Codigos de Falla Generador Cummins

Service Manual

Generator Set

GGLAGGLB

with PowerCommand 2100 Controller

English 42008 9630501 (Issue 3)

iTable of Contents

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

SPECIFICATIONS v. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust Menu 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Faults Menu 2-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Menu 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . History Menu 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . About Menu 2-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Transfer Menu 2-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Control Module (ECM) 2-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 CIRCUIT BOARDS AND MODULESGeneral 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Base Board 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

The engine exhaust from this productcontains chemicals known to the State

of California to cause cancer, birth defects or other reproductive harm.

! !

ii

SECTION TITLE PAGE5 POWER TRANSFER CONTROL (PTC) TROUBLESHOOTING

General 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PTC Module 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sequence of Events 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting using Fault Codes 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PTC Fault Code Troubleshooting Procedure 5-3. . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting with Symptoms 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Source 1 Power Fails, But Genset Does Not Start 5-9. . . . . . . . . . . . . . . . . . . Genset Starts, But Does Not Assume Load 5-11. . . . . . . . . . . . . . . . . . . . . . . . PTC Module Does Not Retransfer When Source 1 Utility Power Is Restored After A Power Failure Or On Initial Installation 5-13. . . . . . . . Genset Continues To Run After Retransfer Of Load To S1 Utility 5-15. . . . . . Genset Starts During Normal Power Service 5-15. . . . . . . . . . . . . . . . . . . . . . . Generator Test Runs But Genset Does Not Assume Load 5-15. . . . . . . . . . . .

6 CONTROL ADJUSTMENT AND SERVICEGeneral 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Board Removal/Replacement 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Modifying Setup Submenus 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Password Submenu 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crank/Idle Setup Menu 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Governor/Regulator Setup Menu 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Transfer Setup Menu 6-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PCC Control Panel Box Components (Standard/Optional) 6-14. . . . . . . . . . . Engine Sensors 6-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Magnetic Speed Pickup Unit (MPU) 6-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Current Transformer (CT) Installation 6-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 SERVICING THE GENERATORTesting the Generator 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Isolating AC Output Problems to Generator or Regulator 7-2. . . . . . . . . . . . . . Generator Disassembly 7-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Reassembly 7-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing the PMG 7-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 BASIC CONTROL (2-WIRE REMOTE)General 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Voltage Regulator 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Control Module (ECM) 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Sensors and DC Supply Connections 8-4. . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 FUEL PRESSURE AND MIXTURE ADJUSTMENTSFuel Systems Beginning Spec C 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gas Supply Pressure 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System Components 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Mixture Adjustment 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Systems Prior to Spec C 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 WIRING DIAGRAMS

iiiMS-4

IMPORTANT SAFETY INSTRUCTIONSSAVE 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.

DANGER This symbol warns of immediatehazards that will result in severe personal injuryor death.

WARNING This symbol refers to a hazard orunsafe practice that can result in severe per-sonal injury or death.

CAUTION This symbol refers to a hazard orunsafe practice that can result in personal inju-ry or 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 cop-per piping on flexible lines as copper will becomebrittle if continuously vibrated or repeatedly bent.

Natural gas is lighter than air, and will tend to gatherunder hoods. Propane is heavier than air, and will

tend to gather in sumps or low areas. NFPA code re-quires all persons handling propane to be trainedand qualified.

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 frommoving 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. Jewelry can short out elec-trical contacts and cause shock or burning.

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

iv

ELECTRICAL SHOCK CAN CAUSESEVERE PERSONAL INJURY OR DEATH

Remove electric power before removing protectiveshields 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.

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 only throughan approved isolation switch or an approved paral-leling device.

GENERAL SAFETY PRECAUTIONS

Coolants under pressure have a higher boiling pointthan 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.

Benzene and lead, found in some gasoline, havebeen identified by some state and federal agenciesas causing cancer or reproductive toxicity. Whenchecking, draining or adding gasoline, take care notto ingest, breathe the fumes, or contact gasoline.

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.

