277 697 400 Series Opman English

GENERATING SET
OPERATORS MANUAL
GENERATING SET
OPERATORS MANUAL
This manual has been designed as a guide to operators to aid in starting, stopping and otherwise operating the generating set.
The Generating Set Technical Operation and Maintenance Manual, the Engine Manual and the Alternator Manuals are designed
for qualified generating set technicians for installation, maintenance and trouble shooting of the set.
Document: OL3- GB
Issue Date: 08/08
Part Number: 277-697
TABLE OF CONTENTS
1.
INTRODUCTION ........................................................................................................................................................................................................... 1
2.
SAFETY......................................................................................................................................................................................................................... 1
2.1
General ................................................................................................................................................................................................................... 1
2.2
Installation, Handling and Towing ........................................................................................................................................................................... 1
2.3
Fire and Explosion .................................................................................................................................................................................................. 1
2.4
Mechanical .............................................................................................................................................................................................................. 1
2.5
Chemical ................................................................................................................................................................................................................. 1
2.6
Noise ....................................................................................................................................................................................................................... 1
2.7
Electrical.................................................................................................................................................................................................................. 1
2.8
First Aid For Electric Shock..................................................................................................................................................................................... 2
3.
GENERAL DESCRIPTION............................................................................................................................................................................................ 3
4.
CONTROL SYSTEM DESCRIPTION AND TROUBLE SHOOTING ............................................................................................................................ 4

4.1
Control System Description and Identification ........................................................................................................................................................ 4
4.2
Functional Description LCP1 Control Systems ....................................................................................................................................................... 7
4.3
Functional Description LCP2 Control Systems ....................................................................................................................................................... 7
4.4
Functional Description PowerWizard Control Systems........................................................................................................................................... 7
4.5
Control System Options and Upgrades................................................................................................................................................................... 8
4.6
Control System Fault Finding/Trouble Shooting Guide LCP1/LCP2..................................................................................................................... 10
4.7
Control System Fault Finding/Trouble Shooting Guide PowerWizard Panels ...................................................................................................... 11
4.8
Load Transfer Panels........................................................................................................................................................................................... 12
4.9
Engine Interface Module Description ................................................................................................................................................................... 12
4.10 Output Circuit Breaker Description....................................................................................................................................................................... 12
5.
OPERATION ............................................................................................................................................................................................................... 13
5.1
General ................................................................................................................................................................................................................. 13
5.2
Pre-Start Checks (applicable to all control systems)............................................................................................................................................. 13
5.3
Normal Startup/Shutdown - LCP1 Keystart Panel ................................................................................................................................................ 13
5.4
Normal Manual Startup/Shutdown - LCP2 Autostart Panels................................................................................................................................. 14
5.5
Automatic Startup/Shutdown - LCP2 Autostart Panels ......................................................................................................................................... 14
5.6
Normal Manual Startup/Shutdown - PowerWizard Autostart Panels .................................................................................................................... 14
5.7
Automatic Startup/Shutdown - PowerWizard Autostart Panels............................................................................................................................. 15
6.
MAINTENANCE .......................................................................................................................................................................................................... 15
6.1 Battery Removal and Fitting................................................................................................................................................................................... 15
HAZARD LABELS................................................................................................................................................................................................................ 16
INDEX .............................................................................................................................................................................................................................. 17
ii
1.
2.4
INTRODUCTION
Mechanical
The generating set is designed with guards for protection
from moving parts. Care must still be taken to protect
personnel and equipment from other mechanical hazards
when working around the generating set.
This generating set is one of a family of heavy duty industrial

generating sets designed to be ready to run when it arrives,
requiring only the addition of coolant, fuel and battery acid. Years
of diesel generating set experience has gone into the set to
produce a quality source of electrical power that is efficient and
reliable.
WARNING:
Do not attempt to operate the generating set with

safety guards removed. While the generating set is
running do not attempt to reach under or around the
guards for any reason.
Keep hands, arms, long hair, loose clothing and

jewellery away from pulleys, belts and other moving
parts.
This Operators Manual has been prepared to assist in operation

of the generating set.
Always ensure that maintenance, adjustments and repairs are
done by personnel who are authorised to do the work and have
been properly trained.
Every generating set is uniquely defined by a model number and
serial number indicated on a rating plate affixed to the panel
enclosure. This information is required when ordering spare
parts or when service or warranty work is required.
2.
Attention: Some moving parts can not be seen clearly

when the set is running.
SAFETY
2.1
General
The generating set is designed to be safe when used in the
correct manner. Responsibility for safety, however, rests
with the personnel who use the set. The following safety
precautions, if followed, will minimise the possibility of
accidents. Before performing any procedure or operating
technique, it is up to the user to ensure that it is safe. The
generating set should only be operated by personnel who
are authorised and trained.
2.5
2.2
Read and understand all safety precautions and

warnings before operating the generating set.
Failure to follow the instructions, procedures, and

safety precautions in this manual may increase the
possibility of accidents and injuries.
Never start the generating set unless it is safe to do

so.
Do not attempt to operate the generating set with a

known unsafe condition.
If the generating set is unsafe, fit danger notices and

disconnect the battery negative ( - ) lead so that it
cannot be started until the condition is corrected.
Disconnect the battery negative ( - ) lead prior to

attempting any repairs or cleaning inside the
enclosure, if equipped.
Install and operate this generating set only in full

compliance with relevant National, Local, or Federal
Codes, Standards or other requirements.
Avoid contact with hot oil, hot coolant, hot exhaust

gases, hot surfaces and sharp edges and corners.
Wear protective clothing including gloves and hat

when working around the generating set.
Chemical
WARNING:
2.6
Do not swallow or have skin contact with fuel, oil,

coolant, lubricants or battery electrolyte. If swallowed,
seek medical treatment immediately. Do not induce
vomiting if fuel is swallowed. For skin contact, wash
with soap and water.
Do not wear clothing that has been contaminated by

fuel or lube oil.
Noise
Generating sets that are not equipped with sound
attenuating enclosures can produce noise levels in excess of
105 dBA. Prolonged exposure to noise levels above 85 dBA
is hazardous to hearing.
WARNING:
!
2.7
Ear protection must be worn when operating or

working around an operating generating set.
Electrical
Safe and efficient operation of electrical equipment can be
achieved only if the equipment is correctly operated and
maintained.
WARNING:
Installation, Handling and Towing
Ensure the generating set, including a mobile set, is

effectively grounded/earthed prior to operation.
Fire and Explosion
Fuels and fumes associated with generating sets can be

flammable and potentially explosive. Proper care in handling
these materials can dramatically limit the risk of fire or
explosion. However, safety dictates that fully charged BC
and ABC fire extinguishers are kept on hand. Personnel
must know how to operate them.
Do not touch electrically energised parts of the

generating set and/or interconnecting cables or
conductors with any part of the body or with any non
insulated conductive object.
Use only Class BC or Class ABC extinguishers on

electrical fires.
A qualified generating set technician should refer to the

Technical Manual for this information.
2.3
Keep access doors on enclosures, if equipped, closed

and locked when not required to be open.
Fuels, oils, coolants, lubricants and battery electrolyte used

in this generating set are typical of the industry. However,
they can be hazardous to personnel if not treated properly.
WARNING:
WARNING:
!
!
Ensure the generating set room is properly ventilated.
!
!
!
Never store flammable liquids near the engine.
!
!
Avoid refilling the fuel tank while the engine is running.
Keep the room, the floor and the generating set clean.
When spills of fuel, oil, battery electrolyte or coolant
occur, they should be cleaned up immediately.
Store oily rags in covered metal containers.
Do not smoke or allow sparks, flames or other sources
of ignition around fuel or batteries. Fuel vapours are
explosive. Hydrogen gas generated by charging
batteries is also explosive.
Do not attempt to operate the generating set with any
known leaks in the fuel system.
2.8
First Aid For Electric Shock
RECOVERY POSITION:
WARNING:
1. Turn the victim onto the side.
Do not touch the victim's skin with bare hands until the
source of electricity has been turned off.
2. Keep the head tilted with the

jaw forward to maintain the
open airway.
Switch off power, if possible.

