It-Manual - PCC 3100 PDF

Table of Contents
SECTION TITLE PAGE

SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
1 INTRODUCTION
About this Manual 1-1
Test Equipment 1-1
How To Obtain Service 1-1
System Overview 1-2
Generator Set Control Function 1-2
2 CONTROL OPERATION 2-1
General 2-1
Safety Considerations 2-1
Sequence of Operation 2-2
PCC Power On/Standby Mode 2-2
Front Panel 2-4
Menu Display and Switches 2-6
Main Menu 2-6
Engine Menu 2-8
Gen Menu 2-10
3 CIRCUIT BOARDS AND MODULES
General 3-1
Digital Board (A32) 3-3
Engine Interface Board (A31) _ 3-4
Analog Board (A33) 3-6
Digital Display Board (A35) 3-7
Customer lntertace'Board (A34) : 3-8
PT/CT Board (A36) '. 3-10
Bus PT Board (A39) 3-11
Genset Communications Module (A41) 3-12
Voltage Regulator Output Module (A37) 3-13
Governor Output Module (A38) 3-14
Master First .Start'Sensor 3-15
4 TROUBLESHOOTING
General 4-1
Safety Considerations 4-1
Status lndicators 4-2
Resetting the Control 4-2
Warning and Shutdown Codes 4-3
PCC Oil Pressure Warning and Shutdown Limits 4-12
) Troubleshooting Procedure 4-13
.· ,./
PCC Fuses 4-56
Load Sharing Controls Troubleshooting Procedure 4-57
SECTION TITLE PAGE .··.·~
5 CONTROL SERVICE AND CALIBRATION .-_;/
General 5-1
Circuit Board Removal/Replacement 5-1
lnitial Start Setup Menu · 5-4
Adjust Menu 5-6
Setup and Calibration Menus 5-8
Calíbration Procedure 5-26
Accessory Box Control Components 5-29
Engine Sensors 5-42
Magnetic Speed Pickup Unit (MPU) lnstallation 5-46
Current Transformer (CT} lnstallation 5-47
6 SERVICING THE GENERATOR
Testing the Generator 6-1
Generator/PCC Control lsolation Procedure 6-2
lnsulation Resistance (Megger) & Polarization lndex (PI) Testing 6-3
Drying the Windings 6-5
Excitar Stator 6-6
Exciter Rectifier Bridge (Rotating Rectifier Assembly} 6-7
Excitar Rotor 6-8
Main Rotor (Generator Field) 6-9
Main Stator 6-1 O
Test the PMG 6-12
Bearing I nspection/Removal/Replacement 6-13
Generator Disassembly 6-15
Generator Reassembly 6-24
Aligning Generator with Engine - 6-28
7 DAY TANK FUEL TRANSFER PUMP ANO CONTROL
Operation ·: 7-2
Wiring Connections /. 7-4
Fuel Transfer Pump Motor Connections 7-6
Testing the Float Switch Assembly 7-7
8 INITIAL SYSTEM STARTUP
General 8-1
The Startup Procsss 8-1
Equipment Appllcation Review 8-2
Individual Generator Set Startup 8-2
Manual System Operation 8-4
Automatic System Operation 8-7
Black Start Testing 8-8
Test Reports and Acceptance 8-8
On Site Power System Application Review
(Diesel/600VAC and Lower) 8-9
9 WIRING DIAGRAMS
General 9-1
¡¡
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 and batter- • Provide an adequate exhaust system to properly
ies. expel discharged gases away f rom enclosed or
sheltered areas and areas where individuals are
Before operatingthe generatorset (genset), read the likely to congregate. Visually and audibly inspect
Operator's Manual and become famíliar 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-
achievedonly if the equipmentis properlyoperated 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 precautíons.
• Be sure the unit is well ventilated.
The following symbols, found throughout this manual,
alert you to potentially dangerous conditions to the op- • Engine exhaust and sorne of its constituents are
erator, service personnel, or the equipment. known to the state of California to cause cancer,
birth defects, and other reproductiva harm.
tt1•t4UtiJ=l;i This symbo/ warns of immediate MOVING PARTS CAN CAUSE SEVERE
hazardswhichwi/1resultin severe personalin
jury or death. PERSONAL INJURY OR DEATH
• Keep your hands, clothing, and jewelry away from
This symbo/refers to a hazard or un
lit.WARNING!
moving parts.
safe practice which can result in severe per
sonal injuryor death. • Before starting work on the generator set, discon-
nect battery charger from its AC source, then dis-
, . ,.. IA CAUTION I This symbo/refers to a hazard or un connect starting batteries, negativa (-) cable first.
{ >) sale practicewhich can resultin personalinjury This will prevent accidental starting.
'<...;.; or product or propertydamage. • Make sure that fasteners on the generator set are
secura. 1ighten supports and clamps, keep guards
FUEL ANO FUMES ARE FLAMMABLE in position over fans, drive belts, etc.
Fire, explosion, and personal injury or death can result • Do not wear loosg clothing or jewelry in the vicinity of
from improper practices. moving parts, or while working on electrical equíp-
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 ;e lf adjustment must be made while the unit is run-
tire 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 ANO
near the generator set or fuel tank.
EXPLOSIVE ENVIRONMENTS
• Fuel lines must be adequately secursd and free of
leaks. Fuel connection at the eng(ne 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 tire, expío-
coated or copper fuel lines with diesel fuel. sion, severa personal injury and death. Do not operate a
genset where a flammable vapor environment can be
• Be sure all fuel supplies have a positiva 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 are- set safely. Contact your authorized Cummins Power
ing, sparking, smoking, etc . Generation distributor for more information.
.)
LS-15M
¡¡¡
ELECTRICAL SHOCK CAN CAUSE changar pressure cap while the engine is running.
SEVERE PERSONAL INJURY OR DEATH To prevent severe scalding, let engine cool down
before removing coolant pressure cap. Turn cap
• Remove electric power before removing protective slowly, and do not open it fully untíl the pressure has
shields or touching electrical equipment. Use rub- been relieved.
ber insulative mats placed on dry wood platforms
over f loors that are metal or concrete when around • Used engine oils have been identified by sorne state
electrical equipment. Do not wear damp clothing or federal agencies as causing cancer or reproduc-
(particularly wet shoes) or allow skin surface to be tiva toxicity. When checking or changing engine oíl,
damp when handling electrical equipment. Do not take care not to ingest, breathe the fumes, or con-
wear jewelry. Jewelry can short out electrical contact used oil.
tacts and cause shock or burning.
• Keep rnulti-class ABC tire extinguishers handy .
• Use extreme caution when working on electrical Class A tires 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. 1 O).
codes. Have all electrical installations performed by
a qualified licensed electrician. Tag and lock open
• Make sure that rags are not left on or near the gener-
ator set.
switches to avoid accidental closure.
• DO NOT CONNECT GENERATOR SET DI- • Make sure generator set is mounted in a manner to
RECTLY TO ANY BUILDING ELECTRICAL SYS- prevent combustible materials from accumulating
TEM. Hazardous voltages can flow from the gen- under ornear the unit.
erator set into the utility line. This creates a potential • Remove all unnecessary grease and oil from the
for electrocution or property damage. Connect only unit. Accumulated grease and oil can cause over-
through an approved isolation switch or an ap- heating and engine damage which present a poten-
proved paralleling device. tial fire hazard.
MEDIUM VOLTAGE GENERATOR SETS
• Keep the generator set and the surrounding area
(601 V to 15kV) clean and free from obstructions. Remove any de-
bris from the set and keep the floor clean and dry.
• Medium voltage acts differently than low voltage.
Special equipment and training is required to work • Do not work on this equipment when mentally or
on or around medium voltage equipment. Operation physically fatigued, or after consuming any alcohol
and maintenance must be done only by persons or drug that makes the operation of equipment un-
trained and qualified to work on such devices. lrn- safe.
proper use or procedures will result in severe per-
sonal injury or death. • Substances in exhaust gases have been identified
by sorne state or federal agencies as causing can-
• Do not work on energizad equipment. Unauthorized cer or reproductiva toxicity. Take care not to breath
personnel must not be permitted near energized or ingest or come into contact with exhaust gases.
equipment. Due to the nature of medium voltage
electrical equipment, induced voltage remains even • Do not store any flammable liquids, such as fuel,
after the equipment is oisconnectedtrom the power cleaners, oil, etc., near the generator set. A tire or
source. Plan the time for maintenance with author- explosion could result.
ized personnel so that the equipment can be de-en-
ergized and safely grounded. ·· 1 • Wear hearing protection when going near an oper-
ating generator set.
GENERAL SAFETY PRECAUTIO.NS
• To prevent serious burns, avoid contact with hot
• Coolants under pressure have a higher boiling point metal parts such as radiator system, turbo charger
than water. DO NOT open a radiator or heat ex- system and exhaust system.
KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE
iv
1. lntroduction
ABOUT THIS MANUAL TEST EQUIPMENT
This manual provides troubleshooting and repair To perform the test procedures in this manual, the
information regarding the PowerCommand® following test equipment must be available
Control 3100 (PCC) and generators for the • True RMS meter for accurate measurement of
generator set (genset) models listed on the front small AC and DC voltages. Fluke models 87 or
cover. Engine service instructions are in the 8060A are good choices.
applicable engine service manual. Operating and • Grounding wrist strap to prevent circuit board
maintenance instructions are in the applicable damage dueto electrostatic discharge (ESO).
Operator's Manual. • Battery Hydrometer
This manual does not have instructions for • Jumper Leads
servicing printed circuit board assemblies. After • Tachometer or Frequency Meter
determining that a printed circuit board assembly is • Wheatstone Bridge or Digital Ohmmeter
faulty, replace it. Do not repair it. Attempts to repair a
• Variac
printed circuit board can lead to costly damage to
the equipment. • Load Test Panel
• Megger or lnsulation Resistance Meter
This manual contains basic (generic) wiring
diagrams and schematics that are included to help • PCC Service Tool Kit (Harness Tool and Sen-
sor Tool)
in troubleshooting. Service personnel must use the
actual wiring diagram and schematic shipped with HOW TO OBTAIN SERVICE
each unit. The wiring diagrams and schematics that Always give the complete Model, Specification and
are maintained with the unit should be updated Serial number of the generator set as shown on the
/::.·:.,. )_.
~t .. .'...·. when modifications are made to the unit.
.: ' nameplate when seeking additional service
''·~.~~ ',
Read Safety Precautions and carefully observe ali information or replacement parts. The nameplate is
instructions and precautions in this manual. located on the side of the generator output box.
LA.WARNING I lncorrectservice or replacement of
parts can result Í!J severe personal injury or
death, andlor equipmentdamage. Service per
sonne/ mustbe trainedand experienced to per
form electrica/and mechanical service. Read
end followSafety Precautions, on pages iii and
iv.
Copyright@ 2001 Cummins Power Generation. Ali rights reservad.

Cummins and PowerCommand are registered trademarks of Cummins lnc .
. >)
1-1
SYSTEM OVERVIEW The PCC monitors frequency from both the
magnetic pick-up (MPU) and the main stator inputs.
The PCC is a microprocessor-based control for
The control sends a low power pulse-width
Cummins generator sets. lt provides fuel control
modulated (PWM) signa! to the governor output
and engine speed governing, main alternator
module, which then sends an amplified signa! to the
voltage output regulation, and complete generator
engine fuel control.
set control and monitoring. lt also provides controls
for automatic and semi-automatic synchronizing The Bus PT module reduces the bus voltage to
and automatic load sharing controls for both approximately 18 VAC and provides a signa! to the
isolated bus or utility (mains) paralleling control for reference in synchronizing the generator ,1
applications. set to the system bus.

The operating software provides control of the The externa! PT/CT module reduces generator
generator set and its performance characteristics, voltage to approximately 18 VAC, and produces a
and displays performance information on a digital representativa AC voltage from CT output current.
display panel. lt accepts menu-driven control and The voltage regulation function sends a low power
setup input from the push button switches on the PWM signal to the voltage regulator output module,
front panel. which then sends an amplified signal to the excitar
stator.
GENERATOR SET CONTROL FUNCTION
Oil, coolant, and exhaust temperatures are sensed
Figure 1-1 shows sorne of the control functions. A by variable resistance element sensors. Oil
more complete block diagram is provided in Section pressure is sensed by a capacitiva element active
3. A system schematic is provided in Section 9. sensor.
Fuel
Governor Control
Output . · .. )
=-
=-=- g¡ ,e,.,1o ...
¡g =--
=---... ,.,.. Sensors
OJ
,. .... 1a.11 ..
,:!:!!2
o e, ... ,
o- -o C)\.tU
e:,..,...,
U.U LI
o . .,.
Ou.u u.u 1..2
=-o o-«
Ll
t5¡:::- [gJ
-w-
u
C> .. ~
1
D.. 2
"" """"'
3
4
¡
Battery
BT1
Bus PT
1 2 3 4
Module
To
Load
FIGURE 1-1. GENERATOR SET CONTROL FUNCTIONS
1-2
2. Control Operation
GENERAL SAFETY CONSIDERATIONS
The following describes the function and operation AC power is present when the set is running. Do not
of the PowerCommand generator set control. Ali in- open the generator output box while the set is run-
dicators, displays, meters and control switches are ning.
located on the face of the control panel as illustrated
in Figure 2-1.
LAWARNING I Contacting high voltage campo
nents can cause electrocution, resulting in se
The PCC control cabinet must be opened only by vere personal injury or death. Do not open the
technically qualified personnel. generator output box while the set is running.
Read and observe ali WARNINGS and CAU·
Normally, generator set configuration options are TIONSin your generator set manua/s.
set at the factory. When a new control is installed on
a generator set or when parts are replaced, the con-
LA CAUTION I The PCC control cabinet must be
opened only by technical/y qua/ified personnel.
trol must be configured for that generator set with
Lower leve/ voltages (18 VAC to 24 VDC) are
the use of the "lnitial Start Setup" portion of the inter-
present in PCC control cabinet. These voltages
na! software. Setup and calibration procedures are
can cause electrica/ shock, resulting in person
described in Section 5.
al injury.
The automatic voltage regulator (AVR) and gover- Even with power removed, improper handling
nor operation characteristic adjustments are also of components can cause electrostatic dls
described in Section 5. charge and damage to circuit components.
2-1
SEQUENCE OF OPERATION one of eight "wake up" inputs from remote sensing
switches.
When the PowerCommand control is in the AUTO
mode, it will cause the generator set to start on re- The wake up signals are:
ceiving a signal from a remote device. The Power-
Command control will initiate a starter cranking sig- • Emergency Stop
na! and verify that the engine is rotating. The Power- • Low Coolant Level
Command control will provide sufficient fuel to the
engine to accelerate to start disconnect speed. On • Low Coolant Temperature
reaching that speed, the control wíll ramp the gener- • Low Fuel
ator set to rated speed and voltage.
• Customer Fault lnputs 2 and 3
On reaching rated speed and voltage, the Power-
Command control checks the system bus voltage. lf • Run Selected on Run/Off/Auto Switch
no bus voltage is present, it will wait for a pulse from • Remota Start Signal in Auto Mode
a remote Master First Start Sensor. On receiving
that pulse, the control will signal the paralleling • Self Test switch
breaker to close. To activate and view the menu displays, press and
lf bus voltage is present, the PowerCommand con- ralease the Self Test switch. The PCC will initialize
trol will check for proper phase rotation, adjust the the operating software and permit operation of the
generator set to the bus voltage and frequency lev- menu display panel. lf no menu selections are
e!, and then synchronize the generator set to the made, the power to the control panel will shut down
system bus. When a synchronous condition is after 30 seconds.
achieved, the control will send a signal to close the
paralleling breaker.
Power On Mode
When the paralleling breaker is closed, the genera- In the Power On (awake) mode (selector switch 85
tor set will assume it's proportional share of the total on the Digital Board is set to the left), the PCC will
.. ·<..... :·:.)
load on the system bus. initialize the operating software and permit opera-
tion of the menu display panel. (See Figure 3-1 for
PCC POWER ON I STANDBY MODE SS location.) Power will stay on until switch (85) is
set to the Standby mode. lt is recommended that
Standby Mode
switch SS be left in the Power On mode in all ap-
In the Standby (sleep) mode (selector switch 85 on plications, except tFiose where auxiliary battery
the Digital Board is set to the right and the generator charging is not available.
set is not running), the control's operating software
is inactiva and the LEDs and displays on front panel IA CAUTION IElectrostatic discharge wi/1 damage
are all off. cfrcuit boards. Always wear a grounding wrist
strap when touching or handling circuit boards
The operating software is initialized and the front or socketmounted /Cs and when disconnect
panel is turned on in response to a run signal or any ing or connecting harness connectors.
2-2
KILOWATT FREQUENCY AC ACAMMETER
METER METER VOLTMETER
(PERCENT LOAD) (PERCENT AMPS)
(DUAL SCALE)
MENU
ACTIVE SWITCH ALPHANUMERIC
SELECTION
INDICATOR DISPLAY
') SWITCH
(1 of 4) (1 of 6)
.,,..------....,
HERTZ
C::,
e::)
Non·Automatlc
Warning ~o e::)
e::)
Upper Scale
Lower Scale
~o
e::) Shutdown
Voltage Amps
~o
313 1 ,a
e::) L1·L2 L1·L2 L1
= Aes et Menu e:, L2·L3 L1·L2 L2
C::, L3·L1
O
L3
e::, Opon
Phase Select
MENU PANEL LAMP EMERGENCY

SWITCH SWITCH STOP PUSH
BUTTON
PARALLELING
BREAKER
PHASE SELECTOR
SWITCHES ANO
SWITCH ANO
INDICATORS NON-AUTOMATIC
INDICATORS
WARNING
SHUTDOWN
STATUS INDICATORS
FIGURE 2~1.FRONT PANEL (PCC 3100)
2-3
FRONT PANEL Reset Switch: Press this switch to reset warning
and shutdown messages after the condition has
Figure 2- 1 shows the features of the front panel. been corrected. To reset a shutdown message with
the Reset switch, the Aun/Off/Auto switch must be
AC Voltmeter:Dual scale ínstrument indicates AC in the Off position.
voltage. Measurement scale in use is shown on
scale indicator lamp. With the Aun/Off/Auto switch in the Auto mode,
shutdown faults can be reset by removing the re-
AC Ammeter: lndicates current output in percent of mote start input and then cycling the remote reset
maximum rated current. (Percent current is based input.
on .8 PF.)
Sel! Test Switch:Press and hold this switch to light
KilowattMeter: lndicates 3-phase AC power out- all front panel LEDs and cycle through all shutdown
put as percent of rated load. and warning messages.
FrequencyMeter: lndicates generator output fre- In the Standby (sleep) mode, with the generator set
quency in hertz. not running, the control's operating software is inac-
tive and the LEDs and displays on front panel are all
Upper and Lower Sea/e lndicatorLamps: lndi- off.
cate AC voltmeter scale.
To actívate and view the menu displays without
DigitalDisplay:This two-line, 16-character per line starting the generator set, press and hold the Self
alphanumeric display is used in the menu-driven Test switch until the front panel LEDs light. The
operating system, in conjunction with the display PCC will initialize the operating software and permit
menu selection switches and the Menu switch. Re- operation of the menu display panel. lf no menu
fer to the menu trees later in this section. The dis- selections are made, a software timer will shut
play is also used to show warning and shutdown down the power after 30 seconds.
messages.
PanelLightsSwitch:Press this switch to turn con-
DisplayMenu Selection Switches:Four momen- trol panel illumination on and off. The illumination <<)
tary switches-two on each side of the digital dis- will shut off after about eight minutes.
play window-are used to step through the various Phase SelectorSwitchand lndicators : Press this
menu options and to adjust generator set pararne- momentary switch to select phases of generator
ters. The green arrow adjacent to the switch is lit output to be measur.ed by the analog AC voltmeter
when the switch can be used (switch is "active"). and ammeter. LEDs indicate the selected phase.
Menu Switch: Press this switch to return the digital Run/Off/Auto Switch:This switch starts and stops
display to the MAIN MENU. Refer to the menu trees the set locally, or enables startlstop control of the
later in this section. erígine from a remote location. (Ground to start.)
2-4
Emergency Stop Button: Push the button in for Shutdown Status lndicator: This red lamp is lit
emergency shutdown of the engine. whenever the control detects a shutdown condition.
After the condition is corrected, shutdown indica-
Remote Reset switch will not reset emergency stop.
tors can be reset by turning the Aun/Off/Auto switch
Can only be reset at the PCC front panel.
to the Off position, and pressing the Aeset switch.
To reset: In Auto mode, shutdowns can be reset by removing
1. Pull the button out or turn the button clockwise the remote start input and then cycling the remete
(button with arrow) and allow it to pop out. reset input.
•)
2. Move the Aun/Off/Auto switch to Off.
3. Press the front panel Aeset switch. Emergency Stop shutdown status (Code 102) can be
4. Select Aun or Auto, as required. reset only at the PCC front panel.
NonAutometic Status lndicator: This red lamp

flashes continuously when the Aun/Off/Auto switch Paralleling Breaker Switches and lndicators:
is not in the Auto position. These two switches are used to manually open or
close the paralleling breaker of the generator set.
Warning Status lndicator: This yellow lamp is lit The lamps are used to indicate the opened or
whenever the control detects a warning condition. closed position of the paralleling breaker.
After the condition is corrected, warning indicators
can be reset by pressing the Aeset switch. (lt is not
necessary to stop the generator set.) The Breaker Operation switches are operational only
when the Aun/Off/Auto switch is in the Aun position.
With the Aun/Off/Auto switch in the Auto mode, The breaker will close when the generator set is syn-
warnings can also be reset by cycling the remete re- chronized with the system bus, or if the system bus
set input after the condition is corrected. is de-energized.
,j
2-5
o~ ~o ····-.,
o~ 2 UNE, 16 CHARACTER PER UNE
MENU DISPLAY
~o
o~ ~o
't
Res et Menu
FIGURE 2-2. DIGITAL DISPLAY AND MENU SELECTION SWITCHES
MENU DISPLAY AND SWITCHES MAIN MENU

The facing page shows the main menu and a block
Figure 2-2 shows the digital display and the menu representation of the available submenus.
selection switches. Refer to heading "Front Panel" As shown in the diagram, the main menu can
which describes the menu display and switches. branch into one of four directions.
To display engine parameters, such as oil pressure
In the Standby Mode, to actívate and view the menu and temperature, water temperature, engine speed .•.•.• )
displays without starting the generator set, press (RPM), and exhaust temperature, press the button
and release the Self Test switch. This will initialize next to the word "ENGINE" in the display. Refer to
the PCC operating software and permit operation of ENG/NE MENU in this section.
the menu display panel. lf no menu selections are To display generator parameters, such as volts,
made, a software timer will shut down the power af- amps, power (kW), and frequency, press the button
ter 30 seconds. In the Power On Mode, power is next to the word "GEN" in the display. Bus voltage,
continuously supplied to the control panel. Display frequency and a digital synchroscope can also be
will always remain on. viewed from this menu branch. Turn to the GEN
MENU in this section.
To adjust output voltage and frequency, or start and
In the digital display, the ">>" symbol indicates that stop delays, press the button next to the word "AD-
selecting the adjacent button causes the operating JUST' in the display. Refer to ADJUST MENU in
program to branch to the next menu display-as Section 5.
shown in the menu diagrams. ·· 1
To display the selected generator set model and the
resident version software, press the button next to
In the digital display, the "<<" symbol indicates that the ">>" in the display. Refer to VERSION & DJS
selecting the adjacent button causes the operating PLAYS MENUS in Section 5.
program to go back to the previous menu display.
2-6
MAIN MENU
PAGES 2-8 & 2-9 PAGES 2-10 & 2-11
RPM << %GOV J REG <<
EXHAUST FREQUENCY
BATTERY << POWER <<

HOURS >> IW',I HAS >>
OIL << VOLTS <<

COOLANT >> AMPS >>
< ENGINE GEN >
< ADJUST >> >
D.........._ RESET MENU > D

CLEAR WARNING AND
.>
RETURN TO
SHUTDOWN MESSAGES MAIN MENU
'~)
t:':.
( . .<:.:.· . ·
.........
.. ít
u.
VOLTAGE
>>
VERSION
,
SECTION 5 SETUP /CAL
HISTORY
1l FREQUENCY
.u >>
(ACCESS CODE)
ít STARTDELAY
u. SEC >>
1l STOP DELAY
u. SEC >>
DISPLAY CAL <<
SECTION 5 METERS >>
ít IDLE SPEED
u. RPM >>
SECTION 5
I
GOV I REG <<
SECTION 5
PARALLEL SETUP
D INACTIVE BUTTON
D < ACTIVE BUTTON
11 < ACTIVE BUTTON SELECTED
2-7
ENGINE MENU
The facing page shows a block representation of BATTERY/HOURS submenu: From the OIU
the ENGINE menu. lf you press the button next to COOLANT submenu, press the button next to the
the word "ENGINE" in the display, the first ENGINE ">>" in the display to move to the BATTERY/
submenu wíll appear. HOURS submenu. Select BATTERY for a display
of battery voltage. Select HOURS for a display of
As shown in the diagram, the ENGINE menu has the number of starts and the running hours. When
three submenus. battery or hours parameters are displayed, press- ·J
ing the button next to the "<<" will return the display
0/UCOOLANT submenu: This is the first subme- ("BACK") to the BATTERY/HOURS submenu.
nu. Select OIL for a display of oil pressure and oil
temperature. Select COOLANT for a display of RPMIEXHAUST submenu: From the BATTERY/
coolant temperature. When oil or coolant parame- HOURS submenu, press the button next to the ">>"
ters are displayed, pressing the button next to the in the display to move to the RPM/EXHAUST sub-
"<<" wíll return the display ("BACK") to the OIU menu. Select RPM for a display of engine RPM.
COOLANT submenu. Select EXHAUST for a display of the (optional) ex-
haust temperature. When RPM or exhaust pararn-
eters are displayed, pressing the button next to the
"<<" will return the display ("BACK") to the RPM/EX-
HAUST submenu.
.)
2-8
I ENGINE I
~:I
.--~---~~~~~IBACK!
ENGINE
ADJUST
GEN~
>> : > :- t1<:
.<, OIL
COOLANT
<< l>D
>> >O
D
o
_PSI/KPA
_ºF / ºC
<< ,>.O
.
t
: O< OIL
.- • .¿-
1
COOLANT
<<
>>
>O
>
D
.--~~~-,-~~~IBACK!
L_ºF / ºC <<
R_ºF / ºC (ar N/A) 0
>.
, O< OIL GEN >O
:- C1.: COOLANT >> >O
, O< OIL
- C1< COOLANT
I BACK I
---~¿I BATTERY
HOURS
<< l>D
>> >O
D
o
BATIERY
_VDC
<~
I BACK I
(~")
"'...:.. ~~··
- - -.-¿O< BATTERY
HOURS
<<
>>
>O
>O
D
D
STARTS
HOURS
<< >.
D
0< BATTERY OJL << >O

- - -Cl"< HOURS < 600LANT >> >D
<.<
:::t> >.
>O
I BACK I
<< D RPM <<
--.• -cr.(<, RPM
EXHAUST l>B o I>~
I BACK !
O< RPM << D L_ºF/ºC (ar N/A) < < >.
') --- ....¿- EXHAUST R_ºF/ºC {ar N/A) D
0< RPM << >. 0< BATTERY << >O

- - - C1< EXHAUST 0 0< HOURS >> >O
1 - - - - lndicates "OR" Condition I
2-9
GEN MENU
The facíng page shows a block representation of turn the display ("BACK") to the POWER/KW
the GEN menu. lf you press the button next to the HOURS submenu.
word "GEN" in the display, the first GEN submenu
will appear. The PF reading will contain an asterisk if the power
factor is leading (for example, *.3PF).
As shown in the diagram, the GEN menu has three Beginning Version 1.06, N/A is displayed in the PF
submenus. field when the generator set is not running.
%GOV/REG!FREQUENCY submenu: From the

VOLTS!AMPS submenu: This is the first subme- POWER/KW HOURS submenu, press the button
nu. Select VOLTS for a display of a line-to-line or next to the ">>" in the display to move to the %GOV/
line-to-neutral selection, or for viewing of the sys- REG/FREQUENCY submenu. Select %GOV/REG
tem bus line-to-line voltage. Select line-line or line- for a display of voltage regulator and governor duty
neutral for the desired voltage display. Select cycle (drive) levels in percentage of maximum. Se-
AMPS for a display of L 1, L2, and L3 current in lect FREQUENCY for a display of the generator
amps. When voltage or current parameters are dis- output frequency the bus frequency, or the digital
played, pressing the button next to the "<<" will re- synchroscope. When voltage regulator and gover-
turn the display ("BACK") to the L-UL-N submenu. nor or frequency parameters are displayed, press-
ing the button next to the "<<" will return the display
lf DELTA is selected in the lnitial Start Setup subme- ("BACK") to the %GOV/REG/FREQUENCY sub-
nu, when selecting VOLTS, the "line-line" or "line- menu.
neutral" submenus will not be displayed, only the
L 12, L23, L31 submenu will be displayed. Bus Frequency (Digital Synchroscope) subme
nu: When the bus frequency (digital synchroscope)
POWER / KW HOURS submenu: From the information is displayed, the operator can observe
VOLTS/AMPS submenu, press the button next to the generator set synchronizing with the system .. -. )
:.,
the ">>" in the display to move to the POWER/KW bus. The display indicates bus frequency and num-
HOURS submenu. Select POWER for a display of ber of degrees from synchronous condition (+ indi-
power output in kilowatts anda power factor value. cates faster, - indicates slower). When the genera-
Select KW HOURS for a display of kilowatt hours. tor set is operating within the sync-check window,
When power or kW hours parameters are dis- an asterisk will índlcate that the paralleling breaker
played, pressing the button next to the "<<' will re- can be closed.
2-10
D< ENGINE GEN >B IGEN!
D< ADJUST >> >D
I BACK I
B< VOLTS << << D I L23 L31 <<
D< AMPS >> BUS l>B o L12
I>~
I BACK I
,, _D_::~ L- L << D I L1N L2N L3N <<
.< L-N BUS 1>8 D I>~
I BACK I
:-LI<
0<~ L-
L-
L
N
<<
BUS I>~ o
D I L12
L23 L31 <~
I BACK I
1
: O<~ L- L <<
-Ll< L- N BUS I>~
I BACK I
D> 1~8 D I~ ,>~
O< VOLTS << > < ENGINE GEN >O

O< AMPS >> >O D< ADJUST >> >0
I BACK I
(:
,,,,) D> ~~~~
POWER << l>D D
D
KW <<
,>~
t:···~,::.. -: .
,_ ','
AMPS KWHRS >> >D PF
·~,.:,
I BACK I
POWER << l>D o KWHRS <<
-~~~ KWHRS >> >D o I>~
I BACK I
-B~~ POWER
KWHRS
<<
>> 1~~
I BACK I
•-LI<
D<~ POWER ;<< ~ D< %GOV /REG << >B
KWHRS >> > ~-O< FREQUENCY D
•
~------------------------·
, : B<
•
1 I BACK I
%GOV J REG << GOV_ % << >B
r CJ-
·< FREQUENCY REG % D
1
-
1 I BACK I
o
'O<
B<
l. - -
%GOV J REG
FREQUENCY
<<
:·8-~ FREQUENCY
HZ
<<
BUS ,>~
:-8- ~ FREQUENCY
HZ
<<
BUS I>~
I BACK I
D BUS FREQUENCY< < >B
1 - - - - lndicates "OR" Condition I D HZ DEG D
2-11
,,
THIS PAGE LEFT INTENTIONALLY BLANK
<>
2-12
3. Circuit Boards and Modules
GENERAL The system schematics are provided in Section 9 of
this manual.
This section describes the function of the PCC clr-
cuit boards and modules that are contained in the LA CAUTION IElectrostatic discharge wi/1 damage
control panel (Figure 3-1) and the accessory box. circuit boards. Always wear a grounding wrist
The block diagram in Figure 3-2, shows both inter- strap when touching or handling circuit boards
na! and externa! components of the PCC system. or socketmounted /Cs.
S5 POWER ON/ J1 (FOR INPOWER
DISPLAY BOARD
A35
(O>
~ /~0·
f ',.·.· ..
......., ·.
'"',.,';,;'·.
CUSTOMER INTERFACE
A34
o
AUN/OFF/AUTO GOVERNOR
SWITCH S12 OUTPUT MODULE
A38
BUS PT MODULE
A39
~~e::=:, PT/CT
BOARD
r-/
1 0o ',~' o
A36
LJ¡_.
VOLTAGE REGULATOR
OUTPUT MODULE
-1
ACCESSORY BOX :
A37
.. ,
) (HC 4/5) lº.
FIGURE 3-1. CIRCUIT BOARD LOCATIONS
3-1
t-----------53
g
\
,-
~1
/~--------r-vv------1--+-----+-_.---1
g -----------
------------ z
~
( ~
- . . .---¡......;~--- :i
:il~ z 53
w
o:
::J
bw
1-
oc~ :---------tJ,---------:--------~-------,
UJ1r
:Et-
I a:w /
I Q
A t.. UJc.;,
::i!: i1: v
o 1-
:J
Q \
f
I
,
Oa:::cn
'-"l•r--------~
o:
<(
cnt-
::::>::)
,,
1
r t,w<C
=,l-
-v---
o~ I
ü
ü~
i~ ~--, t}
I
o
U)
c.
~ ~ 00 1000 o ~
D
w <(=====~
ººººº -I
IZ 1~= 1
a: ......
-,V U)
~
§Z
~
lffi 1 1
(!)
gcn -.. 1\ ,,A---\,~ - -
tü <3 <( ~
1 :E tt
1/\..
,,.....--,/1 ~ I
)
¡~ LD~ ü
1
'º
<Cz~ '
11
-1 ..
~ "::5···o ~
1
1 g º-
U)
z
w
1 <e '
a.. D O O
(f)
---
-
V
I
:i:
··'
e, o o -1
ª
V
o 000
z CI){
a: 11 - w~ f
<(
~
CI)
Q
I
A I t..
'
;z:<t:,-
-LLC')
Z \ I . ~ffi<(
CI)
L----u-----0-------~-------------J
~ LU ~ 1 w~ .
o
r
1 - ,
o
o:
w
~
o
n,
-
u..A.., @
o
-'
w
u:
FIGURE 3-2. BLOCK DIAGRAM
3-2
GOVERNOR OUTPUT MODULE (A38) Fu ses
The governor output module (Figure 3-12) receives The governor output module has three fuses to pro-
a low power pulse-wídth modulated (PWM) signal tect ít from overloads and groundfaults. They are:
from the engine interface board and then sends an F1 Network B+ (1 o Amps)
amplífied signal to drive the governor actuator. The
F2 Switched B+ (10 Amps)-T26
PCC monitors frequency from both the magnetic
pick-up (MPU) and the main stator inputs. F3 Gov Act + (1 O Amps)
LEDs
Connectors The governor output module has two LED's that in-
dicate the following conditions:
The governor output module has one connector:
051 OutputDuty
,. Cycle: brighter = longer duty
JG Connects to Governor Actuator, Governor cycle (Amber). The duty cycle range of the
Orive (from Engíne Interface), B+, T26 PWM signa! is O - 90%. Normal duty cycle is
about 30%.
052 Run signal to Governor Controller (Green)
o o o
1 081 . OUTPUTDUT®E I•
DS2 • GENSITRUN •
.--~~~~~~....;;.._~~__;;==:....___,
FI F2 F3
Network B+ Switched B+ Governor B+
A38-J6 98-6909
J6
FIGURE 3-12. GOVERNOR OUTPUT MODULE (A38)
3-14
VOLTAGE REGULATOR OUTPUT MODULE J10 Connects to engine harness (power)
(A37) J10 wiring connections:
The voltage regulator output module (Figure 3-11) Green Phase A PMG power
is a power amplifier. This board is used to amplify Yellow Phase B PMG power
the pulse-width modulated (PWM) signal from the
PCC to drive the exciter windings. Power from the Orange Phase C PMG power
PMG is used by this board to amplify the PWM sig- Red X (Field +) Output
na!. Brown XX (Field -) Output
Connectors LEDs
The voltage regulator output module has two con-
The voltage_regulator output module has 3 LEO's
nectors. They are:
that indicate...the !?llowing conditions.
J7 Connects to engine harness (control)
DS1 On when voltage regulator isolated supply is
J7 wiring connections: operating (Green)
Gray Regulator Orive (+) Input
DS2 Output Duty Cycle - Brighter when load in-
White Regulator Orive (-) Input creases - larger duty cycle (Amber). The duty
Blue B+ Input (RUN signal) cycle range of the PWM signa! is O - 60%. Be-
Purple Ground Input cause the normal duty cycle is less than 10%,
the output duty cycle LEO, 082 will normally
Grn/Yel Start in
be very dimly lit.
Black Start solenojd
DS3 Backup start disconnect - On when start dis-
connect is true (Green). The backup start dis-
connect is initiated at about 850 RPM, when
sensed PMG voltage is greater than 105 volts
RMS.
( ..
DS1 - ISOLATED SUPPLY

A37-J7 DS2- OUTPUT DUTY CYCLE A37-J10
- A T I NN
r--,r--,
CR10 CR11
1 11 1
J7
I IL __ I J10
FIGURE 3-11. VOLTAGE REGULATOR OUTPUT MODULE (A37)
3-13
GENSET COMMUNICATIONS MODULE PCC data such as voltage, oil pressure, current, en-
(A41) gine speed, and not in auto status; and provides
that information to the network.
The genset communications module (GCM) is re-
The GCM also facilitates remate monitoring and
quired to connect the PCC to a PowerCommand
(LonWorks) network, and communicate with other limited remate control of the genset that PCC con-
network modules. The GCM module is an optional trols. Outputs from the GCM can 'wake up' the PCC
when needed, or issue start commands to the gen-
feature, and it is available as a field upgrade kit for
applications where the feature must be added in the set. The GCM also includes a termínate circuit for
field. The PCC must be operating with firmware ver- use at the end of a network data bus.
sion 1.06 or later. For model DFH gensets only, firm- The GCM module is powered from the genset start-
ware must be version 1.04 or later.) ing batteries. lt is operational at all times when pow-
The GCM provides an interface for data transfer be- ered, even if the PCC is asleep.
tween the PowerCommand control and other mod- The GCM module is mounted on stand-off mount-
ules on the network. lt communicates with the PCC ing legs above the analog board (A33).
through a serial port on the PCC, as well as monitor- Refer to the Power Command Network lnstallation
ing various PCC inputs to determine the operating and Operator's Manual (900-0366) for information
state of the control. For example, the GCM monitors on installation and use of the GCM module.
J7
J7
CJ
"
~ PowerCommond
BATTERY
VOLTAGE
SWITCH S4
UI
,.
)(
a:
)(
)( X !:
:,.
"'
)(
<
"'
)(
' .,; o
..."' >"' o::,:
N
C]}
o .... º"'
FIGURE 3-10. GENSET COMMUNICATIONS MODULE
3-12
BUS PT MODULE (A39)
The bus PT module (Figure 3-9) is mounted inside
the accessory box. This module converts the bus
output voltage (from the load side of the paralleling
@ ~
I l
breaker) to 18 VAC and provides this to the analog
board. lt provides a reference signal to the Power-
o o
Command Control for synchronizing the generator
set output to a system bus. There are tour versions
of this module, for primary voltages of 69, 120, 240
or 346 volts AC line to neutral. For proper operation,
the correct bus PT module must be installed in the
generator set. Correct phasing is also ímportant as
the system uses the bus PT module output for both
protection and control of the generator set.
Connectors
The bus PT module has two terminal blocks. They
are: re I IJ0JJ0JJ0IJ@I
TB1 Bus voltage connections. o A B C N o
N bus neutral
A bus A phase (U)
B bus B phase (V)
e bus e phase (W)
TB2 Bus PT output for PowerCommand control. FIGURE 3-9. BUS PT MODULE
(.
'.·.
3-11
PT/CT BOARD (A36) Connectors
The PT/CT board (Figure 3-8) is mounted inside the The PT/CT board has two connectors. They are:
accessory box. This board converts generator out- J8 Connects to J3 on A34 Customer Interface
put voltage to approximately 18 VAC levels for the board
analog board. lt also converts CT .55 amp (at full J9 Connects to AC harness (generator output
load) output to approximately 1.65 VAC (at full load) voltage and CTs)
input for the analog board. J9 wiringconnections :
There are three versions of this board. For proper Yellow Gen. A In
operation, the PT/CT board must be correctly Orange Gen. B In
matched to the generator set. Red Gen. e In
In addition, there is a specific set of CTs for each Brown Gen. Common In
genset. For proper operatíon, the CTs must also be Whiie CT21 (+) In
correctly matched to the genset output current. Gray 'CT21 (common) In
Grn/Ylw CT22 (+) In
Black · CT22 (common) In
Purple CT23 (+) In
Blue CT23 (common) In
J8
FIGURE 3-8. PT/CT BOARD
3-10
D
o 081 - MA 1ST START ~ 082 - [K14] PRE-LOP
083 - CUST FAULT4
J1
084 - CUST FAULT1
086 - FAULT RESET
D 1
DSS - [K15] LOP
IBLACKl 087-ENGIDLE
DS8 - LOAD DEMANO I
089 - BKR TRIP / INHIBIT
o
0810- BRKR CLOSEO
0811 - CUST FAULT2
o D DS12-[K7]
LOWCOOL
0813- LOW FUEL 1 2
3
OS14, - RMT START li
7
OS15. - CUST FAULT3 9
11
13
15
J.4
19
o 22
25
27
28
31
33 34
J2
IORAY> o
e··•
o DS16 - GLOSE BKR