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

vSpecifications

MODEL GGLA MODEL GGLB

Generator kW Rating See Genset Nameplate See Genset NameplateEngine General Motors Model GM8.1L General Motors Model GM8.1LNatural Gas Consumption atFull Load

Standby Power Rating (60 Hz)Prime Power Rating (60 Hz)

1650 cfh (46.7 m3/hr)1525 cfh (43.2 m3/hr)

2000 cfh (56.6 m3/hr)N/A

Propane Consumption at FullLoad)

Standby Power Rating (60 Hz)Prime Power Rating (60 Hz)

605 cfh (17.1 m3/hr)575 cfh ( 16.3 m3/hr)

650 cfh (18.4 m3/hr)N/A

Natural Gas Supply PressureMinimum at Full LoadMaximum

7.0 inch H2O (1.7 kPa)13.6 inch H2O (3.4 kPa)


Propane Supply Pressure(Vapor Withdrawall)

Minimum at Full LoadMaximum



Maximum Propane Pressure(Liquid Propane)

312 psi (2,153 kPa)

312 psi (2,153 kPa)Fuel Connection Natural Gas &Propane (Vapor Withdrawal) 1.5 Inch NPT 1.5 Inch NPTFuel Connection(Liquid Propane)

1/4 Inch NPT

1/4 Inch NPTExhaust Connection 27/8 Inch O. D. Tube 27/8 Inch O. D. TubeMax. Exhaust Backpressure 20 inch H2O (5.0 kPa) 20 inch H2O (5.0 kPa)Cooling System Capacity 5.9 Gal (22.3 L) 5.9 Gal (22.3 L)Lubricating Oil Capacity 8.0 Qts (7.6 L) including filter 8.0 Qts (7.6 L) including filterLubricating Oil Specifications

15 F (9 C) to 125 F (52 C)0 F (18 C) to 50 F (10 C)25 F (31 C) to 32 F (0 C)

Cummins Premium Blue 15W-40 Oil*10W-30 SJ or SL Oil5W-30 SJ or SL Oil

Cummins Premium Blue 15W-40 Oil*10W-30 SJ or SL Oil5W-30 SJ or SL Oil

Lubricating Oil Filter Fleet Guard LF16109 or AC Delco PF454 Fleet Guard LF16109 or AC Delco PF454Combustion Air Filter Onan Part Number 140-3151 Onan Part Number 140-3151Spark Plugs

QuantityGapMake and Part No.

80.030 Inches

MOTORCRAFT AGSF22FM1with Fine Wire Electrode

80.030 Inches

MOTORCRAFT AGSF22FM1with Fine Wire Electrode

BatteryGroundVoltageGroup NumberMinimum Cold Soak RatingBattery Charging Rate (Max.)

Negative12 Volts

31455 CCA @ 0 F (-18 C)

70 Amps

Negative12 Volts

31455 CCA @ 0 F (-18 C)

70 Amps* See your Cummins Distributor.

vi

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1-1

1. Introduction

ABOUT THIS MANUAL

This manual provides troubleshooting and repairinformation regarding the PowerCommand 2100Control (PCC)1, the Basic Control (2-Wire Remote)and generator for the gensets listed on the frontcover.

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.Operation and Maintenance are covered in thegenset Operaters Manual.Engine service must be performed by anauthorized representative of Power Solutions, Inc.

SYSTEM OVERVIEW

PCC 2100

The PCC is a microprocessor-based control forCummins Power Generation generator sets. Allgenerator set control functions (except engine) arecontained on one circuit board (Base board). TheBase board provides main alternator voltage outputregulation and complete generator set control andmonitoring.The operating software provides control of the gen-erator set and its performance characteristics, anddisplays performance information on a digital dis-play panel. It accepts menu-driven control and set-up input from the push button switches on the frontpanel.

Basic Control (2-Wire Remote)The Basic Control provides for local or remote start-ing and stopping of the genset, generator voltagecontrol and engine control via the engine ECM.Engine Control Module (ECM)Whether the genset is equipped with the PCC or Ba-sic Control, the engine ECM cranks the engine, dis-connects the starter, governs engine speed andperforms all engine control, monitoring and diag-nostic functions.

