Simple Wiring Diagram Ps0500 How To Start Any Generator Using A Cummins Powerstart 500

Simple Wiring Diagram Ps0500 How To Start Any Generator Using A Cummins Powerstart 500
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How to start any generator using a Cummins Powerstart 500 - You can discover the cummins powerstart controller on turbines ranging from 10 kva to a hundred twenty five kva or 10 kw to one hundred kw. In this situation i'm starting a 35 kva cummins diesel generator. My 15 kva cummins has the same controller. More information at the controller can be observed right here: /pdf/. Service guide energy begin 0500 genset models: x1.3, s and b series 2 foreword schedule of abbreviations ac alternating cutting-edge mcb miniature circuit breaker acb air circuit breaker mccb moulded case circuit breaker ach anti-condensation warmers mf mains failed ats automatic switch transfer mfss master first start sensor avr automatic voltage regulator mr mains again mst mains sensing transformer bhp brake horsepower msu mains sensing unit bms building control system mv medium voltage bst busbar sensing transformer nec neutral earthing touch cb circuit breaker cca bloodless cranking amps pc powercommand® chp blended heat and strength pf electricity issue cop non-stop power score p.C power aspect controller ct contemporary transformer % programmable logic controller pmg permanent magnet generator db(a) unit of noise level prp top strength score dc direct current psu power deliver unit dip twin in-line package pt/ct potential transformer / modern-day transformer dmc virtual master manipulate dmsu call for load standby unit qcc quadrature modern-day control emcu engine tracking and manipulate unit rfi radio frequency interference emf electromotive pressure rms root imply rectangular epu engine safety unit rpm revolutions in line with minute rtd resistance temperature detector fss first begin sensor gcp generator control panel v volts genset generator set vac volts, alternating cutting-edge gkwt international kilowatt transducer vcb vacuum circuit breaker vdc volts, direct modern-day hmi human/machine interface vf volt-loose hv excessive voltage vt voltage transformer three ic included circuit lv low voltage i/o enter / output kva apparent energy kvar reactive energy kw active / real energy kwh unit of electrical energy or paintings led light-emitting diode ltp restrained time energy score lta low temperature aftercooling four index sr. Contents page no. 1. Preliminary and protection………………………………..??……… 5 1.1 warning, warning and word styles used on this manual 1.2 general information 1.Three general plant safety code 2. Manipulate gadget…………………………………………..??……. 6 2.1 manipulate machine description 2.2 operating modes 2.3 show module 2.4 configuration mode 2.5 sequence of operation 2.6 preventing 2.7 connector info three. Status indicators…………………………………..??…………… 20 3.1 fault/popularity codes three.2 fault code listing four. Troubleshooting………………………………………..??………... 22 4.1 introduction 4.2 manipulate unit 4.3 troubleshooting procedure for fault codes four.Four fault finding 5. Inpower connectivity……………………………..??……………… 26 6. Calibration method…..??………………...??………………….. 27 7. Wiring diagrams…..??………………...??………………………... 33 5 1. Preliminary and safety 1.1 caution, warning and note patterns used on this manual the subsequent protection styles located at some stage in this manual imply probably unsafe conditions to the operator, provider employees or the equipment. Caution: warns of a threat that could bring about intense non-public injury or loss of life. Warning warns of a threat or an hazardous practice that may bring about product or property damage. Note: a brief piece of textual content giving information that augments the modern textual content. 1.2 popular records this guide have to form a part of the documentation bundle furnished by cummins strength era restricted with unique generator sets. Within the occasion that this guide has been provided in isolation please refer to other cummins electricity generation constrained literature, particularly the health and protection manual (0908-0110-00). Note: it's far in the operator’s hobby to examine and recognize all health and safety statistics collectively with all warnings and cautions contained inside the documentation applicable to the generator set, its operation and every day upkeep. 1.3 generator plant protection code earlier than working the generator set, study the manuals and grow to be acquainted with them and the device. Secure and efficient operation can be achieved simplest if the system is well operated and maintained. Many injuries are resulting from failure to comply with essential regulations and precautions. Warning: unsuitable operation and upkeep can cause intense non-public damage or loss of lifestyles and property by means of fireplace, electrocution, mechanical breakdown or exhaust gas asphyxiation. Read and observe all protection precautions, warnings and cautions throughout this guide and the health and protection guide 0908-0110-00. 