2 DS17- COMMON SHTDN
o 7
DS18 - COMMON WARNING
0819 - LOAD DUMP
9
11 DS20 - READY TO LOAD
13
15 0821 - [K8] PRE-HET
17 J5
J3 19
21
DS22 - [K6] NOT IN AUTO
IBLUEl 23 DS23- [K9] HET
25
27 DS24[K10]0VERSPEEO
~
31 DS25- [K11] OVERCRANK
33 34
OS26 - [K12] LET
o o 0827 - [K13] LOW FUEL
D
FIGURE 3-7. CUSTOMER INTERFACE BOARD
3-9
CUSTOMER INTERFACE BOARD (A34) DS13 Low Fuel Input (Red)
The customer interface board (Figure 3-7) connects DS14 Remote Start input (Green)
to the PT/CT board to bring in voltage and current. lt DS15 Customer Fault #3 input (Red)
also connects to customer inputs and outputs. Note
DS16 Paralleling Breaker Control input relay ener-
that there are two versions of this board, for parallel
gized from Digital board (Green). This out-
and non-parallel generator sets.
put is activated to close the paralle!ing
Connectors breaker.
DS17 Common Alarm output relay energized from
The customer interface board has five connectors. Digital board (Green)
,.
They are: This output is activated only on a shut-
J1 Customer connections down condition.
J2 Customer connections DS18 Spare output relay energized from Digital
J3 A36 PT/CT Board and customer connections board (Green)
J4 Connects to J2 on A32 Digital board This outputis activated only on a warn-
ing condition.
J5 Connects to J4 on A33 Analog board
DS19 Load Dump output relay energized from
LEDs Digital board (Red)
lf overload or underfrequency for 5 sec-
The customer interface board has 27 LED's that i~-
onds, this output is activated (before shut-
dicate the following conditions:
down).
DS1 Master First Start Input (Green) - paralleling DS20 Ready to Load output relay energized from
application only Digital board (Green)
DS2 Pre low oil pressure output relay K14 (Red) This output is activated when AC voltage
DS3 Customer Fault #4 Input (Red) and frequency exceed 90% of nominal.
DS4 Customer Fault #1 Input (Red) DS21 Pre high engine temperature output relay
(:"'.)
DSS Low oil pressure output relay K15 (Red) K8 (Red) ....;,~·..::·'
DS6 Fault Reset Input (Red) DS22 Not in auto output relay K6 (Red)
DS7 Engine ldle (Green) DS23 High engine temperature output relay K9
osa Paralleling Breaker Glose Input (Green) (Red)
[paralleling function is load demand] DS24 Overspeed output relay K1 O (Red)
DS9 Paralleling Breaker Open Input (Green) DS25 Overcrank output relay K11 (Red)
DS10 Paralleling Breaker Position Input (Green) DS26 Low engine temperature output relay K12
DS11 Customer Fault #2 input (Red) (Red)
DS12 Low coolant output relay K17 (Red) DS27 Low fue! output relay K13 (Red)
3-8
DIGITAL DISPLAY BOARD (A35) DS12 Right Top Arrow (Green)
The digital board (Figure 3-6) connects to all meters DS13 Warning (Amber)
and the LEO display. DS14 Lower Scale (Green)
DS15 Shutdown (Red}
Connectors
DS20 Left Bottom Arrow (Green)
The digital board has three connectors. They are: DS21 Right Bottom Arrow (Green)
J1 Connects to front panel membrana switches DS22 Automatic mains failure (AMF} or paralleling
J5 Connects to J2 on A32 Digital board. (With J5 application only: Breaker Closed (Red)
disconnected, the display will be non-func- DS23 Phase A (Green)
tíonal, but the PCC will continue to operate.) DS24 Reset Arrow (Green)
JG Connects to meters, Run/Off/Auto switch, J3 DS25 Men9· Arrow (Green)
on A31 Engine Interface board DS26 AMF appücatíon only: Breaker Open
LEDs (Green)
DS27 Phase B (Green)
The digital board has 18 LED's that are used to indi-
DS29 Phase C (Green)
cate operational status of the generator set and
control panel mode/switch selectíons. ! DS36 AMF application: Breaker Closed (Red} - or
- paralleling application: Breaker Open
DS9 Not In Auto (Red) (Green}
DS1 O Upper Scale (Green) DS37 AMF application only: Breaker Open
DS11 Left Top Arrow (Green). (Green}
(
c:JD59
[:]D513 0511 o 00512 D510 (:]
0514 D
0DS15
= = = =
05200
n-
u-
[:]0522 0$23(:]
OS24D
=
(:]DS26 OS27(:]
[:]0536
== == OS29(:]
= =
(:]DS37
= = J1 J6 = =
FIGURE 3-6. DIGITAL DISPLAY BOARD
/
\
3-7
ANALOG BOARD (A33) Connectors
The analog board (Figure 3-5) is the only circuit The analog board has tour connectors with ribbon , -.
board inside the control that has no LED's. There cables permanently soldered to them. They are: (
are two versions of the analog board that are used
for paralleling and non-paralleling systems. J1 Connects to J2 on A31 Engine Interface
board
This board interprets all analog input signals and
J2 Connects to J3 on A32 Digital board
converts the analog signals to 0-5 VDC for the digi-
tal board. J3 Spare analog inputs
J4 Connects to J1 on A34 Customer Interface
board
J1 L.! ..... J2 L.,.._ ___. .__ __.J3
J4
<:·--,,
( ·.
:
~..:...:..:.····
·/
FIGURE 3·5. ANALOG BOARD
3-6
o
1
3
5
7
9
11
13 J5
15 C0RAYl
7 J2
o 21 I
i!8
§
DS1 • LOW FUEL
OS2 - LO COOL
J7 Q)
33
31
i!9
27
23
083 • LET
1~
19
§
IB J 1 17
15
27 12
11
DS4· AUN SW 9
7
085-AUTO o !I
3
086 - E-STOP 2 1
C)
(.,: h
DS9- REG ~
F1
0810 • GOV 5A CNTRL B+

0$11 • START J,4
F3 CWHITEI
0812 - AUN RLY
5AAUX B+
TP1 c=:i
FIGURE 3-4. ENGINE INTERFACE BOARD
3-5
ENGINE INTERFACE BOARD (A31) J4 Connects to customer connections and to en-
gine harness which includes magnetic pick-
The engine interface board (Figure 3-4) reads user
up.
control inputs, monitors engine, generator and sys-
tem status, and initiates the appropriate action tor J5 Connects to engine sensors.
normal operating and fault conditions (warning or J6 Connects to Genset Control module (GCM).
shutdown). J7 Connects to Genset Control module (GCM).
This board is connected to the engine sensors, bat- Fu ses
tery, starter, governor output module, voltage regu-
lator output module, and the magnetic pick-up The engine interface board has two replaceable ..
fuses. They are:
(MPU).
F1 Centro). B+ (5 Amps)
The engine interface board can also be connected
F3 Aux. Bit- (5 Amps). (Panel lamps and run/start
to an optional network interface module for network contacts). ··
access.
LED's
During a typical start sequence the LED's light as
follows: The engine interface board has 1 O LED's that indl-
cate the following conditions:
1 . DS11 lights when a remote run signal is r~-
ceived and 812 is in the Auto possition, or 812 DS1 Low Fuel Alarm input (Red)
is moved to the Run position. DS2 t.ow Coolant Level Alarm input (Red)
2. DS12 lights when the magnetic pick-up voltage DS3 Low Engine Temperature Alarm input (Red)
is sensed (engine is cranKlng). (When the en- DS4 812 in Aun position (Green). 812 is the Run/
gine is cranking, the mag pickup output should Off/Auto switch.
be a mínimum of 1 volt.) DS5 812 in Auto position (Green)
3. DS11 extinguishes, DS9 lights and DS1 O is DS6 Emergency Stop (Red)
dimly lit when the generator is running.
DS7 Not configured.
Connectors osa Not configured.
DS9 Automatic voltage regulator duty cycle
The engine interface board has seven connectors (Green). Brighter indicates larger duty
and ene terminal strip. They are:
cycle.
J1 Connects to J4 on A32 Digital board. DS10 Governor duty cycle (Green). Brighter indi-
J2 Connects to J1 on A33 Analog board. cates larger duty cycle.
J3 Connects to display board, front panel DS11 8tart pilot relay output (Red)
switches and meters. DS12 Aun pilot relay output (Red)
3-4
DIGITAL BOARD (A32) Connectors
The digital board has five connectors. They are:
The digital circuit board (Figure 3-3) contains the
microprocessor and the operational software tor the J1 Far lnPower Service Tool
control. lt connects to all other boards inside the J2 Connects to J4 on A34 Customer Interface
control. This board also provides the analog-to-digi- board
tal conversions for the PCC. J3 Connects to J2 on A33 Analog board
J4 Connects to J1 on A31 Engine Interface
Switch board
S5 Slide the switch to the left to select the Power JS Connects to JS on A35 Digital Display assem-
On (awake) mode. Control panel power/oper- bly
ating software will remain on until the switch is LEDs I
reset to the Standby mode. lt is recom- The digital boardhas seven LED's that indicate the
mended that switch 85 be left in the Power On following conditions:
mode in all applications, except those where
auxiliary battery charging is not available. OS1 Spare (Green)
OS2 Spare (Green)
Slide right to put the PCC in the Standby
OS3 +18 VDC supply OK (Green)
("sleep") mode. In this mode, the PCC opsr-
OS4 +5 VDC supply OK (Green)
ating software will be initiated by selection of
Run on the tront panel, by pressing the Self OSS Run (Flashes once per second if software
Test switch, by a remate start input (in Auto is running)(Green)
mode), or by any one of severa! "wake-up" DS6 +24 VDC B+ supply OK (Green)
signals from externa! switches. DS7 +12 VDC supply OK (Green)
(
ü
\·.
I SS ol J2
J4
o o
FIGURE 3-3. DIGITAL BOARD
3-3
MASTER FIRST START SENSOR The sequence of operation of the control system is
The First Start Sensor System is an Onan control as follows:
sub-system which is used to sense when a genera- On a signal to start, all generator sets in a system
tor set is ready to close to a de-energized system simultaneously start, and accelerate to rated speed
bus and to prevent more than one generator set and voltage. The Master First Start Sensor continu-
from closing to a dead bus on automatic system ously provides pulses to each PowerCommand
starting. The First Start Sensor System for Power- control. When the PowerCommand control re-
Command generator sets is composed of control al- ceives the pulse from the Master First Start Sensor,
gorithms within the PowerCommand control and a if it is ready to close to the bus, an interlock sígnal is
Master First Start Sensor, whích ís usually mounted sent to all other controls to prevent their respective
ín a remote master control panel. paralleling breakers from closing. A clase signal is
then provided to the generator set paralleling break-
er.
,,
3-15
-,
·\
.!
THIS PAGE LEFT INTENTIONALLY BLANK

.: ·. )
: ,/
I
4. Troubleshoot
ing
GENERAL High voltages are present when the genset is run-
ning. Do not open the generator output box while
The PowerCommand® Control 3100 (PCC) contin- the genset is running.
uously monitors engine sensors for abnormal con-
ditions, such as low oil pressure and high coolant LA.WARNING I lgnition of exp/osive battery gases
temperature. lf any of these conditions occur, the can cause severe personal injury or death. Arc
PCC will light a yellow Warning lamp or a red Shut- ing at battery terminals, light switch or other
down lamp and display a message on the digital dis- equipment, flame, pilot lights and sparks can ig
play panel. nite battery gas. Do not smoke, or switch
In the event of a shutdown fault (red Shutdown troub/e light ON or OFF near battery. Discharge
lamp), the PCC will stop the generator set (genset) static electricity from body before touching bet
and close a set of contacts that can be wired to trip a teries by first touching a grounded metal sur
circuit breaker. lf the genset is stopped for this rea- face.
son, the operator can restart the genset after mak- Ventilate battery area befare working on ornear
ing adjustments or corrections. batteryWear gogglesStop genset and dis
This section contains the following information: connect charger befare disconnecting battery
cablesDisconnect negative () cable first and
• Table 4-1: Contains a list of all status codes, in- reconnect last.
cluding the displayed message and status indi-
cator. Also references the page number that IA CAUTION I Disconnect battery charger from AC
contains a description of each code. source befare disconnecting battery cables.
• Table 4-2: Describes each warning and shut- Otherwise, disconnecting cables can result in
down code, warning and shutdown limits voltage spikes damaging to DC control circuits
where applicable, and basic corrective actions, of the genset.
such as, checking fluid levels, control reset
functions, battery connections, etc. !A.WARNING I Accidental starting of the generator
set can cause severe personal injury or death.
• Table 4-3: Lists the PCC oil pressure warning
Prevent accidental starting by disconnecting
and shutdown limits.
the negative () cable from the battery terminal.
• Tables 4-4 through 4-35: Provide detailed
troubleshooting procedures. · When troubleshooting a generator set that is shut
• Table 4-36: Describes the analog circuit board dówn, make certain the generator set cannot be ac-
inputs and outputs. cidentally restarted as follows:
• Table 4-37: Describes the location and func- 1. Move the Aun/Off/Auto switch on the control
tion of each fuse. panel to the OFF position.
SAFETY CONSIDERATIONS
i 2. Turn off or remove AC power from the battery
!A.WARNING I
Contacting high voltage compo charger.
nents can cause electrocution, resulting in se
vere personal injury or death. Keep the output 3. Remove the negativa(-) battery cable from the
,, box covers in place during troubleshooting. generator set starting battery.
4-1
STATUS INDICATORS Emergency Stop shutdown status (Code 102) can be
reset only at the PCC front panel.
NonAutomatic Status lndicator: This red lamp
flashes continuously when the Run/Off/Auto switch Digital Display: This two-line, 16-character per line
is in the Off position. alphanumeric display is used in the menu-driven
operating system and to show shutdown and warn-
Warning Status lndicator: This yellow lamp is lit
ing messages. Refer to Tables 4-1 and 4-2.
whenever the control detects a warning condition.
After the condition is corrected, warning indicators
RESETIING THE CONTROL
can be reset by pressing the Reset switch. (lt is not
necessary to stop the generator set.) In auto mode, Press the momentary Reset Switch to reset warn-
warning indicators can also be reset by cycling the ing and shutdown messages after the condition has
remote reset input after the condition is corrected. been corrected. To reset a shutdown message with
Shutdown Status lndicator: This red lamp is lit the Reset switch, the Run/Off/Auto switch must be
whenever the control detects a shutdown condition. in the Off Position. (The control cannot go into
Shutdown faults are latched. After the condition is Standby (sleep) mode until all faults have been
corrected, shutdown indicators can be reset by reset.)
turning the Run/Off/Auto switch to the Off position, In Auto mode, warning indicators can also be reset
and pressing the Reset switch. In the Auto position, by cycling the remate reset input after the condition
shutdown faults can be reset by removing the re- is corrected. Shutdown faults can be reset by re-
mete start input and then cycling the remota reset moving the remote start input and then cycling the
input. remote reset input.
. ·.• \': ¡
. ,,/
(=>
(=>
Non-Automatic
Warning ~o C=>
(=>
Upper Scale
Lower Scale
~o
(=> Shutdown
Voltage Amps
~o
arallel tna Break•r 381 181
Cloood [I] (=> L1·l2 L1·L2
(=> L2·L3 L1·l2
L1
L2
(=> L3-L1 L3
= Opon [o] O Phase Seleet
w
Aun Off Auto
WARNING ANO RES ET ALPHANUMERIC

SHUTDOWN SWITCH FAULT MESSAGE
STATUS INDICATORS DISPLAY
FIGURE 4-1. CONTROL PANEL
4-2
TABLE 4-1. WARNING AND SHUTDOWN CODES
BASIC TROUBLE-
CODE MESSAGE STATUS LEO . . . . . . . . . CHECKS . . . SHOOTING
Blank LOAD DEMAND none . . . . . . . . . . . . . . . . . . . 4-5

101 IDLE MODE none . . . . . . . . . . . . . . . . . . . 4-5
102 EMERGENCY STOP Shutdown 4-5
200 LOW OIL PRESSURE Warning 4-5 4-24
201 LOW OIL PRESSURE Shutdown . . . . . . . . . . . . . . . 4-5 4-24
204 OIL PRES SENDER Warning 4-5 4-25
21 O LOW COOLANT TEMP Warning 4-6 4-26
211 HIGH COOLANT TEMP Warning 4-6 4-27
212 HIGH COOLANT TEMP Shutdown 4-6 4-27
213 COOLANT SENDER Warning 4-6 4-25
214 LOW COOLANT LVL Warning 4-7 4-28
215 LOW COOLANT LVL Shutdown 4-7 4-28
220 . . . . . . MAG PICKUP Shutdown . . . . . . . . . . . . . . . 4- 7 4-29
221 FAIL TO CRANK Shutdown 4-7 4-15, 4-23
222 OVERCRANK Shutdown 4-7 4-21
f,.·_:•._~-·. .i.~.> 223 OVERSPEED Shutdown . . . . . . . . . . . . . . . 4-7 4-30

_j 224 FAIL TO SYNCHRONIZE Warning/Shutdown 4-8 4-31
226 FAIL TO CLOSE Shutdown . . . . . . . . . . . . . . . 4-8 4-33
230 LOW OC VOLTAGE Warning 4-8 4-35
231 HIGH OC VOLTAGE Warning -4-8 4-35
232 WEAK BATTERY Warning 4-8 4-35
240 LOW FUEL- DAY Warning 4-9 4-36
241 LOW FUEL
250 . . . . . . EEPROM ERROR
Warning
.
J
Shutdown . . . . . . . . . . . . . . .
4-9
4-9
4-37
4-38
251 EEPROM ERROR Warning 4-9 4-38
252 EEPROM ERROR Warning . . . . . . . . . . . . . . . . 4-9 4-38
4-3
TABLE 4-1. WARNING ANO SHUTDOWN CODES
BASIC TROUBLE-
CODE MESSAGE STATUS LEO . . . . . . . . . CHECKS . . . SHOOTING
260 CUSTOMER FAULT 1* Warning/Shutdown 4-9 4-39

261 GROUND FAULT* Warning/Shutdown 4-9 4-39
262 DAY TANK* Warning/Shutdown . . . . . . . 4-9 4-39
263 HIGH GEN TEMP* Warning/Shutdown . . . . . . . 4-9 4-39
270 PHASE ROTATION Shutdown . . . . . . . . . . . . . . . 4-1 O 4-40
272 FIRST START Warning 4-10 4-42
301 HIGH-AC VOLTAGE Shutdown 4-10 4-43
303 LOW AC VOLTAGE Shutdown 4-10 4-46
313 UNDER FREQUENCY Shutdown 4-10 4-48
320 OVERCURRENT Warning . . . . . . . . . . . . . . . . 4-1 O 4-49
321 OVERCURRENT Shutdown 4-10 4-49
322 SHORT CIRCUIT Shutdown 4-10 4-49
330 OVERLOAD Warning . . . . . . . . . . . . . . . . 4-11 4-49
335 REVERSE POWER Shutdown . . . . . . . . . . . . . . . 4-11 4-50
337 LOSS OF EXCITATION Shutdown 4-11 4-51
* Default message. Editable for customer site requirements. lt is recommended that the bell alarm contacts of the
paralleling breaker be brought back to the control and indicate "Parallel CB Trip" as one customer fault. . >)
.... /
4-4
TABLE 4-2. WARNING AND SHUTDOWN CODES
IA WARNING I Hazards presentin troubleshootingcan causeequipmentdamage, severe personal

injuryor death. Onlytrainedand experienced servicepersonnelwithknowledge of fuels, etectric-
ity, and machineryhazards shouldperformserviceprocedures . Read Safety Precautionspage
and observeali instructionsand precautionsin this manual.
SYMPTOM CORRECTIVE ACTION
MESSAGE: The PowerCommand control has received a signa! to shut down from a
LOAD DEMAND remote device. This is a normal operation mode, which is typically used in
automatic control system to minimize generator set operation hours and
system fuel consumption. When the load demand signa! is removed, the
generator set will automatically start, synchronize, and close to the sys-
tem bus.
MESSAGE: lndicates that the engine is operating in idle mode. When the genset is op-
IDLE MODE erating in the RUN mode, grounding the engine idle input causes genera-
101 - WARNING tor build-up to be inhibited and the engine to be governed at 800 RPM.
When ground is removed from this input, the genset returns to normal
speed and voltage.When the engine idle function is enabled, the control
automatically gensets lower oíl pressure warning and shutdown trip
points to reflect the lower operating speed. When the engine idle function
is removed and the genset reverts to normal operating speed, the control
/:(·_'.·,··
:'~0":: automatically resets oíl pressure warning and shutdown trip points to the
1,,,,:·.·
····~. ,'' ,,
..
normal settings.
Shutdownlamp lights. lndicates local or remote Emergency Stop.

MESSAGE: To reset the local/remota Emergency Stop button:
EMERGENCY STOP Pull the button out (button with arrow = turn clockwise to allow it to pop
102- SHUTOOWN out).
Move the Run/Off/Auto switch to Off.
Press the Reset switch.
Select Run or Auto, as required.
Warninglamp lights. lndicates engine oil pressure has dropped toan unacceptable lev-
MESSAGE: el. lf generator is powering critica! loads and cannot be shut down,
LOW OIL PRESSURE wait until next shutdown period and then follow 201-SHUTDOWN
200 - WARNING
procedure,
Ir
To checkoil pressure, accessthe Oil Pressure menu priorto clear-
ing the fault.
Shutdownlamp lights. lndicates engine oil pressure has dropped below the shutdown trip point.
MESSAGE: Check oíl level, lines and filters. lf oíl system is OK but oíl level is low, re-
LOW OIL PRESSURE plenish. Reset control and restart. Oil pressure limits are listed in Table
201 - SHUTDOWN 4-3.
Warninglamp lights. lndicates that the control has sensed that the engine oil pressure sender is
MESSAGE: out of its working range. Check that the engine oil pressure sender is prop-
OIL PRES SENDER erly connected.
204 - WARNING
4-5
TABLE 4-2. WARNING AND SHUTDOWN CODES (CONT.)
IA WARNING I Hazards present in troub/eshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with know/edge of fuels, e/ectric
ity, and machinery hazards should perform service procedures. Read Safety Precautions page
and observe ali instructions and precautions in this manual.
Warning lamp lights. lndicates engine coolant heater is not operating or is not circulating cool-
MESSAGE: ant. Check far the following conditions:
LOW COOLANT TEMP a. Coolant heater not connected to power supply. Check fer blown fuse
210-WARNING or disconnected heater cord and correct as required.
Set is not operating. Warning occurs
b. Check for low coolant level and replenish if required. Look for pos-
when engine coolant temperature is
sible coolant leakage points and repair as required.
70° F (21 ° C) or lower.
c. Open heater element. Check current draw of heater.
NOTE: In applications where the
ambient temperature falls below
40°F (4°C), Low Coolant Temp
may be indicated even though the
coolant heaters are operating.
Warning lamp lights. lndicates the engine coolant temperature is getting clase to the recom-
MESSAGE: mended maximum temperature limit:
HIGH COOLANT TEMP 215° F (102º C)- standby or 207° F (97° C)- prime.
211 - WARNING lf generator is powering non-critica! and critica! loads and cannot be shut
down, use the following:
a. Reduce load if possible by turning off non-critica! loads.
b. Check air inlets and outlets and remove any obstructions to airflow.
lf engine can be stopped, follow HIGH C-OOLANT TEMP 212 - SHUT-
DOWN procedure.
To check coolant temperature, access the coolant temperature
menu prior to clear~ng the fault.
Shutdown lamp lights. lndicates engine has overheated (coolant temperature has risen above
MESSAGE: the shutdown trip point:
HIGH COOLANT TEMP 223º F (106° C) - standby or 215º F (102º C)- prime. Allow angina to
212- SHUTDOWN cool down completely befare proceeding with the following checks:
i
a. Check fer obstructions to cooling airflow and correctas necessary.
b. Check fan belt and repair or tighten if necessary.
c. Check coolant mixture.
d. Check blower fan and circulation pumps on remete radiator installa-
tions.
e. Reset control and restart after locating and correcting problem.
Warning lamp lights. lndicates that the resistance of the coolant temperatura sender is out of
MESSAGE: range. Check the resistance of the sender. Resistance should be 500 to
COOLANT SENDER 2k ohms.
213-WARNING
4-6
TABLE 4-2. WARNING ANO SHUTDOWN CODES (CONT.)
IA WARNING I Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with know/edge of fuels, e/ectric
Shutdown lamp lights. lndicates engine coolant level has fallen below the trip point. Allow engine
MESSAGE: to cool down completely before proceeding.
LOW COOLANT LVL
a. Check coolant level in both radiator and coolant recovery bottle and
214-WARNING
replenish if low. Look for possible coolant leakage points and repair if
or necessary.
LOW COOLANT LVL
b. lf radiator level is low and coolant bottle level is correct, defective
215-SHUTDOWN
coolant bottle hose or radiator cap.
c. Reset control and restart after locating and correcting problem.
LOW COOLANT LVL Shutdown will not occur if genset is in ldle
mode (low coolant warning only).
Shutdown lamp lights. lndicates 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
Engine will not crank. lndicates possible fault with control or starting system. Check for the fol-
Shutdown lamp lights. lowing conditions:
MESSAGE:
a. Check fuse F3 on the Engine Interface board.
FAIL TO CRANK
b. Poor battery cable connections. Clean the battery cable terminals
221 - SHUTDOWN
and tighten all connections. _
c. Discharged or detective battery. Recharge or replace the battery.
Shutdown lamp lights. lndícates possible fuel system problem.

Engine stops cranking.
a. Check for ernpty fuel tank, fuel leaks, or plugged fuel lines and cor-
MESSAGE:
rectas required.
OVERCRANK
b. Check for dirty fuel filter and replace if necessary.
222 - SHUTDOWN
c. Check for dirty or plugged air filter and replace if necessary.
d. Reset the control and restart after correcting the problem.
Ir
Engine runs and then shuts down. lndicates engine has exceeded normal operating speed. (115% ±1% of
Shutdown lamp lights. nominal).
MESSAGE:
OVERSPEED
223 - SHUTDOWN
4-7
LA WARNING I Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric
Warning (or Shutdown) lamp The generator set has not synchronized to the system bus within the al-
lights. lowable time trame.
MESSAGE: a. Check the governor system stability. Adjust governing and synchro-
FAIL TO SYNCHRONIZE nizer parameters as required.
224 - WARNING
b. Check far fuel system problems which can cause engine instability.
or
FAIL TO SYNCHRONIZE Synchronizing time can be lmproved by widening the synchronizing
224 window and reducing the acceptance time delay.
Warning lamp lights. lndicates that the paralleling breaker has been given a signa! to close, but
MESSAGE: has not closed properly.
FAIL TO CLOSE a. Verify that the charging mechanism of the paralleling breaker is func-
226 - SHUTDOWN tioning properly.
b. Check the close signa! to the breaker.
c. Verify that the auxiliary contact signals from the breaker to the Pow-
erCommand control are operational.
Warning lamp lights. lndicates battery voltage is below 1 O VDC.

MESSAGE: a. Discharged or detective battery.
LOW OC VOLTAGE Check the battery charger fuse.
230 - WARNING Recharge or replace the battery.
b. Poor battery cable connections. Clean the battery cable terminals
and tighten all connections .
.. c. Check engine OC alternator. Replace engine OC alternator if normal
battery charging_, voltage is not obtained.
d. Check battery charge voltage float level if applicable (raise float lev-
e!).
Warning lamp lights. lndicates battery voltage exceeds 32 VDC.

MESSAGE:
HIGH OC VOLTAGE Check voltage float level on battery charger if applicable (lower float lev-
231 -WARNING , el).
Check englne OC altemator. Replace engine OC alternator if normal bat-
tery charging voltage is not obtained.
Warning lamp lights. lndicates battery voltage drops below 60% of nominal for two seconds,
MESSAGE: during starting.
WEAK BATTERY
232 - WARNING Oischarged or detective battery.
See Warning message 230, LOW OC VOLTAGE.
4-8
injury or death. On/y trained and experienced service personnel with know/edge of fuels, electric
ity, and machinery hazards shou/d perform service procedures. Read Safety Precautions page
Warning lamp lights. lndícates day tank fuel supply is running low. Check fuel supply and re-
MESSAGE: plenísh as required.
LOW FUEL-DAY
240 - WARNING
or
LOW FUEL
241 - WARNING
Shutdown lamp lights. lndícates PCC memory error. Data corruption of critica! operating param-
MESSAGE: eters.
EEPROM ERROR
250 - SHUTDOWN
Warning lamp lights. lndicates PCC memory error. Data corruption of noncritlcal operating pa-
MESSAGE: rameters.
EEPROM ERROR
.--)
r..
f·: ···.
251 - WARNING
\~.~~..:· or
252 - WARNING
Shutdown lamp lights. When any one of these customer defined ínputs is closed to ground, the
MESSAGE: corresponding fault message is displayed.. The nature of the fault is an op-
CUSTOMER FAULT 1 tional customer selection. These fault functions can be programmed to
260-SHUTDOWN initiate a shutdown ora warning.
GROUND FAULT
261 - SHUTDOWN 'As indicated by the Shutdown lamp, a shutdown response has been pre-
or selected. •·
DAYTANK Note: Customer fault messages are editable. The message displayed for
262 - SHUTDOWN the code shown (260 thru 263) may have been edited and may not appear
or as shown in this table.
HIGH GEN TEMP
263 - SHUTDOWN ,·
r
4-9
LA WARNING I Hazards present in troub/eshooting can cause equípment damage, severe personal
injury or death. Only trained and experienced service personnel with know/edge of fuels, etectrlc
and observe al/ instructions and precautions in this manual.
Warning lamp lights. When any one of these customer defined inputs is closed to ground, the
MESSAGE: corresponding fault message is displayed. The nature of the fault is an op-
CUSTOMER FAULT 1 tional customer selection. These fault functions can be programmed to
260 - WARNING initiate a shutdown ora warning.
GROUND FAULT
261 - WARNING As indicated by the Warning lamp, a warning response has been prese-
or lected.
DAYTANK Note: Customer fault messages are editable. The message displayed for
262 - WARNING the code shown (260 thru 263) may have been edited and may not appear
or as shown in this table.
HIGH GEN TEMP
263 - WARNING
Shutdown lamp lights. The phase relationship between the generator set and the system bus is
MESSAGE: not matched.
PHASE ROTATION a. Using a phase rotation checker, verify that the generator set phase
270 - SHUTDOWN rotation matches the phase orientation of the system bus.
b. Verify that control wiring to the bus PT module on the PowerCom-
mand control is properly connected.
Shutdown lamp lights. The PowerCommand control is not receiving a proper signal from the sys-
MESSAGE: tem master first start sensor. When this oocurs, the control reverts to a fall-
FIRST START back mode in which breaker closure is automatically allowed if bus is de-
272 - WARNING energized. lf bus voltage is sensed, the control will force the generator set
to synchronize to the system bus befare breaker clase signal is initiated.
Shutdown lamp lights. lndicates that one or rnore of the phase voltages has exceeded 130% of
MESSAGE: nominal, or has exceeded 110% of nominal for 1 O seconds.
HIGH AC VOLTAGE
301 - SHUTDOWN
Shutdown lamp lights. , lndicates that one or more of the phase voltages has dropped below 85%
MESSAGE: .. of nominal far 1 O seconds.
LOW AC VOLTAGE
303 - SHUTDOWN
Shutdown lamp lights. lndicates that engine speed has dropped below 90% of nominal far 1 O
MESSAGE: seconds.
UNDER FREQUENCY Note: Five seconds befare shutdown, a Load Dump signal is initiated.
313 - SHUTDOWN
Check fuel supply, intake air supply and load.
4-10
injury or death. On/y trained and experienced service personnel with knowledge of fuels, electrlc
Warning lamp lights. lndicates that generator output current has exceeded 110% of rated for 60
MESSAGE: seconds.
OVERCURRENT
320 - WARNING Check load and load lead connections.
Shutdown I amp lights. lndicates that generator output current has exceeded 110% of rated, and
MESSAGE: that a PCC time/current calculation has initiated an overcurrent shut-
OVERCURRENT down.
321 - SHUTDOWN
Check load and load lead connections.
Shutdown lamp lights. lndicates that generator output current has exceeded 175% of rated.
MESSAGE:
SHORT CIRCUIT Check load and load lead connections.
322 - SHUTDOWN
,:\.·:._)··
(.f:7"
,.. ''',
:, .....
Warning lamp lights.
MESSAGE:
lndicates that three-phase power output exceeds 105% of standby (or
115% of prime) rating. After five seconds, the Load Dump output is acti-
OVERLOAD vated. Alter 60 seconds, the OVERLOAD warning is activated.
330 - WARNING
Check load and load lead connections.
4-11
IA WARNING I Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, e/ectric
ity, and machinery hazards shou/d perform service procedures. Read Safety Precautions page
and observe al/ instructions and precautions in this manual.
Shutdown lamp lights. lndicates that power is flowing into the generator set, rather than out from
MESSAGE: the unit. This can be caused by engine failure, or inability to carry load, or
REVERSE POWER by a number of control or interconnection problems.
335 - SHUTDOWN a. lf problem occurs at initial startup, verify connection of generator set
CT's, by applying load to the generator set while lt is operating alone
while connected to bus.
b. Verify proper connection of load sharing lines.
c. Verify that the generator set is operating at the correct frequency and
voltage. The no-load voltage of the generator set and other genera-
tor sets should ali be the same.
Shutdown lamp lights. lndicates that the alternator excitation system is improperly adjusted or has
MESSAGE: failed. Loss of Excitation failure may also be caused by operation of filters
LOSS OF EXCITATION and power factor correction capacitors in the generator set loads when the
337 - SHUTDOWN kW load level on the genset is low. The capacitors in the filters and power
factor correction equipment can presenta leading power factor load to the .... . .
generator set, which (correctly) shuts down the generator set through the )
loss of excitation fault. Leading power factor loads can cause the generator :,.,
set to lose control of the output voltage of the genset and can cause kVar
load sharing problems. Therefore, it is necessary to protect the genset from
excessive leading power factor and reverse Var conditions.
a. Start the generator set in the RUN mode and check output voltage
with both the control digital meter set anda calibrated meter. Cali-
brate voltage if necessary. Output voltage should be adjusted to the
same level as ali other generator sets at no load. Make adjustments
as necessary to.correct.
b. Check load sha'ring lines for proper interconnections.
c. See Section 6 of this manual "Servicing the Generator'', Excitar Rec-
tifier, and exciter Rotor.
4-12
TABLE 4-3. PCC OIL PRESSURE WARNING & SHUTDOWN LIMITS
L10/M11 Engine: NORM 30-50 psi (207-345 kPa), IDLE 15 psi (103 kPa)
20 psi (138 kPa) shutdown limit - run mode value
25 psi (172 kPa) warning limit - run mode value
8 psi (55 kPa) shutdown limit - idle mode value
12 psi (83 kPa) warning limit- idle mode value
NTA 855 Engine: NORM 35-50 psi (241-345 kPa), IDLE 15 psi (103 kPa)
12 psi (83 kPa) warning limtt- idle mode value
K19 Engine: NORM 50-70 psi (345-482 kPa), IDLE 20 psi (138 kPa)
15 psi (103 kPa) warning ürnit- idle mode value
V28 Engine: NORM 50-90 psi (345-620 kPa), IDLE 20 psi (138 kPa)
15 psi (103 kPa) warning ümit- idle mode value
10 psi (69 kPa) shutdown limit - idle mode value -
15 psi (103 kPa) warning llmlt- idle mode value
35 psi (241 kPa) shutdown limif run mode value
15 psi (103 kPa) warning lirnit- idle mode value
..
To check oil pressure or en6ine temperature during a warning, access the oil pressure
or engine temperature menÍ.J prior to clearing the fault.
4-13
TROUBLESHOOTING PROCEDURE LED and switch locations for each circuit board and
module are provided in Section 3. The control wiring
The following tables are a guide to help you evalu- and circuit board connections are shown in Section
ate problems with the generator set. You can save 9.
time if you read through the manual ahead of time
and understand the system.
LA CAUTION IAlways set the Run/Off/Auto (512)
To determine the appropriate troubleshooting switch to the Off position and the Power Onl
procedure for the specific problem at hand, be Standby (SS) switch to the Standby position be
sure to refer to the "lndicators" column pro- fare disconnecting or connecting harness con
vided in each troubleshooting table. nectors. Otherwise, disconnecting the harness
connectors can result in voltage spikes high
Try to think through the problem. Go over what was
enough to damage the DC control circuits of the
done during the last service call. The problem could
set.
be as simple as a loose wire, an opened fuse or a
tripped circuit breaker. (Table 4-32 describes the
location and function of each fuse.)
LA CAUTION IE/ectrostatic discharge wi/1 damage
circuit boards. Always wear a wrist strap when
Figure 4-2 shows the location of the components handling circuit boards or socketmounted IC's
within the control panel that are referenced in the and when disconnecting or connecting harness
following troubleshooting procedures. Connector, connectors.
4-14
S5 POWER ON/
STANDBY SWITCH
DISPLAYBOARD @
A35
@ ANALOG BOARD
A33
AUN/OFF/AUTO
SWITCH 812
BUS PT MODULE
A39
OPTIONAL
THERMISTOR
GOVERNOR
RELAY 160°/140° C OUTPUT MODULE
A38
OPTIONAL
COMMON ALARM
RELAY K14
PT/CT BOARD A36
:, 'y--~~~',
•. J ------.. \
OPTIONAL RTD VOLTAGE

RELAY REGULATOR
t
OUTPUT MODULE
A37
ACCESSORY BOX I 1
1
lg_
4-15
TABLE 4-4. ENGINE DOES NOT CRANK-LOCAL OR REMOTE AUN
LA.WARNING I
Many troub/eshooting procedures present hazards that can result in severe personal inju
ry or death. Only trained experienced service personnel with know/edge of fuels, electricity, and ma
chinery hazards should perform service procedures. Review safety precautions on pages iii and iv.
lndicator(s) Possible Cause Corrective Action
"FAIL TO 1. lnsufficient battery voltage. Check the 1 a. Recharge or replace the battery. Specific gravi-
CRANK" following conditions: ty for a fully charged battery is approximately
(221) a. Batteríes not charged. 1.260 at 80º F (27º C).
message 1 b. Clean and tighten or replace the battery cable
b. Battery connections loose or
dirty. connectors and cables at the battery and the
Reset and set.
attempt to c. lnsufficient battery charging volt-
start: age. 1 c. Adjust charge rate of battery charging circuit.
d. Engine DC alternator could be 1 d. Replace engine DC alternator if normal battery
Start LEO bad. charging voltage is not obtained.
DS11 on the
2. Starter could be bad. 2. Reset the control. Attempt to start, and test for
engine
interface board B+ at the starter. lf there is B+ at the starter, the
turns on. starter could be bad. Test starter (see engine
service manual). Replace the starter.
NOTE: 3. lf there is no B+ at the starter, start so- 3. Reset the control. Attempt to start, and test for
These two lenoid K4 could be bad. B+ into and out of start solenoid contacts. lf
indications there is B+ in, but not out, check for B+ at the
suggest that start solenoid coil. lf there is B+ at the coil,
the PCC has check ground connection. lf ground connection
received a is good, the start solenoid is bad. Replace the
start signal start solenoid.
and has sent a lf there is B+ into and out of the start solenoid
start command contacts, check for an open between the start
to the start solenoid contacts and the starter. lf there is no
output (J4-2) B+, go to the ne~t step.
on the engine
interface 4. lf there is no B+ at the start solenoid *4. Disconnect J7/P7 at the regulator output mod-
board. coil (K4), the backup start disconnect ule. Testfor continuity at A37 J7-5/J7-6. lf there
contacts in the regulator output mod- is no continuity, the regulator output module is
ule (A37) could be open (indicating ; bad. Replace A37.
that A37 is bad).
5. lf there is contínuity at A37 J7-5/J7-6, *5. lf there is continuity at A37 J7-5/J7-6, reset the
there may be an open between A37 control, attempt to start, and check for B+ at
and A31, an open between A37 and A37 P7-5.
K4, or A31 may be bad. lf there is B+ at P7-5, there may be an open be-
r tween start solenoid coil (K4) and A37. lf there
is no B+ at P7-5, check for B+ at J4-2 on the en-
gine interface board (A31) while attempting to
start.
lf there is B+ at A31 J4-2, check for an open be-
tween A37 and A31 .
lf there is no B+ at A31 J4-2, (and 0811 is on)
the engine interface board is bad, Replace A31.
6. The mag pickup signal is not being 6. Refer to the mag pickup shutdown message
sensed. (220}.
*CAUTION: Wearing wrist strap, set 512 to Off and A32 55 to 5tandby before connecting/disconnecting harness plugs.
4-16
TABLE 4-5. ENGINE DOES NOT CRANK-LOCAL OR REMOTE RUN
IAWARNING! Many troub/eshootíng procedures present hazards that can result in severe personal ínju
ry or death. Only traíned experienced service personnel with knowledge of fuels, electricity, and me
lndicator( s) Possible Cause Corrective Action
"FAIL TO 1. Fuse F3 on the engine interface board *1. lnstall harness tool between A31 J4/P4. Reset
CRANK" (A31) may be open, or B+ may not be the control. Attempt to start and check for B+ at
(221) getting to F3. J4-2. lf no B+, remove F3 and check continuity.
message lf open, replace the fuse with one of the same
type and amp rating (5 Amps). lf F3 is OK,
Reset and check the B+ supply from the wiring harness.
attempt to
start:
2. Emergency Stop switch S13 or the 2. To isolate:
Start LEO PCC door harness may be bad. • Check for B+ at S13-1 and S 13-2.
DS11 on the
lf there is B+ at S 13-2, but not at S 13-1
engine
(and S13 is NOT in the emergency stop
interface board
position), then S13 is bad. Replace S13.
does NOT
turn on. • lf there is no B+ at S13-2, disconnect
J3/P3, and check for B+ at A31 J3-2. lf
NOTE: there is no B+, replace A31.
These two • lf there is B+ at A31 J3-2, check continuity
indications from P3-2 to P3-6. lf no continuity, repair
suggest that or replace as necessary.
the PCC has
received a
start signal 3. Digital board (A32) may be bad. *3. lnstall harness tool between A32 J4/P4. Reset
and has NOT the control. Attempt to start, and test for ground
sent a start output at A32 J4-3. lf there is no ground output,
command to A32 is bad. ~place A32.
the start output
(J4-2) on the
engine
interface
board. j
4. Engine interface board (A31) may be *4. lf there is a ground output at A32 J4-3, and yet
bad. there is no B+ output at A31 J4-2; then A31 is
bad. Replace A31.
*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby befare connecting/disconnecting harness plugs.
4-17
TABLE 4-6. ENGINE DOES NOT CRANK-REMOTE RUN
!A.WARNING I
ry or death. Only trained experienced service personnel with know/edge of fuels, e/ectricity, and ma
chinery hazards should perform service procedures. Review safety precautions on pages lli and iv.
"FAIL TO 1. The Auto mode signal is not getting *1. lnstall harness tool between A32 J4/P4. Check
CRANK" from engine interface board A31 to far ground output at A32 J4-18.
(221) digital board A32, indicating that A31 is lf there is no ground output (but A31 085 is on)
message bad. engine interface board A31 is bad. Replace
DOES NOT A31.
appearon
lf there is a ground output at A31 J1 -18, pro-
digital display
ceed to the next step.
-and:
Auto LEO 085
on the engine
interface board
(A31) is on -
RMT 8tart 2. The Remota run signal is not getting *2. lnstall harness tool between A32 J4/P4. Reset
LEO 0814 on from customer interface board A34 to the control. Attempt to remote start, and check
the customer A32, indicating that A34 is bad. for ground output at A32 J2-26. lf no ground out-
interface board put (but A34 0814 is on) customer interface
(A34) is on - board A34 is bad. Replace A34.
lf there is a ground output at A32 J2-26, pro-
ceed to the next step.
NOTE:
This condition
suggests that
the PCC
processor
(digital board 3. Digital board (A32) may be bad. *3. lf, when attempting remate start, there is a
-A32)has ground input at A32 J2-26, and a ground input
NOT received at A32 J4-18=-and there is no "FAIL TO
or recognized CRANK" message-and the set does not
a remete start crank; A32 is bad. Replace, A32.
start signal.
*CAUTION: Wearing wrist strap, set 512 to Off and A32 55 to Standby before connecting/disconnecting harness plugs.
4-18
LA.WARNING IMany troubleshooting procedures present hazards that can result in severo personal inju
ry or death. Only trained experienced service personnel with knowledge of fuels, e/ectricity, and me
chinery hazards shou/d perform servíce procedures. Review safety precautíons on pages iii and iv.
"FAIL TO The Auto mode input is not getting from the

CRANK" Auto select switch (812) to engine interface
(221)
board A31 (indicating that 812, A31, or the
message
harness is bad.
DOES NOT
appearon
digital display 1. 812 or the wiring hamess may be bad. *1. Disconnect A31 J3/P3. Check continuity to
-and: ground at A31 J3-11. (J3-11 is ground out to
Auto LED 085 S12. lf ground is not present, replace A31. lf
on the engine ground is present, place 812 in Auto and check
interface board continuity from P3-11 to P3-13. lf no continuity,
(A31) is off - isolate to switch or wiring harness. Repair as
RMT 8tart necessary. lf there is continuity, A31 may be
LED 0814 on bad. Reconnect J3/P3.
the customer
interface board
(A34) is on - 2. Engine interface board A31 may be *2. lnstall harness tool between A32 J4/P4. Check
bad. the 16 volt (nominal) supply at A32 J4-16.
NOTE: lf the voltage is present at A32 J4-16, and

This condition ground is present at A31 P3-13-and yet A31
suggests that DS5 is off; then A31 is bad. Replace A31.
the engine
interface board
(A31) is NOT 3. Digital board A32 may be bad. 3. lf there is no + 16 volt supply voltage at A32
enabling the J4-16, A32 is bad. Replace A32.
remote start
logic on the
digital board.
*CAUTJON: Wearing wrist strap, set S12 to Off and A32 SS to Standby before connecting/disconnecting harness plugs.
4-19
!AWARNING! Many troubleshooting procedures present hazards that can result in severe personal inju
ry or death. Only trained experienced service personnel with know/edge of tuets, electricity, and me
chinery hazards shou/d perform service procedures. Review safety precautions on pages iii and iv.
"FA!L TO The remote start input is not getting from the

CRANK" remete start switch to the output of the cus-
(221)
tomer interface board (A34) (indicating that
message
the switch, A34, or the harness is bad.
DOES NOT
appearon
digital display 1 . The remete start switch or the *1. !nsta!I harness too! between A34 J1 /P1. Reset
-and: wiring harness may be bad. the control. Attempt remote start and check for
Auto LED DSS ground at A34 J1 -13. lf ground level is not pres-
on the engine ent, iso!ate to the switch or the wiring harness
interface board by checking for a start signa! at TB1-5. Repair
(A31) is on - as necessary.
RMT Start
LED DS14 on
2. Customer interface board A34 2. lf ground is present at A34 J1 -13-and yet A34
the customer
may be bad. DS14 is off, rep!ace A34.
interface board
(A34) is off
NOTE:
This condition
suggests that
the remote
start input is
NOT passing
through the
customer
interface board
(A34) to
-
enab!e the
remote start
logic on the i
digital board. ;
I
..
*CAUTION: Wearing wrist strap, set 812 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.
4-20
TABLE 4-9. ENGINE DOES NOT CRANK-LOCAL RUN
!A.WARNING I
ry or death. Only trained experienced service personnel with knowledge of fuels, electricity, and me

"FAIL TO The start input is not getting from the Run/
CRANK"
Off/ Auto select switch (812) to A31 (indi-
(221)
cating that 812, A31, or the harness is bad.
message
DOES NOT
appearon 1 . Run/Off/ Auto select switch 812 or the *1. Check continuity to ground at A31 J3-11. lf
digital display wiring harness may be bad. ground is not present, replace A31. lf ground is
-and: present, place 812 in Run and check continuity
Run LEO 084 from P3-11 to P3-12. lf no continuity, isolate to
on the engine switch or wiring harness. Repair as necessary.
interface board lf there is continuity, A31 may be bad.
(A31) is off-
2. Engine interface board A31 *2. Instan harness tool between A32 J4/P4. Check
NOTE: may be bad. the 16 volt (nominal) supply at A32 J4-16.
This condition
suggests that lf the voltage is present at A32 J4-16, and
the start input ground is present at A31 J3-12-and yet A31
is NOT getting 085 is off, replace A31.
from the
Run/Off/ Auto
7\
({j switch (812) to
the engine 3. Digital board A32 may be bad. 3. lf there is no + 16 volt supply voltage at A32
interface board J4-16, replace A32.
(A31) to
enable the
remate start -
logic on the
digital board.
;
i
•'
¡
*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.
4-21
TABLE 4-10. ENGINE CRANKS BUT DOES NOT START
!A.WARNING I Many troub/eshooting procedures present hazards that can result in severe personal inju
ry or death. Only trained experienced service personnel with know/edge of fuels, e/ectricity, and ma-
"OVERCRANK" Fuel supply or fuel delivery.