Otherwise pull the plug or pull the cable away from the
victim.
3. Make sure the victim cannot roll

forwards or backwards.
If this is not possible, stand on dry insulating material

and pull the victim clear of the conductor, preferably
using insulated material such as dry wood.
4. Check for breathing and pulse

regularly. If either stops,
proceed as above.
If victim is breathing, turn the victim into the recovery

position described below.
WARNING:
If victim is unconscious, perform resuscitation as

required:
OPEN THE AIRWAY:

1. Tilt the victim's head back and lift
the chin upwards.
2. Remove objects from the mouth or
throat (including false teeth,
tobacco, or chewing gum).
BREATHING:
1. Check that the victim is breathing
by looking, listening and feeling for
breath.
CIRCULATION:
1. Check for pulse in the victim's neck.
IF NO BREATHING BUT PULSE IS
PRESENT:
1. Pinch the victim's nose firmly.
2. Take a deep breath and seal your
lips around the victims lips.
3. Blow slowly into the mouth
watching for
the chest to rise. Let the chest fall
completely. Give breaths
at a rate of 10 per minute.
4. If the victim must be left to
get help, give 10 breaths first
and then return quickly and
continue.
5. Check for pulse after every 10
breaths.
6. When breathing restarts, place the victim into the
recovery position described later in
this section.
IF NO BREATHING AND NO PULSE:
1. Call or telephone for medical help.
2. Give two breaths and start chest
compression as follows:
3. Place heel of hand 2 fingers
breadth above ribcage/breastbone
junction.
4. Place other hand on top and interlock
fingers.
5. Keeping arms straight, press down 4-5
cm (1.5-2 inch) 15 times at a
rate of 80 per minute.
6. Repeat cycle (2 breaths, 15
compressions) until medical help
takes over.
7. If condition improves, confirm pulse
and continue with breaths. Check
for pulse after every 10 breaths.
8. When breathing restarts, place the
victim into the recovery position.
Do not give liquids until victim is conscious.
3.
GENERAL DESCRIPTION
This generating set has been designed as a complete package
to provide superior performance and reliability.
Each generating set is provided with a Rating Label affixed to
the panel enclosure. This label contains the information needed
to identify the generating set and its operating characteristics.
This information includes, but is not limited to, the model
number, serial number, output characteristics such as voltage,
phase and frequency, output rating in kVA and kW, and rating
type (basis of the rating). The model and serial numbers uniquely
identify the generating set.
The diesel engine powering the generating set has been chosen
for its reliability and the fact that it has been specifically designed
for powering generating sets. The engine is of the heavy duty
industrial type with 4 stroke compression ignition and is fitted
with all accessories to provide a reliable power supply.
The engine electrical system is 12 volts DC.
The engine cooling system is either air cooled or water cooled.
The air cooled system consists of a high capacity fan to pull cool
air across the engine to cool it. The water cooled system is
comprised of a radiator, pusher fan and a thermostat.
The output electrical power is produced by an alternator fine
tuned to the output of this generating set.
The engine and alternator are coupled together and mounted on
a heavy duty steel baseframe. This baseframe includes a
polyethylene fuel tank with a capacity of approximately 8 hours
operation at full load.
The generating set is fitted with vibration isolators which are
designed to reduce engine vibration being transmitted to the
foundation on which the generating set is mounted. These
isolators are fitted between the engine/alternator feet and the
baseframe.
An exhaust silencer is provided loose for installation with the
generating set. The silencer and exhaust system reduce the
noise emission from the engine and can direct exhaust gases to
safe outlets.
One of several types of control systems and panels may be fitted
to control the operation and output of the set and to protect the
set from possible malfunctions. Section 4 of this manual
provides detailed information on these systems and will aid in
identification of the control system fitted on the generating set.
To protect the alternator a suitably rated circuit breaker, selected
for the generating set model and output rating, is supplied.
4.
depending on the droop of the governor. In practice,

no load frequencies of approximately 52 and 62 Hz for
50 Hz and 60 Hz respectively, are considered normal.
The frequencies will fall, as the set is loaded, to 50 Hz
and 60 Hz at full load.
CONTROL SYSTEM DESCRIPTION AND TROUBLE

SHOOTING
4.1
Control System Description and Identification

4.1.1 Description: An electronic control system has been
designed and installed to control and monitor the generating
set. Depending on the requirements of the set, one of
several different standard control systems may be fitted.
These include the LCP1 Keystart Systems and the LCP2
and PowerWizard Autostart Systems. Other more
specialised systems may be installed for specific installations
in which case separate documentation is provided. The
control panels often use symbols instead of words to
describe the functions of controls and lamps. Figure 4.2
gives a legend for each of the possible symbols.
6.
HOURS RUN METER - A meter that indicates the total

number of hours of generating set operation to aid in
maintenance.
7.
DC BATTERY VOLTMETER - A voltmeter that

indicates the state of charge of the battery. When the
engine is at standstill the normal battery voltage will be
12 to 14 volts. During starting, the needle will drop to
about 70% of normal and oscillate as the engine
cranks. Once the engine has started, the needle
should return to its normal value. If the battery
charging alternator is charging correctly, the voltage
reading will always be higher with the generating set
running than when it is stopped.
8.
FAULT INDICATOR LAMPS - Fault lamps that

illuminate to indicate that the protective circuitry has
sensed the indicated condition. The lamp should be
red on conditions for which the system will initiate a
shutdown of the set. For alarms, the lamp can be red
or amber.
9.
LAMP TEST PUSHBUTTON - A button to illuminate

the fault lamps for testing.
10.
KEY SWITCH (LCP1) - A four position switch that

provides a means of starting and operating the
generating set.
These control systems consist of three major components

working together - a control panel, an engine interface
module and an alternator output circuit breaker.
The control panel provides a means of starting and stopping
the generating set, monitoring its operation and output, and
automatically shutting down the set in the event of a critical
condition arising such as low oil pressure or high engine
temperature. An LCP1, LCP2 or PowerWizard panel is
installed as appropriate for the requirements of the
generating set installation.
The Engine Interface Module is a sealed, engine mounted
module that provides switching relays for the Starter Motor
Solenoid, Glow Plug and Fuel Solenoid. Each of these
circuits is protected with individual fuses mounted in the
module. Individual LEDs illuminate when each circuit is
energised. The Engine Interface Module is available in two
models depending on the type of control panel being used the EIM Basic (with safety relay) and the EIM Plus (with
safety relay and overspeed circuit). The LCP1 Keystart
Panels and PowerWizard panels utilise the EIM Basic and
the LCP2 Autostart Panels utilise the EIM Plus.
Position O - OFF/RESET
Power is turned off and protection circuitry is reset in
this position.
Position
- RUN
DC power is supplied to the control system and on the
LCP1 panel the fault protection timer relay is initiated.
The power output circuit breaker serves to protect the

alternator by automatically disconnecting the load in the
event of overload or short circuit. It also provides a means
of switching the generating set output.
Position
- THERMOSTART
DC power is supplied to the thermostart circuit (only
required on turbocharged engines).
4.1.2 Panel Equipment LCP1/LCP2: Before starting or

running the generating set, the operator should become fully
acquainted with the instruments and controls. The
instruments should be observed from time to time while the
generating set is running so that any abnormal readings can
be detected before problems arise.
Position
- CRANK
DC power is supplied to the starter motor to crank the
engine.
11.
Figure 4.1 shows typical layouts of each of the control

panels. Addition of optional equipment may add items to the
panel so the panel fitted on the generating set may be
slightly different from the typical ones shown. The following
descriptions explain the function of each standard item on
the panels:
1.
Position
- RUN
The autostart function is initiated to immediately start
and run the generating set.
Position O - OFF/RESET
The generating set is shut down if running and
automatic start is inhibited. Protection circuitry is reset
in this position.
AC VOLTMETER - A voltmeter that indicates the AC

