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Controller
PowerStart 0500
English
Original Instructions 9-2011 A040Y520 (Issue 1)
Table of Contents
1. IMPORTANT SAFETY INSTRUCTIONS ....................................................................................... 1
1.1 Warning, Caution and Note Styles Used In This Manual ....................................................... 1
1.2 General Information ................................................................................................................ 1
1.2.1 General Safety Precautions ........................................................................................ 1
1.3 Generator Set Safety Code .................................................................................................... 2
1.3.1 Moving Parts Can Cause Severe Personal Injury Or Death........................................ 3
1.3.2 Positioning of Generator Set....................................................................................... 3
1.4 Electrical Shocks and Arc Flashes Can Cause Severe Personal Injury or Death.................. 3
1.4.1 AC Supply and Isolation............................................................................................... 4
1.5 Fuel And Fumes Are Flammable ............................................................................................ 4
1.5.1 Spillage ....................................................................................................................... 5
1.5.2 Fluid Containment....................................................................................................... 5
1.5.3 Do Not Operate in Flammable and Explosive Environments ...................................... 5
1.6 Exhaust Gases Are Deadly..................................................................................................... 5
1.6.1 Exhaust Precautions ................................................................................................... 5
2. SCHEDULE OF ABBREVIATIONS................................................................................................ 7
3. GLOSSARY.................................................................................................................................... 9
4. INTRODUCTION.......................................................................................................................... 11
4.1 About this Manual ................................................................................................................. 11
4.2 System Overview .................................................................................................................. 11
4.2.1 PowerStart 0500 Components................................................................................... 11
4.3 Test Equipment..................................................................................................................... 11
4.4 How To Obtain Service......................................................................................................... 12
A040Y520 (Issue 1) i
Table of Contents 9-2011
7. TROUBLESHOOTING ................................................................................................................. 35
7.1 General ................................................................................................................................. 35
7.2 InPower Service Tool............................................................................................................ 35
7.3 Network Applications and Customer Inputs.......................................................................... 35
7.4 Safety Consideration............................................................................................................. 35
7.5 Troubleshooting Procedure................................................................................................... 36
7.5.1 Voltage/Continuity Testing ......................................................................................... 36
7.5.2 Reading Fault Codes ................................................................................................. 36
8. MANUFACTURING FACILITIES.................................................................................................. 51
8.1 How to Obtain Service .......................................................................................................... 51
8.1.1 Locating Your Distributor ........................................................................................... 51
ii A040Y520 (Issue 1)
1 Important Safety Instructions
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, read the Operator's Manual and become familiar with it
and the equipment. Safe and efficient operation can be achieved only if the equipment is
properly operated and maintained. Many accidents are caused by failure to follow
fundamental rules and precautions.
DANGER: Warns of a hazard that will result in severe personal injury or death.
WARNING: Warns of a hazard that may result in severe personal injury or death.
CAUTION: Warns of a hazard or an unsafe practice that can result in product or property
damage.
NOTE: A short piece of text giving information that augments the current text.
NOTE: It is in the Operators interest to read and understand all Warnings and
Cautions contained within the documentation relevant to the generator set,
its operation and daily maintenance.
A040Y520 (Issue 1) 1
1. Important Safety Instructions 9-2011
CAUTION: Make sure that rags are not left on or near the engine.
CAUTION: Make sure the generator set is mounted in a manner to prevent combustible
materials from accumulating under the unit.
CAUTION: 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.
CAUTION: 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.
WARNING: 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.
WARNING: Substances in exhaust gases have been identified by some state or federal
agencies as causing cancer or reproductive toxicity. Take care not to breath,
ingest, or come into contact with exhaust gases.
WARNING: Do not store any flammable liquids, such as fuel, cleaners, oil, etc., near the
generator set. A fire or explosion could result.
WARNING: Wear hearing protection when going near an operating generator set.
WARNING: To prevent serious burns, avoid contact with hot metal parts such as the
radiator, the turbo charger, and the exhaust system.
WARNING: Use personal protective equipment when maintaining or installing the
generator set. Examples of personal protective equipment include but are not
limited to: safety glasses, protective gloves, hard hats, steel-toed boots, and
protective clothing.
WARNING: Do not use starting fluids that evaporate. They are highly explosive.
CAUTION: Do not step on the generator set when entering or leaving the generator room.
