Service Manual Generator Set X1.3 & X2.5 Engine with PowerStart 0500 Control C8D5 C11D5 C17D5 C17D5 (Spec E) C22D5 C22D5 (Spec E) C28D5 C28D5 (Spec E) C12D6 C12D6 (Spec E) C16D6 C16D6 (Spec E) C20D6 C20D6 (Spec E) English Original Instructions 08-2017 A029U889 (Issue 3) PowerStart 0500 X1.3 & X2.5 Engine Publication A029U889 Issue 3 - 8-2017 Table of Contents SECTION TITLE PAGE 1 IMPORTANT SAFETY INSTRUCTIONS 5 2 INTRODUCTION 7 2.1 About this Manual 7 2.2 System Overview 7 2.3 Test Equipment 7 2.4 How to Obtain Service 7 CONTROL PANEL OPERATION 8 3.1 General 8 3.2 Alternator Connections 9 3.3 Control Operation 11 3.4 Control Panel 12 3.5 Mode of Operation 14 CIRCUIT BOARD 19 Control Input and Outputs 21 5 TROUBLESHOOTING 24 5.1 Safety Considerations 24 5.2 Troubleshooting Procedure 24 6 Setup and Calibration 34 7 SERVICING THE GENERATOR 39 7.1 Testing the Generator 39 7.2 Generator Baseboard Isolation Procedure 40 7.3 Excitor Stator 41 7.4 Excitor Rectifier Bridge 42 7.5 Main Stator 45 7.6 Generator Disassembly 47 8 WITHDRAWING ROTOR 49 8.1 Generator Reassembly 49 3 4 4.1 page 3 PowerStart 0500 X1.3 & X2.5 Engine SECTION TITLE Publication A029U889 Issue 3 - 8-2017 PAGE 9 WIRING DIAGRAMS 53 9.1 General Information 53 9.2 Wiring Diagram 57 9.3 Battery Charger and Coolant Heater 59 9.4 Customer Connections 62 page 4 Publication A029U889 Issue 3 - 8-2017 PowerStart 0500 X1.3 & X2.5 Engine SECTION 1 – IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries. Before operating the generator set (genset), read the Operator’s Manual and become familiar with it and the equipment. Safe and efficient operation can be achieved only if the equipment is properly operated and maintained. Many accidents are caused by failure to follow fundamental rules and precautions. The following symbols, found throughout this manual, alert you to potentially dangerous conditions to the operator, service personnel, or the equipment. DANGER This symbol warns of immediate hazards which will result in severe personal injury or death. WARNING This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death. CAUTION This symbol refers to a hazard or unsafe practice which can result in personal injury or product or property damage. FUEL AND FUMES ARE FLAMMABLE Fire, explosion, and personal injury or death can result from improper practices. • DO NOT fill fuel tanks while engine is running, unless tanks are outside the engine compartment. Fuel contact with hot engine or exhaust is a potential fire hazard. • DO NOT permit any flame, cigarette, pilot light, spark, arcing equipment, or other ignition source near the generator set or fuel tank. • Fuel lines must be adequately secured and free of leaks. Fuel connection at the engine should be made with an approved flexible line. Do not use zinc coated or copper fuel lines with diesel fuel • Be sure all fuel supplies have a positive shutoff valve. • Be sure battery area has been well-ventilated prior to servicing near it. Lead-acid batteries emit a highly explosive hydrogen gas that can be ignited by arcing, sparking, smoking, etc. EXHAUST GASES ARE DEADLY Provide an adequate exhaust system to properly expel discharged gases away from enclosed or sheltered areas and areas where individuals are likely to congregate. Visually and audibly inspect the exhaust daily for leaks per the maintenance schedule. Make sure that exhaust manifolds are secured and not warped. Do not use exhaust gases to heat a compartment. • Be sure the unit is well ventilated. • Engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm. • MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH • Keep your hands, clothing, and jewelry away from moving parts. • Before starting work on the generator set, disconnect battery charger from its AC source, then disconnect starting batteries, negative (–) cable first. This will prevent accidental starting. • Make sure that fasteners on the generator set are secure. Tighten supports and clamps, keep guards in position over fans, drive belts, etc. • Do not wear loose clothing or jewelry in the vicinity of moving parts, or while working on electrical equipment. Loose clothing and jewelry can become caught in moving parts. • If adjustment must be made while the unit is running, use extreme caution around hot manifolds, moving parts, etc. DO NOT OPERATE INFLAMMABLE AND EXPLOSIVE ENVIRONMENTS. Flammable vapor can cause an engine to overspeed and become difficult to stop, resulting in possible fire, explosion, severe personal injury and death. Do not operate a genset where a flammable vapor environment can be created by fuel spill, leak, etc., unless the genset is equipped with an automatic safety device to block the air intake and stop the engine. The owners and operators of the genset are solely responsible for operating the genset safely. Contact your authorized Cummins Inc. distributor for more information. page 5 Publication A029U889 Issue 3 - 8-2017 PowerStart 0500 X1.3 & X2.5 Engine ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH • • • • Remove electric power before removing protective shields or touching electrical equipment. Use rubber insulative mats placed on dry wood platforms over floors that are metal or concrete when around electrical equipment. Do not wear damp clothing (particularly wet shoes) or allow skin surface to be damp when handling electrical equipment. Do not wear jewelry. Jewelry can short out electrical contacts and cause shock or burning. Use extreme caution when working on electrical components. High voltages can cause injury or death. DO NOT tamper with interlocks. Follow all applicable state and local electrical codes. Have all electrical installations performed by a qualified licensed electrician. Tag and lock open switches to avoid accidental closure. DO NOT CONNECT GENERATOR SET DIRECTLY TO ANY BUILDING ELECTRICAL SYSTEM. Hazardous voltages can flow from the generator set into the utility line. This creates a potential for electrocution or property damage. Connect only through an approved isolation switch or an approved paralleling device. GENERAL SAFETY PRECAUTIONS • • Coolants sunder pressure have a higher boiling point than water. DO NOT open a radiator or heat ex-changer pressure cap while the engine is running. To prevent severe scalding, let engine cool down before removing coolant pressure cap. Turn cap slowly, and do not open it fully until the pressure has been relieved. Used engine oils have been identified by some state or federal agencies as causing cancer or reproductive toxicity. When checking or changing engine oil, take care not to ingest, breathe the fumes, or con-tact used oil. • Keep multi-class ABC fire extinguishers handy. Class A fires involve ordinary combustible materials such as wood and cloth; Class B fires, combustible and flammable liquid fuels and gaseous fuels; Class C fires, live electrical equipment. (ref. NFPA No. 10). • Make sure that rags are not left on or near the generator set. • Make sure generator set is mounted in a manner to prevent combustible materials from accumulating under or near the unit. • Remove all unnecessary grease and oil from the unit. Accumulated grease and oil can cause over-heating and engine damage which present a potential fire hazard. • Keep the generator set and the surrounding area clean and free from obstructions. Remove any debris from the set and keep the floor clean and dry. • Do not work on this equipment when mentally or physically fatigued, or after consuming any alcohol or drug that makes the operation of equipment unsafe. Substances in exhaust gases have been identified by some state or federal agencies as causing cancer or reproductive toxicity. Take care not to breath or ingest or come into contact with exhaust gases. • • Do not store any flammable liquids, such as fuel, cleaners, oil, etc., near the generator set. A fire or explosion could result. • Wear hearing protection when going near an operating generator set. • To prevent serious burns, avoid contact with hot metal parts such as radiator system, turbo charger system and exhaust system. KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE page 6 Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine SECTION 2 – INTRODUCTION 2.1 ABOUT THIS MANUAL This manual provides troubleshooting and repair information regarding the PowerCommand® 1302Control (PCC) and generators for the generator sets (gensets) listed on the front cover. Engine service instructions are in the applicable engine service manual. Operating and maintenance instructions are in the applicable Operator’s Manual. This manual does not have instructions for servicing printed circuit board assemblies. After determining that a printed circuit board assembly is faulty, replace it, do not repair it. Attempts to repair a printed circuit board can lead to costly damage to the equipment. This manual contains basic (generic) wiring diagrams and schematics that are included to help in troubleshooting. Service personnel must use the actual wiring diagram and schematic shipped with each unit. The wiring diagrams and schematics that are maintained with the unit should be updated when modifications are made to the unit. Read Important Safety Instructions and carefully observe all instructions and precautions in this manual. 2.2 SYSTEM OVERVIEW The PCC is a microprocessor-based control for Cummins Inc. generator sets. All generator set control functions are contained on one circuit board (Base board). The Base board provides fuel control, main alternator voltage output regulation and complete generator set control and monitoring. The operating software provides control of the generator set and its performance characteristics, and displays performance information on a digital display panel. It accepts menu-driven control and set-up input from the push button switches on the front panel. 2.3 TEST EQUIPMENT To perform the test procedures in this manual, the following test equipment must be available True RMS meter for accurate measurement of small AC and DC voltages. Fluke models 87 or 8060A are good choices. Grounding wrist strap to prevent circuit board damage due to electrostatic discharge (ESD). Battery Hydrometer. Jumper Leads. Tachometer or Frequency Meter. Wheatstone Bridge or Digital Ohmmeter. Variac. Load Test Panel. Megger or Insulation Resistance Meter. InPower™ Service Tool (PC based genset service tool). PCC1302 Interface Kit (Used with InPower Service Tool) 2.4 HOW TO OBTAIN SERVICE Always give the complete Model, Specification and Serial number of the generator set as shown on the nameplate when seeking additional service information or replacement parts. The nameplate is located on the front of the control panel. WARNING Incorrect service or replacement of parts can result in severe personal injury or death, and/or equipment damage. Service personnel must be trained and experienced to perform electrical and mechanical service. Read and follow Important Safety Instructions on pages iii and iv. page 7 Publication A029U889 Issue 3 - 8-2017 PowerStart 0500 X1.3 & X2.5 Engine SECTION 3 – OPERATOR PANEL OPERATION FIGURE 3-1. PS0500 - CONTROLLER 3.1 GENERAL The PS0500 is a microprocessor-based controller that has these abilities. • Start and stop the genset. • Monitor the status of the genset. • Warn the operator when unsafe conditions are occurring • Shut down the genset to prevent damage • Adjust settings that affect genset behavior. • Provide a way for other devices to remotely start / Stop the genset This is the Operator Manual for the PowerStart 0500 control. It is not the Operator Manual for the generator set (“genset”) or any accessories. The third digit is flashed, followed by a half-second pause, and then the fourth digit is flashed, followed by a two-second pause. The PowerStart 0500 is suitable for non-paralleling generator sets (“gensets”) in standby or Prime power applications. page 8 Note: Other devices that can remotely start / Stop the genset might be as simple as a switch or a push button or as sophisticated as other controllers or computers. This manual introduces the ways the Control can interact with other devices, but this manual cannot identify all of the devices that might be used in every application. Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine 3.2 ALTERNATOR CONNECTIONS This section introduces the connections between the PS0500 and the alternator. Main Alternator Output The PS0500 is connected to the main alternator output to measure genset voltage and genset frequency. The PS0500 is also connected to current transformers (CTs) which reduce the genset current by a known ratio for measuring main alternator output current. See Sequences of Operation for more information about the behavior of this output. Genset Connections This section introduces the connections betweent he PS0500 and other parts of the genset. Some of these connections are flexible and might be made to many types of devices. Customer Input The PS0500 has one customer input that can be configured to invoke a shutdown or Warning response Battery Charger Failed Switch Engine Connections This section introduces the connections between the PS0500 and the engine. The PS0500’s Customer Input may be connected to a battery charger’s status output (discrete) to monitor the battery charger operation. Battery Connections Emergency Stop Buttons The battery provides power for the PS0500 and the PS0500 monitors the battery voltage. The PS0500 may be connected to a push button that shuts the genset down immediately when pressed. Starter The PS0500 is connected to the starter control relay in order to control the starter. See Sequences of Operation for more information about the behavior of this output. FIGURE 3-2. EMERGENCY STOP BUTTON (EXAMPLE) Fuel Shutoff (FSO) Relay The PS0500 is connected to the fuel shutoff control (FSO) in order to control the fuel shutoff solenoid in the fuel supply line. Customer Output The PS0500 has one customer output that can be configured to become active when either a shutdown or Warning fault occurs. page 9 Publication A029U889 Issue 3 - 8-2017 PowerStart 0500 X1.3 & X2.5 Engine PC-based Service Tools The PS0500 or the Operator Panel may be connected to a PC-based service tool, such as InPower. Note: See the PC-based service tool documentation for more information. The PC-based service tool harness (Figure 3-3) is used to connect the PS0500 to a PC-based service tool. FIGURE 3-3. PC-BASED SERVICE TOOL HARNESS Ready to Load The PS0500 may notify a device when event 1465 (Ready to Load) is active. Typically, the device is a programmable logic controller Remote Start The PS0500 may be connected to a device that can generate a remote start signal. Typically, the device is a transfer switch. page 10 Certifications The PS0500 meets or exceeds the requirements of the following codes and standards. • UL 508 • CSA • C282 compliant • 22.2 compliant • NFPA 99 compliant • MS 202C, Method 101 compliant • IEEE C62.41 compliant • IEEE C37.90 compliant • BS ISO 8528−4:2005 • BS EN 50081−1:1992 • BS EN 61000−6−2:2001 • BS EN 61000−6−3:2001 • BS EN 61000−6−4:2001CE Marking: The control system is suitable for use on generator sets to be CE − marked. • BS EN 61000−6−4:2001CE Marking: The control system is suitable for use on generator sets to be CE − marked. Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine 3.3 CONTROL OPERATION In this section, italics are used to identify a specific parameter by name. Safety Considerations AC power is present when the genset is running. Do not open the generator output box while the genset is running. WARNING Contacting high-voltage components can cause electrocution, resulting in severe personal injury or death. Do not open the generator output box while the set is running. Read and observe all WARNINGS and CAUTIONS in your genset manuals. The PS0500 cabinet must be opened only by technically qualified personnel. WARNING The PS0500 cabinet must be opened only by qualified personnel. High-level voltages (up to 600 VAC) are present in the PS0500 cabinet. These voltages can cause electrical shock, resulting in personal injury or death. CAUTION Even with the power removed, improper handling of components can cause electrostatic discharge and damage to circuit components. FIGURE 3-4. CONTROL PANEL BUTTONS TABLE 3-1 CONTROL PANEL BUTTONS BUTTON(S) Manual Auto DESCRIPTION Puts the control in Manual Mode to Start the genset Manually. You have to push the Start button in less than ten seconds after you push the Manual button. Puts the control in Auto Mode. The genset starts and stops when it is told by other devices (such as a transfer switch) Stop Stops the genset Read Safety Precautions, and carefully observe all of the instructions and precautions in this manual. When the genset starts and stops, it follows a series of steps, called a sequence of operation that is intended to Starting and Stopping the Genset maximize the life of the genset. The genset might not start or stop immediately. The buttons related to changing mode of operation are highlighted in figure 3.4 and described in WARNING Table 3.1 The genset might not start or stop immediately. Do not attempt to service the genset if it does not appear to respond immediately. Accidental starting of the genset during troubleshooting can cause severe personal injury or death. page 11 Power Start 0500 X1.3 & X2.5 Engine 3.4 CONTROL PANEL The control panel (Figure 3-5) is the front panel of the PS0500 control FIGURE 3-5. CONTROL PANEL (PS0500) page 12 Publication A029U889 Issue 3 - 8-2017 Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine Conto Panel Description Alpha-numeric LCD Display Buttons and LED Indicators TABLE 3-3. BUTTONS The 2 line 16 Character, Backlit LCD display is used to indicate various genset parameters in several frames. The frames are normally scrolled one after the other for 3 seconds each at a time. The scrolling can be stopped and parameters on a particular frame can be monitored for longer time by pressing the OK button while the frame of interest is being displayed. Pressing the OK button again causes the frames to start scrolling again. The LCD display is also used to present the setup menus during the setup modes. The set up modes are described in detail in a separate section in this manual. LED/BUTTON DESCRIPTION Manual Press this to put the PS0500 in Manual mode from Stop mode. If you do not press the Start button In ten seconds, the control automatically enters the Stop mode The green LED above this button blinks when the PS0500 is in Manual mode. In Manual mode, press this to initiate a Manual Start sequence. In other modes, this button has no effect. Press this to put the PS0500 in Auto mode from Stop mode. The green LED above this button blinks when the PS0500 is in Auto mode. Press this to Stop the running Genset. The Red LED above this button blinks when the PS0500 is in Stop mode. Pressing this button takes the control to STOP mode. This button is used along with the OK button to enter setup mode. Holding these two buttons pressed continuously for 5 Seconds causes the control to enter in setup mode if the control is in STOP mode. This button also wakes up the control from Power Down Sleep Mode. This button is used mainly in “Setup mode” to select menu items. It is also used to Pause / Resume the scrolling of the parameter frames. Start TABLE 3-2. LED INDICATORS AND BUTTONS Auto LED DESCRIPTION Genset Running This green LED is lit when the genset is running at or near rated speed and voltage. Remote Start Shutdown Warning This is not lit while the genset is Stopped. This green LED is lit when the remote start signal is active. This signal has no effect unless the PS0500 is in Auto mode. This red LED is lit when there is any active shutdown fault. Event 1541 (Common Shutdown) is active. This amber LED is lit when there is an active warning fault. Event 1540 (Common Warning) is active. Stop Reset OK page 13 Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine 3.5 MODES OF OPERATION The mode of operation determines the ways the Genset can be started and stopped. The PS0500 runs in one of these modes at any given time.Table 2-3 explains how to change the mode of operation. Stop (Off) Mode Pressing the STOP button will always put the PS0500 in STOP mode and the RED LED above the STOP button will start blinking. In this mode, the PS0500 does not allow the genset to start / Crank. If the genset is running (either in Manual or Auto Mode) when the Stop button is pressed, the PS0500 stops the genset and enters in the STOP mode. Setup Mode The Setup mode can be entered only from Stop mode when the genset is not running. This is accomplished by holding the Reset and the OK buttons pressed for 5 seconds continuously while in stop mode. The RED Stop Led flashes faster (double the normal rate) as long as the control is in setup mode. While in setup mode, pressing Start or Stop button has no effect. Exiting from setup mode will return the control to STOP mode. In the setup mode, a Menu driven setup process is available for making adjustments that are allowed to be made from the control panel. Set up process is described in detail in a separate section later in this manual. Auto Mode Pressing the Auto Button while the PS0500 is in the STOP mode will put the PS0500 in AUTO Mode. Pressing Auto Button while the PS0500 is in Manual Mode (Running or Not Running) has no effect. WARNING In Auto mode, the genset can start at any time. NEVER service the genset in Auto mode. Accidental starting of the genset during troubleshooting can cause severe personal injury or death. Disable the genset before troubleshooting. When the remote start signal becomes active, the PS0500 initiates the start sequence to start the genset. The PS0500 continues to run as long as the signal is active. When the Remote Start signal becomes inactive the PS0500 initiates a normal stop sequence. page 14 Pressing the Stop button shall always deactivate the FSO immediately. Remote Start Signal This signal will start the Genset when these conditions are met. • The PS0500 is in Auto mode • There are no active shutdown faults This signal comes typically from a transfer switch or an external toggle switch. Manual Mode Pressing the Manual Button while the PS0500 is in the Stop Mode will put the PS0500 in the Manual Mode. In this mode, the genset is controlled manually. Pressing the Start button initiates a Manual Start sequence. Remote start signal has no effect. Note: If you do not press the Start button in ten seconds, the PS0500 changes over to STOP (Off) mode. Pressing the Stop button initiates a stop sequence. Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine Power-Down Mode Sequence of Operation The PS0500 can enter power-down or sleep mode, to reduce load on batteries when not being used. Sequences of operation describe the way the PS0500 starts the genset or stops the genset. This is illustrated in Figure 3-6. PS0500 Power-down Mode Table 2-4 shows how much current the PS0500 control module consumes in normal operation and in power-down mode. TABLE 3-4. PS0500 CURRENT CONSUMPTION PS0500 MODE Normal operation Power-down CURRENT 350 mA < 5 mA The PS0500 enters power-down mode when these conditions are met. - The genset is not running. - The Power down Mode Time Delay has expired. - There is no active communication on the RS-485 communication link. - There are no active faults - There are no active Wake Up signals present. In power-down mode, the microprocessor in the control stops, thereby reducing the consumption from battery. Wake Up Signals The PS0500 wakes up from power-down mode when any of these wakeup signals becomes active. − Tool wakeup input (TB15 pin 5) is grounded. − Τhe Reset button on the Control Panel is pressed − Remote Start Signal (Typically, to a transfer switch) is low. Stopped Start Sequence Genset Running Stop Sequence FIGURE 3-6. Sequence of operation Start Sequences The PS0500 follows different start sequences depending on its setup and conditions. If a start sequence is interrupted for any reason except a shutdown fault (for example, the remote start signal becomes inactive), the PS0500 aborts the start sequence and initiates a Stop sequence. Remote Start This sequence begins when these conditions are met. - The PS0500 is in Auto mode. - The remote start signal is active, - There are no active shutdown faults. - This sequence is shown in Figure 3-7. page 15 Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine Cycle Cranking The starter turns on for Cycle Crank Engage Time and turns off for Cycle Crank Rest Time. The starter repeats this process up to Crank Attempts times. The PS0500 turns OFF the Starter Output and keeps it OFF when, The Genset Frequency is >= Starter Disconnect Speed / Frequency Speed gain, (Example: Typically the starter disconnect speed is set to 450 RPM. In case off a four pole alternator the value of the Frequency speed gain is set to 30. So the genset frequency at which the starter disengagement happens would be calculated as 450 / 30 = 15Hz) OR The Battery Charging Alt Voltage >= Start Disconnect threshold If the genset frequency does not reach the start disconnect threshold (15 Hz in above example) before PS0500 finishes the cranking cycle, then it generates shutdown fault 359 (Fail To start). FIGURE 3-7. Remote Start Sequence In this sequence, the PS0500 follows these steps to start the engine. 1. The PS0500 waits until Start Time Delay expires. If the trim Glow Plug Enable is set to Enabled, the PS0500 turns on the Glow Plug Control output. The PS0500 turns off the Glow Plug Output when Glow Plug Timeout Period expires. The PS0500 does not proceed to crank until both Start Time Delay expires and the Glow Plug Output is turned off. 2. The PS0500 turns on the fuel shutoff (FSO) output and the Starter Output. page 16 The PS0500 waits for the Genset to reach the rated frequency and voltage. If that does not happen within 10 seconds from the starter disconnect, the PS0500 generates Shutdown Fault 2335 (loss of AC Sensing). Manual Start This sequence begins when these conditions are met. • The PS0500 is in Manual mode and the Start button is pressed. • There are no active shutdown faults. This sequence is shown in Figure 3-8. There are no active shutdown faults. . Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine Meter Calibration When running in Manual Mode, the control allows meter calibration process to be invoked, when the Genset Running (Ready to Load) state is reached. The Meter Calibration process is invoked by holding the Reset and OK buttons pressed for 5 seconds continuously. The process allows the arrow keys to be used for adjusting the displayed alternator AC Voltage / Current values to actual values (as measured using an independent calibrated instrument) one by one. The Meter Calibration Process is available when running the genset in Manual Mode only. Nominal Voltage and Frequency The PS0500 does not have the control of the genset frequency (speed) and the genset voltage. The nominal voltage and the nominal frequency set-up parameters are used only for calculation of the over voltage, under voltage, over frequency and under frequency fault thresholds and determining if the Genset Running (Ready to Load) state has been reached as described above. Stop Sequences FIGURE 3-8. Manual Start Sequence In this sequence, the PS0500 follows these steps to start the engine. 1. If the trim Glow Plug Enable is set to Enabled, the PS0500 turns on the Glow Plug Control output. The PS0500 turns off the Glow Plug Output when Glow Plug Timeout Period expires. The PS0500 does not proceed to crank until the Glow Plug Output is turned off. 2. The PS0500 turns ON the fuel shutoff (FSO) output and the Starter Output. The cycle cranking process as explained above is followed in Manual Mode also. Genset Running (Ready to Load) The PS0500 enters the Genset Running (Ready to Load) state when the genset frequency and voltage are both >= 90 percent of the nominal frequency and nominal voltage respectively. The PS0500 follows different stop sequences depending on its setup and conditions. Auto Mode In Auto mode the stop sequence begins when these conditions are met. − The genset is running at rated speed and voltage − The remote start signal is inactive. The Genset will continue to run for the Stop Delay time and then the FSO Output will be deactivated by the PS0500. Manual Mode In Manual mode the stop sequence begins when these conditions are met. − The genset is running at rated speed and voltage − The Stop button has been pressed. − There are no active shutdown faults. The FSO Output will be deactivated by the PS0500 immediately when the Stop button is pressed. page 17 Power Start 0500 X1.3 & X2.5 Engine Fault Shutdown In Manual as well as Auto mode, the FSO Output will be deactivated by the PS0500 immediately when any of the shutdown faults becomes active. page 18 Publication A029U889 Issue 3 - 8-2017 Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine SECTION 4. CIRCUIT BOARD TB15 – Tool Connector Arrow at Pin 1 J12 – CT connector Arrow at Pin 1 J12 –Pin 4 J16 – Engine connector Arrow at Pin 1 J16 –Pin 7 J22 – Voltage connector Arrow at Pin 1 TB2 – Customer TB Arrow at Pin 1 page 19 Power Start 0500 X1.3 & X2.5 Engine Publication A029U889 Issue 3 - 8-2017 The dot designates pin 1 on the connectors. TB2 – Customer Terminal Block Customer fault input, Customer output, Glow Plug, Remote Start, Remote E-stop. J22 Alternator Voltage Sense inputs and Field Output • • PS0500 CONTROL BOARD • J16 Engine Connections Coolant Sensor, Lube Oil Pressure sensor, Run / OFF / Auto Switch, FSO, Starter, Battery, Mag Pick Up, Starter Disconnect Feed Back, Battery Charger D+, Chassis GND. Governor PWM • • TB15 – Tools Interface Connector page 20 J12 CT Connections Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine 4.1 CONTROL INPUTS AND OUTPUTS Engine Connector The engine connector (J16) is a 12 pin connector-plug (12 MINI M-N-L). A possible supplier is Molex; their part number is 39299123. The Cummins part number for this connector is 0323-2589. The PCB outline drawing shows where the connector is located as above .Each signal is described as below – Connector Pin J16-1 J16-2 J16-3 J16-4 J16-5 J16-6 J16-7 J16-8 J16-9 J16-10 J16-11 J16-12 Signal Name Coolant temperature sensor Battery charging alternator (WL) Starter Relay Driver (Low Side) Fuel shutoff relay Driver (Low Side) BATChassis GND NC NC Oil Pressure Sensor Starter Disconnect Input Sensor Common BAT + CT Connector The CT connector is a 6- pin MATE-N-LOCK connector. The possible manufacturer is Tyco, and the supplier part number for the part is 643749-1. The Cummins part number for this connector is 0323-2154. Connector details are as follows – Connector pin J12-1 J12-2 J12-3 J12-4 J12-5 J12-6 Signal CT1_input CT2_input CT3_input CT1_COM CT2_COM CT3_COM page 21 Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine Voltage Connector The voltage connection is via a 4 pin header with alternate spaces between the pins. The possible supplier is Tyco with the supplier part number as 282828-4. The Cummins part number for the same is 0323-2225-03. Connector pin J22-1 J22-2 J22-3 J22-4 Signal Gen_V1 Gen_V2 Gen_V3 Gen_N Customer Connections TB2 The customer connection TB2 is a 6 pin terminal block. The possible supplier is Magnum: The terminal pins details are as shown belowTerminal pins TB2-1 TB2-2 TB2-3 TB2-4 TB2-5 TB2-6 Signal Remote start Switch Input Glow Plug Output Relay Driver (Low Side) Customer Output Relay Driver (Low Side) Customer Input E-Stop NC All the inputs are active GND. And outputs are low side drivers. Remote E-Stop switch should have two independent potential free contacts. One NC contact for cutting out the Battery supply to the Fuel Solenoid and another NC contact to disconnect controller’s E-Stop input from GND to indicate to the control when the E-Stop is pushed in active state. Battery Positive is not provided on the Customer terminal block (TB2). External provision needs to be made in the harness to provide fused B+ via a 1 amp fuse for wiring up external relays. External Relays of suitable contact ratings must be used for controlling FSO, Starter, Customer Output and Glow plug. PC Tool Connector The PC tool connector is a dedicated 5 pin connector header block. The possible supplier is Tyco, with the supplier part numbers are 796643-5. The Cummins part number for the same is 0323-2191-04. Terminal pins TB15-1 TB15-2 TB15-3 TB15-4 TB15-5 page 22 Signal GND NC RS485_DATA_A RS485_DATA_B TOOL_WAKEUP Publication A029U889 Issue 3 - 8-2017 Power Start 0500 Connector Part Numbers Quantity Name Description Manufacturer Manufacturer’s part number Cummins part no 1 J22 Alt Voltage Connector TYCO 282828-4 0323-2225-03 1 J12 CT Connector TYCO 643749-1 0323-2154 1 J16 Engine Connector MOLEX 39299123 0323-2589 1 TB2 Customer TB MAGNUM EM257506VC 0323-1677-05 1 TB15 Tool Connector TYCO 796643-5 0323-2191-04 1 J22 TYCO 282809-4 0323-2226-03 1 J12 1-480704-0 0323-1932 350551-1 0323-1200 1 J16 39012120 0323-2602 39000038 0323-2603 EM256506H 0323-1678-05 Alt Voltage Connector CT Connector Crimp Terminals Engine Connector Crimp terminals TYCO MOLEX 1 TB2 Customer TB MAGNUM 1 TB15 Tool Connector TYCO Remarks All these connectors are PCB mounted connectors Communication cable Kit 0541-1199 is used for the tool interface page 23 Power Start 0500 X1.3 & X2.5 Engine Publication A029U889 Issue 3 - 8-2017 SECTION 5 - TROUBLESHOOTING General The PS0500 control continuously monitors engine sensors for abnormal conditions, such as low oil pressure and high coolant temperature. If any of these conditions occur, the control will light a yellow warning lamp or a red shutdown lamp and display a message on the LCD display. PC Based Service Tool The PC based service tool can be used in troubleshooting to perform tests, verify control inputs and outputs, and test protective functions. When used improperly, a PC based service tool can cause symptoms like warnings and shutdowns that appear to be a defective control. When these problems occur, always verify that a self-test or fault simulation (override) have not been left enabled with the tool. If you do not have a PC based service tool, or the enabled fault simulation(s) can not be found using the tool, disconnect battery power to disable the test or override condition. Make sure that parameter adjustments and time delays, related to the fault condition, have been appropriately set for the application. It may be necessary to write the initial capture file to the device or update the calibration file. Updating a calibration file requires a Pro version of many of PC based service tools. Confirm that the installed calibration part number matches the serial plate information. CAUTION Using the wrong capture file can result in equipment damage. Do not swap Controls from another genset model and only use the calibration file shown on the nameplate. 