(222) 1 . Restricted fuel supply due to: ta, Add fuel if low. Prime the fuel system.
message a. Fuel level below pickup tube in 1 b. Open any closed shutoff valve in the fuel line
tank. supplying the engine.
-and b. Closed shutoff valve in supply 1 c. Refer to engine service manual.
line. 1 d. Bleed air from fuel system. Refer to engine ser-
While cranking,
Run LED DS12 c. Fuel injectors clogged. vice manual.
on the d. Air in fuel system.
engine interface
board (A31)
is on. 2. The mechanical fuel linkage could be 2. lnspect the mechanical fuel linkage, and repair
binding, loase, or damaged. or replace as necessary.
and Follow the procedure in the engine repair
manual to check the EFC for binding or dam-
While cranking, age.
Run LED DS2 Disconnect the actuator connector, and con-
onthe nect + 12 VDC from the battery to the actuator.
governor output The actuator should click upon application and
module (A38) removal of the voltage.
is on.
lf the actuator does not click, refer to the engine
manual.
NOTE: lf the actuator clicks, reconnect the wires to the
These actuator.
indications
suggest that the
PCC has sent a 3. Fuel solenoid (K1) on the injection 3a. Reset the control. Attempt to start and check for
run signal to the pump not energizad due to: B+ at the K1 fuel solenoid coil on the injection
fuel solenoid. a. Open in fuel sólenoid circuit or pump and at output of governor module. Check
detective governor module. , continuity from J6-20 and 21 to J6-19.
1
b. Detective fuel solenoid. 3b. Check wiring continuity of fuel solenoid circuit.
Test fuel solenoid.
Repair or replace as necessary.
4. Fuel tank solenoid not' energizad due 4a. Check wiring continuity of fuel tank solenoid oír-
to: cuit.
a. Open in fuel tank solenoid circuit. 4b. Test fuel tank solenoid.
b. Detective fuel tank solenoid. Repair or replace as necessary.
5. Engine fuel injection or other engine 5. Refer to the engine service manual.
problem.
*CAUTION: Wearing wrist strap, set 512 to Off and A32 SS to Standby before connecting/disconnecting harness plugs.
4-22
LA.WARNING I Many troub/eshooting procedures present hazards that can result in severe personal inju
ry or death. Only trained experienced service personnel with knowledge of fuels, e/ectricity,and ma
"OVERCRANK" The run signal is not getting through the Reset the control. Attempt to start and check for B+
(222) governor module to the fuel solenoid. at A31 J4-1.
message
1. The run signal is not getting out of the *1. lnstall harness tool between A31 J4/P4. Reset
-and engine interface board (A31 ). A31 the control. Attempt to start and check far B+ at
may be bad. A31 J4-1. lf there is no B+ at A31 J4-1, replace
While cranking, A31.
Run LEO 0812
on the 2. There is an open between the engine *2. lf there is B+ at A31 J4-1, install harness tool be-
engine interface interface board (A31) and the gover- tween A38 J6/P6. Check far B+ at
board (A31) nor output module (A38). A38 JG-19, while attempting to crank. lf there is
is on. no B+ at A38 J6-19, isolate to connectors and
wiring. Repair or replace as necessary.
and
3. The run signal is not getting through 3. lf there is B+ at A31 J4-1, and there is B+ at A38
the governor output module (A38). JG-19, check continuity from A38 J6-15 to bat-
While cranking, A38 may be bad. tery ground, if not continuity replace harness, if
Run LEO 082
continuity, replace A38.
on the
governor output
module (A38)
is off.
NOTE:
These
indications
suggest that the -
PCC has sent a
run signal to the
governor
module, but the ;
;
signal is not
getting through
the governor
module to the
fuel solenoid.
I
*CAUTION: Wearing wrist strap, set S12 to Off and A32 SS to Standby before connecting/disconnecting harness plugs.
4-23
!AWARNING IMany troub/eshooting procedures present hazards that can result in severe personal inju
ry or death. Only trained experienced service personnel with know/edge of fuels, electricity, and me
"OVERCRANK" The run signal from the digital board (A32) *lnstall harness tool between A32 J4/P4. Attempt to
(222) is not being processed by the engine lnter- start and check for ground signal at A32 J4-8.
message tace board (A31).
-and
Run LEO DS12

Oíl the
engine interface 1 . The run signal is not getting out of the 1 . lf there is no ground signal at A32 J4-8, replace
board (A31) digital board (A32). A32 may be bad. A32.
is off.
2. The run signal is not being processed 2. lf there is a ground signal at A32 J4-8, replace
by the engine interface board (A31 ). A31.
A31 may be bad.
NOTE:
These
indications
suggest that the
PCC has NOT
sent a run
signal-
(fuel solenoid
enable signal)
out to the
governor
module and the -
fuel solenoid.
"FAIL TO The mag pickup signa! is not being Refer to the mag pickup shutdown message
CRANK" sensed. (220).
(221)
message ,.
I
,.
NOTE:
The engine is
cranking but
shutting down
on a 221 fault.
4-24
TABLE 4-13. LOW OIL PRESSURE WARNING (200) OR SHUTDOWN (201)
1AWARNINGl Many troub/eshooting procedures present hazardsthat can result in severe personal inju
ry or death. Only trained experienced service personnel with know/edge of fuels, e/ectricity, and me
"LOWOIL 1. Low oíl level. Clogged lines ar fílters. 1. Check oíl level, lines and filters. lf oil system is
PRESSURE" OK but oil level is low, replenish. Oil pressure
warning limits are lísted in Table 43.
(200) or
shutdown
(201) 2a. Sender or oíl pump could be bad. Or 2. Disconnect the ali pressure sender leads, and
message. the generator set may be shuttíng connect an oil pressure sender símulator to the
down on another fault. harness.
a. lf the control responds to the símulator, recon-
nect the sender, disconnect the run sígnal wíre
at the fuel solenoid, and crank the engine.
Check the oíl pressure reading on the digital
display.
• lf the display shows an acceptable oíl pres-
sure, the problem may not be in the oil or oil
sensing system. The generator set may
be shuttíng down on another fault (out of
fuel, blown governor fuse, intermíttent
connector). Restart the generator set and
monitor the PCC display panel for other
faults.
• lf the display does not show an acceptable
oíl pressure, replace the sender. lf the
PCC sti(( doesn't display an oíl pressure
while crankíng, the oil pump may be faulty.
Refer to tlie engine servíce manual.
2b. Harness or PCC circuit board could be

bad. *b. lf the control does not respond to the simulator,
lsolate to the harness, engine inter- / the PCC or the harness is bad. lnstall harness
tace board (A31), analog board (A33), tool between A31 J2/P2.
or digital board (A32). Check far +5 VDC at the sender (lead marked
E1-B}. lf there is no 5 VDC at the sender
• Check for 5 VDC at A31 J5-18.
I
• lf yes, harness is bad. lf no, check far 5
VDC at A31 J2-24.
• lf yes, A31 is bad. lf no, A33 is bad.
lf there is 5 VDC at the sender, use the sender
simulator to generate a signal to A31 J2-23. lf
the pressure signa! (.5 to 4.5 VDC) does not get
to A31 J2-23, isolate to the harness ar A31. lf
the pressure signal does get to A31 J2-23, refer
to the analog/digital troubleshootíng procedure
(Table 435alb).
4-25
TABLE 4-14. SENDER WARNING$ (204 or 213)
!AWARNING I Many troub/eshooting procedures present hazards that can result in severe personal lnju
ry or death. Only trained experienced service personnel with knowledge of fuels, e/ectricity, and ma
"OIL 1. The sender connections could be bad. 1 . Check the sender connections.
PRESSURE
SENDER"
warning 2. The sender, the harness, engine inter- *2. lsolate to the sender, harness, engine interface
(204) face board (A31 ), digital board (A32), board (A31 ), analog board (A33), or digital
message. or analog board (A33) could be faulty. board (A32).
Disconnect the oíl pressure sender leads, and
connect an oíl pressure sender simulator to the
harness.
"OIL PRES SENDER" warning is displayed
after the fault condition is sensed for 1 O sec-
onds.
a. lf the control responds to the simulator, re-
place the sender.
*b. lf the control does not respond to the simulator,
the PCC or the harness is bad. lnstall harness
tool between A31 J2/P2.
Check for +5 VDC at the sender (lead marked
E1-B). lf there is no 5 VDC at the sender
• Check for 5 VDC at A31 JS-18.
• lf yes, harness is bad. lf no, check for 5
VDC at A31 J2-24.
• lf yes, A31 is bad. lf no, A33 is bad.
lf there is 5 VDC at the sender, use the sender
simulator to generate a signal to A31 J2-23. lf
the pressure signal (.5 to 4.5 VDC) does not get
to A31 J2-23, isolate to the harness or A31. lf
the pressure signal does get to A31 J2-23, refer
to the analog/digital troubleshooting procedure
(Table435a/b).
"COOLANT 1 . The sender connections could be bad. 1. Check the sender connections.
SENDER" ¡
warning 2. The sender, the harness, engine inter- *2. lsolate to the sender, harness, engine interface
(213) face board (A31 ), digital board (A32), board (A31 ), analog board (A33), or digital
message. or analog board (A33) could be faulty. board (A32).
Disconnect the sender, and plug in a resistive
sender simulator to isolate the fault.
place the sender.
b. lf the control does not respond to the simu-
lator, refer to the high coolant temp trou-
bleshooting procedure.
4-26
TABLE 4-15. LOW ENGINE TEMPERATURE WARNING (21 O)
LA.WARNING! Many troubleshooting procedures present hazards that can result in severe personal inju
"LOW DS3 / A31 is on, índícating that engine in- lsolate the source of the signa!.
COOLANT terface board A31 is receiving a low cool- Unplug the coolant temperature switch (S1) and re-
TEMP" ant temp from the sender. set the control.
warning The sender, the harness or A31 could be 1 . lf the 21 O warning message drops out and does
(210} bad. not reappear, replace the sender.
message.
*2. lf the 21 o warning message reappears and re-
Coolant level mains after control reset, disconnect A31 J4
is normal. and check continuity from P4-13 to G N D.
• lf there is continuity, replace the harness.
Heater is OK.
• lf there is no continuity, replace circuit
Coolant temp board A31.
on f ront panel
display is OK.
DS3 on the
engine
interface
board, A31,
is on.
/.7',,.
{L.J)
"LOW DS3 / A31 is off, indicating that engine in- lsolate the source of the signal.
COOLANT terface board A31 is not receiving a low en- Check J4-6/P4-6 on A32.
TEMP" gine temp signa! from the sender-but the
warning *1. lnstall harness'tool between A32 J4/P4.
21 O message indicates that A32, the digital
(210) board, is responding to a false low engine 2. Open J4-6 and reset the control.
message. temp signa!. • lf fault drops out and does not return, re-
A31, the engine interface board, or A32, place A31.
Coolant level
is normal. the digital board, could be bad. • lf fault returns after resetting the control,
replace A32.
Heater is OK.
Coolant temp
on front panel ,-
display is OK.
DS3 on the
engine
interface
board, A31,
is off.
*CAUTION: Wearina wrist strao. set 812 to Off and A32 85 to 8tandbv before connectinci/disconnectina harness oluas.
4-27
TABLE 4-16. HIGH ENGINE TEMPERATURE WARNING (211) OR SHUTDOWN (212)
!AWARNING I
Many troubleshooting procedures present hazards that can result in severe personal inju
ry or death. Only trained experienced service personnel with know/edge of fue/s, e/ectricity, and ma
"HIGH 1. Engine problem: 1. Refer to the engine service manual if there are
COOLANT • Coolant pump could be faulty. any physical indications of overheating.
TEMP" 2. Correct any overload condition.
• Thermostat could be faulty.
warning
• There could be an obstruction in 3. lf there are no physical indications of overheat-
(211) or
the coolant flow. ing, check to see if the PCC accurately displays
shutdown
ambient engine temperature.
(212) • Externa! coolant pump (with re-
message. mate radiator) could be faulty. • lf the PCC ambient coolant temperature
reading is accurate, the engine may be
Coolant • Externa! radiator tan motor (with
overheating. Refer to the engine service
mixture and remote radiator) could be faulty.
manual.
level is normal. 2. The generator set may have been
• lf the PCC ambient coolant temperature
overloaded.
reading is not accurate, isolate to the
No airflow 3. Sender, harness or PCC circuit board sender, harness, engine interface board
obstructions. could be bad. (A31 ), analog board, or digital board.
Fan belt is OK. Disconnect the coolant temperature sender
leads, and connect a coolant temperature
sender simulator to the harness.
place the sender.
*b. lf the control does not respond to the sírnu-
lator, install harness tool between A31
J5/P5. Connect the coolant temperature
sender simulator (and B+) to A31 J5.
• lf the control displays the correct simulated
temperature, replace the harness.
• lf the control does not display the correct
simulated temperature, install harness
tool at A31 J2/P2, and open lines 18/19
(and 14/15, if applicable). Check for conti-
nuity between A31 J2-18 to 19 (far coolant
temp L), and A31 J2-14 to 15 (far coolant
temp R).
• lf no continuity, then A31 is bad.
• lf continuity is OK, then send a simu-
I lated temperature signal and mea-
sure the voltage out of A3i (A31
J2-18 to 19, and A31 J2-14 to 15).
lf voltage is not OK (refer to the ana-
log board inputs and outputs, Table
436), replace A33.
lf voltage is OK, refer to the analog/
digital troubleshooting procedure
(Table 435a/b).
4-28
TABLE 4-17. LOW COOLANT WARNING OR SHUTDOWN (214 / 215)
LA.WARNING I Many troubleshooting procedures present hazards that can result in severe personal inju
"LOW DS2 on A31 is on, indicating that A31 is re- lf the coolant leve! is normal, isolate the source of the
COOLANT ceiving a low coolant signa! from the send- low coolant signal. (This is a ground signal.)
LVL" warning er. Disconnect the signa! lead at the sender and reset
(214) or The sender, the harness or the A31 circuit the control.
shutdown board could be bad. 1. lf the 215 shutdown message drops out and
(215) message
does not reappear, replace the sender.
Coolant level *2. lf the 215 shutdown message reappears and
is normal. remains after control reset, disconnect J4/A31
and check continuity from P4-7 to GND.
DS2 on the • lf there is continuity, replace the harness.
engine
interiace • lf there is no continuity, replace circuit
board, A31, board A31.
is on.
(r) 1------+------+-----------,
"LOW DS2 on A31 is off, indicating that A31 is not lf the coolant leve! is normal, isolate the source of the
COOLANT receiving a low coolant signal from the low coolant signal.
LVL" warning sender-but the 215 message indicates Check J4-4/P4-4 en A32.
(214) or that A32, the digital board, is responding to
*1. lnstall harness tool between A32 J4/P4.
shutdown a false low coolant signar.
(215) message 2. Open the J4-4 circuit and reset the control.
A31, the engine interface board, or A32, the
digital board, could be bad. • lf the fault drops out and does not return,
Coolant level replace A31.
is normal.
• lf the fault returns after resetting the con-
DS2 on the trol, replace A32.
engine
interface
board, A31, r
is off.
4-29
TABLE 4-18. MAG PICKUP SHUTDOWN (220)
LAWARNING I Many troubleshooting procedures present hazards that can result in severe personal inju
ry or death. Only trained experienced service personnel with knowledge of fuels, electricity, and ma
"MAG This indicates that the PCC is not sensing

PICKUP" the mag pickup signa!, or the mag pickup
shutdown frequency does not correspond (in propor-
message (220) tion) to the genset output frequency.
1. The PCC may not be set for the correct 1. Check and correct setting if necessary.
generator set.
2. Loose or damaged mag pickup wire. 2. lnspect the wires, and repair or replace as nec-
essary.
3. Damaged mag pickup (MPU). *3/4 To isolate the problem, reset the control and at-
tempt to start the set in idle mode.
a. lf the engine displays a "FAIL TO CRANK" shut-
down message, or if the engine starts and idles,
but then shuts down on a MAG PICKUP fault,
4. The harness, the engine interface the MPU sender could be bad. Remove the
board (A31 ), the analog board (A33) or MPU connectors and check for 3.5 to 15 VAC at
the digital board (A32) could be bad. the MPU while cranking.
• lf no output, check for damage or debris .
Also check for improper adjustment of the
MPU. (Refer to Section 5.) lf there is still
no output, replace the MPU sender.
• lf the MPU output is OK, install harness
tool between A32 J4/P4. Check for MPU
voltage atA32 J4-10 to 11, while cranking.
lf OK, replace A32. lf not OK, use continu-
ity checks to isolate to A31 or harness.
;
b. lf the engine starts and idles, and does not dis-
j play a fault, then there could be a frequency
mismatch problem.
• Measure generator output frequency with
a digital multimeter and compare to the fre-
quency on the PCC display.
,·
r • lf they do match, multiply the frequency by
,.
30 and compare this number to the RPM
on the PCC display. lf these are not the
same, the MPU sender may be bad. Re-
place the MPU sender
• lf the multimeter and PCC frequencies do
not match, there is a frequency sensing
problem. Verify the accuracy of the PCC
L1 N voltage, and then refer to the analog/
digital troubleshooting procedure (Table
435a/b).
~cAUTION: Wearing wrist strap, set 812 to Off and A32 SS to Standby befare connecting/disconnecting harness plugs.
4-30
TABLE 4-19. OVERSPEED SHUTDOWN {223)
!AWARNING I Many troub/eshooting procedures present hazards that can result in severe personal iniu
"OVERSPEED" 1 . The mechanical fuel linkage could be 1. lnspect the mechanical fuel linkage, and repair
shutdown binding, loose, or damaged. or replace as necessary.
message (223) • Follow the procedure in the engine repair
manual to check the EFC for binding or
damage.
• Disconnect the actuator connector, and
connect +12 VDC from the battery to the
actuator. The actuator should click upon
application and removal of the voltage.
lf the actuator does not click, refer to the
engine manual.
lf the actuator clicks, reconnect the wires
to the actuator.
2. The governor output module (A38) or *2. Reset the control, and start the set while moni-
the digital board (A32) could be bad. toring the PCC duty cycle display.
• lf the duty cycle goes high (above 40%) and the
set shuts down on overspeed, replace A32.
• lf the duty cycle goes to zero and the set shuts
down on overspeed, replace A38.
;
j
.. I
..
4-31
TABLE 4-20a. FAIL TO SYNCHRONIZE (224)
ry or death. Onty trained experienced service personnel with knowledge of fuels, e/ectricity, and ma
"FAIL TO 1. lmproper adjustment of bus or genera- . 1. Verify that the bus voltage is within plus or mi-
SYNCHRO- tor set voltage. nus 5% of the value which is programmed into
NIZE" warning the PowerCommand control, and verify that the
(224) or generator set is operating at proper voltage and
shutdown frequency. Verify that the bus PT module is
(224) properly calibrated. (Refer to Digital Bus Volt
message. age Calibration in Section 5). Check the FAIL
TO SYNCHRONIZE time delay. lt should be set
far approximately 120 seconds. Check parallel-
ing setup adjustments, particularly PERM WIN -
PHASE and PERM WIN - TIME. They are typi-
cally adjusted to 20 degrees and 0.5 seconds.
2. Generator set hunting due to improper 2. Check synchronizer adjustments in the Power-
synchronizing adjustments. Command control set-up. lf you are unsure of
proper adjustment procedure, returning the unit
to it's default values should result in proper op-
eration. The default values are shown in the test
report which is shipped with the generator set.
In particular, check values far paraüelínq func-
tions, governing and voltage regulation.
-
3. Unstable or hunting generator set due 3. lnspect generator set governing system for evi-
to governor component failure or mis- dence of binding or sticking linkages or other
adjustment. ; components which are not operating correctly.
;
Verify that water jacket heaters are operational
and properly functioning. Check and adjust
governor settings as required .
..
I
Continued On Next Piige••.
4-32
TABLE 4-20b. FAIL TO SYNCHRONIZE (224)
!AWARNING I
"FAIL TO 4. Unstable or hunting generator set due 4. This problem is indicated in situations where
SYNCHRO- to air entrained in the fuel system. the generator set performs properly after the
NIZE" warning generator set is up and running with load, but
(224) or experiences "FAIL TO SYNCHRONIZE" alarms
shutdown after it has been shut down for severa! days.
(224) Check the generator set fuel system for leaks or
message. cracks. lf fuel filters have recently been
changed, air may be trapped in the fuel filter
heads. Check to be sure that there is a f uel head
on the engine fuel pump. Check fuel line routing
for overhead loops which could result in the
trapping of air in the system if the system sits
idle for sorne period of time. Parallel systems
should use option C174, the fuel pump feature
option. This feature is available as an aftermar-
ket accessory kit.
Note: The generator set will synchronize
faster as the synchronize acceptance win-
dow is widened (i.e., the value in the PERM
WIN-PHASE is increased) and as the accep-
tance time is minimized (the value in the
PERM WIN-TIME is minimized). Caution
should be taken in utility (mains) paralleling
applications to avoid damage to the genera-
tor set by inappropriate setting of these pa-
rameters.
*CAUTION: Wearing wrist strap, set 512 to Off and A32 SS to Standby before connecting/disconnectinQ harness pluQs.
4-33
TABLE 4-21 a. FAIL TO CLOSE (226)
ry or death. Only trained experienced service personnel with know/edge of tuels, e/ectricity, and ma
chinery hazards shou/d perform service procedures. Review safety precautions on pages iil and iv.

1 . Check the paralleling breaker for lndi- 1. lf the breaker has tripped due to operation of it's
"FAIL TO
CLOSE" cation that the breaker is tripped and interna! trip unit, the alternator and electrical
warning (226) locked out from a signa! issued from distribution system connected to the alternator
or shutdown it's interna! trip unit should be carefully inspected for evidence of
(226) burning or tracking, which might indicate that an
message. electrical fault has occurred. lf no evidence of a
fault is found, reset the trip unit and verify that
the trip settings of the breaker are appropriate
for the application. Reset the fault on the Pow-
erCommand control and check the system op-
eration to verify that the failure to close fault
problem has been eliminated.
2. Breaker charge circuit is not operating 2. Check the circuit breaker status indicators and
properly. (Power circuit breakers only.) verify that the breaker status indicates that the
breaker is properly charged. lf it is, go on to step
3. lf it is not charged, check the charge circuit for
proper operation. Switch the PowerCommand
control RUN/OFF/AUTO switch to OFF and
then manually recharge the paralleling breaker
according to the manufacturer's instructions.
Switch the PowerCommand control RUN/OFF/
AUTO switch back to RUN. The generator set
should start and accelerate to rated speed and
Continued On Next Page ... voltage and the operator should be able to
manually control the circuit breaker from the
pushbuttons on the front panel of the Power-
Command control. In most cases the breaker
should automatically recharge on closing to the
;
j
system bus. lf this does not occur, problem may
be in the control wiring to the breaker, or the
control power source.
NOTE: Sorne breakers are notable to be set
up to charge on closing (they will recharge
.. on opening). lf this is the case with your
I
installation, it is critica! that the generator
.-
set be allowed to operate for a cooldown pe-
riod which is long enough for the breaker to
completely charge befare the generator set
is shut down. lf the generator set is shut
down on a fault condition, the breaker may
require manual recharge before the system
can be put back into automatic operation.
*CAUTION: Wearing wrist strap, set S12 to Off and A32 SS to Standby before connecting/disconnectina harness olugs.
4-34
TABLE 4-21 b. FAIL TO CLOSE {226)
!.AWARNING I Many troub/eshooting procedures present hazards that can result in severe personal inju
ry or death. Only trained experienced service personnel with knowledge of fuels, electricity, and ma
chinery hazards shou/d perform service procedures. Review safety precautions on pages iil and iv.
"FAIL TO 3. Breaker close signal has been issued 3. Disconnect breaker control wiring and verify
CLOSE" from the PowerCommand control, but that the control is sending a close signa! to the
warning (226) has not reached the breaker. breaker. lf the breaker signal is present at the
or shutdown generator set control, reconnect the control wir-
(226) ing at the set, verify that it is present at the
message. breaker terminals.
Note that in Onan paralleling systems, DC pow-
er for operation of the relay comes from the gen-
erator control. Verify that the 20 amp customer
B+ fuse (F1 - engine harness assembly) is OK
and that the pilot relay operates properly.
4. Breaker status (open/close) signals 4. Verify that the breaker auxiliary contact wiring is
are not properly connected to the Pow- properly connected to the generator set. Verify
erCommand control, orare not operat- that the breaker is sending proper condition sig-
ing properly. nals to the generator set, by disconnecting the
control wiring at the breaker and verifying that
the breaker auxiliary contacts changa state
when breaker condition changes. lf they are
functioning properly, verify that the signals are
reaching the generator set by reconnecting the
wiring and the breaker and checking for condi-
tion change at the generator set control acces-
sory box. -
4-35
TABLE 4-22. DC (BATTERY) WARNING$ (230, 231, 232)
LA.WARNING I
ry or death. Only trained experienced service personnel with know/edge of fuels, electricity, and ma-
"LOWOC 1. Weak or discharged battery. 1. Recharge or replace the battery. Specific gravi-
VOLTAGE" ty for a fully charged battery is approximately
(230) or 1.260 at 80° F (27º C).
"WEAK
BATTERY" 2. Low electrolyte level in battery. 2. Replenish electrolyte and recharge battery.
(232),
warning 3. Battery connections loose or dirty. 3. Clean and tighten or replace the battery cable
message. connectors and cables at the battery and the
set.
4. lnsufficient battery charging voltage. 4. Adjust charge rate of battery charging circuit,
according to manufacturers instructions.
5. Engine OC alternator could be bad. 5. Replace engine oc alternator if normal battery

charging voltage is not obtained.
6. lf the batteries are OK, the problem *6. lf the battery voltage, electrolyte, and connec-
may be the harness, the engine ínter- tions are OK, check the battery voltage at A31
face board (A31 ), the digital board J5-17. lf the voltage is not OK (same as battery
(A32), or the analog board (A33). voltage), disconnect J5 and isolate to the har-
ness or A31. .)
lf the voltage is OK, check battery voltage at
A33 J1-31. lf the voltage is not OK, replace
A31. lf the voltage at A33 J1-31 is OK, isolate to
A33 or A32 using the analog input trouble-
shooting procesure (Table 435a/b).
"HIGH OC 1. Excessive battery charqínq voltage. 1. Adjust charge rate of battery charging circuit ac-
VOLTAGE" cording to manufacturers instructions.
;
(231) j
warning 2. Engien OC alternator could be bad. 2. Replace engine OC alternator if normal battery
message. charging voltage is not obtained.
But battery
voltage is OK. 3. lf the battery voltage is OK, the prob- *3. Check the battery voltage at A31 J5-17. lf the
lem may be the en,gine interface board voltage is not OK (same as battery voltage), dis-
(A31 ), the digital .board (A32), or the connect JS and isolate to the harness or A31.
analog board (A33). lf the voltage is OK, check battery voltage at
A33 J1-31. lf the voltage is not OK, replace
A31. lf the voltage at A33 J1 -31 is OK, isolate to
A33 or A32 using the analog input troubleshoot-
ing procedure (Table 435a/b).
4-36
TABLE 4-23. LOW FUEL -DAY WARNING (240)
!Ji.WARNING! Many troubleshooting procedures present hazards that can result in severe personal inju
chinery hazards shou/d perform service procedures. Review safety precautions on pages ;;; and iv.
"LOW FUEL- 081 on A31 is on, indicating that A31 is re- lf the fuel leve! is normal, isolate the source of the low
OAY" ceiving a low fuel signa! from the sender. fuel signa!.
warning The sender, the harness or the A31 circuit Disconnect the signal lead at the sender and reset
message (240) board could be bad. the control.
Fuel leve! is 1. lf the 240 message drops out and does not re-
normal. appear, replace the sender.
*2. lf the 240 message reappears and remains at-
081 on the ter control reset, disconnect J4/A31 and check
engine continuity from P4-14 to GND.
interface • lf there is continuity, replace the harness.
board, A31,
is on. • lf there is no continuity, replace circuit
board A31.
"LOW FUEL- 081 on A31 is off, indicating that the PCC is lf the fuel leve! is normal, isolate the source of the low
DAY" not receiving a low fuel signa! from the fuel signa!.
warning sender-but the 240 message indicates *1. lnstall a breakout connector at A32 J4.
message (240) that A32, the digital board, is responding to
2. Open the J4-15 circuit and reset the control.
a false low fuel signa!.
Fuel leve! is
normal. A31, the engine interface board, or A32, the • lf the fault drops out and does not return,
replace A31 .
digital board, could be bad.
081 (A31) • lf the fault returns after resetting the con-
trol, go to step 3.
and 0813
(A34) are off. 3. lnstall harness tool between A32 J2/P2.
4. Opern the J2-19 circuit and reset the control.
• lf the faulf drops out and does not return,
replace A31.
trol, replace A32.
;
;
,·
I
*CAUTION: Wearinq wrist strap, set 512 to Off and A32 SS to Standby before connecting/disconnectinq harness pluqs.
4-37
TABLE 4-24. LOW FUEL WARNING (241)
!.A.WARNING! Many troub/eshooting procedures present hazards that can result in severe personal inju
ry or death. Only trained experienced service personnel wíth know/edge of fuels, electricity,and ma
chínery hazards shou/d perform service procedures. Review safety precautions on pages iii and iv.
"LOW FUEL" DS13 on A34 is on, indicating that A34 is re- lf the fuel level is normal, isolate the source of the low
warning ceiving a low fuel signa! from the customer fuel signal.
message (241) circuit. Disconnect the signal lead near the control and reset
lf there is no actual fault, the problem may the control.
Fuel level is be a short to ground in the externa! wiring or
normal. 1 . lf the 241 message drops out and does not re-
abad customer interface board (A34}.
appear, there is a short to ground in the externa!
DS13 on the wiring ora faulty sender.
customer *2. lf the 241 message reappears and remains af-
interface ter control reset, disconnect J1/A34 and check
board, A34, is continuity from P1-5 to GND.
Oíl.
• lf there is continuity, find and repair a short
to ground in the externa! wiring.
• lf there is no continuity, replace circuit
i--,...,,, rrl /\ ".l A
"LOW FUEL" DS13 on A34 is off, indicating that the PCC lf the fuel level is normal, isolate the source of the low
warning is not receiving a low fuel signal from the fuel signal.
message (241 ) sender-but the 241 message indicates *1 . lnstall harness tool between A32 J2/P2.
that A32, the digital board, is responding to
Fuel level is 2. Open the J2-19 circuit and reset the control.
a false low f uel signal.
normal. • lf the fault drops out and does not return,
A34, the customer interface board, or A32,
replace A34.
DS13 (A34) is the digital board, could be bad.
off.
trol, replace A32.
;
i
;·
I
..
4-38
TABLE 4-25. EEPROM ERROR SHUTDOWN (250) OR WARNING (251, 252)
LA.WARNING I Many troub/eshooting procedures present hazards that can result in severe personal lnju
chinery hazards shou/d perform service procedures. Review safety precautions on pages ;;; and iv.
"EEPROM The EE memory on the digital board (A32) 1. Perform the initial start setup procedure.
ERROR" may be bad. Turn the Run/Off/Auto switch to Off and reset
shutdown the control. Simultaneously press the RESET,
(250) MENU, and PHASE SELECT keys to start the
message. setup.
Select the correct values, save your choices,
and attempt to start the set.
2. lf the set shuts down on the same EEPROM
ERROR message, replace the digital board
(A32).
"EEPROM The EE memory on the digital board (A32) 1. Perform the adjustment procedures (described
ERROR" may be bad. in Sectíon 5). Save the adjustments.
warning Reset the control. Shut off and restart the set.
(251)
2. lf the control generates the same EEPROM
message.
ERROR message, perform the calibration pro-
cedures in Section 5.
Reset the control. Shut off and restart the set.
ERROR rnessaqe, replace the digital board
(A32).
i
;
"EEPROM The EE memory on the digital board (A32) 1. lf this message occurred during an adjustment,
ERROR" may be bad. option selection, or calibration of the PCC,
warning .. verify the values or choices selected and repeat
(252) I the save operation.
message. -·
Reset the control. Shut off and restart the set.
ERROR message, replace the digital board
(A32).
*CAUTION: Wearing wrist strap, set S12 lo Off and A32 SS to Standby befare connecting/disconnecling harness plugs.
4-39
TABLE 4-26. CUSTOMER FAULTS (260, 261, 262 or 263)
LA.WARNING IMany troub/eshooting procedures present hazards that can result in severe personal lnju
"CUSTOMER lf the corresponding LEO on the customer lsolate the source of the false signa!.
FAULT interface board (A34) is on, then A34 is re- Disconnect the signa! lead near the control and reset
(260, 261, 262 ceiving a signa! from the customer circuit. the control.
or 263) lf there is no actual fault, the problem may 1. lf the message drops out, there is a short to
message. be a short to ground in the externa! wiring or ground in the externa! wiring.
abad customer interface board (A34).
And 2. lf the message remains, replace A34.
corresponding
LEOon
customer
interface board
A34 is on.
"CUSTOMER lf the corresponding LED on the customer lsolate the source of the false signa!.
FAULT interface board (A34) is off, then A34 is not Check J2/P2 on A32.
receiving a signal from the customer circuit.
···)·~ ·
(260, 261, 262 .
*1. lnstall harness tool between A32 J2/P2.
.:
or 263) The message indicates that A32, the digital

message. 2. Open the appropriate circuit J2-3, J2-24, J2-9,
board, is responding to a false signa!.
or J2-15 and reset the control.
A34, the customer interface board, or A32,
And • lf the fault does not return, replace A34.
the digital board, could be bad.
corresponding • lf the fault reappears, replace A32.
LEO on
customer
interface board
A34 is off. r A 34 A32 CUSTOMER FAULT
LED CONNECTOR FAULT # CODE
DS4 J2-3 1 260
DS11 J2-24 2 261
DS15 J2-9 3 262
DS3 J2-15 4 263
¡
4-40
TABLE 4-27a. PHASE ROTATION (270)
LA.WARNING I Many troub/eshooting procedures present hazards that can result in severe personal iniu-
"PHASE 1. Single phase bus condition. 1. Verify that bus voltage is proper and is not single
ROTATlON" phased.
shutdown
(270)
message.
2. Generator set output power feeders 2. Verify phase rotation of the generator set output
are improperly connected. relativa to the system bus. Correct wiring of
power output conductors if required. The phase
relationship between the generator set and the
system bus can be checked by either using a
phase rotation checker, or by using synchroniz-
ing lamps or two voltmeters. The procedure for
using voltmeters for checking phase relation-
ship is as follows:
Energiza the system bus and start the genera-
tor set in question in the RUN mode, but do not
close the paralleling breaker. Connect each
voltmeter from the line to load side of a single
phase of the paralleling breaker (see Figure
8-1). lf the generator set and bus have the same
phase rotation, the voltmeters should rise and
fall in voltage at the same time. lf they are not in
phase, one will ríse while the other falls.
Continued On Next Page ... ;

j
•'
I
,.
*CAUTION: Wearinci wrist strap, set 512 to Off and A32 SS to Standby before ccnnecting/disconnectlnq harness pluqs,
4-41
TABLE 4-27b. PHASE ROTATION (270)
LA.WARNING I
Many troub/eshootíng procedures present hazards that can result in severe personal inju
ry or death. Only trained experienced service personnel with knowledge of fuels, electricity, and me
"PHASE 3. Wiring to bus PT module is not correct. 3. lf power conductors are properly phased, check
ROTATION" the phase rotation of the wiring to the generator
shutdown set CT/PT module (A36) and Bus PT module
(270) (A39). This is done using voltmeters connected
message. as shown in Figure 8-1. Energize the system
bus and start the generator set being tested in
the RUN mode. Operate the display screen on
the PowerCommand control to show the digital
synchroscope (bus frequency). Observe the
voltmeter(s) and the synchronized indicator (*)
on the PowerCommand screen. When the volt-
age of the meter(s) approaches zero, the *
should be displayed. lf the * is on when the volt-
meters are reading their highest value, the Bus
PT module or the genset CT/PT module is in-
correctly wired. lf incorrect wiring is indicated,
switch off the power supply to the system bus
and manually close the paralleling breaker by
pushing the breaker clase switch on the front of
the PowerCommand control. Check the voltage
between phase L1 of the generator CT/PT mod- ... ·.\
ule (J9-4 yellow) and phase L 1 of the Bus PT )

module (terminal TB1-1 on the module). lf there
is voltage difference between these points, re-
verse the wiring between TB1-1 and TB1-3 on
the Bus PT module. Retest the system to be
certain that the phase relationship problem has
been corrected. lf no voltage difference is
sensed at the input to the CT/PT module and
Bus PT module, the problem could be in the wir-
; ing between the Bus PT module and the Power-
;
Command control. Reverse the connections
between terminals TB2-1, 2 with TB2-5, 6. Re-
test the system to make sure that the phase
relationship problem has been corrected.
,·
I
..
4-42
TABLE 4-28. FIRST START (272)
!AWARNING I Many troub/eshooting procedures present hazards that can result in severe personal inju
ry or death. Only trained experienced service personnel with knowledge of tuets, etectricity, and ma
"FIRST 1. Master First Start Sensor has failed. 1 . Verify that the Master First Start Sensor is prop-
START" erly functioning. This can be accomplished by
warning (272) connecting a OC voltmeter from ground to the
message. appropriate terminal on the Master First Start
Sensor··to the PowerCommand Control. The
voltmeter should indicate a pulsing voltage
present on the terminal.
2. lnterconnection between Master First 2. Verify that the voltage pulse is present at the
Start Sensor and the PowerCornmand PowerCommand Control (terminal TB 1-50).
control has failed. Check and repair any problems in the intercan-
nection wiring between the generator set and
the Master First Start Sensor.
-
*CAUTION: Wearing wrist strap, set S12 to Off and A32 SS to Standby before connecting/disconnecting harness pluqs,
4-43
TABLE 4·29a. HIGH AC VOLTAGE SHUTDOWN (301)
!AWARNING! Many troubleshooting procedures present hazards thatcan result in severe personal inju
"HIGH AC 1 . The problem may be in the PCC, the 1. Set the display on the PCC to GEN, VOLTS,
VOLTAGE" alternator, or the interconnection be- L-N.
tween them. a. Start the genset and observe the voltage
shutdown
(301) Note 1 : The PCC may indicate either displayed on the digital display.
message. a low AC Voltage or High AC Voltage b. lf all phases of voltage are balanced and not
shutdown due to the design of the zero, óut lower than normal, the alternator
logic in the control. and the input to the PCC are OK. The prob-
lem is in the excitation circuit for the alterna-
You must first determine if the out- tor. Go to step 2.
put voltage the control sees is low c. lf one or more phases of voltage are high or
or high. the voltages are unbalanced, the PCC is not
!
I measuring al! phases of voltage and is re-
Note 2: Residual voltage is normaíly spondinq to the low "average" of the three
5 to 10% of nominal output voltage. phases of voltage. Go to step 3.
For example, a genset with a 480
volt output, will have a residual volt-
age of 25 ío 50 VAC at normal oper-
ating speed.
2. The problem may be the regulator 2. With OC power to the PCC and with the set not
module (A37), the engine interface running, check A31 OS9, the AVR duty cycle
board (A31 ), or the digital board (A32). LEO. this LEO should be off. lf it si on, go to step
2d.
lsolate the genset output from the load. Oiscon-
nect A37 J1 O, and place the set in ldle mode. In
ldle mode the excitation circuit is disabled. Start
the set and monitor the AC output voltage with a
digital multimeter.
a. lf output voltage is greater than residual (5%
of normal output), go to step 3.
b. lf output voltage stays at O (or residual), and
OS2 on A37 is off, go to step 4.
c. lf output voltage stays at O (or residual), and
082 on A37 is on, look at DS9 on A31.
lf DS9 on A31 is off, replace A37.
d. lf OS9 on A31 is on, connect a breakout con-
nector at A32 J4, and open J4-2.
lf 089 goes out, replace A32.
lf 089 stays on replace A31.
(Continued)
*CAUTION: Wearinq wrist strap, set 512 to Off and A32 S5 to Standby befare connecting/disconnecting harness pJugs.
4-44
TABLE 4-29b. HIGH AC VOL TA GE SHUTDOWN (301)
LA.WARNING I Many troub/eshooting procedures present hazards that can result in severe personal inju
ry or death. Only trained experienced service personnel with knowledge of tuels, electricity, and me