Parts can bend or break leading to electrical shorts, or to fuel, coolant, or exhaust
leaks.
CAUTION: To prevent accidental or remote starting while working on the generator set,
disconnect the negative (-) battery cable at the battery.
WARNING: Ethylene glycol, used as engine coolant, is toxic to humans and animals.
Clean up spills and dispose of used engine coolant in accordance with local
environmental regulations.
WARNING: Moving parts can cause severe personal injury or death. Hot exhaust parts
can cause severe burns. Make sure all protective guards are properly in
place before starting the generator set.
WARNING: Improper operation and maintenance can lead to severe personal injury or
loss of life and property by fire, electrocution, mechanical breakdown, or
exhaust gas asphyxiation. Read and follow all Safety Precautions, Warnings
and Cautions throughout this manual and the documentation supplied with
your generator set.
2 A040Y520 (Issue 1)
9-2011 1. Important Safety Instructions
WARNING: Lifting and repositioning of the generator set must only be carried out using
suitable lifting equipment, shackles, and spreader bars, in accordance with
local guidelines and legislation, by suitably trained and experienced
personnel. Incorrect lifting can result in severe personal injury, death and/or
equipment damage. For more information, contact your authorized
distributor.
WARNING: On an enclosed generator set, the canopy doors must be locked before re-
positioning and they must remain locked during transportation and sitting.
A040Y520 (Issue 1) 3
1. Important Safety Instructions 9-2011
NOTE: It is the policy of Cummins Inc. to perform all electrical work in a de-
energized state. However, employees or suppliers may be permitted to
occasionally perform work on energized electrical equipment only when
qualified and authorized to do so and when troubleshooting, or if de-
energizing the equipment would create a greater risk or make the task
impossible and all other alternatives have been exhausted.
NOTE: Exposed energized electrical work is only allowed as per the relevant
procedures and must be undertaken by a Cummins authorized person with
any appropriate energized work permit for the work to be performed while
using proper PPE, tools and equipment. In summary:
Do not tamper with or bypass interlocks unless you are authorized to do
so.
Understand and assess the risks - use proper PPE. Do not wear jewelry
and ensure that any conductive items are removed from pockets as
these items can fall into equipment and the resulting short circuit can
cause shock or burning. Refer to standard NFPA 70E for PPE standards.
Ensure that an accompanying person who can undertake a rescue is
nearby.
NOTE: Local electrical codes and regulations (for example BS EN 12601:2001) may
require the installation of a disconnect means for the generator set, either on
the generator set or where the generator set conductors enter a facility.
NOTE: The AC supply must have the correct over current and earth fault protection
according to local electrical codes and regulations. This equipment must be
earthed (grounded).
The disconnecting device is not provided as part of the generator set, and Cummins Power
Generation accepts no responsibility for providing the means of isolation.
4 A040Y520 (Issue 1)
9-2011 1. Important Safety Instructions
1.5.1 Spillage
Any spillage that occurs during fueling or during oil top-off or oil change must be cleaned up
before starting the generator set.
WARNING: Engine exhaust and some of its constituents are known to the state of
California to cause cancer, birth defects, and other reproductive harm.
WARNING: Hot exhaust gas can cause burns resulting in severe personal injury.
The exhaust outlet may be sited at the top or bottom of the generator set. Make sure that the
exhaust outlet is not obstructed. Personnel using this equipment must be made aware of the
exhaust position. Position the exhaust away from flammable materials - in the case of exhaust
outlets at the bottom, make sure that vegetation is removed from the vicinity of the exhaust.
WARNING: Inhalation of exhaust gases can result in serious personal injury or death. Be
sure deadly exhaust gas is piped outside and away from windows, doors, or
other inlets to buildings. Do not allow to accumulate in habitable areas.
A040Y520 (Issue 1) 5
1. Important Safety Instructions 9-2011
WARNING: Contaminated insulation is a fire risk which can result in severe personal
injury.
The exhaust pipes may have some insulating covers fitted. If these covers become
contaminated by fuel or oil, they must be replaced before the generator set is run.
To minimize the risk of fire, make sure the following steps are observed:
Make sure that the engine is allowed to cool thoroughly before topping off the oil or
draining the fuel filters.
Clean the exhaust pipe thoroughly.
6 A040Y520 (Issue 1)
2 Schedule of Abbreviations
This list is not exhaustive. For example, it does not identify units of measure or acronyms that
appear only in parameters, event/fault names, or part/accessory names.