TEST EQUIPMENTTo perform the test procedures in this manual, thefollowing test equipment must be available

True RMS meter for accurate measurement ofsmall 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)HOW TO OBTAIN SERVICE

Always 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 ofparts can result in severe personal injury ordeath, and/or equipment damage. Service per-sonnel must be qualified to perform electricaland mechanical service. Read and follow SafetyPrecautions, on pages iii and iv.

1. Copyright 2004 Cummins Power Generation. All rights reserved. Cummins and PowerCommand are registered trademarks of CumminsInc.

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2-1

2. PCC 2100 Control OperationThis section does not apply if the generator set hasa Basic Control. See Section 8.

GENERAL

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.

The PCC 2100 controls the starting and stoppingsequence of the engine through the ECM (mountedon the engine). See Page 2-26 regarding the func-tion and operation of the Engine Control Monitor(ECM) and how it interfaces with the PCC control.

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 theO position.When all conditions are met (i.e., no unacknowl-edged faults and O/Manual/Auto switch is in theO position) 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:

Off/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 network and/or power transfercontrol feature is installed, the sleep mode is notavailable and should not be enabled will cause er-ror condition.)

2-2

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

2-3

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. Select Manual or Auto, as required.

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

Running Indicator: This green lamp is lit wheneverthe generator (local or remote) 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~) Kilowatts (kW) Generator output frequency in Hertz (Hz) 3-Phase line-to-line AC volts (V~) 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. (It is not necessary to stop the gener-ator set.) In auto mode, warning indicators can alsobe reset by cycling the remote reset input after thecondition is corrected.

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.

2-4

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.

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 set(local or remote). If the switch is set to O during setoperation, the engine will immediately shut down(cool-down timers are bypassed). This hot shut-down should be avoided, if possible, to help prolongthe life of the engine.

Configurable IndicatorsThe following configurable indicators (default val-ues shown) can be changed with the InPower ser-vice tool. The configurable items are: change gen-erator event and LED color (green, yellow or red),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 ex-cessive speed.Fail to Start Indicator: This red lamp indicates theengine failed to start.Note the troubleshooting instructions on Page 4-7for ENGINE SHUTDOWN (PCC Code 1311).

2-5

MENU DISPLAY AND BUTTONS

Figure 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 (Figure2-3), 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.

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, pressingthe 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 ).

2-6

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.

AboutPwr Tran

SetupMore>>

FaultsSystem

HistoryMore>>

EngineAlternator

AdjustMore>>

Main Menu 1

Main Menu 2

Main Menu 3

PAGE

2-11

PAGE

2-13

PAGE

2-15

PAGE

2-17

PAGE

2-19

PAGE

2-21

PAGE

6-5

PAGE

2-23

PAGE

2-25

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 MENUFigure 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 hasseven 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: This submenu displaysthe engine oil pressure which can be viewed in PSIor kPA (see Controller Configuration Menu Menu inthis section).Oil Temperature submenu: Not used.Engine Speed submenu: This submenu displaysthe engine RPM.Battery Voltage submenu: This submenu dis-plays the engine battery voltage.Governor Duty Cycle submenu: This submenudisplays the governor duty cycle (drive) levels inpercentage of maximum. THIS MENU IS NOT AC-TIVE BECAUSE THE ENGINE CONTROL MOD-ULE (ECM) GOVERNS ENGINE SPEED.Active Time Delay submenu: This submenu dis-plays the time delay that is currently active: warmup, cool down, start or stop delays.

2-11

ENGINE MENU

EngineAlternator

AdjustMore>>

Coolant Temperaturennn Deg F

Oil Pressurennn PSI

Engine Speednnnn RPM

Battery Voltagenn.n VDC

Governor Duty Cyclennn %

Active Time DelayNone nnnn Sec

Main Menu 1

Oil Temperaturenn Deg F

FIGURE 2-5. ENGINE MENU

2-12

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.)

2-13

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

2-14

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 has fivesubmenus. Each submenu includes a parameter orvalue 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).f 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 displayed value is greater or less than the al-lowed (5%) range, the control will not except the

entry and will return to the previous setting. Retry byentering a smaller 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.THIS FEATURE IS NOT AVAILABLE ON THESE MOD-ELS.

