cumins ps0500 service manual.pdf

8/10/2019 CUMINS PS0500 Service manual.pdf

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Service ManualPower Start 0500

Genset Models:

X1.3, S and B series


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ForewordSchedule of Abbreviations

AC Alternating Current MCB Miniature Circuit BreakerACB Air Circuit Breaker MCCB Moulded Case Circuit BreakerACH Anti-Condensation Heaters MF Mains FailedATS Automatic Transfer Switch MFSS Master First Start SensorAVR Automatic Voltage Regulator MR Mains Returned

MST Mains Sensin TransformerBHP Brake Horsepower MSU Mains Sensing UnitBMS Building Management System MV Medium Voltage

BST Busbar Sensing TransformerNEC Neutral Earthin Contact

CB Circuit BreakerCCA Cold Cranking Amps PC PowerCommandCHP Combined Heat and Power PF Power FactorCOP Continuous Power Rating PFC Power Factor ControllerCT Current Transformer PLC Programmable Logic Controller

PMG Permanent Magnet GeneratordB(A) Unit of noise level PRP Prime Power RatingDC Direct Current PSU Power Supply Unit

DIP Dual In-line Package PT/CT Potential Transformer / CurrentTransformerDMC Digital Master ControlDMSU Demand Load Standb Unit CC uadrature Current Control

EMCU Engine Monitoring and ControlUnit

RFI Radio Frequency Interference

EMF Electromotive Force RMS Root Mean SquareEPU Engine Protection Unit RPM Revolutions Per Minute

RTD Resistance Tem erature DetectorFSS First Start Sensor

GCP Generator Control Panel V VoltsGenset Generator set VAC Volts, Alternating CurrentGKWT Global Kilowatt Transducer VCB Vacuum Circuit Breaker

VDC Volts Direct CurrentHMI Human/Machine Interface VF Volt-freeHV High Voltage VT Voltage Transformer


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IC Integrated Circuit LV Low VoltageI/O Input / Output

kVA Apparent PowerkVAR Reactive Power

kW Active / Real PowerkWh Unit of electrical energy or work

LED Light-Emitting DiodeLTP Limited Time Power RatingLTA Low Tem erature Aftercoolin


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INDEX

Sr. Contents Page no.

1. Preliminary and safety.. 51.1 Warning, Caution and Note styles usedIn this manual

1.2 General information1.3 General plant safety code

2. Control System... 6

2.1 Control System Description2.2 Operating modes2.3 Display Module2.4 Configuration Mode2.5 Sequence of operation2.6 Stopping2.7 Connector Details

3. Status Indicators.. 20

3.1 Fault/Status codes3.2 Fault code list

4. Troubleshooting..... 22

4.1 Introduction4.2 Control unit4.3 Troubleshooting procedure for fault codes4.4 Fault Finding

5. InPower connectivity.. 26

6. Calibration Procedure....... 27

7. Wiring Diagrams........ 33


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1. Preliminary and safety

1.1 Warning, Caution and Note styles used in this manualThe following safety styles found throughout this manual indicate potentially hazardous

conditions to the operator, service personnel or the equipment.WARNING: WARNS OF A HAZARD THAT MAY RESULT IN SEVERE PERSONAL

INJURY OR DEATH.

Caution Warns of a hazard or an unsafe practice that can result in product or propertydamage.

Note: A short piece of text giving information that augments the current text.

1.2 General InformationThis manual should form part of the documentation package supplied by Cummins PowerGeneration Limited with specific generator sets. In the event that this manual has been suppliedin isolation please refer to other Cummins Power Generation Limited literature, in particular theHealth and Safety Manual (0908-0110-00).

Note: It is in the Operators interest to read and understand all Health and Safetyinformation together with all Warnings and Cautions contained within thedocumentation relevant to the generator set, its operation and daily maintenance.

1.3 Generator Plant Safety CodeBefore operating the generator set, read the manuals and become familiar with them and theequipment. Safe and efficient operation can be achieved only if the equipment is properlyoperated and maintained. Many accidents are caused by failure to follow fundamental rules andprecautions.

WARNING: IMPROPER OPERATION AND MAINTENANCE CAN LEAD TOSEVERE PERSONAL INJURY OR LOSS OF LIFE AND PROPERTY BYFIRE, ELECTROCUTION, MECHANICAL BREAKDOWN OR EXHAUSTGAS ASPHYXIATION. READ AND FOLLOW ALL SAFETYPRECAUTIONS, WARNINGS AND CAUTIONS THROUGHOUT THISMANUAL AND THE HEALTH AND SAFETY MANUAL 0908-0110-00.


