Systems Operation

Usage:

Introduction

Reference: Related EMCP II+ Service Literature

* SENR4676, Service Manual, 2301A Speed Control

* SENR3585, Service Manual, 2301A Electric Governor (Load Sharing)

* SENR2928, Service Manual, 2301 Electric Governor

* SENR3028, Service Manual, Caterpillar 3161 Governor

* SENR6430, Service Manual, 524 & 1724 Electrically Powered Governor Systems

* SEBU6874, Owner's Manual, Customer Communication Module For EMCP II

Location Of EMCP II System Components

Instrument Panel

(1) GSC; generator set control.

(2) SP; speed potentiometer. or GS; governor switch (optional).

(3) DRS; diagnostic reset switch.

(4) ECS; engine control switch.

(5) ALM; alarm module (optional) or SLM; synchronizing lights module (optional).

(6) PLS; panel light switch (optional).

(7) ESPB; emergency stop push button.

(8) VAR; voltage adjust rheostat.

Most of the EMCP II components are located on either the instrument panel or on the sub-panel. Other EMCP II components that exist on or near the engine are: engine oil pressure sensor (EOPS), engine coolant temperature sensor (ECTS), magnetic speed pickup (MPU) and engine coolant loss sensor (ECLS) (optional).

Panel Interior - Instrument Panel and Sub-Panel Instrument Panel:

(1) GSC; generator set control.

(2) SP; speed potentiometer. or GS; governor switch (optional).

(3) DRS; diagnostic reset switch.

(4) ECS; engine control switch.

(5) ALM; alarm module (optional) or SLM; synchronizing lights module (optional).

(6) PLS; panel light switch (optional).

(7) ESPB; emergency stop push button.

(8) VAR; voltage adjust rheostat.

(9) RM; relay module (part of GSC). Sub-Panel:

(10) AUX; auxiliary terminal strip.

(11) EG; electronic governor (optional).

(12) RPR; reverse power relay (optional). or OCR; overcurrent relay (optional). or OVR; overvoltage relay (optional).

(13) ATB; AC transformer box.

(14) CB2; circuit breaker 2.

(15) SMMS1; starting motor magnetic switch 1.

(16) SMMS2; starting motor magnetic switch 2 (optional).

(17) AUXREL; auxiliary relay (optional).

(18) RA; Resistor assembly for Altronics Interface Box.

(19) GPHI; ground post high voltage.

Component Description

Generator Set Control (GSC)

Display Area Of Generator Set Control (GSC)
(1) Dedicated shutdown indicators. (2) Fault shutdown indicator. (3) Fault alarm indicator. (4) Upper display. (5) Lower display. (6) Keypad.

The main component of the EMCP II system is the generator set control (GSC). The GSC is designed to operate when powered by only 24 DCV or 32 DCV battery systems. The GSC monitors and controls many of the generator set (genset) functions. The functions and features of the GSC are:

* Controls normal starting and stopping of the engine.

* Shows engine conditions and generator output information on two displays. The displays also show fault codes and GSC programming information.

* Monitors the system for faults. If a fault occurs, the GSC performs a controlled fault shutdown or provides a fault alarm annunciation. The GSC uses indicators and displays to describe the fault to the operator or service technician.

* Contains programmable features for certain applications or customer requirements.

Fault Indicators

The eight fault indicators are used to show and describe a fault that is present. The fault indicators are divided into three groups: fault alarm indicator (3), fault shutdown indicator (2) and dedicated shutdown indicators (1).

The yellow fault alarm indicator (3) FLASHES when the GSC detects a fault that is an alarm fault. The engine continues to run and start. Fault alarm indicator (3) is accompanied by an alarm fault code that is shown on upper display (4) when the alarm codes key is pressed.

The red fault shutdown indicator (2) FLASHES when the GSC detects a fault that is a shutdown fault. The engine is shut down if it is running and is not allowed to start. Fault shutdown indicator (2) is accompanied by a fault code that is immediately shown on upper display (4).

The red dedicated shutdown indicators (1) represent the following shutdown faults: low oil pressure, emergency stop, high water temperature, engine overspeed, low coolant level and engine overcrank. When the GSC detects a fault in one of these areas, the dedicated shutdown indicator (that corresponds to the fault) FLASHES. The engine is shut down if it is running and is not allowed to start. There are no fault codes associated with the dedicated shutdown indicators because each indicator has an interpretive label. The conditions required for each dedicated fault and the results of each dedicated fault are:

Low Oil Pressure - The engine oil pressure drops below the setpoints for low oil pressure shutdown that are programmed into the GSC. There are two low oil pressure setpoints, one for when the engine is at idle speed and the other for when the engine is at rated speed. The low oil pressure indicator FLASHES, the engine is shut down and is not allowed to start.

Emergency Stop - The operator presses the emergency stop push button (ESPB) on the instrument panel. The emergency stop indicator FLASHES, the engine is shut down and is not allowed to start.

High Water Temperature - The engine coolant temperature rises above the setpoint for high water temperature shutdown that is programmed into the GSC. The high water temperature indicator FLASHES, the engine is shut down and is not allowed to start.

Engine Overspeed - The engine speed exceeds the setpoint for engine overspeed that is programmed into the GSC. The engine overspeed indicator FLASHES, the engine is shut down and is not allowed to start.

Low Coolant Level - The engine coolant level drops below the probe of the coolant loss sensor (optional). The engine coolant level indicator FLASHES, the engine is shut down and is not allowed to start.

Overcrank - The engine does not start within the setpoint for total cycle crank time that is programmed into the GSC. The overcrank indicator FLASHES and the engine is not allowed to start.

NOTE: The GSC can be programmed to override the shutdown for low oil pressure, high water temperature and the low coolant level faults. When overridden, these faults are treated as alarm faults. The corresponding dedicated shutdown indicator is ON CONTINUOUSLY (instead of flashing) and the engine continues to run and start (instead of shutting down). The dedicated shutdown indicator that is ON CONTINUOUSLY means that the setpoint for shutdown has been exceeded, but the GSC is programmed to override the shutdown fault and treat the fault as an alarm fault. As provided from the factory, the GSC treats low oil pressure, high water temperature and low coolant level as shutdowns. The operator or service technician must make a conscious decision to override these shutdown faults and have the GSC treat them as alarm faults.

Display

The upper display (4) and lower display (5) of the GSC provide information about the genset.

Upper display (4) shows AC voltage, current and frequency of one phase of the generator output. Each phase can be viewed one at a time by pushing the phase select key. Upper display (4) is also used to show the various fault codes for system faults. For more information on fault codes, see the topic Fault Description.

Lower display (5) shows system battery voltage, engine hours, engine speed, engine oil pressure and engine coolant temperature. The value for one of these conditions is shown for two seconds and then the display scrolls to the value for the next condition. A small pointer identifies the engine condition that corresponds to the value that is showing. When the engine meter key is pressed, lower display (5) stops scrolling and continuously shows one particular value. Now the pointer flashes above the condition whose value is showing.

The relay status indicator is on the lower display also. When a GSC relay is activated, the corresponding indicator (K1, K2, etc.) is shown on lower display (5). When a relay is not activated, the corresponding indicator (K1, K2, etc.) is not shown.

Both displays are used for programming functions when in service mode. For more information, see the topic Service Mode.

Keypad

Keypad (6) is used to control the information that is shown on upper display (4) and lower display (5). The seven keys have two sets of functions, normal functions and service functions. For a description of the service functions of the keys; see the topic Service Mode. The normal functions of the keys are:

Leftmost Key - This key only functions when the GSC is in service mode. See the topic Service Mode.

Phase Select Key - Selects which phase of the generator output is shown on the GSC. Pressing this key allows the operator to check the voltage, current and frequency of each phase one at a time.

Engine Meter Key - Stops the scrolling of engine conditions on lower display (5) and continuously shows the value for one particular engine condition. The pointer flashes to indicate scrolling is stopped. Pressing the key again, resumes the scrolling of engine conditions.

Lamp Test Key - Performs a lamp test on the GSC and the optional alarm module. On the GSC: the eight fault indicators are ON CONTINUOUSLY, every segment of upper display (4) and lower display (5) are ON. On the optional alarm module: all of the indicators are ON and the horn sounds.

Alarm Codes Key - If fault alarm indicator (3) is FLASHING, pressing this key causes upper display (4) to show the corresponding alarm fault code. Pressing this key again, resumes the showing of generator output information on upper display (4). If fault alarm indicator (3) is OFF, this key has no function. For more information on alarm fault codes, see the topic Fault Description.

Exit Key - This key only functions when the GSC is in service mode. See the topic Service Mode.

Service Mode Key - Pressing this key causes the GSC to enter service mode. See the topic Service Mode.

Relays

Relay Module On Rear Of GSC

Relays In Relay Module

The relays are located in the relay module on the rear of the GSC. The relays are permanently attached within the relay module and are not removable. The entire relay module is replaced if a relay is faulty. For more information, see the DC Schematics in the Schematics and Wiring Diagrams section.

Some of the contacts of the relays are internally connected to the terminals of the relay module and are available for customer use. The voltage and current specifications for each terminal (relay) are listed in the following chart.

The relays and the functions are:

K1 - Electronic Governor Relay (EGR):

When the relay is active the normally open contacts close. This signals the optional 2301A governor to accelerate the engine to rated speed.

The relay has no normally closed contacts. K2 - Generator Fault Relay (GFR):

When the relay is active the normally open contacts close. This trips the optional circuit breaker when a shutdown fault occurs.

The relay has no normally closed contacts. K3 - Crank Termination Relay (CTR):

When the relay is active the normally open contacts close. This activates the optional AUX relay (customer use) and enables the optional governor switch which adjusts the governor synchronizing motor.

When the relay is inactive the normally closed contacts close. K4 - Starting Motor Relay (SMR):

When the relay is active the normally open contacts close. This activates the starting motor magnetic switch.

When the relay is inactive the normally closed contacts close. This activates the optional battery charger. K5 - Run Relay (RR):

When the relay is active the normally open contacts close. This powers the optional 2301A governor.

When the relay is inactive the normally closed contacts close. These contacts are for customer use. K6 - Ignition Shutoff Relay (ISR):

When the relay is active the normally open contacts close which grounds the magneto.

When the relay is inactive, the normally closed contacts close. This allows the engine to run. K7 - Fuel Control Relay (FCR):

When the relay is active the normally open contacts close.

On ETR systems, this activates the fuel solenoid during starting and running. Gas engines use the energized to run (ETR) type of fuel system.

ON ETS systems, this activates the fuel solenoid during shutdown. The fuel solenoid is disabled at less than 40 rpm in all modes (normal, shutdown, alarm).

The relay has no normally closed contacts.

Instrument Panel Switches

Instrument Panel Switches
(2) SP; speed potentiometer. (3) DRS; diagnostic reset switch. (4) ECS; engine control switch. (6) PLS; panel light switch (optional). (7) ESPB; emergency stop push button. (8) VAR; voltage adjust rheostat.

Engine control switch (ECS) (4) determines the status of the control panel. In the AUTO position (3 o'clock), the engine starts automatically whenever the remote initiating contact (IC) is closed. The engine also shuts down after the initiate contacts open. A selectable cooldown time is programmable to give a 0 to 30 minute cooldown period before the engine shuts down. The cooldown time is factory set at five minutes. In the MANUAL START position (6 o'clock), the engine starts and runs as long as the ECS is in this position. In the COOLDOWN/STOP position (9 o'clock), the fuel solenoid shuts the engine down after cooldown. In the OFF/RESET position (12 o'clock), the engine shuts down immediately and any fault indicators are reset (except emergency stop).

If red emergency stop push button (ESPB) (7) is pressed, the fuel is shut off. To restart: turn ESPB (7) clockwise until it releases, turn the ECS to OFF/RESET and then to START.

Voltage adjust rheostat (VAR) (8) is used to adjust generator voltage to the desired level.