3. The problem may be the PT/CT mod- *3. Before starting the generator set, discon-
"HIGH AC ule (A36) or the interconnecting wiring nect the harness connector from the PT/CT
VOLTAGE II
to the PT/CT module. module (A36) and connect the harness tool
shutdown between A36 and its harness connector.
(301) NOTE: To calculate the "expected A36
output" voltage range, do the follow- Check the output voltage at the alternator
message.
ing: outp4t terminals and record the voltages.
Determine the ratio between the mea- a. lf the volta{j"es are not balanced, go to step 5.
sured voltage and the expected volt- b. lf the voltages are balanced, calculate the
age. The output (18 VAC) of the PT/CT expected output voltage from the PT/C rnod-
module will also be reduced by this ra- ule (see Note to the left). Measure and re-
tio. cord the outputs from A36 J8 pins 6-5, 4-3,
! and 2-1.
!
_lf the output voltage is proportional to the
álternator output voltage the A36 module
is OK. Go on to step 4.
- lf the voltages are not balanced, replace
A36.
4. The problem may be in the customer *4. Disconnect the plugs in the following steps
interface board (A34} or the intercon- below with the set off then start the set in the
necting wiring. idle mode, and measure voltages with a digi-
tal multimeter.
a. Disconnect J3/P3 (blue} and insert the har-
ness tool. Check the voltage into the cus-
tomer interface board with the harness tool
at J3 terminals 4-6, 5-13, and 7-20. Re-
move the harness tool and reconnect J3 and
P3. These voltages should be the same val-
ues measured in step 3b.
lf the voltages are balanced, continua in this
step. lf the voltages are unbalanced, repair
the harness between the A36 module and
the A34 board.
b. Disconnect J5/P5 on the customer interface
board and insert the harness tool. Check the
voltage out of the customer interface board
at J5 terminals 24-28, 26-28, and 30-28.
These voltages should be the same values
measured in step 3b.
lf the voltages are balanced, go to step 5. lf
the voltages are unbalanced, replace the
customer interface board.
(Continued)
*CAUTION: Wearing wrist strap, set 512 to Off and A32 SS to Standby before connecting/disconnecting harness pluqs,
4-45
TABLE 4-29c. HIGH AC VOLTAGE SHUTDOWN (301)
LA.WARNING! Many troub/eshooting procedures present hazards that can result in severe personal inju
ry or death. Only trained experienced service personnel with knowledge of fue/s, e/ectricity, and ma

5. The problem may be the analog board *5. Using the harness tool, check the "3-phase
"HIGHAC (A33). ave" signal at A33 J2-18.
VOLTAGE"
lf the voltage is within the expected range,
shutdown
NOTE: To determine the "3-phase replace A32. lf the voltage is not within the
(301)
ave" signal voltage range for Step 3b, expected range, replace A33. See Note.
message.
use the following formula: I
Vout 3-phase ave= V¡n (2.9+PT) ±5%
V¡n= Actual generator output voltage

(phase-to-neutral)
PT = PT primary (120, 240 or ~~6)
6. The problem may be in the generator 6. Refer to the generator servicing procedures in
set itself. - Section 6.
4-46
TABLE 4-30b. LOW AC VOLTAGE SHUTDOWN (303)
LAWARNING! Many troub/eshooting procedures present hazards thatcan result in severe personal inju
"LOWAC 5c. The problem may be the PT/CT rnod- c. lf the measured AC voltage is hígh, the control
VOLTAGE" ule (A36), the analog board (A33), the must have lost AC sensing. Check PTs (primary
shutdown customer interface board (A34), or the 1 K-2.5K ohms; secondary 140-225 ohms),
(303) digital board (A32). sensing harness wires, generator output con-
message. nectíons·, and the customer interface board for
contínuify. lf tírese are OK, then check the ana-
log and digital boards, using the analog input
troubleshooting procedure ( Table 436a/b).
!
!
(~i.;}
.._
. . ·~
*CAUTION: Wearing wrist strap, set 512 to Off and A32 SS to Standby befare connecting/disconnecting harness pluqs.
4-48
TABLE 4-31. UNDER FREQUENCY SHUTDOWN (313)
LA.WARNING I Many troubleshooting procedures present hazards that can result in severe personal inju
"UNDER 1. lmproper setup. 1. Check lnitial Setup (set size) and correct, if nec-
FREQUENCY" essary.
shutdown
(313) 2. Overload. 2. Check_Jhe load and correct any overload, if nec-
message. essa!)¡
Disconnect"the load. Reset the control and at-
tempt to restart the generator set.
3. Fuel or air delivery problem. 3. lf the engine starts and runs, refer to the engine
fuel/air delivery service procedures.
,!
4. The governor output module (A38), *4. Disconnect the wire to the fuel solenoid, reset
the digital board (A32), or the engine the control, and crank the set. 082 on the gov-
interface board (A31) could be bad. ernor output module A38 should light.
- lf the duty cycle LEO (DS1) on the governor out-
put module (A38) slowly becomes bright, the
governor output module(A38), the digital board
(A32), and the engine interface board (A31) are
functioning properly.
(_ lf DS1 does not light or instantly becomes
\'..
bright, A31, A32 or A38 may be bad.
A38 - Crank the set, and check the gover-
nor duty cycle on the PCC display. lf the
duty cycle is OK (60% max), replace gov
ernor output module (A38).
lf the duty cycle is not OK, the digital board
(A32) or the engine interface board (A31)
may be bad.
• A31 - Check for continuity: A31 J1-13 to
A31 J4-19 and A31 J1-14 to A31 J4-12. lf
no continuity, replace A31.
• A32 - lf A31 is OK, replace A32
4-49
TABLE 4-32. OVERCURRENT WARNING (320) OR SHUTDOWN (321),
SHORT CIRCUIT SHUTDOWN (322), OR OVERLOAD WARNING (330)
"OVER- 1. Short or Overload. 1. Check the load and load cables. Repair if nec-
CURRENT" essary.
warning (320) ..
or shutdown 2. lncorrect CTs or CT connections. 2. Check¡::;Ts and CT connections. Correct if nec-
(321 ), essary. Refer to Current Transfer lnstallation in
or Sectíon 5.
"SHORT
3. The problem may be a bad PT/CT 3. Disconnect the PT/CT module and check the
CIRCUIT"
module (A36). 3-ohm resistors {J8-15 to 14, J8-22 to 23,
shutdown
J8-7 to 8). Replace the module if necessary.
(322), or
OVERLOAD '
warning (330) 4. The problem may be the customer in- *4. Check continuity from A36-through A34-to
message. terface board (A34) or connections. A33. · Repair the connection or replace A34 if
necessary. Ref er to Section 9 for pin reference.
5. The problem may be the analog board 5. lsolate, using the analog input troubleshooting
(A33) or the digital board {A32). procedure (Table 435a/b). Check the bad
phase or phases.
4-50
TABLE 4-33. REVERSE POWER (335)
"REVERSE 1. lf this shutdown condition occurs 1. Verify proper CT orientation, wiring and
POWER" when a non-paralleled generator connections on the control system. Refer to
shutdown set is loaded, it indicates that the Current Transformer (CT} lnstallation in
(335) generator set output CT's or PT's Section 5. Make sure that the no load fre-
message. are incorrectly installed. quency matches the bus frequency. Check
metering catíbratlon for both generator set
and bus.
2. Verify that the generator set is op- 2. Make adjustments as required for proper
erating at the correct frequency operation.
and voltage. The bus voltaqe and
frequency should be the same as
the no-load generator set frequen-
cy and voltage.
-
3. The load sharing line connections 3. Verify that load sharing connections are
and orientation must be correctly made as noted in the drawings and that
..
accomplished for proper load shar- there are no damaged or disconnected
ing. wires.
4. lf the alarm occurs when a large 4. Apply various load steps to each generator
load is added or shed, dissimilar set in the system, noting the voltage and
transient response of the genera- frequency dips/surges and recovery times.
tor sets in the system may cause The generator sets should be adjusted so
the reverse power condition. that transient load performance is approxi-
mately the same in all machines in the sys-
tem.
5. Reverse power alarm can also in- 5. Verify that the generator set can pick up
dicate that the generator set is un- and carry loads properly, up to the rated ca-
able to carry load properly. pacity of the machi ne. lnability to carry load
can be related to engine misadjustments,
component failures, or poor fuel quality.
Check governing system for binding or
sticking. Check fuel filters and fuel lines for
cracks, leaks or dents. Check air cleaner(s)
for obstructions.
*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness pluns.
4-51
TABLE 4-34. LOSS OF EXCITATION (337)
!AWARNING! Many troubleshooting procedures present hazards that can result in severe personal lnju
ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and
machinery hazards shou/d perform service procedures. Review safety precautions on pages iii and iv.
"LOSS OF 1. lmproper voltage adjustment of the 1. Verify that the no load voltage of the generator
EXCITATION" generator set relative to the system set matches the bus voltage. Check generator
shutdown bus. set metering calibration for both generator set
(337) and bus readings. lf no problems are found,
message. check t~e paralleling adjus:ments in the Power-
Command control, to see 1f they match the de-
fault settings in the generator set test report.
2. Load sharing line mis-connection or 2. Verify load sharing line connections and condi-
dama ge. tion. Make corrections as required.
!
3. lf condition occurs when the geherator 3. Loss 9f Excitation failure may also be caused by
set is lightly Joaded, Jeading power tac operation of filters and power factor correction
tor Joads may cause this condition. capacitors in the generator set loads when the
- kW load leve! on the genset is low. The capaci-
tors in the filters and power factor correction
equipment can present a leading power factor
load to the generator set, which (correctly)
shuts down the generator set through the loss
of excitation fault. Leading power factor loads
can cause the generator set to lose control of
the output voltage of the genset, and can cause
kVar load sharing problems, so it is necessary
to protect the genset f rom excessive leading
power factor and reverse var conditions.
For generator sets prior to the release of
version 2.0 firmware:
Check the load for devices which may apply
leading power factor loads to the generator set.
These include power factor correction capaci-
tors, input filter and sorne non-linear load de-
vices with interna! voltage waveform correction
provisions. These devices may need to be dis-
connected from the bus until other loads are
added to the system.
For generator sets with version 2.0 and
higher firmware:
lf there is a Joss of excitation fault that cannot be
explained by genset component failures or mis-
adjustments, perform the following steps:
(Continued)
4-52
TABLE 4-34. LOSS OF EXCITATION (337) (Continued)
IAWARNING I Many troubleshooting procedures present hazards that can result in severe personal Inju
ry or death. Only trained and experienced service personnel with knowledge of fuels, e/ectricity, and
machinery hazards shou/d perform service procedures. Review safety precautions on pages iii and iv.
"LOSS OF 3. (continued) a. Start the generator set and apply system

EXCITATION" loads in their normal operation sequence.
shutdown Observe the output voltage, power factor,
(337)
and % voltage regulation of the generator
message.
se.t as the loads are applied. (This may
· take more than one test.)
b. lf the voltage does not rise and the % volt-
age regulation is greater than O as the sys-
tem loads are applied, extend the time
delay on loss of excitation shutdown and
!
! repeat the load addition test.
c. lf the increase in time delay does not re-
salve the shutdown condition, contact the
factory far the maximum permissible set-
- ting of the loss of excitation shutdown set
points.
d. lf the voltage rises or the % voltage regula-
tion value drops to O and does not rise as
( load is applied, investigate means to re-
move leading power factor loads from the
genset bus.
4. The generator set may be incapable of 4. See section 6 of this manual, "Servicing the
carrying full reactive load due to com- Generator, Exciter Rectifier and Exciter Rotor''.
ponent failures. See also repair and diagnosis process for "Low
AC Voltage" in this section.
5. lf transient conditions result in this 5. Consult factory.

alarm condition, the PowerCommand
control interna! set points may need
adjustment.
*CAUTION: WearinQ wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness pluqs.
4-53
TABLE 4-35a. TROUBLESHOOTING ANALOG SIGNALS BETWEEN ANALOG AND DIGITAL
BOARDS
LA.WARNING IMany troubleshooting procedures present hazards that can result in severe personal inju
NOTE: Perform this procedure after you have isolated the problem to either the analog
board (A33) or to the digital board (A32). You must have schematics and wiring
diagrams to identify the various inputs and outputs .
..
*1. Check that the input to the analog board is correct. There are a few ¡,ignals (e.g.: 3PH Ave, Une Freq,
Phase Angle 1 to 3, Lead Lag) that are derived from one or more input slqnals.
1 a. To check the sensor input voltages into the analog board, connect the sender simulator and test the
voltage across the + and - inputs at A33 J1 using harness tool. (This assumes that you have verified
that the harness and the engine interface board is good.)
• lf the input voltage to the analog board i&borrect (refer to Table 4-36), go to step 2.
• lf the input voltage to the analog board is incorrect, check for 12 VDC at A32 J3-20 and 5 VDC at
A32 J3-12. Do this with the analog board connected to the digital (A32).
lf the 12 VDC and 5 VDC voltages are OK, replace the analog board.
lf the 12 VDC añd 5 VDC voltages are not OK, disconnect A32 J3 and recheck for 12 VDC at
A32 J3-20 and 5 VDC at A32 J3-12.
lf the 12 VDC and 5 VDC voltages are now OK, replace the analog board.
lf the 12 VDC and 5 VDC voltages are still not OK, replace the digital board.
1 b. To check the AC inputs into the analog board, drive the PT/CT inputs (voltage or current) and verify
that the input is correct.
• lf the input to the analog board is correct, go to step 2.
• lf the input to the analog board is incorrect, disconnect the ribbon cable at A34 JS and check the volt-
age at A34 JS again (Customer Interface).
lf the voltage is now correct, replace the analog board.
lf the voltage is still not correct, the problem is not on the analog or digital boards.
2. lf the input to the analog board is correct, determine whether the signal is multiplexed (refer to Table
4-36). lf the signal is not multiplexed, go to step 2a. lf the signal is multiplexed, go to step 2b.
2a. This step is for non-multiplexed AC signals. Drive the input to the analog board with an AC source,
and test the signal level out of the analog board. You must calculate what the analog output voltage
should be (Table 4-36), assuming the analog board transfer function is linear.
• lf the signal leve! into the digital board is correct, the problem must be on the digital board. Replace
the digital board.
• lf the signal leve! into the digital board is incorrect, remove the ribbon cable connector at A32 J3, and
check the front panel digital display of the bad analog value.
lf the display reads O, replace the analog board.
lf the display reads a value other than O, replace the digital board.
4-54
TABLE 4-35b. TROUBLESHOOTING ANALOG SIGNALS BETWEEN ANALOG AND
DIGITAL BOARDS
NOTE: Perform this procedure after you have isolated the problem to either the analog
board (A33) or to the digital board (A32). You must have schematics and wiring
diagrams to identify the various inputs and outputs.
2b. This step is for multiplexed signals. Is more than one rnultíplexed signa! reading bad?
• No. lf the input to the analog board is correct and only one mujtiplexed signal is reading bad, replace
the analog board. ··
• Yes. lf more than one multiplexed signa! reading is bad, remove the ribbon cable connector at
A32 J3 and check the front panel digital display of the bad ínputs. lt should read O for ali inputs ex-
cept the temperature inputs (which should read less than 32° F or less than Oº C) and power factor
(which should read "NA").
lf any values read incorrectly, replacs the digital board.
lf they ali read correctly, measure voltaqes on the multipJexer control lines (with A32-J3 discon-
nected, measure from Digital board connector J3). voltaqes should be:
A32-J3-23..:. 3.0 ±0.25 VDC

A32-J3-24: 2.4 ±0.25 VDC
A32-J3-27: 1 .4 ±0.25 VDC
A32-J3-33: 3.0 ±0.25 VDC
A32-J3-34: 3.0 ±0.25 VDC
lf these control (select) line voltages are not correct, replace the digital board.
lf these control (select) line voltages are correct (and the input to the analog board is correct),
reconnect the ribbon cable connector (through harness tool) at A32 J3 and check the 5 VDC
reference at A32 J3-12 and the 12 VDC supply at A32 J3-20.
lf the 5 VDC and the 12 VDC voltages are OK, replace the analog board.
lf the 5 VDC and the 12 VDC voltages are not OK, disconnect A32 J3 and check the
voltages again (measured from Digital board side).
lf the 5 VDC and the 12 VDC voltages are OK with A32 J3 disconnected, replace the
analog board.
lf the 5 VDC and the 12 VDC voltages are not OK with A32 J3 disconnected, replace
the digital board.
*CAUTION: Wearing wrist strap, set S12 to Off and A32 55 to Standby before connecting/disconnecting harness plugs.
4-55
TABLE 4-36. ANALOG CIRCUIT BOARD (A33) INPUTS AND OUTPUTS
Input Name Input Input Signal Output Name 1 Output Output

Connection Range Connectionf Signa! Range
L 1 (O to nominal) J4-24 to J4-28 Oto18VAC L10 (ACH1) J2-4 Oto3.0VOC
L2 (O to nominal) J4-26 to J4-28 Oto18VAC L20 (ACH2) J2-13 Oto 3.0 VDC
L3 (O to nominal) J4-30 to J4-28 Oto18VAC L30 (ACH3) J2-1 Oto 3.0 VDC
3PH ave (ACHO) J2-18 Oto 2.9 VDC
Une freq. (HSl.1) J2-21 0-5V sq wave @ L 1 Hz
CT21 (O to ful! load) J4-33 to J4-34 O to 1.65 VAC C1 fltrd (ACH4) .. J2-3 Oto 1.0VDC
CT22 (O to full load) J4-32 to J4-34 I

O to 1.65 VAC C2 fltrd (ACH5) ,• J2-9 O to 1.0 VDC
CT23 (O to full load) J4-31 to J4-34 O to 1.65 VAC C3 fltrd (ACH6) J2-17 O to 1.0 VDC
C1 (ACH7) J2-7 O to 1.0 VDC
C2 (ACH7) J2-7 O to 1.0 VDC

!
! C3 (ACH7) J2-7 O to 1.0VDC
(1 to 0.8 pf) Phase angle 1 (ACH7)3 J2-7 O to 1.0VDC
(1 to 0.8 pf) Phase angla 2 (ACH7)3 J2-7 O to 1.0VDC
(1 to 0.8 pf) - Phase angla 3 (ACH7)3 J2-7 O to 1.0 VDC
(L1 vsCT21) Lead lag (P2A.1)) 3 J2-29 o or 5 VDC (digital)
Bus L1 (O to nominal) 6 J4-15 to J4-18 Oto18VAC Bus L1 (ACH7) J2-7 Oto 3.0 VDC
Bus L2 (O to nominal) 6 J4-16 to J4-18 Oto 18 VAC Bus L2 (ACH7) J2-7 O to 3.0 VDC
Bus L3 (O to nominal) 6 J4-17 to J4-18 Oto18VAC Bus L3 (ACH7) J2-7 O to 3.0 VDC
Bus freq (HS1 .3) J2-22 0SV sq wave @ Bus L1 Hz
Phase rot (P2A.o)s J2-26 O or 5 VDC (digital)
Bus/gen phase dif (ACH7)5 J2-7 o io s.o voc

Bus/gen phase (HS1 .2)5 J2-19 0-SV 120 Hz O to 100% OC
Synch (ACH7)5 J2-7
Battery voltage J1-31 (+) to J1-30(-) O to 32 VDC Battery voltage (ACH7) J2-7 O to 2.9VDC
Oil press (O to 100 psi) (See note 4l 0.5 to 4.5 VDC Oil press (ACH7) J2-7 0.5 to 4.5 VDC
H20 1 (6 to 230° F) J1-19/20 to J1-17/18 700 to 1800 n H201 (ACH7) J2-7 1.4 to 3.7 VDC
H20 2 (6 to 230º F) J1-15/16 to J1-14/15 700 to 1800 Q H202 (ACH7) J2-7 1.4 to 3.7 VDC
Oil temp (6 to 230° F) J1-11/12 to J1-9/10 100 to 1800 n Oil temp (ACH7) J2-7 1.4 to 3.7 VDC
Exh temp 1 (32 to 1471° F) J1-7/8 to J1-5/6 100 to376Q Exh temp 1 (ACH7) J2-7 0.8 to 3.0 VDC
Exh temp 2 (32 to 1471º F) J1-3/4 to J1-1/2 100 to376Q Exh temp 2 (ACH7) J2-7 0.8 to 3.0 VDC
Notes:
1. AII output signals on ACH7 are multiplexed.
2. AII output voltages on A33 J2 are referenced to ground (J2-15 and J2-16).
3. Must have L 1, L2, L3, CT21 , CT22, and CT23 for these phase angle outputs.
4. J1-24 {SVDC), J1-23 (signal), J1-18 (retum).
5. Must have L1, L2, L3, Bus L1, Bus L2, and Bus L3 for these outputs.
6. L1, L2, and L3 can be O to 180º out of phase with Bus L 1, Bus L2, and Bus L3, respectively.
4-56
TABLE 4-37. PCC FUSES
REFERENCE
LOCATION DESIGNATION RATING FUNCTION
Engine Interface A31-F1 5Amp PCC control B+

Engine Interface A31-F3 5Amp Auxiliary B+ (for panel lights, run and start relays)
Governor Output A38-F1 10Amp Network B+ (to TB1 customer termlnal block)
Module
Governor Output A38-F2 10Amp Switched B+ (to TB1 customer terminal block)
Module I
,.,
Governor Output A38-F3 10Amp Governor B+ (power for governor output module and
Module actuator)
TB-Bat (Engine F1 20Amp Customer B+ (to TB1 customer terminal block)
Harness Assembly)
(
\
-, .
4-57
LOAD SHARING CONTROLS lf the generator set is not sharing load properly, the
TROUBLESHOOTING PROCEDURE following procedure can be used to diagnose and
solve the problem:
The generator set load sharing settings in the Pow-
erCommand control are factory set and normally do 1 . The no load speed and voltage of the generator
not require adjustment. The controls are designad set must be the same as the system bus. Mea-
to cause generator sets in the paralleling system to sure the bus voltage and frequency, and the
share load proportionally, based on the standby rat- generator set voltage and frequency with a true
ings of the generator sets in the system. RMS digital meter. Calibrate the voltage and
current sensing circuits of the control, and
When the system is operating normally, the genera-
make required adjustments to voltage and fre-
tor sets in an isolated bus (not utility/mains paral-
quency to match bus conditions. Adjusting the
leled) paralleling system will share both real (kW)
voltage and frequency after the generator set is
and reactive (amps) load equally, within plus or mi-
paralleleíí to the bus will cause load sharing to
nus 5%. For example, if two 1000 kW generator
be unequal between generator sets.
sets are paralleled and serving a 2000 kW load, the
generator sets should each carry between 950 and 2. Check to make sure that the load sharing con-
1050 kW. trol wiring is properly connected.
In actual practice, load sharing may be much more 3. Check to make sure that each generator set in
precise than plus or minus 5%, but you should nót the system is capable of carrying its rated load.
be concerned about operational problems unless
4. Fine adjustment to the amount of load carried
the load sharing is in error by more than 5%. lf dis-
by each generator set can be made by adjust-
similar generator sets are useq in a system, there
ing the KW BALANCE and KVAR BALANCE
may be load sharing inequities for a short time when
loads are applied, but the steady state load sharing settings under the paralleling setup menu
( Sectíon 5).
should perform to the plus or minus 5% standard.
5. lf the generator sets share load approximately
lf the generator set is paralleled to a utility (mains)
gird, the amount of load on the generator set is pro-
equally, but there is an oscillating load circulat- @)
ing between the generator sets, the governor
grammed into the control in the setup mode or set
gain may be set too high. Reduce the governor
f rom a remote device. lt is NOT a function of the load
gain (see Setup Menu, Sectíon 5).
sharing control system. See Sectíon 5 for more in-
formation on load sharing set-up functions, and util- 6. Consult factory for any other load sharing prob-
ity (mains) paralleling set-up. lems.
4-58
5. Control Service and Calibration
GENERAL CIRCUIT BOARD
This section contains circuit board removal and re-
REMOVALJREPLACEMENT
placement procedures, calibration procedures for No special tools (other than a grounding wrist strap)
the genset control and test procedures for the gen- are required to remove a circuit board from inside
erator and engine components. Refer to the figures the control panel or the accessory box.
included with this information and also the Wiring There are severa! circuit boards that, when re-
Diagrams section when instructed. placed, require you to recalibrate the control panel
functions. Table 5-1 lists the circuit boards and the
Before servicing the PCC, ali settings should be re-
corded. This will enable correct and complete read-
appropriate procedure to perform to recalibrate the
justment of the PCC in the event that all previous en- control panel. The circuit board locations are shown
tries are lost during servicing. in Figure 5-1.
Before you attempt to remove a circuit board, read
the Circuit Board Removal Safety Precautions in
this section.
TABLE 5-1. CONTROL PANEL RECALIBRATION
CIRCUIT BOARD ADJUSTMENT PROCEDURE/PAGE

,. ...
( ..
...
Analog Board (A33) 1. Voltage, Current and PF. Setup and Calibration Menus (Page 5-8)
2. Coolant Temperature L & R
Digital Board (A32) Must recalibrate all values, starting with 1. lnitial Start Setup (Page 5-4).
the lnitial Start Setup procedure. 2. Adjust Menu (Page 5-6).
3. Setup and Calibration Menus (Page
5-8).
PT/CT Board (A36) Voltage, Current and PF. Setup and Calibration Menus (Page 5-8)
Bus PT Module (A39) Voltage Setup and Calibration Menus (Page 5-8)
5-1
85 POWER ON/
STANDBY SWITCH
DISPLAY BOARD @
A35
©> ·· ANALOG BOARD
' A33
GOVERNOR
OUTPUT MODULE
A38
BUS PT MODULE
A39
·. j <: ~~1 .
,,-··-..,
• • 1
~
PT/CTBOARD
O
A36
·1
l:J
VOLTAGE REGULATOR ACCESSORY BOX
OUTPUT MODULE
A37 L.J (HC 4/5)
5-2
Circuit Board Removal Safety Precautions !AWARNING I lgnitian of expiosive battery gases
can cause severe personal injury or death. Arc
To prevent circuit board damage dueto electrostatic ing at battery terminals, light switch ar other
discharge (ESO), a grounding wrist strap must be equipment, flame, pitot lights and sparks can ig
worn when handling circuit boards or socket- nite battery gas. Do not smoke, ar switch
mounted IC's. (The wrist strap does not provide a troúble light ON ar OFF near battery. Discharge
direct short to ground, but is typically rated at static electricity trom bady befare tauching bat
approximately 1 megohm to ground.) teries by first tauching a graunded metal sur
face.
Attach the clip to a non -painted surface of the con-
trol box and place the strap around your wrist before Ventilate battery area befare warking on ar near
handling a circuit board. batteryWear gagglesStap genset and dis
cannect charger before discannecting battery
LA CAUTION IElectrostatic discharge will damage cebtes=Disconnect negative () cable first and
circuit boards. Always wear a graunding wrist recannect last.
strap when handling circuit baards ar socket !A CAUTlON I Discannect battery charger trom AC
maunted IC's. source befare discannecting battery cables.
Otherwise, disconnecting cables can result in
Turn off or remove AC power from the battery char- voltage spikes damaging to DC control circuits
ger and then remove the negative (-) battery cabte of the set ..
from the set starting battery. This is to make sure
that the set will not start while working on it and to LA.WARNING I Accidental starting of the generator
avoid circuit board damage_caused by voltage set can cause severe personal injury ar death.
spikes when removing and replacing circuit board Prevent accidental starting by disconnecting
connectors. the negative () cable from the battery terminal.
(
1,,,
[]] o
7
WRISTSTRAP
NON-PAINTED
SURFACE
GROUND LEAD CLIP
FIGURE 5-2. WRIST STRAP

INITIAL START SETUP MENU
The facing page shows a block representation of STANDBYIPRIME submenu: Use the buttons next
the INITIAL START SETUP menu. to the "íl' .U" symbols to toggle the standby/prime op-
!A CAUTION I Se/ecting this menu resets ali oper tion. Press the button next to the ">>" in the display
ating parameters to the default va/ues for the to move to the model select submenu.
se/ected set. Al/ previous/y se/ected setup and
adjustment settings wi/1 be /ost. Therefore, this
procedure must be performed by technical/y
qua/ified personnel only.
This menu appears on the digital display when the
MODEL se/ect submenu:... Use the buttons next to
PCC has not been set up for use with a generator
set during factory test, or the digital board was re- the "1l" and ".U." symbols to select the correct genera-
placed in the PCC. tor set model number, frequency and power rating.
When this display is showing, you must go through

the lnitial Start Setup menu to select the operating
parameters for the generator set. These include
whether the set will be used for Prime Power or
Standby use, the Model Number of the generator
VOLTAGE SELECT submenu: Use the buttons
set, and its operating frequency and output voltage.
next to the "1l" and ".!.!" symbols to select the correct
These choices must be saved ínto the PCC's read-
only memory befare the PCC will accept changes generator set nominal line-to-line output voltage.
made to other menus.
lf the PCC is already set up to operate with a specific
generator set, this menu will not appear when power
is applied. To reset the control and display the lnitial
Start Setup menu, you can press RESET, MENU, and
PHASE SELECT buttons at the same time.
DELTA/ WYE submenu: Use the buttons next to
lf you choose to do this, the governor/regulator ad- the "ft" and ".!.!" symbols to select the delta or wye op-
justments and the setup options will be reset to the
default settings (including the editable customer
tion.
fault messages). Display calibrations (volts, amps,
PF and coolant temperature) are retained (not reset).
To ensure correct and complete readjustment of the
PCC, it is suggested that ali settings be recorded be-
fore you perform the reset function.
!ACAUTION llmproper setup, calibration, orad SAVE submenu: From the model select submenu,
justments can cause equipment malfunction or press the button next to the ">>" in the display to
damage. Setup, calibration, and adjustment move to the SAVE submenu. Select SAVE to save
must be performed by technical/y qua/ified per your changes. The MAIN MENU will then be dis-
sonnel only. played.
5-4
INITIAL START SETUP
(lt can be invoked by simultaneously pressing
the Reset, Menu, and Phase Select keys.)
O STANDBY/PRIME O
D< .U.1l >> >•
O<
D<
MODEL
(kw mmitt f@Q) > > >. O I
O<
D<
VOLTAGE SELECT
(vac) L-L VAC >> >.
o
!
o un DELTA/WYE o
D< >> >.
('..: ..
o
.< SAVE >> >O
o D> l~B
! TO LOOP BACK & CHECK:
0 0
B> 1->
1 ......-
1
.....0--<-I U 1l
STANDBY/PRIME
>>
1 - - - - lndicates "OR'' Condition I
5-5
ADJUST MENU
The ADJUST submenus permit adjustment of the VOLTAGE submenu: This is the first submenu.
output voltage and frequency and the start and stop Use the buttons next to the "ll" and ".()." symbols to
delay times of the generator set. adjust output voltage ± 5%.
The complete calibration procedure is described in
the Calibration Procedure in this section. FREQUENCY submenu: From the VOLTAGEsub-
menu, press the button next to the ">>" in the dis-
The facing page shows a block representation of play to move to the FREQUENCY submenu. Use
the ADJUST menu. lf you press the button next to the buttons nsxt to the "11'" and ".U." symbols to adjust
the word "ADJUST" in the Main menu, the VOLT- output frequency '± 5%.
AGE ADJUST submenu will appear.
As shown in the diagram, the ADJUST menu has START DELA Y submenu: This dela y applies only
five submenus, including a save/exit procedure. to remote starting in the Auto mode. From the FRE-
QUENCY submenu, press the button next to the
Voltage and frequency can be adjusted only whe.h ">>" in the display to move to the START DELAY
the generator set is running under normal operating submenu. -Use the buttons next to the "'ft" and ".()."
parameters (not in idle mode). For example, if volt-
symbols to set the start delay. The start delay ad-
age adjustment is selected when the set is in ldle
mode or not running, the digital display will be:
justment range is O to 300 seconds.
"lf VOLTAGE" STOP DELA Y submenu: This delay applies only

".U. N/A >>" to remote stopping in the Auto mode. From the
START DELAY submenu, press the button next to
the ">>" in the display to move to the STOP DELAY
submenu. Use the buttons next to the "1l'" and ".U."
symbols to set the stop delay. The stop delay ad-
justment range is O to 600 seconds.
IDLE SPEED submenu: From the STOP DELAY

submenu, press the button next to the ">>" in the
display to move to the IDLE SPEED submenu. Use
the buttons next to the "11'" and ".U." symbols to set the
idle speed. The idle speed adjustment range is 800
RPM ±100 RPM. (Default value is 800 RPM.)
The idle speed can be adjusted only when the gener-
ator set is running in the idle mode. When not in idle
mode, N/A is displayed in RPM field.
SAVE/EXIT submenu: From the STOP DELAY

submenu, press the button next to the ">>" in the
display to move to the SAVE/EXIT submenu. Select
SAVE to save your changes. At the CHANGES
SAVED submenu, select EXIT to return to the main
menu.
lf you select SAVE, the adjustments will be retained
after shutdown, and will be in effect when the set is
restarted. Jf you select EXIT without saving first, the
adjustments will remain in effect until the genset is
shut down, but will be reset (and will not be in effect)
when the set is restarted.
5-6
I ADJUST I
.<
0< ENGINE
ADJUST
GEN
>>
>0
>D
0< 1l' VOLTAGE o

O< il >> >.
0< 1l' FREQUENCY O I

O< il >> >•
0<
O<
1l'
il
START DELAY
SEC >> >. O
0< 11' STOP DELAY O

O< il SEC >> .:-•
O< 1l' IDLE SPEED o

O< u. RPM >> >.
(,
\·.
.< SAVE o CHANGES SAVED ENGINE GEN >D

O< EXIT >> • ll<
1
EXIT >> > < ADJUST >> >D
1
1
.o CHANGES SAVED 1l' VOLTAGE o

-t1< EXIT >> > < il >> >O
D> l>B D< ADJUST >> l:B
O> I>~ O< il >> l>B
5-7
SETUP AND CALIBRATION MENUS The facing page shows a block representation of
the VERSION submenus. lf you press the button
The setup and calibration menus allow you to cali- next to the ">>" in the Main menu display, the VER-
brate the PCC with the reading from a calibrated SION/SETUP/CAL menu will appear.
meter. There are tour setup and calibration menus
that are selectable from the SETUP/CAL menu: IA. CAUTION Ilmproper calibration or adjustment
• VERSION ANO DISPLAYS of the PowerCommand control can cause
equipment malfunction or damage. Calibration
• METERS and adjustment must be performed by techni
• GOVERNOR/REGULATOR cal/y qualified personnel only.
• SETUP
VERSIONsubmenu: lf you select VERSION, the
These tour menus are intended for qualified service display wi)I stíow the generator set model number,
personnel only. For this reason, a three-digit access frequency, and kW rating, and the date and version
code must be entered before you can proceed to of the operating software.
those menus.
To display the generator set configuration options,
ENTER CODE submenu: press the button next to the ">>" in the submenu that
The access code for your PCC is: 5 7 4. displays the model number, frequency and etc. This
menu provídes the following information:
To enter the code:
1. Press the button next to the."11" to increment the • Generator set voltage
first digit.
• WYE or DELTA
2. Press the button next to the ">>" to select the
second digit. • Standby or Prime
3. Press the button next to the "11" to increment the
second digit.
• Parallel or Single (·--:-
.:
··.,.)
..
........ :.,···
/
4. Press the button next to the ">>" to select the HISTORY: From the VERSION, SETUP/CAL
third digit. menu, press the button next to the ">>" in the dis-
play to move to the HISTORY submenu. Press the
5. Press the button next to the "11" to increment the button next to "HISTORY" to display the last (latest)
third digit. recorded error message.
6. Press the button next to the ">>" to proceed to
the DISPLAYS/METERS submenu. (Pro- The software will record (save) up to 20 error mes-
vided, of course, that you have correctly en- sages. The last error detected will always be dis-
tered the access code.) played first. As each new error is detectad, the old-
The following sub-sections describe how to select est error recorded after 20 will be deleted.
and make changes to the setup and calibration me-
nus and save the changes made to these menus. To view the generator set runtime at which the error
occurred and to scroll through the remaining re-
Version Menu corded errors, press the button next to the ">>" in
the error message menu to display the RUNTIME,
The VERSION menu allows you to verify the model NEWER/OLDER menu.
number and frequency of the generator set, the
date and version of the operating software and gen- The buttons next to NEWER and OLDER are used
erator set configuration options. From the VER- to scroll up and down through the error messages.
SION menu you can also review a History file, that For example, pressing OLDER will display the next
can contain up to 20 error messages. oldest recorded error message. When pressing
NEWER and the last (newest) error message is dis-
The complete calibration procedure is described in played, or OLDER and oldest error is displayed, the
the Calibration Procedure in this section. display will return to the HISTORY menu.
5-8
I VERSION MENUS I
O< ENGINE GEN >O

0< ADJUST >> >.
I BACK I
.<
O<
VERSION
SETUP/CAL
<<
>>
_>O __ O -1 (kW)
>lj , tf ___
1
(model) (hz) <<
V:_._>> 1:~
I BACK I
1
1
1 I
:_ O -1 (kW) (model) !bzl < < l>O o V

C1 V:_._>> >. o __ <~
DISPLAY$ VOLTAGE & GEN

SET CONFIGURATION
O< VERSION << >. O< ENGINE, GEN >O
O< SETUP/CAL >> >O 0< ADJUST >> >0
I BACK I
O<
O<
VERSION
SETUP/CAL
<<
>> ;w
>O
-
·,-cr ·
1
O~
DISPLAYS ERROR
MESSAGE AND CODE
O< VEAS ION << >O •• < HISTORY << o

.< SETUP/CAL >> >O - t:J"- >> >.
O< o o o
+
ENTER CODE RUNTIME
O< v. --- >> >. .< NEWER OLDER >.
, ____
1 _.,_ ___
REFER TO FOLLOWING
MENUS IN THIS SECTION
5-9
Displays Menu bols to calibrate the selected voltage, current, PF or
coolant temperature reading. Press the button next
The DISPLAYS submenus permit calibration of the to the ">>" in the display to move to the next adjust-
digital voltage, current, power factor (PF) and cool- ment.
ant temperature displays. Calibration is accom-
plished by using this section of the menu software to "VOLTS L 12," "VOLTS L23," and "VOLTS L31" refer
adjust the display so that it matches the reading tak- to voltages measured from L 1 to L2, L2 to L3, and
en on an accurate, recently calibrated meter. L3 to L1, respectively. Note that the system includes
bus voltage reading provisions ("BUS VOLTS L 12,"
The complete calibration procedure is described in "BUS VOLTS L23," and "BUS VOLTS L31"), which
the Calibration Procedure in this section. must be calibrated separately from the generator
set voltage settings.
The facing page shows a block representation of
the DISPLAYS submenus, which is the first of tour "PF1, PF2 and PF3" will display N/A when the gen-
SETUP/CAL menus. lf you press the button next to erator set is not runnínq.
the ">>" in the Main menu display, the VERSION/ "COOLANT TEMP R" will display "N/A'' if the genset
SETUP/CAL menu will appear. has only one sensor. To calibrate coolant tempera-
ture display, a precislon resistor (provided in the en-
!A CAUTION ! lmproper calibration or adjustment gine sensor tool) must be temporally substituted for
of the PowerCommand control can cause the temperature sender. Refer to Calibration Proce
equipment malfunction or damage. Calibratian dure in this section.
and adjustment must be performed by tecbni
cally qua/ified personnel only. SAVEIEX/t submenu: From the AMPS L3 subme-
nu, press the button next to the ">>" in the display to
DISPLAYSsubmenus: The DlSPLAYS submenus move to the SAVE/EXIT submenu. Select SAVE to
are intended for qualified service personnel only. save your changes. At the CHANGES SAVED sub-
For this reason, a three-digit access code must be menu, select EXIT to return to the DISPLAYS/ME-
entered before you can proceed to those menus. TERS submenu.
Select SETUP/CAL. The display will show the EN- lf you select SAVE, the adjustments will be retained ftt.:.
Q· .)
1
TER CODE submenu. Enter access code (574) as after shutdown, and will be in effect when the set is
restarted. lf you select EXIT without saving first, the · º''
previously described in this section.
adjustments will remain in effect until the genset is
Select DISPLAYS to proceed to the DISPLAYS sub- shut down, but will be reset (and wlll not be in effect)
menus. Use the buttons next to the "1l" and ".U." sym- when the set is restarted.
5-10
I DISPLAYS MENU I
O< VERSION << >O
.< SETUP/CAL >> >O O< ít AMPS L3 o
O< .u. >> >.
O< ENTER CODE o
O< .u. --- >> >. O< 1t PF1 o
O< .u. >> >.
.< DISPLAYCAL << >O
O< METERS >> >O O< 1t PF2 o
O< .u. >> >.
O< 1t VOLTS L12 o
D< .u. >> >. O< 1t PF3 o
O< .u. >> >.
O< ft VOLTS L23 o O< 1t COOLANT TEMP L o

O< .u. >> >.
O< .u. -. º F >> >.
O< 1l
O< .u.
VOLTS L31
>> .>.o O< 1t
O> >.
o
O< ft AMPS L1 o
O< Jj. >> >. O< ít BUS VOLTS L12 o
e·
",,'
O< Jj. >> >.
O< 1l AMPS L2 o
O< il >> >. O< ít BUS VOLTS L23 o
O< .u. >> >.
O< 1t BUS VOLTS L31 o

O< Jj. >> >.
0<1 SAVE VOLTS L12

O< EXIT >> I>~ D< ftJJ.
O<'
>> !>B
o o O<
·<1
1>8 << >O
SAVE CHANGES SAVED DISPLAY CAL
O< EXIT >> r 11< EXIT >> >O D< METERS >> >0
•
1
1
:o CHANGES SAVED ft VOLTS L12 o