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2. Control System

2.1 Control System DescriptionThe control system is used to start and stop the generator set, and provides full generator

set monitoring capability and protection in a stand-alone situation (non paralleling) from thedisplay screen. It monitors the engine for temperature, oil pressure, battery voltage, estop andgenset hours, and provides voltage and current metering. In the event of a fault the unit willindicate the fault type and automatically shut down the generator set on critical faults.

All indicators, control buttons and the display screen are on the face of the display moduleas illustrated in Figure 1.

There are two fault level signals generated by the control system as follows: Warning: - signals an imminent or non-critical fault for the engine. The control provides an

indication only for this condition. Shutdown: - signals a potentially critical fault for the engine. The control will immediately

take the engine OFF-load and automatically shut it down.

The standard control system operates on 12 VDC battery power. The auxiliary equipmentoperates on LV AC power. The history data is stored in non-volatile memory and will not bedeleted due to loss of battery power.

Figure 1 Typical Control System Panel

KEY

1. Display Module2. Emergency Stop Button

NOTE: Normally E-stop placement on canopy is totally under OEM scope.


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2.2 Operating Modes The PowerStart 0500 control is operated by the Manual / Start / Stop / Auto buttons on thedisplay module face.

2.2.1 OFF Mode

Note: Some published control service literature may refer to this mode as the STOP

mode.

When in the OFF mode, the control does not allow the generator set to start. Refer to Section4.2.7 Auto and Manual Run Modes to re-start the generator set.

If the generator set is running, in either Manual Run or Auto mode, and the Stop button ispressed, a normal shutdown sequence will be initiated.

In OFF Mode the red LED above the Stop button will be lit .

2.2.2 Manual Run Mode

When in Manual Run mode, the generator set starts and continues to run until the control isput into the OFF mode. Pressing the Stop button initiates a normal shutdown sequence that doesnot include a time delay stop. While in the Manual Run mode, any remote start signal is ignored.

2.2.3 Auto Mode

When in Auto mode, the control allows the generator set to be started at any time, with aremote signal only. When a remote start signal is received, the generator set starts after a timedelay start is completed (default delay is zero seconds).

When a remote start signal is removed, the control performs a normal shutdown sequencewhich includes a time delay stop (default delay is zero seconds).

If the generator set is running in Auto mode and the Stop button is pressed, the controlimmediately stops the generator set and the control transitions to the OFF mode.

2.2.4 Sleep Mode

The PowerStart 0500 control enters a low power (Sleep) mode of operation where thecurrent drawn is less than 60 milliamps (DC) at normal battery voltage levels. Sleep mode isautomatically enabled, and the display module will turn itself OFF after five minutes of keypadinactivity when in OFF mode.

When in Auto mode, the Sleep mode is enabled only when the trim Wake in AutoEnabled is enabled. If the trim is disabled (which is the default value), the Sleep mode will neverbe enabled when in Auto mode.

It awakes from the sleep mode if the reset button is pressed or if there is a Tool wakeupinput or a Remote Start signal is received or an E-stop signal is received both in Stop as well asAuto mode.


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The control will not enter the Sleep mode if there are any active, unacknowledged, shutdownfaults or if the control is in the Manual Run mode.

2.2.5 Battle Short ModeThe purpose of Battle Short Mode is to satisfy local code requirements, where necessary.

Battle Short mode is a generator set mode of operation that prevents the generator set from beingshutdown by all but a few, select, critical shutdown faults.

Caution: All shutdown faults, including those overridden by Battle Short, must be actedupon immediately to ensure the safety and well being of the operator and thegenerator set.

WARNING: USE OF THE BATTLE SHORT MODE FEATURE CAN CAUSE A FIREOR ELECTRICAL HAZARD, RESULTING IN SEVERE PERSONALINJURY OR DEATH AND/OR PROPERTY AND EQUIPMENT DAMAGE.OPERATION OF THE SET MUST BE SUPERVISED DURING BATTLESHORT OPERATION.

This feature must only be used during supervised, temporary operation of the generator set. Thefaults that are overridden when in Battle Short mode can affect generator set performance, or cancause permanent engine, alternator or connected equipment damage.

Only trained and experienced service personnel should enable this feature. When shipped fromthe factory, this feature is disabled.