Speed potentiometer (SP) (2) is used to raise and lower engine speed when the genset has an electronic governor. Optional governor switch (GS) (2) is used to raise and lower engine speed when the governor has a speed adjust motor.

Optional panel light switch (PLS) (6) turns ON and OFF the panel lamps.

Diagnostic reset switch (DRS) (3) clears all diagnostic codes that are stored in the Electronic Ignition System (EIS). For more information, see the Electronic Troubleshooting module for the particular engine.

EMCP II Sensors

The GSC monitors four engine sensors: the engine oil pressure sensor, engine coolant temperature sensor, engine coolant loss sensor (optional) and the engine magnetic pickup (speed sensor).

Engine Oil Pressure Sensor

The engine oil pressure sensor is an input of the GSC. The purpose of the sensor is to tell the GSC what the engine oil pressure is. The GSC shows the engine oil pressure on the lower display and also uses the sensor information to determine when a low oil pressure fault exists. The engine oil pressure sensor is mounted on the outside of one of the engine oil galleries. The exact location depends upon the engine model.

The engine oil pressure sensor is a pulse-width-modulated (PWM) type of sensor. This sensor continuously generates a PWM signal, in which the duty cycle varies from 10 to 90% in proportion to the oil pressure of the engine. The GSC receives the PWM signal and measures the duty cycle to determine the oil pressure of the engine. The base frequency of the signal is constant at 500 ± 150 Hz. The signal wire (connector contact C) of the oil pressure sensor connects to connector contact 8 of the GSC. The sensor is supplied operating power (8 DCV) at connector contact A from the GSC (connector contact 9).

There are five setpoints related to engine oil pressure that are programmed into the GSC. The related setpoints are: P03, P04, P12, P13 and P14. See Setpoint Programming - OP5 within the topic Service Mode.

Engine Coolant Temperature Sensor

The engine coolant temperature sensor is an input of the GSC. The purpose of the sensor is to tell the GSC what the engine coolant temperature is. The GSC shows the engine coolant temperature on the lower display and also uses the sensor information to determine when a high coolant temperature fault exists. The engine coolant temperature sensor is mounted in the water jacket, usually towards the front of the engine. The exact location depends upon the engine model.

The engine coolant temperature sensor is a pulse-width-modulated (PWM) type of sensor. This sensor continuously generates a PWM signal, in which the duty cycle varies from 10 to 95% in proportion to the coolant temperature of the engine. The GSC receives the PWM signal and measures the duty cycle to determine the coolant temperature of the engine. The base frequency of the signal is constant at 455 Hz (370 to 550 Hz). The signal wire (connector contact C) of the coolant temperature sensor connects to connector contact 7 of the GSC. The sensor is supplied operating power (8 DCV) at connector contact A from the GSC (connector contact 9).

There are four setpoints related to engine coolant temperature that are programmed into the GSC. The related setpoints are: P03, P04, P15 and P16. See Setpoint Programming - OP5 within the topic Service Mode.

Engine Coolant Loss Sensor

The engine coolant loss sensor is optional and is an input of the GSC. The purpose of the sensor is to tell the GSC when the engine has lost coolant. The GSC uses the sensor information to determine when a low coolant level fault exists. The engine coolant loss sensor is usually mounted near the top of the engine radiator. The exact location depends upon the engine model.

The engine coolant loss sensor sends the GSC either a battery negative (B-) signal for normal level or a +5 DCV signal for low level. The signal wire (connector contact C) of the coolant loss sensor connects to connector contact 13 of the GSC. The sensor is supplied operating power (8 DCV) at connector contact A from the GSC (connector contact 9).

There are three setpoints related to engine coolant loss that are programmed into the GSC. The related setpoints are: P04, P05 and P06. See Setpoint Programming - OP5 within the topic Service Mode.

Engine Magnetic Pickup

The engine magnetic pickup is an input of the GSC. The purpose of the sensor is to tell the GSC what the engine speed is. The GSC shows the engine speed on the lower display and also uses the sensor information for tasks such as activating an engine overspeed shutdown, terminating engine cranking and determining the oil step speed. The engine magnetic pickup is mounted on the flywheel housing of the engine.

The sensor creates a sine wave signal from passing ring gear teeth at the rate of one pulse per tooth. The sensor sends the GSC a sine wave signal in which the frequency is in direct proportion to the speed of the engine. The GSC receives the sine wave signal and measures the frequency (one pulse per gear tooth) to determine the speed of the engine. The wires of the sensor connect to connector contacts 1 and 2 of the GSC within a shielded cable. One wire is grounded near the GSC.

There are four setpoints related to engine speed that are programmed into the GSC. The related setpoints are: P09, P10, P11 and P12. See Setpoint Programming - OP5 within the topic Service Mode.

Modes Of Operation

Display Area Of Generator Set Control (GSC)
(1) Dedicated shutdown indicators. (2) Fault shutdown indicator. (3) Fault alarm indicator. (4) Upper display. (5) Lower display. (6) Keypad.

The GSC has four modes of operation. A brief description of each follows. See the individual topic for more detailed information.

Normal Mode: The GSC uses normal mode for the normal operation of the genset. The operator can identify normal mode by observing the display area. When in normal mode: all the dedicated and fault shutdown indicators are OFF, the fault alarm indicator is OFF and "SERV" is NOT SHOWING on the upper display.

Alarm Mode: The GSC automatically goes into alarm mode to alert the operator that an alarm fault (non-critical) is occurring. The operator can identify alarm mode by observing the display area. When in alarm mode, the fault alarm indicator is FLASHING.

Shutdown Mode: The GSC automatically goes into shutdown mode to shut the engine down and alert the operator that a shutdown fault (critical) is occurring. The operator can identify shutdown mode by observing the display area. When in shutdown mode, a dedicated or fault shutdown indicator is FLASHING.

Service Mode: The GSC goes into service mode when the operator presses the service mode key on the keypad. The operator or service person uses service mode to: assist with troubleshooting of diagnostic faults, to satisfy special applications, to satisfy customer needs and to verify or calibrate or adjust genset functions. The operator can identify service mode by observing the display area. When in service mode, "SERV" is SHOWING on the upper display.

Normal Mode

The purpose of normal mode is to monitor and control the genset. The GSC controls the engine according to the information received from the operator (panel switches, controls) and from the engine sensors. Some of the functions performed by the GSC while in normal mode are: engine starting, monitoring of important genset conditions, showing the operator the important genset conditions, fault detection and engine stopping. The operator can identify normal mode by observing the display area. When in normal mode: all shutdown indicators are OFF, the fault alarm indicator is OFF and "SERV" is NOT SHOWING on the upper display. When the GSC is in normal mode, the engine is able to start or run.

Engine Starting Sequence

1. The GSC receives an engine start signal. The possible engine start signals are:

* ECS turned to START by the operator.

* The remote initiate contacts (IC) close while the ECS is in the AUTO position.

2. The GSC checks the system before beginning the cranking sequence. The GSC checks that:

* No system faults are present.

* All previous faults have been reset (removed by turning the ECS to OFF/RESET).

* The engine is not already running.

* The service mode is not activated.

3. At the beginning of a crank cycle the GSC checks the crank time delay setpoint.

If the crank time delay setpoint is greater than 0 seconds, then for the setpoint amount of time (factory default is 5 seconds) The GSC will:

* Activate the ignition shutoff relay (ISR) (grounds the magneto)

* Activate the fuel control relay (FCR) on ETS fuel systems or deactivate on ETR fuel systems. Gas engines use the energized to run (ETR) type of fuel system.

* Activate the starting motor relay (SMR).

If the crank time delay setpoint is 0 seconds (or when it reaches 0 seconds), then the GSC will:

* Deactivate the ignition shutoff relay (ISR) which removes grounds from the magneto.

* Deactivates the fuel control relay (FCR) on ETS fuel systems or activates on ETR fuel systems. Gas engines use the energized to run (ETR) type of fuel system.

* Activates (or maintains active state) the starting motor relay (SMR).

4. While the starting motor is cranking, the GSC shows the status of the relays on the relay status indicators of the lower display.

* K4, K5, K7 for ETR fuel systems. Gas engines use the energized to run (ETR) type of fuel system.

* K4, K5 for ETS fuel systems.

5. The GSC deactivates the starting motor relay (SMR) and activates the crank termination relay (CTR) when the engine speed reaches the setpoint for crank terminate speed (factory default is 400 rpm).

6. The GSC activates the electronic governor (EG) relay when the oil pressure reaches the setpoint for low oil pressure at idle speed. The factory default is 70 kPa (10 psi). The EG relay signals the electronic governor (EG) to accelerate the engine to rated speed.

7. The GSC shows:

* AC voltage, current and frequency for one phase at a time on the upper display.

* System battery voltage, engine hours, engine rpm, oil pressure and coolant temperature on the lower display.

* The relay status on the relay status indicators of the lower display. K1, K3, K5, K7 for ETR fuel systems and K1, K3, K5 for ETS fuel systems. Gas engines use the energized to run (ETR) type of fuel system.

Engine Stopping Sequence

1. The GSC receives an engine stop signal. The possible engine stop signals are:

* ECS turned to STOP by the operator.

* The remote initiate contacts (IC) open while the ECS is in the AUTO position.

2. After receiving the stop signal, the GSC checks that no system faults are present.

3. The GSC begins the cooldown time (factory default is five minutes).

4. If programmed to do so, the GSC activates the spare output. This output can activate a slave relay during cooldown which in turn activates the optional circuit breaker and takes the generator off load.

5. After the cooldown time reaches the setpoint, the GSC deactivates the run relay (RR) and the electronic governor (EG) relay is deactivated after the engine oil pressure decreases to less than the setpoint for low oil pressure shutdown at idle speed (P14). Also the GSC shuts off the fuel by deactivating the fuel control relay (FCR) for ETR systems and activating the FCR for ETS systems. Gas engines use the energized to run (ETR) type of fuel system.

On ETS systems; after engine speed drops below 40 rpm and oil pressure drops below 80 kPa (12 psi), then the GSC activates the fuel control relay (FCR) for 70 seconds.

6. As soon as engine speed reaches 0 rpm, the GSC deactivates the crank terminate relay (CTR) and a restart is now allowed.

If a start signal is received before 0 rpm is reached, the fuel is turned on and the engine is allowed to run. If it does not run, the starting motor relay (SMR) does not activate until the crank termination relay (CTR) is deactivated at 0 rpm.

7. The GSC shows the status of the relays on the relay status indicators of the lower display. All relay indicators should be OFF, except on ETS systems the K7 indicator remains ON for 70 seconds after engine speed and oil pressure are 0.

NOTE: If desired, the engine can be shutdown immediately by turning the ECS to OFF/RESET. The cooldown timer is bypassed and the spare data output is deactivated.

Alarm Mode

The purpose of alarm mode is to alert the operator that an alarm fault is occurring. An alarm fault is non-critical but potentially serious. An alarm fault precedes certain dedicated shutdown faults. When an alarm fault exists, the GSC automatically activates alarm mode and alerts the operator by FLASHING the fault alarm indicator. To identify what the alarm fault is, the operator presses the alarm codes key and then a corresponding fault code is shown on the upper display. This fault code can be an alarm fault code, spare fault code or a diagnostic fault code. For more information on fault codes, see the topic Fault Description. When the GSC is in alarm mode the engine is able to start or run.

Alarm faults depend upon certain setpoints. The GSC does not diagnose alarm faults and they are not recorded in the fault log. The alarm fault codes and the related setpoints are:

AL1 - High engine coolant temperature alarm. When coolant temperature rises to within 6°C (11°F) of the P15 setpoint, a high coolant temperature alarm is issued by the GSC. Then the GSC FLASHES the fault alarm indicator and alarm code AL1 is shown on the upper display after the alarm codes key is pressed.

P15 is the setpoint for high water temperature shutdown. This setpoint tells the GSC at what coolant temperature to declare that a high coolant temperature shutdown fault exists. When the setpoint is reached, the GSC FLASHES the dedicated shutdown indicator for high water temperature and the engine is shutdown.

