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Contents

OPERATION AND MAINTENANCE MANUAL

for
CUMMINS
POWER GENERATION SYSTEMS
(STANDARD PCC AND PCCP CONTROL SYSTEM)

Publication 3461(GB)
Issue: 4
March 2003

Cummins Power Generation Ltd

Manston Park
Columbus Avenue
Manston, Ramsgate
Kent CT12 5BF
England
Main Office: Tel: +44 (0) 1843 255000
Fax: +44 (0) 1843 255900
Spares Dept: Tel: +44(0) 1843 255575
Fax: +44(0) 1843 255913
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Table of Contents

SECTION TITLE PAGE

PRELIMINARY PAGES
Table of Contents (this page) iii
Guide to Abbreviations iv
Safety Warnings v
Radio Frequency Warning vi
Standards, Codes & Regulations vii
Generator Plant Safety Code viii

1 INTRODUCTION 1-1
2 SYSTEM DESCRIPTION 2-1
3 SYSTEM OPERATION 3-1
4 MAINTENANCE 4-1
5 TROUBLESHOOTING 5-1
6 APPENDICES

Note: A detailed contents page appears at the beginning of each section

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Guide to Abbreviations
AC Alternating Current
ACB Air Circuit Breaker
ACH Anti-Condensation Heaters
AVR Automatic Voltage Regulator
BHP Brake Horsepower
CB Circuit Breaker
dB(A) decibel (‘A’ weighting)
DC Direct Current
DIP Dual In-line Pin
DMC Digital MasterControlTM
EMF Electromotive Force
FSS First Start Sensor
GKWT Global Kilowatt Transducer
HV High Voltage
I/O Input / Output
kVA Apparent Power
kVAR Reactive Power
kW Active / Real Power
kWh Unit of electrical energy or work
LED Light-Emitting Diode
LV Low Voltage
MCCB Moulded Case Circuit Breaker
MF Mains Failed
MFSS Master First Start Sensor
MR Mains Returned
MV Medium Voltage
PCC PowerCommandTM Control
PLC Programmable Logic Controller
PMG Permanent Magnet Generator
PSU Power Supply Unit
PT/CT Potential Transformer / Current Transformer
QCC Quadrature Current Control
RMS Root Mean Square
RPM Revolutions per minute
RTD Resistance Temperature Detector
VAC Volts, Alternating Current
VCB Vacuum Circuit Breaker
VDC Volts, Direct Current

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Safety Warnings
WARNING
It is important to read and understand all safety notices provided in this manual.
Improper operation or maintenance could result in a serious accident, or damage to
the equipment, causing injury or death.

ELECTRICITY
DANGER
ELECTRICITY CAN KILL!
LETHAL VOLTAGES MAY BE PRESENT IN MUCH OF THE EQUIPMENT
REFERRED TO IN THIS MANUAL.

HIGH PRESSURES
DANGER
LIQUIDS OR GASES THAT ARE HIGHLY PRESSURISED CAN GO THROUGH
YOUR SKIN AND INTO YOUR BODY. THEY CAN ALSO BADLY DAMAGE
EQUIPMENT.

MAINTENANCE
WARNING
Maintenance should only be carried out by authorised and qualified maintenance
engineers who are familiar with the equipment and its operation.

DANGER
BEFORE CARRYING OUT ANY MAINTENANCE, ISOLATE ALL SUPPLIES TO
THE GENERATOR AND THE CONTROL PANELS. RENDER THE GENERATOR
INOPERATIVE BY DISCONNECTING THE PLANT BATTERY.

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Radio Frequency

NO RADIO FREQUENCY
COMMUNICATIONS EQUIPMENT
MAY BE OPERATED IN THE
VICINITY OF THIS APPARATUS

The apparatus has been tested according to European Standards EN 50081-2 and EN 50082-2
specifying the limits of Radio Frequency immunity and emissions to meet the essential
requirements of the EMC directive 89/336/EEC.
From these tests the manufacturer has established that as a precaution against undue effects, no
radio frequency communications equipment should be operated at a distance of less than 3 metres
from any part of the apparatus when the generator could, or is relied upon to provide power.
The effective separation distance should be increased if the radio frequency communications
equipment is found to interfere with the apparatus, the onus lies with the customer to effectively test
for adverse effects on the apparatus before usage of the equipment.

Engine Warning
WARNING

DO NOT OPERATE A DIESEL ENGINE WHERE THERE ARE OR CAN BE

COMBUSTIBLE VAPORS. These vapors can be sucked through the air intake system
and cause engine acceleration and over-speeding, which can result in a fire, an
explosion and extensive property damage. Numerous safety devices are vailable,
such as air intake shutdown devices, to minimize the risk of over-speeding where an
engine, due to its application, might operate in a combustible environment, such as
due to a fuel spill or gas leak. Remember, Cummins has no way of knowing the use
you have for your engine. THE EQUIPMENT OWNER AND OPERATOR ARE
RESPONSIBLE FOR SAFE OPERATION IN A HOSTILE ENVIRONMENT. CONSULT
YOUR CUMMINS AUTHORIZED REPAIR LOCATION FOR FURTHER INFORMATION.

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Standards, Codes & Regulations

The generator and its control system are manufactured under a registered quality control system
approved to BS EN ISO 9001 (1994). The following regulations are observed where applicable:
• The Health & Safety at work Act 1974.
• The Control of Substances Hazardous to Health Act 1974, 1988 & 1989.
• IEE Wiring Regulations for Electrical Installations (16th Edition).
• The Electricity at Work Regulations 1989.
• The Environmental Protection Act 1990.
• The Health & Safety at Work Regulations 1992.
• The EMC Directive 89/336/EEC.
• The LV Directive 73/23/EEC.
• The Machinery Directive 89/392/EEC.

STANDARDS
The generator and its control system has been designed, constructed and tested generally in
accordance with the following Standards where applicable:
• BS 4999 General requirements for rotating electrical machines.
(IEC 341)
• BS 5000 Rotating electrical machines of particular types or for particular
(IEC 341) applications.
• BS 5514 Reciprocating internal combustion engines: performance.
(ISO 30462)
• BS 7671 Requirements for electrical installations.
(IEC 3641) IEE Wiring Regulations (sixteenth edition).
• BS 7698 Reciprocating internal combustion engine driven alternating current
(ISO 85282) generating sets.
• BS EN 50081 Electromagnetic compatibility. Generic emission standard.
(EN 500812)
• BS EN 50082 Electromagnetic compatibility. Generic immunity standard.
(EN 500822)
• BS EN 60439 Specification for low-voltage switchgear and control gear
(IEC 4391) assemblies.
(EN 604392)
• BS EN 60947 Specification for low voltage switchgear and control gear.
(IEC 9471)
(EN 609472)

KEY:
1
A related, but not equivalent, standard: A BSI publication, the content of which to any
extent at all, short of complete identity or technical equivalence, covers subject matters
similar to that covered by a corresponding international standard.
2
An identical standard: A BSI publication identical in every detail with a corresponding
international standard.

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Personnel engaged in the installation,

Generator Plant Safety Code

commissioning, operation and maintenance
INTRODUCTION of this equipment must be competent and
Before operating the generator set, read experienced in these fields. They must also
the Operator’s Manual and become familiar comply with all current relevant national and
with it and the equipment. Safe and efficient international statutory requirements and
operation can be achieved only if the regulations.
equipment is properly operated and NOISE
maintained.
! Generating sets emit noise and it is
recommended that the personnel exposed
to noise should wear adequate protection,
Caution / Warning to indicate a risk
eg ear defenders.
of personal injury.
FIRE HAZARDS
Caution / Warning of Pressure ! With the use of fuel, lubricating oils and
Hazard. Indicates a risk of personal batteries there is a fire hazard. Naked
injury from pressurised fluids. flames or sparks should not be allowed
near the generating set, fuel tank and
Caution / Warning of batteries particularly when they are on
charge. Fuel vapours are explosive and
Temperature Hazard. Indicates a
explosive hydrogen is generated by
risk of personal injury from high
batteries during charging.
temperature
! Appropriate fire fighting equipment should
Caution / Warning of Radio be to hand (CO2 or BCF type fire
Frequency Hazard Indicates a risk extinguishers are recommended).
of operating radio frequency
communications equipment in the
! Do not refill the fuel tank when the engine
is running.
vicinity of the plant.

Caution / Warning of High Voltage

Hazard Indicates a risk of personal
injury from electric shock.

Caution / Warning of High Voltage

Hazard Indicates that earth leads
only must be connected at this point.

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EXHAUST GAS HAZARDS ! On automatically / remotely starting plant,

a warning plate advising personnel that the
! Exhaust fumes are toxic and all necessary plant may start automatically without
measures must be taken to ensure that warning should be prominently displayed.
they do not escape or re-circulate into the
plant room or any buildings. ! Appropriate personal protective equipment
should be worn when working on the
HIGH TEMPERATURE HAZARDS generator or any associated equipment.
! Avoid contact with exhaust, radiator and
components likely to become hot when FLUIDS
generator is running. Also avoid contact ! With the use of fuel, lubricating oils,
with hot oil, coolant and exhaust gases. coolant additives and battery electrolyte
! DO NOT attempt to remove a radiator or there is a health risk through exposure to
heat exchanger pressure cap while the these fluids unless protective action is
generator is running. Always allow the taken. Avoid contact and always wear the
generator set to cool before removing. appropriate personal protective equipment.

ELECTRICAL HAZARDS GENERATOR SET WARNING LABELS

! The generator should only be connected to Warning signs are provided on the generator
loads compatible with its electrical at the point of risk. Always take the necessary
characteristics and rated output. precautions indicated by these signs to avoid
injury. A Safety Precautions warning card is
! The generator must be connected to the also provided with each generator.
load only by suitably trained and qualified
engineers who are authorised to do so.
Connection must also be in compliance
with relevant codes and standards.
! Before any maintenance work is carried
out, all ac and dc supplies to the generator
should be isolated, the plant battery
disconnected and suitable warning plates
stating “Maintenance in Progress”
should be displayed prominently.
! The appropriate neutral earthing
requirements must be complied with, or
adequate means incorporated to ensure
that an isolated neutral system is
adequately protected against voltage rises
and undetected earth faults
To prevent irreparable damage to the
battery charging system:
! Never disconnect the battery whilst the
plant is running.
! Never disconnect the charging leads
whilst the plant is running.
Note: The charge alternator output
lead is live at all times.

GENERAL

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SECTION 1

INTRODUCTION

CONTENTS

INTRODUCTION 1-2
GENERAL 1-2
GENERATING SET IDENTIFICATION 1-2
AFTER SALES SERVICES 1-2
Maintenance 1-2
Warranty 1-2
Spares 1-2
Overseas 1-2

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engineers provided by the Customer Service

INTRODUCTION Department.

GENERAL Warranty
Before any attempt is made to operate the All generating Sets have a 12 months
generator, the reader should take time to read warranty from the commissioning date as
this manual and to familiarise him or herself standard. Extended warranty coverage is also
with the Warnings and Operating Procedures. available. In the event of a breakdown, when
prompt assistance can normally be given by
GENERATING SET IDENTIFICATION factory trained service engineers with facilities
Each generating set is provided with a to undertake all minor and many major repairs
Generating Set Rating Plate as shown below. to equipment on site.
This provides information unique to the
generator. Spares
An extensive Spare Parts Department is
available for any emergency breakdown and
for the engineer who carries out his own
routine maintenance.
Please quote Plant Nos., Serial Nos., and
Part Nos. when ordering spares.

Overseas
Agents and representatives in almost 100
countries throughout the world offer
installation and after sales service for the
equipment. Cummins Power Generation can
provide the name and address of its agent for
your specific location.
For details on any of the above services
contact:
Cummins Power Generation Ltd
AFTER SALES SERVICES Manston Park,
Cummins Power Generation offer a full Columbus Avenue,
range of after sales services as follows: Manston, Ramsgate,
Kent. CT12 5BF
Maintenance England.
Tel: +44 (0) 1843-255000
For customers who wish to have their Fax: +44 (0) 1843-255900
generating sets expertly serviced at regular
intervals the Customer Service Department
offers a complete maintenance contract
package. This covers all items subject to
routine maintenance and includes a detailed
report on the condition of the set. In addition,
this can be linked to a 24-hour call-out
arrangement, providing assistance 365 days
a year if necessary. Specialist engineers are
available to maintain optimum performance
levels from customer’s generating sets and it
is recommended that maintenance tasks are
only undertaken by trained and experienced

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SECTION 2

SYSTEM DESCRIPTION

CONTENTS

2. SYSTEM DESCRIPTION 2-3

2.1 Generator Components 2-3
2.1.1 Engine 2-4
2.1.2 Alternator 2-4
2.1.3 Generator Rating 2-4
2.1.4 Generator Construction 2-4
2.1.5 Fuel System 2-4
2.1.6 Cooling System 2-5
2.1.7 Engine Exhaust (Option) 2-5
2.1.8 DC Electrical System 2-5
2.2 Control System 2-6
2.2.1 Control System Components 2-6
2.2.2 Alarm Module (Option) 2-7
2.2.3 Starting Control System 2-8
2.2.4 Customer Connections 2-8
2.2.5 Output Contacts 2-9
2.2.6 DC Power 2-9
2.2.7 Paralleling Protection 2-9
2.2.8 Communications Network (Option) 2-10
2.2.9 Remote Start / Stop Scheduling (Option) 2-10
2.2.10 Earth Fault (Option) 2-10
2.3 Circuit Breakers and Change-over Contactors 2-10
2.3.1 Circuit Breakers (Option) 2-10
2.3.2 Change-over Panel (Option) 2-10
2.4 Heaters 2-11
2.4.1 Coolant Heater (Option) 2-11
2.4.2 Alternator Heater (Option) 2-11
2.5 Mains Powered Battery Charger (Option) 2-12
2.5.1 Operation 2-12
2.5.2 Boost Charge (Option) 2-12

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2. System Description
2.1
2.1 Generator Components
The main components of the Generator System are shown below. Various options are
included. Refer to the Engine and Alternator Manuals for location of other components, eg, oil
filler, dipstick, etc.

Note that the Load Terminal Box, item 9, is mounted optionally on the LH or RH side and
includes the load connection gland plate (with optional entry point location).

KEY:
1. Radiator 9. Load Terminal Box (LH / RH)
2. Exhaust Outlets 10. Bedframe
3. Air Cleaners 11. Alternator
4. Control Housing 12. Starter Motor
5. Load Output Circuit Breaker (LH / RH) 13. Coolant Heater
6. Generating Set Rating Plate (LH / RH) 14. Engine
7. Alarm Module 15. Oil Filters (RH side)
TM
8. PowerCommand Control Panel

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2.1
2.1 .1 Engine
All generators employ a 4-stroke, water-cooled engine and incorporate governor control
and full engine protection system. Refer to the Generating Set Rating Plate and Generator
Set Test Record provided at the rear of this manual for engine type and rating details.
For further information refer to the Engine manufacturer’s manual supplied with this
manual.

2.1
2.1 .2 Alternator
All generator types use ac alternators of a brushless, rotating field design which eliminates
the maintenance associated with slip rings and brushes. Refer to the Generating Set Rating
Plate and Generator Set Test Record provided at the rear of this manual for alternator type
and rating details.
For further information refer to the Alternator manufacturer’s manual supplied with this
manual.

2.1
2.1 .3 Generator Rating
For details of your generator rating refer to the Generating Set Rating Plate, and to the
Generator Test Record provided at the rear of this manual.

2.1
2.1 .4 Generator Construction
Generators are constructed as a single module with the engine and alternator connected
through a coupling chamber with resilient mountings to form one unit. The engine and
alternator are mounted on a bedframe on resilient mountings. This results in one unit of
immense strength and rigidity, with accurate alignment between the engine and alternator,
and effective damping of engine vibration.

2.1
2.1 .5 Fuel System
A base fuel tank formed from fabricated sheet sections can be provided as an option. The
tank is fitted with a large filler cap with in-built coarse filter, and provides a minimum of 8
hours operation at a nominal 100% load.
Free standing main tanks with stands providing 450, 900 and 1350 litre capacity are
available as options.

2. 1 .5 .1 Fuel Transfer Pumps (Option)

Free standing fuel tanks can be filled manually using an optional hand fuel transfer pump.
Alternatively, fuel tanks (base tank or free standing) can be filled automatically using an
electrical fuel transfer pump. This pump, which is supplied complete with starter, operates
under the control of Low and High Fuel Level switches fitted to the tank.
On automatically filled systems, the base tank filler cap is replaced with an overflow /
breather connection to allow piping to a safe area or return to a bulk tank.
2. 1 .5 .2 Fuel / Water Separators (Option)
Optional Set-mounted fuel / water separators are available to provide protection for the
engine fuel injection system where water-free fuel supplies cannot be guaranteed.

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2.1
2.1 .6 Cooling System
The engine cooling system consists of a radiator and pusher fan, mechanically driven
water pump and a thermostat. The fan drives air through the radiator and removes surface
heat from the engine and alternator. The alternator has its own internal cooling fan.

2.1
2.1 .7 Engine Exhaust (Option)
Exhaust systems, which are optional and supplied in loose form, reduce engine noise to
acceptable levels and pipe exhaust gases to an area where they will not present a hazard.
Industrial and residential types are available as options. Flexible bellows are also available as
an option.

2.1
2.1 .8 DC Electrical System
A 12 or 24 volt battery system (determined by generator type) provides multi attempt
engine starting and dc power for the generator control system.

