Service Manual

Power Start 0500

Genset Models:
X1.3, S and B series

Foreword
Schedule of Abbreviations
AC
ACB
ACH
ATS
AVR

Alternating Current
Air Circuit Breaker
Anti-Condensation Heaters
Automatic Transfer Switch
Automatic Voltage Regulator

BHP
BMS
BST

Brake Horsepower
Building Management System
Busbar Sensing Transformer

CB
CCA
CHP
COP
CT

Circuit Breaker
Cold Cranking Amps
Combined Heat and Power
Continuous Power Rating
Current Transformer

dB(A)
DC
DIP

Unit of noise level

Direct Current
Dual In-line Package

DMC
DMSU

Digital Master Control

Demand Load Standby Unit

EMCU
EMF
EPU

Engine Monitoring and Control

Unit
Electromotive Force
Engine Protection Unit

FSS

First Start Sensor

GCP
Genset
GKWT

Generator Control Panel

Generator set
Global Kilowatt Transducer

HMI
HV

Human/Machine Interface
High Voltage

MCB
MCCB
MF
MFSS
MR

Miniature Circuit Breaker

Moulded Case Circuit Breaker
Mains Failed
Master First Start Sensor
Mains Returned

MST
MSU
MV

Mains Sensing Transformer

Mains Sensing Unit
Medium Voltage

NEC

Neutral Earthing Contact

PC
PF
PFC
PLC
PMG
PRP
PSU

PowerCommand
Power Factor
Power Factor Controller
Programmable Logic Controller
Permanent Magnet Generator
Prime Power Rating
Power Supply Unit
Potential Transformer / Current
Transformer

PT/CT

QCC

Quadrature Current Control

RFI

Radio Frequency Interference

RMS
RPM
RTD

Root Mean Square

Revolutions Per Minute
Resistance Temperature Detector

V
VAC
VCB
VDC
VF
VT

Volts
Volts, Alternating Current
Vacuum Circuit Breaker
Volts, Direct Current
Volt-free
Voltage Transformer

IC
I/O

Integrated Circuit
Input / Output

kVA
kVAR
kW
kWh

Apparent Power
Reactive Power
Active / Real Power
Unit of electrical energy or work

LED
LTP
LTA

Light-Emitting Diode
Limited Time Power Rating
Low Temperature Aftercooling

LV

Low Voltage

INDEX
Sr.

Contents

1.

Preliminary and safety..

1.1
Warning, Caution and Note styles used
In this manual
1.2
General information
1.3
General plant safety code

2.

Control System...

2.1
2.2
2.3
2.4
2.5
2.6
2.7
3.

Control System Description

Operating modes
Display Module
Configuration Mode
Sequence of operation
Stopping
Connector Details

Status Indicators..
3.1
3.2

4.

Page no.

20

Fault/Status codes
Fault code list

Troubleshooting..... 22
4.1
4.2
4.3
4.4

Introduction
Control unit
Troubleshooting procedure for fault codes
Fault Finding

5.

InPower connectivity.. 26

6.

Calibration Procedure....... 27

7.

Wiring Diagrams........ 33

1. Preliminary and safety

1.1 Warning, Caution and Note styles used in this manual
The following safety styles found throughout this manual indicate potentially hazardous
conditions to the operator, service personnel or the equipment.
WARNING: WARNS OF A HAZARD THAT MAY RESULT IN SEVERE PERSONAL
INJURY OR DEATH.
Caution

Warns of a hazard or an unsafe practice that can result in product or property

damage.

Note:

A short piece of text giving information that augments the current text.

1.2 General Information

This manual should form part of the documentation package supplied by Cummins Power
Generation Limited with specific generator sets. In the event that this manual has been supplied
in isolation please refer to other Cummins Power Generation Limited literature, in particular the
Health and Safety Manual (0908-0110-00).
Note:

It is in the Operators interest to read and understand all Health and Safety
information together with all Warnings and Cautions contained within the
documentation relevant to the generator set, its operation and daily maintenance.

1.3 Generator Plant Safety Code

Before operating the generator set, read the manuals and become familiar with them and the
equipment. Safe and efficient operation can be achieved only if the equipment is properly
operated and maintained. Many accidents are caused by failure to follow fundamental rules and
precautions.
WARNING: IMPROPER OPERATION AND MAINTENANCE CAN LEAD TO
SEVERE PERSONAL INJURY OR LOSS OF LIFE AND PROPERTY BY
FIRE, ELECTROCUTION, MECHANICAL BREAKDOWN OR EXHAUST
GAS ASPHYXIATION. READ AND FOLLOW ALL SAFETY
PRECAUTIONS, WARNINGS AND CAUTIONS THROUGHOUT THIS
MANUAL AND THE HEALTH AND SAFETY MANUAL 0908-0110-00.

