How To Read Control Panel DC Schematics

TYPICAL DC SCHEMATIC

Generator Mounted Control Panel (Type 1 - Prior To Caterpillar Parts Service)

Introduction

The uses of the generator mounted control panel are:

To help control the electric power made by the generator set

To monitor (check) the operation of the generator set.

To help protect the generator set from damage caused by low oil pressure, high coolant temperature, overspeed and overcrank.

To help with the transfer of electrical load to and from the generator set.

To help parallel two or more units onto the same bus.

Identification

The location of the control panel is on the top of the regulator housing. Identification of some of the control panel components is given on black plastic plates. The position of control panel switches is also given on these plates. The control panel has an eleven place model number on the panel nameplate.

NOTE: Parts for this control panel are not serviced by Caterpillar Tractor Company.

Wiring

Wiring diagram No. 1 shows wiring connections for control panels made before the remote annunciator panel and prealarm module were available through Caterpillar.

Wiring diagram No. 2 shows wiring connections for control panels made after remote annunciator panel 3N7325 and prealarm module 3N5569 were available through Caterpillar.

Wiring diagram No. 3 is for packaged generator sets with a two element speed switch (OSS and USS) in place of overspeed switch (OS).

NOTE: A photograph of the panel is shown after wiring diagram No. 2.

WIRING DIAGRAM No. 1
NOTE: Customer must supply wires shown dotted.
NOTE A: To initiating contactor at automatic transfer switch.
NOTE B: The yellow wire from voltage level rheostat (R2) to terminal (7) on the regulator terminal strip must be disconnected at terminal (7).
NOTE C: Terminals 15, 16, 17, 18 and 19 of TS2 available for remote annunciator panel.

WIRING DIAGRAM No. 2
NOTE: Customer must supply wires shown dotted.
NOTE A: To initiating contactor at automatic transfer switch.
NOTE B: The yellow wire from voltage level rheostat (R2) to terminal (7) on the regulator terminal strip must be disconnected at terminal (7).
NOTE C. Terminals in optional remote annunciator panel.
NOTE D: Used only with optional remote annunciator panel, prealarm module, or PSG governor. Jumper B+ from TS1-2 to TS1-30 to TS1-29 to TS1-15 with R#14
NOTE E: Used only with governor switch and PSG governor.
NOTE F: Connected to optional prealarm module.
NOTE G: Connected to auxiliary contact (N.O.) on emergency side of transfer switch. Used only with optional remote annunciator panel for generator indication.
NOTE H: To optional prealarm module. Connect wire 37 to terminal 1 on the low oil pressure indicator. Connect wire 50 to the normally open contact on the oil pressure timer.

WIRING DIAGRAM NO. 3
NOTE: Customer must supply wires shown dotted.
NOTE A: To initiating contactor at automatic transfer switch.
NOTE B: The yellow wire from voltage level rheostat (R2) to terminal (7) on the regulator terminal strip must be disconnected at terminal (7).
NOTE C. Terminal in optional remote annunciator panel.
NOTE D: Used only with optional remote annunciator panel, prealarm module, or PSG governor. Jumper B+ from TS1-2 to TS1-30 to TS1-29 to TS1-15 with R#14
NOTE E: Used only with governor switch and PSG governor.
NOTE F: Connected to optional prealarm module.
NOTE G: Connected to auxiliary contact (N.O.) on emergency side of transfer switch. Used only with optional remote annunciator panel for generator indication.
NOTE H: To optional prealarm module. Connect wire 37 to terminal 1 on the low oil pressure indicator. Connect wire 50 to the normally open contact on the oil pressure timer.

CONTROL PANEL-AUTOMATIC POSITION

ACS Engine Control Switch

AR Arming Relay

AR1 Normally Open Contact Of Arming Relay

AR2 Normally Open Contact Of Arming Relay

AR3 Normally Closed Contact of Arming Relay

BATT Battery

CB Circuit Breaker

D Diode

ENFL/RE Engine Failure Light/Reset Switch

FPS Fuel Pressure Switch

I Remote Initating Contact

MS Magnetic Switch

PL Panel Light

PLS Panel Light Switch

PS Pinion Solenoid

OCI Overcrank Indicator

OCT Overcrank Timer

OP Oil Pressure Sender

OPG Oil Pressure Gauge

OPI Oil Pressure Indicator

OPS Oil Pressure Switch

OSI Overspeed Indicator

OSS Overspeed Switch

PSW Pressure Switch

RR Run Relay

RR1 Normally Open Contact of Run Relay

RR2 Normally Closed Contact of Run Relay

RS Rack Solenoid

SM Starting Motor

SR Shutdown Relay

SR1 Normally Open Contact of Shutdown Relay

SR2 Normally Closed Contact of Shutdown Relay

USS Underspeed Switch (if equipped)

WT Water Temperature Sender

WTG Water Temperature Gauge

WTI Water Temperature Indicator

WTS Water Temperature Switch

Components

NOTE: For specifications on components located on the engine, make reference to the ENGINE SERVICE MANUAL.

CONTROL PANEL (TYPE 1 - PRIOR TO CATERPILLAR PARTS SERVICE)

ACA Alternating current ammeter

ACS Engine control switch

ACV Alternating current voltmeter

AS Ammeter selector switch (Ammeter/voltmeter selector switch AVS, if so equipped)

ENFL/RE Engine failure light/reset switch

FM Frequency meter

PL1,2 Panel lamps

PLS Panel lamp switch

OCI Overcrank indicator

OPG Oil pressure gauge

OPI Oil pressure indicator

OSI Overspeed indicator

WTG Water temperature gauge

WTI Water temperature indicator

VLR Voltage level rheostat

1. Button (direct current ammeter DCA, if so equipped)

2. Button (governor switch GS, if so equipped)

ACA Alternating Current Ammeter

AC ammeter (ACA) gives an indication, in amperes, of the current from each phase of the generator to the load. Either ammeter selector switch (AS) or ammeter/voltmeter selector switch (AVS) connect the ammeter to the current transformer on phase T1, T2 or T3; see Contact Charts. Ammeters normally have an input range from 0 to 5 amperes. Current transfer (CT1, CT2 or CT3) causes a reduction of the actual line current, in its respective phase lead, to a level within the input range of the ammeter. The ammeter is calibrated (has marks) to give an indication of the actual current flow in one phase lead of the generator.

NOTE: X gives an indication of a closed contact

AMMETER SELECTOR SWITCH (AS)

AMMETER/VOLTMETER SELECTOR SWITCH (AVS)

ACS Engine Control Switch

Engine control switch (ACS) controls the engine start and stop systems. To start the engine, move the switch to the manual position. To stop the engine, move the switch to the STOP or OFF position. For standby application (engine starts when remote initiating contact I closes) move the switch to the AUTO position. For more information on the operation of this switch, make reference to the AUTOMATIC START/STOP SYSTEM.

ACV Alternating Current Voltmeter

AC voltmeter (ACV) shows the potential difference (voltage) between phase T1 and T2, when the panel is equipped with an ammeter selector switch (AS) only. If the panel is equipped with an ammeter/voltmeter selector switch (AVS), the potential difference between T1-T2, T2-T3 or T3-T1 can be seen. Turn the switch to position 1, 2 or 3 respectively. Make reference to the ALTERNATING CURRENT AMMETER.

DCA Direct Current Ammeter

Direct current ammeter (DCA) goes in place of plug (1). This ammeter shows the amount of DC current in amperes, that flows in the alternator circuit (if so equipped).

ENFL/RE Engine Failure Light/Reset Switch

Engine failure light/reset switch (ENFL/RE) will activate when the engine has a failure. One or more of the shutdown indicators will also activate to give an indication of the problem. Shutdown relay (SR) will activate to start the shutdown sequence. Make reference to SHUTDOWN CAUSED BY ENGINE FAILURE and ENGINE DOES NOT START.

FM Frequency Meter

Frequency meter (FM) shows the hertz (cycles per second) of the electricity made when the generator set is in operation. There is a direct relation between the frequency of the electricity and the rpm of the generator set; see formula.

GS Governor Switch

Governor switch (GS) is in place of button (2) when the engine is equipped with a remote control synchronizing motor for the governor. Engine speed is controlled with this switch.

OPG Oil Pressure Gauge

Oil pressure gauge (OPG) shows the pressure, in psi, of engine lubrication oil. When fuel pressure switch (FPS), pressure switch (PSW) or normally open contact of the arming relay (AR2) is closed, oil pressure gauge (OPG) is connected across battery voltage. There is a relation between the current flow in this circuit and the engine oil pressure read on oil pressure gauge (OPG). Oil pressure sender (OP) controls the current flow by a change in resistance according to the change in engine oil pressure.

PL1,2 Panel Lamps

Light for the control panel is given by panel lamps (PL1 and PL2). These lamps are controlled by panel light switch (PLS).

VLR Voltage Level Rheostat

Voltage level rheostat (VLR) takes the place of voltage level rheostat (R2) on the generator regulator assembly. It is used to adjust the voltage output of the generator.

NOTE: Make reference to OPERATION OF GENERATOR; REGULATOR ADJUSTMENT. On generators equipped with a generator mounted control panel, the yellow wire from voltage level rheostat (R2) to terminal (7) on the regulator terminal strip is disconnected at terminal (7).

WTG Water Temperature Gauge

Water temperature gauge (WTG) shows the temperature, in degrees fahrenheit, of engine coolant. When fuel pressure switch (FPS), pressure switch (PSW) or normally open contact of the arming relay (AR2) is closed, water temperature gauge (WTG is connected across battery voltage. There is a relation between the current flow in this circuit and the coolant temperature read on water temperature gauge (WTG). Water temperature sender (WT) controls the current flow by a change in resistance according to the change in coolant temperature.

Automatic Start/Stop System

Introduction

The automatic start/stop system is normally used for standby operation. That is, without an operator. The generator set must start, pick up the load, operate the load, and stop after the load is removed. An automatic transfer switch controls the transfer of load to and from the generator set. When normal (commercial) power has a failure, initiating contactor (I), part of the automatic transfer switch, closes. This will begin the automatic start sequence. When the engine starts, the control panel instruments will show voltage and frequency. The automatic transfer switch will transfer the load to the generator set when voltage and frequency reach approximately rated value. When normal power returns, the automatic transfer switch will transfer the load back to normal power. Initiating contactor (I) will open. This will begin the automatic stop sequence. The generator set will also stop automatically if the engine has a failure.

NOTE: For specifications on components located on the engine, make reference to the ENGINE SERVICE MANUAL.

Automatic Start

CONTROL PANEL AUTOMATIC POSITION-ENGINE CRANKS

With engine control switch (ACS) in the AUTO position, contacts 1, 2 and 6 are closed. When commercial (normal) power has a failure, initiating contactor (I) closes. This makes a complete circuit from battery (BATT) to energize run relay (RR), magnetic switch (MS) and overcrank timer (OCT).

When run relay (RR) is energized, contacts (RR2) open and contacts (RR1) close. (RR2) open prevents current flow to rack solenoid (RS) through fuel pressure switch (FPS) or pressure switch (PSW). (RR1) closed makes it possible to energize oil pressure indicator (OPI).

When magnetic switch (MS) is energized, (MS) contacts close and pinion solenoid (PS) is energized. This causes (PS) contacts to close, starting motor (SM) will crank the engine. (FPS) or (PSW) will close. This energizes water temperature gauge (WTG) and oil pressure gauge (OPG).

When overcrank timer (OCT) is energized, a timer will start. After the engine cranks for approximately 30 seconds, the timer will stop. (OCT) contacts will close. Make reference to ENGINE DOES NOT START.

Manual Start

The current flow for manual start is similar to automatic start except engine control switch (ACS) is turned to the MAN position. Contact (2) is open and contact (3) is closed. It is not necessary for initiating contactor (I) to close. Run relay (RR), magnetic switch (MS) and overcrank timer (OCT) will energize as soon as contact (3) is closed.

Engine Starts

At 600 rpm, underspeed switch (USS), closes (if so equipped). Oil pressure increases. This activates oil pressure switch (OPS). The normally closed contact opens and the normally open contact closes. The arming relay (AR) is now connected across battery voltage. Contacts (AR1) close and lock in the arming relay. Contacts (AR2) close to help complete a circuit to rack solenoid (RS) for shutdown. Contacts (AR3) open. This de-energizes overcrank timer (OCT) and magnetic switch (MS). (MS) contacts open to de-energize pinion solenoid (PS). (PS) contacts open to de-energize starting motor (SM).

CONTROL PANEL AUTOMATIC POSITION-ENGINE STARTS

Engine Does Not Start

If the engine does not start in approximately 30 seconds, (OCT) contacts will close. This completes the circuit to overcrank indicator (OCI), engine failure light/reset switch (ENFL/RE) and shutdown relay (SR).

(SR1) contacts close to lock in the shutdown relay. (SR2) contacts open. This de-energizes run relay (RR), magnetic switch (MS) and overcrank timer (OCT). (MS) contacts open and de-energize pinion solenoid (PS). (PS) contacts open and de-energize starting motor (SM). Fuel pressure switch (FPS) or pressure switch (PSW) will open. This de-energizes water temperature gauge (WTG) and oil pressure gauge (OPG).