AL2 - Low engine coolant temperature alarm. When coolant temperature decreases to setpoint P16, then the GSC FLASHES the fault alarm indicator and alarm code AL2 is shown on the upper display after the alarm codes key is pressed.

P16 is the setpoint for low water temperature alarm. This setpoint tells the GSC at what coolant temperature to declare that a low coolant temperature alarm fault (AL2) exists.

AL3 - Low engine oil pressure alarm. When oil pressure drops to within 34 kPa (5 psi) of the P13 or P14 setpoint, a low oil pressure alarm is issued by the GSC. Then the GSC FLASHES the fault alarm indicator and alarm code AL3 is shown on the upper display after the alarm codes key is pressed.

P13 is the setpoint for low oil pressure shutdown at rated speed. This setpoint tells the GSC at what oil pressure to declare that a low oil pressure shutdown fault exists with the engine at rated speed. When the setpoint is reached, the GSC FLASHES the dedicated shutdown indicator for low oil pressure and the engine is shutdown.

P14 is the setpoint for low oil pressure shutdown at idle speed. This setpoint tells the GSC at what oil pressure to declare that a low oil pressure shutdown fault exists with the engine at idle speed. When the setpoint is reached, the GSC FLASHES the dedicated shutdown indicator for low oil pressure and the engine is shutdown.

For more setpoint information see the topic Service Mode.

Alarm faults do not have an immediate adverse effect on the genset. However, the operator should investigate the cause of the alarm fault condition at the earliest opportunity. If the operation of the genset is mandatory, the starting and stopping procedures are exactly the same as in normal mode. The GSC will respond to operator input from the panel switches and the engine sensors. The engine is able to start or run while an alarm fault is present.

NOTE: If a shutdown fault is overridden (by operator programming) to be an alarm fault, then the corresponding dedicated shutdown indicator is ON CONTINUOUSLY if the particular fault occurs. The ON CONTINUOUSLY state means that the normal shutdown response has been overridden by the operator and the shutdown fault is treated as an alarm fault. A fault code is not shown on the upper display for the overridden shutdown faults. The dedicated shutdown indicator remains ON CONTINUOUSLY until the fault is corrected and the engine control switch is turned to the OFF/RESET position. The shutdown faults that can be overridden are: low oil pressure, high coolant temperature and low coolant level. For more information, see P03 and P06 within the topic Setpoint Programming OP5. Also, see the topic Shutdown Mode.

Alarm Mode Sequence

1. An alarm fault occurs.

2. The GSC detects the alarm fault and FLASHES the fault alarm indicator. The GSC does not change the status or operation of the genset.

3. Pressing the alarm codes key causes the upper display to show a corresponding fault code.

4. Correct the alarm fault; see the topic Alarm Fault Troubleshooting in the Testing And Adjusting section.

5. When the alarm fault is no longer occurring (corrected), the GSC turns OFF the fault alarm indicator and removes the fault code from the upper display. The GSC now returns to normal mode.

Shutdown Mode

The purpose of shutdown mode is to prevent damage to the engine or generator when a shutdown fault is occurring. A shutdown fault is critical. When a shutdown fault occurs, the GSC automatically activates shutdown mode until the shutdown fault is corrected. When in shutdown mode, the GSC shuts the engine down, prevents engine starting and alerts the operator.

The GSC alerts the operator and identifies the shutdown fault by FLASHING the corresponding shutdown indicator. The name of the shutdown indicator identifies the shutdown fault. The shutdown indicators are: low oil pressure, emergency stop, high water temperature, engine overspeed, low coolant level, engine overcrank and fault shutdown.

If the fault shutdown indicator is FLASHING, the cause is related to electrical component failure and additional diagnostic information is available. A diagnostic fault code is shown on the upper display which more precisely identifies the cause of the shutdown fault. For more information, see the topic Fault Description.

Shutdown Mode Sequence

1. A shutdown fault occurs and the GSC detects it.

2. To shut off the fuel, the GSC deactivates the fuel control relay (FCR) for ETR systems and activates the FCR for ETS systems. Gas engines use the energized to run (ETR) type of fuel system.

3. To prevent engine starting, the GSC deactivates the run relay (RR) and the starting motor relay (SMR).

4. The GSC activates the genset fault relay.

5. For an emergency stop fault, engine overspeed fault, or speed sensor fault (CID 190), the GSC activates the ignition shutoff relay (ISR) for 15 seconds.

6. As the engine comes to a stop, the GSC deactivates the crank termination relay (CTR) when engine speed reaches 0 rpm. The electronic governor (EG) relay is deactivated when the engine oil pressure reaches the setpoint [70 kPa (10 psi)] for low oil pressure shutdown at idle speed (P14).

7. For ETS fuel systems, a timer within the GSC is set to keep the fuel control relay (FCR) active for 70 seconds after engine speed decreases to 40 rpm and oil pressure decreases to 80 kPa (12 psi).

8. If engine speed does not decrease at least 100 rpm within five seconds, the GSC activates the ignition shutoff relay (ISR) for 15 seconds. (The ISR was already activated for an emergency stop fault, engine overspeed fault, or speed sensor fault).

9. The GSC FLASHES the corresponding shutdown indicator. If the fault shutdown indicator is FLASHING, the cause is related to electrical component failure and a diagnostic fault code is shown on the upper display. See the topic Fault Description.

10. The lower display continues to show the engine data.

11. The relay status indicators show:

K6 for 15 seconds - for an emergency stop fault, engine overspeed fault, speed sensor fault or if engine speed does not decrease at least 100 rpm.

K7 (ETS fuel systems) for 70 seconds after engine speed decreases to 40 rpm and oil pressure decreases to 80 kPa (12 psi). (K7 is not shown for ETR fuel systems.)

Engine Start Sequence (After Shutdown)

1. Correct the shutdown fault. See the topic Fault Identification in the Testing And Adjusting section.

2. Reset the GSC by turning the ECS to OFF/RESET. If no shutdown fault is active, the GSC returns to normal mode and the engine is able to start.

Service Mode

GSC Display Area With Service Mode Descriptions Of Keypad
(1) Dedicated shutdown indicators. (2) Fault shutdown indicator. (3) Fault alarm indicator. (4) Upper display. (5) Lower display. (6) Keypad.

The purpose of service mode is: to assist with troubleshooting of diagnostic faults, to satisfy special applications, to satisfy customer needs, and to verify or calibrate or adjust genset functions. Service mode has ten selectable options for viewing, entry, clearing, programming, verification and calibration of information by service personnel. The ten options are:

OP1 - Fault log viewing.OP2 - Setpoint viewing.OP3 - Password entry.OP4 - Fault log clearing.OP5 - Setpoint programming.OP6 - Spare Input/Output programming.OP7 - Hourmeter programming.OP8 - Voltmeter/Ammeter programming.OP9 - Engine setpoint verification.OP10 - AC calibration.

The keypad and the display of the GSC are used for activating service mode and selecting the desired option. When in service mode the keys of the keypad have a different meaning than usual. The name of each key when in service mode is shown in the preceding illustration. Also a film (label) on the vandal door of the control panel identifies each key when in service mode. The service functions of the keys are:

Scroll Right Key - This key is used to view and scroll information. This key represents the number 1 when entering the password.

Scroll Up Key - This key is used to scroll up through information or to adjust the value of information upwards. This key represents the number 2 when entering the password.

Scroll Down Key - This key is used to scroll down through information or to adjust the value of information downwards. This key represents the number 3 when entering the password.

NOTE: To rapidly scroll through a large range of information, press and hold the appropriate scroll key.

Select Key - This key is used to select the option or the information that is to be viewed or changed. Also, this key is used to start or stop the scrolling of information.

Enter Key - This key is used to enter into the memory of the GSC, the information that has been changed with the other keys.

Exit Key - This key is used to exit service mode and return the display to normal. The "SERV" indicator on the upper display is NOT SHOWING when the GSC is NOT in service mode.

Service Mode Key - This key is used to access (enter) service mode. The "SERV" indicator on the upper display FLASHES whenever the GSC is in service mode and the keypad performs service mode functions.

Procedure To Enter Service Mode

1. Press the service mode key on the keypad of the GSC. The "SERV" indicator on the upper display FLASHES whenever the GSC is in service mode.

2. The desired option can now be selected; see the following description of each option.

3. To return to normal mode, press the exit key a few times until the "SERV" indicator is not showing.

NOTE: Any active shutdown fault (any shutdown indicator FLASHING) must be made inactive in order to access service mode. To change a shutdown fault from an active shutdown fault to an inactive, the shutdown fault must no longer be occurring (must be corrected) and the ECS must be turned to the OFF/RESET position. If the jumper from terminal 6 to terminal 9 is not installed on the ECS, the GSC does not power up in OFF/RESET and any active shutdown fault must be corrected before entering service mode.

NOTE: To enter service mode options OP4 through OP8, the engine must be shutdown. Turn the ECS to the STOP position.

Service mode options OP4 through OP10 are password protected to reduce the possibility of information being altered by mistake. OP3 is the password entry option and the password must be correctly entered before access is gained to OP4 through OP10; see the topic Password Entry OP3. Options OP1 and OP2 are for the viewing of information and are not password protected.

Fault Log Viewing - OP1

OP1 is the option for viewing of diagnostic fault codes (CID FMI) that are recorded in the fault log of the GSC. The fault log contains a history of diagnostic faults that have occurred in the genset system since the last service call (the last clearing of diagnostic fault codes). Also, the number of occurrences are totalled and shown on the upper display with the CID and FMI codes. The purpose of the fault log is to assist service personnel when troubleshooting the genset system.

Only inactive diagnostic faults are stored in the fault log. An active diagnostic alarm fault ("DIAG" is FLASHING) becomes inactive ("DIAG" is ON CONTINUOUSLY) when the fault is no longer occurring and also for diagnostic shutdown faults the ECS must be turned to OFF/RESET. The GSC stores a maximum of 12 inactive diagnostic fault codes in the fault log. If an additional diagnostic fault becomes inactive, the GSC automatically clears the earliest inactive diagnostic fault code and puts the additional inactive diagnostic fault code in the fault log.

The GSC automatically clears any inactive diagnostic fault codes that have been stored in the fault log for more than 750 hours. For example; if a CID 190 FMI 3 fault code is logged at 10 hours and a CID 100 FMI 4 fault code is logged at 20 hours, then the GSC clears the CID 190 FMI 3 fault code when the hourmeter is at 760 hours and the CID 100 FMI 4 fault code remains logged until the hourmeter is at 770 hours. This feature prevents the fault log from becoming cluttered with fault codes that service personnel have corrected but forgot to clear.

When a diagnostic fault changes from active to inactive, the GSC functions as follows:

a. The diagnostic fault is recorded in the fault log of the GSC.

b. The "DIAG" indicator changes from FLASHING (active diagnostic fault) to ON CONTINUOUSLY (inactive diagnostic fault) if no other active faults are present.

c. The fault alarm indicator or fault shutdown indicator changes from FLASHING to OFF.

NOTE: Any active shutdown fault (any shutdown indicator FLASHING) must be made inactive in order to access service mode and view the fault log. To change a shutdown fault from an active shutdown fault to an inactive, the shutdown fault must no longer be occurring (must be corrected) and the ECS must be turned to the OFF/RESET position.

Procedure To View The Fault Log

NOTE: For a list of all diagnostic fault codes, see the Diagnostic Fault Codes chart in the Testing And Adjusting section.

1. Press SERVICE MODE key to enter service mode. "OP 1" is showing on the lower display. For more information see the topic Service Mode.

2. Press SELECT key. The CID/FMI fault codes for diagnostic faults are scrolled on the upper display (if more than one fault code is in the log). Each fault code has the number of occurrences showing above the COUNT indicator. The lower display shows the hourmeter value of the last occurrence of each fault.