voltage generated at the alternator output terminals.
The reading indicated on the voltmeter will vary
depending on the position of the voltmeter selector
switch (item 2). It should not, however, vary while the
set is operating. If the meter gives no reading while the
generating set is running, ensure that the AC voltmeter
selector switch is not in the OFF position.
2.
AC VOLTMETER SELECTOR SWITCH - A selector

switch allowing the operator to select voltage reading
between phases or between a phase and neutral. The
OFF position allows the voltmeter "zero" position to be
checked while the generating set is running.
3.
AC AMMETER - An ammeter that indicates the AC

electrical current being delivered which is dependant
on the connected load. A separate reading from each
of the phases is possible using the ammeter selection
switch (item 4). If the meter gives no reading while the
generating set is running, ensure that the AC ammeter
selector switch is not in the OFF position.
4.
AC AMMETER SELECTOR SWITCH - A selector

switch allowing the operator to select a current reading
from each of the phases. The OFF position allows the
ammeter "zero" position to be checked while the
generating set is running.
5.
FREQUENCY METER - A meter that indicates the

output frequency of the generating set. At partial load
the frequency will be slightly higher than normal,
CONTROL SWITCH (LCP2) - A three position switch

that provides a means of controlling the generating set
functions.
Position
- AUTO
The control circuitry is ready to initiate an automatic

start upon receiving a remote start signal.
12.
13.
EMERGENCY STOP PUSHBUTTON - A red lockdown pushbutton that immediately shuts down the
generating set and will inhibit start until the pushbutton
has been released by turning it clockwise. Pressing
this button also illuminates the OVERSPEED fault
lamp even though an overspeed has not occurred.
Prior to restarting the set, this fault lamp must be reset
by turning the Control Switch to Position O (Off).
THERMOSTART PREHEAT BUTTON (LCP2

Turbocharged only) - A button to activate the
thermostart preheat circuit.
4.1.3 Panel Equipment for PowerWizard: Before starting
or running the generating set, the operator should become
fully acquainted with the control modules display and push
buttons. The display should be observed from time to time
while the generating set is running so that any abnormal
readings can be detected before problems arise.
Figure 4.1 (c) shows a typical layout of the PowerWizard
control panel. Addition of optional equipment may add items
to the panel so the panel fitted on the generating set may be
slightly different from the typical one shown. The following
key will cause the check mark to disappear, disabling

the function. If the box does not have a check mark
inside the box, pressing the Right key will cause a
check mark to appear, Enabling the function.
14. ENTER - The Enter key is used during menu
navigation to select menu items in order to navigate
forward/downward in the menu/sub-menu structure.
The Enter key is also used during setpoint
programming in order to save setpoints changes.
Pressing the Enter key during setpoint programming
causes setpoint changes to be saved to memory.
15. DOWN - The Down key is used to navigate down
through the various menus or monitoring screens. The
Down key is also used during setpoint entry. During
numeric data entry the Down key is used in order to
decrement the digits (0-9). If the setpoint requires
selection from a list, the Down key is used to navigate
DOWN through the list.
16. LEFT - The Left key is used during setpoint
adjustment. During numeric data entry, the Left key is
used to choose which digit is being edited. The Left
key is also used during certain setpoint adjustments to
select or deselect a check box. If a box has a check
mark inside the box, pressing the Left key will cause
the check mark to disappear, disabling the function. If
the box does not have a check mark inside the box,
pressing the Left key will cause a check mark to
appear, enabling the function.
17. EMERGENCY STOP PUSHBUTTON - A red lock-down
pushbutton that immediately shuts down the generating
set and will inhibit start until the pushbutton has been
released by turning it clockwise. Prior to restarting the
set, this fault must be reset by pressing the stop button
on the module and resetting the fault in the event log
menu.
18. MODULE DATA LINK CONNECTION - This enables
the service tool to communicate with the module.
4.1.4 Display Preferences for PowerWizard Panels: To
change the display preferences, from the main menu scroll
down to the 'Preferences' item (last in the menu). Press the
'Enter' Key. Scroll down through the preferences menu until
the desired display preference is highlighted. Press 'Enter' to
adjust this preference.
CONTRAST: The display contrast may require adjustment
from the factory default depending on viewing angle and
ambient temperature. The contrast is adjusted between 0%
and 100% by pressing the left and right keys. Pressing Enter
accepts the changes and Escape aborts the changes.
BACKLIGHT: The backlight is usually left at 100%, however
on occasions the user may wish to reduce the backlight
intensity. The backlight can be adjusted between 0 to 100%
by pressing the left and right keys. Pressing Enter accepts
the changes and Escape aborts the changes.
PRESSURE UNITS: The pressure units can be adjusted
between kPa/psi/bar. Use the left and right keys to select the
preferred pressure units. Pressing Enter accepts the new
pressure units; pressing escape aborts the change in
pressure units.
TEMPERATURE UNITS: The temperature units can be
adjusted between C and F. Use the left and right keys to
select the preferred temperature units. Pressing Enter
accepts the change; pressing escape aborts the change.
VOLUME: Volume is used on some optional parameters
(such as fuel consumption rate). It can be selected between
Litres, US Gallons and Imperial Gallons using the left and
right keys. Pressing enter accepts the new volume units;
pressing escape aborts the change to the volume units.
DISPLAY LANGUAGE: The display language can be
adjusted between the customer language and 'Technician
English'. 'Technician English' is a reduced version of the
display strings in English to facilitate factory testing and
commissioning. As it is not a complete set of display strings,
it is not suitable for customer use.
descriptions explain the function of each standard item on

the panels:
1.
DISPLAY SCREEN - This screen will display all the
generating sets information from sensor readings to
event logs. Please see section 4.1.4 for display
preferences.
2.
AC OVERVIEW - The AC Overview key will navigate
the display to first screen of AC information. The AC
Overview information contains various AC parameters
that summarize the electrical operation of the
generating set.
3.
ENGINE OVERVIEW - The Engine Overview key will
navigate the display to the first screen of engine
information. The Engine Overview information
contains various engine parameters that summarize
the operation of the generating set.
4.
YELLOW WARNING LIGHT - A flashing yellow light
indicates that there are unacknowledged active
warnings. A solid yellow light indicates that there are
acknowledged warnings active. If there are any active
warnings the yellow light will change from flashing
yellow to solid yellow after the Alarm Acknowledge key
is pressed. If there are no longer any active warnings,
the yellow light will turn off after the Acknowledge key
is pressed.
5. RED SHUTDOWN LIGHT - A flashing red light
indicates that there are unacknowledged active
shutdown events. A solid red light indicates that there
are acknowledged shutdown events active. If there are
any active shutdown events the red light will change
from flashing red to solid red after the Alarm
Acknowledge key is pressed. Any condition that has
caused a shutdown event must be manually reset. If
there are no longer any active shutdown events, the red
light will turn off.
6. ALARM ACKNOWLEDGMENT SILENCE - Pressing
the Acknowledge key will cause the horn relay output
to turn off and silence the horn. Pressing the key will
also cause any yellow or red flashing lights to turn off or
to become solid depending on the active status of the
alarms. The Acknowledge key may also be configured
to send out a Global Alarm Silence on J1939 Data
Link which will silence horns on annunciators.
7. LAMP TEST - Pressing and holding the Lamp Test
key will cause all of the LEDs and the display screen
pixels to turn on solid until the key is released.
8. RUN - Pressing the RUN key will cause the engine to
enter the RUN mode.
9. AUTO - Pressing the AUTO key will cause the engine
to enter the AUTO mode.
10. STOP - Pressing the STOP key will cause the engine
to enter the STOP mode.
11. UP - The Up key is used to navigate up through the
various menus or monitoring screens. The Up key is
also used during setpoint entry. During numeric data
entry the Up key is used in order to increment the digits
(0-9). If the setpoint requires selection from a list, the
Up key is used to navigate UP through the list.
12. ESCAPE - The ESCAPE key is used during menu
navigation in order to navigate up through the
menu/sub-menu structure. Each key press causes the
user to move backwards/upwards through the
navigation menus. The Escape key is also used to
cancel out of data entry screens during setpoint
programming. If the Escape key is pressed during
setpoint programming, none of the changes made on
screen will be saved to memory.
13. RIGHT - The Right key is used during setpoint
adjustment. During numeric data entry, the Right key
is used to choose which digit is being edited. The
Right key is also used during certain setpoint
adjustments to select or deselect a check box. If a box
has a check mark inside the box, pressing the Right
Figure 4.1 (a): Diagram of Typical LCP1 Control Panel
Figure 4.1 (b): Diagram of Typical LCP2 Control Panel
Figure 4.1 (c): Diagram of Typical PowerWizard Control Panel
be inhibited until the protection circuits of the control system

are reset by turning the Control Switch to Position O (Off).
4.2 Functional Description LCP1 Control Systems