Overcrank indicator (OCI) will pop out (move out suddenly) and engine failure light/reset switch (ENFL/RE) will give light. To start the engine do the steps that follow:

1. Turn engine control switch (ACS) to OFF or STOP. This will prevent the engine from starting if it is not desired.

2. Push engine failure light/reset switch (ENFL/RE). This will open (ENFL/RE) contacts and de-energize shutdown relay (SR) and engine failure light/reset switch (ENFL/RE).

3. Release the engine failure light/reset switch. If the light goes out, go to the next step. If the light is still on (OCT) contacts are still closed. A thermal protector keeps (OCT) contacts closed to protect the starting motor. Push and release the engine failure light/reset switch at short intervals until the light goes out.

4. Push overcrank indicator button (OCI) back in.

5. Turn the engine control switch to AUTO. If the engine does not start in approximately 30 seconds, the overcrank indicator will pop out and the engine failure light/reset switch will give light.

6. Turn engine control switch (ACS) to OFF or STOP. Correct the problem that caused the engine not to start. Make reference to TROUBLESHOOTING.

CONTROL PANEL AUTOMATIC POSITION-ENGINE DOES NOT START

Return of Commercial (Normal) Power

When commercial power returns, the automatic transfer switch transfers the load to comercial power. Initiating contacts (I) open. This de-energizes run relay (RR) and arming relay (AR).

When run relay (RR) is de-energized, contacts (RR2) close and contacts (RR1) open. (RR2) closed energizes rack solenoid (RS). The rack solenoid moves the rack to the FUEL OFF position. (RR1) open prevents an indication of low oil pressure with normal shutdown.

When arming relay (AR) is de-energized, contacts (AR1 and AR2) open and contacts (AR3) close. (AR1) open prevents the arming relay from being energized before the engine starts. (AR2) open prevents current flow to rack solenoid (RS) when engine control switch (ACS) is in the OFF or STOP position. (AR3) closed helps complete the circuit to magnetic switch (MS) and overcrank timer (OCT).

When the engine stops, fuel pressure switch (FPS) or pressure switch (PSW) opens. This de-energizes water temperature gauge (WTG), oil pressure gauge (OPG) and rack solenoid (RS).

Diode (D1) releases any voltage in the coil of rack solenoid (RS) when it is de-energized.

CONTROL PANEL AUTOMATIC POSITION-COMMERCIAL POWER RETURNS

Manual Shutdown

When engine control switch (ACS) is turned to the STOP or OFF position, contacts (9 or 10) close and contacts (2 and 3) are open. (9 or 10) closed completes a circuit to rack solenoid (RS). The rack solenoid moves the rack to the fuel OFF position. When contacts (2 and 3) are both open, no shutdown indicators can operate. This also de-energizes run relay (RR) and arming relay (AR). (RR2) opens, (RR1) closes. (AR1 and AR2) open, (AR3) closes.

Fuel pressure switch (FPS) or pressure switch (PSW) will open when the engine stops. This de-energizes water temperature gauge (WTG), oil pressure gauge (OPG) and rack solenoid (RS).

Diode (D1) releases any voltage in the coil of rack solenoid (RS) when it is de-energized.

The system is ready to start if engine control switch (ACS) is turned to MAN or AUTO.

CONTROL PANEL STOP POSITION-MANUAL SHUTDOWN

Shutdown Caused By Engine Failure

The packaged generator set has shutdown sensors, shutdown indicators and a shutdown circuit for the conditions that follow:

1. Low oil pressure

2. High water temperature

3. Overspeed

4. Overcrank

For information about overcrank shutdown, make reference to ENGINE DOES NOT START.

Conditions (1, 2 or 3) will energize its respective indicator, engine failure light/reset switch (ENFL/RE) and shutdown relay (SR).

(SR1) contacts close to lock in the shutdown relay. (SR2) contacts open. This de-energizes run relay (RR). (RR2) closes and (RR1) opens. (RR2) closed energizes rack solenoid (RS). The rack solenoid moves the rack to the fuel OFF position. Fuel pressure switch (FPS) or pressure switch (PSW) will open when the engine stops. This de-energizes water temperature gauge (WTG), oil pressure gauge (OPG) and rack solenoid (RS). The correct indicator will pop out (move out suddenly) to show the cause of the shutdown. To start the engine do the steps that follow:

1. Turn engine control switch (ACS) to OFF or STOP. This will prevent the engine from starting if it is not desired.

2. Identify and correct the problem that caused the shutdown.

3. Push engine failure light/reset switch (ENFL/RE). This will open (ENFL/RE) contacts and de-energize shutdown relay (SR).

4. Push the indicator button that is out.

5. Reset oil pressure or overspeed switch if necessary.

The system is ready to start if engine control switch (ACS) is turned to MAN or AUTO.

CONTROL PANEL AUTOMATIC POSITION-HIGH WATER TEMPERATURE SHUTDOWN

Generator Mounted Control Panel - (Type 2 - Change Level 0 Thru 1)

Introduction

The uses of the generator mounted control panel are:

To help control the electric power made by the generator set

To monitor (check) the operation of the generator set.

To help protect the generator set from damage caused by low oil pressure, high coolant temperature, overspeed and overcrank.

To help with the transfer of electrical load to and from the generator set.

To help parallel two or more units onto the same bus.

Identification

The location of the control panel is on the top of the regulator housing. This panel has a place for a heat switch and prealarm module. The control panel has a 12 place model number on the panel nameplate. The model number gives an indication of the control panel component part numbers. Make reference to the Parts Book, GENERATOR MOUNTED CONTROL PANEL, Form No. SEBP1068. The last digit of the model number is the change level to which the panel was built.

Wiring

The earlier type control panels are equipped with either a mechanical or an electrical type speed switch. See wiring diagrams that follow and photo illustration for identification.

WIRING DIAGRAM

A AMMETER

ALT ALTERNATOR

APR ANNUNCIATOR PANEL-REMOTE

ARX AUXILIARY RELAY MODULE

ATS AUTOMATIC TRANSFER SWITCH

AUX AUXILIARY CONTACT

B+ BATTERY POSITIVE

B- BATTERY NEGATIVE

BATT BATTERY

CB CIRCUIT BREAKER

CCM CYCLE CRANKING MODULE

CT CURRENT TRANSFORMER

GS GOVERNOR SWITCH

GSM GOVERNOR SYNCHRONIZING MOTOR

HS HEAT SWITCH

I INITIATING CONTACT (FOR CUSTOMER USE)

LFS LOW FUEL LEVEL SWITCH

LWT LOW WATER TEMPERATURE SWITCH

MS MAGNETIC SWITCH

MSG MAGNETIC SWITCH (GLOW PLUGS)

OCI OVERCRANK INDICATOR

OP OIL PRESSURE GAUGE SENDING UNIT

OPI LOW OIL PRESSURE INDICATOR

OPP OIL PRESSURE SWITCH (PRE-ALARM)

OPS OIL PRESSURE SWITCH (SHUTDOWN)

OSI OVERSPEED INDICATOR

OSS OVERSPEED SWITCH (SHUTDOWN)

PAM PRE-ALARM MODULE

PS PINION SOLENOID

PSW PRESSURE SWITCH

RS SHUTOFF SOLENOID

SM STARTING MOTOR

TS TERMINAL STRIP

USS UNDERSPEED SWITCH

WT WATER TEMPERATURE GAUGE SENDING UNIT

WTI HIGH WATER TEMPERATURE INDICATOR

WTP WATER TEMPERATURE SWITCH (PRE-ALARM)

WTS WATER TEMPERATURE SWITCH (SHUTDOWN)
Wire and Cable shown as dash lines (---) are to be put on by the customer.
TS2 Terminal numbers are shown on control panel schematics.
The wiring diagram shows the connections for all available attachments. The unit will have wiring only for the attachments which are installed.
TS3-6. Before connecting TS2-80 to TS3-6, remove yellow wire from TS3-7. Put insulation on the end of the yellow wire so it can not make electrical contact with TS3-7.
Jumper wires from B+ to TS1-2 to TS1-30 to TS1-29 to TS1-15 are for use with annunciator panel (remote) or pre-alarm module only.
TS1-38 is the terminal for connection of the indicator light on the annunciator panel (remote) which shows that the generator is working.
When cycle cranking module (CCM) is installed remove the jumper wire from TS2-4A to TS2-4.
Do not operate alternator (ALT) without a battery (BATT) connected in the circuit. Do not polarize the alternator. Do not try to charge a common battery (BATT) with the alternator (ALT) and a DC generator at the same time.
TS1-37 is the terminal for the connection of the low oil pressure indicator (OPP) in the pre-alarm module.
TS1-39 is the terminal for the connection of remote shutdown and pre-alarm indicators when the pre-alarm module is used.

CONTROL PANEL WITH MECHANICAL SPEED SWITCH AUTOMATIC POSITION

Components

NOTE: For specifications on components located on the engine, make reference to the ENGINE SERVICE MANUAL.

CONTROL PANEL (TYPE 2 - CHANGE LEVEL 0 THRU 1)

ACA Alternating current ammeter

ACS Engine control switch

ACV Alternating current voltmeter

AVS Ammeter/voltmeter selector switch

ENFL/RE Engine failure light/reset switch

FM Frequency meter

PL1,2 Panel lamps

PLS Panel lamp switch

OCI Overcrank indicator

OPG Oil pressure gauge

OPI Oil pressure indicator

OSI Overspeed indicator

WTG Water temperature gauge

WTI Water temperature indicator

VLR Voltage level rheostat

1. Button (direct current ammeter DCA, if so equipped)

2. Button (heat switch HS, if so equipped)

3. Button (governor switch GS, if so equipped)

4. Panel (prealarm module PAM, if so equipped)

ACA Alternating Current Ammeter

AC ammeter (ACA) gives an indication, in amperes, of the current from each phase of the generator to the load. Ammeter/voltmeter selector switch (AVS) is used to connect the ammeter to the current transformer on phase T1, T2 or T3; see Contact Chart. Ammeters normally have an input range from 0 to 5 amperes. Current transformer (CT1, CT2 or CT3) causes a reduction of the actual line current, in its respective phase lead, to a level within the input range of the ammeter. The ammeter is calibrated (has marks) to give an indication of the actual current flow in one phase load of the generator.

AMMETER/VOLTMETER SELECTOR SWITCH (AVS)

NOTE: X gives an indication of a closed contact, X on the line gives an indication of "make before break"

ACS Engine Control Switch

Engine control switch (ACS) controls the engine start and stop systems. To start the engine move the switch to the manual position. To stop the engine, move the switch to the STOP or OFF position. For standby application (engine starts when remote initiating contact I closes) move the switch to the AUTO position. For more information on the operation of this switch, make reference to the AUTOMATIC START/STOP SYSTEM.

ACV Alternating Current Voltmeter

AC voltmeter (ACV) shows the potential difference (voltage) between phase T1-T2, T2-T3 or T3-T1 at position 1, 2 or 3 respectively. Make reference to the ALTERNATING CURRENT AMMETER.

DCA Direct Current Ammeter

Direct current ammeter (DCA) goes in place of plug (1). This ammeter shows the amount of DC current in amperes, that flows in the alternator circuit (if so equipped).

ENFL/RE Engine Failure Light/Reset Switch

Engine failure light/reset switch (ENFL/RE) will activate when the engine has a failure. One or more of the shutdown indicators will also activate to give an indication of the problem. Shutdown relay (SR) will activate to start the shutdown sequence. Make reference to SHUTDOWN CAUSED BY ENGINE FAILURE and ENGINE DOES NOT START.

FM Frequency Meter

Frequency meter (FM) shows the hertz (cycles per second) of the electricity made when the generator set is in operation. There is a direct relation between the frequency of the electricity and the rpm of the generator set; see formula.

GS Governor Switch

Governor switch (GS) is in place of button (3) when the engine is equipped with a remote control synchronizing motor for the governor. Engine speed is controlled with this switch.

HS Heat Switch

Heat switch (HS) is in place of button (2) when the engine is equipped with glow plugs. This switch is used to operate the glow plugs for cold weather starting.

OPG Oil Pressure Gauge

Oil pressure gauge (OPG) shows the pressure, in psi, of engine lubrication oil. When pressure switch (PSW) or normally open contact of the arming relay (AR2) is closed, oil pressure gauge (OPG) is connected across battery voltage. There is a relation between the current flow in this circuit and the engine oil pressure read on oil pressure gauge (OPG). Oil pressure sender (OP) controls the current flow by a change in resistance according to the change in engine oil pressure.

PAM Prealarm Module

Make reference to ATTACHMENTS.

PL1,2 Panel Lamps

Light for the control panel is given by panel lamps (PL1 and PL2). These lamps are controlled by panel light switch (PLS).

VLR Voltage Level Rheostat

Voltage level rheostat (VLR) takes the place of voltage level rheostat (R2) on the generator regulator assembly. It is used to adjust the voltage output of the generator.

NOTE: Make reference to OPERATION OF GENERATOR. REGULATOR ADJUSTMENT. On generators equipped with a generator mounted control panel, the yellow wire from voltage level rheostat (R2) to terminal (7) on the regulator terminal strip is disconnected at terminal (7).

