Safety Precautions
SAVE THESE INSTRUCTIONS − This
manual contains important instructions
that should be followed
during installation and maintenance of
the generator set and batteries.
Before operating the generator set
(genset),
read the Operator’s Manual and become
familiar with it and the equipment.
Safe and efficient operation
can be achieved only if the
equipment is properly operated and
maintained.
Many accidents are caused by failure to
follow fundamental rules and
precautions. The following symbols,
found throughout this manual,
alert you to potentially dangerous
conditions to the operator, service
personnel, or the equipment
DANGER This symbol warns of
immediate
hazards which will result in severe
personal injury or death.
WARNING This symbol refers to a
hazard or unsafe practice which can
result in severe personal injury or
death.
CAUTION This symbol refers to a
hazard or unsafe practice which can
result in personal injury or product or
property damage.
FUEL AND FUMES ARE FLAMMABLE
Fire, explosion, and personal injury or
death can result from improper
practices.
− DO NOT fill fuel tanks while engine is
running, unless tanks are outside the
engine compartment. Fuel contact with
hot engine or exhaust is a potential fire
hazard.
− DO NOT permit any flame, cigarette,
pilot
light, spark, arcing equipment, or other
ignition source near the generator set or
fuel tank.
− Fuel lines must be adequately secured
and free of leaks. Fuel connection at the
engine should be made with an
approved flexible line. Do not use zinc
coated or copper fuel lines with diesel
fuel.
− Be sure all fuel supplies have a
positive shutoff valve.
− Be sure battery area has been well-
ventilated prior to servicing near it.
Lead-acid batteries emit a highly
explosive hydrogen gas that can
be ignited by arcing, sparking, smoking,
etc.
EXHAUST GASES ARE DEADLY
− Provide an adequate exhaust system
to properly expel discharged gases
away from enclosed or sheltered areas
and areas where individuals are likely to
congregate. Visually and audibly inspect
the exhaust for leaks daily or per the
maintenance schedule. Make sure
that exhaust manifolds are secured and
not warped. Do not use exhaust gases
to heat a compartment.
− Be sure the unit is well ventilated.
− Engine exhaust and some of its
constituents are known to the state of
California to cause cancer, birth defects,
and other reproductive harm.
MOVING PARTS CAN CAUSE
SEVERE PERSONAL INJURY OR
DEATH
− Keep your hands, clothing, and jewelry
away from moving parts.
− Before starting work on the generator
set, disconnect battery charger from its
AC source, then disconnect starting
batteries, negative (−) cable first. This
will prevent accidental starting.
− Make sure that fasteners on the
generator set are secure. Tighten
supports and clamps, keep guards in
position over fans, drive belts, etc.
− Do not wear loose clothing or jewelry
in the vicinity of moving parts, or while
working on electrical equipment. Loose
clothing and jewelry can become caught
in moving parts.
− If adjustment must be made while the
unit is running, use extreme caution
around hot manifolds, moving parts, etc.
DO NOT OPERATE IN FLAMMABLE
AND EXPLOSIVE ENVIRONMENTS
Flammable vapor can cause an engine
to overspeed and become difficult to
stop, resulting in possible fire, explosion,
severe personal injury and death. Do
not operate a genset where a flammable
vapor environment can be created by
fuel spill, leak, etc., unless the genset is
equipped with an automatic safety
device to block the air intake and stop
the engine. The owners and operators
of the genset are solely responsible for
operating the genset safely. Contact
your authorized Cummins Power
Generation distributor for more
information.
ELECTRICAL SHOCK CAN CAUSE
SEVERE PERSONAL INJURY OR
DEATH
− Remove electric power before
removing protective shields or touching
electrical equipment. Use rubber
insulative mats placed on dry wood
platforms over floors that are metal
or concrete when around electrical
equipment. Do not wear damp clothing
(particularly wet shoes) or allow skin
surface to be damp when handling
electrical equipment. Do not
wear jewelry. Jewelry can short out
electrical contacts and cause shock or
burning.
− Use extreme caution when working on
electrical components. High voltages
can cause injury or death. DO NOT
tamper with interlocks.
− Follow all applicable state and local
electrical codes. Have all electrical
installations performed by a qualified
licensed electrician. Tag and lock open
switches to avoid accidental closure.
− DO NOT CONNECT GENERATOR
SET DIRECTLY TO ANY BUILDING
ELECTRICAL SYSTEM.
Hazardous voltages can flow from
the generator set into the utility line. This
creates a potential for electrocution or
property damage. Connect only through
an approved isolation switch or an
approved paralleling device.
MEDIUM VOLTAGE GENERATOR
SETS (601V to 15kV)
− Medium voltage acts differently than
low voltage. Special equipment and
training is required to work on or around
medium voltage equipment. Operation
and maintenance must be done only by
persons trained and qualified to work on
such devices. Improper use or
procedures will result in severe personal
injury or death.
− Do not work on energized equipment.
Unauthorized personnel must not be
permitted near energized equipment.
Due to the nature of medium voltage
electrical equipment, induced voltage
remains even after the equipment
is disconnected from the power source.
Plan the time for maintenance with
authorized personnel so that the
equipment can be deenergized
and safely grounded.
GENERAL SAFETY PRECAUTIONS
− Coolants under pressure have a
higher boiling point than water. DO NOT
open a radiator or heat exchanger
pressure cap while the engine is
running. To prevent severe scalding,
let engine cool down before removing generator set. A fire or explosion could
coolant pressure cap. Turn cap slowly, result.
and do not open it fully until the − Wear hearing protection when near an
pressure has been relieved. operating generator set.
− Used engine oils have been identified − To prevent serious burns, avoid
by some state or federal agencies as contact with hot metal parts such as
causing cancer or reproductive toxicity. radiator system, turbo charger system
When checking or changing engine oil, and exhaust system.
take care not to ingest, breathe the
fumes, or contact used oil. KEEP THIS MANUAL NEAR THE
GENSET FOR EASY REFERENCE
− Keep multi-class ABC fire
extinguishers handy. Class A fires DISPOSE OF THIS UNIT PROPERLY
involve ordinary combustible
materials such as wood and cloth; Class
B fires, combustible and flammable
liquid fuels and gaseous fuels; Class C
fires, live electrical equipment. (ref.
NFPA No. 10).
− Make sure that rags or combustible
material are not left on or near the
generator set.
− Make sure generator set is mounted in
a manner to prevent combustible
materials from accumulating
under or near the unit.
− Remove all unnecessary grease and
oil from the unit. Accumulated grease
and oil can cause overheating and
engine damage which present a
potential fire hazard.
− Keep the generator set and the
surrounding area clean and free from
obstructions. Remove any debris from
the set and keep the floor clean and dry.
− Do not work on this equipment when
mentally or physically fatigued, or after
consuming any alcohol or drug that
makes the operation of equipment
unsafe.
− Substances in exhaust gases have
been identified by some state or federal
agencies as causing cancer or
reproductive toxicity. Take care not to
breath or ingest or come into contact
with exhaust gases.

− Do not store any flammable liquids,

such as fuel, cleaners, oil, etc., near the
 1. System Overview
Read Safety Precautions, and carefully observe
all of the instructions and precautions in this
manual. Keep this manual with the other genset
and/or controller manuals.
ABOUT THIS MANUAL
You should have a basic understanding of
generators and power generation before you read
this manual.
The PS0500 is a microprocessor-based controller
that has these abilities.
• Start and stop the genset.
• Monitor the status of the genset.
• Warn the operator when unsafe conditions
are occurring
• Shut down the genset to prevent damage
• Adjust settings that affect genset behavior.
• Provide a way for other devices to remotely
start / Stop the genset
This is the Operator Manual for the PowerStart
0500 control. It is not the Operator Manual for the
generator set (“genset”) or any accessories.
DESCRIPTION
The PowerStart 0500 is suitable for non-paralleling
generator sets (“gensets”) in standby or
Prime power applications.
The PowerStart 0500 control is shown below.
Note: other devices that can remotely start / Stop
the genset might be as simple as a switch or a push
button or as sophisticated as other controllers or
computers. This manual introduces the ways the
Control can interact with other devices, but this
manual cannot identify all of the devices that might
be used in every application.
ALTERNATOR CONNECTIONS
This section introduces the connections between
the PS0500 and the alternator.
Main Alternator Output
The PS0500 is connected to the main alternator
output to measure genset voltage and genset
frequency.
The PS0500 is also connected to current
transformers (CTs) which reduce the genset
current by a known ratio for measuring main
alternator output current.
Battery-charging Alternator
The PS0500 may be connected to the battery-
charging alternator to make sure the battery-
charging alternator is recharging the battery
properly.
ENGINE CONNECTIONS
the PS0500 and other parts of the genset. Some of
these connections are flexible and might be made
to many types of devices.
Customer Input
The PS0500 has one customer input that can be
configured to invoke a shutdown or Warning
response
Battery Charger Failed Switch
The PS0500’s Customer Input may be connected
to a battery charger’s status output (discrete) to
monitor the battery charger operation.
Emergency Stop Buttons
The PS0500 may be connected to a push button
that shuts the genset down immediately when
pressed.

