Professional Documents
Culture Documents
GenSet Model
DFLB, DFLC, DFLD, DFLE, DFMB
California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
LS-14M
Redistribution or publication of this document,
iii by any means, is strictly prohibited.
ELECTRICAL SHOCK CAN CAUSE GENERAL SAFETY PRECAUTIONS
SEVERE PERSONAL INJURY OR DEATH • Coolants under pressure have a higher boiling point
than water. DO NOT open a radiator or heat ex-
• Remove electric power before removing protective changer pressure cap while the engine is running.
shields or touching electrical equipment. Use rub- Allow the generator set to cool and bleed the system
ber insulative mats placed on dry wood platforms pressure first.
over floors that are metal or concrete when around
electrical equipment. Do not wear damp clothing • Used engine oils have been identified by some state
(particularly wet shoes) or allow skin surface to be or federal agencies as causing cancer or reproduc-
damp when handling electrical equipment. Do not tive toxicity. When checking or changing engine oil,
wear jewelry. Jewelry can short out electrical con- take care not to ingest, breathe the fumes, or con-
tacts and cause shock or burning. tact used oil.
• Use extreme caution when working on electrical • Keep multi-class ABC fire extinguishers handy.
Class A fires involve ordinary combustible materials
components. High voltages can cause injury or
such as wood and cloth; Class B fires, combustible
death. DO NOT tamper with interlocks.
and flammable liquid fuels and gaseous fuels; Class
• Follow all applicable state and local electrical C fires, live electrical equipment. (ref. NFPA No. 10).
codes. Have all electrical installations performed by • Make sure that rags are not left on or near the en-
a qualified licensed electrician. Tag and lock open gine.
switches to avoid accidental closure.
• Make sure generator set is mounted in a manner to
• DO NOT CONNECT GENERATOR SET DIRECT- prevent combustible materials from accumulating
LY TO ANY BUILDING ELECTRICAL SYSTEM. under the unit.
Hazardous voltages can flow from the generator set • Remove all unnecessary grease and oil from the
into the utility line. This creates a potential for elec- unit. Accumulated grease and oil can cause over-
trocution or property damage. Connect only through heating and engine damage which present a poten-
an approved isolation switch or an approved paral- tial fire hazard.
leling device.
• Keep the generator set and the surrounding area
clean and free from obstructions. Remove any de-
MEDIUM VOLTAGE GENERATOR SETS
bris from the set and keep the floor clean and dry.
(601V to 15kV) • Do not work on this equipment when mentally or
physically fatigued, or after consuming any alcohol
• Medium voltage acts differently than low voltage. or drug that makes the operation of equipment un-
Special equipment and training is required to work safe.
on or around medium voltage equipment. Operation • Substances in exhaust gases have been identified
and maintenance must be done only by persons by some state or federal agencies as causing can-
trained and qualified to work on such devices. Im- cer or reproductive toxicity. Take care not to breath
proper use or procedures will result in severe per- or ingest or come into contact with exhaust gases.
sonal injury or death.
• Do not store any flammable liquids, such as fuel,
• Do not work on energized equipment. Unauthorized cleaners, oil, etc., near the generator set. A fire or
personnel must not be permitted near energized explosion could result.
equipment. Due to the nature of medium voltage
electrical equipment, induced voltage remains even
• Wear hearing protection when going near an oper-
after the equipment is disconnected from the power ating generator set.
source. Plan the time for maintenance with autho- • To prevent serious burns, avoid contact with hot
rized personnel so that the equipment can be de-en- metal parts such as radiator, turbo charger and ex-
ergized and safely grounded. haust system.
WARNING
The following describes the function and operation Check the engine oil level. Keep the oil level near as
of the PowerCommand Control 3100 (PCC). All in- possible to the dipstick high mark without overfilling.
dicators, displays, meters and control switches are
Coolant
located on the face of the control panel as illustrated
in Figure 3-1. Check the engine coolant level. Refer to “Cooling
Systems” in the Maintenance section of this manu-
This section covers prestart checks, starting and als for proper procedure.
stopping and operating the generator set. Each op-
erator should read through this entire section before Fuel
attempting to start the set. It is essential that the op-
Make sure the fuel tanks have sufficient fuel and
erator be completely familiar with the set and the
that fuel system is primed. Check to make sure
PCC control. Refer to Section 8 for operating rec-
there are no leaks and that all fittings are tight.
ommendations.
Exhaust
PRESTART CHECKS
Check to make sure entire exhaust system is tight,
Before starting, be sure the following checks have that no combustible materials are near system, and
been made and the unit is ready for operation. gases are discharged away from building openings.