Caution: If this mode of operation is selected, the protection of load devices will bedisabled.Cummins Power Generation Limited will not be responsible for any claimresulting from the use of this mode.

Note: The Battle Short feature must be enabled or disabled using the PC Service tool.

When Battle Short mode is enabled (Default is Disabled), the Warning status indicator lights, andcode 1131 Battle Short Active is displayed.

When Battle Short mode is enabled and an overridden shutdown fault occurs, the shutdown lampremains lit even though the set continues to run. Fault code 1416 Fail to Shutdown isdisplayed. If the OK button is pressed to acknowledge the fault, the fault pop up is cleared fromthe display but remains in one of the scrolling screens displaying the fault code and its descriptionto indicate that it is an active fault as long as Battle Short mode is enabled.

Battle Short is suspended and a shutdown occurs immediately if any of the following criticalshutdown faults occur: Speed Signal Lost (Loss of Speed Sense) Fault code 121 Overspeed Fault code 234 Local Emergency Stop Fault code 1433 Excitation Fault (Loss of Voltage Sense) Fault code 2335 Fault code 1123 Shutdown After Battle Short is then displayed.


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2.3 Display Module - Front PanelFigure 2 shows the features of the front panel. It includes four LED indicators, the graphicaldisplay, and six buttons used to navigate through the menus and adjust parameters.

KEY

1. LED Indicator Genset Running 7. Auto Mode Button2. LED Indicator Remote Start 8. Reset Button3. LED Indicator Shutdown 9. Stop Button4. LED Indicator Warning 10. OK Button

5. Manual Mode Button 11. Alpha numeric LCD Display6. Start Button

2.3.1 Alpha numeric LCD Display

The 2 line 16 Character, Backlit LCD display is used to indicate various generator set parametersin several frames. The frames scroll sequentially and display for 2 seconds. The scrolling can bestopped and parameters on a particular frame can be monitored for longer by pressing the OKbutton (See Figure 2 ). Pressing the OK button again causes the frames to start scrolling again.The display is also used to present the setup menus in the configuration mode.

L1N=000 L2N=000

L3N=000 HZ=00.02 SEC

CURRENT FLT=212

CLNT TEMPOOR WRN2 SEC 2 SEC

L12=000 L23=000L13=000 HZ=00.0

E STOP=INACTIVECUST IN=INACTIVE

2 SEC 2 SEC

I1=00.0 KVA=00.0I2=00.0 I3=00.0

BATT VOLTS=11.7GENSET HRS=00000


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2 SEC 2 SEC

KVA1 KVA2 KVA300.0 00.0 00.0

2 SECOIL PRESS=003PSICLNT TEMP=342F

Figure 1 Scrolling display messages

2.3.2 LED IndicatorsPS0500 includes four LED indicators, the graphical display and six buttons used to navigatethrough the menus and adjust parameters.

Genset RunningThis green LED is lit when the generator set is running at or near rated speed and voltage.

ShutdownThis red lamp is lit when the control detects a Shutdown condition. The generator set cannot bestarted when this lamp is on. After the condition has been corrected, the lamp can be reset bypressing the Stop button.

Note:When Battle Short mode has been enabled and an overridden shutdown fault

occurs, the Shutdown lamp will be lit even though the generator set will continu

to run.

Warning

This yellow lamp is lit whenever the control detects a Warning condition. This lamp isautomatically shut OFF when the Warning condition no longer exists.

Remote StartThis green lamp indicates the control is receiving a remote run signal.

2.3.3 Control Panel Buttons

Manual

Press this button to put the control in Manual mode from OFF mode. If the Start button is notpressed within ten seconds of the pressing of the Manual Button, the control automatically returnsto OFF mode The green LED above this button lights when the control is in Manual mode.

Auto

Press this button to put the control in Auto mode from OFF mode. The green LED above thisbutton lights when the control is in Auto mode. In Auto mode, the generator set starts and runswhen a remote start signal is received. It is also used to exit from configuration mode.


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Stop

Press this button to switch to the OFF mode from both Manual as well as Auto modes. The RedLED above this button lights when the control is in OFF mode .

Start

In Manual mode, press this button to initiate a Manual Start sequence. In Auto mode, this buttonhas no effect.

Reset

This button wakes the control from Power Down Sleep Mode. The control enters configurationmode when Reset button and Stop button are pressed together. To enter in configuration mode itis necessary that the control is in Stop mode.