WTG Water Temperature Gauge

Water temperature gauge (WTG) shows the temperature, in degrees fahrenheit, of engine coolant. When pressure switch (PSW) or normally open contact of the arming relay (AR2) is closed, water temperature gauge (WTG) is connected across battery voltage. There is a relation between the current flow in this circuit and the coolant temperature read on water temperature gauge (WTG). Water temperature sender (WT) controls the current flow by a change in resistance according to the change in coolant temperature.

Automatic Start/Stop System

Introduction

The automatic start/stop system is normally used for standby operation. That is, without an operator. The generator set must start, pick up the load, operate the load, and stop after the load is removed. An automatic transfer switch controls the transfer of load to and from the generator set. When normal (commercial) power has a failure, initiating contactor (I), part of the automatic transfer switch, closes. This will begin the automatic start sequence. When the engine starts, the control panel instruments will show voltage and frequency. The automatic transfer switch will transfer the load to the generator set when voltage and frequency reach approximately rated value. When normal power returns, the automatic transfer switch will transfer the load back to normal power. Initiating contactor (I) will open. This will begin the automatic stop sequence. The generator set will also stop automatically if the engine has a failure.

NOTE: There are two types of automatic start/stop systems used with the earlier type generator mounted control panel. One uses a mechanically driven speed switch (USS and OSS) and an oil pressure switch (OPS) that is the shape of a cylinder. The other uses an electrical speed switch (DSS) and an oil pressure switch that is the shape of a box.

Automatic Start

CONTROL PANEL WITH MECHANICAL SPEED SWITCH
AUTOMATIC POSITION-ENGINE CRANKS

With engine control switch (ACS) in the AUTO position, contacts 1, 2 and 6 are closed. When commercial (normal) power has a failure, initiating contactor (I) closes. This makes a complete circuit from battery (BATT) to energize run relay (RR), magnetic switch (MS), dual speed switch (DSS) (if so equipped) and overcrank timer (OCT).

When run relay (RR) is energized, contacts (RR2) open and contacts (RR1) close. (RR2) open prevents current flow to rack solenoid (RS) through pressure switch (PSW). (RR1) closed makes it possible to energize oil pressure indicator (OPI).

When magnetic switch (MS) is energized, (MS) contacts close and pinion solenoid (PS) is energized. This causes (PS) contacts to close, starting motor (SM) will crank the engine. (FPS) or (PSW) will close. This energizes water temperature gauge (WTG) and oil pressure gauge (OPG).

When overcrank timer (OCT) is energized, a timer will start. After the engine cranks for approximately 30 seconds, the timer will top. (OCT) contacts will close. Make reference to ENGINE DOES NOT START.

When dual speed switch (DSS) (if so equipped) is energized, the magnetic pickup relays the engine rpm to the switch. The dual speed switch has an underspeed (USS) circuit and an overspeed (OSS) circuit.

Manual Start

The current flow for manual start is similar to automatic start except engine control switch (ACS) is turned to the MAN position. Contact (2) is open and contact (3) is closed. It is not necessary for initiating contactor (I) to close. Run relay (RR), magnetic switch (MS) and overcrank timer (OCT) will energize as soon as contact (3) is closed.

CONTROL PANEL WITH ELECTRONIC SPEED SWITCH
AUTOMATIC POSITION-ENGINE CRANKS

Engine Starts

At 600 rpm, underspeed switch (USS) closes. Oil pressure increases. This activates oil pressure switch (OPS). The normally closed contact opens and the normally open contact closes. The arming relay (AR) is now connected across battery voltage. Contacts (AR1) close and lock in the arming relay. Contacts (AR2) close to help complete a circuit to rack solenoid (RS) for shutdown. Contacts (AR3) open. This de-energizes magnetic switch (MS). (MS) contacts open to de-energize pinion solenoid (PS). (PS) contacts open to de-energize starting motor (SM). Contacts (AR4) open to de-energize overcrank timer (OCT).

CONTROL PANEL WITH ELECTRONIC SPEED SWITCH
AUTOMATIC POSITION-ENGINE STARTS

CONTROL PANEL WITH MECHANICAL SPEED SWITCH
AUTOMATIC POSITION-ENGINE STARTS

Engine Does Not Start

If the engine does not start in approximately 30 seconds, overcrank timer (OCT) will let current flow to overcrank indicator (OCI), engine failure light/reset switch (ENFL/RE) and shutdown relay (SR).

(SR1) contacts close to lock in the shutdown relay. (SR2) contacts open. This de-energizes run relay (RR) and magnetic switch (MS). (MS) contacts open and de-energize pinion solenoid (PS). (PS) contacts open and de-energize starting motor (SM). Pressure switch (PSW) will open. This de-energizes water temperature gauge (WTG) and oil pressure gauge (OPG).

Overcrank indicator (OCI) will pop out (move out suddenly) and engine failure light/reset switch (ENFL/RE) will give light. To start the engine, do the steps that follow:

1. Turn engine control switch (ACS) to OFF or STOP. This will prevent the engine from starting if it is not desired. It will also de-energize overcrank timer (OCT) and overcrank indicator (OCI).

2. Push and release engine failure light/reset switch (ENFL/RE). This will open (ENFL/RE) contacts for a moment and de-energize shutdown relay (SR) and engine failure light/reset switch (ENFL/RE).

3. Push overcrank indicator button (OCI) back in.

4. Turn the engine controls switch to AUTO. If the engine does not start in approximately 30 seconds, the overcrank indicator will pop out and the engine failure light/reset switch will give light.

5. Turn engine control switch (ACS) to OFF or STOP. Correct the problem that caused the engine not to start. Make reference to TROUBLESHOOTING.

CONTROL PANEL WITH ELECTRONIC SPEED SWITCH
AUTOMATIC POSITION-ENGINE DOES NOT START

CONTROL PANEL WITH MECHANICAL SPEED SWITCH
AUTOMATIC POSITION-ENGINE DOES NOT START

Return of Commercial (Normal) Power

When commercial power returns, the automatic transfer switch transfers the load to commercial power. Initiating contacts (I) open. This de-energizes run relay (RR) and arming relay (AR).

When run relay (RR) is de-energized, contacts (RR2) close and contacts (RR1) open. (RR2) closed energizes rack solenoid (RS). The rack solenoid moves the rack to the FUEL OFF position. (RR1) open prevents an indication of low oil pressure with normal shutdown.

When arming relay (AR) is de-energized, contacts (AR1 and AR2) open and contacts (AR3 and AR4) close. (AR1) open prevents the arming relay from being energized before the engine starts. (AR2) open prevents current flow to rack solenoid (RS) when engine control switch (ACS) is in the OFF or STOP position. (AR3) closed helps complete the circuit to magnetic switch (MS). (AR4) closed helps complete the circuit to and overcrank timer (OCT).

When the engine stops, pressure switch (PSW) opens. This de-energizes water temperature gauge (WTG), oil pressure gauge (OPG) and rack solenoid (RS).

Diode (D1) releases any voltage in the coil of rack solenoid (RS) when it is de-energized.

CONTROL PANEL WITH ELECTRONIC SPEED SWITCH
AUTOMATIC POSITION-COMMERCIAL POWER RETURNS

CONTROL PANEL WITH MECHANICAL SPEED SWITCH
AUTOMATIC POSITION-COMMERCIAL POWER RETURNS

Manual Shutdown

When engine control switch (ACS) is turned to the STOP or OFF position, contacts (9 or 10) close and contacts (2 and 3) are open. (9 or 10) closed completes a circuit to rack solenoid (RS). The rack solenoid moves the rack to the fuel OFF position. When contacts (2 and 3) are both open, no shutdown indicators can operate. This also de-energizes run relay (RR) and arming relay (AR). (RR2) opens, (RR1) closes. (AR1 and AR2) open, (AR3 and AR4) close.

Pressure switch (PSW) will open when the engine stops. This de-energizes water temperature gauge (WTG), oil pressure gauge (OPG) and rack solenoid (RS).

Diode (D1) releases any voltage in the coil of rack solenoid (RS) when it is de-energized.

The system is ready to start if engine control switch (ACS) is turned to MAN or AUTO.

CONTROL PANEL WITH ELECTRONIC SPEED SWITCH
STOP POSITION-MANUAL SHUTDOWN

CONTROL PANEL WITH MECHANICAL SPEED SWITCH
STOP POSITION-MANUAL SHUTDOWN

Shutdown Caused by Engine Failure

The packaged generator set has shutdown sensors, shutdown indicators and a shutdown circuit for the conditions that follow:

1. Low oil pressure

2. High water temperature

3. Overspeed

4. Overcrank

For information about overcrank shutdown, make reference to ENGINE DOES NOT START.

Conditions (1, 2 or 3) will energize its respective indicator, engine failure light/reset switch (ENFL/RE) and shutdown relay (SR).

(SR1) contacts close to lock in the shutdown relay. (SR2) contacts open. This de-energizes run relay (RR). (RR2) closes and (RR1) opens. (RR2) closed energizes rack solenoid (RS). The rack solenoid moves the rack to the fuel OFF position. Pressure switch (PSW) will open when the engine stops. This de-energizes water temperature gauge (WTG), oil pressure gauge (OPG) and rack solenoid (RS). The correct indicator will pop out (move out suddenly) to show the cause of the shutdown. To start the engine, do the steps that follow:

1. Turn engine control switch (ACS) to OFF or STOP.

This will prevent the engine from starting if it is not desired.

2. Identify and correct the problem that caused the shutdown.

3. Push engine failure light/reset switch (ENFL/RE). This will open (ENFL/RE) contacts and de-energize shutdown relay (SR).

4. Push the indicator button that is out.

5. Reset oil pressure or overspeed switch if necessary.

The system is ready to start if engine control switch (ACS) is turned to MAN or AUTO.

CONTROL PANEL WITH ELECTRONIC SPEED SWITCH
AUTOMATIC POSITION-HIGH WATER TEMPERATURE SHUTDOWN

CONTROL PANEL WITH MECHANICAL SPEED SWITCH
AUTOMATIC POSITION-HIGH WATER TEMPERATURE SHUTDOWN

Generator Mounted Control Panel (Type 3 - Change Level 2 Thru 8)

Introduction

The uses of the generator mounted control panel are:

To help control the electric power made by the generator set.

To monitor (check) the operation of the generator set.

To help protect the generator set from damage caused by low oil pressure, high coolant temperature, overspeed and overcrank.

To help with the transfer of electrical load to and from the generator set.

To help parallel two or more units onto the same bus.

Identification

The location of the control panel is on the top of the regulator housing. This panel has a place for a heat switch and prealarm module. The shutdown indicators are relay lamp type. The control panel has a 12 place model number on the panel nameplate. The model number gives an indication of the control panel component part numbers. Make reference to the Parts Book, GENERATOR MOUNTED CONTROL PANEL, Form No. SEBP1068. The last digit of the model number is the change level to which the panel was built.

Wiring

See the pages that follow for wiring diagrams, schematics and photo illustrations for identification.

GENERATOR MOUNTED COMPONENTS AND ANNUNCIATOR PANEL (REMOTE)

GENERATOR TERMINAL STRIP TS1, REGULATOR TERMINAL STRIP TS3. GENERATOR, CURRENT TRANSFORMERS AND CIRCUIT BREAKER

A AMMETER (CONTROL PANEL MOUNTED)

ALT CHARGING ALTERNATOR (NOTE H)

APR ANNUNCIATOR PANEL-REMOTE

ARX AUXILIARY RELAY MODULE (CONTROL PANEL MOUNTED)

AUX AUXILIARY CONTACT (NOTE E)

B+ BATTERY POSITIVE

B- BATTERY NEGATIVE

BATT BATTERY

CB CIRCUIT BREAKER

CCM CYCLE CRANKING MODULE (CONTROL PANEL MOUNTED)

CT CURRENT TRANSFORMER

CTS CRANK TERMINATE SWITCH

DSS DUAL SPEED SWITCH

GS GOVERNOR SWITCH (CONTROL PANEL MOUNTED)

GSM GOVERNOR SYNC MOTOR

HS HEAT SWITCH (CONTROL PANE MOUNTED)

LFS LOW FUEL LEVEL SWITCH

LWT LOW WATER TEMP SWITCH

MS MAGNETIC SWITCH (CRANK CIRCUIT)

MSG MAGNETIC SWITCH (GLOW PLUG CIRCUIT)

OCI OVERCRANK INDICATOR

OP OIL PRESSURE GAUGE SENDER

OPI LOW OIL PRESSURE INDICATOR

OPP OIL PRESSURE SWITCH (PRE-ALARM)

OPS OIL PRESSURE SWITCH (SHUTDOWN)

OSI OVERSPEED INDICATOR

OSS OVERSPEED SWITCH (SHUTDOWN)

PAM PREALARM MODULE (CONTROL PANEL MOUNTED)

PS PINION SOLENOID

PSW PRESSURE SWITCH

SS SHUTOFF SOLENOID

SM STARTING MOTOR

TS TERMINAL STRIP

USS UNDERSPEED SWITCH (CRANK TERMINATION)

WT WATER TEMPERATURE GAGE SENDER

WTI HIGH WATER TEMPERATURE INDICATOR

WTP WATER TEMPERATURE SWITCH (PRE-ALARM)

WTS WATER TEMPERATURE SWITCH (SHUTDOWN)