The LCP1 Control Systems provide for manual starting and
stopping of the generating set and provide protection for the
engine against both high engine temperature and low oil
pressure.
Manually the generating set can be stopped at any time by

pressing the Emergency Stop Pushbutton or by turning the
Control Switch to Position O (Off). The set will also
automatically shutdown when the remote start signal is
removed.
4.2.1 Functions (LCP1): Section 5 of this manual provides

detailed guidance and checklists for the operation of the
generating set. This section provides a more detailed
description of the functions of the control system during
operation.
WARNING:
WARNING:
4.3.2 Protective Circuits (LCP2): When high engine

temperature is sensed, the High Engine Temperature
fault
lamp illuminates and the generating set is automatically shut
down. The fault lamp will remain illuminated and the engine
locked out until the fault has been acknowledged and reset by
turning the Control Switch to Position O (Off).
The Key Switch must not be turned to position
(Thermostart) or (Crank) while the

engine is running.
During start, turning the Key Switch through Position

(Run) to Position
(Thermostart) activates the
thermostart, if fitted. This preheats the induction air and
should be held for 7 seconds. Turning the Key Switch further
to position (Crank) provides power to the starter motor
which cranks the engine. The starter motor will be disengaged
when the Key Switch is released so it must be held in this
position until the engine starts and then immediately released
and allowed to return to Position (Run).
When low oil pressure is sensed, the Low Oil Pressure

fault lamp illuminates and the generating set is automatically
shut down. Reset is effected by turning the Control Switch to
Position O (Off).
Engine speed is monitored by the Overspeed circuit located in
the EIM Plus. When Engine overspeed is sensed the
Overspeed
fault lamp illuminates and the generating set
will shut down. The fault lamp will remain illuminated and the
engine locked out until the fault has been reset by turning the
Control Switch to Position O (Off). The OVERSPEED
fault lamp will also illuminate when the Emergency Stop
Pushbutton has been pressed, even though an overspeed has
not occurred.
Note:
Position
is only used on generating sets with
turbocharged engines.
To prevent overheating of the starter motor the engine should

not be cranked for more than 5 to 7 seconds. An interval of 10
seconds should be allowed between start attempts. If the
engine has not started after 4 attempts, refer to a qualified
generating set technician.
The additional possible Shutdown circuits (not all available on

all sets) include shutdown on:
Once the generating set is running properly, the electrical load

is applied to the set by switching the alternator output circuit
breaker to "ON" (handle in the up position).
Low Coolant Level (on water cooled engines)

Low Fuel Level
The additional possible Alarm circuits (not all available on all
sets) include alarms for:
When shutting down the generating set, the load should be

first turned off by switching the alternator output circuit breaker
to "OFF" (handle down). This allows the engine to cool prior to
stopping it. After a few minutes the Key Switch is turned to
Position "O" (Off) which shuts the generating set down.
Low Coolant Temperature (on water cooled engines)

Low Fuel Level
4.4
In case of emergency where immediate shutdown is

necessary, the Key Switch should be turned to Position "O"
(Off) immediately without first disconnecting the load.
If at any time the generating set stops because of a
fault, the fault should be rectified before trying to
restart the generating set.
4.4.1 Function (PowerWizard): Section 5 of this manual

provides detailed guidance and checklists for the operation of
the generating set. This section provides a more detailed
operation.
4.2.2 Protective Circuits (LCP1): When high engine

temperature is sensed, the High Engine Temperature fault
lamp illuminates and the generating set is automatically shut
down. The fault lamp will remain illuminated and the engine
locked out until the fault has been acknowledged and reset by
turning the Key Switch to Position "O" (Off).
When the RUN key is pressed or a remote start signal is

received with the module in AUTO mode, the control system
will initiate its automatic start sequence.
When low lube oil pressure is sensed the Low Oil Pressure
fault lamp illuminates and the generating set is
automatically shut down. Reset is effected by turning the Key
Switch to Position "O" (Off).
4.3
Functional Description PowerWizard Control Systems

The PowerWizard Control Systems provide for automatic
starting and stopping of the generating set from a remote
signal as well as manual starting and stopping. This makes it
appropriate for standby generating systems. Protection is
provided by the control system against high engine
temperature, low oil pressure, fail to start and overspeed.
WARNING

restart the generator.
If the engine fails to fire after 3 start attempts then the module
will go into the shutdown mode as it has detected a FAIL TO
START. Refer to a qualified generating set technician to
determine the cause of failure to start. Start will be inhibited
until the FAIL TO START shutdown event has been reset.
Functional Description LCP2 Control Systems
Manually the generating set can be stopped at any time by

pressing the STOP key. A COOLDOWN time will then
commence before the set will stop. The set will also
automatically stop when the remote start signal is removed.
Again, a COOLDOWN time will then commence before the set
will stop. The set will immediately stop by pressing the
Emergency Stop Pushbutton.
The LCP2 Control Systems provide for automatic starting and

stopping of the generating set from a remote signal as well as
manual starting and stopping. This makes it appropriate for
standby generating systems. Protection is provided by the
control system against high engine temperature, low oil
pressure, fail to start and overspeed.
4.3.1 Function (LCP2): Section 5 of this manual provides
detailed guidance and checklists for the operation of the
generating set. This section provides a more detailed
operation.
WARNING:
When the Control Switch is turned to Position (Run) or a

remote start signal is received with the Control Switch with the
Control Switch in Position
(Auto), the control system will
initiate its automatic start sequence.

restart the generator.
4.4.2 Protective Circuits (PowerWizard): When high engine

temperature is sensed, the generating set is automatically shut
down. The RED SHUTDOWN LIGHT will begin to flash until
the ACKNOWLEGE key is pressed. The RED SHUTDOWN
LIGHT will stay on until the fault has been resolved on the
generating set and the HIGH ENGINE TEMPERATURE
shutdown event has been reset.
If the engine fails to fire after 3 start attempts then the FAIL TO
START lamp will illuminate. Refer to a qualified generating set
technician to determine the cause of failure to start. Start will
7
When low oil pressure is sensed, the generating set is

automatically shut down. The RED SHUTDOWN LIGHT will
begin to flash until the ACKNOWLEGE key is pressed. The
RED SHUTDOWN LIGHT will stay on until the fault has been
resolved on the generating set and the LOW OIL PRESSURE
shutdown event has been reset.
Engine speed is monitored by the speed sensor in the fly
wheel housing of the generating set. When overspeed is
sensed, the generating set is automatically shut down. The
RED SHUTDOWN LIGHT will begin to flash until the
ACKNOWLEGE key is pressed. The RED SHUTDOWN
LIGHT will stay on until the fault has been resolved on the
generating set and the OVERSPEED shutdown event has
been reset.
The additional possible Shutdown circuits (not all available on
all sets) include shutdown on:
Low Coolant Level (on water cooled engines)
Low Fuel Level
The additional possible Alarm circuits (not all available on all
sets) include alarms for:
Low Coolant Temperature (on water cooled engines)
Low Fuel Level
4.5
Control System Options and Upgrades

