960-0522 qsx15 service

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according to the size of each page you wish to print. Redistribution or publication of this documentby any means, is strictly prohibited.Redistribution or publication of this documentby any means, is strictly prohibited.

GenSet ModelDFEG, DFEH, DFEJ, DFEK

Printed in U.S.A. 960-0522 11-2004

Service Manual

with PowerCommand ControlPCC2100

Redistribution or publication of this documentby any means, is strictly prohibited.Redistribution or publication of this documentby any means, is strictly prohibited.

iTable of Contents

SECTION TITLE PAGEIMPORTANT SAFETY INSTRUCTIONS iii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 INTRODUCTIONAbout this Manual 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Overview 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Equipment 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How to Obtain Service 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 CONTROL OPERATIONGeneral 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel Power On/Off Modes 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Panel 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Menu Display and Buttons 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Menus 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controller Configuration Menu 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Menu 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Menu 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust Menu 2-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Faults Menu 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Menu 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . History Menu 2-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . About Menu 2-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 CIRCUIT BOARDS AND MODULESGeneral 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control System Overview 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Base Board 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 TROUBLESHOOTINGGeneral 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . InPower Service Tool 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Network Application and Customer Inputs 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . Safety Considerations 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Procedure 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


ii

SECTION TITLE PAGE5 CONTROL ADJUSTMENT AND SERVICE

General 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Board Removal/Replacement 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Modifying Setup Submenus 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Password Submenu 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crank/Idle Setup Menu 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Governor/Regulator Setup Menu 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PCC Control Panel Box Components (Standard/Optional) 5-12. . . . . . . . . . . Current Transformer (CT) Installation 5-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 SERVICING THE GENERATORTesting the Generator 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator/Base Board Isolation Procedure 6-2. . . . . . . . . . . . . . . . . . . . . . . . . Testing the PMG 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Disassembly 6-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Reassembly 6-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 OPTIONAL ENCLOSURE FUEL TANK SYSTEMGeneral 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Connections 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Transfer Pump 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Fuel Fill Box 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Alarm Panel 7-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rupture Basin Leak Detect Switch Test 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 WIRING DIAGRAMSGeneral 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


LS-14Liii

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS This manual containsimportant instructions that should be followed duringinstallation and maintenance of the generator and batter-ies.

Before operating the generator set (genset), read theOperators Manual and become familiar with it and theequipment. Safe and efficient operation can beachieved only if the equipment is properly operatedand maintained. Many accidents are caused by failureto follow fundamental rules and precautions.

The following symbols, found throughout this manual,alert you to potentially dangerous conditions to the oper-ator, service personnel, or the equipment.

This symbol warns of immediatehazards which will result in severe personal in-jury or death.

WARNING This symbol refers to a hazard or un-

safe practice which can result in severe person-al injury or death.

CAUTION This symbol refers to a hazard or un-

safe practice which can result in personal injuryor product or property damage.

FUEL AND FUMES ARE FLAMMABLEFire, explosion, and personal injury or death can resultfrom improper practices. DO NOT fill fuel tanks while engine is running, un-

less tanks are outside the engine compartment.Fuel contact with hot engine or exhaust is a potentialfire hazard.

DO NOT permit any flame, cigarette, pilot light,spark, arcing equipment, or other ignition sourcenear the generator set or fuel tank.

Fuel lines must be adequately secured and free ofleaks. Fuel connection at the engine should bemade with an approved flexible line. Do not use zinccoated or copper fuel lines with diesel fuel.

Be sure all fuel supplies have a positive shutoffvalve.

Be sure battery area has been well-ventilated priorto servicing near it. Lead-acid batteries emit a highlyexplosive hydrogen gas that can be ignited by arc-ing, sparking, smoking, etc.

EXHAUST GASES ARE DEADLY Provide an adequate exhaust system to properly

expel discharged gases away from enclosed orsheltered areas and areas where individuals arelikely to congregate. Visually and audibly inspectthe exhaust daily for leaks per the maintenanceschedule. Make sure that exhaust manifolds are se-cured and not warped. Do not use exhaust gases toheat a compartment.

Be sure the unit is well ventilated. Engine exhaust and some of its constituents are

known to the state of California to cause cancer,birth defects, and other reproductive harm.

MOVING PARTS CAN CAUSE SEVEREPERSONAL INJURY OR DEATH Keep your hands, clothing, and jewelry away from

moving parts. Before starting work on the generator set, discon-

nect battery charger from its AC source, then dis-connect starting batteries, negative () cable first.This will prevent accidental starting.

Make sure that fasteners on the generator set aresecure. Tighten supports and clamps, keep guardsin position over fans, drive belts, etc.

Do not wear loose clothing or jewelry in the vicinity ofmoving parts, or while working on electrical equip-ment. Loose clothing and jewelry can becomecaught in moving parts.

If adjustment must be made while the unit is run-ning, use extreme caution around hot manifolds,moving parts, etc.

DO NOT OPERATE IN FLAMMABLE ANDEXPLOSIVE ENVIRONMENTSFlammable vapor can cause an engine to overspeed andbecome difficult to stop, resulting in possible fire, explo-sion, severe personal injury and death. Do not operate agenset where a flammable vapor environment can becreated by fuel spill, leak, etc., unless the genset isequipped with an automatic safety device to block the airintake and stop the engine. The owners and operators ofthe genset are solely responsible for operating the gen-set safely. Contact your authorized Cummins PowerGeneration distributor for more information.


iv

ELECTRICAL SHOCK CAN CAUSESEVERE PERSONAL INJURY OR DEATH Remove electric power before removing protective

shields or touching electrical equipment. Use rub-ber insulative mats placed on dry wood platformsover floors that are metal or concrete when aroundelectrical equipment. Do not wear damp clothing(particularly wet shoes) or allow skin surface to bedamp when handling electrical equipment. Do notwear jewelry. Jewelry can short out electrical con-tacts and cause shock or burning.

Use extreme caution when working on electricalcomponents. High voltages can cause injury ordeath. DO NOT tamper with interlocks.

Follow all applicable state and local electricalcodes. Have all electrical installations performed bya qualified licensed electrician. Tag and lock openswitches to avoid accidental closure.

DO NOT CONNECT GENERATOR SET DIRECT-LY TO ANY BUILDING ELECTRICAL SYSTEM.Hazardous voltages can flow from the generator setinto the utility line. This creates a potential for elec-trocution or property damage. Connect onlythrough an approved isolation switch or an ap-proved paralleling device.

GENERAL SAFETY PRECAUTIONS Coolants under pressure have a higher boiling point

than water. DO NOT open a radiator or heat ex-changer pressure cap while the engine is running.Allow the generator set to cool and bleed the systempressure first.

Used engine oils have been identified by some stateor federal agencies as causing cancer or reproduc-tive toxicity. When checking or changing engine oil,take care not to ingest, breathe the fumes, or con-tact used oil.

Keep multi-class ABC fire extinguishers handy.Class A fires involve ordinary combustible materialssuch as wood and cloth; Class B fires, combustibleand flammable liquid fuels and gaseous fuels; ClassC fires, live electrical equipment. (ref. NFPA No. 10).

Make sure that rags are not left on or near the en-gine.

Make sure generator set is mounted in a manner toprevent combustible materials from accumulatingunder the unit.

Remove all unnecessary grease and oil from theunit. Accumulated grease and oil can cause over-heating and engine damage which present a poten-tial fire hazard.

Keep the generator set and the surrounding areaclean and free from obstructions. Remove any de-bris from the set and keep the floor clean and dry.

Do not work on this equipment when mentally orphysically fatigued, or after consuming any alcoholor drug that makes the operation of equipment un-safe.

Substances in exhaust gases have been identifiedby some state or federal agencies as causing can-cer or reproductive toxicity. Take care not to breathor ingest or come into contact with exhaust gases.

Do not store any flammable liquids, such as fuel,cleaners, oil, etc., near the generator set. A fire orexplosion could result.

Wear hearing protection when going near an oper-ating generator set.

To prevent serious burns, avoid contact with hotmetal parts such as radiator, turbo charger and ex-haust system.


1-1

1. IntroductionABOUT THIS MANUAL

This manual provides troubleshooting and repairinformation regarding the PowerCommand 2100Control (PCC) and generators for the generatorsets (gensets) listed on the front cover. Operatingand maintenance instructions for the generator setare in the applicable Operators Manual.Engine troubleshooting, repair and maintenanceinformation is provided in the applicable engineservice manual.This manual does not have instructions forservicing printed circuit board assemblies. Afterdetermining that a printed circuit board assembly isfaulty, replace it, do not repair it. Attempts to repair aprinted circuit board can lead to costly damage tothe equipment.This manual contains basic (generic) wiringdiagrams and schematics that are included to helpin troubleshooting. Service personnel must use theactual wiring diagram and schematic shipped witheach unit. The wiring diagrams and schematics thatare maintained with the unit should be updatedwhen modifications are made to the unit.Read Safety Precautions and carefully observe allinstructions and precautions in this manual.