2. Control System
2.1 Control System Description
The control system is used to start and stop the generator set, and provides full generator
set monitoring capability and protection in a stand-alone situation (non paralleling) from the
display screen. It monitors the engine for temperature, oil pressure, battery voltage, estop and
genset hours, and provides voltage and current metering. In the event of a fault the unit will
indicate the fault type and automatically shut down the generator set on critical faults.
All indicators, control buttons and the display screen are on the face of the display module
as illustrated in Figure 1.
There are two fault level signals generated by the control system as follows:

Warning: - signals an imminent or non-critical fault for the engine. The control provides an
indication only for this condition.

Shutdown: - signals a potentially critical fault for the engine. The control will immediately
take the engine OFF-load and automatically shut it down.

The standard control system operates on 12 VDC battery power. The auxiliary equipment
operates on LV AC power. The history data is stored in non-volatile memory and will not be
deleted due to loss of battery power.

Figure 1

KEY
1.
2.

Typical Control System Panel

Display Module
Emergency Stop Button

NOTE: Normally E-stop placement on canopy is totally under OEM scope.

2.2 Operating Modes

The PowerStart 0500 control is operated by the Manual / Start / Stop / Auto buttons on the
display module face.

2.2.1 OFF Mode

Note: Some published control service literature may refer to this mode as the STOP
mode.
When in the OFF mode, the control does not allow the generator set to start. Refer to Section
4.2.7 Auto and Manual Run Modes to re-start the generator set.
If the generator set is running, in either Manual Run or Auto mode, and the Stop button is
pressed, a normal shutdown sequence will be initiated.
In OFF Mode the red LED above the Stop button will be lit.

2.2.2 Manual Run Mode

When in Manual Run mode, the generator set starts and continues to run until the control is
put into the OFF mode. Pressing the Stop button initiates a normal shutdown sequence that does
not include a time delay stop. While in the Manual Run mode, any remote start signal is ignored.

2.2.3 Auto Mode

When in Auto mode, the control allows the generator set to be started at any time, with a
remote signal only. When a remote start signal is received, the generator set starts after a time
delay start is completed (default delay is zero seconds).
When a remote start signal is removed, the control performs a normal shutdown sequence
which includes a time delay stop (default delay is zero seconds).
If the generator set is running in Auto mode and the Stop button is pressed, the control
immediately stops the generator set and the control transitions to the OFF mode.

2.2.4 Sleep Mode

The PowerStart 0500 control enters a low power (Sleep) mode of operation where the
current drawn is less than 60 milliamps (DC) at normal battery voltage levels. Sleep mode is
automatically enabled, and the display module will turn itself OFF after five minutes of keypad
inactivity when in OFF mode.
When in Auto mode, the Sleep mode is enabled only when the trim Wake in Auto
Enabled is enabled. If the trim is disabled (which is the default value), the Sleep mode will never
be enabled when in Auto mode.
It awakes from the sleep mode if the reset button is pressed or if there is a Tool wakeup
input or a Remote Start signal is received or an E-stop signal is received both in Stop as well as
Auto mode.

The control will not enter the Sleep mode if there are any active, unacknowledged, shutdown
faults or if the control is in the Manual Run mode.

2.2.5 Battle Short Mode

The purpose of Battle Short Mode is to satisfy local code requirements, where necessary.
Battle Short mode is a generator set mode of operation that prevents the generator set from being
shutdown by all but a few, select, critical shutdown faults.
Caution:

All shutdown faults, including those overridden by Battle Short, must be acted
upon immediately to ensure the safety and well being of the operator and the
generator set.

WARNING: USE OF THE BATTLE SHORT MODE FEATURE CAN CAUSE A FIRE
OR ELECTRICAL HAZARD, RESULTING IN SEVERE PERSONAL
INJURY OR DEATH AND/OR PROPERTY AND EQUIPMENT DAMAGE.
OPERATION OF THE SET MUST BE SUPERVISED DURING BATTLE
SHORT OPERATION.
This feature must only be used during supervised, temporary operation of the generator set. The
faults that are overridden when in Battle Short mode can affect generator set performance, or can
cause permanent engine, alternator or connected equipment damage.
Only trained and experienced service personnel should enable this feature. When shipped from
the factory, this feature is disabled.
Caution:

If this mode of operation is selected, the protection of load devices will be

disabled.
Cummins Power Generation Limited will not be responsible for any claim
resulting from the use of this mode.

Note:

The Battle Short feature must be enabled or disabled using the PC Service tool.

