Technical Training Participant’s Guide

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 PowerStart0500 Module
Table Of contents
Introduction.…………….……………………………………………..3

Overview………………...……………………………………………. 5

How to operate me……...……..…………………………………….7

PS0500 control features..…………………..……………………...25

Mounting Guidelines…….…………….………………………… . 28

Control outputs/inputs………………………………………..…...29

Control systems………….………………..…………………….….34

Setup Trims and adjustments……………………………............40

Meter Calibrations……………….…………………………….……44

Wiring diagram…….…………….…………………………….…….51

Environmental capability…………………………………….…….52

Faultcode list……………………………………………………..….53

Troubleshooting………………………………………………….…54

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 Introduction
Welcome! Welcome to the training module for the PowerStart 0500. This module was
written by the Cummins Sales and Service India Limited-Electronic Cell department for your use
and reference. We suggest you read through the entire Introduction to become familiar with the
module’s structure. Then, just follow along in the module during your training session.

Module Purpose
The purpose of the Power Start 0500 training module is to help you to understand the
Power Start 0500 which is going to be used on Low Horse Power (LHP) genset.
With this information, you will be better prepared to meet your customers’ varying needs.

Module Audience
This module was written for dealer service technicians who have previous experience with or
knowledge of electrical engine, and generator basics.

Module Structure
This module contains lessons on related topics. Each lesson follows a carefully designed training
format, including a warm up, presentation, and activity (or exercise).

Module Assessment
After completing all the lessons in the module, you will complete a module assessment. The
module assessment lets us evaluate the level of knowledge you have on the topic after
completing the module.

Module Comment Form

You will also complete a module comment form. This form gives you the chance to comment on
the usefulness and effectiveness of the training module and make suggestions for improvements.
We will use the results from the module assessment and module comment form to help us
determine if there is a need to modify the module.

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Overview

The PS0500 controller is a microprocessor-based generator set monitoring, metering,

and control system. The control provides a simple operator interface to the Genset and engine
parameters, remote start / stop control and generator set protective functions. The control does
not have in-built speed governing and voltage regulation features. It does not support magnetic
pickup connectivity.

The PS0500 series controllers are designed for use on engines from 10 to 100 KW
range, it means it is genset controller without AVR controller in the range of 12.5KVA to 125KVA
for non-paralleling applications. The control can also be configured for various frequency (50 Hz /
60 Hz operation), voltage configuration up to 600 Vrms L-L. The control is designed for mounting
on the generator set.

The control also has a 16X2 LCD module with seven indicator LEDs and six tactile feel
pushbuttons, which can be used for navigation.

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Tactile Push
16 X 2 Alphanumeric
Buttons
display
•Manual
•Auto
•Start Genset sta
•Stop LEDs
•Reset
•Ok

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Module assessment :

1) What is operating range of engine KVA rating for PS0500?

2) What are the functions of PS0500 controller?

3) Will PS0500 support voltage regulation?

4) What is maximum line to line RMS voltage reading configured in PS0500?

5) Can we get MPU support for PS000?

6) Can we start engine remotely by PS0500?

7) Will PS0500 support paralleling operation?

8) How many push buttons are uses in PS0500?

9) How many indicator LEDs are use in PS0500?

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How to operate PS0500

The reason to include this module,is to make everyone aware of the product and its
operations.
One who will go through this will be very well educated about PS0500,its
operations,applications.

This is basic block diagram for PS0500,which will be refer throughout this module for
your reference.

PS0500

LCD Display
(16*2)

Genset Running
Manual Start Auto
Remote Start

Shutdown

Reset Stop OK Warning

PowerStart

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 Lets first know how to start PS0500 after connecting it to 12V battery supply.
PS0500

BattVolts =-------
GensetHrs=------

Genset Running
Manual Start Auto
Remote Start

Shutdown

Reset Stop OK Warning

PowerStart

Press this button

Once you press this push buttons all LED’s will glow for 1 second. And LED above
STOP button will start bblinking continuosly.While as on display show message shown
as in above picture.

The display of PS0500 has three display mode-

1)Monitor
2)Set Up
3)Calibration

Monitor mode allows user to monitor the Genset parameters

Monitor mode has 2 modes of operations
Scroll - The display will scroll the screen one by
one
Scroll Stop – User can monitor a desired screen
continuously

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In scroll mode one will observe following screens,the screens will scroll in the time span
of 2 sec.

L1N=000 L2N=000 Current Flt=212

L3N=000 HZ=00.0 Clnt TempOOR Wrn
2 sec delay

2 sec delay

L12=000 L23=000 E Stop=Inactive

L13=000 HZ=00.0 Cust In=Inactive

2 sec 2 sec
delay delay
I1=00.0 KVA=00.0 Batt Volts=11.7
I2=00.0 I3=00.0 Genset Hrs=00000

2 sec delay 2 sec

delay
KVA1 KVA2 KVA3 Oil Press=003PSI
2 sec
00.0 00.0 00.0 delay
Clnt Temp=342F

Following is the explanation for all above screens.

L1N=000 L2 N=000
L3N=000 HZ=00.0

Table

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 L1N Line1 to Neutral Voltage

L2N Line2 to Neutral Voltage

L3N Line3 to Neutral Voltage

HZ Frequency

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

Table
L12 Line 1 to Line 2 Voltage

L23 Line 2 to Line 3 Voltage

L13 Line 1 to Line 3 Voltage

HZ Frequency

I1=0.0 KVA=00.0
I2=00.0 I3=00.0

I1 Line 1 current

KVA Total power

I2 Line 2 current

I3 Line 3 current

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 KVA1 KVA2 KVA3
00.0 00.0 00.0

Table

KVA1 Line1 Power

KVA2 Line2 Power

KVA3 Line3 Power

Oil Press=003PSI
Clnt Temp=342F

Table

Oil Press Oil Pressure

Clnt Temp Coolant Temperature

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 Batt Volts=11.7
Genset Hrs=00000

Table

Batt Volts Battery Voltage

Genset Hrs Genset Hours

E Stop=Inactive
Cust In=Inactive

NOTE: E Stop and Cust In shows the status of the

Table input that whether it is active or inactive

E Stop Emergency Stop

Cust In Customer Input

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 Current Flt=212
Clnt Temp OOR Wrn
NOTE: It displays the type of the warning for
the fault condition

Table
Current Flt Current Fault

Clnt Temp OOR Wrn Coolant Temperature Out Of Range

Warning

How to enter the Scroll Stop Monitor mode ?

L1N=000 L2N=000
L3N=000 HZ=00.0

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Press Ok button to stop the scrolling and enter scroll stop to
monitor the parameters on specific screen continuously
How to exit from the Scroll Stop Monitor mode ?

L1N=000 L2N=000 L12=000 L23=000

L3N=000 HZ=00.0 L13=000 HZ=00.0
OK

Press Ok button on front

panel

To enter into SETUP mode-

After going to stop mode only we can enter in to Setup mode.

Entering into the

Reset Ok Config Mode…
Press
For 5
Sec No Navigation is needed

SW PART 3267727
SW VER 1.01

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One need to understand key to operate-

Keys Properties

Will go to the next value

Will go to the Previous value

Will go down

It shows the default value. when we select the particular

* value it will comes to that value

Following are the screens of the display when you will enter setup mode.Use
above explain keys to go through and to change the value.
Jus look down for more clear understanding.