WARNING: ADJUSTING THE SETTINGS IN CONFIGURATION MODE MUSTONLY BE DONE BY TECHNICALLY TRAINED AND EXPERIENCEDSERVICE PERSONNEL. THE FREQUENCY SETTINGS MUST ONLY BEADJUSTED TO CORRESPOND TO THE PARAMETERS OF THEINSTALLED INPUT POWER SUPPLY. SAVING SETTINGS THAT DONOT CORRESPOND TO THE POWER SUPPLY CAN CAUSE SEVEREPERSONAL INJURY AND EQUIPMENT OR PROPERTY DAMAGE.

OK

This button is used to acknowledge the fault pop ups. It is also used to Pause / Resume thescrolling of the parameter frames. It is used to select the menu items and the parameters in theselected menu in the configuration mode. The selected parameter will be preceded by an *asterisk and will get saved when the configuration mode will be exited using Auto button.

Note: Manual, Auto, OK and Reset buttons are used for navigation in the configuration mode.

2.3.4 Default Settings

The control panel can display SAE or Metric units of measurement and should be set during theinitial setup of the generator set. Qualified service personnel are required to change the defaultsetting. Contact your authorised distributor.

2.3.5 Fault Messages

A Fault message is an indicator of a Warning or Shutdown condition that is also announced witha lamp indicator. Fault messages include the fault code number and a short description.

The below table provides a list of fault codes, fault types, messages displayed, and descriptions ofthe faults.


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2.3.6 Fault Acknowledgement

Shutdown Faults are reset after a shutdown fault is cleared when engine comes to a standstill andall start commands are removed.

In Manual mode, the start command is removed when the Stop button, on the front panel, ispressed.

In Auto Mode, the start command is removed when the Remote Start signal is removed.

Faults are removed from the display when they are cleared.

Note: Faults are re-announced if they are detected again after being acknowledged.

2.3.7 Display Module - Auto and Manual Run Modes

Auto, Manual Run and OFF modes can be selected as follows:

Selecting Auto ModeTo switch to Auto mode,

a) Ensure that it is safe to do so before proceeding to change the mode.

b) Press the Stop button to ensure that the control is in the OFF mode.

c) Press the Auto button while in the OFF mode. The green LED above this button is lit when the

control is in Auto mode.

To disable Auto mode, press the Stop button.

The generator set is now ready to receive a remote start signal that will initiate the Auto run

mode.

WARNING: SHOULD A REMOTE START SIGNAL BE RECEIVED, THE GENERATOR SETWILL START AUTOMATICALLY. ENSURE THERE IS NO DANGER TOPERSONNEL OR EQUIPMENT SHOULD THE GENERATOR SET STARTWITHOUT WARNING.

WARNING: MANUAL RUN MODE CANNOT BE SELECTED FROM AUTO MODE. THECONTROL HAS TO BE IN STOP MODE BEFORE CHANGING THE MODE.SWITCHING TO STOP MODE WILL RESULT IN THE GENERATOR SETSHUTTING DOWN.

Selecting Manual Run Mode

To switch to Manual Run mode,

a) Ensure that it is safe to do so before proceeding to change the mode.

b) Press the Stop button to ensure that the control is in the OFF mode


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c) Press the Manual button on the front panel while in the OFF mode. The green LED above thisbutton is lit when the control is in Manual mode.

To disable Manual Run mode, press the Stop button.

Note: Auto mode cannot be selected whilst in Manual Run mode. The control has to be inOFF mode before changing the mode. Switching to OFF mode will result in thegenerator set shutting down.

Selecting OFF ModeTo switch to OFF mode.

a) Ensure that it is safe to do so before proceeding to stop the set

b) Press the Stop button on the front panel. The red LED above the Stop button is lit when thecontrol is in the OFF mode

2.4 Configuration ModeWARNING: ADJUSTING THE SETTINGS IN CONFIGURATION MODE MUST ONLY BE

DONE BY TECHNICALLY TRAINED AND EXPERIENCED SERVICEPERSONNEL. THE FREQUENCY SETTINGS MUST ONLY BE ADJUSTED TOCORRESPOND TO THE PARAMETERS OF THE INSTALLED INPUT POWERSUPPLY. SAVING SETTINGS THAT DO NOT CORRESPOND TO THE POWERSUPPLY CAN CAUSE SEVERE PERSONAL INJURY AND EQUIPMENT ORPROPERTY DAMAGE.

Configuration mode is used to adjust the parameters of the generator set and must only be done bytechnically trained and experienced service personnel.6 membrane keys are used to step through thedifferent menu options and to adjustparameters.