When Battle Short mode is enabled (Default is Disabled), the Warning status indicator lights, and
code 1131 Battle Short Active is displayed.
When Battle Short mode is enabled and an overridden shutdown fault occurs, the shutdown lamp
remains lit even though the set continues to run. Fault code 1416 Fail to Shutdown is
displayed. If the OK button is pressed to acknowledge the fault, the fault pop up is cleared from
the display but remains in one of the scrolling screens displaying the fault code and its description
to indicate that it is an active fault as long as Battle Short mode is enabled.
Battle Short is suspended and a shutdown occurs immediately if any of the following critical
shutdown faults occur:

Speed Signal Lost (Loss of Speed Sense)

Fault code 121

Overspeed

Fault code 234

Local Emergency Stop

Fault code 1433

Excitation Fault (Loss of Voltage Sense)

Fault code 2335

Fault code 1123 Shutdown After Battle Short is then displayed.

2.3 Display Module - Front Panel

Figure 2 shows the features of the front panel. It includes four LED indicators, the graphical
display, and six buttons used to navigate through the menus and adjust parameters.

KEY
1.
2.
3.
4.
5.
6.

LED Indicator Genset Running

LED Indicator Remote Start
LED Indicator Shutdown
LED Indicator Warning
Manual Mode Button
Start Button

7.
8.
9.
10.
11.

Auto Mode Button

Reset Button
Stop Button
OK Button
Alpha numeric LCD Display

2.3.1 Alpha numeric LCD Display

The 2 line 16 Character, Backlit LCD display is used to indicate various generator set parameters
in several frames. The frames scroll sequentially and display for 2 seconds. The scrolling can be
stopped and parameters on a particular frame can be monitored for longer by pressing the OK
button (See Figure 2). Pressing the OK button again causes the frames to start scrolling again.
The display is also used to present the setup menus in the configuration mode.
L1N=000 L2N=000
L3N=000 HZ=00.0

2 SEC

CURRENT FLT=212
CLNT TEMPOOR WRN

2 SEC

2 SEC

L12=000 L23=000
L13=000 HZ=00.0

E STOP=INACTIVE
CUST IN=INACTIVE

2 SEC

2 SEC

I1=00.0 KVA=00.0
I2=00.0 I3=00.0

BATT VOLTS=11.7
GENSET HRS=00000

2 SEC

2 SEC

KVA1 KVA2 KVA3

00.0 00.0 00.0

2 SEC

Figure 1

OIL PRESS=003PSI
CLNT TEMP=342F

Scrolling display messages

2.3.2 LED Indicators

PS0500 includes four LED indicators, the graphical display and six buttons used to navigate
through the menus and adjust parameters.

Genset Running
This green LED is lit when the generator set is running at or near rated speed and voltage.

Shutdown
This red lamp is lit when the control detects a Shutdown condition. The generator set cannot be
started when this lamp is on. After the condition has been corrected, the lamp can be reset by
pressing the Stop button.
Note:When Battle Short mode has been enabled and an overridden shutdown fault
occurs, the Shutdown lamp will be lit even though the generator set will continu
to run.

Warning
This yellow lamp is lit whenever the control detects a Warning condition. This lamp is
automatically shut OFF when the Warning condition no longer exists.

Remote Start
This green lamp indicates the control is receiving a remote run signal.

2.3.3 Control Panel Buttons

Manual
Press this button to put the control in Manual mode from OFF mode. If the Start button is not
pressed within ten seconds of the pressing of the Manual Button, the control automatically returns
to OFF mode The green LED above this button lights when the control is in Manual mode.
Auto
Press this button to put the control in Auto mode from OFF mode. The green LED above this
button lights when the control is in Auto mode. In Auto mode, the generator set starts and runs
when a remote start signal is received. It is also used to exit from configuration mode.

10

Stop
Press this button to switch to the OFF mode from both Manual as well as Auto modes. The Red
LED above this button lights when the control is in OFF mode.
Start
In Manual mode, press this button to initiate a Manual Start sequence. In Auto mode, this button
has no effect.
Reset
This button wakes the control from Power Down Sleep Mode. The control enters configuration
mode when Reset button and Stop button are pressed together. To enter in configuration mode it
is necessary that the control is in Stop mode.
WARNING: ADJUSTING THE SETTINGS IN CONFIGURATION MODE MUST
ONLY BE DONE BY TECHNICALLY TRAINED AND EXPERIENCED
SERVICE PERSONNEL. THE FREQUENCY SETTINGS MUST ONLY BE
ADJUSTED TO CORRESPOND TO THE PARAMETERS OF THE
INSTALLED INPUT POWER SUPPLY. SAVING SETTINGS THAT DO
NOT CORRESPOND TO THE POWER SUPPLY CAN CAUSE SEVERE
PERSONAL INJURY AND EQUIPMENT OR PROPERTY DAMAGE.
OK
This button is used to acknowledge the fault pop ups. It is also used to Pause / Resume the
scrolling of the parameter frames. It is used to select the menu items and the parameters in the
selected menu in the configuration mode. The selected parameter will be preceded by an *
asterisk and will get saved when the configuration mode will be exited using Auto button.
Note: Manual, Auto, OK and Reset buttons are used for navigation in the configuration mode.