This section introduces the connections between

the PS0500 and the engine.

Battery Connections

The battery provides power for the PS0500 and

the PS0500 monitors the battery voltage.

Starter
The PS0500 is connected to the starter control
relay in order to control the starter.

See Sequences of Operation for more

information about the behavior of this output.
FIGURE 1-2. EMERGENCY STOP BUTTON
Fuel Shutoff (FSO) Relay (EXAMPLE)
The PS0500 is connected to the fuel shutoff
control (FSO) in order to control the fuel shutoff
solenoid in the fuel supply line.
Customer Output
See Sequences of Operation for more
information about the behavior of this output. The PS0500 has one customer output that can be
configured to become active when either a
GENSET CONNECTIONS shutdown or Warning fault occurs.

This section introduces the connections between

PC-based Service Tools
The PS0500 or the Operator Panel may be • CE Marking: The control system is
connected to a PC-based service tool, such as suitable for use on generator sets to be
InPower. CE − marked.

Note: See the PC-based service tool

documentation for more information.

The PC-based service tool harness (Figure 1-7)

is used to connect the PS0500 to a PC-based
service tool.

FIGURE 1-7. PC-BASED SERVICE TOOL

HARNESS

Ready to Load

The PS0500 may notify a device when event

1465 (Ready to Load) is active. Typically, the
device is a programmable logic controller

Remote Start

The PS0500 may be connected to a device that

can generate a remote start signal. Typically, the
device is a transfer switch.

CERTIFICATIONS

The PS0500 meets or exceeds the requirements

of the following codes and standards.
• UL 508
• CSA
• C282 compliant
• 22.2 compliant
• NFPA 99 compliant
• MS 202C, Method 101 compliant
• IEEE C62.41 compliant
• IEEE C37.90 compliant
• BS ISO 8528−4:2005
• BS EN 50081−1:1992
• BS EN 61000−6−2:2001
• BS EN 61000−6−3:2001
• BS EN 61000−6−4:2001
 2. Control Operation
In this section, italics are used to identify a
specific parameter by name.
SAFETY CONSIDERATIONS
AC power is present when the genset is running.
Do not open the generator output box while the
genset is running.
WARNING Contacting high-voltage
components can cause electrocution,
resulting in severe personal injury or death.
Do not open the generator output box while
the set is running. Read and observe all
WARNINGS and CAUTIONS in your genset
manuals.
The PS0500 cabinet must be opened only by
technically qualified personnel.
WARNING The PS0500 cabinet must be opened
only by qualified personnel. High-level
voltages (up to 600 VAC) are present in the
PS0500 cabinet. These voltages can cause
electrical shock, resulting in personal injury
or death.
CAUTION Even with the power removed,
improper handling of components can cause
electrostatic discharge and damage to circuit
components.
Read Safety Precautions, and carefully
observe all of the instructions and precautions in
this manual.
STARTING AND STOPPING THE GENSET
The buttons related to changing mode of
operation are highlighted in figure 2.1 and
described in Table 2.1
FIGURE 2-1. CONTROL PANEL BUTTONS
TABLE 2-1 CONTROL PANEL BUTTONS
BUTTON(S) DESCRIPTION
Manual Puts the control in Manual Mode to
Start the genset Manually.
You have to push the Start button in
less than ten seconds after you push
the Manual button.
Auto Puts the control in Auto Mode. The
genset starts and stops when it
is told by other devices (such as a
transfer switch)
Stop Stops the genset
When the genset starts and stops, it follows a
series of steps, called a sequence of operation
that is intended to maximize the life of the
genset. The genset might not start or stop
immediately.
WARNING The genset might not start or stop
immediately. Do not attempt to service the
genset if it does not appear to respond
immediately. Accidental starting of the
genset during troubleshooting can cause
severe personal injury or death.
 The control panel (Figure 2-2) is the front panel
of the PS0500 control.
CONTROL PANEL

FIGURE 2-2. CONTROL PANEL (PS0500)

Control Panel Description
Alpha-numeric LCD Display
The 2 line 16 Character, Backlit LCD display is
used to indicate various genset parameters in
several frames. The frames are normally
scrolled one after the other for 3 seconds each
at a time. The scrolling can be stopped and
parameters on a particular frame can be
monitored for longer time by pressing the OK
button while the frame of interest is being
displayed. Pressing the OK button again causes
the frames to start scrolling again. The LCD
display is also used to present the setup menus
during the setup modes. The set up modes are
described in detail in a separate section in this
manual.
TABLE 2-2. LED INDICATORS AND BUTTONS
LED DESCRIPTION
Genset This green LED is lit when the genset
Running is running at or near rated speed and
voltage.
This is not lit while the genset is
Stopped.
Remote This green LED is lit when the remote
Start start signal is active. This signal has
no effect unless the PS0500 is in Auto
mode.
Shutdown This red LED is lit when there is any
active shutdown fault. Event 1541
(Common Shutdown) is active.
Warning This amber LED is lit when there is an
active warning fault. Event 1540
(Common Warning) is active.
Buttons and LED Indicators
TABLE 2-3. BUTTONS
LED/BUTTO DESCRIPTION
N
Manual Press this to put the PS0500 in
Manual mode from Stop mode. If
you do not press the Start button
In ten seconds, the control
automatically enters the Stop mode
The green LED above this button
blinks when the PS0500 is in
Manual mode.
Start In Manual mode, press this to
initiate a Manual Start sequence. In
other modes, this button has no
effect.
Auto Press this to put the PS0500 in
Auto mode from Stop mode.
The green LED above this button
blinks when the PS0500 is in Auto
mode.
Stop Press this to Stop the running
Genset. The Red LED above this
button blinks when the PS0500 is in
Stop mode. Pressing this button
takes the control to STOP mode.
Reset This button is used along with the
OK button to enter setup mode.
Holding these two buttons pressed
continuously for 5 Seconds causes
the control to enter in setup mode if
the control is in STOP mode. This
button also wakes up the control
from Power Down Sleep Mode.
OK This button is used mainly in “Setup
mode” to select menu items. It is
also used to Pause / Resume the
scrolling of the parameter frames.
MODES OF OPERATION
The mode of operation determines the ways the
Genset can be started and stopped. The
PS0500 runs in one of these modes at any given
time.
Table 2-3 explains how to change the mode of
operation.
Stop (Off) Mode
Pressing the STOP button will always put the
PS0500 in STOP mode and the RED LED
above the STOP button will start blinking.
In this mode, the PS0500 does not allow the
genset to start / Crank.
If the genset is running (either in Manual or Auto
Mode) when the Stop button is pressed, the
PS0500 stops the genset and enters in the
STOP mode.
Setup Mode
The Setup mode can be entered only from Stop
mode when the genset is not running. This is
accomplished by holding the Reset and the OK
buttons pressed for 5 seconds continuously
while in stop mode. The RED Stop Led flashes
faster (double the normal rate) as long as the
control is in setup mode. While in setup mode,
pressing Start or Stop button has no effect.
Exiting from setup mode will return the control to
STOP mode.
In the setup mode, a Menu driven setup process
is available for making adjustments that are
allowed to be made from the control panel. Set
up process is described in detail in a separate
section later in this manual.
Auto Mode
Pressing the Auto Button while the PS0500 is in
the STOP mode will put the PS0500 in AUTO
Mode. Pressing Auto Button while the PS0500 is
in Manual Mode (Running or Not Running) has
no effect.
WARNING In Auto mode, the genset can start
at any time. NEVER service the genset in
Auto mode. Accidental starting of the genset
during troubleshooting can cause severe
personal injury or death. Disable the genset
before troubleshooting.
When the remote start signal becomes active,
the PS0500 initiates the start sequence to start
the genset. The PS0500 continues to run as
long as the signal is active. When the Remote
Start signal becomes inactive the PS0500
initiates a normal stop sequence.
Pressing the Stop button shall always deactivate
the FSO immediately.
Remote Start Signal
This signal will start the Genset when these
conditions are met.
• The PS0500 is in Auto mode
• There are no active shutdown faults
This signal comes typically from a transfer
switch or an external toggle switch.
Manual Mode
Pressing the Manual Button while the PS0500 is
in the Stop Mode will put the PS0500 in the
Manual Mode.
In this mode, the genset is controlled manually.
Pressing the Start button initiates a Manual Start
sequence. Remote start signal has no effect.
Note: If you do not press the Start button in ten
seconds, the PS0500 changes over to STOP (Off)
mode.
Pressing the Stop button initiates a stop
sequence.
Power-Down Mode
The PS0500 can enter power-down or sleep
mode, to reduce load on batteries when not
being used.
PS0500 Power-down Mode
Table 2-4 shows how much current the PS0500 Stopped
control module consumes in normal operation
and in power-down mode.