5.1 SAFETY CONSIDERATIONS WARNING Contacting high voltage components can cause electrocution, resulting in severe personal injury or death. Keep the output box covers in place during Trouble shooting. WARNING Ignition of explosive battery gases can cause severe personal injury or death. Arcing at battery terminals, light switch or other equipment, flame, pilot lights and sparks can ignite battery gas. Do not smoke, or switch trouble light page 24 ON or OFF near battery. Discharge static electricity from body before touching batteries by first touching a grounded metal surface. Ventilate battery area before working on or near battery—Wear goggles—Stop genset and disconnect charger before disconnecting battery cables—Disconnect negative (-) cable first and reconnect last. CAUTION Disconnect battery charger from AC source before disconnecting battery cables. Reading Fault Codes The fault code and message can be viewed on the display. After the fault is acknowledged and corrected, the recorded fault will be deleted from the control panel memory, but will remain in a data log to maintain a fault code history. A PC based service tool is required to view this data log. 5.2 TROUBLESHOOTING PROCEDURE The following tables are a guide to help you evaluate problems with the generator set. You can save time if you read through the manual ahead of time and understand the system. Voltage/Continuity Testing Voltage and continuity tests are required in the following tables. In some cases, it is necessary to remove a plug to complete the test. Where required, the corrective action will mention when it is necessary to remove a plug for testing. In other cases, the plug cannot be removed for testing. When plug removal is not mentioned, testing must be performed by inserting a narrow meter probe into the back of the plug. Power Start 0500 X1.3 & X2.5 Engine Publication A029U889 Issue 3 - 8-2017 TABLE 20-1. ENGINE DOES NOT CRANK IN MANUAL MODE Reason: This indicates that the control has not received or recognized a manual start signal. Effect: Engine will not start. POSSIBLE CORRECTIVE ACTION CAUSE 1. No power Check if the control is in Manual supplied to mode and when the Start button is control pressed, and that there are no shutdown faults present. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. Check for blown fuses. 2. Control not properly calibrated or corrupt calibration. 3. The Emergency Stop switch or wiring is defective. 5. Oil Pressure switch or wiring is defective 6. Oil Pressure sender, setup on wiring is defective. TABLE 20-2. ENGINE DOES NOT CRANK IN REMOTE MODE Reason: This indicates that the PS0500 control has not received or recognized a remote start signal. Effect: Engine will not start in remote mode, but starts in manual mode. POSSIBLE CORRECTIVE ACTION CAUSE 1. The remote Check if the control is in Auto mode start switch or and there are no shutdown faults wiring is faulty. present. Attempt to start, and check for ground at TB2-1. If ground level is not present, isolate to the remote switch or wiring. Repair as necessary. If ground level is present then the control is bad. Replace the control Remove connector P16 and check for B+ at P16-12 and GND at P16-5. If B+ or ground missing, check the harness. If B+ and ground check OK, cycle power to control by reconnecting P16. Press Reset Button to wake the control up. And retry operation. Confirm that the installed calibration part number matches the serial plate information. Re-enter calibration file if necessary. With Emergency Stop push button not activated (switch closed), remove leads from TB2-5 and B- and check for continuity between these two leads. If circuit is open, isolate to Emergency Stop switch and wiring. If there is continuity, go to next step. Remove P16 connection and check wiring between P16-9 and P16-11 to the switch. Verify control is configured for the type of sensor installed. Verify proper operation of the switch Remove P16 connection and check wiring between P16-9, P16-11 to the sender. Verify control is configured for the type of sender. Verify operation of the sender page 25 Power Start 0500 X1.3 & X2.5 Engine TABLE 20-3. WARNING AND SHUTDOWN CODES FAULT CODE CORRECTIVE ACTION Indicates engine has overheated 151 (coolant temperature has risen HIGH COOLANT above the shutdown trip point). TEMP Lamp: Shutdown Allow engine to cool down completely before proceeding with the following checks: a. Check coolant level and replenish if low. Look for possible coolant leakage points and repair if necessary. b. Check for obstructions to cooling airflow and correct as necessary. c. Check fan belt and repair or tighten if necessary. d. Check blower fan and circulation pumps on remote radiator installations. e. Reset control and restart after locating and correcting problem. Indicates engine oil pressure has 415 dropped below the shutdown trip LOW OIL point. Check oil level, lines and PRESSURE Lamp: Shutdown filters. If oil system is OK but oil level is low, replenish. Reset control and restart. If oil switch is used, check switch performance. Indicates that one or more of the 1446 phase voltages has exceeded HIGH AC 130% of nominal for 0 second, or VOLTAGE Lamp: Shutdown has exceeded high ac voltage threshold for High AC Voltage time delay seconds. Indicates that one or more of the 1447 phase voltages has dropped LOW AC below low ac voltage threshold for VOLTAGE Lamp: Shutdown low ac voltage time delay seconds. Indicates frequency is 10% above 1449 base frequency for approximately OVER 10 seconds. FREQUENCY Lamp: Shutdown Indicates that Frequency had 1448 dropped below 90% of nominal for UNDER approximately 10 seconds. FREQUENCY Lamp: Shutdown Check fuel supply, intake air supply and load. Indicates remote Emergency 1434 Stop. To reset the remote EMERGENCY Emergency Stop button: STOP Lamp: Shutdown 1. Open (disable) remote page 26 Publication A029U889 Issue 3 - 8-2017 emergency stop button. Press the OFF button. Select the desired operating mode (manual or auto). Indicates possible fuel system or air induction problem. (Engine cranks but fails to start) a. Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as required. b. Check for dirty fuel filter and replace if necessary. c. Check for dirty or plugged air filter and replace if necessary. d. Reset the control and restart after correcting the problem. Genset continues to run after receiving shutdown command from the controller. Check the FSO Relay and related wiring. Check that the FSO is not mechanically stuck A shutdown fault occurred while the Battle Short mode was enabled. Check fault history for faults that may have been bypassed. Indicates engine is operating near cooling system capacity. Increase in load or higher ambient temperature may cause High Coolant Temp (151) shutdown. Review code 151 correction list for other possible causes. Indicates engine coolant heater is not operating or is not circulating coolant. Check for the following conditions: a. Coolant heater not connected to power supply. Check for blown fuse or disconnected heater cord and correct as required. b. Check for low coolant level c. and replenish if required. Look for possible coolant leakage points and repair as required. Open heater element. Check current draw of heater. 2. 359 FAIL TO START Lamp: Shutdown 2677 FAIL TO STOP Lamp: Shutdown 1123 SHUTDOWN AFTER BS Lamp: Shutdown 146 HIGH COOL TEMP. Lamp: Warning 1435 LOW COOLANT TEMP Lamp: Warning Set is not operating. Warning occurs when engine coolant temperature is 70F (21C) or lower. NOTE: In applications where the ambient temperature falls below 40F (4C), Power Start 0500 X1.3 & X2.5 Engine Publication A029U889 Issue 3 - 8-2017 Low Coolant Temp may be indicated even though the coolant heaters are operating. 1312 CUSOMER INPUT FAULT Lamp: Warning Or Shutdown Depending on the setup Coolant temperature must be below 70F (default setting) for one minute to activate warning and be above 70F for five minutes before the warning can be cleared. 144 COOL SENSOR OOR Lamp: Warning Indicates that the control has sensed that the engine coolant temperature sensor output is out of range (high or low). Check sender/connectors/wires. This fault will only occur if water temperature sensor is equipped on the genset. Indicates battery voltage supply to the control is approaching a low level at which unpredictable operation will occur. a. Discharged or defective battery.Check the battery charger fuse.Recharge or replace the battery. b. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. c. Check battery wiring/calibration. Check engine DC alternator. Replace engine DC alternator if normal battery charging voltage is not obtained. e. Check battery charge voltage float level if applicable (raise float level). 441 LOW BATTERY Lamp: Warning 1131 BATTLE SHORT ACTIVE Lamp: Warning 2678 CHARGER FAILURE Lamp: Warning Indicates the Customer Input is active. Example inputs: Low Fuel Day Tank, Water In Fuel, Ground Fault, etc. If multiple of these are connected in parallel, check if any one of them is active. Indicates that the control is in Battle Short mode - used to bypass several fault shutdowns for genset operation during emergencies. Indicates the battery charging alternator has not reached an acceptable voltage range within the selected period (default = 120 1416 FAIL TO SHUTDOWN Lamp: Warning 1442 WEAK BATTERY Lamp: Warning seconds). Refer to engine service manual if this fault occurs. If not failed, check wiring. Genset continues to run after receiving shutdown command from the controller. Battle Short feature enabled - used to bypass several critical fault shutdowns for genset operation during emergencies. Indicates that during cranking, the battery voltage is at or below the weak battery warning trip point for a time greater than or equal to the weak battery set time. See code 441 for corrective action. CODE 151/146 - HIGH OR PRE-HIGH COOLANT TEMPERATURE (SHUTDOWN/SHUTDOWN) Reason: Engine coolant temperature has exceeded the warning threshold for pre-high/high coolant temperature. Effect: 146 – . Warning Lamp lights , Faul code pops up. 151.- Engine will shut down 1. Fault simulation was enabled with a PC based service tool. 2. Engine or sensor circuitry problem. 3. The sensor could be bad. 1. With a PC based service tool, verify that the fault simulation is not enabled for the coolant sensor. If you do not have a PC based service tool, remove battery power from the control to disable fault simulation overrides. Check the sensor accuracy with a thermocouple or similar temperature probe. • If the coolant temperature reading is accurate, the engine may be overheating. Refer to the engine service manual. • If the coolant temperature reading is not accurate, go to next step. Disconnect the sensor and connect a coolant temperature sensor simulator to the harness. If the control responds to the simulator, replace the sensor. If control does not respond, go to next step. 4. The harness or Control could be bad. 4. Measure the resistance of the coolant sensor and reconnect harness to sensor. Remove connector P16 from Control and check resistance between pins P161 and P16-11. page 27 Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine • • If resistance is not the same, harness is bad. If resistance is the same, Control is bad. CODE 143/ 415 - LOW OIL OR PRE-LOW PRESSURE (WARNING/SHUTDOWN) Reason: Engine oil pressure has dropped below the warning/shutdown threshold for low/high oil pressure. Effect: 143. – Warning Lamp lights, Engine will shut down for code 415. – Engine shuts down POSSIBLE CAUSE 1. Fault simulation was enabled with a PC based service tool. 2. Low oil level. Clogged lines or filters. 3. Sensor or oil pump could be bad. Or the generator set may be shutting down on another fault. 4. Harness or Control could be bad. page 28 CORRECTIVE ACTION With a PC based service tool, verify that the fault simulation is not enabled for the oil pressure sensor. If you do not have a PC based service tool, remove battery power from the control to disable fault simulation overrides. Check oil level, lines and filters. If oil system is OK but oil level is low, replenish. Disconnect the oil pressure sensor leads, and connect an oil pressure sensor simulator to the harness. a. If the control responds to the simulator, reconnect the sensor, disconnect the + signal wire at the fuel solenoid, and crank the engine. Check the oil pressure reading on the digital display. • If the display shows an acceptable oil pressure, the problem may not be in the oil or oil sensing system. The genset may be shutting down on another fault (out of fuel, intermittent connector). Restart the genset and monitor the display panel for other faults. • If the display does not show an acceptable oil pressure, replace the sensor. If the Control still doesn’t display an oil pressure while cranking, the oil pump may be bad. Refer to the engine service manual. b. If the control does not respond to the simulator, go to next step. If the control does not respond to the simulator, the Control or the harness is bad. Check the resistance in P16-9 and 5. Low Oil Pressure fault set points could be incorrect. P16-11 (Sensor COMM). If the resistance signal (100 to 33 Ohm) does not get to P16, isolate to the harness. If the resistance does go to P16, the Control is bad. Verify set points against the normal operating pressures of the engine. Refer to engine manual. CODE 1446 - HIGH AC VOLTAGE (SHUTDOWN) Reason: One or more of the phase voltages has exceeded 130% of nominal for 1 seconds, or has exceeded the High AC Voltage Threshold for the High AC Voltage Delay seconds. Effect: Engine will shut down. POSSIBLE CORRECTIVE ACTION CAUSE 1. Fault simulation 1. With a PC based service tool, was enabled with verify that the related fault a PC based simulation is not enabled. service tool. If you do not have a PC based service tool, remove battery power from the control to disable fault simulation overrides. 