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Main Menu
Alt SetUp

Main Menu
Units

Main Menu
Sensor Config

Main Menu
Customer I/O

Main Menu
Battle Shot

Main Menu
Flt History

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 Phase Type
*3 Phase

Phase Type
Main Menu Single2 wire
Phase Type Phase Type CT Ratio
Single 3 wire *100:5
Main Menu
CT Ratio CT Ratio
200:5
Main Menu
Alt SetUp Main Menu Connection type
Connect type *Star Connect

Connection type NomVolt L-L

Main Menu Delta Connect *416 Volts
NomVolt L-L
NomVolt L-L
440 Volts
Freq Main Menu
*50 Hz Freq NomVolt L-L
480 Volts
Freq
60 Hz NomVolt L-L
600 Volts

Setup screen

Units
*USA

Main Menu
Units

Units
Metric

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 Oil Pr Input
*Sensor

Main Menu Sensor config Oil Pr Input

Sensor Config Oil Pr Input Switch

Setup screen

Customer O/P1
*Warning faults

Customer O/P1
Shutdown faults
Customer I/O
Customer O/p1 Customer O/P1
Main Menu Glow Plug
Customer I/O
Customer I/O
Customer O/P2
Customer O/P2
*Warning Faults
Customer I/O
Cust I/P Flt 1 Customer O/p2
Shutdown Faults
Cust I/P Flt1
*Warning Faults Customer O/P2
Genset Running
Cust I/P Flt1
Shutdown Faults

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 Battle Shot
*Inactive
Main menu
Battle Shot
Battle Shot
Active

Hours Flt 1
0000.00 212

Hours Flt 2
0002.10 002
Main Menu
Flt History Hours Flt 3
0002.09 215

Hours Flt 4
0002.00 074

Hours Flt 5
0001.88 213

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To enter into CALIBRATION MODE-

Entering into the

Reset Ok Config Mode…
Press
For 5 Sec
No Navigation is needed

SW PART 3267727
SW VER 1.01

Meter calibration screens

Keys Action

will increase the voltage value

will decrease the voltage value

will calibrate next value

will calibrate previous value

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 Voltage Screen Current Screen

. L1N L2N L3N I1 I2 I3

234 235 234 025 024 024

Initially dot is set to default value( set to L1N). If we press the

the next values

When the dot is on L3N and [ (button)] is pressed, then current screen will
be loaded

When the dot is on I1 and [ (button)] is pressed, then voltage screen will
be loaded

This will guide you for calibrations of voltages and currents.

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For any shutdown shutdown LED will glow.

LCD Display
(16*2)

Genset Running
Manual Start Auto
Remote Start

Shutdown

Reset Stop OK Warning

PowerStart

This LED will glow

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For any warning ,warning LED will glow-

LCD Display
(16*2)

Genset Running
Manual Start Auto
Remote Start

Shutdown

Reset Stop OK Warning

PowerStart

Warning LED will glow

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Assessment module-
One need to use PS500 once.It is mandatory for all participants to practice
on PS0500 to get to introduced to system.

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PS0500 Control Features

• Operates on 12 VDC
The operating voltage for PS0500 is 12VDC.
• Low power sleep mode
• Phase voltage and current sensing. Current sensing with an external 0 - 5 amp current
transformers.

• Engine starter and fuel shutoff relay driver - capable of driving 1A load. There are no on-
board relays present. External relays are required to be wired for starter and fuel shutoff.
Relay K7 drives starter while as relay K8 drives Fuel shutoff valve. E-stop on canopy is
connected through this relay supply connections. As you push E-stop on canopy relay
supply will disconnect and engine will stop immediately. These connections for relay driver
are coming from J16 connector pin no’s 3 and 4 respectively. Pole connection P1 and P2
are connected to starter positive. While as output for both the relays are connected to pull
and hold of Fuel shut off coil respectively.

• Generator set monitoring - Display status of critical engine parameters like battery voltage ,
coolant temperature , lube oil pressure , engine run hours, All parameters are scrolling on
the display one by one. One can observe that parameter by seeing in to the display
continuously. To watch single parameter one has to press OK push button on the screen
while screen is scrolling. Screen will stop at that particular parameter and one can see
required and wanted parameter. One has to push OK button on PS0500 to start scrolling of
display again.
• Generator set monitoring - Display status of critical electrical parameters like line to line
voltage , line to neutral voltage , current for three phase , operating frequency, KVA ratings
for three phases.

• Genset protection – Engine and Alternator protection features

 Low lube oil pressure warning /shutdown
 High coolant temp warning /shutdown
 Low/high/ weak battery voltage warning
 Fail to start warning
 High / low AC voltage shutdown
 Under / over frequency shutdown
 Loss of AC sense shutdown

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 All the above said protection can be seen on display as well as in InPower. All the necessary
adjustments can be done through InPower on case of any of above cases.PS0500 has
InPower compatibility.
It can be connected to InPower same as that of one connects for PCC1301.One must have
registered dongle (P/N=0326-6648-04), InPower V6.0 (0326-6957-02), communication cable
of PCC1301 (P/N=0338-5490), laptop.
• Customer Input - One discrete customer input, active GND. Customer Output – One Low
Side driver output for driving external relay.

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Module Assessment
1) What is CT ratio?

2) What is maximum load current capacity for relay driver?

3) Which relay drives fuel shut off valve?

4) What is operating voltage for PS0500?

5) What is driven by relay K7?

6) Which push is use to stop scrolling of display?

7) Which are the parameters observe in display?

8) Which engine protection is provided in PS0500?

9) Is there any protection given for battery voltage?

10) Do we have under frequency protection provided in PS0500?

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Mounting Guidelines
The control is suitable for non-engine mounting. As such should not be directly mounted on the
engine.
The control may be mounted on a suitable frame on top of the alternator, or on a frame supported
from the genset base rail or on a stand alone mounting frame suitably isolated from the vibration
of the genset. Appropriate vibration isolators should be used to make sure that the control is not
subjected to vibration levels beyond the specifications.
To avoid occurrences of the control board being exposed to conditions beyond their
specifications, care should be taken not to mount them close to the engine exhaust pipes. Also
mounting them in a manner that would expose them to direct sunlight, rain/snow should be
avoided.

Grooves
to put
Screw

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 Control outputs and Inputs

TB15 – Tool Connector

Arrow at Pin 1

J12 – CT connector
Arrow at Pin 1

J12 –Pin 4

J16 – Engine connector

Arrow at Pin 1

J16 –Pin 7

J22 – Voltage conn

Arrow at Pin 1
TB1 – Customer TB
Arrow at Pin 1

Engine Connector
The engine connector (J16) is a 12 pin connector-plug (12 MINI M-N-L). A possible supplier is
Molex; their part number is 39299123. The Cummins part number for this connector is 0323-
2589. The PCB outline drawing shows where the connector is located as above .Each signal is
described as below –

Connector Pin Signal Name

J16-1 NC
J16-2 NC

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 J16-3 Oil pressure sensor
J16-4 Starter disc input
J16-5 Sensor Common
J16-6 BAT +
J16-7 Coolant temperature sensor
J16-8 Battery charging alternator (WL)
J16-9 Starter Relay Driver (Low Side)
J16-10 Fuel shutoff relay Driver (Low Side)
J16-11 BAT-
J16-12 Chassis GND

CT Connector
The CT connector is a 6- pin MATE-N-LOCK connector. The possible manufacturer is Tyco, and
the supplier part number for the part is 643749-1. The Cummins part number for this connector is
0323-2154. Connector details are as follows –

Connector pin Signal

J12-1 CT1_input
J12-2 CT2_input
J12-3 CT3_input
J12-4 CT1_COM
J12-5 CT2_COM
J12-6 CT3_COM

Voltage Connector
The voltage connection is via a 4 pin header with alternate spaces between the pins. The
possible supplier is Tyco with the supplier part number as 282828-4. The Cummins part number
for the same is 0323-2225-03.

Connector pin Signal

J22-1 Gen_V1
J22-2 Gen_V2
J22-3 Gen_V3
J22-4 Gen_N

Customer Connection TB
The customer connection TB2 is a 6 pin terminal block. The possible supplier is Magnum:
The terminal pins details are as shown below-

Terminal pins Signal

TB2-1 Remote start Switch Input
TB2-2 Customer Output Relay Driver
(Low Side)
TB2-3 Glow Plug Output Relay Driver
(Low Side)
TB2-4 Remote E-Stop
TB2-5 Customer Input

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 TB2-6 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 controller’s 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 be made in the harness to provide the B+ signal for convenience of wiring up external relays
and may be used as relay supply (high side) for FSO, Starter, Customer Output and Glow plug
Relays via a 1 Amp Fuse.

PC Tool Connector
The PC tool connector is a dedicated 5 pin connector header block. The possible supplier is
Tyco, with the supplier part numbers are 796643-5. The Cummins part number for the same is
0323-2191-04.

