DG and ATS

DG and ATS troubleshooting within solutions
Contents
Introduction.............................................................................................................................................................. 2
1.Troubleshooting Symptoms/practical on site ................................................................................................... 2
1.1 If DG hold alarm over coolant temperature ...................................................................................................... 2
1.2 If DG hold low coolant temperature .................................................................................................................. 4
1.3 If DG hold alarm over speed shutdown ............................................................................................................. 4
1.4 If DG hold alarm under speed (under freq.) shutdown or pickup ....................................................................... 5
1.5 If the Engine (DG) Stops after starting (not running) ......................................................................................... 6
1.6 If the engine does not crank or crank slowly ...................................................................................................... 7
1.7 The engine cranks but will not start (fail to start) .............................................................................................. 9
1.8 If DG hold alarm low oil pressure shutdown .................................................................................................... 10
1.9 If DG hold low or high BV. ............................................................................................................................. 11
1.20 If DG hold alarm over current shutdown ....................................................................................................... 12
2. Controlling parts and theirs function.................................................................................................................... 13
2.1 Cummins DG modules type how can us. .......................................................................................................... 13
 Symbols Used ........................................................................................................................................... 14
2.1.2 Manual Run Mode........................................................................................................................................................... 17
2.1.3 Auto Mode ....................................................................................................................................................................... 17
PCC 1302 Connectors ................................................................................................................................. 21
TB1 Customer Connections ........................................................................................................................ 22
J20 Gen Set Inputs and Outputs ................................................................................................................. 23
J11 Engine Inputs and Outputs ................................................................................................................... 24
J12 Genset CT Connections ........................................................................................................................ 25
2.1.9 J22 Voltage Sensing Inputs ................................................................................................................................................. 26
J25 Display Connections ........................................................................................................................... 28
TB15 Modbus Connection ...................................................................................................................... 29
2.2 Automatic Transfer Switch(ATS) .............................................................................................................. 30
2.3 The typical wiring diagram of TS1311And Sequence of events ......................................................................... 37
3. GU320B Controller Operation Manual Brief Introduction .................................................................................... 41
3.1 Connecting Terminals: ................................................................................................................................... 43
3.2 Typical Wiring Diagram:................................................................................................................................ 44
4.TU510A Auto Transfer Controller(ATS) ............................................................................................................... 48
4.1 The Connecting Terminals of MG Model: ....................................................................................................... 50
4.2 The typical wiring diagram of MG Model ....................................................................................................... 51
5. InteliLiteNT AMF20/25 ....................................................................................................................................... 54
5.1 Binary inputs ................................................................................................................................................. 59
5.2 AMF 25 wiring diagram ................................................................................................................................. 62
6.Conclusion ........................................................................................................................................................... 63
Introduction
This manual use as a reference and guideline us to easily handling of our site faults. My initiative to
prepared this from past learning and experience when I work on DG and power section. let’s as see some
question when someone on site
1.What kind of fault happen when DG hold alarm, one power technician or how another staff can give
solutions?
2.What the employees should be done if he/she encounters it?
1.Troubleshooting Symptoms/practical on site
Use the charts given on the following pages to help find the case and maintain of a
malfunction. Read each row of blocks from top to bottom. Follow the arrows through the
chart to identify action to be taking.
1.1 If DG hold alarm over coolant temperature

 Stope one (1): -cause Action to be taking
Add coolant as necessary and repair any

If the coolant level is low or leaks
the radiator water is not full
OK
Reduce the number of connected
appliances, especially air conditioners
If the load is not sharing and load battery chargers
OK
Inspect radiator fans clean or repair if

If the radiator fan is necessary.
damaged or closed by debris
OK
Inspect radiator tube(hose) or repair if

If the radiator tube(hose) is necessary.
torn or clogged.
OK
If the incorrect oil level Add or drain engine oil.