2. Single step 2. Clear fault and restart genset. large block load removal. 3. Fault threshold 3. Reset the threshold to the is not set correctly highest allowable setting. with Determine the required operating InPower. range before adjusting the threshold. 4. AVR or 4. Refer to Generator AVR Board generator is bad. Isolation Procedure in Alternator manual to determine if the AVR board is causing the high AC voltage shutdown fault. 5. Voltage sense See Section 17 for proper connections/set corrective actions. up could be incorrect. CODE 1447 - LOW AC VOLTAGE (SHUTDOWN) Reason: One or more of the phase voltages has dropped below the Low AC Voltage Threshold for Low AC Voltage Delay seconds. Effect: Engine will shut down. POSSIBLE CORRECTIVE ACTION CAUSE 1. Fault simulation 1. With a PC based service tool, was enabled with a verify that the related fault PC based service simulation is not enabled. tool. If you do not have a PC based Power Start 0500 X1.3 & X2.5 Engine 2. Fault threshold is not set correctly with a PC based service tool. 3. Overload. 4. Improper connections have been made at the generator output terminals. 5. Voltage sense or setup wiring connection could be incorrect. 6. The rotating rectifier assembly (diodes CR1 through CR6) is faulty. 7. Loose connector or Control is bad. 8. AVR or Alternator is bad. 9. Voltage sense connections/setup could be incorrect Publication A029U889 Issue 3 - 8-2017 service tool, remove battery power from the control to disable fault simulation overrides. 2. Reset the threshold to the lowest allowable setting. Determine the required operating range before adjusting the threshold. 3. Check the load and correct any overload. Check operation by disconnecting load and restarting generator set. 4. Reconnect according to the appropriate reconnection diagram. See Section 17. 5. Check that Voltage senses inputs P22-1 to 4 are connected to the correct voltage sensing point at alternator. 6. Check each diode. See genset service manual 8. Repair connections (P22) or replace the Control if necessary. 4. Refer to Alternator / AVR Board Isolation Procedure in Alternator manual to determine if the AVR board is causing the Low AC voltage shutdown fault. See section 17 for proper connections CODE 1449 - OVER FREQUENCY (SHUTDOWN) Reason: Generator AC output frequency is high. Effect: Generator set will shut down. POSSIBLE CORRECTIVE ACTION CAUSE 1. Fault 2. Reset the threshold to the highest threshold is not allowable setting. Determine the set correctly required operating range before with adjusting the threshold. PC based service tool. 2. Fuel or air 3. Refer to the engine service manual. delivery problem. 3. Loose 4. Repair connections (P22 – 1 to 4) connector or or replace the Control if necessary. Control is bad. CODE 1448 - UNDER FREQUENCY (SHUTDOWN) Reason: Generator AC output frequency is low. Effect: Generator set will shut down. POSSIBLE CORRECTIVE ACTION CAUSE 1. Fault 2. Reset the threshold to the lowest threshold is not allowable setting. Determine the set correctly required operating range before with adjusting the threshold. PC based service tool. 2. Overload. 3. Check the load and correct any overload. Check operation by disconnecting load and restarting generator set. 3. Fuel or air 4. Refer to the engine service manual. delivery problem. 4. Governor 5. Check fuel shutoff solenoid fault. adjustment (refer to Section 8). 5. Loose 6. Repair connections (P22 – 1 to 4) connector or or replace the Control if necessary. Control is bad. CODE 234 - OVERSPEED (SHUTDOWN) Reason: Engine speed signal indicates an engine speed greater than shutdown threshold. Effect: Engine will shut down. POSSIBLE CORRECTIVE ACTION CAUSE 1. Cold engine 1. Overspeed can occur when starting (no coolant a very cold engine. Clear fault and heaters) restart genset. 2. Single step large block load removal. 3. Fault simulation was enabled with a PC based service tool. 4. Fault threshold is not set correctly with PC based service tool. 5. Monitor the engine rpm using InPower. 2. Clear fault and restart genset. 3. With PC based service tool, verify that the fault simulation is not enabled for the coolant sensor. If you do not have PC based service tool, remove battery power from the control to disable fault simulation overrides. 4. Reset the threshold to the highest allowable setting. Determine the required operating range before adjusting the threshold. 5. If the RPM is not correct, refer to fault code 1449 for corrective action. page 29 Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine 6. Governor fault. 7. Mechanical Fuel system setup could be incorrect. 6a. Check fuel shutoff solenoid adjustment (refer to Section 8). 6b. Replace defective injection pump unit. Verify fuel stop settings for the application. CODE 359 - FAIL TO START (SHUTDOWN) MECHANICAL GOVERNED ENGINE Reason: This indicates that the engine failed to start after expiration of last crank time. Effect: Engine will not start. POSSIBLE CORRECTIVE ACTION CAUSE 1. Restricted fuel 1a. Add fuel if low. Prime the fuel supply due to: system. a. Fuel level 1b. Open any closed shutoff valve below in the fuel line supplying the engine. pickup tube 1c. Refer to engine service manual. in tank. 1d. Bleed air from fuel system. b. Closed Refer to engine service manual. shutoff valve in supply line. c. Fuel injectors clogged. d. Air in fuel system. 2. Glow plugs are not heating due to: a. Glow plug(s) is bad. b. Control is bad. c. Glow Plug Relay is bad. 3. Fuel solenoid on the injection pump not energized due to: a. Fuse may be open. b. Fuel solenoid is bad. c. Control/K7 Fuel Relay is bad. The Control determines at what temperature and duration of time that the glow plugs will be energized. Using sensed coolant temperature, the glow plugs are energized at 77F (25C) and colder. The glow plugs are energized for up to 15 seconds when the coolant temperature is 5F (-20.5C) or colder. Time duration (15-0 seconds) is linear between -5F and 77F. With coolant temperature colder than 77F (25C): 2a. Each glow plug should be warm to the touch if the engine has just been cranking. First clean and tighten the terminal of any cold glow plug and then replace it if necessary. 2b. Attempt to start and check for if Glow plug relay energizes. TB2- page 30 5. The engine fuel system is worn or 2 should be at GND potential. If the TB2-2 is at GND and K2 relay is not working check relay coil. • If TB2-2 is not at GND potential replace the Control. • If B+ is present, check for open circuit between glow plug relay contact and glow plugs. Isolate to fuse, K7 relay, fuel solenoid or Control. 3a. Remove fuse (if installed) and check continuity. If open, replace the fuse with one of the same type and amp rating. If fuse reopens, check wiring continuity of fuel solenoid circuit/test fuel solenoid. Binding in the solenoid linkage can prevent activation of the hold coil circuitry in the solenoid. Make sure solenoid shaft moves completely in and out freely. (Applies to solenoids with both Pull and Hold coils.) 3b. Attempt to start and check for B+ at the fuel solenoid coil. • If B+ is present, fuel solenoid is bad. • If B+ is not present, go to step c. 3c. Check wiring continuity/test K7 relay or fuel pilot: Remove lead from K7-COM (fuel pilot). Attempt to start and check for GND at lead COM. • If there is no GND, check for open circuit between K7 COM and Base card. • If GND is present, reconnect lead COM to relay. Remove lead from N/O connection. Attempt to start and check for B+ at terminal N/O connection. • If B+ is present, check for open circuit between N/O connection and fuel solenoid(+). • If B+ is not present, check for relay contacts. 4. Service according to the engine service manual. Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine malfunctioning or has lost prime (fuel lift pump, injection pump, injectors, timing). 6. The engine is 5. Service according to the engine worn or service manual. malfunctioning mechanically. CODE 1312 - CONFIGURABLE INPUT (SHUTDOWN) Reason: The nature of the fault is an optional configurable selection. Effect: Shutdown. POSSIBLE CAUSE CORRECTIVE ACTION If there is no actual Disconnect the signal lead from fault, the problem TB2 and reset the control. Check may be an external the following two points. wiring problem. • Customer Input – TB2-4 If the message drops out, the external wiring has a short circuit. Grounding of the input activates fault. CODE 146 - HIGH COOLANT TEMP (WARNING) Reason: Effect: POSSIBLE CORRECTIVE ACTION CAUSE 1. Refer to 1. Refer to code 151. code 151. CODE 1435 - LOW COOLANT TEMPERATURE (WARNING) Reason: Engine coolant temperature has dropped below the warning threshold for low coolant temperature. Effect: No action is taken by the control. Engine may not start due to slow cranking speed. POSSIBLE CORRECTIVE ACTION CAUSE 1. Fault 1. With PC based service tool, verify simulation was that the fault simulation is not enabled enabled with for the coolant sensor. PC based If you do not have a based service service. tool, remove battery power from the control to disable fault simulation overrides. 2. Fault 2. Reset the threshold to the lowest threshold is not allowable setting. Determine the set correctly required operating range before with adjusting the threshold. a PC based service tool. 3. The engine 3. Coolant heater not operating due coolant heater to: could be bad. (Radiant heat should be felt with hand held close to outlet hose.) • Coolant heater not connected to power. Check for blown fuse, or disconnected heater cord and correct as required. • Low coolant level. Look for possible coolant leakage points and repair as required. • Defective heater element/thermostat. With coolant heater removed from engine and power disconnected, flush with cold tap water for two minutes to close internal heater thermostat (opens at 100˜ F and closes at 80˜ F). Check resistance across input power leads: a. Open - replace coolant heater. b. Closed - coolant heater OK (coil resistance of 10 to 60 ohms) 4. The sensor 4. Inspect the sensor and engine connections harness connector pins. Repair or could be bad. replace as necessary. 5. The sensor 5. Disconnect the sensor, and plug in could be bad. a resistive sensor simulator to isolate the fault. If the control responds to the simulator, replace the sensor. If control does not respond, harness or Control are bad. 6. The harness 6. Measure the resistance of the or Control could coolant temperature sensor and be reconnect harness to sensor. Remove bad. connector P16 from Control and check resistance between pins P16-1 and P16-11 (Sensor Common). • If resistance is not the same, harness is bad. • If resistance is the same, Control is bad. CODE 1312 - CONFIGURABLE INPUT (WARNING) Reason: The nature of the fault is an optional configurable selection. Effect: Warning. POSSIBLE CORRECTIVE ACTION CAUSE If there is no Disconnect the signal lead from TB2 actual fault, the and reset the control. Check the problem may following pins .Customer Input – be an external TB2-4 If the message drops out, the wiring problem. external wiring has a short circuit. Grounding of the input activates fault. page 31 Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine CODE 144 - COOLANT SENSOR OOR (HIGH/LOW) (WARNING) Reason: This indicates that the coolant temperature sensor signal is out of range - shorted high or low. Effect: No engine protection for coolant temperature during genset operation. Possible white smoke. POSSIBLE CORRECTIVE ACTION CAUSE 1. The sensor 2. Inspect the sensor and engine connections harness connector pins. Repair or could be bad. replace as necessary. 