Terminal pins Signal

TB15-1 GND
TB15-2 NC
TB15-3 RS485_DATA_A
TB15-4 RS485_DATA_B
TB15-5 TOOL_WAKEUP

Connector Part Numbers

Remarks
Manufacturer’s Cummins
Quantity Name Description Manufacturer
part number part no

Alt Voltage All these

1 J22 TYCO 282828-4 0323-2225-03 connectors
Connector
are PCB
1 J12 CT Connector TYCO 643749-1 0323-2154 mounted
connectors
Engine
1 J16 MOLEX 39299123 0323-2589
Connector
EM257506VC
1 TB2 Customer TB MAGNUM 0323-1677-05
796643-5
Tool
1 TB15 TYCO 0323-2191-04
Connector

Remarks
Manufacturer’s Cummins
Quantity Name Description Manufacturer
part number part no

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 Alt Voltage All these
1 J22 TYCO 282809-4 0323-2226-03 connectors
Connector
CT Connector 1-480704-0 0323-1932 are used in
1 J12 TYCO the harness
Crimp
350551-1 0323-1200
Terminals
Engine
39012120 0323-2602
Connector
1 J16 MOLEX
Crimp 39000038
0323-2603
terminals
EM256506H
1 TB2 Customer TB MAGNUM 0323-1678-05

Communication cable Kit 0541-1199 is used for

Tool the tool interface
1 TB15 TYCO
Connector

Wiring Information

• For connecting Battery supply, use two twisted pair wires minimum 1 sq mm cable size
(16 Gauge).
• The On board drivers are low side drivers capable of driving 1AMP. External relays with
an appropriate contact rating should be used in the FSO, Glow Plug, Customer Output
and Starter solenoid circuits. Also make sure to use appropriate wire size based on the
current drawn by the solenoids.
• For connecting current transformers use three twisted pair wires minimum 1 sq mm (16
Gage).
• For All other connections use minimum 0.8 Sq mm (18 Gauge) wires.

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Module assessment
1) What is function for TB1?

2) How many pins are in engine connector?

3) Which pin has received battery negative on engine connector?

4) Which is pin on engine connector for sensor common signal?

5) What is Cummins P/N for J-16 connector?

6) What is Cummins P/N for J-12 connector?

7) On what pin no, voltage neutral signal goes on voltage connector?

8) What is Cummins P/N for voltage connector?

9) How to protect controller?

10) What is Cummins P/N for tool connector?

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Control System

Engine Sensors
Coolant Temperature Sensor
The PS0500 control can be programmed to use one of the following temperature sensors.

Internal P/N. Man / Man P/N Resistive Temp Range Threading

0193-0529-01 AirPax / 5024-0250 -40 to +230 F 3/8 “NPTF
0193-0529-02 AirPax / 5024-0274 -40 to +230 F M14 X 1.5 with “O” Ring

Coolant Temperature Sensor Connector

Internal Man Man P/N Comments

P/N.
0323-1755 Packard 121621893 Plastic shell with seal
0323-1818 Delphi 12124075 Socket Connector

Temperature sensor

Lube Oil Pressure Sensor

The PS0500 control can be programmed to use the following pressure sensors. While using the
single wire sensor the Sensor return wire from harness needs to be grounded to Engine body.

Internal P/N. Man/ Sensor Type Range / Unit Nominal

Man P/N Resistance /
Voltage
0193-0430-01(Dual wire) F.W. Standard Resistive 0-100 PSIG 240 – 33 Ohms
Murphy Sender
ES2P-100
0193-0244 (Single Wire) - Standard Resistive 0-100 PSIG 240 – 33 Ohms
Sender
3814118 Pricol Resistive Sender 0-5 Kg/Cm2 0 – 134 Ohms
0309-0641-XX - Switch - -

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Pressure sensor

- 35 -
Part Number - 3814118
Lube Oil Pressure Switch
The Part number for Lube Oil Pressure Switch is 0309-0641-XX. XX - depends on the trip
pressure point. Select proper lube oil pressure switch.
If an oil pressure switch is used, the active state (active high or active low) of the switch must be
configured using a PC based service tool. A software trim allows selection of the active state of
the switch. The trim parameter for this is,
Lube Oil Pressure Switch Polarity = Active High, Active Low.

While using the switch the Display will only show the status of oil pressure as “OK” or “Not OK”.
The input is active low i.e. when the pressure is healthy the input is low.

Engine Control

Remote Start Mode

The control accepts a ground signal from remote devices to automatically start the generator set
and immediately accelerate to rated speed and voltage. The control can incorporate a time delay
start and stop in AUTO mode. The ground signal needs to be removed to stop the set in normal
condition.

Emergency Stop
The Emergency Stop will be active when the ground signal is removed. This means a normally
closed emergency stop switch needs to be wired between TB2-4 to Battery ground. Activation of
the emergency will stop the generator set immediately to shut down. The generator set is
prevented from running or cranking with the switch latched to open position. 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 controller’s E-Stop input
to GND to indicate to the control when the E-Stop is pushed in active state.

Sleep Mode
When the mode select switch is in the STOP or AUTO position, the control will go into a low-
power-consumption mode until the Reset button on the panel is operated or Remote start is
received. The control will also wake-up after receiving a Remote start command if the control
goes to sleep mode during Auto mode. If any warning or shutdown fault is active then control will
enter the sleep mode.

• The “Sleep in AUTO” mode can be enabled or disabled from service tool.
• The “Sleep in AUTO” is defaulted as Disable.

Engine Starting
The control system supports automatic engine starting. It requires an external suitable contact
rating relay for the starter motor and fuel shutoff. Primary and backup start disconnects are
achieved by one of two methods.
Battery charging alternator feedback
Main alternator output frequency.

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Cycle Cranking
Configurable for number of starting cycles (1 to 7) and duration of crank and rest periods. Control
includes starter protection algorithms to prevent the operator from specifying a starting sequence
that might be damaging.

Glow Plug Control

The control supports programmable glow plug control. This feature can be disabled when not
required. The trim parameter for this is Glow Plug = Enable/Disable. If Glow Plug is disabled then
the output can be configured as common warning or common shutdown.

Time Delay Start and Stop (Cool down)

The control can be configured for time delay of 0-300 seconds prior to starting after receiving a
remote start signal, and for time delay of 0-600 seconds prior to shut down after receiving signal
to stop in Auto modes. Default for start time delay is 0 while stop time delay period is 120
second.

Engine Speed Sensing

The PS0500 control derives the engine speed from the alternator output frequency. Starter
disconnect is derived from the battery charging alternator or alternator frequency.

Battle Short Mode

The PS0500 control can be programmed to work in battle short mode by setting the battle short
trim to enable by manufacturing tool or PC based service tool only.

Genset Protective Functions

On operation of a protective function the control will indicate a fault by lighting the respective LED
on the control. The warning or shutdown LED will glow, fault code and short description will be
displayed on the display. The nature of the fault and time of occurrence will be logged. The
service manual and PC based service tool provide service keys and procedures based on the
service codes provided.
The control provides the following system protective functions:
• Configurable Alarm and Status Inputs – The PS0500 control will accept one alarm
input to indicate customer-specified conditions. The input is programmable for warning or
shutdown. The fault condition on this input will be annunciated as “Cust I/P Flt”
• Emergency Stop - Annunciated whenever the emergency stop signal is received from
an external switch.
Engine Protection
• Over Speed Shutdown – Engine Over Speed default setting is 115% (configurable with
a PC based service tool) of the rated engine speed nominal. Control includes time delays
to prevent nuisance shutdown signals.

- 37 -
 • Low Lube Oil Pressure Warning/Shutdown - Level is preset (configurable with a PC
based service tool) to match the capabilities of the engine used. Control includes time
delays to prevent nuisance warning/shutdown signals.
• High Engine Temperature Warning/Shutdown - Level is preset (configurable with PC
based service tool) to match the capabilities of the engine used. Control includes time
delays to prevent nuisance warning/shutdown signals.
• Low Battery Voltage Warning - Indicates battery charging system failure by
continuously monitoring battery voltage. Control includes time delays to prevent nuisance
warning signals.
• High Battery Voltage Warning – Indicates battery charging system is of higher level by
continuously monitoring battery voltage. Control includes time delays to prevent nuisance
warning signals.
• Weak Battery Voltage Warning - Control system will test the battery bank each time the
generator set is signaled to start, and indicate a warning if the generator set battery
indicates impending failure. Control includes time delays to prevent nuisance warning
signals.
• Fail to Start Shutdown. Control has completed the programmed crancking cycle but
generator does not start. After predefined crank attempts the control will declare the Fail
to Start shutdown fault.
• Cranking Lockout - The control will not allow the starter to attempt to engage or to crank
the engine when the genset is running.
• Sensor Failure Indication – Out of range high / low diagnostic logic is provided. Control
will detect analog sensor or interconnecting wiring failures.
Alternator Protection
• High / Low AC Voltage Shutdown – The control will announce the faults when ever the
voltage is higher than 110% of the rated voltage for 5 seconds continuously or voltage is
higher than 130% of the rated voltage (Instantaneous). Threshold for Low AC voltage
fault is 85% of the rated voltage for 5 seconds continuous.
• Under/Over Frequency - Under frequency fault is announced if the frequency is less
than the normal frequency by 6Hz for 10 seconds continuous. Over frequency fault is
announced if the frequency is more than the normal frequency by 6Hz for 10 seconds
continuous.
• Loss Of Sensing AC Voltage Shutdown – Loss of sensing AC voltage detects the loss
of voltage sensing or senses the loss of zero crosses. This fault will also be the primary
way to detect short circuit conditions.

