alert you to potentially dangerous conditions to the oper-
• Engine exhaust and some of its constituents are
known to the state of California to cause cancer,
ator, service personnel, or the equipment.
birth defects, and other reproductive harm.
This symbol warns of immediate
MOVING PARTS CAN CAUSE SEVERE
hazards which will result in severe personal in-
jury or death. PERSONAL INJURY OR DEATH
• Keep your hands, clothing, and jewelry away from
WARNING This symbol refers to a hazard or un-
moving parts.
safe practice which can result in severe person-
al injury or death. • Before starting work on the generator set, discon-
nect battery charger from its AC source, then dis-
CAUTION This symbol refers to a hazard or un- connect starting batteries, negative (−) cable first.
safe practice which can result in personal injury This will prevent accidental starting.
or product or property damage. • Make sure that fasteners on the generator set are
secure. Tighten supports and clamps, keep guards
FUEL AND FUMES ARE FLAMMABLE in position over fans, drive belts, etc.
Fire, explosion, and personal injury or death can result • Do not wear loose clothing or jewelry in the vicinity of
from improper practices. moving parts, or while working on electrical equip-
ment. Loose clothing and jewelry can become
• DO NOT fill fuel tanks while engine is running, un- caught in moving parts.
less tanks are outside the engine compartment.
Fuel contact with hot engine or exhaust is a potential • If adjustment must be made while the unit is run-
fire hazard. ning, use extreme caution around hot manifolds,
moving parts, etc.
• DO NOT permit any flame, cigarette, pilot light,
spark, arcing equipment, or other ignition source DO NOT OPERATE IN FLAMMABLE AND
near the generator set or fuel tank.
EXPLOSIVE ENVIRONMENTS
• Fuel lines must be adequately secured and free of
leaks. Fuel connection at the engine should be Flammable vapor can cause an engine to overspeed and
made with an approved flexible line. Do not use zinc become difficult to stop, resulting in possible fire, explo-
coated or copper fuel lines with diesel fuel. sion, severe personal injury and death. Do not operate a
genset where a flammable vapor environment can be
• Be sure all fuel supplies have a positive shutoff created by fuel spill, leak, etc., unless the genset is
valve. equipped with an automatic safety device to block the air
• Be sure battery area has been well-ventilated prior intake and stop the engine. The owners and operators of
to servicing near it. Lead-acid batteries emit a highly the genset are solely responsible for operating the gen-
explosive hydrogen gas that can be ignited by arc- set safely. Contact your authorized Cummins Power
ing, sparking, smoking, etc. Generation distributor for more information.
LS-16L
iii
ELECTRICAL SHOCK CAN CAUSE • Keep multi-class ABC fire extinguishers handy.
SEVERE PERSONAL INJURY OR DEATH Class A fires involve ordinary combustible materials
such as wood and cloth; Class B fires, combustible
• Remove electric power before removing protective and flammable liquid fuels and gaseous fuels; Class
shields or touching electrical equipment. Use rub- C fires, live electrical equipment. (ref. NFPA No. 10).
ber insulative mats placed on dry wood platforms
over floors that are metal or concrete when around • Make sure that rags or combustible material are not
electrical equipment. Do not wear damp clothing left on or near the generator set.
(particularly wet shoes) or allow skin surface to be
damp when handling electrical equipment. Do not • Make sure generator set is mounted in a manner to
wear jewelry. Jewelry can short out electrical con- prevent combustible materials from accumulating
tacts and cause shock or burning. under or near the unit.
• Use extreme caution when working on electrical
components. High voltages can cause injury or • Remove all unnecessary grease and oil from the
death. DO NOT tamper with interlocks. unit. Accumulated grease and oil can cause over-
heating and engine damage which present a poten-
• Follow all applicable state and local electrical tial fire hazard.
codes. Have all electrical installations performed by
a qualified licensed electrician. Tag and lock open • Keep the generator set and the surrounding area
switches to avoid accidental closure. clean and free from obstructions. Remove any de-
• DO NOT CONNECT GENERATOR SET DIRECT- bris from the set and keep the floor clean and dry.
LY TO ANY BUILDING ELECTRICAL SYSTEM.
Hazardous voltages can flow from the generator set • Do not work on this equipment when mentally or
into the utility line. This creates a potential for elec- physically fatigued, or after consuming any alcohol
trocution or property damage. Connect only or drug that makes the operation of equipment un-
through an approved isolation switch or an ap- safe.
proved paralleling device.
• Substances in exhaust gases have been identified
GENERAL SAFETY PRECAUTIONS by some state or federal agencies as causing can-
• Coolants under pressure have a higher boiling point cer or reproductive toxicity. Take care not to breath
than water. DO NOT open a radiator or heat ex- or ingest or come into contact with exhaust gases.
changer pressure cap while the engine is running. • Do not store any flammable liquids, such as fuel,
To prevent severe scalding, let engine cool down
cleaners, oil, etc., near the generator set. A fire or
before removing coolant pressure cap. Turn cap
explosion could result.
slowly, and do not open it fully until the pressure has
been relieved. • Wear hearing protection when near an operating
• Used engine oils have been identified by some state generator set.
or federal agencies as causing cancer or reproduc-
tive toxicity. When checking or changing engine oil, • To prevent serious burns, avoid contact with hot
take care not to ingest, breathe the fumes, or con- metal parts such as radiator system, turbo charger
tact used oil. system and exhaust system.
KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE
iv
1. Introduction
ABOUT THIS MANUAL TEST EQUIPMENT
This manual provides PowerCommand® Control To perform the test procedures in this manual, the
3201 (PCC) calibration and adjustment following test equipment must be available
procedures, control operation, alternator test and • True RMS meter for accurate measurement of
repair procedures. small AC and DC voltages.
Operating and maintenance instructions are in the • Battery Hydrometer
applicable Operator’s Manual. Generator set • Jumper Leads
troubleshooting and repair (control and engine) • Tachometer or Frequency Meter
information is provided in the following manual. • Wheatstone Bridge or Digital Ohmmeter
• Troubleshooting and Repair Manual Power- • Variac
Command Control QSX15, (QSK23), QSK45, • Load Test Panel
QSK60 Generator Sets, Bulletin No. 402-1419 • Megger or Insulation Resistance Meter
(Not shown on front cover, but includes QSK23 • InPower™ Service Tool (PC based genset ser-
information.) vice tool)
Read Important Safety Instructions and carefully
observe all instructions and precautions in this
HOW TO OBTAIN SERVICE
manual. Always give the complete Model, Specification and
Serial number of the generator set as shown on the
nameplate when seeking additional service
information or replacement parts. The nameplate is
located on the side of the generator output box.
WARNING Incorrect service or replacement of
parts can result in severe personal injury or
death, and/or equipment damage. Service per-
sonnel must be trained and experienced to per-
form electrical and mechanical service. Read
and follow Important Safety Instructions, on
pages iii and iv.
Copyright© 2005 Cummins Power Generation. All rights reserved.

Cummins and PowerCommand are registered trademarks of Cummins Inc.
InPower is a registered trademark of Cummins Inc.
1-1
THIS PAGE LEFT INTENTIONALLY BLANK
1-2
2. Control Operation
GENERAL present, it will wait for a pulse from a remote Master
First Start Sensor. On receiving that pulse, the con-
The following describes the function and operation trol will signal the paralleling breaker to close.
of the PowerCommand® Control 3200 (PCC). All in-
dicators, control switches/buttons and graphical If bus voltage is present, the control will check for
display are located on the face of the control panel proper phase rotation, adjust the generator set to
as illustrated in Figure 2-1. the bus voltage and frequency level, and then syn-
Normally, generator set configuration options are chronize the generator set to the system bus. When
set at the factory. When a new control is installed on a synchronous condition is achieved, the control will
a generator set or when parts are replaced, the con- send a signal to close the paralleling breaker.
trol must be configured for that generator set. Setup
and calibration procedures are described in Sec- When the paralleling breaker is closed, the genera-
tion 3. tor set will assume it’s proportional share of the total
load on the system bus.
SEQUENCE OF OPERATION
CONTROL PANEL POWER ON/OFF
When the PowerCommand control is in the AUTO
MODES
mode, it will cause the generator set to start on re-
ceiving a signal from a remote device. The control
The power on/off modes of the control panel and op-
will initiate a starter cranking signal and verify that
erating software are Power On, Screen Saver and
the engine is rotating. The control will provide suffi-
Sleep/Awake.
cient fuel to the engine to accelerate to start discon-
nect speed. On reaching that speed, the control will
ramp the generator set to idle (warm-up) or rated Power On Mode: In this mode, power is continu-
ously supplied to the control panel. The control’s
speed and voltage.
operating software and control panel LEDs/graphi-
On reaching rated speed and voltage, the control cal display will remain active until the Screen Saver
checks the system bus voltage. If no bus voltage is mode is activated.
2-1
Screen Saver Mode: Power to the graphical dis- Manual/Auto switch is in the Auto position) the
play will be removed after 10 minutes (generator set Sleep mode will be activated.
not running or running). The 10 minute timer resets
and begins after each control panel action (any but- The operating software is initialized and the control
ton or switch selection) or signal received by the op- panel LEDs and graphical display is turned on in re-
erating software. The bottom LEDs of the Analog sponse to one of the following:
AC Metering Panel (bar graphs) may remain on dur- • moving/pressing any control panel switch/but-
ing Screen Saver mode, indicating that the operat- ton.
ing software is active (Awake mode).
• a remote start input signal (generator set in
When a “Warning” signal is sensed by the PCC (for Auto mode), or
example, low coolant temp), the control will display • customer fault 2 or 3 only (shutdown or warning
the warning message. The control will remain active indicator is on).
until the Fault Acknowledge button is pressed to
clear the warning message and start the 10 minute To activate the control and view the menu display
timer. without starting the generator set, press any button
on the control panel.
Sleep/Awake Mode: In the Sleep mode, the con-
trol’s operating software is inactive and the LEDs The InPower service tool is required to enable or
and the graphical display on the control panel are all disable the Sleep mode. When shipped from the
off. Sleep mode is a feature that is used to reduce factory, the Sleep mode is disabled. When disabled,
battery power consumption when the control is in the operating software will always remain active
the Auto mode and is not being used. (Awake mode) when the control is in Auto mode.
When all conditions are met (i.e., no unacknowl- InPower service tool is required to selected desired
edged faults, Screen Saver Mode is active, and O/ mode.
2-2
OPERATOR PANEL SWITCH PANEL
REMOTE START,
NOT IN AUTO,
SHUTDOWN,
WARNING
STATUS INDICATORS
ANALOG AC PANEL LAMP/ FAULT EMERGENCY
METERING LAMP TEST ACKNOWLEDGE STOP PUSH
PANEL BUTTON BUTTON BUTTON
DISPLAY MENU EXERCISE MANUAL RUN/

SELECTION BUTTONS BUTTON & STOP BUTTON
(1 of 6) INDICATOR & INDICATOR
GRAPHICAL 0/MANUAL/AUTO
DISPLAY SWITCH
FIGURE 2-1. CONTROL PANEL ASSEMBLY (FULL-FEATURED)
2-3
CONTROL PANEL ASSEMBLY Scales for each function are in % of nominal values.
Resolution is 1% for values close to nominal, and in-
The control panel assembly (Figure 2-1) consist of creases at values further from nominal.
two panels, the Operator Panel and the Switch Pan-
el. Graphical Display: The graphical display is capa-
ble of displaying up to 9-lines of data with approxi-
Dependent on site requirements, the Operator Pan- mately 27 characters per line. The display is used to
el is either mounted on the control panel assembly view the menus of the menu-driven operating sys-
(full-featured) as shown in Figure 2-1 or contained tem.
in a separate enclosure and mounted remotely of
the control panel assembly. The top three lines of the graphical display contain
the following control information in the order de-
The function of several buttons on the control panel scribed:
will vary dependent on the location of the control
panel (remote or local of the control panel assem- • State Line − modes of operation, such as
bly). If the function differs, it is noted as either “re- Stopped, Time Delay To Start, Warm Up At
mote” or “local operator panel” in the button de- Idle, etc. (see Figure 2-2), and paralleling op-
scription. erations, such as Standby, Dead BUS Close,
Synchronize, Load Share and Load Govern.
Operator Panel
• Action Line − system actions, such as Warning,
The operator panel contains the following compo- Derate, Shutdown Cool-down and Shutdown,
nents: and fault codes.
Analog AC Metering Panel: This panel simulta- • Description Line − Fault code messages.
neously displays 3-phase line to line AC volts and
current, kW, power factor and frequency. Display Menu Selection Buttons: Six momentary
buttons—three on each side of the graphical dis-
The meter panel is composed of a series of LEDs, play window—are used to navigate through the sys-
that are configured in bar graphs for each function. tem control menus and to adjust generator set pa-
The LEDs are color coded, with green indicating rameters. The button is active when the message
normal range values, amber for warning levels and adjacent to the button is highlighted (displayed in in-
red for shutdown conditions. verse video).
2-4
Switch Panel Fault Acknowledge: Press this button to acknowl-
edge warning and shutdown messages after the
The switch panel contains the following compo- fault has been corrected.
nents:
To acknowledge a Warning message, the 0/Manu-
Emergency Stop Button: Push the button in for al/Auto switch can be in any position. (It is not nec-
emergency shutdown of the engine. If the engine is essary to stop the generator set to acknowledge an
not running, pushing the button in will prevent the inactive Warning condition.) To acknowledge a
starting of the engine, regardless of the start signal shutdown message with this button, the 0/Manual/
source (local or remote). Auto switch must be in the 0 (Off) position.
To reset: This button is also used to blink a fault code if the
1. Pull the button out. Shutdown or Warning Status Indicator is lit. (This
2. Move the 0/Manual/Auto switch to 0. function is used when the control does not contain a
3. Press the front panel Fault Acknowledge graphical display.) Refer to Reading Fault Codes in
button. this section, which describes how to use this button
4. Select Manual or Auto, as required. for interpreting fault codes.
Remote Start Indicator: This green lamp is lit Panel Lamp/Lamp Test Button: Press this button
whenever the control is receiving a remote run sig- to turn on or off the panel lamp. Press and hold
nal. When flashing, it indicates a load demand stop down this button for three seconds or more to turn
mode. all control panel LEDs on to make sure all lamps illu-
minate. The illumination will shut off after releasing
Not in Auto Indicator: This red lamp flashes con- the button.
tinuously when the 0/Manual/Auto switch is not in
the Auto position. (If in Auto position and lamp is Exercise Button: Press this button to initiate a pre-
flashing, service is required.) programmed exercise sequence. To start the exer-
cise sequence, press and hold down the Exercise
Shutdown Status Indicator: This red lamp is lit button and move the O/Manual/Auto switch from
whenever the control detects a shutdown condition. Auto to Manual and back to Auto or from Manual to
The generator set can not be started when this lamp Auto.
is on. After the condition is corrected, shutdown in-
dicators can be reset by turning the 0/Manual/Auto Manual Run/Stop Button: This button starts and
switch to the 0 position, and pressing the Fault Ac- stops the set locally and will bypass Time Delay to
knowledge button. Start and Stop sequences. The 0/Manual/Auto
switch must be in the Manual position to enable this
Dependent upon the specific fault that occurs, the button.
engine may or may not shut down immediately. A
fault that could cause engine damage, causes an 0/Manual/Auto Switch: Manual position enables
immediate engine shutdown (bypasses engine the use of the switch panel Manual Run/Stop but-
cool-down sequence). All other faults would allow ton.
the engine to run during the cool-down sequence Auto position enables start/stop control of the en-
before engine shutdown. In this case, the Shutdown gine from a remote location. (Disables the use of the
Status Indicator blinks during the cooldown period. switch panel Manual Run/Stop button.)
Warning Status Indicator: This yellow lamp is lit 0 (Off) position prevents the starting of the set (local
whenever the control detects a warning condition. or remote). If moved to 0 during set operation, will
After the condition is corrected, warning indicators cause an immediate engine shutdown (bypasses
can be reset by pressing the Fault Acknowledge cool-down timers). This hot shutdown should be
button. (It is not necessary to stop the generator set avoided, if possible, to help prolong the life of the
if the fault becomes inactive during genset opera- engine. Hot shutdowns are logged by the system
tion.) software.
2-5
READING FAULT CODES A three digit fault code is indicated by three sets of
blinks separated by a two second pause. The first
If the genset contains the optional graphical display set corresponds to the hundreds position, the sec-
and a fault occurs, the fault code/message will be ond to the tens position and the third to the ones dig-
displayed in the display Description Line (Figure it. Example for Code No. 213:
2-2). If the control does not contain the graphical
display, the fault code is read from the Warning and Shutdown LED:
Shutdown status indicators. blink-blink-pause-blink-pause-blink-blink-blink
Reading Fault codes Using Warning/Shutdown Warning LED:

Indicators: If the Warning or Shutdown status indi- blink (2 seconds)
cator is lit, press and hold the Fault Acknowledge The light will display the fault codes (active or inac-
button and release after one second or more. After tive) in succession, starting with the most recent. Up
one second, the Shutdown lamp will begin to blink to 32 (unacknowledged) fault codes can be stored
the active fault code(s) as follows. in control panel memory.
The Warning lamp is used to indicate the start of a To return the control to the most recent fault code,
new code. The Warning lamp will remain on for 2 press and release the Fault Acknowledge button
seconds, followed by the Shutdown lamp blinking (less than one second) and repeat procedure.
the fault code. This sequence occurs three times for
each code. The fourth flash of the Warning lamp in- When the fault code is acknowledged and cor-
dicates the beginning of the second fault code. rected, the recorded fault will be deleted from the
LED fault log, but will remain in a data log that main-
There are distinct pauses between repetitions of the tains a fault code history. (The InPower service tool
code blink transmissions of the Shutdown lamp. is required to view this data log.)
2-6
MENU DISPLAY AND SWITCHES Menu Buttons: Six momentary buttons—three on
each side of the graphical display window—are
Figure 2-2 shows the graphical display and the used to navigate through the system control menus
menu selection buttons. and to adjust generator set parameters. The button
Graphical Display: The graphical display is capa- is active when the message or symbol adjacent to
ble of displaying up to 9-lines of data with approxi- the switch is highlighted (displayed in inverse vid-
mately 27 characters per line. The display is used to eo). The displayed message or symbol indicates
view the menus of the menu-driven operating sys- the function of the button.
tem. Refer to the menu trees later in this section.
The display is also used to show the following sys- In the graphical display, the “B” symbol indicates
tem information: that selecting the adjacent button causes the operat-
ing program to go to the next menu display—as
• State Line − modes of operation, such as shown in the menu diagrams.
Stopped, Time Delay To Start, Warm Up At
Idle, etc., and paralleling operations, such as
Standby, Dead BUS Close, Synchronize, etc. In the graphical display, the “Y” symbol indicates
that selecting the adjacent button causes the operat-
• Action Line − system actions, such as Warning, ing program to go back to the previous menu display.
Derate, Shutdown Cool-down and Shutdown,
and fault codes.
In the graphical display, the “ ” symbol indicates
• Description Line − Fault code/status mes- that selecting the adjacent button causes the operat-
sages. ing program to go back to Main Menu A (Figure 2-4).
STATE LINE
ACTION LINE
DESCRIPTION LINE
MENU DISPLAY
AREA
GRAPHICAL
DISPLAY
MENU MENU
BUTTONS BUTTONS
FIGURE 2-2. GRAPHICAL DISPLAY AND MENU SELECTION BUTTONS
2-7
LANGUAGE/UNITS SELECTION MENU
During any control panel operation, you can select
one of three languages and change how units are
displayed by pressing the two lower menu buttons LANGUAGE ENGLISH
+ LOCATION LOCAL
(one on each side of display). When pressing these TEMP °F
two buttons simultaneously, the language/units PRESS FLD PSI ENTER
menu will appear (Figure 2-3). After making desired → PRESS GAS INHG
selections, press the ENTER button in this menu to FLOW AIR CFM
change and save the selections.
Use the + buttons to select the desired option for
each field. Use the arrow (→) button to move to the
FIGURE 2-3. LANGUAGE/UNITS MENU
next field. Selected field is highlighted.
Language: Used to select desired language (de-
fault = English).
Location: This selection must be set to Local when
the graphical display is mounted on the generator
set front control panel or Remote when mounted re-
motely from the generator set.
The Local/Remote selection determines which but-
tons in the Control submenu (page 2-13) are active
(displayed).
Temp: Used to select °F or °C for temperature read-
ings.
Pressure Fluid: Used to select PSI, KPA, BAR or
IN for pressure readings.
Pressure Gas: Used to select INHG or MMHG for
pressure readings.
Flow Air: Used to select CFM or CMM for air flow
readings.
2-8
MAIN MENU _\_ Button (Paralleling Applications Only)
Figure 2-4 shows the main menus (Menu A and When displayed, indicates that the feature for gen-
Menu B) of the system control. The two main menus erator set paralleling applications is installed. This
are used to divide the system submenus into major button is used to open and close the generator set
categories, such as, Engine Data, Alternator Data, circuit breaker (CB). The symbol indicates if the CB
Control, etc. is opened or closed. Opened _\_, push to close.
To view system data, simply press the appropriate Closed _−_, push to open.
menu button to select the category. After pressing
the desired menu button, refer to the page number With the control panel 0/Manual/Auto switch in the
Auto position, the opening and closing of the CB is
shown in Figure 2-4 for detailed information related
controlled by the control system software. The CB
to the selected category.
symbol will indicate an open or closed CB, but the
In the following figures, the boxed/highlighted field button will be inactive when the control is in Auto.
indicates that the adjacent menu button is active.
Also, the submenus are shown in the order in which In the Manual position, the CB can only be closed
they are displayed when scrolling up Y or down B. by using this button. When manually closed and the
CB opens, it must be closed again by using this but-
Adjust Button ton. To close the CB, press and hold the button until
The Adjust submenu is intended for qualified site the symbol indicates a closed CB. (CB close will oc-
personnel only. Note that a password may be as- cur only when setup conditions allow − dead bus or
signed to allow only authorized operators to modify generator synchronized with bus.)
this data. (Password is not required if not assigned.)
Power Trans Button (Power Transfer
Setup Button Control Applications Only)
The Setup submenu is described in Section 3. When displayed, indicates that the Power Transfer
The “Adjust” and “Setup” submenus can be viewed, Control (PTC) feature is installed. Refer to page
but not modified without entering the correct pass- 2-17 for PTC Data submenu description. The PTC
words. setup submenu is described in Section 3.
2-9
MENU A
MENU MENU
BUTTONS PAGE MENU BUTTONS
2-11 B
ENGINE MORE>>
PAGE ALTERNATOR POWER TRAN or _\_ Page
2-12 CONTROL HISTORY/ABOUT 2-9
PAGE PAGE
2-13 2-14
MENU B
Section
3
ADJUST
PARALLEL DATA PAGE
SETUP BACK<< 2-16
GRAPHICAL
Section DISPLAY MENU
3 A
FIGURE 2-4. SYSTEM CONTROL MAIN MENUS A AND B
2-10
ENGINE SUBMENUS
If you press the “ENGINE” button in Menu A, the En-

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

TIMING PRESS 50 PSI Y
AFTERCOOLER TEMP 76 °F
AMBIENT PRESS 88 INHG
FIGURE 2-5. ENGINE SUBMENUS
2-11
ALTERNATOR SUBMENUS
If you press the “ALTERNATOR” button in Menu A,

the Alternator Data submenus will appear (Figure ALTERNATOR
2-6).
Voltage L-L and L-N: Indicates voltage Line-to
Line and Line-to-Neutral. Note that the Line-to-Neu-
tral column will not be displayed for a 3 phase/3 wire V L-L L-N AMPS
system. Accuracy 1%. L1 480 277 1340 Y
L2 480 277 1290
The voltage Line-to-Line (L1, L2 and L3) are mea- L3 480 277 1260 B
sured between L1 to L2, L2 to L3 and L3 to L1, re- FREQUENCY 60.0 HZ
spectively. AVR DUTY CYCLE 10.3 %
Amps: All phases. Accuracy 1%.

Frequency: Generator set output frequency.
AVR DUTY CYCLE: Displays voltage regulator kW kVA PF
(drive) level in percentage of maximum. L1 350 500 .80 Y
L2 350 500 .80
kW, kVA and PF: Displays generator set kW and L3 350 500 .80
kVA output (average and individual phase, and di- TOT 1050 1500 .80
rection of flow) and power factor with leading/lag-
ging indication. Accuracy 5%.
The PF reading will contain an asterisk if the power
factor is leading (for example, *.30). FIGURE 2-6. ALTERNATOR SUBMENUS
2-12
CONTROL SUBMENU
If you press the “CONTROL” button in Menu A, the

Control submenu will appear (Figure 2-7). CONTROL
(Local)
Local CONTROL Submenu Function
When the operator panel is mounted on the control

panel assembly, the Run Mode Idle/Rated button is
active (displayed). Note in Figure 2-7 that this but- + RUN MODE IDLE Y
ton is not displayed in remote applications. B
ENABLE SYNC
The shaded area in Figure 2-7 displays the se-
lected/active mode of operation, either IDLE or
RATED.
Remote CONTROL Submenu Functions

BARGRAPH TEST Y
When the operator panel (Figure 2-1) is mounted
remotely of the control panel assembly, the menu
buttons in the Control submenu are used to perform
the following remote operations. (To activate these
menu buttons for remote/local use, refer to page
2-8.)
CONTROL
The 0/Manual/Auto switch must be in the Auto posi- (Remote)
tion to activate the Remote Menu Buttons of the Con-
trol submenu.
Remote START or STOP Button: This button is

used to start and stop the generator set when the
START GENSET Y
operator panel is mounted in a remote location.
FAULT ACKNOWLEDGE B
When the generator set is operating, Stop will be ENABLE SYNC

displayed for this button and Start will be displayed
when not operating.
Fault Acknowledge Button: Used to reset inactive

Warning messages, not Shutdown messages.
BARGRAPH TEST Y
Local/Remote CONTROL Submenu
Function
Bargraph Test: The function of this button remains

the same and is not dependent on operator panel
location. This button sequentially lights the LEDs to FIGURE 2-7. CONTROL SUBMENU
test the bar graph display.
Enable Sync: Displayed in paralleling applications

only. Intended for service personnel to turn off the
synchronizer for troubleshooting/testing purposes.
2-13
HISTORY/ABOUT SUBMENUS
If you press the “HISTORY/ABOUT” button in Menu

A, the History/About submenus will appear (Figure HISTORY/ABOUT
2-8).
HISTORY: The control maintains a data log of the
number of engine starts and number of operating
hours for the engine and control, and the megawatt STARTS 533
and maximum torque hours of the generator set. ENGINE HOURS 1236 Y
This information is stored in non-volatile memory CONTROL HOURS 7879
KWHRS 890 B
and will not be deleted due to loss of battery power.
ABOUT: The About submenus provide the follow-
ing generator set information.
• Genset model and wattage (kW/MW)
• Output voltage and WYE, DELTA or SINGLE
HISTORY-HRS@ %MAX TORQUE
• Frequency 50 or 60 Hz 12345@0-9 23455@50-59 Y
• Rating: Standby, Prime or Base 12345@10-19 12345@60-69
12345@20-29 12345@70-79 B
• Version level of the controller and panel operat- 12345@30-39 12345@80-89
ing software.
MODEL 1750DQKB Y
VOLTAGE 416 WYE
FREQUENCY 60 B
RATING STANDBY
CONTROLLER VERSION
RTOP DN30008.DFA Y
BATS APR 23 1999
OP PANEL VERSION B
RTOP 1.09 AUG 17 1999
BATS 1.02 MAY 6 1999
CONTINUED TO NEXT PAGE
FIGURE 2-8. HISTORY/ABOUT SUBMENUS
2-14
HISTORY/ABOUT SUBMENUS (CONT.)
FAULT HISTORY: The control maintains a data log

of all fault conditions as they occur, and time stamps HISTORY/ABOUT (CONT.)
them with the control and engine operating hours.
Up to 32 (unacknowledged) fault codes can be
stored in control panel memory. After the fault is ac-
knowledged and corrected, the recorded fault will
be deleted from the control panel memory, but will FAULT HISTORY: 1 OF 24
+ CNTL HOURS 459 Y
remain in a data log that maintains a fault code his- OCCURRENCES 5
tory. (The InPower service tool is required to view ENGINE HOURS 334
this data log.) FAULT CODE 1437
(FAULT DESCRIPTION)
The Fault History display line: 1 of 24 indicates that
24 faults are recorded and that the most recent fault
(1) detected by the controller is displayed.
The Occurrences display line: In this example, 5 in- FIGURE 2-8. HISTORY/ABOUT SUBMENUS (CONT.)
dicates that this is the fifth occurrence of this fault.
(The InPower service tool is required to review the
last four faults of this code.)
The Occurrences number is incremented for each
new occurrence of the same fault. The controller
must detect that the original sensed fault is cor-
rected before it will increment the occurrence num-
ber for that fault.
For example, when a Low Oil Pressure fault is de-
tected, the controller will increment the Occurrences
number by 1. This fault will remain active until the
fault is acknowledged and the controller detects that
the fault is corrected. An active fault will prevent the
controller from incrementing the Occurrences num-
ber each time the engine is started. When the con-
troller detects that the oil pressure is normal the fault
will become inactive, allowing the occurrences num-
ber to be incremented for the next detected Low Oil
Pressure fault.
2-15
PARALLEL DATA SUBMENU
If you press the “PARALLEL DATA” button in Menu _\_ Button: Used to open and close the generator
B, the Parallel Data submenu will appear (Figure set circuit breaker (CB). The symbol indicates if the
2-9). This menu is displayed in paralleling applica- CB is opened or closed. Opened _\_, push to close.
tions only. Closed _−_, push to open.
PARALLEL DATA STATUS LINE: The top line of With the control panel 0/Manual/Auto switch in the
the graphical display is used to indicate the follow- Auto position, the opening and closing of the CB is
ing PARALLEL DATA status: controlled by the control system software. The CB
− STANDBY: Indicates no paralleling activity is symbol will indicate an open or closed CB, but the
occurring at present. button will be inactive when the control is in Auto.
− DEAD BUS CLOSE: Indicates first genset in
system to close to bus. In the Manual position, the CB must be closed by
this button. When manually closed and the CB
− SYNCHRONIZE: Genset is synchronizing to
opens, it must be closed again by using this button.
bus.
To close the CB, press and hold the button until the
− LOAD SHARE: Genset has closed to bus and symbol indicates a closed CB. (CB close will occur
is sharing load with other gensets in system. only when setup conditions allow − dead bus or
− LOAD GOVERN: Genset closed to bus in par- generator synchronized with bus.)
allel with utility (mains).
BUS Voltage L-L: The BUS voltage Line-to-Line
(L1, L2 and L3) are measured between L1 to L2, L2
to L3 and L3 to L1, respectively. PARALLEL DATA
BUS/GEN HZ: BUS/GEN hertz.

BUS/GEN SYNC STATUS: The bottom line of the LOAD GOVERN
graphical display is used to indicate the following V BUS GEN
BUS/GEN Sync status: L1 480 480 Y
L2 480 480
− NOT SYNCHRONIZING: Genset is in service L3 480 480 _\_
mode that does not allow auto sync feature. HZ 60.1 60.1
(Selected via InPower service tool − deactivate DEG −122 NOT SYNCHRONIZING
to allow synchronization.)
− SYNCHRONIZING: Genset is synchronizing to
bus.
− READY TO CLOSE: In manual mode, push cir-
cuit breaker close button to close breaker. FIGURE 2-9. BUS DATA SUBMENU
2-16
POWER TRANSFER MAIN/SUBMENUS
If you press the “POWER TRANS” button in Menu The symbol displayed in the middle of the Pow-
A, the Power Transfer main menu will appear (Fig- er Transfer main menu indicates which breaker
ure 2-10). The Power Transfer Control (PTC) fea- (utility or genset) is closed/opened to the load. The
ture must be installed to display this menu. symbol presently shown indicates that the utility
breaker is closed and supplying power to the load.
The PTC feature enables the PCC to monitor the
utility voltage (mains) and frequency for failure and
The Power Transfer main menu also indicates if the
control the opening and closing of the contacts (cir-
utility and the generator set are available to accept
cuit breakers) for the utility (S1) and the genset
load. When the control detects that either source is
(S2).
ready to accept load, UTILITY and/or GENSET will
If utility fails, the control will initiate the genset start- be displayed in inverse video.
ing sequence, open S1 and close S2 to the load.
When utility returns, the load is retransferred to the The Power Transfer main menu has four submenu
utility (S1 closes/S2 opens) and the control initiates groups. Refer to the page numbers shown in Figure
the genset shutdown sequence. 2-10 for the Power Transfer submenu descriptions.
2-17
PTC Status Line the genset will continue to run even if a genset
warning or derate fault occurs. This test can be
The top line of the graphical display is used to indi- performed with or without load (refer to TEST/
cate the following PTC status: EXERCISE submenu in Section 3).
− NOT ENABLED: PTC is not enabled. Control − TEST: Test sequence initiated through Remote
panel switch in O (Off) position. Start switch with emergency start sequence
− MANUAL: Control panel switch is in Manual disabled (TB8-3 terminal closed). Test mode is
position. All PTC actions or genset start/stop non-emergency, which means that a retransfer
actions are manually controlled. to utility will occur if any problems occur with
− NORMAL UTIL: Load is connected to the util- the genset while testing with load. This test can
ity. be performed with or without load (refer to
− RETRAN: Retransfer of load to utility. TEST/EXERCISE submenu in Section 3).
− RETRAN OVRD: Immediate retransfer of load − EXERCISE: Exercise sequence initiated
to utility due to genset fault (e.g., warning, der- through control panel. This test can be per-
ate, or shutdown w/cooldown fault). The re- formed with or without load (refer to TEST/EX-
transfer timer is ignored as is the retransfer in- ERCISE submenu in Section 3). A retransfer to
hibit. utility will occur if any problems occur with the
− EMERG TEST: Emergency Test sequence ini- genset during the exercise sequence.
tiated through Remote Start switch with emer- − UTILITY FAIL: Utility has failed. (Initiates
gency start sequence enabled (TB8-3 terminal transfer of load to genset if O/MANUAL/AUTO
opened). Emergency test mode means that switch is in AUTO.)
MENU MENU
BUTTONS PAGE PTC STATUS LINE PAGE BUTTONS
2-19 2-22
B UTILITY GENSET B
PAGE STATUS
2-20 TRANSFER CONTROL
DEG −123 SYNCHRONIZING
PAGE MENU
2-21 A
FIGURE 2-10. POWER TRANSFER MAIN MENU
2-18
UTILITY (PWR TRAN) SUBMENUS
If you press the “Utility” button in the Power Transfer

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

to Line and Line-to-Neutral. Note that the Line-to-
Neutral column will not be displayed for a 3 phase/3 UTILITY:
V L-L L-N AMPS Y
wire system. Accuracy 1%. L1 480 277
L2 480 277 1320 B
L3 480 277
The voltage Line-to-Line (L1, L2 and L3) are mea- FREQUENCY 60.0 HZ
sured between L1 to L2, L2 to L3 and L3 to L1, re-
spectively.
Amps: L2 only. Accuracy 1%.