A variety of options may be fitted to customise the control
system to a specific installation. The following sections cover
the use and operation of some of these options.
4.5.1 Battery Trickle Chargers: These chargers are designed
to ensure that the starter batteries maintain their charge even if
the generating set is not operated for long periods.
Control switches for the chargers are not normally fitted to
prevent inadvertent switching off of the charger. The control
system will automatically disconnect the charger on startup of
the generating set. While the engine is running the batteries
are charged by the engine driven battery charging alternator.
4.5.2 Heaters: In addition to conventional space heaters that
are useful in keeping the generating set warm and dry in cold
or humid environments, two types of heater may be fitted on
the generating set.
For water cooled engines, immersion type heaters (engine
heaters) may be fitted in the engine coolant system to ensure
that the engine is easy to start and able to take load more
quickly.
Panel anti-condensation heaters (panel heaters) may be fitted
in the control panel to keep moisture levels down.
KEY SWITCH / CONTROL SWITCH
A1
Off
A3
Run
A2
Crank
A4
Auto
FAULT LAMPS
B1
Fail to Start
B4
Overspeed
B2
High Engine Temperature
B5
Other Shutdown Fault
B3
Low Oil Pressure
PANEL
C1
AC Voltmeter
C4
Battery Voltmeter
C2
AC Frequency Meter
C5
Lamp Test Switch
C3
AC Ammeter
Figure 4.2: Legend of LCP1 and LCP2 Control Panel Symbols
4.6
Control System Fault Finding/Trouble Shooting Guide

LCP1/LCP2
FAULT
Engine Fails
to Start
(LCP1 Only)
SYMPTOM
Engine Does
Not Crank
when Key
Switch Turned
to Position
Engine Fails
to Start
(LCP2 Only)
(Crank)
Engine Does
Not Crank
when Start
Signal Given,
Either
Manually Via
Control Switch
or
Automatically
Via a Remote
Signal
FAULT
Alarm for
Low Fuel
Level
(Optional
Alarm LCP2 Only)
Alarm for
Low Coolant
Temp.
(Optional
Alarm LCP2 Only)
No Voltage
Produced
When
Generating
Set is
Running
(All control
systems)
Generating
Set Does
Not Go On
Load
(All control
systems)
SYMPTOM
Low Fuel
Level
Alarm Lamp
Illuminates
REMEDY
1. Check fuel level in day tank.
Fill as necessary.
2. Refer to a qualified
Low Coolant
Temp Alarm
Lamp
Illuminates
1. Check that the immersion

heaters are switched on and
are operating.
No Voltage On
AC Voltmeter
Or On
Separate
Meter
1. Check voltmeter selector

switch is not in the OFF
position.
FAULT
Generating
Set Does
Not Stop
Manually
(All control
systems)
SYMPTOM
Generating
Set Continues
Running After
Being
Switched Off
Generating
Set Does
Not Stop
When In
Auto Mode
(LCP2 Only)
Generating
Set Does Not
Stop After
Remote Start
Signal is
Removed
Generating
Set is Running
but the Load is
Not Being
Powered
FAULT
Engine Fails
To Start
(All control
systems)
REMEDY
1. Check operation of Key
Switch.
2. Check no fault lamps
illuminated. Reset, if required,
after remedying indicated fault.
1. Check all Emergency Stop
Pushbuttons are released
(including any remote buttons).
If no remote stop is used, have
the technician ensure "Remote
Stop" terminals are linked.
2. Check that Control Switch is
not off.
3. Check no fault lamps are
illuminated. Reset, if required,
Engine
Stops Due
to High
Engine
Temp.
(All control
systems)
Engine
Stops Due
to Low Oil
Pressure
(All control
systems)
1. Check circuit breaker is ON

(handle up).
REMEDY
1. Check Key Switch or Control
Switch position, as appropriate.
2. Check that the generating
set stops when the Emergency
Stop Pushbutton is depressed.
1. Check that generating set
stops when the Emergency
Stop Pushbutton is depressed
or the Control Switch is turned
off.
10
SYMPTOM
Engine
Cranks But
Does Not
Fire Or
Engine
Starts But
Stops After
20 Seconds.
(Fail To
Start
Fault Lamp
Illuminates
on LCP2
Panel.)
High Engine
Temp
Fault Lamp
Illuminates
Low Oil
Pressure
Fault
Lamp
Illuminates
FAULT
Engine
Stops Due
to
Overspeed
(LCP2 Only)
SYMPTOM
Overspeed
Fault
Lamp
Illuminates
Engine
Stops Due
to Low
Coolant
Level
(Optional
Shutdown LCP2 Only)
Engine
Stops Due
to Low Fuel
Level
(Optional
Shutdown LCP2 Only)
Low
Coolant
Level Fault
Lamp
Illuminates
Low Fuel
Level Fault
Lamp
Illuminates
REMEDY
1. Check fuel level.
2. Check that Canopy External
Emergency Stop Pushbuttons, if
fitted, are not depressed.
1. Check engine was not

overloaded.
2. Check radiator obstructions.
REMEDY
Note: The OVERSPEED fault
lamp will also illuminate after the
Emergency Stop Pushbutton has
been depressed even though
there has been no overspeed
condition. The Emergency Stop
Pushbutton and any remote stop
buttons must be released before
the fault can be cleared.
1. Refer to a qualified generating
set technician.
set technician.

Fill as necessary.
set technician.
4.7
Control System Fault Finding/Trouble Shooting Guide

PowerWizard Panels
FAULT
Engine Fails
to Start
SYMPTOM
Engine Does
Not Crank
when Start
Signal Given,
Either
Manually Via
Run Key or
Automatically
Via a Remote
Signal
REMEDY
1. Check all Emergency Stop
Pushbuttons are released.
2. Check that the Stop Light is
not on.
3. Check no Shutdown events
are active. Reset, if required,
SYMPTOM
Low Fuel
Level
Alarm in event
log. Amber
LED
Illuminates
Low Coolant
Temp Alarm
in event log.
Amber LED
Illuminates
No Voltage On
AC Sensing
display screen
REMEDY
Fill as necessary.
Generating
Set is Running
but the Load is
Not Being
Powered
1. Check circuit breaker is ON

(handle up).
FAULT
Generating
Set Does
Not Stop
Manually
SYMPTOM
Generating
Set Continues
Running After
Being
Switched Off
Generating
Set Does
Not Stop
When In
Auto Mode
Generating
Set Does Not
Stop After
Remote Start
Signal is
Removed
REMEDY
1. Check Stop key as
appropriate.
2. Check that the generating
set stops when the Emergency
Stop Pushbutton is depressed.
3. Check the Cooldown timer
has timed out.
1. Check that generating set
stops when the Emergency
Stop Pushbutton is depressed
or the Stop key is held down
for 5 seconds and Cooldown
time is skipped.
FAULT
Alarm for
Low Fuel
Level
(optional)
Alarm for
Low Coolant
Temp.
(optional)
No Voltage
Produced
When
Generating
Set is
Running
Generating
Set Does
Not Go On
Load
FAULT
Engine Fails
To Start
Engine
Stops Due
to High
Engine
Temp.
Engine
Stops Due
to Low Oil
Pressure
1. Check that the immersion

heaters are switched on and
are operating.
1. Check AC sensing fuses F1
- F3
FAULT
Engine
Stops Due
to
Overspeed
Engine
Stops Due
to Low
Coolant
Level
(optional)
Engine
Stops Due
to Low Fuel
Level
(optional)
11
SYMPTOM
Engine
Cranks But
Does Not
Fire Or
Engine
Starts But
Stops After
20 Seconds.
High Engine
Temp in
event log.
Red
Shutdown
LED
Illuminates
Low Oil
Pressure in
event log.
Red
Shutdown
LED
Illuminates
REMEDY
1. Check fuel level.
2. Check that Canopy External
Emergency Stop Pushbuttons, if
fitted, are not depressed.
set technician.
SYMPTOM
Overspeed
in event log.
Red
Shutdown
LED
Illuminates
Low
Coolant
Level in
event log.
Red
Shutdown
LED
Illuminates
Low Fuel
Level in
event log.
Red
Shutdown
LED
Illuminates
REMEDY
set technician.
1. Check engine was not

overloaded.
2. Check radiator obstructions.
set technician.

set technician.