6 2. Manipulate machine 2.1 control gadget description the manage system is used to begin and prevent the generator set, and presents complete generator set monitoring capability and protection in a stand-on my own situation (non paralleling) from the show display. It monitors the engine for temperature, oil pressure, battery voltage, estop and genset hours, and presents voltage and modern-day metering. In the event of a fault the unit will suggest the fault kind and mechanically close down the generator set on important faults. All signs, control buttons and the show screen are on the face of the display module as illustrated in figure 1. There are fault level alerts generated by way of the manipulate gadget as follows: • caution: - indicators an impending or non-essential fault for the engine. The control offers an indication simplest for this situation. ?? shutdown: - alerts a potentially essential fault for the engine. The manipulate will right now take the engine off-load and automatically shut it down. The standard manage device operates on 12 vdc battery energy. The auxiliary equipment operates on lv ac energy. The history facts is stored in non-unstable reminiscence and could not be deleted due to lack of battery electricity. Parent 1 typical manipulate gadget panel key 1. Display module 2. Emergency forestall button note: usually e-forestall placement on canopy is totally under oem scope. 7 2.2 operating modes the powerstart 0500 manipulate is operated via the guide / start / prevent / vehicle buttons at the display module face. 2.2.1 off mode observe: a few published control service literature may also confer with this mode as the forestall mode. Whilst in the off mode, the manage does no longer allow the generator set to begin. Refer to segment 4.2.7 – car and guide run modes – to re-begin the generator set. If the generator set is strolling, in either manual run or vehicle mode, and the prevent button is pressed, a ordinary shutdown series can be initiated. In off mode the pink led above the stop button could be lit. 2.2.2 manual run mode whilst in manual run mode, the generator set starts and keeps to run until the control is positioned into the off mode. Urgent the forestall button initiates a everyday shutdown collection that does not encompass a time put off prevent. Whilst in the manual run mode, any far flung start sign is ignored. 2.2.Three vehicle mode whilst in automobile mode, the control lets in the generator set to be started at any time, with a remote signal only. When a far flung begin signal is acquired, the generator set starts offevolved after a time postpone start is completed (default put off is zero seconds). When a remote begin sign is eliminated, the manipulate performs a normal shutdown sequence which includes a time put off prevent (default delay is 0 seconds). If the generator set is running in vehicle mode and the stop button is pressed, the control right away stops the generator set and the manage transitions to the off mode. 2.2.4 sleep mode the powerstart 0500 manipulate enters a low energy (sleep) mode of operation in which the contemporary drawn is much less than 60 milliamps (dc) at normal battery voltage levels. Sleep mode is automatically enabled, and the display module will flip itself off after five mins of keypad state of being inactive whilst in off mode. When in automobile mode, the sleep mode is enabled only while the trim “wake in auto enabled” is enabled. If the trim is disabled (which is the default fee), the sleep mode will by no means be enabled when in automobile mode. It awakes from the sleep mode if the reset button is pressed or if there is a device wakeup input or a faraway start signal is obtained or an e-stop signal is obtained both in forestall as well as car mode. 8 the control will now not enter the sleep mode if there are any lively, unacknowledged, shutdown faults or if the control is in the manual run mode. 2.2.5 conflict brief mode the motive of war brief mode is to satisfy nearby code necessities, wherein important. Struggle brief mode is a generator set mode of operation that prevents the generator set from being shutdown by all however a few, choose, essential shutdown faults. Warning: all shutdown faults, inclusive of those overridden by using warfare brief, need to be acted upon at once to make certain the safety and well being of the operator and the generator set. Caution: use of the struggle short mode function can reason a hearth or electric hazard, resulting in severe personal injury or death and/or property and gadget harm. Operation of the set have to be supervised for the duration of conflict quick operation. This option need to best be used in the course of supervised, temporary operation of the generator set. The faults that are overridden when in struggle short mode can have an effect on generator set overall performance, or can motive everlasting engine, alternator or connected equipment damage. Best skilled and skilled carrier employees must enable this option. Whilst shipped from the factory, this feature is disabled. Caution: if this mode of operation is chosen, the protection of load gadgets can be disabled. Cummins energy era constrained will now not be liable for any declare due to using this mode. Word: the conflict short characteristic ought to be enabled or disabled the usage of the pc provider device. While struggle