2. 1 .8 .1 Battery System
Battery type, size and voltage are selected to suit the generator capacity and application
on ordering and include lead acid and NiCad types. (All types are options).
Lead acid batteries are Set-mounted. NiCad batteries are free standing.

2. 1 .8 .2 Charge Alternator
An engine driven charge alternator is provided as standard to maintain the battery in a
charged condition when the engine is running.

2. 1 .8 .3 Mains Powered Battery Charger (Option)

Optional single phase, mains powered battery chargers, which can be panel or wall
mounted, are available to maintain the battery in a charged condition when the generator is
not running.

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2.2
2.2 Control System
The main control panel and its associated equipment are located in the Control Housing,
which is mounted on the bedframe at the rear of the genset. A Load Terminal Box will be
mounted on either the left or right side of the housing, as required for the site.
The PowerCommand™ Control (PCC) digital control system effects automatic start-up
and shutdown routines, regulates engine speed and, in the PCCP form provides automatic
paralleling. The PCC also monitors the health of the engine, alternator and auxiliary systems
continuously, and will effect an automatic shutdown if a serious fault occurs.
The PCC control module is provided in two models:
1) PCC model for single gensets and
2) PCCP model for multiple gensets all automatically paralleling to the generator bus.
This manual covers both models of PCC control; the single set and the paralleling version.
The PCC operates in conjunction with an array of sensors and senders located on the
engine, alternator and auxiliary systems. Digital data is passed between digital components
over a digital data link.
An important function of the control system is to continuously monitor the genset for faults.
If a fault occurs during engine running, the PCC will provide an indication for the operator and,
if the fault is serious, effect an automatic, fully programmed, shutdown. One of three fault
level signals are generated by the PCC. The three fault levels are:
“Warning”, signals an imminent or ‘non-fatal’ engine fault. The PCC provides an
indication only for this condition.
“Fault”, a potentially damaging condition, and the PCC will automatically subject the
engine to an off-load, cool-down run then shuts it down.
“Shutdown”, a potentially ‘fatal’ fault for the engine, and the PCC will automatically
take the engine off-load and shut it down immediately, without a cool-down run.
The control systems operate on 12 or 24VDC battery power. Data backup is taken care of
by a small rechargeable battery installed within the PCC enclosure. Auxiliary equipment
operates on LV AC power.

2.2
2.2 .1 Control System Components
2. 2 .1 .1 Control Panel
The main control panel for the genset forms the front panel of a PowerCommand™
Control (PCC) enclosure.

International PCC Panel

(PCCP Model)

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2. 2 .1 .2 Control Modules
Inside the Control Housing are four modules that are required for the operation of the PCC.
The modules are:
PT / CT Module.
Governor Module.
AVR Module (Automatic Voltage Regulator).
Digital I /O Module.

2. 2 .1 .3 Sensors / Senders
Various genset parameters are measured by sensors, senders, RTDs etc and the
resulting signals are applied to the PCC.
Engine-mounted sensors are able to monitor the following systems:
Fuel
Lube Oil
Cooling System
Charge Air / Exhaust
Miscellaneous Areas
Alternator-mounted sensors are able to monitor the following parameters — (option)
Winding Temps

2.2
2.2 .2 Alarm Module (Option)
The Alarm Module provides audible warnings. The front panel has a warning horn, two
indicator lights and one spring loaded push-switch. The two indicator lights, Alarm and Horn
Silenced, show respectively that the horn has been activated and that the adjacent Push to
Silence Horn push-switch has been pressed.

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2.2
2.2 .3 Starting Control System
PowerCommand™ Control uses a multi-function control system which integrates fuel
ramping and field excitation to minimise frequency and voltage overshoot and to limit black
smoke emission on starting. This control system includes the following functions:
Fuel Ramping
Upon receiving the start signal, the digital control system energises the engine fuel system
only enough to allow the engine to start. When the control system senses that the engine has
reached start disconnect speed, it gradually increases fuel flow to ramp up engine speed, for
controlled acceleration up to rated operating conditions. This minimises black smoke
emission and frequency overshoot, as well as improving cold starting capability.
Fail to Crank
As the start signal is initiated, the control system checks the speed monitoring pick-up to
check that the engine is rotating. If the engine is not rotating, the control system switches off
the starter and then makes two further attempts. If the final attempt fails, a shutdown
message is signalled on the alphanumeric display and the genset cannot be started until the
fault is cleared. This process helps prevent starter or ring gear damage.
Temperature Dynamic Governing
A temperature dynamic adjustment capability enhances cold starting ability and improves
stability when the engine is cold starting by automatically adjusting governing characteristics
based on engine temperature. It also helps limit black smoke emission on cold starting.
Digital Excitation Control
The genset voltage regulation system is 3-phase sensing and includes torque matching to
provide enhanced load pick-up capability. During starting, the control system ramps output
voltage to rated value to minimise voltage overshoot.
Cycle Cranking
The PowerCommand™ Control system includes a standard cycle cranking system which
allows the operator to select continuous or cycle cranking mode. The operator can select 3, 4
or 5 cranking cycles, and adjust the crank / rest times (7 - 20s). The standard setting is 3
cranking cycles, with 5s crank and 10s rest between.
Battery Monitoring System
The PowerCommand™ Control system continuously monitors the battery charging
system for low and high DC voltage. Functions and messages include:
“Low DC voltage” - battery voltage less than 25VDC
“High DC voltage” - battery voltage greater than 32VDC.
“Weak battery” - main battery dip is monitored at start-up and, if the dip goes below
14.4VDC for more than 2s, the indication will be given.
“First Start Sensor” - provides a positive interlock to prevent multiple gensets from
simultaneously closing to a dead system bus. A back-up system is provided to allow
normal system operation in the event that the primary first start sensor fails.

2.2
2.2 .4 Customer Connections
All customer connections to the PowerCommand™ Control are made in the Control
Housing which is mounted on the genset bedframe. Connections are made via large, clearly
labelled terminal blocks.

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2.2
2.2 .5 Output Contacts
The PCC provides control, alarm and status output signals, which are used to energise /
de-energise associated relays. The relays are located within the PCC panel and contacts are
provided for customer use. Signals are provided for the following relays:
Common warning alarm relay - Operates on all warning conditions. Rated at 2A,
30VDC.
Common shutdown alarm relay - Operates on all shutdown conditions. Rated at 2A,
30VDC.
Ready to load relay - Operates when the genset reaches 90% of rated voltage and
frequency. Rated at 2A, 30VDC.
Auxiliary “Run” relays (up to 3 optional) - Each relay is rated at 2A, 30VDC.
Breaker operation contacts - Provide breaker open and breaker close signals for a
paralleling circuit. Rated at 5A, 30VDC.
Load shed relay - Operates when an “overload” warning occurs for a specified
period of time. Rated at 6A, 30VDC.

2.2
2.2 .6 DC Power
The PowerCommand™ Control system is powered by the genset’s battery system. The
control system will function over a voltage range of 8 to 34VDC.

2.2
2.2 .7 Paralleling Protection
The PowerCommand™ Control system incorporates AmpSentryTM Protection for
automatic paralleling operations. This is a comprehensive power monitoring and control
system, integral with the PowerCommand™ Control, that guards the electrical integrity of the
alternator and power system from the effects of overcurrent, short circuit, over / under
voltage, over / under frequency, overload, reverse power, loss of excitation, alternator phase
rotation and paralleling circuit breaker failure to close. Current flow is regulated to 300% for
both single phase and 3-phase faults when a short circuit condition is sensed.
If the genset is operating for an extended period at a potentially damaging current flow
level, an overcurrent alarm will sound to warn the operator of an impending problem before it
causes a system failure. If an overcurrent condition persists for the time pre-programmed in
the time current characteristic for the alternator, the permanent magnet generator (PMG)
excitation system is de-energised, avoiding alternator damage. The overcurrent protection is
time delayed in accordance with the alternator thermal capacity. This allows current to flow
until secondary fuses or circuit breakers operate, isolating the fault and thus achieving
selective co-ordination (discrimination).
After the fault is cleared, AmpSentryTM Protection softly loads the genset by a controlled
ramping of output voltage to rated level, allowing the genset to resume normal operation
without potentially damaging voltage overshoot.
Fixed over / under voltage and under frequency time delayed set points also provide a
degree of protection for load equipment. Over / under voltage conditions trigger a shutdown
message on the alphanumeric display; and under frequency conditions prompt both a
warning and shutdown message, depending on the length of time and magnitude of variance
under rated frequency.
AmpSentry Protection includes an overload signal that can be used in conjunction with
transfer switches or Master Controls to automatically shed load, preventing a potential genset

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shutdown. The overload signal is programmable for operation at a specific kW level, on the
basis of an under frequency condition, or both.
AmpSentryTM Protection for paralleling also includes protection for genset reverse power,
loss of excitation, alternator phase rotation and circuit breaker failure to close. It includes
permissive (synchronising check) functions for automatic and manual breaker closure
operations.

2.2
2.2 .8 Communications Network (Option)
The PowerCommand™ Control system includes a Generator Control Module (GCM)
which provides for communications over the PowerCommand™ Communications Network.
The network is suitable for local or remote control and monitoring functions using
PowerCommand™ Software for WindowsTM.

2.2
2.2 .9 Remote Start / Stop Scheduling (Option)
PowerCommand™ Software for WindowsTM provides for remote monitoring of the genset,
or set of gensets, using a laptop PC. The software provides detailed information on the status
of the gensets and their associated accessories.
A remote access, single-site version of PowerCommand™ is provided for each site.
Alternatively, one remote access, multi-site version of PowerCommand™ can be provided
for a host monitoring computer.

2.2
2.2 .10 Earth Fault (Option)
The Earth Fault option, which employs an Earth Fault Unit, is designed to detect current
flow in the neutral earth and provide a shut down alarm on the detection of an earth fault.
A separate Earth Fault Reset button is provided on the Control Housing to allow resetting
of an earth fault alarm. The resulting shutdown indication on the control unit must be reset,
using the procedure detailed in Section 4.

2.3
2.3 Circuit Breakers and Change-over Contactors
2.3
2.3 .1 Circuit Breakers (Option)
All generators can be equipped with optional mechanically operated 3 or 4 pole circuit
breakers (MCCB’s), mounted in the Load Terminal Box. The circuit breaker is used to isolate
the generator output from the load.
Up to 1250 amp generator rating, circuit breakers are installed in a Set-mounted load box
which is close coupled to the alternator output terminal box. Customer cables are fed to the
circuit breaker via a bottom or side exit gland plate.
Above 1250 amp generator rating circuit breakers are installed in a free-standing
enclosure. With this arrangement the control panel remains Set-mounted using resilient
mountings to reduce vibration.

2.3
2.3 .2 Change-over Panel (Option)
Change-over Panels, fitted with either 3 or 4-pole contactors, are available as options.
Up to 1250 amp generator rating, change-over panels are wall mounted.
Above 1250 amp generator rating, change-over panels are free standing.

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2.4
2.4 Heaters
2.4
2.4 .1 Coolant Heater (Option)
An optional coolant heater is provided for increasing the jacket temperature of a non-
running engine during cold weather conditions. The heater is controlled by an associated
thermostat, but is locked out by the PCC at engine start.
The coolant heater is supplied with 230V ac via the engine heater supply, the associated
thermostat and an isolator relay which is controlled by the PCC.

WARNING
Always isolate the coolant heater from the ac supply before working
on the engine or heater.

Caution: The coolant heater is in no way intended to protect the

engine and cooling system from freezing in sub zero
conditions. If there is any danger from freezing, then a
suitable antifreeze agent must be added to the cooling
system.

2.4
2.4 .2 Alternator Heater (Option)
The alternator heater option maintains the alternator windings above ambient temperature
when the generator is not running. This prevents condensation forming within the alternator
windings. The heater is locked out by the PCC at engine start.
The alternator heater is supplied with 230V ac via the engine heater supply, the associated
thermostat and an isolator relay. The relay is controlled by the PCC.

WARNING
Always isolate the alternator heater from the ac supply before
working on the alternator or heater.

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2.5
2.5 Mains Powered Battery Charger (Option)
2.5
2.5 .1 Operation
This unit maintains the lead-acid or NiCad battery in a fully charged condition without over-
charging. The unit also provides rapid charging, when necessary, at a current of up to the
rated output.
The charger’s electronic control circuit allows the charger to be left in circuit during engine
cranking and to operate in parallel with the charge alternator.
The charger will supply current to the battery system when the battery terminal voltage is
equal to the set float voltage, at which point only a trickle charge current is present. When the
battery becomes discharged due to a load being present and the terminal voltage falls, the
charger will again supply current to restore the voltage of the battery to the float voltage.
Should a charge fail condition occur for longer than 10 seconds then the charge fail relay
will energise, and its contact close. Charger operation is indicated by a red LED.
NOTE: The LED will light even if the charger output fuse is blown.

2.5
2.5 .2 Boost Charge (Option)
During trickle charging, not all cells in the battery receive the same charge and over a
period of several months this may affect battery performance. It is therefore normal to give
batteries a regular charge at their full rate to return all cells to full capacity. This is referred to
as boost charging (also known as equalise charging).
If the charger is fitted with a Boost Charge switch the BOOST position should be
selected at intervals detailed by the battery manufacturer (normally around every 6 months).

Caution: Batteries should not be left on boost charge for extended

periods as this will result in excessive water consumption,
gassing and may impair battery performance.

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SECTION 3

SYSTEM OPERATION

CONTENTS

3. SYSTEM OPERATION 3-3

3.1 Safety 3-3
3.2 Introduction 3-4
3.3 Maintenance 3-4
3.3.1 Control Mode Definitions 3-4
3.4 Functional Description 3-5
3.4.1 Sequence of Operation 3-5
3.4.2 Control Panel 3-6
3.4.3 Emergency Stop Controls 3-22
3.5 Fault Alarms & Shutdowns 3-23
3.5.1 Alarm 3-23
3.5.2 Controlled Shutdown 3-23
3.5.3 Immediate Shutdown 3-23
3.6 Pre-start Checks 3-24
3.7 Start / Run Procedures 3-25
3.7.1 Operating Options 3-25
3.7.2 Lockout 3-26
3.7.3 Manual Start Procedure 3-27
3.8 Paralleling (PCCP only) 3-28
3.8.1 Speed and Voltage Matching 3-28
3.8.2 Operation When in Parallel 3-28
3.9 Shutdown Procedures 3-29
3.9.1 Normal Stop 3-29
3.9.2 Emergency Stop 3-29
3.9.3 Emergency Stop Reset 3-29
3.10 Locking the Genset Out of Service 3-30
3.10.1 Introduction 3-30
3.10.2 Immobilising the Plant for Safe Working 3-30
3.11 Genset Output Metering 3-31
3.11.1 Load Voltage 3-31
3.11.2 Load Current 3-31
3.11.3 Load Power 3-32
3.11.4 Genset Frequency 3-32
3.11.5 Bus Synchronisation 3-32
3.11.6 Duty Cycles 3-32
3.12 Engine Metering 3-33
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3.13 Heaters 3-33

3.13.1 Coolant Heater (Option) 3-33
3.13.2 Alternator Heater (Option) 3-33
3.14 Digital MasterControl (Option) 3-33
3.15 Test Runs 3-34
3.15.1 Off-load Initial Run 3-34
3.15.2 On-load Initial Run 3-36
3.15.3 Maintenance Test Run 3-38

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3. System Operation
3.1
3.1 Safety
Genset operations should only be carried out by suitably qualified and experience
personnel. Before operating the system, the operator should become familiar with the Safety
Precautions for Generating Plant given at the front of this manual. Observe the following
WARNINGS and CAUTIONS at all times.

WARNING
Before operating the plant become familiar with the equipment and
how it is operated (including all controls, manually operated valves
and alarm devices). Safe and efficient operation can only be
achieved if the plant is operated correctly.

WARNING
Contacting high voltage components can cause electrocution,
resulting in severe personal injury or death. Do not open the
generator output box while the genset is running. Read and observe
all WARNINGS and CAUTIONS in your genset manuals.

Caution: The PCC front panel must only be opened by technically

qualified personnel. Lower level voltages (18VAC to 24VAC)
are present in the PCC. These voltages can cause electrical
shock, resulting in personnel injury.
Even with power removed, improper handling of components
can cause electrostatic discharge and damage circuit board
components.

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3.2
3.2 Introduction
This Section describes the control settings required for operation of the genset, and the
sequences that occur during generator start-up and running. Normal and emergency stop
procedures are described, together with alarm and shut down procedures, and controls. The
text should be read in conjunction with the System Description, together with the Engine and
Alternator Operating Manuals.

3.3
3.3 Maintenance
To secure maximum performance and reliability from your generating set it is essential
that certain components are inspected periodically and, where necessary, maintenance
procedures carried out as detailed in the Maintenance section.