SYSTEM OVERVIEWThe generator set control system consist of thePCC control and the engine control module(CM570).The PCC is a microprocessor-based control forCummins Power Generation generator sets. Theoperating software provides control of thegenerator set and its performance characteristics,and displays performance information on a digitaldisplay panel. It accepts menu-driven control andsetup input from the push button switches on thefront panel.

The PCC circuit (Base) board provides: Voltage regulation, Alternator/genset protection and diagnostics, Speed governing (via, CM570 module) and Starter control

The Engine Control Module (CM570) provides: Fuel system/combustion control Engine protection and diagnostics Speed sensor processing

The CM570 module fault codes and engine status(oil pressure, coolant temperature, etc.) aredisplayed on the PCC digital display panel.

TEST EQUIPMENTTo perform the test procedures in this manual, thefollowing test equipment must be available True RMS meter for accurate measurement of

small AC and DC voltages. Fluke models 87 or8060A are good choices.

Grounding wrist strap to prevent circuit boarddamage due to electrostatic discharge (ESD).

Battery Hydrometer Jumper Leads Tachometer or Frequency Meter Wheatstone Bridge or Digital Ohmmeter Variac Load Test Panel Megger or Insulation Resistance Meter PCC Service Tool Kit (Harness Tool and Sen-

sor Tool) InPower Service Tool (PC based genset ser-

vice tool) InSite Service Tool (PC based CM570 engine

control module service tool)


1-2

HOW TO OBTAIN SERVICEAlways give the complete Model, Specification andSerial number of the generator set as shown on thenameplate when seeking additional serviceinformation or replacement parts. The nameplate islocated on the side of the generator output box.

WARNING Incorrect service or replacement of

parts can result in severe personal injury ordeath, and/or equipment damage. Service per-sonnel must be trained and experienced to per-form electrical and mechanical service. Readand follow Important Safety Instructions onpages iii and iv.

Copyright 2004 Cummins Power Generation. All rights reserved.Cummins and PowerCommand are registered trademarks of Cummins Inc.InPower and InSite are registered trademarks of Cummins Inc.


2-1

2. Control OperationGENERAL

The following describes the function and operationof the PowerCommand 2100 Control (PCC). Allindicators, control switches/buttons and digital dis-play are located on the face of the control panel asillustrated in Figure 2-1.

CONTROL PANEL POWER ON/OFFMODES

The power on/off modes of the control panel and op-erating software are Power On, Screen Saver andSleep/Awake.

Power On Mode: In this mode, power is continu-ously supplied to the control panel. The controlsoperating software and control panel LEDs/digitaldisplay will remain active until the Screen Savermode is activated.

Screen Saver Mode: Power to the digital display isremoved after 30 minutes (generator set not run-ning or running). The 30 minute timer resets and be-gins after each control panel action (any button orswitch selection) or signal received by the operatingsoftware. All LEDs on the control panel operate nor-mally during Screen Saver mode, indicating that theoperating software is active (Awake mode).When a Warning signal is sensed by the PCC (forexample, low coolant temp), the control displays thewarning message.

Sleep/Awake Mode: In the Sleep mode, the con-trols operating software is inactive and the LEDsand the digital display on the control panel are all off.Sleep mode is a feature used to reduce batterypower consumption when the control is not beingused and the O/Manual/Auto switch is in the O posi-tion.

When all conditions are met (i.e., no unacknowl-edged faults and O/Manual/Auto switch is in the Oposition) the Sleep mode is activated.The operating software is initialized and the digitaldisplay and control panel LEDs are turned on in re-sponse to moving/pressing the following controlpanel switch/buttons: O/Manual/Auto switch Emergency Stop button Fault Acknowledge/Reset button Panel Lamp/Lamp Test button

To activate the control and view the menu displaywithout starting the generator set, press Fault Ac-knowledge or Panel Lamp button or move modeswitch from O to Manual.The InPower service tool is required to enable ordisable the Sleep mode. When shipped from thefactory, the Sleep mode is disabled. When disabled,the operating software will always remain active(Awake mode). (If the network feature is installed,the sleep mode is not available and should not beenabled will cause error condition.)


2-2

BATTLE SHORT MODE (OPTIONAL)The purpose of Battle Short mode is to satisfy localcode requirements where necessary.The Battle Short mode prevents the genset from be-ing shutdown by all but a select few critical shutdownfaults. All shutdown faults, including those over-ridden by Battle Short, must be acted upon im-mediately to ensure the safety and well being ofthe operator and the genset.

WARNING Use of the Battle Short mode can

cause a fire or electrical hazard, resulting in se-vere personal injury or death and/or propertyand equipment damage. Operation of the gen-set must be supervised during Battle Shortmode operation.This feature must only be used during supervised,temporary operation of the genset. The faults thatare overridden during Battle Short mode consist offaults that can affect genset performance or causepermanent engine, alternator, or connectedequipment damage. Operation may void genera-tor set warranty if damage occurs that relates tofault condition.

When Battle Short mode is enabled, the Warningstatus indicator is lit, along with displayed fault code1131 Battle Short Active.With Battle Short mode enabled and an overriddenshutdown fault occurs, the shutdown fault is an-nounced but the genset does not shut down, andfault code 1416 Fail To Shut Down is displayed.

The Fault Acknowledgement/Reset button will clearthe fault message, but will remain in the Fault/Histo-ry file with an asterisk sign (* equals active fault) aslong as Battle Short mode is enabled.Battle Short is suspended and a shutdown occursimmediately if: Any of the following critical shutdown faults

occurs:

Overspeed Fault code 234 Position Sensor Fault code 236 CAN Data Link Failure Fault code 781 CAN - Engine Shut Down Fault code

1245 Emergency Stop Fault code 1433 Remote Emergency Stop Fault code

1434 Excitation Fault Fault code 2335

Moving the customer installed Battle Shortswitch to OFF with an active but overriddenshutdown fault or a shutdown fault that wasoverridden at any time. (Fault code 1123 Shutdown After Battle Short will be dis-played for this type of shutdown.)

The software for the Battle Short feature must beinstalled at the factory or ordered and installed byan authorized service representative. Wheninstalled, the InPower service tool is required to en-able the Battle Short mode feature and to configurea Customer Input (1, 2, 3 or 4) for an external switchinput. This switch (customer supplied) allows theoperator to enable/disable the Battle Short mode.


2-3

PANELLAMP(1 of 3)

CONFIGURABLEINDICATORS

MANUALRUN/STOPBUTTON

OFF/MANUAL/AUTO SWITCH

SHUTDOWNAND WARNING

STATUSINDICATORS

EMERGENCYSTOP PUSH

BUTTON(Pull to reset)

HOMEBUTTON

ANALOG ACMETERING

PANEL(OPTIONAL)

DIGITALDISPLAY

MENUSELECTION

BUTTON (1 of 4)

PREVIOUSMAIN MENU

BUTTON

FAULTACKNOWLEDGEMENT/

RESET BUTTON

RUNNING/REMOTESTART/NOT IN AUTO

INDICATORS

PANEL LAMPAND LAMP

TESTBUTTON

FIGURE 2-1. FRONT PANEL


2-4

FRONT PANELFigure 2-1 shows the features of the front panel.

Digital Display: This two-line, 20-characters perline alphanumeric display is used to view menus ofthe menu-driven operating system. Refer to themenu trees later in this section. The display is alsoused to show warning and shutdown messages.

Display Menu Selection Buttons: Four momen-tary buttonstwo on each side of the digital displaywindoware used to step through the variousmenu options and to adjust generator set parame-ters. A green triangle ( or ), arrow ( , , , or ),>>, or plus/minus sign (+ or ) in the digital displayadjacent to the button is shown when the button canbe used (button is active). Refer to Menu DisplayAnd Buttons later in this section.

Home Button: Press this button ( ) to view theHome Menu. Refer to the menu trees later in thissection.

Previous Main Menu Button: Press this button ( )to view the previous Main Menu. All main menus in-clude both types of green triangles ( and ). Referto the menu trees later in this section.

NOTE: The up and down arrows ( and ) are usedto navigate between submenus.

Emergency Stop Button: Push this button in foremergency shutdown of the generator set. This willstop the generator set immediately and preventstarting of the set from any location (local and re-mote).To reset:

1. Pull the button and allow it to pop out.2. Turn the O/Manual/Auto switch to O (Off).3. Press the front panel Fault Acknowledge/Re-

set button.4. Return O/Manual/Auto switch to desired posi-

tion.

Emergency Stop shutdown can be reset only at thePCC front panel.

Running Indicator: This green lamp is lit wheneverthe generator set is running.