TABLE 2-4. PS0500 CURRENT CONSUMPTION Start Sequence

PS0500 MODE CURRENT
Normal operation 350 mA
Power-down < 5 mA
Genset Running
The PS0500 enters power-down mode when
these conditions are met.

− The genset is not running. Stop Sequence

− The Power down Mode Time Delay has
expired.
− There is no active communication on the RS-
FIGURE 2-7. Sequence of operation
485 communication link.
− There are no active faults
− There are no active Wake Up signals present.
Start Sequences
The PS0500 follows different start sequences
In power-down mode, the microprocessor in the depending on its setup and conditions.
If a start sequence is interrupted for any reason
control stops, thereby reducing the consumption
except a shutdown fault (for example, the
from battery.
remote start signal becomes inactive), the
Wake Up Signals PS0500 aborts the start sequence and initiates a
Stop sequence.
The PS0500 wakes up from power-down mode
Remote Start
when any of these wakeup signals becomes
active. This sequence begins when these conditions
are met.
− Tool wakeup input (TB15 pin 5) is grounded.
− Τhe Reset button on the Control Panel is
− The PS0500 is in Auto mode.
pressed
− The remote start signal is active,
− Remote Start Signal (Typically, to a transfer
− There are no active shutdown faults.
switch) is low.
This sequence is shown in Figure 2-8.
SEQUENCES OF OPERATION

Sequences of operation describe the way the

PS0500 starts the genset or stops the genset.
This is illustrated in Figure 2-7.

Stopped
Start Delay and
Preheat if enabled
Start Engine after Start
Delay expires and
Preheat conditions are
met
Wait For the Genset to
reach 90 % of Nominal
Frequency and
Voltage
Genset Running
FIGURE 2-8. Remote Start Sequence
In this sequence, the PS0500 follows these
steps to start the engine.
1. The PS0500 waits until Start Time Delay
expires.
If the trim Glow Plug Enable is set to Enabled,
the PS0500 turns on the Glow Plug Control
output. The PS0500 turns off the Glow Plug
Output when Glow Plug Timeout Period expires.
The PS0500 does not proceed to crank until
both Start Time Delay expires and the Glow
Plug Output is turned off.
2. The PS0500 turns on the fuel shutoff (FSO)
output and the Starter Output.
Cycle Cranking
− Τhe starter turns on for Cycle Crank Engage
Time and turns off for Cycle Crank Rest
Time. The starter repeats this process up
to Crank Attempts times.
The PS0500 turns OFF the Starter Output and
keeps it OFF when,
− The Genset Frequency is >= Starter
Disconnect Speed / Frequency Speed gain,
(Example: Typically the starter disconnect speed
is set to 450 RPM. In case off a four pole
alternator the value of the Frequency speed gain
is set to 30. So the genset frequency at which
the starter disengagement happens would be
calculated as 450 / 30 = 15Hz)
OR
The Battery Charging Alt Voltage >= Start
Disconnect threshold
If the genset frequency does not reach the start
disconnect threshold (15 Hz in above example)
before PS0500 finishes the cranking cycle, then
it generates shutdown fault 359 (Fail To start).
The PS0500 waits for the Genset to reach the
rated frequency and voltage. If that does not
happen within 10 seconds from the starter
disconnect, the PS0500 generates Shutdown
Fault 2335 (loss of AC Sensing).
Manual Start
This sequence begins when these conditions
are met.
− The PS0500 is in Manual mode and the Start
button is pressed.
− There are no active shutdown faults.
This sequence is shown in Figure 2-9.

Stopped
Turn ON Glow Plug
Output and Wait for
Preheat conditions to
be met if Glow Plug is
enabled
Start Engine
Wait For the Genset to
reach 90% of Nominal
Frequency and
Voltage
Genset Running
FIGURE 2-9. Manual Start Sequence
In this sequence, the PS0500 follows these
steps to start the engine.
1. If the trim Glow Plug Enable is set to Enabled,
the PS0500 turns on the Glow Plug Control
output. The PS0500 turns off the Glow Plug
Output when Glow Plug Timeout Period expires.
The PS0500 does not proceed to crank until the
Glow Plug Output is turned off.
2. The PS0500 turns ON the fuel shutoff (FSO)
output and the Starter Output.
The cycle cranking process as explained
above is followed in Manual Mode also.
Genset Running (Ready to Load)
The PS0500 enters the Genset Running (Ready
to Load) state when the genset frequency and
voltage are both >= 90 percent of the nominal
frequency and nominal voltage respectively.
Meter Calibration
When running in Manual Mode, the control
allows meter calibration process to be invoked,
when the Genset Running (Ready to Load) state
is reached. The Meter Calibration process is
invoked by holding the Reset and OK buttons
pressed for 5 seconds continuously. The
process allows the arrow keys to be used for
adjusting the displayed alternator AC Voltage /
Current values to actual values (as measured
using an independent calibrated instrument) one
by one.
The Meter Calibration Process is available when
running the genset in Manual Mode only.
Nominal Voltage and Frequency
The PS0500 does not have the control of the
genset frequency (speed) and the genset
voltage.
The nominal voltage and the nominal frequency
set-up parameters are used only for calculation
of the over voltage, under voltage, over
frequency and under frequency fault thresholds
and determining if the Genset Running (Ready
to Load) state has been reached as described
above.
Stop Sequences
The PS0500 follows different stop sequences
depending on its setup and conditions.
Auto Mode
In Auto mode the stop sequence begins when
these conditions are met.
− The genset is running at rated speed and
voltage
− The remote start signal is inactive.
− There are no active shutdown faults.
The Genset will continue to run for the Stop
Delay time and then the FSO Output will be
deactivated by the PS0500.

Manual Mode

In Manual mode the stop sequence begins when

these conditions are met.
− The genset is running at rated speed and
voltage
− The Stop button has been pressed.
− There are no active shutdown faults.

The FSO Output will be deactivated by the

PS0500 immediately when the Stop button is
pressed.

Fault Shutdown

In Manual as well as Auto mode, the FSO

Output will be deactivated by the PS0500
immediately when any of the shutdown faults
becomes active.
3. Setup and Calibration
Read Safety Precautions, and carefully
observe all of the instructions and
precautions in this manual.
CAUTION: Only qualified technicians
should adjust the parameters
described in this section. Failure to
follow this may affect genset
operation and may cause damage to
the genset or to equipment
connected to the genset.
holding the Reset and the OK buttons
pressed for 5 seconds continuously
while in stop mode. The RED Stop Led
flashes faster (double the normal rate)
as long as the control is in setup mode.
Pressing ← button while in Main Menu exits
the setup mode. Navigation through the
setup menus is described further in a
separate section later.
MENU Description

In this section, italics are used to identify Tables 3.1 to 3.15 show a summary of
a specific parameter by name. the menus offered on the control panel
of the PS0500.
PARAMETERS
Table 3.1 Main Menu Description
See Section 4 for more information
about parameters that you can adjust in Menu Description
the Operator Panel.
Alt Setup Use this menu to select
Capture File alternator setup
parameters like Single /
Use InPower to save the current Three phase, 50 / 60 Hz
settings in a capture file on a PC or operation, Wye / Delta ,
network. You can use the capture file to Voltage etc.
look at the current settings while you are Units Use this menu to select
away from the PS0500 or to restore Metric or US units for
settings if you have to reset the PS0500 Coolant Temperature and
for any reason. See the InPower User Oil Pressure
Guide for more information. Oil Pr Input Use this menu to select the
sensor types used with oil
While InPower can be used with the pressure
PS0500 for facilitating the setup, it is not Customer I/O Use this Menu to configure
essential for carrying out the basic setup the response to Customer
operations. The basic setup can be input and to configure
performed directly from the control panel usage of the customer
of PS0500. Following paragraphs output
Describe the process of carrying out Flt History Use this menu to view last
basic setup from the control panel. five faults that are stored in
the control
Entering and leaving the Setup Mode Load Defaults Use this menu to set the
default values.
The Setup mode can be entered only
from Stop mode when the genset is not
running. This is accomplished by
Table 3.2 Alt Setup Menu Table 3.5 CT Ratio Sub Menu