3.3
3.3 .1 Control Mode Definitions
The following Control Mode Definitions are used in this manual:

Control Definition Initiating Condition / Generator

Mode Reset Load
Normal A stop initiated Stop with PowerCommandTM Auto ramping
Stop manually during STOP switch. down of load
normal genset Manually reset any alarm at before
running. PowerCommandTM before stopping.
restart..
Alarm Alarm condition Non critical alarm condition. Loading
with alarm Alarm reset at maintained.
indication / horn / PowerCommandTM.
beacon.
Controlled Alarm condition Alarm requiring controlled Auto ramping
Shutdown with alarm engine stop. Switch off & down of load.
indication / horn / manually reset at
beacon. PowerCommandTM before
restart.
Immediate Critical alarm Critical alarm condition. All of load
Shutdown condition with Switch off & manually reset dumped
immediate engine at PowerCommandTM before immediately
stop alarm restart.
indication / horn /
beacon.
Lockout Engine inhibited Start inhibit due to critical Load
from starting with fault condition. Reset at previously
alarm indication / PowerCommandTM when removed.
horn / beacon. alarm condition is clear. Engine
stopped

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3.4
3.4 Functional Description
3.4
3.4 .1 Sequence of Operation
The genset is either run automatically using a remote start signal or manually by using the
genset controls. Genset indications are provided on the PCC. If a fault is sensed at start-up,
the engine is locked out and will not start.
When the PCC is put in the RUN mode, the genset performs an automatically sequenced
manual start. First, the PCC initiates a starter cranking signal and verifies that the engine is
rotating. Then it provides sufficient fuel to the engine to accelerate to start-disconnect speed.
After the initial start procedure, the control system ramps the genset to rated speed and
voltage. On reaching rated speed and voltage, the PCC checks the system bus voltage. If the
genset is working in a multiple (paralleling) genset installation and no bus voltage is present, it
waits for a pulse from a remote Master First Start Sensor (MFSS). On receiving that pulse,
the control will signal the paralleling breaker to close.
If bus voltage is present, the PCC checks for proper phase rotation, adjusts the genset to
the bus voltage and frequency level, and then synchronises the genset to the system bus
automatically. When a synchronous condition is achieved, the main breaker can be closed.
When the main breaker is closed, the genset assumes its proportional share of the total load
on the system bus.

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3.4
3.4 .2 Control Panel
3. 4 .2 .1 Front Panel

1 2 3 4

5
16

6
15

14
7

13

11
12 10 9

1. % Kilowatt Meter 9. Menu “Home” Switch

2. Frequency Meter 10. Panel Lights Switch
3. AC Voltmeter 11. Self-test Switch
4. % AC Ammeter 12. Run / Off / Auto Switch
5. System Control Selection Switches 13. Breaker Control Push-buttons
6. Voltage Meter Scale Indicator Lamp 14. Reset Switches
7. Phase Selector Switch + Indicators 15. Status Indicators
8. Emergency Stop Switch 16. Digital Display & Status Panel

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Control Panel Switches and Indicators.

1. Kilowatt Meter:— Indicates 3-phase AC

power output as % of rated load.

2. Frequency Meter:— Indicates generator

output frequency in Hz.

3. AC Voltmeter:— Dual scale instrument

which indicates AC voltage.
Measurement scale is shown on scale
indicator lamp.
4. AC Ammeter:— Indicates current output
in % of maximum rated output (percent
current is based on 0.8 Power Factor).

5. System Control Selection Switches:—

Four membrane switches - two on each
side of the alphanumeric display window
- are used to step through the various
menu options and to adjust genset
parameters. The green arrow on the
alphanumeric display adjacent to the
switch is lit when the switch can be used
(switch is "active").
6. Voltage Meter Scale Indicator
Lamps:— Indicate AC Voltmeter scale
selected.

7. Phase Selector Switch and

Indicators:— Press this momentary
switch to select phases of generator
output to be measured by the analogue
AC Voltmeter and Ammeter. LEDs Phase
indicate the selected phase. Selector

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8. Emergency Stop Push-switch:—

Push the switch for an emergency
shutdown of the engine. To reset at the
PCC:
a) Turn the Emergency Stop switch
clockwise and allow it to pop out.
b) Move the Run / Off / Auto switch to Off.
c) Press the Reset membrane switch.
d) Select Run or Auto, as required.
9. Menu “Home” Switch:— At any time,
press this membrane switch to return the
alphanumeric display to the MAIN MENU.
Refer to the menu trees later in this
section.
10.Panel Lights Switch:— Press this
membrane switch to turn control panel
illumination on and off. The illumination
will shut off automatically after about 8
min to save battery power.
11.Self-test Switch:— Press and hold this
membrane switch to light all front panel
LEDs and cycle through all shutdown and
warning messages.
In the Standby (sleep) mode, the control's
operating software is inactive and the
LEDs and displays on the front panel are
all deactivated.
To activate and view the menu displays
without starting the genset, press and
hold the Self-test switch until the front
panel LEDs are lit. The PCC will initialise
the operating software and reactivate the
menu display panel. If no menu se-
lections are made, a software timer will
shut down the display after 30s.

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12. Run l Off l Auto Switch:— This switch OFF
starts and stops the genset locally, or
AUTO
enables start / stop control of the engine RUN
from a remote location. (Ground to
start.)
“OFF” - de-energises all primary DC
circuits, preventing genset operation.
When the switch is in this position, a
“Non-automatic” indicator LED will flash
continuously.
“RUN” - energises the control system
and initiates genset starting and
operation. The breaker control switches
are enabled only in the “RUN” position.
The “Non-automatic” indicator will flash
when the switch is in the “RUN” position,
indicating that the paralleling breaker will
not automatically close.
“AUTO” - enables the control system to
receive a start signal from a remote
location.
13. Breaker Control Push-buttons.—
(Paralleling Systems only) These push-
button controls are used to manually CLOSED
control the opening and closing of the
generator paralleling breaker when in the
RUN mode. The breaker close operation OPEN
is operated through a permissive function
(with dead bus logic) to prevent
accidental out of phase paralleling of the
generator set to the system bus.
14.Reset Switch:— Press this membrane
switch to reset warning and shutdown
messages after the condition has been
corrected. To reset a shutdown message
with the Reset switch, the Run / Off /
Auto switch must be in the Off position.
With the Run / Off / Auto switch in the
Auto mode, shutdown faults can be reset
by removing the start input and then
cycling the remote reset input.

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15.Status Indicators:— Non Automatic

Indicator flashes continuously when the Non-Automatic
RUN/OFF/AUTO switch is in the OFF or
RUN position. Warning
Warning Indicator is illuminated to Shutdown
indicate that a condition outside desired
parameters has occurred. The reset
switch is used to clear this message
when the warning condition is corrected.
Shutdown Indicator illuminates when a
shutdown condition has occurred. The
reset switch is used to clear this
message when the shutdown condition is
corrected.
16. Alphanumeric Display and Status
Panel:— This two-line 16-character per
line digital display is used in the menu-
driven operating system, in conjunction
with the Menu Selection switches and
the Menu switch. Refer to the menu
trees later in this manual. The display is
also used to show warning and
shutdown messages.

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3. 4 .2 .2 Alphanumeric Display and Switches

The illustration shows the PCCs alphanumeric display and the menu selection membrane
switches. Refer to heading "Front Panel" which describes the display and all the switches.

In the Standby (sleep) Mode, to activate and view the menu displays without starting the
genset, press and release the Self-test membrane switch (see Front Panel illustration). This
will initialise the PCC operating software and permit operation of the menu display panel. If no
menu selections are made, a software timer will shut down the display after 30s.
In the Power On (awake) Mode, power is continuously supplied to the control panel and
the alphanumeric display will remain on.
NOTES: In the alphanumeric display, the ">>" symbol indicates that selecting
the adjacent membrane switch causes the operating program to branch
to the next menu display as shown in the menu diagrams.
The "<<" symbol indicates that selecting the adjacent membrane switch
causes the operating program to return to the previous menu displayed.

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3. 4 .2 .3 Main Menu
The facing page shows the MAIN MENU and a block representation of the menu tree,
including all available sub-menus. Initially the alphanumeric display shows the titles in the
central block (ie, ENGINE, GEN, ADJUST, >>). Pressing a membrane switch next to a title
displays the next indication in the tree.
As shown in the diagram, the MAIN MENU can branch into one of four directions.
ENGINE: To display engine parameters, such as oil pressure and temperature, water
temperature, engine speed (rpm), and exhaust temperature, press the membrane
switch next to the word 'ENGINE" in the display. Refer to ENGINE MENU.
GEN: To display generator parameters, such as volts, amps, power (kW), and
frequency, press the membrane switch next to the word “GEN" in the display. Bus
voltage, frequency and a digital synchroscope can also be viewed from this menu
branch. Refer to GEN MENU.
ADJUST: To adjust output voltage and frequency, or start and stop delays, press the
membrane switch next to the word "ADJUST” in the display. Refer to ADJUST
MENU.
>> (version) : To display the selected genset model and the resident version
software, press the membrane switch next to the ">>“ in the display. From this
selection, you can also review a History file that can record and save up to 20 error
messages. Refer to VERSION MENU.

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3. 4 .2 .4 Engine Menu
The facing page shows a block representation of the ENGINE menu tree, including all
available sub-menus. Pressing the membrane switch next to the word "ENGINE" in the
display introduces the first ENGINE sub-menu.
As shown in the diagram, the ENGINE menu has three sub-menus.
OIL / COOLANT sub-menu: This is the first sub-menu. Select OIL for a display of oil
pressure and oil temperature. Select COOLANT for a display of coolant temperature.
When oil or coolant parameters are displayed, pressing the membrane switch next to
the "<<“ will return the display (“BACK”) to the OIL COOLANT sub-menu.
BATTERY / HOURS sub-menu: From the OIL COOLANT sub-menu, press the
membrane switch next to the ">>" in the display to move to the BATTERY / HOURS
sub-menu. Select BATTERY for a display of battery voltage. Select HOURS for a
display of the number of starts and the running hours. When battery or hours
parameters are displayed, pressing the membrane switch next to the "<<" will return
the display ("BACK') to the BATTERY / HOURS sub-menu.
RPM / EXHAUST sub-menu: From the BATTERY / HOURS sub-menu, press the
membrane switch next to the ">>" in the display to move to the RPM / EXHAUST sub-
menu. Select RPM for a display of engine RPM. Select EXHAUST for a display of the
(optional) exhaust temperature. When RPM or exhaust parameters are displayed,
pressing the membrane switch next to the “<<“ will return the display (“BACK”) to the
RPM / EXHAUST sub-menu.

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3. 4 .2 .5 Gen Menu
The facing page shows a block representation of the GEN (generator) menu tree,
including all available sub-menus. Pressing the membrane switch next to the word "GEN" in
the display introduces the first GEN sub-menu.
As shown in the diagram, the GEN menu has three sub-menus.
VOLTS / AMPS sub-menu: This is the first sub-menu. Select VOLTS for a display of
a line-to-line or line-to-neutral selection, or for viewing of the system bus line-to-line
voltage. Select line-line or line-neutral for the desired voltage display. Select AMPS for
a display of Ll, L2, and L3 current in amps. When voltage or current parameters are
displayed, pressing the membrane switch next to the "<<“' will return the display
("BACK") to the L-L / L-N sub-menu.
NOTE: If DELTA is selected in the Initial Start Set-up sub-menu when selecting
VOLTS, the "line-line" or "line-neutral" sub-menus will not be displayed.
Only the Ll2, L23, L31 sub-menu will be displayed.
POWER / KW HOURS sub-menu: From the VOLTS / AMPS sub-menu, press the
membrane switch next to the ">>" in the display to move to the POWER / kW
HOURS sub-menu. Select POWER for a display of power output in kilowatts and a
power factor value. Select kW HOURS for a display of kilowatt hours. When power or
kW hours parameters are displayed, pressing the membrane switch next to the "<<“
will return the display ("BACK”) to the POWER / kW HOURS sub-menu.
NOTES: The PF reading will contain an asterisk if the power factor is leading
(for example, *.3PF).
Beginning at PowerCommandTM Version 1.06, N/A is displayed in the PF
field when the genset is not running.
% GOV / REG / FREQUENCY sub-menu: From the POWER / kW HOURS sub-
menu, press the membrane switch next to the ">>" in the display to move to the %
GOV / REG / FREQUENCY sub-menu. Select % GOV / REG for a display of voltage
regulator and governor duty cycle (drive) levels in percentage of maximum. Select
FREQUENCY for a display of the generator output frequency the bus frequency, or
the digital synchroscope. When voltage regulator and governor or frequency
parameters are displayed, pressing the membrane switch next to the “<<“ will return
the display ("BACK") to the % GOV / REG / FREQUENCY sub-menu.
Bus Frequency (Digital Synchroscope) sub-menu: When the bus frequency
(digital synchroscope) information is displayed, the operator can observe the genset
synchronising with the system bus. The display indicates bus frequency and number
of degrees from synchronous condition (+ indicates faster, - indicates slower). When
the genset is operating within the sync-check window, an asterisk will indicate that the
paralleling breaker can be closed.
When –– –– –– is displayed, the synchroniser is not active.

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3. 4 .2 .6 Adjust Menu
The facing page shows a block representation of the ADJUST menu. If you press the
button next to the word “ADJUST” in the display, the VOLTAGE ADJUST sub-menu will
appear.
As shown in the diagram, the ADJUST menu has five sub-menus, including a save/exit
procedure.
Voltage and frequency can be adjusted only when the generator set is running under
normal operating parameters (not in idle mode). For example, if voltage adjustment is
selected when the set is in Idle mode or not running, the alphanumeric display will be:

“⇑ VOLTAGE”
“⇓ N/A >>”

VOLTAGE sub-menu: This is the first sub-menu. Use the buttons next to the “⇑” and
“⇓” symbols to adjust output voltage ± 5%.
FREQUENCY sub-menu: From the VOLTAGE sub-menu, press the button next to
the “>>” in the display to move to the FREQUENCY sub-menu. Use the buttons next
to the “⇑” and “⇓” symbols to adjust output frequency ± 5%.
START DELAY sub-menu: This delay applies only to remote starting in the Auto
mode. From the FREQUENCY sub-menu, press the button next to the “>>” in the
display to move to the START DELAY sub-menu. Use the buttons next to the “⇑” and
“⇓” symbols to set the start delay. The start delay adjustment range is 0 to 300s.
STOP DELAY sub-menu: This delay applies only to remote stopping in the Auto
mode. From the START DELAY sub-menu, press the button next to the “>>” in the
display to move to the STOP DELAY sub-menu. Use the buttons next to the “⇑” and
“⇓” symbols to set the stop delay. The stop delay adjustment range is 0 to 600s
IDLE SPEED sub-menu: From the STOP DELAY sub-menu, press the button next
to the “>>” in the display to move to the IDLE SPEED sub-menu. Use the buttons next
to the “⇑” and “⇓” symbols to set the idle speed. The idle speed adjustment range is
800 rpm ±100 rpm (Default value is 800 rpm). The idle speed can be adjusted only
when the generator set is running in the idle mode. When not in idle mode, N/A is
displayed in rpm field.
Note ! The IDLE SPEED sub-menu will not be used for generator sets that do
not require their speed to be reduced to idle before shutting down. Under
this circumstance only the STOP DELAY sub menu is used to initiate a
cooling run before shutting down the generator set.
SAVE/EXIT sub-menu: From the STOP DELAY sub-menu, press the button next to
the “>>” in the display to move to the SAVE/EXIT sub-menu. Select SAVE to save
your changes. At the CHANGES SAVED sub-menu, select EXIT to return to the main
menu.
If you select SAVE, the adjustments will be retained after shutdown, and will be
in effect when the set is restarted. If you select EXIT without saving first, the
adjustments will remain in effect until the generator set is shut down, but will
be reset (and will not be in effect) when the set is restarted.

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3. 4 .2 .7 Version Menu
The facing page shows a block representation of the VERSION sub-menus. If you press
the button next to the “>>” in the Main menu display, the VERSION/SET-UP/CAL menu will
appear.
VERSION sub-menu: If you select VERSION, the display will show the genset model
number, frequency and kW rating, and the date and version of the operating software.
To display the generator set configuration options, press the button next to the “>>” in
the sub-menu that displays the model number, frequency, etc. This menu provides
the following information:
• Generator set voltage.
• WYE (ie, STAR) or DELTA and Full or Standard.
• Standby or Prime.
• 1 or 3 phase.
To modify any of these entries, you must return to the “Initial Start Set-up” sub-menus
described in the Service manual.
HISTORY: From the VERSION menu, press the button next to the “>>” in the display
to move to the HISTORY sub-menu. Press the button next to “HISTORY” to display
the last (latest) recorded error message.
The software will record (ie, save) up to 20 error messages. The last error detected
will always be displayed first. As each new error is detected, the oldest error
recorded after 20 will be deleted.
To view the generator set runtime at which the error occurred and to scroll through
the remaining recorded errors, press the button next to the “>>” in the error message
menu to display the RUNTIME, NEWER/OLDER menu.
The buttons next to NEWER and OLDER are used to scroll up and down through the
error messages. For example, pressing OLDER will display the next oldest recorded
error message. When pressing NEWER and the last (newest) error message is
displayed, or OLDER and oldest error is displayed, the display will return to the
HISTORY menu.

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3.4
3.4 .3 Emergency Stop Controls
3. 4 .3 .1 Emergency Stop Switches
PCC Switch
The Emergency Stop push-switch located in the lower right hand corner of the PCC front
panel is a mechanically latched switch which will unconditionally stop the engine when
pressed. Also when the switch is pressed the PCC panel will display the shutdown condition
by illuminating the red Shutdown status LED and displaying the following message on the
alphanumeric display:
EMERGENCY STOP
102 - SHUTDOWN
The Emergency Stop push-switch must not be used for a normal shutdown, as this will
prevent a cooling run in which the lubricating oil and engine coolant carry away heat from the
engine combustion chamber and bearings in a safe manner.
Plant Room Switches (Optional)
The remote Emergency Stop push-switches located in the Plant Room are mechanically
latched switches which will unconditionally stop the engine when pressed. Also when a
switch is pushed, the PCC panel will display the shutdown condition by illuminating the red
Shutdown status LED and displaying the following message on the alphanumeric display:
EMERGENCY STOP
102 - SHUTDOWN
A remote Emergency Stop push-switch must not be used for a normal shutdown, as this
will prevent a cooling run in which the lubricating oil and engine coolant carry away heat from
the engine combustion chamber and bearings in a safe manner.