Remote Start Indicator: This green lamp is litwhenever the control is receiving a remote start sig-nal.

Not in Auto Indicator: This red lamp flashes con-tinuously when the O/Manual/Auto switch is not inthe Auto position.

Analog AC Metering Panel (Optional): This panelsimultaneously displays (in percent of genset ratedoutput): 3-phase line-to-line AC current (A~) (L1, L2

and L3); Single phase line-to-line (L1 and L2) Kilowatts (kW) Generator output frequency in hertz (Hz) 3-phase line-to-line AC volts (V~) (L1, L2 and

L3); Single phase line-to-neutral (L1) Power Factor (PF) (shown in 0.2 increments)

Shutdown Status Indicator: This red lamp is litwhenever the control detects a shutdown condition.The generator set cannot be started when this lampis on. After the condition is corrected, shutdown in-dicators can be reset by turning the O/Manual/Autoswitch to the O position and pressing the Fault Ac-knowledge/Reset button.

Warning Status Indicator: This yellow lamp is litwhenever the control detects a warning condition.After the condition is corrected, warning indicatorscan be reset by pressing the Fault Acknowledge/Reset button. (The majority of faults can be resetwithout stopping generator set.) In auto mode,warning indicators can also be reset by cycling theremote reset input after the condition is corrected.

This lamp is also lit when Battle Short mode is en-abled and a overridden shutdown fault occurs.

Some warnings remain active after the condition iscorrected and the control reset button is pressed.This will require the genset to be shutdown to resetthe warning indicator.

Fault Acknowledge/Reset Button: Press this but-ton to acknowledge warning and shutdown mes-sages after the fault has been corrected. Pressingthis button clears the fault from the current fault list.

To acknowledge a Warning message, the O/Manu-al/Auto switch can be in any position. (It is not nec-essary to stop the generator set to acknowledge aninactive Warning condition.) To acknowledge ashutdown message with this button, the O/Manual/Auto switch must be in the O position.


2-5

Panel Lamp and Lamp Test Button: Press thisbutton to turn the control panel lamps on or off. Thelights will shut off after about ten minutes. Press andhold this button to test all front panel LEDs and me-ters. The meters will light one bar at a time. (Test canbe enabled during genset operation.)Manual Run/Stop Button: This button starts andstops the set locally and will bypass Time Delay toStart and Stop sequences. The O/Manual/Autoswitch must be in the Manual position to enable thisbutton.

O/Manual/Auto Switch: The Manual position en-ables the use of the Manual Run/Stop button.The Auto position enables start/stop control of theengine from a remote location. (It disables the useof the Manual Run/Stop button.)The O (Off) position prevents the starting of the gen-erator set (local or remote). If the switch is set to Oduring generator set operation, the engine will im-mediately shut down (cool-down timers are by-passed). This hot shutdown should be avoided tohelp prolong the life of the generator set.

Configurable IndicatorsThe following configurable indicators (default val-ues shown) can be changed with the InPower ser-vice tool. The configurable items are: generatorevent (fault/status) and LED color (green, yellow orred), and enable/disable indicator.Low Oil Pressure Warning Indicator: This yellowlamp indicates the oil pressure is lower than the nor-mal range of operation.High Engine Temperature Warning Indicator:This yellow lamp indicates the engine temperatureis higher than the normal range of operation.Low Oil Pressure Shutdown Indicator: This redlamp indicates the engine has shut down becauseof low oil pressure.Overspeed Shutdown Indicator: This red lamp in-dicates the engine has shut down because of excessivespeed.

Fail to Start Indicator: This red lamp indicates theengine failed to start.

MENU DISPLAY AND BUTTONSFigure 2-2 shows the digital display and the menuselection buttons.Digital Display: The two-line, 20 characters perline, digital display is used to view the menus of themenu-driven operating system. Refer to the menutrees later in this section. The display is also used toshow fault messages.Display Menu Selection Buttons: Four momen-tary buttonstwo on each side of the digital displaywindoware used to step through the variousmenu options and to adjust generator set parame-ters. The button is active when a symbol adjacent tothe button is displayed. The displayed symbol indi-cates the function of the button. In the digital display for main menus (Figure

2-3), the and symbols indicate that pressingthe adjacent button causes the operating pro-gram to go to the selected submenu (e.g., En-gine Menu in Figure 2-5).

In the digital display, the More>> symbol indi-cates that pressing the adjacent button causesthe operating program to go to the next mainmenu, as shown in Figure 2-3.

In the digital display, the or symbols indi-cate that pressing the adjacent button causesthe operating program to go to the next or pre-vious submenu, as shown in the menu dia-grams. Only the symbol is displayed in thefirst submenu. Only the is displayed in thelast submenu. Both symbols are displayed inthe rest of the submenus.

In the digital display, the plus or minus symbols(+ or ) indicate that pressing the adjacent but-ton can be used to change a parameter or val-ue shown on the display.

When there is a choice of two parameters, oneparameter is associated with the + symbol andthe other is associated with the symbol.When changing values, pressing the button ad-jacent to the + symbol increase the value andpressing the button adjacent to the symboldecreases the value. Only one numeric char-acter of a field can be changed at a time.


2-6

In the digital display, the or symbol indicatesthat pressing the adjacent button causes theoperating program to move the cursor to thenext numeric character. The selected numericcharacter can then be changed by pressing thebuttons adjacent to the + and symbols. Onlythe symbol is displayed when the cursor is onthe first character of a field that can bechanged. Only the is displayed when the cur-sor is on the last character. Both symbols aredisplayed when the cursor is on any other char-acter.

After adjusting values/parameters, pressing

the symbol results in the changes beingsaved. If the Home button or Previous MainMenu button is pressed before pressing the symbol, the changes are not saved.

Home Button: Pressing this button causes the op-erating system to show Main Menu 1 (Figure 2-3) inthe digital display.

Previous Main Menu Button: Pressing this buttoncauses the operating system to show the previousMain Menu in the digital display. All main menus in-clude both types of green triangles ( and ).

HOMEBUTTON

PREVIOUS MAINMENU BUTTON

2 LINE, 20 CHARACTERS PER LINE

MENU DISPLAY

DIGITAL DISPLAY

FIGURE 2-2. DIGITAL DISPLAY AND MENU SELECTION BUTTONS


2-7

MAIN MENUSFigure 2-3 shows the three major main menus avail-able to the user. Figure 2-3 also includes referencesto pages in this section where you can find addition-al information on submenus. When viewing a sub-menu, you can press the previous main menu but-ton at any time to view its main menu.

As shown in the illustration, each main menu canbranch into one of four directions. Press the buttonnext to More>> in the display to view the next Mainmenu. Main Menu 1 is redisplayed when you pressthe button next to More>> in the Main Menu 3 dis-play.

About SetupMore>>

FaultsSystem

HistoryMore>>

EngineAlternator

AdjustMore>>

Main Menu 1

Main Menu 2

Main Menu 3

PAGE211

PAGE215

PAGE217

PAGE219

PAGE221

PAGE223

PAGE55

PAGE225

FIGURE 2-3. MAIN MENUS


2-8

CONTROLLER CONFIGURATION MENU

Figure 2-4 shows a block representation of the Con-troller Configuration menus. These menus are usedto change the default language, temperature units,and pressure units to be displayed in menus.

To view the first Controller Configuration menu,make sure Main Menu 1 is displayed and simulta-neously press the Home Menu and Previous MainMenu buttons.

As shown in the diagram, the Controller Configura-tion menu has three submenus.

Press the buttons next to the and symbols in thedigital display to navigate between the menus.

Press the button next to the symbol in the displayuntil the + and symbols are displayed.Press the button next to the + or symbol to selectthe desired option.

After selecting option, pressing the symbol resultsin the changes being saved. If the Home button orPrevious Main Menu button is pressed beforepressing the symbol, the changes are not saved.Language Selected submenu: Used to select de-sired language (default = English).Temperature Units submenu: Used to selectFahrenheit or Centigrade for temperature readings.Fluid Pressure Units submenu: Used to selectPSI or kPA for pressure readings.


2-9

CONTROLLER CONFIGURATION MENU

EngineAlternator

AdjustMore>>

+Language Selected English

Language SelectedEnglish

Temperature UnitsDeg F

+Temperature Units Deg C

Fluid Pressure UnitsPSI

+Fluid Pressure Units kPa

Back

Back

Back

Main Menu 1

FIGURE 2-4. CONTROLLER CONFIGURATION MENU


2-10

ENGINE MENU

Figure 2-5 shows a block representation of the En-gine menu. If you press the button next to the wordEngine in the display, the first Engine submenu isdisplayed.

As shown in the diagram, the Engine menu hasfourteen submenus. The data in the submenus willvary according to the type and number of sensorsprovided with the engine.

Press the buttons next to the and symbols in thedigital display to navigate between the menus.Press the Home button or the Previous Main Menubutton to return to Main Menu 1.