AmpSentry and InPower are trademarks of Cummins Inc. PowerCommand is a registered
trademark of Cummins Inc.
A040Y520 (Issue 1) 7
2. Schedule of Abbreviations 9-2011
8 A040Y520 (Issue 1)
3 Glossary
Term Definition
Accessory A part comes standard with the product. An accessory is optional and provides additional
Part interfaces or functionality.
Active General terms to describe the states for inputs, signals, or outputs that have only two states
Inactive (like true/false or 1/0). For example, a low coolant level switch is either on (active) or off
(inactive). The Ready to Load output is either on (active) or off (inactive). Usually, the
expected state is inactive.
For events/faults, this term describes the time the PCC generates the event/fault through the
time the event/fault is cleared.
Active-closed Some inputs and outputs use resistance to distinguish between active and inactive. If an input
Active-open or output is active-closed, the input or output is active if there is no resistance between two
pins. If an input or output is active-open, the input or output is active if there is infinite
resistance between two pins.
Active-high Some inputs and outputs use voltage differential to distinguish between active and inactive. If
Active-low an input or output is active-high, a high voltage differential means the input or output is active,
and a low voltage differential means the input or output is inactive. If an input or output is
active-low, a low voltage differential means the input or output is active, and a high voltage
differential means the input or output is inactive.
Configurable analog "Configurable input" refers to discrete inputs (for example, open or closed). "Configurable
input analog input" refers to analog inputs (for example, 0-5 VDC).
Configurable input
Configurable analog "Configurable output" refers to discrete outputs (for example, open or closed). "Configurable
output analog input" refers to analog outputs (for example, 0-5 VDC).
Configurable output
Connection A connection between two devices. A connection might be as simple as one pin-to-pin
connection, or it might require several pins as well as additional components such as relays,
fuses, etc. This term also includes some settings that refer to the physical (for example,
normally-closed vs. normally-open) or electrical (for example, active-high vs. active-low)
characteristics of the connection.
Connector This term has no meaning if you do not have access to the PCC control board or the back
panel of the Operator Panel.
One or more pins that are in the same housing. Many times, the pins are related by function
(for example, pins that are connected to the engine) or by electrical characteristics (for
example, relay outputs).
This term also refers to the end of a wire or harness that is plugged into the housing.
Event Used to notify the operator or external devices whether or not certain conditions are true.
Fault Each event or fault has two sets of conditions. When the first set of conditions becomes true,
the event or fault becomes active. This might turn on or turn off a light or LED, display a
warning on the PCC, shut down the genset, or so on. When the second set of conditions
becomes true, the event or fault becomes inactive and can be cleared.
The PCC generates a fault when the conditions indicate a more serious problem; the PCC
generates an event only for information purposes.
Low-side driver When this output is active, it provides a path to ground. When this output is inactive, it blocks
the path to ground.
Mode A term to describe certain states that affect the PCC's behavior. The PCC is either in a
Mode of operation particular mode or not in a particular mode, and the PCC's behavior changes accordingly.
Sometimes, the PCC is always in one mode out of a set of two or more modes. For example,
the PCC is always in one of the modes of operation: Off mode, Auto mode, or Manual mode.
Mounting The physical placement and installation of the PCC or the Operator Panel.
A040Y520 (Issue 1) 9
3. Glossary 9-2011
Term Definition
Normally-closed Some inputs and outputs use open circuits and short circuits to distinguish between active
Normally-open and inactive. If an input or output is normally-closed, an open circuit means the input or
output is active, and a short circuit means the input or output is inactive. If an input or output
is normally-open, a short circuit means the input or output is active, and an open circuit
means the input or output is inactive.
Parameter Refers to monitored values or settings in the PCC or the Operator Panel that can be looked at
and, in some cases, adjusted. Some parameters are protected by passwords.
In this manual, italics are used to identify a specific parameter by name.
Pin A specific point on the PCC or the Operator Panel to which it is acceptable to connect a
specific point on an external device. For example, a B+ pin might be connected to the positive
terminal on the battery. It takes more than one pin to connect an external device to the PCC.
For example, it takes B+ and Ground to connect the battery to the PCC.
Depending on the access you have to the controller, you might see a specific pin on the PCC
control board, the terminal at the end of a harness, a wire that runs between the PCC and the
external device, or nothing at all.