3. Press SELECT key. The fault codes stop scrolling.

4. Press SCROLL RIGHT key. If more than one count of a particular fault code is logged, the first occurrence with it's hourmeter value is showing on the lower display.

5. Press SELECT key. Fault codes continue scrolling.

6. Press EXIT key. "OP 1" is showing on lower display.

7. Press EXIT key. The display returns to normal.

Setpoint Viewing - OP2

OP2 is the option for viewing the setpoints of important genset conditions. The setpoints affect the proper operation and serviceability of the engine, and the accuracy of the information shown on the display. Viewing the setpoints is done with the engine running or stopped.

The setpoints viewed (stored in the GSC) should match the specified setpoints of the control panel. For more information on setpoints, see the topic Setpoint Programming OP5.

The setpoints and the default values are:

P01 - Fuel Solenoid Type. Default value is 0 (ETR).P02 - Units Shown. Default value is 0 (English).P03 - Shutdown Override For Engine Fault. Default value is 0 (shutdown).P04 - Shutdown Override For Sensor Fault. Default value is 0 (override).P05 - Coolant Loss Sensor. Default value is 0 (not installed).P06 - Shutdown Override For Coolant Loss Fault. Default value is 0 (shutdown).P07 - System Voltage. Default value is 0 (24V).P08 - Upper Display Enable/Disable. Default value is 0 (enable).P09 - Ring Gear Teeth. Default value is 136 teeth.P10 - Engine Overspeed. Default value is 2120 rpm.P11 - Crank Terminate Speed. Default value is 400 rpm.P12 - Oil Step Speed. Default value is 1350 rpm.P13 - Low Oil Pressure Shutdown At Rated Speed. Default value is 205 kPa (30 psi).P14 - Low Oil Pressure Shutdown At Idle Speed. Default value is 70 kPa (10 psi).P15 - High Water Temperature Shutdown. Default value is 107°C (225°F).P16 - Low Water Temperature Alarm. Default value is 21°C (70°F).P17 - Total Cycle Crank Time. Default value is 90 seconds.P18 - Cycle Crank Time. Default value is 10 seconds.P19 - Cooldown Time. Default value is five minutes.P20 - AC Voltage Full Scale. Default value is 700 volts.P21 - AC Current Full Scale. Default value is 600 amps.P22 - GSC Engine Number. Default value is 01.P23 - Engine Type. Default value is 0 (MUI diesel).P24 - Crank Time Delay. Default value is 5 seconds.

NOTE: Any active shutdown fault (any shutdown indicator FLASHING) must be made inactive in order to access service mode and view the setpoints. To change a shutdown fault from an active shutdown fault to an inactive, the shutdown fault must no longer be occurring (must be corrected) and the ECS must be turned to the OFF/RESET position.

Procedure To View The Setpoints

1. Press SERVICE MODE key to enter service mode. "OP 1" is showing on the lower display. For more information see the topic Service Mode.

2. Press SCROLL UP key. "OP 2" is showing.

3. Press SELECT key. "P01" followed with the value of the setpoint is showing.

4. Press SCROLL UP or SCROLL DOWN key. The next setpoint with it's value is showing. Repeat this step until all the desired setpoints and their values are viewed.

5. Press EXIT key. "OP 1" is showing on lower display.

6. Press EXIT key. The display returns to normal.

Password Entry - OP3

OP3 is the option for entering the password that is required for accessing OP4 through OP10. Service mode options OP4 through OP10 are password protected to reduce the possibility of information being altered by mistake. Options OP1 and OP2 are for the viewing of information and are not password protected.

Password entry consists of actuating the scroll keys in the correct sequence by service personnel. The password is the same for every GSC and is not changeable. After the password is entered, the OP4 through OP10 options can be accessed. If a mistake is made during password entry, FAIL is briefly shown on the upper display and then five dashes are shown with the first one flashing. Pressing the select key starts the password entry process again.

NOTE: Any active shutdown fault (any shutdown indicator FLASHING) must be made inactive in order to access service mode and enter the password. To change a shutdown fault from an active shutdown fault to an inactive, the shutdown fault must no longer be occurring (must be corrected) and the ECS must be turned to the OFF/RESET position.

Procedure To Enter The Password

1. Press SERVICE MODE key to enter service mode. "OP 1" is showing on the lower display. For more information see the topic Service Mode.

2. Press SCROLL UP key twice. "OP 3" is showing.

3. Press SELECT key. "PE - - - - -" is showing.

4. Press SELECT key. "PE - - - - -" with the first dash flashing is showing.

5. Press SCROLL RIGHT key. "PE 1 - - - -" with the second dash flashing is showing.

6. Press SCROLL DOWN key. "PE 13- - -" with the third dash flashing is showing.

7. Press SCROLL UP key. "PE 132- -" with the fourth dash flashing is showing.

8. Press SCROLL DOWN key. "PE 1323-" with the fifth dash flashing is showing.

9. Press SCROLL RIGHT key. "PE 13231" with all digits not flashing is showing.

10. Press ENTER key. "PE PASS" is showing.

11. Press EXIT key. "OP 1" is showing.

NOTE: After the password is entered, any option can be accessed any number of times. The password remains in effect until service mode is exited. If the operator attempts to enter the password twice, "PE PASS" reappears on the lower display.

Fault Log Clearing - OP4

OP4 is the option for clearing a diagnostic fault from the fault log of the GSC. After a diagnostic fault is investigated and/or corrected, it should be cleared from the fault log to avoid confusion during future service calls. After all diagnostic faults are cleared and the GSC is in normal mode, the "DIAG" indicator is not shown on the upper display. Also see the topic Fault Log Viewing OP1.

Procedure For Clearing Faults

1. Turn the ECS to the STOP position to shutdown the engine. Enter service mode and enter password. See the Procedure To Enter The Password within the topic Password Entry - OP3. "OP 1" is showing on lower display. For more information see the topic Service Mode.

2. Press SCROLL UP key three times. "OP 4" is showing on the lower display.

3. Press SELECT key. A CID/FMI fault code and the counts (number of occurrences) are showing. The lower display shows the hourmeter value of the last occurrence of the fault.

4. Press SELECT key. The CID/FMI fault code, count and hourmeter value all flash.

5. Press ENTER key for two seconds.

If there is only one CID/FMI fault code, the CID/FMI that was flashing disappears and the upper display is blank except for the flashing "SERV" indicator. "OP 1" is showing on the lower display. Proceed to the next step.

If there is more than one CID/FMI fault code, the CID/FMI that was flashing disappears and the upper display shows the next CID/FMI with it's count and hourmeter value. Repeat steps 4 and 5 until all faults are erased. The lower display then shows "OP 1". Proceed to the next step.

6. Press EXIT key. "OP 1" is showing on lower display.

7. Press EXIT key. The display returns to normal.

Setpoint Programming - OP5

OP5 is the option for programming the setpoints of important genset conditions. The setpoints affect the proper operation and serviceability of the engine, and the accuracy of the information shown on the display. The setpoints are programmed (set) in the GSC at the factory. However, the setpoints may need changed when the GSC is moved from one engine to another or to adapt to a particular situation (for example: cycle crank time and cooldown time).

The setpoints are:

P01 - Fuel Solenoid TypeP02 - Units ShownP03 - Shutdown Override For Engine FaultP04 - Shutdown Override For Sensor FaultP05 - Coolant Loss SensorP06 - Shutdown Override For Coolant Loss FaultP07 - System VoltageP08 - Upper Display Enable/DisableP09 - Ring Gear TeethP10 - Engine OverspeedP11 - Crank Terminate SpeedP12 - Oil Step SpeedP13 - Low Oil Pressure Shutdown At Rated SpeedP14 - Low Oil Pressure Shutdown At Idle SpeedP15 - High Water Temperature ShutdownP16 - Low Water Temperature AlarmP17 - Total Cycle Crank TimeP18 - Cycle Crank TimeP19 - Cooldown TimeP20 - AC Voltage Full ScaleP21 - AC Current Full ScaleP22 - GSC Engine NumberP23 - Engine TypeP24 - Crank Time Delay

Procedure For Setpoint Programming

2. Press SCROLL UP key four times. "OP 5" is showing on the lower display.

3. Press SELECT key. "P01" followed with the value of the setpoint is showing.

4. Press SCROLL UP or SCROLL DOWN key. The next setpoint with it's value is showing. Repeat this step until the desired setpoint is showing.

5. Press SELECT key. The value of the setpoint is flashing.

6. Press SCROLL UP or SCROLL DOWN key to adjust the value of the setpoint.

NOTE: To adjust the value of some setpoints, it is necessary to press and release the scroll key several times in order for the value to change. To rapidly scroll through a large range of values, press and hold the appropriate scroll key.

7. Press ENTER key. The value of the setpoint stops flashing. Repeat steps 4, 5, 6 and 7 until all the desired setpoints are adjusted.

8. Press EXIT key. "OP 1" is showing on the lower display.

9. Press EXIT key. The display returns to normal.

Setpoint Description

P01 - Fuel Solenoid Type: This setpoint tells the GSC the type of fuel system solenoid used on the genset. The factory default is 0. The values are:

0 - for an energize to run (ETR) fuel solenoid. Gas engines use the energized to run (ETR) type of fuel system.

1 - for an energize to shutoff (ETS) fuel solenoid.

P02 - Units Shown: This setpoint tells the GSC which type of measurement units to show on the display. The factory default is 0. The values are:

0 - for English units (psi, degrees F).

1 - for metric units (kPa, degrees C).

P03 - Shutdown Override For Engine Fault: This setpoint tells the GSC how to respond to a low engine oil pressure or high coolant temperature fault. The factory default is 0. The values are:

0 - for engine shutdown.

1 - for alarm only (shutdown override, no engine shutdown).

NOTE: Shutdown override for a fault with low oil pressure or high coolant temperature is intended to be only temporary. When programmed to override these faults (P03 = 1), closely monitor the oil pressure and coolant temperature on the lower display. Do not override shutdown on a permanent basis unless regulations or codes specific to the application require it.

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NOTICE

If the genset is unattended for any length of time and shutdown is overridden (P03 =1), a low oil pressure fault or high coolant temperature fault could cause permanent damage to the engine.

P04 - Shutdown Override For Sensor Fault: This setpoint tells the GSC how to respond to a diagnostic fault with the engine oil pressure sensor, coolant temperature sensor, sensor power supply or coolant loss sensor. The factory default is 0. The values are:

0 - for alarm only (shutdown override, no engine shutdown).

1 - for engine shutdown.

P05 - Coolant Loss Sensor: This setpoint tells the GSC whether or not the optional engine coolant loss sensor is installed on the genset. The factory default is 0. The values are:

0 - for gensets without coolant loss sensor.

1 - for gensets with coolant loss sensor.

P06 - Shutdown Override For Coolant Loss Fault: This setpoint tells the GSC how to respond to an engine coolant loss fault. The factory default is 0. The values are:

0 - for engine shutdown.

1 - for alarm only (shutdown override, no engine shutdown).

NOTE: Shutdown override for a coolant loss fault is intended to be only temporary. Do not override shutdown on a permanent basis unless regulations or codes specific to the application require it.

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NOTICE

If the genset is unattended for any length of time and shutdown is overridden (P06 = 1), a coolant loss fault could cause permanent damage to the engine.

P07 - System Voltage: This setpoint tells the GSC the system voltage (battery voltage) used on the genset. The factory default is 0. The values are:

0 - for 24 volts.

1 - for 32 volts.

P08 - Upper Display Enable/Disable: This setpoint tells the GSC whether to enable or disable the showing of AC values on the upper display. All other information such as diagnostic fault codes and service mode values will continue to be shown on the upper display. The factory default is 0. The values are:

0 - for upper display enabled.

1 - for upper display disabled.

P02 - Ring Gear Teeth: This setpoint tells the GSC the number of teeth on the ring gear of the engine. The factory default is 136 teeth. The value is selectable from 95 to 350 teeth in increments of one tooth.

