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Safety Precautions

SAVE THESE INSTRUCTIONS This


manual contains important instructions
that should be followed
during installation and maintenance of
the generator set and batteries.
Before operating the generator set
(genset),
read the Operators 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 wellventilated 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 for leaks daily or 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 IN FLAMMABLE
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 Power
Generation distributor for more
information.
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.
MEDIUM VOLTAGE GENERATOR
SETS (601V to 15kV)
Medium voltage acts differently than
low voltage. Special equipment and
training is required to work on or around
medium voltage equipment. Operation
and maintenance must be done only by
persons trained and qualified to work on
such devices. Improper use or
procedures will result in severe personal
injury or death.
Do not work on energized equipment.
Unauthorized personnel must not be
permitted near energized equipment.
Due to the nature of medium voltage
electrical equipment, induced voltage
remains even after the equipment
is disconnected from the power source.
Plan the time for maintenance with
authorized personnel so that the
equipment can be deenergized
and safely grounded.
GENERAL SAFETY PRECAUTIONS
Coolants under pressure have a
higher boiling point than water. DO NOT
open a radiator or heat exchanger
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 contact 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 or combustible
material 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 overheating 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 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
DISPOSE OF THIS UNIT PROPERLY

1. System Overview
Read Safety Precautions, and carefully observe
all of the instructions and precautions in this
manual. Keep this manual with the other genset
and/or controller manuals.

This is the Operator Manual for the PowerStart


0500 control. It is not the Operator Manual for the
generator set (genset) or any accessories.

DESCRIPTION
ABOUT THIS MANUAL
You should have a basic understanding of
generators and power generation before you read
this manual.

The PowerStart 0500 is suitable for non-paralleling


generator sets (gensets) in standby or
Prime power applications.
The PowerStart 0500 control is shown below.

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

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.

ALTERNATOR CONNECTIONS

This section introduces the connections between


the PS0500 and the alternator.

the PS0500 and other parts of the genset. Some of


these connections are flexible and might be made
to many types of devices.

Main Alternator Output


Customer Input
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.

Battery-charging Alternator
The PS0500 may be connected to the batterycharging alternator to make sure the batterycharging alternator is recharging the battery
properly.

ENGINE CONNECTIONS

The PS0500 has one customer input that can be


configured to invoke a shutdown or Warning
response

Battery Charger Failed Switch


The PS0500s Customer Input may be connected
to a battery chargers status output (discrete) to
monitor the battery charger operation.

Emergency Stop Buttons


The PS0500 may be connected to a push button
that shuts the genset down immediately when
pressed.

This section introduces the connections between


the PS0500 and the engine.

Battery Connections
The battery provides power for the PS0500 and
the PS0500 monitors the battery voltage.

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.

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.
See Sequences of Operation for more
information about the behavior of this output.

GENSET CONNECTIONS
This section introduces the connections between

PC-based Service Tools

FIGURE 1-2. EMERGENCY STOP BUTTON


(EXAMPLE)

Customer Output
The PS0500 has one customer output that can be
configured to become active when either a
shutdown or Warning fault occurs.

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 1-7)


is used to connect the PS0500 to a PC-based
service tool.

FIGURE 1-7. 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.

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 85284:2005
BS EN 500811:1992
BS EN 6100062:2001
BS EN 6100063:2001
BS EN 6100064:2001

CE Marking: The control system is


suitable for use on generator sets to be
CE marked.

2. 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.

Read Safety Precautions, and carefully


observe all of the instructions and precautions in
this manual.

STARTING AND STOPPING THE GENSET


The buttons related to changing mode of
operation are highlighted in figure 2.1 and
described in Table 2.1

FIGURE 2-1. CONTROL PANEL BUTTONS

TABLE 2-1 CONTROL PANEL BUTTONS


BUTTON(S) DESCRIPTION
Manual
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.
Auto
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

When the genset starts and stops, it follows a


series of steps, called a sequence of operation
that is intended to maximize the life of the
genset. The genset might not start or stop
immediately.
WARNING 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.

The control panel (Figure 2-2) is the front panel


of the PS0500 control.

CONTROL PANEL

FIGURE 2-2. CONTROL PANEL (PS0500)

Control Panel Description


Alpha-numeric LCD Display

TABLE 2-3. 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/BUTTO
N
Manual

Start

Auto
TABLE 2-2. LED INDICATORS AND BUTTONS
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.