2.3.4 Default Settings

The control panel can display SAE or Metric units of measurement and should be set during the
initial setup of the generator set. Qualified service personnel are required to change the default
setting. Contact your authorised distributor.

2.3.5 Fault Messages

A Fault message is an indicator of a Warning or Shutdown condition that is also announced with
a lamp indicator. Fault messages include the fault code number and a short description.
The below table provides a list of fault codes, fault types, messages displayed, and descriptions of
the faults.

11

2.3.6 Fault Acknowledgement

Shutdown Faults are reset after a shutdown fault is cleared when engine comes to a standstill and
all start commands are removed.
In Manual mode, the start command is removed when the Stop button, on the front panel, is
pressed.
In Auto Mode, the start command is removed when the Remote Start signal is removed.
Faults are removed from the display when they are cleared.
Note: Faults are re-announced if they are detected again after being acknowledged.

2.3.7 Display Module - Auto and Manual Run Modes

Auto, Manual Run and OFF modes can be selected as follows:

Selecting Auto Mode

To switch to Auto mode,
a) Ensure that it is safe to do so before proceeding to change the mode.
b) Press the Stop button to ensure that the control is in the OFF mode.
c) Press the Auto button while in the OFF mode. The green LED above this button is lit when the
control is in Auto mode.
To disable Auto mode, press the Stop button.
The generator set is now ready to receive a remote start signal that will initiate the Auto run
mode.
WARNING:

SHOULD A REMOTE START SIGNAL BE RECEIVED, THE GENERATOR SET

WILL START AUTOMATICALLY. ENSURE THERE IS NO DANGER TO
PERSONNEL OR EQUIPMENT SHOULD THE GENERATOR SET START
WITHOUT WARNING.

WARNING:

MANUAL RUN MODE CANNOT BE SELECTED FROM AUTO MODE. THE

CONTROL HAS TO BE IN STOP MODE BEFORE CHANGING THE MODE.
SWITCHING TO STOP MODE WILL RESULT IN THE GENERATOR SET
SHUTTING DOWN.

Selecting Manual Run Mode

To switch to Manual Run mode,
a) Ensure that it is safe to do so before proceeding to change the mode.
b) Press the Stop button to ensure that the control is in the OFF mode

12

c) Press the Manual button on the front panel while in the OFF mode. The green LED above this
button is lit when the control is in Manual mode.
To disable Manual Run mode, press the Stop button.
Note:

Auto mode cannot be selected whilst in Manual Run mode. The control has to be in
OFF mode before changing the mode. Switching to OFF mode will result in the
generator set shutting down.

Selecting OFF Mode

To switch to OFF mode.
a) Ensure that it is safe to do so before proceeding to stop the set
b) Press the Stop button on the front panel. The red LED above the Stop button is lit when the
control is in the OFF mode

2.4 Configuration Mode

WARNING:

ADJUSTING THE SETTINGS IN CONFIGURATION MODE MUST ONLY BE

DONE BY TECHNICALLY TRAINED AND EXPERIENCED SERVICE
PERSONNEL. THE FREQUENCY SETTINGS MUST ONLY BE ADJUSTED TO
CORRESPOND TO THE PARAMETERS OF THE INSTALLED INPUT POWER
SUPPLY. SAVING SETTINGS THAT DO NOT CORRESPOND TO THE POWER
SUPPLY CAN CAUSE SEVERE PERSONAL INJURY AND EQUIPMENT OR
PROPERTY DAMAGE.

Configuration mode is used to adjust the parameters of the generator set and must only be done by
technically trained and experienced service personnel.6 membrane keys are used to step through the
different menu options and to adjust
parameters.

13

Reset

Entering into the

Config Mode

Ok

Press
For 5
Sec

No Navigation is needed

SW PART 3267727
SW VER 1.12

As seen from the above figure, on pressing RESET and OK button on PS0500 for 5 seconds,
controller enters into configuration mode. Before displaying the menu, software part no. and version are
displayed. One needs to understand key to operate.

Keys

Properties
Will go to the next value
Will go to the previous value

Will go down
It shows the default value.
When selected for a

Particular value, comes which

Indicates that value has been set

In Configuration mode the PowerStart 0500 control has the following menus:

Alt Setup: Select alternator set-up parameters (Single / Three phase, 50 / 60 Hz operation,
Star / Delta, Voltage etc.)

Units: Select SAE or Metric units of measure for Coolant Temperature and Oil Pressure

Oil Pr Input: Select the oil pressure sensor type.

Customer I/O: Configure the response to Customer Input and use of the Customer Output

Flt History: Displays the last five faults.