UTILITY:
Frequency: Utility frequency. kW kVA PF Y
L1
L2 125 175 .96
kW, kVA and PF: Displays (L2 only) utility kW and L3
kVA output (average and direction of flow) and pow- TOT
er factor with leading/lagging indication. Accuracy
5%.
FIGURE 2-11. UTILITY SUBMENUS
factor is leading (for example, *.30).
2-19
STATUS (PWR TRAN) SUBMENUS
If you press the “Status” button in the Power Trans-

fer Main menu, the Status submenus will appear STATUS
(Figure 2-12).
Connected: Indicates which source(s) is con-
nected to the load.
Available: Indicates when the corresponding UTIL GEN
sources have acceptable output voltage and fre- CONNECTED YES NO Y
quency. Both can be available simultaneously. AVAILABLE YES NO
VOLT L12 480 0 B
Volt L12: Indicates utility and generator set Line 1 to HZ 60.0 0.0
Line 2 voltage. KW L2 456 0
HZ: Utility and generator set output frequency.
KW L2: Utility and generator set Phase B (L2) kW
output.
Transfer Inhibit: This feature is used to control TRAN INH OFF
load transfer to the genset. When activated, load RETRAN INH ON Y
transfer to the genset will not take place if the utility
fails.
Transfer inhibit is controlled by connecting a remote
contact between TB3-57 and TB3-58. Closing the
contact enables the feature and opening the con-
tact disables it. When enabled, the event is dis-
played on the graphical display. FIGURE 2-12. STATUS SUBMENUS
Retransfer Inhibit: This feature is used to prevent
the PTC from automatically transferring the load
back to the utility. When activated, load transfer will
not take place unless the genset fails (Retransfer
Inhibit is ignored if the genset fails).
Retransfer inhibit is controlled by connecting a re-
mote contact between TB3-64 and TB3-65. Closing
the contact enables the feature and opening the
contact disables it. When enabled, the event is dis-
played on the graphical display.
2-20
TRANSFER CONTROL (PWR TRAN) SUBMENU
If you press the “TRANSFER CONTROL” button in

the Power Transfer Main menu, the Transfer Con- TRANSFER CONTROL
trol submenu will appear (Figure 2-13).
The symbol displayed in the middle of the
TRANSFER CONTROL submenu indicates which
breaker (utility or genset) is closed/opened to the UTILITY GENSET
load. The symbol presently shown indicates that the
utility breaker is closed and supplying power to the CB ENABLE CB ENABLE
load. << BACK
During genset operation in the manual mode, you

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

ENABLE UTIL CB
In the example in Figure 2-13, the CB ENABLE but-
ton for “Utility” was pressed. (If the CB ENABLE CANCEL
button for the “Genset” was pressed, ENABLE
GEN CB would be displayed in the second subme-
nu, allowing you to open or close the genset circuit
breaker.)
After pressing the “utility” CB ENABLE button, the
second submenu will be displayed allowing you to UTILITY GENSET
either CANCEL or ENABLE the entered selection.
OPEN UTIL CB ENABLE
Pressing the CANCEL button will return the display << BACK
to the previous menu.
Pressing the ENABLE button will display the third
submenu. With this submenu displayed you can re-
turn to the second submenu without opening the
utility circuit breaker (press <<BACK) or you can
press the OPEN UTIL button. UTILITY GENSET
Pressing the OPEN UTIL button will display the CLOSE UTIL CB ENABLE
fourth submenu, indicating that the utility circuit << BACK
breaker is now opened.
Note that the fourth submenu displays CLOSE
UTIL. Pressing this button will close the utility circuit
breaker and redisplay the third submenu. FIGURE 2-13. TRANSFER CONTROL SUBMENUS
2-21
GENSET (PWR TRAN) SUBMENUS
If you press the “Genset” button in the Power Trans-

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

Line and Line-to-Neutral. Note that the Line-to-Neu-
tral column will not be displayed for a 3 phase/3 wire GENSET:
system. Accuracy 1%. V L-L L-N AMPS Y
L1 480 277 1320
L2 480 277 1320 B
The voltage Line-to-Line (L1, L2 and L3) are mea- L3 480 277 1320
sured between L1 to L2, L2 to L3 and L3 to L1, re- FREQUENCY 60.0 HZ
spectively.
Amps: All phases. Accuracy 1%.
Frequency: Generator set output frequency. GENSET:

kW kVA PF Y
kW, kVA and PF: Displays generator set kW and L1 100 150 .97
L2 125 175 .96
kVA output (average and individual phase, and di- L3 150 200 .95
rection of flow) and power factor with leading/lag- TOT 375 525 .96
ging indication. Accuracy 5%.

factor is leading (for example, *.30). FIGURE 2-14. GENSET SUBMENUS
2-22
3. Control Calibration and Adjustment
GENERAL The Setup submenus are intended for qualified ser-
This section contains calibration and adjustment vice personnel only. The Adjust submenu is in-
procedures for the generator set control. tended for qualified service and site personnel only.
For this reason, a password must be entered before
MODIFYING SETUP/ADJUST SUBMENUS this data can be modified. The Setup and Adjust
The Setup and Adjust submenus allow you to cali- submenus can be viewed, but not modified without
brate the graphical display meters and to adjust entering the correct password.
system parameters, customer defined faults, gen-
erator set voltage/frequency and paralleling ap- Saving Menu Changes
plications. Changes are automatically saved when the menu is
CAUTION Improper calibration or adjustment exited.
of the control can cause equipment malfunction
or damage. Calibration and adjustment must be
performed by technically qualified personnel
only.
3-1
PASSWORD Menu unauthorized adjustment, the entered password is
valid for 10 minutes after the last button is pressed
To allow the site personnel to modify only the Adjust (i.e., the password will need to be reentered after
submenu and not the Setup submenus, two pass- the ten minute time−out.
words are assigned within the system software. An
Application password is used for the Setup sub- Entering Password
menus and a User password is used for the Adjust
submenu. To enter the password:
The two passwords are assigned during the initial 1. Display submenu to modify.
installation of the generator set (via InPower) and
2. Press either the + or − button within the dis-
will vary between sites. The installer must make
played submenu. The Password menu ap-
sure that the passwords are available to the ap-
pears.
propriate personnel.
3. Press the + and − button to select the first char-
When the generator set is first installed, the Applica- acter of the password (A−Z or 0−9). (Enter Ap-
tion and User password are both set to GENSET to plication password for Setup submenus; En-
allow initial modification of the Setup and Adjust ter User password for Adjust submenu.)
submenus. Assign new passwords when site instal-
lation is complete. 4. Press the → button to select the next character
field. Selected character field is highlighted.
When viewing the Adjust menu, pressing the + or −
5. Repeat steps 3 and 4 to enter remaining pass-
button will display the User Password menu.
word characters.
When viewing a Setup menu, pressing the + or − 6. Press the Enter button after entering the pass-
button will always display the Application Password word. The submenu selected in step 1 will re-
menu. appear.
After entering the correct password, the system will 7. After making desired changes to submenu, exit
allow you to modify the submenus. To help prevent submenu to save changes.
+ OR − BUTTON + OR − BUTTON
ENTER APPLICATION PASSWORD ENTER USER PASSWORD

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

PAGE ISOLATED BUS
3-7 UTILITY
PAGE MENU
3-11 A
FIGURE 3-2. SETUP SUBMENUS
3-3
GOVERNING/VOLT REG SUBMENU
If you press the “GOVERNING/VOLT REG” button

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

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

the Setup menu, the Customer Faults submenus CUSTOMER FAULTS
will appear (Figure 3-4).
There are a total of four customer fault inputs.
(Faults 3 and 4 paralleling only.) The message dis-
played at the bottom of the menu can be modified
for each of these faults in addition to selecting the CUSTOMER FAULT1:
+ ENABLE ON Y
following operating parameters for each fault.
− ACTIVE CLOSED B
• Enable − On or Off RESPONSE WARNING
→
• Active − Closed or Open ***CUSTOMER FAULT1 ******************
• Response − Shutdown, Cooldown, Derate or
Warning
Shutdown: Genset will immediately shut
down. Normally used for engine faults.
Cooldown: Cooldown sequence will be initi- CUSTOMER FAULT2:
+ Y
ated before shutdown. Should not be used for
engine faults. − B
RESPONSE WARNING
Derate: Used to lower kW output of genset for →
warnings such as pre-high coolant tempera- ***CUSTOMER FAULT2 ******************
ture, etc. Paralleling application − controller will
reduce precentage of kW load sharing on the
set. Non-paralleling application − controller will CONTINUES THROUGH TWO
ADDITIONAL MENUS FOR A
lower percentage of kW load by operating load TOTAL OF FOUR POSSIBLE
shed relay contacts. CUSTOMER FAULT MESSAGES
Warning: Display message, genset continues
to operate.
The Enable and the Active fields apply to the Fault 1 FIGURE 3-4. CUSTOMER FAULTS SUBMENUS
and 4 submenus only.
With the Active field selected, pressing the + or −
buttons will toggle the selection between CLOSED
and OPEN. Use same operation for remaining field
selections.
To enter the desired customer fault message, press
the B or Y button to display the submenu that con-
tains the customer fault message (1 through 4) to be
changed. Use the → button to scroll down through
the menu selections to the editable fault message
(bottom menu line).
Use the → button to move to each character posi-
tion within the fault message line.
With the desired character position selected, use +
or − buttons to select the appropriate character.
If these messages are changed, you should note
these changes in the Troubleshooting section of the
Operator’s manual for this generator set.
3-5
CALIBRATION SUBMENUS
If you press the “CALIBRATION” button in the Setup

menu, the Calibration submenus will appear (Fig- CALIBRATION
ure 3-5).
VOLTAGE CALIBRATION
field. Exit menu to safe changes.
+ L1 480 -X.X% Y
L2 480 -X.X%
The Calibration submenus allow you to calibrate the − L3 480 -X.X% B
control with the reading from a calibrated meter. →
Calibration is accomplished by using this section of
the menu software to adjust the display so that it
matches the reading taken on an accurate, recently
calibrated meter.
Calibration is normally only required when replac-
CURRENT CALIBRATION
ing certain circuit cards. Refer to the Calibration L1 234 -X.X%
+ Y
Procedure in this section which contains a list of the L2 123 -X.X%
− B
cards that require control calibration. L3 562 -X.X%
→
When performing Bus Voltage Calibration from the
graphical display, the genset must be off and the Bus
live. If the genset is running, it will synchronize to the
Bus.
BUS VOLTAGE CALIBRATION

+ L1 480 -X.X% Y
L2 480 -X.X%
− L3 480 -X.X%
→
FIGURE 3-5. CALIBRATION SUBMENUS
3-6
ISOLATED BUS / UTILITY Submenus and frequency in a range of minus 40% to plus 10%
(Paralleling Application) of normal bus conditions. When the paralleling
breaker has closed, the control will bring the gener-
The Isolated BUS submenus (Figure 3-6) and the ator set back to normal voltage and frequency.
Utility submenus (Figure 3-7) adjust the control pa-
rameters for generator set protection, synchroniz- When the generator set is paralleled to another
ing and load sharing for both isolated bus and utility generator set, the control provides automatic load
(mains) paralleling applications. Utility (mains) par- sharing functions for both real (kW) and reactive
allel applications may require adjustment of both (kVAR) loads. Load sharing is proportional between
the Isolated BUS and Utility submenus. generator sets based on their standby ratings. If two
generator sets of different sizes are paralleled, they
Always perform ISO BUS calibration before Utility will assume the same percentage of the system
BUS calibration.
load automatically. This can easily be verified on the
The sync check (permissive) function is operational kW Load LED bar graph on the front of the control
in both automatic and manual (RUN) modes. The panel.
control will make sure that the generator set is at
proper voltage, within the defined sync check win- When the utility paralleling mode is enabled and the
dow for the defined period of time and that phase generator set paralleling breaker is closed, the gen-
erator set will assume load based on external ana-
rotation is correct. When all criteria are met, the par-
alleling breaker is closed automatically by the con- log input signal. The input signal must be calibrated
trol (auto mode), or by operation of the breaker from 0−5 VDC. When the signal is at 0.5 to 1 VDC,
the control will operate the generator at no load in
close switch by the operator (manual mode).
parallel with the utility (mains) source. At 4.5 VDC
The synchronizing function of the control is enabled and greater, the control will operate the generator
when the control has brought the generator set to set at 110% of the generator set base load setting.
90% of rated speed and voltage, and has sensed When the load govern signal is between 1 VDC and
that bus voltage is available. The control automati- 4.5 VDC the control will operate the generator set at
cally adjusts the generator set speed and voltage to a load level which is determined by a linear relation-
match the bus frequency and voltage. The control ship between the kW reference and the load govern
can force the generator set to match bus voltage signal.
3-7
ISOLATED BUS SUBMENUS
If you press the “ISOLATED BUS” button in the Set-

up menu, the Isolated BUS submenus will appear ISOLATED BUS
(Figure 3-6).
field. Exit menu to safe changes. ISOLATED BUS:
+ SYNC TIME LIMIT 120 SEC Y
SYNC TIME LIMIT: This parameter adjusts the time REV PWR LMT 10 %
delay in seconds before the Fail To Synchronize − REV PWR TIME 3 SEC B
alarm will operate. → PERM WIN-PH 20 DEG
PERM WIN-TIME .5 SEC
REVERSE PWR LMT: Adjusts the reverse power
set point. For PowerCommand generator sets, a
typical set point is 10-15%.
CONTINUED TO NEXT PAGE
REVERSE PWR TIME: Adjusts the reverse power
function time delay. A typical time delay which is
suitable for PowerCommand generator sets is 3
seconds.
FIGURE 3-6. ISO BUS SUBMENUS
Lower reverse power set points can result in nui-
sance reverse power shutdown faults.
PERM WIN-PHASE: Adjusts the width of the per-
missive (sync-check) acceptance window. The ad-
justment range is from five to twenty electrical de-
grees. Recommended set point is 20 degrees for
isolated bus applications, and 15 degrees for utility
(mains) paralleling applications.
PERM WIN-TIME: Adjusts the time period (in sec-
onds) for which the generator set must be synchro-
nized with the system bus, before a breaker close
signal is issued by the PowerCommand control.
Available range is 0.5 to 5 seconds. Recommended
value for PowerCommand generator sets is 0.5
seconds for isolated bus applications.
3-8
Adjusting the control for a smaller sync-check win-
dow or longer time delay will cause synchronizing
ISOLATED BUS (CONT.)
time to be extended.
SYNC GAIN: The sync gain adjustment controls
how quickly the governor will respond to try to mini-
mize the bus/generator phase difference. Increas-
ing the gain speeds up the response. If the gain is ISOLATED BUS:
too high instability can result. + SYNC GAIN 1.0 Y
KW BALANCE 0.3
KW Balance and KVAR Balance changes should be − KVAR BALANCE 1.2 B
equally shared among all generator sets. → KW GAIN 1.0
KVAR GAIN 1.0
KW BALANCE: This function adjusts the kW load
sharing function of the generator set. Before adjust-
ing this value, all generator set calibrations should
be performed. If the total load on the system is not CONTINUED TO NEXT PAGE
shared proportionately, the kW Balance can be
used to adjust the generator set for more precise
load sharing. Increasing the kW Balance value will
cause the generator set to reduce the percentage of FIGURE 3-6. ISO BUS SUBMENUS (CONT.)
the total kW load on that set.
KVAR BALANCE: This function adjusts the kVAR
load sharing function of the generator set. Before
adjusting this value, all generator set calibrations
should be performed. If the total load on the system
is not shared proportionately, the kVAR balance can
be used to adjust the generator set for more precise
load sharing. Increasing the kVAR balance value
will cause the generator set to reduce the percent-
age of the total kVAR load on that set.
KW GAIN: Adjusts the rate of change of kW load on
the generator set. With a constant load on the sys-
tem, if the generator set load is constantly chang-
ing, reduce the gain adjustment on the generator
set. This also allows modification of the rate of load
assumption on transient load change.
KVAR GAIN: Adjusts the rate of change of kVAR
load on the generator set. With a constant load on
the system, if the generator set load is constantly
changing, reduce the gain adjustment on the gener-
ator set. This also allows modification of the rate of
load assumption on transient load change.
3-9
1ST FAIL TIME: Time delay in seconds after a sig-
nal from the first start master is not sensed by the ISOLATED BUS (CONT.)
PCC that a FIRST START FAIL warning is dis-
played.
RAMP UNLOAD TIME: When a load demand stop
input is sensed the load is ramped down from the
present load level on the set to the ramp unload lev- ISOLATED BUS:
+ 1ST FAIL TIME 12 SEC Y
el in the time specified in seconds. RAMP UNLD 20 SEC
− RAMP UNLD LEVEL 10 %
RAMP UNLOAD LEVEL: The load demand ramp
→ RAMP LOAD TIME 3 SEC
unload function will ramp the load down from the LOSS FIELD 20 SEC
present level on the set to this level before opening
the set circuit breaker. Value shown is in % of genset
standby rating.
FIGURE 3-6. ISO BUS SUBMENUS (CONT.)
RAMP LOAD TIME: When the load demand stop
signal is removed the load is ramped from 0kW to
the load share level in the specified time after the
circuit breaker closes.
LOSS FIELD TIME: Adjusts the loss of field func-
tion time delay. A typical delay which is suitable for
PowerCommand generator sets is 2 seconds.
3-10
UTILITY SUBMENUS
If you press the “UTILITY” button in the Setup