Buttons and LED Indicators

Stop

Reset

OK

DESCRIPTION
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.

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.
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.

Power-Down Mode
The PS0500 can enter power-down or sleep
mode, to reduce load on batteries when not
being used.

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 2-4. PS0500 CURRENT CONSUMPTION
PS0500 MODE
CURRENT
Normal operation
350 mA
Power-down
< 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 RS485 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.
he Reset button on the Control Panel is
pressed
Remote Start Signal (Typically, to a transfer
switch) is low.

SEQUENCES OF OPERATION
Sequences of operation describe the way the
PS0500 starts the genset or stops the genset.
This is illustrated in Figure 2-7.

Stopped

Start Sequence

Genset Running

Stop Sequence

FIGURE 2-7. 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 2-8.

Stopped
Start Delay and
Preheat if enabled

Start Engine after Start


Delay expires and
Preheat conditions are
met

Wait For the Genset to


reach 90 % of Nominal
Frequency and
Voltage

Genset Running

FIGURE 2-8. 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.
Cycle Cranking
he 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).
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 2-9.

Stopped

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.

Meter Calibration
Turn ON Glow Plug
Output and Wait for
Preheat conditions to
be met if Glow Plug is
enabled

Start Engine

Wait For the Genset to


reach 90% of Nominal
Frequency and
Voltage
Genset Running

FIGURE 2-9. 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)

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
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.
There are no active shutdown faults.

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.
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.

3. 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

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 3.1 to 3.15 show a summary of
the menus offered on the control panel
of the PS0500.
Table 3.1 Main Menu Description

See Section 4 for more information


about parameters that you can adjust in
the Operator Panel.

Menu

Description

Alt Setup

Use this menu to select


alternator setup
parameters like Single /
Three phase, 50 / 60 Hz
operation, Wye / Delta ,
Voltage etc.
Use this menu to select
Metric or US units for
Coolant Temperature and
Oil Pressure
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
Use this menu to view last
five faults that are stored in
the control
Use this menu to set the
default values.

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

Units

Oil Pr Input

Customer I/O

Flt History

Load Defaults

Table 3.2 Alt Setup Menu

Table 3.5 CT Ratio Sub Menu

SubMenu

Description

Phase Type

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

CT Ratio
Connect Type

Nom LL Voltage

Frequency

Menu Items
50:5
75:5
100:5
150:5
200:5
250:5
300:5
Table 3.6 Nom LL Voltage
Sub Menu

Menu Items
190
200

Table 3.3 Frequency Sub Menu

208
220
230
240
380
400
416
440
460
480
600

Menu Items
50 Hz
60 Hz
Table 3.4 Phase Type Sub Menu

Menu Items
Single 3 Wire
3 Phase
Single 2 wire
Table 3.4 Connect Type Sub Menu

Table 3.7 Units Menu

Menu Items
Star Connect
Delta Connect

Menu
Item

Description

Metric

Select this item to


choose Metric Units for
the display of Coolant
Temperature and Oil
Pressure

US

Select this item to


choose US Units for the
display of Coolant
Temperature and Oil
Pressure

Table 3.14 Customer O/P2 menu


MenuItems
ShutDown
Warning
Genset Running

Table 3.9 Oil Pr Input

Table 3.15 Flt History Menu

SubMenu Description
Sensor
Select this if using a Sender
Switch
Select this if using a Switch

MenuItems
Fault 1 Fault 5

Table 3.10 Oil Pressure Sensor Sub


Menu
MenuItems
ONAN
CIL

Description
View the last 5
faults stored in the
control

Table 3.16 Load Default


MenuItems
Confirmation
Screen

Description
To confirm the
action press OK

Table 3.11 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 3.12 Cust I/P Flt Submenu


MenuItems
ShutDown
Warning
Table 3.13 Customer O/P1 menu
MenuItems
Glow Plug
Warning
Shutdown

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

//

Let us say you pressed . The display


will now look like this.

Nom LL Voltage
190

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 .

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.

Nom LL Voltage

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

Alt Setup

//

//

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.

* 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).