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3.5
3.5 Fault Alarms & Shutdowns
If a fault condition is sensed by the PCC, one of the following three events will be initiated
depending on the seriousness of the fault. Refer to Section 3, Control System, for further
information.

3.5
3.5 .1 Alarm
In the event of PowerCommandTM detecting a non-critical condition, an alarm indication
will be initiated and a beacon will be activated. If the genset is loaded, that loading will be
maintained and the generator will continue to run at regulated speed.

3.5
3.5 .2 Controlled Shutdown
In the event of a fault condition that is serious, but not considered fatal to the engine, a
controlled shutdown will be automatically initiated by the PCC. First an indication is initiated
and a beacon is activated. Then the genset load is ramped down before the generator circuit
breaker is opened, and the engine enters a cooling run under the control of the PCC before
stopping.

3.5
3.5 .3 Immediate Shutdown
In the event of a fault condition that may be fatal to the engine, an immediate shutdown is
initiated. Again an indication is initiated and a beacon is activated. This time the generator
circuit breaker is be opened without ramping down the load and the engine is stopped
immediately, without a cooling run.

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3.6
3.6 Pre-start Checks
Before starting the plant manually, or selecting auto operation, always carry out the
following checks to ensure that the unit is ready for operation:
Lubrication - Check the engine lubricating oil level and ensure that the level is always
maintained as detailed in the engine operating manual.
Coolant - Check the engine coolant level and ensure that the level is maintained at
the coolant expansion tank.

Caution: Do not attempt to remove a radiator pressure cap while the

generator is running, or is stationary but hot. Always allow it
to cool before removing.
Cooling Air Inlet / Outlets - Ensure that the cooling air inlets / outlets are
unobstructed.
Exhaust Outlet - Ensure that exhaust components are secured and not warped, and
that the exhaust outlet is unobstructed.
Fuel Supply - Ensure that the fuel tank is filled to the normal level and that the fuel
system is primed and all the valves required for operation are open.
Engine Governor - Check that the actuator oil level is correct.
Auxiliary AC Supplies - Ensure that all auxiliary equipment is receiving power from
the Load Terminal Box.
Emergency Stop / Fire Detection Equipment - Ensure that all related equipment is
fully operational.

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3.7
3.7 Start / Run Procedures
WARNING
Do not allow the genset to start unless it is safe to do so. Ensure that
all Pre-start Checks are carried out before starting the genset.

Caution: Avoid off load running. A minimum loading of 50% is

recommended. This loading will help prevent injector
“clogging” by carbon deposits due to unburned fuel, and
reduce the risk of fuel dilution of the engine lubricating oil.

3.7
3.7 .1 Operating Options
The genset is normally operated remotely, using a remote start signal. However, manual
operation of each genset is also possible by using the PCC systems on their own.
An additional option in the control system is that the PCC can either be set to run with its
indicators blanked, to save battery power, or with the indicators showing all the time if the
optional battery charger is used. Either way, the PCC is still functioning in the background.
In the Standby (sleep) mode selector switch S5, located on a printed circuit board inside
the PCC, is set to on. If no menu selections are made, the power to the control panel will shut
down after 30s. The PCCs operating software is inactive and the LEDs and displays on the
front panel are all deactivated. The panel appears to be ‘dead’.
In the Power On (awake) mode, switch S5 is set to off. The PCC initialises the operating
software and activates the menu display panel continuously. It is recommended that switch
S5 be left in the Power On mode, unless battery charging is not available.

Caution: Electrostatic discharge will damage circuit boards. To

prevent this damage, always wear a grounding wrist strap
when touching or handling either circuit boards or socket-
mounted lCs, and also when disconnecting or connecting
harness connectors.

3. 7 .1 .1 Wake Up Signals
If the PCC is set to Standby mode, the operating software is initialised and the front panel
automatically reactivated in response to a run signal or any one of eight "wake up" signals
from remote sensing switches. The wake up signals are:
Emergency Stop.
Low Coolant Level.
Low Coolant Temperature.
Low Fuel
Customer Fault Inputs 2 and 3.
Run Selected on Run / Off / Auto Switch.
Remote Start Signal in Auto Mode.
Self-test membrane switch operation.
3. 7 .1 .2 Automatic Operation
Automatic control of the genset is provided by positioning of the Run / Off / Auto switch.
to the AUTO position.

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Note that a red Non-automatic Status Indicator lamp on the PCC flashes continuously
when the Run / Off / Auto switch is not in the Auto position.

3. 7 .1 .3 Manual Operation
Manual control of the genset is effected by using the Run / Off / Auto switch Run / Off
positions. The red Non-automatic Status indicator lamp will flash continuously with the Run /
Off / Auto switch not in the Auto position.

3.7
3.7 .2 Lockout
The engine will be inhibited from starting if a critical fault condition exists when an attempt
is made to start the genset. An indication is initiated and a horn and beacon are activated.
Additionally, a number of non-critical circumstances arise where starting is prevented such
as:
Barring gear engaged.
Low battery voltage.
HV Switchgear protection.

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3.7
3.7 .3 Manual Start Procedure
3. 7 .3 .1 Start Sequence
The following description applies to automatic or manual operation. In an automatic
sequence, with the Run / Off / Auto switch set to the Auto position, a remote start signal is
applied to the PCC. The manual sequence is initiated directly by setting the Run / Off / Auto
switch to the Run position.
The installed generators start independently of each other, controlled by their respective
PCCs. During starting, automatic checks are carried out for the integrity of various protection
systems, such as the speed probe and the critical temperature sensors. The PCC will not
allow the genset to continue the starting sequence if the integrity of a sensor is considered to
be in doubt by the PCC check system.
The starting sequence consists of three cranking intervals of approximately 5s, each
followed by a rest period of 15s. If, at any time during the sequence, the engine is sensed to
have achieved firing speed (a speed calculated to be beyond the starter motor capability), the
remainder of the sequence is aborted. If, at the end of the third crank period, firing speed has
not been detected, the PCC ends the start sequence and a fail to start situation is indicated
as an "overcrank".

3. 7 .3 .2 Run-up to Speed
When the engine is called to start, and firing speed is attained, the starter motor function
ceases and is then locked out. The run-up sequence is closely controlled by the
PowerCommandTM software, to reduce smoke emission.

3. 7 .3 .3 Generator Running
Upon attaining correct speed (frequency), and correct output voltage, the generator is
deemed to be running by the PCC. During running, all systems associated with the engine
and its auxiliary systems will be monitored by the PCC to control the generator and to detect
any abnormal conditions.
If in Auto mode, the genset will continue to run off load until signalled by the PCC to close
the main breaker. In Manual (Run) mode, it will continue to run off load until the mode switch
is changed to another control mode. Automatic synchronisation is provided for the manual
paralleling.

Caution: The engine should not be allowed to run off-load for extended
periods, except as absolutely necessary during maintenance
or cooling cycles.

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3.8
3.8 Paralleling (PCCP only)
3.8
3.8 .1 Speed and Voltage Matching
Once the generator has achieved nominal voltage and frequency, the genset is ready to
be paralleled with the busbar supply. Each genset is paralleled completely independently of
the others.
The PCC monitors both the incoming supply and the busbar voltage and frequency and
adjusts the incoming supply to match the busbar supply over a wide span of busbar
parameters. Synchronisation is achieved under full control, and at the correct phase
coincidence.
In Automatic mode, the PCC receives a breaker close signal when synchronisation has
been achieved and signals the main breaker to close. In Run mode, the main breaker is
closed to connect the genset to the busbars by using the breaker Open/Close push-buttons.

3.8
3.8 .2 Operation When in Parallel
When in parallel with the busbar supply, the genset voltage and frequency are dependant
upon the busbar parameters, and control is changed to kW and kVAr load management.
Each genset is individually controlled by separate PCCs.
Apart from the protection systems, there is no common coupling between gensets. This
allows for any genset or its relevant controls to be under maintenance without affecting the
others.
When the control system detects that the generator is up to speed and voltage, the load is
then ramped from the mains to the generator, the engine governor control system keeping
the electrical output within the correct parameters.

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3.9
3.9 Shutdown Procedures
Specific procedures must be followed to shut down the power plant, either in emergency
or in normal use. Additional reset procedures must also be followed in order to put the power
plant back to work.

3.9
3.9 .1 Normal Stop
A Normal Stop is initiated either by the removal of the remote start signal or by turning the
Run / Off / Auto switch on the PCC to Off.
In the event of a Normal Stop, load will be ramped down before the generator circuit
breaker is opened, and the engine enters a cooling run under the control of the PCC before
stopping. The cooling run allows for the safe dissipation of excess heat, before the engine
stops and the cooling system is de-energised.

3.9
3.9 .2 Emergency Stop
Press the Emergency Stop push-switch located in the lower right hand corner of the
PCCs front panel.
or
Press one of the remote Emergency Stop push-switches located in the Plant Room
(if separate switches are provided).
NOTE: When an emergency stop is initiated all generator load is dumped
immediately and the engine is stopped without a cooling run.

Caution: Do not use an emergency stop control for a normal stop.

3.9
3.9 .3 Emergency Stop Reset
After an emergency stop, one of the following reset procedures must be carried out to
return the genset to an operating condition.

3. 9 .3 .1 Push-switch Reset
To carry out a reset from an emergency stop condition initiated by an Emergency Stop
push-switch:
1. Turn the activated Emergency Stop push-switch clockwise to unlatch it.
2. Move the Run / OFF / Auto switch on the PCC panel to Off.
3. Press the PCC panel Reset button.
4. Select Run or Auto as required on the PCC panel.
Caution: Ensure that the cause of the emergency is fully investigated
and remedied before an emergency stop reset and genset
start are attempted.

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3.10
3.10 Locking the Genset Out of Service
3.10
3.10.1
.1 Introduction
Before any work is carried out for maintenance, etc, the plant must be immobilised. Even
if the plant is put out of service using the Off position of the Run / Off / Auto switch on the
PCC panel, the plant cannot be considered safe to work on until the engine is properly
immobilised as detailed in the following procedures.

WARNING
Before carrying out any maintenance always immobilise the plant.

3.10
3.10.2
.2 Immobilising the Plant for Safe Working
NOTE: Shut down the engine first, as described under “Normal Stop”.
To immobilise the engine:
1. Turn the Run / Off / Auto switch on the PCC panel to Off position.

2. As an additional precaution, disconnect the starter / control system batteries.

3. Fit warning notices at each of the above points to indicate “Maintenance in

Progress - Plant Immobilised for Safe Working”.

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3.11
3.11 Genset Output Metering
Two types of metering are provided on the PCC, analogue and digital. Four analogue
meters provide indications of voltage, current, frequency and power for ‘walkby’ observations.
Additional indications, which allow for better interpretation of the genset power situation, are
provided on the GEN menu of the digital alphanumeric display. Details of how to access the
menu and its sub-menus are given under “Control Panel”.

3.11
3.11.1
.1 Load Voltage
The analogue, dual scale, ac voltmeter on the PCC displays the outgoing load voltage of
the generator. By using the Phase Select switch, the operator can choose which phase is
displayed. Indication of the phase selected is given by illumination of the appropriate phase
selector indicator light. The upper or lower scale of the voltmeter is selected automatically
and identified by illumination of the upper or lower scale indicator light.
Additional indications can be shown on the alphanumeric display. The indications are
genset output voltage (3-phase, line-to-line or line-to-neutral) and parallel bus voltage (3-
phase, line-to-line).
The generator output voltage is given on the Plant Rating Plate on the generator and on
the Generator Set Test Record provided at the rear of this manual.

WARNING
Under no circumstances must the Set be operated at a greater
voltage than the rated voltage stamped on the generator rating plate.
Serious damage or injury may result if this condition is allowed to
occur.

3.11
3.11.2
.2 Load Current
An analogue ac ammeter is provided to indicate the outgoing load current in each phase of
the generator output. By using the Phase Select switch, the operator can choose which
phase is displayed. Indication of the phase selected is given by illumination of the appropriate
phase selector indicator light.
Additional indications of genset output current can be accessed by selecting the GEN
menu on the alphanumeric display.
The generator output current is given on the Generator Plant Rating Plate on the generator
and on the Generator Set Test Record provided at the rear of this manual.

WARNING
Under no circumstances should the load current be allowed to rise
above the rated output current, allowing for any overload rating
given. If high current readings are encountered, the power factor of
the load should be checked.

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3.11
3.11.3
.3 Load Power
The analogue kilowatt meter displays 3-phase ac power output as a percentage of rated
load. This is a true indication of total kW load, regardless of the power factor.
Additional indications of power can be shown on the alphanumeric display. The indications
are ac kilowatt load and ac kilowatt hours. Power Factor (PF) is also shown, with a display of
0 - 1, leading or lagging. An asterisk is included for leading power factors.

3.11
3.11.4
.4 Genset Frequency
The analogue frequency meter displays the output frequency of the genset in Hz.
Additional indications are provided on the alphanumeric display. The indications are genset
output frequency and parallel bus frequency.
Frequency is directly related to engine speed and, for a nominal engine speed of 1500 rpm
(or 1800 rpm), the relationship between engine speed and frequency is given by the following
formula:
Hz = RPM / 30 (for a 4-pole machine)
Where Hz represents the output frequency of
the alternator and RPM is the engine speed

The generator output frequency is given on the Plant Rating Plate on the generator and the
Generator Set Test Record provided at the rear of this manual.

Caution: Under no circumstances must the Set be operated outside

the rated frequency range stamped on the generator rating
plate. Serious damage or injury may result if this condition is
allowed to occur.

3.11
3.11.5
.5 Bus Synchronisation
A synchroscope can be shown on the alphanumeric display, and this provides a visual
display of the genset synchronising with the system bus under full control of the PCC. Bus
frequency is shown, along with degrees difference (plus or minus). An asterisk is included on
the display when genset frequency is within a sync-check ‘window’, signalling that the
operator can effect closure of the paralleling breaker.
Note that the PCC inhibits closure of the paralleling breaker outside the sync-check
window. Therefore the breaker close control can be operated even before synchronisation,
although the breaker will not close until a signal is sent from the PCC to allow it.

3.11
3.11.6
.6 Duty Cycles
To complete the observations of genset power status provided by the PCC, the GEN
menu of the alphanumeric display can be set to show percentages of generator exciter duty
and governor duty.

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3.12
3.12 Engine Metering
Engine and auxiliary system parameters are constantly monitored by the PCC. No action
is required by the operator, except for maintenance as described in Section 5. Indications for
the following critical parameters can be displayed on the alphanumeric display, by using the
ENGINE menu as detailed under “Control Panel”:
Oil temperature.
Coolant temperature.
Exhaust gas temperature.(option)
Oil pressure.
Engine speed.
Battery voltage.
Engine operating hours.
Number of starts.

3.13
3.13 Heaters
3.13
3.13.1
.1 Coolant Heater (Option)
In cold weather conditions the optional coolant heater will be controlled by its associated
thermostat to maintain a reasonable engine temperature. The heater is locked out by the
PCC at engine start.

WARNING
Always isolate the supply to the coolant heater / thermostat before
carrying out any maintenance on the engine.

Caution: The coolant heater is in no way intended to protect the

engine and cooling system from freezing in sub zero
conditions. If there is any danger of freezing then a suitable
antifreeze agent must be added to the cooling system.

3.13
3.13.2
.2 Alternator Heater (Option)
The optional alternator heater, which is designed to maintain the alternator winding above
ambient temperature, prevents the formation of condensation within the windings. A
thermostat controls the heater, but the heater is locked out by the PCC at engine start.

WARNING
Always isolate the supply to the alternator and the thermostat before
carrying out maintenance on the alternator.

3.14
3.14 Digital MasterControl (Option)
The Digital MasterControl (DMC) is a stand-alone system that controls multiple genset
installations and utility supply switching. The control equipment includes a touchscreen,
digital meters and annunciators, all mounted in a single enclosure.

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3.15
3.15 Test Runs
3.15
3.15.1
.1 Off-load Initial Run
Caution: One operator should be in complete charge, or working
under the direction of someone who is. Remember that,
upon starting of the engine, cables and switchgear will
become energised, possibly for the first time. Furthermore,
equipment that does not form part of the generator
installation may become electrically charged. This work
should only be carried out by competent personnel.

Caution: Do not use an Emergency Stop switch to shut down an

engine, unless a serious fault develops. The normal method
of shutdown is to set the Run / Off / Auto switch to Off and
allow the PCC to perform a controlled shutdown.

Caution: Avoid off-load running for other than short periods. The
engine must be shut down as soon as possible after the
appropriate functions have been checked.

WARNING
Do not attempt to start the generator until it is safe to do so. Warn all
others in the vicinity that the Genset is available to start.

The PCC will automatically make up to three start attempts, and lock the engine out of
service if the third attempt fails. If the PCC senses an operating fault, either a Warning will be
indicated on the PCC or the engine will be shut down automatically. Automatic shutdowns
require no operator action other than to observe the detail.
If low ambient temperatures prevail at start-up, the engine will automatically enter a warm-
up idling mode then run up to speed when the engine temperature is stabilised.
Note that the Non-Automatic LED on the PCC will be illuminated whenever the Run / Off /
Auto switch is not set to Auto. Also, if the PCC is set to operate with the Standby (Sleep)
Mode active, the PCC indications may de-activate and need to be reactivated (press the
Self-test membrane switch to reactivate).
1. As a precautionary measure, for the initial runs only, place suitable fire extinguishers at
strategic locations around the Genset. Also ensure that all test personnel are fully aware
of the positions of all emergency shutdown switches and fire break glass units (as fitted).