2. The sensor 3. Disconnect the sensor, and plug in could be bad. a resistive sensor simulator to isolate the fault. If the control responds to the simulator, replace the sensor. If control does not respond, go to next step. 3. The harness 4a. Remove connector P16 from or Control could Control and disconnect sensor. be bad. Check pins P16-1 and P16-11 (Sensor common) for short circuit as follows: • Check for a short circuit to the engine block ground (more than 200k ohms OK). Check for a short circuit from pin to pin (more than 200k ohms OK).Repair or replace as necessary. 4b. Measure the resistance of the coolant sensor and reconnect harness to sensor. Remove connector P16 from Control and check resistance between pins P16-1 and P16-11 (Sensor Common). • If resistance is not the same, harness is bad. • If resistance is the same, Control is bad. CODE 441 - LOW BATTERY (WARNING) Reason: Low voltage has been detected for battery. Effect: The control’s voltage supply approaching level at which unpredictable operation may occur. POSSIBLE CORRECTIVE ACTION CAUSE 1. Weak or 1. Recharge or replace the battery. discharged Specific gravity for a fully charged battery. battery is approximately 1.260 at 80F (27C). 2. Low 2. Replenish electrolyte and recharge electrolyte level battery. in battery. page 32 3. Battery connections loose or dirty. 4. Insufficient battery charging voltage. 5. Engine DC alternator could be bad. 3. Clean and tighten or replace the battery cable connectors and cables at the battery and the set. 4. Adjust charge rate of AC powered battery charging circuit, according to manufactures instructions. 5. Replace engine DC alternator if normal battery charging voltage (12 to 14 VDC) is not obtained. 6. If the batteries are OK, the problem may be the harness or the Control. 6. Remove connector P16 from Control and check battery voltage at P16-12 (B+) to P16-5 (GND). • If the voltage at P16 is not the same as the battery voltage, the harness is bad. If the voltage at P16 is OK, the Control is bad. 7. Check fault threshold against requirement of the application. 7. Fault threshold could be bad. CODE 442 - HIGH BATTERY VOLTAGE (WARNING) Reason: High voltage has been detected for battery. Effect: Control damage will occur. POSSIBLE CORRECTIVE ACTION CAUSE 1. Excessive 1. Adjust charge rate of AC powered battery charging battery charging circuit according to voltage. manufacturers instructions. 2. Engine DC 2. Replace engine DC alternator if alternator could normal battery charging voltage be bad. (12 to 14 VDC) is not obtained. 3. Fault 3. Check fault threshold against threshold could requirement of the application. be bad. CODE 143 - LOW OIL PRESSURE (WARNING) Reason: Effect: POSSIBLE CAUSE CORRECTIVE ACTION 1. Refer to code 415. 1. Refer to code 415. CODE 141 - OIL PRESSURE SENSOR OOR (HIGH/LOW) (WARNING) Reason: This indicates that the engine oil pressure sensor signal is out of range - shorted high or low. Effect: No engine protection for oil pressure during genset operation. POSSIBLE CORRECTIVE ACTION CAUSE 1. The sensor 2. Inspect the sensor and engine connections harness connector pins. Repair or could be bad. replace as necessary. 2. The sensor 3. Disconnect the oil pressure sensor Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine could be bad. leads, and connect an oil pressure sensor simulator to the harness. “OIL PRESSURE SENSOR OOR” warning is displayed after the fault condition is sensed for 10 seconds. 3. The harness could be bad. 4. The Control If the control responds to the simulator, replace the sensor. If control does not respond, go to next step. 4. Remove connector P7 from Control and connector from sensor. Check P16-9 and P16-11 as follows: • Check for a short circuit from pin to pin (more than 200k ohms OK). • Check for an open circuit (10 ohms or less OK). Repair or replace as necessary. 5. With all connectors attached, could be bad. check pressure signal (.500 to .033 VDC) at P16-9 and P16-11 (Sensor Common). If in range, replace Control. CODE 1442 - WEAK BATTERY (WARNING) Reason: Effect: POSSIBLE CORRECTIVE ACTION CAUSE 1. Refer to code 1. Refer to code 441. 441 page 33 Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine SECTION 6 – SETUP AND CALIBRATION Read Safety Precautions, and carefully observe all of the instructions and precautions in this manual. CAUTION Only qualified technicians should adjust the parameters described in this section. Failure to follow this may affect genset operation and may cause damage to the genset or to equipment connected to the genset. In this section, italics are used to identify a specific parameter by name. Parameters See Section 4 for more information about parameters that you can adjust in the Operator Panel. Capture File Use InPower to save the current settings in a capture file on a PC or network. You can use the capture file to look at the current settings while you are away from the PS0500 or to restore settings if you have to reset the PS0500 for any reason. See the InPower User Guide for more information. While InPower can be used with the PS0500 for facilitating the setup, it is not essential for carrying out the basic setup operations. The basic setup can be performed directly from the control panel of PS0500. Following paragraphs Describe the process of carrying out basic setup from the control panel. Entering and leaving the Setup Mode The Setup mode can be entered only from Stop mode when the genset is not running. This is accomplished by holding the Reset and the OK buttons pressed for 5 seconds continuously while in stop mode. The RED Stop Led flashes faster (double the normal rate) as long as the control is in setup mode. Pressing ← button while in Main Menu exits the setup mode. Navigation through the setup menus is described further in a separate section later. MENU Description Tables 6.1 to 6.18 show a summary of the menus offered on the control panel of the PS0500. Table 6.1 Main Menu Description Menu Description Alt Setup Use this menu to select alternator setup parameters like Single / Three phase, 50 / 60 Hz operation, Wye / Delta , Voltage etc. Units Use this menu to select Metric or US units for Coolant Temperature and Oil Pressure Oil Pr Input Use this menu to select the sensor types used with oil pressure Use this Menu to configure the response to Customer input and to configure usage of the customer output Customer I/O Flt History Use this menu to view last five faults that are stored in the control Load Defaults Use this menu to set the default values. page 34 Power Start 0500 X1.3 & X2.5 Engine Publication A029U889 Issue 3 - 8-2017 Table 6.2 Alt Setup Menu SubMenu Phase Type CT Ratio Connect Type Nom LL Voltage Frequency Table 6.5 Nom LL Voltage Sub Menu Description Select this submenu to choose between single / three phase operation Select this submenu to choose the CT Ratio Select this submenu to choose between Wye / Delta connection of alternator windings Select this submenu to choose the alternator nominal voltage Select this submenu to choose the frequency of operation Menu Items 190 200 208 220 230 240 380 400 416 440 460 Table 6.3 Frequency Sub Menu 480 600 Menu Items 50 Hz Table 6.6 Connect Type Sub Menu 60 Hz Menu Items Table 6.4 CT Ratio Sub Menu Single 3 Wire 3 Phase Single 2 wire Menu Items 50:5 75:5 100:5 150:5 200:5 250:5 Table 6.7 Connect Type Sub Menu Menu Items Star Connect Delta Connect 300:5 page 35 Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine Table 6.8 Units Menu Table 6.13 Customer O/P1 menu Menu Item Metric US Description Select this item to choose Metric Units for the display of Coolant Temperature and Oil Pressure Select this item to choose US Units for the display of Coolant Temperature and Oil Pressure Table 6.9 Oil Pr Input SubMenu Description Sensor Select this if using a Sender Switch Select this if using a Switch Menu Items Glow Plug Warning Shutdown Table 6.14 Customer O/P2 menu Menu Items ShutDown Warning Genset Running Table 6.15 Flt History Menu Menu Items Fault 1 – Fault 5 Description View the last 5 faults stored in the control Table 6.10 Oil Pressure Sensor Sub Menu Table 6.16 Load Default MenuItems ONAN CIL Menu Items Confirmation Screen Table 6.11 Customer I/O Menu SubMenu Cust I/P Flt Customer O/P1 Customer O/P2 Description Choose the response to the input when active Choose the function of this output Choose the function of this output Table 6.12 Cust I/P Flt Submenu MenuItems ShutDown Warning page 36 Description To confirm the action press OK Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine Navigation The manual (↑), Reset (↓ //), OK (→) and Auto (←) buttons are used for navigation during the setup. As long as setup mode is not exited these buttons will only act as arrow keys. The RED Stop lamp flashes at twice the normal rate as long as the setup mode is not exited and the control is not returned to STOP mode. Navigation Example (Set the nominal LL voltage to 440) ← Main Menu // Alt Setup → The Fig above shows the basic elements of a Setup Menu. Line 1 always bears the Menu Name and Line 2 shows items in the Menu. The symbols ←, / /, → indicate that the buttons bearing those symbols are active and can be used as follows ← // → Back Button (↓) Scroll Down to the next item Select the item shown on line 2 When a menu or submenu containing more choices is selected, the Name of the Menu or Submenu moves to line 1 and the choices in the menu are displayed on line 2. / / (↓) button can then be used to scroll through the choices available in the Menu, and → (OK) button can be used to choose the item shown on line 2. The ← button can be used to go back one level up in the menu. Here in the current example, pressing → will take you to the Alt Setup menu. The Name of the chosen Menu (Alt Setup) will move into the line 1 and the first choice within that menu (phase type) will be shown on line 2. ← Alt Setup Phase Type // → You can now press / / (↓) button to scroll through the choices available in the Alt Setup Menu one by one. When the choice that you want appears on line 2, pressing → will take you into that submenu. Here in our example, let us say, you pressed / / (↓) until “Nom LL Voltage” submenu was displayed in line 2. ← Alt Setup Nom LL Voltage // → Pressing → will take you into the choices available for nominal line to line voltages. Pressing ← will take you to the main menu and pressing / / (↓) will take you to the next item within Alt Setup Menu. Let us say you pressed →. The display will now look like this. page 37 Power Start 0500 X1.3 & X2.5 Engine Publication A029U889 Issue 3 - 8-2017 ← Nom LL Voltage 190 // → Pressing / / (↓) will show all the choices available for nominal LL voltage one by one. Let us say you pressed / / (↓) until 440 was displayed. ← Nom LL Voltage // 440 → Pressing → will select that as the Nominal LL Voltage. An asterisk (*) will appear in line 2 indicating that to be the current selection. The → at the end of line 2 will change to ← indicating that the only active buttons now are / / (↓) and ←. ← Nom LL Voltage // * 440 ← Pressing ← button will take you to one level up in the menu tree at a time. You have to press ← several times to reach the main menu. Pressing ← button while at the