Fill as necessary.
set technician.
4.8 Load Transfer Panels

When the generating set is installed to automatically provide
standby power in the event of mains failure, a load transfer
panel is required. This transfer panel is designed to sense when
the mains have failed, signal the generating set to start, switch
the load from the failed mains to the generating set and then
switch it back after the mains are re-established. See
Figure 4.3
Figure 4.3: Function of a Load Transfer Panel

A choice of load transfer panels is offered. Please refer to the
CTI manual for full details on the CTI Transfer Sytem.
4.8.1 ATI Intelligent Load Transfer Panel: The ATI Intelligent
Load Transfer Panel is designed to work with the LCP2 and
PowerWizard Autostart Control Systems to form an automatic
mains failure system.
4.9
Status Panel: The front of the door has the status panel and
main control switch. This status panel has four indicator LEDs
as shown in Figure 4.4. Pressing the Lamp Test Button will
illuminate these indicator LEDs.
Item
1.
2.
3.
4.
5.
Item
1.
2.
3.
4.
5.
6.
7.
Description
Item Description
Glow Plug Symbol
8.
Secondary Socket
Fuel Symbol
9.
Starter Solenoid Fuse
Fuel Solenoid Fuse
10. Starter LED
Fuel LED
11.
Overspeed Set-up LED
Main Connector Socket 12.
Overspeed Adjuster
Glow Plug Fuse
13.
Starter Symbol
Glow Plug LED
Figure 4.5: Engine Interface Module
There are two versions of the Engine Interface Module available
- EIM Basic and EIM Plus.
EIM Basic: The EIM is utilised in conjunction with the LCP1
Keystart panel/PowerWizard Autostart panels. It consists of
three relays to carry currents associated with the Fuel Control
Solenoid, Starter Motor Solenoid and the Glow Plug. The
module is powered directly from the battery.
EIM Plus: The EIM Plus is used in conjunction with the LCP2
Autostart Panel and occasionally with the LCP1 Keystart panel.
It consists of the same three relays as above plus circuitry to
monitor engine speed via a magnetic pick-up mounted on the
engine flywheel housing and to set the Overspeed Trip Point.
The module is powered directly from the battery. The EIM Plus
monitors the speed signal from the magnetic pick-up. If the
engine speed rises above a certain pre-settable value, the
module sends a zero volt signal to the generating set control
panel to activate the Overspeed Fault circuitry.
4.10 Output Circuit Breaker Description
The alternator output circuit breaker is a miniature case circuit
breaker (MCB) of sufficient rating for the generating set output.
Electrical output is switchable through this device, with ON
being indicated by the handle being up. The breaker will carry
its rated current continuously but will trip to off-position if the
rating on any one phase is exceeded for a period depending on
the percentage overload and the circuit breaker characteristics.
Description
Mains Available Status LED
Mains on Load Status LED
Generator on Load Status LED
Generator Available Status LED
No Generator or mains on Load Status LED
Figure 4.4: ATI Series Load Transfer Panel Status Display

Controls: The test key on the front panel has three modes:AUTOMATIC MODE - The normal position for automatic
operation.
TEST WITHOUT LOAD - For testing the generating set without
connecting the load.
TEST WITH LOAD - For testing the generating set with the load
connected.
WARNING:
retransfer to take place, the operator presses the Retransfer

Button which causes the load to be transferred back to the
mains and, after a cool down period, automatically shuts down
the generator.
4.8.2 TC Compact Load Transfer Panel: The TC Compact
Load Transfer Panel is designed to work with the Autostart
Control Systems (LCP2) to form an automatic mains failure
system.
Status Panel and Controls: The status panel has two
indicator lamps. They show that the load is either connected to
the mains supply or to the generating set. The controls consist
of a Mode Selector Switch with three positions:AUTOMATIC MODE - The normal position for automatic
operation.
TEST WITHOUT LOAD - For testing the generating set without
connecting the load.
TEST WITH LOAD - For testing the generating set with the load
connected.
The TC Series Load Transfer Panel operates as follows:
On mains failure the generating set is automatically started and
the contactors closed to connect the load to the generator.
On restoration of mains power the load is transferred back to
the mains and the generating set is shutdown.
Engine Interface Module Description
The Engine Interface Module is a sealed, engine mounted
module that provides switching relays for the Starter Motor
Solenoid, Glow Plug (only on turbocharged generating sets) and
Fuel Solenoid. Each of these circuits is protected with
individual fuses mounted in the module. Individual LEDs
illuminate when each circuit is energised.
Internal maintenance should only be carried out by

trained personnel due to the high voltages present
inside the enclosure.
The ATI series Load Transfer Panel operates as follows:

On mains failure, the generating set is automatically started and
the switch transfers to connect the load to the generator.
On restoration of mains power, the load is transferred back to
the mains. After a cool down period, the generating set is
automatically shut down.
Manual Retransfer Function: If enabled, this allows the
operator to manually control the timing of the retransfer of the
load from the generating set to the restored mains supply. The
control is a simple push button on the ATI control module.
With the Manual Retransfer function enabled or disabled, on
mains failure the generating set will start and accept load in the
normal sequence. With the Manual Retransfer Function
disabled, the load will be automatically retransferred back to the
mains when available as described above.
With the Manual Retransfer function enabled, on restoration of
the mains, the Mains Available indicator will illuminate but the
generator will continue to supply load. When it is convenient for
12
5.
OPERATION
5.1
General
The generating set is equipped with an electronic control
system. This will be one of a range of systems such as the
Powerwizad, LCP1 or LCP2 control system. See Section 4 of
this manual to identify which system is fitted on the generating
set and for a functional description of each.
These control systems allow the operator to manually or
automatically control the generating set. They have protection
circuits to detect an alarm fault or shut down the set if problems
occur. Details of the capabilities of each system are contained
in Section 4. The LCP1/LCP2 control panels use symbols
instead of words to describe the functions of the controls and
lamps. Figure 4.2 gives a legend for each of the possible
symbols.
Check the battery electrolyte level - fill with distilled water

as necessary.
8.
Check the control panel and the generating set for heavy
accumulation of dust and dirt - clean as necessary.
These can pose an electrical hazard or give rise to cooling
problems.
9.
Check the air filter restriction indicator, if fitted - replace

the filter as necessary.
10. Clear the area around the generating set of any insecure
items that could inhibit operation or cause injury. Ensure
cooling air ventilation screens are clear.
11. Visually check the entire generating set for signs of leaks
from the fuel system, cooling system or lubrication seals.
12. Periodically drain exhaust system condensate traps, if
equipped.
The following procedures detail the steps required to prepare

the set for operation and start and stop it normally. A qualified
generating set technician should start the set for the first time
after installation or after the set has been out of service for a
time for maintenance purposes. Section 5.2, Pre-Start Checks
are applicable with all control systems. Section 5.3 covers
operation of the LCP1 Keystart Control Systems. Sections 5.4,
and 5.5 cover operation of the LCP2 Series Autostart Control
Systems. Section 5.6 and 5.7 cover operation of the
PowerWizard series Autostart control systems.
5.2
7.
13. Ensure the Alternator Output Circuit Breaker is in the

"OFF" (handle down) position.
5.3
Normal Startup/Shutdown - LCP1 Keystart Panel

The following procedure should be used for normal starts on a
generating set equipped with an LCP1 Keystart Control System:
Note:
Pre-Start Checks (applicable to all control systems)

The following checks should be performed prior to starting the
generating set:
1.
Complete Pre-Start checks as per Section 5.2.
2.
Check the battery voltage by turning the keyswitch from

Position O (Off) to Position (Run) and reading the
battery voltmeter. A fully charged battery will indicate 12
to 14 volts. Return the keyswitch to Position O (Off).
WARNING:
As generating sets with autostart control panels

(PowerWizard/LCP2) can be remotely started without
warning, always ensure the control panel is switched
off before carrying out any checks.
Note:
19. Ensure the Control Switch/Key Switch is Off on the