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2. On the PCC, set the Run / Off / Auto switch to Run and check that the engine starts and
runs automatically. The PCC may make up to three start attempts before it terminates
the automatic start-up function. If all three start attempts fail, the fault must be
investigated before the system is reset and another start-up is initiated.
3. During start-up and the initial run, observe the PCC and check for unusual indications that
may highlight a problem. Also observe the associated power systems for signs of
flashovers, burning, etc. Should any items require urgent attention, shut down the Genset
immediately and rectify the fault, using skilled assistance if required.
4. Check the engine / associated pipe-work, including the exhaust system, for leaks. In the
event of a fuel or exhaust leak, shut down the Genset immediately. Also make careful
observations of any sign of a malfunction of the engine, alternator and auxiliary systems.
5. Activate the PCCs ENGINE menu and check the engine lubrication oil pressure (consult
the engine handbook for correct value). Also check the engine speed and ensure that the
engine is running at around nominal speed. The speed governing should be stable with no
tendency to hunt.
Engine operating speed is adjusted at the factory to 1500 rpm at full load (50 Hz Sets)
and 1800 rpm at full load (60 Hz Sets).
The no-load operating speed is within 2 to 2.5 Hz higher than the full load operating
speed.
6. Activate the PCCs GEN menu and check the alternator output voltage and frequency.
Refer to the alternator handbook.

Caution: Take extreme care when working on a hot exhaust

system. In case of a fuel or lubricating oil leak, the spilled fluid should
be absorbed using a proprietary material (Fullers Earth granules or
similar).
Sawdust should not be used, due to the fire hazard that would be
created.

7. After a short period of running off-load, shut down the Genset by returning the Run / Off /
Auto switch to Off. A controlled shutdown is effected by the PCC, and this may include a
short cooldown run.

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3.15
3.15.2
.2 On-load Initial Run
If the generator is in order on the off-load initial run, arrange for an on-load (mains failure)
test run. This should be performed during a non-critical period, as it may be necessary to
stop the Genset during the test.

Caution: One operator should be in complete charge, or working

under the direction of someone who is. Remember that,
upon starting of the engine, cables and switchgear will
become energised, possibly for the first time. Furthermore,
equipment that does not form part of the generator
installation may become electrically charged. This work
should only be carried out by competent personnel.

Caution: Do not use an Emergency Stop switch to shut down an

engine, unless a serious fault develops. The normal method
of shutdown is to set the Run / Off / Auto switch to Off and
allow the PCC to perform a controlled shutdown.

WARNING
Do not attempt to start the generator until it is safe to do so. Warn all
others in the vicinity that the Genset is available to start.

1. Initiate an engine start as follows:

a) Manual Start Gensets — at the PCC, set the Run / Off / Auto switch to Run. The
engine starts and runs up to speed.
b) Automatic / Remote Start Gensets — at the PCC, set the Run / Off / Auto switch
to Auto and initiate a Genset start from the remote location. The engine should start
and run up to speed.
c) Automatic Mains Fail Gensets— at the PCC, set the Run / Off / Auto switch to
Auto and initiate a manual start from the remote location. The engine will start and run
up to speed.
2. On Manual Start Gensets, the circuit breaker will have to be closed once the generator
has attained its operating speed and voltage. The PCCs automatic synchroniser will
prevent closure of the breaker until full synchronisation is effected. If required, the PCCs
GEN menu can be checked for sync indications.

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3. Observe the Genset and power system performance closely. In the unlikely event of an
engine fire, activate a Fire Break Glass unit (if fitted). This will result in an immediate
shutdown and fire alarm indications.

Warning
Personal safety must come before engine safety. The above procedure is
to be carried out only if the situation allows it. Always obey instructions
given by emergency service personnel, and observe local fire regulations
at all times.

4. Allow the Genset to run for 15 min on-load to check initial readings and functions of the
engine. Engine parameters can be checked on the PCCs ENGINE menu and power
parameters on the analogue meters and the GEN menu.
5. Oil pressure should be maintained after an initial drop and should stabilise as the engine
temperature stabilises. The pressure should always be within the manufacturer's
specification.
6. Engine temperature should rise rapidly and then stabilise after a few minutes. The normal
running temperature should be within the range 80OC and 95OC.
7. Voltage should be maintained within ± 2% for stable load conditions.
8. Frequency should be maintained within 2 Hz for all stable loads between zero and full-
load.
9. Check all engine systems for leaks. If any leaks are detected, the Genset should be shut
down by setting the Run / Off / Auto switch to Off, and the leaks rectified. If the leak is
serious or may cause immediate danger, use an Emergency Stop switch to shut down
the engine.
10. On satisfactory completion of the test the generator can be signalled to stop (set the Run
/ Off / Auto switch to Off) and the mains supply can be returned. The Genset will
automatically be put into a cooling run off-load before performing a controlled shutdown.
11. Complete a Commissioning Form, if required.

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3.15
3.15.3
.3 Maintenance Test Run
On completion of all maintenance, and only when it is safe to run the generator, a Test
Run should be carried out. This test should be performed at least weekly on engines that
have not been run.
Note that the control system (ie, the PCC) will make up to three start attempts
automatically, and will indicate a Shutdown if the third attempt fails. If a fault condition arises,
running faults will be displayed on the PCC. The indications should be noted down to assist in
fault finding, as detailed in Section 6.
To carry out a test run, perform the following:
1. Re-connect all supplies to the generator.
2. Re-connect the plant battery.
3. Check the output of the battery charger (if fitted).
4. Perform a self test on the PCC by pressing and holding the Self Test membrane switch.
Ensure that the PCC illuminates all LEDs and cycles through all warning and shutdown
messages. Release the switch at end of test cycle.

WARNING
Do not attempt to start the generator until it is safe to do so.

5. Start the genset as follows:

a) Set the fuel shut-off lever to the Work position (open).
b) On Manual Start Gensets, turn the Run / Off / Auto switch to the Run position and
the engine should start automatically.
c) On Automatic / Remote Start Gensets ensure that the Run / Off / Auto switch is
set to the Auto position. Initiate a genset start by giving a remote start signal

Caution: If the genset fails to start after three attempts, and the PCC
indicates a shutdown, the fault must be cleared before any further
start attempts are made. Refer to Section 6 for fault finding.
6. If the genset fails to start, as detailed above, reset the control system as follows then
identify and clear the fault before any further start attempts are made:
a) Return the Run / Off / Auto switch to the Off position.
b) Press the Reset button. Do NOT attempt a restart.

7. With the genset running, activate the ENGINE menu on the PCC and check the following
engine parameters:
a) Oil pressure should be maintained after an initial drop. The pressure should always
be within the manufacturer's specification.
b) Engine temperature should rise rapidly and then stabilise after a few minutes. The
normal running temperature should be within the range 800C - 950C.
8. Load the genset to at least 50% rated kilowatt output and observe the
performance closely. Avoid off-load running for extended periods.

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9. Check the engine and associated pipework, including the exhaust system, for leaks.
In the event of an exhaust leak, the genset should be shut down immediately and
measures taken to ensure personal safety. Observe the ‘Exhaust Gas Hazards’
safety requirements listed in Section 2.

WARNING
Risk of Toxic Fumes

Caution: Take extreme care when working on a hot exhaust system. In case of a
fuel or lubricating oil leak, the spilled fluid should be absorbed using a
proprietary material (Fullers Earth granules or similar). Sawdust should
not be used, due to the fire hazard that would be created.
10. Activate the GEN menu on the PCC and check the generator output by observing the
analogue meters and the more detailed information on the digital display:
a) Voltage should be maintained within ± 2% for stable load conditions.
b) Frequency should be maintained within 2 Hz for all stable loads between zero and
full-load.
Note: If required, the Phase Select switch can be used to select alternative
phase data on the analogue voltmeter and ammeter.

11. This operation applies to the initial start-up only. Confirm correct operation of the
emergency stop facility as follows:
a) Press the Emergency Stop push-button on the PCC and ensure that the engine
shuts down immediately, without a cooling run.
b) When the engine has stopped rotating, turn the Emergency Stop push-switch
clockwise to unlatch the switch.
c) Return the Run / Off / Auto switch to Off.
d) Press the Reset membrane switch.

12. As soon as possible after the emergency stop, set the Run / Off / Auto switch on the
PCC to Run or Auto as required for a restart. Ensure that the genset starts and runs
and that the engine temperature stabilises. Avoid off-load running for extended
periods.
13. If Plant Room Emergency Stop push-switches are provided, repeat the above two
paragraphs for each of the push-buttons provided, always allowing time for the engine
temperature to stabilise. Bear in mind that shutting the engine down without a cooling
run can cause overheating, so space the checks accordingly.
NOTE: The requirement for further checks on the emergency shutdown system
will depend on generator usage. Contact an authorised Service Department for a
site-specific recommendation.

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14. Perform the following procedure to shut down the genset, and ensure that the engine
completes a short cooling run before shutting down:
a) On Manual Start Gensets, turn the Run / Off / Auto switch to the Off position.
b) On Automatic/Remote Start Gensets remove the remote start signal.

15. Return the genset to its normal operating mode as required.

16. Keep a record of all maintenance work carried out.

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SECTION 4

MAINTENANCE

CONTENTS

SAFETY 2

SUGGESTED MAINTENANCE SCHEDULE 3

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SAFETY
Maintenance work, particularly in confined
areas, should be carried out by two engineers
working together.
Ensure that adequate lighting and staging
(where required) are installed.

Caution: Maintenance should only be

carried out by authorised and qualified
maintenance engineers who are familiar
with the equipment and how it is operated.

Caution: Before carrying out any

maintenance work, become familiar with
the Generator Plant Safety Code given in
the preliminary pages of this manual.

WARNING: Before carrying out any

maintenance work LOCK OFF for safe
working:

1. Select the MODE switch on the set

Control Panel to OFF
2. Isolate all supplies to the generator
3. Isolate the battery charger
4. Disconnect the battery
5. Remove the starter control wires.
6. A suitable warning plate stating
‘Maintenance in Progress’ should be
displayed prominently.

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SUGGESTED MAINTENANCE SCHEDULE

ITEM TASK WEEKLY / 10 MONTHLY / YEARLY / 200
HOURS 100 HOURS HOURS
Engine Check all exhaust components / connections l
Check lubrication oil level l
Change lubrication oil and filter l
Check fuel tank level l
Check coolant level l
Drain water from fuel pre-filter (where fitted) l
Change coolant filter (where fitted) l
Change fuel pre-filter (where fitted) l
Clean charger air cooler (where fitted). 800 hours
Check fuel injector settings See Engine Manual
Check valve clearances See Engine Manual
Check anti-freeze / inhibitor content Change every two years
Check ‘vee’ belt tension l
Clean air filter or check oil bath
Check all pipework for leaks l
Drain sediment from fuel tank l
Check and clean radiator matrix l
Perform any maintenance tasks specified in As directed
the Engine Manufacturer’s Manual
Periodically clean the engine l
Check electrolyte level in battery l
Check state of charge l l
Set Electrics Clean battery terminals and regrease l
Check fuel solenoid and linkage l
Check all electrical connections l
Clean all apertures (with vacuum cleaner) l
Alternator Grease bearings if required See manufacturer’s data
Check all ventilation points l
Perform any maintenance tasks specified in As directed
the Alternator Manufacturer’s Manual
Clean the alternator l
Control Panel Check circuit breaker contacts l
Carry out a Lamp Test l
Check all fuses and tripping devices l
Clean the control panel l
Check security of all fixings as required l
General Check plant room for cleanliness l
Have set / panel inspected by manufacturer l
Check air inlets / outlets for freedom from l
obstruction
Test Run Run the set on-load — at least 50% load l
Check anti-vibration mounts l
Check all systems functioning l
Check operation of EMERGENCY STOP l

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SECTION 5
TROUBLESHOOTING

CONTENTS

TROUBLESHOOTING 2
INTRODUCTION 2
CONTROL UNIT DC POWER SUPPLY (PCL SYSTEMS ONLY) 2
FAULT FINDING CHARTS 3
Engine Starting Faults 3
Engine Running Faults 4
Electrical Output Faults 6

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TROUBLESHOOTING
INTRODUCTION
Fault diagnosis charts are provided in this
section to help in locating the possible causes
of faults in the generating set.
The engine manufacturer's handbook
contains its own fault finding charts and
covers many possible engine faults. Similarly,
the alternator manufacturer’s book provides
fault finding details. We have highlighted
many common faults here.

CONTROL UNIT DC POWER SUPPLY

(PCL SYSTEMS ONLY)
The Control Unit (PCL 001 and 002) is
powered from the plant battery or from a low
voltage DC supply. The unit will operate from
any supply between 8 and 35 volts. The unit is
capable of withstanding the voltage dips seen
during cranking down to 0V for 50msecs.
This is achieved without the need for
internal batteries.

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FAULT FINDING CHARTS

Engine Starting Faults

Symptom Possible Cause Remedy
ENGINE DOES NOT CRANK : Shutdown alarm condition active. Reset shutdown alarm after
with function switch set to clearing fault.
correct position.
AIR START Check-Compressor. Check-
Low starting air pressure. Reducing valve. Check-Start
Solenoid.
ELECTRIC START Check electolyte for correct
specific gravity and level.
Starting batteries discharged Check charger function.
or battery life span exceeded. Test, and renew batteries if
required.
Air start or electric starter motor Turn flywheel with barring gear to
pinion locked or not engaging. release pinion and / or remove
(if applicable) motor. Clean & grease pinion.
Damaged teeth on motor pinion Repair or renew start motor.
or flywheel starter ring. Seek qualified technical advice.
Coolant or fuel in one or more Refer to engine manual.
cylinders.
ENGINE CRANKS BUT FAILS Fuel tank empty. Fill to required level.
TO START(after a predetermined Fuel solenoid faulty. If jammed, free up. Renew coil or
number of start attempts) entire solenoid valve.
OR -- ENGINE CRANKS AND Waxed fuel / blocked filters. Change filters and switch
STARTS BUT FAILS TO heaters on.
CONTINUE TO RUN Engine too cold. Ensure heaters are operative.
No fuel at pump / injector unit(s). Check fuel supply pump. Ensure
all bleed screws are closed.
Pressurise the fuel system and
bleed off any air.
Air filter clogged. Remove & clean / renew.
Governor faulty / blown fuse. Check fuse. Check linkage is
free.
Governor speed probe faulty. Renew probe.
Fuel limiter in governor or Install new governor or actuator.
actuator malfunctioning.
No fuel control output from panel. Check fuses, relays.
Over-speed trip operated. Find cause-rectify. Reset trip.
ENGINE STARTS BUT FAILS Air in fuel. Bleed air from fuel system.
TO RUN UP TO SPEED. Fuel tank level low. Fill to required level.
OR ENGINE LOSES Obstruction in spill return line. Ensure all valves are open.
SPEED WHEN ON LOAD Fuel filters choked. Renew filters.
Excessive governor droop. Refer to governor manual.
setting.
Air cleaner blocked. Clean / replace air cleaner.
High exhaust gas back- Check for obstruction such as
pressure. collapsed silencer or trunking.
Turbocharger faulty. Seek qualified technical help.
Load step excessive. Reduce load steps.
Engine overloaded. Reduce load level.

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Engine Running Faults

Symptom Possible Cause Remedy
EXCESSIVE BLACK SMOKE Engine overloaded. Reduce load level.
Blocked air cleaner. Clean / Replace air cleaner.
High exhaust gas back pressure. Check for obstruction such as
collapsed silencer or trunking.
Injectors / pumps require Service / renew injectors / pumps.
servicing. Refer to engine manual.
Turbocharger requires servicing. See engine manual .
Excessive light load running. Ensure correct loading.
Overheating. See “ENGINE OVERHEATS”.
EXCESSIVE WHITE SMOKE. Incorrect inlet and or exhaust Check valve clearances and
With engine misfiring. valve clearances. adjust if required.
Damaged valves / seats. See engine manual section .
Faulty pump / injectors. See engine manual section .
Excessive light load running. Ensure correct loading.
Turbocharger turbine seal faulty. See engine manual.
Contaminated fuel. Check fuel system for
contaminates Discard fuel and
replace if necessary.
EXCESSIVE BLUE SMOKE Worn pistons / piston rings - Check engine for worn parts and
liners / valve stems or valve replace as necessary referring to
guides. the engine manual.
Excessive light load running. Ensure correct loading.
Turbocharger compressor seal See engine manual.
faulty. Section.
High engine oil level. Reduce to correct level.
Contaminated fuel. Check fuel system for
contaminates. Discard fuel and
replace if necessary.
ENGINE OVERHEATS Radiator air matrix choked. Clean radiator air matrix.
Radiator fan motor faulty. Test circuitry - replace motor if
necessary.
Loss of coolant. Top-up to required level. Ascertain
reason for loss and rectify.
Cooling pumps faulty. Check pump drives and impellers
for wear. Overhaul or renew.
Ventilation louvres not open Open louvres
ENGINE OVERSPEEDS Governor faulty / Renew actuator or governor if
Actuator faulty. required - see engine manual.
Restricted fuel spill return line. Check for obstruction. Ensure
that all valves are open.
ENGINE WILL NOT STOP / Fuel drain-off solenoid valve If faulty, renew coil or replace
STOPS VERY SLOWLY faulty. whole unit.
Worn injector valves. Overhaul - replace injectors.
Actuator / drain off seals faulty. Replace seals / renew actuator.