Sensor Refers to a device that measures something and reports one of many (or unlimited) values.
For example, a coolant level sensor reports the current level of coolant.
Sequence of A term used to describe the steps the PCC follows when it starts the genset or when it stops
operation the genset.
Signal A term used for convenience to talk about two or more connections as a single input. Usually,
all of these connections have the same effect on the PCC's behavior, and it does not matter
which connection is active.
For example, the term remote start signal" is used frequently. In Auto mode, the PCC starts
the genset when the remote start signal is active. The remote start signal may come from any
of several connections: a switch connected to the remote start pin, the Operator Panel, a PLC
(programmable logic controller) connected on Modbus, InPower, etc. It is not important
between these connections when explaining the way the remote start signal affects the PCC's
decisions to start and stop the genset. It is only important whether or not any of them are
active.
Switch Refers to a device that measures something and reports one of two states, active or inactive,
about something. For example, a low coolant level switch is active when the coolant level is
too low, but the low coolant level switch does not report what the coolant level really is.
In some cases, this may refer to a physical switch (similar to a light switch) instead.
Trim Refers to the subset of parameters that can be adjusted, as opposed to parameters that can
only be monitored.
10 A040Y520 (Issue 1)
4 Introduction
Read Chapter 1 and carefully observe all instructions and precautions in this manual. Keep this
manual with the other generator set and/or controller manuals.
A040Y520 (Issue 1) 11
4. Introduction 9-2011
WARNING: Incorrect service or replacement of parts can result in severe personal injury
or death, and/or equipment damage. Service personnel must be trained and
experienced to perform electrical and mechanical service. Read and follow
Important Safety Instructions.
12 A040Y520 (Issue 1)
5 Control System - PowerStart 0500
5.1 PowerStart 0500 Components
The PowerStart 0500 System consists of the following:
A PS 0500 Integral Control Board
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5. Control System - PowerStart 0500 9-2011
No. Description
1 Display Module
2 Emergency Stop Button
14 A040Y520 (Issue 1)
9-2011 5. Control System - PowerStart 0500
Shutdown, warning and remote start LED indicators are available on front display.
NOTE: If the Start button is not pressed in ten seconds, the PS0500 changes over to
Stop (Off) mode.
WARNING: In Auto mode, the generator set can start at any time. Never service the
generator set in Auto mode. Accidental starting of the generator set during
troubleshooting can cause severe personal injury or death. Disable the
generator set before troubleshooting.
When the remote start signal becomes active, the PS0500 initiates the start sequence to start
the generator set. 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.
A040Y520 (Issue 1) 15
5. Control System - PowerStart 0500 9-2011
When in Auto mode, the Sleep mode is enabled only when the trim "Wake in Auto Enabled" is
enabled. If the trim is disabled (which is the default value), the Sleep mode will never be
enabled when in Auto mode.
It awakes from the Sleep mode if the reset button is pressed or if there is a Tool wakeup input
or a Remote Start signal is received or an E-stop signal is received both in Stop as well as Auto
mode.
The control will not enter the Sleep mode if the there are any active, unacknowledged,
shutdown faults or if the control is in the Manual Run mode.
NOTE: To enable the Sleep mode when the control is in Auto mode, contact your
authorized distributor.
NOTE: The PS0500 control does not support a customer selectable Battle Short
Mode. However, Cummins Service Technicians can invoke the mode of
operation using a service tool for troubleshooting purpose if required.
Battle Short mode is a generator set mode of operation that prevents the generator set from
being shutdown by all but a few select, critical shutdown faults.
CAUTION: All shutdown faults, including those overridden by Battle Short, must be acted upon
immediately to ensure the safety and well being of the operator and the generator
set.
WARNING: Use of the Battle Short mode feature can cause a fire or electrical hazard,
resulting in severe personal injury or death and/or property and equipment
damage. Operation of the generator set must be supervised during battle
short operation.
This feature must only be used during supervised, temporary operation of the generator set.
The faults that are overridden in Battle Short mode can affect generator set performance, or can
cause permanent engine, alternator or connected equipment damage.
Battle Short mode prevents the generator set from being shutdown by all but a select few critical
shutdown faults. All shutdown faults, including those overridden by Battle Short, must be acted
upon immediately to ensure the safety and well being of the operator and the genset.