Load Defaults: Resets to the default values.

14

Lamp/LED Test: Tests all the LEDs on the PS0500 display module.

2.5 Sequence of Operation

The generator set is run automatically using a Remote Start signal, or Manually using the
generator set control panel buttons. LEDs are provided on the display module front panel to
indicate the operating run mode of the generator set. The PowerStart 0500 control initiates a
starter cranking signal and will perform an automatically sequenced manual start, under a
complete engine protection system combined with full monitoring capability. If a fault is sensed
at Start-up, the engine is locked out and will not start.
The choice of Auto or Manual run mode is decided by authorised personnel during the
generator set initial setup.

2.5.1 Starting
Before attempting to start the generator set, the operator should read through this entire
manual, together with the Health and Safety manual and the specific engine manual provided as
part of the documentation pack supplied with the generator set. It is essential that the operator be
completely familiar with the generator set and the PowerStart 0500 control.
The following sub-sections cover the systems used to start and stop the generator set.
Before starting the generator set, make sure that exhaust and fuel fittings are tight and
properly positioned, and that proper maintenance and pre-start checks have been performed.
The generator set can be configured for a number of starting cycles (one to seven) with set
times for crank and rest periods for all starting modes (manual/remote). The default setting is for
three start cycles, composed of fifteen seconds of cranking and 5 seconds of rest.

2.5.2 Starting at Display Panel (Manual Run Mode)

To start the generator set in the Manual Run mode, press the Start button within 10 seconds of
pressing the Manual button. Follow the instructions in Section 4.2.9 (Selecting Manual Run
Mode).
Note: Any Remote Start/Stop signal is ignored whilst in Manual Run Mode.
The PowerStart 0500 control will initiate a starter cranking signal and will perform an
automatically sequenced manual start, under a complete engine protection system combined with
full monitoring capability. This will activate the engine control system and the starting procedure.
The starter will begin cranking, and after a few seconds the engine will start and the starter will
disconnect.
In the Manual Run mode the control will not complete the Time Delay to Start or Time Delay to
Stop.
The Remote Start red LED, and the Manual Run, green LED will be lit.
If the engine does not start, the starter will disengage after a specified period of time and the
control will indicate a Fail to Start Shutdown.

15

Wait a minimum of two minutes for the starter motor to cool and then repeat the starting
procedure. If the engine does not run after a second attempt, refer troubleshooting guidelines.

2.5.3 Starting from Remote Location (Auto Mode)

To start the generator set in the Auto Run mode, press the Auto button from the menu bar of the
display module front panel. Follow the instructions in Section 4.2.8 (Selecting Auto Mode).
The Auto, green LED will be lit.
Only on receipt of a remote start signal, and after a Time Delay to Start, will the PowerStart 0500
control initiate the starting sequence as above.
The Remote Start LED will be lit.

2.6 Stopping
2.6.1 Stopping at Display Panel (Manual Mode)
The module will not respond to any Remote Stop signal whilst in Manual Run Mode. When in
Manual run mode, pressing the Stop button will initiate a normal (Manual) shutdown sequence.
In the Manual Run mode the control will not complete the Time Delay to Stop.
Note: Remove load and run set for five minutes to reduce engine heat before pressing the OFF
button.

2.6.2 Stopping from Remote Location (Auto Mode)

In Auto mode, the control allows the generator set to be started with a Remote Start Signal only.
If the control receives a Remote Stop signal, the generator set will complete its normal shutdown
sequence which includes a Time Delay Stop (Default is zero seconds).
If the generator set is running in Auto mode and the Stop button is pressed, the control
immediately stops the generator set without completing the Time Delay to Stop and the control
transitions to the OFF mode.

2.6.3 Emergency Stop (Code 1434)

The Emergency Stop Button is situated on the front of the Control Panel. This is a mechanically
latched switch that will unconditionally stop the engine when pressed, bypassing any time delay
to stop. Push this button in for Emergency Shutdown of the engine.
Note : If the engine is not running, pushing the button in will prevent the starting of the engine,
regardless of the start signal source (Manual or Auto - remote).
When the Stop Button is pressed the display panel will indicate the Shutdown condition by
illuminating the red Shutdown status LED
graphical LCD display:

16

and displaying the following message on the

If a Stop Button is activated the following message will be displayed;

Fault: 1434
EMERGENCY SH
To reset:
a)

Press the OK button on the Display Module to acknowledge the fault.

b)

Press the Stop button and pull, or twist and pull, the button out to reset the fault condition

c)

Press the Auto or Manual Run Button, as previously determined.