SubMenu Description Menu Items

Phase Type Select this submenu to
choose between single / 50:5
three phase operation 75:5
CT Ratio Select this submenu to 100:5
choose the CT Ratio
150:5
Connect Type Select this submenu to
choose between Wye / 200:5
Delta connection of 250:5
alternator windings 300:5
Nom LL Voltage Select this submenu to
choose the alternator
Table 3.6 Nom LL Voltage
nominal voltage
Sub Menu
Frequency Select this submenu to
choose the frequency of Menu Items
operation 190
200
Table 3.3 Frequency Sub Menu
208
Menu Items
220
50 Hz 230
60 Hz 240
Table 3.4 Phase Type Sub Menu 380
400
Menu Items 416
Single 3 Wire 440
3 Phase 460
Single 2 wire 480
600
Table 3.4 Connect Type Sub Menu
Table 3.7 Units Menu
Menu Items
Star Connect Menu Description
Item
Delta Connect
Metric Select this item to
choose Metric Units for
the display of Coolant
Temperature and Oil
Pressure
 US Select this item to
choose US Units for the Table 3.14 Customer O/P2 menu
display of Coolant
Temperature and Oil MenuItems
Pressure ShutDown
Warning
Genset Running

Table 3.9 Oil Pr Input Table 3.15 Flt History Menu

SubMenu Description MenuItems Description

Sensor Select this if using a Sender Fault 1 – Fault 5 View the last 5
Switch Select this if using a Switch faults stored in the
control
Table 3.10 Oil Pressure Sensor Sub
Menu Table 3.16 Load Default
MenuItems
ONAN MenuItems Description
CIL Confirmation To confirm the
Screen action press OK
Table 3.11 Customer I/O Menu
Navigation
SubMenu Description
Cust I/P Flt Choose the The manual (↑), Reset (↓ //), OK (→)
response to the and Auto (←) buttons are used for
input when active navigation during the setup. As long as
Customer O/P1 Choose the setup mode is not exited these buttons
function of this will only act as arrow keys. The RED
output Stop lamp flashes at twice the normal
Customer O/P2 Choose the rate as long as the setup mode is not
function of this exited and the control is not returned to
output STOP mode.

Table 3.12 Cust I/P Flt Submenu Navigation Example

(Set the nominal LL voltage to 440)
MenuItems
ShutDown
Warning ← Main Menu //
/ Alt Setup →
Table 3.13 Customer O/P1 menu

MenuItems The Fig above shows the basic

Glow Plug elements of a Setup Menu.
Warning
Shutdown Line 1 always bears the Menu Name
and Line 2 shows items in the Menu.

The symbols ←, / /, → indicate that the

buttons bearing those symbols are
active and can be used as follows
← Back Button
// (↓) Scroll Down to the next item
→ Select the item shown on line 2
When a menu or submenu containing
more choices is selected, the Name of
the Menu or Submenu moves to line 1
and the choices in the menu are
displayed on line 2. / / (↓) button can
then be used to scroll through the
choices available in the Menu, and →
(OK) button can be used to choose the
item shown on line 2. The ← button can
be used to go back one level up in the
menu.
Here in the current example, pressing →
will take you to the Alt Setup menu. The
Name of the chosen Menu (Alt Setup)
will move into the line 1 and the first
choice within that menu (phase type) will
be shown on line 2.
← Alt Setup //
Phase Type →
You can now press / / (↓) button to scroll
through the choices available in the Alt
Setup Menu one by one. When the
choice that you want appears on line 2,
pressing → will take you into that
submenu.
Here in our example, let us say, you
pressed / / (↓) until “Nom LL Voltage”
submenu was displayed in line 2.
← Alt Setup //
Nom LL Voltage →
Pressing → will take you into the
choices available for nominal line to line
voltages. Pressing ← will take you to the
main menu and pressing / / (↓) will take
you to the next item within Alt Setup
Menu.
Let us say you pressed →. The display
will now look like this.
← Nom LL Voltage //
190 →
Pressing / / (↓) will show all the choices
available for nominal LL voltage one by
one. Let us say you pressed / / (↓) until
440 was displayed.
← Nom LL Voltage //
440 →
Pressing → will select that as the
Nominal LL Voltage. An asterisk (*) will
appear in line 2 indicating that to be the
current selection. The → at the end of
line 2 will change to ← indicating that
the only active buttons now are / / (↓)
and ←.
← Nom LL Voltage //
* 440 ←
Pressing ← button will take you to one
level up in the menu tree at a time. You
have to press ← several times to reach
the main menu. Pressing ← button while
at the main menu shall exit the setup
mode. Following message shall be
displayed before leaving the setup
mode.
Current Config
Saved ←
Press ← to leave setup mode and
resume normal operation. The red Stop
LED will resume flashing with normal
rate (1 Hz).
4. Parameters
CAUTION: Parameters (nominal
voltage, frequency, CT Ratio etc.) are
set to appropriate values at the
Genset manufacturing time based on
the application requirements. In case
of a replacement control, however,
the control would have the default
values as indicated in the table 4.1
and these would need to be adjusted
as required. Use caution while
replacing the control the field. Only
qualified technicians should adjust
the parameters described in this
section. Failure to follow this may
affect genset operation and may
cause damage to the genset or to
equipment connected to the genset
It is intended that there will be only one
calibration (0326-7727) for the PS0500
series control.

Table 4.1 Adjustable Parameters

PS0500 Default
Parameter Control Possible value
Group Name InPower Panel Values Units
Lo High

Nominal
Voltage (L- Yes Yes 190 600 416 V AC
Genset L)
Nominal Yes 50 or 60 50
Frequency Yes Hz
Connectio Yes Delta or WYE WYE
n type Yes -
Yes Single or Three
Phase Three
type Yes -
Yes 10/15/20/30/ 20
CT ratio Yes 40/50/60
Engine Oil Yes Sensor or Sensor
Pressure switch
Input Type Yes N/A
Cycle Yes 3
Crank Attempt
Attempts 1 7 s
Cycle Yes 5
Crank time 3 30 Sec
Cycle Yes 5
Crank
Rest time 0 60 Sec
Battle Yes Enable or Disable
Short Disable
Enable NA
Start Time Yes 0
Delay 0 300 Sec
 PS0500 Default
Parameter Control Possible value
Group Name InPower Panel Values Units
Yes 120
Stop Time
Delay 0 600 Sec
Customer Yes Shutdow
Configurable Input Warning, n
I/O Function Yes Shutdown,
Yes Turn on if any Turn on
shutdown fault if any
is active/ Turn shutdow
On if any n fault is
warning fault active,
is active/
/Turn on when
Customer genset
output running
Function Yes
High AC Yes 110 %
Alternator Voltage
Protection Threshold 105 125 %
High AC Yes 5
Voltage
Delay 1 10 Sec
Low AC Yes 85%
Voltage
Threshold 50 95 %
Low AC Yes 5
Voltage
Delay 2 20 Sec
Under Yes 5
Frequency
Threshold 2 10 Hz
Under Yes 1000
Frequency ½
Delay 500 2000 cycles
Over Yes 5
Frequency
Threshold 2 10 Hz
Over Yes 1000
Frequency 1/2
Delay 100 2000 cycles
Low Oil Yes 25
Pressure
Protection – Shutdown
Engine Threshold 10 100 Psig
Low Oil Yes 5
Pressure
Shutdown
Delay 2 15 Sec
Low Oil Yes 30
Pressure
Warning
Threshold 10 100 Psig
 PS0500 Default
Parameter Control Possible value
Group Name InPower Panel Values Units
Low Oil Yes 5
Pressure
Warning
Delay 2 15 Sec
High Yes 212
Coolant
Temperatu
re
Shutdown
Threshold 180 300 deg f
High Yes 5
Coolant
Temperatu
re
Shutdown
Delay 2 10 Sec
High Yes 200
Coolant
Temperatu
re Warning
Threshold 150 290 deg f
High Yes 5
Coolant
Temperatu
re Warning
Delay 2 10 Sec
Low 11
Battery
Voltage
Threshold Yes 11 13 VDC
Low Yes 30
Battery
Delay 2 60 Sec
High Yes 16
Battery
Voltage
Threshold 14 17 VDC
High Yes 30
Battery
Delay 2 60 Sec
Weak Yes 8
Battery
Voltage
Threshold 6 10 VDC
Weak Yes 3
Battery
Delay 1 5 sec
 5. Hardware
TB15 – Tool Connector
Arrow at Pin 1

J12 – CT connector
Arrow at Pin 1

J12 –Pin 4

J16 – Engine connector

Arrow at Pin 1

J16 –Pin 7

J22 – Voltage connector

Arrow at Pin 1

TB2 – Customer TB
Arrow at Pin 1
The dot designates pin 1 on the connectors,

TB2 – Customer Terminal Block

Customer fault input, Customer output, Glow
Plug, Remote Start, Remote E-stop.