Only trained and experienced service personnel should enable this feature. When shipped from
the factory, this feature is disabled.
CAUTION: If this mode of operation is selected, the protection of load devices will be disabled.
Cummins Power Generation Limited will not be responsible for any claim resulting
from the use of this mode.
NOTE: The Battle Short feature must be enabled or disabled using the PC Service
tool.
When Battle Short mode is enabled and an overridden shutdown fault occurs, the shutdown
lamp remains lit even though the generator set continues to run. Fault code 1416 - Fail to Shut
Down is displayed. If the OK button is pressed to acknowledge the fault, the fault message is
cleared from the display but remains in one of the scrolling screens displaying the fault code
and its description to indicate that it is an active fault as long as Battle Short mode is enabled.
16 A040Y520 (Issue 1)
9-2011 5. Control System - PowerStart 0500
A040Y520 (Issue 1) 17
5. Control System - PowerStart 0500 9-2011
18 A040Y520 (Issue 1)
9-2011 5. Control System - PowerStart 0500
A040Y520 (Issue 1) 19
5. Control System - PowerStart 0500 9-2011
LED Description
Genset Running This green LED is lit when the generator set is running at
or near rated speed and voltage.
This is not lit while the generator set is stopped.
Remote Start This green LED is lit when the remote start signal is
active. This signal has no effect unless the PS0500 is in
Auto mode.
Shutdown This red LED is lit when there is any active shutdown
fault. Event 1541 (Common Shutdown) is active.
Warning This amber LED is lit when there is an active warning
fault. Event 1540 (Common Warning) is active.
LED/Button Description
Manual Press this to put the PS0500 in Manual mode from Stop
mode. If you do not press the Start button within ten
seconds, the control automatically enters the Stop mode.
The green LED above this button blinks when the PS0500
is in Manual mode.
Start In Manual mode, press this to initiate a Manual Start
sequence. In other modes, this button has no effect.
Auto 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.
Stop Press this to Stop the running generator set.
The red LED above this button blinks when the PS0500 is
in Stop mode. Pressing this button takes the control to
Stop mode.
Reset This button is used along with the OK button to enter the
setup mode. Holding these two buttons pressed
continuously for five 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.
OK 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.
20 A040Y520 (Issue 1)
9-2011 5. Control System - PowerStart 0500
NOTE: Faults are re-announced if they are detected again after being acknowledged.
WARNING: When changing modes, the generator set may start or stop without warning.
Ensure there is no danger to personnel or equipment should the generator
set start or stop when changing modes.
A040Y520 (Issue 1) 21
5. Control System - PowerStart 0500 9-2011
WARNING: Should a remote start signal be received, the generator set will start
automatically. Ensure there is no danger to personnel or equipment should
the generator set start without warning.
WARNING: Manual run mode cannot be selected from Auto mode. The control has to be
in Stop mode before changing the mode. Switching to Stop mode will result
in the generator set shutting down.
CAUTION: Ensure that there is no danger to personnel or equipment when the generator set
is started.
NOTE: Auto mode cannot be selected while in Manual mode. The control has to be
in Off mode before changing the mode. Switching to Off mode will result in
the generator set shutting down.
CAUTION: Ensure that there is no danger to personnel or equipment if the generator set is
stopped.
22 A040Y520 (Issue 1)
9-2011 5. Control System - PowerStart 0500
CAUTION: Only qualified technicians should adjust the parameters described in this section.
Failure to follow this may affect generator set operation and may cause damage to
the generator set or to equipment connected to it.
Menu Description
Alt Setup Use this menu to select alternator setup parameters like
Single/Three phase, 50/60 Hz operation, Wye/Delta,
Voltage etc.
A040Y520 (Issue 1) 23
5. Control System - PowerStart 0500 9-2011
Menu Items
50 Hz
60 Hz
Menu Items
50:5
75:5
100:5
150:5
200:5
250:5
300:5
Menu Items
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9-2011 5. Control System - PowerStart 0500
190
200
208
220
230
240
380
400
416
440
460
480
600
Menu Items
Single 3 Wire
3 Phase
Single 2 Wire
Menu Items
Start Connect
Delta Connect
SubMenu Description
Sensor Select this if using a Sender.
Switch Select this if using a Switch.
A040Y520 (Issue 1) 25
5. Control System - PowerStart 0500 9-2011
Menu Items
CPGF
CIL
SubMenu Description
Cust I/P Flt Choose the response to the input when active.