P10 - Engine Overspeed: This setpoint tells the GSC at what engine speed to declare that an engine overspeed fault exists. The engine overspeed setpoint (for all 60 Hz applications) is 1.18 times the rated speed. The factory default is 2120 rpm. The value is selectable from 500 to 4330 rpm in increments of 10 rpm.

P11 - Crank Terminate Speed: This setpoint tells the GSC at what engine speed to disengage the starting motor during engine cranking. The factory default is 400 rpm. The value is selectable from 100 to 1000 rpm in increments of 10 rpm.

P12 - Oil Step Speed: This setpoint tells the GSC the engine speed to use for distinguishing between rated speed and idle speed when a low oil pressure fault exists. The factory default is 1350 rpm. The value is selectable from 400 to 1800 rpm in increments of 10 rpm.

P13 - Low Oil Pressure Shutdown At Rated Speed: This setpoint tells the GSC at what oil pressure to declare that a low oil pressure shutdown fault exists with the engine at rated speed (the engine speed must have exceeded the oil step speed for nine seconds). The factory default is 205 kPa (30 psi). The value is selectable from 34 to 420 kPa (5 to 60 psi) in increments of one.

G3400 ... 275 kPa (40 psi)

G3500 ... 207 kPa (30 psi)

NOTE: When oil pressure drops to within 34 kPa (5 psi) of the P13 setpoint, an oil pressure alarm is issued by the GSC and the optional alarm module.

P14 - Low Oil Pressure Shutdown At Idle Speed: This setpoint tells the GSC at what oil pressure to declare that a low oil pressure shutdown fault exists with the engine at idle speed (the engine must have been running for at least nine seconds and the engine speed must be less than the oil step speed). The factory default is 70 kPa (10 psi). The value is selectable from 20 to 336 kPa (3 to 50 psi) in increments of one.

G3400 ... 100 kPa (15 psi)

G3500 ... 70 kPa (10 psi)

NOTE: When oil pressure drops to within 34 kPa (5 psi) of the P14 setpoint, an oil pressure alarm is issued by the GSC and the optional alarm module.

P15 - High Water Temperature Shutdown: This setpoint tells the GSC at what coolant temperature to declare that a high coolant temperature shutdown fault exists (after a 10 second delay). The factory default is 107°C (225°F). The value is selectable from 94 to 123°C (201 to 253°F) in increments of one degree.

G3400 ... 105°C (221°F)

G3500 ... 109°C (228°F)

NOTE: When coolant temperature rises to within 6°C (11°F) of the P15 setpoint, a high coolant temperature alarm is issued by the GSC and the optional Alarm Module.

P16 - Low Water Temperature Alarm: This setpoint tells the GSC (and the optional alarm module) at what coolant temperature to declare that a low coolant temperature alarm fault exists (after a two second delay). The factory default is 21°C (70°F). The value is selectable from 0 to 36°C (32 to 97°F) in increments of one degree.

P17 - Total Cycle Crank Time: This setpoint tells the GSC at what cycle crank time to declare that an overcrank fault exists. The factory default is 90 seconds. The value is selectable from 5 to 360 seconds in increments of five seconds.

P18 - Cycle Crank Time: This setpoint tells the GSC the amount of time to crank and then to rest the starting motor during a single crank cycle. The factory default is 10 seconds. The value is selectable from 5 to 300 seconds in increments of five seconds.

P19 - Cooldown Time: This setpoint tells the GSC the amount of time to allow the engine to run after a normal shutdown is initiated. The factory default is 5 minutes. The value is selectable from 0 to 30 minutes in increments of one minute.

P20 - AC Voltage Full Scale: This setpoint tells the GSC the full scale (maximum) AC voltage of the genset. The GSC measures the AC voltage and shows it on the display. The values are: 700V, 150V, 300V, 500V, 500V, 750V, 3.0kV, 4.5kV, 5.25kV, 9.0kV, 15.0kV and 18.0kV. The setpoint is factory set at 700V for all standard EMCP II equipped gensets. The factory default is 700V. The other values are for switch gear applications and require the use of external potential transformers and the removal of the AC voltage range jumper located in the relay module. See the topic AC Voltage Range Selection in the Testing And Adjusting section.

P21 - AC Current Full Scale: This setpoint tells the GSC the full (maximum) AC current of the genset. The GSC measures the AC current and shows it on the display. The values are: 75A, 100A, 150A, 200A, 300A, 400A, 600A, 800A, 1000A, 1200A, 1500A, 2000A, 2500A, 3000A and 4000A. The factory default is 600A. The generator must be equipped with the proper corresponding current transformers.

P22 - GSC Engine Number: This setpoint informs other devices on the CAT Data Link of the engine number for the GSC. The values are from 01 through 08. The factory default is 01.

P23 - Engine Type: This setpoint tells the GSC whether the genset engine is a mechanical unit injector (MUI) diesel, spark ignited (SI) or electronic unit injector (EUI) engine. The factory default is 0. The values are:

0 - for MUI diesel.

1 - for SI.

2 - for EUI diesel

P24 - Crank Time Delay: This setpoint tells the GSC the amount of time to delay activation of the FCR during a crank cycle. This setpoint is for spark ignited engines only. The P24 setpoint only functions when the P23 setpoint is set to 1 (spark ignited engine). The factory default is 5 seconds. The value is selectable from 0 to 20 seconds in increments of one second.

Spare Input/Output Programming - OP6

OP6 is the option for programming of the spare inputs and spare output. The GSC has three spare inputs and a spare output for satisfying the needs of the customer. The spare inputs and output are accessed on the auxiliary terminal strip (AUX) within the control panel on the left wall. The terminations are

* Spare Input 1 (SP1) is marked as SW1 at terminal 1 of the auxiliary terminal strip.

* Spare Input 2 (SP2) is marked as SW2 at terminal 2 of the auxiliary terminal strip.

* Spare Input 3 (SP3) is marked as SW3 at terminal 3 of the auxiliary terminal strip.

* Spare Output is marked as SPARE at terminal 5 of the auxiliary terminal strip.

The setpoints for the spare inputs and the spare output are:

SP01 - Spare Fault 1 Active State. The value is either 0 for active low or 1 for active high. The factory default is 0.

SP02 - Spare Fault 1 Response. The value is either 0 for shutdown or 1 for alarm. The factory default is 0.

SP03 - Spare Fault 2 Active State. The value is either 0 for active low or 1 for active high. The factory default is 0.

SP04 - Spare Fault 2 Response. The value is either 0 for shutdown or 1 for alarm. The factory default is 0.

SP05 - Spare Fault 3 Active State. The value is either 0 for active low or 1 for active high. The factory default is 0.

SP06 - Spare Fault 3 Response. The value is either 0 for shutdown or 1 for alarm. The factory default is 0.

SP07 - Spare Output Active State. The value is either 0 for active low or 1 for active high. The factory default is 0.

SP08 - Spare Fault 1 Delay Time. The value is selectable from 0 to 250 seconds in increments of 1 second. The factory default is 0 seconds.

SP09 - Spare Fault 2 Delay Time. The value is selectable from 0 to 250 seconds in increments of 1 second. The factory default is 0 seconds.

SP10 - Spare Fault 3 Delay Time. The value is selectable from 0 to 250 seconds in increments of one second. The factory default is 0 seconds.

SP11 - Spare Output Response.

* 1 for spare fault 1.

* 2 for spare fault 2.

* 3 for spare fault 3.

* 4 for spare fault 1, 2, or 3.

* 5 for any alarm fault code or diagnostic alarm fault code.

* 6 for any alarm spare fault code, alarm fault code or diagnostic alarm fault code.

* 7 for engine cooldown.

* 8 for engine coolant loss.

The factory default for SP11 is 7 (cooldown).

Spare Inputs

The spare inputs are referred to as SP1, SP2 and SP3. The active state, response taken and time delay for each spare input is programmable. The GSC responds to the active state of an input and the response can be delayed.

The GSC has to be told (programmed) whether the active input state is high (+5 DCV to B+) or low (B-). When an input is programmed for a HIGH active state, a high at the input is considered a spare fault and a low at the input is considered a normal condition. When an input is programmed for a LOW active state, a low at the input is considered a spare fault and a high at the input is considered a normal condition.

NOTE: If an input is left floating (for example an open switch), the internal circuitry of the GSC pulls the input high and the GSC responds accordingly.

The GSC has to be told (programmed) how to respond to a spare fault (active). The response is to treat the condition as a fault shutdown or a fault alarm. Spare faults that are programmed to shutdown, are ignored by the GSC when engine speed is less than crank termination speed.

The GSC has to be told (programmed) how much time to delay the response to a spare fault (active input). After a spare fault occurs, the GSC does not respond (indicators are not activated, codes are not shown and engine operation is not changed) until the time delay has elapsed. The time delay is selectable from 0 to 250 seconds.

When a fault occurs in a spare input (input active) and it is programmed as an alarm:

a. The GSC waits for the time delay to elapse.

b. The fault alarm indicator FLASHES.

c. The corresponding code SP1, SP2 or SP3 is shown on the upper display of the GSC when the alarm codes key is pressed.

d. The engine continues to run or start.

When a fault occurs in a spare input (input active) and it is programmed as a shutdown:

a. The GSC waits for the time delay to elapse.

b. The fault shutdown indicator FLASHES.

c. The corresponding code SP1, SP2 or SP3 is immediately shown on the upper display of the GSC.

d. The engine is shut down or does not start.

The fault shutdown indicator remains FLASHING and the spare fault code remains shown until the ECS is turned to OFF/RESET. After turning the ECS to OFF/RESET and correcting the cause of the spare fault, the engine is able to start and run.

NOTE: Spare faults are not logged into the GSC fault log.

NOTE: If it is not desired to use the spare inputs, program the spare inputs for a LOW active state and connect nothing to the spare input wiring.

Spare Output

The spare output responds (high or low) to a selected trigger condition. The response and the trigger condition are programmable.

The GSC has to be told (programmed) whether the active state of the spare output is to be high or low. An active low state means that the output is pulled to battery negative when active. The output draws approximately 80mA when in the low state. An active high state means that the output will be allowed to float high (about 5.0 volts DC). When in the high state the spare output is floating and is capable of driving high impedance logic circuits only. When in the high state, the spare output will not drive low impedance loads such as relays.

The GSC has to be told (programmed) what condition is to trigger the spare output to the active state. The possible trigger conditions that can activate the spare output are:

a. An active SP1 fault code that is an alarm fault.

b. An active SP2 fault code that is an alarm fault.

c. An active SP3 fault code that is an alarm fault.

d. Any active SP1, SP2 or SP3 fault code that is an alarm fault.

e. Any active alarm fault code (AL1, AL2 or AL3) or diagnostic fault code (CID FMI) that is an alarm fault.

f. Any active alarm fault (SP1, SP2, SP3, AL1, AL2, AL3 or CID FMI).

g. Activate during cooldown time.

h. Activate during a coolant loss alarm or shutdown condition.

NOTE: A common use of the spare output is to activate the shunt trip coil of the AC circuit breaker during engine cooldown.

NOTE: The GSC diagnoses a fault in the spare output circuit. See CID 334 in the topic Diagnostic Faults of the Testing And Adjusting section.

Procedure For Spare Input/Output Programming

1. Turn the ECS to the STOP position to shutdown the engine. Enter service mode and enter password. See the procedure To Enter The Password within the topic Password Entry - OP3. "OP 1" is showing on lower display. For more information see the topic Service Mode.

2. Press SCROLL UP key five times. "OP 6" is showing on the lower display.

3. Press SELECT key. "SP01" followed with the value of the setpoint is showing.

4. Press SCROLL UP or SCROLL DOWN key. The next setpoint with it's value is showing. Repeat this step until the desired setpoint is showing.

5. Press SELECT key. The value of the setpoint is flashing.

6. Press SCROLL UP or SCROLL DOWN key to adjust the value of the setpoint.

7. Press ENTER key. The value of the setpoint stops flashing. Repeat steps 4, 5, 6 and 7 until all the desired setpoints are adjusted.