Standby Mode: In this mode, the control’s operat- With the switch set to Standby mode, pressing the
ing software is inactive and the LED’s and displays Self Test button will allow you to activate and view
on the front panel are all off. The operating software the menu displays without starting the generator
is initialized and the front panel is turned on in re- set. If no menu selections are made, a software tim-
sponse to one of the following: er will shut down the power after 30 seconds.
• moving the Run/Off/Auto switch to the Run When left in the Standby mode, and a “Warning”
position, signal is sensed by the PCC (for example, low cool-
ant temp), the control will wake up and display the
• pressing the Self Test button, warning message. The control will remain active
• a remote start input signal (generator set in until the warning condition is corrected and the Re-
Auto mode), or set button is pressed to clear the warning message.
AC Ammeter: Indicates current output in percent of Phase Selector Switch and Indicators: Press this
maximum rated current. momentary switch to select phases of generator
output to be measured by AC voltmeter and amme-
Kilowatt Meter: Indicates 3-phase AC power out- ter. LEDs indicate the selected phase.
put as percent of rated load.
Run/Off/Auto Switch: This switch starts and stops
Frequency Meter: Indicates generator output fre- the set locally, or enables start/stop control of the
quency in hertz. engine from a remote location. (Ground to start.)
Emergency Stop Button: Push the switch in for
Upper and Lower Scale Indicator Lamps: Indi-
emergency shutdown of the engine.
cate AC voltmeter scale.
To reset:
Digital Display: This two-line, 16-character per line Pull the button out or turn the button clockwise
alphanumeric display is used in the menu-driven (button with arrow) and allow it to pop out. Move
operating system, in conjunction with the display the Run/Off/Auto switch to Off.
menu selection switches and the Menu switch. Re- Press the front panel Reset switch.
fer to the menu trees later in this section. The dis- Select Run or Auto, as required.
play is also used to show warning and shutdown
Non-Automatic Status Indicator: This red lamp
messages.
flashes continuously when the Run/Off/Auto switch
Display Menu Selection Switches: Four momen- is not in the Auto position.
tary switches—two on each side of the digital dis- Warning Status Indicator: This yellow lamp is lit
play window—are used to step through the various whenever the control detects a warning condition.
menu options and to adjust generator set parame- After the condition is corrected, warning indicators
ters. The green arrow adjacent to the switch is lit can be reset by pressing the Reset switch. (It is not
when the switch can be used (switch is “active”). necessary to stop the generator set.) In auto mode,
warning indicators can also be reset by cycling the
Menu Switch: Press this switch to return the digital
remote reset input after the condition is corrected.
display to the MAIN MENU. Refer to the menu trees
later in this section. Shutdown Status Indicator: This red lamp is lit
whenever the control detects a shutdown condition.
Reset Switch: Press this switch to reset warning After the condition is corrected, shutdown indica-
and shutdown messages after the condition has tors can be reset by turning the Run/Off/Auto switch
been corrected. To reset a shutdown message with to the Off position, and pressing the Reset switch. In
the Reset switch, the Run/Off/Auto switch must be auto mode, shutdown faults can be reset by remov-
in the Off position. ing the remote start input and then cycling the re-
mote reset input.
In Auto mode, shutdown faults can be reset by re-
moving the remote start input and then cycling the Emergency Stop shutdown status (Code 102) can be
remote reset input. reset only at the PCC front panel.
The set will stop after the stop time delay timer When the engine idle function is enabled, the con-
(0−600 seconds) has timed out. Refer to Time Delay trol automatically sets lower oil pressure warning
Stop in the Adjust menu. and shutdown trip points to reflect the lower operat-
ing speed. When the engine idle function is re-
Emergency Stop (Code 102) moved and the set reverts to normal operating
speed, the control automatically resets oil pressure
The emergency stop button is located on the lower warning and shutdown trip points to the normal set-
right side of control panel (Figure 3-1). Push the but- tings.
ton in for emergency stop. The red Shutdown status
LED will light, and the digital display message will Remote Emergency Stop Input: Grounding this
be: “EMERGENCY STOP input causes an immediate shutdown. Emergency
102 − SHUTDOWN” stop must be reset at the front panel.
MENU DISPLAY AND SWITCHES play window—are used to step through the various
menu options and to adjust generator set parame-
Figure 3-2 shows the digital display and the menu ters. The green arrow adjacent to the switch is lit
selection switches. when the switch is available for use (is active).
In Standby Mode, to activate and view the menu dis-
plays without starting the generator set, press and
Menu Switch: Press this momentary switch to re-
release the Self Test switch. This will initialize the turn the digital display to the main menu. (Refer to
PCC operating software and permit operation of the the main menu diagram on the next page.
menu display panel. If no menu selections are made,
a software timer will shut down the display power af- Reset Switch: Press this momentary switch to re-
ter 30 seconds. In Power On Mode, power is continu- set warning and shutdown messages after the con-
ously supplied to the control panel. Display will al- dition has been corrected.
ways remain active.