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 is only enabled whenthe genset is started in manual mode. Idle Start canalso be enabled while the set is running in manualmode. THE IDLE FEATURE IS NOT AVAILABLE ONTHESE MODELS.

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 6. 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.

2-15

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

FIGURE 2-7. ADJUST MENU

2-16

FAULTS MENU

Figure 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 theword 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 Menu

button 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

2-17

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

2-18

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.

If a PCC 2100 control genset, in the network, con-tains the Power Transfer Control (PTC) feature, agenset system submenu will be displayed for thegenset and the ATS System submenu will be dis-played for the PTC feature.

2-19

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

2-20

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 the Previous Main Menu button to returnto Main 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.

2-21

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

2-22

ABOUT MENU

Figure 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 the Previous Main Menu button to return

to Main 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.

2-23

AboutPwr Tran

SetupMore>>

ABOUT MENU

Main Menu 3

Modelxxxxxxxxxxxxxxx

RatingStandby nn.n kW

Software Versionnn.nnn

FIGURE 2-12. ABOUT MENU

2-24

POWER TRANSFER MENUFigure 2-13 shows a block representation of thePower Transfer menu. If you press the button nextto the word Pwr Tran in the display, the first PowerTransfer submenu is displayed. (The Power Trans-fer Control feature must be installed to display thissubmenu.)With this option installed, the control will monitor theutility voltage (mains) and frequency for failure. Ifpower fails, the PTC control will start the generator,open the mains circuit breakers and close the gen-erator circuit breakers.As shown in the diagram, the Power Transfer menuhas five submenus.

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

S1 (Source 1) submenu: This submenu showspower transfer source voltage. The voltages 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.)

S1 (L-N Source) submenu: This submenu is dis-played only if the control system is configured forlinetoneutral voltage sensing of source 1. Singlephase only L1 to N and L2 to N.

Frequency submenu: This menu shows powertransfer frequency.

Source 1 submenu: This submenu shows utilitystatus (On, Ok, or NA). On means Source 1 is con-nected and available. Ok means Source 1 is avail-able but not connected. NA means Source 1 is notavailable.

Genset submenu: This submenu shows generatorstatus (On, Ok, or NA). On means the genset isconnected and available. Ok means the genset isavailable but not connected. NA means the gen-set is not available.

Active Transfer Timer submenu: This submenushows the time delay, in seconds.

2-25

S1On

AboutPwr Tran

SetupMore>>

POWER TRANSFER MENU

Main Menu 3

S1 L12 L23 L31V nnn nnn nnn

Frequencynn.n Hz

GensetOn

Active Tran TimerTD Re-Trans nnn Sec

S1 L1N L2NV nnn nnn

FIGURE 2-13. POWER TRANSFER MENU

2-26

ENGINE CONTROL MODULE (ECM)The PCC 2100 controls the starting and stoppingsequence of the engine through the ECM (mountedon the engine), energizes the starter solenoidthrough start relay K4 and disconnects the starter.The ECM governs engine speed and performs allengine control, monitoring and diagnosticfunctions.Note: The PCC 2100 monitors engine oil pressure,coolant temperature, coolant level and speed. TheECM also monitors engine coolant temperature us-ing a different sensor.

If the ECM shuts down the engine, it will send asignal to the PCC 2100, which will display,ENGINE WARNING (Code 1311). The engineshutdown code can be determined by pressing thefault code switch located on the engine (Figure2-14). The fault code will display as flashes whenthe switch is pushed on. Each digit of the three digitnumerical fault code will be displayed as flashes.There will be a brief pause between digits and alonger pause before the repetition.Engine Serial Number Less Than 8.1L13788 Ifthere are no faults and the engine ECM is workingproperly the fault light will flash the code 123when the switch is pushed to the ENGINE FAULTFLASH position, as follows:

flash-PAUSEflashflash-PAUSEflashflashflashLONGER PAUSEREPEAT

Note: Code 123 may, instead, be indicating higherthan expected engine coolant temperature. If over-heating is suspected, measure coolant temperaturewith a gauge while the engine is warming up. If thetemperature exceeds 225 F, service the cooling sys-tem as necessary. If temperature is not higher thanexpected but shutdown recurs, the coolant sensormay be faulty. Call Power Solutions, Inc.