Engine Running Faults (Continued)

Symptom Possible Cause Remedy

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ENGINE SPEED UNSTABLE Governor control unit faulty. Check linkage is free. Refer to
governor manual.
Actuator faulty. Overhaul or replace.
Restriction in spill return line. Check for obstruction. Ensure all
valves are open.
Restricted exhaust system. Check for obstruction such as
collapsed silencer or trunking.
Incorrect gain adjustment on Refer to governor manual.
governor.
Disrupted screen connection from Carry out a continuity test to locate
probe. the fault.
EXCESSIVE VIBRATION DUE TO Pump injector unit(s) faulty. Overhaul or replace. See engine
ENGINE MISFIRING manual section.
Inlet or exhaust valves sticking. Lubricate with half and half fuel oil
and lubricating oil.
Badly worn valve stems and / or Inspect and renew as required.
guides.
Burned valve seats / valves. Overhaul and replace.
ROTARY VIBRATION Alternator / engine misaligned. Seek qualified technical help.
Coupling faulty. Renew coupling. Seek qualified
technical help.
Alternator shaft distorted. Seek qualified technical help.
NO SPEED CONTROL (TRIM) Speed control faulty. Renew control unit.
Seek qualified technical help.
Governor control box faulty. Renew control box .
Seek qualified technical help.
Disrupted connections. Check and test connections.
Incorrect fuel limit setting. Adjust fuel limit setting. Refer to
governor manual.
ENGINE STOPS DUE TO LOW Low oil level. Top up oil to correct level.
OIL PRESSURE
Choked filter or dirty oil cooler. Change filter / clean cooler.
Internal or external oil leakage. Determine by inspection and
rectify.
Oil pressure relief valve faulty or Overhaul or adjust.
requiring adjustment.
Oil pump faulty. Remove, inspect. Overhaul or
renew.
Worn engine bearings. Inspect bearings and crankshaft
journals. Replace with new parts
as necessary.
ENGINE STOPS DUE TO HIGH Low coolant level. Top up with coolant and inspect for
TEMPERATURE leakage.
Radiator matrix choked. Clean radiator matrix.
Radiator fan motor faulty. Test circuitry. Replace motor if
necessary.
Cooling pumps faulty. Check pump drives and impellers
for wear. Overhaul or renew.
Charge failure Faulty charge alternator or battery Rectify fault or replace charge
charger alternator /battery charger
Engine stops due to fuel starvation Fuel tank low level, fuel system Check the fuel system for any of
leakage or fuel pipe blockage these faults

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Electrical Output Faults

Symptom Possible Cause Remedy
SET TRIPS ON EARTH FAULT Insulation in terminal box or Test all cables for earth fault.
cables faulty. Locate faulty section. Renew
section of cable or make good
insulation.
Earth fault in alternator stator Seek qualified technical help.
windings.
Current transformer(s) faulty. Test transformers for continuity
and earth fault. Replace if faulty.
Earth Fault relay malfunction Replace relay
Multiple neutral earths. Seek qualified technical help.
VOLTAGE DOES NOT BUILD Low residual or incorrect polarity Field flashing is required.
UP TO RATED VALUE between exciter output and Refer to alternator manual for
generator field. these instructions.
Exciter defective. Test Exciter output and refer to
alternator manual.
Short circuited rotating diodes. Test and replace defective
diodes. Refer To alternator
manual.
Open circuit connection to main Test for and locate fault in field.
field. Make good or seek qualified
technical help.
Prime mover not up to required Check governor linkage.
speed. Check fuel filters.
Defective Automatic Voltage Check and repair or replace.
Regulator.
POOR REGULATION Prime mover not up to speed. Bring up to rated speed.
Check governor and fuel control
linkage.
Fault in exciter or rotating Test diodes and exciter. Refer to
diodes. alternator manual section.
Faulty Automatic Voltage Test regulator. Repair or replace.
Regulator. Refer to alternator manual.
POOR VOLTAGE STABILITY Prime mover speed unstable. Refer to governor manual and to
engine manual.
Potentiometers out of Refer to alternator manual
adjustment. section. AVR.
Fault in exciter or rotating Test diodes and exciter. Refer to
diodes. alternator manual.
Faulty Automatic Voltage Test regulator. Repair or replace.
Regulator. Refer to alternator manual. AVR.
VOLTAGE RECOVERY SLOW Potentiometers poorly adjusted. Adjust potentiometers referring
WITH LOAD CHANGE to alternator manual.
Slow prime mover response Refer to governor and / or engine
time. manual.
PARALLELED GENERATORS Improve governor setting. Refer to governor manual.
DO NOT SHARE REAL kW
LOAD EQUALLY

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Electrical Output Faults (Continued.)

Symptom Possible Cause Remedy
OUTPUT VOLTAGE FALLS OFF Blown excitation power circuit Check fuse and replace if
AS LOAD INCREASES fuse. necessary.
Exciter defective. May require Field Flashing.
Refer to alternator manual
section AVR.
Diodes faulty. Test and replace as necessary.
See alternator manual.
Automatic Voltage Regulator. Repair or replace regulator.
Refer to alternator manual AVR
Short circuit on main field Seek qualified technical help
Permanent Magnet Generator Seek qualified technical help
fault
Surge suppressor faulty Replace
Poor load power factor (lagging). Alter nature of loading to
improve power factor - if
possible.
OUTPUT VOLTAGE RISES AS Excessive leading power factor. Alter nature of loading to
LOAD INCREASES improve power factor - if
possible.
SYSTEM DOES NOT START Function switch on Mains Set Function switch to AUTO.
ON MAINS FAILURE Failure Unit not in AUTO.
Global Emergency Stop button Release Emergency Stop
on Common Control Unit button.
depressed
No sets available. Check set status.
SET DOES NOT SUPPLY LOAD Defective circuit breaker or coil. Renew coil or entire breaker
Alternator voltage low / high. Ascertain reason for wrong
voltage and take the required
action.
Faulty synchronisation. Retry / Seek qualified technical
help.
SYSTEM DOES NOT SUPPLY Defective circuit breaker Seek qualified technical help.
LOAD interlocks.
Circuit breaker trip unit requires Reset or Seek qualified
resetting technical help.

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Control System Faults

SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION

Control does not power-up when the There is no DC power to the a) Check the battery electrolyte level and
Run/Off/Auto switch is set to Run or control. specific gravity.
the Self-test switch is pressed. b) Check terminals are clean and tight.
c) Check Fuse 1 on the engine interface
board.
d) Contact an authorised service centre.
Warning, Shutdown, and Non- None a) Indicates all engine systems are normal.
Automatic lamps are not lit. Digital b) No corrective action required.
display shows main menu or
selected menu.
Non-Automatic lamp flashes. Run-Off-Auto switch is not in the a) Move the Run-Off-Remote switch to the
Auto position. This will prevent Auto position for automatic operation.
automatic starting. b) None Automatic lamp stops flashing.
MESSAGE: PCC idles the engine at start up if a) Indicates that the engine is operating in
o
IDLE MODE jacket temperature is below 40 C, idle mode.
101 — Indication Only and continues to do so until this b) When the genset is operating in the
Engine continues to operate at temperature is reached. RUN mode, grounding the engine idle
reduced rpm. PCC idles the engine during input causes generator build-up to be
cooling run before shutting down. inhibited and the engine to be governed
The above conditions only apply to at idling speed.
engines requiring these procedures c) When ground is removed from this input,
to be set up. the genset returns to normal speed and
voltage.
d) When the engine idle function is
enabled, the control automatically sets
lower oil pressure warning and shutdown
trip points to reflect the lower operating
speed.
e) When the engine idle function is
removed and the genset reverts to
normal operating speed, the control
automatically resets the oil pressure
warning and shutdown trip points to the
normal settings.
Shutdown lamp lights. Local or remote Emergency Stop To Reset —
MESSAGE: Operated a) Turn the switch clockwise and allow it to
EMERGENCY STOP un-latch.
102 — SHUTDOWN b) Move the Run-Off-Auto switch to OFF.
Engine shuts down and will not c) Press the Reset switch.
crank. d) Select Run or Auto as required.
Warning lamp lights. Indicates that the engine oil a) The engine must be stopped as soon as
MESSAGE: pressure has dropped to an possible to prevent serious damage. If
LOW OIL PRESSURE unacceptable level. Possibly due to the engine can be stopped, do so.
200 — WARNING high oil temperature, low oil level, b) If the generator is powering critical loads
Engine continues to operate. dirty filters, dirty cooler, relief valve and cannot be shut down, wait until the
failure, potential oil pump failure, next shut down period then follow the
excessively worn engine bearings next procedure, Low Oil
— eventual bearing failure. Pressure.Shutdown
Shutdown lamp lights. Indicates that the engine oil a) Check all possible causes as in 200 —
MESSAGE: pressure has dropped below the warning.
LOW OIL PRESSURE shutdown trip point. The reason for b) Rectify the problem.
201 — SHUTDOWN this shutdown must be determined c) Reset the control system and re-start.
Engine shuts down. before restarting the engine. Check d) Check engine running conditions under
possible causes as in 200 — no load.
warning e) Contact an authorised service centre if
the problem persists.
Warning lamp lights. Indicates that the engine oil a) Check that the engine oil pressure
MESSAGE: pressure sender is not functioning sender is properly connected.
OIL PRES SENDER correctly. b) Contact an authorised service centre if
204 — WARNING problem persists.

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SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION

Warning lamp lights. Indicates that the engine coolant Check for the following conditions:
MESSAGE: heater is not operating or is not a) Coolant heater not connected to the
LOW COOLANT TEMP circulating coolant. power supply.
210 — WARNING b) Check for blown fuse or disconnected
The genset is in standby mode but heater cord and correct as required.
is not operating. Warning occurs c) Check for low coolant level and replenish
when the engine coolant if required.
temperature is 21°C (70°F) or lower. d) Look for possible coolant leakage points
Note: In applications where the and repair as required.
ambient temperature falls below 4°C e) Contact an authorised service centre if
(40°F), Low Engine Temp may be none of above.
indicated even though the coolant Note: This signal wakes-up the PCC from the
heaters are operating. Standby condition.
Warning lamp lights. Indicates that the engine has If the engine can be stopped.
MESSAGE: begun to overheat and the coolant a) Allow the engine to cool before checking
HIGH COOLANT TEMP temperature has risen to an the coolant level and replenish if
211 — WARNING unacceptable level: required.
Engine continues to operate. 101°C (215°F) – Standby / 97°C b) Determine reason for coolant loss and
(207°F) – Primary rectify.
If the generator is powering non- c) Check coolant pump & pump drive.
critical and critical loads and d) Check radiator matrix for air-born debris
cannot be shut down — reduce the and clean if required or if heat exchanger
load if possible by turning off non- is employed check raw water pump and
critical loads. raw water supply.
Check air inlets and outlets and e) Check fan belt and/or fan motor circuitry.
remove any obstructions to airflow. f) Access the Coolant Temp menu prior to
clearing the fault.
g) Run engine on no load test after
rectifying the fault.
Shutdown lamp lights. Indicates that the engine has Allow the engine to cool down completely
MESSAGE: overheated (coolant temperature before proceeding with the following checks:
HIGH COOLANT TEMP has risen above the shutdown trip a) Check the coolant level and replenish if
212 — SHUTDOWN point: low.
Engine shuts down. 101°C (215°F) – Standby / 97°C b) Look for coolant leakage and repair if
(207°F) – Primary necessary.
c) Check for obstructions to cooling airflow
and correct as necessary.
d) Carry out all checks as in 211 —
warning
e) Run engine on no load test after
rectifying the fault.
Warning lamp lights. Indicates that the resistance of the a) Check the sender. Resistance should be
MESSAGE: coolant temperature sender is out 500 to 2k ohm.
ENG COOLANT SENDER of range. b) If faulty — fit new sender.
213 — WARNING
Shutdown lamp lights. Indicates that the engine coolant a) Check the coolant level and replenish if
MESSAGE: level has fallen below the trip point. low.
LOW COOLANT LVL Allow the engine to cool down b) Look for possible coolant leakage points
214 — WARNING completely before proceeding. and repair if necessary.
Engine shuts down Note: This signal wakes up the c) Reset the control system and restart
or PCC. after locating and correcting the
LOW COOLANT LVL (Low Coolant Warning only). problem.
215 — SHUTDOWN d) Contact authorised service centre if
problem persists.
e) LOW COOLANT LVL Shutdown will not
occur if genset is in idle mode

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SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION

Shutdown lamp lights. Indicates that the magnetic pick-up a) Check that the pickup sensing head is
MESSAGE: speed indication is not being clean.
MAG PICKUP sensed or does not match the b) Check cable for continuity and good
220 — SHUTDOWN genset output frequency. screening.
Engine shuts down c) Restart and check RPM on the digital
display.
d) Contact an authorised Service Centre if
the problem persists.
Engine will not crank Indicates a possible fault with the Check for the following conditions:
Shutdown lamp lights. control or starting system. a) Check fuse F3 on the Engine Interface
MESSAGE: Discharged or defective battery. Board.
FAIL TO CRANK Poor battery cable connections. b) Recharge or replace the battery
221 — SHUTDOWN Locked starter motor or damaged c) Clean the battery cable terminals and
flywheel starter ring. tighten all connections including starter
motor.
d) Contact an authorised service centre for
service of starter and starting system.
Shutdown lamp lights. Indicates a possible fuel problem a) Replenish fuel supply tank.
Engine Stops Cranking or air induction problem: b) Renew fuel filters.
MESSAGE: Fuel supply tank low level or c) Ensure engine heaters are operating.
OVERCRANK contaminated fuel. d) Clean/renew induction filters.
222 — SHUTDOWN Fuel filters choked. e) Reset air shut off valves
Waxed fuel. f) Reset the control system and restart
Air induction filters choked. after correcting the problem.
Air shut-off valves operated. g) Contact an authorised service centre if
none of the above.
Engine runs and then shuts down. Indicates that the engine has a) Contact an authorised service centre.
Shutdown lamp lights. exceeded its normal operating
MESSAGE: speed trip point. Possible governor
OVERSPEED problem.
223 — SHUTDOWN
Warning lamp lights. Indicates that the battery voltage is a) Check the battery electrolyte level and
MESSAGE: below 24V dc. specific gravity.
LOW DC VOLTAGE Discharged or defective battery. b) Repair battery charger.
230 — WARNING Battery charger fault/fuse. c) Recharge or replace the battery.
d) Poor battery cable connections.
e) Clean the battery cable terminals and
tighten all connections.
f) Contact an authorised service centre if
none of the above.
Warning lamp lights. Indicates that the battery voltage a) Contact an authorised service centre.
MESSAGE: exceeds 32V dc.
HIGH DC VOLTAGE
231 — WARNING
Warning lamp lights. Indicates the battery voltage a) See Warning Message 230 LOW DC
MESSAGE: dropping below 60% of nominal for VOLTAGE.
WEAK BATTERY two seconds, during starting.
232 — WARNING Discharged or defective battery.
Engine continues to run.
Warning lamp lights. Indicates that the day tank fuel a) Check the fuel supply and replenish as
MESSAGE: supply is running low. required.
LOW FUEL DAY Note: This signal wakes up the PCC.
240 — WARNING
Warning lamp lights. Indicates that the fuel supply is a) Check the fuel supply and replenish as
MESSAGE: running low. required.
LOW FUEL
241 — WARNING
Shutdown lamp lights. Indicates PCC memory error. Data a) Contact an authorised service centre.
MESSAGE: corruption of critical operating
EEPROM ERROR parameters.
250 — SHUTDOWN

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SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION

Warning lamp lights. Indicates PCC memory error. Data a) Contact an authorised service centre.
MESSAGE: corruption of non-critical operating
EEPROM ERROR parameters.
251 — WARNING
or
252 — WARNING
Engine continues to run.
Shutdown lamp lights. QST30 SERIES ONLY. a) Check fuel pump connections
MESSAGE: Indicates that one, or both, of the b) Check left and right actuator fuses (A38-
RACK POSITION fuel racks is not at the commanded F1 & F2) on the Governor Output Module
260 — WARNING position. c) Contact an Authorised Service Centre
Shutdown lamp lights. When any one of these a) Contact an authorised service centre.
MESSAGE: customer defined inputs is
CUSTOMER FAULT 1 closed to ground, the
260 — SHUTDOWN corresponding fault message is
(not applicable for QST30 series) displayed. The nature of the
or
fault is an optional customer
GROUND FAULT
selection. These fault functions
261 — SHUTDOWN
or can be programmed to initiate a
RUPTURE BASIN shutdown or a warning.
262 — SHUTDOWN Customer fault 261 or 262 input
or can “wake-up” the control if it is
HIGH GEN TEMP not operating.
263 — SHUTDOWN As indicated by the Shutdown
Engine shuts down. lamp, a shutdown response has
been pre-selected.
Note: Customer fault messages
are editable. The message
displayed for the code shown
(260 to 263) may have been
edited and will not appear as
shown in this table.
Note: for QST30 series the code
260 is reserved for the RACK
POSITION fault and is not
available as Customer Fault 1.
Warning lamp lights. When any one of these customer- a) Contact an authorised service centre.
MESSAGE: defined inputs is closed to ground,
CUSTOMER FAULT 1 the corresponding fault message is
260 — WARNING displayed. The nature of the fault is
(not applicable for QST30 series) an optional customer selection.
or These fault functions can be
GROUND FAULT programmed to initiate a shutdown
261 — WARNING or a warning. Customer fault 261 or
or 262 input can “wake-up” the control
RUPTURE BASIN if it is not operating.
262 — WARNING As indicated by the Warning lamp,
or a shutdown response has been
pre-selected.
HIGH GEN TEMP
Note: Customer fault messages are
263 — WARNING
editable. The message displayed
for the code shown (260 to 263)
may have been edited and will not
appear as shown in this table.
Note: for QST30 series the code
260 is reserved for the RACK
POSITION fault and is not
available as Customer Fault 1.