CONTROL PANEL COMPONENTS (PARTIAL) AND CONTROL PANEL TERMINAL STRIP TS2
NOTE: DOTTED WIRES BY CUSTOMER
NOTE A: To normally open initiating contacts I of automatic transfer switch.
NOTE B: The yellow wire from voltage level rheostat (R2) to terminal 7 on the regulator terminal strip is disconnected at terminal 7.
NOTE C: Some generator sets without an annunciator panel (remote) or a prealarm module are not equippEd with B+ connection from TS1-2 to TS1-30 to TS1-29 and TS1-15.
NOTE D: Some generator sets are grounded at the line from the current transformer's neutral. Some are grounded through a jumper between TS1-20 and a terminal strip support screw.
NOTE E: To normally open auxiliary contact on emergency side of transfer switch, if the generator set is equipped with an annunciator panel (remote). Used to give generating indication.
NOTE F: Red jumper between TS2-4A and TS2-4 is not used with cycle cranking module.
NOTE G: Do not operate the alternator without a battery connected in the circuit. Do not polarize alternator. Do not charge a common battery with the alternator and a DC generator at the same time.
NOTE H: To optional remote low lubrication oil pressure indicator installed by the customer.
NOTE I: To optional remote shutdown indicator installed by the customer.
NOTE J: On some generator sets, underspeed switch (USS) is connected to the common terminal on oil pressure switch (OPS). Connect the wire to the normally open terminal on oil pressure switch (OPS) to help prevent low oil pressure shutdown when engine oil pressure does not increase as fast as engine speed during engine starting.
NOTE K: If terminal 1 is connected to terminal 2, speed switch will shutdown engine at 3/4 overspeed set point. Speed switches with a verify button do not have terminal 1. Push the verify button to shutdown the engine at 3/4 overspeed set point.
NOTE L: Some frequency meters are connected phase (TS2-FM to TS3-22 to stator T7) to neutral (TS2-T0 to TS3-26 to stator T0). Others are connected phase (TS2-FM to TS3-22 to stator T7) to ground (control panel chassis). When the frequency meter is connected phase to ground, terminal TS2-T0 has a mark 93 and is not connected to TS3-26.
NOTE M: CTS is a replacement for USS. CTS, crank terminate switch, gives a better description of the actual purpose of the switch.

CONTROL PANEL
AUTOMATIC POSITION

RELAY CONTACT SCHEMATIC

RELAY LAMP COMPONENT WIRING

RELAY LAMP SCHEMATIC

Components

NOTE: For specifications on components located on the engine, make reference to the ENGINE SERVICE MANUAL.

CONTROL PANEL (TYPE 3 - CHANGE LEVEL 2 THRU 8)

ACA Alternating current ammeter

ACS Engine control switch

ACV Alternating current voltmeter

AVS Ammeter/voltage selector switch

DCA Direct current ammeter

ENFL/RE Engine failure light/reset switch

FM Frequency meter

PL1,2 Panel lamps

PLS Panel lamp switch

OCI Overcrank indicator

OPG Oil pressure gauge

OPI Oil pressure indicator

OSI Overspeed indicator

WTG Water temperature gauge

WTI Water temperature indicator

VLR Voltage level rheostat

1. Button (heat switch HS, if so equipped)

2. Button (governor switch GS, if so equipped)

3. Panel (prealarm module PAM, if so equipped)

INSIDE CONTROL PANEL (TYPE 3 - CHANGE LEVEL 2 THRU 8)
4. Location for CDT (cool down timer if so equipped). 5. Location for AUX (auxiliary relay, if so equipped). 6. Location for CCM (cycle crank module, if so equipped).

ACA Alternating Current Ammeter

AC ammeter (ACA) gives an indication, in amperes, of the current from each phase of the generator to the load. Ammeter/voltmeter selector switch (AVS) is used to connect the ammeter to the current transformer on phase T1, T2 or T3; see Contact Chart. Ammeters normally have an input range from 0 to 5 amperes. Current transformer (CT1, CT2 or CT3) causes a reduction of the actual line current, in its respective phase lead, to a level within the input range of the ammeter. The ammeter is calibrated (has marks) to give an indicatio of the actual current flow in one phase load of the generator.

NOTE: Several methods have been used to connect control panel instruments. The recommended method is shown in the diagrams.

AMMETER/VOLTMETER SELECTOR SWITCH (AVS) WIRING DIAGRAMS

NOTE: X gives an indication of a closed contact, X on the line gives an indication of "make before break".

ACS Engine Control Switch

Engine control switch (ACS) controls the engine start and stop systems. To start the engine, move the switch to the manual position. To stop the engine move the switch to the STOP or OFF position. For standby application (engine starts when remote initiating contact I closes), move the switch to the AUTO position. For more information on the operation of this switch, make reference to the AUTOMATIC START/STOP SYSTEM.

ACV Alternating Current Voltmeter

AC voltmeter (ACV) shows the potential differential (voltage) between phase T1-T2, T2-T3 or T3-T1 at position 1, 2 or 3 respectively. Make reference to the ALTERNATING CURRENT AMMETER.

DCA Direct Current Ammeter

This ammeter shows the amount of DC current in amperes, that flows in the alternator circuit (if so equipped).

ENFL/RE Engine Failure Light/Reset Switch

Engine failure light/reset switch (ENFL/RE) will activate when the engine has a failure. One or more of the shutdown indicators will also activate to give an indication of the problem. Shutdown relay (SR) will activate to start the shutdown sequence. Make reference to SHUTDOWN CAUSED BY ENGINE FAILURE and ENGINE DOES NOT START.

FM Frequency Meter

Frequency meter (FM) shows the hertz (cycles per second) of the electricity made when the generator set is in operation. There is a direct relation between the frequency of the electricity and the rpm of the generator set; see formula.

GS Governor Switch

Governor switch (GS) is in place of button (2) when the engine is equipped with a remote control synchronizing motor for the governor. Engine speed is controlled with this switch.

HS Heat Switch

Heat switch (HS) is in place of button (1) when the engine is equipped with glow plugs. This switch is used to operate the glow plugs for col weather starting.

OPG Oil Pressure Gauge

Oil pressure gauge (OPG) shows the pressure, in psi, of engine lubrication oil. When pressure switch (PSW) is closed, oil pressure gauge (OPG) is connected across battery voltage. There is a relation between the current flow in this circuit and the engine oil pressure read on oil pressure gauge (OPG). Oil pressure sender (OP) controls the current flow by a change in resistance according to the change in engine oil pressure.

PAM Prealarm Module

Make reference to ATTACHMENTS.

PL1,2 Panel Lamps

Light for the control panel is given by panel lamps (PL1 and PL2). These lamps are controlled by panel light switch (PLS).

VLR Voltage Level Rheostat

Voltage level rheostat (VLR) takes the place of voltage level rheostat (R2) on the generator regulator assembly. It is used to adjust the voltage output of the generator.

NOTE: Make reference to OPERATION OF GENERATOR; REGULATOR ADJUSTMENT. On generators equipped with a generator mounted control panel, the yellow wire from voltage level rheostat (R2) to terminal (7) on the regulator terminal strip is disconnected at terminal (7).

Automatic Start/Stop System

Introduction

The automatic start/stop system is normally used for standby operation. That is, without an operator. The generator set must start, pick up the load, operate the load, and stop after the load is removed. An automatic transfer switch controls the transfer of load to and from the generator set. When normal (commercial) power has a failure, initiating contactor (I), part of the automatic transfer switch, closes. This will begin the automatic start sequence. When the engine starts, the control panel instruments will show voltage and frequency. The automatic transfer switch will transfer the load to the generator set when voltage and frequency reach approximately rated value. When normal power returns, the automatic transfer switch will transfer the load back to normal power. Initiating contactor (I) will open. This will begin the automatic stop sequence. The generator set will also stop automatically if the engine has a failure.

NOTE: For specifications on components located on the engine, make reference to the ENGINE SERVICE MANUAL.

Automatic Start

CONTROL PANEL
AUTOMATIC POSITION-ENGINE CRANKS

With engine control switch (ACS) in the AUTO position, contacts 1, 2 and 6 are closed. When commercial (normal) power has a failure, remote start initiating contact (I) closes. This makes a complete circuit from battery (BATT) to energize run relay (RR) and magnetic switch (MS).

When run relay (RR) is energized, contacts (RR2) open and contacts (RR1) close. (RR2) open prevents current flow to shutoff solenoid (SS) through pressure switch (PSW). (RR1) closed energizes dual speed switch (DSS) and overcrank timer (OCT).

When dual speed switch (DSS) is energized, a magnetic pickup relays engine rpm to the switch. The dual speed switch has a crank terminate (CTS) circuit and an overspeed (OSS) circuit.

When overcrank timer (OCT) is energized, a timer will start. After the engine cranks for approximately 30 seconds the timer will stop. (OCT) contacts will close. Make reference to ENGINE DOES NOT START.

When magnetic switch (MS) is energized, (MS) contacts close and pinion solenoid (PS) is energized. This causes (PS) contacts to close, starting motor (SM) will crank the engine. (PSW) will close. This energizes water temperature gauge (WTG) and oil pressure gauge (OPG).

Manual Start

The current flow for manual start is similar to automatic start except engine control switch (ACS) is turned to the MAN position. Contact (2) is open and contact (3) is closed. It is not necessary for remote start indicating contact (I) to close. Run relay (RR) and magnetic switch (MS) will energize as soon as contact (3) is closed.

Engine Starts

At 600 rpm, crank terminate switch (CTS) closes. Oil pressure increases. This activates oil pressure switch (OPS). The normally closed contact opens and the normally open contact closes. The arming relay (AR) is now connected across battery voltage. Contacts (AR1) close and lock in the arming relay. Contacts (AR2) open. This de-energizes magnetic switch (MS). (MS) contacts open to de-energize pinion solenoid (PS). (PS) contacts open to de-energize starting motor. Contacts (AR3) open to de-energize overcrank timer (OCT).

CONTROL PANEL
AUTOMATIC POSITION-ENGINE STARTS

Engine Does Not Start

If the engine does not start in approximately 30 seconds, overcrank timer (OCT) will let current flow to overcrank indicating relay (OCIR). (OCIR) contacts close and current flows to energize engine fault light (ENFL) and shutdown relay (SR).

(SR) contacts open. This de-enrgizes run relay (RR) and magnetic switch (MS).

When run relay (RR) is de-energized, contacts (RR2) close and contacts (RR1) open. (RR2) closed completes a circuit to shutoff solenoid (SS) until pressure switch (PSW) opens. (RR1) open de-energizes arming relay (AR), dual speed switch (DSS) and overcrank timer (OCT).

NOTE: Pressure switch (PSW) is not always closed when the engine cranks. Pressure caused by starting motor rotation of the engine is not always enough to close (PSW).

When magnetic switch (MS) is de-energized, (MS) contacts open. This de-energizes pinion solenoid (PS). (PS) contacts open and de-energize starting motor (SM).

Overcrank indicating relay (OCIR) and engine fault light (ENFL) will give light. To start the engine, do the steps that follow:

1. Turn engine control switch (ACS) to OFF or STOP. This will prevent the engine from starting if (ENFL) is pushed.

2. Push and release engine fault light (ENFL). This will open (ENFL) contacts for a moment and de-energize overcrank indicating relay (OCIR). (OCIR) contacts will open and de-energize engine fault light (ENFL) and shutoff relay (SR).

3. Turn the engine control switch to AUTO. If the engine does not start in approximately 30 seconds, the overcrank indicating relay and engine fault light will give light.

4. Turn engine control switch (ACS) to OFF or STOP. Correct the problem that caused the engine not to start. Make reference to TROUBLESHOOTING.

CONTROL PANEL
AUTOMATIC POSITION-ENGINE DOES NOT START

Return of Commercial (Normal) Power

When commercial power returns, the automatic transfer switch transfers the load to commercial power. Remote start initiating contacts (I) open. This de-energizes run relay (RR).

When run relay (RR) is de-energized, contacts (RR2) close and contacts (RR1) open. (RR2) closed completes a circuit to shut-off solenoid (SS). The shut-off solenoid moves the rack to the fuel OFF position. After the engine stops (PSW) will open to de-energize the shut-off solenoid. (RR1) open de-energizes arming relay (AR) and dual speed switch (DSS).

Diode (D1) is in the shut-off solenoid circuit to help prevent electrical sparks (arching), at the shut-off solenoid contacts, when the shut-off solenoid is de-energized.

CONTROL PANEL
AUTOMATIC POSITION-AUTOMATIC SHUTDOWN

Manual Shutdown

When engine control switch (ACS) is turned to the STOP or OFF position, contacts (9 or 10) close and contacts (2 and 3) are both open, no shutdown indicators can operate. (9 to 10) closed completes a circuit to shut-off solenoid (SS). The shut-off solenoid moves the rack to the fuel OFF position. (2 and 3) open de-energizes run relay (RR).

When run relay (RR) is de-energized, contacts (RR2) close and contacts (RR1) open. (RR2) closed completes a parallel circuit to shut-off solenoid (SS). This circuit is necessary to stop the engine when the engine control switch is in the AUTO or MAN position. After the engine stops, (PSW) will open to de-energize the shut-off solenoid. (RR1) open de-energizes arming relay (AR) and dual speed switch (DSS).

Diode (D1) helps prevent electrical sparks (arcing), at the contacts in the shut-off solenoid circuit when the shut-off solenoid is de-energized.