main menu shall exit the setup mode. Following message shall be displayed before leaving the setup mode. Current Config Saved ← Press ← to leave setup mode and resume normal operation. The red Stop LED will resume flashing with normal rate (1 Hz). page 38 Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine SECTION 7 - SERVICING THE GENERATOR 7.1 TESTING THE GENERATOR These tests can be performed without removing the generator. Before starting tests, disconnect the negative (–) cable from the battery to make sure the engine will not start while performing these tests. CAUTION Disconnect battery charger from AC source before disconnecting battery cables. Otherwise, disconnecting cables can result in voltage spikes damaging to DC control circuits of the set. WARNING Ignition of explosive battery gases can cause severe personal injury or death. Arcing at battery terminals, light switch or other equipment, flame, pilot lights and sparks can ignite battery gas. Do not smoke, or switch trouble light ON or OFF near battery. Discharge static electricity from body before touching batteries by first touching a grounded metal surface. Ventilate battery area before working on or near battery—Wear goggles—Stop genset and disconnect charger before disconnecting battery cables— Disconnect negative (–) cable first and reconnect last WARNING Accidental starting of the generator set can cause severe personal injury or death. Prevent accidental starting by disconnecting the negative (–) cable from the battery terminal. FIGURE 7.1 Po P1 Appropriate frame and type of connection is used to meet the application requirements in terms of single phase three phase, 50 Hz, 60 Hz temperature rise and the KVA rating page 39 Power Start 0500 X1.3 & X2.5 Engine 7.2 GENERATOR/BASE BOARD ISOLATION PROCEDURE The following procedure is used to determine if the generator or the control Base board is causing a high AC voltage shutdown fault. 1. Throw the line circuit breaker OFF and shutdown the set. CAUTION This test involves unregulated excitation of the generator. To prevent dam-age to the generator due to over current, make sure that all loads have been disconnected and that all faults have been cleared from the power output terminals of the generator. WARNING HAZARDOUS VOLTAGE. Touching Un-insulated parts inside the control housing and power output boxes can result in severe personal injury or death. Measurements and adjustments must be done with care to avoid touching hazardous voltage parts. Stand on a dry wooden platform or rubber insulating mat, make sure your clothing and shoes are dry, remove jewelry and use tools with insulated handles. 2. Remove the side access cover of the control housing to access the exciter stator leads (X and XX). Disconnect the X and XX leads from the AC harness (quick connect type connectors). 3. Prepare to measure output voltage across the generator terminals while the set is running. page 40 Publication A029U889 Issue 3 - 8-2017 4. Bring two jumpers from a 12 volt battery for connection to the exciter stator X (Field +) and XX (Field –) leads. Connect the jumper from the positive (+) post of the battery to the X lead. Be prepared to connect the jumper from the negative (–) post oft he battery to the XX leads. If one of the 12 volt cranking batteries is used, bring the jumpers from the battery connected on the grounded side of the system to avoid inadvertently imposing 24 volts on the system. 5. Check polarity again. Polarity must be corrector this test will be inconclusive because the induced and residual magnetic polarities in the exciter stator will be opposed. Genset may shut down on a fault condition with in 5 to15 seconds due to the exciter stator leads being disconnected from the Base board. Clear fault and start genset to check next phase. 6. Start the set and connect the jumper from the battery negative (–) terminal to the XX lead. 7. The generator circuitry is probably okay if rated output voltage or higher is obtained and the voltages for all phases are balanced when the exciter is powered by a 12 volt battery. Refer to Section 4to troubleshoot the PCC control circuitry. (Normal excitation voltage ranges from approximately 10 VDC at no-load to approximately 40 VDC at full–load.) 8. If the voltages are unbalanced, trouble shoot the main stator first. If the voltages are uniformly low, troubleshoot the exciter and field circuits first. Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine 7.3 EXCITER STATOR Testing Winding Resistance: Measure winding resistance with a stone bridge or digital ohm-meter. Replace the stator if winding resistance is not as specified by Table 7-2. Testing Winding Insulation Resistance: Disconnect the exciter stator leads X and XX from their connectors in the AC harness and isolate them from ground. Using an ohmmeter, measure resistance between either lead and the stator laminations. Re-place the stator if insulation resistance is less than 1megohm (1,000,000 ohms) Flashing the Field (Self-Excited Generators Only): If necessary, flash the exciter field before or after installation. Apply 110 to 220 VAC for one to two seconds to the X and XX leads of the exciter stator. The generator must be shut down, the Baseboard disconnected, a diode used to establish correct polarity and a 3 amp fuse to prevent over-excitation. See the diagram. Alternatively, while the set is running and disconnected from all loads, apply a 12 VDC battery for one to two seconds as shown in the diagram. Polarity must be correct: + to X, – to XX. FIGURE 7-2. TESTING AND FLASHING THE EXCITER STATOR page 41 Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine 7.4 EXCITER RECTIFIER BRIDGE (Rotating Rectifier Assembly) The exciter rectifier bridge is mounted on the exciter rotor, inboard, facing the main rotor. It consists of a positive plate and a negative plate, split diametrically. Each carries three diodes, three terminal posts for connecting exciter rotor leads to the diode pig-tails and a terminal for the main rotor (generator field) lead. A surge suppresser is connected across the two plates to prevent transient voltages that could damage the diodes. Testing Diodes: Disconnect the diode pigtails from the terminal posts. Using an ohmmeter, measure electrical resistance between each diode pigtail and the plate on which the diode is mounted. Reverse the meter test probes and repeat the tests. The electrical resistance across each diode should be high in one direction and low in the other. If the resistance is high or low in both directions, replace the diode. Replacing Diodes: Make sure the replacement diode is of the correct polarity. Disconnect the pig tail from the terminal post and unscrew the old diode. Apply heat-sink compound under the head of the diode. Make sure the compound does not get on the threads. Torque the diodes to 36 to 42 in-lbs (4 to 4.8Nm) and the pigtail terminals to 24 in-lbs (2.7 Nm) when reassembling. Surge Suppresser Testing and Replacement: Remove the suppresser. Replace the suppresser if it appears to have overheated or if ohmmeter readings indicate less than infinite resistance (end of scale) in both directions. Torque the terminals to 24in-lbs (2.7 Nm) when reassembling. CAUTION Layers of dust can cause diodes to overheat and fail. Brush dust off regularly. FIGURE 7–3. TESTING THE ROTATING RECTIFIER ASSEMBLY page 42 Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine assembly if the resistance of any winding is not as specified in Figure 7-4. Exciter Rotor Testing Winding Resistance: Testing Winding Insulation Resistance: Disconnect the six rotor winding leads from the terminal posts on the rectifier assembly. With a Wheatstone bridge, mea-sure electrical resistance across each pair of rotor windings: U (CR1 or CR4) and V (CR2 or CR5), V(CR2 or CR5) and W (CR3 or CR6), W (CR3 orCR6) and U (CR1 or CR4). See the winding schematic. Replace the whole rotor shaft Using an ohmmeter, measure the resistance between any rotor winding lead or the terminal to which it is connected and the rotor laminations. Replace the whole rotor shaft assembly if insulation resistance is less than 1 megohm. FIGURE 7–4. TESTING THE EXCITER ROTOR page 43 Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine Main Rotor (Generator Field) Testing Winding Insulation Resistance Testing Winding Resistance: Using an ohmmeter, measure the resistance between either lead of the main rotor windings, or the terminal to which it is connected, and the main rotor laminations. Replace the rotor if insulation resistance is less than 1 mega ohm. Disconnect the two leads of the main rotor from the terminals on the rotating rectifier assembly. See Figure 7-5. Measure electrical resistance between the two leads with a Wheatstone bridge or digital ohmmeter. Replace the rotor if the resistance is not as specified in Table 6-1. Connect the rotor leads and torque the terminals to 24 in-lbs (2.7 Nm) when reassembling. NOTE : Incorrect resistances indicate faulty windings and component replacement is necessary. FIGURE 7–5. TESTING THE MAIN ROTOR page 44 Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine 7.5 MAIN STATOR Testing Winding Resistance: Measure electrical resistance across each pair of stator leads (U1-U2, U5-U6, VI-V2, V5-V6, W1-W2 and W5W6) with a Wheatstone bridge or ohmmeter having at least0.001 ohm precision. Replace the stator if the resistance of any winding is not as specified in Table6-1. Alternatively, winding resistance can be measured lineto-line at the generator terminals (U-V, V-W,W-U)on “star” connected generators. On a 600 volt generator, line-to-line resistance should be twice the table value (two winding elements in series). On a “series star” connected generator, line-to-line resistance should be four times the table value (four winding elements in series). On a “parallel star” connected generator, line-to-line resistance should be the same as the table value (two sets of two winding elements in series). Single phase only windings can be measured at W-V and should be twice the table value. Testing Winding Insulation Resistance: Disconnect the AVR completely, (AT THE AVR), before carrying out this test. Disconnect any connections from Neutral to Earth.The Stator insulation should be checked with an Insulation tester. The test instrument should be 500 or 1000 volts for low voltage Generators (up to 690V). For low voltage machines (up to 690V), the MINIMUM insulation value is 1.0 Meg-Ohm to Earth (Ground). WINDINGS MUST BE DRIED OUT IF BELOW 1.0 MEG-OHM. NOTE Faults on the stator winding or cables may also cause noticeable load increase on the engine when excitation is applied. FIGURE 7.6 TESTING THE GENERATOR STATOR page 45 Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine Main Excitation Windings: If after establishing and correcting any fault on the rectifier assembly the output is still low when separately excited, then the main rotor, exciter stator and exciter rotor winding resistances should be checked (see Resistance Charts), as the fault must be in one of these windings. The exciter stator resistance is measured across leads F1 and F2. The exciter rotor is connected to six studs, which also carry the diode lead terminals. The main rotor winding is connected across the two rectifier plates. The respective leads must be disconnected before taking the readings. Resistance values should be within 10% of the values given in the table below ALTERNATOR FRAME SIZE P044D Main Rotor (Ohms) 0.437 Exciter stator (Ohms) 17.5 Exciter Rotor (Ohms) 0.211 P044E 0.415 17.7 0.211 P044F P044G P044H P144D P144E P144F P144G P144H P144J P144K 0.465 0.551 0.545 0.657 0.67 0.708 0.857 0.89 0.983 0.99 18.5 18.5 18.5 18.5 19.36 20.25 22.25 22.9 22.9 22.9 0.228 0.228 0.228 0.228 0.215 0.201 0.201 0.21 0.21 0.21 Main Stator Resistance ALTERNATOR FRAME SIZE Main stator winding resistances (Ohms) Windings P044D 12 Lead Reconnect able* P044E 1.33 P044F 0.95 P044G 0.625 P044H 0.51 P144D P144E 0.353 1.908 0.3 *- Note :These Windings are referred by the alternator Manufacturer as “311” Winding no. page 46 Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine 7.6. GENERATOR DISASSEMBLY The generator is heavy. You will need an assistant and a hoist of sufficient capacity to remove and service the generator. WARNING Accidentally dropping the generator can damage it and cause severe personal injury and death. The hoist, straps and chains must have sufficient capacity and be attached properly so that the load cannot shift. Before starting, disconnect the negative (–) cable from the battery to make sure the set will not start while working on it. WARNING Ignition of explosive battery gases can cause severe personal injury or death. Arcing at battery terminals, light switch or other equipment, flame, pilot lights and sparks can ignite battery gas. Do not smoke, or switch trouble light ON or OFF near battery. Discharge static electricity from body before touching batteries by first touching a grounded metal surface. Ventilate battery area before working on or near battery—Wear goggles—Stop genset and disconnect charger before disconnecting battery cables— Disconnect negative (–) cable first and reconnect last. CAUTION Disconnect battery charger from AC source before disconnecting battery cables. Otherwise, disconnecting cables can result in voltage spikes damaging to DC control circuits of the set . WARNING Accidental starting of the generator set can cause severe personal injury or death. Prevent accidental starting by disconnecting the negative (–) cable from the battery terminal. Removing The Generator Control Housing 1. Disconnect the line cables and conduit. For reconnections later, make sure each cable is clearly marked to indicate the correct terminal. 