LCP1/LCP2 Panels.
WARNING:
The Stop Key is activated on the PowerWizard Panel.
Do not remove the radiator cap on water cooled

engines when the coolant is hot. Do not add large
amounts of cold coolant to a hot system as serious
damage could result.
2.
Diesel engines normally consume lube oil at a rate of .25%

to 1% of the fuel consumption.
Check the engine oil and coolant levels (water cooled
engines) - replenish as necessary.
When filling the fuel tank, do not smoke or use an

open flame in the vicinity.
3.
Check the fuel level - fill as necessary.
Before adjusting fan and alternator belts disconnect

the battery negative (-) lead.
4.
Check the condition and tension of the fan and engine

alternator belts - tighten as necessary.
5.
Check all hoses for loose connections or deterioration tighten or replace as necessary.
6.
WHEN ENGINE HAS STARTED

4.
Check the battery terminals for corrosion - clean as

necessary.
WARNING:
When working with the batteries, do not smoke or use

an open flame in the vicinity. Hydrogen gas from
batteries is explosive.
Do not short the positive and negative terminals

together.
Position
is only used on generating sets with
turbocharged engines.
Do not crank the engine for more than 5 to 7 seconds
should the engine fail to start. Allow an interval of 10
seconds and always turn the Key Switch fully off (Position
O) between cranking attempts. If, after 4 cranking
attempts, the engine still has not started, refer to the trouble
shooting guide in Section 4 or the Engine Manual to
determine the cause of failure to start.
WARNING:
Note:
WARNING:
The Key Switch must not be turned to position

(Thermostart) or (Crank) while the engine is
running.
3. Start: Turn the Key Switch from Position "O" (Off) through
Position (Run) to Position
(Thermostart) to
activate the thermostart, if fitted. Hold for 7 seconds to
preheat the induction air. After this time, the Key Switch
should be further turned to Position (Crank) to crank
the engine. When the engine starts, release the Key
Switch immediately allowing it to return to Position
(Run).
Note:
The engine will not start if any fault indicators are

illuminated. Reset the control system by turning the Key
Switch to Position "O" (Off). Ensure the faults have been
corrected prior to attempting to start the generating set.
Or
WARNING:
The generating set may be stopped at any time by pushing

the Emergency Stop Pushbutton or turning the Key Switch
to Position "O" (Off).
Check for any abnormal noise or vibration.
5.
Check for fluid leakage or leaks in the exhaust system.
6.
Switch the Alternator Output Circuit Breaker to "ON"

(handle up).
7.
Shutdown: To shut the generating set down, turn off the

load by switching the Alternator Output Circuit Breaker to
"OFF" (handle down). Allow the generating set to run
without load for a few minutes to cool. Then turn the Key
Switch to Position "O" (Off). The generating set will
shutdown.
In case of an emergency where immediate shutdown is
necessary, the Key Switch should be turned to Position
"O" (Off) immediately without disconnecting the load.
13
turning it clockwise. The fault lamp must also be reset by

Note:
5.4
1.
Turning the Key Switch to Position "O" (Off) will also reset
the protective circuits after a fault has been detected.
Ensure that the fault has been rectified prior to restarting
the generating set.
Normal Manual Startup/Shutdown - LCP2 Autostart Panels

The following procedure should be used for normal manual
starts on a generating set equipped with an LCP2 Autostart
Control System:
1.

the Emergency Stop Pushbutton or turning the Control
Switch to Position O (Off).
Automatic Start: Ensure the Emergency Stop Pushbutton

Turn
and any remote Stop Pushbuttons are released.
the Control Switch to Position
(Auto).
3.

(handle up).
The generating set is now ready to automatically start when it

receives a remote start signal. When the start signal is
removed it will automatically stop.
Pressing the Emergency Stop Pushbutton also illuminates

the Overspeed
fault lamp even though an
overspeed has not occurred. Prior to restarting the set,
the Emergency Stop Pushbutton must be released by
turning it clockwise. The fault lamp must also be reset by
5.6
Note:
The engine will not start if any fault indicators are

illuminated. Reset the control system by turning the Key
Switch to Position "O" (Off). Ensure the faults have been
corrected prior to attempting to start the generating set.
2. Manual Start: Ensure the Emergency Stop Pushbutton and

any remote Stop Pushbuttons are released.
For Turbocharged engines only: If the engine is cold, prior
to turning the Control Switch to Position (Run) push in
the Thermostart pushbutton labelled
and hold for
15 seconds.
Turn the Control Switch to Position
Normal Manual Startup/Shutdown - PowerWizard Autostart

Panels
The following procedure should be used for normal manual
starts on a generating set equipped with an PowerWizard
Autostart Control System:
Note:
1.
(Run).

Check the control panel for indications of abnormal
operation, particularly abnormally high temperature or
abnormally low oil pressure, when engine gauges have
been fitted. The oil pressure should be in the normal
range within about 10 seconds of starting.
6.

(handle up).
7.

load by switching the Alternator Output Circuit Breaker to
"OFF" (handle down). Allow the generating set to run
without load for a few minutes to cool. Then turn the
Control Switch to Position O (Off). The generating set
will shutdown.

3.
Automatic Startup/Shutdown - LCP2 Autostart Panels

The following procedure should be used for preparing a
generating set equipped with an LCP2 Autostart Control System
to be started from a remote location.
Note:
The engine will not start if any shutdown fault has not been
reset in the module. The event log is the menu to reset
faults. Ensure the faults have been corrected prior to
attempting to start the generating set.
After the glow plug time has exceeded the engine will
automatically crank up to 3 times or until the engine fires. If
the engine does not fire, the control system locks-out on
Fail to Start and this will activate the FAIL TO START
shutdown in the module. If this happens refer to the trouble
shooting guide in section 4.7 or a qualified generating set
technician to determine the cause of failure to start.

the Emergency Stop Pushbutton or turning the Control
Switch to Position O (Off).
Pressing the Emergency Stop Pushbutton also illuminates
the Overspeed
fault lamp even though an
overspeed has not occurred. Prior to restarting the set,
the Emergency Stop Pushbutton must be released by
14
4.
5.
Check the control panel for indications of abnormal

operation, particularly abnormally high temperature or
abnormally low oil pressure. Pressing the ENGINE
OVERVIEW key will display these readings. The oil
pressure should be in the normal range within 10 seconds
of starting.
6.

(handle up).
7.

load by switching the alternator Output Circuit Breaker to
OFF (handle down). Press the STOP key and this will
activate the COOLDOWN timer to allow the generating set
to cool without load. After the COOLDOWN timer has
timed out the engine will stop. The COOLDOWN timer
can be bypassed by holding the STOP key for 5 seconds
then selecting the option to SKIP COOLDOWN by
pressing the ENTER key.

necessary, the Emergency Stop Button should be pushed
immediately without disconnecting the load.
5.5
If the Engine is cold then it is recommended to activate the

glow plugs before the engine is started. This will be
activated automatically for the pre-set time when the RUN
key is pressed.
5.
Prior to restarting the set, the EMEGENCY STOP fault

must be reset by pressing the STOP key on the module
and resetting the fault in the event log.
2. Manual Start: Ensure the Emergency Stop Pushbutton and

any remote Stop Pushbuttons are released.