quick mode is enabled (default is disabled), the warning reputation indicator lighting, and code 1131 – war quick active – is displayed. Whilst struggle short mode is enabled and an overridden shutdown fault occurs, the shutdown lamp remains lit despite the fact that the set continues to run. Fault code 1416 – fail to shutdown – is displayed. If the ok button is pressed to well known the fault, the fault pop up is cleared from the display but remains in one of the scrolling monitors displaying the fault code and its description to signify that it is an active fault as long as battle brief mode is enabled. War short is suspended and a shutdown takes place right away if any of the following important shutdown faults arise: • velocity signal lost (loss of speed sense) fault code 121 • overspeed fault code 234 • nearby emergency stop fault code 1433 • excitation fault (loss of voltage experience) fault code 2335 • fault code 1123 – shutdown after conflict short – is then displayed. 9 2.3 show module - the front panel figure 2 indicates the functions of the the front panel. It includes four led signs, the graphical show, and 6 buttons used to navigate via the menus and modify parameters. Key 1. Led indicator – genset going for walks 7. Vehicle mode button 2. Led indicator – far flung begin eight. Reset button three. Led indicator – shutdown nine. Stop button four. Led indicator – caution 10. Adequate button five. Manual mode button 11. Alpha numeric liquid crystal display show 6. Begin button 2.Three.1 alpha numeric liquid crystal display display the two line 16 character, backlit liquid crystal display display is used to signify various generator set parameters in numerous frames. The frames scroll sequentially and display for 2 seconds. The scrolling may be stopped and parameters on a particular body can be monitored for longer by means of pressing the ok button (see discern 2). Urgent 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.Zero 2 sec modern flt=212 clnt tempoor wrn 2 sec 2 sec l12=000 l23=000 l13=000 hz=00.Zero e stop=inactive cust in=inactive 2 sec 2 sec i1=00.0 kva=00.0 i2=00.Zero i3=00.Zero batt volts=11.7 genset hrs=00000 10 2 sec 2 sec kva1 kva2 kva3 00.Zero 00.Zero 00.0 2 sec oil press=003psi clnt temp=342f discern 1 scrolling display messages 2.3.2 led indicators ps0500 includes four led indicators, the graphical display and six buttons used to navigate via the menus and modify parameters. Genset walking this inexperienced led is lit while the generator set is strolling at or near rated pace and voltage. Shutdown this pink lamp is lit whilst the manage detects a shutdown circumstance. The generator set can't be commenced when this lamp is on. After the circumstance has been corrected, the lamp can be reset with the aid of urgent the forestall button. Word:when struggle short mode has been enabled and an overridden shutdown fault happens, the shutdown lamp can be lit despite the fact that the generator set will continu to run. Caution this yellow lamp is lit each time the manage detects a caution condition. This lamp is robotically close off whilst the caution condition no longer exists. Remote start this green lamp indicates the control is receiving a far flung run sign. 2.3.Three manage panel buttons manual press this button to put the manipulate in manual mode from off mode. If the start button isn't pressed inside ten seconds of the urgent of the guide button, the control robotically returns to off mode the inexperienced led above this button lighting fixtures when the manipulate is in manual mode. Car press this button to put the manipulate in auto mode from off mode. The green led above this button lighting whilst the control is in vehicle mode. In car mode, the generator set starts offevolved and runs whilst a far off begin sign is acquired. It's also used to exit from configuration mode. 11 stop press this button to switch to the off mode from both manual in addition to auto modes. The crimson led above this button lighting fixtures while the control is in off mode. Begin in guide mode, press this button to provoke a manual begin series. In automobile mode, this button has no impact. Reset this button wakes the manipulate from power down sleep mode. The manage enters configuration mode when reset button and prevent button are pressed together. To go into in configuration mode it is important that the control is in forestall mode. Warning: adjusting the settings in configuration mode should simplest be completed with the aid of technically educated and experienced carrier employees. The frequency settings need to handiest be adjusted to correspond to the parameters of the established input power deliver. Saving settings that do not correspond to the electricity supply can reason extreme personal damage and device or assets damage. Adequate this button is used to renowned the fault pop ups. It's also used to pause / resume the scrolling of the parameter frames. It's far used to select the menu objects and the parameters inside the selected menu inside the configuration mode. The selected parameter might be preceded by way of an * asterisk and could get saved when the configuration mode will be exited the use of car button. Be aware: guide, car, adequate and reset buttons are used for navigation inside the configuration mode. 2.Three.4 default settings the manipulate panel can display sae or metric devices of dimension and need to be set during the preliminary setup of the generator set. Qualified provider personnel are required to alternate the default putting. Touch your permitted distributor. 