2.7 CONNECTOR DETAILS

2.7.1 Description
TB15 Tool Connector
Arrow at Pin 1

J12 CT
connector
Arrow at Pin 1

J12 Pin 4

J16 Engine
connector arrow
at Pin 1

J22 Voltage
connector
Arrow at Pin 1

J16 Pin 7

TB2 Customer TB
Arrow at Pin 1

17

Following are the description for all the terminals on PS0500

2.7.2 Engine Connector

The engine connector (J16) is a 12 pin connector-plug (12 MINI M-N-L).
The PCB outline drawing shows where the connector is located as above .Each signal is described as below

Connector Pin
J16-1
J16-2
J16-3
J16-4
J16-5
J16-6
J16-7
J16-8
J16-9
J16-10
J16-11
J16-12

Signal Name
Coolant temperature sensor
Battery charging alternator (WL)
Starter Relay Driver (Low Side)
Fuel shutoff relay Driver (Low Side)
BATChassis GND
NC
NC
Oil Pressure Sensor
Starter Disconnect Input
Sensor Common
BAT +

2.7.3 CT Connector
The CT connector is a 6- pin MATE-N-LOCK connector.
Connector details are as follows
Connector pin
J12-1
J12-2
J12-3
J12-4
J12-5
J12-6

Signal
CT1_input
CT2_input
CT3_input
CT1_COM
CT2_COM
CT3_COM

2.7.4 Voltage Connector

The voltage connection is via a 4 pin header with alternate spaces between the pins.
Connector pin
J22-1
J22-2
J22-3
J22-4

Signal
Gen_V1
Gen_V2
Gen_V3
Gen_N

18

2.7.5 Customer Connection TB - 2

The customer connection TB2 is a 6 pin terminal block. The terminal pins details are as shown belowTerminal pins
TB2-1
TB2-2
TB2-3
TB2-4
TB2-5
TB2-6

Signal
Remote start Switch Input
Glow Plug Output Relay Driver
(Low Side)
Customer Output Relay Driver
(Low Side)
Customer input
E-stop
NC

Returns for all the above connections are required to be connected externally.
All the inputs are active GND. Remote E-Stop switch should have two independent potential free contacts.
One NC contact for cutting out the Battery supply to the Fuel Solenoid and another NC contact to connect
controllers E-Stop input to GND to indicate to the control when the E-Stop is pushed in active state.

Battery Positive is not provided on the Customer terminal block (TB2). External provision needs to be
made in the harness to provide the B+ signal for convenience of wiring up external relays and may be used
as relay supply (high side) for FSO, Starter, Customer Output and Glow plug Relays via a 1 Amp Fuse.

2.7.6 PC Tool Connector

The PC tool connector is a dedicated 5 pin connector header block.
Terminal pins
TB15-1
TB15-2
TB15-3
TB15-4
TB15-5

Signal
GND
NC
RS485_DATA_A
RS485_DATA_B
TOOL_WAKEUP

19

3. Status Indicators

Display Panel

Genset Running
This green LED is lit when the generator set is running at or near rated speed and voltage.

Shutdown
This red lamp is lit when the control detects a Shutdown condition. The generator set cannot be
started when this lamp is on. After the condition has been corrected, the lamp can be reset by
pressing the OFF button.
Note:

When Battle Short mode has been enabled and an overridden shutdown fault
occurs, the Shutdown lamp will be lit even though the generator set will continue
to run.

Warning
This yellow lamp is lit whenever the control detects a Warning condition. This lamp is
automatically shut OFF when the Warning condition no longer exists.

Remote Start
This green lamp indicates the control is receiving a remote run signal.

20

3.1 Fault Code list

CTG

CODE

LAMP

DESCRIPTION

141

Warning

Indicates the oil pressure sensor output is out of range (OOR), low.

143**

Warning

144

Warning

146**

Warning

151**

Shutdown

359

Shutdown

415**

Shutdown

441**

Warning

442**

Warning

1123*

Shutdown

1131*

Warning

1312

Configurable

Indicates the engine oil pressure is approaching an unacceptable

level.
Indicates the coolant temperature sensor output is out of range
(OOR), low.
Indicates that the engine is operating near cooling system capacity.
Increase in load or higher ambient temperature may cause High
Coolant Temp (code 151) shutdown.
Indicates that the engine coolant temperature is above normal and
has reached the Shutdown trip point.
The system has failed to start after a set number of crank attempts.
This indicates a possible fuel system or air induction problem
(engine cranks but fails to start).
Indicates the engine oil pressure has dropped below normal and has
reached the shutdown trip point.
Indicates battery voltage supply to the control is approaching a low
level at which unpredictable operation can occur.
Indicates battery voltage supply to the control is approaching a high
level at which damage to the control can occur.
A shutdown fault occurred while the Battle Short mode was
enabled.
Indicates that the control is in Battle Short mode used to bypass
several fault shutdowns for generator set operation during
emergencies.
The nature of the fault is an optional customer selection.