In the digital display, the “>>” symbol indicates that
Digital Display: This two-line, 16-character per line selecting the adjacent button causes the operating
alphanumeric display is used in the menu-driven program to branch to the next menu display—as
operating system, in conjunction with the display shown in the menu diagrams.
menu selection switches and the Menu switch.
In the digital display, the “<<” symbol indicates that
Display Menu Selection Switches: Four momen- selecting the adjacent button causes the operating
tary switches—two on each side of the digital dis- program to go back to the previous menu display.
⇑ VOLTAGE
⇓ _______ >> VERSION
SETUP / CAL
⇑ FREQUENCY
⇓ _______ >> PAGES 3-16 & 3-17
⇑ START DELAY
⇓ _______ SEC >>
⇑ STOP DELAY
⇓ _______SEC >>
PAGES 3-14 & 3-15
INACTIVE BUTTON
The facing page shows a block representation of OIL/COOLANT submenu: This is the first subme-
the ENGINE menu. If you press the button next to nu. Select OIL for a display of oil pressure and oil
the word “ENGINE” in the display, the first ENGINE temperature. Select COOLANT for a display of
submenu will appear. coolant temperature. When oil or coolant parame-
ters are displayed, pressing the button next to the
As shown in the diagram, the ENGINE menu has
“<<” will return the display (“BACK”) to the OIL/
three submenus.
COOLANT submenu.
BACK
< OIL << > L___°F / °C << >
< COOLANT >> > R___°F / °C (or n/a)
BACK
< OIL << >
< COOLANT >> >
BACK
< BATTERY << > BATTERY << >
< HOURS >> > ___V DC
BACK
< BATTERY << > STARTS ___ << >
< HOURS >> > HOURS ___
BACK
< RPM << > RPM << >
< EXHAUST ___
BACK
< RPM << > L___°F/°C (or n/a) << >
< EXHAUST R___°F/°C (or n/a)
The facing page shows a block representation of VOLTS/AMPS submenu: This is the first subme-
the GEN menu. If you press the button next to the nu. Select VOLTS for a display of a line-line or line-
word “GEN” in the display, the first GEN submenu neutral selection. Select line-line or line-neutral for
will appear. the desired voltage display. Select AMPS for a dis-
play of L1, L2, and L3 current in amps. When volt-
As shown in the diagram, the GEN menu has three age or current parameters are displayed, pressing
submenus. the button next to the “<<” will return the display
(“BACK”) to the L-L/L-N submenu.
If DELTA is selected in the Initial Start Setup subme-
nu, when selecting VOLTS, the “line-line” or “line-
neutral” submenus will not be displayed, only the
L12, L23, L31 submenu will be displayed.
BACK
< VOLTS << > < L−L << > L12 L23 L31 << >
< AMPS >> > < L−N ___ ___ ___
BACK
< L−L << > L1N L2N L3N << >
< L−N ___ ___ ___
BACK
< L−L << >
< L−N
BACK
< VOLTS << > L1 L2 L3 << >
< AMPS >> > ___ ___ ___
BACK
< VOLTS << > < POWER << > ___ KW << >
< AMPS >> > < KW HRS >> > ___ PF
BACK
< POWER << > KW HRS << >
< KW HRS >> > ____________
BACK
< POWER << >
< KW HRS >> >
BACK
< POWER << > < %GOV / REG << >
< KW HRS >> > < FREQUENCY
BACK
< %GOV / REG << > GOVERNOR_ % << >
< FREQUENCY REGULATOR_ %
BACK
< %GOV / REG << > FREQUENCY << >
< FREQUENCY ___ HZ
The facing page shows a block representation of VOLTAGE submenu: This is the first submenu.
the ADJUST menu. If you press the button next to Use the buttons next to the “⇑” and “⇓” symbols to
the word “ADJUST” in the display, the VOLTAGE adjust output voltage ± 5%.
ADJUST submenu will appear.
As shown in the diagram, the ADJUST menu has FREQUENCY submenu: From the VOLTAGE sub-
five submenus, including a save/exit procedure. menu, press the button next to the “>>” in the dis-
play to move to the FREQUENCY submenu. Use
Voltage and frequency can be adjusted only when the buttons next to the “⇑” and “⇓” symbols to adjust
the generator set is running under normal operating output frequency ± 5%.
parameters (not in idle mode). For example, if volt-
age adjustment is selected when the set is in Idle
mode or not running, the digital display will be: START DELAY submenu: This delay applies only
to remote starting in the Auto mode. From the FRE-
QUENCY submenu, press the button next to the
“⇑ VOLTAGE ” “>>” in the display to move to the START DELAY
“⇓ N/A >>” submenu. Use the buttons next to the “⇑” and “⇓”
symbols to set the start delay. The start delay ad-
justment range is 0 to 300 seconds.