2.3.5 fault messages a fault message is an indicator of a caution or shutdown circumstance that is additionally introduced with a lamp indicator. Fault messages encompass the fault code range and a quick description. The underneath table gives a list of fault codes, fault types, messages displayed, and descriptions of the faults. 12 2.3.6 fault acknowledgement shutdown faults are reset after a shutdown fault is cleared when engine involves a standstill and all begin commands are removed. In manual mode, the begin command is removed when the stop button, at the the front panel, is pressed. In automobile mode, the begin command is removed when the faraway begin sign is removed. Faults are eliminated from the display while they're cleared. Notice: faults are re-announced if they may be detected again after being mentioned. 2.Three.7 display module - car and manual run modes auto, manual run and rancid modes can be selected as follows: selecting vehicle mode to exchange to automobile mode, a) make sure that it's far secure to do so earlier than proceeding to exchange the mode. B) press the prevent button to make sure that the manage is inside the off mode. C) press the automobile button at the same time as within the off mode. The inexperienced led above this button is lit while the manage is in automobile mode. To disable auto mode, press the stop button. The generator set is now ready to acquire a remote begin sign so that it will initiate the auto run mode. Warning: have to a faraway begin sign be obtained, the generator set will start routinely. Make sure there's no risk to personnel or device have to the generator set begin without caution. Warning: guide run mode can't be decided on from car mode. The control needs to be in forestall mode earlier than changing the mode. Switching to prevent mode will bring about the generator set shutting down. Selecting manual run mode to interchange to manual run mode, a) make certain that it's miles secure to achieve this before intending to change the mode. B) press the forestall button to make certain that the manipulate is within the off mode thirteen c) press the manual button on the front panel at the same time as within the off mode. The green led above this button is lit when the manipulate is in manual mode. To disable guide run mode, press the forestall button. Note: vehicle mode can not be selected while in guide run mode. The control needs to be in off mode before converting the mode. Switching to off mode will result in the generator set shutting down. Choosing off mode to interchange to off mode. A) make sure that it's miles secure to accomplish that before proceeding to forestall the set b) press the prevent button on the the front panel. The crimson led above the stop button is lit whilst the manipulate is inside the off mode 2.4 configuration mode caution: adjusting the settings in configuration mode must simplest be accomplished by technically educated and skilled service employees. The frequency settings must handiest be adjusted to correspond to the parameters of the installed input power deliver. Saving settings that don't correspond to the energy supply can motive extreme non-public harm and equipment or property harm. Configuration mode is used to adjust the parameters of the generator set and need to best be performed by way of technically skilled and experienced service employees.6 membrane keys are used to step thru the one of a kind menu alternatives and to alter parameters. 14 as visible from the above determine, on pressing reset and ok button on ps0500 for 5 seconds, controller enters into configuration mode. Before displaying the menu, software program component no. And version are displayed. One wishes to recognize key to function. Keys houses in configuration mode the powerstart 0500 manage has the following menus: • alt setup: choose alternator set-up parameters (single / three section, 50 / 60 hz operation, famous person / delta, voltage and many others.) ?? units: pick sae or metric gadgets of degree for coolant temperature and oil pressure • oil pr input: pick the oil stress sensor type. ?? client i/o: configure the reaction to customer enter and use of the customer output • flt history: presentations the remaining 5 faults. ?? load defaults: resets to the default values. Will visit the next price will visit the preceding value will pass down * it shows the default cost. Whilst selected for a particular cost, * comes which shows that fee has been set adequate press for five sec moving into the config mode… reset sw part 3267727 sw ver 1.12 no navigation is needed 15 • lamp/led take a look at: tests all of the led’s at the ps0500 show module. 