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As seen from the above figure, on pressing RESET and OK button on PS0500 for 5 seconds,controller enters into configuration mode. Before displaying the menu, software part no. and version aredisplayed. One needs to understand key to operate.

Keys Properties

In Configuration mode the PowerStart 0500 control has the following menus:

Alt Setup: Select alternator set-up parameters (Single / Three phase, 50 / 60 Hz operation,Star / Delta, Voltage etc.) Units: Select SAE or Metric units of measure for Coolant Temperature and Oil Pressure Oil Pr Input: Select the oil pressure sensor type. Customer I/O: Configure the response to Customer Input and use of the Customer Output Flt History: Displays the last five faults. Load Defaults: Resets to the default values.

Will go to the next value

Will go to the previous value

Will go down

*It shows the default value.When selected for a

Particular value, * comes whichIndicates that value has been set

Ok

PressFor 5Sec

Entering into theConfig ModeReset

SW PART 3267727SW VER 1.12

No Navigation is needed


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Lamp/LED Test: Tests all the LEDs on the PS0500 display module.

2.5 Sequence of OperationThe generator set is run automatically using a Remote Start signal, or Manually using the

generator set control panel buttons. LEDs are provided on the display module front panel toindicate the operating run mode of the generator set. The PowerStart 0500 control initiates astarter cranking signal and will perform an automatically sequenced manual start, under acomplete engine protection system combined with full monitoring capability. If a fault is sensedat Start-up, the engine is locked out and will not start.

The choice of Auto or Manual run mode is decided by authorised personnel during thegenerator set initial setup.

2.5.1 StartingBefore attempting to start the generator set, the operator should read through this entire

manual, together with the Health and Safety manual and the specific engine manual provided aspart of the documentation pack supplied with the generator set. It is essential that the operator becompletely familiar with the generator set and the PowerStart 0500 control.

The following sub-sections cover the systems used to start and stop the generator set.

Before starting the generator set, make sure that exhaust and fuel fittings are tight andproperly positioned, and that proper maintenance and pre-start checks have been performed.

The generator set can be configured for a number of starting cycles (one to seven) with settimes for crank and rest periods for all starting modes (manual/remote). The default setting is forthree start cycles, composed of fifteen seconds of cranking and 5 seconds of rest.

2.5.2 Starting at Display Panel (Manual Run Mode)

To start the generator set in the Manual Run mode, press the Start button within 10 seconds ofpressing the Manual button. Follow the instructions in Section 4.2.9 (Selecting Manual RunMode).

Note: Any Remote Start/Stop signal is ignored whilst in Manual Run Mode.

The PowerStart 0500 control will initiate a starter cranking signal and will perform anautomatically sequenced manual start, under a complete engine protection system combined withfull monitoring capability. This will activate the engine control system and the starting procedure.

The starter will begin cranking, and after a few seconds the engine will start and the starter willdisconnect.

In the Manual Run mode the control will not complete the Time Delay to Start or Time Delay toStop.

The Remote Start red LED, and the Manual Run, green LED will be lit.

If the engine does not start, the starter will disengage after a specified period of time and thecontrol will indicate a Fail to Start Shutdown.


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If a Stop Button is activated the following message will be displayed;

Fault: 1434EMERGENCY SH

To reset:

a) Press the OK button on the Display Module to acknowledge the fault.

b) Press the Stop button and pull, or twist and pull, the button out to reset the fault condition

c) Press the Auto or Manual Run Button, as previously determined.

2.7 CONNECTOR DETAILS2.7.1 Description

Enginennector arrowPin 1

CTnnectorow at Pin 1

2 Pin 4

6 Pin 7J22 VoltageconnectorArrow at Pin 1

TB2 Customer TBArrow at Pin 1

TB15 Tool ConnectorArrow at Pin 1


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Following are the description for all the terminals on PS0500

2.7.2 Engine Connector

The engine connector (J16) is a 12 pin connector-plug (12 MINI M-N-L).The PCB outline drawing shows where the connector is located as above .Each signal is described as below

Connector Pin Signal NameJ16-1 Coolant temperature sensorJ16-2 Battery charging alternator (WL)J16-3 Starter Relay Driver (Low Side)J16-4 Fuel shutoff relay Driver (Low Side)J16-5 BAT-J16-6 Chassis GNDJ16-7 NCJ16-8 NC

J16-9 Oil Pressure SensorJ16-10 Starter Disconnect InputJ16-11 Sensor CommonJ16-12 BAT +

2.7.3 CT Connector

The CT connector is a 6- pin MATE-N-LOCK connector.Connector details are as follows

Connector pin SignalJ12-1 CT1_inputJ12-2 CT2_inputJ12-3 CT3_inputJ12-4 CT1_COMJ12-5 CT2_COMJ12-6 CT3_COM

2.7.4 Voltage Connector

The voltage connection is via a 4 pin header with alternate spaces between the pins.