< ⇑ VOLTAGE
< ⇓ _______ >> >
< ⇑ FREQUENCY
< ⇓ _______ >> >
The facing page shows a block representation of VERSION submenu: If you select VERSION, the
the VERSION submenus. If you press the button display will show the generator set model number,
next to the “>>” in the Main menu display, the VER- frequency, and kW rating, and the date and version
SION/SETUP/CAL menu will appear. of the operating software.
To display the generator set configuration options,
press the button next to the “>>” in the submenu that
displays the model number, frequency and etc. This
menu provides the following information:
• Generator set voltage
• WYE or DELTA
• Standby or Prime
• Parallel or Single
HISTORY: (Beginning Version 1.06) From the VER-
SION menu, press the button next to the “>>” in the
display to move to the HISTORY submenu. Press
the button next to “HISTORY” to display the last (lat-
est) recorded error message.
The software will record (save) up to 20 error mes-
sages. The last error detected will always be dis-
played first. As each new error is detected, the old-
est error recorded after 20 will be deleted.
To view the generator set runtime at which the error
occurred and to scroll through the remaining re-
corded errors, press the button next to the “>>” in
the error message menu to display the RUNTIME,
NEWER/OLDER menu.
The buttons next to NEWER and OLDER are used
to scroll up and down through the error messages.
For example, pressing OLDER will display the next
oldest recorded error message.
ALPHANUMERIC
WARNING AND FAULT MESSAGE
SHUTDOWN DISPLAY
STATUS INDICATORS
RESET
SWITCH
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform service procedures. Read Safety Precautions page
and observe all instructions and precautions in this manual.
Control does not power up when the There is no DC power to the control.
Run/Off/Auto switch is set to Run or the
Self Test switch is pressed. a. Check for battery disconnected, discharged, or improperly con-
nected.
b. Contact an authorized service center.
Warning, Shutdown, and Non-Auto- Indicates all engine systems are normal. No corrective action require
matic lamps are not lit. Digital display
shows main menu or selected menu.
Non-Automatic lamp flashes. Indicates Run/Off/Auto switch is not in the Auto position. This will pre-
vent automatic starting if an automatic transfer switch is used. Move
the Run/Off/Auto switch to the Auto position for automatic operation.
MESSAGE: Indicates that the engine is operating in idle mode. When the set is op-
IDLE MODE erating in the RUN mode, grounding the engine idle input causes gen-
101 − WARNING erator build-up to be inhibited and the engine to be governed at 800
Engine continues to operate at reduced RPM.
RPM. When ground is removed from this input, the set returns to normal
speed and voltage.When the engine idle function is enabled, the con-
trol automatically sets lower oil pressure warning and shutdown trip
points to reflect the lower operating speed. When the engine idle func-
tion is removed and the set reverts to normal operating speed, the con-
trol automatically resets oil pressure warning and shutdown trip points
to the normal settings.
Warning lamp lights. Indicates engine oil pressure has dropped to an unacceptable level. If
MESSAGE: generator is powering critical loads and cannot be shut down, wait until
LOW OIL PRESSURE next shutdown period then follow, 201 Low Oil Pressure procedure. If
200 − WARNING engine can be stopped, follow 201 procedure.
To check oil pressure, access Oil Pressure menu prior to clearing
the fault.
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform service procedures. Read Safety Precautions page
and observe all instructions and precautions in this manual.
Shutdown lamp lights. Indicates engine oil pressure has dropped below the shutdown trip
MESSAGE: point. Check oil level, lines and filters. If oil system is OK but oil level is
LOW OIL PRESSURE low, replenish. Reset control and restart. Oil pressure limits are listed
201 − SHUTDOWN in Specifications. Contact an authorized service center.
Warning lamp lights. Indicates that the engine oil pressure sender is not functioning correct-
MESSAGE: ly. Check that the engine oil pressure sender is properly connected.
OIL PRES SENDER Contact an authorized service center.
204 − WARNING
Warning lamp lights. Indicates engine coolant heater is not operating or is not circulating
MESSAGE: coolant. Check for the following conditions:
LOW COOLANT TEMP a. Coolant heater not connected to power supply. Check for blown fuse
210 − WARNING
or disconnected heater cord and correct as required.
Set is in standby mode but is not operat-
ing. Warning occurs when engine cool- b. Check for low coolant level and replenish if required. Look for possi-
ant temperature is 70° F (21° C) or low- ble coolant leakage points and repair as required.
er. NOTE: In applications where the
c. Contact an authorized service center if none of the above.
ambient temperature falls below
40°F (4°C), Low Engine Temp may be
indicated even though the coolant
heaters are operating.