2.5 series of operation the generator set is run automatically the use of a faraway start signal, or manually the usage of the generator set manage panel buttons. Leds are furnished on the show module front panel to indicate the working run mode of the generator set. The powerstart 0500 manipulate initiates a starter cranking sign and could perform an routinely sequenced guide start, below a entire engine protection device combined with complete monitoring functionality. If a fault is sensed at begin-up, the engine is locked out and could not start. The selection of vehicle or manual run mode is determined through authorized employees during the generator set preliminary setup. 2.Five.1 beginning before trying to begin the generator set, the operator need to study via this entire manual, collectively with the fitness and protection guide and the precise engine manual supplied as part of the documentation p.C. Provided with the generator set. It is essential that the operator be completely familiar with the generator set and the powerstart 0500 control. The following sub-sections cowl the systems used to begin and forestall the generator set. Before starting the generator set, ensure that exhaust and fuel fittings are tight and properly located, and that proper maintenance and pre-begin assessments had been executed. The generator set may be configured for some of starting cycles (one to seven) with set instances for crank and relaxation intervals for all beginning modes (manual/remote). The default setting is for three start cycles, composed of fifteen seconds of cranking and 5 seconds of relaxation. 2.5.2 beginning at display panel (guide run mode) to begin the generator set in the manual run mode, press the start button inside 10 seconds of urgent the manual button. Observe the instructions in segment 4.2.9 (choosing guide run mode). Note: any faraway begin/forestall signal is overlooked whilst in guide run mode. The powerstart 0500 manipulate will initiate a starter cranking sign and will carry out an routinely sequenced manual start, underneath a complete engine safety device mixed with full monitoring functionality. This may set off the engine control device and the starting technique. The starter will start cranking, and after some seconds the engine will start and the starter will disconnect. Inside the guide run mode the manipulate will now not whole the time postpone to begin or time delay to forestall. The faraway start purple led, and the manual run, inexperienced led might be lit. If the engine does no longer start, the starter will disengage after a distinctive time frame and the control will suggest a fail to begin shutdown. Sixteen wait not less than two mins for the starter motor to cool and then repeat the starting manner. If the engine does no longer run after a 2nd try, refer troubleshooting guidelines. 2.Five.3 beginning from far off vicinity (auto mode) to begin the generator set within the auto run mode, press the auto button from the menu bar of the display module front panel. Follow the commands in segment 4.2.8 (selecting car mode). The auto, inexperienced led could be lit. Most effective on receipt of a remote start signal, and after a time postpone to begin, will the powerstart 0500 manage initiate the beginning series as above. The far flung start led will be lit. 2.6 stopping 2.6.1 stopping at display panel (guide mode) the module will now not reply to any remote forestall sign even as in manual run mode. While in guide run mode, urgent the prevent button will initiate a normal (manual) shutdown sequence. Inside the manual run mode the manipulate will now not whole the time put off to stop. Word: do away with load and run set for 5 mins to lessen engine warmth earlier than pressing the off button. 2.6.2 stopping from far flung area (auto mode) in auto mode, the control lets in the generator set to be started with a far off begin sign only. If the control receives a far flung forestall sign, the generator set will whole its regular shutdown collection which includes a time postpone forestall (default is zero seconds). If the generator set is going for walks in auto mode and the stop button is pressed, the manage at once stops the generator set with out completing the time put off to prevent and the manage transitions to the off mode. 2.6.3 emergency forestall (code 1434) the emergency forestall button is situated on the the front of the manage panel. This is a routinely latched switch a good way to unconditionally prevent the engine when pressed, bypassing any time postpone to stop. Push this button in for emergency shutdown of the engine. Note : if the engine isn't always jogging, pushing the button in will save you the starting of the engine, no matter the begin sign source (guide or automobile - remote). While the forestall button is pressed the show panel will suggest the shutdown circumstance by using illuminating the crimson shutdown fame led and displaying the following message on the graphical liquid crystal display show: 17 if a stop button is activated the subsequent message may be displayed; fault: 1434 emergency sh to reset: a) press the good enough button on the show module to renowned the fault. B) press the prevent button and pull, or twist and pull, the button out to reset the fault situation c) press the automobile or guide run button, as previously determined. 