CONTROL PANEL
STOP POSITION-MANUAL SHUTDOWN

Shutdown Caused by Engine Failure

The packaged generator set has shutdown sensors, shutdown indicators and shutdown circuit for the conditions that follow.

1. Low oil pressure

2. High water temperature

3. Overspeed

4. Overcrank.

For information about overcrank shutdown, make reference to ENGINE DOES NOT START.

Conditions (1, 2 or 3) will energize its respective indicating relay. The number (2) contacts of the respective relay will close to energize engine fault light (ENFL) and shut-off relay (SR). The number (1) contacts of the respective relay will close to lock in the relay.

When shutdown relay (SR) is energized, (SR) contacts open. This de-energizes run relay (RR). Contacts (RR2) close and contacts (RR1) open. (RR2) closed completes a circuit to shut-off solenoid (SS) until pressure switch (PSW) opens. (RR1) open de-energizes arming relay (AR) and dual speed switch (DSS).

Diode (D1) helps prevent electrical sparks (arcing) at the contacts in the shut-off solenoid circuit, when the shut-off solenoid is de-energized.

Engine fault light (ENFL) and the indicating relay for the fault condition will give light. To start the engine, do the steps that follow.

1. Turn engine control switch (ACS) to OFF or STOP.

This will prevent the engine from starting if (ENFL) is pushed.

NOTE: For start up when (OCIR) indicating relay gives light, make reference to ENGINE DOES NOT START.

2. Correct the problem that caused the engine to shutdown.

3. Push and release engine fault light (ENFL). This will open (ENFL) contacts for a moment and de-energize the indicating relay. The indicating relay contacts will open and de-energize engine fault light (ENFL) and shutdown relay (SR).

NOTE: Reset oil pressure or overspeed switch if necessary. The system is ready to start if engine control switch (ACS) is turned to MAN or AUTO.

CONTROL PANEL
AUTOMATIC POSITION-SHUTDOWN (HIGH WATER TEMPERATURE)

Generator Mounted Control Panel (Type 4 - Change Level 9 Thru 11)

Introduction

The uses of the generator mounted control panel are:

To help control the electric power made by the generator set.

To monitor (check) the operation of the generator set.

To help protect the generator set from damage caused by low oil pressure, high coolant temperature, overspeed and overcrank.

To help with the transfer of electrical load to and from the generator set.

To help parallel two or more units onto the same bus.

Identification

The location of the control panel is on the top of the regulator housing. This panel has a place for a heat switch and prealarm module. The shutdown indicators are relay lamp type. The control panel has either a 12 or 13 place model number on the panel nameplate. The model number gives an indication of the control panel component part numbers. Make reference to the Parts Book, GENERATOR MOUNTED CONTROL PANEL, Form No. SEBP1068. The last digit (or two digits) of the model number is the change level to which the panel was built.

Wiring

See the pages that follow for wiring diagrams, schematics and photographs for identification.

GENERATOR TERMINAL STRIP TS1, REGULATOR TERMINAL STRIP TS3. GENERATOR, CURRENT TRANSFORMERS AND CIRCUIT BREAKER

A AMMETER (CONTROL PANEL MOUNTED)

ALT CHARGING ALTERNATOR (NOTE H)

APR ANNUNCIATOR PANEL - REMOTE

ARX AUXILIARY RELAY MODULE (CONTROL PANEL MOUNTED)

AUX AUXILIARY CONTACT (NOTE F)

B+ BATTERY POSITIVE

B- BATTERY NEGATIVE

BATT BATTERY

CB CIRCUIT BREAKER

CCM CYCLE CRANKING MODULE (CONTROL PANEL MOUNTED)

CT CURRENT TRANSFORMER

CTS CRANK TERMINATE SWITCH

DSS DUAL SPEED SWITCH

GS GOVERNOR SWITCH (CONTROL PANEL MOUNTED)

GSM GOVERNOR SYNC MOTOR

HS HEAT SWITCH (CONTROL PANEL MOUNTED)

LFS LOW FUEL LEVEL SWITCH

LWT LOW WATER TEMP SWITCH

MS MAGNETIC SWITCH (CRANK CIRCUIT)

MSG MAGNETIC SWITCH (GLOW PLUG CIRCUIT)

OCI OVERCRANK INDICATOR

OP OIL PRESSURE GAUGE SENDER

OPI LOW OIL PRESSURE INDICATOR

OPP OIL PRESSURE SWITCH (PRE-ALARM)

OPS OIL PRESSURE SWITCH (SHUTDOWN)

OSI OVERSPEED INDICATOR

OSS OVERSPEED SWITCH (SHUTDOWN)

PAM PREALARM MODULE (CONTROL PANEL MOUNTED)

PS PINION SOLENOID

PSW PRESSURE SWITCH

SS SHUTOFF SOLENOID

SM STARTING MOTOR

TS TERMINAL STRIP

WT WATER TEMPERATURE GAGE SENDER

WTI HIGH WATER TEMPERATURE INDICATOR

WTP WATER TEMPERATURE SWITCH (PRE-ALARM)

WTS WATER TEMPERATURE SWITCH (SHUTDOWN)

CONTROL PANEL COMPONENTS (PARTIAL) AND CONTROL PANEL TERMINAL STRIP TS2

NOTE A: Wire and cable shown dotted to be furnished by customer.

NOTE B: To be wired to engine starting contact (N.O.) in auto transfer switch by customer.

NOTE C: Each wire on terminal strip is identified on each end - corresponding to terminal strip number.

NOTE D: Remove yellow wire and insulate from terminal 7 at TS3 before connecting wire from TS2.

NOTE E: Use 3 wire diagram with sodine 3 wire synchronizing motor. Use 2 wire diagram with 2 wire permanent magnet motor.

NOTE F: To be wired to auxiliary contact (N.O.) on emergency side of transfer switch. Req'd only when optional generator set annunciator panel (remote) is provided. (generating indication).

NOTE G: Red jumper wire from TS2-4A to TS2-4 must be removed when cycle cranking module is used.

NOTE H: Do not operate alternator without a battery connected in the system. Do not polarize alternator. Do not operate alternator simultaneously with a DC generator to charge a common battery.

NOTE I: Provides 24 volts for remote low oil pressure (pre-alarm) (OPP) indication when pre-alarm module is used.

NOTE J: Provides 24V for customer provided remote shutdown and pre-alarm indicator when pre-alarm module is used.

CONTROL PANEL
AUTOMATIC POSITION

RELAY CONTACT SCHEMATIC

RELAY LAMP COMPONENT WIRING

RELAY LAMP SCHEMATIC

Components

NOTE: For specifications on components located on the engine, make reference to the ENGINE SERVICE MANUAL.

CONTROL PANEL (TYPE 4 - CHANGE LEVEL 9 THRU 11)

ACA Alternating current ammeter

ACS Engine control switch

ACV Alternating current voltmeter

AVS Ammeter/voltage selector switch

FM Frequency meter

PL1,2 Panel lamps

PLS Panel lamp switch

OCI Overcrank indicator

OPG Oil pressure gauge

OPI Oil pressure indicator

OSI Overspeed indicator

WTG Water temperature gauge

WTI Water temperature indicator

VLR Voltage level rheostat

1. Button (Direct current ammeter DCA)

2. Button (heat switch HS, if so equipped)

3. Panel (prealarm module PAM, if so equipped)

INSIDE CONTROL PANEL (TYPE 4 - CHANGE LEVEL 9 THRU 11)
4. Location for CDT (cool down timer, if so equipped). 5. Location for AUX (auxiliary relay, if so equipped). 6. Location for CCM (cycle crank module, if so equipped).

ACA Alternating Current Ammeter

AC ammeter (ACA) gives an indication, in amperes, of the current from each phase of the generator to the load. Ammeter/voltmeter selector switch (AVS) is used to connect the ammeter to the current transformer on phase T1, T2 or T3; see Contact Chart. Ammeters normally have an input range from 0 to 5 amperes. Current transformer (CT1, CT2 or CT3) causes a reduction of the actual line current, in its respective phase lead, to a level within the input range of the ammeter. The ammeter is calibrated (has marks) to give an indication of the actual current flow in one phase load of the generator.

NOTE: Several methods have been used to connect control panel instruments. The recommended method is shown in the diagrams.

AMMETER/VOLTMETER SELECTOR SWITCH (AVS) WIRING DIAGRAMS

NOTE: X gives an indication of a closed contact, X on the line gives an indication of "make before break."

ACS Engine Control Switch

Engine control switch (ACS) controls the engine start and stop systems. To start the engine, move the switch to the MANUAL position. To stop the engine move the switch to the STOP or OFF/RESET position. For standby application (engine starts when remote initiating contact I closes), move the switch to the AUTO position. To start after engine shutdown caused by high water temperature, low oil pressure or overspeed, turn switch to STOP position and correct fault. Then move switch to OFF/RESET position. Engine can now be started in MANUAL or AUTO position. For more information on the operation of this switch, make reference to the AUTOMATIC START/STOP SYSTEM.

NOTE: X gives an indication of a closed contact, X on the line gives an indication of "make before break."

ACV Alternating Current Voltmeter

AC voltmeter (ACV) shows the potential differential (voltage) between phase T1-T2, T2-T3 or T3-T1 at position 1, 2 or 3 respectively. Make reference to the ALTERNATING CURRENT AMMETER.

DCA Direct Current Ammeter

DC Ammeter (DCA) is used in place of button (1) when the ammeter is ordered. This ammeter shows the amount of DC current in amperes, that flows in the alternator circuit (if so equipped).

FM Frequency Meter

Frequency meter (FM) shows the hertz (cycles per second) of the electricity made when the generator set is in operation. There is a direct relation between the frequency of the electricity and the rpm of the generator set; see formula.

GS Governor Switch

Governor switch (GS) is used when the engine is equipped with a remote control synchronizing motor for the governor. Engine speed is controlled with this switch.

HS Heat Switch

Heat switch (HS) is in place of button (2) when the engine is equipped with glow plugs. This switch is used to operate the glow plugs for cold weather starting.

OPG Oil Pressure Gauge

Oil pressure gauge (OPG) shows the pressure, in psi, of engine lubrication oil. When pressure switch (PSW) is closed, oil pressure gauge (OPG) is connected across battery voltage. There is a relation between the current flow in this circuit and the engine oil pressure read on oil pressure gauge (OPG). Oil pressure sender (OP) controls the current flow by a change in resistance according to the change in engine oil pressure.

PAM Prealarm Module

Make reference to ATTACHMENTS.

PL1, 2 Panel Lamps

Light for the control panel is given by panel lamps (PL1 and PL2). These lamps are controlled by panel light switch (PLS).

VLR Voltage Level Rheostat

Voltage level rheostat (VLR) takes the place of voltage level rheostat (R2) on the generator regulator assembly. It is used to adjust the voltage output of the generator.

NOTE: Make reference to OPERATION OF GENERATOR; REGULATOR ADJUSTMENT. On generators equipped with a generator mounted control panel, the yellow wire from voltage level rheostat (R2) to terminal (7) on the regulator terminal strip is disconnected at terminal (7).

Automatic Start/Stop System

Introduction

The automatic start/stop system is normally used for standby operation. That is, without an operator. The generator set must start, pick up the load, operate the load, and stop after the load is removed. An automatic transfer switch controls the transfer of load to and from the generator set. When normal (commercial) power has a failure, initiating contactor (I), part of the automatic transfer switch, closes. This will begin the automatic start sequence. When the engine starts, the control panel instruments will show voltage and frequency. The automatic transfer switch will transfer the load to the generator set when voltage and frequency reach approximately rated value. When normal power returns, the automatic transfer switch will transfer the load back to normal power. Initiating contactor (I) will open. This will begin the automatic stop sequence. The generator set will also stop automatically if the engine has a failure.

NOTE: For specifications on components located on the engine, make reference to the ENGINE SERVICE MANUAL.

Automatic Start

CONTROL PANEL
AUTOMATIC POSITION-ENGINE CRANKS

With engine control switch (ACS) in the AUTO position, contacts (10) and (9) are closed. When commercial (normal) power has a failure, remote start initiating contact (I) closes. This makes a complete circuit from battery (BATT) to energize run relay (RR) and magnetic switch (MS).

When run relay (RR) is energized, contacts (RR2) open and contacts (RR1) close. (RR2) open prevents current flow to shutoff solenoid (SS) through pressure switch (PSW). (RR1) closed energizes dual speed switch (DSS) and overcrank timer (OCT).

When dual speed switch (DSS) is energized, a magnetic pickup relays engine rpm to the switch. The dual speed switch has a crank terminate (CTS) circuit and an overspeed (OSS) circuit.

When overcrank timer (OCT) is energized, a timer will start. After the engine cranks for approximately 30 seconds the timer will stop. (OCT) contacts will close. Make reference to ENGINE DOES NOT START.

When magnetic switch (MS) is energized, (MS) contacts close and pinion solenoid (PS) is energized. This causes (PS) contacts to close, starting motor (SM) will crank the engine. (PSW) will close. This energizes water temperature gauge (WTG) and oil pressure gauge (OPG).

Manual Start

The current flow for manual start is similar to automatic start except engine control switch (ACS) is turned to the MAN position. Contact (10) is open and contact (11) is closed. It is not necessary for remote start indicating contact (I) to close. Run relay (RR) and magnetic switch (MS) will energize as soon as contact (11) is closed.