Customer O/P1 Choose the function of this output.
Customer O/P2 Choose the function of this output.
Menu Items
ShutDown
Warning
Menu Items
Glow Plug
Warning
Shutdown
Menu Items
ShutDown
Warning
Genset Running
26 A040Y520 (Issue 1)
9-2011 5. Control System - PowerStart 0500
5.9.4 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 twice the normal rate as long as the setup mode is not exited and the control is not
returned to Stop mode.
For example, if you need to set the nominal LL voltage to 440 you will see the Setup Main
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
A040Y520 (Issue 1) 27
5. Control System - PowerStart 0500 9-2011
28 A040Y520 (Issue 1)
6 Control Adjustment and Service
6.1 General
This section contains circuit board removal and replacement procedures and adjustment
procedures for the generator set control.
This section also describes the function and operation of engine sensors, generator set options,
and other special features of the generator set control system, such as, customer connection
points, optional run relays, etc. Installation information is also provided for these items where
necessary.
WARNING: Incorrect service or replacement of parts can result in severe personal injury
or death, and/or equipment damage. Service personnel must be trained and
experienced to perform electrical and mechanical service.
WARNING: HAZARDOUS VOLTAGE. The PS0500 control must be opened only by
technically qualified personnel. Site power for optional equipment and
generator set voltages of up to 600 VAC are present on the control board.
These voltages can cause electrical shock, resulting in personal injury.
A040Y520 (Issue 1) 29
6. Control Adjustment and Service 9-2011
6.2.2 CT Connector
The CT connector is a 6-pin MATE-N-LOCK connector. Connector details are as described
below.
30 A040Y520 (Issue 1)
9-2011 6. Control Adjustment and Service
TB15-4 RS485_DATA_B
TB15-5 TOOL_WAKEUP
CAUTION: Disconnect battery charger from AC source before disconnecting battery cables.
Otherwise, disconnecting cables can result in voltage spikes damaging to DC
control circuits of the set.
WARNING: Accidental starting of the generator set can cause severe personal injury or
death. Prevent accidental starting by disconnecting the negative (-) cable
from the battery terminal.
CAUTION: Electrostatic discharge will damage circuit boards. Always wear a grounding wrist
strap when handling circuit boards or socket-mounted ICs.
Before starting procedure, disconnect the negative (-) cable from the battery. This is to make
sure the set will not start while working on it and to avoid circuit board damage, caused by
voltage spikes when removing and replacing circuit board connectors.
1. Press the STOP button to switch to the Off mode.
2. Turn off or remove AC power from the battery charger.
3. Press the Emergency Stop button and wait at least 30 seconds before completing Step 4.
4. Remove the negative (-) battery cable from the generator set starting battery.
A040Y520 (Issue 1) 31
6. Control Adjustment and Service 9-2011
5. To prevent circuit board damage due to electrostatic discharge (ESD), a grounding wrist
strap must be worn when handling circuit boards or socket-mounted IC's. (The wrist strap
does not provide a direct short to ground, but is typically rated at approximately 1 megohm
to ground.)
6. Attach the clip to the chassis ground screw in the mounting area of the control board and
place the strap around your wrist before handling a circuit board.
32 A040Y520 (Issue 1)
9-2011 6. Control Adjustment and Service
A040Y520 (Issue 1) 33
6. Control Adjustment and Service 9-2011
34 A040Y520 (Issue 1)
7 Troubleshooting
7.1 General
The PowerStart0500 (PS0500) continuously monitors the generator set for abnormal conditions,
such as high oil pressure and high coolant temperature. If any of these conditions occur, the
control will light an amber Warning lamp or a red Shutdown lamp and display a message on the
LCD display.
CAUTION: Using the wrong capture file can result in equipment damage. Do not swap
Controls from another generator set model and only use the calibration file shown
on the nameplate.
A040Y520 (Issue 1) 35
7. Troubleshooting 9-2011
CAUTION: Disconnect battery charger from AC source before disconnecting battery cables.
Otherwise, disconnecting cables can result in voltage spikes damaging to DC
control circuits of the generator set .
NOTE: Each fault code "warning" can be changed to "shutdown" using InPower.
Default settings are used in this manual. It is recommended that all changes
to settings be recorded at each site to aid in the troubleshooting of the
generator set.