2. Disconnect the remote control wiring and conduit. For reconnections later, make sure each wire is clearly marked to indicate the correct terminal. 3. Disconnect all engine wiring harness connections in the generator control and output boxes. For reconnections later, make sure each wire is clearly marked to indicate the correct terminal. 4. Disconnect all generator control leads (winding taps) from connections in the output box. For reconnections later, make sure each wire is clearly marked to indicate the correct terminal. 5. If the set has a mounted line circuit breaker, disconnect the cables to the circuit breaker. For reconnections later, make sure each cable is clearly marked to indicate the correct terminal. 6. Attach a hoist to the generator output box, loosen the mounting bolts on the sides of the generator and remove the box. Withdrawing The Generator From The Set CAUTION Do not use fan blade to bar over engine. That can damage blades and cause property damage and personal injury. 1. The rotor will be carried inside the stator when the generator is withdrawn from the engine. Bar the engine until one of the four poles of the rotor points straight down so that the rotor will rest on the face of the pole when the generator is withdrawn. 2. CAUTION The rotor can be damaged if it rests on the edges of the winding slot between two poles. 2. Attach lifting eyes and a hoist of sufficient capacity (Figure 6-7). 3. Take up hoist slack and remove the two through bolts securing the generator to the rubber isolation mounts. 4. Raise the generator end approximately one inch (12 mm) and securely block the engine under the flywheel housing. Lower the generator slightly so that the blocks carry most of the weight. 5. Remove the bolts securing the generator drive discs to the flywheel. 6. Loosen all the bolts securing the generator adapter casting to the flywheel housing. Adjust the hoist to carry the full weight of the generator, remove the bolts and pull the generator away. Never withdraw the generator leaving the rotor to hang by the drive discs. The weight of the rotor will damage the drive discs. page 47 Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine 25 CINCH STRAP AROUNDTHE MIDDLEOF THE ROTOR FIGURE 7-7. GENERATOR ASSEMBLY page 48 Power Start 0500 X1.3 & X2.5 Engine SECTION 8 – WITHDRAWING THE ROTOR FROM THE GENERATOR 1. Remove the generator adaptor casting on the drive disc end and the end plate on the bearing end. 2. Using a hoist of sufficient capacity, cinch a lifting strap on the drive end of the rotor. Lift the bearing end of the rotor by a Eye Bolt and push it towards the drive end of the generator until half the width of the rotor core protrudes from the stator. Release the weight of the rotor and recinch the lifting strap around the middle of the rotor core. Withdraw the rotor until it is free of the stator, guiding it by Publication A029U889 Issue 3 - 8-2017 hand on both ends to prevent contact with the stator windings 3. Rest the rotor in a cradle, solidly supporting it on two pole faces—not on the drive discs, blower or exciter. 4. Remove the retaining clip if the rotor shaft bearing is to be removed. 8.1 Generator Reassembly Reassembling is the reverse of disassembling. Note the following. The Assembly Torques are specified in the succeeding page. page 49 Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine Generator Assembly Tools and Torque Values Part Description Earth lead to NDE bracket EBG Str Hsg to NDE bracket EBG Str to EBG Str Hsg Excitor stator to NDE bracket Stator Lead to terminal studs Diode fitting Small Terminal box to NDE bracket EBG Rtr to shaft Coupling disc to flywheel DE Adaptor to Flywheel housing Clamping spacer to rectifier hub Rectifier hub to excitor rotor core Rotor leads to Clamping spacer EBG Housing cover to housing Terminal block to NDE bracket Varistor to rectifier hub AVR cover to NDE bracket AVR to NDE bracket Axial air inlet cover to NDE bracket DE Air outlet cover Fan to fan hub 290 and 344 Radial Inlet cover to Nde bracket Terminal box lid to terminal box Coupling disc to shaft Tool Torque value Nm 10mm socket head box screw driver or 10mm socket 6 10 10 10 6.5 11mm socket head box screw driver / Crimping Tool 150mm long x 8mm socket or 8mm socket head box screw driver 17mm socket 17mm socket x 60mm long( non-standard) 17mm socket x 75mm long(STD.) 8 mm socket 8mm open type spanner 8mm socket head box screw driver or 8mm socket 8mm socket with Allen key bit. 2.8/3.6 5 50 51 51 2.8/3.6 2.8/3.6 2.8/3.6 6.5 5 2.8/3.6 5 5 5 6.5 5 5 5 75 DE Adaptor to frame blocks T' type wrench with extension rod and 13mm socket 26 NDE bracket to Frame blocks T' type wrench with extension rod and 13mm socket 26 page 50 Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine GENSET SPECIFICATIONS 3-Phase Ratings 50 Hz Model Standby Prime kW (kVA) kW (kVA) C8D5 6.6 (8.25) 6 (7.5) C11D5 8.8 (11) 8 (10) C17D5, C17D5 (Spec E) 13 (16.5) 12 (15) C22D5, C22D5 (Spec E) 17 (22) 16 (20) C28D5, C28D5 (Spec E) 22 (27.5) 20 (25) 60 Hz Model Standby Prime kW (kVA) kW (kVA) C12D6, C12D6 (Spec E) 12 (15) 11 (13) C16D6, C16D6 (Spec E) 16 (20) 15 (18) C20D6, C20D6 (Spec E) 20 (25) 18 (22) Generator set specifications:Governor regulation class ISO8528 Part 1 Class G2 Voltage regulation, no load to full load ± 1% Random voltage variation ± 1% Frequency regulation Droop Random frequency variation ± 0.25% page 51 Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine Engine specifications X1.3 Design 4 cycle, in-line, naturally aspirated X2.5 4 cycle, in-line, naturally aspirated Bore 95mm (3.74 in) 91.44mm (3.6 in) Stroke 91mm (3.58 in.) 127mm (5 in) Displacement 1.3 liter (78.72 in.³ ) 2.5 liter ( 152.56 in.³ ) Cylinder block Alloy Cast iron, In-line, 2 cylinder Alloy Cast iron, In-line, 2 cylinder Battery capacity 32 Ampere-Hour 63 Ampere-Hour Battery charging alternator N/A N/A Starting voltage 12 volt, negative ground 12 volt, negative ground Fuel system Direct injection: Number 2 diesel fuel Direct injection: Number 2 diesel fuel Fuel filter Single element, Spin-on fuel filter cum Water Separator, Filtration efficiency 25 micron 99%(min) ,Water Separation efficiency 90% (min) Single element, Spin-on fuel filter cum Water Separator, Filtration efficiency 25 micron 99%(min) ,Water Separation efficiency 90% (min) Air cleaner type Dry replaceable element Dry replaceable element Spin on full flow filter , Filtration efficiency 25 micron 99%(min) 122°F (50°C) ambient radiator with coolant Recovery System Spin on full flow filter , Filtration efficiency 25 micron 99%(min) 122°F (50°C) ambient radiator with coolant Recovery System Lube oil filter type(s) Standard cooling system Alternator specifications Design Brushless, 4 pole, revolving field Stator 2/3 pitch Rotor Single bearing, flexible disc Insulation system Class H Standard temperature rise 163 ºC standby @ 27 ºC ambient Exciter type Torque match (shunt) standard, EBS optional EBS(Excitation Boost System) Phase rotation A (U), B (V), C (W) Alternator cooling Telephone influence factor (TIF) Shaft mounted centrifugal fan THD < 1.8 % on no-load and < 5 % under non-distorting balanced linear load < 50 Telephone harmonic factor (THF) < 2% AC waveform total harmonic distortion Available voltages 50 Hz line–neutral/line-line ( Std Voltage -) 230/400 (STD) 240/416 220/380 127/220 138/240 254/440 265/460 277/480 120/208 133/230 Generator set options and accessories Engine Alternator Control panel Generator set 0 208/240/480 Volt coolant heater. Exhaust system page 52 105 C Temp Rise Alternator Shunt Trip 125°C Temp Rise Alternator Auxiliary Contacts 150°C Temp Rise Alternator Earth Fault Relay EBS (Excitation Boost System) 120/240 V, 25 W, anticondensation heater. Standard Residential Grade exhaust Silencer Heavy Duty Air Cleaner Electronic Governing Battery Charger 1500 /3000 hours Maintenance Kit Power Start 0500 X1.3 & X2.5 Engine Publication A029U889 Issue 3 - 8-2017 SECTION 9 - WIRING DIAGRAMS 9.1 GENERAL INFORMATION This section consists of the schematic and connection wiring diagrams referenced in the text. The following drawings are included. • • • • • • • Page 54, 3 Phase Reconnect Wiring Diagram Page 56, 1 Phase NON Reconnect Wiring Page 57, Wiring Diagram Page 58, Battery Charger and Coolant Heater Connections (optional) Page 59, 3 Phase - Mechanical Governor wiring Page 122, Engine Harness Jumper (PC2100 to PCC1302) Page 123, Customer Connections NOTE: P1 Alternators for X1.3 have Winding 311 for 3 phase for 50 05/06 Winding for 50/60 Hz Single phase respectively. NOTE: The Wiring Drawings are representative drawings. For service, use drawing supplied with geneset pasted on the backside of the door of the pedestal panel The Drawings can be downloaded from the PGBU Engineering Database. page 53 Power Start 0500 X1.3 & X2.5 Engine 3 Phase Reconnectable, 12 Lead CT Secondary Connection NOTE: Sense Lead N is Not Used. Tape End and Tie Back . page 54 Publication A029U889 Issue 3 - 8-2017 Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine 3 Phase Reconnectable, 12 Lead CT Secondary Connection (continued) 8–3 page 55 Power Start 0500 X1.3 & X2.5 Engine 1 Phase NON -Reconnectable, 4 Lead CT Secondary Con page 56 Publication A029U889 Issue 3 - 8-2017 Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine 9.2 WIRING DIAGRAM Wiring diagram for X1.3 generator set page 57 Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine Wiring diagram for X2.5 generator set page 58 Power Start 0500 X1.3 & X2.5 Engine Publication A029U889 Issue 3 - 8-2017 9.3 BATTERY CHARGER AND COOLANT HEATER CONNECTIONS (optional) page 59 Power Start 0500 X1.3 & X2.5 Engine page 60 Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine Publication A029U889 Issue 3 - 8-2017 page 61 Publication A029U889 Issue 3 - 8-2017 Power Start 0500 X1.3 & X2.5 Engine 9.4 CUSTOMER CONNECTIONS page 62 page 63 power.cummins.com Copyright E 2017 Cummins Inc. All rights reserved. Cummins, the “C” logo, PowerCommand, AmpSentry, and InPower are trademarks of Cummins Inc. Other company, product, or service names may be trademarks or service marks of others. Specifications are subject to change without notice.