Coolant Temperature submenu: This submenudisplays the engine coolant temperature which canbe viewed in degrees Fahrenheit or Centigrade(see Controller Configuration Menu in this section).Oil Pressure submenu (Only available on somemodels): This submenu displays the engine oilpressure which can be viewed in PSI or kPA (seeController Configuration Menu in this section).Oil Temperature submenu (Only available onsome models): This submenu displays the engineoil temperature which can be viewed in degreesFahrenheit or Centigrade (see Controller Configu-ration Menu in this section).Engine Speed submenu: This submenu displaysthe engine RPM.Battery Voltage submenu: This submenu dis-plays the engine battery voltage.


2-11

ENGINE MENU

EngineAlternator

AdjustMore>>

Coolant Temperaturennn Deg F

Oil Pressurennn PSI

Engine Speednnnn RPM

Battery Voltagenn.n VDC

Main Menu 1

Oil Temperaturennn Deg F

CONTINUED

FIGURE 2-5. ENGINE MENU


2-12

ENGINE MENU (CONT.)

Governor Torque submenu: This submenu dis-plays the governor torque levels in percentage ofmaximum value.

Fuel Temperature submenu: This submenu dis-plays the fuel temperature which can be viewed indegrees Fahrenheit or Centigrade (see ControllerConfiguration Menu in this section).

Fuel Rate submenu: This submenu displays thefuel rate which can be displayed in gallons per houror liters per hour (see Controller ConfigurationMenu in this section).

Coolant Pressure submenu: This submenu dis-plays the coolant pressure which can be viewed inPSI or kPA (see Controller Configuration Menu inthis section).

Barometric Pressure submenu: This submenudisplays the barometric pressure which can beviewed in inch of mercury (inHg) or kPa (see Con-troller Configuration Menu in this section).Boost Pressure submenu: This submenu dis-plays the boost pressure which can be viewed ininch of mercury (inHg) or kPa (see Controller Con-figuration Menu in this section).Intake Manifold submenu: This submenu dis-plays the intake manifold temperature which can beviewed in degrees Fahrenheit or Centigrade (seeController Configuration Menu in this section).Fuel Outlet Pressure submenu: This submenudisplays the fuel outlet pressure which can beviewed in PSI or kPA (see Controller ConfigurationMenu in this section).Active Time Delay submenu: This submenu dis-plays the time delay that is currently active: warmup, cool down, start or stop delays.


2-13

ENGINE MENU (Cont.)

Governor Trqnnn %

Fuel Temperaturennnn Deg F

Coolant Pressurennn PSI

Barometric Pressnnn InHg

Boost Pressnnn InHg

Fuel Ratennn.nn Gal/hr

CONTINUED

Intk Manifold Tempnnnn Deg F

Fuel Outlet Pressnnn PSI

Active Time DelayNone nnnn Sec

FIGURE 2-5. ENGINE MENU (CONT.)


2-14

ALTERNATOR MENUFigure 2-6 shows a block representation of the Al-ternator menu. If you press the button next to theword Alternator in the display, the first Alternatorsubmenu is displayed.As shown in the diagram, the Alternator menu haseleven submenus.

Press the buttons next to the and symbols in thedigital display to navigate between the menus.Press the Home button or the Previous Main Menubutton to return to Main Menu 1.

Line-to-Line Voltage submenu: The voltage Line-to-Line (L1, L2 and L3) are measured between L1 toL2, L2 to L3 and L3 to L1, respectively. (Singlephase L1 to L2 only.)Line-to-Neutral Voltage submenu: Note that theLine-to -Neutral column will not be displayed for a 3phase/3 wire system. Single phase L1 to N and L2to N.Amps submenu: All phases. (Single phase L1and L2 only.)Frequency submenu: Generator set output fre-quency.Total Real Power submenu: This submenu dis-plays the total amount of real power output, in kilo-watts (kW).Real Power submenu: This submenu displays theamount of real power output for L1, L2, and L3, inkilowatts (kW). (Single phase L1 and L2 only.)Total Apparent Power submenu: This submenudisplays the total amount of apparent power output,in kilovolt amps (kVA).Apparent Power submenu: This submenu dis-plays the amount of apparent power output for L1,L2, and L3, in kilovolt amps (kVA). (Single phase L1 and L2 only.)Total Power Factor submenu: This submenu dis-plays the power factor with leading/lagging indica-tion.The PF reading will contain an asterisk if the powerfactor is leading (for example, Total PF 0.9 * ).Power Factor submenu: This submenu displays apower factor value for L1, L2, and L3. (Singlephase L1 and L2 only.)The PF reading will contain an asterisk if the powerfactor is leading (for example, PF L1 0.9*).AVR Duty Cycle submenu: This submenu dis-plays the voltage regulator (drive) level in percent-age of maximum. (Where maximum is 100% DutyCycle, software clamps Duty Cycle maximum to60% for PMG and 90% for shunt.)


2-15

ALTERNATOR MENU

EngineAlternator

AdjustMore>>

Volts L12 L23 L31 V nnn nnn nnn

Volts L1N L2N V nnn nnn

Amps L1 L2 L3 nnn nnn nnn

Frequency nn.n Hz

Power L1 L2 L3kW nn.n nn.n nn.n

Total Power nnn kW

Total Power nn.n kVA

Power L1 L2 L3 kVA nn.n nn.n nn.n

Total PF n.nn*

PF L1 L2 L3 *n.nn *n.nn *n.nn

AVR Duty Cyclennn %

Main Menu 1

FIGURE 2-6. ALTERNATOR MENU


2-16

ADJUST MENUFigure 2-7 shows a block representation of the Ad-just menu. If you press the button next to the wordAdjust in the display, the first Adjust submenu isdisplayed.As shown in the diagram, the Adjust menu hasseven submenus. Each submenu includes a pa-rameter or value that can be changed.

Press the buttons next to the and symbols in thedigital display to navigate between the menus.Press the Home button or the Previous Main Menubutton to return to Main Menu 1.Adjusting Values/Parameters:1.. Press the button next to the symbol in the dis-

play until the + and symbols are displayed.2.. If necessary, press the button next to the or

symbols to move to the numeric character youwish to change.

3.. Press the button next to the + symbol to in-crease the value or select parameter; press thebutton next to the symbol to decrease the val-ue or select parameter.

4.. After adjusting values/selecting parameters,pressing the symbol results in the changesbeing saved. (When adjusting values, makesure the cursor is on the last numeric characterbefore pressing the symbol).If the Home button or Previous Main Menu but-ton is pressed before pressing the symbol,the changes are not saved.

Voltage Adjust submenu: Voltage can be ad-justed to 5 percent of the nominal voltage. For ex-ample, if genset output voltage is 208 volts, the volt-age can be adjusted from 198 to 218 volts.If the entered value is greater or less than the allowed(5%) range, the control will not accept the entry andwill return to the previous setting. Retry by entering asmaller change in one volt increments.Frequency Adjust submenu: Frequency can beadjusted to 5 percent of the nominal frequency.For example, if the genset frequency is 60.0 Hz, thefrequency can be adjusted from 57.0 to 63.0 Hz.Start Delay submenu: Start Delay can be set from0 to 300 seconds (default = 0). This function is by-passed during a manual start/stop sequence.Stop Delay submenu: Stop Delay can be set from0 to 600 seconds (default = 0). This function is by-passed during a manual start/stop sequence andengine shutdown faults.Rated To Idle: Rated To Idle delay can be set from 0to 10 seconds (default = 0). (Enter 1 or more to en-able.) Entering a non-zero delay will cause the gen-set to delay the transition to Cooldown At Idle.Idle Start submenu (Only available on somemodels): Idle Start can be enabled or disabled (de-fault = Disable). This function can only be used inmanual mode and can be enabled or disabled be-fore or during genset operation.Enabling Idle Start will cause the genset to run inidle mode until Idle Start is disabled. A warning isdisplayed if genset is left in idle more than 10 min-utes. Long periods of engine idling can eventuallyaffect engine performance and may void enginewarranty.The idle speed can be adjusted from 700 to 1100RPM (default of 800 RPM). Refer to Crank/Idle Set-up Menu in Section 5. A countdown timer is used tolimit engine idle time. With InPower, idle time can beadjusted from 0 to 60 minutes in 1 minute incre-ments.Keyswitch submenu: Used to turn Keyswitchpower to CM570 module on/off. To select OFF, gen-set speed must be zero.The keyswitch on/off control is intended to aid or beused in downloads to the CM570 module, via InSite.