- t:I< EXIT >> > < il >> >O
O< SAVE DISPLAY CAL << >O

.< EXIT >> > < METERS >> >O
5-11
Meters Menu Select SETUP/CAL. The display will show the EN-
TER CODE submenu. Enter access code (574) as
The METERS submenus permit calibration of the previously described in this section.
control's analog meters to match the calibrated digi-
Select METERS to proceed to the METERS sub-
tal values. (Calibrate the digital display before cali-
menus. Use the buttons next to the "ll" and ".U." sym-
brating the analog meters.) This calibration is ac-
bols to calibrate the selected meter to match the
complished by using this section of the menu soft-
"CAL TO:" value provided on the digital display.
ware to adjust the selected meter reading so that it
Press the button next to the ">>" in the display to
matches the reading provided on the digital display.
move to the next calibration.
The complete calibration procedure is described in "VOLT METER" and "% AMPERES" calibration ret-
the Calibration Procedure in this section. erence the phase that is indicated on the phase
selection LE9's.
The facing page shows a block representation of
NOTE: The o/o AMPERES meter scale is based on a 0.8
the METERS submenus, which is the second of
power factor. (100% of rated current is full load cur-
tour SETUP/CAL menus. lf you press the button rent at 0.8 PF.) ·
next to the ">>" in the Main menu display, the VER-
SION/SETUP/CAL submenu will appear. SAVEIEXITsubmenu: From the HERTZ subme-
'
nu, press the button next to the ">>" in the display to
LA CAUTION I lmproper calibration or eajustment move to the SAVE/EXIT submenu. Select SAVE to
of the PowerCommand control can cause save your changes. At the CHANGES SAVED sub-
equipment malfunction or damage. Calibration menu, select EXIT to return to the DISPLAYS/ME-
and adjustment must be performed by techni TERS submenu.
cally qualified personnel only.
lf you select SAVE, the adjustments will be retained
METERS submenu: The METERS submenus are restarted. lf you select EXIT without saving first, the
intended for qualified service personnel only. For adjustments will !emain in effect ~ntil the !;!enset is @\:,1
this reason, a three-digit access code must be en- shut down, but w1II be reset (and will not be m effect) \(_,,/
tered before you can proceed to those menus. when the set is restarted. -
5-12
f METERS MENU I
O< VERSION << >O
.< SETUP/CAL >> >O
O< ENTER CODE D

D< --- •1
>> >D
O< DISPLAY CAL << ENTER CODE O
:- - - - - - - - - - - - - -cr< METERS >> > < .__ 1t - - - >> _, >O
O< DISPLAY CAL << >O I
.< METERS >> >O
0< 1'tAC VOLTS O

0< .U CAL TO: >> >.
0< 1t % AMPERES O
0< .U CAL TO: >> >.
O< n %LOAD o
O< .u CAL TO: >> >.
( .. •
v :
O< 1l' HERTZ o

O< .u CAL TO: >> >.
.< SAVE o o CHANGES SAVED o O< DISPLAY CAL << >O

O< EXIT >> >'ti-,-.<- EXIT >> >O < METERS >> >O
1
•o CHANGES SAVED 11' ACVOLTS o

... C1< EXIT >> > < .u CAL TO: >> >O
O< SAVE DISPLAY CAL << >O

.< EXIT >> > < METERS >> >D
D> ~>• O< . . _.U_c_A_L_T_o_:-==-->_>__.
>D
5-13
Governor I Regulator Menu GOV GAIN: lf the gain adjustment is set too high,
engine speed will "hunt'' or oscillate. lf gain is set too
low, the engine will respond too slowly to changes in
load-overspeed may result.
The GOV/REG submenus permit adjustment of
voltage regulator and governor parameters. For paralleling applications the default value for gov-
ernor gain is 70.
AII GOV/REG menu values, except for REG VHZ and
GOV RAMP, will display "100%". The expression GOV INTEGRAL: lf this adjustment is set too low,
"100%" represents the factory setting (default value) the engine will respond too slowly to changes in
for the selected set. When increasing or decreasing load. lf it is set too high, engine response will be un-
the value, you are increasing or decreasing from the stable.
factory default value. (For example, entering "200%"
will double the value; "50%" will decrease the value GOV RAMP:·This adjustment sets the time for the
by one half.) engine to rarñp to.full operating speed. This adjust-
ment applies only to set start up and does not affect
Default values are preset by the factory. Due to site the transient response. (Adjustable range: O
variables, the default values may need to be adjusted through 1 O seconds.)
to attain peak performance.
REG GAIN: lf the gain adjustment is set too high,
The facing page shows a block representation <:Íf output voltage will be unstable. lf gain is set too low,
the GOV/REG submenus, which is the third of tour the output voltage will respond sluggishly to
SETUP/CAL menus. lf you press the button next to changes in load-overshoot may result.
the ">>" in the Main menu display, the VERSION/
REG INTEGRAL: lf this adjustment is set too low,
SETUP/CAL submenu will appear,
the output voltage will respond sluggishly to
LA CAUTION I lmproper calíbration or adjustment changes in load, resulting in a droop-type response
of the PowerCommand control can cause lf it is set too high, output voltage will be unstable.
equipment malfunction or damage. Calibration REG VHZ: This underfrequency roll-off adjustment
and adjustment must be performed by techni controls how much excitation is reduced in re-
cally qualified personnel only. sponse to underfrequency. lf the value is set too
low, excitation will be cut too fast, and the voltage
GOVIREG submenu: The GOV/REG submenus
will drop too much. lf set too high, the generator set
are intended for qualified service personnel only.
may not be able to pick up rated load in one step.
For this reason, a three-digit access code must be
(Adjustable range: 1 through 50; normal range 7
entered before you can proceed to those menus.
through 21.)
Select SETUP/CAL. The display will show the EN- SAVE/EXIT submenu: From the REG VHZ subme-
TER CODE submenu. Enter the access code (574) nu, press the button next to the ">>" in the display to
as previously described in this section. move to the SAVE/EXIT submenu. Select SAVE to
From the DISPLAYS/METERS submenu, press the save your changes. At the CHANGES SAVED sub-
button next to the ">>" in the display to move to the menu, select EXIT to return to the DISPLAYS/ME-
GOV/REG/SETUP submenu. Select GOV/REG to TERS submenu.
proceed to the GOV/REG submenus. lf you select SAVE, the adjustments will be retained
Use the buttons next to the "1l" and "JJ." symbols to restarted. lf you select EXIT without saving first, the
adjust the selected governor and regulator parame- adjustments will remain in effect until the genset is
ters. Press the button next to the ">>" in the display shut down, but will be reset (and will not be in effect)
to move to the next adjustment. when the set is restarted.
5-14
I GOVERNOR/REGULATOR MENU I
.<
0< VERSION
SETUP/CAL
<<
>>
>0
>O
O<
O<
ENTER CODE
U _ _ _ >>
O
>D
O< DISPLAY CAL << >O

O< METERS >> >.
O< GOV/REG << >. O< DISPLAY CAL << >O

o PARALLEL SETUP >O O< METERS >> >O
I
.< GOV / REG << >O

o SETUP >O
O< GOVGAIN o
D< % >> >.
O<
O<
GOV INTEGRAL
% >> . . .o
O< GOVRAMP o
O< >> >.
(•
,'
O< REG GAIN o

O< % >> >.
O< REG INTEGRAL o

O< % >> >.
O< REG VHZ o

O< >> >.
.< SAVE o o CHANGES SAVED o O< DISPLAY CAL << >O

O< EXIT >> >tl-·-·<
•
EXIT >> >O O< METERS >> >O
·o CHANGES SAVED ít GOVGAIN o

·-cr< EXIT >> > > >O
<< >D
>> >> >D
D<I SAVE GOVGAIN

D< EXIT %
5-15
Setup Menu
The SETUP submenus permít selectíon of several From the DISPLAYS/METERS submenu, press the
configuration and operation options. Setup option button next to the ">>" in the display to move to the
defaults are listed in Table 5-2. GOV/REG/SETUP submenu. Select SETUP to
proceed to the SETUP submenus.
Use the buttons next to the "'ft.!J!' symbols to toggle
TABLE 5-2. SETUP DEFAULTS
the setup options. Press the button next to the ">>"
SELECTION DEFAULT in the display to move to the next adjustment.
CYCLE CRANK ON lf the cycle cranking option is selected, the menu will
SYSTEM OF UNITS IMPERIAL prompt for the selection of cycle number (3, 4, or 5)
*CUSTOMER FAULT 1 WARN and crank a~d rest times (7 to 20 seconds).
*GRNDFAULT WARN ..
*DAYTANK WARN An in-line engine that has the EGT (exhaust gas
*HIGH GEN TEMP WARN temp.) option, select "YES" for EGT L and 'NO" for
EGTL NO EGTR.
EGTR NO
LOWCOOLANT SHTD Edit Customer Fault Message(s): The tour cus-
!
LANGUAGE ENGLISH ! tomer fault messages shown in Table 2-1 are edit-
able. To enter the desired customer fault message,
* Default display messages for customer faults 1 press the button next to the ">>" in the display to dis-
through 4. To change the customer fault mes- play the customer fault message to be changed.
sage(s), to display the desirea fault condition, refer Press the upper-left button by the display to select
to heading Edit Customer Fault Messages. the desired character. Press the upper-right button
to move the cursor to the next character to be
The facing page shows a block representation of changed. (Holding this button down will return the
the SETUP submenus, which is the fourth of four cursor to the first position.) The message can be up
S ETU P/CAL menus. lf you press the button next to to 16 characters. The fault code number will remain
the ">>" ín the Main menu display, the VERSION/ the same, this code cannot be edited.
SETUP/CAL submenu will appear.
lf these messages are changed, you should note
LA CAUTION I lmproper calibration or adjustment these changes in the Troub/eshootingsection of the
Operator's manual for this generator set.
of the PowerCommand control can cause
equipment malfunction or damage. Calibration SAVEIEXITsubmenu: From the LANGUAGE sub-
and adjustment must be performed by techni menu, press the button next to the ">>" in the dis-
ca/ly qualified personnel only. play to move to the SAVE/EXIT submenu. Select
SAVE to save your changes. At the CHANGES
SETUP submenu: The SETUP submenus are in- SAVED submenu, select EXIT to return to the DIS-
tended for qualified service personnel only. For this PLAYS/METERS submenu.
reason, a three-digit access code must be entered
before you can proceed to those menus. lf you select SAVE, the adjustments will be retained
restarted. lf you select EXIT without saving first, the
Select SETUP/CAL. The display will show the EN- adjustments will remain in effect until the genset is
TER CODE submenu. Enter the access code (574) shut down, but will be reset (and will not be in effect)
as previously described in this section. when the set is restarted.
5-16
I SETUP MENU I
O< VERSION << >O
.< SETUP/CAL >> >O
O< ENTER CODE o IF CYCLE CRANK ON :

O< --- >> >O

#OFCYCLE S
(3, 4, 5 or 6) >>
o
>.
METERS >>
O< >.
o RES ET MENU >O
O< GOV I REG << >O

O< 1l CRANK TIME
Jj. (7 to 20)
- SEG n
PARALLEL SETUP D< >> >.
O< >.
o RESET MENU >D
o O> >.-- O<
o rESET
(7 to 20) >>
MENU
>.
>D
------------------
D SYSTEM OF UNITS D
O< 1l Jj. METor IMP>> >.
D< CUSTOMEA FAULT1 >O

o 1l Jj.
EGTL
YES/ NO
D
O< >> >.
D< 1l!J. SHTD / WARN >> >.
( O< GROUND FAULT >o D

1lU
EGTR
YES/ NO >>
o
D< 1l U SHTD / WARN >> >. D< >.
D< RUPTURE BASIN >D D LOW COOLANT LVL D

O< 'fl'Jj. SHTD / WARN >> >. O< nu SHTD /WARN >> >.
O< HIGH GEN TEMP >o 1l LANGUAGE

D< D
D< 1l !J. SHTD / WARN >> >. D< Jj. >> >.
.<
D<
SAVE
EXIT >> ;o
D D
··-iii<
1
CHANGES SAVED
EXIT >>
D
>D
D<
D<
DISPLAY CAL
METE AS
<<
>>
>D
>D
•
:_o_ CHANGES SAVED
EXIT
D D
'fl'U
CYCLE CRANK
ON /OFF
o
D< >> >. D< >> >O
D< SAVE D D< DISPLAY CAL << >O

.< EXIT >> >D D< METE AS >> >D
D< SAVE o o CYCLE CRANK D

D< EXIT >> >. D< 'fl'Jj. ON /OFF >> >D
1---- lndicates "OR'' Condition j
5-17
Paralleling Setup Menu set at 110% of the generator set base load setting.
When the load govern signa! is between 1 VDC and
4.5 VDC the control will operate the generator set at
The PARALLELING SETUP submenus adjust the
a load level which is determined by a linear relation-
control parameters for generator set protection,
ship between the kW reference and the load govern
synchronizing and load sharing for both isolated
signal.
bus and utility (mains) paralleling applications. Util-
ity (mains) parallel applications may require adjust- ISOLATED BUS ADJUSTMENTS
ment of both the "isolated bus" and "utility'' branch
submenus. SYNC TIME LIMIT:This parameter adjusts the time
delay in seconds before the Fail To Synchronize
The sync check (permissive) function ís operational alarm will operate.
in both automatic and manual (RUN) modes. The
control will make sure that the generator set is at PWR LIMl'T (%): Adjusts the reverse power set
proper voltage, within the defined sync check win- point. For PowerCommand generator sets, a typical
dow for the defined period of time and that phase set point is 10-15%.
rotation is correct. When ali criteria are met, the par-
alleling breaker is closed automatically by the con- PWR LIMIT (TIME): Adjusts the reverse power
trol (auto mode), or by operation of the breaker function time delay. A typical time delay which is
close switch by the operator (run mode). i
suitable for PowerCommand generator sets is 3
seconds. ·.
The synchronizing function of the PowerCommand Lower reverse power set points can result in nuí-
control is enabled when the control has brought the sance reverse power shutdown faults.
generator set to rated speed and voltage, and has
sensed that bus voltage is available. The control au- PERM WINPHASE: Adjusts the width of the per-
tomatically adjusts the generator set speed and missive (sync-check) acceptance window. The ad-
voltage to match the bus frequency and voltage. justment range is from five to _tw~nty electrical de- (''\
The control can force the generator set to match a grees. Recommended set point rs 20 degrees for \;¿,/
bus voltage and frequency in a range of minus 40% isolated bus applications, and 15 degrees for utility
to plus 10% of normal bus conditions. When the (mains) paralleling applications.
paralleling breaker has closed, the control will bring
the generator set back to normal voltage and fre- PERM WINTIME: Adjusts the time period (in sec-
quency. onds) for which the generator set must be synchro-
nized with the system bus, before a breaker clase
When the generator set is paralleled to another signa! is issued by the PowerCommand control.
generator set, the control provides automatic load Available range is 0.5 to 5 seconds. Recommended
sharing functions for both real (kW) and reactive value for PowerCommand generator sets is 0.5
(kVAR) loads. Load sharing is proportional between seconds for isolated bus applications.
generator sets based on their standby ratings. lf two
generator sets of different sizes are paralleled, they Adjusting the control for a smaller sync-check win-
dow or longer time delay will cause synchronizing
will assume the same percentage of the system
time to be extended.
load automatically. This can easily be verified on the
analog % Load meters on the front of the Power-
SYNC GAIN: The sync gain adjustment controls
Command control panel.
how quickly the governor will respond to try to mini-
mize the bus/generator phase difference. lncreas-
When the utility paralleling mode is enabled and the ing the gain speeds up the response. lf the gain is
generator set paralleling breaker is closed, the gen- too high instability can result.
erator set will assume load based on externa! ana-
log input signal. The input signal must be calibrated SYNC INTEGRAL: The sync integral adjustment
from 0-5 VDC. When the signal is at 0.5 to 1 VDC, controls the rate at which the governor will be ad-
the control wíll operate the generator at no load in justed to try to minimize the bus/generator phase
parallel with the utility (mains) source. At 4.5 VDC difference. The lower the number the slower the re-
and greater, the control will operate the generator sponse.
5-18
I PARALLELING SETUP MENU I
O< VERSION << >O
.< SETUP/CAL >> >D
O< ENTER CODE o

O< >> >D
---
O< METERS >> >.
I
O< GOV / REG << >O

.< PARALLEL SETUP >O
O< ISO BUS << >O

.< UTILITY o I B (CONTINUED) 1
.< ISO BUS << >O

O< UTILITY o
D< 1t SYNC TIME LMT o
O< J.l 120 >> >.
('.;:..
O< fi -PWR LMT (%) o
O< J.l 10 >> >.
D< fi -PWR LMT (TIME) o

O< J.l 3 >> >.
D< fi PERM WIN-PHASE o

O< J.l 20 >> >.
D< 1t PERM WIN-TIME o

O< J.l .5 >> >•
D< fi SYNCGAIN o
O< J.l 95 >> >.
D< 1t SYNC INTEGRAL o

O< J.l 12 >> >.
A (CONTINUED)

5-19
ISOLATED BUS ADJUSTMENTS (Cont.) (A) ator set. This also allows modification of the rate of
KW BALANCE: This function adjusts the kW load load assumption on transient load change.
sharing function of the generator set. Before adjust- 1 ST START FAIL: Time dela y in seconds after a
ing this value, all generator set calibratíons should signal from the first start master is not sensed by the
be performed. lf the total load on the system is not PCC that a FIRST START FAIL warning is dis-
shared proportionately, the kW Balance can be played.
used to adjust the generator set for more precise RAMP UNLD TIME: When a load demand stop in-
load sharing. lncreasing the kW Balance value will put is sensed the load is ramped down from the
cause the generator set to reduce the percentage of present load level on the set to the ramp unload lev-
the total kW load on that set. el in the time specified in seconds.
KVAR BALANCE: This function adjusts the kVAR RAMP UNLD LEVEL: The load demand ramp un-
load sharing function of the generator set. Before load function _vvill ramp the load down from the pres-
adjusting this value, all generator set calibrations ent level on t.,he set to this level before opening the
should be performed. lf the total load on the system set circuit breake'r. Value shown is in % of genset
is not shared proportionately, the kVAR balance can standby rating.
be used to adjust the generator set for more precise RAMP LOAD TIME: When the load demand stop
load sharing. lncreasing the kVAR balance value signal is removed the load is ramped from OkW to
will cause the generator set to reduce the percent- the load share level in the specified time after the
age of the total kVAR load on that set. · circuit breaker closes.
KW GAIN: Adjusts the rate of change of kW load on LOSS FIELD (LOSS OF EXCITATION) TIME and
the generator set. With a constant load on the sys- LEVEL: Adjusts the time delay on the Loss of Ex-
tem, if the generator set load is constantly chang- citation fault. Generator sets with version 1.07 and
ing, reduce the gain adjustmeTlt on the generator higher (9-26-96 and later) firmware may be ad-
set. This also allows modification of the rate of load justed for time delay on this condition. the default
assumption on transient load change. value is 2 seconds.
KVAR GAIN: Adjusts the rate of change of kVAR Generator sets with version 2.0 and higher firmware
load on the generator set. With a constant load on allow adjustment of both time delay and reverse ~;'.>,
(·.:· ..'·.':·:.}
the system, if the generator set load is constantly VAR set point. Default values are 1 o seconds and <:. . .>····'
changing, reduce the gain adjustment on the gener- 20%.
5-20
I PARALLELING SETUP MENU (Cont.) 1
A (CONTINUED)
O< 11' l<:N BALANCE o

O< .u. 165 + _% >> >.
O< 11' KVAR BALANCE o

O< .u. o+ - % >> >. I
O< 11' l<:N GAIN o

O> >.
O< 11' KVAR GAIN o

O< .u. 300 >> >.
O< 'fl' -1 ST START FAIL o

O< .u. 10 >> >.
O< 1l RAMP UNLD TIME o

O> >.
O< 11' RAMP UNLD LEVEL o

O> >.
O< 1l RAMP LOAD TIME o

O< .u. 10 >> >.
O< 1l LOSS FIELD TIME o

O< .u. 2 >> >.
O< 1l LOSS FLD LEVEL o

O> >.
O< SAVE o O< DISPLAY CAL << >O

.< EXIT >> >O O< METERS >> >O
O< SAVE o O< GOV/REG << >O

O< EXIT >> >. < PARALLEL SETUP >O
5-21
UTILITY (MAINS) ADJUSTMENTS (B) erator set has closed to the system bus when utility
BASE LOAD (%): Controls the maxímum kW load (mains) paralleled. Decreasing this value will result
level that the generator set will operate at when par- in slower loading of the generator set.
alleled with the utility (mains). The value shown indi- KVAR INTEGRAL: The kVAR integral adjustment
cates the steady state load on the generator as a is used to control the response of the generator set
percent of the generator set standby rating. to large load changes when utility (mains) paral-
Check generator set ratings for maximum load level leled. Use of a higher integral value will result in
at which the generator set should operate when slower response and reduced kVAR overshoot on
paralleled with the utility (maíns). Extended opera- load assumption or rejection, especíally on large
i,¡;
tion at load levels in excess of the generator set rat- system load changes. Decreased integral values
ing can cause abnormal engine wear or premature will also result in slower load acquisition and rejec-
engine faílure. tíon.
PF LEVEL: Adjusts the power factor that the gener- RAMP LOAP TIME: This is the ramp time from
ator set will run at when paralleled to the utility present set load to level determined by the load set
(mains). Recommended setting is 1.0. analog input. This is active when the control fírst en-
KW GOVERN GAIN: Controls the rate that the gen- ters the load govern mode.
erator set kW load is increased after the generator RAMP UNLD TIME: This is the ramp time from
set has closed to the system bus when utility present set load to the O kW. This ramp is active
(maíns) paralleled. Decreasíng this value wíll result when the load set analog input is less than 0.5 volts.
in slower loading of the generator set. MULTIPLEISINGLE: This selection modifies the se-
KW INTEGRAL: The kW integral adjustment is quence of operation and functions of the inputs and
used to control the response of the generator set to outputs of the control on TB 1 to allow for application
large load changes when utility' (mains) paralleled. of the control in multiple generator set applications
Use of a higher integral value will result in slower re- ("Multiple" selection), where generator sets are par-
sponse, and reduced kW overshoot on load as- alleled to each other and may also be paralleled to a
sumption or rejection, especially on large system utility (mains) service; or for applications where a
load changes. Decreased integral values will also single generator set is used with a breaker pair for
result in slower load acquisition and rejection. closed transition power transfer functions ("Single"
KVAR GOVERN GAIN: Controls the rate that the selection). See Table53for a description of the op-
generator set kVAR load is increased after the generation and use of TB1-51 input.
5-22
Multiple - In the MULTIPLE configuration, the con- tíons in the system.
trol is set up for proper operation in a system where U pon receiving a start signa!, the gensets automati-
the gensets are configured similar to that shown in cally start, select one generator set in the system to
Figure 5-3 or 5-4. In these illustrations, 52-Gn are be the first one to close to the bus using the Fírst
the paralleling circuit breakers and 52-Fn are feeder Start Sensor system, synchronize, and load share.
circuit breakers that provide generator set power to Upon receiving a signal to the control that the gen-
load transfer devices. 52-U is a utility (mains) circuit erator sets are closed to the utility (mains), the gen-
breaker and 52-GM is a generator bus main break- erator sets automatically ramp to their preset base
er. 52-U and 52-GM provide power transfer tune- load level.
..
B~SVOLT
SENSE
52-G1 52·G2 52-G3
52-F1 52-F1 52-F1

•
.
SWITCHGEAR
------ ------- -------·
TO LOADS
( ...
-." FIGURE 5-3. TYPICAL MULTIPLE CONFIGURATION
BUS VOLT
SENSE
FROM
UTILITY (MAINS)
52-G1 52-G2 52-G3
52-GM 52-U
TO LOADS
52-F1 52-F1 52-F1
, SWITCHGEAR
------------------------------------
• ------ ------- -------
TO LOADS
FIGURE 5-4. TYPICAL MULTIPLE CONFIGURATION
5-23
Single - The SINGLE configuration (limited to When utility (mains) power returns, the remote de-
ONLY the electrical configuration shown ín Figure vice tums on the synchronizer in the PCC, the PCC
5-5) allows for incorporation of a single PowerCom- synchronizes the genset-to-utility (mains) service,
mand generator set in a power system that provides and the remote device closes the utility (mains)
load transfer functions and various utility paralleling breaker (52-U). When the PCC senses that 52-U is
functions. In the SINGLE configuration, Power- closed, it checks the voltage on the externa! load set
Command provides all the generator set control terminals (TB 1-59 and 60) and ramps to the corn-
functions including synchronizing, load govern (im- manded load level. The remete device control sys-
port/export control and var/PF control), and genset tem determines when to open the genset breaker
breaker control functions; equipment provided by by removing the start signar from the genset control.
others provides utility (mains) breaker control, utility When it is removed, the genset ramps down to zero
load and opens the genset breaker (52-G 1 ).
source sensing, and other functions.
lf the generator set receives a start signa! when the
The PCC monitors the position of the generator set utility (mains) servlce is available, the generator set
breaker (52-G1) and the utility (mains) breaker starts and accelerates to rated voltage and frequen-
(52-U). In a black start condition, the generator set cy. lt automatically synchronizes and clases its
receives a start signal from a remote device. lf the breaker. When the generator breaker is closed, the
PCC senses no voltage available on the bus volt- generator set ramps to the load level commanded
age connection and the utility (mains) breaker ¡s by the signal on the externa! load set terminals
open, it closes the generator set breaker. · (TB1-59 and 60).
FROM
UTILITY (MAINS)
BUS VOLT
SENSE
,,....•.•..
(
- - - 1
::·:.:.
·
:·.\ ~
....:..,,;: /
52·G1 52-U
52·F1 52-F1 52-F1
' SWITCHGEAR
'L - - - - - - - - - - - - - - - - - - ... • - • • - - - - - - - - - - - - - -•
TO LOAD(S)
(# LOADS OPTIONAL)
FIGURE 5-5. UTILITY-SINGLE CONFIGURATION
5-24
I PARALLELING SETUP MENU (Cont.) 1
s-
B (CONTINUED)
O< 11' BASE LOAD% o

O< u. 80 >> >.
O< 11' PF LEVEL o

O< .u. 1.00 >> >. I
O< 11' KW GOVERN GAIN o

O< .u. 100 >> >.
O< 11' KWINTEGRAL !

o
O< u. 4 >> >.
O< 11' i<VAR GOVERN GAIN o

O< u. 300 >> >.
O< 11' KVAR INTEGRAL o

( .· O< JJ 200 >> >.
O< 11' RAMP LOAD TIME o

O< .u. 10 >> >.
O< 11' RAMP UNLD TIME o

O< .u. 10 >> >.
O< 11' MULTIPLE/SINGLE o

O< .u. SINGLE>> >.
O< SAVE o O< DISPLAY CAL << >O

.< EXIT >> >O O< METERS >> >O
O< SAVE o O< GOV /REG << >O

O< EXIT >> >. O< PARALLEL SETUP o
5-25
CALIBRATION PROCEDURE 4. Start the genset and allow the genset to reach
normal operating speed.
!A.WARNING! Contacting high voltage compo
nents can cause e/ectrocution, resulting in se 5. Adjust VOLTAGE (genset output voltage) so
vere personal injury or death. Calibration and that the calibrated voltmeter reads the desired
adjustment must be performed by technical/y voltage. (Use a calibrated voltmeter because
qualified personnel on/y. Read and observe ali the value displayed on the PCC digital display
WARNINGSand CAUT/ONS in your generator may not be calibrated at this time; therefore, its
set manua/s. accuracy is unknown.)
LA CAUTION I lmproper calibration or adjustment 6 Select the Frequency adjust menu.
of the PowerCommand control can cause 7. Verify that the frequency displayed on the cali-
equipment ma/function or damage. Calibration brated meter is the desired frequency. lf not,
and adjustment must be performed by techni adjust tothe desired frequency. (Note: lf the
cal/y qua/ified personnel only. frequen6y reading on the digital display is not
the same as frequency shown on calibrated
The calíbration procedure is divided into 7 subsec-
meter, there is an equipment malfunction.)
tions, with the subsections arranged in a specified
order. lf two or more of the following subsections are 8. lf no frequency or voltage adjustment was
required to calibrate the PCC, they must be corn- made, select EXIT. lf an adjustment was made,
pleted in the order shown. · SAVE, then EXIT.
When removing and replacing a defective circuit Digital Voltage Display Calibration
board, you may have to perform one or more of the
following subsections. Table 5-1 (Control Panel Re- The paralleling bus must be de-energized while
calibration) provides a list of the circuit boards that voltage calibrations are performed. lf this is not
require calibration when replaced and the calibra- possible, disconnect and isolate bus voltage in-
tion procedure(s) that must be performed. puts to the Bus PT Module (A39) before attempt-
ing voltage calibration.
Use a calibrated RMS multimeter for accurate mea-
surements. Fluke models 87 or 8060A are good 9. Select ">>" from the Main Menu (Page 5-9). ()
choices. From this menu proceed to the VOLTS L 12
menu (Page 5-11).
lnitial Start Setup 1 O. With the genset OFF, attach a calibrated fre-
1. Refer to Page 5-4, which describes how and quency/voltmeter to the AC output from L 1 to
when you should perform this procedure. L2.
To verify if the PCC is set to operate with a spe- 11 . Start the genset and allow it to reach normal
cific generator set, refer to the VERSIONmenu operating speed.
(Page 5-9). This menu will show the generator 12. Calibrate voltage reading for VOLTS L 12 so
set model number, frequency, and kW rating. lf that the reading on the digital display agrees
any of these values are incorrect, you must per- with the calibrated voltmeter.
form the lnitial Start Setup procedure.
13. Shut the generator set OFF.
Voltage and Frequency Adjustment 14. Repeat steps 1 O through 13 for L23 and L31.
2. With the generator set OFF, attach a calibrated (In step 1 O attach meter to the AC output from
frequency/voltmeter to the AC output from L 1 L2 to L3 to calibrate VOLTS L23and then L3 to
to L2. L 1 to calibrate VOLTS L31.)
3. SelectADJUSTtrom the Main Menu (page 5-7) 15. lf no calibration was made, select EXIT. lf a cal-
to display the VOLTAGEadjust menu. ibration was made, SAVE, then EXIT.
5-26
Digital Ammeter Display Calibration 27. Calíbrate the reading for PF1 so that the read-
ing on the digital display agrees with power fac-
16. Select ">>" from the Main Menu (Page 5-9).
tor meter.
From thís menu proceed to the AMPS L 1 menu
(Page 5-11 ). 28. Repeat steps 24 through 27 for L2 and L3. (In
17. With the genset OFF, attach a calibrated am- step 24, attach meter to L2 to calibrate PF2 and
meter to L 1. then L3 to calibrate PF3.)
18. Start the genset and allow it to reach normal 29. lf no calibration was made, select EXIT. lf a cal-
operating speed. ibration was made, SAVE, then EXIT.
19. Load the genset to maximum rated kVA at Digital Bus Voltage Calibration
rated voltage.
20. Calibrate the reading for AMPS L 1 so that the 30. Select ">>" from the Main Menu (Page 5-9).
reading on the digital display agrees with cali- From thJs menu proceed to the Bus Volts L12
brated ammeter. menu (Page ·5-11).
21. Repeat steps 17 through 20 for L2 and L3. (In 31. With the genset OFF, attach a calibrated fre-
step 17, attach meter to L2 to calibrate AMPS quency/voltmeter to the alternator AC output
L2 and then L3 to calibrate AMPS L3.) from L 1 to L2.
22. lf no calibration was made, select EXIT. lf a cal- The paralleling bus must be de-energized while
ibration was made, SAVE, then EXIT. ! voltage calibrations are performed. lf this is not
possíble, disconnect and isolate bus voltage in-
Digital Power Factor Display Calibration puts to the Bus PT Module (A39) before attempt-
Power factor calibration is not r:equired except in ap- ing voltage calibration.
plications requiring a hígher accuracy than ±5%. lf
32. Start the genset and allow it to reach normal
the ±5% accuracy is not acceptable, further calibra-
operating speed and voltage.
tion will require reactive load sufficient to reach 0.8
PF at rated load, and calibrated instruments with 33. Push the breaker close switch on the front of
±1 % accuracy or better. Typical load rack instru- the PowerCommand control and verify that the
ments are not accurate enough to perform this pro- paralleling breaker has closed by observing the
cedure. closed lamp on the control panel and physical
check of the breaker.
From this menu proceed to the PF1 menu 34. Calibrate the voltage reading for Bus Volts L 12
(Page 5-11). so that the reading on the digital display
matches the reading on the calibrated meter.
24. With the genset OFF, attach the power factor
meter to L 1. 35. Shut the generator set OFF.
25. Start the genset and allow it to reach normal 36. Repeat steps 31 through 35 for Bus Volts L23
operating speed. and Bus Volts L31.
26. Load the genset to maximum rated kVA at 37. lf no calibration was made, select EXIT. lf a cal-
rated voltage. ibration was made, SAVE, then EXIT.
5-27
Digital Coolant Temperature Display Analog meter calibration
Calibration
A engine sensor calibration too! is required to per- From this menu proceed to the AC VOLTS
form this procedure. CAL TO; menu {Page 5-13).
30. With the genset OFF, replace the coolant tem- 36. Start the genset and allow the genset to reach
perature sender with the precision resistor pro- normal operating speed.
vided in the calibration too!. 37. Calibrate the analog Voltmeter to the digitally
31. Select ">>" from the Main Menu {Page 5-9). displayed value.
From this menu proceed to the COOLANT
38. Calibrate the analog % Amps meter to the digi-
TEMP L menu {5-11).
tally displayed value.
32. Calibrate the temperatura reading to match the
temperature indicated on the calibration too!. 39. Oallbrate the analog % Load meter to the digi-
tally displayed value.
33. Repeat step 32 for COOLANT TEMP R if the
engine uses two sensors. 40. Calibrate the analog Frequency meter to the
34. lf no calibration was made, select EXIT. lf a cal- digitally displayed value.
ibration was made, SAVE, then EXIT. 41. SAVE, then EXIT.
5-28
ACCESSORY BOX CONTROL contains components that provide connection
COMPONENTS points for remote control and monitor options. The
set can be equipped with one or more of the follow-
The generator set accessory box (Figure 5-6} which ing components (customer terminal block TB1 is
is located on the backside of the control housing, standard}.
OPTIONAL
CUSTOMER TERMINAL RUN RELAYS
BLOCK (TB1) K11,K12&K13
OPTIONAL
RTD RELAY OPTIONAL
THERMISTOR
r=:-.
...__ __ __.,
I I
RELAY 160/140° C
o o
OPTIONAL
//
COMMON ALARM
RELAY K14
IHC6/71 (/
OPTIONAL THERMISTOR o o
RELAY 160/140° C
OPTIONAL COMMON
ALARM RELAY K14
-.: : : ~tfflH~J~LJ~-'-~--
OPTIONAL RUN RELAYS
K11, K12 & K13
º ®o o
OPTIONAL
RTD RELAY
!HC 4/5!
FIGURE 5-6. ACCESSORY BOX COMPONENTS
5-29
TB1 Customer lnputs
Refer to Page 9-9 for typical connections to TB1.
TABLE 5-3. A39/A40 TB1 CUSTOMER INPUTS

A39/A40 TB1
TERMINAL# FUNCTION DESCRIPTION
A39 1, 2, 3, 4 Bus PT Input (On Phase to Neutral input voltages from system bus (load side of paralleling
Bus PT Module) breaker.
A40 5 Remate Start Clase to ground to start generator set. (RUN/OFF AUTO switch must be
in AUTO posítion.) ..
6 Re mote Grounding this input causes a~ imfnediate shutdown.
Emergency Stop
16 -19 Customer Fault Grounding these terminals initiates an alarm or shutdown condítíon in
the control.
20 Fault Reset Applying a rnornentary ground signa! to this terminal clears warning or
shutdown faults in the control. (Except Emergency Stop.)
21 Engine ldle Applying a ground signa! at this terminal will cause engine to run at
recommended idle speed. Voltage will be disabled.
22 Low Fuel - Grounding this input activates the Low Fue! warning.
35 Rupture Basin Applying a ground signal to this point will cause the generator set to
Alarm annunciate a Rupture Basin Alarm.
41,42 Common Alarm Form C output contact for remate indication of warning condition on
Warning generator set.
46 Utility Parallel Apply a 24VDC sígnal to terminal 46 to indicate to the control that it is
Signa! operating in parallel with a utility (mains) service.
47 Utility Parallel Apply a ground signa! to terminal 47 to indicate to the control that it is
Signa! operating in parallel with a utility (mains) service.
50 Master First For isolated bus or multiple generator set utility (mains) applications, a
Start/Synchronizer B+ signa! from a remate Master First Start Sensor is applied on this
Enable terminal. For single generator set utility (mains) parallel applications,
apply 24VDC to this terminal to enable synchronizer function in control.
CONTINUED
5-30
TABLE 5-3. A39/A40 TB1 CUSTOMER INPUTS (Cont.)
A39/A40 TB1
A40 51 Load Demand Clase to ground to initiate load demand mode in PowerCommand
control. (Select "Multiple" in Paralleling Setup Menu to enable load
demand mode.)
1-------· ------------- --------------------------------------------------
51 Utility Single For single generator set utility (mains) applications ("SINGLE" selected
Verify in the Paralleling Setup Menu), this terminal must be connected
[strapped] to ground to enable breaker closure. (Version 1.06, beginning
9-26-96 only.) -·
52 Breaker Open / Glose to ground to manually operr'the paralleling breaker or inhibit
lnhibit breaker closure.
53 Breaker Position Glose to ground to indicate breaker closed.
54, 55 kVAR Load Load Sharin.g Unes. Connect to load sharing lines in other generator
Share sets in the system,
56, 57 kW Load Share Load Sharing Unes. Connect to load sharing lines in other generator
sets in the system.
59,60 Externa! Load Analog O - 5 VDC input to control kW load level on generator set when
Set the generator set is paralleled to utility.
Remote Start: When the Aun/Off/Auto switch is in message. This allows each customer "default'' fault
(,': - the Auto position, grounding this input initiates the message to be customized to represent the type of
engine cranking and start sequence. This circuit device that is attached the the fault input.
must be opened to permit resetting a shutdown con-
dition with the Reset input. The "default" message that is displayed, when
Low Fue/: Grounding this input actuates the Low ground is applied to the input, is as follows:
Fuel warning. This input can be connected to a local
day tank orto a main fuel tank that is located on site. Fault 1 = CUSTOMER FAULT1
When the switch grounds this designated input, the Fault 2 = GRND FAULT
input will "wake up" the control, if it is not operating, Fault 3 = DAY TANK
and then initiate the fault. Fault 4 = HIGH GEN TEMP
Customer Fault lnputs 1 through 4: Grounding lf Fault 2 or 3 input is grounded, the control will
any one of these inputs activates the corresponding "wake up" if it is not operating, and then initiate the
warning or shutdown sequence. Warning or shut- fault.
down status is selected in the setup menu.
Externa! sensing equipment must be connected to Fault Reset: When the Aun/Off/Auto switch is in
the designated digital input. the Auto position and the remote start switch is
open, grounding this input resets any warning and
The tour customer fault messages can be sepárate- latched shutdown fault (except Emergency Stop,
ly edited in the setup menu to display any desired which must be reset at the front panel.)
5-31
Engine /die: When the set is operating in the RUN used to enable the synchronizer in the PowerCom-
mode, grounding this input causes generator build mand control. (See Paralleling Setup Menu, path
up to be inhibited and the engine to be governed at B.) A 24VDC signal applied to the terminal will
800 RPM. When ground is removed from this input, cause the generator set to synchronize with the
the set returns to normal speed and voltage. voltage reference signa! applied to the bus PT mod-
Engine idle operation is applicable only in the AUN ule (A39).
mode. The PCC operating program does not permit
engine idle operation when the set is operating in Ali PCC's in a system should be programmed to a dif-
AUTO mode. ferent first start fail time. This will help prevent simul-
taneous closure of breakers in the event of a failure
When the engine idle function is enabled, the con- of the master first start module
trol automatically sets lower oil pressure warning
and shutdown trip points to reflect the lower operat- Load Demend: On receipt of a signal on the Load
ing speed. When the engine idle function is re- Demand tepninats (normally open, close to
moved and the set reverts to normal operating ground), the genefator set will ramp down to a mini-
speed, the control automatically resets oil pressure mum load level and the paralleling breaker will
warning and shutdown trip points to the normal set- open. The generator set will run for a cool-down pe-
tings. riod and shut down. LOAD DEMAND SHUTDOWN
will be displayed on the PowerCommand panel.
Remate Emergency Stop: Grounding this input
causes an immediate shutdown. Emergency stóp When the Load Demand input is removed, the gen-
must be reset at the front panel. erator set will start, synchronize and close to the
system bus and accept it's proportional share of the
Master First Start/Synchronizer Enab/e: This in-
total load on the bus.
put is received from a Master First Start Sensor,
which is mounted remotely from the PowerCom- The Load Demand function of the PowerCommand
mand control. The input is a pulsed signal which is control is only active when the RUN/OFF/AUTO
used by the PowerCommand control to enable safe switch is in the AUTO position and "PARALLEL" is
closing of the paralleling breaker when the system
bus is de-energized. the control will receive a pulse
selected in the Paralleling Setup Menu. (~~>)
from the Master First Start Sensor approximately Utility Single Verify: For single generator set utility l."
once per second. lf the PowerCommand control (mains) applications, this input must be strapped to
does not receive a pulse within the programmable ground before the generator set breaker will close
time delay (default is 10 seconds), the FIRST when the utility breaker is opened.
START warning is displayed by the control and a
backup system is enabled by the control. The Load Demand function of the PowerCommand
control is only active when the RUN/OFF/AUTO
When the system is set up for paralleling a single switch is in the AUTO position and "SINGLE" is se-
generator set with a utility (mains) bus, this input is lected in the Paralleling Setup Menu.
5-32
Utility (Mains) Para/le/ Input: Closure of a normal- For Load Set Voltage of 1.0 volts and lower, the gen-
!Y open contact ~o ground on terminal 47 and apply- set will ramp to no load. For Load Set Voltage levels
mg a 24VDC s1gnal to terminal 46 will cause the 4.5 volts and higher, the genset will be controlled to
PowerCommand control to begin operation in a util- the preset base load.
ity (mains) paralleling mode. The ground signa! is
usually applied by operation of auxiliary contacts in A change in the Load Set Voltage will cause the
the utility paralleling breaker. In this operation genset to ramp to the new commanded kW level.
mode, the control will ignore inputs from the load Ramp rate is controlled by Ramp Load Time and
sharing lines and operate at the load level which is Ramp Unload Time. (See Utílíty (Mains) Adjust
determined by the magnitude of the Load Govern ments elsewhere in this section.) In the load govern
signa! and the base load adjustment in the control state, kVar load is always a function of the preset
setup. power factor and the % kW load.
Para/le/ Brijaker Open/C/ose lnhibit: This func-
Load Govern: This input is enabled when the con-
tion is operational only when the AUN/OFF/AUTO
trol has received a utility (mains) parallel input. A
switch is in the AUTO position. Closing a normally
0-5V signal applied to terminals 59 and 60 will di-
open contact to ground on this contact will cause
rect the control to operate the genset at a fraction of
the paralleling breaker to open if it is closed, or pre-
the preset base load(%}. Operating load level is de-
termined by the formula: !
vent it from closing if it is open. Removing the
ground signal will cause the PowerCommand con-
31.4 * (Load Set Voltage - 1) = % kW load ~ trol to return to normal operation.
5-33
Operating PowerCommand in Droop Mode governor and voltage regulation system droop lev-
el:
The PowerCommand control is designed to operate
1. Set the no load speed and voltage at the de-
isochronously (with no intended droop) so that volt-
sired level. Bus must be de-energized when
age and frequency are as constant as possible
this setting is made, or disconnect Bus PT
when the generator set is paralleled to other Power-
Command generator sets. In certain situations, module.
however, such as paralleling with other generators 2. Apply 100% load to the generator set, and ad-
that are operating in droop mode, it may be neces- just the KW load sharing gain to obtain the de-
sary to operate the control in a droop mode for fre- sired full load operating frequency. Adjust the
quency, voltage, or both. KVAR load sharing gain to obtain the desired
full load operating voltage. Refer to Figure 5-7
Note that when the generator set is paralleled to a for typical gain settings for specific droop lev-
utility (mains) service it is recommended that the els. .1
control be operated in its utility parallel mode, rather 3. Repeat the process for other generator sets in
than in droop, even if other generator sets in the the system.
system operate in droop for that function. The droop
4. When initial settings have been made, test the
mode in PowerCommand will only work when all the
system with all available load, and verify that
other generator sets in the system are operating ir;1
the generator sets share load approximately
droop and the system bus voltage and frequency
equally at no load and maximum available
change with load. load. ·
PowerCommand controls that are set up to operate Proper adjustment of load sharing in droop opera-
in droop mode must include the paralleling option tion requires use of both real and reactive load
(H532). The generator set should be set up for mul- banks. lt is possible that precise load sharing will not
tiple unit paralleling, but load sharing interconnect- be possible with all generator sets in the system at all
ing wiring is not used. Connect a 5K resistor across load levels, due to the non-linearity of the droop
terminal A40-TB1-54 and 55 (KVAR) to cause volt- characteristic of some generator sets. In that case, it P... •··.··_....· ,·•·.·..,.·.,,·-.·•,··,.·'.
age to droop. A 5K resistor across terminal is generally best to set up the system so that avail- \ .. :.:_ . ,
able load is equally shared at the maximum load leve!
A40-TB1-56 and 57 (KW) will cause frequency to
expected on the system. Note also that the synchro-
droop. Resistors can be used on one or both of the nizer is active and functional in PowerCommand
load sharing terminal connections, depending on even when the system is set up for droop load shar-
the needs of the application. ing. Manual paralleling and system synchronizing
should be performed by the PowerCommand con-
Complete all start up procedures as described in trol. lt is recommended that paralleling breakers be
Section 8 of this manual up to the point that you are electrically operated by the PowerCommand con-
ready to make load sharing adjustments. To set the trol.
5-34
%DROOP
9.00
8.00
--%DROOP @1800 RPM
7.00 - - - - - % DROOP @1500 RPM
6.00
5.00
4.00
3.00
2.00
.!
1.00
O.DO
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
LOAD SHARE GAIN
'
FIGURE 5~7. PERCENT SPEED DROOP VERSUS KW LOAD SHARE GAIN
(.
5-35
TB 1 Customer Outputs
Refer to Page 9-9 for typical connections to TB1.
TABLE 5-4. TB1 CUSTOMER OUTPUTS