J22
Alternator Voltage J16 Engine Connections
Sense inputs and Coolant Sensor, Lube Oil
• • Pressure sensor, Run / OFF /
Field Output
Auto Switch, FSO, Starter,
Battery, Mag Pick Up, Starter
PS0500 Disconnect Feed Back,
CONTROL BOARD Battery Charger D+, Chassis
• GND. Governor PWM
•
•

TB15 – Tools J12 CT Connections

Interface Connector
Control Inputs and Outputs

Engine Connector
The engine connector (J16) is a 12 pin connector-plug (12 MINI M-N-L). A possible supplier is
Molex; their part number is 39299123. The Cummins part number for this connector is 0323-
2589. The PCB outline drawing shows where the connector is located as above .Each signal is
described as below –

Connector Pin Signal Name

J16-1 Coolant temperature sensor
J16-2 Battery charging alternator
(WL)
J16-3 Starter Relay Driver (Low
Side)
J16-4 Fuel shutoff relay Driver (Low
Side)
J16-5 BAT-
J16-6 Chassis GND
J16-7 NC
J16-8 NC
J16-9 Oil Pressure Sensor
J16-10 Starter Disconnect Input
J16-11 Sensor Common
J16-12 BAT +

CT Connector
The CT connector is a 6- pin MATE-N-LOCK connector. The possible manufacturer is Tyco, and
the supplier part number for the part is 643749-1. The Cummins part number for this connector is
0323-2154. Connector details are as follows –

Connector pin Signal

J12-1 CT1_input
J12-2 CT2_input
J12-3 CT3_input
J12-4 CT1_COM
J12-5 CT2_COM
J12-6 CT3_COM
Voltage Connector
The voltage connection is via a 4 pin header with alternate spaces between the pins. The
possible supplier is Tyco with the supplier part number as 282828-4. The Cummins part number
for the same is 0323-2225-03.

Connector pin Signal

J22-1 Gen_V1
J22-2 Gen_V2
J22-3 Gen_V3
J22-4 Gen_N

Customer Connection TB
The customer connection TB2 is a 6 pin terminal block. The possible supplier is Magnum:
The terminal pins details are as shown below-

Terminal Signal
pins
TB2-1 Remote start Switch Input
TB2-2 Glow Plug Output Relay
Driver (Low Side)
TB2-3 Customer Output Relay
Driver (Low Side)
TB2-4 Customer Input
TB2-5 E-Stop
TB2-6 NC

All the inputs are active GND. And outputs are low side drivers. Remote E-Stop switch should
have two independent potential free contacts. One NC contact for cutting out the Battery supply
to the Fuel Solenoid and another NC contact to disconnect controller’s E-Stop input from GND to
indicate to the control when the E-Stop is pushed in active state.

Battery Positive is not provided on the Customer terminal block (TB2). External provision needs
to be made in the harness to provide fused B+ via a 1 amp fuse for wiring up external relays.
External Relays of suitable contact ratings must be used for controlling FSO, Starter, Customer
Output and Glow plug.

PC Tool Connector
The PC tool connector is a dedicated 5 pin connector header block. The possible supplier is
Tyco, with the supplier part numbers are 796643-5. The Cummins part number for the same is
0323-2191-04.

Terminal Signal
pins
TB15-1 GND
 TB15-2 NC
TB15-3 RS485_DATA_A
TB15-4 RS485_DATA_B
TB15-5 TOOL_WAKEUP

Connector Part Numbers

Remarks
Manufacturer’s Cummins
Quantity Name Description Manufacturer
part number part no

Alt Voltage All these

1 J22 TYCO 282828-4 0323-2225-03 connectors
Connector
are PCB
1 J12 CT Connector TYCO 643749-1 0323-2154 mounted
connectors
Engine
1 J16 MOLEX 39299123 0323-2589
Connector
EM257506VC
1 TB2 Customer TB MAGNUM 0323-1677-05
796643-5
Tool
1 TB15 TYCO 0323-2191-04
Connector

Remarks
Manufacturer’s Cummins
Quantity Name Description Manufacturer
part number part no

Alt Voltage All these

1 J22 TYCO 282809-4 0323-2226-03 connectors
Connector
CT Connector 1-480704-0 0323-1932 are used in
1 J12 TYCO the harness
Crimp
350551-1 0323-1200
Terminals
Engine
39012120 0323-2602
Connector
1 J16 MOLEX
Crimp 39000038
0323-2603
terminals
EM256506H
1 TB2 Customer TB MAGNUM 0323-1678-05