Warning lamp lights. Indicates engine has begun to overheat and coolant temperature has
MESSAGE: risen to an unacceptable level:
HIGH COOLANT TEMP (215° F − standby / 207° F − primary).
211 − WARNING If generator is powering non-critical and critical loads and cannot be
shut down, use the following:
a. Reduce load if possible by turning off non-critical loads.
b. Check air inlets and outlets and remove any obstructions to airflow.
If engine can be stopped, follow the next procedure.
To check coolant temperature, access Coolant Temp menu prior
to clearing the fault.
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform service procedures. Read Safety Precautions page
and observe all instructions and precautions in this manual.
Shutdown lamp lights. Indicates engine has overheated (coolant temperature has risen
MESSAGE: above the shutdown trip point:
HIGH COOLANT TEMP 223° F − standby / 215° F − primary) or the coolant level is low. Allow
212 − SHUTDOWN engine to cool down completely before proceeding with the following
checks:
a. Check coolant level and replenish if low. Look for coolant leakage
and repair if necessary.
b. Check for obstructions to cooling airflow and correct as necessary.
c. Check fan belt and repair or tighten if necessary.
d. Reset control and restart after locating and correcting problem. Con-
tact an authorized service center if none of the above.
Warning lamp lights. Indicates that the resistance of the coolant temperature sender is out
MESSAGE: of range. Contact an authorized service center.
ENG COOLANT SENDER
213 − WARNING
Shutdown lamp lights. Indicates engine coolant level has fallen below the trip point. Allow en-
MESSAGE: gine to cool down completely before proceeding.
LOW COOLANT LVL a. Check coolant level and replenish if low. Look for possible coolant
214 − WARNINGor
leakage points and repair if necessary.
LOW COOLANT LVL
215 − SHUTDOWN b. Reset control and restart after locating and correcting problem. Con-
tact an authorized service center.
LOW COOLANT LVL Shutdown will not occur if generator set is
in Idle mode (low coolant warning only).
Shutdown lamp lights. Indicates mag pickup speed indication is not being sensed or does not
MESSAGE: match generator set output frequency.
MAG PICKUP a. Restart and check RPM on the digital display.
220 − SHUTDOWN
b. Contact an authorized service center.
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform service procedures. Read Safety Precautions page
and observe all instructions and precautions in this manual.
Shutdown lamp lights. Indicates possible fault with control or starting system. Check for the
Engine will not crank. following conditions:
MESSAGE: a. Poor battery cable connections. Clean the battery cable terminals
FAIL TO CRANK and tighten all connections.
221 − SHUTDOWN
b. Discharged or defective battery. Recharge or replace the battery.
c. Contact an authorized service center for service of starter and start-
ing system.
Shutdown lamp lights. Indicates engine has exceeded normal operating speed. (2070 rpm @
Engine runs and then shuts down. 60 hz; 1800 rpm @ 50 hz)
MESSAGE: Contact an authorized service center.
OVERSPEED
223 − SHUTDOWN
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform service procedures. Read Safety Precautions page
and observe all instructions and precautions in this manual.
Warning lamp lights. Indicates battery voltage drops below 60% of nominal for two seconds,
MESSAGE: during starting.
WEAK BATTERY Discharged or defective battery.
232 − WARNING See Warning message 230, LOW DC VOLTAGE.
Warning lamp lights. Indicates day tank fuel supply is running low. Check fuel supply and
MESSAGE: replenish as required.
LOW FUEL DAY
240 − WARNING
Warning lamp lights. Indicates fuel supply is running low. Check fuel supply and replenish
MESSAGE: as required.
LOW FUEL
241 − WARNING
Shutdown lamp lights. Indicates PCC memory error. Data corruption of critical operating pa-
MESSAGE: rameters. Contact an authorized service center.
EEPROM ERROR
250 − SHUTDOWN
Warning lamp lights. Indicates PCC memory error. Data corruption of noncritical operating
MESSAGE: parameters. Contact an authorized service center.
EEPROM ERROR
251 − WARNING
or
252 − WARNING
Shutdown lamp lights. When any one of these customer defined inputs is closed to ground,
MESSAGE: the corresponding fault message is displayed. The nature of the fault is
CUSTOMER FAULT 1 an optional customer selection. These fault functions can be pro-
260 − SHUTDOWN grammed to initiate a shutdown or a warning.
or As indicated by the Shutdown lamp, a shutdown response has been
GROUND FAULT preselected.Contact an authorized service center.
261 − SHUTDOWN Note: Customer fault messages are editable. The message displayed
or for the code shown (260 thru 263) may have been edited and may not
DAY TANK appear as shown in this table.