Connector pin SignalJ22-1 Gen_V1J22-2 Gen_V2J22-3 Gen_V3J22-4 Gen_N


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2.7.5 Customer Connection TB - 2The customer connection TB2 is a 6 pin terminal block. The terminal pins details are as shown below-

Terminal pins SignalTB2-1 Remote start Switch Input

TB2-2 Glow Plug Output Relay Driver(Low Side)

TB2-3 Customer Output Relay Driver(Low Side)TB2-4 Customer inputTB2-5 E-stopTB2-6 NC

Returns for all the above connections are required to be connected externally.

All the inputs are active GND. Remote E-Stop switch should have two independent potential free contacts.One NC contact for cutting out the Battery supply to the Fuel Solenoid and another NC contact to connect

controllers E-Stop input to GND to indicate to the control when the E-Stop is pushed in active state.

Battery Positive is not provided on the Customer terminal block (TB2). External provision needs to bemade in the harness to provide the B+ signal for convenience of wiring up external relays and may be usedas relay supply (high side) for FSO, Starter, Customer Output and Glow plug Relays via a 1 Amp Fuse.

2.7.6 PC Tool Connector

The PC tool connector is a dedicated 5 pin connector header block.

Terminal pins SignalTB15-1 GNDTB15-2 NCTB15-3 RS485_DATA_ATB15-4 RS485_DATA_BTB15-5 TOOL_WAKEUP


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3. Status Indicators

Display Panel

Genset RunningThis green LED is lit when the generator set is running at or near rated speed and voltage.

ShutdownThis red lamp is lit when the control detects a Shutdown condition. The generator set cannot bestarted when this lamp is on. After the condition has been corrected, the lamp can be reset bypressing the OFF button.

Note: When Battle Short mode has been enabled and an overridden shutdown faultoccurs, the Shutdown lamp will be lit even though the generator set will continueto run.

WarningThis yellow lamp is lit whenever the control detects a Warning condition. This lamp isautomatically shut OFF when the Warning condition no longer exists.

Remote StartThis green lamp indicates the control is receiving a remote run signal.


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3.1 Fault Code list

CTG CODE LAMP DESCRIPTION

C 141 Warning Indicates the oil pressure sensor output is out of range (OOR), low.

B 143** Warning Indicates the engine oil pressure is approaching an unacceptablelevel.

C 144 Warning Indicates the coolant temperature sensor output is out of range(OOR), low.

C 146** Warning Indicates that the engine is operating near cooling system capacity.Increase in load or higher ambient temperature may cause HighCoolant Temp (code 151) shutdown.

D 151** Shutdown Indicates that the engine coolant temperature is above normal andhas reached the Shutdown trip point.

D 359 Shutdown The system has failed to start after a set number of crank attempts.This indicates a possible fuel system or air induction problem(engine cranks but fails to start).

A 415** Shutdown Indicates the engine oil pressure has dropped below normal and hasreached the shutdown trip point.

D 441** Warning Indicates battery voltage supply to the control is approaching a lowlevel at which unpredictable operation can occur.

D 442** Warning Indicates battery voltage supply to the control is approaching a highlevel at which damage to the control can occur.

B 1123* Shutdown A shutdown fault occurred while the Battle Short mode wasenabled.

D 1131* Warning Indicates that the control is in Battle Short mode used to bypassseveral fault shutdowns for generator set operation duringemergencies.

E 1312 Configurable The nature of the fault is an optional customer selection.

B 1416* Warning Indicates that a shutdown fault is active, but is being bypassed byBattle Short.

D1434 Shutdown

Indicates a Remote Emergency Stop has been activated.

D 1435** Warning Indicates that the engine coolant temperature is below the adjustedsetpoint. This may indicate that the coolant heater is not operatingor is not circulating coolant.

D 1442** Warning Indicates that the generator set battery voltage is below batterythresholds during cranking.

A 1446** Shutdown Indicates that one or more measured AC output voltages haveexceeded the threshold for longer than a specified time limit. Thethreshold and time limits are 130% of nominal for zero seconds or110% of nominal for ten seconds.

