Service Manual

Controller

PowerStart® 0500

English
Original Instructions 9-2011 A040Y520 (Issue 1)
Table of Contents
1. IMPORTANT SAFETY INSTRUCTIONS ....................................................................................... 1
1.1 Warning, Caution and Note Styles Used In This Manual ....................................................... 1
1.2 General Information ................................................................................................................ 1
1.2.1 General Safety Precautions ........................................................................................ 1
1.3 Generator Set Safety Code .................................................................................................... 2
1.3.1 Moving Parts Can Cause Severe Personal Injury Or Death........................................ 3
1.3.2 Positioning of Generator Set....................................................................................... 3
1.4 Electrical Shocks and Arc Flashes Can Cause Severe Personal Injury or Death.................. 3
1.4.1 AC Supply and Isolation............................................................................................... 4
1.5 Fuel And Fumes Are Flammable ............................................................................................ 4
1.5.1 Spillage ....................................................................................................................... 5
1.5.2 Fluid Containment....................................................................................................... 5
1.5.3 Do Not Operate in Flammable and Explosive Environments ...................................... 5
1.6 Exhaust Gases Are Deadly..................................................................................................... 5
1.6.1 Exhaust Precautions ................................................................................................... 5

2. SCHEDULE OF ABBREVIATIONS................................................................................................ 7

3. GLOSSARY.................................................................................................................................... 9

4. INTRODUCTION.......................................................................................................................... 11
4.1 About this Manual ................................................................................................................. 11
4.2 System Overview .................................................................................................................. 11
4.2.1 PowerStart 0500 Components................................................................................... 11
4.3 Test Equipment..................................................................................................................... 11
4.4 How To Obtain Service......................................................................................................... 12

5. CONTROL SYSTEM - POWERSTART 0500 .............................................................................. 13

5.1 PowerStart 0500 Components.............................................................................................. 13
5.2 Control Description ............................................................................................................... 13
5.3 PS0500 Features .................................................................................................................. 14
5.3.1 Local Status Output ................................................................................................... 14
5.4 Operating Modes .................................................................................................................. 15
5.4.1 Off Mode .................................................................................................................... 15
5.4.2 Manual Mode ............................................................................................................. 15
5.4.3 Auto Mode.................................................................................................................. 15
5.4.4 Sleep Mode ................................................................................................................ 15
5.4.5 Battle Short Mode ...................................................................................................... 16
5.4.6 Setup Mode................................................................................................................ 17
5.5 Control Board........................................................................................................................ 17
5.6 Operator Panel...................................................................................................................... 18
5.6.1 Alpha Numeric LCD Display ...................................................................................... 19
5.6.2 LED Indicators and Buttons ....................................................................................... 20

A040Y520 (Issue 1) i
Table of Contents 9-2011

5.7 System Messages................................................................................................................. 20

5.7.1 Default Settings.......................................................................................................... 21
5.7.2 Fault Messages.......................................................................................................... 21
5.7.3 Fault Acknowledgement............................................................................................. 21
5.8 Selecting Auto, Manual Run, and Off Modes ....................................................................... 21
5.8.1 Selecting Auto Mode.................................................................................................. 21
5.8.2 Selecting Manual Mode ............................................................................................. 22
5.8.3 Selecting Off Mode .................................................................................................... 22
5.8.4 Configuration Mode.................................................................................................... 22
5.9 Setup and Calibration ........................................................................................................... 23
5.9.1 Capture File................................................................................................................ 23
5.9.2 Entering and Leaving the Setup Mode ...................................................................... 23
5.9.3 Menu Description ....................................................................................................... 23
5.9.4 Navigation .................................................................................................................. 27

6. CONTROL ADJUSTMENT AND SERVICE ................................................................................. 29

6.1 General ................................................................................................................................. 29
6.2 Control Inputs and Outputs................................................................................................... 29
6.2.1 TB1 Customer Inputs ................................................................................................. 29
6.2.2 CT Connector............................................................................................................. 30
6.2.3 Voltage Connector ..................................................................................................... 30
6.2.4 TB1 Customer Inputs ................................................................................................. 30
6.2.5 PC Tool Connector .................................................................................................... 30
6.3 Control Board Removal/Replacement .................................................................................. 31
6.3.1 Control Board Removal Safety Precautions .............................................................. 31
6.4 Current Transformer (CT) Installation................................................................................... 32

7. TROUBLESHOOTING ................................................................................................................. 35
7.1 General ................................................................................................................................. 35
7.2 InPower Service Tool............................................................................................................ 35
7.3 Network Applications and Customer Inputs.......................................................................... 35
7.4 Safety Consideration............................................................................................................. 35
7.5 Troubleshooting Procedure................................................................................................... 36
7.5.1 Voltage/Continuity Testing ......................................................................................... 36
7.5.2 Reading Fault Codes ................................................................................................. 36

8. MANUFACTURING FACILITIES.................................................................................................. 51
8.1 How to Obtain Service .......................................................................................................... 51
8.1.1 Locating Your Distributor ........................................................................................... 51

APPENDIX A. WIRING DIAGRAMS ................................................................................................. 53

ii A040Y520 (Issue 1)
1 Important Safety Instructions
SAVE THESE INSTRUCTIONS - This manual contains important instructions that should be
followed during installation and maintenance of the generator set and batteries.
Before operating the generator set, read the Operator's Manual and become familiar with it
and the equipment. Safe and efficient operation can be achieved only if the equipment is
properly operated and maintained. Many accidents are caused by failure to follow
fundamental rules and precautions.

1.1 Warning, Caution and Note Styles Used In This

Manual
The following safety styles and symbols found throughout this manual indicate potentially
hazardous conditions to the operator, service personnel or the equipment.

DANGER: Warns of a hazard that will result in severe personal injury or death.

WARNING: Warns of a hazard that may result in severe personal injury or death.

CAUTION: Warns of a hazard or an unsafe practice that can result in product or property
damage.

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

1.2 General Information

This manual should form part of the documentation package supplied by Cummins Power
Generation with specific generator sets. In the event that this manual has been supplied in
isolation please contact your authorized distributor.

NOTE: It is in the Operator’s interest to read and understand all Warnings and
Cautions contained within the documentation relevant to the generator set,
its operation and daily maintenance.

1.2.1 General Safety Precautions

WARNING: Coolants under pressure have a higher boiling point than water. DO NOT
open a radiator or heat exchanger pressure cap while the engine is
running. Allow the generator set to cool and bleed the system pressure first.
To prevent severe scalding, let the engine cool down before removing the
coolant pressure cap. Turn the cap slowly, and do not open it fully until the
pressure has been relieved.
WARNING: Used engine oils have been identified by some state or federal agencies as
causing cancer or reproductive toxicity. When checking or changing engine
oil, take care not to ingest, breathe the fumes, or contact used oil.
NOTE: Keep multi-class ABC fire extinguishers handy. Class A fires involve ordinary
combustible materials such as wood and cloth; Class B fires involve
combustible and flammable liquid fuels and gaseous fuels; Class C fires
involve live electrical equipment. (ref. NFPA No. 10 in applicable region)

A040Y520 (Issue 1) 1