2.7 connector information 2.7.1 description j16 – engine connector arrow at pin 1 j12 – ct connector arrow at pin 1 j12 –pin four j16 –pin 7 j22 – voltage connector arrow at pin 1 tb2 – patron tb arrow at pin 1 tb15 – tool connector arrow at pin 1 18 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). Signal is defined as underneath – connector pin signal call j16-1 coolant temperature sensor j16-2 battery charging alternator (wl) j16-3 starter relay driving force (low facet) j16-four gasoline shutoff relay driver (low side) j16-5 bat- j16-6 chassis gnd j16-7 nc j16-eight nc j16-9 oil pressure sensor j16-10 starter disconnect input j16-11 sensor commonplace j16-12 bat 2.7.Three ct connector the ct connector is a 6- pin mate-n-lock connector. Connector info are as follows – connector pin sign j12-1 ct1_input j12-2 ct2_input j12-three ct3_input j12-4 ct1_com j12-five ct2_com j12-6 ct3_com 2.7.4 voltage connector the voltage connection is thru a 4 pin header with exchange spaces between the pins. Connector pin signal j22-1 gen_v1 j22-2 gen_v2 j22-3 gen_v3 j22-4 gen_n 19 2.7.Five consumer connection tb - 2 the customer connection tb2 is a 6 pin terminal block. The terminal pins info are as proven below- terminal pins signal tb2-1 remote begin switch input tb2-2 glow plug output relay driving force (low aspect) tb2-3 customer output relay driver (low facet) tb2-4 consumer enter tb2-five e-stop tb2-6 nc returns for all of the above connections are required to be related externally. All the inputs are energetic gnd. Far off e-prevent transfer must have two independent potential loose contacts. One nc touch for reducing out the battery supply to the gas solenoid and any other nc touch to attach controller’s e-prevent enter to gnd to suggest to the control while the e-stop is pushed in energetic state. Battery positive isn't always provided at the patron terminal block (tb2). Outside provision desires to be made within the harness to provide the b signal for convenience of wiring up outside relays and may be used as relay supply (excessive side) for fso, starter, client output and glow plug relays through a 1 amp fuse. 2.7.6 computer device connector the pc tool connector is a devoted 5 pin connector header block. Terminal pins sign tb15-1 gnd tb15-2 nc tb15-3 rs485_data_a tb15-four rs485_data_b tb15-5 tool_wakeup 20 3. Reputation signs display panel genset running this green led is lit whilst the generator set is jogging at or near rated speed and voltage. Shutdown this red lamp is lit while the manipulate detects a shutdown situation. The generator set cannot be began while this lamp is on. After the condition has been corrected, the lamp may be reset with the aid of pressing the off button. Word: when struggle brief mode has been enabled and an overridden shutdown fault happens, the shutdown lamp will be lit even though the generator set will retain to run. Warning this yellow lamp is lit on every occasion the manage detects a warning condition. This lamp is robotically close off whilst the caution circumstance no longer exists. Far flung begin this inexperienced lamp suggests the manage is receiving a far off run sign. 21 three.1 fault code list ctg code lamp description c 141 caution suggests the oil strain sensor output is out of variety (oor), low. B 143** warning shows the engine oil stress is drawing near an unacceptable degree. C one hundred forty four caution indicates the coolant temperature sensor output is out of variety (oor), low. C 146** warning indicates that the engine is working close to cooling device capability. Boom in load or better ambient temperature can also motive high coolant temp (code 151) shutdown. D 151** shutdown suggests that the engine coolant temperature is above regular and has reached the shutdown journey point. D 359 shutdown the device has didn't begin after a set wide variety of crank tries. This indicates a probable fuel machine or air induction trouble (engine cranks but fails to start). A 415** shutdown indicates the engine oil pressure has dropped underneath ordinary and has reached the shutdown experience factor. D 441** warning indicates battery voltage supply to the control is drawing near a low level at which unpredictable operation can arise. D 442** warning indicates battery voltage deliver to the manage is drawing close a excessive degree at which damage to the manipulate can occur. B 1123* shutdown a shutdown fault befell even as the warfare brief mode changed into enabled. D 1131* warning suggests that the control is in struggle brief mode – used to bypass several fault shutdowns for generator set operation in the course of emergencies. E 1312 configurable the nature of the fault is an non-obligatory customer selection. B 1416* caution shows that a shutdown fault is lively, but is being bypassed by using struggle brief. D 1434 shutdown shows a faraway emergency prevent has been activated. D 1435** warning shows that the engine coolant temperature is underneath the adjusted setpoint. This can imply that the coolant heater is not operating or is not circulating coolant. D 1442** warning indicates that the generator set battery voltage is below battery thresholds at some stage in cranking. A 1446** shutdown shows that one or greater