Engine Serial Number 8.1L13788 Or Greater Ifthere are no faults and the engine ECM is workingproperly the fault light will flash the code 166when the switch is pushed to the ENGINE FAULTFLASH position, as follows:

flash-PAUSEflashflash-flashflash-flashflash-PAUSEflashflash-flashflash-flashflash-

LONGER PAUSEREPEAT

CAUTION Do not leave the Fault Code Switchin the ENGINE FAULT FLASH position. Doing socould lead to battery drawdown and will causethe PCC to continuously display ENGINEWARNING.

Note: See the troubleshooting instructions on Page4-9 for ENGINE WARNING (PCC Code 1311).

Use the engine fault code enable switch beforecalling Power Solutions, Inc. for engine service sothat the service technician can better assemble theright tools and replacement parts.

The wiring harness and software required for per-forming engine diagnostics using a PC (laptop) areavailable from Cummins Power Generation.

ENGINEFAULTFLASH

NORMAL

FLASHINGLIGHT

FIGURE 2-14. ENGINE FAULT CODE SWITCH

3-1

3. PCC 2100 Base Circuit Board

This section does not apply if the generator set hasa Basic Control. See Section 8.

GENERALWARNING 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 dry wooden platform or rubber insu-lating mat, make sure your clothing and shoesare dry, remove jewelry and use tools with insu-lated handles.

This section describes the function of the Power-Command 2100 Control (PCC) base circuit boardin the control box (Figure 3-1). The block diagram inFigure 3-2, shows the external connections of thePCC system. The system schematics are providedin Section 10.

CAUTION Electrostatic discharge can dam-age electronic circuit boards. Always wear agrounding wrist strap when touching or han-dling circuit boards.

BASEBOARD

DISPLAYBOARD

BARGRAPH BOARD(OPTIONAL)

INDICATORBOARD

FRONT CONTROLPANEL ASSEMBLY

(MEMBRANE BUTTONS)

CONTROLPANEL BOX

FIGURE 3-1. CIRCUIT BOARD LOCATIONS

3-2

SHUN

T O

RO

PTIO

NAL

PMG

FIGURE 3-2. BLOCK DIAGRAM

3-3

BASE BOARD

The base circuit board (Figure 3-3) contains all ofthe electronic circuitry required to operate the gen-erator set. The Base board provides main alternator

voltage output regulation, and complete generatorset control and monitoring.The following paragraphs describe each of the con-nectors (J), fuses (F) and terminal boards (TB)shown in Figure 3-3.

J6 NCM

J4DIGITAL DISPLAY

J2LED BOARD &

BARGRAPH

J1HARNESSS12, S13

J9InPOWER

J3MEMBRANE

F4

F1 F2 F3

J7ENGINE

J8 ACGENERATOR

TB2PTC

TB1CUSTOMER CONNECTIONS

F4

XX

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

FIGURE 3-3. BASE BOARD

3-4

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)

3-5

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

3-6

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]

3-7

Connector J7J7 connects to the engine sensors, battery, starter,governor actuator and magnetic pickup.

PIN 1

BASEBOARD

PIN 4

PIN 36

J7

FIGURE 3-8. J7 ENGINE HARNESS CONNECTOR

CONNECTOR J7PIN SIGNAL

5, 6, 7, 8 GND1, 2, 3, 4 B+ IN

910

GEN SW B+FUEL SOL

1112

CT1CT1COM

131721

OIL PRESS OUTOIL PRESS COMOIL PRESS 5V

1516

CT2CT2COM

18 ALT FLASHOUT1920

CT3CT3COM

2327

GEN SW B+START SOL B

243614

ACTUATOR +GND

ACTUATOR SIG252933

MAG PICKUP+MAG PICKUP

GND3034

COOLANT SNDERCOOLANT SNDER COM

313235

COOL LVL B+COOL LVL RTNCOOL LVL GND

3-8

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 Customer switched B+ (to T26 engine terminal block)F4 5A Base board power supply fuseF5 2A B+ supply to Power Transfer Control (PTC) module (optional) (PCB P/N 300-5381)

RS1 (Fuse/AutoReset)

0.9A B+ supply to Power Transfer Control (PTC) module (optional) (PCB P/N 327-1379)

TB1 Customer ConnectionsCustomer monitor/control connections are at-tached to terminal board TB1. Optional equipmentsuch 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 10 for TB1 connections.