262 − SHUTDOWN
or
HIGH GEN TEMP
263 − SHUTDOWN
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform service procedures. Read Safety Precautions page
and observe all instructions and precautions in this manual.
Warning lamp lights. When any one of these customer defined inputs is closed to ground,
MESSAGE: the corresponding fault message is displayed. The nature of the fault is
CUSTOMER FAULT 1 an optional customer selection. These fault functions can be pro-
260 − WARNING grammed to initiate a shutdown or a warning.
or As indicated by the Warning lamp, a warning response has been pre-
GROUND FAULT selected.
261 − WARNING Note: Customer fault messages are editable. The message displayed
or for the code shown (260 thru 263) may have been edited and may not
RUPTURE BASIN appear as shown in this table.
262 − WARNING
or
HIGH GEN TEMP
263 − WARNING
Shutdown lamp lights. Indicates that one or more of the phase voltages has exceeded 130%
MESSAGE: of nominal, or has exceeded 110% of nominal for 10 seconds.
HIGH AC VOLTAGE Contact an authorized service center.
301 − SHUTDOWN
Shutdown lamp lights. Indicates that one or more of the phase voltages has dropped below
MESSAGE: 85% of nominal for 10 seconds.
LOW AC VOLTAGE Contact an authorized service center.
303 − SHUTDOWN
Shutdown lamp lights. Indicates that engine speed has dropped below 90% of nominal for 10
MESSAGE: seconds.
UNDER FREQUENCY NOTE: Five seconds before shutdown, a Load Dump signal is initi-
313 − SHUTDOWN ated.
Contact an authorized service center.
Warning lamp lights. Indicates that generator output current has exceeded 110% of rated
MESSAGE: for 60 seconds.
OVERCURRENT Contact an authorized service center.
320 − WARNING
Shutdown lamp lights. Indicates that generator output current has exceeded 110% of rated,
MESSAGE: and that a PCC time/current calculation has initiated an overcurrent
OVERCURRENT shutdown.
321 − SHUTDOWN Contact an authorized service center.
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform service procedures. Read Safety Precautions page
and observe all instructions and precautions in this manual.
Shutdown lamp lights. Indicates that generator output current has exceeded 175% of rated.
MESSAGE: Contact an authorized service center.
SHORT CIRCUIT
322 − SHUTDOWN
Warning lamp lights. Indicates that three-phase power output exceeds 105% of standby (or
MESSAGE: 115% of prime) rating. After five seconds, the Load Dump output is ac-
OVERLOAD tivated. After 60 seconds, the OVERLOAD warning is activated.
330 − WARNING Contact an authorized service center.
Engine starts from generator control Check the control wiring between the remote switch and the PCC.
panel but will not start automatically or Contact an authorized service center.
from a remote panel. (Note: The Run/
Off/Auto switch must be in the Auto posi-
tion for automatic or remote starting).
OIL PRESSURE
GAUGE
RUN/STOP/REMOTE
SWITCH
COOLANT RESET/LAMP
TEMPERATURE TEST/ PANEL
GAUGE LAMP SWITCH
INDICATOR
LAMPS
DC VOLTMETER
RUNNING
TIME METER
EMERGENCY STOP
PUSHBUTTON
• SWITCH OFF (flashing red) indicates genera- FIGURE 5-2. INDICATOR LAMPS
tor set is not in automatic start mode.
A−C VOLTS
VOLTAGE
AC AMMETER ADJUST
A−C AMPERES
EXCITATION
FREQUENCY/ FIELD BREAKER
RPM METER RPM
HERTZ PHASE
SELECTOR
SWITCH
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform service procedures. Read Safety Precautions page
and observe all instructions and precautions in this manual.
1. Green RUN lamp lights following en- 1. Indicates all engine systems are normal. No corrective action re-
gine startup. quired.
2. PRE HI ENGINE TEMP lamp lights. 2. Indicates engine has begun to overheat and engine temperature has
Engine continues to operate. (Engine risen to approximately 215°F (102° C) or coolant level is low on op-
can be programmed to shut down.) tionally wired sets. If generator is powering non-critical and critical
loads and cannot be shut down, use the following:
a. Reduce load if possible by turning off non-critical loads.
b. Check air inlets and outlets and remove any obstructions to air-
flow.
If engine can be stopped, follow procedure in step 3.
3. HI ENG TEMP lamp lights. Engine 3. Indicates engine has overheated (engine temperature has risen
shuts down. above 222°F/106°C) or coolant level is low. Allow engine to cool
down completely before proceeding with the following checks:
a. Check coolant level and replenish if low. Look for possible cool-
ant leakage points and repair if necessary.
b. Check for obstructions to cooling airflow and correct as neces-
sary.
c. Check for a slipping fan belt and tighten if loose.
d. Reset control and restart after locating and correcting problem.