measured ac output voltages have exceeded the brink for longer than a specified time restrict. The brink and cut-off dates are a hundred thirty of nominal for zero seconds or one hundred ten of nominal for ten seconds. A 1447** shutdown indicates that the measured ac output voltage is underneath the edge for longer than a detailed time limit. The brink and closing dates are eighty five of nominal for ten seconds. A 1448** shutdown shows that the alternator frequency is 6 hertz under the nominal frequency. A 1449** shutdown shows that the alternator frequency is 6 hertz above the nominal frequency. A 2335 shutdown suggests that a loss of voltage or frequency sensing from the generator has occurred. A 2677 shutdown the generator set keeps to run after receiving a prevent command from the controller. 22 four. Troubleshooting 4.1 advent fault codes records together with caution and shutdown records is furnished in this section to assist in finding and figuring out the feasible reasons of faults inside the generator set gadget. Refer additionally to the operator’s engine specific manual furnished as a part of the generator set documentation percent. This latter manual will incorporate in addition statistics concerning the strolling and care of the generator set and also particular gadget instructions which can vary from the usual generator set. Four.2 manage unit the generator set control device constantly video display units engine sensors for extraordinary conditions, which includes low oil pressure and high coolant temperature. If any of those conditions arise, the manipulate will light a yellow caution lamp or a red shutdown lamp and will display a message at the graphical show panel. Within the event of an engine shutdown fault (red shutdown led), the manage will stop the engine without delay. This section lists the warning and shutdown fault codes/messages and indicates feasible reasons of the fault. 4.3 troubleshooting tactics for fault code four.2 code: 143 indicates engine oil strain has dropped underneath the caution journey factor. If generator is powering important masses and can not be close down, wait till subsequent shutdown period and then follow the fault code 415 procedure. Lamp: warning message: pre-low oil pressure code: 146 shows engine is working near cooling machine potential. Boom in load or higher ambient temperature may additionally motive high coolant temp (151) shutdown. Evaluate fault code 151 correction listing for different feasible reasons. Lamp: caution message: pre-excessive cool temp code: 151 indicates engine has overheated (coolant temperature has risen above the shutdown ride point). Permit engine to settle down absolutely earlier than proceeding with the subsequent assessments: a) look for feasible coolant leakage factors and restore if essential. Check coolant degree and refill if low b) take a look at for obstructions to cooling airflow and correct as necessary c) test fan belt and restore or tighten if vital 23 lamp: shutdown d) take a look at blower fan and stream pumps on remote radiator installations message: high coolant temp e) reset manage and restart after locating and correcting hassle. Code: 359 suggests possible fuel machine or air induction hassle. (Engine cranks however fails to start). Allow engine to settle down completely earlier than intending with the following assessments: f) take a look at for empty gas tank, gasoline leaks, or blocked gas traces and accurate as required g) take a look at for dirty gas filter out and replace if essential lamp: shutdown h) test for grimy or blocked air filter and update if vital message: fail to start i) reset control and restart after correcting the trouble. Code: 415 indicates engine oil pressure has dropped under the shutdown journey point. Allow engine to calm down absolutely earlier than intending with the following exams: j) check the oil level, strains and filters lamp: shutdown okay) if the oil device is good enough but the oil degree is low, refill message: low oil pressure l) reset control and restart after locating and correcting hassle. Code: 441 indicates battery voltage deliver to the manage is drawing close a low level at which unpredictable operation will arise. If engine may be stopped permit engine to settle down absolutely earlier than intending: m) negative battery cable connections. Clean the battery cable terminals and tighten all connections n) test battery rate voltage waft stage if relevant (increase go with the flow level) o) discharged or defective battery lamp: warning take a look at the battery charger fuse message: low bat voltage recharge or update the battery. Code: 442 indicates battery voltage deliver to the manage is coming near a excessive level at which damage to the manage can arise. If engine can be stopped permit engine to calm down absolutely before proceeding: lamp: caution p) negative battery cable connections. Easy the battery cable terminals and tighten all connections message: high bat voltage q) take a look at battery rate drift stage if relevant (lower waft level). Code: 1131 suggests that the manage is in war short mode – used to pass numerous fault shutdowns consequently allowing generator set operation at some point of