Engine Starts

At 600 rpm, crank terminate switch (CTS) closes. Oil pressure increases. This activates oil pressure switch (OPS). The normally closed contact opens and the normally open contact closes. The arming relay (AR) is now connected across battery voltage. Contacts (AR1) close and lock in the arming relay. Contacts (AR2) open. This de-energizes magnetic switch (MS). (MS) contacts open to de-energize pinion solenoid (PS). (PS) contacts open to de-energize starting motor. Contacts (AR3) open to de-energize overcrank timer (OCT).

CONTROL PANEL
AUTOMATIC POSITION-ENGINE STARTS

Engine Does Not Start

If the engine does not start in approximately 30 seconds, overcrank timer (OCT) will let current flow to overcrank indicating relay (OCIR). (OCIR) contacts close to lock in the (OCIR) relay and close shutdown relay (SR).

(SR) contacts open. This de-energizes run relay (RR) and magnetic switch (MS).

When run relay (RR) is de-energized, contacts (RR2) close and contacts (RR1) open. (RR2) closed completes a circuit to shutoff solenoid (SS) until pressure switch (PSW) opens. (RR1) open de-energizes arming relay (AR), dual speed switch (DSS) and overcrank timer (OCT).

NOTE: Pressure switch (PSW) is not always closed when the engine cranks. Pressure caused by starting motor rotation of the engine is not always enough to close (PSW).

When magnetic switch (MS) is de-energized, (MS) contacts open. This de-energizes pinion solenoid (PS). (PS) contacts open and de-energize starting motor (SM).

Overcrank indicating relay (OCIR) will give light. To start the engine, do the steps that follow:

1. Turn engine control switch (ACS) to OFF/RESET. This will open (ACS) contact (15) and de-energize overcrank indicating relay (OCIR). (OCIR) contacts will open and de-energize the shutoff relay (SR).

2. Turn the engine control switch to MANUAL or AUTO if I contact is closed. If the engine does not start in approximately 30 seconds, the overcrank indicating relay will give light.

3. Turn engine control switch (ACS) to STOP position. Observe fault lights and turn ACS to OFF/RESET. Correct the problem that caused the engine not to start. Make reference to TROUBLESHOOTING.

CONTROL PANEL
AUTOMATIC POSITION-ENGINE DOES NOT START

Return of Commercial (Normal) Power

When commercial power returns, the automatic transfer switch transfers the load to commercial power. Remote start initiating contacts (I) open. This de-energizes run relay (RR).

When run relay (RR) is de-energized, contacts (RR2) close and contacts (RR1) open. (RR2) closed completes a circuit to shut-off solenoid (SS). The shut-off solenoid moves the rack to the fuel OFF position. After the engine stops (PSW) will open to de-energize the shut-off solenoid. (RR1) open de-energizes arming relay (AR) and dual speed switch (DSS).

Diode (D1) is in the shut-off solenoid circuit to help prevent electrical sparks (arcing), at the shut-off solenoid contacts, when the shut-off solenoid is de-energized.

CONTROL PANEL
AUTOMATIC POSITION-AUTOMATIC SHUTDOWN

Manual Shutdown

When engine control switch (ACS) is turned to the STOP position or OFF/RESET position, contacts (10 and 11) are open. With contacts (10 and 11) open, the run relay (RR) de-energizes. In addition, the STOP position closes contacts (5 and 8). This provides another path to the shutoff solenoid (SS).

When run relay (RR) is de-energized, contact (RR2) closes and contact (RR1) opens. With (RR2) closed, it completes a circuit to the shut-off solenoid (SS). If the STOP position is used, closed contact (RR2) completes a parallel circuit to shutoff solenoid (SS). (This parallel circuit is necessary to stop the engine when the engine control switch is in the AUTO or MAN position.) After the engine stops, (PSW) will open to de-energize the shutoff solenoid. With contact (RR1) open, the arming relay (AR) and the dual speed switch (DSS) are de-energized.

Diode D1 helps prevent electrical sparks (arcing) at the contacts in the shutoff solenoid circuit when the shutoff solenoid is de-energized.

CONTROL PANEL
STOP POSITION-MANUAL SHUTDOWN

Shutdown Caused by Engine Failure

The packaged generator set has shutdown sensors, shutdown indicators and shutdown circuit for the conditions that follow.

1. Low oil pressure

2. High water temperature

3. Overspeed

4. Overcrank

For information about overcrank shutdown, make reference to ENGINE DOES NOT START.

Conditions (1, 2 or 3) will energize its respective indicating relay. The number (2) contacts of the respective relay will close to energize shut-off relay (SR). The number (1) contacts of the respective relay will close to lock in the relay.

When shutdown relay (SR) is energized, (SR) contacts open. This de-energizes run relay (RR). Contacts (RR2) close and contacts (RR1) open. (RR2) closed completes a circuit to shut-off solenoid (SS) until pressure switch (PSW) opens. (RR1) open de-energizes arming relay (AR) and dual speed switch (DSS).

Diode (D1) helps prevent electrical sparks (arcing) at the contacts in the shut-off solenoid circuit, when the shut-off solenoid is de-energized.

Indicating relay for the fault condition will give light. To start the engine, do the steps that follow.

1. Turn engine control switch (ACS) to OFF or STOP.

NOTE: For start up when (OCIR) indicating relay gives light, make reference to ENGINE DOES NOT START.

2. Correct the problem that caused the engine to shutdown.

3. Rotate ACS to OFF/RESET position. This de-energizes the indicating relay. The indicating relay contacts will open and de-energize the shutdown relay (SR).

NOTE: Reset oil pressure or overspeed switch if necessary. The system is ready to start if engine control switch (ACS) is turned to MAN or AUTO.

CONTROL PANEL
AUTOMATIC POSITION-SHUTDOWN (HIGH WATER TEMPERATURE)

Generator Mounted Control Panel - (Type 5 - Change Level 12)

Introduction

The uses of the generator mounted control panel are:

To help control the electric power made by the generator set.

To monitor (check) the operation of the generator set.

To help protect the generator set from damage caused by low oil pressure, high coolant temperature, overspeed and overcrank.

To help with the transfer of electrical load to and from the generator set.

To help parallel two or more units onto the same bus.

Identification

The location of the control panel is on the top of the regulator housing. This panel has a place for a heat switch and prealarm module. The shutdown indicators are relay lamp type. The control panel has a 13 place model number on the panel nameplate located inside bottom surface of control panel. The model number gives an indication of the control panel component part numbers. Make reference to the Parts Book, GENERATOR MOUNTED CONTROL PANEL, Form No. SEBP1068. The last two digits of the model number are the change level to which the panel was built.

Wiring

See the pages that follow for wiring diagrams, schematics and photographs for identification.

REMOTE AND ENGINE MOUNTED ELECTRICAL COMPONENTS

GENERATOR TERMINAL STRIP TS1, REGULATOR TERMINAL STRIP TS3, GENERATOR, CURRENT TRANSFORMERS AND CIRCUIT BREAKER.

A AMMETER (CONTROL PANEL MOUNTED)

ALT CHARGING ALTERNATOR (NOTE H)

APR ANNUNCIATOR PANEL - REMOTE

ARX AUXILIARY RELAY MODULE (CONTROL PANEL MOUNTED)

ASO AIR SHUT-OFF SOLENOID

AUX AUXILIARY CONTACT (NOTE F)

B+ BATTERY POSITIVE

B- BATTERY NEGATIVE

BATT BATTERY

CB CIRCUIT BREAKER

CCM CYCLE CRANKING MODULE (CONTROL PANEL MOUNTED)

CDT COOL DOWN TIMER (CONTROL PANEL MOUNTED)

CT CURRENT TRANSFORMER

CTS CRANK TERMINATE SWITCH

DSS DUAL SPEED SWITCH

GS GOVERNOR SWITCH (CONTROL PANEL MOUNTED)

GSM GOVERNOR SYNC MOTOR

HS HEAT SWITCH (CONTROL PANEL MOUNTED)

LFS LOW FUEL LEVEL SWITCH

LWT LOW WATER TEMP SWITCH

MS MAGNETIC SWITCH (CRANK CIRCUIT)

MSG MAGNETIC SWITCH (GLOW PLUG CIRCUIT)

OCI OVERCRANK INDICATOR

OP OIL PRESSURE GAUGE SENDER

OPI LOW OIL PRESSURE INDICATOR

OPP OIL PRESSURE SWITCH (PREALARM)

OPS OIL PRESSURE SWITCH (SHUTDOWN)

OSI OVERSPEED INDICATOR

OSS OVERSPEED SWITCH (SHUTDOWN)

PAM PREALARM MODULE (CONTROL PANEL MOUNTED)

PS PINION SOLENOID

SS SHUTOFF SOLENOID

SM STARTING MOTOR

TD TIME DELAY RELAY

TS TERMINAL STRIP

WT WATER TEMPERATURE GAGE SENDER

WTI HIGH WATER TEMPERATURE INDICATOR

WTP WATER TEMPERATURE SWITCH (PRE-ALARM)

WTS WATER TEMPERATURE SWITCH (SHUTDOWN)

CONTROL PANEL COMPONENTS (PARTIAL) AND CONTROL PANEL TERMINAL STRIP TS2

NOTE: A: Wire and cable shown dotted to be furnished by customer.

NOTE B: To be wired to engine starting contact (N.O.) in auto transfer switch by customer.

NOTE C: Each wire on terminal strip is identified on each end - corresponding to terminal strip number.

NOTE D: Remove yellow wire and insulate from terminal 7 at TS3 before connecting wire from TS2.

NOTE E: Use 3 wire diagram with Bodine 3 wire synchronizing motor. Use 2 wire diagram with 2 wire permanent magnet motor.

NOTE F: To be wired to auxiliary contact (N.O.) on emergency side of transfer switch. Required only when optional generator set annunciator panel (remote) is provided. (Generating indication).

NOTE G: Red jumper wire from TS2-4A to TS2-4 must be removed when cycle cranking module is used.

NOTE H: Do not operate alternator without a battery connected in the system. Do not polarize alternator. Do not operate alternator simultaneously with a DC generator to charge a common battery.

NOTE I: Provides 24 volts for remote low oil pressure (pre-alarm) (OPP) indication when pre-alarm module is used.

NOTE J: Provides 24V for customer provided remote shutdown and pre-alarm indicator when pre-alarm module is used.

NOTE K: Jumper wire from TS2-72 to TS2-73 must be removed when ammeter is used.

NOTE L: Jumper wire from TS2-13 to TS2-133 to be removed if additional fault shutdowns are added. Example: Reverse power relay or remote shutdown.

NOTE M: When adding the engine cool down timer option, wires from TS1-13 and TS1-14 should be reconnected to CDT-3 and CDT-2.

RELAY CONTACT SCHEMATIC

RELAY LAMP COMPONENT WIRING

RELAY LAMP SCHEMATIC

Components

NOTE: For specifications on components located on the engine, make reference to the ENGINE SERVICE MANUAL.

PANEL DOOR (TYPE 5 - CHANGE LEVEL 12) (FRONT VIEW)

PANEL DOOR (TYPE 5 - CHANGE LEVEL 12) (TOP VIEW WITH DOOR OPEN)

LOGIC PANEL (TYPE 5 - CHANGE LEVEL 12) (FRONT VIEW INSIDE PANEL)

1. 60 AMP CIRCUIT BREAKER (ALTERNATOR)

2. 20 AMP CIRCUIT BREAKER (AIR SHUT-OFF)

3. 10 AMP CIRCUIT BREAKER (CONTROL)

4. 20 AMP CIRCUIT BREAKER (SHUTDOWN)

A AMMETER

ACA ALTERNATING CURRENT AMMETER

ACS ENGINE CONTROL SWITCH

ACV ALTERNATING CURRENT VOLTMETER

AVS AMMETER/VOLTAGE SELECTOR SWITCH

CDT COOL DOWN TIMER

CDTR COOL DOWN TIMER RELAY

CCM CYCLE CRANKING MODULE

CCT CYCLE CRANKING RELAY

F1 FUSE

F2 FUSE

F3 FUSE

FM FREQUENCY METER

GS GOVERNOR SWITCH

HS HEAT SWITCH

OCI OVERCRANK INDICATOR

OCIR OVERCRANK INDICATOR RELAY

OCT OVERCRANK TIMER

OPG OIL PRESSURE GAUGE

OPI OIL PRESSURE INDICATOR

OPIR OIL PRESSURE INDICATOR RELAY

OSI OVERSPEED INDICATOR

OSIR OVERSPEED INDICATOR RELAY

PAM PREALARM MODULE

PL1, 2 PANEL LAMPS

PLS PANEL LAMP SWITCH

WTG WATER TEMPERATURE GAUGE

WTI WATER TEMPERATURE INDICATOR

WTIR WATER TEMPERATURE INDICATOR RELAY

VLR VOLTAGE LEVEL RHEOSTAT

ACA Alternating Current Ammeter

AC ammeter (ACA) gives an indication, in amperes, of the current from each phase of the generator to the load. Ammeter/voltmeter selector switch (AVS) is used to connect the ammeter to the current transformer on phase T1, T2 or T3; see Contact Chart. Ammeters normally have an input range from 0 to 5 amperes. Current transformer (CT1, CT2 or CT3) causes a reduction of the actual line current, in its respective phase lead, to a level within the input range of the ammeter. The ammeter is calibrated (has marks) to give an indication of the actual current flow in one phase load of the generator.