Contact an authorized service center if none of the above.
4. PRE LO OIL PRES lamp lights. En- 4. Indicates engine oil pressure has dropped to 20 psi (138 kPa). If gen-
gine continues to operate. (Engine erator is powering critical loads and cannot be shut down, wait until
can be programmed to shut down.) next shutdown period and then follow step 5 procedure. If engine can
be stopped, follow procedures in step 5.
5. LO OIL PRES lamp lights. Engine 5. Indicates engine oil pressure has dropped to 14 psi (97 kPa). Check
shuts down. NOTE: See also step 6. oil level, lines and filters. If oil system is OK but oil level is low, replen-
ish. Reset control and restart. Contact an authorized service center if
oil pressure is not in the range of 25 to 40 psi (172 to 275 kPa).
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform service procedures. Read Safety Precautions page
and observe all instructions and precautions in this manual.
6. OVERCRANK lamp lights and engine 6. Indicates possible fuel system problem.
stops cranking.
a. Check for empty fuel tank, fuel leaks, or plugged fuel lines and
correct as required.
or
b. Check for dirty fuel filter and replace if necessary (see Mainte-
Engine runs, shuts down, and LO OIL nance section).
PRES lamp lights..
c. Check for dirty or plugged air filter and replace if necessary (see
Maintenance section).
d. Reset the control and restart after correcting the problem. Con-
tact an authorized service center for service if none of the
above.
7. OVERSPEED lamp lights and the en- 7. Indicates engine has exceeded normal operating speed. Contact an
gine shuts down. authorized service center for service.
8. SWITCH OFF lamp flashes. 8. Indicates Run/Stop/Remote switch is in the Stop position which will
prevent automatic starting if an automatic transfer switch is used.
Move the Run/Stop/Remote switch to the Remote position for auto-
matic starting.
9. LO FUEL lamp lights. Engine contin- 9. Indicates diesel fuel supply is running low. Check fuel supply and re-
ues to run. plenish as required.
10. LO FUEL LAMP lights. Engine shuts 10. Indicates engine has run out of fuel. Check fuel level and replenish as
down and LO OIL PRES lamp lights. required.
11. LO ENG TEMP lamp lights. Set is in 11. Indicates engine coolant heater is not operating, not not circulating
standby mode but is not operating. coolant or ambient temperature too cold for heater to keep up with
demand. Check for the following conditions:
(Lamp lights when engine coolant
a. Coolant heater not connected to power supply. Check for blown
temperature is 70° F (21° C) or lower.
fuse or disconnected heater cord and correct as required.
Since the lamp goes out after the en-
gine warms up, there should be no b. Check for low coolant level and replenish if required. Look for
cause for alarm even during initial possible coolant leakage points and repair as required.
generator set operation.)
c. Contact an authorized service center if none of the above.
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform service procedures. Read Safety Precautions page
and observe all instructions and precautions in this manual.
12. The FAULT 1 or FAULT 2 fault lamp 12. The standard undesignated fault functions are programmed to shut
lights. Engine shuts down immediate- down the set when a fault is sensed. Fault 1 is time delayed while
ly, engine runs for several seconds Fault 2 is immediate. The nature of the fault is an optional selection
and then shuts down, or engine con- that is determined when the set installation is designed. The undes-
tinues to run. ignated fault functions may also be programmed for non-shutdown
or non-time delay.
13. Fault lamp lights but no fault exists. 13. The monitor board or a sensor may be at fault. Contact an authorized
Engine gauges show oil pressure, en- service center for service.
gine temperature, and frequency
(speed) are within normal limits.
14. The BASIN (optional) fault lamp lights. 14. Indicates fuel is leaking from inner tank to outer basin or the sensor
Engine continues to run or is in stand- may be defective. Contact an authorized service center for service.
by mode. (Engine can be programmed
to shut down.)
15. Engine starts from generator control 15. Remote circuit breaker is tripped. Reset breaker and restart. Contact
panel but will not start automatically or an authorized service center if breaker trips after resetting.
from a remote panel. (Note: The Run/
Stop/Remote switch must be in the
Remote position for automatic or re-
mote starting).
16. Engine will not crank. 16. Indicates possible fault with control or starting system. Check for the
following conditions:
a. Fault lamp on. Correct fault and reset control.
b. Poor battery cable connections. Clean the battery cable termi-
nals and tighten all connections.
c. Discharged or defective battery. Recharge or replace the bat-
tery.
d. Emergency stop button (if equipped) pushed in. To reset, pull
switch out and move Run/Stop/Remote switch to Stop position.
Then push test switch to Reset/ Lamp position.
e. Contact an authorized service center if none of the above.