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Module assessment:
1) What is P/N for temperature sensor?

2) What is resistive temperature range for temperature sensor?

3) What is connector p/n for temperature manufacture by Packard?

4) Is pressure sensor use is three wires?

5) What is resistance range for pressure sensor?

- 39 -
 Setup, Trims and Adjustments

Setup
While applying a PS0500 control to a new application, the following parameters should be
ensured to have appropriate values. The table below lists the default values of the various
parameters. Some of these parameters can be adjusted using the operator panel but the others
require use of InPower.

It is intended that there will be only one software part number (0327-7727) for the PS0500
control.

Parameters like nominal voltage, frequency, CT Ratio etc need to have appropriate values at the
manufacturing time based on the application requirements. This may be accomplished by
InPower

The default values are intended to be suitable for major volume application. As of now it is
known to be S and B series Gensets and sub 12 kW Gensets manufactured in India.

Operator Default
InPower Panel value
Group Parameter Name Adjustability Adjustability Possible Values Units
Adjustment Lower Higher

Setup –
Nominal Voltage (L-L) Y Y 190 600 416 V AC
Genset
Y 50 or 60 50
Nominal Frequency Y Hz
Delta or WYE WYE
Y Y
Connection type -
Single Phase 2 wire,
Single Phase 3 wire or
Y Y Three
Three Phase
Phase type -
CT ratio Y Y 50 to 300 100 Amp
Oil Pressure Input Sender
Y Y
Type Switch Sender N/A
Oil Pressure Sensor Onan
Y Y
Type Onan CIL N/A
Cycle Crank Attempts Y N 1 7 3 Attempts
Cycle Crank time Y N 3 30 5 Sec
Cycle Crank Rest time Y N 0 60 5 Sec
Enable or Disable Disable
Y N
Battle Short Enable NA
Start Time Delay Y N 0 300 0 Sec
Stop Time Delay Y N 0 600 120 Sec
Sleep In AUTO Mode Y N Enable Disable Disable N/A
Speed/Hz gain Select Y N 20,30 and 60 30 N/A
Setup -
Configurabl
e I/O

- 40 -
 Operator Default
InPower Panel value
Group Parameter Name Adjustability Adjustability Possible Values Units
Active open or Active Active
Customer Input Active Y N closed closed
State Select N/A
Customer Input Fault Y Shutdown
Select Trim Y Warning or Shutdown, N/A
Y Common warning, Common
Customer output #1 Common Shutdown or Warning
Function Y Glow-Plug N/A
Y Common warning, Common
Customer output #2 Common Shutdown or Shutdown
Function Y Genset Running N/A
Alternator
Protection High AC Voltage Y N 105 125 110 % %
Adjust Threshold
High AC Voltage Delay Y N 1 10 5 Sec
Low AC Voltage Y N 90%
Threshold 50 95 %
Low AC Voltage Delay Y N 2 20 5 Sec
Under Frequency
Y N 2 10 6 Hz
Threshold
Under Frequency N 1000
Y
Delay 500 2000 ½ cycles

Over Frequency Y N 2 10 6
Shutdown Threshold Hz
Over Frequency Delay Y N 100 2000 1000 1/2 cycles
Protection – Low Oil Pressure Y N 29
Engine Shutdown Threshold 10 100 Psig
Low Oil Pressure Y N 5
Shutdown Delay 2 15 Sec
Low Oil Pressure Y N 36
Warning Threshold 10 100 Psig
Low Oil Pressure Y N 5
Warning Delay 2 15 Sec
High Coolant Y N 209
Temperature
Shutdown Threshold 180 300 deg f
High Coolant Y N 5
Temperature
Shutdown Delay 2 10 Sec
High Coolant Y N 203
Temperature Warning
Threshold 150 290 deg f
High Coolant Y N 5
Temperature Warning
Delay 2 10 Sec
Low Battery Voltage 11
Threshold for 12 V
battery Y N 11 13 VDC
Low Battery Delay for Y 30
12 V battery N 2 60 Sec

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 Operator Default
InPower Panel value
Group Parameter Name Adjustability Adjustability Possible Values Units
High Battery Voltage Y 16
Threshold for 12 V
battery N 14 17 VDC
High Battery Delay for Y 30
12 V battery N 2 60 Sec
Weak Battery Voltage Y 8
Threshold for 12 V
battery N 6 10 VDC
Weak Battery Delay for Y 3
12 V battery N 1 5 Sec

Install a PC based service tool onto desktop or laptop.

To install a PC based service tool follow in the installation instructions for the tool.

Creating and saving calibrations in the control via Capture File

Saving calibrations in the control –

Once trim or parameters has been changed, save trims in the control, disconnect the PC
based service tool and do a power down reset of the control. Repower the control,
reconnect with the service tool and take a Capture file.

Restoring Calibration -
To reconfigure a control with the content of a Capture File, connect to the controller with
the service tool, connect to the desired Capture File and drag the content of the Capture
File to the control and save trims.

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Module assessment
1) Which parameters need to have appropriate values at the time of manufacturing?

2) Which engine families will support PS0500?

3) What is range for nominal voltages (L-L)?

4) How many cycle crank attempts can be set in PS0500?

5) What is start time delay provided?

6) What is default value for stop time delay?

7) What is range of High AC voltage threshold?

8) What is default value for under frequency threshold?

9) What is Low oil pressure shutdown threshold default value?

10) What is default value for High coolant temperature threshold?

11) What are default value for high coolant temperature warning threshold and delay?

12) What is weak battery voltage threshold default value?

13) What are default value for low battery & high battery voltage threshold?

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Meter Calibration
PS0500 can be calibrating from DISPLAY and InPower as well.

Procedure to calibrate display:

The display of the PS0500 control may need to be calibrated.

The meter calibration is done when the genset is running.

The display must be calibrated as per the procedure below -

1. To enter meter calibration, press “Reset” while holding down “OK” for 5 seconds.
2. A screen will appear saying “Entering Calibration”

DISPLAY INTERFACE
- Setup

To enter into the Set up mode :

 After going to the stop mode only we can enter the Setup mode

Entering into the

Reset Ok Config Mode…
Press
For 5 Sec
No Navigation is needed

SW PART 3267727
SW VER 1.01

23
3.
4. Some of the pushbuttons on the operator panel are used for navigation as indicated by
an arrow on the pushbutton.

Keys Function
Will go to the next value

Will go to the Previous value

// Will go down

* It shows the default value.

when we select the particular
value it will comes to that
value

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 5. When in meter calibration, the voltage screen will be displayed first as below.

6. Increase/Decrease the L1-N voltage by pressing the ↑/ ↓ till the desired value is achieved.
7. Press → (OK) to OK this setting and move to L2-N voltage.
8. Increase/Decrease the L2-N voltage by pressing the ↑/ ↓ till the desired value is achieved.
9. Press → (OK) to OK this setting and move to L3-N voltage.
10. Increase/Decrease the L3-N voltage by pressing the ↑/ ↓ till the desired value is achieved.
11. Press → (OK). The screen will change to Current Calibration as below

12. Press → (OK) to move to I1 current.

13. Repeat the same for I2 and I3 calibration.
14. Press → (OK) to exit the Meter calibration. This will also save the adjusted values of the
voltage and current in the control.

This is display interface setup .Anyone can calibrate using this guide.

