The engine does not shut down when a shutdown fault occurs.
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| Illustration 1 | g00445004 |
Fuel Control Relay For ETR Systems | |
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| Illustration 2 | g00445005 |
System Schematic For Air Shutoff Relay (ASR) | |
Note: It is extremely important that GSC setpoint P23 is correct for the engine application. Make certain setpoint P23 is programmed correctly for the engine application before continuing with this procedure.
Note: It is extremely important that GSC setpoint P01 is correct for the engine. All generator sets packaged in Larne, Ireland covered by this manual must ALWAYS have this setpoint programmed to 0 (ETR fuel solenoid) for both fuel solenoid types (ETR or ETS).
There are several possible causes why an engine is not shutting down when a shutdown fault occurs.
- Operator Error: The operating conditions of the generator may not be understood by the operator. Ensure that the condition is one that should cause an engine shutdown.
- Programming Error - Fault Is Overridden Or Disabled: It is possible to program the GSC in order to override certain shutdown faults. An overridden shutdown fault will be treated as an alarm fault. The YELLOW fault alarm indicator will be FLASHING instead of the RED fault shutdown indicator. If the GSC is programmed in order to disable a particular fault, there will not be any fault indicators or codes shown on the GSC. In these cases, it is a good idea to check any setpoints related to that fault. For example, if a generator is not shutting down when an overvoltage fault occurs, make sure setpoint P104(Overvoltage shutdown enable) is programmed correctly.
- Programming Error - Setpoints Incorrect For Application Or Customer Needs: It is possible to program the GSC setpoints to a value that does not allow the situation to be recognized by the GSC as a shutdown condition. In this case, check the appropriate setpoints for correct values. For example, if the generator is not shutting down when a high coolant temperature condition occurs, make sure setpoint P15 (High Water Temperature Shutdown) is correct for the application.
- Faulty Component: Some examples of faulty components that could prevent the GSC from shutting down the engine are: GSC and a broken or shorted harness wire.. In this case, the GSC will be issuing a command to shut down the engine due to a diagnostic code, but the engine remains running.
Test Step 1. CHECK FOR DIAGNOSTIC CODES
- Check the GSC for a diagnostic code on the upper display.
Expected Result:
The GSC should show a diagnostic code on the upper display.
Results:
- YES - The GSC shows a diagnostic code on the upper display.
Repair: See theTesting and Adjusting section of this book for the diagnostic code that is displayed on the GSC.
Stop.
- NO - The GSC does NOT show a diagnostic code on the upper display. Proceed to Test Step 2.
Test Step 2. CHECK THE YELLOW FAULT ALARM INDICATOR
- Check the display area of the GSC for the yellow fault alarm indicator.
Expected Result:
The yellow fault alarm indicator should be illuminated CONTINUOUSLY.
Results:
- YES - The yellow fault alarm indicator is illuminated CONTINUOUSLY.
Repair: The GSC has been programmed to override the normal shutdown response and the GSC treats the condition as an alarm fault. The engine will continue to run. In order to view the setpoints, see System Operation, "Engine/Generator Setpoint Viewing OP2". In order to reprogram the setpoints, see System Operation, "Engine/Generator Programming OP5".
Stop.
- NO - The yellow fault alarm indicator is not illuminated at all. Proceed to Test Step 3.
Test Step 3. CHECK FOR RED FAULT SHUTDOWN INDICATOR.
- Check the display area of the GSC for the red fault shutdown indicator.
Expected Result:
The red fault shutdown indicator should be FLASHING.
Results:
- YES - The red fault shutdown indicator is FLASHING and the engine remains running. Proceed to Test Step 4.
- NO - All fault indicators are OFF. A problem that is occurring should cause the GSC to shut down the engine. It is possible to program the GSC setpoints to a value that does not allow the situation to be recognized by the GSC as a shutdown condition.
Repair: Check the appropriate setpoints for correct values. In order to view the setpoints, see Systems Operation, "Engine/Generator Setpoint Viewing OP2". In order to reprogram the setpoints, see Systems Operation, "Engine/Generator Programming OP5"
Stop.
Test Step 4. CHECK THE SYSTEM BY USING THE ESPB.
The engine remains running and the fault shutdown indicator is FLASHING.
- Push the emergency stop push button (ESPB).
Expected Result:
The engine should shut down.
Results:
- OK - The engine does shutdown. The relay module is faulty.
Repair: Replace the GSC relay module. See Testing and Adjusting, "Relay Module - Replace". Verify that the repair corrects the problem.
Stop.
- NOT OK - The engine does NOT shut down. Proceed to Test Step 5.
Test Step 5. CHECK GSC SETPOINT P01 (FUEL SOLENOID TYPE)
The engine remains running after pushing the ESPB and the red fault shutdown indicator is flashing.
- Check setpoint P01 (Fuel Solenoid Type). In order to view the setpoints, see Systems Operation, "Engine/Generator Setpoint Viewing OP2".
Expected Result:
Setpoint P01 should be programmed to "0".
Note: All generator sets packaged in Larne, Ireland that are covered by this manual must always have this setpoint programmed to "0" (ETR fuel solenoid) for both fuel solenoid types (ETR or ETS).
Results:
- YES - Setpoint P01 is programmed to "0". Proceed to Test Step 6
- NO - Setpoint P01 is programmed to "1". The setpoint is programmed incorrectly.
Repair: Reprogram the setpoint to a value of "0". In order to reprogram the setpoint, see Systems Operation, "Engine/Generator Programming OP5".
Stop.
Test Step 6. CHECK VOLTAGE AT THE FUEL CONTROL SOLENOID
The engine remains running after pushing the ESPB and the red fault shutdown indicator is FLASHING.
- At the fuel control solenoid, measure the voltage.
Expected Result:
The voltage measured at the fuel control solenoid should be approximately the same as the nominal battery voltage (+/- 2 volts).
Results:
- OK - The battery voltage is correct at the FCS. The FCS has failed or there is a problem with the engine fuel system.
Repair: Refer to the appropriate engine service manual. Replace the FCS or repair the fuel system.
Stop.
- NOT OK - Battery voltage is not correct at the FCS. The Emergency Fuel Control Relay (EFCR) has failed.
Repair: Replace the Emergency Fuel Control Relay (EFCR). Verify that the repair corrects the problem.
Stop.