8. Press EXIT key. "OP 1" is showing on the lower display.

9. Press EXIT key. The display returns to normal.

Hourmeter Programming - OP7

OP7 is the option for programming the hours shown on the hourmeter. The hours can be increased but not decreased. This allows the hours on a new GSC to exactly match the hours of the GSC it is replacing. This improves the tracking of engine maintenance (such as oil changes) when the GSC is replaced. Also, if the GSC is moved from one engine to another, the hours can be changed to match the new engine (provided the new hours are more than the old hours). Also, if the hourmeter shows all dashes, the hours can be reprogrammed.

Procedure For Hourmeter Programming

This procedure uses as an example a new GSC with 0 hours. The hours are to be set to a value of 1234. This procedure applies to any value of hours desired (as long as the hours are increased).

2. Press SCROLL UP key six times. "OP 7" is showing on the lower display.

3. Press SELECT key. The present hourmeter value (0 in this example) is showing.

4. Press SELECT key. "000000" with the first digit flashing is showing.

5. Press SCROLL RIGHT key two times. "000000" with the third digit flashing is showing.

6. Press SCROLL UP key. "001000" with the third digit flashing is showing.

7. Press SCROLL RIGHT key. "001000" with the fourth digit flashing is showing.

8. Press SCROLL UP key two times. "001200" with the fourth digit flashing is showing.

9. Press SCROLL RIGHT key. "001200" with the fifth digit flashing is showing.

10. Press SCROLL UP key three times. "001230" with the fifth digit flashing is showing.

11. Press SCROLL RIGHT key. "001230" with the sixth digit flashing is showing.

12. Press SCROLL UP key four times. "001234" with the sixth digit flashing is showing.

13. Press ENTER key. "001234" flashes on the lower display and "ArE YOU SUrE" is showing on the upper display.

For yes, press ENTER key. "001234" stops flashing.

For no, press SELECT key. "000000" with the first digit flashing is showing. Repeat this procedure to program the hourmeter again.

NOTE: If the original hourmeter value is to be kept in the GSC memory when the display shows "ArE YOU SUrE", press exit key two times for a normal display. The original hourmeter value remains in the GSC.

NOTE: If the hours entered are less than that already stored in the GSC, then the upper display briefly shows "Error". The display then shows the original hours that are stored in the GSC with the first digit flashing.

14. Press EXIT key. "OP 1" is showing on lower display.

15. Press EXIT key. The display returns to normal. The programmed value for the hourmeter should show on the lower display as the engine data scrolls.

Voltmeter/Ammeter Programming - OP8

OP8 is the option for programming the calibration value of the voltmeter and ammeter. When either the GSC or the AC transformer box (ATB) is replaced, the calibration values, written on the ATB bar code sticker, must be programmed into the GSC to assure accurate voltage and current values. There are five transformers in the ATB that the GSC monitors for voltage and current information. Each transformer has individual characteristics that effect the voltage and current measurements by the GSC. At the factory, these characteristics are measured, assigned a calibration value and recorded on the bar code sticker which is located on the lower left side of the ATB. When the genset is assembled at the factory, the calibration values on the bar code sticker are programmed into the GSC. The calibration value of a transformer is from 0 to 255 in increments of one.

The setpoints for the calibration value of the voltmeter and ammeter are:

AC01 - A-B Voltage Calibration. The value is selectable from 0 to 255 in increments of one.

AC02 - B-C Voltage Calibration. The value is selectable from 0 to 255 in increments of one.

AC03 - C-A Voltage Calibration. The value is selectable from 0 to 255 in increments of one.

AC04 - A Current Calibration. The value is selectable from 0 to 255 in increments of one.

AC05 - B Current Calibration. The value is selectable from 0 to 255 in increments of one.

AC06 - C Current Calibration. The value is selectable from 0 to 255 in increments of one.

Procedure For Voltmeter/Ammeter Programming

2. Press SCROLL UP key seven times. "OP 8" is showing on the lower display.

3. Press SELECT key. "AC01" followed with the value (0 to 255) of the setpoint is showing.

4. Press SELECT key. The value of the setpoint is flashing.

5. Press SCROLL UP or SCROLL DOWN key to adjust the value of the setpoint.

6. Press ENTER key. The value of the setpoint stops flashing.

7. Press SCROLL UP key. Repeat steps 3, 4, 5 and 6 for setpoints AC02 through AC06.

8. Press EXIT key. "OP 1" is showing on the lower display.

9. Press EXIT key. The display returns to normal.

Engine Setpoint Verification - OP9

OP9 is the option for verifying that EMCP II operates correctly when a fault occurs with low oil pressure, high coolant temperature or engine overspeed. An engine overspeed fault causes the GSC to shut the engine down. A low oil pressure or high water temperature fault causes the GSC to either shut the engine down or sound the alarm, according to the programmed setpoint P03.

The setpoints verified by this procedure are:

P03 - Shutdown Override For Engine Fault. The value is either 0 for shutdown or 1 for alarm (override). The factory default is 0.

P10 - Engine Overspeed. The value is selectable from 500 to 4330 rpm in increments of 10 rpm. The factory default is 2120 rpm.

P13 - Low Oil Pressure Shutdown At Rated Speed. The value is selectable from 34 to 420 kPa (5 to 60 psi) in increments of one. The factory default is 205 kPa (30 psi).

P14 - Low Oil Pressure Shutdown At Idle Speed. The value is selectable from 20 to 336 kPa (3 to 50 psi) in increments of one. The factory default is 70 kPa (10 psi).

P15 - High Water Temperature Shutdown. The value is selectable from 94 to 123°C (201 to 253°F) in increments of one degree. The factory default is 107°C (225°F).

The following conditions are required before the engine setpoints are verified:

a. The setpoints listed previously must be correct for the engine application. To view the setpoints, see Setpoint Viewing OP2 within the topic Service Mode. To program the setpoints, see Setpoint Programming OP5 within the topic Service Mode.

b. The engine is checked at idle and rated speed. No faults should be present at the initial start up. If necessary troubleshoot and correct any fault.

Procedure For Overspeed Verification

1. Start and run the engine at rated speed. Enter service mode and enter password. See the Procedure To Enter The Password within the topic Password Entry - OP3. "OP 1" is showing on lower display. For more information see the topic Service Mode.

2. Press SCROLL UP key eight times. "OP 9" is showing on the lower display.

3. Press SELECT key. The value (2120 is the default value) of overspeed setpoint P10 is showing on the upper display. "SC1" followed with the present engine speed value is showing on the lower display.

4. Press SELECT key. The setpoint value (2120 is the default value) is flashing on the upper display.

5. Press SCROLL DOWN key to decrease the setpoint value (2120 is the default value) that is flashing on the upper display. The setpoint value decreases by 10 rpm with each press of the scroll down key. Continue pressing until the setpoint value decreases past the present engine speed value that is showing on the lower display.

When the setpoint value is less than the present engine speed value, the engine shuts down with the indicator for engine overspeed flashing. The GSC is no longer in service mode.

Procedure For Low Oil Pressure Verification

2. Press SCROLL UP key eight times. "OP 9" is showing on the lower display.

4. Press SCROLL UP key one time. The value [205 kPa (30 psi) is the default value] of the P13 setpoint for low oil pressure shutdown at rated speed is showing on the upper display. "SC2" followed with the present oil pressure value is showing on the lower display.

5. Press SELECT key. The setpoint value [205 kPa (30 psi) is the default value] is flashing on the upper display.

6. Press SCROLL UP key to increase the setpoint value [205 kPa (30 psi) is the default value] that is flashing on the upper display. The setpoint value increases by five with each press of the scroll up key. Continue pressing until the setpoint value increases past the present oil pressure value that is showing on the lower display.

When the setpoint value is greater than the present oil pressure value, the engine shuts down with the indicator for low oil pressure flashing. The GSC is no longer in service mode.

Procedure For High Water Temperature Verification

2. Press SCROLL UP key eight times. "OP 9" is showing on the lower display.

4. Press SCROLL UP key two times. The value [107°C (225°F) is the default value] of the P15 setpoint for high water temperature shutdown is showing on the upper display. "SC3" followed with the present coolant temperature value is showing on the lower display.

5. Press SELECT key. The setpoint value [107°C (225°F) is the default value] is flashing on the upper display.

6. Press SCROLL DOWN key to decrease the setpoint value [107°C (225°F) is the default value] that is flashing on the upper display. The setpoint value decreases by five degrees with each press of the scroll down key. Continue pressing until the setpoint value decreases past the present coolant temperature value that is showing on the lower display.

When the setpoint value is less than the present coolant temperature value, the engine shuts down with the indicator for high water temperature flashing. The GSC is no longer in service mode.

AC Calibration - OP10

OP10 is the option for calibrating the voltmeters of gensets operating in parallel. The AC voltage measurements of the GSC are calibrated at the factory with an accurate standard. However, when two gensets are paralleled, the application may require the paralleled gensets to have exactly the same voltage value. To do this, the AC calibration of one GSC is changed to match the voltage value of another genset.

NOTE: It is NOT recommended that the AC calibration be altered under any other circumstances. Performing this procedure takes the GSC out of factory calibration.

Procedure For Voltmeter Calibration

The paralleled gensets must be running at rated speed and adjusted to the desired voltage.

1. On the GSC to be calibrated, enter service mode and enter password. See the Procedure To Enter The Password within the topic Password Entry - OP3. "OP 1" is showing on lower display. For more information see the topic Service Mode.

2. Press SCROLL UP key nine times. "OP 10" is showing on the lower display.

3. Press SELECT key. "AC CAL" is showing on lower display. The present A-B voltage value is showing on the upper display.

4. Press SELECT key. The voltage value is flashing.

5. Press SCROLL UP or SCROLL DOWN key to adjust the voltage value to exactly match the other genset(s) running in parallel. Voltage value continues to flash.

6. Press ENTER key. The value of the setpoint stops flashing.

7. Press SCROLL UP key. Repeat steps 3, 4, 5 and 6 for the B-C voltage and the C-A voltage.

8. Press EXIT key. "OP 1" is showing on the lower display.

9. Press EXIT key. The display returns to normal.

Fault Description

A fault is any condition that does not conform (an abnormal condition) to the rules (program) by which the GSC operates. A fault is either active (occurring now) or inactive (previously occurred). Some examples of a fault are:

Coolant temperature is 123°C (254°F) - this is a high water temperature fault.

Engine speed is 4500 rpm - this is an engine overspeed fault.

Broken wire in engine harness - this is a diagnostic fault.

A failed oil pressure sensor - this is a diagnostic fault.

There is a degree of severity attached to every fault, which also describes the GSC response to the fault. Faults are either an alarm (non-critical) fault or a shutdown (critical) fault. An alarm fault provides an early warning to the operator of a possible future shutdown fault. For an alarm fault, the GSC automatically activates alarm mode and the fault alarm indicator FLASHES. For more information see the topic Alarm Mode. A shutdown fault tells the GSC to shut the engine down in order to prevent engine or generator damage. For a shutdown fault, the GSC automatically activates shutdown mode which shuts down the engine and FLASHES the corresponding shutdown indicator. For more information see the topic Shutdown Mode.

NOTE: For certain faults, the shutdown response or alarm response is selectable by service personnel. See the topic Spare Fault Codes and the topic Diagnostic Fault Codes.

Most faults have a code. There are three types of fault codes. The type is derived from the GSC input that is involved. The three types of fault codes are: alarm fault codes, spare fault codes and diagnostic fault codes. When the GSC detects a fault, a specific fault code is assigned to the fault. The fault code identifies the type of fault and the specific fault within the type. The fault code is shown on the upper display either immediately or when requested by the operator. For shutdown faults, the corresponding fault code is immediately shown on the upper display. For alarm faults, the operator must press the alarm codes key and then the fault code is shown on the upper display.