2-17

Voltage Adjustnnn V

Frequency Adjustnn.n Hz

Start Delaynnn Sec

+Voltage Adjust nnn V

+Frequency Adjust nn.n Hz

+Start Delay nnn Sec

Back

Back

Back

ADJUST MENU

EngineAlternator

AdjustMore>>

Main Menu 1

Idle Start Disable

+Idle Start Enable

Back

Stop Delaynnn Sec

+Stop Delay nnn Sec

Back

Rated To Idle Delaynn Sec

+Rated To Idle Delay nn Sec

Back

Keyswitch On

+Keyswitch Off

Back

FIGURE 2-7. ADJUST MENU


2-18

FAULTS MENUFigure 2-9 shows a block representation of theFaults menu. Up to 20 of the most recent faults canbe viewed. An example of how a fault code is dis-played is shown in Figure 2-8.The available menus are dependent on the numberof faults that have occurred. If there are no faults, the symbol next to the

word Faults is not displayed and no Faultmenus are available.

If more than one fault has occurred, pressthe button next to the word Fault in thescreen display to view the Faults Main Menu.As shown in the diagram, the Faults MainMenu has two submenus. Press the PreviousMain Menu button to return to the FaultsMain Menu. Press the Previous Main Menubutton a second time to return to MainMenu 2.

Press the Home button at any time to return to MainMenu 1.

History submenu: From the Faults Main Menu,press the button next to the word History in the dis-play to view up to twenty of the most recent ac-knowledged faults. Press the buttons next to the and symbols in the digital display to navigate be-tween the menus. Press the Previous Main Menubutton to return to the Faults Main Menu.

Current Fault submenu: From the Faults MainMenu, press the button next to the word Current inthe display to view up to twenty of the most recentunacknowledged faults. Press the Previous MainMenu button to return to the Faults Main Menu.

FAULTDESCRIPTION

W = WARNINGS = SHUTDOWN

ASTERISK =ACTIVE FAULT

HOUR FAULTOCCURRED

FAULTCODE

FIGURE 2-8. HISTORY/CURRENT FAULT SUBMENU


2-19

FaultsSystem

HistoryMore>>

FAULTS MENU

Main Menu 2

History

nnnnn @Hr nnnnn.nW xxxxxxxxxxxxxxxxxxxx


nnnnn @Hr nnnnn.nS xxxxxxxxxxxxxxxxxxxx

Fault 1

Fault 2

Fault 20

Faults Main Menu

Current



Fault 2

Fault 20

nnnnn @Hr nnnnn.nS xxxxxxxxxxxxxxxxxxxx

Fault 1

FIGURE 2-9. FAULTS MENU


2-20

SYSTEM MENUFigure 2-10 shows a block representation of theSystem menu. If you press the button next to theword System in the display, the System MainMenu is displayed. This menu is displayed only ifthe network communications module (NCM) fea-ture is installed. The System Main Menu allows youto view the status and load of other PCC equipmentconnected on a common network with the PCC2100 control.As shown in the diagram, the System Main Menuhas three submenus.When viewing ATS and Genset System submenus,press the buttons next to the and symbols in thedigital display to navigate between the menus.Press the Previous Main Menu button to return tothe System Main Menu. Press the Previous MainMenu button a second time to return to MainMenu 2. Press the Home button to return to MainMenu 1.

ATS System submenus: From the System MainMenu, press the button next to the word ATS in thedisplay to view the first of up to 16 ATS System sub-menus. An ATS system must be available in the net-work to display this submenu.

The ATS submenu allows viewing of the transferswitch name (configured with InPower), kW load (ifmonitored by the ATS system), status (e.g., not inauto), and source connected and availability (ON =source connected, OK = source available, or NA =source not available).

Master System submenu: From the System MainMenu, press the button next to the word Master inthe display to view the Master System submenu. Amaster controller must be available in the networkto display this submenu.

The master submenu allows viewing of the mastercontroller name (configured with InPower), kW loadand operational state.

Genset System submenus: From the SystemMain Menu, press the button next to the word Gen-set in the display to view the first of up to 16 GensetSystem submenus. One genset must be availablein the network to display this submenu.

The genset submenu allows viewing of the gensetname (configured with InPower), kW load and op-erational state.


2-21

ATSMaster

Genset

FaultsSystem

HistoryMore>>

SYSTEM MENU

Main Menu 2

System Main Menu

ATSnameTag01>nnnnkWNon Auto S1=On, S2=On

ATSnameTag02>nnnnkWNonAut o S1=Ok, S2=NA

GensetName01>nnnnkWWarning Fail2Start

GensetName02>nnnnkWNonAuto Alarm

ATSnameTag16>nnnnkWNonAuto S1=Ok, S2=NA

ATS Menu 1

ATS Menu 2

ATS Menu 16

GensetName16>nnnnkWNonAuto Alarm

Genset Menu 1

Genset Menu 2

Genset Menu 16

Master>nnnn kWShutdwn N=On,E=NA

FIGURE 2-10. SYSTEM MENU


2-22

HISTORY MENU

Figure 2-11 shows a block representation of theHistory menu. If you press the button next to theword History in the display, the first History subme-nu is displayed.

As shown in the diagram, the History menu has fivesubmenus. This information is stored in non-volatilememory and will not be deleted due to loss of bat-tery power.

Press the buttons next to the and symbols in thedigital display to navigate between the menus.Press the Previous Main Menu button to return toMain Menu 2. Press the Home button to return toMain Menu 1.

Number of Starts submenu: This submenu showsthe number of engine starts.

Engine Hours submenu: This submenu showsthe number of operating hours for the engine.

Control Hours submenu: This submenu showsthe number of operating hours for the control.

Kilowatt Hours submenu: This submenu showsthe number of kilowatt (kW) or megawatt (MW)hours.

Genset Duty Cycle submenu: This submenushows the percent of genset operating hours thatare less than 30 percent of rated load and percent ofhours that are greater than 90 percent.


2-23

FaultsSystem

HistoryMore>>

HISTORY MENU

Main Menu 2

Number Startsnnnnn

Engine Hours nnnnn Hours

Control Hours nnnnn Hours

kW Hours nnnnn kW Hrs

Genset Duty Cycle Hr 90:nn%

FIGURE 2-11. HISTORY MENU


2-24

ABOUT MENUFigure 2-12 shows a block representation of theAbout menu. If you press the button next to the wordAbout in the display, the first About submenu isdisplayed.As shown in the diagram, the About menu has threesubmenus.

Press the buttons next to the and symbols in thedigital display to navigate between the menus.Press the Previous Main Menu button to return toMain Menu 3. Press the Home button to return toMain Menu 1.

Model submenu: This submenu shows the gensetmodel.

Rating submenu: This submenu shows the rating(Standby or Prime) and number of kilowatts (kW)).

Software Version submenu: This submenushows the software version level. This informationis required to service the generator set.


2-25

AboutPwr Tran

SetupMore>>

ABOUT MENU

Main Menu 3

Modelxxxxxxxxxxxxxxx

RatingStandby nn.n kW

Software Versionnn.nnn

FIGURE 2-12. ABOUT MENU


2-26

THIS PAGE LEFT INTENTIONALLY BLANK


3-1

3. Circuit BoardsGENERAL

WARNING HAZARDOUS VOLTAGE. Touching

uninsulated parts inside the control panel boxcan result in severe personal injury or death.Measurements and adjustments must be donewith care to avoid touching hazardous voltageparts.Stand on a clean dry wooden platform or cleanrubber insulating mat, make sure your clothingand shoes are dry, remove jewelry and use toolswith insulated handles.

This section describes the function of the Power-Command 2100 Control (PCC) base circuit boardthat is contained in the control panel box (Figure3-1). The block diagram in Figure 3-2, shows the ex-ternal connections of the PCC system. The systemschematics are provided in Section 8 of this manu-al.

CAUTION Electrostatic discharge will damage

circuit boards. Always wear a grounding wriststrap when touching or handling circuit boards.

BASEBOARD

DISPLAYBOARD

BARGRAPH BOARD(OPTIONAL)

INDICATORBOARD

FRONT CONTROLPANEL ASSEMBLY

(MEMBRANE BUTTONS)

CONTROLPANEL BOX

FIGURE 3-1. CIRCUIT BOARD LOCATIONS


3-2

FIGURE 3-2. BLOCK DIAGRAM


3-3

CONTROL SYSTEM OVERVIEWThe generator set control system consist of thePCC control and the engine control module(CM570). The block diagram in Figure 3-3 showsthe external connections between the PCC Baseboard and the CM570 module.

The PCC provides: Voltage regulation, Alternator/genset protection and diagnostics, Speed governing (via, CM570 module) Starter control

The engine control CM570 module provides: Fuel system/combustion control Engine protection and diagnostics Speed sensor processing

CAN/J1939 DatalinkInformation transferred over the data link is used bythe PCC to display engine status (sensor, warningand shutdown conditions). The datalink mustremain active at all times. If not, the PCC will detectthe inactive datalink and display a datalink errorshutdown condition.