menu, the Utility submenus will appear (Figure 3-7). UTILITY
field. Exit menu to safe changes.
BASE LOAD (%): This controls the maximum kW UTILITY:
+ BASE LOAD 80% Y
load level that the generator set will operate at when PF LEVEL 1.00
paralleled with the utility (mains). The value shown − RAMP LOAD 3 B
indicates the steady state load on the generator as → RAMP UNLD 20
MODE MULTIPLE
a percent of the generator set standby rating.
Check generator set ratings for maximum load level
at which the generator set should operate when
paralleled with the utility (mains). Extended opera-
tion at load levels in excess of the generator set rat-
UTILITY:
ing can cause abnormal engine wear or premature + KW GOVERN GAIN 1.00 Y
engine failure. KVAR GOVERN GAIN 1.00
−
PF LEVEL: Adjusts the power factor that the gener- →
ator set will run at when paralleled to the utility
(mains). Recommended setting is 1.0.
RAMP LOAD TIME: This is the ramp time from
present set load to level determined by the load set
analog input. This is active when the control first en- FIGURE 3-7. UTILITY SUBMENUS
ters the load govern mode.
RAMP UNLOAD TIME: This is the ramp time from
present set load to 0 kW. This ramp is active when
the load set analog input is less than 0.5 volts.
MODE − MULTIPLE/SINGLE: This controls wheth-
er the set is to operate as part of a multiple set or
single set (PLTE or PLTF) system. (Refer to “LOAD
DEMAND SHUTDOWN” and “SINGLE MODE EN-
ABLE” function descriptions in wiring diagram,
page 5-8.)
KW GOVERN GAIN: This controls the rate that the
generator set kW load is increased after the genera-
tor set has closed to the system bus when utility
(mains) paralleled. Decreasing this value will result
in slower loading of the generator set.
KVAR GOVERN GAIN: This controls the rate that
the generator set kVAR load is increased after the
generator set has closed to the system bus when
utility (mains) paralleled. Decreasing this value will
result in slower loading of the generator set.
3-11
POWER TRANSFER CONTROL MAIN To adjust PTC system parameters, press the ap-
MENUS propriate PTC main menu button and refer to the
page number shown in Figure 3-8 for detailed infor-
If you press the “POWER TRANSFER SETUP” but-
mation related to the submenu selected.
ton in the Setup menu 2 in Figure 3-2, the two main
menus of the optional Power Transfer Control
(PTC) feature will appear (Figure 3-8).
PAGE PTC MAIN

3-13 MENU 1
UTILITY SENSORS Y
PAGE GENSET SENSORS B NEXT
3-15 MENU
TIMERS
PAGE
3-17
PTC MAIN
MENU 2
PAGE
TEST/EXERCISE Y
3-18
FIGURE 3-8. PTC SETUP MAIN MENUS
3-12
UTILITY SENSORS SUBMENUS
If you press the “UTILITY SENSORS” button in the U CT RATIO: Enter the CT Ratio of the Utility L2 CT.
PTC Main Menu 1, the Utility Sensors submenus This is the Ratio to 1 Amp. Range: 1−18000 (1A).
will appear (Figure 3-9).
The following field descriptions show the valid field CAUTION This CT must be rated for 1 Amp
entries and default value (shown in parenthesis) for output (e.g. NOT 5 Amp). Be sure CT secondary
each field. circuit has burden resistor or a shorting jumper
in place before putting power through the CT.
Use the + and − buttons to increase or decrease the Example: CT Ratio = 2650:1. Thus enter 2650.
field. Exit menu to save changes.
U SENSOR TYPE: Enter the line-to-line (L-N) for 3
phase line-neutral voltage sensing or line-to-line
U PT VOLT LL: Enter the value of the utility line-to- (L-L) for 3 phase line-line voltage sensing. This ap-
line voltage which yields 100% voltage at the termi- plies to both the utility undervoltage and overvol-
nals of the utility (bus) PT module. tage sensors. Range: L−L, L−N (L−N).
Range: 1−15000V, adjustable by standard nominal U <wye> <delta>: Enter utility connection type.
voltage values, 100V, 10V and 1V increments (1V). Range: Delta, Wye (Wye).
The 100% voltages for each of the four possible util-
ity (bus) PT modules are as follows, based on mod- U UNLOADED KW: Enter the kW on utility Line 2 at
ule dash number: which the utility is considered as unloaded. This is
−01 = 208 volts LL the L2 kW level at which a closed transition soft
−02 = 416 volts LL transfer will disconnect from the utility.
−03 = 600 volts LL
−04 = 120 volts LL UTILITY UNDERVOLTAGE: Non-adjustable field,
always enabled.
Example 1: Nominal Utility voltage is 480V. This
means that utility (bus) PT module number −02 UTILITY OVERVOLTAGE, FREQUENCY: Used to
should be used. The voltage which will yield 100% enable or disable menu function. Choose Enabled
volts at this PT module is 416 per the above table. or Disabled (Enabled).
Thus enter 416V.
Example 2: Nominal Utility voltage is 4160V. A pri- UV PICKUP: Enter a number between 85 and
mary stage transformer with a ratio of 4200/240 is 100% of the nominal voltage (90%).
used. This means that utility (bus) PT module num-
ber −01 should be used. The voltage which will yield UV DROP OUT: Enter a number between 75 and
the 100% volts (208V from above table) is calcu- 98% of the under-voltage pick-up percentage
lated as follows: (90%).
208 x (4200/240) = 3640. Thus enter 3640V.
UV DELAY: Enter a time between 0.1 and 5.0 sec-
U NOM VOLT LL: Enter the nominal utility line-to- onds (0.5 seconds).
line voltage. For example, 480, 4160, etc.. Range:
1−15000 V, adjustable by standard nominal voltage UV MIN PHASE: Displays the lowest line voltage of
values, 100V, 10V and 1V increments (1V). the three utility phases.
3-13
OV PICKUP: This adjusts the over-voltage pickup
as a percentage of the over-voltage drop-out. Enter UTILITY SENSORS
a number between 95 and 99% (95%).
OV DROP OUT: Enter a percentage between 105
and 135% of the nominal voltage (110%).
OV DELAY: Enter a range between 0 and 120 sec- U PT VOLT LL 416
+ U NOM VOLT LL 480 Y
onds (3 seconds). U CT RATIO: 1 1000
− U SENSOR TYPE L−L B
OV MAX PHASE: Displays the highest line voltage
→
of the three utility phases. U UNLOADED KW 50 KW
CENTER (FREQ): Enter a frequency between 45
and 65 Hz (60 Hz).
PICK UP (FREQ): Enter a percentage between 5
and 20% of the nominal frequency (10%). UTILITY UV: ENABLED
+ % VLL Y
DROP OUT (FREQ): Enter a percentage between PICK UP 95 475
− DROP OUT 85 465 B
1 and 5% of the nominal frequency (1%). → DELAY 0.5 S
MIN PHASE 470
DELAY (FREQ): Enter a time between 0.1 and 15.0
seconds (5.0 seconds).
FREQUENCY: This field displays the sensed utility
line frequency.
UTILITY OV: DISABLED
+ % VLL Y
PICK UP 95 487
→ DELAY 3.0 S
MAX PHASE 485
UTILITY FREQ: DISABLED

+ CENTER 60 HZ Y
PICK UP 10 %
− DROP OUT 1 %
→ DELAY 1.0 S
FREQUENCY 60.5 HZ
FIGURE 3-9. UTILITY SENSORS SUBMENUS
3-14
GENSET SENSORS SUBMENUS
If you press the “GENSET SENSORS” button in the G RAMP UNLOAD: Enter the ramp time for the
PTC Main Menu 1, the Genset Sensors submenus genset ramp unload rate during a closed transtion
will appear (Figure 3-10). soft load retransfer. Ramp rate is −100%kW divided
by this time setting. Range: 0−900 seconds (20
The following field descriptions show the valid field sec).
entries and default value (shown in parenthesis) for
each field. G UNLOADED KW: Enter the %kW (based on
standby rating) that the genset is considered un-
loaded. This is the %kW level at which a closed tran-
ton to move the cursor within a field or to the next sition soft retransfer will disconnect from the gen-
field. Exit menu to save changes. set. Range: 0−100% (5%).
G NOM VOLT LL: Non-adjustable field, displays GEN UNDERVOLTAGE: Non-adjustable field, al-
current setting of genset nominal voltage. (See Ad- ways enabled.
just submenu to adjust the output voltage ±5%.) GEN OVERVOLTAGE, FREQUENCY: Used to en-
G SENSOR TYPE: Enter the line-to-line (L-N) for 3 able or disable menu function. Choose Enabled or
phase line-neutral voltage sensing or line-to-line Disabled (Enabled).
(L-L) for 3 phase line-line voltage sensing. This ap- UV PICKUP: Enter a number between 85 and
plies to both the genset undervoltage and overvol- 100% of the nominal voltage (90%).
tage sensors. Range: L−L, L−N (L−N).
UV DROP OUT: Enter a number between 75 and
G BASE LOAD: Enter the maximum load the gen- 98% of the under-voltage pick-up percentage
set will carry during a closed transition. Range: (90%).
0−100% (80%).
UV DELAY: Enter a time between 0.1 and 5.0 sec-
G RAMP LOAD: Enter the ramp time for the genset onds (4 seconds).
ramp load rate during a closed transition soft load
transfer. Ramp rate is +100%kW divided by this UV MIN PHASE: Displays the lowest line voltage of
time setting. Range: 0−900 seconds (20 sec). the three genset phases.
3-15
OV PICKUP: This adjusts the over-voltage pickup
as a percentage of the over-voltage drop-out. Enter GENSET SENSORS
a number between 95 and 99% (95%).
OV DROP OUT: Enter a percentage between 105
and 135% of the nominal voltage (110%).
OV DELAY: Enter a range between 0 and 120 sec- G NOM VOLT LL 480
+ G SENSOR TYPE L−L Y
onds (3 seconds). G BASE LOAD 80.0%
− G RAMP LOAD 20 S B
OV MAX PHASE: Displays the highest line voltage G RAMP UNLOAD 20 S
→
of the three genset phases. G UNLOADED KW 5 %
CENTER (FREQ): Enter a frequency between 45
and 65 Hz (60 Hz).
PICK UP (FREQ): Enter a percentage between 5
and 20% of the nominal frequency (10%). GEN UV: ENABLED
+ % VLL Y
DROP OUT (FREQ): Enter a percentage between PICK UP 95 475
1 and 5% of the nominal frequency (1%). → DELAY 1.0 S
MIN PHASE 470
DELAY (FREQ): Enter a time between 0.1 and 15.0
seconds (5.0 seconds).
FREQUENCY: Displays the sensed genset line fre-
quency.
GEN OV: DISABLED
+ % VLL Y
PICK UP 95 487
→ DELAY 8.0 S
MAX PHASE 485
GEN FREQ: DISABLED

+ CENTER 59 HZ Y
PICK UP 12 %
− DROP OUT 2 %
→ DELAY 5.0 S
FREQUENCY 60.0 HZ
FIGURE 3-10. GENSET SENSORS SUBMENUS
3-16
TIMERS SUBMENU
If you press the “TIMERS” button in the PTC Main

Menu 1, the Timers submenu will appear (Figure TIMERS
3-11).
The following field descriptions show the valid field
each field.
START DELAY 60 S
Use the + and − buttons to increase or decrease the + STOP DELAY 60 S Y
values in the following fields. Use the arrow (→) but- TRANSFER 10 S
ton to move the cursor within a field or to the next − RETRANSFER 900 S
field. Exit menu to save changes. → PGM TRANSIT 5 S
MAX PARALLEL 30 S
START DELAY: Sets time delay for genset engine
start. Prevents nuisance genset starting during brief
power interruptions.
Enter a range from 0 to 300 seconds (0 seconds).
FIGURE 3-11. TIMERS SUBMENU
STOP DELAY: Sets the time delay for engine cool-
down following a re-transfer. This stop delay works
in conjunction with and is activated at the same time
as the normal cooldown timer. (Will extend normal
cooldown timer if entered time is greater.)
Enter a time from 0 to 600 seconds (0 seconds).
TRANSFER: In a Normal to Emergency transfer
this function allows the genset to stabilize before
the load is applied. Enter a time from 0 to 120 sec-
onds (10 seconds).
RETRANSFER: In a Emergency to Normal transfer
this function allows the utility to stabilize before the
load is applied.
PGM TRANSIT: Sets the time delay for Pro-
grammed Transition. A setting of 0.0 disables the
program.
MAX PARALLEL: Sets the maximum time during
closed transition that utility and genset can be paral-
leled.
3-17
TEST/EXERCISE SUBMENU
If you press the “TEST/EXERCISE” button in the