TB2 Power Transfer Control (PTC)ConnectionsTB2 is used to connect the optional PTC module tothe control. With this option installed, the control willmonitor the utility voltage (mains) and frequency forfailure. If power fails, the PTC control will start thegenerator, open the mains circuit breakers andclose the generator circuit breakers. Refer to Cus-tomer Connections diagram in Section 10 for TB2connections.

4-1

4. PCC 2100 TroubleshootingThis section does not apply if the generator set hasa Basic Control. See Section 8.

GENERAL

The PowerCommand 2100 Control (PCC) contin-uously monitors engine sensors for abnormal con-ditions, such as low oil pressure and high coolanttemperature. 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 canresult 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 gasescan 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 fromAC source before disconnecting battery cables.Otherwise, disconnecting cables can result involtage spikes damaging to DC control circuitsof the genset.

WARNING Accidental starting of the generatorset 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, as follows, that the generatorset cannot be accidentally restarted:

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.

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: Describes how to troubleshoot en-gine problems that are not within the detectablerange of the PCC control.

Table 4-4: Describes how to troubleshoot aCheck Engine lamp fault for gensets that con-tain the low emissions option.

Table 4-5: Describes each status, warning andshutdown code, warning and shutdown limitswhere applicable, and basic corrective actions,such as, checking fluid levels, control resetfunctions, battery connections, etc.

Fault Code Tables: Provide detailed trouble-shooting procedures. In the following tables,the fault codes are used as the table referencenumber and are arranged in numeric order.

4-3

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 9. Figure 4-2 shows theconnections for supplying DC power to the controlcircuits.

CAUTION Always set the O/Manual/Autoswitch 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 dam-age circuit boards. Always wear a wrist strapwhen handling circuit boards or when discon-necting or connecting harness connectors. SeeCircuit Board Removal/Replacement in Sec-tion 6.Relay K4Relay K4 is the Starter Pilot relay that is used to en-ergize the starter solenoid. K4 is part of the wiringharness.Relay K12Relay K12 provides Switched B+ as the run signalfor the ECM. It is part of the wiring harness. The cir-cuit is protected by fuse F1 (15 amp) in the wiringharness.

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

K4 K12

FIGURE 4-1. PCC CONTROL COMPONENTS

4-4

B+ CABLERoute Cable Between Starter

and Engine to Keep AwayFrom Hot Exhaust PipeB CABLE

SECURE THE 2 WIRING HARNESS ENG GNDRING TERMINALS WITH THE GROUND SCREW

CONNECT THE 2 WIRING HARNESSB1 BATT RING TERMINALS TO THE

STARTER SOLENOID BATT TERMINALAND THE B1 SW RING TERMINAL TO

THE SOLENOID SW TERMINALRoute Leads Between Starter and Engine

to Keep Away From Hot Exhaust Pipe

LOCATION OF WIRING HARNESS TBBATT TERMINAL BLOCK

REFER TO THE WIRING HARNESS DRAWING ON PAGE 10-5

FIGURE 4-2. DC SUPPLY CONNECTIONS

4-5

WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury

or 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.)

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

b. 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 BATT and GND terminal blocks mounted onengine block (Figure 4-2).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.)

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.

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.

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.

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, the Base board is bad.

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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.


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

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.

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.

TABLE 4-3. ENGINE LACKS POWER OR IS UNSTABLE (NO FAULT MESSAGE)

Reason: This indicates that the PCC has not received or recognized a genset fault.Effect: Engine approaching level at which unpredictable operation may occur.


1. Ambient temperature and/or altitude arelimiting maximum engine power.

Refer to the generator set Specification Sheet for site derating fac-tors.

2. The engine air filter element is dirty. Replace the air filter element.3. The exhaust system is blocked. . Repair as necessary.4. The fuel supply pressure or energy con-

tent is insufficient.a. Check the fuel supply pressure (7.0 to 13.6 inches WC) and

readjust if necessary.b. Check with the propane supplier or the gas utility to confirm the en-

ergy content of the gaseous fuel being used. Propane must haveapproximately 2500 BTUs per cubic foot and natural gas 1000BTUs per cubic foot.