CAUTION: Always make sure that the PCC is in the OFF mode before disconnecting or
connecting harness connectors. Otherwise, disconnecting the harness connectors
can result in voltage spikes high enough to damage the DC control circuits of the
set.
CAUTION: Electrostatic discharge will damage circuit boards. Always wear a wrist strap when
handling circuit boards or when disconnecting or connecting harness connectors.
See Circuit Board Removal/Replacement in Chapter 6 on page 29.
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9-2011 7. Troubleshooting
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7. Troubleshooting 9-2011
38 A040Y520 (Issue 1)
9-2011 7. Troubleshooting
b. If you do not have a PC based service tool, remove battery power from the control to
disable fault simulation overrides.
2. Low oil level. Clogged lines or filters.
a. Check oil level, lines and filters.
b. If oil system is Ok but oil level is low, replenish.
3. Sensor or oil pump could be bad. Or the generator set may be shutting down on another
fault.
a. Disconnect the oil pressure sensor leads, and connect an oil pressure sensor
simulator to the harness.
If the control responds to the simulator, reconnect the sensor, disconnect the +
signal wire at the fuel solenoid, and crank the engine. Check the oil pressure
reading on the digital display.
If the display shows an acceptable oil pressure, the problem may not be in
the oil or oil sensing system. The generator set may be shutting down on
another fault (out of fuel, intermittent connector). Restart the generator set
and monitor the display panel for other faults.
If the display does not show an acceptable oil pressure, replace the sensor.
If the control still doesn't display an oil pressure while cranking, the oil pump
may be bad. Refer to the engine service manual.
If the control does not respond to the simulator, go to the next step.
4. Harness or control could be bad.
a. 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 not go to P16, the control is bad.
5. Low oil pressure fault set points could be incorrect.
a. Verify set points against the normal operating pressures of the engine. Refer to the
engine service manual.
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7. Troubleshooting 9-2011
40 A040Y520 (Issue 1)
9-2011 7. Troubleshooting
b. If the control responds to the simulator, replace the sensor. If the control does not
respond, go to the next step.
4. The harness or control could be bad.
a. Measure the resistance of the coolant sensor and reconnect the harness to the
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.
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7. Troubleshooting 9-2011
42 A040Y520 (Issue 1)
9-2011 7. Troubleshooting
Binding in the solenoid linkage can prevent activation of the hold coil circuitry in
the solenoid. Make sure solenoid in shaft moves completely in and out freely.
(Applies to solenoids with both pull and hold coils).
Fuel solenoid is bad.
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 next step.
Control/K7 Fuel Relay is bad.
Check wiring continuity/test K7 relay or fuel pilot. Remove lead from K7-COM
(fuel pilot). Attempt to start and check for GND at lead COM.
If there is no GND, check for open circuit between K7 COM and base card.
If GND is present, reconnect lead COM to relay. Remove lead from N/O
connection. Attempt to start and check for B+ at terminal N/O connection.
If B+ is present, check for open circuit between N/O connection and fuel
solenoid (+).
If B+ is not present, check for relay contacts.
The engine fuel system is worn or malfunctioning or has lost prime (fuel lift pump,
injection pump, injectors, timing).
Service according to the engine service manual.
The engine is worn or malfunctioning mechanically.
Service according to the engine service manual.
4. Improper connections have been made at the generator output terminals.
a. Reconnect according to the appropriate reconnection diagram.
5. The voltage sense or setup wiring connection could be incorrect.
a. Check that voltage senses inputs P22-1 to 4 are connected to the correct voltage
sensing point at alternator.
6. The rotating rectifier assembly (diodes CR1 through CR6) is faulty.
a. Check each diode. See the generator set service manual.
7. Loose connector or control is bad.
a. Repair connections (P22) or replace the control if necessary.
8. AVR or alternator is bad.
a. Refer to Alternator/AVR Board Isolation Procedure in Alternator service manual to
determine if the AVR board is causing the low AC voltage shutdown fault.
9. Voltage sense connections/setup could be incorrect.
a. See wiring diagrams for proper connections.