1416*

Warning

1434

Shutdown

1435**

Warning

1442**

Warning

1446**

Shutdown

1447**

Shutdown

1448**

Shutdown

1449**

Shutdown

2335

Shutdown

2677

Shutdown

Indicates that a shutdown fault is active, but is being bypassed by

Battle Short.
Indicates a Remote Emergency Stop has been activated.
Indicates that the engine coolant temperature is below the adjusted
setpoint. This may indicate that the coolant heater is not operating
or is not circulating coolant.
Indicates that the generator set battery voltage is below battery
thresholds during cranking.
Indicates that one or more measured AC output voltages have
exceeded the threshold for longer than a specified time limit. The
threshold and time limits are 130% of nominal for zero seconds or
110% of nominal for ten seconds.
Indicates that the measured AC output voltage is below the
threshold for longer than a specified time limit. The threshold and
time limits are 85% of nominal for ten seconds.
Indicates that the alternator frequency is 6 Hertz under the nominal
frequency.
Indicates that the alternator frequency is 6 Hertz above the nominal
frequency.
Indicates that a loss of voltage or frequency sensing from the
generator has occurred.
The generator set continues to run after receiving a stop command
from the controller.

21

4. Troubleshooting
4.1 Introduction
Fault codes information together with Warning and Shutdown information is provided in this
section to assist in locating and identifying the possible causes of faults in the generator set
system. Refer also to the Operators engine specific manual supplied as part of the generator set
documentation pack. This latter manual will contain further information regarding the running
and care of the generator set and also specific equipment instructions that may differ from the
standard generator set.

4.2 Control Unit

The generator set control system continuously monitors engine sensors for abnormal conditions,
such as low oil pressure and high coolant temperature. If any of these conditions occur, the
control will light a yellow Warning lamp or a red Shutdown lamp and will display a message on
the graphical display panel. In the event of an engine shutdown fault (red Shutdown LED), the
control will stop the engine immediately.
This section lists the Warning and Shutdown Fault Codes/Messages and suggests possible causes
of the fault.

4.3 Troubleshooting Procedures for Fault Code

4.2

CODE:

143

LAMP:
MESSAGE:

Warning
PRE-LOW OIL
PRESSURE

CODE:

146

LAMP:
MESSAGE:

Warning
PRE-HIGH COOL
TEMP

CODE:

151

Indicates engine oil pressure has dropped below the warning trip point.
If generator is powering critical loads and cannot be shut down, wait
until next shutdown period and then follow the fault code 415
procedure.

Indicates engine is operating near cooling system capacity. Increase in

load or higher ambient temperature may cause High Coolant Temp
(151) shutdown. Review fault code 151 correction list for other possible
causes.

Indicates engine has overheated (coolant temperature has risen above

the shutdown trip point). Allow engine to cool down completely before
proceeding with the following checks:
a) Look for possible coolant leakage points and repair if necessary.
Check coolant level and replenish if low
b) Check for obstructions to cooling airflow and correct as necessary
c) Check fan belt and repair or tighten if necessary

22

LAMP:

Shutdown

d) Check blower fan and circulation pumps on remote radiator

installations

MESSAGE:

HIGH COOLANT
TEMP

e) Reset control and restart after locating and correcting problem.

CODE:

359

Indicates possible fuel system or air induction problem. (Engine cranks

but fails to start). Allow engine to cool down completely before
proceeding with the following checks:

LAMP:

Shutdown

f) Check for empty fuel tank, fuel leaks, or blocked fuel lines and
correct as required
g) Check for dirty fuel filter and replace if necessary
h) Check for dirty or blocked air filter and replace if necessary

MESSAGE:

Fail to Start

i) Reset control and restart after correcting the problem.

CODE:

415

Indicates engine oil pressure has dropped below the shutdown trip point.
Allow engine to cool down completely before proceeding with the
following checks:
j) Check the oil level, lines and filters

LAMP:

Shutdown

k) If the oil system is OK but the oil level is low, replenish

MESSAGE:

LOW OIL
PRESSURE

l) Reset control and restart after locating and correcting problem.

CODE:

441

Indicates battery voltage supply to the control is approaching a low

level at which unpredictable operation will occur. If engine can be
stopped allow engine to cool down completely before proceeding:
m) Poor battery cable connections. Clean the battery cable terminals and
tighten all connections
n) Check battery charge voltage float level if applicable (raise float
level)
o) Discharged or defective battery

LAMP:

Warning

Check the battery charger fuse

MESSAGE:

LOW BAT
VOLTAGE

Recharge or replace the battery.

CODE:

442

Indicates battery voltage supply to the control is approaching a high

level at which damage to the control can occur. If engine can be stopped
allow engine to cool down completely before proceeding:

LAMP:

Warning

p) Poor battery cable connections. Clean the battery cable terminals and
tighten all connections

MESSAGE:

HIGH BAT
VOLTAGE

q) Check battery charge float level if applicable (lower float level).