4. Parameters
Parameters (nominal
voltage, frequency, CT Ratio etc.) are
set to appropriate values at the
Genset manufacturing time based on
the application requirements. In case
of a replacement control, however,
the control would have the default
values as indicated in the table 4.1
and these would need to be adjusted
as required. Use caution while
replacing the control the field. 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

CAUTION:

It is intended that there will be only one


calibration (0326-7727) for the PS0500
series control.

Table 4.1 Adjustable Parameters

Group

Genset

Parameter
Name

Nominal
Voltage (LL)
Nominal
Frequency
Connectio
n type

InPower

PS0500
Control
Panel

Yes

Yes

Yes

190

600

Default
value
Units

416

50 or 60

50

Delta or WYE

WYE

Single or
Three

Three

10/15/20/30/
40/50/60
Sensor or
switch

20

Yes
Yes

Phase
type

Yes
Yes
Yes
Yes

Sensor

Yes

N/A

Yes

3
1

30

Yes

Attempt
s
5

Yes

Yes

V AC

Hz

Yes
Yes

CT ratio
Engine Oil
Pressure
Input Type
Cycle
Crank
Attempts
Cycle
Crank time
Cycle
Crank
Rest time
Battle
Short
Enable
Start Time
Delay

Possible
Values
Lo
High

Sec
5

0
60
Enable or
Disable

Sec
Disable
NA

Yes

0
0

300

Sec

Group

Configurable
I/O

Parameter
Name
Stop Time
Delay
Customer
Input
Function

InPower
Yes

PS0500
Control
Panel

Alternator
Protection

Protection
Engine

Default
value
Units
120

600

Yes
Yes
Yes

Customer
output
Function
High AC
Voltage
Threshold
High AC
Voltage
Delay
Low AC
Voltage
Threshold
Low AC
Voltage
Delay
Under
Frequency
Threshold
Under
Frequency
Delay
Over
Frequency
Threshold
Over
Frequency
Delay
Low Oil
Pressure
Shutdown
Threshold
Low Oil
Pressure
Shutdown
Delay
Low Oil
Pressure
Warning
Threshold

Possible
Values

Warning,
Shutdown,
Turn on if any
shutdown fault
is active/ Turn
On if any
warning fault
is active/
/Turn on when
genset
running

Sec
Shutdow
n
Turn on
if any
shutdow
n fault is
active,

Yes
Yes

110 %
105

125

Yes

%
5

10

Yes

Sec
85%

50

95

Yes

%
5

20

Yes

Sec
5

10

Yes

Hz
1000

500

cycles

2000

Yes

5
2

10

Yes

Hz
1000

100

1/2
cycles

2000

Yes

25

10

100

Yes

Psig
5

15

Yes

Sec
30

10

100

Psig

Group

Parameter
Name
Low Oil
Pressure
Warning
Delay
High
Coolant
Temperatu
re
Shutdown
Threshold
High
Coolant
Temperatu
re
Shutdown
Delay
High
Coolant
Temperatu
re Warning
Threshold
High
Coolant
Temperatu
re Warning
Delay
Low
Battery
Voltage
Threshold
Low
Battery
Delay
High
Battery
Voltage
Threshold
High
Battery
Delay
Weak
Battery
Voltage
Threshold
Weak
Battery
Delay

InPower
Yes

PS0500
Control
Panel

Possible
Values

Default
value
Units
5

15

Yes

Sec
212

180

300

Yes

deg f
5

10

Yes

Sec
200

150

290

Yes

deg f
5

10

Sec
11

Yes
Yes

11

13

VDC
30

60

Yes

Sec
16

14

17

Yes

VDC
30

60

Yes

Sec
8

10

Yes

VDC
3

sec

5. Hardware
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

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

J12 CT Connections

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 03232589. 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

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 Connection TB
The customer connection TB2 is a 6 pin terminal block. The possible supplier is Magnum:
The terminal pins details are as shown below-

Terminal
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 controllers 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

Signal
GND

TB15-2
TB15-3
TB15-4
TB15-5

NC
RS485_DATA_A
RS485_DATA_B
TOOL_WAKEUP

Connector Part Numbers


Quantity

Name

Description

Manufacturer

Manufacturers
part number

Cummins
part no

J22

Alt Voltage
Connector

TYCO

282828-4

0323-2225-03

J12

CT Connector

TYCO

643749-1

0323-2154

J16

Engine
Connector

MOLEX

39299123

0323-2589

TB2

Customer TB

MAGNUM

TB15

Tool
Connector

TYCO

Quantity

Name

J22

J12

J16

Description
Alt Voltage
Connector
CT Connector
Crimp
Terminals
Engine
Connector
Crimp
terminals