A 1447** Shutdown Indicates that the measured AC output voltage is below thethreshold for longer than a specified time limit. The threshold andtime limits are 85% of nominal for ten seconds.

A 1448** Shutdown Indicates that the alternator frequency is 6 Hertz under the nominalfrequency.

A 1449** Shutdown Indicates that the alternator frequency is 6 Hertz above the nominalfrequency.

A 2335 Shutdown Indicates that a loss of voltage or frequency sensing from thegenerator has occurred.

A 2677 Shutdown The generator set continues to run after receiving a stop commandfrom the controller.


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4. Troubleshooting

4.1 IntroductionFault codes information together with Warning and Shutdown information is provided in this

section to assist in locating and identifying the possible causes of faults in the generator setsystem. Refer also to the Operators engine specific manual supplied as part of the generator setdocumentation pack. This latter manual will contain further information regarding the runningand care of the generator set and also specific equipment instructions that may differ from thestandard generator set.

4.2 Control UnitThe generator set control system continuously monitors engine sensors for abnormal conditions,such as low oil pressure and high coolant temperature. If any of these conditions occur, thecontrol will light a yellow Warning lamp or a red Shutdown lamp and will display a message onthe graphical display panel. In the event of an engine shutdown fault (red Shutdown LED), the

control will stop the engine immediately.This section lists the Warning and Shutdown Fault Codes/Messages and suggests possible causesof the fault.

4.3 Troubleshooting Procedures for Fault Code4.2

CODE: 143 Indicates engine oil pressure has dropped below the warning trip point.If generator is powering critical loads and cannot be shut down, waituntil next shutdown period and then follow the fault code 415procedure.

LAMP: WarningMESSAGE: PRE-LOW OIL

PRESSURE

CODE: 146 Indicates engine is operating near cooling system capacity. Increase inload or higher ambient temperature may cause High Coolant Temp(151) shutdown. Review fault code 151 correction list for other possiblecauses.

LAMP: WarningMESSAGE: PRE-HIGH COOL

TEMP

CODE: 151 Indicates engine has overheated (coolant temperature has risen abovethe shutdown trip point). Allow engine to cool down completely beforeproceeding with the following checks:

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

b) Check for obstructions to cooling airflow and correct as necessary

c) Check fan belt and repair or tighten if necessary


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LAMP: Shutdown d) Check blower fan and circulation pumps on remote radiatorinstallations

MESSAGE: HIGH COOLANTTEMP

e) Reset control and restart after locating and correcting problem.

CODE: 359 Indicates possible fuel system or air induction problem. (Engine cranks

but fails to start). Allow engine to cool down completely beforeproceeding with the following checks:

f) Check for empty fuel tank, fuel leaks, or blocked fuel lines andcorrect as required

g) Check for dirty fuel filter and replace if necessaryLAMP: Shutdown h) Check for dirty or blocked air filter and replace if necessary

MESSAGE: Fail to Start i) Reset control and restart after correcting the problem.

CODE: 415 Indicates engine oil pressure has dropped below the shutdown trip point.Allow engine to cool down completely before proceeding with thefollowing checks:

j) Check the oil level, lines and filtersLAMP: Shutdown k) If the oil system is OK but the oil level is low, replenish

MESSAGE: LOW OILPRESSURE

l) Reset control and restart after locating and correcting problem.

CODE: 441 Indicates battery voltage supply to the control is approaching a lowlevel at which unpredictable operation will occur. If engine can bestopped allow engine to cool down completely before proceeding:

m) Poor battery cable connections. Clean the battery cable terminals andtighten all connections

n) Check battery charge voltage float level if applicable (raise float

level)o) Discharged or defective battery

LAMP: Warning Check the battery charger fuse

MESSAGE: LOW BATVOLTAGE

Recharge or replace the battery.

CODE: 442 Indicates battery voltage supply to the control is approaching a highlevel at which damage to the control can occur. If engine can be stoppedallow engine to cool down completely before proceeding:

LAMP: Warning p) Poor battery cable connections. Clean the battery cable terminals and

tighten all connectionsMESSAGE: HIGH BAT

VOLTAGEq) Check battery charge float level if applicable (lower float level).

CODE: 1131 Indicates that the control is in Battle Short mode used to bypassseveral fault shutdowns therefore allowing generator set operationduring emergencies.