DISPLAY INTERFACE
- Setup Phase Type
*3 Phase

Phase Type
Single2 wire
Main Menu
Phase Type
Phase Type CT Ratio
Single 3 wire *100:5
Main Menu
CT Ratio CT Ratio
200:5
Main Menu
Alt SetUp Main Menu Connection type
Connect type *Star Connect

Connection type NomVolt L-L

Main Menu Delta Connect *416 Volts
NomVolt L-L
NomVolt L-L
440 Volts
Freq Main Menu
*50 Hz Freq
NomVolt L-L
480 Volts
Freq
60 Hz NomVolt L-L
600 Volts
26

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Procedure to calibrate from InPower:

One need to have latest INCAL cd for successful and appropriate calibration, communication
cable for PCC1301 (P/N=0338-5490), Laptop loaded with InPower V6.0.Adapter (0324-0021),
Dongle (0998-0077-04).

Before going for calibration one need to check site setup for PS0500.

Go to START command for windows

ALL PROGRAMMS
Open Power Generation folder

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Open SETUP
Go to SITE SETUP

- 47 -
Click on ADD
SITE TYPE: PHYSICAL
Site ID: PS0500
Protocol: mon
COM Port: Respective to each computer.
Click on OK.

- 48 -
Then we have to open InPower
Connect to PS0500 site.
Go to Device

Click on Initial calibration

Do all the steps same as that one need to do for PCC1301.

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Module assessment:

1) Can we calibrate controller from display?

2) Which are two push buttons use to enter in meter calibration?

3) Write down the procedure for meter calibration of voltage.

4) Write down procedure for site setup in InPower.

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Wiring Diagram

- 51 -
Environmental Capability

The control board is designed to withstand vibration levels of 50 mm / sec in 20 to 100 Hz range
and of 3.3 G in the range of 100 -2000 Hz.

The base control is designed for proper operation without recalibration in ambient temperatures
from –20 Deg C to +70 Deg C, and for storage from –30 Deg C to +70 Deg C. Control will
operate with humidity up to 95%, non-condensing, and at altitude up to 13,000 feet (5000
meters).
The control board has conformal coating. The high voltage part of the circuit board is covered
with protective cover.
The front panel of the control has an overlay to protect from the effects of dust, moisture, oil, and
exhaust fumes.
The control system is specifically designed and tested for resistance to RFI / EMI and the effects
of vibration to provide a long reliable life when mounted on a generator set. The control includes
transient voltage surge suppression to provide compliance to referenced standards

Fuse Details
A fast acting ceramic fuse with a rating of ten amperes shall be placed inline with the Sense U
(J13-4) voltage sensing lead.

A fast acting Auto type fuse with a rating of five amperes shall be placed inline with the B+ supply
for the control.

A fast acting Auto type fuse with a suitable rating shall be placed inline with the Pull and Hold
supply of the Fuel Shut off valve.

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Fault Code List
Fault Description Fault
Code
Shutdown Faults
Common Shutdown 157
High Coolant Temp. Shutdown 151
Low Oil Pressure Shutdown 415
High AC Voltage Shutdown 1446
Low AC Voltage Shutdown 1447
Over Frequency Shutdown 1448
Under Frequency Shutdown 1449
Loss of AC Voltage Sensing Shutdown 2335
Engine Overspeed Shutdown 234
Emergency Shutdown 1434
Fail To Start Shutdown 359
Fail To Stop Shutdown 2677
Configurable Fault Input#2 Shutdown 1312
Shutdown After Battle Short 1123
Fault Description Fault
Code
Warning Faults
Common Warning 156
High Coolant Temp. Warning 146
Low Coolant Temp. Warning 1435
Coolant Temp. OOR Warning 144
Low Battery Voltage Warning 441
High Battery Volatge Warning 442
Low Oil Pressure Warning 143
Oil Pressure OOR Warning 141
Battle Short Mode Active Warning 1131
Battery Charging Failure Warning 2678
Fail to Shutdown Warning 1416
Weak Battery Voltage Warning 1442

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Troubleshooting
GENERAL
The PS0500 control continuously monitors engine sensors for abnormal conditions, such as low
oil pressure and high coolant temperature. If any of these conditions occur, the control will light a
yellow warning lamp or a red shutdown lamp and display a message on the LCD display.

PC BASED SERVICE TOOL

The PC based service tool can be used in troubleshooting to perform tests, verify control inputs
and outputs, and test protective functions.

When used improperly, a PC based service tool can cause symptoms like warnings and
shutdowns that appear to be a defective base board. When these problems occur, always verify
that a self-test or fault simulation (override) have not been left enabled with the tool. If you do not
have a PC based service tool, or the enabled fault simulation(s) can not be found using the tool,
disconnect battery power to disable the test or override condition.

Make sure that parameter adjustments and time delays, related to the fault condition, have been
appropriately set for the application. It may be necessary to write the initial capture file to the
device or update the calibration file. Updating a calibration file requires a Pro version of many of
PC based service tools. Confirm that the installed calibration part number matches the serial plate
information.

CAUTION using the wrong capture file can result in equipment damage. Do not swap Base
boards from another genset model and only use the calibration file shown on the
nameplate.

SAFETY CONSIDERATIONS
WARNING Contacting high voltage components can cause electrocution, resulting in severe
personal injury or death. Keep the output box covers in place during troubleshooting.

WARNING Ignition of explosive battery gases can cause severe personal injury or death. Arcing
at battery terminals, light switch or other equipment, flame, pilot lights and sparks can ignite
battery gas. Do not smoke, or switch trouble light ON or OFF near battery. Discharge static
electricity from body before touching batteries by first touching a grounded metal surface.

Ventilate battery area before working on or near battery—Wear goggles—Stop genset and
disconnect charger before disconnecting battery cables—Disconnect negative (-) cable
first and reconnect last.

CAUTION Disconnect battery charger from AC source before disconnecting battery cables.

READING FAULT CODES

The fault code and message can be viewed on the display. After the fault is acknowledged and
corrected, the recorded fault will be deleted from the control panel memory, but will remain in a
data log to maintain a fault code history. A PC based service tool is required to view this data log.

TROUBLESHOOTING PROCEDURE
The following tables are a guide to help you evaluate problems with the generator set. You can
save time if you read through the manual ahead of time and understand the system.

Voltage/Continuity Testing
Voltage and continuity tests are required in the following tables. In some cases, it is necessary to

- 54 -
remove a plug to complete the test. Where required, the corrective action will mention when it is
necessary to remove a plug for testing. In other cases, the plug cannot be removed for testing.
When plug removal is not mentioned, testing must be performed by inserting a narrow meter
probe into the back of the plug.

TABLE 20-1. ENGINE DOES NOT CRANK IN MANUAL MODE (NO FAULT MESSAGE)
Reason: This indicates that the control has not received or recognized a manual start signal.
Effect: Engine will not start.
POSSIBLE CAUSE CORRECTIVE ACTION
1. No power supplied Check wakeup conditions
to control.
Poor battery cable Poor battery cable connections. Clean the battery cable terminals and
connections. tighten all connections.
Clean the battery
cable terminals and Remove connector P16 and check for B+ at P16-6 and GND at P16-11.
tighten all connections. If B+ or ground missing, isolate to harness and TB BAT terminal
mounted on engine block. If B+ and ground check OK, cycle power to
Fuse Blown base board by reconnecting P16 and retry operation.
2. Base board not Confirm that the installed calibration part number matches the serial
properly calibrated or plate information. Re-enter calibration file if necessary.
corrupt calibration.
3. The Emergency With Emergency Stop push button not activated (switch closed),
Stop switch or wiring is remove configurable leads from TB2-4 and B- and check for continuity
defective. between these two leads. If circuit is open, isolate to Emergency Stop
switch and wiring. If there is continuity, go to next step.

5. Oil Pressure switch Remove P16 connection and check wiring between P16-3 and P16-5 to
or wiring is defective the switch.
Verify control is configured for the type of switch installed.
Verify proper operation of the switch
6. Oil Pressure sender, Remove P16 connection and check wiring between P16-3, P16-5 to the
setup on wiring is sender. Verify control is configured for the type of sender. Verify
defective. operation of the sender

TABLE 20-2. ENGINE DOES NOT CRANK IN REMOTE MODE

(NO FAULT MESSAGE)
Reason: This indicates that the PS0500 control has not received or recognized a remote start
signal.
Effect: Engine will not start in remote mode, but starts in manual mode.
POSSIBLE CAUSE CORRECTIVE ACTION
1. The remote start Reset the control. Attempt to start, and check for ground at TB2-1.
switch or configurable If ground level is not present, isolate to the remote switch or
wiring is faulty. configurable wiring. Repair as necessary.