TB1
1 B+ Auxiliary Power 24 VDC control power supply, fused at 20 amps.
2 Switched B+ 24 VDC control power available when genset is running, fused at 1 O

Auxiliary Power amps.
..
3,4 Ground I
.
7,8,9 Common Form C contact set to indicate to a remate device that a generator set
Shutdown shutdown fault has occurred.
10, 11 Parallel Breaker Normally open contact which clases to clase a remate paralleling
N-K20 Clase Signal breaker.
I
.
14, 15 Network Data Terminationé far network data twisted pair, operational when generator
set is equipped with generator cornmunicatlons module (GCM).
23-32,33 NFPA Fault Normally open contact which clases to indicate that a specific fault has
Contacts - occurred in the generator set. Common is terminal 33.
38,40 Ready to Load lndicates that the generator set is at rated frequency and voltage and is
ready to accept load. Normally open contact between 38 and 40, which
is common.
39,40 Load Dump Normally open contact which clases to indicate that the generator set is
overloaded.
41, 42 Common Warning Normally open contact that clases to indicate a warning condition on the
generator set.
43,44 Common Warning Normally closed contact that opens to indicate a warning condition on
the generator set
48,49 Parallel Breaker Normally closed contact which opens to clase the paralleling breaker.
N-K21 Open Signal
5-36
Paralleling Breaker Control: Contacts are pro- Common Alarm: One set of form-C contacts, rated
vided to allow the PowerCommand control to oper- for 2 amps at 30 VDC. Any shutdown causes the
ate a remote paralleling circuit breaker. A normally common alarm relay to be energized. This output is
open contact will close to signa! the paralleling often used to energize an audible alarm.
breaker to close. A normally closed contact will
open to open the paralleling breaker. Load Dump: One set of normally open (NO) con-
tacts, rated for 2 amps at 30 VDC. lf an overload oc-
When the RUN/OFF/AUTO switch is in the RUN curs which causes generator set frequency to drop
position the breaker signals will be initiated on op- more than 3 hertz below nominal for more than 3
eration of the paralleling breaker control switches seconds, or a load of more than 105% of the stand-
on the front panel of the PowerCommand control. by rating is applied to the generator set for more
The breaker control switches on the front panel of than 60 seconds, the normally open load dump con-
the control are not operational in other control op- tacts are closed. This relay is energized befare
eration modes. shutdown (ter overload or underfrequency) occurs.
Ready To Load: One set of normally open (NO)
When the RUN/OFF/AUTO switch is in the AUTO contacts, rated for 2 amps at 30 VDC. This output is
position, the PowerCommand control will automati- activated whenever AC voltage and frequency ex-
cally close the paralleling breaker if the system bus ceed 90% of nominal.
is de-energized and the master first start sensor
pulse is received, or if synchronous condition wíth Switched B+: This is a fused 1 O amp, 24 volt
the bus is achieved. switched output. This output is activated by the run
pilot signa!, at the governor output module. (Fuse is
Warning Alarm: One set of _[lOrmally open (NO) located on Governor Output Module.)
and one set of normally closed (NC), rated for 2
B+: This is a fused 20 amp, 24 volt output. (Fuse is
amps at 30 VDC. Any warning causes the warning
located on TB-BAT terminal block of the engine har-
alarm relay (labeled Spare Relay on Customer In-
ness.)
terface board) to be energized. This output is often
used to energize an audible alarm.
5-37
Run Relays (K11, K12, 13) fans, pumps and motorízed air dampers. The run
relays are energized when the generator set reach-
The optional run relays are raíl mounted insíde the es operating speed.
accessory box (Figure 5-6). The raíl mount allows
you to easily remove and replace the snap-on re- The contacts are rated:
lays. 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
5-8) are used to control auxiliary equipment such as • 3 amps at 480/600 VAC, 80%PF
K11, K12,K13 ~~
-c..__,:. 4
2
8 CUSTOMEA
K11, K12, K13 ~
CONNECTIONS
T ;;>- 5
3
K11, K12, K13 ~ 9
T 6
"'
K11 K12 K13

AUN AELAY AUN RELAY AUN RELAY
@@@ NO @@@ NO @@@ NO

@®CD NC @®CD NC @®CD NC
ll-h_c_o_,_L_ A40-TB1 -4
COM (B-)
FIGURE 5-8. OPTIONAL RUN RELAYS (K11, K12, K13)
5-38
Shutdown Alarm Relay (K14) vices such as audible alarms. Any generator set
shutdown will energize the alarm relay.
The optional shutdown alarm relay is rail mounted
inside the accessory box (Figure 5-6). The rail The contacts are rated:
mount allows you to easily remove and replace the
snap-on relay. • 10 amps at 28 VDC or 120 VAC, 80%PF
The three-pole, double-throw shutdown alarm relay • 6 amps at 240 VAC, 80%PF
(Figure 5-9) is often used to energize warning de- • 3 amps at 480/600 VAC, 80%PF
_,
K14
CU.STOMER
K14
CONNECTIONS
K14
(.
J ./" "
JUMPERWIRE K14
REQUIRED FOR K14 COMMON SHUTDOWN
RELAY OPTION ALARM
A40-TB1-4 @@@ NO
(GND) ~
@®CD NC
A40-TB1-8
(COMMON
SHUTDOWN ALARM)
A40-TB1-1 A40-TB1-7
(B+) (COMMON SHUTDOWN
®® G) ALARM)
FIGURE 5·9. OPTIONAL SHUTDOWN ALARM RELAY (K14)
5-39
RTD Relay (Optional) LED's are used to indicate which inputs exceed the
setpoint.
The optional RTD relay is raíl mounted inside the
accessory box (Figure 5-6). This relay is used to The relay terminals 11, 12 and 14 are for customer
monitor six separata temperature zones in the gen- connection. These terminals can be attached to any
erator windings using resistive temperature detec- one of the tour Customer Fault inputs on TB 1 to pro-
tors (RTDs). The relay determines the sensed tem- vide a warning/shutdown condition or to other cus-
perature and acts to isolate, alarm, or initiate cor- tomer warning devices. (Refer to Setup Menu in this
rectiva action. section, which describes how to modify the custom-
er fault message and to select a warning or shut-
The RTD relay (Figure 5-1 O) compares the six in-
down condition.)
puts to the predeterminad setpoint (temperature
setpoint is factory adjusted). lf one or more of the in- The contacts..are rated:
puts exceed the setpoint, the output relay is ener-
gized. LED's indicate the state of the output relay • 240 VAé, 5 amps non-inductiva
(green for normal, red for tripped). Additional red • 24 VDC, 25 amps resistive
TEMPERATURE RELAY CONNECTIONS

REO
WHITE
WHITE
REO
WHITE
WHITE
RED
WHITE TO RTD TERMINAL
WHITE BLOCK
REO
WHITE
WHITE
REO
WHITE
WHITE
RED
1 1 1
tJJ tJJ tJJ tJJ tJJ

1 2 3 1 2 3 1 2 3 1 2 3 1 2 3
•
1
1
1
A B e o E
R
T
o
e e -
•
rr .
ALARM SAFE
SET F
(+) PWR (-) 1

12 11 14 3 2
1 1
L A40TB1-4 1
L WHITE
OUTPUT RELAY WHITE
(CUSTOMER USE) 24VDC (GROUND)
A40TB1-2
(SWITCHED B+)
FIGURE 5-10. RTD RELAY (OPTIONAL)
5-40
Thermistor Relay (Optional) when the thermistor chain resistance reaches 3000
±500 ohms.
The optional thermistor relays are raíl mounted in-
side the accessory box (Figure 5-6). Each relay The relay terminals 1, 2 and 3 are for customer con-
monitors three thermistors (one per phase) that are nection and are normally connected to a breaker
connected in series inside the generator. One se- shunt trip ora load shed circuit (Figure 5-11).
ries or chain of thermistors are rated at 140º e and The contacts are rated:
the other at 160º C. The 140º C relay is commonly
used in a pre-alarm circuit and the 160º C relay in a • 3 amps at 250 VAC
shut-down circuit. The relay will energize (trip) • 1 amp at 480 VAC
THERMISTORS WHITE/RED
0
A B0C~ /'
BLUE ----------... ~
A40-TB1-4 FAULT CHANNELS

(GROUND) (CUSTOMER
CONNECTIONS)
A40-TB1-2
(SWITCHED B+)
RELAY CONTACTS
FIGURE 5·11. THERMISTOR RELAY (OPTIONAL}
5-41
ENGINE SENSORS ers to which the PCC responds. The switches func-
tion by closing the fault or warning circuit to the en-
Figures 5-12 through 5-15 show the locations of the gine chassis ground (battery negative [-]). The low
oil and coolant temperature and oil pressure send- coolant leve! switch has its own ground wire.
LOWCOOLANT
L10 & M11 LEVEL SWITCH
SERIES COOLANT TEMPERATURE
SENDER ¡_
D o
o
OIL PRESSURE OIL TEMPERATURE
SENDER (FAR SIDE) SENDER (FAR SIDE)
NT855 & N14

SERIES
D
FIGURE 5-12. ENGINE SENSOR LOCATIONS (L10 & M11 / NT855 & N14 SERIES ENGINES)
5-42
LOWCOOLANT
COOLANT TEMPERATURE TEMPERATURE LOW COOLANT
KT19 SERIES SENDER (1WO) SWITCH LEVEL SWITCH
D t-------,---L_J
•
..._______
D
__ ~_·
OIL TEMPERATURE
SENDER (FAR SIDE)
-\--
OIL PRESSURE
SENDER (FAR SIDE)
....-_:·.
( .. COOLANT TEMPERATURE
LOW COOLANT
VTA28 SERIES LOW COOLANT GAUGE SENDER
LEVEL SWITCH
\
TEMPERATURE
(FAR SIDE)
D
l"·- ...
SENDER SENDER
FIGURE 5M13. ENGINE SENSOR LOCATIONS (KT19 /VTA28 SERIES ENGINES)
5-43
TABLE 4-30a. LOW AC VOLTAGE SHUTDOWN (303)
ry or death. Only trained experienced service personne/ with know/edge of fuels, e/ectricity, and me
"LOWAC 1. PMG or field wiring could be faulty. 1. lf output voltage is low and both A37/DS2 and
VOLTAGE" A31/DS1 O are on, check and repair the PMG or
shutdown field wiring.
(303) 2. The rotating rectifier assembly (diodes 2. Check each diode according to Servicing the
message. CR1 through CR6} is faulty. Generiitor in Section 6. Service as necessary.
I
3. Overload. 3. Check the load and correct any overload.
4. There may be a loose connector in the 4. Check connectors J8 and J9 on A36, J3 and JS
control loop. on A34, and J7 on A37.
*5. lsolate the genset output from the load. Reset
the control, restart the set, and measure AC
!
!
output voltage with a multimeter.
Sa. The problem may be the analog board a. lf output voltage is high, refer to the trouble-
(A33) or the digital board (A32). shooting section for High AC Voltage Shutdown
(301 ).
- lf output voltage is normal, the problem must be
in the voltage sensing circuitry (A32 or A33}.
Sb. The problem may be the regulator lsolate, using the analog input troubleshooting
module (A37), the engine interface procedure ( Table 436a/b). Check the phase
board (A31 ), or the digital board (A32). that shows a low voltage on the PCC display.
(. . ..... *b. lf output voltage is low, the control cannot drive
the output voltage high enough. The problem
could be A37, A31, or A32. Restart the set and
monitor isolated B+ supply LED A37 /DS 1 ,
output duty cycle LED A37/DS2, and
AVR duty cycle LEO A31/DS10.
• If A37/DS1 is not on, disconnect A3 J7/P7
and check far B+ at P7-1. (Control must be in
Run mode for B+ reading.)
• lf B+ is OK to A37, replace A37 .
• lf A37/DS1 is on, check A31/DS10 (with the
set running).
• lf A31/DS1 O is not on with set running, check
far continuity: A31 J1-2 to J4-10 and A31
J1-1 to J4-11 (270 ohms). lf no continuity, re-
place A31.
• lf A31 is OK, replace A32 .
• lf A31 /DS1o is on with set running and
A37/DS2 is not on, check the harness.
• lf the harness is OK, replace A37.
(Continued)
*CAUTION: Wearing wrist strap, set 512 to Off and A32 55 to Standby before connecting/disconnecting harness plugs.
4-47
KT38 SERIES COOLANT TEMPEAATURE
SENDERS (TWO)
D o
OIL PRESSURE OIL TEMPERATURE ('"..:"··~\
,- ./
..,·... , ..
FIGURE 5-14. ENGINE SENSOR LOCATIONS (KT38 SERIES ENGINE)
5-44
se ,ce ,He GENERATORS
3 PHASE RECONNECTABLE
VOLTAGE CONNECTION VOLTAGE CONNECTION THIS DRAWING APPLIES TO:
CURRENT TRANSFORMER SECONDARY CONN 1-J CURRENT TRANSFORMER SECONDARY CONN 1-2 MODEL BEGIN
220/380V. 50 ;80 HZ (R099) 268/460V, 60 HZ (R027)
SPEC LETTER
100/200V. 50HZ (R79) 110/190V. 50HZ {R004) 115/200V, SOHZ (ROSO)
110/220V, 50HZ (R028) 120/208V. 50;60 HZ (R098) 1J3/2JOV, 50;60 HZ (R057) 2J0/400V. 50 HZ (R029) 260/450V, 50;60 HZ (R109) DFAA E
115/2JOV, 50HZ (R071) 127/220V. 50;60HZ (R020) 139/240V, 60HZ (R067) 240/416V. 50 HZ (ROOJ) 277/480V, 60 HZ (R002) DFAB E
120/240V, SOHZ (R106) 115/220V , 50HZ 255/440V, 50;60 HZ (R023) 200/J46V, 50 HZ {R068) DFAC E
• RANGE • • RANGE • • RANGE • DFBF L
100 - 120/200 - 240V 110 - 139/190 - 240V 220 - 277/380 - 480V DFCB L
CT21 CT21
LI (U) DFCC L
DFCE A
L2(V)
UI (T1}
DFEB K
DFEC D
DFED A
DFFB L
DFGA E
.DFGB E
bFJA L
LJ(W) DFJB L
LO(N) DFJC L
SERIES DELTA PARALLEL STAR SERIES STAP DFJD D
3 PHASE 4 WIRE 3 PHASE 4 WIRE 3 PHASE 4 WIRE DFLB L
OUTPUT TERMINALS OUTPUT TERMINALS OUTPUT TERMINALS DFLC L
U .V .W .N. U .V .W .N. U .V .W .N. DFLD L
DFMB L
FRAME 4 DQAA A
FRAME 4 FRAME 4
DQAB A
l .
DQBA A
W5(T9)
W2(T6)
5
U2r4
V2
W2 T5 ,_
T6 /
N ,'-
U6 {TT11
V6 1 ºj N
W6r12~
V6 T11
DQBB A
w "'- W6 T12 U6 T10

w w
•
W1 T3 6 6 .....
W5(T9) W1 (T3) W1 (T3)
V6fT11)
V5(T8) V V1 T2) 7 ... V V
V5(T8) V1 (T2) V1 (T2)
U6 (T1 O) 7
NOTES:
V2(T5)
U5(T7) u U 1 (T 1 ) 8 u u 1. UVW PHASE SEQUENCE WITH C.W. ROTATION
U5 (T7) U1 (r t ) U 1 (Tl ) FACING DRIVE END.
U2(T4) W6(T12)8
2. TIE BACK UNUSED LEADS.
3. WHEN RECONNECTING GENERATOR LEADS, BOLTS
SHOULD BE TORQUED AT 68 ~6 FT-LBS.
FOR FRAMES 5, 6 AND 7.
FRAME 5 ,6 ,& 7 FRAME 5,6,& 7 FRAME 5 ,6 ,& 7
4-. WHEN RECONNECTING GENERATOR LEADS, BOLTS
~-.r---5 SHOULD BE TORQUED AT 22 ~2 FT-LBS.
N U6~T1
V6 T11 O! N
5 W6{T121
V6 Tl 1
FOR FRAMES 4- •
5. NEUTRAL FLOATED FOR DELTA CONFIGURATION.
W6 T12 U6 T10 TIE LEAD 5 BACK INTO HARNESS.
Wl {T3) W5(T9)
v
6 W2(T6) W5 (T9) W1 (T3) 5.------1-- Wl (T3) 6. The dot on the side of the current transformer (Cl)
W5
W2 ~T9}
T6 6 W2 (T 6) must face the generator. A dot is also used to mark ter-
V5 T8 V6fT1
V1 T2 V5(T8) minal 1. CT terminal 1 connects to the meteñng circuit
V2(T5) V5 (TB) Vl (T2) 7 V1 (T2) Terminal 213 connects to ground.
V2 {T5) U6(T10)1 7 V2{T5)
U5 (T7) ui (T1 ) U2(T4) U5(T7) Ul (Tl ) 8
U5 (T7)
U1 (T1 )
U2 {T 4) W6 (T 12 )8 8
U2(T4) No. 625-3100 sh 1 of 2
Rev. F Sys: Revisio
Modified 4/3/97
AC RECONNECT WIRING DIAGRAM (SHEET 3 OF 4)

9-5
THIS DRAWJNG APPLIES TO:
MODEL BEGIN
se ,ce ,He GENERATORS DFAA

DFAB
SPEC LETTER
E
E
DFAC E
3 PHASE NON-RECONNECTABLE DFBF L
MEDIUM VOLTAGE DFCB L
CURRENT TRANSFORMER CURRENT TRANSFORMER SECONDARY CONN 1 - 2 DFCC L
CURRENT TRANSFORMER SECONDARY CONN 1 - 2 SECONDARY CONN 1 - 2 DFCE A
DFEB K
2400/4160V, 60 HZ {R107) 1905V, 50HZ {R120) 346/600V, 60HZ (R114) DFEC D
~ 1905/JJOOV, 50;60HZ {R108) 2400V, 60 HZ (R121) 220/380V, 50 ;60 HZ {R099) 230/400V, 50 HZ (R029)
240/416V, 80 HZ (ROOJ) 254/440V, 50HZ (R023) DFED A
13800V, 60 HZ
277/480V, 60 HZ (R002) 220/440V, 50 HZ (R019) DFFB L
L1 (U) 347/&00V, 60 HZ (R114) SPECIAL WINOINC 240/480V, 60 HZ (R119) DFGA E
UI (TI) CT21
CT I L 1 (U)
120/208V , 80 HZ (R098) SPECIAL WINOINC DFGB E
PU2 .--------"'""'**:f-- 127/220V, 80 HZ (R020) SPECIAL WINOING CT21 DFJA L
.......,,,:-,:,"T"'""--L.Jl-i+ L1 (U ) _, DFJB L
LO(N) U1 (TI );------'"'=k,J- L1 {U) DFJC L
CT21 DFJD D
DFLB L
CT22 DFLC L
L2(V) DFLD L
L3(W)
LO{N) DFMB L
CT23 CT23
DQAA A
DQAB A
~----- LJ (W) L2(V) DQBA A
~~q~~
u2h4j
--e• l3(W)
~-----"L-l--1+
'-------LO(N)
L3 {W) DQBB A
CT23
W1 {TJ) ---+,. FRAME 4 ,5 ,& 6
FRAME 5,6, & 7 FRAME 5,6,& 7 FRAME 4
Vl (T2) ----
N N W5(T9)
W5(T9)
W2(T6) W2(T6) W2(T6)
W1 (TJ) W5(T9) W1 T3 6
V5(T8) W2(T6) V6 T11)
(-NEWAGE-) V2(T5) V2(T5) 6
TRANSFORMER V5{T8) V5(T8} V1 T2
U5(T7) V1 {T2) ~---..;~~~ 7 V2(T5) U6 T10) 7
PRIMARY JUMPERS U2(T4) V2(T5)
PTU U2(H) 7 U5(T7) U5(T7} U1 T1
PU2--- U1 (T1) -----'-''--'--<-- 8 U2(T4) W6(T12) 8
WYE CONNECTIONS; U2(H)
PV1 - PW1 - PU1 8
PU1
A - 4160 VOLT WYE

!~ AUX-'Z
------- 7B
B - 3300 VOLT WYE
PV1
PW1
N PRIMARY JUMPERS
DELTA CONNECTIONS;
PV1 - PU2
PWl - PV2
PUl - PW2
A - 2400 VOLT DELTA
No. 625-3100 sh 2 of 2
Rev. F Sys: Revisio
Modified 4/3/97
AC RECONNECT WIRING DIAGRAM (SHEET 4 OF 4)

9-6
ll.lSTll'ICR COtN:CTIOf'5(5[[ S!fiT 3)
A.'HKIATOR QJSHKR C<JKCTICJIS(S[[ SIEH Jl
O' N ' - "' ' N
GOV
ACT •
1
c;ov ACT<+>
COY ACTC->
J6-0
A38
GOVERNOR
JG-7
JC-12
1,-1,
§
OUTPUT JO-••
STAGE
RUN-J ~ ,s ..z t 300-1307
--· no+
RuN-~ ~ n-20
JS-2
G21
JG-3 cev rn,_
GENERATOR
!¡
RUN-1 ~ J&-22 JZC1 :2l) JI(1:23)
Cr.RAY> CBLACKJ ( 12 LEADl
J&-1s J&-1 , 16 n-1, 2J
RIJN~
OIL PRESS -sv .,., _J'"i,(111)
J7( J :30) k~J7(1:30>
TB BAT
1
E1~5V :~
CUT ~__,O~l~L~PR:,,,,E~ss,..,,cu,,_,_T-1<:~·
...... ··u..·,1 A41 A33 UI JTJC
VI )TI I
CND GCM ANALOG
~c.._.:::AGH=D'-"O,_,IL,_,_P,,RE,,,s.,s'--l«~~f-"-"'
•• '="',
1 300-1090-02 Jl( 1:23) cJl Jz9 JI Jl Jl Js5 Js' Jl J: HI >T12
HAG PICKUP (OPTIONAL)
~o:,,
CBLUCI
~ +[XttT(KP t ·tttr, 1t11nt----''~·~-·~~''>---ll--+--+-t--t--t~~-+~:-.
~
~ 11AQ - ...........
,,...._
,.,.~,,>ó------"C"'T2"'t._ J8-lS
'--~S~Hl~E~L~D--------' ~~c..__-_.E"'XH~T,eEc,~.P:....,1---!<"•f-""''c,.,·»-'-,.I 11( 1 :]1) E---+,,>--l
J5( J :J1J
A31 A34 N"='IJ"U~_,)!!----.....!,C.!.T~Ce!O~H!- ".i J8- "1
1-«~
JS-8 l V
J6-I H'{---,11 n CJM'f
Q.6TOIOI Cllff:CTl()6(5rE Sl«T 3)

i' E:XH TEl1P 2" .,., 1"1: tci
ENGil'E CUSTOMER N·=-i.:·
·u~,,)l!-----~cT,.,2s,;2'----'J
J&-22
rn:(---_.E"'XH~T,,E'-'HP'--'2---!l<"•~=""-',I INTERFACE JM J3
INTERFACE A36
l"'"..u,
"""-''~;,>l.-----=Ca.:.T_;Ce,O"'N'-----ilJI-Zl
1 300-1083 JICl::14) J2(ls94J 300-4462 PT/CT
N·~-11U·-~~-,)!1!------=-cT,_,z~•'----'JJe-a 300-4308
...
TB BAT
N·~-=·--~~·!----.....!,C.!.T~ce!°""'-----l!Je-,.
FI
'' J2l 1 :30 H:~:-------------' "I
""....,_••:u..~>';------'O:.:t..:N_;L"'t._ JI-,
AGHD BAT SC:KSE .... H J5( 1 :23) J3( l t34)

n,c:
...•......
'~i Ll CON
l"'......,..._~,,>!11-------""--'='-----'JJl-5
••<...._~>lt------'º~•..:N_;Le,2._ JB-4
SI lCRAY> "I
l
LOW C.NG TCP1P · 14 1":11 t,..z.a.u.2L~~l,_ _.L~2_;Ce,O"'H'-----'JJO-l
RS232
SJ
U)M íuEL L.,_,..(14) I
CONNECTOR
I
l'-''.._..,,,,.._~)!1------=º~·~N-'L:.:l._
__ --;¡Jl-2
O>WOX•---~l~S~-•~~.,>'-v~••-'1'-'--+--+--+---<
JI "I
,u.s•••·~-~~i----'-L~J,._,,C~ONe,__
~J&-I
·1
19-2 ,, MCS>
LOH COOI..ANT n J4t7) 001---~~~,,>~'--<I--~
NE.T B.. ;; J4 f~) A32 1 ..... t---~'~·--~·
~,,,-..N~<S~>'-O--+--+--+---<l---+--+-0--'-0----i
CNTRt. 8+ .,., t.a u:
OIGIT~
1
S7f:,~----'
c
Jl<li34, IE---+:H 14( 1 :34) J2<1:l4>H:+----ll J4( l:~•O
AIJX 8+ '' 1<1 '":11'\
300-4079
RUKf'-
~-------------=IIUN""'--t<,'.~,.._.~"..._I
,,>1i--------eus.,.,...._L._t
N".:.··=·-·.,_~ -'Jl"a2-s A39
TJ T9 Tlii Ti! TU T:5 TI t? T<II
C!<40 l"".u..'>L'""'-~_,>r---------'L~l'--"'RT~TB2-5 BUS PT
....... ---,
START~
.,------------~ST~AR,,,.,_T-f<':~,·~·,....._••...,_, CIRCUIT BREAK(R/
~ RUN-Z ~~--------~
" J4(
,
1 :2l>
tMHITE>
·~ ,,):1-
('1"¡:.··=·-·c.,_ eu.,.,se...s,LZs....;¡
TBZ-4
rar-:
300-1309
1:-------,JI
BUSLI
GENERATOR RECONNECTION
ll.Clil Y:l.ltlCE Cl)01'10ACCMCCtlCIH 9010 " 1
•~''ª' ./),.---------'L"'Z'-"R"-T-,IT.Bl-l
J
r¡-------,)1 BUS U
N"¡:.··=·-·lL·~):1:--------8US"""w,.Ll~T82-2TBl-2 WiTOl'CR
J_
STARt SOL
..,.._, >- '"':urua .. Jl( 1: 141 .t5( 1160)

K4, l
START
Set.
__ K1.Z "
T 1 ,,1
,.. .,•,,u•.....
··-~",>ljl---------~L~l-'R~T~.JTBZ-1
rai-a l<-------,JIBUS L3
TBl--11:-------.J
1
BUS
LO
CXMCCTICHi
1
1(1
DTI t.l~°' • ,.
"~T
(~ ~L
1, :: ::
RON ouT ••••
::::: JS<:,601
DIGITAL DISPLAY ASSEMBL Y
A35
H22
7. AMPS
1121
VOLTS
M23
f"REO ~ LOAD
!
• 1
~=
300-~0BI I= I=
DT2 ~ NET RTN 1--~R~...
e:..,ou,,,.T_""'·-·I.L.1·./l,.,-Jl~'~"~'-~·~v~•""~T~)~J~·~-~·~~-------,r------a..a.a........a=.-------,,---------1
nux RTN
>--------~----~--~~---~~---~-'C~N~T"'-=~RT~H~~
1 ~.:lR : ~ T I tSTOP SET
OND
••••
''""' Ull9> rox OND J6-I<
<I=-« [> O PQW[R O = -·"•'•
= '-"'''
CN~NO STOP r-'-<> •••• • .. ,, o;-;,...... D JG-G Vot..YS
~-i_J
1....__ I sw RUN RO.AY U• ,~, .. ,
Jl(l4)5Elí TEST JG-1
c,a-.., r.i, D
L!_J
D (1 .,_. ,... [> J6-" rREO
••n••
o
512 • 3 AUTO
RUNJ'OFF"'
D
t
RUTO~ RUN ""' 16-5 POW(R
S.lffMl r-1L,pu
1
i I G)fD 1,1111
AUTO JG-2
.JG-8 tt(T(R RTN
(MHITE)
No. 612-6675 sh 1of 3

Rev. B Sys: HP
Modified 11 /7/96
BLOCK DIAGRAM (12 LEAD)

9-7
OJSTOIG C~CTIONSC51:E !HIT Jl
AIIUCIATOR OJSTcnR CCll,(Cl!ONSCSE[ Sl([T Jl
...-
....... .... ... ' ...
- ::, o '
"':e ~_,o oz
.... ¡¡' ~ u
. . M N - ~
~ ...z e .. 1 3"' 3
=
3
= =· -
"' - =
... 3 %
... z ... .
. ~" ....~. .....
' ... ·1'
?; ?; o
·1'. _, g
su
. t; . .. . ...._,... g. 8. . ,.;
"' .... ...
o u
o
=... .
(
~ "..¿ :.~ ...e .¿ ~.. ..."' "'" ~ ~ ...¿
N
z o ¡!
- ...
i ..."'. ~.. "'::;" ::; ::; ::;
:,
"'¡j
::,
e
,e
3 e "'a:"'
u u
z .J N Q e: 'f "'
3 "'
"'.... "'".. "'.... "'..
.... s ~
o ,:
[!; e _,
o z u
...
.. 1: 3 ..... "' ~"' . ~" "'.¿ ...¡'¡
..,
::! ¿ "'l,!
... ...oz
:e
~ .,¡_ .J .,¡_ :,!
" ... ...o " ...
>
..
< o
"' "o
Q
3 o >
Q
8
,:
..."
% m
¡'¡ ~
z ...
a
o: ,: Q
u u
u
3 o:~ o: ~ 3 ,:
:,
o
i
,f; ,"'';
:' ;
GOV
ACT + COV ACTC+-) 1
J6-6
_I ccv 1tc.n->
A38 JG-7~
J6-IZ
l&-8
GOVERNOR J&-1?
OUTPUT
Ti!~ -
SI< ••
J6-4 STAGE
J&-11
1
1~
.r..:
t tt20 t
f----: 300-4307
le~
RUN-] JG-ZI
--·· ftD+
t
f----;
JG-Z(' ACND HZO
G21
1
RUN-2 JG-20
--·· nn_
GENERATOR
le~
J6-J(' r tao 2 J2( l:2]) JI ( 1 :231
RUN-1 f----; J6-c'.? (GRAY) (Dl.AOC) C6 LEADl
.1&:-19 Jli-1.9 16 JG-15 23 ACNO HlO Z
I<~
1
O[L PRCSS +sv
!<~
i
El~sv ~
1 ~
I<~
OlL PRCSS OUT
OUTI--"«('---"=-'-"='-""-'--'< A41 A33 UI
.f"IAG PtCKUP
CND
( nGNO OlL PRLSS
I<~ 1
GCM
(OPTIONAL)
ANALOG
3 00-1080-02 J3Ch23) ~
... V6 us
VI
MI
~c::fl MG
<BLUE.>
,, 1
~ 1' '---~SH~l~E~L~D-------~
+
MC-
+ EXH l[t'.? 1
'<~
1 11 .. ··-· ClZI
OO<llt
:e~ 5---•~>>--iJS< 1
t ~~
JB-15
- EXH T[t".? l JH 1: 30 i 34 >
A31 1 A34 CT COP'I
JB-14 JQ.a ''
,, L
• CXH T[l".P Z
I<~ ENGINE JG-1 1-<qJl
,._, 1-< CUSTOMER CT22
J8•22 °"'
CUSTOl'O COll\t:CT!ONSCS[( Sl(CT 3l
...,,,.
13
INTERFACE INTERFACE A36
~ - [XH T(t':P 2
:e~ •- CT CON
1
....
t ~§
300---t--~'!..
e f"l
" . .,, . , ....
,,, ..... ........
20A
ª
- ~ GEN Ll JB-6 J9-? ...... 1
+ 8ATT SENSE
Al:HD IAT SENSC ',, ..... H JS<l123> JJCl134)

Ll COt1
GEN L2
JB-5
JB-4
,, í.:_lJ
1---~Jc,Oc;c-., _G-1~,~~
~
....
(t;ltAY) lllC
51
LOM ENG TEHP · •41 l"I\ L2 COt1 JB-J J9·i ,, U(I >
'1>J.(II
"' RS2J2
·-
:-¿
53 COHNECTOR GEN Ll
4
1.ow FlJ€L
I I ·-
JS-2
-«>: ,,
-
, ... I
.•..
. . ., ..
JI
'" 1..3 CON
LOH COOLAN.T
JB-1
ID
J9-2 ,,
,, wu; >
NET B• ¡.,., t41c1 A32 J'9-I ,, HC5)
¡~~ "4'~'
..
CNTRI... O•
IE'---~")--1 DIGITAL
57f· .,
JI ll t34> J1( 1 :34 J l?<l:34>1-(·~--ll J"IC 1:30
AUX 8+
300-4 079
¡¡ ......
sic; .<
.. ' RUN<- RuN
,-------------"""-~'.~"-'-.1.L..I
BUS LI TBZ-6 A39
MG V6 U6 LO
BUS PT
.... 1
CND
START<,'--------------"S~TAR=.,T_,,:~,,_.~~··•~r~•..._•11---,
LI RT
rse-s CIRCUIT BREAK(R/
=·}
BUS LZ 300-4309 GENERATOR R(CONN(CTION
H
TDZ-,4
,, 1
RUH-Z~>---------- ·-· ... ~, .... •• 1 L2 RT TBc?-J
TBl-1
1
"I J eus 1
1
START SOL -- ·--- •• 1 BUS L] TBl-2 1..2
¡~~ TBZ-Z
RUN-1 )- __ )(4,2 :,,, re r ·- J"3[lr 14> J5Cl:60J
TDl-J :1 BUS LJ ~~CJ6
11
T
LJ RT
'I
. 't~l•6• ··'
K•. 1 ,, 1 TB2-I
STA2T 1
1 TDl-"I ~ eus LO
1
..
SOL
¡
KI
+ ruEL ,,,
.... , .. ,
RUH IN
BTI -....=- Gl
SOt. }! AHPS VOLTS FREO ~ LOAD
l-=- ....
RUN IN .TSCl:60)
A35
... OUN OUT
..... DIGITAL DISPLAY ASSEMBLY
"100-4091
H22 - H21
¡:,;
- H23
I=
- H24
~
-
....
Nf:T RTN RUN OUT
D D

BT2 Jl(B) SV<BAT> J5-13
=-- ...
c::=, .. e::> c.,., Sut1
T
AUX RTN [STOP SCT ~ic
JG-7 A!1?S
513 2 .n , J3HU AUX c;MD J&-14 c:=:,.._su11
~:~-L·
CHO
=-
CNTRL RTN Y":I,, ... ,
D D ..

-
'fsh ... ,.,,... JC-& VOLTS
+IBV "" rtJ
[TI D<I-· 1>0

~l SW RUN RELAY B+- M 4 e::,, ..... C:::, U-UU-i,f U
J3C 14)5ELF lE.ST JG-1 e=:> u,uu,u " J6-4 f'Ri::O

512 ~~ AUTO ,.,.,, e::,..., ...
-.:.~ ......
"""
RUN J6-3
=-@] Os., .... D '-1L•pl.l
º"'-"'-' J6-5
¡
I GN:O """(
AUTO J&-:,.,
J6-B NE.TER ATN
CWH!T(>
No. 612-6675 sh 2 of 3
Rev. B Sys: HP
Modified 11 /7/96
BLOCK DIAGRAM (6 LEAD)

9~8
CUSTOMER TERMINAL BLOCK (PARALLELING)
TBI TBI
.. TB BAT-Fl
Pl2-2
1
2
1 ,..._ B+C20A
FUSED)
2 ,- SWITCHED B+CIOA FUSED>
A34-Pl-lB
P12-9
34
35
3<1
35
-
,-
RETURN
RUPTURE BASIN
CONT HTR 1
3 ,..._ GROUND
GND-ENG 3 36 36 ,-
CONTROL !>c..
CONT HTR 2 12 O OR 24 OVAC } BOX HEATER ~
--
4 ,- GROUND 37 ,-
}&
4 37
A34-Pl-l3
A3'1-Pl-7
s
6
5
6
REMOTE
REMOTE
START
EMERGENCY STOP
1 ~: 1 1
1 1
A34-P2-l<I
A3<1-P2-13
38
39
38 ,._ CN/0)
39 ,-
READY
C N/0 l LOAD
TO LOAD~
DUMP & NOTES:
í1: A3'1-P2-IO 7 7 ,_ CN/0)

1 A34-P2-12 40
"º4 1 ,-
,-
COMMON 8 APPLY A GROUND TO ACTJVATE INPUT. CUSTOMER íAULT 2 ANO CUSTOMER rAULT J
IY
A34-P2-9
A3'1-P2-l l
8 8 ,_ CCOM)
9 ,_ (N/C)
}
COMMON
SI-IJTOOHN
J>c..2
as ~: A3<1-P2-B
A3'1-P2-7
41 CN/0)
CN/0) }WARNING,¡},
·wAKE LJP• CONTROL. USE COPPER STRANDED HIRE. 20 GA rOR RUNS LESS THAN
1000 FT. 10 GA rOR RUNS rROM 1000 TO 2000 FT. CLESS THAN SOmA CURRENTl
9 '12 '12
& 2A
,-
A' 1 30VOC RELAY CONTACTS. THIS RELAY PICKS UP ON SHUTIJOHNS ONLY.
A3'1-P2-'1 A34-P2-S ALARM @
- IY O
y:
lo 10 (N/0) 43 '13 ,-
CN/Cl
A34-P2-3
11 11 ,_ CN/0)
BREAKER J>c..3
} CONTROL as 1
.,r I
A34-P2-6 44 4<1 ,- CN/CJ 8 SA @ JOVDC RELAY CON"TACTS. THIS RELAY PJCKS UP TO CLOSE THE BREAKER ANO
IJROPS OUT TO OPEN THE BREAKER.
12 ,_
P12-S
}&
12 NET POWERC+l <15 45
& REFER
P12-6
Pl2-7CREDl
13 13 ,_ NET POWERC->
A3'1-P3-9
A34-P3-I
46 46 - B+ IN
}&1
TO ONAN 900-0366 POHER COMMANO N[THORK ANO OPERATION MANUAL FOR
INTERCONNECTION INSTRUCTIONS COPTIONAL PCC ~'ETHORK INTERFACE NODULEl.
14 J 4 ,_ NET DATA l 47 47 ,- UTILITY CB AUX ,& íAULT.
IA JOVOC !SOi.ATEO RELAY CONTACTS. THESE RELAYS PICKS UP ON THE GIVEN
@
A34-P2-16
15 ,_
P 12-8 CBLACK) 15 IY
48 48 ,- C N/C)
NET DATA 2 .,rI - }BREAKER A
Pl2-J/A3'1-Pl-9
16 ,_
A34-P2-2
- e N/C)
-
1 CONTROL ~ ~ 120VAC OR 240VAC e SO WATTS COPTIONALI.
16 CUSTOMER FAULT 49 49
A3'1-Pl-12 17 17 ,_ CUSTOMER FAULT 2
A34-Pl-17 50 50 MASTER START SENSOR/SYNC ENABLEÁ1, &. 2AAC VOLTAGE
30VOC !SOi.ATEO RELAY CONTACTS. THJS RELAY PICKS UP HHEN GENERATOR
@
ANO FREOUENCY EXCEED 90% Of NOMINAL.
A3<l-Pl-6 A34-Pl-3
18 18 ,_ CUSTOMER FAULT 3 51 51 ,- LOAD DEMAND/UTILITY SINGLEL11_
A3'1-Pl-16 19 19 ,_ CUSTOMER FAULT 4
A34-Pl-l l
52 52 - CB OPEN/CLOSE INHIBIT~ & 2ArREOUENCY
lOVOC RELAY CONTACTS. THTS RELAY PICKS UP Ir AN OVERLOAD OR UNDER-
@
CONDITION OCCURS.
-
}~
A34-PJ-2 A34-PJ-<I
20 ,_
20 FAULT RESET 53 53 CB POSITION ~
.& TERMINAL BLOCK RATlNG
A3<l-P 1-1 O
21 21 ,_ ENGINE IDLE
A34-Pl-22CGREEN)
54 54 - GREENCKVAR +) 20A, GOOV
22 TO 12 GA H[RE
A3<1-Pl-5 22 22 ,_ LOW FUEL
A34-Pl-23CRED> 55 55 - REDCKVAR -) TOROUE TERMINAL SCREHS TO 7 IN-LBS C O. 8 NIII
~: 1 1
A34-P3-2
A3'1-P3-JO
23
24
23 ,_
24 ,._
NOT ON AUTO
PRE-HIGH ENGINE TEMP
A34-PI-BCBLACK>
A34-Pl-15CWHITEl
56
57
56 -
57 -
BLACKCKW
WHITECKW
+)
-)
.11. SAOCCURS.30VDC RELAY CONTACTS. THIS RELAY PICKS UP HHEN A WARNING
@ CONDITION
~:
1 1
A34-PI-I
A3<1-P3-J I
25 25 ,_ HIGH ENGINE TEMP 58 58 - SHEILD A1 Al'Pl Y B+ TO B+ ANO A GROUNO TO CIRCUIT BREAKER AUXIUARY TO INOICATE A
}A
A34-P2-IS
1 1 A3<1-P3-12 26 26 ,._ OVERSPEED 59 59 - EXTERNAL LOAD SET - UTILITY BREAKER CLOSURE CLESS THAN 50,oA).
~:
1 1
A3<1-P3-16 27 27 ,_ OVERCRANK
A34-P2-23
60 60 - EXTERNAL LOAD SET+ Li1 5ATO eOPENJOVDC RELAY CONTACTS. THIS RELAY PICKS UP TO CLOSE ANO DROPS OUT
A3'1-P3-17 REMO TE »; THE GENERATOR C[RCUIT BREAK[R.
28 ,_
1 1
28 LOW ENGINE TEMP ANNUNCIATOR ill
~: &
1 1
A34-P3-18
29 29 ,_ LOW FUEL PULSEO INPUT TO ENABLE GENSET AS íIRST ON LINE íOR MUL TIPLE UNITS.
[N snr..1.E/UTILITY PARALLEL HOOC, APPLY 24VOC TO ENABLE SYNCHRONIZER.
A3<1-Pl-2 I
1 1
30 30 ,_ LOW COOLANT
~:
1 1 ~ IN HULTIPLE UNIT OPERAT!ON HOOC APPLY GROUNO TO CAUSE LOAD DEMAND STOP.
A34-PJ-19
31 31 ,_ PRE-LOW OIL PRESSURE IN SIN"ol.E 1'.00C, GROUND TERMINAL TO ENABLE BREAKER CLOSURL
32 ,._
1 1 A34-Pl-20
1 1
A3<1-P3-19
32 LOW OIL PRESSURE .&_ Al'PLY A GROUND TO REMOTELY OPEN OR INHIBIT CLOSURE OF THE GENERATOR
33 33 ,._ COMMON CJRCUIT BREAKER HHEN PCC IS IN AUTO HODE CLESS THAN SOmA>.
& APPLY A GROUND TO lNDl CATE GENERATOR CIRCUIT