NOTE: Several methods have been used to connect control panel instruments. The recommended method is shown in the diagrams.

(600V Control Panel Only)

AMMETER/VOLTMETER SELECTOR SWITCH (AVS) WIRING DIAGRAMS

NOTE: X gives an indication of a closed contact, X on the line gives an indication of "make before break."

ACS Engine Control Switch

Engine control switch (ACS) controls the engine start and stop systems. To start the engine, move the switch to the MANUAL position. To stop the engine move the switch to the STOP or OFF/RESET position. For standby application (engine starts when remote initiating contact I closes), move the switch to the AUTO position. To start after engine shutdown caused by high water temperature, low oil pressure or overspeed, turn switch to STOP position and correct fault. Then move switch to OFF/RESET position. Engine can now be started in MANUAL or AUTO position. For more information on the operation of this switch, make reference to the AUTOMATIC START/STOP SYSTEM.

NOTE: X gives an indication of a closed contact, X on the line gives an indication of "make before break."

ACV Alternating Current Voltmeter

AC voltmeter (ACV) shows the potential differential (voltage) between phase T1-T2, T2-T3 or T3-T1 at position 1, 2 or 3 respectively. Make reference to the ALTERNATING CURRENT AMMETER.

DCA Direct Current Ammeter

DC Ammeter (DCA) is used when the ammeter is ordered. This ammeter shows the amount of DC current in amperes, that flows in the alternator circuit (if so equipped).

FM Frequency Meter

Frequency meter (FM) shows the hertz (cycles per second) of the electricity made when the generator set is in operation. There is a direct relation between the frequency of the electricity and the rpm of the generator set; see formula.

GS Governor Switch

Governor switch (GS) is used when the engine is equipped with a remote control synchronizing motor for the governor. Engine speed is controlled with this switch.

HS Heat Switch

Heat switch (HS) is when the engine is equipped with glow plugs. This switch is used to operate the glow plugs for cold weather starting.

OPG Oil Pressure Gauge

Oil pressure gauge (OPG) shows the pressure, in psi, of engine lubrication oil. When pressure switch (PSW) is closed, oil pressure gauge (OPG) is connected across battery voltage. There is a relation between the current flow in this circuit and the engine oil pressure read on oil pressure gauge (OPG). Oil pressure sender (OP) controls the current flow by a change in resistance according to the change in engine oil pressure.

PAM Prealarm Module

Make reference to ATTACHMENTS.

PL1, 2 Panel Lamps

Light for the control panel is given by panel lamps (PL1 and PL2). These lamps are controlled by panel light switch (PLS).

VLR Voltage Level Rheostat

Voltage level rheostat (VLR) takes the place of voltage level rheostat (R2) on the generator regulator assembly. It is used to adjust the voltage output of the generator.

NOTE: Make reference to OPERATION OF GENERATOR; REGULATOR ADJUSTMENT. On generators equipped with a generator mounted control panel, the yellow wire from voltage level rheostat (R2) to terminal (7) on the regulator terminal strip is disconnected at terminal (7).

Automatic Start/Stop System

Introduction

The automatic start/stop system is normally used for standby operation. That is, without an operator. The generator set must start, pick up the load, operate the load, and stop after the load is removed. An automatic transfer switch controls the transfer of load to and from the generator set. When normal (commercial) power has a failure, initiating contactor (I), part of the automatic transfer switch, closes. This will begin the automatic start sequence. When the engine starts, the control panel instruments will show voltage and frequency. The automatic transfer switch will transfer the load to the generator set when voltage and frequency reach approximately rated value. When normal power returns, the automatic transfer switch will transfer the load back to normal power. Initiating contactor (I) will open. This will begin the automatic stop sequence. The generator set will also stop automatically if the engine has a failure.

The packaged generator set has shutdown sensors, shutdown indicators and shutdown circuit for the conditions that follow.

1. Low oil pressure

2. High water temperature

3. Overspeed

4. Overcrank

NOTE: For specifications on components located on the engine, make reference to the ENGINE SERVICE MANUAL.

Automatic Start

With engine control switch (ACS) in the AUTO position, contacts (10) and (9) are closed. When commercial (normal) power has a failure, remote start initiating contact (I) closes. This makes a complete circuit from battery (BATT) to energize run relay (RR) through normally closed contacts of the four engine fault relays (OPR), (WTRI), (OSRI), (OCR).

When run relay (RR) is energized, contact (RR2) opens and contact (RR1) closes. (RR2) open prevents current flow to shutoff solenoid (SS). (RR1) closed energizes the (MS) through a normally closed (AR2) contact. At the same time power is applied to the overcrank timer (OCT). A magnetic pickup relays engine rpm to the dual speed switch (DDS). The dual speed switch has a crank terminate (CTS) circuit and an overspeed (OSS) circuit.

When overcrank timer (OCT) is energized, a timer will start. After the engine cranks for approximately 30 seconds the timer will stop. (OCT) contacts will open. Make reference to ENGINE DOES NOT START.

When magnetic switch (MS) is energized, (MS) contacts close and pinion solenoid (PS) is energized. This causes (PS) contacts to close, starting motor (SM) will crank the engine.

Manual Start

The current flow for manual start is similar to automatic start except engine control switch (ACS) is turned to the MAN position. Contact (10) is open and contact (11) is closed. It is not necessary for remote start indicating contact (I) to close. Run relay (RR) and magnetic switch (MS) will energize the same as with Automatic Start.

CONTROL PANEL AUTO POSITION (ENGINE CRANKS)

Engine Starts

At 600 rpm, crank terminate switch (CTS) closes. This energizes the arming relay (AR). Contact (AR2) opens which disconnects the circuit to (MS) and the overcrank timer (OCT). The contact (AR1) closes to lock in the (AR) relay. Contact (AR3) closes to turn on the water temperature and oil pressure gauges.

At this same time, the (CTS) contact arms the time delay relay (TDR). The TDR has a fixed 9 second delay to allow for oil pressure build up. When oil pressure comes up, it actuates the oil pressure switch (OPS). The (OPS) contact clears the failure circuit and closes the (TDR) timer bypass contact.

When the TDR contact closes, it energizes the time delay auxiliary (TDX). The TDX arms the oil pressure failure circuit along with the shut-off solenoid (SS) and the optional air shut-off solenoid (ASO).

CONTROL PANEL AUTO POSITION (ENGINE STARTS)

Engine Does Not Start

If the engine does not start in approximately 30 seconds, overcrank timer (OCT) will let current flow to overcrank indicating relay (OCR). Contact (OCR2) closes to lock in the (OCR) relay and contact (OCR1) opens to open the RR relay circuit. This de-energizes run relay (RR) and magnetic switch (MS).

When run relay (RR) is de-energized, contact (RR2) closes and contact (RR1) opens. Contact (RR2) closed completes a circuit to shutoff solenoid (SS) until TDX opens.

NOTE: TDR contact closes after 9 seconds into the 30 second cranking cycle. The TDX relay in turn energizes. This causes the TDX contacts to close. The TDX contacts will remain closed for 70 seconds after the end of the 30 second cranking cycle.

Contact (RR1) open de-energizes arming relay (AR), and overcrank timer (OCT).

When magnetic switch (MS) is de-energized, (MS) contacts open. This de-energizes pinion solenoid (PS). (PS) contacts open and de-energize starting motor (SM).

Overcrank indicating relaying (OCR) will give light. To start the engine, do the steps that follow:

1. Turn engine control switch (ACS) to OFF/RESET. This will open (ACS) contact (IS) and de-energize overcrank indicating relay (OCR). Contact OCR1 will close so that the run relay (RR) can be energized.

2. Turn the engine control switch to MANUAL or AUTO if I contact is closed. If the engine does not start in approximately 30 seconds, the overcrank indicating relay will give light.

3. Turn engine control switch (ACS) to STOP position. Observe fault lights and turn ACS to OFF/RESET. Correct the problem that caused the engine not to start. Make reference to TROUBLESHOOTING.

NOTE: If the engine can not be started or stopped with the panel controls, check the condition of circuit breaker (CB2). (There is no visual indication of its condition). Press to reset.

CONTROL PANEL AUTOMATIC POSITION (ENGINE DOES NOT START)

Return of Commercial (Normal) Power

When commercial power returns, the automatic transfer switch transfers the load to commercial power. Remote start initiating contacts (I) open. This de-energizes run relay (RR).

When run relay (RR) is de-energized, contacts (RR2) close and contacts (RR1) open. (RR2) closed completes a circuit to shut-off solenoid (SS). The shut-off solenoid moves the rack to the fuel OFF position. (RR1) opens to de-energize the arming relay (AR).

After the engine stops, (TDX) contact will open to de-energize the shut-off solenoid.

NOTE: TDX is operated by the TDR time delay relay. It has a fixed delay on drop out of 70 seconds. This means, the shut-off solenoid will remain energized for 70 seconds each time the unit is shutdown.

Diode (D1) is in the shut-off solenoid circuit to help prevent electrical sparks (arcing), at the shut-off solenoid contacts, when the shut-off solenoid is de-energized.

CONTROL PANEL AUTOMATIC POSITION (AUTO SHUTDOWN)

Manual Shutdown

When engine control switch (ACS) is turned to the STOP position or OFF/RESET position, contacts (10 and 11) are open. With contacts (10 and 11) open, the run relay (RR) de-energizes.

When run relay (RR) is de-energized, contact (RR2) closes and contact (RR1) opens. With (RR2) closed, it completes a circuit to the shut-off solenoid (SS). With contact (RR1) open, the arming relay (AR) is de-energized.

After the engine stops, (TDX) will open to de-energize the shutoff solenoid.

NOTE: TDX will remain closed for 70 seconds after the engine oil pressure switch (OPS) has gone to its normally closed position.

Diode D1 helps prevent electrical sparks (arcing) at the contacts in the shutoff solenoid circuit when the shutoff solenoid is de-energized.

NOTE: The shutdown solenoid (SS) is protected against overload by a circuit breaker (CB1). If the engine does not shut down when the ACS is turned to STOP, check the condition of CB1. Press to reset. [Button does not pop out when breaker is tripped].

CONTROL PANEL STOP POSITION (MANUAL SHUTDOWN)

Engine Shutdown Caused by Water Temperature Failure

When engine coolant temperature becomes too high, the normally open water temperature switch (WTS) closes. This, in turn, energizes the water temperature relay (WTR). Contact (WTR1) closes to lock in the relay (WTR).

The normally closed contact (WTR2) opens. This de-energizes run relay (RR). Contact (RR2) closes and contact (RR1) opens. (RR2) closed completes a circuit to shut-off solenoid (SS) until (TDX) opens (70 seconds after OPS opens). (RR1) open de-energizes the arming relay (AR).

Diode (D1) helps prevent electrical sparks (arcing) at the contacts in the shut-off solenoid circuit, when the shut-off solenoid is de-energized.

The water temperature indicating relay (WTR) will light. To start the engine, do the steps that follow:

1. Turn engine control switch (ACS) to OFF or STOP.

NOTE: For start-up when (OCR) indicating relay gives light, make reference to topic ENGINE DOES NOT START.

2. Correct the high water temperature problem.

3. Rotate ACS to OFF/RESET position. This de-energizes the (WTR). Contact (WTR1) will close to energize the run relay coil. Contact (WTR2) will open to de-energize the shutdown solenoid.

4. The system is ready to start if engine control switch (ACS) is turned to MAN or AUTO.

CONTROL PANEL SHUTDOWN (HIGH WATER TEMPERATURE)

Engine Shutdown Caused by Oil Pressure Failure

Because crank termination is the job of the speed switch (C.T.S.), a time delay relay (TDR) and time delay auxiliary (TDX) is required for oil pressure build-up after start-up.

When the engine is started and C.T.S. (crank termination switch) closes (at 600 rpm), the arming relay (AR) is energized. Contact (AR2) opens to de-energize the starting motor. Contact (AR1) closes to lock-in the (AR) relay. At this same time, (TDR) begins a 9 second delay. If oil pressure comes up and (OPS) goes to the N.O. position, the 9 second delay is bypassed and (TDX) will be energized immediately. At this time, the oil pressure failure circuit is armed thru the (TDX) contact.

NOTE: The shutdown and air shut-off circuits are also armed by TDX.

If a loss of oil pressure occurs, the oil pressure switch (OPS) will close. This causes (OPR) to energize through the contact TDX and diode D1. Then (OPR1) contact opens to de-energize the run relay (RR) circuit. Contact (OPR2) closes to lock-in the relay (OPR) thru the OFF/RESET switch.

The engine will shut down when the normally closed (RR2) contact closes to energize the shutdown solenoid (SS).

If the engine should accidentally be started without oil in the crankcase, it will shutdown after the 9 second delay.

The time delay relay (TDR) also provides a 70 second delay before opening the shutdown and air shut-off solenoids after the engine stops.

CONTROL PANEL OIL PRESSURE FAILURE SHUTDOWN

Shutdown Caused By Overspeed

When the engine is shutdown due to an overspeed condition, the overspeed relay (OSR) is energized and locked in by the overspeed switch (OSS) contact of the dual speed switch (DSS).