Communication cable Kit 0541-1199 is used for

Tool the tool interface
1 TB15 TYCO
Connector
6. Troubleshooting
GENERAL
The PS0500 control continuously monitors
engine sensors for abnormal conditions,
such as low oil pressure and high coolant
temperature. If any of these conditions
occur, the control will light a yellow warning
lamp or a red shutdown lamp and display a
message on the LCD display.
PC BASED SERVICE TOOL
The PC based service tool can be used in
troubleshooting to perform tests, verify
control inputs and outputs, and test
protective functions.
When used improperly, a PC based service
tool can cause symptoms like warnings and
shutdowns that appear to be a defective
control. When these problems occur, always
verify that a self-test or fault simulation
(override) have not been left enabled with
the tool. If you do not have a PC based
service tool, or the enabled fault
simulation(s) can not be found using the
tool, disconnect battery power to disable the
test or override condition.
Make sure that parameter adjustments and
time delays, related to the fault condition,
have been appropriately set for the
application. It may be necessary to write the
initial capture file to the device or update the
calibration file. Updating a calibration file
requires a Pro version of many of PC based
service tools. Confirm that the installed
calibration part number matches the serial
plate information.
CAUTION Using the wrong capture file
can result in equipment damage. Do not
swap Controls from another genset
model and only use the calibration file
shown on the nameplate.
SAFETY CONSIDERATIONS
WARNING Contacting high voltage
components can cause electrocution,
resulting in severe personal injury or death.
Keep the output box covers in place during
Trouble shooting.
WARNING Ignition of explosive battery
gases can cause severe personal injury or
death. Arcing at battery terminals, light
switch or other equipment, flame, pilot lights
and sparks can ignite battery gas. Do not
smoke, or switch trouble light ON or OFF
near battery. Discharge static electricity from
body before touching batteries by first
touching a grounded metal surface.
Ventilate battery area before working on
or near battery—Wear goggles—Stop
genset and disconnect charger before
disconnecting battery cables—
Disconnect negative (-) cable first and
reconnect last.
CAUTION Disconnect battery charger from
AC source before disconnecting battery
cables.
READING FAULT CODES
The fault code and message can be viewed
on the display. After the fault is
acknowledged and corrected, the recorded
fault will be deleted from the control panel
memory, but will remain in a data log to
maintain a fault code history. A PC based
service tool is required to view this data log.
TROUBLESHOOTING
PROCEDURE
The following tables are a guide to help you
evaluate problems with the generator set.
You can save time if you read through the
manual ahead of time and understand the
system.
Voltage/Continuity Testing
Voltage and continuity tests are required in
the following tables. In some cases, it is
necessary to remove a plug to complete the
test. Where required, the corrective action
will mention when it is necessary to remove
a plug for testing. In other cases, the plug
cannot be removed for testing. When plug
removal is not mentioned, testing must be
performed by inserting a narrow meter probe
into the back of the plug.
TABLE 20-1. ENGINE DOES NOT CRANK
IN MANUAL MODE
Reason: This indicates that the control has
not received or recognized a manual start
signal.
Effect: Engine will not start.
POSSIBLE CORRECTIVE ACTION
CAUSE
1. No power Check if the control is in
supplied to Manual mode and when the
control Start button is pressed, and
that there are no shutdown
faults present.
Poor battery cable
connections. Clean the
battery cable terminals and
tighten all connections.
Check for blown fuses.
Remove connector P16 and
check for B+ at P16-12 and
GND at P16-5. If B+ or
ground missing, check the
harness. If B+ and ground
check OK, cycle power to
control by reconnecting
P16. Press Reset Button to
wake the control up. And
retry operation.
2. Control not Confirm that the installed
properly calibration part number
calibrated or matches the serial plate
corrupt information. Re-enter
calibration. calibration file if necessary.
3. The With Emergency Stop push
Emergency button not activated (switch
Stop switch closed), remove leads from
or wiring is TB2-5 and B- and check for
defective. continuity between these
two leads. If circuit is open,
isolate to Emergency Stop
switch and wiring. If there is
continuity, go to next step.
5. Oil Remove P16 connection
Pressure and check wiring between
switch or P16-9 and P16-11 to the
wiring is switch.
defective Verify control is configured
for the type of sensor
installed.
Verify proper operation of
the switch
6. Oil Remove P16 connection
Pressure and check wiring between
sender, setup P16-9, P16-11 to the
on wiring is sender. Verify control is
defective. configured for the type of
sender. Verify operation of
the sender
TABLE 20-2. ENGINE DOES NOT CRANK
IN REMOTE MODE
Reason: This indicates that the PS0500
control has not received or recognized a
remote start signal.
Effect: Engine will not start in remote mode,
but starts in manual mode.
POSSIBLE CORRECTIVE ACTION
CAUSE
1. The remote Check if the control is in
start switch or Auto mode and there are
wiring is no shutdown faults present.
faulty. Attempt to start, and check
for ground at TB2-1.
If ground level is not
present, isolate to the
remote switch or wiring.
Repair as necessary.
If ground level is present
then the control is bad.
Replace the control
TABLE 20-3. WARNING AND SHUTDOWN VOLTAGE voltages has exceeded
CODES Lamp: Shutdown 130% of nominal for 0
FAULT CODE CORRECTIVE second, or has
ACTION exceeded high ac
151 Indicates engine has voltage threshold for
HIGH COOLANT overheated (coolant High AC Voltage time
TEMP temperature has risen delay seconds.
Lamp: Shutdown above the shutdown 1447 Indicates that one or
trip point). LOW AC more of the phase
Allow engine to cool VOLTAGE voltages has dropped
down completely Lamp: Shutdown below low ac voltage
before proceeding with threshold for low ac
the following checks: voltage time delay
a. Check coolant seconds.
level and 1449 Indicates frequency is
replenish if OVER 10% above base
low. Look for FREQUENCY frequency for
possible Lamp: Shutdown approximately 10
coolant seconds.
leakage points 1448 Indicates that
and repair if UNDER Frequency had
necessary. FREQUENCY dropped below 90% of
b. Check for Lamp: Shutdown nominal for
obstructions to approximately 10
cooling airflow seconds.
and correct as Check fuel supply,
necessary. intake air supply and
c. Check fan belt load.
and repair or 1434 Indicates remote
tighten if EMERGENCY Emergency Stop. To
necessary. STOP reset the remote
d. Check blower Lamp: Shutdown Emergency Stop
fan and button:
circulation 1. Open (disable)
pumps on remote
remote radiator emergency
installations. stop button.
e. Reset control 2. Press the OFF
and restart button.
after locating 3. Select the
and correcting desired
problem. operating
415 Indicates engine oil mode (manual
LOW OIL pressure has dropped or auto).
PRESSURE below the shutdown 359 Indicates possible fuel
Lamp: Shutdown trip point. Check oil FAIL TO START system or air induction
level, lines and filters. Lamp: Shutdown problem. (Engine
If oil system is OK but cranks but fails to start)
oil level is low, a. Check for
replenish. Reset empty fuel
control and restart. If tank, fuel
oil switch is used, leaks, or
check switch plugged fuel
performance. lines and
1446 Indicates that one or correct as
HIGH AC more of the phase required.
 b. Check for dirty or lower. replenish if
fuel filter and NOTE: In required. Look for
replace if applications possible coolant
necessary. where the leakage points and
c. Check for dirty ambient repair as required.
or plugged air temperature c. Open heater
filter and falls below element. Check
replace if 40F (4C), current draw of
necessary. Low Coolant heater.
d. Reset the Temp may
control and be indicated Coolant temperature must
restart after even though be below 70F (default
correcting the the coolant setting) for one minute to
problem. heaters are activate warning and be
2677 Genset continues to operating. above 70F for five minutes
FAIL TO STOP run after receiving before the warning can be
Lamp: Shutdown shutdown command cleared.
from the controller. 1312 Indicates the Customer
Check the FSO Relay CUSOMER Input is active.
and related wiring. INPUT
Check that the FSO is FAULT Example inputs: Low Fuel
not mechanically stuck Lamp: Day Tank, Water In Fuel,
Warning Or Ground Fault, etc.
1123 A shutdown fault Shutdown
SHUTDOWN occurred while the Depending If multiple of these are
AFTER BS Battle Short mode was on the setup connected in parallel, check
Lamp: Shutdown enabled. Check fault if any one of them is active.
history for faults that
may have been 144 Indicates that the control
bypassed. COOL has sensed that the engine
SENSOR coolant temperature sensor
OOR output is out of range (high
Lamp: or low). Check
146 Indicates engine is
Warning sender/connectors/wires.
HIGH COOL operating near cooling
This fault will only occur if
TEMP. system capacity. Increase in
water temperature sensor is
Lamp: load or higher ambient
equipped on the genset.
Warning temperature may cause
441 Indicates battery voltage
High Coolant Temp (151)
LOW supply to the control is
shutdown. Review code 151
BATTERY approaching a low level at
correction list for other
Lamp: which unpredictable
possible causes.
Warning operation will occur.
1435 Indicates engine coolant
a. Discharged or
LOW heater is not operating or is
defective battery.
COOLANT not circulating coolant.
Check the battery
TEMP Check for the following
charger fuse.
Lamp: conditions:
Recharge or
Warning a. Coolant heater not
replace the battery.
Set is not connected to power
b. Poor battery cable
operating. supply. Check for
connections. Clean
Warning blown fuse or
the battery cable
occurs when disconnected
terminals and
engine heater cord and
tighten all
coolant correct as required.
connections.
temperature b. Check for low
c. Check battery
is 70F (21C) coolant level and
wiring/calibration.
 d. Check engine DC
alternator. Replace
engine DC
alternator if normal
battery charging
voltage is not
obtained.
e. Check battery
charge voltage float
level if applicable
(raise float level).
442 Indicates battery voltage