CLESS THAN SOmAl.
BREAKER l 5 CLOSED
Áh PARALLEL LOAD SHARE LINES CO - lmA>. USE ~ CONDUCTOR SHIELDED CABt.E,

18 CA STRANDEO. t1AXJl1UH RUN 500 rr.
k ANALOG 0-SVOC INPUTS TO CONTROL GENERATOR LOAD IN UTlll TY PARALLELING
MOOE.
No. 612-6675 sh 3of 3

Rev. e Sys: HP
Modified 12/31/96
PCC CUSTOMER CONNECTIONS

9-9
POWER SUPPLY
CR19 ~--------, THIS IS A REPRESENTATIVE (GENERIC)
--
/-'\. 22
J4
L2
II~ FI
SA
TBI. 1 1 SCHEMATIC/WIRING DIAGRAM. FOR
1 1
<6 CNllll.B• IN
-,
"' CONTROL•.,
VOLTAGE
CNTRlB+ >
JOOuH
'-----'-+-------"CN:'-'Te,Rle..,:B.:..•
-;.' _,_.,,2:..j
GND l 3
~ ;J "'"' TB 1 . 2 :
1
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
(16 OORI.Rffllli~~FILITR=~-L~_------------~-------------~-----+~=-.~1.~~ TBl.3: J? INCLUDED WITH YOUR GENSET.
~
_ 1 L..:...() TBI. 4 1
L 5 NET B+ IN CND NET 3t L--------~ 2~
CNTRL B+ I O
, ~ P1NETWORKan,
B+ IN h'ET CND
1 OITRL Bt 12
,15 NETRTH IN ~N!..!:F~I!L1l!E~R~...,~~--"'"-'c.:,e.-----------------------------, GND 11
rnNETHORK..,nl----~h'CT:.:..1~8~V•:__ 1 GND 13
' ~
N:T Bt l'I
N:T Flllf:R•
~~~~T~~T Clllll---~N:~T-4~B~V~R~lll'--------------------------~
1 N:T Bt 16
., 2 3 h'ET PCWCR-
¡
¡-< VCC ~(<"'"FOR RE:FERENCE ONL y 1 N:T Bt IB
NET GND IS
".,17 ~--....;..'... '°' va: ... 1-'.---------------, 1

1
NET GND 17
NET GND 19
HET DATA! I RS'185 0<11a. l-'''--------------+~ NET 48V• 20
I INTERFACE I
' ~--l----~ICT- T,DI-'-------------, 1 NET 48Vt 22
1 1 NET iBY RTN 21 J?
.,18 HCT DATAZ J6 L---J6 ..J I NET iBY RTN 23 TO NETHORK
' C23 AIJ)( 8+ 30 '> INTERFACE
MODULE
<E 2 O SHIELD ~ } TO NETHORK AIJX GND 29
1(
, luf
rh ~~-2-~
CGROlPID 7
INTERFACE
MODULE
BATT+ BATT+ 6 I
/14 LOH FLCL IN BATT- ;:::- BATT- 5·
VCC 2
' VCC
(-STOP SET _ E-STOP S(T B
.,7 LCII COOI.IWT IN - - ll\JI PILOT OR 25
J4 ' 1 1 Sii CNTRL 28
., 13 LOIC ENG T01' IN 27
Rl.tl_!!OH o----'ll\Jl=-'l!ON=-=-;,-,
ENGINE 7
AUTO IN
HARNESS ' F3 AIJTO_IN ==--PC""c--wooc~-- 26 ....
CONNECTOR
CHHITE) e
.,4
AIJX B+ IN
.-J
'" AUX
VOLTAGE
.. ,
k
r.;¡¡;¡¡;¡---¡;;..i..._-------~AIJX~B+!._ ~-~·'5A
U""
PCC
PCC
PCC
RTS
OTR
RXD
9
'I
3 (
!
AIJX RTN IN1 "' FIL TER Cllll _
' AIJX:GNo
PCC TXO 1
,2 START OUT 1 J
JI
' 1 PCC TXD 5
, 1 Rl.tl OUT I J PCC RXD 9
' C37
- PCC DTR 20
-
220pf PCC RTS 30
~=
2
PCC HDOG 19
., 22 ~.llG PIO<IJ' p;ilOUND . CNTRL_B+

CNTRL Bt
CNTRL Bt
27
25
-, INPUT
FILTE:R g. .... >---
""' 1 CNTRL Bt
GND
29
24
- ~- -
., 21 ~.llG PIO<lJl - ISO H QITI¡..,,
CND GND 26
'
-
CR21 1 GNO 2B
N o Sii OITRL Bt - 1 SH CNTRL 34
GOV ORIVE
- -
(19 t N N N
oo GOV ORIVE•"'t ,~~~,
~
rl
"- "- LOH Fin 15
on
"'oc -' oc -o:
,:· ""FILTER lOII COOI. 4
,_
/12__ GO_V-c.OR-'I
__
VE'-----' N-
', 1 O u u
J
LI
H
Ji
REG ORIVE +
TO DIGITAL
'., 11 BOARD
'
J5
(9
~i"'
'-'
e 1051 i R9 ••
VVv
270 VCCO-
~---VC:.=C
REC
GND IREC-l
2
I
..=2;.::2'-4
r H201 (120) ~~J2 RLtl e
/3 ,w o
ii:r
..
.1r,oH20 1 TEMPo,oo 17 ,
> 11 AGNO H201 re FIL TER w e I"'' i ra - N
oc 21
,_;'-.!:.!"' CRIS R4
E-STOP RCSET 12°7
' ~16 u
l
N
e¡·•
VV V
33
1 Kt.r 510
SPARE_DIG.1,0~:
/4
)12
I H202
AGND H202 ·i ""H2 O 2 TEMP ""' I
r,rFJLTER ...,
'"''"
,,.,., ' ~l'I
~--'----'---~B'-i 1-~l__..._
2
~A.J\,.---l--~--- '--4llfl----
START 3
L!4 ~G +ISV 16
"'.
' IB V Oll PRESS .... (1"'8) 24 1- 1 uo Rltl 31
"º
AUTO I e
r~
1 Oll PRESS+ fl "Hll 23
> 1O Oll PRESS- ~~~SSURE""' ..., e 131 i 22 E-STOP IN 7
... .... E-STOP SET 32
...
llO
FIL TER , ... ,,, 21
2 ACND O!L P
--
...."'
>6 T EX TEK'I e 1 osz ) e G!ÍD :ro..
o e,
21 EXH TEK'I+ EXHAUST ""'º' 7 . .... ::,
...
..,
0/ll
JS 7 EXH TElf'I- TEHP 1 e 139l 6 ..JU)
FIL TER '
,,..
ENGINE 14 AGND EXH TI "4"' 5 li 1------1---4---4----4---i------------i-----------------~-ri=E·STOP_SET
....., e 144l J2 .__

HARNESS B [ EX TEK'2 h1
""'
"
TO ANALOG " ¡;,
l---0
.
CONNECTOR 15 EXH TEK'2+ EXHAUST fl4"il 3 AIJTO_IH
i.
¡
~._
CGRAYJ 22 EXH TEK'2- e, osz ) 2 BOARD
.......,, ......
>-
i
TEMP 2
23 AGND EXH T2 FILTE:R .... ...... - ce
"'.......
l
...
fl 47 l 1
12 ~ so "'... ...:z :5
:¡; :5 o
.......... ~
/5
) 13
l O!L TOf'
AGND O!L T
....
""
~~~TJ~HP ::,
(154)
c iss i
~
1O >
"'
:,e
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~ ~
:::,
"'
g
::,
<C
',
:;1
17
~~1:
7 6 2 3 5
)9 ~;L~~~SE: 1 30 '!,
8
'Y 'i"
,v 'V '1/ ,v4 '1/
4 1
,1/ '1/
2
'1/
3
' 1 1 1 1
1 1 1 1 1
~ 1 1 1 r 1 1 1 1 1 I· I 1 1 I
CG.'lOUND l---~-tJt-L----' L4 )-...J L-1 1--'
19 l. 1 1 1 1 1 NO. 300-4083 sh 1of4
( a PCC_TXD J3 \. E-STOP E-STOP RUN/AUTO
2
( O a PCC_RXO
AIJTO_!N
'-----~~-~---~~--'\( } REV.E
MODIFJED 7/18/94 (
CNTRL_B+ r>-----'::....:...--'o J3 ..
'"'-.:. ,
TO FRONTaPANEL
ENGINE INTERFACE BOARD (A31)

9-10
THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATICJWIRING DIAGRAM. FOR
R9
C36
33pf WIRING DIAGRAM PACKAGE THAT WAS
PSI INCLUDED WITH YOUR GENSET.
El ~
"'
U) R7 1 vcc
+ISV +ISV "' "- 12HHz.
3Jpl -c-
POHER Ul GND
SUPPLY •ISV RTN

GND-,. "'
Kl.3
67 046
B+ +lZV XTALI
8037
POTC:~-~·~·
... XTAL2
...,.,..., CIH,(Cl(JI
w CND re Qrll #IIT IOCJ,C:~
PICO
:g ~D
1----.~N~t
E:A
UH> VR2 ACROUN~ .-t-+----;.;;..¡
ANCND
Al5/P<l.7
1--.,-'--,----f--l---r--~~VRD'
nt1/P'4.6
6.BV 1---+.c,VPO
CRS " lNST AJJ/P4.St...::-;-,,~~-"""'---~"--i--!-+--1--1
At2,P1 ...
"'"' :::; 1---~-1 BUSWOTH
Al)/P 3
Ato,P 2
SS ypp A9,P1. I
o-!i
HAC PU HSI.O
~:~p ~:=~
SH CNTRL 8+- AO,P ... O
HSl,I
CÑD GÑD AD1..,Pl.'1
IS~: CÑO KSI.O
AD6/P3.6
.. LOM COOL PIAZ HS0.5/HSI. J
A05/P3.S
E-STOP PIA3 HSO. 41/HSI. 2
TO ENGINE '"'z'-'-.._.....,_...,.,~ AD1/PJ ...
mrrrsr ~~~: ~
( 19 HSO. J
INTERFACE RUN :~~C:gyrDRlVE .._ .¡... ¡..,.._- rs
BOARD
::~~~::rni~~'t-;:::::;::::::;:::;::::::;;:::::::-----tf-rf----...::""'-R~j~z-'---'
10 MAG PU ADI/PJ. I
300-4 083 Nlv• vccPMNI O HSQ.O
~-'----,.----,.,;;Gu"H:~"~'"~G~P~U_-~1~---1J11(;No ADO/PJ.O
8 21
+lZV
START
25
s hD VOLTS
KVAR
COf1t1 CNTRL POWER 31
KM
.
F'RtOIA:NCY
~"'------,,.....--<:vcc
12 19
13 GOV RCSET PCC0:71
34
( 00
PHM Rxo,PALE/P2. t =--- ~-1'----+-ll-L--l A( O: 15) ,ALE .HR.RD 21
01 V+ COH Txo,snLE/PYEZR ....Pl. o : PBC0:7J
( 16 220 S¡O: tS) ,ALE.WR,RD 07 >--+-t-+-i:,....
ACH7/PO.7/PnQD.J
_.¡...__ ..¡_.1..._...,1 AD(0:7>
~·
( 17 A7 #ft.OC: PS,7
+ os l--i-H1,.;0;.-l
ACHG/PO, 6/PnOO. Z es 8255 PA<o,n I-...J.4---'
(1
<i" REC
GNU <REG ->
220 AO(O:?J "6 DflJf
AS... r os I--I-H1;.;1;.,l
ACHS/PO.Sl'PtiOD. 1
Pl.6
Pl,5
TO CUST
-b A4
A3
o• 1--+-H'-'•;.,lACWI/PO, ...,PHOD. O
03 l---i-H~7i-iACHJ/PO. J
Pl.1~;;,;.'1-+-1!-+...;,.......;-+-+-+-tl-+--f-,.._
Pl.3
_, INTERFACE
BOARD
GÑD A2 02 >--+-t-+-5,.... ACH2/PO.2
JS Al 01 >--+-!-+...,... ACHJ/PO, 1
PLZ 33 300-1082
56 R(SET v==-i.f!L_ _!~f-t-lH--=-J
AO 00 ACHO,PO. O
Pl.1
PI.O
SPARE
AC CONT
32
JI
FREOLICNCY PlA(0:1> ROY TO LO.AD 3 O
SB PO!<CR LOAD DUKP l.9
YO\. 15
16 PlA .. PIB>~ IO
60
IS PIAS 12PIB3~
PIBS~ 11
2 11 PlA6
17PIB4~
13 PIA? +tSV :,-,) ta
12 PIBO 22Pt8G~
11 PIBI P2BO~
REH_Ei!5TO? ~
10 P192
PIDO~
8 9 P183
10 PID(0:7>
12 16 PIB ..
15 PIOS
14 14 PIB&
J3
13 PIB7
16
•t2V ACHO 18
19 PICI 1~
13
PIC2
20 9 PIC3
089 pin J 1. 7 > DSR RS232DSR
22 ü R><D 3 .JI..! 2 DTR
TO DISPLAY
.sll2!Ll!.....-.!'..!E.r
,..:.a==.:L-f '::n
l'llill'a.
TxD 2
DTR 6
Jl.5<---~R__,
J 1 •3 T RS232TxD
23
BOARD 26 DSR 4
300-4081
GND s .J 1. 9 ~CH.(,,,.D !!&f:2!!:!J-,--f'-"'=-----' 3J
30
31
32
26
CSC0:7) TO ANALOG
34
CÑD JO BOARD
36
PZA(0:7) 300-~ 080
~2
P2A4
38
P2A'5
•• P2Aló
JP2A7
:r.
'"
••
Rl2
360
••
••
~10
I~
so cHo cÑD
~:..:....-----<
+5 RtF'
(52
~:=...---,~-----e.e SM CNTRL B+-
f--""-------c vcc
(53
NO. 300-4079
REV. D
MODIFIED 6/3/94
DIGITAL BOARD (A32)

9-11
THIS IS A REPRESENTATIVE(GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING,REFER TO THE
WIRING DJAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.
TO n.. 1 MUXOUT
3 00-4 082 !
us
4051
A 10
11
~ 9
INH ~
-, VEF~ e
GND 6 y
~----------,-+-l------------~~~!1L~Ti~~~r,p~l:'..J:~!'-'~l....~~t,~¡¡--IUV--~'IIJ)('-:I
EX T!:'11'2 15 n X2 A vcc
BATT!:RY VOLTACE 12 n XJ 74HCQ6 TO DIGITAL
51 1 "' X1i UJ0.2 BOARD
52 s ... xs 3 00-4 0,9
12 1 ~ 141 1-<2.sv_REr
53 2 n XG
S.!.!...a,_ X7
1
~
L f-GRtuNo - v- 7 :.....,I1 ~ P< ~ PARALLELINGv-
ref ou< _
PARA KM J
5: I 3 -p_l1nc pp ,n PHH KW ~¡ 1 ~-------t------t--t-it-+-------------------+-+-t-i,-'
OP 7~~{;.• ----------+------1-+--,..-t--------------------~
~;--is
+ v+ AHP : ,r I I .> ~ ~OUND p - v+--< +l 2V ~vcc R2
[
L.:
Kt ~
=:--:-J L:
·
ve >
Pwt1 KVAA
Lf-v~
+12V ~
LiiJ~ H-=~~l~~HI~~
LINE FREO 2 eLK ,¡¡_ PWH KM
---,..--------~~"-º-L~A~G-----------------------------------------
LINE FR!:O
~
GÑD
BUS FRE.O HU5 r
1 ~J_~-~~+~~+G~fiS
+ v+s OP AHP o VCC 7~~~7.Í PHASE ROT
:;1 IQ.
i
[ R12 e--"-- eNTRL 6
;•zv
9
L~1·· m ~ :~~.{ ~1 ;}!.~¿ CRJ7 ve ve HUXCLl\l1Pvee vce
(;(-'J'-•'-(~3"3a-----<~!~To_sw - v- AGROUND _. ve~~ 2 e Y 3 KI >-.--:.--~ +12V v+ VOLTAC!: v-
Jf-
~rü ~rü
+J2V+.---1
~z-------~-~-=,,,,.-----~---<+
,31 BATT S!:NSE + R~
v+ BUSPRPQ •PRO
5
AG~OUMO
- - - -
... l"" ... -- . . .
<;:JO' [>AGROUND 1.0011 ;~ OP AIIP ZBZr ~
2
CLK • IIIZIJl4 GÑD
¿9 S +12V >-- ¡-,
-u::~
~ D lO "'- ~03 v+ ::~ v-
~~ 2_ +12V u, •CLR 7~?J.-;.1 '1PS2222A ve>--- ve BUFFER 1 'Q' U7O AGROUND AGROUND
_¡-J..++..jJ-1._J
+--_~__
1 1_,rO
~il' Ve>--"1":t--;_!!BA!!,T!_T~E~R!:!Y~V~OL!:_T!!A~G!::!!-,_ 01 02 OJ O< AGROUND TLt2426
24
( 25 I\AGROUND
yV OtL PR(SS AGROUND VRE:F"OUT
CR 12
v .. - ', co '>; C..~O
2.SV_REF G2 1 3 +S REF'
.. +I ,..
:rf.s
'22{-",..:2c::J -;O;;l"'L'°"=P;;,RE;;S;;S,;.•c-----------lV+IN3 HIRE VREF'- - ••
/
?f~
UJ0.4 ;~ >~
:20-{-<-=2~1----¡f>~G~~~~D _
<--~----~º~'~L-P_RE=S=S~-------------<V-IN SENSOR VOUTt----+--º~IL~PR~E=S~S---------~
v- ve_ ~7<HCB6 .
SPI SP2 SP3 SP4
~T~
l}}}
IOUT
:.!.
v+- 1
{-,~l-=9 H~2,;.0,;.l~+-----------+--IY+IN
~/1-'8-'~----~H~Z~O~l~------------+--IV-JN
4 WlRC
¡iN:~
VA'(F"-
VOUlf-+-f-+---'--'H2~0=--I-------------' vec B y
1
¡,
3 s
w
7
ACROUNO
: 16(
17
~~G~~~D - v- ve - -..; 'V
M
"' ..; "- N y U) o,
AGRi,ND
' {-,~l~5 i WIR( VR~;=

H~2~0~2~•-----------+>---i!~~~ ... ... ..,"' .., .., ..."' .., ..,"'
M M M
f>~G~~N~El' I?
TO ~·~·-'""""' H~2=0~2~------------+--IV-JN
~~..~~ VOUTf-+-f-+---'--'H2~0=2~------------~ U31.2
300-4083 '12(13
' ..,~1~1 ~0.e,IL~T'éE"-M°"P"'I-~ _,,_._.~~~~ 4 WIRE VR~;
(-',,l~O....._'.------=º=IL~T~E~M~,P-=1--_-------11----iV-JN
~v-
VOUTf-+-f-+--"O~IL~T-=E~HP"-------------~ ~~N:~
ve-
= ~:!
';,a..~ l.
,,8 {-(-' 9'-----,[>rc;:,ir~HPJ f- v- VC - •CLR
',-/'----~E~X~H'--"T"'E~H~P~I+ 4 MIRE VR~;~ . . . ,---.!~~~ .,--

CND
~,_6_'-.-----~E~XH~T-=E~ll~P-=1--_-------t--1V-JN VOUTt--f-t-t--~E~X_T=E~H=P-=1------------~ ¡¡~~
• ( s c~~{'~HPz l>f~ v- ve - '
/3 EXH TE11P2+ lOUT v+-
/2 <-,-----~E°'x-H~T"'E-ll~Pz'"--------- ....... ---.v+JN ~e~~ VRCF- ex TENP2
( l
;¿,.
__'ª_•_A_>_v~ov~uc~r;::1:t:::~v-c~~~-------------J
~-~:==-'N
'-ll AGROUNO ,:,. 2.SV_REf' ----<+12V
AGR:OUND
No. 300-4080 sh 1of 5
Rev. e Sys: 'HP
Modified 2/5/96
ANALOG BOARD (A33)

9-12
THIS IS A REPRESENTATIVE(GENERIC)
J3 J4
J l. 17
/17 mSTER rs IN
(960) TROUBLESHOOTING, REFER TO THE
J l. 1 ~ /2 2 ~ WIRING DIAGRAM PACKAGE THAT WAS
IN MO
IN~ 1
( 1 ~ IIOT PRl:-lOP JI. 16
Jl .22
rh ~ PliC-fCT IN ""-e? LOP
'
( 16 CUST FLT~ [11 ~------1 IMI
1
¡+ QJTI 1----11---------- INCLUDED WITH YOUR GENSET.
, 22 PA.~ ll NE I JH CGll~D ~ 10 IN~) 1'!11:-ICT J l. g INPUT
IL---------111<2 ami----11---------~
~OS ICTIN~ TO
.r',23
i .23 TO ~ oc ANNUNCIATOROSIN~ >DIGITAL
BOARD
'-
_ _,-------llm F~~~E:1&
<,'~9:....__CUS==.T:...:..:fl~T~l~l,::H
__, IN4
runl-----11---------~
ruT4 1----11--------
PAR LIIE 2 111 CUSTOMER .~ ur INTERFACE oc IN~~ 300-4079 J l. 2
TERMINAL""' ,c....!..!!__
) IS te nn, irr IN~
13 ,2 ílTRESCT IN 1
', B a
Ji.
PARLIN( 3 IN ~- oa
BLOCK ~ llJlllN LO F1U IN~
-,
J l. 1 O
E,...c:....-..==:.;=-:"--""------,~ oe PARALLEL (960)
19 PRl:-l!P LO OXl. ~: ¡,.--- ') ~ , 1O EHC lll.E IN
5
J,1.·5l PAR LIIE 4 IN "" f"ILTER 1
E,...:.:::...._~:.:..::c:,.:,:..;..!'-'-----..l~
J2. l
UP
LO COO..
(lllO 9fl10t ~
SN &t -+-+- J' l. 3
, 3 8KR CLOSE IN ~--------1
1
JNI
8'
ern 1---1-------~
TO ( 1 "r J J'-1. 1 ¡ '-------- 11<2 INPUT am 1---i-------
CUSTOMER
TERMINAL
BLOCK
J2.21
~21 BUS A IN
rh
CGROUiD
TO
CUSTOMER
TERMINAL
'
~'-1~1---=:BKR;;.;..;:Ol'EN::.=.l~H
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IS
23
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3
'
J2.22
AUTO SWHCH I I , 12 CUST íLT 2 IN ENGJDLE
BKR CLS
28
31
, 22 BUS B IN
P~LEL LINE 1
PARALLEL LINE 2
19
20 • JI' .5
11
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'
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300-4079
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9
300-4080 rh [!:
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J3.21
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21
7
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J2.6 1----~vA~.r--~\!:Jl~.l---..-~4~
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J2.13 K7.3 390 Green e~~? 1
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J3.20
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1
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BLOCK ,9 COH ALA!ln COl1
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Rl7 1: ~U9
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2
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PARALLEL VERSION ONLY COHT OP""tH 2
J2.15
IS CO-SVDC> CB05>
JHI CIJTJ HATT+
J2.23 HATT
23 (581) FIL TER
11<2 aJT2 ~n-
No. 300-4462 sh 1 of 2
Rev. D Sys: HP
Modified 2/5/96
CUSTOMER INTERFACE BOARD (A34)

9-13
-
UI U2 U3
Dl.GZ416 Ill..Q416 Dl..G241G
u•
OLC.!416 SCHEMATIC/WIRING DIAGRAM. FOR
.15.32 JS.2 15.17 t
~ CC:I AO~
8 ... l.
<..
CCI AO I~ :,
i,
2-
en AO~
J.
2.
CEI AO~ TROUBLES HOOTING, REFER TO THE
(~ 2
~ Cl'.2 CE2 Al~ CE2 Al~ CE2 Al~
...,
A1~
.JS .4 JS. I .15.33
• ~~~~ DO~ DO~
ºº~
f!-- ~ CLR~
•
Cl_R CLR~ CLR CLR~ CLR
01~
CLR~
•
CLR
01~
021 !! ::, INCLUDED WITH YOUR GENSET.
l ...
DI~ 4
1 '"-~
JS.34 JS.6 JS.19 4
CUE IR r¡:¡--¡;¡;-. CUE IR~ CUE IR~ CUE
~ ~
... m tTri.ii' 03~
IS.a~ BL BL DJ~ BL
~~ BL
cJn(¿t
JS.3 JS.35 U25 eLal!'<
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lBL~ D<~ 04~ lBL~ 131~
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8 ICS1 7'4HClS1
JS.36 JS.10 JS.21
10 ~R
cu
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12
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JS.36 JS.14 JS.23
~ ~
JS.16~
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JS.39
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BOARD
~ J5.20~ JS.9 ~ JS.41
20
J5.42 ' J5.22 ~ JS.27 ~
U8 U9 UIO UII
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=\
JS.2<~ JS. 11 JS.43
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JS.28~ JS. 13 JS.45
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1
Cl.R DI 1
1 1
4 4 4 4
28
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JS.46 JS.30
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GÑD GÑD CÑO vcc vcc vcc
BAD(G:?>, BACO: 12) ,BMR,BRD,BCS7 VCC
JI .9
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DSELF TEST
JI. 7 U7. 1
,7 PHASE StLECT 1 2
I
yª ...
' UG. I IK
1 .... 2
JI .12 IK• U7.2
CB CLOSED 3
~12
I
1
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3 ... . 4
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U7.3
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r
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J5.55
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ü:;~-; ~:::~] ru;
üf~ ...~~; - . .
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JS.56
...~56 DRtSCT
NO. 300-4286 sh 1
REV. G Sys. HP
MODIFIED 3/17/95
DISPLAY BOARD (A35)

9-14
112
YELLOH GEN A IN
J9-4
T3 JB.6
4 7 GEN A 6 Jl7 JB. 15
(11
>
o o WHITE CTI 15
(}:'.: (\J
("\)
JB.5 J9-9
> "<T (}:'.: (T)
o 6 GEN A COM 5 o .!
in
el'.: (T)
J16 18. 14
GRAY CTI 14
J9-8
11 1
:JRANGE GEN 8 IN JI9 JB.22
J9-3 TAN CT2 : 22
T2 JB.4 J9-l 1
7 GEN B 4
(\J
>
o o o
(Y) lD
(}:'.: [\J
JS.3 el'.: (Y)
> ,;¡- (}:'.: (T)
o 6 GEN 8 COM 3 - 118 18.23

BLACK CT2 COM 23
J9-]0
JI5 J8.8
PURPLE en 8
110 J9-7
RED GEN C IN
o
J9-2 ~
JB.2 (}:'.: (Y)
7 GEN C 2
> JI4 JB.7
o o BLUE CT3 COM 7
(}:'.: (\J
> "<T (}:'.: (T) JB. 1 J9-6
GEN_C COM 1
J9
BROHN GEN COM IN
J9-l
PT VOLTAGE TABLE
GEN
ASSY DHG NO.
PRI SEC R 1, R2, R3 Value
300-4250-01 120V 18V Slk ohms
3 00-425 0-02 240V l 8V 5lk ohms
300-4250-03 346V 18V 11 Ok ohms
..
NO. 300-4250 sh1
REV. C SYS. HP
MOOIFIEO 1/24/95
PC/CT BOARD (A36)

9-15
TB 1. 1
1 BUS A IN
TB2.6
? GEN A 6
(T)
>
o
Cl C\J (\J
> s:r (Y TB2.5
GEN A COH 5
I
TB 1. 2
2 BUS B IN
T2 TB2.4
? GEN B 4
(\J
>
o
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> s:r TB2.3
• 6 GEN B COH 3
TB 1. 3
3 BUS C IN
Tl TB2.2
? GEN C 2
>
o
(Y C\J
> s:r TB2. l
• 6 GEN C COH 1
TB 1. 4
4 BUS NIN
PT VOLTAGE TABLE
GEN
ASSY DWG NO.
PRI SEC Rl, R2, R3 VAL U E
300-4322-01 12 ov lBV 51K OHMS
300-4322-02 240V IBV 51K OHMS
300-4322-03 346V lBV 11 OK OHMS
300-4322-04 69V 18V SIK OHMS
No. 300-4322 sh 1 of 2
Rev. E Sys: HP
Modified 2/5/96
BUS PT BOARD (A39)

9-16
17
GREEN P2
JI0-1
~
o to
(D
(T) cr ~
o N
JG
'
r,
YELLOW P3 IY
JI 0-4JS
ORANGE P4
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:,
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u
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3
JI I 052
BLACK CR7 R9 CR4 J3
J7-6 XCFIElD+) RED
(1)
cr J 1 0-6
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N
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V
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CYCLE
cr
cr (T) (T)
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en 6.2K
cr (")
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o et:
o TSC428 u
cr ti)
"- J2 ... + 7
JS u RIS N 2 [> MTHl4NSOE
PURPLE GND GRAY REG + ~
o
:,
(1)
u Al Yl
J7-2 17-3 1 QI
270 1 lD 4 R7
5
-
GÑo 1 A2 Y2
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u 1 > N :,
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o cr
-U
(1)
100
o
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to ~o
O!
ISO GNO l ISO GNU 2
NOTE: 1SO_GND 1 and ISO_GND_2 connected at

sourcc of 01 only
NO. 300-4085 sh1

REV. F
MODIFIED 6{7/94
VOLTAGE REGULATOR OUTPUT MODULE {A37)

9-17
Fl WIRING DIAGRAM PACKAGE THAT WAS
J6. 1 lOA J6. 7 INCLUDED WITH YOUR GENSET.
1 B+ B+CFUSED) 7
J6. 16 F2
16 > <+-
lOA J6. 12
Cl'. lO u :J
> !'1 SW B+CFUSED) 12
J6.9 ,.,
9 /' J6.4
4
F3
GND IOA CR8 J6. l?
GND 17 I
J6. 19 O)
19 o O::: J6. 18
.u GND 18
JS.20
20 K l. 2
3 GND
J6.21 CD <+· y
21 RUN u J
O)
o
o O::: o
r-,
CRlO V
Rl2 - J6.6
GND GOV ACT C +) 6
o
~I~
r-,
y 160
CD (.!)
O::: Cl'. OUTPUT
...J Ul u ..: DUTY CYCLE O:::
u
<[ 7805 o 051 Zl
z +SV CR4
Zl?
I SV 3 "x'
::)H
O:: ({)
e G
o
6 GND Amber
r-; ru Q) (Y)
> + <+-
O:::
Q)
O::: ,;¡- e.o 2
~
lí)~ J ru
u 2
Q s,
l?
> N u O) u J5.8
GOV ACTC-) 8
lO
y
Z2
o N o 'X , U1
.------------. 6 (Y) <r ru Cl'. e.o y
GND I U2
O::: in O::: O) O::: tn u O:::
J6.2 Rl 1 H 11 L1
2 GOV DR+ 1 I 1
1
1 G JS.23
270
1
1 es C4 23
14
(D---o) y >
-
e.o 1 Q2 o ru lO
O::: 1 + + O::: Cl'. (Y) <+-
u 1 1 Ouf I Ouf (Y)
MPS2222A > lf) u :J
o; !'1
J6.3 1 J6. 15
___________
!'1
u
3 GOV DR- 21 __. 15
GND
NO. 300-4084 sh1

REV. D (·-·-~·
MODIFIED 6/7/94
GOVERNOR OUTPUT BOARD (A38)

9-18
I") I")
\
I")
I
-
<, <, <,
(\J (\J (\J
1 1 1 1 o 1 1
;;;
I")
(\J "I
I")"'
(\J I
(\J -
(\J I
(\J
(\J 1 -
(\J "'
I
-
(\J 1
u ~"'
g:
1- 1- 1-"'
u~
1- "'
u~ u~
1- "'
u~
1- "'
u ~
P9 8 ]1----------lll l l l l l l l l l l l l l l l l l l l l lf il#! =
o o o
-- Ñ í=>1 ~
a- 1
"'
1
e- o-
10 ~ -o ~ ¡-..~ co ~
TABULATION
FROH TO
STATION STATION
A36-P9-1 I CT22-I
A36-P9-10 CT22-2/3
A36-P9-9 CT21-I
A36-P9-6 CT21-2/3
A36-P9-7 CT23-I
A36-P9·6 CT23-2/3
A36-P9-4 6
A36-P9-3 7
A36-P9-2 6
A36-P9-I 5
11 FRAME 4 THRU 7 11
NO. 338-3019 sh1

REV. C
MODIFIED 6/9194
PT/CT WIRING HARNESS

9-19
A38
P6 TB-BAT
CGOV) (SEE IJETAIL"A")
A37 K4-S2
PlO ---- rar-a (CHHJll)
(DO.a)
(AVR)
rer-t
A37 ~
P7 BI-BAT
S7-SIG
(AVR) IP,-71
(111-<llfl
S7 (+)
CP4-22) BI-BAT IT8-9ATI
PI-A (a..EAR) CT&-IIATl
(P4-21)
p 1-8 (lll.ACK)
CP4-9)
PI-SHlaD
El J.t_1,
P4 57 (-)
(CKKIGI
P5
AG'2(PIO-I)
l't«lP3 CP 10-4>
PMlP4CPIO-!S)
X+(PI0-6)
XX-CPI0-3)
ICT C-l
1-.1
Gl-0+
11'6-221
E2-6
11'11-111
PIHH E6-A
1'11-7 E6-II
E6
THIS DRAWING APPLI ES TO:

MODEL THROUGH
SPEC LETTER
--
DFAA E
- --
tr7+
tr7-
TIHIAT
81
PI
WlTOMJ!L ,_
-PJDCLP
IUPl DFAB E
II-IIAT IU-IIAT
l
+ '"
112
KI
PIEDT PD.01' -
Sl"Hl'IDI 8IUNIID
ftE.SUMIII)
IILllf l'l.mlll DFAC E
P7-2
PIC>-1
PIC>-4 181-1
......
l'IH7
.......
fn+
81-IIAT ------' NO. 338-2938
REV.E
Al2IIIMIKR DETAIL "A" MODIFIED 8/15/94
L10 ENGINE HARNESS DIAGRAM

9-20
A38
P6 TB-BAT
(GOV) (SEE DETAil "A")
A37
P10 ---- TB1-3
(AVR) (GND-DICI)
DETAIL "A"
TB1-1
A37 (TIHIAT)
P7 57-SIG
(AVR) (P4-7)
K4-S1
(P7-6) S7(+)
~ {TB-BAT)
I
P1
P4
MAG PICK-UP
j Et-A
(PS-2)
A------ 57(-)
{GNO-ENG)
E4
P5
ACT-+
(P6-6)
ACT (-)
LEAD TABULATION LEAD TABULATION T26 (P6-8)
FROM TO ,. FROM TO
STATION STATION STATION STATION
P4-6 TB-BAT VR21 VOLTAGE REGULATOR
P4-16 GND-ENG 59 RUPTURE BASIN
P4-5 TB-BAT 58 LOW FUEL
P4-15 GND-ENG 57 LOW COOLANT LEVEL (LCL)
P4-7 S7-SIG
P4-1 SS THERM05TAT (PRE-HET)
P4-3 TB-BAT PS-15 S5 SWITCH-PRE55 (PRE-LOP)
P4-4 GND-ENG PS-23 54 SWITCH LOW ENGIHE TEMP (LET)
P4-2 P7-5 P6-6 53 SWITCH-OVERSPEEO {OS)
P4-1 P6-19 P6-8 52 THERM05TAT (HET)
4- 4 1-BAT
P4-22 GND-ENG 51 SWITCH-OIL PRE55 (LOP)
P4-21 81-GND P1 MAG PICKUP
P4-9 TB-BAT K4 5TARTER PILOT 50LENOID
P4-19 GND-ENG K2 PREHEAT 50LENOIO (GLOW PLUG5)
12 6-3 K4-BA K1 FUEL SOLENOIO
P4-10 P7-3 K4 +
P4-11 P7-4 TB-BAT HTR
G1
ENGINE HEATER
ALTERNATOR
THIS DRAWING APPLIES TO:
P6-7 J12-5 GND-ENG E7 EXH TEMP fRIGHT) MODEL BEGIN
GND-ENG J12-6 P10-1 E6 EXH TEMP LEFT)
P4-1 J12-7 P10-4 ES TACHOMETER SPECLETTER
P4-18 P4-18 P10-5
PS-.S E2-A P10-6 E4 5ENDER-OIL TEMP DFAA F
PS-11 E2-B P10-3 E3 5ENOER-WATER TEMP fRIGHT) DFAB F
PS-2 El-A J12-2 E2 5ENDER-WATER TEMP LEFT)
P5-18 Et-B El 5ENDER-OIL PRE5SURE DFAC F
P5-1 E1-C BT1 BATTERY-5TORAGE
P5-21 ES-A DOAA A
P5-7 E6-B 81 STARTER & 50LENOID DOAB A
TB-BAT TB1-1 A12 GOVERNOR
GN - N 1-
P5-5 E4-A K4-S2
P5-13 E4-B S9
P5-17 TB-BAT GND
P5-9 GND-ENG NO. 338-3393
REV.8
MODIFIED 4/15/97
L10 & M11 ENGINE HARNESS DIAGRAM

9-21
HTRl-1 HTRl-2
(1261
(CH>-EIGI S8 S9
Jl2 V (p.i-1,1 (J12-9J
A38
P6
(GOVJ
SEE DETAIL "A"
TB-BAT
A37
PIO
CAVR) GI-GtO
UH>-E«ll
GHlJT S7-SIG
(81-eAT) IP.l-71
A37 J
P7
CAVR)
1
1
1
1
1
8
P4 !
'1
1
l.EAII TMU..ATIOI
FRIM 10
P5 ------ 11.00-- -
IITATIOI IITATIOI
E2
P4-16 PIG>2(PIO-I J
P4"" E2-B
P4-18 Pl«lP3(PI0-4)
(Pfl-l 11
Pl«lP4CPI0-!5)
X+(PI0-6)
XX-(PI0-3) (1'15-7)
GND-ENG E6-A E6
-
N-111 IOTEti
Pll-2
PII-I&
J12-II ll1IE 9)
E2-A
El-A
EHS
PI-A
CP4-22l
PI-B
(P4-21 l
PI-SHIELD
IN-131
(P4-9J
Pll-21 E6-A
Plt-7 E6-9
-• ~-
-;;·
,n
86
S4
1..111 R.E.
1..111 IDUMT I..E'll1. ILa.l
lKJINDSl'AT(PAE~I
tlm'OH'IIEN IPAE-IJPI
S3
12
IIIITQI 1..111 --
9IIITQHMSISUD
lKJINDSl'ATUEr)
-
(OSI llETI P4-6
N-tl
THIS DRAWING APPLIES TO:
Tll-1
11
PI
~-IUPI
IWJ PlDCll'
p~
Plt-17
MODEL THROUGH
IU
IC2
8T.urmt PJUII' 9ILDmD
l'IE€AT m.emD (Q..flll lPUIIIIJ P5-I
P5-16
SPEC LETTER
1(1 R.E.SI.DlllD
,n+
GI
O•
111...nmMTIII
DHllM' IRIDffl 81-eAT -----~ DFBF L
E60
es
u
DHllM'
TACIOEml
IIENEHIIL
(LST)
llM' DETAIL "A" DFCB L

Do
E2
IECEHIAlER 1EM' IRmffl
IEMEMU.llR 1EM' 11.EFTJ
DFCC L
El IIENEHIIL-
IITI IIATlD!'f-
81 lll'Nmll • m.emD
Al2 CIMJIIOI NO . 338-2604
REV. E
MODIFIED 8/12/94
NT855 ENGINE HARNESS DIAGRAM

9-22
TBl-1
1)..,38
{c~) TB-BAT
SEE DETAIL "A"
DETAIL "A"
A37
PtO
(AVR)
A37
P7
(AVR)
E2-A
(pi¡'...,3)
E2
P5
PMGP2f 10-1? E2-B
PMGPJ P10-4 (P5-11)
PMGP4 P10-5)
X+( 10-61
XX-(P10- )
LEAD TABULATION LEAD TABULATION

FROM TO FROM TO
STATION STATION STATION STATION
P4-6 TB-BAT GND-ENG
P4-16 GND-ENG TB-BAT P6-1
P4-5 TB-BAT TB-BAT P6-16 Pt T26
P4-15 GND-ENG K1 P6-20
P4-7 S7-SIG P7-1 P6-21
4-1 S4 Gl-0+ P6-22
P4-3 TB-BAT P6-4
GND-ENG P6-15 VR21 VOLTAGE REGULATOR
P4-4 GND-ENG SB LOW FUEL
P4-2 P7-5 GND-ENG P6-23 S7 LOW COOLANT LEVEL (LCL)
P4-1 P6-19 ACT+ P6-6
4-14 ACT- P6-8 56 THERMOSTAT (PRE-HET)
P4-22 G1-B+ 81-BAT SS SWITCH-PRESS (PRE-LOP)
PI-A ~MAG PUl G1-GND GND-ENG SWITCH LOW ENGINE TEMP (LET)
P4-21 Pt-8 MAG PU S4
P4-9 PI (SHIELD) GND-ENG 81-GND S3 SWITCH-OVERSPEED (OS)
P4-19 P6-2 S7+ TB-BAT S2 THERMOST AT (HET)
S7- GND-ENG
P4-12 6-3
81-BAT K4-BAT S1 SWITCH-OIL PRESS (LOP) THIS DRAWING APPLIES TO:
P4-10 P7-3 Pl MAG PICKUP MODEL BEGIN
P4-11 P7-4 81-SW K4 +
81-BAT TB-BAT K4 STARTER PILOT SOLENOID
P6-7 J12-5 K2 PREHEAT SOLENOID (GLOW PLUGS) SPEC LETTER
GND-ENG J12-6 P7-2 GND-ENG
PMGP2 PI0-1 KI FUEL SOLENOID DFBF M
P4-1 J12-7
PMGP3 Pl0-4
P4-t8 P4-18
PMGP4 P10-5 HTR ENGINE HEATER DFCB M
P5-3 E2-A GI ALTERNATOR
P5-11
P5-2
E2-B
El-A
X+
XX-
P10-6
P10-3
E7
E6
f
EXH TEMP RIGHT)
EXH TEMP LEFT)
DFCC
DFCE
M
A
PS-18 E1-B P6-12 J12-2 ES TACHOMETER
-1 DQBA A
P5-1 Et-C
PS-21 E6-A P5-4 P5-12 E4 SENDER-OIL TEMP DQBB A
P5-7 E6-8 P3-A G1-B+ E3 SENDER-WATER TEMP ~RIGHT)
TB-BAT TBl-1 P3-B T26 E2 SENDER-WATER TEMP LEFT)
GND-ENG T81-3 P3-C G1-GND Et SENDER-OIL PRESSURE
" P5-5 E4-A P7-6 K4-S1 BT1 BATTERY-STORAGE
i\ P5-13 E4-B GND-ENG K4-S2
.:.:<":l J12-9 S9 81 STARTER & SOLENOID NO. 338-3392
PS-17 TB-BAT A12 GOVERNOR REV.C
P5-9 GND-ENG GND-ENG GND MODIFIED 4/15/97
NT855 & N14 ENGINE HARNESS DIAGRAM