EXCEPTION: There are no fault codes for the shutdown faults that correspond to the dedicated shutdown indicators. Each of these shutdown faults are identified to the operator by the nomenclature nearest to the dedicated shutdown indicator.

Alarm Fault Codes

Alarm fault codes are associated with specific alarm faults and provide an early warning to the operator of a possible future shutdown fault. When one of the specific alarm faults occurs, the GSC activates alarm mode and the fault alarm indicator FLASHES. When the alarm codes key is pressed, the corresponding alarm fault code is shown on the upper display.

The alarm fault codes and the associated alarm faults are:

AL1 - High Water Temperature Alarm. This alarm fault occurs when the engine coolant increases to within 6°C (11°F) of setpoint P15 (high water temperature shutdown) for ten seconds. (If the temperature continues to rise and exceeds setpoint P15, then the alarm fault becomes a shutdown fault and the GSC shuts the engine down.)

AL2 - Low Water Temperature Alarm. This alarm fault occurs when the engine coolant temperature decreases to less than setpoint P16 (low water temperature alarm) for two seconds.

AL3 - Low Oil Pressure Alarm. This alarm fault occurs when the engine oil pressure decreases to within 34 kPa (5 psi) of setpoints P13 or P14 (low oil pressure shutdown) for nine seconds. (If the pressure continues decreasing to less than setpoint P13 or P14, then the alarm fault becomes a shutdown fault and the GSC shuts the engine down.)

Spare Fault Codes

Spare fault codes are associated with the spare inputs and are either alarm faults or shutdown faults. The three spare inputs and a spare output are for satisfying the needs of the customer. The spare inputs are programmable in regards to active state (high or low), severity (alarm or shutdown) and delay time. See Spare Input/Output Programming OP6 within the topic Service Mode. The spare inputs and the corresponding spare fault codes are referred to as SP1, SP2 and SP3.

For a spare input that is programmed as an alarm fault, the GSC activates alarm mode and the fault alarm indicator FLASHES. When the alarm codes key is pressed, the corresponding spare fault code (SP1, SP2 or SP3) is shown on the upper display. Also see the topic Alarm Mode.

For a spare input that is programmed as a shutdown fault: the GSC activates shutdown mode, the fault shutdown indicator FLASHES and the upper display immediately shows SP1, SP2 or SP3. When spare faults are programmed to shutdown, SP1 is ignored by the GSC when engine speed is less than crank termination speed. SP2 and SP3 are recognized by the GSC at all engine speeds. Also see the topic Shutdown Mode.

Due to the programmability of the spare faults, it is the duty of the operator, service personnel or customer to record and to inform the necessary personnel of the actual meaning of a spare fault code (SP1, SP2 or SP3).

Diagnostic Fault Codes

Diagnostic fault codes are associated with failed electrical components or circuits that provide information to or receive information from the GSC. These faults are either alarm faults or shutdown faults.

For a diagnostic fault that is an alarm fault, the GSC activates alarm mode and the fault alarm indicator FLASHES. When the alarm codes key is pressed, the corresponding diagnostic fault code is shown on the upper display. Also see the topic Alarm Mode.

For a diagnostic fault that is a shutdown fault, the GSC activates shutdown mode, the fault shutdown indicator FLASHES and the upper display immediately shows the corresponding diagnostic fault code. Also see the topic Shutdown Mode.

The diagnostic fault code closely identifies the cause of the fault. Each diagnostic fault consists of two identifiers and an indicator. The identifiers are shown on the upper display. Service personnel interpret the identifiers to assist with troubleshooting. The identifiers and indicator are:

* Component Identifier (CID) - The CID is a three digit code that tells which component is faulty. The CID is shown on the upper display. For example; "190" means the circuit for the engine magnetic pickup (MPU) is faulty. For a list of CID codes, see the topic Diagnostic Faults in the Testing And Adjusting section.

* Failure Mode Identifier (FMI) - The FMI is a two digit code that tells what type of failure has occurred. The FMI is shown on the upper display at the same time as the CID. For example; "3" means the signal voltage is too high. For a list of FMI codes, see the topic Diagnostic Faults in the Testing And Adjusting section.

* "DIAG" indicator - When "DIAG" is FLASHING, the diagnostic fault code (CID FMI) shown on the upper display is active (present now). When "DIAG" is ON CONTINUOUSLY there is an inactive diagnostic fault and the CID FMI are recorded in the fault log. Also, see Fault Log Viewing OP1 within the topic Service Mode. When "DIAG" is absent (not showing), there are NO diagnostic fault codes detected or recorded.

NOTE: The alarm response or shutdown response of four diagnostic faults is programmable by service personnel. An alarm response is normal (P04 = 0), unless programmed for a shutdown response (P04 = 1). See Setpoint P04 within the topic Setpoint Programming. The diagnostic faults are: oil pressure sensor (CID 100), coolant temperature sensor (CID 110), coolant loss sensor (CID 111) and sensor power supply (CID 269).

The combination of CID, FMI and "DIAG" indicator describes one diagnostic fault. For example; if the upper display shows:

a. "190 3"

b. "DIAG" indicator is FLASHING

Then the signal that is being received by the GSC from the engine speed sensor (CID is 190) is too high (FMI is 3) at this time ("DIAG" is FLASHING).

The GSC has a fault log to help with troubleshooting of diagnostic faults. Inactive diagnostic fault codes (CID FMI) are recorded in the fault log for viewing at a later time. Also, the number of occurrences are totalled and shown on the upper display with the CID and FMI codes. An active diagnostic alarm fault ("DIAG" is FLASHING) becomes inactive ("DIAG" is ON CONTINUOUSLY) when the fault is no longer occurring and also for diagnostic shutdown faults the ECS must be turned to OFF/RESET. The GSC stores a maximum of 12 diagnostic fault codes in the fault log. If an additional diagnostic fault becomes inactive, the GSC automatically clears the earliest diagnostic fault code and puts the additional diagnostic fault code in the fault log. Inactive diagnostic fault codes that are more than 750 engine hours old are cleared automatically by the GSC. Only diagnostic fault codes are recorded in the fault log. Alarm fault codes and spare fault codes are not recorded in the fault log. See Fault Log Viewing OP1 within the topic Service Mode.

After a diagnostic fault is investigated and/or corrected, clearing it from the fault log will avoid confusion during a future service call. When all diagnostic faults are cleared from the fault log and no active diagnostic faults exist the "DIAG" indicator is OFF (absent). See Fault Log Clearing OP4 within the topic Service Mode.

Optional Modules

Alarm Modules

Alarm Module
(1) Amber LED's. (2) Red LED's. (3) Lamp test switch. (4) Alarm silence switch. (5) Horn.

The alarm module (ALM) is an attachment located on the instrument panel. Red LED's (2) and amber LED's (1) are the visual indicators. Horn (5) is the audible indicator. The ALM is designed to operate when powered by only 24 DCV or 32 DCV battery systems.

There are five versions of the basic module. The modules are either alarm modules or a remote annunciator. The term remote annunciator is used but, it is the same basic alarm module. The versions are:

* Standby NFPA 99 alarm module.

* NFPA 99 remote annunciator, used with standby NFPA 99 alarm module.

* Standby NFPA 110 alarm module, used with NFPA 110 remote annunciator panel. See Remote Annunciator Panel (NFPA 110).

* Prime power alarm module.

* EMCP remote annunciator.

The difference between these modules is in the graphics film on the front of the panel and the jumper wires on the rear. See the DC schematic in the Schematics And Wiring Diagrams section. The NFPA 99 remote annunciator and the EMCP remote annunciator also have a lamp test switch. The following description of operation refers to the alarm/remote annunciator module as the annunciator module.

The purpose of the alarm modules (ALM) is to give a warning of conditions that are becoming a problem before conditions are bad enough to shut down the engine or keep it from starting.

If, with the ECS in the COOLDOWN/STOP or AUTO positions, an alarm fault develops prior to or while the genset is running, that fault is indicated by the optional alarm module and/or the remote annunciator.

Description Of Operation

NOTE: In the following description the word annunciator is used to mean either alarm module or remote annunciator module.

The annunciator module receives data from three sources: switch inputs, internal circuitry and a serial data link from the generator set control (GSC).

Switch Inputs

Up to four inputs are available for switch (i.e., Low Fuel Level) connections. Switch inputs are activated when connected to battery negative (-B). See Table 1.

Internal Circuitry

Internal circuitry is used to determine and annunciate if the DC battery supply voltage is below the setpoint (factory set at 24 DCV).

Data Link

The annunciator module receives data from the generator set control (GSC) by a serial data link. The items included in this data stream of information are:

1 - Coolant temperature has exceeded the high temperature alarm setpoint programmed into the generator set control (GSC).

2 - Oil pressure is below the low oil pressure alarm setpoint programmed into the generator set control (GSC).

3 - Coolant temperature is below the low temperature alarm setpoint programmed into the generator set control (GSC).

4 - The engine control switch (ECS) is not in the AUTO or MAN/START position.

5 - Oil pressure is below the low oil pressure shutdown setpoint programmed into the generator set control (GSC).

6 - Coolant temperature has exceeded the high water temperature shutdown setpoint programmed into the generator set control (GSC).

7 - The engine failed to start (overcrank).

8 - The engine speed exceeded the engine overspeed setpoint programmed into the generator set control (GSC).

9 - The engine shut down due to a coolant loss fault.

10 - The engine shut down due to a spare fault.

11 - The engine shut down due to an emergency stop fault.

12 - The engine shut down due to a diagnostic fault.

Data items 1 through 8 control the operation of the LED's and the horn as indicated in Table 1. Data items 9 through 12 control the operation of the horn only.

The maximum number of modules, alarm or CIM, connected to the serial data link is three. The maximum distance between a module and the GSC is 305 m (1000 ft).

LED And Horn Operation

When an alarm fault occurs, the LED corresponding to that fault flashes at two hertz and the horn sounds. If the alarm fault is NOT LATCHED, the LED and horn turn off as soon as the alarm fault ceases. If the alarm fault is LATCHED, the LED continues to flash until the acknowledge/silence input is activated. See Table 1 for LATCHED alarm faults and the LED and horn functions for each operating mode.

Normally switch input 3 (terminal 10) and switch input 4 (terminal 11) only operate LED's 7 and 8. However, it is possible for switch inputs 3 and 4 to also operate the horn. To do so, connect terminal 10 (sw input 3) to terminal 3 and connect terminal 11 (sw input 4) to terminal 4.

Alarm Silence

Activating the alarm silence switch (4) causes the horn to cease and the LED to stay on continuously.

Data Link Malfunction

If the data link malfunctions, the LED's controlled by the data link flashes at 0.5 hertz. The switch controlled LED's function normally.

Lamp Test

Activating the lamp test switch (3) results in sounding the horn and turning on all LED's continuously for 10 seconds or until the switch is deactivated.

Mode Selection

The annunciator module operates in one of the five modes described in Table 2. The modes are selected by connections made to the mode select inputs (terminals 5 and 6) and switch 2 input (terminal 9) as shown in Table 2.

Remote Annunciator Panel - NFPA 110

Alarm Module
(1) Amber LED's. (2) Red LED's. (3) Lamp test switch. (4) Alarm silence switch. (5) Horn.

NFPA 110 Remote Annunciator Panel
(6) Trouble light. (7) Horn. (8) Alarm silence switch. (9) Load light.

This remote panel functions in conjunction with the NFPA 110 alarm module. The alarm module is mounted in the right side of the instrument panel. When an alarm occurs on the alarm module or a fault occurs on the generator set control (GSC), horns (5) and (7) sound in both the alarm module and the remote annunciator. Trouble light (6) lights in the remote annunciator panel. The appropriate alarm LED also lights in the alarm module or the appropriate fault indicator flashes in the generator set control (GSC). The remote annunciator is designed to operate when powered by only 24 DCV or 32 DCV battery systems.