CODE:

1131

Indicates that the control is in Battle Short mode used to bypass

several fault shutdowns therefore allowing generator set operation
during emergencies.

LAMP:

Warning

23

MESSAGE:

BATTLE SHORT ACTIVE

CODE:

1311, 1312, 1317,

1318

The nature of the fault is an optional customer selection. Example

inputs: Low Fuel Day Tank, Water In Fuel, Ground Fault, etc.
Each of the fault functions can be programmed (using InPower service
tool or access to Setup menu), as follows:
r) Event , Warning or Shutdown level if Function Select = Fault Input

LAMP:

Configurable

s) Change display name using up to 32 characters

MESSAGE:

CONFIGURABLE INPUT 1, 2, 3, 4

CODE:

1416

LAMP:

Warning

MESSAGE:

FAIL TO SHUTDOWN

CODE:

1433/1434

The generator set continues to run after receiving a shutdown command

from the controller. The Battle Short feature is enabled this is used to
bypass several critical fault shutdowns therefore allowing generator set
operation during emergencies.

Indicates local or remote Emergency Stop. Emergency Stop shutdown

status can be reset only at the local control panel. After locating and
correcting problem, reset the local/remote Emergency Stop button as
follows:
t) De-activate (disable) emergency stop button
u) Press the O (OFF) button
v) Select the desired operating mode (manual or remote).

CODE:

1435

Indicates engine coolant heater is not operating or is not circulating

coolant. If engine can be stopped allow engine to cool down completely
before proceeding with the following checks:
w) The coolant heater not connected to power supply.
Check for blown fuse or disconnected heater cable and correct as
required
x) Look for possible coolant leaks and repair as required
Check for low coolant level and replenish if required.

LAMP:

Warning

Set is not operating. Warning occurs when engine coolant temperature

is 21oC (70oF) or lower.

MESSAGE:

LOW COOLANT
TEMP

NOTE: In applications where the ambient temperature falls below

4oC (40oF), Low Coolant Temp may be indicated even though the
coolant heaters are operating.

CODE:

1442

Indicates that during cranking, the battery voltage is at, or below, the
weak battery warning trip point for a time greater than, or equal to, the
weak battery set time.

24

LAMP:

Warning

MESSAGE:

WEAK BATTERY

See code 441 for corrective action

CODE:

1448

Indicates that the generator set frequency has dropped below 90% of
nominal for approximately ten seconds. Allow engine to cool down
completely before proceeding with the following checks:
y) Check the fuel supply
z) Check the air intake supply, the load and correct any overload.

4.4 FAULT FINDING

Should a fault condition occur during operation follow the procedures in the following
tables to locate and correct the problem. For any symptom not listed, contact an authorised
service centre for assistance.
Before starting any fault finding, ensure that the following basic checks are carried out:

All switches and controls are in their correct positions

The fuel oil level is correct

The lubricating oil level is correct

The coolant level is correct

The radiator matrix is free from obstruction

The battery charge condition is satisfactory and the connections are secure

The generator set electrics and alternator connections are secure

The panel connections are secure

The protection circuits have been reset

Blown fuses have been replaced

Tripped contactors or circuit breakers have been reset

25

5. Inpower Connectivity
1. PS0500 can be connected with inpower using the communication cable (Part
no. 0338-4590) and RS485-232 convertor (Part no. 0324-0021).
2. Configure the site of PS0500 in Inpower before moving ahead.
3. Connect one end of the cable to TB15 connector of PS0500
4. Connect the other end of cable to RS 485-232 convertor.
5. Connect the RS232 side of the convertor towards laptop
6. Open Inpower and connect the PS0500 with the created site.

LAPTOP

26

RS 485-232
convertor
P/N 03240021

P/N of
cable
0338-4590

6. Calibration Procedure
NOTE: PS0500 is calibrated from factory. You are not advised to do the calibration for the new
part. Only the required CT ratio has to be selected as per the engine model. Please confirm with
AO/ZO before performing calibration.
1. Got to Device -> Initial Calibration

27

2. The select calibration window will appear. Select 0326-7727 and click next.

3. History window will appear. The latest calibration should be 1.14 or above. Click NEXT

28

4. Save and Restore parameter window will appear. Click NEXT after this.

5. Click the feature number as A029W892 and click FINISH.

29

6. Window of Calibration will pop up. Click YES to continue calibration.

7. Window of Device Explorer will pop up and click yes for continuing the calibration.

30

8. Progress window will appear. Dont click anything and allow the calibration to happen.

10. A window of EROOR might pop up. Click OK and continue.

31

11. Once the calibration is completed, the window for successful calibration will pop up. Click OK to finish
the calibration.

32

7. Wiring Diagram

33