PTC Main Menu 2, the Test/Exercise submenu will TEST/EXERCISE
appear (Figure 3-12).
The following field descriptions show the valid field
each field.
Use the + and − buttons to increase or decrease the + Y
values in the following fields. Use the arrow (→) but- MODE CT-SOFT
ton to move the cursor within a field or to the next −
field. Exit menu to save changes. → TEST WITH LOAD OFF
EXER WITH LOAD OFF
MODE: Indicates the generator set application type
for PTC option.
OT-PGM TRAN − Open transition load transfer.
CT-MOMENT − Closed transition load transfer
FIGURE 3-12. TIMERS SUBMENU
with momentary (<100ms) overlap.
CT-SOFT − Closed transition load transfer with
load ramping.
TEST WITH LOAD: Feature allows genset Test se-
quence, which is initiated through the Remote Start
(TEST) switch, to operate with or without load. De-
fault: OFF
EXER WITH LOAD: Feature allows genset Exer-
cise sequence, which is initiated through control
panel Exercise button to operate with or without
load. Default: OFF
3-18
ADJUST SUBMENU are disabled to prevent inadvertent misadjustment
of the paralleling load sharing functions.
Figure 3-13 shows the main menus (Menu A and
Menu B) of the system control and the Adjust sub- Use the + and − buttons to increase or decrease the
menu. values in the following fields. Use the arrow (→) but-
To display the Adjust submenu, press the MORE>> field. Exit menu to safe changes.
button in Menu A and then the ADJUST button in
Menu B. START DELAY: This delay applies only to remote
starting in the Auto mode. The Start Delay adjust-
The Adjust submenus are intended for qualified ment range is 0 to 300 seconds.
service personnel and site personnel only and may
require a USER password. If a password is re- STOP DELAY: This delay applies only to remote
quired, the USER password menu will appear when stopping in the Auto mode. The Stop Delay adjust-
you try to modify the Adjust submenus. (Refer to ment range is 0 to 600 seconds.
PASSWORD Menu in this section to enter pass-
word. VOLTAGE: Used to adjust the output voltage ±5%.
Changes are automatically saved when you exit FREQUENCY: Used to adjust the frequency ±3 Hz.
this menu.
VOLTAGE/SPEED DROOP: These two submenus
If the generator set is operating in parallel with a apply to a genset that has the paralleling option and
system bus, the voltage and frequency adjustments is configured to operate in droop mode.
MENU A
ADJUST:
MENU START DELAY 5 SEC
ENGINE MORE>> + Y
B STOP DELAY 11 SEC
ALTERNATOR _\_ − VOLTAGE 208 1.2 % B
CONTROL HISTORY/ABOUT → FREQ 60.0 HZ -0.0 HZ
MENU B
ADJUST:
+ STANDBY Y
VOLTAGE DROOP OFF
ADJUST − BUS L1 480 V B
BUS DATA → POWER FACTOR 0.80
MENU VOLT 4.99 %
SETUP BACK<<
A
ADJUST:
+ STANDBY Y
SPEED DROOP OFF
− BUS FREQ 60.0 HZ
→ TOTAL KW 300 KW
FREQ 60.0 0.40 HZ
FIGURE 3-13. ADJUST SUBMENU
3-19
CALIBRATION PROCEDURE display of the genset that is running when the bus is
energized. If it is necessary to adjust the output volt-
There are several circuit cards/modules that, when age display of the genset that is running, the InPower
removed and replaced, require you to recalibrate service tool must be used to switch off the synchro-
the control panel display for genset voltage and cur- nizer function of the control.
rent and bus voltage. 1. Display the Voltage Calibration submenu
Note that the type of calibration to perform varies for (Page 3-6).
each card. The letters A, B and C are used to desig- 2. With the genset OFF, attach a calibrated volt-
nate which of the following three calibration proce- meter to the AC output from L1 to L2. (L1 to
dures are required for each card/module. Neutral for single phase alternators.)
• Genset/Parallel board (A, B & C) 3. Start the genset and allow it to reach normal
operating speed.
• PT/CT board (A & B) 4. Calibrate voltage reading for L1 so that the
• Bus PT (C) reading on the display agrees with the cali-
• CT’s (B) brated voltmeter.
5. Shut the generator set OFF.
6. Repeat steps 2 through 5 for L2 and L3. (In step
WARNING Contacting high voltage compo- 2 attach meter to the AC output from L2 to L3 to
nents can cause electrocution, resulting in se- calibrate L2 and L3 to L1 to calibrate L3.)
vere personal injury or death. Calibration and 7. Exit menu to safe changes.
adjustment must be performed by technically
(B) Genset Ammeter Display Calibration
qualified personnel only. Read and observe all
WARNINGS and CAUTIONS in your generator 1. Display the Current Calibration submenu
set manuals. (Page 3-6).
CAUTION Improper calibration or adjustment 2. With the genset OFF, attach a calibrated am-
of the PowerCommand control can cause meter to L1.
equipment malfunction or damage. Calibration 3. Start the genset and allow it to reach normal
and adjustment must be performed by techni- operating speed.
cally qualified personnel only. 4. Load the genset to maximum rated kVA at
rated voltage.
Use a calibrated RMS multimeter for accurate mea-
surements. 5. Calibrate the reading for L1 current so that the
reading on the display agrees with calibrated
(A) Genset Voltage Display Calibration ammeter.
6. Repeat steps 2 through 5 for L2 and L3. (In step
The PowerCommand control automatically synchro-
nizes to the system bus when bus voltage is avail-
2, attach meter to L2 to calibrate L2 current and
able and the genset is running. Consequently, it is L3 to calibrate L3 current.)
not possible to calibrate the genset output voltage 7. Exit menu to safe changes.
3-20
(C) Bus Voltage Calibration meter to TB1-A (L1) and TB1-B (L2) of the bus
PT module (Figure 3-14).
The PowerCommand control automatically synchro- 3. Start another genset and allow it to reach nor-
nizes to the system bus when bus voltage is avail- mal operating speed and voltage. Connect op-
able and the genset is running. Consequently, it is erating genset to the bus.
not possible to calibrate the genset bus voltage dis- 4. Calibrate the voltage reading for Bus Volts L1
play of the genset that is running when the bus is en-
so that the reading on the display matches the
ergized. If it is necessary to adjust the bus voltage
display of the genset that is running, the InPower
reading on the calibrated meter.
service tool must be used to switch off the synchro- 5. Shut the generator set OFF.
nizer function of the control. 6. Repeat steps 2 through 5 for Bus Volts L2 and
L3. (In step 2 attach meter to the AC output
1. Display the Bus Voltage Calibration submenu from L2 to L3 to calibrate L2; L3 to L1 to cali-
(Page 3-6). brate L3.)
2. With all gensets OFF, attach a calibrated volt- 7. Exit menu to safe changes.
CONTROL
BOX DOOR
TB1-A (L1) TB1-C (L3)

TB1-B (L2)
FIGURE 3-14. BUS PT MODULE
3-21
CONTROL BOX WIRING 3-15). Optional equipment such as a remote annun-
ciator panel, sensing devices used to monitor gen-
The generator set control box assembly, which can set operation, remote start/stop switches, control
be located on either side of the genset, contains box heater, and etc. are also attached to these ter-
connection points for remote control and monitor
minal blocks. Driver signals for customer supplied
options.
relays are also provided for several alarm and shut
Customer monitor/control connections are at- down conditions. Refer to Customer Connections
tached to terminal blocks TB3 and TB8 (see Figure diagram in Section 7.
3-22
CONTROL WIRING
OPTIONAL OPTIONAL ACCESS
RUN RELAYS SHUTDOWN
K11, K12 & K13 ALARM RELAY K16
TB8
CARD
CAGE
FIGURE 3-15. CONTROL BOX ASSEMBLY INTERIOR
3-23
RUN RELAYS (K11, K12, K13) as fans, pumps and motorized air dampers. The run
relays are energized when the generator set reach-
The optional run relays are rail mounted inside the es operating speed.
control box (Figure 3-15). The rail mount allows you
to easily remove and replace the snap-on relays. The contacts are rated:
The generator set can be equipped with one, two or
three run relays. • 10 amps at 28 VDC or 120 VAC, 80%PF
The three-pole, double-throw run relays (Figure • 6 amps at 240 VAC, 80%PF
3-16) are used to control auxiliary equipment such • 3 amps at 480/600 VAC, 80%PF
K11, K12, K13
CUSTOMER
K11, K12, K13
CONNECTIONS
K11, K12, K13
K11 K12 K13

RUN RELAY RUN RELAY RUN RELAY
NO NO NO
NC NC NC
COIL TB3-7
TB3-5
(SWITCHED B+) COM (GND)
FIGURE 3-16. OPTIONAL RUN RELAYS (K11, K12, K13)
3-24
ALARM RELAY (K16) as audible alarms. Any generator set shutdown will
energize the alarm relay.
The optional alarm relay is rail mounted inside the
control box (Figure 5-2). The rail mount allows you The contacts are rated:
to easily remove and replace the snap-on relay. • 10 amps at 28 VDC or 120 VAC, 80%PF
The three-pole, double-throw alarm relay (Figure • 6 amps at 240 VAC, 80%PF
5-4) is often used to energize warning devices such • 3 amps at 480/600 VAC, 80%PF
K16
CUSTOMER
K16
CONNECTIONS
K16
K16
SHUTDOWN ALARM
NO
NC
COIL TB3-18
TB3-17
(COM ALARM) COM (GND)
FIGURE 3-17. OPTIONAL ALARM RELAY (K16)
3-25
MAGNETIC SPEED PICKUP UNIT (MPU)
INSTALLATION
To install the MPU sensor, bar the engine until a MAGNETIC
gear tooth on the flywheel lines up in the center of PICKUP
the mounting hole. Thread the sensor in gently by SENSOR
hand until it just touches the gear tooth. Back it out
one quarter turn and set the locknut.
CAUTION Do not use fan blade to bar over en-
gine. That can damage blades and cause prop-
erty damage and personal injury.
ENGINE
FLYWHEEL
RING GEAR
FIGURE 3-18. MPU SENSOR
3-26
4. Servicing the Generator
GENERAL WARNING Incorrect service or replacement of
parts can result in severe personal injury or
This section describes how to isolate a voltage fault death, and/or equipment damage. Service per-
to the PCC control circuitry or generator, and the sonnel must be trained and experienced to per-
procedures to test, disassemble and reassemble form electrical and mechanical service.
the generator (Figure 4-1).
WARNING HAZARDOUS VOLTAGE. The
PCC1301 control box must be opened only by
technically qualified personnel. Voltages of up
to 600 VAC are present in the PCC box. These
voltages can cause electrical shock, resulting
in personal injury.
EXCITER
RECONNECTION
STATOR
TERMINALS
END BRACKET
PMG
STATOR
END
STATOR BEARING
BLOWER PMG
ROTOR
COUPLING
EXCITER
ROTOR
ROTATING
RECTIFIER
ASSEMBLY
DRIVE ROTOR
DISCS
FRAME
END BRACKET/ENGINE
ADAPTOR
AIR DISCHARGE
PRESSURE COVERS
ROTOR
PLATE
SHAFT
FIGURE 4-1. TYPICAL GENERATOR
4-1
GENERATOR/PCC CONTROL ISOLATION 4. Bring two jumpers from a 12 volt battery for
PROCEDURE connection to the X (Field +) and XX (Field −)
pins of plug 10.
The following procedure is used to determine if the X = Red wire of connector 10-6
generator or the PCC control circuitry is causing a XX = Brown wire of connector 10-3
high/low AC voltage shutdown fault. Connect the jumper from the positive (+) post
of the battery to the X pin (red wire) of 10-6. Be
1. Throw the line circuit breaker OFF and shut prepared to connect the jumper from the nega-
down the set. tive (−) post of the battery to the XX pin (brown
wire) of 10-3. If one of the 12 volt cranking bat-
CAUTION This test involves unregulated
teries is used, bring the jumpers from the bat-
excitation of the generator. To prevent dam- tery connected on the grounded side of the sys-
age to the generator due to overcurrent, tem to avoid inadvertently imposing 24 volts on
make sure that all loads have been discon- the system.
nected and that all faults have been cleared
5. Check polarity again. Polarity must be correct
from the power output terminals of the gen-
erator. or this test will be inconclusive because the in-
duced and residual magnetic polarities in the
exciter stator will be opposed.
WARNING HAZARDOUS VOLTAGE.
Touching uninsulated parts inside the con- 6. Start the set and connect the jumper from the
trol housing and power output boxes can battery negative (−) terminal to the XX lead.
result in severe personal injury or death. 7. The generator circuitry is probably okay if rated
Measurements and adjustments must be output voltage or higher is obtained and the
done with care to avoid touching hazard- voltages for all phases are balanced when the
ous voltage parts. exciter is powered by a 12 volt battery. Refer to
Troubleshooting and Repair Manual Power-
Stand on a dry wooden platform or rubber Command Control to troubleshoot the PCC
insulating mat, make sure your clothing control circuitry. (Normal excitation voltage
and shoes are dry, remove jewelry and use ranges from approximately 10 VDC at no-load
tools with insulated handles. to approximately 40 VDC at full−load.)
8. If the voltages are unbalanced, troubleshoot
2. Open the door of the control box assembly and the main stator first. If the voltages are uniform-
remove plug 10 from connector 10 of the volt- ly low, troubleshoot the exciter and field circuits
age regulator output module. first. Perform the Winding Resistance Test pro-
3. Prepare to measure output voltage across the cedure for the desired windings as noted in this
generator terminals while the set is running. section.
4-2
TESTING THE GENERATOR Insulation Resistance Testing
These tests can be performed without removing the The insulation resistance test should be performed
generator. Before starting tests, disconnect the before the initial start-up of the generator set or
negative (−) cable from the battery to make sure the when low winding insulation is suspected, e.g.
engine will not start while performing these tests. damp or wet windings.
A 500 VAC megger is recommended for insulation
WARNING Ignition of explosive battery gases testing. A test consists of applying the test potential
can cause severe personal injury or death. Arc- between the winding and ground (winding lamina-
ing at battery terminals, light switch or other tions).
equipment, flame, pilot lights and sparks can ig-
nite battery gas. Do not smoke, or switch Resistance values of at least 5.0 megohms should
trouble light ON or OFF near battery. Discharge be obtained for a new generator with dry windings.
static electricity from body before touching bat- For a set that has been in service, the resistance
teries by first touching a grounded metal sur- reading should not be less than 1 megohm.
face. If low readings are obtained, the cause should be in-
vestigated and corrected before the generator set is
Ventilate battery area before working on or near
returned to service.
battery—Wear goggles—Stop genset and dis-
connect charger before disconnecting battery If moisture is determined to be the cause of low test
cables—Disconnect negative (−) cable first and readings, a winding drying process will be required.
reconnect last. Megger Testing:
CAUTION Disconnect battery charger from AC 1. Open the control box door and remove connec-
source before disconnecting battery cables. tor 10 from the AVR module.
Otherwise, disconnecting cables can result in 2. Disconnect the AC voltage sense leads from
voltage spikes damaging to DC control circuits the generator output terminals. The AC voltage
of the set. sense leads are marked 5, 6, 7 and 8. Refer to
the appropriate Reconnection Diagram in Sec-
WARNING Accidental starting of the generator
tion 7.
set can cause severe personal injury or death.
3. If the RTD (resistive thermal device) option is
Prevent accidental starting by disconnecting
installed, ground all six RTD temperature
the negative (−) cable from the battery terminal.
leads. Each RTD has three leads, one red and
two white leads. Total of 18 leads must be
grounded.
4. Perform the Insulation Resistance Test proce-
dure for the desired windings as noted in this
section.
Drying the Windings: If low readings are obtained
or the set has been in standby for a long time in high
humidity conditions, the windings should be dried
out and the test repeated. Use the generator heat-
ers (if so equipped) or blow warm air through the
generator from front to back with a fan.
4-3
Exciter Stator Testing Winding Insulation Resistance: Discon-
nect exciter stator leads F1 and F2 from their con-
Testing Winding Resistance: Measure winding nectors in the AC wiring harness and isolate them
resistance with a Wheatstone bridge or digital ohm- from ground. Connect either one to the megger and
meter. Replace the stator if winding resistance is conduct the test as instructed under Insulation Re-
not as specified by Table 4-1. sistance Testing.
MEASURE WINDING IN- MEASURE WINDING RESISTANCE

SULATION RESISTANCE BE- BETWEEN THE TWO STATOR
TWEEN EITHER LEAD AND LEADS, F1 (X) AND F2 (XX)
THE STATOR LAMINATIONS
FIGURE 4-2. TESTING THE EXCITER STATOR
4-4
Exciter Rectifier Bridge (Rotating Rectifier sistance is high or low in both directions, replace the
Assembly) diode.
The exciter rectifier bridge is mounted on the exciter Replacing Diodes: Make sure the replacement
rotor, inboard, facing the main rotor. It consists of a diode is of the correct polarity. Disconnect the pigtail
positive plate and a negative plate, split diametrical- from the terminal post and unscrew the old diode.
ly. Each carries three diodes, three terminal posts Apply heat-sink compound under the head of the
for connecting exciter rotor leads to the diode pig- diode. Make sure the compound does not get on the
tails and a terminal for the main rotor (generator threads. Torque the diodes to 36 to 42 in-lbs (4 to 4.8
field) lead. A surge suppresser is connected across Nm) and the pigtail terminals to 24 in-lbs (2.7 Nm)
the two plates to prevent transient voltages that when reassembling.
could damage the diodes.
Surge Suppresser Testing and Replacement:
Remove the suppresser. Replace the suppresser if
Testing Diodes: Disconnect the diode pigtails from it appears to have overheated or if ohmmeter read-
the terminal posts. Using an ohmmeter, measure ings indicate less than infinite resistance (end of
electrical resistance between each diode pigtail and scale) in both directions. Torque the terminals to 24
the plate on which the diode is mounted. Reverse in-lbs (2.7 Nm) when reassembling.
the meter test probes and repeat the tests. The
electrical resistance across each diode should be CAUTION Layers of dust can cause diodes to
high in one direction and low in the other. If the re- overheat and fail. Brush dust off regularly.
DIODE (ONE OF SIX) TERMINAL

DISCONNECT THE DIODE PIG- (ONE OF SIX)
TAIL FROM THE TERMINAL
AND MEASURE ELECTRICAL
RESISTANCE BETWEEN THE
PIGTAIL AND THE METAL DIODE PLATES
PLATE UNDER THE DIODE (TWO)
SURGE SUPPRESSER
REMOVE TO TEST
FIGURE 4-3. TESTING THE ROTATING RECTIFIER ASSEMBLY
4-5
Exciter Rotor Testing Winding Insulation Resistance: Connect
Testing Winding Resistance: Disconnect the six any lead to the megger and conduct the test as
rotor winding leads from the terminal posts on the instructed under Insulation Resistance Testing.
rectifier assembly. With a Wheatstone bridge, mea-
sure electrical resistance across each pair of rotor
windings: U (CR1 or CR4) and V (CR2 or CR5), V
(CR2 or CR5) and W (CR3 or CR6), W (CR3 or
CR6) and U (CR1 or CR4). See the winding sche-
matic. Replace the whole rotor shaft assembly if the
resistance of any winding is not approximately
0.136 ohms.
MEASURE WINDING INSULATION

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

LEADS FROM THEIR TERMINALS AND
MEASURE ELECTRICAL RESISTANCE
ACROSS EACH PAIR OF WINDINGS: U-V,
V-W, W-U
FIGURE 4-4. TESTING THE EXCITER ROTOR
4-6
Main Rotor (Generator Field) Testing Winding Insulation Resistance: Connect
Testing Winding Resistance: Disconnect the two either lead to the megger and conduct the test as
leads of the main rotor from the terminals on the ro- instructed under Insulation Resistance Testing.
tating rectifier assembly. See Figure 4-4. Measure
electrical resistance between the two leads with a
Wheatstone bridge or digital ohmmeter. Replace
the rotor if the resistance is not as specified in Table
4-1. Connect the rotor leads and torque the termi-
nals to 24 in-lbs (2.7 Nm) when reassembling.
MEASURE WINDING INSULATION RE-