When alarm silence switch (4) or (8) is pressed on either the remote panel or the alarm module, the horns on both cease sounding. Also, trouble light (6) on the remote panel goes out. The LED on the alarm module or GSC remains on. Another alarm fault reactivates the horns, LED and light as before.

Trouble light (6) also acts as a test switch on the remote panel. When light (6) is pressed, horn (7) and light (6) turn on. The alarm module is not affected by the test switch.

Load light (9) is triggered by a transfer switch or similar devise. When the transfer switch provides a ground signal, load light (9) is ON.

Custom Alarm Module (CAM)

Custom Alarm Module (CAM)
(1) Amber LED's. (2) Red LED's. (3) Lamp test switch. (4) Alarm silence switch. (5) Horn.

The custom alarm module (CAM) is an attachment that can be mounted at the genset or at a remote location. The purpose of the CAM is to annunciate faults, alarms or other conditions from customer supplied inputs. The CAM operates when powered only by 24 DCV or 32 DCV battery systems. The custom alarm module (CAM) is equipped with a horn, alarm silence switch, a lamp test switch and 8 switched inputs for customer use.

NOTE: A basic version of the CAM also exists. The basic version does not have a horn, an alarm/silence switch or a lamp test switch. The basic CAM is to be used with an existing fully equipped CAM or an existing alarm module (ALM).

Alarm Operation

A given switch input corresponds to 1 of 8 LED's on the face of the CAM. The LED's will FLASH at a rate of 2 hertz when the corresponding input is closed to battery negative. The red LED's are used to display shutdown conditions, and the amber LED's are used to display alarm conditions.

When an input corresponding to one of the red shutdown LED's is activated (connected to battery negative), the LED will flash and the horn will sound. When the input is disconnected from battery negative, the horn will continue to sound and the red LED will continue to flash until the alarm silence switch is pressed.

When an input corresponding to one of the amber alarm LED's is activated, the LED will flash (the horn does NOT sound). When the input is disconnected from battery negative, the amber LED will turn off.

Alarm Silence Function

The alarm silence switch is activated by connecting the corresponding input to battery negative.

When an input is connected to battery negative, activating the alarm silence switch causes the horn to cease and causes the LED to change from flashing to ON continuously. The alarm silence function will be overridden if the status of any of the eight switched inputs changes causing additional inputs to be closed to battery negative.

The alarm silence function will not be overridden if the change in status is the opening of any of the inputs from battery negative. The LED's will turn off when their corresponding input is disconnected from battery negative.

Lamp Test Function

Activating the lamp test switch results in sounding the horn and turning on all LED's continuously for 10 seconds or until the switch is deactivated. The lamp test input can be wired to the switch of another alarm module.

Customized Labeling

The condition being monitored by each LED is determined by the customer. The 130-3326 Film provides a wide variety of labels for the customer to customize the CAM to their application.

Synchronizing Lights Module

Synchronizing Lights Module
(1) Synchronizing lights. (2) Synchronizing switch.

The optional synchronizing lights (SL) module is located on the instrument panel (same location as for the optional alarm module). The SL module is not used when the panel is equipped with an electronic governor.

Synchronizing lights (SL) are used as an aid in manually paralleling generator units independent of load. Each of two lights are connected across the generator to the load side of the generator output circuit breaker. The voltage of two phases are measured and the lights indicate when the voltages are in phase. When the voltages are in phase, closing the circuit breaker puts the generator on-line with the other generator unit(s).

NOTE: For a complete explanation on how to parallel two units, make reference to the Operation and Maintenance Manual for SR4 Generators and Control Panels, Form No. SEBU6150 or Form No. SEBU6918.

Synchronizing Module Installation

Show/hide table

To avoid electrical shock and personal injury, shutdown all on-line gensets before installing or repairing the synchronizing module.

NOTE: For connection of the synchronizing light module and connection of resistor taps in the module, see the Main Chassis Wiring Diagram in the Schematics And Wiring Diagrams section.

Make an orderly shutdown of all generators connected to the system. Then connect synchronizing module wires to the terminals as follows:

a. Wire L1 to terminal L1 of TBC on the AC transformer box (ATB).

b. Wire L3 to terminal L3 of TBC on the AC transformer box (ATB).

c. Wire T11 to terminal 2 of fuse F13 on the AC transformer box (ATB).

d. Wire T13 to terminal 2 of fuse F15 on the AC transformer box (ATB).

The customer is responsible for providing proper wire and fusing to connect L1 and L3 to the load side of the generator output circuit breaker. See the AC Schematic in the Schematics And Wiring Diagrams section.

Adjust the connection of wires T11 and T13 on the taps of synchronizing resistors (SLR1) and (SLR2) respectively as required for the particular generator AC voltage.

208V line to line ... taps E to D (1760 Ohms)

240V line to line ... taps E to C (2400 Ohms)

300V line to line ... taps E to B (5600 Ohms)

380V line to line ... taps E to B (5600 Ohms)

400V line to line ... taps E to B (5600 Ohms)

416V line to line ... taps E to A (7200 Ohms)

480V line to line ... taps E to A (7200 Ohms)

NOTE: Remove the synchronizing module cover for access to the resistor taps.

Example: For a generator with 400 volts line to line, wire T11 connects to tap B of SLR1 and wire T13 connects to tap B of SLR2. See the Main Chassis Wiring Diagram in the Schematics And Wiring Diagrams section.

Synchronizing Lights Module - With Reverse Power Relay

NOTE: The synchronizing lights module (with reverse power relay) option looks and operates the same as the module without the reverse power relay with the exception of the reverse power relay (RPR) mounted on the sub-panel within the control panel.

For information on the synchronizing lights module, see the previous section on the Synchronizing Lights Module.

Introduction

The reverse power relay (RPR) provides system protection when the genset is in parallel with other units. If for some reason the engine loses power, the other parallel unit attempts to motorize (drive electrically) the engine and generator. As long as voltage is present at the generator leads, the voltage regulator maintains the field excitation. The engine and generator remain magnetically coupled and the generator then drives the engine. Instead of power going OUT, power flows INTO the failing generator. This reverse flow of power could possibly result in overloading of the other generators and the whole system.

The reverse power relay (RPR) is a single phase relay which is energized by power (amp-volts) in only one direction (power into generator instead of out). In a reverse power fault, the relay (RPR) (located on AC Schematic) closes its contact across RPR (5 and 6) (line 19) (located on DC Schematic). The GSC records an SP1 fault and the engine is shutdown. If the generator output breaker is equipped with shunt trip, the generator is taken off line. See the Schematics And Wiring Diagrams section.

After the reverse power fault is corrected, the generator set control (GSC) is reset by turning the engine control switch (ECS) to the OFF/RESET position. Also reset the generator output breaker if equipped with shunt trip.

The operation of the RPR is tested by pushing the test button on the RPR while the generator is on load. Depress and hold the test button for 10 to 15 seconds (until time delay elapses).

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To avoid personal injury from electrical shock, do NOT touch the high voltage terminal while adjusting the reverse power relay.

The relay trip point is field adjustable, but is normally factory set at approximately 15% of the generator rated kW (for on-line generators operating at 15% or more of rated kW).

Overvoltage Relay (OVR)

The overvoltage relay (OVR) is an option and mounts to the sub-panel within the control panel. The OVR provides system protection for line to line overvoltages. The OVR is a three phase relay with an adjustable pickup setpoint from 100 to 125% of its nominal rating. The setpoint also has an adjustable time delay from 0.5 to 20 seconds.

If system voltage exceeds the setpoint for more than the time delay setting, then contacts 7 and 8 of the OVR will close. The generator set control (GSC) will record an SP1 fault and the engine is shutdown. If the generator set is equipped with an optional circuit breaker with shunt trip, the generator is taken off line. See the Schematics And Wiring Diagrams section.

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To avoid personal injury from electrical shock, do NOT touch the high voltage terminals while adjusting the over voltage relay.

After the SP1 fault is corrected, the generator set control (GSC) is reset by turning the engine control switch (ECS) to the OFF/RESET position. If equipped with shunt trip, the generator output breaker must also be reset. The pickup setpoint and time delay are field adjustable. The pickup setpoint is factory set to the maximum value (125% of nominal relay rating).

Overcurrent Relay (OCR)

The overcurrent relay (OCR) is an option and mounts to the sub-panel within the control panel. The OCR provides system protection for excessive line current. The OCR is a three phase relay which uses a solid state sensor to detect excessive line currents. The relay receives a 0 to 5 amp AC signal from the secondary of the generator current transformers (CT's). Each generator is equipped with three CT's which are sized according to the voltage and kilowatt rating of the generator. The CT provides a 5 amp AC signal when the generator is operating at approximately 115% of the generator rating. The OCR has an adjustable pickup setpoint from 1 to 5 amps. The setpoint also has an adjustable time delay which allows the standard inverse time delay to be increased from 0.5 to 20 seconds. The OCR requires DC power to operate, see the DC Schematics in the Schematics And Wiring Diagrams section.

If any one of the three phase currents exceeds the setpoint for more than the time delay setting, then contacts 11 and 12 of the OCR will close. The generator set control (GSC) will record an SP1 fault and the engine is shutdown. If the generator set is equipped with an optional circuit breaker with shunt trip, the generator is taken off line. See the Schematics And Wiring Diagrams section.

Customer Interface Module (CIM)

Customer Interface Module (CIM)
(1) Relay board. (2) Electronic control.

Reference: For more information, see the Schematics And Wiring Diagrams section.

The CIM provides an interface (separate relay contacts) between the GSC and switch gear. The two major components of CIM are relay board (1) and electronic control (2). Electronic control (2) connects to the same serial data link as the alarm annunciator. CIM operation is similar to the alarm annunciator except that the data link information is decoded into discrete outputs. The outputs then drive the relays located on relay board (1). The relay contacts are used to sound a horn, flash a lamp or trigger some other action. Once an output is activated, it remains energized until the initiating faults are cleared. If a malfunction in the serial data link occurs, all electronic control outputs (therefore all relays also) flash at 0.5 Hz. The CIM is designed to operate when powered by only 24 DCV or 32 DCV battery systems.

The available serial data link information is:

- High coolant temperature alarm.

- Low oil pressure alarm.

- Low coolant temperature alarm.

- Engine control switch (ECS) NOT in auto.

- Low oil pressure shutdown.

- High coolant temperature shutdown.

- Overcrank.

- Overspeed.

- Diagnostic failure (GSC).

Application Guidelines

Lamp Test

When a lamp test signal is received, the CIM activates all outputs for 10 seconds or until test signal is deactivated. Two lamp test signals are possible, the CIM lamp test is activated when:

Terminal 5 is connected to terminal 7 of electronic control (2).

The GSC lamp test signal is received over the data link.

NOTE: CIM ignores the GSC lamp test signal when terminal 6 is connected to terminal 7 of electronic control (2).

Outputs:

- The relays on relay board (1) are fuse protected. The contacts are flashed silver and are rated at 1 amp 28 DCV. The relays draw 20 mA (at 24 DCV).

- The driver outputs of electronic control (2) are intended to drive incandescent lamps or relay loads. The driver outputs draw up to 600 mA (15 - 45 DCV).

Specifications:

- For CIM installation, the maximum distance between electronic control (2) and the GSC is 305 m (1000 ft).

- The operating voltage range is 15 to 45 DCV (24 DCV nominal)

- CIM is capable of operating with or without earth ground.

- The terminals on electronic control (2) are 6.4 mm (.25 in) push-on connectors.

- Customer connections at relay board (1) are 6-32 screw terminals.

Customer Communication Module (CCM)

The customer communication module (CCM) provides a two-way communication link between the GSC and a host computer of the customer. The CCM converts data from standard RS-232 format to CAT data link format and vice versa. The purpose of the CCM is to allow an operator at the host computer to remotely control and monitor the generator set.

The addition of a specified modem allows two-way communication when the generator set and host computer are separated by great distances.

For more information regarding the CCM, see the Operation & Maintenance Manual, Customer Communication Module For EMCP II, SEBU6874.