If ground level is present then the control is bad. Replace the control

TABLE 20-3. WARNING AND SHUTDOWN CODES

FAULT CODE CORRECTIVE ACTION
151 Indicates engine has overheated (coolant temperature has risen above
HIGH COOLANT the shutdown trip point).
TEMP Allow engine to cool down completely before proceeding with the
Lamp: Shutdown following checks:
a. Check coolant level and replenish if low. Look for possible

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 coolant leakage points and 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.
415 Indicates engine oil pressure has dropped below the shutdown trip
LOW OIL PRESSURE point. Check oil level, lines and filters. If oil system is OK but oil level is
Lamp: Shutdown low, replenish. Reset control and restart. If oil switch is used, check
switch performance.
1446 Indicates that one or more of the phase voltages has exceeded 130% of
HIGH AC VOLTAGE nominal for 0 second, or has exceeded high ac voltage threshold of
Lamp: Shutdown nominal for time delay seconds.
1447 Indicates that one or more of the phase voltages has dropped below
LOW AC VOLTAGE low ac voltage threshold for time delay seconds.
Lamp: Shutdown
1448 Indicates frequency is 10% above base frequency for approximately 10
OVER FREQUENCY seconds.
Lamp: Shutdown
1449 Indicates that engine speed has dropped below 90% of nominal for
UNDER FREQUENCY approximately 10 seconds.
Lamp: Shutdown Check fuel supply, intake air supply and load.
234 Indicates engine has exceeded normal operating speed. The default
OVERSPEED thresholds are 1725 RPM (50 Hz) or 2075 RPM (60 Hz).
Lamp: Shutdown
Possible causes are single step large block load removal or flammable
vapors drawn into the intake air passage. Reset control and restart after
locating and correcting problem.
1434 Indicates remote Emergency Stop. To reset the remote Emergency
EMERGENCY STOP Stop button:
Lamp: Shutdown 1. Open (disable) remote emergency stop button.
2. Press the OFF button.
3. Select the desired operating mode (manual or remote).
359 Indicates possible fuel system or air induction problem. (Engine cranks
FAIL TO START but fails to start)
Lamp: Shutdown a. Check for empty fuel tank, fuel leaks, or plugged fuel lines and
correct as required.
b. Check for dirty fuel filter and replace if necessary.
c. Check for dirty or plugged air filter and replace if necessary.
d. Reset the control and restart after correcting the problem.
2677 Genset continues to run after receiving shutdown command from the
FAIL TO STOP controller.
Lamp: Shutdown
1312 The nature of the fault is an optional configurable selection. Example
CONFIGURABLE inputs: Low
INPUT #2 Fuel Day Tank, Water In Fuel, Ground Fault, etc.
Lamp: Shutdown Each of the fault functions can be programmed (using service tool or
operator panel), as follows:
• Warning or Shutdown (Default: Warning) (See fault code 1312
for Warning)

1123 A shutdown fault occurred while the Battle Short mode was enabled.
SHUTDOWN AFTER Check fault history for faults that may have been bypassed.
BS

- 56 -
Lamp: Shutdown

146 Indicates engine is operating near cooling system capacity. Increase in

HIGH COOL TEMP. load or higher ambient temperature may cause High Coolant Temp
Lamp: Warning (151) shutdown. Review code 151 correction list for other possible
causes.
1435 Indicates engine coolant heater is not operating or is not circulating
LOW COOLANT coolant.
TEMP Check for the following conditions:
Lamp: Warning a. Coolant heater not connected to power supply. Check for blown
Set is not operating. fuse or disconnected heater cord and correct as required.
Warning occurs when b. Check for low coolant level and replenish if required. Look for
engine coolant possible coolant leakage points and repair as required.
temperature is 70F c. Open heater element. Check current draw of heater.
(21C) or lower. NOTE:
In applications where Coolant temperature must be below 70F (default setting) for one minute
the ambient to activate warning and be above 70F for five minutes before the
temperature falls warning can be cleared.
below 40F (4C), Low
Coolant Temp may
be indicated even
though the coolant
heaters are
operating.
1312 The nature of the fault is an optional configurable selection. Example
CONFIGURABLE inputs: Low Fuel Day Tank, Water In Fuel, Ground Fault, etc.
INPUT Each of the fault functions can be programmed (using service tool), as
Lamp: Warning follows:
• Warning or Shutdown (Default: Warning) (See fault code 1312
for Shutdown)

144 Indicates that the control has sensed that the engine coolant
COOL SENSOR OOR temperature sensor output is out of range (high or low). Check
Lamp: Warning sender/connectors/wires. This fault will only occur if water temperature
sensor is equipped on the genset.
441 Indicates battery voltage supply to the control is approaching a low level
LOW BATTERY at which unpredictable operation will occur.
Lamp: Warning 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 all connections.
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).
442 Indicates battery voltage supply to the control is approaching a high
HIGH BATTERY level at which damage to the control can occur. Check float level on
Lamp: Warning battery charger if applicable (lower float level).
Check battery wiring/calibration.
141 Indicates that the control has sensed that the engine oil pressure
OIL PRESS SENSOR sensor output is out of range (high or low). Check
OOR sender/connectors/wires. This warning will only occur if genset is

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Lamp: Warning equipped with an oil pressure sender.

1131 Indicates that the control is in Battle Short mode - used to bypass
BATTLE SHORT several fault shutdowns for genset operation during emergencies.
ACTIVE
Lamp: Warning
2678 Indicates the battery charging alternator has not reached an acceptable
CHARGER FAILURE voltage range within the selected period (default = 120 seconds). Refer
Lamp: Warning to engine service manual if this fault occurs. If not failed, check wiring.
220 Genset continues to run after receiving shutdown command from the
FAIL TO SHUTDOWN controller. Battle Short feature enabled - used to bypass several critical
Lamp: Warning fault shutdowns for genset operation during emergencies.
1442 Indicates that during cranking, the battery voltage is at or below the
WEAK BATTERY weak battery warning trip point for a time greater than or equal to the
Lamp: Warning weak battery set time. See code 441 for corrective action.

CODE 151/146 - HIGH OR PRE-HIGH COOLANT TEMPERATURE

(SHUTDOWN/SHUTDOWN)
Reason: Engine coolant temperature has exceeded the warning threshold for pre-high/high
coolant temperature.
Effect: Calibration-dependent. No action is taken by the Control for code 146. Engine will shut
down for code 151.
1. Fault simulation was 1. With a PC based service tool, verify that the fault simulation is not
enabled with a PC enabled for the coolant sensor.
based service tool. If you do not have a PC based service tool, remove battery power from
the control to disable fault simulation overrides.
2. Engine or sensor Check the sensor accuracy with a thermocouple or similar temperature
circuitry problem. probe.
• If the coolant temperature reading is accurate, the engine may
be overheating. Refer to the engine service manual.
• If the coolant temperature reading is not accurate, go to next
step.
3. The sensor could be Disconnect the sensor and connect a coolant temperature sensor
bad. simulator to the harness.

If the control responds to the simulator, replace the sensor. If control

does not respond, go to next step.
4. The harness or 4. Measure the resistance of the coolant sensor and reconnect harness
Base board could be to sensor. Remove connector P16 from Base board and check
bad. resistance between pins P16-7 (H20) and P16-5 (H20 COM).
• If resistance is not the same, harness is bad.
• If resistance is the same, Base board is bad.

CODE 2/215 - LOW OIL OR PRE-LOW PRESSURE (WARNING/SHUTDOWN)

Reason: Engine oil pressure has dropped below the warning/shutdown threshold for low/high oil
pressure.
Effect: Calibration-dependent. No action is taken by the Control for code 215. Engine will shut
down for code 2.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Fault simulation was With a PC based service tool, verify that the fault simulation is not
enabled with a PC enabled for the oil pressure sensor.
based service tool. If you do not have a PC based service tool, remove battery power from

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 the control to disable fault simulation overrides.
2. Low oil level. Check oil level, lines and filters. If oil system is OK but oil level is low,
Clogged lines or filters. replenish.
3. Sensor or oil pump Disconnect the oil pressure sensor leads, and connect an oil pressure
could be bad. Or the sensor simulator to the harness.
generator set may be
shutting down on a. If the control responds to the simulator, reconnect the sensor,
another fault. disconnect the + signal wire at the fuel solenoid, and crank the engine.
Check the oil pressure reading on the digital display.
• If the display shows an acceptable oil pressure, the problem
may not be in the oil or oil sensing system. The genset may be
shutting down on another fault (out of fuel, intermittent
connector). Restart the genset and monitor the display panel for
other faults.
• If the display does not show an acceptable oil pressure, replace
the sensor. If the Control still doesn’t display an oil pressure
while cranking, the oil pump may be bad. Refer to the engine
service manual.
b. If the control does not respond to the simulator, go to next step.
4. Harness or Base If the control does not respond to the simulator, the Base board or the
board could be bad. harness is bad.
Check the resistance in P16-3 and P16-5 (Sensor COMM). If the
resistance signal (100 to 33 Ohm) does not get to P16, isolate to the
harness. If the resistance does go to P16, the Base board is bad.
5. Low Oil Pressure Verify set points against the normal operating pressures of the engine.
fault set points could Refer to engine manual.
be incorrect.