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

FROM THE ROTATING RECTIFIER ASSEMBLY
AND MEASURE THE WINDING RESISTANCE
BETWEEN THEM
FIGURE 4-5. TESTING THE MAIN ROTOR
4-7
Main Stator Winding Resistance: Disconnect all main stator
Winding Insulation Resistance: Test each wind- leads from the terminals to which they are con-
ing separately. Disconnect the winding lead from its nected. Using a Wheatstone bridge having at least
grounded neutral connection and isolate it (see re- 0.001 ohm precision, measure electrical resistance
connection drawing). Leave the other windings across each pair of stator leads (see reconnection
grounded. Connect either or both winding leads to drawing). Replace the stator if the resistance of any
the megger and conduct the test as instructed un- winding is not as specified in Table 4-1.
der Insulation Resistance Testing.
WHEATSTONE
BRIDGE
FIGURE 4-6. TESTING THE GENERATOR STATOR
4-8
TABLE 4-1. WINDING RESISTANCE VALUES*
MAIN STATOR
FRAME EXCITER EXCITER MAIN
MODEL WINDING WINDING WINDING WINDING
SIZE STATOR ROTOR ROTOR
11 12 17 07
5C 17 0.174 1.55 0.0068 N/A 0.0105 N/A
DFEG 5D 17 0.174 1.77 0.0057 N/A 0.0079 N/A
thru
DFEK 5E 17 0.174 1.96 0.0043 N/A 0.0068 N/A
5F 17 0.174 2.16 0.0037 N/A 0.0049 N/A
6G 17 0.158 1.44 0.0037 0.0148 N/A 0.011
DQCA 6H 17 0.158 1.54 0.0027 0.0108 N/A 0.0072
thru
DQCC 6J 17 0.158 1.73 0.0024 0.0096 N/A 0.006
6K 17 0.158 1.95 0.0019 0.0076 N/A 0.0052
* Resistance figures are approximate, at 68° F (20° C) + 10%.
TESTING THE PMG 3. Measure voltage across lead pairs J10-1 &
J10-4, J10-4 & J10-5, and J10-5 & J10-1. Volt-
WARNING HAZARDOUS VOLTAGE.
age should be at least 150 VAC for 50 Hz sets
Touching uninsulated parts inside the con-
and at least 180 VAC for 60 Hz sets, and should
trol housing and power output boxes can
result in severe personal injury or death. be approximately the same for each set of
Measurements and adjustments must be leads. If the voltages are low or uneven, check
done with care to avoid touching hazard- all the leads and connections between the volt-
ous voltage parts. age regulator output stage module and the
PMG and repair as necessary before disas-
Stand on a dry wooden platform or rubber
sembling the PMG.
insulating mat, make sure your clothing
and shoes are dry, remove jewelry and use 4. Stop the set and measure electrical resistance
tools with insulated handles. across lead pairs J10-1 & J10-4, J10-4 &
1. Disconnect plug J10 from the voltage regulator J10-5, and J10-5 & J10-1 with a Wheatstone
output stage module. bridge or digital ohmmeter. Each winding
2. Start the engine at the set and let the speed sta- should have a resistance of approximately 2.6
bilize. ohms.
4-9
BEARING REMOVAL/REPLACEMENT Bearing Replacement
When replacing bearing onto rotor shaft, be sure to
Bearing Removal apply pressing force to the inner face of the bearing
only. Install the bearing in reverse order of removal.
The end bearing is enclosed in a pre-packed car-
tridge housing and must only be dismantled as nec- Bearing Lubrication
essary for relubrication, replacement, or when a
major overhaul is carried out on the generator set. When re-lubricating or replacing the bearing, re-
view the following.
Removal of the bearing can only be accomplished
• Recommended Lubricant: Lithium based
after removal of the endbracket, as follows:
grease, Mobilux No. 2 or Shell Alvania R3.
1. Remove the four screws holding bearing cap. • Temperature Range: -22°F to +248°F (-30°C to
2. Remove cap. +120°C).
• Quantity: 2.74 oz. (81 ml). The grease should
3. Remove circlip.
be equally divided between the bearing, the
4. Remove bearing cartridge housing complete bearing cap cavity, and the bearing cartridge
with bearing. cavity.
4-10
GENERATOR DISASSEMBLY 3. Remove the lower back panel of the control
housing (see Figure 4-7).
The following procedures provide information for
removal and reassembly of the PMG, exciter, con- 4. Remove the three M5X12mm capscrews and
trol housing, and stator/rotor assemblies. Be sure to lockwashers from the PMG cover, and remove
read through this section first, before performing cover.
procedures listed, to determine the steps most ap- 5. Disconnect the PMG wiring harness connector.
propriate for the service attention required.
6. Remove the four bolts and clamps retaining the
Permanent Magnet (PMG) Removal exciter stator housing to the endbracket.
WARNING Ignition of explosive battery gases 7. Tap the stator housing out of its spigot, and
can cause severe personal injury or death. Arc- carefully remove from generator endbracket.
ing at battery terminals, light switch or other The highly magnetic rotor will attract the stator
equipment, flame, pilot lights and sparks can ig- core; care must be taken to avoid any contact
nite battery gas. Do not smoke, or switch which may damage the windings.
trouble light ON or OFF near battery. Discharge
static electricity from body before touching bat- 8. Remove the hex head through-bolt from the ro-
teries by first touching a grounded metal sur- tor shaft and firmly pull the complete rotor as-
face. sembly from its location. Keep the rotor clean
by avoiding contact with metal dust or particles.
Ventilate battery area before working on or near CAUTION The rotor assembly must not be
battery—Wear goggles—Stop genset and dis-
dismantled, or the magnetic properties will
connect charger before disconnecting battery
be destroyed.
cables—Disconnect negative (−) cable first and
reconnect last. Permanent Magnet (PMG) Installation
1. Install the complete rotor assembly to the end
CAUTION Disconnect battery charger from AC of the main rotor shaft using the hex head
source before disconnecting battery cables. through-bolt. Keep the rotor clean by avoiding
Otherwise, disconnecting cables can result in contact with metal dust or particles.
voltage spikes damaging to DC control circuits
of the set. 2. Carefully locate the stator housing to position
on the generator endbracket. Fasten in place
WARNING Accidental starting of the generator using the 4 bolts and clamps, and tighten se-
set can cause severe personal injury or death. curely.
Prevent accidental starting by disconnecting
The highly magnetic rotor will attract the stator
the negative (−) cable from the battery terminal. core, care must be taken to avoid any contact
1. Turn off and disconnect battery charger (if which may damage the windings.
equipped). 3. Connect the PMG wiring harness connector.
2. Disconnect the negative (-) battery cable to 4. Install the PMG assembly cover using the three
prevent accidental starting of the generator set M5x12mm capscrews and lockwashers, and
while servicing. tighten securely.
4-11
UPPER ACCESS
PANEL LOCATION
(BOTH SIDES)
UPPER FRONT
PANEL
LOWER BACK
PANEL
LOWER FRONT SIDE
PANELS PANEL
DFEG−DFEK CONTROL HOUSING
CONTROL HOUSING
CONTROL HOUSING
ACCESS COVERS
(BOTH SIDES)
GENERATOR AIR INLET

GENERATOR
COVER (ROTATING
AIR DISCHARGE
RECTIFIER ACCESS)
COVERS
DQCA−DQCC CONTROL HOUSING
FIGURE 4-7. CONTROL HOUSING ASSEMBLIES
4-12
Main Stator and Rotor Removal is controlling weight of control housing as-
1. Remove the PMG, refer to Permanent Magnet sembly.
Generator Removal, earlier this section. b. Remove control housing fasteners, and
remove the control housing assembly
2. DFEG−DFEK: Remove the lower back panel,
from the generator.
the two lower front panels and the upper ac-
cess panels of the control housing assembly
(see Figure 4-7). 12. DQCA−DQCC Control Housing Removal
3. DQCA−DQCC: Remove the upper access a. Loosen the fasteners that secure the con-
panels of the control housing assembly. trol housing side panels to generator.
4. Remove the air inlet and discharge panels of Make sure that hoisting device is control-
the generator. ling weight of control housing assembly.
b. Remove control housing fasteners, and
CAUTION Do not use fan blade to bar over
remove the control housing assembly
engine. That can damage blades and cause
from the generator. Replace panel fasten-
property damage and personal injury.
ers to their respectable positions for safe
5. Crank or bar the engine/generator to position keeping, and tighten finger-tight.
the rotor such that a full pole face is at the bot-
tom of the main stator core. Proper positioning To remove the stator and rotor at the same time,
can be viewed through the generator access skip to step 30. To remove the stator and rotor
individually, continue with step 13.
openings. Refer to engine service manual for
proper cranking or barring procedure. 13. Remove the four bolts retaining the bearing
6. Disconnect all load wires from the reconnec- cartridge housing in the endbracket (outer four
tion terminal block assembly. If equipped with bolts).
the circuit breaker option, disconnect load 14. Remove the eight bolts holding the endbracket
wires from circuit breaker. Check that all leads to the generator housing.
are labeled to ease reassembly.
15. Insert two bolts (M10) in the two holes provided
7. Disconnect the remote control wiring and con- for “jacking” purposes, on the endbracket cen-
duit from the control housing. For reconnec- ter line. Screw bolts in until endbracket spigot
tions later, make sure each wire is clearly is clear of locating recess.
marked to indicate the correct terminal.
16. Carefully tap the whole assembly off the bear-
8. Disconnect the engine harness connectors ing cartridge housing, ensuring the endbracket
(INLINE A, B, and C) and the DC power con- is supported to prevent the exciter stator from
nector for the engine block heaters (INLINE F) damaging the windings on the exciter rotor.
and place harness on top of control housing.
9. Mark and disconnect the wires to the CT’s. WARNING To prevent personal injury, use
adequate lifting devices to support heavy
10. Use a hoist or similar lifting device to support components. Keep hands and feet clear
the control housing assembly. while lifting.
WARNING To prevent personal injury, use 17. The exciter stator is now accessible for inspec-
adequate lifting devices to support heavy tion and removal from endbracket/engine
components. Keep hands and feet clear adaptor.
while lifting. 18. The end bearing can now be removed if re-
11. DFEG−DFEK Control Housing Removal quired. Refer to Bearing Removal in this sec-
tion.
a. Loosen the fasteners that secure the con-
trol housing side and bottom panels to 19. Remove the fasteners from the two generator
generator. Make sure that hoisting device mounting feet brackets.
4-13
20. Using an adequate lifting device, lift the gener- place by supporting the flywheel housing. A
ator (at lifting eyes provided, and main stator length of steel channel and wooden blocking is
housing) until the mounting feet brackets are required to support the rear of the engine.
clear of the frame member (see Figure 4-8). Place the channel and blocking under the fly-
wheel housing. Lower the generator until most
21. If the engine does not have chassis mounts at of the genset weight is supported by the block-
generator end, block the rear of the engine in ing (see Figure 4-8).
STATOR ROTOR
ASSEMBLY ASSEMBLY
LIFT LIFT
USE FORKLIFT OR
OTHER ADEQUATE
LIFTING DEVICE TO
SLIGHTLY LIFT ROTOR
SHAFT UNTIL ROTOR
CAN BE SUPPORTED
BY HOIST/SLING.
BLOCKING UNDER
STATOR MOUNTING FEET ROTOR ENGINE FLYWHEEL
ASSEMBLY BRACKETS ASSEMBLY HOUSING
FIGURE 4-8. REMOVING STATOR ASSEMBLY
4-14
22. Disconnect the grounding strap from the fly- assembly. Do not allow rotor assembly to hang
wheel housing. on engine flywheel.
23. Using a forklift, position a lifting bar of the forklift CAUTION Drive disc damage can be
(inside and inline with the generator) under the caused by allowing the rotor assembly to
rotor shaft. Lift the rotor shaft slightly so that ro- hang on flywheel. Use adequate hoist and
tor is not resting on inside of stator assembly. sling to support the rotor assembly.
See Figure 4-9.
26. Reposition or add hoist and sling support for
24. Verify that the stator is adequately supported the main rotor, and remove the forklift. See Fig-
and then carefully remove the capscrews from ure 4-9, Rotor Lift detail.
the stator attachment ring.
WARNING To prevent personal injury, use
adequate lifting devices to support heavy components. Keep hands and feet clear
components. Keep hands and feet clear while lifting.
while lifting. 27. Remove the stator assembly, being careful not
to drag the windings on the rotor. Place stator
CAUTION Improper stator assembly rig- assembly away from the chassis in the horizon-
ging and handling can result in damage to tal position.
stator and rotor assemblies. Lifting eyes 28. Using the hoist and sling to support the rotor,
may not be at center-of-gravity position of carefully remove the capscrews and flat wash-
stator assembly. Therefore, lifting and mov- ers that secure the drive discs to the engine fly-
ing the stator assembly alone, by hoisting wheel.
at lifting eyes only, presents the hazard of
load imbalance; allowing one end to drop WARNING To prevent personal injury, use
and other end to rise. Make sure the stator adequate lifting devices to support heavy
is adequately hooked/strapped to maintain components. Keep hands and feet clear
level control of stator assembly while lifting while lifting.
and moving. 29. Remove the rotor assembly and place it on
25. Being careful not to drag the windings on the wood blocks in the horizontal position. To avoid
rotor, move the stator assembly sufficiently possible distortion, do not allow the drive discs
away from engine to sling and support the rotor and fan to rest on anything.
4-15
EXCITER
RECONNECTION
STATOR
TERMINALS
END BRACKET
PMG
STATOR
END
STATOR BEARING
BLOWER PMG
ROTOR
COUPLING
EXCITER
ROTOR
ROTATING
RECTIFIER
ASSEMBLY
DRIVE ROTOR
DISCS
FRAME
END BRACKET/ENGINE
ADAPTOR
AIR DISCHARGE
PRESSURE COVERS
ROTOR
PLATE
SHAFT
STATOR LIFT
(EXAMPLE)
ROTOR LIFT
(EXAMPLE)
FIGURE 4-9. TYPICAL GENERATOR ASSEMBLY
4-16
Generator Assembly Removal
GENERATOR
30. Remove the fasteners from the two generator LIFTING
mounting feet brackets. POSITIONS
31. Using an adequate lifting device, lift the gener-

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

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

quately supported. Carefully remove the caps-
crews securing the engine adaptor endbracket
to the engine flywheel housing.

components. Keep hands and feet clear
while lifting.
CAUTION Improper generator assembly