17. No AC output voltage. 17. Field breaker is tripped. Reset breaker. Contact an authorized ser-
vice center if voltage buildup causes breaker to trip.
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform service procedures. Read Safety Precautions page
and observe all instructions and precautions in this manual.
18. RUN or fault lamp(s) does not light 18. Contact an authorized service center for assistance.
when Lamp Test switch is engaged.
19. Green RUN lamp does not light follow- 19. Indicates possible Start/Disconnect relay failure. Contact an autho-
ing engine startup. rized service center for assistance.
SERVICE TIME
Month- 6
Daily Weekly Yearly
MAINTENANCE ITEMS See ly Month 4000 −
or after or after or after
Engine or after s or af- 4500
8 50 500
Schdl. 100 ter 250 Hours
Hours Hours Hours
Hours Hours
General Genset Inspection X1 X2
Check Coolant Heater X
Check Oil Level X
Check Coolant Level X
Check Fuel Level X
Check Charge Air Piping X
Check Air Cleaner (Clean if required) X3
Check Battery Charging System X
Drain Water and Sediment from Fuel Tank X5
Drain Exhaust Condensate Trap X
Check Starting Batteries X
Change Air Cleaner Element X3
Check Radiator Hoses for Wear & Cracks X
Test Generator Insulation Resistance X7
Grease generator bearing (P7 only) X
Drain Fuel Filter(s) X1
Check Anti-freeze and DCA Concentration X1
Change Crankcase Oil and Filter X1, 6
Check Drive Belt Tension X1
Change Coolant Filter X1
Clean Crankcase Breather X1
Change Fuel Filters X1
Clean Cooling System X1
X1 Refer to Cummins Engine Operation and Maintenance Manual for maintenance interval and/or procedure.
X2 Check for oil, fuel, cooling and exhaust system leaks. Check exhaust system audibly and visually with set running and repair any
leaks immediately.
3
X Perform more often in dusty conditions.
X4 Visually check belt for evidence of wear or slippage. Replace if hard or brittle.
X5 Drain 1 cup or more of fuel to remove water and sediment.
X6 If genset is used for standby applications, change oil every 12 months or 250 hours, whichever comes first.
X7 This procedure should be followed periodically throughout the life of the generator set, or if the generator has set idle for a period
of time with no generator heaters used. Contact your authorized service center.
Ventilate battery area before working on or near 2. Turn off or remove AC power from the battery
battery—Wear goggles—Stop genset and dis- charger.
connect charger before disconnecting battery
3. Remove the negative (−) battery cable from the
cables—Disconnect negative (−) cable first and
generator set starting battery.
reconnect last.
CAUTION Disconnect battery charger from Mechanical Inspection
AC source before disconnecting battery cables. With the generator set stopped, check for loose
Otherwise, disconnecting cables can result in belts and fittings, leaking gaskets and hoses, or any
voltage spikes damaging to DC control circuits signs of mechanical damage. If any problems are
of the set. found, have them corrected immediately.
Gensets are shipped with oil added. Be sure to check OIL FILL
oil level before initial start.
Oil Viscosity
Coolant Heater
Check the operation of the coolant heater by verify-
ing that hot coolant is being discharged from the
outlet hose. Do not touch outlet hose − if heater is
operational, radiant heat should be felt with hand
held close to outlet hose. DRAIN INLET
WARNING Contact with cooling system or en-
gine can result in serious burns. Do not touch
cooling system or engine during genset mainte-
nance until they are cool.
FIGURE 7-2. COOLANT HEATER
CHARGE-AIR PIPING
Inspect the charge air piping and hoses, daily, for
leaks, holes, cracks, or loose connections. Tighten
the hose clamps if necessary.
Inspect the charge air cooler for dirt and debris
blocking the fins. Check for cracks, holes, or other
damage.
FUEL SYSTEM
Refer to the Cummins engine Operation and Main-
tenance Manual for fuel system maintenance.
SLING
FAN BELT
FAN SUPPORT
BRACKET
REMOVE SIX
CAPSCREWS
(3 EA SIDE)
SHOCK ABSORBER
ATTACH WRENCH
HERE AND TURN IN
DIRECTION OF ARROW
TO RELIEVE IDLER
SPRING PRESSURE
Generator sets on continuous standby must be able CAUTION To avoid damage to heater, be sure
to go from a cold start to being fully operational in a the cooling system is full before applying power
matter of seconds. This can impose a severe bur- to the heater.
den on engine parts.
HIGH OPERATING TEMPERATURE
Regular exercising keeps engine parts lubricated,
prevents oxidation of electrical contacts and in gen- Refer to the genset nameplate for the maximum
eral helps provide reliable engine starting. ambient operating temperature, if applicable.