CODE 1446 - HIGH AC VOLTAGE (SHUTDOWN)

Reason: One or more of the phase voltages has exceeded 130% of nominal for 1 second, or has
exceeded the High AC Voltage Threshold for the High AC Voltage Delay seconds.
Effect: Engine will shut down.
POSSIBLE CAUSE CORRECTIVE ACTION
1. Fault simulation was 1. With a PC based service tool, verify that the related fault simulation is
enabled with a PC not enabled.
based service tool. If you do not have a PC based service tool, remove battery power from
the control to disable fault simulation overrides.
2. Single step large 2. Clear fault and restart genset.
block load removal.
3. Fault threshold is 3. Reset the threshold to the highest allowable setting. Determine the
not set correctly with required operating range before adjusting the threshold.
InPower.
4. AVR or generator is 4. Refer to Generator AVR Board Isolation Procedure in Alternator
bad. manual to determine if the AVR board is causing the high AC voltage
shutdown fault.
5. Voltage sense See Section 17 for proper corrective actions.
connections/set up
could be incorrect.

CODE 1447 - LOW AC VOLTAGE (SHUTDOWN)

Reason: One or more of the phase voltages has dropped below the Low AC Voltage Threshold
for Low AC Voltage Delay seconds.
Effect: Engine will shut down.
POSSIBLE CAUSE CORRECTIVE ACTION
1. Fault simulation was 1. With a PC based service tool, verify that the related fault simulation is

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enabled with a PC not enabled.
based service tool. If you do not have a PC based service tool, remove battery power from
the control to disable fault simulation overrides.
2. Fault threshold is 2. Reset the threshold to the lowest allowable setting. Determine the
not set correctly with required operating range before adjusting the threshold.
A PC based service
tool.
3. Overload. 3. Check the load and correct any overload. Check operation by
disconnecting load and restarting generator set.
4. Improper 4. Reconnect according to the appropriate reconnection diagram.
connections have See Section 17.
been made at the
generator output
terminals.
5. Voltage sense or 5. Check that Voltage senses inputs P22-1 to 4 are connected to the
setup wiring correct voltage sensing point at alternator.
connection could be
incorrect.
6. The rotating rectifier 6. Check each diode. See genset service manual
assembly (diodes CR1
through CR6) is faulty.
7. Loose connector or 8. Repair connections (P22) or replace the Base board if necessary.
Base board is bad.
8. AVR or Alternator is 4. Refer to Alternator / AVR Board Isolation Procedure in Alternator
bad. manual to determine if the AVR board is causing the Low AC voltage
shutdown fault.
9. Voltage sense See section 17 for proper connections
connections/setup
could be incorrect

CODE 1448 - OVER FREQUENCY (SHUTDOWN)

Reason: Generator AC output frequency is high.
Effect: Generator set will shut down.
POSSIBLE CAUSE CORRECTIVE ACTION
1. Fault threshold is 2. Reset the threshold to the highest allowable setting. Determine the
not set correctly with required operating range before adjusting the threshold.
PC based service tool.
2. Fuel or air delivery 3. Refer to the engine service manual.
problem.
3. Loose connector or 4. Repair connections (P22 – 1 to 4) or replace the Base board if
Base board is bad. necessary.

CODE 1449 - UNDER FREQUENCY (SHUTDOWN)

Reason: Generator AC output frequency is low.
Effect: Generator set will shut down.
POSSIBLE CAUSE CORRECTIVE ACTION
1. Fault threshold is 2. Reset the threshold to the lowest allowable setting. Determine the
not set correctly with required operating range before adjusting the threshold.
PC based service tool.
2. Overload. 3. Check the load and correct any overload. Check operation by
disconnecting load and restarting generator set.
3. Fuel or air delivery 4. Refer to the engine service manual.
problem.
4. Governor fault. 5. Check fuel shutoff solenoid adjustment (refer to Section 8).
5. Loose connector or 6. Repair connections (P22 – 1 to 4) or replace the Base board if

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Base board is bad. necessary.

CODE 234 - OVERSPEED (SHUTDOWN)

Reason: Engine speed signal indicates an engine speed greater than shutdown threshold.
Effect: Engine will shut down.
POSSIBLE CAUSE CORRECTIVE ACTION
1. Cold engine (no 1. Overspeed can occur when starting a very cold engine. Clear fault
coolant heaters) and restart genset.

2. Single step large 2. Clear fault and restart genset.

block load removal.
3. Fault simulation was 3. With PC based service tool, verify that the fault simulation is not
enabled with a PC enabled for the coolant sensor.
based service tool. If you do not have PC based service tool, remove battery power from
the control to disable fault simulation overrides.
4. Fault threshold is 4. Reset the threshold to the highest allowable setting. Determine the
not set correctly with required operating range before adjusting the threshold.
PC based service tool.

5. Monitor the engine 5. If the RPM is not correct, refer to fault code 1448 for corrective
rpm using InPower. action.
6. Governor fault. 6a. Check fuel shutoff solenoid adjustment (refer to Section 8).
6b. Replace defective injection pump unit.
7. Mechanical Fuel Verify fuel stop settings for the application.
system setup could be
incorrect.

CODE 359 - FAIL TO START (SHUTDOWN)

MECHANICAL GOVERNED ENGINE
Reason: This indicates that the engine failed to start after expiration of last crank time.
Effect: Engine will not start.
POSSIBLE CAUSE CORRECTIVE ACTION
1. Restricted fuel 1a. Add fuel if low. Prime the fuel system.
supply due to: 1b. Open any closed shutoff valve in the fuel line supplying the engine.
a. Fuel level 1c. Refer to engine service manual.
below pickup 1d. Bleed air from fuel system. Refer to engine service manual.
tube in tank.
b. Closed shutoff
valve in supply
line.
c. Fuel injectors
clogged.
d. Air in fuel
system.

2. Glow plugs are not The Base board determines at what temperature and duration of time
heating due to: that the glow plugs will be energized. Using sensed coolant
a. Glow plug(s) is temperature, the glow plugs are energized at 77F (25C) and colder. The
bad. glow plugs are energized for up to 15 seconds when the coolant
b. Base board is temperature is -5F (-20.5C) or colder. Time duration (15-0 seconds) is
bad. linear between -5F and 77F.

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 c. Glow Plug
Relay is bad. With coolant temperature colder than 77F (25C):

2a. Each glow plug should be warm to the touch if the engine has just
been cranking. First clean and tighten the terminal of any cold glow plug
and then replace it if necessary.
2b. Attempt to start and check for if K2 energises. TB2-3 should be at
GND potential. If the TB2-3 is at GND and K2 relay is not working check
relay coil.
• If TB2-3 is not at GND potential replace the Base Board.
• If B+ is present, check for open circuit between glow plug relay
contact and glow plugs.
3. Fuel solenoid on Isolate to fuse, K8 relay, fuel solenoid or Base board.
the injection pump
not energized due to: 3a. Remove fuse (if installed) and check continuity. If open, replace the
a. Fuse may be fuse with one of the same type and amp rating. If fuse reopens, check
open. wiring continuity of fuel solenoid circuit/test fuel solenoid.
b. Fuel solenoid
is bad. Binding in the solenoid linkage can prevent activation of the hold coil
c. Base board/K8 circuitry in the solenoid. Make sure solenoid shaft moves completely in
Fuel Relay is and out freely. (Applies to solenoids with both Pull and Hold coils.)
bad.
3b. Attempt to start and check for B+ at the fuel solenoid coil.
• If B+ is present, fuel solenoid is bad.
• If B+ is not present, go to step c.