The normally closed contact (OSR2) opens to de-energize the run relay (RR). The normally open contact (OSR1) closes to complete a circuit through the closed (TDX1) contact. This energizes the optional air shutoff solenoid (ASO).

Closed contacts (RR2) and (TDX2) will energize the shutdown solenoid (SS). As soon as the oil pressure switch (OPS) starts to close, (TDR) starts a time delay for 70 seconds. After 70 seconds, the (TDR) contact opens and de-energizes relay (TDX). Then all (TDX) contacts open.

To reset the overspeed fault relay, rotate the (ACS) to OFF/RESET. This will de-energize the dual speed switch and permit the OSS contact to open.

Before restarting, check for possible causes of the overspeed.

NOTE: The shutdown solenoid and air shut-off solenoid are each protected with thermal type circuit breakers. If either solenoid does not energize to shutdown, check breaker condition by pressing button to reset.

CONTROL PANEL SHUTDOWN (OVERSPEED)

Generator Mounted Control Panel Attachments

Identification And Location

CONTROL PANEL (FRONT VIEW) (TYPICAL)
A. Ammeter. GS. Governor Switch. HS. Heat switch. PAM. Prealarm Module.

OPEN CONTROL PANEL (TYPE 2)
A. Ammeter. GS. Governor Switch. HS. Heat switch. PAM. Prealarm Module.

OPEN CONTROL PANEL (TYPICAL FOR TYPE 3 AND 4)
1. Location for D.C. ammeter. 2. Location for glow plug heat switch. 3. Location for governor switch. 4. Synchronizing Lights Module.

INSIDE CONTROL PANEL HOUSING (TYPE 2)

AR ARMING RELAY

ARX AUXILIARY RELAY MODULE

CCM CYCLE CRANKING MODULE

CCT CYCLE CRANKING RELAY

CRC CYCLE CRANK LOGIC TIMER

D1-D5 DIODE

F1-F3 FUSE

OCT OVERCRANK TIMER

P1 POTENTIOMETER FOR CRANK TIME

P2 POTNETIOMETER FOR REST TIME

RR RUN RELAY

SR SHUTDOWN RELAY TERMINAL STRIP POINT (CONTROL PANEL)

INSIDE CONTROL PANEL HOUSING (TYPICAL FOR TYPE 3 AND 4)
5. Location for Cool Down Timer (CDT). 6. Location for Cool Down Timer-Relay (CDTR). 7. Location for Auxiliary Relay (AUX). 8. Location for Cycle Crank Relay (CCT). 9. Location for Cycle Cranking Module (CCM). AR. Arming Relay. OCT. Overcrank Timer. RR. Run Relay. SR. Shutdown Relay.

SCHEMATIC OF CONTROL PANEL WITH ALL ATTACHMENTS SHOWN (TYPE 2)
The schematic shows the normal condition of all relays.

SCHEMATIC OF CONTROL PANEL WITH ALL ATTACHMENTS SHOWN (TYPE 3)
The schematic shows the normal condition of all relays.

SCHEMATIC OF CONTROL PANEL WITH ALL ATTACHMENTS SHOWN (TYPE 4)
The schematic shows the normal condition of all relays.

SCHEMATIC OF CONTROL PANEL WITH ALL ATTACHMENTS SHOWN (TYPE 5)
The schematic shows the normal condition of all relays.

Prealarm Module

PREALARM MODULE (PAM)

ADR ALARM DISCONNECT RELAY

ALM ALARM (SONALERT)

D DIODE

HWI HIGH WATER TEMP. INDICATOR

LFI LOW FUEL LEVEL INDICATOR

LFS LOW FUEL LEVEL SWITCH

LOI LOW OIL PRESSURE INDICATOR

LWI LOW WATER TEMPERATURE INDICATOR

LWT LOW WATER TEMPERATURE SWITCH

OPP OIL PRSSURE SWITCH-PRELIMINARY

OPT OIL PRESSURE TIMER

PAL PRELIMINARY ALARM LIGHT

PB ALARM SILENCE PUSH BUTTON

RR RUN RELAY

SR SHUTDOWN RELAY (TYPE 1 THROUGH 4 CONTROL PANELS)

WAR WARNING ALARM RELAY

WTP WATER TEMPERATURE SWITCH-PRELIMINARY TERMINAL BOARD POINT IN PANEL TERMINAL BOARD POINT ON ENGINE ENGINE MOUNTED EQUIPMENT

NOTE A: Terminal (32) is energized by battery positive when the engine cranks. Battery positive is removed when the engine stops.

NOTE B: Terminal (37) can be connected to a remove low lubrication oil pressure indicator installed by the customer.

NOTE C: Type 5 Control Panel requires diodes to sound an alarm on overspeed and overcrank conditions.

PREALARM MODULE (PAM)

The prealarm module fits the requirements in National Fire Protection Association-76A paragraph 631. It fits in the right side of the control panel. The purpose of the prealarm module is to give a warning of conditions that can become a problem before they are serious enough to keep the engine from starting or running. The prealarm module activates its warning system for the following conditions:

When the engine has one of these conditions, the switch which measures it closes. This closes the circuit to the indicator in the control panel for that condition. The indicators are circuit breakers of the push button type. When the circuit breaker first gets the current from the switch, it is in its normally closed position. The circuit is closed to the warning auxiliary relay (WAR) which activates and closes its own hold in circuit and the circuit to the alarm (ALM) which is a warning horn. The circuit breaker activates and opens the circuit to the warning alarm relay (WAR) and closes the circuit to the preliminary alarm light (PAL). This makes the preliminary alarm light (PAL) operate. The preliminary alarm light (PAL) and the alarm (ALM) operate until they are manually disconnected by the operator. The alarm silence push button (PB), when pushed by the operator, closes the circuit to the alarm disconnect relay (ADR). It activates and closes its own hold in circuit. At the same time, it opens the circuit to the alarm (ALM) and to warning alarm relay (WAR). When the circuit to the warning alarm relay (WAR) opens, its contacts move to their normal positions. This disconnects the alarm disconnect relay (ADR). When the operator pushes the push button for the circuit breaker, it disconnects the preliminary alarm light (PAL).

NOTE: If the engine still has the same conditions, the alarm system activates again when the tush button for the circuit breaker is pushed.

The circuit which is between the indicator for low oil pressure in the engine (LOW LUBE PRESSURE PREALARM) and the oil pressure switch-preliminary (OPP) is open until the run relay (RR) contacts and the oil pressure timer (OPT) contacts are closed. The run relay (RR) closes its contacts when the signal to start the engine is felt. The oil pressure timer (OPT) starts to operate at the same time. After approximately 90 seconds, the oil pressure timer (OPT) closes it contacts. The oil pressure switch preliminary (OPP) opens at approximately 19 psi (130 kPa) when the pressure is increasing. It closes at approximately 15 psi (105 kPa) when the pressure is decreasing. If the oil pressure switch-preliminary (OPP) is closed for any reason, it now causes the circuit breaker for the LOW LUBE PRESSURE PREALARM to activate. The alarm system activates normally from this point.

When the engine has a normal shutdown, the circuit to run relay (RR) is disconnected. Run relay (RR) contacts go to the normally open position in the oil pressure circuit. This keeps the oil pressure switch-preliminary (OPP) from activating the low oil pressure indicator (LOI) when the oil pressure decreases because of normal engine shutdown.

The alarm (ALM) in the prealarm module operates when the automatic start-stop system causes shutdown of the engine because of an engine problem. When the shutdown relay (SR) is activated by one of the switches in the automatic start-stop system, some of the contacts close a circuit through terminal 39 which activates the warning alarm relay (WAR). This causes alarm (ALM) to operate. (See Note C.)

NOTE: This does not cause the preliminary alarm light (PAL) to operate.

The alarm silence push button (PB) must be manually operated to stop the operation of the alarm (ALM).

Cycle Cranking Module

NOTE: Jumper between TB2-4 and 4a must be removed when the cycle cranking module is used.

WIRING DIAGRAM

The cycle cranking module (CCM) has a cycle cranking relay (CCT) and a cycle crank logic timer (CRC). The cycle crank relay (CCT) controls the circuit to the magnetic switch (MS) which controls the circuit to the starting motor (SM). The cycle crank logic timer (CRC) controls the cycle crank relay (CCT). The overcrank timer (OCT) controls the time that the cycle crank module (CCM) is activated.

The cycle crank logic timer (CRC) has a CRANK POT (P1) and a REST POT (P2). When the cycle cranking module (CCM) is activated, the cycle crank relay (CCT) is in its normally closed condition. The starting motor activates. At the same time the cycle crank logic timer (CRC) starts to measure the time electronically. The time for operation of the starting motor is controlled by the adjustment of CRANK POT (P1). When the time is done, the cycle crank logic timer (CRC) activates the cycle crank relay (CCT). The cycle crank relay (CCT) opens the circuit that controls the starting motor (SM). At the same time the cycle crank logic timer (CRC) starts to measure the time, according to the adjustment of REST POT (P2). When the time is done, the cycle crank logic timer (CRC) opens the circuit to the cycle crank relay (CCT) and starts to measure time according to CRANK POT (P1) again. The CRANK POT (P1) and REST POT (P2) are each adjusted to 10 seconds at the factory. This series of cycles does not stop until the circuit, which activates the cycle cranking module (CCM), is opened by the shutoff relay (SR) or arming relay (AR).

CYCLE CRANKING MODULE
CCT CYCLE CRANK RELAY
CRC CYCLE CRANK LOGIC TIMER

The overcrank timer (OCT) is adjusted to activate the shutdown relay after a total of 90 seconds when the cycle cranking module (CCM) is installed. When the engine starts the overcrank timer (OCT) and cycle cranking module (CCM) are disconnected by the arming relay (AR).

Heat Switch

NOTE: Available on Type 2, Type 3 and Type 4 control panels.

Heat switch (HS) is used on generator sets equipped with glow plugs. When the heat switch is held closed, magnetic switch (MSG) is energized. This closes magnetic switch contacts and glow plugs (GP) heat the precombustion chambers to aid cold weather starting. When the heat switch is released, the magnetic switch is de-energized and current flow to the glow plugs stops.

Ammeter

NOTE: Available on all control panels.

Ammeter (A) is a DC ammeter used to show the rate of charge or discharge in the alternator circuit. The purpose of the optional alternator circuit is to charge batteries (BATT).

Governor Switch

NOTE: Available on all control panels.

When the engine governor is equipped with a synchronizing motor, governor switch (GS) is used to change engine rpm. Move the switch up to increase rpm, down to decrease rpm.

Auxiliary Relay Module

NOTE: Available on all control panels.

Auxiliary relay module (ARX) is in a parallel circuit with arming relay (AR). The (ARX) coil is energized during engine operation. The auxiliary relay module has both normally open and normally closed contacts. They are available for use as desired by the customer.

AUXILIARY RELAY MODULE (ARX)

Synchronizing Lights Module

NOTE: Available for Type 3 and 4 control panels. This module is located in the same place as prealarm module (PAM).

BACK OF SYNCHRONIZING LIGHTS MODULE

1. Terminal L3.

2. Terminal T1.

3. Terminal L1.

4. Terminal T3.

Terminal T1 (2) connects to a terminal of phase 1 on the generator side of the circuit breaker.

Terminal T3 (4) connects to a terminal of phase 3 on the generator side of the circuit breaker.

Terminal L3 (1) connects to the terminal of phase 3 on the load side of the circuit breaker.

Terminal L1 (3) connects to terminal of phase 1 on the load side of the circuit breaker.

NOTE: IF the synchronizing lights rapidly go ON and OFF, when the engine is running, do not close the circuit breaker. Check for one of the conditions that follow.

Engine speed (frequency) not the same as the load.

Voltage level not the same as the load.

Wires from the synchronizing lights module not correctly connected to the phase terminals on the circuit breaker.

If each light goes ON and OFF, but not at the same time, the phase rotation of the generator is opposite to the phase rotation of the load.

Remote Annunciator Panel

NOTE: Available for all control panels.

If ordered, an annunciator panel is available for installation in an area where the safety indicators on the generator set can be constantly checked. Horn (H) and one of the panel lights (L1 through L4) operate for the following conditions: a safety shutdown caused by low oil pressure, high water temperature, overspeed or overcrank. The horn and a light will also operate to show conditions of low fuel level or low water temperature. The low fuel level light (L5) operates when the fuel supply is only enough to keep the engine running for three hours. The low water temperature light (L6) operates when the water temperature is below 70°F (21°C). This condition shows that the jacket water heater (attachment) is either disconnected or has a failure.

ANNUNCIATOR PANEL

The annunciator panel is also equipped with two lights (L8 and L9) to show high or low battery voltage. The high voltage light (L8) operates when the battery voltage is approximately 29 volts. The low voltage light (L9) operates when the battery voltage is approximately 25 volts. The horn does not operate for a high or low voltage condition. A generating light (L7) is connected to terminal point 38 on the terminal strip in the generator housing. An auxiliary contact (normally open) on the emergency side of the remote transfer switch is connected between terminal point 38 and terminal point 30 on the same terminal strip. When the transfer switch has connected the load to the generator set and the generator is operating, light (L7) will also operate.

To stop the horn from operating, push alarm silence switch (S1). This "turns off" the silicon control rectifier (SCR1). To test the condition of the panel lights, push lamp test switch (S2).