A040Y520 (Issue 1) 43
7. Troubleshooting 9-2011
Possible Causes:
1. Weak or discharged battery.
2. Low electrolyte level in battery.
3. Battery connections loose or dirty.
4. Insufficient battery charging voltage.
5. Engine DC alternator could be bad.
6. If the batteries are okay, the problem may be the harness or the control.
7. Fault threshold could be bad.
Diagnosis and Repair:
1. Weak or discharged battery.
a. Recharge or replace the battery. Specific gravity for a fully charged battery is
approximately 1.260 at 80F (27C).
2. Low electrolyte level in battery.
a. Replenish electrolyte and recharge battery.
3. Battery connections loose or dirty.
a. Clean and tighten to replace the battery cable connectors and cables at the battery
and the generator set.
4. Insufficient battery charging voltage.
a. Adjust charge rate of AC powered battery charging circuit, according to manufacture's
instructions.
5. Engine DC alternator could be bad.
a. Replace engine DC alternator if normal battery charging voltage (12 to 14 VDC) is not
obtained.
6. If the batteries are okay, the problem may be the harness or the control.
a. Remove connector P16 from control and check battery voltage at P16-2 (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 okay, the control is bad.
7. Fault threshold could be bad.
a. Check fault threshold against requirement of the application.
44 A040Y520 (Issue 1)
9-2011 7. Troubleshooting
A040Y520 (Issue 1) 45
7. Troubleshooting 9-2011
NOTE: In applications where the ambient temperature falls below 40F (4C), low
coolant temperature may be indicated even though the coolant heaters are
operating.
Check the following conditions:
Coolant heater not connected to power supply. Check for brown fuse or disconnected
heater cord and correct as required.
Check for low coolant level and 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 warming can be cleared.
46 A040Y520 (Issue 1)
9-2011 7. Troubleshooting
A040Y520 (Issue 1) 47
7. Troubleshooting 9-2011
3. Overload.
a. Check the load and correct any overload. Check operation by disconnecting load and
restarting generator set.
4. Improper connections have been made at the generator output terminals.
a. Reconnect according to the appropriate reconnection diagram.
5. The voltage sense or setup wiring connection could be incorrect.
a. Check that voltage senses inputs P22-1 to 4 are connected to the correct voltage
sensing point at alternator.
6. The rotating rectifier assembly (diodes CR1 through CR6) is faulty.
a. Check each diode. See the generator set service manual.
7. Loose connector or control is bad.
a. Repair connections (P22) or replace the control if necessary.
8. AVR or alternator is bad.
a. Refer to Alternator/AVR Board Isolation Procedure in Alternator service manual to
determine if the AVR board is causing the low AC voltage shutdown fault.
9. Voltage sense connections/setup could be incorrect.
a. See wiring diagrams for proper connections.
48 A040Y520 (Issue 1)
9-2011 7. Troubleshooting
4. Governor fault.
a. Check fuel shutoff solenoid adjustment.
5. Loose connector or control is bad.
a. Repair connections (P22-1 to 4) or replace the control if necessary.
A040Y520 (Issue 1) 49
7. Troubleshooting 9-2011
50 A040Y520 (Issue 1)
8 Manufacturing Facilities
NORTH AMERICA EMEA, CIS ASIA PACIFIC
Cummins Power Generation Limited Cummins Power Generation Limited Cummins Power Generation Limited
1400 73rd Ave. NE Columbus Avenue 10 Toh Guan Road #07-01
Minneapolis, MN 55432 USA Manston Park TT International Tradepark
Manston, Ramsgate Singapore 608838
Kent CT12 5BF
United Kingdom
Phone +1 763 574 5000 Phone +44 1843 255000 Phone +65 6417 2388
Toll Free +1 800 888 6626 Fax +44 1843 255902 Fax +65 6417 2399
Fax +1 763 574 5298
A040Y520 (Issue 1) 51
8. Manufacturing Facilities 9-2011
52 A040Y520 (Issue 1)
Appendix A. Wiring Diagrams
Table of Contents
Figure 13. PS0500 Wiring Digaram ............................................................................................................ 55
A040Y520 (Issue 1) 53
Appendix A. Wiring Diagrams 9-2011
Note: This section contains basic (generic) wiring diagrams and schematics to help in troubleshooting.
Service personnel must use the wiring diagrams and schematics shipped with the unit. These wiring
diagrams and schematics should be updated when modifications are made to the unit.
54 A040Y520 (Issue 1)
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A040Y520 (Issue 1) 55
Appendix A. Wiring Diagrams 9-2011
56 A040Y520 (Issue 1)
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