HIGH supply to the control is
BATTERY approaching a high level at
Lamp: which damage to the control
Warning can occur. Check float level
on battery charger if
applicable (lower float
level).
Check battery
wiring/calibration.
141 Indicates that the control
OIL PRESS has sensed that the engine
SENSOR oil pressure sensor output is
OOR out of range (high or low).
Lamp: Check
Warning sender/connectors/wires.
This warning will only occur
if genset is equipped with
an oil pressure sender.
1131 Indicates that the control
BATTLE is in Battle Short mode -
SHORT used to bypass several
ACTIVE fault shutdowns for genset
Lamp: Warning operation during
emergencies.
2678 Indicates the battery
CHARGER charging alternator has
FAILURE not reached an acceptable
Lamp: Warning voltage range within the
selected period (default =
120 seconds). Refer to
engine service manual if
this fault occurs. If not
failed, check wiring.
1416 Genset continues to run
FAIL TO after receiving shutdown
SHUTDOWN command from the
Lamp: Warning controller. Battle Short
feature enabled - used to
bypass several critical
fault shutdowns for genset
operation during
emergencies.
1442 Indicates that during
WEAK cranking, the battery
BATTERY voltage is at or below the
Lamp: Warning weak battery warning trip
point for a time greater
than or equal to the weak
battery set time. See code
441 for corrective action.
CODE 151/146 - HIGH OR PRE-HIGH
COOLANT TEMPERATURE
(SHUTDOWN/SHUTDOWN)
Reason: Engine coolant temperature has
exceeded the warning threshold for pre-
high/high coolant temperature.
Effect: 146 – . Warning Lamp lights , Faul
code pops up. 151.- Engine will shut down
1. Fault 1. With a PC based
simulation was service tool, verify that the
enabled with a fault simulation is not
PC based enabled for the coolant
service tool. sensor.
If you do not have a PC
based service tool,
remove battery power
from the control to disable
fault simulation overrides.
2. Engine or Check the sensor
sensor circuitry accuracy with a
problem. thermocouple or similar
temperature probe.
• If the coolant
temperature
reading is
accurate, the
engine may be
overheating. Refer
to the engine
service manual.
• If the coolant
temperature
reading is not
accurate, go to
next step.
3. The sensor Disconnect the sensor and
could be bad. connect a coolant
temperature sensor
simulator to the harness.
If the control responds to
the simulator, replace the
sensor. If control does not
respond, go to next step.
4. The harness 4. Measure the resistance
or Control of the coolant sensor and
could be bad. reconnect harness to
sensor. Remove
connector P16 from
Control and check
resistance between pins
P16-1 and P16-11.
• If resistance is not
the same, harness
is bad.
• If resistance is the
same, Control is
bad.
CODE 143/ 415 - LOW OIL OR PRE-LOW
PRESSURE (WARNING/SHUTDOWN)
Reason: Engine oil pressure has dropped
below the warning/shutdown threshold for
low/high oil pressure.
Effect: 143. – Warning Lamp lights, Engine
will shut down for code 415. – Engine shuts
down
POSSIBLE CORRECTIVE ACTION
CAUSE
1. Fault With a PC based service
simulation tool, verify that the fault
was enabled simulation is not enabled
with a PC for the oil pressure sensor.
based service If you do not have a PC
tool. based service tool, remove
battery power from the
control to disable fault
simulation overrides.
2. Low oil Check oil level, lines and
level. filters. If oil system is OK
Clogged lines but oil level is low,
or filters. replenish.
3. Sensor or Disconnect the oil pressure
oil pump sensor leads, and connect
could be bad. an oil pressure sensor
Or the simulator to the harness.
generator set
may be a. If the control responds to
shutting down the simulator, reconnect the
on another sensor, disconnect the +
fault. signal wire at the fuel
solenoid, and crank the
engine.
Check the oil pressure
reading on the digital
display.
• If the display shows
an acceptable oil
pressure, the
problem may not be
in the oil or oil
sensing system.
The genset may be
shutting down on
another fault (out of
fuel, intermittent
connector). Restart
the genset and
monitor the display
panel for other
faults.
• If the display does
not show an
acceptable oil
pressure, replace
the sensor. If the
Control still doesn’t
display an oil
pressure while
cranking, the oil
pump may be bad.
Refer to the engine
service manual.
b. If the control does not
respond to the simulator, go
to next step.
4. Harness or If the control does not
Control could respond to the simulator,
be bad. the Control or the harness
is bad.
Check the resistance in
P16-9 and P16-11 (Sensor
COMM). If the resistance
signal (100 to 33 Ohm)
does not get to P16, isolate
to the harness. If the
resistance does go to P16,
the Control is bad.
5. Low Oil Verify set points against the
Pressure fault normal operating pressures
set points of the engine. Refer to
could be engine manual.
incorrect.
CODE 1446 - HIGH AC VOLTAGE
(SHUTDOWN)
Reason: One or more of the phase voltages
has exceeded 130% of nominal for 1
seconds, or has exceeded the High AC
Voltage Threshold for the High AC Voltage
Delay seconds.
Effect: Engine will shut down.
POSSIBLE CORRECTIVE ACTION
CAUSE
1. Fault 1. With a PC based a PC based required operating
simulation was service tool, verify that service tool. range before adjusting
enabled with a the related fault the threshold.
PC based simulation is not 3. Overload. 3. Check the load and
service tool. enabled. correct any overload.
If you do not have a PC Check operation by
based service tool, disconnecting load and
remove battery power restarting generator
from the control to set.
disable fault simulation 4. Improper 4. Reconnect
overrides. connections have according to the
2. Single step 2. Clear fault and restart been made at the appropriate
large block load genset. generator output reconnection diagram.
removal. terminals. See Section 17.
3. Fault 3. Reset the threshold to
threshold is not the highest allowable 5. Voltage sense 5. Check that Voltage
set correctly with setting. Determine the or setup wiring senses inputs P22-1 to
InPower. required operating range connection could 4 are connected to the
before adjusting the be incorrect. correct voltage sensing
threshold. point at alternator.
4. AVR or 4. Refer to Generator 6. The rotating 6. Check each diode.
generator is bad. AVR Board Isolation rectifier assembly See genset service
Procedure in Alternator (diodes CR1 manual
manual to determine if through CR6) is
the AVR board is faulty.
causing the high AC 7. Loose 8. Repair connections
voltage shutdown fault. connector or (P22) or replace the
5. Voltage sense See Section 17 for Control is bad. Control if necessary.
connections/set proper corrective
up could be actions. 8. AVR or 4. Refer to Alternator /
incorrect. Alternator is bad. AVR Board Isolation
Procedure in Alternator
CODE 1447 - LOW AC VOLTAGE manual to determine if
(SHUTDOWN) the AVR board is
Reason: One or more of the phase voltages causing the Low AC
has dropped below the Low AC Voltage voltage shutdown fault.
Threshold for Low AC Voltage Delay 9. Voltage sense See section 17 for
seconds. connections/setup proper connections
Effect: Engine will shut down. could be incorrect
POSSIBLE CORRECTIVE
CAUSE ACTION CODE 1449 - OVER FREQUENCY
1. Fault simulation 1. With a PC based (SHUTDOWN)
was enabled with service tool, verify that Reason: Generator AC output frequency is
a PC based the related fault high.
service tool. simulation is not Effect: Generator set will shut down.
enabled. POSSIBLE CORRECTIVE ACTION
If you do not have a CAUSE
PC based service tool, 1. Fault 2. Reset the threshold to
remove battery power threshold is the highest allowable
from the control to not set setting. Determine the
disable fault simulation correctly with required operating range
overrides. PC based before adjusting the
2. Fault threshold 2. Reset the threshold service tool. threshold.
is not set correctly to the lowest allowable 2. Fuel or air 3. Refer to the engine
with setting. Determine the delivery service manual.
problem. based service If you do not have PC
3. Loose 4. Repair connections (P22 tool. based service tool, remove
connector or – 1 to 4) or replace the battery power from the
Control is Control if necessary. control to disable fault
bad. simulation overrides.
4. Fault 4. Reset the threshold to
CODE 1448 - UNDER FREQUENCY threshold is the highest allowable
(SHUTDOWN) not set setting. Determine the
Reason: Generator AC output frequency is correctly with required operating range
low. PC based before adjusting the
Effect: Generator set will shut down. service tool. threshold.
POSSIBLE CORRECTIVE ACTION
CAUSE 5. Monitor the 5. If the RPM is not correct,
1. Fault 2. Reset the threshold to engine rpm refer to fault code 1449 for
threshold is the lowest allowable using corrective action.
not set setting. Determine the InPower.
correctly with required operating range 6. Governor 6a. Check fuel shutoff
PC based before adjusting the fault. solenoid adjustment (refer
service tool. threshold. to Section 8).
6b. Replace defective
2. Overload. 3. Check the load and injection pump unit.
correct any overload. 7. Mechanical Verify fuel stop settings for
Check operation by Fuel system the application.
disconnecting load and setup could
restarting generator set. be incorrect.
3. Fuel or air 4. Refer to the engine
delivery service manual.
problem. CODE 359 - FAIL TO START
4. Governor 5. Check fuel shutoff (SHUTDOWN)
fault. solenoid adjustment (refer MECHANICAL GOVERNED ENGINE
to Section 8). Reason: This indicates that the engine
5. Loose 6. Repair connections (P22 failed to start after expiration of last crank
connector or – 1 to 4) or replace the time.
Control is Control if necessary. Effect: Engine will not start.
bad. POSSIBLE CORRECTIVE
CAUSE ACTION
CODE 234 - OVERSPEED (SHUTDOWN) 1. Restricted fuel 1a. Add fuel if low.
Reason: Engine speed signal indicates an supply due to: Prime the fuel system.
engine speed greater than shutdown a. Fuel level 1b. Open any closed
threshold. below shutoff valve in the
Effect: Engine will shut down. pickup fuel line supplying the
POSSIBLE CORRECTIVE ACTION tube in engine.
CAUSE tank. 1c. Refer to engine
1. Cold 1. Overspeed can occur b. Closed service manual.
engine (no when starting a very cold shutoff 1d. Bleed air from fuel
coolant engine. Clear fault and valve in system. Refer to
heaters) restart genset. supply engine service
line. manual.
2. Single step 2. Clear fault and restart c. Fuel