3c. Check wiring continuity/test K8 relay or fuel pilot:

Remove lead from K8-COM (fuel pilot). Attempt to start and check for
GND at lead COM.
• If there is no GND, check for open circuit between K8-COM and
Base card.
• If GND is present, reconnect lead COM to relay. Remove lead
from N/O connection. Attempt to start and check for B+ at
terminal N/O connection.
• If B+ is present, check for open circuit between N/O connection
and fuel solenoid (+).
• If B+ is not present, check for relay contacts.
5. The engine fuel 4. Service according to the engine service manual.
system is worn or
malfunctioning or has
lost prime (fuel lift
pump, injection pump,
injectors, timing).
6. The engine is worn 5. Service according to the engine service manual.
or malfunctioning
mechanically.
CODE 1312 - CONFIGURABLE INPUT (SHUTDOWN)
Reason: The nature of the fault is an optional configurable selection.
Effect: Shutdown.
POSSIBLE CAUSE CORRECTIVE ACTION
If there is no actual Disconnect the signal lead from TB2 and reset the control. Check the
fault, the problem may following two points.
be an external wiring • CUST_IN#2 – TB2-5
problem. If the message drops out, the external wiring has a short circuit.
Grounding of the input activates fault.

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CODE 146 - HIGH COOLANT TEMP (WARNING)
Reason:
Effect:
POSSIBLE CAUSE CORRECTIVE ACTION
1. Refer to code 151. 1. Refer to code 151.
CODE 1435 - LOW COOLANT TEMPERATURE (WARNING)
Reason: Engine coolant temperature has dropped below the warning threshold for low coolant
temperature.
Effect: No action is taken by the control. Engine may not start due to slow cranking speed.
POSSIBLE CAUSE CORRECTIVE ACTION
1. Fault simulation was 1. With PC based service tool, verify that the fault simulation is not
enabled with PC enabled for the coolant sensor.
based service. If you do not have a based service tool, remove battery power from the
control to disable fault simulation overrides.
2. Fault threshold is 2. Reset the threshold to the lowest allowable setting. Determine the
not set correctly with required operating range before adjusting the threshold.
A PC based service
tool.
3. The engine coolant 3. Coolant heater not operating due to:
heater could be bad. • Coolant heater not connected to power. Check for blown fuse,
(Radiant heat should or disconnected heater cord and correct as required.
be felt with hand • Low coolant level. Look for possible coolant leakage points and
held close to outlet repair as required.
hose.) • Defective heater element/thermostat. With coolant heater
removed from engine and power disconnected, flush with cold
tap water for two minutes to close internal heater thermostat
(opens at 100F and closes at 80F). Check resistance across
input power leads:
a. Open - replace coolant heater.
b. Closed - coolant heater OK (coil resistance of 10 to 60
ohms)
4. The sensor 4. Inspect the sensor and engine harness connector pins. Repair or
connections could be replace as necessary.
bad.
5. The sensor could be 5. Disconnect the sensor, and plug in a resistive sensor simulator to
bad. isolate the fault.
If the control responds to the simulator, replace the sensor. If control
does not respond, harness or Base board are bad.
6. The harness or 6. Measure the resistance of the coolant temperature sensor and
Base board could be reconnect harness to sensor. Remove connector P16 from Base board
bad. and check resistance between pins P16-7 (H20) and P16-5
(Sensor Common).
• If resistance is not the same, harness is bad.
• If resistance is the same, Base board is bad.
CODE 1312 - CONFIGURABLE INPUT (WARNING)
Reason: The nature of the fault is an optional configurable selection.
Effect: Warning.
POSSIBLE CAUSE CORRECTIVE ACTION
If there is no actual Disconnect the signal lead from TB1 and reset the control. Check the
fault, the problem may following pins.
be an external wiring • CUST_IN2 – TB2-5
problem. If the message drops out, the external wiring has a short circuit.
Grounding of the input activates fault.

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CODE 144 - COOLANT SENSOR OOR (HIGH/LOW) (WARNING)
Reason: This indicates that the coolant temperature sensor signal is out of range - shorted high
or low.
Effect: No engine protection for coolant temperature during genset operation. Possible white
smoke.
POSSIBLE CAUSE CORRECTIVE ACTION
1. The sensor 2. Inspect the sensor and engine harness connector pins. Repair or
connections could be replace as necessary.
bad.
2. The sensor could be 3. Disconnect the sensor, and plug in a resistive sensor simulator to
bad. isolate the fault.
If the control responds to the simulator, replace the sensor. If control
does not respond, go to next step.
3. The harness or 4a. Remove connector P16 from Base board and disconnect sensor.
Base board could be Check pins P16-7 (H20) and P16-5 (Sensor common) for short circuit
bad. as follows:
• Check for a short circuit to the engine block ground (more than
200k ohms OK).
• Check for a short circuit from pin to pin (more than 200k ohms
OK).
Repair or replace as necessary.

4b. Measure the resistance of the coolant sensor and reconnect

harness to sensor. Remove connector P16 from Base board and check
resistance between pins P16-7 (H20) and P16-5 (Sensor Common).
• If resistance is not the same, harness is bad.
• If resistance is the same, Base board is bad.
CODE 441 - LOW BATTERY (WARNING)
Reason: Low voltage has been detected for battery.
Effect: The control’s voltage supply approaching level at which unpredictable operation may
occur.
POSSIBLE CAUSE CORRECTIVE ACTION
1. Weak or discharged 1. Recharge or replace the battery. Specific gravity for a fully charged
battery. battery is approximately 1.260 at 80F (27C).
2. Low electrolyte level 2. Replenish electrolyte and recharge battery.
in battery.
3. Battery connections 3. Clean and tighten or replace the battery cable connectors and cables
loose or dirty. at the battery and the set.
4. Insufficient battery 4. Adjust charge rate of AC powered battery charging circuit, according
charging voltage. to manufactures instructions.
5. Engine DC 5. Replace engine DC alternator if normal battery charging voltage (12
alternator could be to 14 VDC) is not obtained.
bad.
6. If the batteries are 6. Remove connector P16 from Base board and check battery voltage
OK, the problem may at P16-6 (B+) to P16-11 (GND).
be the harness or the • If the voltage at P16 is not the same as the battery voltage, the
Base board. harness is bad.
• If the voltage at P16 is OK, the Base board is bad.
7. Fault threshold 7. Check fault threshold against requirement of the application.
could be bad.

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CODE 442 - HIGH BATTERY VOLTAGE (WARNING)
Reason: High voltage has been detected for battery.
Effect: Control damage will occur.
POSSIBLE CAUSE CORRECTIVE ACTION
1. Excessive battery 1. Adjust charge rate of AC powered battery charging circuit according
charging voltage. to manufacturers instructions.
2. Engine DC 2. Replace engine DC alternator if normal battery charging voltage
alternator could be (12 to 14 VDC) is not obtained.
bad.
3. Fault threshold 3. Check fault threshold against requirement of the application.
could be bad.
CODE 143 - LOW OIL PRESSURE (WARNING)
Reason:
Effect:
POSSIBLE CAUSE CORRECTIVE ACTION
1. Refer to code 415. 1. Refer to code 415.
CODE 141 - OIL PRESSURE SENSOR OOR (HIGH/LOW) (WARNING)
Reason: This indicates that the engine oil pressure sensor signal is out of range - shorted high or
low.
Effect: No engine protection for oil pressure during genset operation.
POSSIBLE CAUSE CORRECTIVE ACTION
1. The sensor 2. Inspect the sensor and engine harness connector pins. Repair or
connections could be replace as necessary.
bad.
2. The sensor could be 3. Disconnect the oil pressure sensor leads, and connect an oil
bad. pressure sensor simulator to the harness.

“OIL PRESSURE SENSOR OOR” warning is displayed after the

fault condition is sensed for 10 seconds.

If the control responds to the simulator, replace the sensor. If control

does not respond, go to next step.
3. The harness could 4. Remove connector P7 from Base board and connector from sensor.
be bad. Check P16-3 and P16-5 as follows:
• Check for a short circuit from pin to pin (more than 200k ohms
OK).
• Check for an open circuit (10 ohms or less OK).
Repair or replace as necessary.
4. The Base board 5. With all connectors attached, check pressure signal (.500 to .033
could be bad. VDC) at P16-3 and P16-5 (Sensor Common). If in range, replace Base
board.
CODE 1442 - WEAK BATTERY (WARNING)
Reason:
Effect:
POSSIBLE CAUSE CORRECTIVE ACTION
1. Refer to code 441 1. Refer to code 441.

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