EM257506VC

Remarks

All these
connectors
are PCB
mounted
connectors

0323-1677-05

796643-5
0323-2191-04

Manufacturer

Manufacturers
part number

Cummins
part no

TYCO

282809-4

0323-2226-03

1-480704-0

0323-1932

350551-1

0323-1200

39012120

0323-2602

TYCO

MOLEX

39000038

Remarks

All these
connectors
are used in
the harness

0323-2603

EM256506H
1

TB2

Customer TB

TB15

Tool
Connector

MAGNUM

TYCO

0323-1678-05
Communication cable Kit 0541-1199 is used for
the tool interface

6. Troubleshooting
resulting in severe personal injury or death.

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.

SAFETY CONSIDERATIONS
WARNING Contacting high voltage
components can cause electrocution,

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 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 batteryWear gogglesStop
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.

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.

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
supplied to Manual mode and when the
control
Start button is 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.

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.

5. Oil
Pressure
switch or
wiring is
defective

6. Oil
Pressure
sender, setup
on wiring is
defective.

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

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
start switch or Auto mode and there are
wiring is
no shutdown faults present.
faulty.
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

TABLE 20-3. WARNING AND SHUTDOWN


CODES
FAULT CODE
CORRECTIVE
ACTION
151
Indicates engine has
HIGH COOLANT
overheated (coolant
TEMP
temperature has risen
Lamp: Shutdown
above the shutdown
trip point).
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.
415
Indicates engine oil
LOW OIL
pressure has dropped
PRESSURE
below the shutdown
Lamp: Shutdown
trip point. Check oil
level, lines and filters.
If oil system is OK but
oil level is low,
replenish. Reset
control and restart. If
oil switch is used,
check switch
performance.
1446
Indicates that one or
HIGH AC
more of the phase

VOLTAGE
Lamp: Shutdown

1447
LOW AC
VOLTAGE
Lamp: Shutdown

1449
OVER
FREQUENCY
Lamp: Shutdown
1448
UNDER
FREQUENCY
Lamp: Shutdown

1434
EMERGENCY
STOP
Lamp: Shutdown

359
FAIL TO START
Lamp: Shutdown

voltages has exceeded


130% of nominal for 0
second, or has
exceeded high ac
voltage threshold for
High AC Voltage time
delay seconds.
Indicates that one or
more of the phase
voltages has dropped
below low ac voltage
threshold for low ac
voltage time delay
seconds.
Indicates frequency is
10% above base
frequency for
approximately 10
seconds.
Indicates that
Frequency had
dropped below 90% of
nominal for
approximately 10
seconds.
Check fuel supply,
intake air supply and
load.
Indicates remote
Emergency Stop. To
reset the remote
Emergency Stop
button:
1. Open (disable)
remote
emergency
stop button.
2. Press the OFF
button.
3. 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.

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)

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 and

or lower.
NOTE: In
applications
where the
ambient
temperature
falls below
40F (4C),
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

144
COOL
SENSOR
OOR
Lamp:
Warning

441
LOW
BATTERY
Lamp:
Warning

c.

replenish if
required. Look for
possible coolant
leakage points and
repair as required.
Open heater
element. Check
current draw of
heater.

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.
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
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.

442
HIGH
BATTERY
Lamp:
Warning

141
OIL PRESS
SENSOR
OOR
Lamp:
Warning

1131
BATTLE
SHORT
ACTIVE
Lamp: Warning
2678
CHARGER
FAILURE
Lamp: Warning

1416
FAIL TO
SHUTDOWN
Lamp: Warning

d. 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).
Indicates battery voltage
supply to the control is
approaching a high level at
which damage to the control
can occur. Check float level
on battery charger if
applicable (lower float
level).
Check battery
wiring/calibration.
Indicates that the control
has sensed that the engine
oil pressure sensor output is
out of range (high or low).
Check
sender/connectors/wires.
This warning will only occur
if genset is equipped with
an oil pressure sender.