5. The engine misfires or backfires underhigh load.

a. Replace the spark plugs with ones of the correct make andgap. See Specifications.

b. Readjust the air/fuel mixture (Section 9).c. Have an authorized Power Solutions, Inc. representative

service the engine.6. The engine hunts at no load. a. Readjust the fuel-air mixture (Section 9).

b. Have an authorized Power Solutions, Inc. representativeservice the engine.

8. The engine is worn. Have an authorized Power Solutions, Inc. representativeservice the engine.

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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 4-5. WARNING AND SHUTDOWN CODES

FAULT CODE CORRECTIVE ACTION

121SPEED SIGNAL LOSTLamp: Shutdown

Indicates mag pickup speed indication is not being sensed.Restart and check RPM on the digital display.

135OIL PRESSURE SENSOR HLamp: Warning

Indicates that the control has sensed that the engine oil pressure sender signal isshorted high. Check sender/connectors/wires.

141OIL PRESSURE SENSOR LLamp: Warning

Indicates that the control has sensed that the engine oil pressure sender signal isshorted low. Check sender/connectors/wires.

143PRE-LOW OIL PRESLamp: Warning

Indicates engine oil pressure has dropped to an unacceptable level. If generator ispowering critical loads and cannot be shut down, wait until next shutdown periodand then follow code 415 procedure.

144COOL SENSOR HIGHLamp: Warning

Indicates that the control has sensed that the engine coolant temperature signal isshorted high. Check sender/connectors/wires.

145COOL SENSOR LOWLamp: Warning

Indicates that the control has sensed that the engine coolant temperature signal isshorted low. Check sender/connectors/wires.

146PRE-HIGH COOL TMPLamp: Warning

Indicates engine has begun to overheat (coolant temperature has risen to an un-acceptable level.If generator is powering non-critical and critical loads and cannot be shut down,use the following:

a. Reduce load if possible by turning off non-critical loads.b. Check air inlets and outlets and remove any obstructions to airflow. If engine can

be stopped, follow code 151 procedure.151HIGH COOLANT TEMPLamp: Shutdown

Indicates engine has overheated (coolant temperature has risen above the shut-down trip point).Allow engine to cool down completely before proceeding with the following checks:

a. Check coolant level and replenish if low. Look for possible coolant leakage pointsand repair if necessary.

b. Check for obstructions to cooling airflow and correct as necessary.c. Check fan belt and repair or tighten if necessary.d. Check blower fan and circulation pumps on remote radiator installations.e. Reset control and restart after locating and correcting problem.

197LOW COOLANT LEVELLamp: Warning(Optional)

Indicates engine coolant level has fallen below the warning trip point. Allow engineto cool down completely before proceeding.


b. Reset control and restart after locating and correcting problem.

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WARNING

TABLE 4-5. WARNING AND SHUTDOWN CODES (CONT.)


234OVERSPEEDLamp: Shutdown

Indicates engine has exceeded normal operating speed. Possible causes aresingle step large block load removal or starting a very cold engine.

235LOW COOLANT LEVELLamp: Shutdown

Indicates engine coolant level has fallen below the shutdown trip point. Allow en-gine to cool down completely before proceeding.


b. Reset control and restart after locating and correcting problem.

359FAIL TO STARTLamp: Shutdown

Indicates possible fuel system problem. (Engine cranks but fails to start)a. Open any closed manual fuel valve.b. If disconnected, reconnect the engine wiring harness connector to the

solenoid fuel valve (K1).c. Check fuse F1 and replace if blown (15 amp).d. Check for B+ at terminal 4 on run relay K12 while cranking. Repair as necessary.e. Reconnect any loose spark plug cable.f. Replace the spark plugs with ones of the correct make and gap. See

Specifications.g. Check the fuel supply pressure (7.0 to 13.6 inches WC) and readjust if

necessary.h. Readjust the no-load air/fuel mixture (Section 9).i. Reset the control and restart after correcting the problem.