large block genset. injectors
load removal. clogged.
3. Fault 3. With PC based service d. Air in fuel
simulation tool, verify that the fault system.
was enabled simulation is not enabled
with a PC for the coolant sensor. 2. Glow plugs are The Control
not heating due to: determines at what a. Fuse may installed) and check
a. Glow temperature and be open. continuity. If open,
plug(s) is duration of time that b. Fuel replace the fuse with
bad. the glow plugs will be solenoid is one of the same type
b. Control is energized. Using bad. and amp rating. If fuse
bad. sensed coolant c. Control/K7 reopens, check wiring
c. Glow Plug temperature, the glow Fuel Relay continuity of fuel
Relay is plugs are energized at is bad. solenoid circuit/test
bad. 77F (25C) and colder. fuel solenoid.
The glow plugs are
energized for up to 15 Binding in the solenoid
seconds when the linkage can prevent
coolant temperature is activation of the hold
-5F (-20.5C) or colder. coil circuitry in the
Time duration (15-0 solenoid. Make sure
seconds) is linear solenoid shaft moves
between -5F and 77F. completely in and out
freely. (Applies to
With coolant solenoids with both
temperature colder Pull and Hold coils.)
than 77F (25C):
3b. Attempt to start
2a. Each glow plug and check for B+ at
should be warm to the the fuel solenoid coil.
touch if the engine has • If B+ is
just been cranking. present, fuel
First clean and tighten solenoid is
the terminal of any bad.
cold glow plug and • If B+ is not
then replace it if present, go to
necessary. step c.
2b. Attempt to start
and check for if Glow 3c. Check wiring
plug relay energizes. continuity/test K7 relay
TB2-2 should be at or fuel pilot:
GND potential. If the Remove lead from K7-
TB2-2 is at GND and COM (fuel pilot).
K2 relay is not working Attempt to start and
check relay coil. check for GND at lead
• If TB2-2 is not COM.
at GND • If there is no
potential GND, check
replace the for open circuit
Control. between K7-
• If B+ is COM and
present, check Base card.
for open circuit • If GND is
between glow present,
plug relay reconnect lead
contact and COM to relay.
glow plugs. Remove lead
3. Fuel solenoid Isolate to fuse, K7 from N/O
on the injection relay, fuel solenoid or connection.
pump Control. Attempt to
not energized due start and
to: 3a. Remove fuse (if check for B+
 at terminal code 151.
N/O CODE 1435 - LOW COOLANT
connection. TEMPERATURE (WARNING)
• If B+ is Reason: Engine coolant temperature has
present, check dropped below the warning threshold for low
for open circuit coolant temperature.
between N/O Effect: No action is taken by the control.
connection Engine may not start due to slow cranking
and fuel speed.
solenoid(+). POSSIBLE CORRECTIVE ACTION
• If B+ is not CAUSE
present, check 1. Fault 1. With PC based service
for relay simulation tool, verify that the fault
contacts. was enabled simulation is not enabled for
5. The engine fuel 4. Service according to with PC the coolant sensor.
system is worn or the engine service based If you do not have a based
malfunctioning or manual. service. service tool, remove battery
has lost prime (fuel power from the control to
lift pump, injection disable fault simulation
pump, injectors, overrides.
timing). 2. Fault 2. Reset the threshold to the
6. The engine is 5. Service according to threshold is lowest allowable setting.
worn or the engine service not set Determine the required
malfunctioning manual. correctly with operating range before
mechanically. a PC based adjusting the threshold.
CODE 1312 - CONFIGURABLE INPUT service tool.
(SHUTDOWN) 3. The 3. Coolant heater not
Reason: The nature of the fault is an engine operating due to:
optional configurable selection. coolant • Coolant heater not
Effect: Shutdown. heater could connected to power.
POSSIBLE CORRECTIVE be bad. Check for blown
CAUSE ACTION (Radiant fuse, or
If there is no actual Disconnect the signal heat should disconnected heater
fault, the problem lead from TB2 and be felt with cord and correct as
may be an external reset the control. hand required.
wiring problem. Check the following held close to • Low coolant level.
two points. outlet hose.) Look for possible
• Customer coolant leakage
Input – TB2-4 points and repair as
If the message drops required.
out, the external wiring • Defective heater
has a short circuit. element/thermostat.
Grounding of the input With coolant heater
activates fault. removed from
engine and power
disconnected, flush
with cold tap water
for two minutes to
CODE 146 - HIGH COOLANT TEMP close internal heater
(WARNING) thermostat (opens at
Reason: 100F and closes at
Effect: 80F). Check
POSSIBLE CORRECTIVE ACTION resistance across
CAUSE input power leads:
1. Refer to 1. Refer to code 151. a. Open -
 replace the nput activates fault.
coolant
heater.
b. Closed - CODE 144 - COOLANT SENSOR OOR
coolant (HIGH/LOW) (WARNING)
heater OK Reason: This indicates that the coolant
(coil temperature sensor signal is out of range -
resistance shorted high or low.
of 10 to 60 Effect: No engine protection for coolant
ohms) temperature during genset operation.
4. The 4. Inspect the sensor and Possible white smoke.
sensor engine harness connector POSSIBLE CORRECTIVE ACTION
connections pins. Repair or replace as CAUSE
could be necessary. 1. The sensor 2. Inspect the sensor and
bad. connections engine harness connector
5. The 5. Disconnect the sensor, could be bad. pins. Repair or replace as
sensor could and plug in a resistive necessary.
be bad. sensor simulator to isolate 2. The sensor 3. Disconnect the sensor,
the fault. could be bad. and plug in a resistive
If the control responds to the sensor simulator to isolate
simulator, replace the the fault.
sensor. If control does not If the control responds to
respond, harness or Control the simulator, replace the
are bad. sensor. If control does not
6. The 6. Measure the resistance of respond, go to next step.
harness or the coolant temperature 3. The 4a. Remove connector P16
Control could sensor and reconnect harness or from Control and
be harness to sensor. Remove Control could disconnect sensor. Check
bad. connector P16 from Control be bad. pins P16-1 and P16-11
and check resistance (Sensor common) for short
between pins P16-1 and circuit as follows:
P16-11 • Check for a short
(Sensor Common). circuit to the
• If resistance is not engine block
the same, harness ground (more than
is bad. 200k ohms OK).
• If resistance is the • Check for a short
same, Control is circuit from pin to
bad. pin (more than
CODE 1312 - CONFIGURABLE INPUT 200k ohms OK).
(WARNING) Repair or replace as
Reason: The nature of the fault is an necessary.
optional configurable selection.
Effect: Warning. 4b. Measure the resistance
POSSIBLE CORRECTIVE ACTION of the coolant sensor and
CAUSE reconnect harness to
If there is no Disconnect the signal lead sensor. Remove connector
actual fault, from TB2 and reset the P16 from Control and
the problem control. Check the following check resistance between
may be an pins. pins P16-1 and P16-11
external • Customer Input – (Sensor Common).
wiring TB2-4 • If resistance is not
problem. If the message drops out, the same, harness
the external wiring has a is bad.
short circuit. Grounding of • If resistance is the
 same, Control is CODE 442 - HIGH BATTERY VOLTAGE
bad. (WARNING)
CODE 441 - LOW BATTERY (WARNING) Reason: High voltage has been detected for
Reason: Low voltage has been detected for battery.
battery. Effect: Control damage will occur.
Effect: The control’s voltage supply POSSIBLE CORRECTIVE ACTION
approaching level at which unpredictable CAUSE
operation may occur. 1. Excessive 1. Adjust charge rate of AC
POSSIBLE CORRECTIVE ACTION battery powered battery charging
CAUSE charging circuit according to
1. Weak or 1. Recharge or replace the voltage. manufacturers instructions.
discharged battery. Specific gravity for 2. Engine DC 2. Replace engine DC
battery. a fully charged battery is alternator alternator if normal battery
approximately 1.260 at 80F could be bad. charging voltage
(27C). (12 to 14 VDC) is not
2. Low 2. Replenish electrolyte obtained.
electrolyte and recharge battery. 3. Fault 3. Check fault threshold
level in threshold against requirement of the
battery. could be bad. application.
3. Battery 3. Clean and tighten or CODE 143 - LOW OIL PRESSURE
connections replace the battery cable (WARNING)
loose or dirty. connectors and cables at Reason:
the battery and the set. Effect:
4. Insufficient 4. Adjust charge rate of AC POSSIBLE CAUSE CORRECTIVE
battery powered battery charging ACTION
charging circuit, according to 1. Refer to code 1. Refer to code 415.
voltage. manufactures instructions. 415.
5. Engine DC 5. Replace engine DC CODE 141 - OIL PRESSURE SENSOR
alternator alternator if normal battery OOR (HIGH/LOW) (WARNING)
could be bad. charging voltage (12 to 14 Reason: This indicates that the engine oil
VDC) is not obtained. pressure sensor signal is out of range -
shorted high or low.
6. If the 6. Remove connector P16 Effect: No engine protection for oil pressure
batteries are from Control and check during genset operation.
OK, the battery voltage at P16-12 POSSIBLE CORRECTIVE ACTION
problem may (B+) to P16-5 (GND). CAUSE
be the • If the voltage at 1. The sensor 2. Inspect the sensor and
harness or the P16 is not the connections engine harness connector
Control. same as the could be bad. pins. Repair or replace as
battery voltage, the necessary.
harness is bad.
• If the voltage at 2. The sensor 3. Disconnect the oil
P16 is OK, the could be bad. pressure sensor leads, and
Control is bad. connect an oil pressure
7. Fault 7. Check fault threshold sensor simulator to the
threshold against requirement of the harness.
could be bad. application.
“OIL PRESSURE
SENSOR OOR” warning
is displayed after the
fault condition is sensed
for 10 seconds.

If the control responds to

the simulator, replace the
 sensor. If control does not at P16-9 and P16-11
respond, go to next step. (Sensor Common). If in
3. The 4. Remove connector P7 range, replace Control.
harness could from Control and connector CODE 1442 - WEAK BATTERY
be bad. from sensor. (WARNING)
Check P16-9 and P16-11 Reason:
as follows: Effect:
• Check for a short POSSIBLE CORRECTIVE ACTION
circuit from pin to CAUSE
pin (more than 1. Refer to 1. Refer to code 441.
200k ohms OK). code 441
• Check for an open
circuit (10 ohms or
less OK).
Repair or replace as
necessary.
4. The Control 5. With all connectors
could be bad. attached, check pressure
signal (.500 to .033 VDC)