4.

the Emergency Stop Pushbutton or holding down the
STOP key for 5 seconds on the module and selecting the
SKIP COOLDOWN option by pressing the ENTER key.
Note:
The engine will automatically crank up to 3 times or until the

engine fires. If the engine does not fire, the control system
locks-out on "Fail to Start" and illuminates a fault lamp on
the control panel. If this happens refer to the trouble
shooting guide in Section 4.5 or a qualified generating set
technician to determine the cause of failure to start.
3.
The engine will not be able to start if any fault indicators

are illuminated. Reset the control system by turning the
Control Switch to Position O (Off). Ensure the faults
have been corrected prior to attempting to start the
generating set.
2.
Note:
Note:

necessary, the Emergency Stop Button should be pushed
immediately without disconnecting the load.
5.7
Automatic Startup/Shutdown - PowerWizard Autostart

Panels
The following procedure should be used for preparing a
generating set equipped with an PowerWizard Autostart Control
System to be started from a remote location.
Note:
1.

the Emergency Stop Pushbutton or holding down the
STOP key for 5 seconds on the module and selecting the
SKIP COOLDOWN option by pressing the ENTER key.
Prior to restarting the set, the EMEGENCY STOP fault
must be reset by pressing the STOP key on the module
and reseting the fault in the event log.
Battery acid can burn clothing and skin and even cause
blindness if it leaks, so wear protective clothing when inspecting
a battery prior to its disconnection / transportation
Disconnect the battery safely before inspecting it (see below)
Before removing a battery, carry out a thorough inspection of its

condition. Use a torch if visibility is poor to check all sides of the
battery for any marks, dents or leaks
If the battery has any severe dents or leaks then contact a

professional battery engineering service for assistance and get
it repaired or replaced, do not attempt to remove it
During transport, cover the terminals so they cannot be shorted

out
Keep the battery upright at all times
When removing a battery for whatever reason always ensure all

load is removed before disconnecting the battery so that no
sparks are created. Disconnect the negative cable first followed
by the positive cable to avoid short circuit against any metal
framework, then remove the hold down clamp or strap securing
the battery base. The battery can be fairly heavy so be careful
when lifting and carrying the battery. Seek assistance if
required.
When refitting the battery, ensure the terminal posts are

correctly aligned with the cables to avoid wrong connection and
place the new battery into the hold-down tray and re-attach the
hold-down clamp or strap. Attach and tighten the positive
battery cable to the positive terminal first. Then attach and
tighten the negative battery cable to the negative terminal.
Note:
The engine will not start if any shutdown fault has not been
reset in the module. The event log is the menu to reset
faults. Ensure the faults have been corrected prior to
attempting to start the generating set.
2.
Automatic Start: Ensure the Emergency Stop Pushbutton

and any remote Stop Pushbuttons are released. Press the
AUTO key on the module.
3.

(handle up).
The generating set is now ready to automatically start when it

receives a remote start signal. When the start signal is
removed it will automatically stop after the cooldown period.
6.
MAINTENANCE
A good maintenance programme is the key to long generating set
life. Maintenance and service should only be carried out by
qualified technicians. Records of this work should be kept to aid in
developing an efficient maintenance programme.
In general, the generating set should be kept clean. Do not permit
liquids such as fuel or oil film to accumulate on any internal or
external surfaces or on, under or around any acoustic material, if
fitted. Wipe down surfaces using an aqueous industrial cleaner. Do
not use flammable solvents for cleaning purposes.
Any acoustic material with a protective covering that has been torn
or punctured should be replaced immediately to prevent
accumulation of liquids or oil film within the material.
Refer to a qualified generating set technician for details of required
preventative maintenance.
6.1 Battery Removal and Fitting

Batteries, as used in generators, by law, must not be disposed of
with household waste.
Batteries contain hazardous materials and in the charged state,

each cell contains electrodes of lead metal (Pb) and lead (IV)
dioxide (PbO2) in an electrolyte of about 33.5% w/w (6 Molar)
sulphuric acid (H2SO4). In the discharged state both electrodes turn
into lead(II) sulfate (PbSO4) and the electrolyte loses its dissolved
sulphuric acid and becomes primarily water.
It can be damaging to the environment to send these to landfill,
burning batteries can also cause atmospheric pollution.
Dealing with lead acid batteries can be hazardous so it is important
to follow all safety guidelines.
15
HAZARD LABELS
Some or all of these hazard warning labels will appear on your generating set:
16
INDEX
Rating Label ..........................................................................................3
Safety ....................................................................................................1
Chemical...........................................................................................1
Electrical ...........................................................................................1
Fire and Explosion ............................................................................1
Handling............................................................................................1
Installation.........................................................................................1
Mechanical........................................................................................1
Noise.................................................................................................1
Towing ..............................................................................................1
Shutdown
LCP1 Panel.....................................................................................13
LCP2 Panel.....................................................................................14
PowerWizard Panels ......................................................................14
Startup
LCP1 Panel.....................................................................................13
LCP2 Panel.....................................................................................14
PowerWizard Panels ......................................................................14
TC Compact Load Transfer Panel.......................................................12
Glow Plugs ............................................................................................3
ATI Intelligent Load Transfer Panel.....................................................12
Trouble Shooting ...........................................................................10, 11
Voltmeter ...............................................................................................4
Ammeter ............................................................................................... 4
Battery Trickle Chargers ....................................................................... 8
Battery Voltmeter .................................................................................. 4
Circuit Breaker ...................................................................................... 8
Control Switch....................................................................................... 4
Control System ..................................................................................... 4
LCP1 Panel ...................................................................................... 4
LCP2 Panels .................................................................................... 4
PowerWizard Panels........................................................................ 4
Electric Shock ....................................................................................... 2
Emergency Stop ............................................................................... 4, 5
Engine Interface Module..................................................................... 12
Fault Finding ................................................................................. 10, 11
Fault Lamps ...................................................................................... 4, 5
First Aid................................................................................................. 2
Frequency Meter................................................................................... 4
Heaters ................................................................................................. 8
Hours Run Meter .................................................................................. 4
Key Switch ............................................................................................ 4
Load Transfer Panels ......................................................................... 12
Maintenance ....................................................................................... 15
Panel Equipment .................................................................................. 4
Pre-Start Checks ................................................................................ 13
17

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GENERATING SET

CONTROL SYSTEM DESCRIPTION AND TROUBLE SHOOTING ............................................................................................................................ 4

This generating set is one of a family of heavy duty industrial

Do not attempt to operate the generating set with

Keep hands, arms, long hair, loose clothing and

This Operators Manual has been prepared to assist in operation

Attention: Some moving parts can not be seen clearly

Read and understand all safety precautions and

Failure to follow the instructions, procedures, and

Never start the generating set unless it is safe to do

Do not attempt to operate the generating set with a

If the generating set is unsafe, fit danger notices and

Disconnect the battery negative ( - ) lead prior to

Install and operate this generating set only in full

Avoid contact with hot oil, hot coolant, hot exhaust

Wear protective clothing including gloves and hat

Do not swallow or have skin contact with fuel, oil,

Do not wear clothing that has been contaminated by

Ear protection must be worn when operating or

Installation, Handling and Towing

Ensure the generating set, including a mobile set, is

Fire and Explosion

Fuels and fumes associated with generating sets can be

Do not touch electrically energised parts of the

Use only Class BC or Class ABC extinguishers on

A qualified generating set technician should refer to the

Keep access doors on enclosures, if equipped, closed

Fuels, oils, coolants, lubricants and battery electrolyte used

Ensure the generating set room is properly ventilated.

Never store flammable liquids near the engine.

Avoid refilling the fuel tank while the engine is running.

First Aid For Electric Shock

1. Turn the victim onto the side.

2. Keep the head tilted with the

Switch off power, if possible.

3. Make sure the victim cannot roll

If this is not possible, stand on dry insulating material

4. Check for breathing and pulse

If victim is breathing, turn the victim into the recovery

If victim is unconscious, perform resuscitation as

OPEN THE AIRWAY:

Do not give liquids until victim is conscious.

depending on the droop of the governor. In practice,

CONTROL SYSTEM DESCRIPTION AND TROUBLE

Control System Description and Identification

HOURS RUN METER - A meter that indicates the total

DC BATTERY VOLTMETER - A voltmeter that

FAULT INDICATOR LAMPS - Fault lamps that

LAMP TEST PUSHBUTTON - A button to illuminate

KEY SWITCH (LCP1) - A four position switch that

These control systems consist of three major components

The power output circuit breaker serves to protect the

4.1.2 Panel Equipment LCP1/LCP2: Before starting or

Figure 4.1 shows typical layouts of each of the control

AC VOLTMETER - A voltmeter that indicates the AC

AC VOLTMETER SELECTOR SWITCH - A selector

AC AMMETER - An ammeter that indicates the AC

AC AMMETER SELECTOR SWITCH - A selector

FREQUENCY METER - A meter that indicates the

CONTROL SWITCH (LCP2) - A three position switch

The control circuitry is ready to initiate an automatic

THERMOSTART PREHEAT BUTTON (LCP2

key will cause the check mark to disappear, disabling

descriptions explain the function of each standard item on