415LOW OIL PRESSURELamp: Shutdown

Indicates engine oil pressure has dropped below the shutdown trip point. Check oillevel, lines and filters. If oil system is OK but oil level is low, replenish. Reset con-trol and restart.

441LOW BAT VOLTAGELamp: Warning

Indicates battery voltage supply to the control is approaching a low level at whichunpredictable operation will occur.

a. Discharged or defective battery.Check the battery charger fuse.Recharge or replace the battery.

b. Poor battery cable connections. Clean the battery cable terminals and tighten allconnections.

c. Check battery wiring/calibration.d. Check engine DC alternator. Replace engine DC alternator if normal battery

charging voltage is not obtained.e. Check battery charge voltage float level if applicable (raise float level).

442HIGH BAT VOLTAGELamp: Warning

Indicates battery voltage supply to the control is approaching a high level at whichdamage to the control can occur. Check float level on battery charger if applicable(lower float level). Check battery wiring/calibration.

4-9


WARNING



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.

1311ENGINE WARNINGLamp:Warning

NOTE: The ECM, rather than the PCC, may cause engine shutdown if high en-gine temperature, overspeed, or failure to start occurs, and will send a signalto the PCC to display ENGINE WARNING (Code 1311). In the mean time, as theengine slows to a stop, the PCC may display a subsequent fault, such as un-der/over voltage, under/over frequency or low oil pressure, and will displaythis fault as the last fault. To determine whether engine shutdown is the realcause for generator set shutdown, rather than the last fault displayed on thePCC, look up the previous fault in PCC fault history (Page 2-16). If the previousfault is ENGINE WARNING (Code 1311), see Page 2-26 for instructions on howto use the engine fault code switch to determine the ECM fault code.

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.

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.

4-10


WARNING



1417POWER DOWN ERRORLamp: Warning

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

1433EMERGENCY STOPLamp: Shutdown

Indicates local Emergency Stop. To reset the local/remote Emergency Stop button:a. Pull the button out.b. Move the O/Manual/Auto switch to O.c. Press the front panel Fault Acknowledge/Reset button.d. Select Manual or Auto, as required.

1434REMOTE E-STOPLamp: Shutdown

Indicates remote Emergency Stop. See code 1433 to reset.

1435LOW COOLANT TEMPLamp: WarningSet is not operating. Warningoccurs when engine coolanttemperature is 70 F (21 C)or lower. NOTE: In applica-tions where the ambienttemperature falls below 40F (4 C), Low Coolant Tempmay be indicated eventhough the coolant heatersare operating.

Indicates engine coolant heater is not operating or is not circulating coolant.Check for the following conditions:

a. Coolant heater not connected to power supply. Check for blown fuse or discon-nected heater cord and correct as required.

b. Check for low coolant level and replenish if required. Look for possible coolantleakage points and repair as required.

c. Open heater element. Check current draw of heater.Coolant temperature must be below 70 F (default setting) for one minute to acti-vate warning and be above 70 F for five minutes before the warning can becleared.

1438FAIL TO CRANKLamp: Shutdown

Indicates possible fault with control, speed sensing or starting system.

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.

4-11


WARNING



1447LOW AC VOLTAGELamp: Shutdown

Indicates that one or more of the phase voltages has dropped below 85% of nomi-nal for 10 seconds.

1448UNDER FREQUENCYLamp: Shutdown

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

1449OVER FREQUENCYLamp: Warning

Indicates frequency is 10% above base frequency for 20 seconds.

1452GEN CB NOT CLOSELamp: Warning

Refer to Section 5.

1453GEN CB NOT OPENLamp: Warning

Refer to Section 5.

1459REVERSE POWERLamp: Shutdown

Indicates improper CT phasing. Check wiring to voltage sense circuit. Refer to CTInstallation in Section 6.

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.

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WARNING



2327PTC FAULTLamp: Warning

Refer to Section 5.

2329LOW S1 FREQUENCYLamp: Warning

Refer to Section 5.

2331LOW S1 VOLTAGELamp: Warning

Refer to Section 5.

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.

2337PWR TRAN DISABLEDLamp: Warning

Refer to Section 5.

Codigos de Falla Generador Cummins

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