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SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION

Shutdown lamp lights. Indicates that one of the phase a) Contact an authorised service centre.
MESSAGE: voltages has exceeded 130% of
HIGH AC VOLTAGE nominal, or has exceeded 110% of
301 — SHUTDOWN nominal for 10 seconds.
Engine shuts down.
Shutdown lamp lights. Indicates that one of the phase a) Contact an authorised service centre.
MESSAGE: voltages has dropped below 85%
LOW AC VOLTAGE of nominal for 10 seconds.
303 — SHUTDOWN
Engine shuts down.
Shutdown lamp lights. Indicates that engine speed has a) Contact an authorised service centre.
MESSAGE: dropped below 90% of nominal for
UNDER FREQUENCY 10 seconds.
313 — SHUTDOWN Note: Five seconds before
Engine shuts down. shutdown, a Load Dump signal is
initiated.

Warning lamp lights. Indicates that the generator output a) Contact an authorised service centre.
MESSAGE: current has exceeded 110% of
OVERCURRENT rated value for 60 seconds.
320 — WARNING
Engine continues to run.
Shutdown lamp lights. Indicates that the generator a) Contact an authorised service centre.
MESSAGE: output current has exceeded
OVERCURRENT 110% of rated value and that a
321 — SHUTDOWN PCC time/current calculation
Engine shuts down. has initiated an overcurrent
shutdown.

Shutdown lamp lights. Indicates that the generator output a) Contact an authorised service centre.
MESSAGE: current has exceeded 175% of
SHORT CIRCUIT rated value.
322 — SHUTDOWN
Engine shuts down.
Warning lamp lights. Indicates that the 3-phase power a) Contact an authorised service centre.
MESSAGE: exceeds 105% of standby (or
OVERLOAD 115% of prime) rating.
330 — WARNING After 5 seconds the Load Dump
Engine continues to run. output is activated.
After 60 seconds the OVERLOAD
warning is activated.
Shutdown lamp lights. Indicates improper CT or PT a) Contact an authorised service centre.
MESSAGE: phasing (Non-paralleling units
REVERSE POWER only).
335 — SHUTDOWN
Engine starts from the generator Check the control wiring between a) Contact an authorised service centre.
control panel but will not start the remote switch and the PCC.
automatically or from a remote
panel.
Note: The Run-Off-Auto switch must
be in the Auto position for automatic
or remote starting.
a) Contact an authorised service centre.
No ac output voltage.

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SECTION 6

APPENDICES

CONTENTS
Appendix A Battery Chargers (5A & 10A)
Appendix B Storage, Commissioning and Maintenance of Lead Acid Batteries
Appendix C Storage, Commissioning and Maintenance of Nickel-Cadmium Alkaline
Batteries
Appendix D Installation and Maintenance of Enclosures and Trailers
Appendix E Automatic Transfer Switch (ATS) Control Unit

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APPENDIX A

BATTERY CHARGERS (5A & 10A)

Boost charge ommences on the operation of
the BOOST switch located on the front panel
DESCRIPTION of the unit.
The 5 Amp and 10 Amp Battery Chargers are
of the constant voltage, current limited type,
designed for the charging of vented or sealed
lead acid and nickel cadmium batteries. They
are also capable of supplying a standing load
whilst simultaneously maintaining the battery
to its fully charged state. Designed to be left
in circuit during cranking and to operate in
parallel with the charge alternator mounted on
the engine.
Features:

• Boost charge facility

• Charge fail facility
• Short circuit protected
• Reverse power protected
• Constant voltage
• Current limited 5A Charger
• R.f. suppression
The chargers are supplied loose for wall
mounting.

OPERATION
As the charge cycle commences, current is
limited to the maximum allowable by the
electronic control circuitry. As the battery
becomes increasingly charged, the current
demanded by the battery reduces
proportionally, until the battery terminal float
voltage equals the reference voltage of the
charger at which point the charger maintains
a trickle charge only, which is insufficient to
either overcharge the battery or cause 10A Charger
“gassing” effects.

1. A BOOST CHARGE facility enables the

constant voltage of the charger to be
increased, allowing charge time to be
reduced and periodic equalisation of
battery cells to take place.

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CONTROLS AND INDICATORS

Controls
The following controls are provided:
POWER ON / OFF
Switches the unit On / Off .
BOOST
A Boost Charge facility enables the constant
voltage of the charger to be increased,
allowing charge time to be reduced and
periodic equalisation of battery cells to take
place. Boost charge is obtained when the
BOOST switch is placed in the ON position.
Battery Charger 5A
Note: The charger should not be left in the
“BOOST” position for excessive periods or
gassing of the battery will occur.
In the OFF position boost charging does not
take place.

INDICATORS AND METERS

The following indicators are provided:
POWER ON
This indicator illuminates when the POWER
switch is in the ON power and AC power is
supplied to the unit.
CHARGE CURRENT METER Battery Charger 10A
This indicates the output current of the
battery charger in amps.

SPECIFICATION
SUPPLY VOLTAGE:
220 to 250 Volts, 50-60Hz AC only. CHARGE FAILURE:
Others available on request Relay energises 10 secs after charge failure
OUTPUT TRANSISTORS: TEMPERATURE RANGE:
Rated at 15 Amps RMS, electronically -10 to +60 oC
regulated to the current set by control
PROTECTIONS:
BOOST: Short Circuit / Over Voltage / Over Current /
Increase of 0.35V per cell on connection of Reverse Polarity / Reverse Power
the 'BOOST" terminals circuitry.
RELAY CONTACT RATINGS:
Volts free, 16 A max., resistive.
MECHANICAL DETAILS
5A - 160 x 200 x 160mm (h x w x d)
10A - 300 x 380 x 210mm (h x w x d)

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APPENDIX B

STORAGE, COMMISSIONING AND MAINTENANCE

OF LEAD ACID BATTERIES
Safety Precautions
The handling and proper use of lead-acid batteries is not hazardous providing the correct
precautions are observed and personnel are trained in their use.

General Precautions
! Never lay tools or metal objects across the top of the battery.
! Keep batteries upright.
! Use tools with insulated handles.
Fire Hazard
! During the charging of a battery, explosive gases are given off. Keep the battery well
ventilated and away from naked flames and sparks. NO SMOKING.
! Before disconnecting a battery, always remove power from the mains powered battery
charger (where fitted) BEFORE disconnecting the charger leads.
! When putting a battery into service on a Set, connect the earth lead LAST; when removing
the battery, disconnect the earth lead FIRST.

WARNING
Ensure that batteries are charged in a well ventilated area, away from naked flames
and sparks.

WARNING
Before disconnecting the battery, always remove power from the mains powered
battery charger (where fitted).

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Fluid Hazard
! Take care when filling batteries with electrolyte. and always wear personal protective
equipment

WARNING
Never add undiluted sulphuric acid to a battery.

WARNING
Always wear an acid-proof protective apron, goggles and gloves when handling
electrolyte. If electrolyte is splashed on the skin or in the eyes, flush the affected
areas immediately with water and seek medical advice.

Introduction
Batteries are an essential part of any standby generator system and some 90% of all generator
failures are due to batteries.
It is therefore vital that batteries are stored, commissioned and maintained as detailed overleaf.
Reference should also be made to the Battery Manufacturer’s leaflet.
Batteries are usually supplied with the generator in ‘dry-charged’ form. In order to commission dry-
charged lead-acid batteries, pre-mixed electrolyte of the correct type and specific gravity must be
added to the cells of the battery.

Storage
Dry-charged batteries should be stored in a cool, dry place, upright and with the vent caps
securely in place.
Batteries must never be stacked one on top of another and must be protected from the floor by a
wooden pallet or suitably thick cardboard sheet.

Commissioning
Lead-acid batteries supplied in dry-charged form are commissioned as follows:

Pre-Commissioning Procedure
1. Check for any mechanical damage to the battery case or terminals, and ensure that the
battery is clean and dry.
2. Smear the battery terminals with petroleum jelly to prevent corrosion.
3. Remove the vent plugs and break any seals (if present), taking care not to damage the
plates or separators. The broken seal will fall into the bottom of the chamber and do no
harm.

Filling with Electrolyte

1. Fill each cell of the battery with dilute sulphuric acid (electrolyte) of the correct specific
gravity (SG) as shown in Table 1, and according to the levels given in Table 2.
2. The filling operation must be completed in one operation.

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3. Allow the battery to soak for between 10 to 15 minutes. If the electrolyte level has fallen, it
should be restored by adding electrolyte of the correct SG to the levels given in Table 2.
4. After filling, the battery must be placed on a commissioning charge within 1 hour.
Charging must take place before any load is placed on the battery. (Details given
overleaf).
Caution: Failure to give this commissioning charge may impair the charge capacity and life
of the battery.

Charging
1. Charge the battery at the current rating given in Table 2 for a minimum of 4 hours in order
to ensure that the acid is sufficiently mixed within the battery. The charging period may
need to be extended if the battery has been in storage.
2. At the end of the charging process, the electrolyte levels must be checked and restored if
necessary by the addition of electrolyte of the correct SG. The vent caps must then be
replaced.
Note: Any further topping-up of the electrolyte must be made
using distilled, or de-ionised water.
3. When the Set is running, check the charge alternator output using an induction
ammeter.

Fitting the battery to the Set

1. A battery must not be fitted to a Set without charge if the SG of the electrolyte has fallen
below 1.240 during storage.
2. Battery hold-down bolts must be tight but not over tight.
3. Re-smear the terminals with petroleum jelly, if necessary.
4. Fit the vents firmly in position and ensure that the battery is clean and dry.
5. Ensure correct polarity when connecting the battery to the Set. Even momentary incorrect
connection can cause damage to the electrical system. Connect the positive generator
cable FIRST, followed by the negative ground.
6. Terminal connections must be tight but not over tight.

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Maintenance
Batteries require attention at all times, even when not working. A battery will not last if it is
neglected. Maintenance is carried out as follows:

General
1. Keep the battery, and the battery area, clean and dry. To avoid contamination of the
battery, only clean it when the vent plugs are in place.
2. Filled and charged batteries must be stored in a cool, dry, well ventilated place.
3. Ensure that the vent caps are securely screwed down, or pushed home.
4. Keep the battery terminals and connections free from corrosion and coated in petroleum
jelly.

Electrolyte
1. Maintain the electrolyte to the levels indicated in Table 2 by the addition of distilled, or de-
ionised water only. Replace the vent plugs once filling is completed.
Caution: NEVER add tap or well water and NEVER allow the battery electrolyte to drop
below the top of the plates.

Charging
Where generators are used infrequently, battery re-charging must take place when the SG drops
below 1.220 (or 1.180 in tropical climates) until the SG in all cells rises and remains constant for 3
hours. In all cases where use is infrequent, batteries must be put on a monthly re-charge schedule
to ensure that a fully charged condition is maintained.

Caution: NEVER allow a battery to become completely flat (fully discharged), or to stand in
a discharged condition, or damage will result.

1. Remove the vent caps before carrying out charging.

2. Do not put a filled battery into storage without first giving the battery a commissioning
charge.
3. Batteries must be given a further charge every 6 months at the normal initial charge rate
until the voltage and SG cease to rise.
4. At the end of the charging process, the electrolyte levels must be checked and restored, if
necessary, by the addition of electrolyte of the correct SG. The vent caps must then be
replaced.
Note: Any further topping-up of the electrolyte must be made using distilled or de-ionised
water.

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Trickle / Boost Charging (Option)

Where a mains-powered battery charger is provided (and switched ON), the battery will
automatically receive a ‘trickle-charge’ to prevent the battery becoming discharged below its
optimum charge level.
During trickle-charging, not all cells in the battery receive the same charge; over a period of
several months this may affect battery performance. It is therefore good practice to give batteries a
regular charge at their full rate to return all cells to full capacity. This is referred to as boost-
charging, or equalise-charging.
If the charger is fitted with a Boost Charge switch, the Boost position should be selected at
intervals detailed by the battery manufacturer (normally around every 6 months).

Caution: Batteries should not be left on Boost Charge for extended periods as this will result
in excessive water consumption, gassing, and may impair battery performance.

A Boost Charge not exceeding twice the bench charge rate may be used, providing that:
! Electrolyte temperature does not exceed 43°C.

! The battery volts do not reach 15V (for a 12V battery).

If either of these situations should arise, reduce the charge rate to the normal bench rate. For
tropical climates the temperature must not exceed 49°C.
Note: The charge period should be extended:
1. to 8 hours if the battery has been in storage for 3 months or more, at temperatures in
excess of 30°C, or if humidity is above 80%.
2. to 12 hours if the battery has been in storage for 12 months or more.
At the end of the charging process, the electrolyte levels must be checked and restored if
necessary by the addition of electrolyte of the correct SG. The vent caps must then be replaced.
Note: Any further topping-up of the electrolyte must be made
using distilled or de-ionised water.

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Electrolyte Specific Gravity and Temperature

Table 1 shows the specific gravity (SG) of electrolyte, corrected to 25°C. To correct the SG
reading for other temperatures, apply the correction formula shown in the note on temperature
correction.
TABLE 1

SPECIFIC GRAVITY

TEMPERATURE For Filling New Cells At end of Charge

Ambient temperature normally below 32°C 1.270 1.270 – 1.290

Ambient Temperature frequently above 32°C 1.240 1.240 – 1.260

Maximum permissible temperature of electrolyte 45°C 45°C

during charge

Temperature Correction
Correct the specific gravity as follows:
1. For every 10°C above 25°C, subtract 0.007 (7 points).
2. For every 10°C below 25°C, add 0.007 (7 points).
For example:
if the Specific Gravity at 25°C is 1.260,
then the Specific Gravity at 15°C is 1.267

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Electrolyte Levels and Bench Charging Rates

The following Table shows the electrolyte level to be expected at a range of bench charging rates:
TABLE 2

Battery Electrolyte Bench

Type Level Above Charging
Plates (mm) Rate (A/hour)

001 8 3.0
007 8 3.5
015 8 4.0
016 8 4.0
017 8 9.0
035 8 3.5
036 8 3.5
037 8 4.0
038 8 4.0
046 8 6.0
047 8 3.0
048 8 4.0
049 8 4.0
063 8 4.0
065 8 5.0
067 8 7.0
068 8 7.0
069 8 7.0
070 8 7.0
071 8 6.0
072 8 8.0
073 8 6.0
074 8 7.0
075 8 7.0
077 8 4.0
078 12 5.0
083 8 3.5
084 8 4.0
085 8 5.0
090 12 7.0
091 8 6.0
092 12 5.0
093 8 6.0
097 8 6.0
154 4 3.5
175 8 7.0

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191 6 6.0

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TABLE 2 (Continued)

Battery Electrolyte Bench

Type Level Above Charging
Plates (mm) Rate (A/hour)

154 4 3.5
175 8 7.0
191 6 6.0
221 8 8.0
222 8 12.0
279 8 6.0
312 8 14.0
313 8 14.0
315 8 14.0
319 8 14.0
320 8 14.0
321 8 14.0
322 8 14.0
324 8 20.0
325 8 20.0
327 8 11.0
328 8 20.0
329 8 20.0
332 8 25.0
333 8 11.0
386 8 6.0
404 8 7.0
414 8 20.0
415 8 20.0
471 8 15.0
484 8 25.0
501 8 9.0
511 8 10.0
521 8 12.0
531 8 13.0
541 8 15.0
543 8 15.0

591 8 14.0
602 8 8.0
612 8 9.0
635 16 12.0
643 16 9.0
644 16 12.0

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645 16 9.0
646 16 8.0

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TABLE 2 (Continued)

Battery Electrolyte Bench

Type Level Above Charging
Plates (mm) Rate (A/hour)

647 16 12.0
648 16 12.0
649 16 9.0
655 16 12.0
656 16 12.0
663 16 9.0
664 16 9.0
665 16 9.0
678 8 6.0
679 16 9.0
701 8 16.0
702 8 20.0
703 8 25.0
711 8 16.0
712 8 20.0
713 8 25.0
721 8 15.0
722 8 20.0
732 8 15.0
733 8 20.0
769 8 45.0

Note: NOTE: 1. If not listed in Table 2, use the bench rate given in the catalogue, or
charge at a current equal to 10% of the nominal capacity at the 20 hour rate (A/hour),
or 5% of the reserve capacity in minutes.

Note: 2. Batteries of the 800 series should be prepared in accordance Storage,

commissioning and
maintenance of lead acid batteries with the instructions supplied with each battery.

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Fault Finding
The following table shows some typical faults, their possible causes and remedies.
TABLE 3 — Fault Finding

SYMPTOM POSSIBLE FAULT REMEDY

Battery completely discharged Poor battery terminal connection Clean connections, replace and
tighten

Charge alternator / alternator Check alternator and

connection fault connections

Mains battery charger / charger Check battery charger, charger

connections fault / mains supply mains supply and charger
fault connections

Blown fuse Replace fuse

Battery fault Remove and check using

specialist equipment

Battery low charge Poor battery connection Clean connections, replace and
tighten

Charge alternator / alternator Check alternator and

connection fault connections

Mains battery charger / charger Check battery charger and

connections fault charger connections

Inequality in cell charge Boost (equalise) charge required.