rigging and handling can result in damage
to stator and rotor assemblies. Lifting eyes
may not be at center-of-gravity position of
stator assembly. Therefore, lifting and mov-
ing the generator by hoisting at lifting eyes
only, presents the hazard of load imbal-
ance; allowing one end to drop and other
end to rise. Make sure the generator is ade-
quately hooked/strapped to maintain level
control of assembly while lifting and mov-
ing.
36. Remove the generator assembly away from
engine. Place generator assembly on floor with
a piece of wood beneath the stator housing (to-
ward PMG end) to allow for endbracket remov-
al, if desired.
4-17
GENERATOR REASSEMBLY 6. Install the mounting feet bracket fasteners; and
tighten securely.
Generator reassembly is the reverse of disassem-
bly procedure. If endbracket has been removed, continue with
To assemble the stator and rotor at the same time, step 7, otherwise skip to step 16.
continue with step 1. To assemble the stator and ro-
7. Lift slightly on end of rotor shaft and install
tor individually, skip to step 17.
wooden shims to hold rotor on center with sta-
1. Using an adequate lifting device, locate the tor.
generator assembly into position near the en-
gine flywheel housing. Align the holes of the ro- 8. If removed, refer to Bearing Removal/Replace-
tor drive discs with the holes of the engine fly- ment procedure in this section to install end
wheel. Install the capscrews and flat washers bearing.
that secure the drive discs to the engine fly- 9. Install two threaded studs into end bearing car-
wheel, hand tighten. tridge to aid subsequent procedures. Position
the end bearing cartridge assembly close to
proper position for hole alignment with end-
adequate lifting devices to support heavy bracket.
while lifting. 10. Assemble exciter stator, if removed, to inside of
endbracket. Tighten fasteners to 4.5 ft-lbs. (6
CAUTION Improper generator assembly N•m) torque.
rigging and handling can result in damage
to stator and rotor assemblies. Lifting eyes 11. Install endbracket to the stator frame using the
may not be at center-of-gravity position of proper capscrews and lock washers, but do not
stator assembly. Therefore, lifting and mov- tighten securely as yet.
ing the generator by hoisting at lifting eyes 12. Insert and start the threads of the bearing car-
only, presents the hazard of load imbal- tridge fasteners, and remove threaded align-
ance; allowing one end to drop and other ment studs, through the endbracket into the
end to rise. Make sure the generator is ade- cartridge housing.
quately hooked/strapped to maintain level
control of assembly while lifting and mov- 13. Lift slightly on endbracket and remove wooden
ing. shims holding rotor on center with stator.
2. Align the holes of the engine adaptor endbrack- 14. Securely tighten the endbracket fasteners.
et with the holes in the flywheel housing and 15. Tighten the bearing cartridge fasteners to 4.5
install the capscrews and lock washers. Refer ft-lbs. (6 N•m) torque.
to Table 4-2 for torque specifications.
3. Secure the rotor assembly to the flywheel. Re- TABLE 4-2. GENERATOR MOUNTING TORQUE
fer to Table 4-2 for torque specifications. FLYWHEEL HSG.
ROTOR ASSEM.
4. Lift the generator slightly and remove any MODEL ENDBRACKET TO
TO FLYWHEEL
blocking from under the flywheel housing. Low- ENGINE ADAPTER
er the generator (see Figure 4-10). DFEG− 75−85 ft-lbs. 65−70 ft-lbs.
DFEK (102−115 N•m) (88−95 N•m)
5. Connect the grounding strap to the flywheel
housing using a capscrew and EIT locking DQCA− 125−145 ft-lbs. 56−64 ft-lbs.
washer; and tighten securely. DQCC (165−195 N•m) (75−85 N•m)
4-18
16. Install the PMG assembly, if removed. Refer to 21. Reassemble engine adaptor endbracket to
Permanent Magnet (PMG) Installation. stator frame if removed. Using an adequate lift-
ing device, carefully move the stator into posi-
Perform the ‘Aligning Generator with Engine’ tion over the rotor assembly, being careful not
procedures, later in this section, then return to to drag the windings on the rotor.
the following steps.
To assemble the control housing, skip to step adequate lifting devices to support heavy
37. components. Keep hands and feet clear
while lifting.
To assemble the stator and rotor individually be-
gin here. CAUTION Improper stator assembly rig-
17. If removed, replace exciter rotor and rotating ging and handling can result in damage to
rectifier assembly to main rotor shaft. Recon- stator and rotor assemblies. Lifting eyes
nect main rotor wire leads to positive and nega- may not be at center-of-gravity position of
tive terminals of rectifier assembly. stator assembly. Therefore, lifting and mov-
ing the stator assembly alone, by hoisting
18. If removed, install the drive disk spacer, drive
at lifting eyes only, presents the hazard of
disc and pressure plate on the rotor shaft.
load imbalance; allowing one end to drop
Install the cap screws and flat washers and
and other end to rise. Make sure the stator
tighten to 352 ft-lbs. (476 N•m).
is adequately hooked/strapped to maintain
19. Using a hoist and sling to support the rotor, level control of stator assembly while lifting
align the holes in the drive disc with the corre- and moving.
sponding holes in the flywheel. 22. Using a forklift, position a lifting bar of the forklift
(inside and inline with the generator) under the
rotor shaft. Lift the rotor shaft slightly so that ro-
adequate lifting devices to support heavy tor is not resting on inside of stator assembly.
while lifting. 23. Remove the hoist/sling support of the rotor as-
sembly. Align the holes of the engine adaptor
20. Secure the rotor assembly drive disc to the fly-
endbracket with the holes in the flywheel hous-
wheel using appropriate capscrews and flat
ing and install the capscrews and lock wash-
washers. Refer to Table 4-2 for torque specifi-
ers. Refer to Table 4-2 for torque specifications.
cations. Do not allow rotor assembly to hang on
engine flywheel. 24. Using an adequate lifting device, slightly raise
the generator so that the wooden blocking and
CAUTION Drive disc damage can be steel channel can be removed from under the
caused by allowing the rotor assembly to flywheel housing; then lower the generator so
hang on flywheel. Use adequate hoist and the full weight is resting on the generator
sling to support the rotor assembly. mounting feet brackets.
4-19
25. Connect the grounding strap to the flywheel 35. Tighten the bearing cartridge fasteners to 4.5
housing using a capscrew and EIT locking ft-lbs. (6 N•m) torque.
washer; and tighten securely. 36. Install the PMG assembly, if removed. Refer to
26. Install the mounting feet bracket fasteners; and Permanent Magnet (PMG) Installation.
tighten securely.
27. Lift slightly on end of rotor shaft and install adequate lifting devices to support heavy
wooden shims to hold rotor on center with sta- components. Keep hands and feet clear
tor. while lifting.
37. Use an adequate lifting device to lift the control
28. If removed, refer to Bearing Removal/Replace-
housing in position for mounting. Replace the
ment procedure in this section to install end
capscrews and lock washers and tighten to 18
bearing.
ft-lbs. (24 N•m) torque.
29. Install two threaded studs into end bearing car- 38. Connect all control wires and generator leads
tridge to aid subsequent procedures. Position using the proper generator set AC and DC wir-
the end bearing cartridge assembly close to ing diagram/schematic.
proper position for hole alignment with end-
bracket. 39. Reassemble any engine air intake compo-
nents removed during generator disassembly.
30. Assemble exciter stator, if removed, to inside of 40. Reassemble the covers over the generator air
endbracket. Tighten fasteners to 4.5 ft-lbs. (6 discharge openings and fasten securely.
N•m) torque.
41. If equipped with the circuit breaker option, re-
31. Install endbracket to the stator frame using the connect load wires to circuit breaker. Recon-
proper capscrews and lock washers, but do not nect all lead wires to the terminal block assem-
tighten securely as yet. bly using proper reconnection diagram in Sec-
tion 7.
32. Insert and start the threads of the bearing car-
tridge fasteners, and remove threaded align- 42. Verify that all connections are proper and se-
ment studs, through the endbracket into the cure and then install the air inlet panel and ac-
cartridge housing. cess covers to control housing.
33. Lift slightly on endbracket and remove wooden 43. Connect the negative (-) battery cable and test
shims holding rotor on center with stator. the generator set for operation. If objectionable
vibration is present, refer to Aligning Generator
34. Securely tighten the endbracket fasteners. with Engine procedure later this section.
4-20
ALIGNING GENERATOR WITH ENGINE flex in alternate directions twice for each engine rev-
Proper alignment of the generator and engine as- olution. It is important to minimize the amount of
semblies is necessary to avoid premature wear and disc flexing since, if it is excessive, the drive disc will
improper operation of the genset. Review the fol- crack. Although perfect bearing alignment is desir-
lowing alignment conditions and procedures for able, it is more important to keep disc deflection to
aligning the generator assembly to engine flywheel the minimum possible. This procedure assumes
housing. that the pilot bore of the drive discs are in the exact
Angular Misalignment: Is the result of the genera- center and the flywheel counterbore (pilot) has no
tor bearing center axis not aligning with axis of the practical runout. Under these conditions, perfect
engine crankshaft. This condition creates an angle Angular alignment will be attained when no deflec-
between the generator shaft axis and the crank- tion of the disks is measured.
shaft axis. The cause of this type of misalignment is
Excessive Axial misalignment will cause more gen-
usually shimming error.
erator vibration than Angular misalignment.
Axial Misalignment: Is the result of the generator
shaft axis not aligning with engine crankshaft axis. Either type of misalignment may be present in a
The tolerances in the bolted flywheel and drive disc generator set assembly, with angular misalignment
connection may add up to displace the generator being the most common problem. Angular align-
axially relative to the crankshaft axis. ment may also be effected by set installation condi-
Misalignment Symptoms: If the assembly is al- tions and/or mishandling during shipping of the gen-
lowed to run under these conditions, the discs must set.
4-21
Angular Alignment Procedure disc at the bolt circle diameter, see Figure 4-11. Bar
the engine over in a clockwise rotation as viewed
WARNING Accidental starting of the generator from engine flywheel. Do not allow it to roll back on
set during this procedure presents the hazard compression at the end of the travel of each read-
of severe personal injury or death. Make sure to ing. It is unnecessary to zero the indicator since the
disconnect the negative (-) battery cable(s) be- total indicator reading (T.I.R.) of the deflection mea-
fore beginning. surement to the bolt heads is what is required. T.I.R.
Fasten a dial indicator to either the generator shaft will be the sum of the maximum positive and nega-
or the cooling fan with the sensing point resting on tive dial indicator readings as the engine completes
the capscrew head or the flat surface of the drive one revolution.
SEE DETAIL A
CLAMP DIAL
INDICATOR
FLEX
DISCS
GENERATOR AND
MOUNTING BOLT
ENGINE AXIAL
TO DISC
CRANKSHAFT ALIGNMENT, SEE
MEASUREMENT
CENTERLINE FIGURE 4-13
DETAIL A
SHIMS
FIGURE 4-11. ANGULAR ALIGNMENT MEASUREMENT
4-22
Sample Generator Runout Readings 2. Measure the distance from the generator side
of the flex discs to the center of the generator
When taking the deflection readings described,
mounting bolt, refer to Figure 4-11. (For exam-
make a diagram similar to the example shown in
ple; a HC6 Frame’s distance is 28.4”.)
Figure 4-12, where a total indicator reading of .025”.
(The highest positive value of +.010 and the largest 3. Compare the distance measured in steps 1 and
negative value of -.015”.) The indicator is closer to 2. (28.4” vs 10.7” or a 2.65 to 1 ratio.) Multiply
the top and further away at the bottom. This exam- this ratio times one half the T.I.R. (In our exam-
ple indicates that the generator bearing is high. ple, .025” divided by 2 is .0125”. This, times
Since the side readings are equal, the generator is 2.65 equals .033”. Therefore, remove .033” of
centered side to side. To lower the generator, re- shims from under both mounting feet.)
move equal shims from under both generator In general, the T.I.R. should not be more than .001”
mounting feet. To approximate the amount of shims for each inch of radius (center of shaft to indicator
to remove or add: axis). If we use our example of 10.7”, then the maxi-
1. Measure the distance between the center of mum T.I.R. would be .011”. This would only require
the generator shaft to the point the indicator is a correction of .014” from the T.I.R. of .025”. (A read-
measuring at. (For example; a SAE 18 Disc ing of +.002 at the top and -.009 at the bottom would
coupling distance is 10.7”). fall within the satisfactory range.)
+.010
+.010
MEASURED AT
BOLT CIRCLE
DIAMETER
-.002
-.004
10.7 IN.
-.010
-.010
-.015
-.015
FIGURE 4-12. ANGULAR ALIGNMENT MEASUREMENT READINGS (Example)
4-23
Axial Alignment Procedure varying surface quality of the generator shaft’s drive
disc mounting hub.
Axial misalignment needs to be checked only when
an objectionable vibration is present. The goal of the Axial realignment is to reduce the
vibration level of the genset while it is operating. A
If excessive vibration remains after the angular small improvement in the T.I.R. runout may have
alignment, check for concentric alignment of the dramatic effects in the mechanically measured or
generator shaft/engine crankshaft axes. physically observed vibration levels.
Fasten dial indicator holding device to skid base, To correct for an out of tolerance T.I.R. indication,
engine block, or generator shell with a magnetic remove the capscrews connecting drive discs and
base or clamp and position so the sensor point of in- flywheel. Mark the drive discs and flywheel with re-
dicator rests on the generator shaft hub, see Figure spect to each other. Rotate either the engine or gen-
4-13. Bar the engine over in a clockwise rotation as erator so that drive discs holes are repositioned
viewed from engine flywheel, through a couple of 180 degrees from their original location. Put the
rotations. Record indicator readings in eight equally drive discs capscrews back in and retorque. Re-
spaced points around the shaft diameter. This will check shaft alignment as before. If shaft T.I.R.
provide a T.I.R. for Axial shaft misalignment. runout remains unchanged then the discs should be
The maximum allowable T.I.R. runout is subjective, rotated to either 30, 60, or 90 degrees from original
the optimal T.I.R. for runout would be .000”, howev- location to correct the out of tolerance condition. If
er, that may not be attainable. The recommendation the T.I.R. does not improve after repositioning, a
of this procedure will be to reduce the measured closer inspection of the flywheel pilot and drive disc
T.I.R. runout by one half. Specific out-of-tolerance runouts is required. This will help determine the
runout levels are difficult to establish due to the cause of the Axial misalignment.
ANGULAR ALIGNMENT,
SEE FIGURE 4-11
GENERATOR
SHAFT HUB
DIAL
INDICATOR
GENERATOR
CLAMP
AND ENGINE
CRANKSHAFT SEE DETAIL A FAN HOUSING
CENTERLINE
DETAIL A
FIGURE 4-13. AXIAL ALIGNMENT MEASUREMENT
4-24
5. Enclosure Fuel Tank System (DFEG-EK)
GENERAL PCC Customer Inputs
This section describes the operation and testing of
the components of the optional fuel tank system PCC Customer Switch 1 (Rupture Basin) and Local
shown in Figure 5-1. Low Fuel Switch Input are prewired to the sub-base
fuel tank when shipped from the factory.
When a sub-base fuel tank is provided, a fuel trans-
fer pump with control, an external fuel alarm panel
and external fuel fill box are available as an option. The “Low Fuel” warning message, when displayed
by the PCC, indicates that the fuel level has
WIRING CONNECTIONS dropped below the low fuel level (approximately
Fuel Transfer Control Customer Outputs 62%).
Refer to Enclosure/Options Wiring (DFEG−DFEK)

diagram in Section 7 for customer connections to The “Rupture Basin” warning message is used to in-
remote annunciators. dicate that fuel is detected in the fuel tank basin.
FUEL TRANSFER
CONTROL
FUEL ALARM
PANEL
EXTERNAL
FUEL FILL BOX
FUEL FILL
(INTERNAL)
FIGURE 5-1. FUEL TANK SYSTEM OPTIONAL COMPONENTS
5-1
FUEL TRANSFER PUMP Control Panel Switches and Indicators
The following paragraphs describe the operation of
the control switches and indicators.
The fuel transfer pump and control are available as
an option when a sub-base fuel tank is provided. Indicators:
The automatic control operates the fuel pump to • FUEL LEVEL (green): indicates in percent the
maintain a reservoir of fuel in the sub-base tank. amount of fuel that is contained in the sub-base
tank.
• HIGH FUEL (red): indicates that the fuel has
This section explains functions of the control panel reached an abnormally high level. It indicates a
lamps, components and operation/testing of the possible failure of the ”pump-off” float gauge in
day tank fuel control system. All red color lamps in- the sub-base tank. The lamp will turn off when
dicate a fault condition. the fuel level drops to normal.
FIGURE 5-2. TRANSFER PUMP CONTROL FRONT PANEL
5-2
• LOW FUEL (red): indicates that the fuel level the normally closed contact to provide a signal
has dropped below the low fuel level. This if a fault does occur.
warning enables the operator time to react to a • POWER ON (green): indicates that AC power
potential problem before low fuel shutdown oc- is available to the control.
curs. It indicates a possible empty main fuel
tank, fuel line restriction, pump failure, or failure Switches:
of the float gauge. • ON: This pushbutton activates the control after
• CRITICAL LOW FUEL (red): indicates that the the OFF pushbutton has been pressed.
fuel level has dropped to tank bottom. This • OFF: This pushbutton disables the control for
warning enables the operator time to shut routine maintenance to the tank system without
down generator set before fuel runs out, pre- disrupting the control. NOTE: This also de-ener-
venting loss of prime or engine damage. It indi- gizes the ECM FUNCTIONAL relay which will ac-
cates a possible empty main fuel tank, fuel line tivate a customer alarm wired to this relay.
restriction, pump failure, or failure of the float
gauge.
• TEST: This pushbutton will test all front panel
lamps for three seconds and activate pump/
The control should be wired to shut down the motor for as long as the button is pressed. All
genset (optional) as continued operation will al- alarm relays will not activate but will maintain
low air to enter the engine injection pump ne- their original state.
cessitating bleeding to restart the engine. The
control will reset after restoring the tank fuel Operation
level. This will also restore engine operation if The following steps describe how to operate the day
the tank control has been connected to shut tank controller.
down the engine.
NOTE: When power is applied to the control or is re-
CAUTION Continued operation with a stored after a power interruption, the control will au-
CRITICAL LOW FUEL fault can lead to a low tomatically go to the power on mode (functions the
fuel shutdown if the fuel level float switch same as pressing the ON switch). The pump will start
fails. if the control detects low fuel in tank.
• FUEL IN RUPTURE BASIN (red): indicates 1. Press the control ON switch for automatic op-
that the fuel has flooded the safety basin sur- eration. The green PUMP light will come on
rounding the fuel tank. The basin float switch and the pump will fill the tank. The level of fuel in
turns off the fuel pump. The pump cannot func- the tank will be automatically kept between a
tion again until the basin is drained of fuel. Pos- set of pump-on and pump-off float gauge.
sible cause, leak in fuel tank.
When filling an empty tank, the red CRITICAL
• PUMP (green): indicates that the fuel pump is LOW FUEL and LOW FUEL lights will come on
running. It will come on and go off as fuel is when the control switch is pushed to the ON
pumped to maintain the fuel tank level. position. This is normal. The red lights will turn
off as the tank is filled.
• ECM FUNCTIONAL (green): indicates no
faults are detected within the control circuitry 2. The green PUMP light indicates when the
(including float gauge). If a fault occurs, the pump is running. It will come on and off as fuel
lamp will go out and de-energize the control is pumped to maintain the proper level in the
relay. It is suggested that the customer wire to tank.
5-3
EXTERNAL FUEL FILL BOX cal high fuel condition, check the following possible
causes before replacing the valve.
The external fuel fill box plumping may contain the
optional overflow preventive valve (OFPV), which is • Defective Critical High switch mounted on fuel
used to prevent the overfilling of the fuel tank. The tank. (Critical High switch remains closed with
valve will energize (close) when a Critical High fuel fuel gauge indicating less than 95% full.)
condition (95% full) is detected/displayed by the Ex-
ternal Alarm panel. • Defective External Alarm panel. Refer to En-
closure/Options Wiring (DQCA−DQCC) dia-
If the valve remains closed after correcting the criti- gram in Section 7.
OVERFLOW
PREVENTIVE
VALVE (OFPV)
(OPTIONAL)
EXTERNAL
FUEL FILL BOX
FIGURE 5-3. OPTIONAL FUEL (SPILL) FILL BOX
5-4
EXTERNAL ALARM PANEL Solenoid Override Button
The following paragraphs describe the operation of The Solenoid Override Button is only provided on
the external alarm panel components. the Alarm Panel when the optional overflow preven-
tive valve (Figure 5-3) is provided with the external
Overfill Indicator/Horn/Mute Button fill box feature.
This switch is used to release the delivery hose