LAMP: Warning


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MESSAGE: BATTLE SHORT ACTIVE

CODE: 1311, 1312, 1317,1318

The nature of the fault is an optional customer selection. Exampleinputs: Low Fuel Day Tank, Water In Fuel, Ground Fault, etc.

Each of the fault functions can be programmed (using InPower service

tool or access to Setup menu), as follows:r) Event , Warning or Shutdown level if Function Select = Fault Input

LAMP: Configurable s) Change display name using up to 32 characters

MESSAGE: CONFIGURABLE INPUT 1, 2, 3, 4

CODE: 1416 The generator set continues to run after receiving a shutdown commandfrom the controller. The Battle Short feature is enabled this is used tobypass several critical fault shutdowns therefore allowing generator setoperation during emergencies.

LAMP: Warning

MESSAGE: FAIL TO SHUTDOWN

CODE: 1433/1434 Indicates local or remote Emergency Stop. Emergency Stop shutdownstatus can be reset only at the local control panel. After locating andcorrecting problem, reset the local/remote Emergency Stop button asfollows:

t) De-activate (disable) emergency stop buttonu) Press the O (OFF) buttonv) Select the desired operating mode (manual or remote).

CODE: 1435 Indicates engine coolant heater is not operating or is not circulatingcoolant. If engine can be stopped allow engine to cool down completelybefore proceeding with the following checks:

w) The coolant heater not connected to power supply.Check for blown fuse or disconnected heater cable and correct asrequired

x) Look for possible coolant leaks and repair as requiredCheck for low coolant level and replenish if required.

LAMP: Warning Set is not operating. Warning occurs when engine coolant temperatureis 21 oC (70 oF) or lower.

MESSAGE: LOW COOLANTTEMP

NOTE: In applications where the ambient temperature falls below4oC (40oF), Low Coolant Temp may be indicated even though thecoolant heaters are operating .

CODE: 1442 Indicates that during cranking, the battery voltage is at, or below, theweak battery warning trip point for a time greater than, or equal to, theweak battery set time.


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LAMP: WarningSee code 441 for corrective actionMESSAGE: WEAK BATTERY

CODE: 1448 Indicates that the generator set frequency has dropped below 90% ofnominal for approximately ten seconds. Allow engine to cool downcompletely before proceeding with the following checks:

y) Check the fuel supplyz) Check the air intake supply, the load and correct any overload.

4.4 FAULT FINDINGShould a fault condition occur during operation follow the procedures in the following

tables to locate and correct the problem. For any symptom not listed, contact an authorisedservice centre for assistance.

Before starting any fault finding, ensure that the following basic checks are carried out: All switches and controls are in their correct positions The fuel oil level is correct The lubricating oil level is correct The coolant level is correct The radiator matrix is free from obstruction The battery charge condition is satisfactory and the connections are secure The generator set electrics and alternator connections are secure The panel connections are secure

The protection circuits have been reset Blown fuses have been replaced Tripped contactors or circuit breakers have been reset


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5. Inpower Connectivity

1. PS0500 can be connected with inpower using the communication cable (Part

no. 0338-4590) and RS485-232 convertor (Part no. 0324-0021).

2. Configure the site of PS0500 in Inpower before moving ahead.

3. Connect one end of the cable to TB15 connector of PS0500

4. Connect the other end of cable to RS 485-232 convertor.

5. Connect the RS232 side of the convertor towards laptop

6. Open Inpower and connect the PS0500 with the created site.

RS 485-232convertorP/N 0324-

0021

LAPTOPP/N ofcable0338-459


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6. Calibration Procedure

NOTE : PS0500 is calibrated from factory. You are not advised to do the calibration for the newpart. Only the required CT ratio has to be selected as per the engine model. Please confirm withAO/ZO before performing calibration.

1. Got to Device -> Initial Calibration


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2. The select calibration window will appear. Select 0326-7727 and click next.

3. History window will appear. The latest calibration should be 1.14 or above. Click NEXT


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4. Save and Restore parameter window will appear. Click NEXT after this.

5. Click the feature number as A029W892 and click FINISH.


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6. Window of Calibration will pop up. Click YES to continue calibration.

7. Window of Device Explorer will pop up and click yes for continuing the calibration.


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8. Progress window will appear. Dont click anything and allow the calibration to happen.

10. A window of EROOR might pop up. Click OK and continue.


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11. Once the calibration is completed, the window for successful calibration will pop up. Click OK to finishthe calibration.


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7. Wiring Diagram

cumins ps0500 service manual.pdf

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