Battery fault Remove and check using

specialist equipment

Battery overcharged Charge alternator fault Check charge alternator

Mains battery charger fault Check mains battery charger

Battery terminals getting hot Poor battery connection Clean terminals, reconnect and
tighten securely

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APPENDIX C

STORAGE, COMMISSIONING AND MAINTENANCE

OF NICKEL-CADMIUM ALKALINE BATTERIES
Safety Precautions
The handling and proper use of Nickel-Cadmium Alkaline (NiCad) batteries is not hazardous
providing the correct precautions are observed and personnel are trained in their use.

General Precautions
! Never allow tools or metal objects to rest on or fall across the top of the battery.

! Keep batteries upright.

! Use tools with insulated handles.

Fire Hazard
! During the charging of a battery, explosive gases are given off. Keep the battery well ventilated and away
from naked flames and sparks. NO SMOKING.

! Before disconnecting a battery, always remove power from the mains powered battery charger (where fitted)
BEFORE disconnecting the charger leads.

! When putting a battery into service on a Set, connect the earth lead LAST; when removing the battery,
disconnect the earth lead FIRST.

Fluid Hazard
! NiCad battery electrolyte is alkaline, corrosive and toxic.

! Take care when filling batteries with electrolyte and always wear personal protective equipment.

! Only top-up with pure distilled water.

WARNING
Never add sulphuric acid in any form to a NiCad battery.

In the event of an accident:

• Wash skin burns with copious amounts of clean water, then immediately cover the
affected area with gauze.
• Wash eyes with copious amounts of clean, tepid water. A supply of clean, tepid water
should be available whenever electrolyte is handled.
• Where necessary, seek medical attention.

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Introduction
Batteries are an essential part of any standby generator system and some 90% of all generator
failures are due to batteries.
It is therefore vital that batteries are stored, commissioned and maintained as detailed overleaf.
Reference should also be made to the Battery Manufacturer’s leaflet.
Batteries are usually supplied with the generator in ‘dry-charged’ form. In order to commission
NiCad batteries, the procedure detailed overleaf must be carried out.

Installation and Commissioning

Preparation for Service
Unpack immediately on receipt and examine for damage.

Batteries delivered ‘Filled and Discharged

1. Immediately on arrival, remove the sealing tape and transit stoppers from the individual
cell vents.
2. Check the electrolyte level in all cells and if necessary top-up with pure distilled water to
10mm below the specified maximum level.
Batteries Delivered ‘Empty and Discharged’
1. A battery may remain in the ‘empty and discharged’ condition for some time if not required
to be placed in service immediately.
2. When required for use, remove the sealing tape and transit stoppers.
3. Fill the cells with electrolyte to the correct level and allow to stand for at least 24 hours
after filling. Adjust the electrolyte level after this period if required.
4. Close the vent caps, or replace the plastic screw-in vents after removing the small rubber
stoppers.

Installation
1. Install the battery in a clean, well lit, and well ventilated area. If installed in a cubicle,
adequate ventilation must be provided. If the battery must be placed on the floor it is
necessary to use battens, preferably on insulators. This will raise crates or cell bottoms
clear of any damp or dust which may accumulate. Avoid installing batteries in a hot area.
For optimum efficiency it is preferable to operate NiCad batteries within the range 15°C to
25°C. It is essential that filler openings of all cells are readily accessible.
2. Place crates or tapered blocks of cells in the correct position for connecting-up as a
battery. Fit inter-crate, or inter-block connectors and then the main battery leads. Tighten
all nuts firmly with a box spanner.
Caution: Ensure correct polarity when connecting the battery to the Set. Even momentary
incorrect connection may cause damage to the electrical system. Connect the
positive generator cable FIRST, followed by the negative ground.

3. Smear the battery terminals with petroleum jelly to prevent corrosion.

Commissioning Charge (‘Filled and Discharged’ Batteries)

NiCad batteries supplied ‘filled and discharged’ require to be charged before being put into service.
This charge should be for not less than twice as long as the normal boost re-charge, or for at least
24 hours at the high charge rate.

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The charging details are as follows:

TABLE 1 — Battery Behaviour when C/5* Current is Available

UHP/UHS/HPB MP/MPB/MS/VP/R LP/LPB

VOLTS/CELL V VOLTS/CELL
VOLTS/CELL

Commissioning charge within 24 hours 1.67 1.70 1.72

Normal (boost) recharge in 8 hours 1.68 1.70 1.72
Recommended float voltage for fully 1.45 1.46 1.47
automatic operation

*C is the nominal capacity of the battery.

Check electrolyte levels in cells after commissioning and adjust by adding pure distilled water as
described under topping-up.
Note: Batteries should not be left on boost charge for extended periods as
electrolyte consumption is greatly increased.

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Maintenance
Battery Cleanliness
Cells and crates must be kept clean and dry at all times.

Terminals and Connectors

Cell and battery terminals and connectors should be kept corrosion-free and greased with
petroleum jelly.
At least once a year, check that all terminals and connectors are tight. This is particularly
important where batteries are subject to vibration.
Check that all terminals and connectors are free from corrosion. Clean and re-grease if
necessary.

Topping-Up
The electrolyte level must never be allowed to fall below the top plates.
Ideally, where topping-up is required, carry out before charging, using pure distilled water only. Do
not fill above the correct level.
Very high consumption of electrolyte indicates that the cells are being over-charged. A zero
consumption of electrolyte suggests that the charging rate is probably insufficient.
To determine the electrolyte level, proceed as follows:
1. Insert the level-testing tube (which must be clean) into the cell vent until it touches the top
of the plate group.
2. Place a finger over the end of the tube.
3. Withdraw the tube.
4. The height of electrolyte retained in the tube indicates the level of electrolyte above the
plates.

Specific Gravity Checks

Specific gravity does not vary with the state of charge but falls gradually during service.
New cells contain electrolyte with a specific gravity in the range 1.190 to 1.220 for standard cells
type R and 3. Cells should not be used with a specific gravity below 1.145. These figures are for an
electrolyte temperature of 20°

Trickle / Boost Charge (Option)

Where a mains-powered battery charger is provided (and switched ON), the battery will
automatically receive a trickle charge to maintain the battery in a fully charged condition.
During trickle charging, not all cells in the battery receive the same charge, and over a period of
several months this may affect battery performance. It is therefore normal to give batteries a regular
charge at their full rate to return all cells to full capacity. This is referred to as Boost or Equalise
Charging.
If the charger is fitted with a Boost Charge switch, the BOOST position should be selected at
intervals detailed by the battery manufacturer (normally around every 6 months).

Caution: Batteries should not be left on Boost Charge for extended periods
as this can result in excessive water consumption, gassing, and
may impair battery performance.

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Storage
If NiCad batteries are not put into service immediately they should be stored in a clean, cool, dry
and well ventilated place on open shelves.
! Plastic cells should not be exposed to direct sunlight.
! Before storage, ensure that cells are given a protective coating of petroleum jelly on the
glands, connectors and steel cell tops.
! The electrolyte level should be at the specified maximum level.
! Vents must be correctly seated with the vent plugs firmly in position.
! KEEP TRANSIT PLUGS INSERTED.
If excessive loss of electrolyte is found in cells supplied ‘filled and discharged’, the cells must be
correctly filled before storage — using the topping-up procedure described.

Cells ‘Filled & Discharged’ or ‘Filled & Partially Charged’

Cells ‘Filled and Discharged’ or ‘Filled and Partially Charged’ can be stored for up to a maximum
of one year. The cells should be sealed with the transit plugs, supplied with the cells, firmly fitted.
Check the plugs periodically.
If, for unavoidable reasons, cells have to be stored for more than one year, they must be
maintained as follows:
1. Remove the plugs from the cells.
2. Charge to 200% of capacity at an available rate (C/5 for 10 hours or C/10 for 20 hours)
and then discharge at the same rate to 1.1 volts per cell.
3. Replace the plugs firmly and return the cells / batteries to storage.
4. Repeat every 12 months.
If cells have to be stored for more than one year, at least two charge/discharge cycles are
recommended before putting the battery into service.

Cells ‘Discharged and Empty’

Cells ‘Discharged and Empty’ can be stored for an indefinite period. It is important that they are
sealed with the transit vent plugs fitted firmly in position. These should be checked periodically
during storage.

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Fault Finding
The following table shows some typical faults, their possible causes and remedies.
TABLE 2 — Fault Finding

SYMPTOM POSSIBLE FAULT REMEDY

Battery completely discharged Poor battery terminal connection Clean connections, replace and
tighten

Charge alternator / alternator Check alternator and

connection fault connections

Mains battery charger / charger Check battery charger, charger

connections fault / mains supply mains supply and charger
fault connections

Blown fuse Replace fuse

Battery fault Remove and check using

specialist equipment

Battery low charge Poor battery connection Clean connections, replace and
tighten

Charge alternator / alternator Check alternator and

connection fault connections

Mains battery charger / charger Check battery charger and

connections fault charger connections

Inequality in cell charge Boost (equalise) charge required.

Battery fault Remove and check using

specialist equipment

Battery overcharged Charge alternator fault Check charge alternator

Mains battery charger fault Check mains battery charger

Battery terminals getting hot Poor battery connection Clean terminals, reconnect and
tighten securely

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APPENDIX D

INSTALLATION AND MAINTENANCE OF

ENCLOSURES AND TRAILERS
Introduction
Silencing and weather protection of generating Sets is accomplished in a wide variety of
applications with a range of enclosures.
Acoustic enclosures are designed to reduce noise emitted from a generating Set. A range of types
provide noise reductions from 15dB(A) to 30dB(A) and above. EEC rated types are also available.
In general, 15dB(A) and EEC rated enclosures are used for construction site work and the
30dB(A) enclosures for permanent installations when emergency standby generators are located
near residential areas.

Installation
Preparing for Installation
Prepare for installation as follows:
1. Position the enclosure in the required place.
2. Open the canopy doors and carry out the full installation procedure as described in the
Generator Control System manual.
3. Carry out generator commissioning as described in the Generator Control System
manual.
Caution: Plugs / wiring of adequate current, voltage and insulation rating must be used.

Caution: All non-current carrying metalwork associated with the equipment must be
bonded to a suitable earth connection.

Positioning
Select a position for the enclosure which is as close as possible to the load to be supplied,
ensuring that the following conditions are met:

Ground Condition
The ground must be dry, level and firm enough to support the weight of the enclosure without any
sinking with time.

Access
There must be adequate access for installation, commissioning and maintenance of the
generator.

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Ventilation and Exhaust

The positioning of the enclosure should be such that generator exhaust and cooling air flows do
not create a nuisance, or potential source of danger to personnel, or buildings etc.

Maintenance
External Surfaces
All external surfaces should be inspected for damage periodically, and cleaned to remove any
build-up of dirt.

Doors
Inspect the neoprene seal for damage and replace if necessary.
Apply grease to the door hinges.
Check the door handles, locks and internal panic-release mechanisms for correct operation.

Air Inlets / Outlets

Check that the air inlet and outlet ventilation grilles are free from clogging by debris, and that no
objects are placed against them.

Exhaust System
The exhaust system should be inspected for leaks and damage.
Check that the exhaust pipe exit is free from obstruction and clear of debris.
Ensure that no materials or debris have come into contact with the exhaust system, particularly
surfaces which become hot when the generator is in operation.

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Trailers
Introduction
Generating Sets from 3 kVA to 4000 kVA can be used as mobile units with a range of trailers. This
range includes two / four wheel, articulated and truck-mounted types.

Installation
Positioning
Select a position for the trailer which is as close as possible to the load to be supplied, ensuring
that the following conditions are met:

Ground Condition
The ground must be dry, level and firm enough to support the weight of the trailer without any
sinking with time.

Access
There must be adequate access for installation, commissioning and maintenance of the
generator.

Ventilation and Exhaust

The positioning of the generator should be such that its exhaust and cooling air flows do not create
a nuisance, or potential source of danger to personnel, buildings, etc.

Preparing for Installation

Prepare for installation as follows:
1. Tow the trailer to the selected position.
2. Prepare to disconnect from the towing vehicle, ie disconnect the lighting system, lower
the jockey wheel, etc as appropriate.
3. Disconnect from the towing vehicle, apply the handbrake and chock the wheels.
4. Ensure that the trailer is level by adjusting the jockey wheel etc. as appropriate.
5. Lower the prop stands where provided.
6. Open the canopy doors and carry out the full installation procedure as described in the
Generator Control System manual.
Caution: Plugs / wiring of adequate current, voltage and insulation rating must be used.

Caution: All non-current carrying metalwork associated with the equipment must be
bonded to a suitable earth connection.

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Transporting
When preparing to transport the generator, proceed as follows:
1. With the generator shut down and isolated from the mains supply, disconnect all cables
from the generator, store cables safely and ensure that any connecting sockets are
covered to prevent the ingress of dust and moisture.
2. Close and lock all canopy doors to prevent them opening during transit.
3. Remove all wheel chocks and store them safely.
4. Raise any prop-stands and securely lock them in the fully raised position.
5. Carefully release the handbrake and using the drawbar (and jockey wheel where fitted),
connect the trailer to the towing vehicle.
6. Ensure that the handbrake is fully released and the jockey wheel (If fitted) is in the fully
raised position and securely locked.
7. Connect the trailer lighting plug to the towing vehicle and check for correct operation of
the trailer’s lighting system.

Maintenance
Basic maintenance for the trailer should be performed as follows:
1. All external surfaces should be periodically inspected for damage, and cleaned to remove
any build-up of dirt.
2. Periodically inspect the trailer’s lighting system for damage and check for correct
operation.
3. Periodically inspect the trailer’s braking system and carry out any appropriate
maintenance, eg apply grease to the handbrake ratchet and exposed inner sections of the
handbrake cable.
4. Periodically check the pneumatic tyres for correct inflation pressure, wear, or damage,
etc.
5. Apply grease to the sliding sections of the prop-stands and jockey-wheel as appropriate.
6. Where possible, periodically prepare the trailer for transportation as described above and
then move it to a new site to allow the running gear and braking system to be used and
checked.
Note: Refer to the Trailer Manufacturer’s Installation and Servicing
Instructions for further information.

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APPENDIX E

SYSTEM PCL - 005

AUTOMATIC TRANSFER SWITCH (ATS)
CONTROL UNIT

DESCRIPTION
System PCL - 005 is a fully configurable
Automatic Transfer Switch (ATS) Control Unit
designed to monitor an incoming utility supply
(1 or 3 phase) for under / over voltage and
under / over frequency. Should these fall
outside preset limits the unit will issue a start
command to the generating set controller.
Once the set is available (up to speed and
voltage limits) the unit will control the transfer
devices and switch the load from the supply
to the generating set. Should the utility supply
return to within limits the unit will command a Construction and Power Source
return to the utility supply and shut down the
generator, after a suitable cooling run. The unit is housed in robust, DIN case with
connection to the module being through plug
Various timing sequences are used to and socket connection.
prevent nuisance starting and supply breaks.
The unit features a self seeking power supply
Configuration which will take power from the utility or
generator AC supply. (A DC supply is not
Configuration is by PC-based software and essential for basic operation).
a proven interface using an FCC68 socket on
the rear of the module. This allows rapid and
secure configuration of the unit and also
allows a relay expansion module to be
utilised. The FCC68 socket also provides full,
real time diagnostics on the status of the unit,
its inputs and outputs.
Configuration and connection options also
allow for a wide range of higher functions
such as ‘Auto Start Inhibit’, ‘Manual Restore to
Mains’, ‘Load Inhibit’ (both supply and
generator). ‘Lamp Test’, push button transfer
control, external supply or generator failure
inputs, etc.

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OPERATION CONTROLS AND INDICATORS

Operating Modes
Operator control is provided by a front panel
mounted, four position keyswitch with the
following positions:
Run on Load: Runs the generator and takes
up the load regardless of the utility supply
condition.
Auto: Starts the generator and takes up the
load when the supply fails, transfers
automatically back to the supply if the
supply returns.
Auto Start, Manual Restore: Starts the
generator and takes up the load when the
supply fails. It does not transfer
automatically back to the supply when the
supply returns.
Run Off Load: Runs the generator off load CONTROLS
for testing purposes but transfers the load
to the generator if the supply fails. The unit The unit is provided with a keyswitch (key
automatically transfers the load back to the removable) with the following positions:
supply on its return. RUN ON LOAD (bottom left)
Indicators The unit starts the generator and supplies a
A clear mimic diagram with ‘International’ signal to close the generator contactor to take
symbols and LED indication provides ‘at a up the load when the generator is available
glance’ information on supply availability and (up to speed and voltage), regardless of uitility
load switching status. Further LED indication supply condition.
is provided for Start Delay in Progress’ and AUTO (top left)
‘Mains Return Timer Active’. Two user
configurable LED’s are provided to allow the The unit automatically starts the generator
user to display specific states. when the supply fails and provides a signal to
close the generator contactor when the
generator is available. On return of the supply
the unit automatically initiates load transfer
back to the supply and shuts down the
generator (after a predetermined cooling run).
AUTO START, MANUAL RESTORE (top
right)
Starts the generator and supplies a signal to
close the generator contactor when the
supply fails. Does not initiate automatic
transfer back to the supply on its return.
RUN OFF LOAD bottom right)
Runs the generator off load for test purposes
but transfers the load to the generator if the
supply fails. The unit transfers the load back
to the supply if the supply returns.

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Indicators
Indication is provided by LED’s as follows:
Pre-defined LED’s
Mains Available LED (top right)
Mains on Load LED (bottom right)
Generator Available LED (top left)
Generator on Load LED (bottom left)

Start Delay in Progress (top right)

Mains Return Time Active LED (bottom right)

Configurable LED’s
2 User Configurable LED’s (top & bottom left)

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