Fuel Shutoff (FSO) Valve ControlWith the O/Manual/Auto switch in either the Manualor Auto position, the FSO relay will be energized, al-lowing the CM570 module to energize the FSO so-lenoid/valve and start fueling. The only time thePCC will open the FSO relay to stop fueling is duringan Emergency Stop or Stop controller mode.In the event that the CM570 module is locked andthe FSO driver is stuck on, the PCC will sense thatthe CM570 module is not responding and will shut-down the system by de-energizing the FSO relay.

Keyswitch ControlThe Keyswitch input to the CM570 module remainsactive during all controller modes (EmergencyStop, O/Manual/Auto) other than when the PCCSleep Mode is active. The Keyswitch input is con-trolled by the Keyswitch Relay which is energizedby the PCC Keyswitch Relay Driver.The Keyswitch input is required to be independentof the Emergency Stop switch in order to maintaintransmission of engine data during the emergencyshutdown. When resetting the PCC after the emer-gency stop, the PCC will de-energize the KeyswitchRelay for a predetermined time. This will reset anyE-stop conditions in the CM570 module.

PCC BASE BOARD

ESTOPSUPPLY

FSO RELAYDRIVER

KEYSWITCHRELAY DRIVER

CAN/J1939 DATALINK

FUEL SHUTOFF (FSO)SOLENOID/VALVE

KEYSWITCHRELAY

B+

FSO RELAY

B+

CM570 MODULE

FSO DRIVER

KEYSWITCHINPUT

FIGURE 3-3. CONTROL SYSTEM BLOCK DIAGRAM


3-4

BASE BOARDThe following paragraphs describe the Base boardconnectors (J), fuses (F) and terminal boards (TB)shown in Figure 3-3.

J6NCM

J4DIGITAL DISPLAY

J2LED BOARD &

BARGRAPH

J1HARNESSS12, S13

J9InPOWER

J3MEMBRANE

F4

F1 F2 F3J7

ENGINE J8 ACGENERATOR

TB2 TB1CUSTOMER CONNECTIONS

F4

XX

XX = F5 (PCB P/N 300-5381)RS1 (PCB P/N 327-1379)

J10CM570

DATALINK

FIGURE 3-3. BASE BOARD


3-5

Connector J1J1 connects to the Emergency Stop switch (S13)and the O/Manual/Auto control panel switch (S12).

WIRE TABULATIONSIGNAL FROM TO

GND S12-4 J1-8OFF (O) S12-1 J1-7MANUAL S12-3 J1-6

AUTO S12-5 J1-5ESTOP-NC1 S13-1 J1-2ESTOP-NC2 S13-2 J1-1ESTOP-NO1 S13-3 J1-3ESTOP-NO2 S13-4 J1-4

J1

EMERGENCY STOPSWITCH

O/MANUAL/AUTOSWITCH

PIN 1

S13S12

15

3

4

1 4

32

BASEBOARD

PIN 2

FIGURE 3-4. CONNECTOR J1 (CONTROL HARNESS)


3-6

Connector J2J2 connects to LED (indicator) board and bargraphboard of front control panel assembly.

PIN 1

BASEBOARD

PIN 15

J2

FIGURE 3-5. J2 LED/BARGRAPH CONNECTOR

Connector J3J3 connects to membrane buttons of front controlpanel assembly.

PIN 10

BASEBOARD

J3

FIGURE 3-6. J3 MEMBRANE CONNECTOR

CONNECTOR J2PIN SIGNAL1 MOSI

2, 4, 6, 16 GND3 SCK5 SEL_A7 SEL_B

10, 14, 15 VCC9 SEL_C11 SEL_D13 BAR_ENABLE

CONNECTOR J3PIN SIGNAL1 HOME MENU

3-7

Connector J4

J4 connects to display menu of front control panelassembly.

PIN 1

BASEBOARD

PIN 13

J4

FIGURE 3-7. J4 DISPLAY MENU CONNECTOR

CONNECTOR J4PIN SIGNAL1 GND2 VCC3 N.U.4 RS5 R/W6 ENABLE DISPLAY7 D[0]8 D[1]9 D[2]10 D[3]11 D[4]12 D[5]13 D[6]14 D[7]


3-8

Connector J7J7 connects to the generator CTs, engine battery,K4 (starter) and K10 (fuel) pilot relays.

PIN 1

BASEBOARD

PIN 4

PIN 36

J7

FIGURE 3-8. J7 HARNESS CONNECTOR

CONNECTOR J7PIN SIGNAL

5, 6, 7, 8 GND (Base Bd)1, 2, 3, 4 B+ IN (Base Bd)

910

GEN SW B+FUEL SOL B (K10-6)

1112

CT1CT1COM

1516

CT2CT2COM

18 ALT FLASHOUT1920

CT3CT3COM

2327

GEN SW B+ (K4-S1)START SOL B (K4-S2)


3-9

Connector J8J8 connects directly to the generator to monitor andcontrol AC output of the genset.

PIN 1

BASEBOARD

PIN 4

PIN 24

J8

FIGURE 3-9. J8 AC GENERATOR CONNECTOR

CONNECTOR J8PIN SIGNAL COMMENTS412207

U1 (T1)V2 (T2)W3 (T3)N (T4)

Used for alternatorvoltage sensing andpower factor anglesensing

135

FIELD +FIELD

Excitation drive output

212223

AC2 (PMG2)AC3 PMG3)AC4 (PMG4)

Used for excitationpower (Shunt con-nection pins 21 &22 only)

TABLE 3-1. BASE BOARD FUSESREFERENCE

DESIGNATIONRATING FUNCTION

F1 10A Customer B+ (to TB1 customer terminal block)F2 5A Customer switched B+ (to TB1 customer terminal block)F3 2A Switched B+ (to K4 Starter Pilot relay & coolant heater control turns off coolant

heater during genset operation)F4 5A Base board power supply fuse

TB1 Customer Connections

Customer monitor/control connections are at-tached to terminal board TB1. Optional equipment

such as sensing devices used to monitor genset op-eration, remote start/stop switches and etc. are at-tached to this terminal. Refer to Customer Connec-tions diagram in Section 8 for TB1 connections.


3-10

THIS PAGE LEFT INTENTIONALLY BLANK


4-1

4. TroubleshootingGENERAL

The PowerCommand 2100 Control (PCC) contin-uously monitors the generator set for abnormal con-ditions, such as high or low frequency, voltage, cur-rent and also engine faults via the CM570 enginecontrol module. If any of these conditions occur, thePCC will light a yellow Warning lamp or a red Shut-down lamp and display a message on the digital dis-play panel.

INPOWER SERVICE TOOL

The InPower service tool can be used in trouble-shooting to perform tests, verify control inputs andoutputs, and test protective functions. Refer to theInPower Users Guide, provided with the InPowersoftware for test procedures.

InPower, when used improperly, can cause symp-toms like warnings and shutdowns that appear to bea defective base board. When these problems oc-cur, always verify that a self-test or fault simulation(override) have not been left enabled with InPower.If you do not have InPower, or the enabled fault sim-ulation(s) can not be found using InPower, discon-nect battery power to disable the test or overridecondition.

Make sure that parameter adjustments and time de-lays, related to the fault condition, have been appro-

priately set for the application. It may be necessaryto write the initial capture file to the device or updatethe calibration file.

Updating a calibration file requires the InPower Proversion. Confirm that the installed calibration partnumber matches the serial plate information.

CAUTION Using the wrong calibration file can

result in equipment damage. Do not swap Baseboards from another genset model and only usethe calibration file shown on the nameplate.

Some features are not available until the hardwarefor that feature is installed and InPower Pro is usedto update (enable) that feature. Confirm that thefeature is installed and enabled prior to trouble-shooting the base board for symptoms related to afeature.

NETWORK APPLICATIONS ANDCUSTOMER INPUTS

In applications with networks and remote customerinputs, the genset may start unexpectedly or fail tocrank as a result of these inputs. These symptomsmay appear to be caused by the base board. Verifythat the remote input is not causing the symptom orisolate the control from these inputs before trouble-shooting the control.


4-2

SAFETY CONSIDERATIONSWARNING

Contacting high voltage compo-nents can cause electrocution, resulting in se-vere personal injury or death. Keep the outputbox covers in place during troubleshooting.High voltages are present when the genset is run-ning. Do not open the generator output box whilethe genset is running.

WARNING Ignition of explosive battery gases

can cause severe personal injury or death. Arc-ing at battery terminals, light switch or otherequipment, flame, pilot lights and sparks can ig-nite battery gas. Do not smoke, or switchtrouble light ON or OFF near battery. Dischargestatic electricity from body before touching bat-teries by first touching a grounded metal sur-face.Ventilate battery area before working on or nearbatteryWear gogglesStop genset and dis-connect charger before disconnecting batterycablesDisconnect negative () cable first andreconnect last.