emergencies. Lamp: warning 24 message: struggle brief energetic code: 1311, 1312, 1317, 1318 the character of the fault is an non-compulsory customer selection. Example inputs: low gasoline day tank, water in gasoline, floor fault, and so forth. Every of the fault capabilities may be programmed (the usage of inpower provider device or get right of entry to to setup menu), as follows: r) event , warning or shutdown stage if characteristic pick = fault input lamp: configurable s) alternate display name the use of up to 32 characters message: configurable enter 1, 2, three, 4 code: 1416 the generator set continues to run after receiving a shutdown command from the controller. The struggle short feature is enabled – this is used to bypass several crucial fault shutdowns consequently allowing generator set operation throughout emergencies. Lamp: warning message: fail to shutdown code: 1433/1434 indicates local or far flung emergency forestall. Emergency prevent shutdown reputation may be reset simplest on the nearby manipulate panel. After locating and correcting problem, reset the neighborhood/far off emergency forestall button as follows: t) de-activate (disable) emergency stop button u) press the o (off) button v) select the preferred working mode (guide or remote). Code: 1435 suggests engine coolant heater isn't always working or isn't always circulating coolant. If engine may be stopped allow engine to quiet down absolutely earlier than proceeding with the following checks: w) the coolant heater not linked to strength deliver. Test for blown fuse or disconnected heater cable and accurate as required x) search for viable coolant leaks and restore as required test for low coolant level and replenish if required. Lamp: caution set is not running. Caution takes place whilst engine coolant temperature is 21 o c (70 o f) or lower. Message: low coolant temp word: in applications where the ambient temperature falls beneath 4oc (40of), low coolant temp may be indicated despite the fact that the coolant warmers are operating. Code: 1442 shows that during cranking, the battery voltage is at, or under, the weak battery warning ride factor for a time extra than, or equal to, the susceptible battery set time. 25 lamp: caution see code 441 for corrective motion message: susceptible battery code: 1448 shows that the generator set frequency has dropped under 90 of nominal for approximately ten seconds. Allow engine to settle down completely earlier than proceeding with the following assessments: y) check the gasoline deliver z) check the air consumption supply, the weight and correct any overload. Four.4 fault locating need to a fault situation arise in the course of operation comply with the approaches in the following tables to locate and correct the problem. For any symptom now not indexed, touch an accepted carrier centre for help. Earlier than starting any fault finding, make sure that the following simple exams are carried out: • all switches and controls are of their accurate positions • the gasoline oil stage is correct • the lubricating oil level is accurate • the coolant stage is correct • the radiator matrix is free from obstruction • the battery price condition is great and the connections are cozy • the generator set electrics and alternator connections are relaxed • the panel connections are cozy • the safety circuits had been reset • blown fuses were changed • tripped contactors or circuit breakers have been reset 26 five. Inpower connectivity 1. Ps0500 can be related with inpower using the verbal exchange cable (component no. 0338-4590) and rs485-232 convertor (element no. 0324-0021). 2. Configure the site of ps0500 in inpower before shifting ahead. Three. Connect one give up of the cable to tb15 connector of ps0500 4. Connect the alternative stop of cable to rs 485-232 convertor. Five. Connect the rs232 facet of the convertor closer to pc 6. Open inpower and connect the ps0500 with the created website online. Rs 485-232 convertor p/n 0324- 0021 pc p/n of cable 0338-4590 27 6. Calibration procedure word: ps0500 is calibrated from manufacturing facility. You aren't advised to do the calibration for the new element. Most effective the desired ct ratio needs to be decided on as per the engine version. Please verify with ao/zo earlier than acting calibration. 1. Were given to device -> initial calibration 28 2. The pick calibration window will seem. Choose 0326-7727 and click on next. Three. Records window will seem. The modern calibration ought to be 1.14 or above. Click subsequent 29 4. Store and repair parameter window will seem. Click on subsequent after this. Five. Click on the function range as a029w892 and click finish. 30 6. Window of calibration will pop up. Click sure to keep calibration. 7. Window of tool explorer will pop up and click on yes for persevering with the calibration. 31 8. Development window will appear. Don’t click on something and permit the calibration to show up. 10. A window of eroor may pop up. Click ok and retain. 32 eleven. Once the calibration is finished, the window for a success calibration will pop up. Click on good enough to complete the calibration. 33 7. Wiring diagram.

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