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 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 prehigh/high coolant temperature.
Effect: 146 . Warning Lamp lights , Faul
code pops up. 151.- Engine will shut down
1. Fault
1. With a PC based
simulation was service tool, verify that the
enabled with a
fault simulation is not
PC based
enabled for the coolant
service tool.
sensor.
If you do not have a PC
based service tool,
remove battery power
from the control to disable
fault simulation overrides.
2. Engine or
Check the sensor
sensor circuitry accuracy with a
problem.
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.
3. The sensor
Disconnect the sensor and
could be bad.
connect a coolant
temperature sensor
simulator to the harness.
1442
WEAK
BATTERY
Lamp: Warning

4. The harness
or Control

If the control responds to


the simulator, replace the
sensor. If control does not
respond, go to next step.
4. Measure the resistance
of the coolant sensor and

could be bad.

reconnect harness to
sensor. Remove
connector P16 from
Control and check
resistance between pins
P16-1 and P16-11.
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.

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

4. Harness or
Control could
be bad.

5. Low Oil
Pressure fault
set points
could be
incorrect.

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 doesnt
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 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 was
enabled with a
PC based
service tool.

2. Single step
large block load
removal.
3. Fault
threshold is not
set correctly with
InPower.

4. AVR or
generator is bad.

5. Voltage sense
connections/set
up could be
incorrect.

1. With a PC based
service tool, verify that
the related fault
simulation is not
enabled.
If you do not have a PC
based service tool,
remove battery power
from the control to
disable fault simulation
overrides.
2. Clear fault and restart
genset.
3. Reset the threshold to
the highest allowable
setting. Determine the
required operating range
before adjusting the
threshold.
4. Refer to Generator
AVR Board Isolation
Procedure in Alternator
manual to determine if
the AVR board is
causing the high AC
voltage shutdown fault.
See Section 17 for
proper corrective
actions.

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
CAUSE
ACTION
1. Fault simulation 1. With a PC based
was enabled with
service tool, verify that
a PC based
the related fault
service tool.
simulation is not
enabled.
If you do not have a
PC based service tool,
remove battery power
from the control to
disable fault simulation
overrides.
2. Fault threshold
2. Reset the threshold
is not set correctly to the lowest allowable
with
setting. Determine the

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

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
threshold is
the highest allowable
not set
setting. Determine the
correctly with
required operating range
PC based
before adjusting the
service tool.
threshold.
2. Fuel or air
3. Refer to the engine
delivery
service manual.

problem.
3. Loose
connector or
Control is
bad.

4. Repair connections (P22


1 to 4) or replace the
Control if necessary.

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
threshold is
the lowest allowable
not set
setting. Determine the
correctly with
required operating range
PC based
before adjusting the
service tool.
threshold.
2. Overload.

3. Fuel or air
delivery
problem.
4. Governor
fault.
5. Loose
connector or
Control is
bad.

3. Check the load and


correct any overload.
Check operation by
disconnecting load and
restarting generator set.
4. Refer to the engine
service manual.
5. Check fuel shutoff
solenoid adjustment (refer
to Section 8).
6. Repair connections (P22
1 to 4) or replace the
Control if necessary.

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
1. Overspeed can occur
engine (no
when starting a very cold
coolant
engine. Clear fault and
heaters)
restart genset.
2. Single step
large block
load removal.
3. Fault
simulation
was enabled
with a PC

2. Clear fault and restart


genset.
3. With PC based service
tool, verify that the fault
simulation is not enabled
for the coolant sensor.

based service
tool.

4. Fault
threshold is
not set
correctly with
PC based
service tool.
5. Monitor the
engine rpm
using
InPower.
6. Governor
fault.

7. Mechanical
Fuel system
setup could
be incorrect.

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.
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
CAUSE
ACTION
1. Restricted fuel
1a. Add fuel if low.
supply due to:
Prime the fuel system.
a. Fuel level
1b. Open any closed
below
shutoff valve in the
pickup
fuel line supplying the
tube in
engine.
tank.
1c. Refer to engine
b. Closed
service manual.
shutoff
1d. Bleed air from fuel
valve in
system. Refer to
supply
engine service
line.
manual.
c. Fuel
injectors
clogged.
d. Air in fuel
system.
2. Glow plugs are

The Control

not heating due to:


a. Glow
plug(s) is
bad.
b. Control is
bad.
c. Glow Plug
Relay is
bad.