CAUTION Disconnect battery charger from AC

source before disconnecting battery cables.Otherwise, disconnecting cables can result involtage spikes damaging to DC control circuitsof the genset.

WARNING Accidental starting of the generator

set can cause severe personal injury or death.Prevent accidental starting by disconnectingthe negative () cable from the battery terminal.

When troubleshooting a generator set that is shutdown, make certain the generator set cannot be ac-cidentally restarted as follows:

1. Move the O/Manual/Auto switch on the controlpanel to the O position.

2. Turn off or remove AC power from the batterycharger.

3. Remove the negative () battery cable from thegenerator set starting battery.


4-3

TROUBLESHOOTING PROCEDUREThe following tables are a guide to help you evalu-ate problems with the generator set. You can savetime if you read through the manual ahead of timeand understand the system.Try to think through the problem. Go over what wasdone during the last service call. The problem couldbe as simple as a loose wire, an opened fuse or atripped circuit breaker.

NOTE: Each fault code warning can be changed toshutdown using InPower. Default settings areused in this manual. It is recommended that allchanges to settings be recorded at each site to aid inthe troubleshooting of the genset.

This section contains the following information: Table 4-1 and 4-2: Describes how to trouble-

shoot a local/remote fail to crank problem whencontrol panel does not indicate fault condition.

Table 4-3: Provides a list of the CM570 enginecontrol module fault codes that are sent to thePCC2100. Troubleshooting procedures forthese faults are found in the engine servicemanual.

Table 4-4: Describes each generator status,warning and shutdown code, warning and

shutdown limits where applicable, and basiccorrective actions, such as, control reset func-tions, battery connections, etc.

Fault Code Tables: Provide detailed trouble-shooting procedures for generator faults listedin Table 4-4. In the following tables, the faultcodes are used as the table reference numberand are arranged in numeric order.

Figure 4-1 shows the location of the componentswithin the control panel that are referenced in thefollowing troubleshooting procedures. Connectorlocations for each circuit board are provided in Sec-tion 3. The control wiring and circuit board connec-tions are shown in Section 8.

CAUTION Always set the O/Manual/Auto

switch to the O position before disconnectingor connecting harness connectors. Otherwise,disconnecting the harness connectors can re-sult in voltage spikes high enough to damagethe DC control circuits of the set.

CAUTION Electrostatic discharge will damage

circuit boards. Always wear a wrist strap whenhandling circuit boards or when disconnectingor connecting harness connectors. See CircuitBoard Removal/Replacement in Section 5.


4-4

BASEBOARD

DISPLAYBOARD

BARGRAPH BOARD(OPTIONAL)

INDICATORBOARD

FRONT CONTROLPANEL ASSEMBLY

(MEMBRANE BUTTONS)

O/MANUAL/AUTOSWITCH (S12)

TB2 (16) TB1 (122)

EMERGENCY STOPBUTTON

CHASSIS GROUNDSCREW

AUX RELAYS(OPTIONAL)LOCATION

CONTROL ALIVEINDICATOR

RELAYS MOUNTED ONBACK OF CONTROL

K11 K10

KEYSWITCHPILOT RELAY FSO PILOT

RELAY

FIGURE 4-1. PCC CONTROL COMPONENTS

Relay K10Fuel Shutoff (FSO) relay is used by the PCC Baseboard and the engine control (CM570) module tocontrol the fuel shutoff valve of the engine. K10 ispart of the engine harness assembly.

Relay K11The Keyswitch Pilot relay, which is energized by thePCC Base board, controls the Keyswitch input tothe CM570 module. K11 is part of the engine har-ness assembly.


4-5

WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injuryor death. Only trained and experienced service personnel with knowledge of fuels, electricity, and ma-chinery hazards should perform service procedures. Read Safety Precautions page and observe allinstructions and precautions in this manual.

TABLE 4-1. ENGINE DOES NOT CRANK IN MANUAL MODE(NO FAULT MESSAGE)

Reason: This indicates that the PCC has not received or recognized a manual start signal.Effect: Engine will not start.

POSSIBLE CAUSE CORRECTIVE ACTION

1. No power supplied to control. (ControlAlive indicator on Base board is notflashing.)

1a. Poor battery cable connections. Clean the battery cable terminalsand tighten all connections.

1b. Remove F4 and check continuity. If open, replace the fuse with oneof the same type and amp rating (5 Amps).If F4 is OK, remove connector P7 and check for B+ at P7-1 throughP7-4 and GND at P7-5 through P7-8. If B+ or ground missing,iso-late to harness and TB BAT terminal mounted on engine block.If B+ and ground check OK, Base board may be defective. Cyclepower to Base board by reconnecting P7. If Control Alive indicatordoes not blink, replace Base board.

2. Base board not properly calibrated orcorrupt calibration. (Control Alive indica-tor flashes every 1/2 second.)

2. Confirm that the installed calibration part number matches the seri-al plate information. Re-enter calibration file if necessary. (Whenproperly installed, Control Alive indicator flashes every second.)

3. The Emergency Stop switch or wiring isdefective.

3. With Emergency Stop push button not activated, remove connec-tor P1 and check for continuity between P1-1 (ESTOP-NC1) andP1-2 (ESTOP-NC2). (If circuit is open, the control will detect a localE-Stop condition but will not display the E-Stop condition.) If circuitis open, isolate to Emergency Stop switch and wiring.If there is continuity, go to next step.

4. The Manual input is not getting from theManual select switch (S12) to the Baseboard indicting that S12, Base board orthe harness is bad.

4. With S12 in Manual, remove connector P1 from the Base boardand check for continuity from P1-6 (MAN) to P1-9 (GND). If no con-tinuity, isolate to switch and wiring.If there is continuity, go to next step.

5. The Manual Run/Stop button, harnessor the Base board is bad.

5. Remove connector P3 from the Base board and check for continu-ity from P3-9 (MAN RUN/STOP) to P3-10 (GND). If no continuitywhen pressing the Manual Run/Stop button, replace front mem-brane panel. If there is continuity (200 ohms or less), the Baseboard is bad.


4-6

WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injuryor death. Only trained and experienced service personnel with knowledge of fuels, electricity, and ma-chinery hazards should perform service procedures. Read Safety Precautions page and observe allinstructions and precautions in this manual.

TABLE 4-2. ENGINE DOES NOT CRANK IN REMOTE MODE(NO FAULT MESSAGE)

Reason: This indicates that the PCC has not received or recognized a remote start signal.Effect: Engine will not start in remote mode, but starts in manual mode.

POSSIBLE CAUSE CORRECTIVE ACTION

1. The remote start switch or customer wir-ing is faulty.

1. Reset the control. Attempt to start, and check for ground at TB1-1.If ground level is not present, isolate to the remote switch or cus-tomer wiring. Repair as necessary.If ground is present, go to next step.

2. The Auto mode input is not getting fromthe Auto select switch (S12) to the Baseboard indicting that S12, Base board orthe harness is bad.

2. With S12 in Auto, remove connector P1 from the Base board andcheck for continuity from P1-5 (AUTO) to P1-9 (GND). If no conti-nuity, isolate to switch or wiring harness. If there is continuity, theBase board is bad.


4-7

TABLE 4-3. CM570 ENGINE CONTROL MODULE FAULT CODES *

CODE LAMP FAULT DESCRIPTION111 Shtdn Internal ECM error122 Wrng Manifold air press sensor high123 Wrng Manifold air press sensor low135 Wrng Oil pressure sensor high141 Wrng Oil pressure sensor low143 Wrng Low oil pressure144 Wrng Coolant temp sensor high145 Wrng Coolant temp sensor low146 Wrng High coolant temp warning151 Shtdn High coolant temp alarm152 Wrng Low coolant temp153 Wrng Manifold air temp sensor high154 Wrng Manifold air temp sensor low155 Shtdn Manifold air temp alarm187 Wrng Sensor supply 2 low197 Wrng Coolant level warning212 Wrng Oil temperature sensor high213 Wrng Oil temperature sensor low214 Shtdn High oil temperature219 Wrng Oil tank level low221 Wrng Air pressure sensor high222 Wrng Air pressure sensor low223 Wrng CORS value driver shorted low227 Wrng Sensor supply 2 high234 Shtdn Overspeed235 Shtdn Coolant level alarm236 Shtdn Position sensor

254** Shtdn Fuel shutoff valve255** Wrng High FSO voltage259 Wrng Fuel shutoff valve284 Wrng Crankshaft sensor supply low295 Wrng Air pressure sensor error341 Wrng ECM data lost343 Wrng Internal ECM error

CODE LAMP FAULT DESCRIPTION352 Wrng Sensor supply 1 low378 Shtdn Front fueling act undercurrent379 Shtdn Front fueling act overcurrent386 Wrng Sensor supply 1 high394 Shtdn Front timing act undercurrent395 Shtdn Front timing act overcurrent396 Shtdn Rear fueling act undercurrent397 Shtdn Rear fueling act overcurrent398 Shtdn Rear timing act undercurrent399 Shtdn Rear timing act overcurrent415 Shtdn Low oil pressure alarm419 Wrng Intake mfld pres imbalance421 Wrng High oil temperature422 Wrng Coolant level sen data error426 None CAN datalink error433 Wrng Intake mfld data error434 Wrng Power lost with ignition435 Wrng Oil pressure data error449 Wrng High fuel supply pressure482 Wrng High fuel supply pressure488 Wrng High intake manifold temp496 Wrng Camshaft speed sensor supply

voltage problem546 Wrng Fuel pressure sensor high547 Wrng Fuel pressure sensor low689 Wrng Crankshaft sensor error697 Wrng ECM internal temp sen high698 Wrng ECM internal temp sen low731 Wrng Cam/Crank misalignment778 Wrng Camshaft sensor

1245** Shtdn CAN - Engine shutdown1248 Wrng CAN - Engine warning cond

* Refer to engine service manual for troubleshooting.** Refer to detailed troubleshooting procedure in this section.