The overfill alarm Indicates that the fuel has
pressure caused by the closing of the overflow pre-
reached an abnormally high level (95%). Immedi-
ventive valve. This valve automatically closes dur-
ately stop adding fuel. It also indicates a possible
ing an overfill alarm, stopping the filling of the tank
failure of the “pump-off” float gauge for fuel systems
and creating pressure between the valve and the
that contain the fuel transfer pump.
delivery hose. Before disconnecting the delivery
hose, always press this button after an overfill warn-
The horn can be turned off by pressing the mute but-
ing to release fuel back pressure into the sub-base
ton. The indicator will turn off when the fuel level
tank.
drops to normal.
Test Button
Fuel Gauge
Press the TEST switch to test the indicator light and
Indicates the amount of fuel that is contained in the the horn. The test will remain active for as long as
sub-base tank. the button is pressed.
FUEL
GAUGE
OVERFILL
INDICATOR
SOLENOID OVERRIDE
BUTTON (OPTIONAL) HORN
TEST BUTTON MUTE BUTTON
FIGURE 5-4. EXTERNAL ALARM PANEL
5-5
RUPTURE BASIN LEAK DETECT SWITCH 2. Move the O/Manual/Auto switch to the MANU-
TEST AL position.
The rupture basin leak detect switch (Figure 5-5) is 3. Activate leak detect switch (move float up-
provided with sub-base fuel tanks used with the op- ward).
tional enclosure. This switch should be checked
once a year to make sure switch is properly operat- 4. Check control display for Rupture Basin fault
ing. In some areas, weekly inspections may be re- message. If no indication of fault, repair defec-
quired by safety code regulations. tive circuit. Refer to Enclosure/Options Wiring
To test the leak detect switch: (DQCA−DQCC) diagram in Section 7.
1. Remove the pipe fitting/switch assembly from 5. Apply thread sealant to pipe fitting and install
the rupture basin tank. switch assembly.
LEAK DETECT ENCLOSURE

SWITCH ASSEMBLY SUB-BASE
FUEL TANK
FIGURE 5-5. RUPTURE BASIN LEAK DETECT SWITCH
5-6
6. Enclosure Fuel Tank System (DQCA-CC)
GENERAL PCC Customer Inputs
This section describes the operation and testing of
the components of the optional fuel tank system PCC Customer Fault Inputs 3 (Low Fuel) and 4
shown in Figure 6-1. (Rupture Basin) are prewired to the sub-base fuel
tank when shipped from the factory.
When a sub-base fuel tank is provided, a fuel trans-
fer pump with control and external or internal fuel
alarm panel are available as options. The “Low Fuel” warning message, when displayed
by the PCC, indicates that the fuel level has
WIRING CONNECTIONS dropped below the low fuel level (approximately
Fuel Transfer Control Customer Outputs 62%).
See Enclosure/Options Wiring (DQCA−DQCC) dia-

gram in Section 7 for customer connections to re- The “Rupture Basin” warning message is used to in-
mote annunciators. dicate that fuel is detected in the fuel tank basin.
FUEL TRANSFER EXTERNAL

PUMP AND CONTROL FUEL ALARM
PANEL
INTERNAL FUEL
ALARM PANEL
FIGURE 6-1. FUEL TANK SYSTEM OPTIONAL COMPONENTS
6-1
FUEL TRANSFER PUMP • SYSTEM TEST: This switch will test all front
panel lamps and activate pump/motor for as
The fuel transfer pump and control are available as long as the switch is in the System Test posi-
an option when a sub-base fuel tank is provided. tion. All alarm relays will not activate but will
The automatic control operates the fuel pump to
maintain their original state.
maintain a reservoir of fuel in the sub-base tank.
• RESET: This switch will reset the control sys-
This section explains functions of the control panel
tem after a latched alarm event.
lamps, components and operation/testing of the
day tank fuel control system.
Operation
Control Panel Switches and Indicators
The following paragraphs describe the operation of The following steps describe how to operate the day
the control switches and indicators. tank controller.
Indicators: 1. Activate the control ON switch for automatic

operation. The PUMP light will come on and the
• POWER: indicates that AC power is available
to the control. pump will fill the tank. The level of fuel in the
tank will be automatically kept between a set of
• PUMP: indicates that the fuel pump is running. pump-on and pump-off float gauge switches.
It will go on and off as fuel is pumped to main-
tain the fuel tank level. 2. The PUMP light indicates when the pump is
• CRITICAL HIGH: indicates that the fuel has running. It will go on and off as fuel is pumped to
reached an abnormally high level. It indicates a maintain the proper level in the tank.
possible failure of the ”pump-off” float gauge in
the sub-base tank. The lamp will turn off when
the fuel level drops to normal.
• LOW FUEL SUPPLY TANK: indicates that the
fuel level in the main fuel tank has dropped be-
low the customer set low fuel level. This signal
is used by the fuel system control to stop the
operation of the fuel transfer pump to prevent
pump damage. The control will enable the fuel
transfer pump operation after tank fuel level is
restored.
• RUPTURE BASIN: indicates that the fuel has
flooded the safety basin surrounding the fuel
tank. The basin float switch turns off the fuel
pump. The pump cannot function again until
the basin is drained of fuel. Possible cause,
leak in fuel tank.
Switches:
• ON: This switch activates the control.
• OFF: This switch disables the control for rou-
tine maintenance to the tank system without
disrupting the control.
• TEST: This switch will activate the pump for as
long as the switch is in the Test position. All
alarm functions will operate accordingly.
Pump-on and pump-off float switches will re- FIGURE 6-2. TRANSFER PUMP CONTROL FRONT
main de-energized. PANEL
6-2
EXTERNAL/INTERNAL ALARM PANELS The horn can be turned off by pressing the mute but-
ton. The indicator will turn off when the fuel level
The following paragraphs describe the operation of drops to normal.
the external/internal alarm panel components.
Fuel Gauge
Overfill Indicator/Horn/Silence Button Indicates the amount of fuel that is contained in the
sub-base tank.
The overfill alarm Indicates that the fuel has Test Button
reached an abnormally high level (95%). Immedi-
ately stop adding fuel. It also indicates a possible Press the TEST switch to test the indicator light and
failure of the “pump-off” float gauge for fuel systems the horn. The test will remain active for as long as
that contain the fuel transfer pump. the button is pressed.
OVERFILL
INDICATOR/ FUEL
TEST BUTTON GAUGE
HORN
HORN
SILENCE
BUTTON
HORN SILENCE/
TEST BUTTON
INTERNAL ALARM PANEL

HORN
EXTERNAL ALARM PANEL
FIGURE 6-3. EXTERNAL AND INTERNAL ALARM PANELS
6-3
RUPTURE BASIN LEAK DETECT SWITCH 2. Move the O/Manual/Auto switch to the MANU-
TEST AL position.
The rupture basin leak detect switch (Figure 6-4) is 3. Activate leak detect switch (move float up-
provided with sub-base fuel tanks used with the op- ward).
tional enclosure. This switch should be checked
once a year to make sure switch is properly operat- 4. Check control display for Rupture Basin fault
ing. In some areas, weekly inspections may be re- message. If no indication of fault, repair defec-
quired by safety code regulations. tive circuit. Refer to Enclosure/Options Wiring
To test the leak detect switch: (DQCA−DQCC) diagram in Section 7.
1. Remove the pipe fitting/switch assembly from 5. Apply thread sealant to pipe fitting and install
the rupture basin tank. switch assembly.
ENCLOSURE
SUB-BASE
LEAK DETECT FUEL TANK
SWITCH ASSEMBLY
FIGURE 6-4. RUPTURE BASIN LEAK DETECT SWITCH
6-4
7. Wiring Diagrams
GENERAL • Page 7-13, Fuel Tank Wiring, Enclosure
(DFEG−DFEK)
This section consists of the schematic and connec-
tion wiring diagrams referenced in the text. The fol- • Page 7-14, Customer Connections, Enclosure,
lowing drawings are included. (DFEG−DFEK)
• Page 7-2/7-3, AC Reconnect Wiring Diagram • Page 7-15, Alarm Panel Wiring, Enclosure
• Page 7-4, DC Power and Starter Wiring (DFEG− (DFEG−DFEK)
DFEK) • Page 7-16, DC Power and Starter Wiring
• Page 7-5, Engine Sensors (DFEG−DFEK) (DQCA−DQCC)
• Page 7-6, Control Wiring (DFEG−DFEK) • Page 7-17, Engine Sensors (DQCA−DQCC)
• Page 7-7, Generator/Bus Connections (DFEG− • Page 7-18, Control Wiring (DQCA−DQCC)
DFEK)
• Page 7-19, Generator/Bus Connections
• Page 7-8/7-9, Customer Connections (DFEG−
(DQCA−DQCC)
DFEK)
• Page 7-10, TB3 Terminal Descriptions (DFEG− • Page 7-20/7-21, Customer Connections
DFEK) (DQCA−DQCC)
• Page 7-11, Customer Connections Terminal • Page 7-22, TB3 Terminal Descriptions (DQCA−
Strip, Enclosure (DFEG−DFEK) DQCC)
• Page 7-12, Wiring Options, Enclosure (DFEG− • Page 7-23/7-24, Enclosure/Options Wiring
DFEK) (DQCA−DQCC)
7-1
THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.
No. 625-3100 sh 1 of 2
Rev. G
Modified 04-98
AC RECONNECT WIRING DIAGRAM (SHEET 1 OF 2)
7-2
No. 625-3100 sh 2 of 2
Rev. G
Modified 04-98
AC RECONNECT WIRING DIAGRAM (SHEET 2 OF 2)
7-3
THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.
No. 630-2592 sh 1 of 11
Rev. E
Modified 12-03
DC POWER AND STARTER WIRING (DFEG−DFEK)
7-4
No. 630-2592 sh 2 of 11
Rev. E
Modified 12-03
ENGINE SENSORS (DFEG−DFEK)
7-5
No. 630-2592 sh 3 of 11
Rev. E
Modified 12-03
CONTROL WIRING (DFEG−DFEK)
7-6
No. 630-2592 sh 4 of 11
Rev. E
Modified 12-03
GENERATOR / BUS CONNECTIONS (DFEG−DFEK)
7-7
No. 630-2592 sh 5 of 11
Rev. E
Modified 12-03
CUSTOMER CONNECTIONS (DFEG−DFEK)
7-8
No. 630-2592 sh 6 of 11
Rev. E
Modified 12-03
CUSTOMER CONNECTIONS (DFEG−DFEK)
7-9
No. 630-2592 sh 7 of 11
Rev. E
Modified 12-03
TB3 TERMINAL DESCRIPTIONS (DFEG−DFEK)
7-10
No. 630-2592 sh 8 of 11
Rev. E
Modified 12-03
CUSTOMER CONNECTIONS TERMINAL STRIP, ENCLOSURE (DFEG−DFEK)
7-11
No. 630-2592 sh 9 of 11
Rev. E
Modified 12-03
WIRING OPTIONS, ENCLOSURE (DFEG−DFEK)
7-12
No. 630-2592sh 10 of 11
Rev. E
Modified 12-03
FUEL TANK WIRING, ENCLOSURE (DFEG−DFEK)
7-13
No. 630-2592sh 11 of 11
Rev. E
Modified 12-03
CUSTOMER CONNECTIONS, ENCLOSURE (DFEG−DFEK)
7-14
HIGH FUEL CRITICAL

FUEL GAUAGE HIGH
ALARM PANEL WIRING WITH TRANSFER PUMP CONTROL
OVERFILL VALVE
(USED WITH
SPILL FILL BOX)
HIGH FUEL
FUEL GAUAGE ALARM PANEL WIRING WITHOUT TRANSFER PUMP CONTROL No. 541-1066 sh 2/3 of 3
Rev. B
Modified 12-03
ALARM PANEL WIRING, ENCLOSURE (DFEG−DFEK)
7-15
No. 630-2878 sh 1 of 7
Rev. B
Modified 12-04
DC POWER AND STARTER WIRING (DQCA−DQCC)
7-16
No. 630-2878 sh 2 of 7
Rev. B
Modified 12-04
ENGINE SENSORS (DQCA−DQCC)
7-17
No. 6 sh 3 of 7
Rev. C
Modified -04
CONTROL WIRING (DQCA−DQCC)
7-18
No. 630-2878 sh 4 of 7
Rev. B
Modified 12-04
GENERATOR/BUS CONECTIONS (DQCA−DQCC)
7-19
No. 630-2878 sh 5 of 7
Rev. B
Modified 12-04
CUSTOMER CONNECTIONS
7-20
No. 630-2878 sh 6 of 7
Rev. B
Modified 12-04
CUSTOMER CONNECTIONS (DQCA−DQCC)
7-21
No. 630-2878 sh 7 of 7
Rev. B
Modified 12-04
TERMINAL DESCRIPTIONS (DQCA−DQCC)
7-22
No. 620-0281 sh 1 of 2
Rev. A
Modified 11-04
ENCLOSURE/OPTIONS WIRING (DQCA−DQCC) (SHEET 1 OF 2)
7-23
No. 620-0281 sh 2 of 2
Rev. A
Modified 11-04
ENCLOSURE/OPTIONS WIRING (DQCA−DQCC) (SHEET 2 OF 2)
7-24
Cummins Power Generation
1400 73rd Ave. NE
Minneapolis, MN 55432 USA
Phone 1 763 574 5000
Toll-free 1 800 888 6626
Fax 1 763 574 5298
Email [email protected]
www.cumminspower.com
CumminsR, the “C” logo, and “Our energy working for you.”
are trademarks of Cummins Inc.
E2007 Cummins Power Generation, Inc. All rights reserved.

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Service Manual

English 03-2008 960−0521 (Issue 3)

SECTION TITLE PAGE

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

Copyright© 2005 Cummins Power Generation. All rights reserved.

DISPLAY MENU EXERCISE MANUAL RUN/

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

Reading Fault codes Using Warning/Shutdown Warning LED:

FIGURE 2-2. GRAPHICAL DISPLAY AND MENU SELECTION BUTTONS

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

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

BLOWBY FLOW 25 CFM

FIGURE 2-5. ENGINE SUBMENUS

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

Amps: All phases. Accuracy 1%.

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

When the operator panel is mounted on the control

Remote CONTROL Submenu Functions

Remote START or STOP Button: This button is

When the generator set is operating, Stop will be ENABLE SYNC

Fault Acknowledge Button: Used to reset inactive

Bargraph Test: The function of this button remains

Enable Sync: Displayed in paralleling applications

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

CONTINUED TO NEXT PAGE

FIGURE 2-8. HISTORY/ABOUT SUBMENUS

FAULT HISTORY: The control maintains a data log

BUS/GEN HZ: BUS/GEN hertz.

FIGURE 2-10. POWER TRANSFER MAIN MENU

If you press the “Utility” button in the Power Transfer

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

Amps: L2 only. Accuracy 1%.

If you press the “Status” button in the Power Trans-

If you press the “TRANSFER CONTROL” button in

During genset operation in the manual mode, you

Example (Figure 2-13)

If you press the “Genset” button in the Power Trans-

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

Amps: All phases. Accuracy 1%.

Frequency: Generator set output frequency. GENSET:

The PF reading will contain an asterisk if the power

ENTER APPLICATION PASSWORD ENTER USER PASSWORD

SETUP SUBMENU PASSWORD MENU ADJUST SUBMENU PASSWORD MENU

FIGURE 3-1. PASSWORD MENUS

POWER TRANSFER SETUP Y

FIGURE 3-2. SETUP SUBMENUS

If you press the “GOVERNING/VOLT REG” button

Use the + and − buttons to increase or decrease the

If you press the “CUSTOMER FAULTS” button in

If you press the “CALIBRATION” button in the Setup

BUS VOLTAGE CALIBRATION

FIGURE 3-5. CALIBRATION SUBMENUS

If you press the “ISOLATED BUS” button in the Set-

If you press the “UTILITY” button in the Setup

PAGE PTC MAIN

FIGURE 3-8. PTC SETUP MAIN MENUS

UTILITY FREQ: DISABLED

FIGURE 3-9. UTILITY SENSORS SUBMENUS

GEN FREQ: DISABLED

FIGURE 3-10. GENSET SENSORS SUBMENUS