1
OK
Check the belt and replace it if

If the belt is damaged necessary.
OK
If the fan is not engaging Check the fan sensor and replace it
if necessary.
OK
Check the radiator cap and replace it

If the radiator cap is if necessary.
incorrect, damage and rust
OK
Check the thermostat and replace it if

If the thermostat is faulty necessary.
OK
Remove injection pump check

If there is an
calibration
overloaded injection
pump
OK
Measure cylinder block coolant
pressure. Check and replace water
If the water pump is faulty pump
OK
Check hose clamps for leaks on the

suction side of the pump. Other
If there is a problem with check for compression leak through
the air cooling system. cylinder head gasket.
OK
Contact to power team.
1.2 If DG hold low coolant temperature

 Stop one: - cause Action to be taking
Check the cooling rate and add if

If there is a low cooling necessary
rate or leakage.
OK
Check the fan is working and replace if

If the fan is damaged necessary.
OK
Check and clean sensor and coolant

passage. Test and replace if necessary
If the temperature sensor
is faulty
OK
Check the gauge and replace if

If the temperature gauge is necessary.
faulty
OK
If the thermostats are faulty Check the thermostats and replace if

necessary.
OK
Contact to power team. 3

1.3 If DG hold alarm over speed shutdown

 Stope one: - cause Action to be taking
If the governor does not work Check governor and replace if necessary.
or damage
OK
If the Air filter is dirty Check the air filter and replace if
necessary.
OK
Check the generator rotor and replace if

If the generator rotor is faulty
necessary.
and lose
OK
Check the speed sensor and replace if

If the speed sensor sends the
wrong signal necessary.
OK
Check the DG controller and replace if

If there is a wrong setting in necessary.
governor or DG controller
(module)
OK
Check load and load share.

If there is a sudden load loss
OK
4
1.4 If DG hold alarm under speed (under freq.) shutdown or pickup

Stope one: -cause Action to be taking
Sustained overload or fuel Check load sharing and fuel solenoid coil
solenoid is faulty and replace if necessary.
OK
Check the governor and replace if

Governor out of adjustment
necessary.
or damaged
OK
Check the air filter and replace if

If the Air filter is dirty or necessary.
damage
OK
Check the fuel filter and replace if

If the fuel filter is dirty or necessary.
damage
OK
Inspect the fuel line for the engine and

If the engine does not get make sure there is fuel. Or check fuel tank
enough fuel
OK
If there is a wrong message Check the governor, DG

(setting) in governor, DG controller(module) and control board and
controller (control board, replace if necessary.
module)
OK
5
1.5 If the Engine (DG) Stops after starting (not running)

 Stope one: -cause Action to be taking
If the fuel filter is dirty or

Check the fuel filter and replace if
damage
necessary.
OK
If the air filter or intake Check the air filter and intake system and
system is blocked replace if necessary.
OK
If the oil sensor(sender), switch Check the oil sensor(sender), switch and
or sender connection are faulty sender connection and replace if
necessary.
OK
If the engine output frequency

(<45 or >55) or RPM (<1450 or
>1550) and 3-ph(1-ph) voltage are Check the suitable engine output
not a suitable frequency, RPM and 3-ph(1-ph) and also
the range.
OK
Check the DC connection suitable and

If DC connection is not neutral connection.
suitable or neutral lose
OK
6
1.6 If the engine does not crank or crank slowly

 Step one: -cause Action to be taking
If the starter battery does not Check the starter battery and replace if
work. necessary. Check battery connection
cable. Always tighten loose battery
OK terminals and keep the terminals clean.
The emergency stop button is Check the emergency stop button

not pressed.
OK
Check the starter motor and replace if

If the starter motor is faulty necessary
OK
Check the AUTO mode

If not automatic mode
OK
Check the DG controller(module) and

If the DG controller(module)
replace if necessary.
is faulty
OK
Check the crank relay and lines

If the crank (starter) relay is connection and replace if necessary.
faulty or lose lines connection
OK
7
Check and tighten connections.