4-8

Hazards present in troubleshooting can cause equipment damage, severe personalinjury or death. Only trained and experienced service personnel with knowledge of fuels, electric-ity, and machinery hazards should perform service procedures. Read Safety Precautions pageand observe all instructions and precautions in this manual.

WARNING

TABLE 4-4. WARNING AND SHUTDOWN CODES

FAULT CODE CORRECTIVE ACTION

427CAN DATALINK LOSTMESSAGESLamp: Warning

Datalink fault. Indicates that important data was lost between the Base board andthe CM570 engine control module. (Refer to detailed troubleshooting procedure inthis section.)

781CAN DATALINK FAILEDLamp: Shutdown

Datalink failure. No communications between the Base board and the CM570 en-gine control module. (Refer to detailed troubleshooting procedure in this section.)

1123SHUTDOWN AFTER BSLamp: Shutdown

A shutdown fault occurred while Battle Short was enabled and Battle Short transi-tioned from enabled to disabled. Review Fault History and perform corrective ac-tion.

1124DELAYED SHUTDOWNLamp: Warning

A shutdown fault became active while the Delayed Shutdown feature was en-abled. The shutdown will be delayed by the delayed shutdown time entered. Re-view Fault History and perform corrective action.

1131BATTLE SHORT ACTIVELamp: Warning

Indicates that the control is in Battle Short mode used to bypass several criticalfault shutdowns for genset operation during emergencies. No corrective actionneeded. (Refer to Battle Short Mode description in Section 2.)

1245CANENGINE SHUTDOWNLamp: Shutdown

The CM570 engine control module indicated to the PCC that it is shutting downthe engine but did not send any other fault condition over the datalink. (Refer todetailed troubleshooting procedure in this section.)

1311, 1312, 1317, 1318CUSTOMER INPUT #1 #4Lamp: Warning/Shutdown ornone for status message.

The nature of the fault is an optional customer selection. Example inputs: LowFuel Day Tank, Water In Fuel, Ground Fault, Low Starting Hydraulic Pressure,Low Starting Air Pressure, etc.Each of the fault functions can be programmed (using service tool), as follows:

Enable/disable input (Default: enable) Status, Warning or Shutdown (Default: #1None, #2 thru #4Warning) Active closed or open (Default: closed [ground]) Change display name using up to 19 characters (Default: #1 Customer Fault 1,

#2Ground Fault, #3Low Fuel, #4Rupture Basin Fault)1313 1316NETWORK FAULT 1 thru 4Lamp: Warning/Shutdown ornone for status message.

Indicates network input (#1#4) is in an active state.Each of the fault functions can be programmed (using service tool), as follows: Status, Warning or Shutdown Change display name using up to 19 characters

1334CRIT SCALER ORLamp: Shutdown

Incorrect feature or calibration was entered into control.

1335NONCRIT SCALER ORLamp: Warning

Incorrect feature or calibration was entered into control.


4-9


WARNING

TABLE 4-4. WARNING AND SHUTDOWN CODES (CONT.)


1416FAIL TO SHUTDOWNLamp: Warning

Genset continues to run after receiving shutdown command from the controller.Battle Short feature enabled used to bypass several critical fault shutdowns forgenset operation during emergencies. (Refer to Battle Short Mode description inSection 2.)

1417POWER DOWN ERRORLamp: Warning

Indicates that the controller can not power down because of some unknown condi-tion. Possible drain on battery. Replace Base board.

1433EMERGENCY STOPLamp: Shutdown

Indicates local Emergency Stop. To reset the local/remote Emergency Stop button:1. Pull the Emergency Stop button out.

2. Move the O/Manual/Auto switch to O.

3. Press the front panel Fault Acknowledge/Reset button.

4. Return O/Manual/Auto switch to desired position.1434REMOTE E-STOPLamp: Shutdown

Indicates remote Emergency Stop. See code 1433 to reset.

1438FAIL TO CRANKLamp: Shutdown

Indicates possible fault with control, speed sensing or starting system. (Refer todetailed troubleshooting procedure in this section.)

1442WEAK BATTERYLamp: Warning

Indicates that during cranking, the battery voltage is at or below the weak batterywarning trip point for a time greater than or equal to the weak battery set time. Seecode 441 for corrective action.

1443BATTERY FAILEDLamp: Shutdown

Dead battery engine will not start. See code 441 for corrective action.

1444KW OVERLOADLamp: Warning

Indicates that generator output power exceeded 105% of genset rating.Check load and load lead connections.

1445SHORT CIRCUITLamp: Shutdown

Indicates that generator output current has exceeded 175% of rated.Check load and load lead connections. (Fault may not reset for several minutes.)

1446HIGH AC VOLTAGELamp: Shutdown

Indicates that one or more of the phase voltages has exceeded 130% of nominal,or has exceeded 110% of nominal for 10 seconds. (Refer to detailed troubleshoot-ing procedure in this section.)

1447LOW AC VOLTAGELamp: Shutdown

Indicates that one or more of the phase voltages has dropped below 85% of nomi-nal for 10 seconds. (Refer to detailed troubleshooting procedure in this section.)

1448UNDER FREQUENCYLamp: Shutdown

Indicates that engine speed has dropped below 90% of nominal for 10 seconds.Check fuel supply, intake air supply and load.


4-10


WARNING



1449OVER FREQUENCYLamp: Warning

Indicates frequency is 10% above base frequency for 20 seconds. (Refer to de-tailed troubleshooting procedure in this section.)

1459REVERSE POWERLamp: Shutdown

Indicates improper CT phasing. Check wiring to voltage sense circuit. Refer to CTInstallation in Section 5.

1461LOSS OF FIELDLamp: Shutdown

Indicates loss of field (electric) due to reverse kVAR.

1466MODEM FAILURELamp: Warning

Indicates that control can not communicate with the modem. Check for open, shortcircuit to ground, and loose connections to the modem.

1468NETWORK ERRORLamp: Warning

Indicates momentary loss of communication from the LonWorks Network. Refer tothe LonWorks Network publications for more specific troubleshooting methods.

1469SPEED/HZ MATCHLamp: Shutdown

Indicates that measured speed and measured AC output frequency do not agree.Check calibration file.

1471OVER CURRENTLamp: Warning

Indicates that generator output current has exceeded 110% of rated for 60 sec-onds.Check load and load lead connections.

1472OVER CURRENTLamp: Shutdown

Indicates that generator output current has exceeded 110% of rated, and that acontrol time/current calculation has initiated an overcurrent shutdown.Check load and load lead connections. (Fault may not reset for several minutes.)

2323 2326NETWORK FAULT 5 thru 8Lamp: Warning/Shutdown ornone for status message.

Indicates network input (#5#8) is in an active state. See 13131316 fault codecorrective action.

2335EXCITATION FAULTLamp: Shutdown

Indicates a loss of all three voltage sense leads or failure in excitation circuit.Check field wiring (X1 and X2) for shorts or opens.

2336MEMORY ERRORLamp: Shutdown

Indicates control memory error. Data corruption of critical operating parameters.Try reloading calibration file.

2341HIGH CONTROL TEMPLamp: Warning

Control temperature is above normal (158 F [70 C]) for a time greater than con-trol temperature set time. Check genset room air flow.

2342TOO LONG IN IDLELamp: Warning

Indicates genset has been in Idle mode too long. Exit idle mode.


4-11


WARNING



2967GOVERNOR FAULTLamp: Warning

Governor hardware drive circuitry contains a fault condition.

2968AVR FAULTLamp: Warning

Indicates AVR hardware contains a fault condition.

2969LON FAILURELamp: Warning

Indicates no communications with LonWorks board.

2972FIELD OVERLOADLamp: Shutdown

AVR Field has been at Max Field for a time greater than the allowed Max FieldTime.


960-0522 qsx15 service

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