9-23
A38
P6
(GOVl HTRl-1
(1'26)
HTRl-2
(ENHHJI
'SEE DETAIL "A".
~p \ I
TB-BAT
Gl-0+
IK-22)
l
GHNl
A37 BI-BAT
PIO E2
(AVR)
S4
(P4-l3)
A37
P7 S7 +
(AVRl (TIHIATJ
S7 -
(CH>-ell)
S7-SIG
IP4-71
P4
E6
P5 IIJ.OCI ------------
f>IG>2(PIO-I)
PIG>3(PI0-4)
PMGP4(PIO-!S)
X+(PI0-6)
XX-CPI0-3)
PI-A
(P4-22)
P4-16
P4-t5
P4-IIJ
Pl-8 o
(P4-21 l
PI-SHIE.D EI-C
(l~-11
CP4-9l
89
CJ12-tl
[4-A
ll'IHI)
E4
-.. ~-
.,
'11121
...a
111
WLT-
LOW FtB.
n.-.TAT
IEU.A11Jt
LOW aa.Nd'
llm'DH'IIEIB
IZ\IEL
ll'RE-tETl
na.>
(l'RE-ul')
LOW ECJNE 10I' 11.f:Tl
-
IIII1Q(
~108)
12 n.-.TAT IIEl'I
•• _,._..
PI
IC4
IIIITOHJIL -
8TMITTR ~ 8IUHIID
IUPI P4-6
P4-II TBl-1
-
IC! PIEEAT llllMIID ltLCII PLIIBI
1(1 RE.IQ.DCID> P&-17
111
E7e
-'LlBNl11Jt
ElN nN' (lllDfr) ...-1,
N-1
--
EII
E4
_,_
EN nN' lllFTI
TAODEIIR
U+
81-U.T-----~
ESo
-- ,_ (lllDfr) DETAIL "A"
-
E2 IECIEJHIATBI 1DP IUFTI
El
IITI IATIDIY-
81 8TMITTR•DDmD
+ 1
xx- Plo-;J Al:l
--
N-1:l JllKt
N-7 Jl2-I
N0.338-2605
P7-6 IC4-91 REV. E
MODIFIED 8/12/94 ( ..'. .
·.·
..
·;
Jl2-9 99
'~-.-- ·
K19 ENGINE HARNESS DIAGRAM

9-24
a
ese P«rTE 6>
HTRl-1 KTRl-2
(1'26) (EIG-GO) E4
A38 Jl2 ~
y
P6
(GOV)
\
\
'
. ' E4-II
(P!i--13)
''
,
,,,
1
Gl-0+
, (1'6-22)
A37
PIO
(AVR) ,,
' El
E3-A
A37 '
1 El--5
'
(1'!5-18)
P7 1
(AVR) 1 K4+
(BI--SW)
''
1
1
OWJ
PIQHP) ----11.00----- --a.oo--------
E7
KI
("6-20)
PI-A
(P4-22) CLEAR
Pl-8 Bl-tlAT
(P4-2 I ) BLACK (Gl-oJTI
PI-SHIELD
8 (P4-9)
.;
87-
(IH>-EG)
Pl«lP2(PIO-I)
PIG>3(P 10-4) j=j=:::::=;~./
S7-SIG
IP4-7)
PIG>4(PI0-5)
P5 X+(PI0-6)
XX-(PI0-3) S7+
(Ta-llAT)
..
''
I ' ' ''\ ~ltU 'iOLTACIE -.a..ATIIR
,1 ~ ,n
9(,
Lllll F\El.
Lllll aD..NIT I.E't'EL (La..)
11EMlSTAT IPAE-fETl
HTR2-I HTR2-2 a, 8lfI10H'IIEllS IPAE-1.!Pl
.
(1'261 (ENIHN)) S& lllrlDI Lllll U1:DE 1EII' ILETl
113 IIIIITDHMRIHm <mJ
82 11EMlSTAT(IET)
IIIITOHIJI. PIIEIIII IUPl
PI IWI PJtlCII'
IC4 trTAlrTER PlUIT ll1.EJIJJD p¿...
ICl PAEIEATll1.EJIJJD ICUIII PUJlll) P4-II
kl RE. 9CLElllID Tlll-1
P4-;J
GI .11.,-TDR P!i--17
E7• ElCH 1EII' (RIIHT) 1'6-1
me ElCH 1EII' (L.EFT)
+ EII TACIDEUI P6-16
)()(- PIC)-;J u !IDIEHDL 1EII' 'IO+
P6-12 Jl2-2 111-IIAT --------'
"6-7 Jl2-I Do -1Elt 10P IIIIGIITI
- -
E2 IENIEIHIA1Elt 10P (l.lFT)
111-il-'T 'IIHIAT
El
ITI
111
IIATTEn'-crTllllAGE
IENIEJHDl. -
STAlrTER lo ll1.EJIJJD
DETAIL "A"
T26 HIR2-I
HTll2-2 Al2
NO. 338-3015
RE'I. D
MODIFIED 8/16/94
VTA28 ENGINE HARNESS DIAGRAM

9-25
(SEE NJTE 6)
HTRl-1 HTRl-2
n»> CEJG-QC>I
A38
P6
(GOVJ \! ''
(SEE DETAIL "A")
TB BAT ,~,
Gl-0+
A37
PIO E2
IAVRJ
A37
P7
(AVRJ
S4
11'4·131
81-IIAT
(01-<IJT)
8
!!
P4
8 E3
IJ
P5
PIG'2(PIO-I J
Pl«JP3(PI0-41
Pl«JP4(PI0-51
X+(PI0-61
XX-(PI0-31
,~,,
,,-111
.
N-il
PI-A El-11 Et-A

IP4-22l c...EAR (PIH8l lP.HII
PHI 1
(P4-21 I 111.ACK 1
PI-SHIELD
(P4-9J
1
1 f~.,
1
,, El
¡' \~ KTR2-2
KTR2-I
(125) CDIIHNII
-...
.,
14111 lla.T-~na
••
G
l.1111 R.B.
1..111 aa.NIT
nEKJll'ATIPE~
~o&:l~UD)
~(Dll
u:wi. (LCL) --·
N-il
N-;J
1'11-17
-"
.,.
Tll·I
e nENIBTATOE"I 11-e.\T-----~
••
PI
lllrlDMm.
-PmCIP -- (UP)
DETAIL "A"
IU
....__
IITMIDIP'nJffSIUJIIID
-...
IC2 l'IEEAT 8IUNIID COUllll'lJJIII)
MI
~-
ª'
Do
M.'IBNllllt
DH 1DP amtlT)
DHlDP IUFTl
m TMHIE1Bt
E4 --=.lDP
1
pe IEJl&-W.TDI 1DP IUD«I
.,.,
- ..
PIC>~ D. -TDI 1DP CLUTI
... Tl'EII\'__
-
Jl2-2
Jl2-I
•• STMn'III! • ll1.IMllO
NO. 338-2606
111-IIAT
125
'IIHIAT
HIR2-I
Hl1l2-2
Al2
REV.D
MODIFIED 8/15/94 (
KT38 ENGINE HARNESS DIAGRAM
9-26
HTRl-1 HTRl-2
IBG-IHII
(1'261
(SEE DETAIL "A")
y TB BAT E3
A38 /
P6 \ ,'
CGOV) ' I
39.00 ''1
1
1
+
•
'
1 K4-BAT
A37 191-eATl
PIO
CAVR)
A37 S7-
IQO-E!Gl
P7 ci-orr
CAVR) ,--- IBI-BAT>
!
I
1
1
1 E4
1
1
1
1
LEAD TAllUUTJXII
FIUC ro
-
STATJXII BTATJXII
r•-.. S4
P4-16 ~
TIHIAT
CP4-13)
P4-G
-
P4-III
P4-7 87-c?G Pt«lP2[PIO-I)
,.,_,
P4-l:J
P44
S4
111-tlAT PMlP3[PI0-41
PMlP4(PI0-5)
X+(PI0-6)
P4-2 P7-G
P4-J P&-19 XX-(PI0-31
IKHNJ 1(4-92
- .
P4-2a PI-A (Mola PU)
P4-21 PHI (11/aPU)
P4-9 Pl(tlGE.D)
P4-19 P6-2
P4-12 1
N-JO P7-;J 1
P4-II P7-4 1
P4-ll Jl2-G MAG 1 El-ti El-A
P4-23 Jl2-6
P4-17 Jl2-7
PICK-lP 1 (P!!-111) 11'5-2)
P4-18 Jl:1-11
I'
Pll-;J
Pll-11
E2-A
E:HI PHlHia.D I ' '• El G~-ENG
\
EI-C
Pll-4 ES-A (P4-9)
' E6
Pll-12 EHI Pl-8
(P4-21) ,f \~
(P!S-ll
--
Pll-2 El-A PI-A
Pll-18 El-ti HTR2-2
Pll-1 EI-C
(P4-22) HTR2-I
(1'26) IE>IHN)l
1'26 HIRl-1
HIRl-2
Pll-21 E6-A
1'5-7 E:6-11
1'26 HIR2-I
HTA2-2
PII-US 11:1-A
~
-
E7-tl
-..-
P!H5 E4-A
Pll-13 u-e
- ---
Pll-17 TIHIAT
Pll-9
18-tlAT P&-1 VRal VO.TAIIE-..ATIR
18-tlA7 P&-16 LIII FI.EL
KI P6-20 S7 L.111 COCUHr LLVEL IU:U
P7-I 1'6-21
Gl-1» -AT IPRE-IET>
lllrTtJH'IIEJB IJIIE-LIP)
1'26 84 9IIITDf L.111 OCDIE 1DP ll.El'l
P&-111 a
--
.araHMIIIPEEII (09)
82 -ATOEl
ICT+
N:T 91 aatal-CIIL - (Llp)
GHIUT 111-eAT PJ IWI PIDO.P
GI-GN> IU SfMTDI PD.DT m:.DCDD
K2 -.U.T811.EN1111(-PU.WI
KI FI.E..811.EN1111 N-6
87+ 111-eAT
-- -
87- GI AL-TIR N-tl 1111-1
81-eAT K4-eAT E7• DH 1DP (IIDHTl N~
--
IIHIII IG4. p. DHlDP <UJ'Tl Pll-17
EII TMHM:lER
P7-6 IC4-SI E4 IEJIDEII-OJLTEI' 1'6-1
P7-2 1'6-16
PI0-1 Do IECEHIAlER 1DP (RIDIT) 87+
PI0-4 El llHIEIHIATER 1DP (UFTl
PMGP4 Plo-11 El 91-eAT -------'
IITI IIATIEW-tmllAIIE
X+ Plo-6 111 BTMTER,..__
xx-
P&-12
PIO-;J
Jl2-2 A12 &IMJNR
DETAIL "A"
P&-7 Jl2-I
111-eAT 7111-1
ENHH) 71114
111-eAT TIHIAT NO. 338-2607
REV. O
MODIFIED B/16/94
KT50 ENGINE HARNESS DIAGRAM

9-27
VR21 VOLTAGE REGULATOR
S8 LOI FU[L
S7 LOI COOLANT LEYEL ILCLl
S6 THERMOSTAT CPRE-HETJ
S5 SWITCH-PRESS IPRE-LOPl LEAD TABULATIOH
S4 SWITCH LOW ENGINE TEMP <LETl FROM TO
STATION STATIOH
S3 SWITCH-OYERSPEED !OSJ P4-6 TB-BAT
S2 THERMOSTAT (HETl P4-16 GHD-ENG
SI SWITCH-OIL PRESS ILOP) P4-5 16-BAT
PI MAG PICKUP P4-15 GND-EKG
K4 STARTER PILOT SOLEHOID P4-7 S7-D
K2 PREHEAT SOLENOID CGLOW PLUGSJ P4-13 S4
KI FUEL SOLENOID P4-3 TB-BAT
TB BAT (SEE DETAil "A") HTR ENGIHE HEATER P4-4 GND-ENG
GI ALTERNATOR P4-2 P7-5
E7 EXH TEMP <RIGHTl P4-I P6-19
[6 EXH TEMP I LEFT l GHD [HG U-S2
~~8 [5 TACHOMETER
(GOV) P4-22 PI-A IMAG PU)
[4 SENDER-OIL TEMP ./
P4-21 PI-B IMAG PU)
E3 SENDER-IATER TEMP IRIGHT) P4-9 PI (SHIELDl
[2 SENDER-IATER TEMP ILEFTI PH9 P6-2
El S[NDER-OIL PRESSURE P4-12 P6-3
A37 BTI BA TTERY-STORAGE PHO P7-3
PIO BI STARTER & SOLENOID P4- II P7-4
(AVR)
Al2 GOYERNOR P6-7 Jl2-5
BI-SWI GND-ENG Jl2-6
(81-Sll2l PH 7 ISEE Jl2-7 !SEE
A37 BI-SW2 "4-18 NOTE 8l Jl2-8 NOTE 8l
P7
<AVRl
(81-SWI>
P5-3 E2-A
PS-11 E2-B
E4 P5-4 [3-A
PS-12 E3-B
[4-8
CP5-1Jl PS-2 El·A
PS-18 [1·8
P5·1 EI-C
GI-B+ P3-A
BI-SWI BI-SW2
,~" '" ,
(¿.)
P5·21 [6-A
P5-7 [6-8
¡.t'
p S4 T26 P3-8
(P4-l 3) GI-GND P3-C
PMGP2(PIO-I) PS-15 El-A
PMGP3( P 10-4 PS-22 [7-8
PMGP4(PI0-5) P5-5 E4-A
X+ (PI0-6) [4-8
PS-13
PS-17 TB-BAT
El-A PS-9 GKD-ENG
(P5-2l TB-BAT P6-I
TB·BAT P6·16
KI P6·20
PI EI ci~:~ > P7-I P6-21
!MAG GND-ENG GI-D+ P6-22
PICK-UP> E6 CSEE NOTE 7l LEAD TABULATIOH
FROM TO T26 P6-4
STATIOH STATION GHD·ENG P6-15
Pl-2 GND-ENG GHD-[NG P6-23
PMGP2 PI0-1 ACT+ P6-6
PMGP3 PI0-4 ACT- P6·8
PMGP4 PI0-5 Gl-8+ 81-BAT
X+ PI0-6 GI -GND GND-EHG
XX- PI0-3 GND-ENG BI-GND
DETAil "A" P6-12 Jl2-2 S7-C TB-BAT
TB-BAT TB-BAT TBl-1 Sl-8 GHD·ENG
GND-[NG TBl-3 81 ·BAT K4-8AT
81-BAT TB-BAT 81-SW K4 +
TEST S7-A P7-6 K4-SI
No. 338-4321 sh 2 of 2
Rev. D
Modified 7-04
K50 ENGINE HARNESS DIAGRAM (DFLB-SPEC T, DFLC-SPEC W, DFLE-SPEC F)

9-28
LEAD TABtLATION
FROM TO
STATION STATION
Pl2-I SEE NOTE 8
Pl2-2 ra1-2 TBI
Pl-13 ra1-5
Pl-7 rar-s
P2-IO TBl-7
P2-9 TBl-8
P2-I I TBl-9
P2-4 TBl-10
P2-3
Pl2-5
TBl-11 P 1 (BLACK)
ra1-12
Pl2-6 ra1-13
Pl2-7 RED rnl-14 RED
Pl2-8 8U< ra1-15 BU<
Pl-9 TBl-16
Pl-12 TBl-17
Pl-6 TBl-18 !
Pl-16
Pl-2
TBl-19
TBl-20 P2 (GRAY)
Pl-10 TBl-21
Pl-5 TBl-22
P3-2 TBl-23
P3-IO TBl-24
P3-I I TBl-25
P3-12
P3-16
P3-17
TBl-26
TBl-27
TBl-28
P3
P3-18
Pl-21
TBl-29
TBl-30 BLUE A39-TB2-I
Pl-19 TBl-31 A39-TB2-2
Pl-20 TBl-32 A39-TB2-3
P3-19
Pl-18
TBl-33
TIU-34 A39-TB2-4 A39
Pl2-9 ra1-35
A39-TB2-5
HTR I ra1-36 A39-TB2-6
HTR 2 ra1-37
P2-14 TBl-38 \
P2-13 TBl-39
1
tj
P2-12 TBl-40
P8-I P3-20
P8-2 ,P3-7
P8-3 P3-13
P8-4 P3-5
P8-5 P3-6
P8-6
P8-7
P3-4
P3-23
P8 (GRAY)
P8-8 P3-8
P8-14 P3-14
P8-15 P3-22
P8-22 P3-15
P8-23 P3-21
P2-8 TBl-41
P2-7 ra1-,2
P2-5 TBl-43
P2-6 TBI-«
Pl2
P3-9 TBl-46
P3-I TBl-47
P2-16 TBl-48
P2-2 TBl-49
Pl-17 TBl-50
Pl-3 TBl-51
Pl-11 TBl-52
Pl-4 TBl-53
Pl-22 TBl-54
Pl-23 TBl-55
Pl-8 TBl-56
Pl-15 TBl-57
Pl-1 TBl-58
P2-15 TBl-59
P2-23 TBl-60
P2-21 TB2-6
P2-17 TB2-5
P2-22 T82-4
P2-18 TB2-3
P2-20 TB2-2 No. 338-3200 sh 1 of 1
P2-19 TB2-I Rev. B Sys: HP
Modified 2-96
ACCESSORY BOX INERCONNECTION HARNESS DIAGRAM (HC 4 AND 5)

9-29
PI CBLACK) (
(· ',
\•
P2 (GRAY)
P3
BLUE
---::..,~~.....
,',
' '
\
\\
\
'\ J
\ \
1 \
I I
tÍ :
t1 P8 (GRAY)
Pl2
LEAD T. ll..ATION LEAD TABI.LATION

FROM TO FROM
LEAD li 1.1..ATION
TO FROM TO e?:\ ' . . . !
STATION STATION STATION STATION ~.~ ..:. ./

STATION STATION
P2-8 lBl-41
Pl2-2 TBl-2 Pl-19 TBl-31 P2-7 TBl-42 A39-Til2-6
Pl2-I TBl-16 Pl-20 TBl-32 P2-5 lBl-43 A39-TD2~
P3-19 TBl-33 P2-6 lBl-44 A39-lll2-.(
Pl-13 TBl-5 Pl-18 lBl-34 A39-TB2-3
Pl2-9 TBl-35
A39-11l2-2
Pl-7 TBl-6 lfTR I TBl-36 P3-9 lBl-46 A39-lB2-I
P2-IO TBl-7 HTR 2 TBl-37 P3-I lBl-47
P2-9 lBl-8 P2-14 TBl-38 P2-16 lBl-48
P2-I I TBl-9 P2-13 lBl-39 P2-2 TBl-49
P2-4 lBl-10 P2-12 TBl-40 Pl-17 lBl-50
P2-3 TBl-11 P8-I P3-20 Pl-3 lBl-51
Pl2-5 TBl-12 P8-2 P3-7 Pl-11 TBl-52
Pl2-6 TBl-13 P8-3 P3-13 Pl-4 lBl-53
P12-7 (RED) lBl-14 RED PS-4 P3-5 Pl-22 TBl-54
Pl2-8 (BLK) lBl-15 BU< PS-5 P3-6 Pl-23 lBl-55
Pl-9 TBl-16 P8-6 P3-4 Pl-8 lBl-56
Pl-12 TBl-17 PS-7 P3-23 Pl-15 TBl-57
Pl-6 TBl-18 P8-8 P3-8 Pl-1 TBl-58
Pl-16 lBl-19 P2-15 lBl-59
Pl-2 TBl-20 P2-23 lBl-60
Pl-10 TBl-21 P8-14 P3-14 P2-21 TB2-6
Pl-5 TBl-22 P8-15 P3-22 P2-17 TB2-5
P3-2 TBl-23 P8-22 P3-15 P2-22 TB2-4
P3-IO lBl-24 P8-23 P3-21 P2-18 TB2-3
P3-I I TBl-25 P2-20 1B2-2
P3-12 lBl-26 P2-19 TB2-I
P3-16 TBl-27
P3-l7 TBl-28
P3-18 lBl-29
Pl-21 TBl-30
"'
No. 338-3202 sh 1 of 2
Rev. B Sys: HP ( ·~_,- .·
Modified 2-96
ACCESSORY BOX INTERCONNECTION HARNESS DIAGRAM (HC 6 AND 7)

9-30
PLW SCHEMATIC NOTES:
DESIGNATION COLUMN I
(REF) 1. ltem 23, transformer, is
llll-:S.
~-----PI03-GND ENml
not included for kits
------, .-----PI03-4 IRllO where battery connec-
~---P 103-WHITE 01 CBIOl-2 POLE AC CIRCUIT tions will be made at
---PI03-3 B+ } USED W/0 BREAKER, 15 AMP, 7.5 AMP
PI03-I ..----Gt,OTRANSFORMER TB1-19 and TB1-20•
2. Tag the control box to indi-
02 5102-2 POI...E SWITCH cate supply voltage.
03 PI03 - 120/240V PUMP MOTOR
04 1<104 - SYSTEM REAOY INTERLOCK 17
23 TRANSFORIER
05 TI05 - 120/240V TRANSFORMER 22 COIINECTOR-KNOCKOU T
21 CCNIECTOR-ROEX
B+
F8+f#I o
22 23 24 215 26 27 28 J4 20 JJMPER-TERMINAL
19
1B2
1111-:!0
18
17
o~ o- 06
1111-19
CRI06- RECTIFIER BRIDGE 16
J6-I
II EHERGENCY 15
07 RlM C8107 - 2 AMP CIRCUIT BREAl<ER ~ 14
S 1021 oa•-----. 13
08 2~º0FF J6-2
K 108-HIGH FUEL RESET 27. 138 12
09 3 ON 1 K 109-LOW FUEL RESET 23 ,134), 11 HARIESS-CONTROL.
SI 11 RESET
----,.,0 10
11 .--------------<>--OOFF
KI 10-LO st-UTDOWN RESET ~.
SIII-SINGLE POI...E SWITCH
,40 10
9 CIRCUIT BOARD ASS Y.
...--+---~·
~J--- 12 KI 12-BASIN FAlLT RESET 21~,41,~
J6-7
13 3 TEST 8 CIRCUIT BREAKER 2 POLE
KI 13-CPTIGIAI... FA\l.T RESET 15,@)43,4! 7 CIRCUIT BREAKER I POLE
14 '
1 1 15 DS 1 15-0PTIONAL FAUL T LAMP 6 SWITCH-ROCKER
5 SWITCH-ROCKER
1 1 16 Rll7 K 4 4 LAMP ASSY.-7 LITE
1 1 17 DS 1 17-SYSTEM READY LAMP
3 RELAY-2PST
1 1 18 1<118-SYSTEM READY RELAY 42 2 COVER-CONTROL
1 19 1 CONTROL BOX
1 1 1 KI 12
Lr-1 20 nDC llOtSIIPTIXN CR MATERIAi.
l~-1--- 21 DSl21-BASIN FAULT LAMP

22 K 9
o 23
24
DSl23-LOW FUEL FAULT LAMP
25 DSl25-LO st-UTDOWN FAULT LAMP

26 K 08
27 DSl27-HIGH F1JEL FAULT LAMP
28
R 129 1111-21 ~m K 108-HIGH FUEL SET @ 27, 38
CBI07 29 K 12 -Wa_-Gl------~---"--.JVV....._
__ - Kl306- - =; >- -
30 t--Yt- ...... -+---o.iiJ---+--4~-o,ro-.-~!--'--.-=-:~~~ r'..'~ Kl30-PI.J4> RB.AY 03, 30
JJ-10 JJ-7 ~ ~
31 PUi>
a. DSl32
32 DSl32-PI.W ~ LAMP
33 JHILOV
FlEL K109
34 1<109-LOW A.EL SET@ 23.39
35 K 1 1 O-LO SKITOOWN SET @. 25 ,40
36 KI 12-BASIN FAll..T SET@ 21,41,,;s,Q
Kll3
37 1112-22 '::' KI 13-0PTIOOAI.. FAULT SET@ 15,43,M
KI08 SCI-EMATIC KEY,
TBl-10--f J- TBl-11 HIGH F1JEL FAULT CONTACTS EACH CQl4)0NENT IS LOCATEO BY PART
K109 N.JeER. ON THE RIGHT HMO SIDE, A
í¡
0 AC TBl-12--f l- TBl-13 LOW FUEL FAULT CONTACTS DESCRIPTION IS GIVEN OF THE PART At,O ITS
o TEST ON
KI 10
Fl..N:TIOOAI.. LOCATIONS.
TBl-14--f l- TBl-15 LOW SHJTOOWN FAULT CONTACTS

L,41 ~T~~~
CIROJIT 8REAl<ER
PI.Si TO RESET [®] [®]OFF TBl-16--f
1<112
J- TBl-17 BASIN FAll..T CONTACTS
~~.IN FAlLT RESET 21
Lv con..
o RESET EJ.ERGEOCY 42
1<118
TB2-26--f J- TB2-27 SYSTEM READY CONTACTS
RELAY SET
tt1 LDE 36
NIO CCNTACTS
DC ttl LnES 21 ANl 41
RUN Kll3
ITIEN OESCRIPTim.
TB2-23~ TB2-24 OPTIONAL FAlLT CONTACTS
0 NO. 625-2141
KI 13
44 TB2-25 REV. H
MODIFIED
FRONT VIEW
DAY TANK PUMP CONTROL WIRING
9-31
POhER COMMAND CONTROL
r---------------------------, r------------A32-------------,
¡
1
\~? ¡
~NE 1
:
: DIGITAL
301>-'1079
1 1 1 Kl.3
CHTAL 8+
a+<BAT> >-"T""-----t-------------~~~~------~~-;11 >-----~,~~---------------r---"-'-'co.i~>--------:if'-i;;,¡"'----,--~vv\r-------=-,1v=5----,
-··
1
,----a..L~~-~:; ZJ
AlB
GoVERNOR
, r3
OUTl'UT STAGE
---=
301>-'1307 Sl3
.
330
DIER
STOP - 1
lu
t
2 -IN
¡¡; ~ 4
o-c-~==~~~~~.13=-~1.a,i,~)----i
04 QCI) u
: R11
~
ESTO!'SET
L--------=~~~------~.13=-5~~~·>----------------r----'VV\r---
750
I
-
-OUT
4-
IUll'l.TIIII NOTES:
THE FOLLOHING IS THE SEQUENCE OF
EVENTS FOR LOCAL START AND RUN.
STMT l. 512 IS SET TO THE RUN POSITION.
5N CHTAL 8+ 2. RUN PILOT RELAY Kl ON DIGITAL BOARD
;;: (A32> IS ENERGIZED.
3. B+ IS NOH APPLIED TO THE POHER
N
"'u 5N DmlL 8+
SUPPLY SECTION OF ENGINE INTERFACE
BOARD <A31) ANO THE DIGITAL BOARD
3 (A32).
TP2 l'SI 4. RUN LEO 054 ON ENGINE INTERFACE
n G). 8+ BOARD (A31) IS ON.
•••v
- -
+18V +18V
5. THE DIGITAL BOARD INITIATES A START
B+IIIIIT> DRIVE.
6. START RELAY KI ON ENGINE·INTERFACE
BOARD <A31> IS ENERGIZED.
TONICRO-CONTROU..Dl 7. B+ IS NOH APPLIED TO THE STARTER
SOLENOID.
512 8. ENGINE HOULD CRANK.
AIWOIT
MSTO
9. THE DIGITAL BOARD (A32) MONITORS
5N - RD.AY 8+ STMT STMT THE MAG PICKUP ANO INITIATES A RUN
K4.J TONICRO-CONTROU..Dl DRIVE.
STMT 1 10. RUN RELAY K3 ON ENGINE INTERFACE
Slll.
KI 1
"'1TO BOARD (A31) IS ENERGIZED.
"lE.. + ~---"'1Ta=:=º----------_:;n~-~·"il1:4>-------.....--------1-----1 TO NICRO-CONTROU..Dl 11. B+ IS NOH APPLIED TO THE FUEL
SOi.
-=-an _..-=------------"...._._: .:a:_=-----•1r-• SOLENOID,ALTERNATOR Gl,REGULATOR
1
o.a.7 __ DSt OPTO ... ...._"""ll>>--------(flE"'1'--"'3._J __ lO NICIIO-CllNTIIOU. OUTPUT STAGE (A37>.
12. LEDS DS1 ON REGULATOR OUTPUT STAGE
r----il-i------------'CHTAL==..::RTN=..-"'IN::,_ ..,u;-c.,_q¡I>--:::i.. - ISO : : (A37) AND 052 ON GOVERNOR OUTPUT STAGE
-=-•T2 : ~ DS5 c:reon ......... '-JI,) 7---=EST=OP'----••
(~IE.., ....
-... -·lO nrCIIO-COMTIIOU.. (A38) ARE ON.
13. RELAY Kl ON THE GOVERNOR OUTPUT STAGE
l--------~--------'------'-------'----_...-------------------'------f--t-----------~-:,:::~RTN:e.:..:,~I~N,.__ ~4~-4~1>--:::i.. RDIOTE : : <A38) IS ENERGIZED.
1 -~QCII Gr.. n 1 1 14. SH B+ IS NOW APPLIED TO TERMINAL 26
1 - 1 1 ANO CUSTOMER CONNECTIONS.
15. ENGINE WOULD RUN.
16. THE DIGITAL BOARD (A32) MONITORS
THE MAG PICKUP AND HHEN THE ENGINE
REACHES 475 RPM THE START DRIVE
'------------=='------------~.13~-~·~·!)>--
.......----..~--3-4---a;-"1.
DS& ......
~.u..;;~~·'-ll, ~
IS REMOVED.
1 ~ 1 1 ~ 17. START RELAY Kl ON ENGINE INTERFACE
t1AG PICKUP ,.....,-=..c•::._---lf---------------------------~4-=,!li1 ¡t-¡~ dEr4-lO IW. + .ffl. o TO nICRO-CONTROU..Dt BOARD CA31) IS DE-ENERGIZED,REHOVlNG
B+ TO THE STARTER SOLENOID. RELAY
9._tl!Y---,,_=,-:-:::-----tr----------------------------=-~>-----------------------------"-31'--..,¡~¡~ d,t•¡¡ tlAG - ,,,,. O TO NICIIO-COltTlKIU. CONTACT Kl.2 IS OPEN,START LED 0511
1 • IS OFF.
~~ 1 • 19. HHEN PHG OUTPUT REACHES IOSVAC<SSO RPM),
I CGROUND . :· 1 1 BACK-UP START DISCONNECT RELAY Kl ON REG-
L...--------------------------J L...--------------------------J ULATOR OUTPUT STAGE (A37) IS ENERGlZED,
RELAY CONTACT Kl.3 IS OPEN,BACK-UP
START DISCONNECT LEO DS3 IS ON.
!_No. 612-6679 sh 1 of 2
Rev. B Sys: HP
Modified 11/21/95
SEQUENCE OF OPERATION (LOCAL START ANO RUN)

9-32
POWER COMMAND CONTROL
A3B
GOVERNOR
OUTPUT STAGE
3011-4307
....
-o--<
-1
B+(IIAT)
~
"'
u
"'u
·'
-~ Rl'I'
750
RDI ESTOP
A3?
RI.N l'LT IIR NOTES:
REGULATOR THE FOLLOHING IS THE CONDITION
OUTPtJT STAGE
3011-4306 OF THE POHER COMMAND CONTROL
Kl.3 IN THE "OFF" POSITION.
8 STMT
l. 512 IS SET TO THE OFF POSITION.
2. RUN PILOT RELAY Kl ON DIGITAL BOARD
CA32) IS DE-ENERGIZED.
SM CHTRL 8+
"'3
TP2 PSI
8+
8HIIAT>
Sl2
RIWOIT I
MITO I
KI
K4.I
STMT
SOt. 2 ¡l;J :
~l~,....:SM:::..:Rllll:::::::_,AEl.,,,,,~~Y,_,,8+"'--~DL-4;;:..;~~>--~---~...L.--'V\/\,~,---~ST~MT!>.!.......al.Jl.=.t~>-----<1~:::.L-~ST~MT~----+TONlCRO-COHTIIOU.DI
ntEl..
SOL
+ __&~_,,_ 05 MITO
...,,
J3-13;J')----~-----1.----I
...=.BTI 07 RI.N J3-1~>-------11--~---'----I :Jl-311):,-----(1:~~'71---3-I RUN=----t ..-+t TO NICRO-<XINTROU..E
1
.=.BT2
,---
I
.....+------~CHTRL,:::.,.::::,~RTM~~I~N---'~4~-~·>---i_
1 ~
DS4
DSSGr-Hft
AUN
OPTO
ISO
1
1
:, 1 :)
1
1
(1'~Ll4::;;-;.:.7
_ __.EST=OP,:;..._ ....,_ _.., TO "ICRO-<XINTROU.DI
t------'------'-----'-----'----'----------.....l..---l---l:.,_-----~-~~RTN.!.!!,.~I~N---~4~--4~1>-----:i... IIDIOTE l :
I A1!1C""GND GrHft 1 1
1 - 1 1
L------~GNll::.:::c------~J3~-..,t~l~i,~--:r~-....L~-K2-34--EST-OP--DS-6----i~~:,~1~~2~4~>----~
1 ~ 1 1 ~
,....IIAG=e....::;.+ __
--='-~--' -l---------------...:L:t::5~l) :11-11'~ ,J,:,4- 10
"';V>-----<~ IIAG + .nn. Ir TO NICRO-<XIHT'ROLLE
'---t--!Y----.::,,w;=-------t---------------"-='-'''lil) 31-llf> &ez4-ll IIAG - 'W' .. TO NICRO-<XINTROU.DI
SHIELO
:L.--------------------------J
~ : ¡L.--------------------------J
..No. 612-6679 sh 2 of 2
Rev. B Sys: HP
Modified 11/21/95
SEQUENCE OF OPERATION (LOCAL STOP)

9-33
POWER COMMAND CONTROL
r------------A3i-------------,
I ENCIHE 1
r------------A3z-------------,
11 DIGITAL.
;,
l INTERf"ACE 1 30Cl-4079
1 301>-'1083 1 1
l l l
I Fl 1 1
Dt-CIIAT> >--r------t------------------OITlll..~~a,.~--------=Z4~-i;~l~----------~--:!.!.:~D-----------i:tf'.i=!Si!.---~--JIJ\I\,------"'~~.,__----,
A3B
l
l F3
GOVERNOR
OIITPUT STAGE
~~:._.~·
. ,.:h 1
30Cl-4307
... ...
u<
-1
B+CIIATJ
~oo--2---==---a,.:.IN
4 c:,m
__.Gtj-':=4
n-1 ·~
1 ~
3 "'u I
-~ 1
1
Rl1
ESTOP SET
>---------------~--.....,,""'~---
750
-
RUN OUT ROt ESTO#'
A31 - PLT III

REGIA.ATOR
0UTPUT STAGE
30Cl-4306
Kl.3
& START
·:- 1- r. :
r-.., ---.--:
11 SINlf 11,NI
1 • ,~. ~ SN OITIII.. a,.

,.. e e I "'
u
c:a,c,A u:
1¡¡¡~~1:l ~: TPZ PSI
B+
- -- 1 NOTES:
ll+CIIATI
L----=°-1 THE FOLLOHING 15 THE SEQUENCE OF
EVENTS FOR LOCAL EHERGENCY STOP.
SlZ
l. Sl3 IS SET TO THE EHERGENCY STOP
RlJIVOfT POSITION.
IAIITO 2. B+ IS NOH REHOVED FROH THE FUEL
K4.Z K4. t
SOLENOID,THE GOVERNOR OUTPUT
START 1
STAGE CA39) AND THE REGULATOR OUTPUT
SOL
1
STAGE C A37 ) •
KI RUN LED D512 ON INTERFACE BOARD CA31)
FIJD. + -IIC ..:...--~11 1 '"'-'-'º'------------n==--~11;4~~--------~-------+----1 IS OFF.
SOL
-=.en LED D52 ON GOVERNOR OUTPUT STAGE CA39)
:)>--------<{Er~4~-3~1~~-=-----t
..-••TO"ICRO-COHIROI..LE
1
0"-1-----"-=------------n""---_.l"-ll:
>---------1-----,--DS_.4-----I OPTO IS Off,
LED DSl ON REGULATOR OUTPUT STAGE CA37)
..------ll---f-----------~CHTAL.,,,.,,:,.;RTM"-"''-"'IN::.... .,g;4-;;.ui~I~ RUN ISO 1 1 IS Off.
-=.BT2 : ~ D5S Cnen 1-7 :, (~~Z::.4"'--7,__...EST::.:.Of'=----1
..-••TO KICIIO-CONJROI.LE 3. RELAY Kl ON THE GOVERNOR OUTPUT STAGE
e
CA39) IS DE-ENERGIZED.
1--------....L--------.L..----L..----...l------'-------------------.L..----l-+-----------~MJX~RTM~~IN:!.------"!.:l.=L-,lil~ II010TE l l 4. SH B+ IS NOW REMOVED FROH TERHINAL 26
AND CUSTOHER CONNECTIONS.
9
I M.DC~QGJ C.r••n 1 1 S. EHERGENCY STOP RELAY K2 <SET> ON THE
KEY 1 - l I
ENGINE INTERFACE BOARD (A31) IS
!, ~ ~:·
ENERGIZED AND LATCHED.
°"'1i- NIO CONTACT G_OSED ..._ ..,,c:ND:= n=--
...1~• u.,w -
6, RELAY CONTACT K2,3 ON THE ENGINE
INTERFACE BOARD CA31) IS NOH OPEN,
REHOVING B+ TO THE EHERGENCY STOP
.nn. HAG PICK-t.P SIGWL I t.ÑD l 1 ~
SHITCH (513>.
7, RELAY CONTACT K2,4 ON THE ENGINE
~ DIGIT~ SIGWL .....-'tw.=..;+::....-----11-----------------------------"=-,q¡I) l\-1~ dz4-to ,w¡ + .nn. • TO KICIIO-CONJROI.LE INTERFACE BOARD CA31) IS NOW CLOSED,
__ .=,~-' ,w¡ - Z4-21 1) Zl-11:b (kZ4-1l tw. - 'W' a TO KICRO-COHtROl.1.E GROUNDING THE ESTOP LINE TO THE
T COltiON POtER COtH:CTION DIGITAL BOARD CA32).
'----~--1=~--ft-----1-----------------------------..U::24ii·~ :l :l e. ESTOP LED D56 ON ENGINE INTERFACE
1 CGRUlNII BOARD CA3l) IS ON.
L.--------------------------~ L.--------------------------~
- -
9. THE ENGINE HOULD STOP RUNNING.
N0.612-6680 sh10t1
REV.A
MODIFIED 8/25/94
SEQUENCE OF OPERATION (LOCAL EMERGENCY STOP)

9-34

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Table of Contents

SECTION TITLE PAGE

5 CONTROL SERVICE AND CALIBRATION .-_;/

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

Copyright@ 2001 Cummins Power Generation. Ali rights reservad.

applications. set to the system bus.

FIGURE 1-1. GENERATOR SET CONTROL FUNCTIONS

MENU PANEL LAMP EMERGENCY

FIGURE 2~1.FRONT PANEL (PCC 3100)

Non­Autometic Status lndicator: This red lamp

o~ 2 UNE, 16 CHARACTER PER UNE

FIGURE 2-2. DIGITAL DISPLAY AND MENU SELECTION SWITCHES

MENU DISPLAY AND SWITCHES MAIN MENU

BATTERY << POWER <<

OIL << VOLTS <<

< ENGINE GEN >

< ADJUST >> >

D.........._ RESET MENU > D

D < ACTIVE BUTTON

11 < ACTIVE BUTTON SELECTED

0< BATTERY OJL << >O

0< RPM << >. 0< BATTERY << >O

1 - - - - lndicates "OR" Condition I

%GOV/REG!FREQUENCY submenu: From the

O< VOLTS << > < ENGINE GEN >O

THIS PAGE LEFT INTENTIONALLY BLANK

S5 POWER ON/ J1 (FOR INPOWER

FIGURE 3-2. BLOCK DIAGRAM

FIGURE 3-12. GOVERNOR OUTPUT MODULE (A38)

DS1 - ISOLATED SUPPLY

FIGURE 3-11. VOLTAGE REGULATOR OUTPUT MODULE (A37)

FIGURE 3-10. GENSET COMMUNICATIONS MODULE

FIGURE 3-8. PT/CT BOARD

o DS16 - GLOSE BKR

FIGURE 3-7. CUSTOMER INTERFACE BOARD

FIGURE 3-6. DIGITAL DISPLAY BOARD

J1 L.! ..... J2 L.,.._ ___. .__ __.J3

FIGURE 3·5. ANALOG BOARD

0810 • GOV 5A CNTRL B+

FIGURE 3-4. ENGINE INTERFACE BOARD

FIGURE 3-3. DIGITAL BOARD

THIS PAGE LEFT INTENTIONALLY BLANK

= Opon [o] O Phase Seleet

WARNING ANO RES ET ALPHANUMERIC

FIGURE 4-1. CONTROL PANEL

Blank LOAD DEMAND none . . . . . . . . . . . . . . . . . . . 4-5

f,.·_­:•._~-·. .i.~.> 223 OVERSPEED Shutdown . . . . . . . . . . . . . . . 4-7 4-30

260 CUSTOMER FAULT 1* Warning/Shutdown 4-9 4-39

IA WARNING I Hazards presentin troubleshootingcan causeequipmentdamage, severe personal

SYMPTOM CORRECTIVE ACTION

Shutdownlamp lights. lndicates local or remote Emergency Stop.

SYMPTOM CORRECTIVE ACTION

SYMPTOM CORRECTIVE ACTION

Shutdown lamp lights. lndícates possible fuel system problem.

SYMPTOM CORRECTIVE ACTION

Warning lamp lights. lndicates battery voltage is below 1 O VDC.

Warning lamp lights. lndicates battery voltage exceeds 32 VDC.

SYMPTOM CORRECTIVE ACTION

SYMPTOM CORRECTIVE ACTION

SYMPTOM CORRECTIVE ACTION

SYMPTOM CORRECTIVE ACTION

PT/CT BOARD A36

OPTIONAL RTD VOLTAGE

NonAutometic Status lndicator: This red lamp

J1 L.! ..... J2 L.,.._ _. . __.J3

f,.·_:•._~-·. .i.~.> 223 OVERSPEED Shutdown . . . . . . . . . . . . . . . 4-7 4-30

Bus freq (HS1 .3) J2-22 0SV sq wave @ Bus L1 Hz