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):

3. Fuel solenoid
on the injection
pump
not energized due
to:

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.
TB2-2 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

a. Fuse may
be open.
b. Fuel
solenoid is
bad.
c. Control/K7
Fuel Relay
is bad.

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 K7COM (fuel pilot).
Attempt to start and
check for GND at lead
COM.
If there is no
GND, check
for open circuit
between K7COM 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.

5. The engine fuel


system is worn or
malfunctioning or
has lost prime (fuel
lift pump, injection
pump, injectors,
timing).
6. The engine is
5. Service according to
worn or
the engine service
malfunctioning
manual.
mechanically.
CODE 1312 - CONFIGURABLE INPUT
(SHUTDOWN)
Reason: The nature of the fault is an
optional configurable selection.
Effect: Shutdown.
POSSIBLE
CORRECTIVE
CAUSE
ACTION
If there is no actual Disconnect the signal
fault, the problem
lead from TB2 and
may be an external reset the control.
wiring problem.
Check the following
two points.
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 code 151.
1. Refer to

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
simulation
tool, verify that the fault
was enabled simulation is not enabled for
with PC
the coolant sensor.
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
threshold is
lowest allowable setting.
not set
Determine the required
correctly with operating range before
a PC based
adjusting the threshold.
service tool.
3. The
3. Coolant heater not
engine
operating due to:
coolant
Coolant heater not
heater could
connected to power.
be bad.
Check for blown
(Radiant
fuse, or
heat should
disconnected heater
be felt with
cord and correct as
hand
required.
held close to
Low coolant level.
outlet hose.)
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
100F and closes at
80F). Check
resistance across
input power leads:
a. Open -

4. The
sensor
connections
could be
bad.
5. The
sensor could
be bad.

replace
coolant
heater.
b. Closed coolant
heater OK
(coil
resistance
of 10 to 60
ohms)
4. Inspect the sensor and
engine harness connector
pins. Repair or replace as
necessary.

5. Disconnect the sensor,


and plug in 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
6. Measure the resistance of
harness or
the coolant temperature
Control could sensor and reconnect
be
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
actual fault,
from TB2 and reset the
the problem
control. Check the following
may be an
pins.
external
Customer Input
wiring
TB2-4
problem.
If the message drops out,
the external wiring has a
short circuit. Grounding of

the nput activates fault.

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
connections
engine harness connector
could be bad.
pins. Repair or replace as
necessary.
2. The sensor 3. Disconnect the sensor,
could be bad.
and plug in 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
4a. Remove connector P16
harness or
from Control and
Control could
disconnect sensor. Check
be bad.
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 controls voltage supply
approaching level at which unpredictable
operation may occur.
POSSIBLE
CORRECTIVE ACTION
CAUSE
1. Weak or
1. Recharge or replace the
discharged
battery. Specific gravity for
battery.
a fully charged battery is
approximately 1.260 at 80F
(27C).
2. Low
2. Replenish electrolyte
electrolyte
and recharge battery.
level in
battery.
3. Battery
3. Clean and tighten or
connections
replace the battery cable
loose or dirty.
connectors and cables at
the battery and the set.
4. Insufficient
4. Adjust charge rate of AC
battery
powered battery charging
charging
circuit, according to
voltage.
manufactures instructions.
5. Engine DC
5. Replace engine DC
alternator
alternator if normal battery
could be bad.
charging voltage (12 to 14
VDC) is not obtained.
6. If the
batteries are
OK, the
problem may
be the
harness or the
Control.

7. Fault
threshold
could be bad.

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.

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
battery
powered battery charging
charging
circuit according to
voltage.
manufacturers instructions.
2. Engine DC
2. Replace engine DC
alternator
alternator if normal battery
could be bad.
charging voltage
(12 to 14 VDC) is not
obtained.
3. Fault
3. Check fault threshold
threshold
against requirement of the
could be bad.
application.
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
connections
engine harness connector
could be bad.
pins. Repair or replace as
necessary.
2. The sensor
could be bad.

3. Disconnect the oil


pressure sensor 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.
If the control responds to
the simulator, replace the

3. The
harness could
be bad.

4. The Control
could be bad.

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, 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 441.
1. Refer to
code 441