If the starting circuit connection
is losing or corroded
OK
If no DC voltage reaches Check that the DC voltage reaches the

the starter motor and fuel starter motor and fuel solenoid.
solenoid.
OK
If the DG output fuse or Check the DG output fuse and breaker

breaker(trip) is burns and replace if necessary.
OK
8
1.7 The engine cranks but will not start (fail to start)
If the fuel filter is dirty or Check the fuel filter and replace if
damage necessary.
OK
If the fuel pump is dirty or Check the fuel pump and replace if
faulty necessary.
OK
Check the fuel solenoid and replace if

If the fuel solenoid is faulty necessary.
OK
If the DG controller(module) Check the DG controller(module) and

is faulty. replace if necessary.
OK
Check that the DC voltage reaches the

If no DC voltage reaches the starter motor.
fuel solenoid.
OK
Check and tighten connections.

If the starting circuit
connection is loose or
corroded
OK
Check the fuel relay and replace if

If the fuel relay is faulty or necessary.
loose connection.
OK

9
1.8 If DG hold alarm low oil pressure shutdown

If the oil level is low or Check the oil level and add if
radiator water is not full. necessary. And check the radiator
water.
OK
If the oil filter is dirty or Check the oil filter and replace if
damage necessary.
OK
If the oil lines are dirty or Check the oil lines and replace if
damage and leakage necessary.
OK
Check the condition of the oil and

If the oil is dirty or out of
service if necessary.
service.
OK
Check the DG controller(module) if

If there is a wrong setting in necessary.
DG controller(module)
OK
If the oil sender is faulty or Check the oil sender and sender lines
sender lines are damage and replace if necessary.
OK
If oil is above the full mark on Check the oil and drain the excess oil if
lipstick. necessary.
OK
Contact to power team. 10

1.9 If DG hold low or high BV.

 Stope one: -cause Action to be taking
If the batter cable connection

is poor(lose) or damage
Check the battery cable connection
and replace if necessary.
OK
If the battery charge is faulty

Check the battery charge and replace
if necessary.
OK
If the DG belt is damage

Check the DG belt and replace if
necessary.
OK
If the DG dynamo is damage

Check the DG dynamo and replace if
necessary.
OK
If the battery charge fuse is Check the battery charge fuse and
burned replace if necessary.
OK
If the battery is dead
Check the condition of the battery and

replace if necessary.
OK
11
1.20 If DG hold alarm over current shutdown

 Stope one: - cause Action to be taking
Check load balance and load sharing

If not load balance.
if necessary.
OK
Check grounding lines connection.

If there is a grounding
problem.
OK
Check the loads that come

If suddenly an incorrect load suddenly, such as air conditioner,
load battery ……...
OK
If there is a wrong setting in Check the DG controller(module)and

DG controller(module) replace if necessary.
OK
If the current lines(sensor) Check the current lines(sensor) and

are lose or damage. And ground.
there is a ground problem
OK
12
2. controlling parts and theirs function

2.1 Cummins DG modules type how can us.
See the module we use: -
o Power commend
Graphical Display
LED Indicators
Display Menu Selection Previous & Off Mode

“Soft Buttons” “Fixed Buttons”
 Graphical Display
The graphical display is used to view menus of the menu-driven operating system.
 Display Menu Selection Buttons
These are 4 “soft” buttons. The functions of these buttons changes depending on what
is displayed above the button on the graphical display.
 Previous Main Menu Level Button
Press this button to view the previous main menu. This button is also used to
acknowledge warning and shutdown messages after a fault has been corrected.
13
 Off Button
Press this button to switch to the off mode. If the gen set (DG) is running, the gen set
(DG) will immediately shut down. This button is also used to acknowledge warning and
shutdown messages after a fault has been corrected.
 LED Indicators
The HMI display panel has 6 LED indicators.
• Not in Auto (Red) is lit when the control is not set in Auto Mode.
• Shutdown (Red) is lit when the control detects a shutdown condition. The
gen set (DG) cannot be started when this lamp is lit. After the condition
has been corrected, the lamp can be reset by pressing the Off button.
• Warning (Amber) is lit whenever the control detects a warning condition. This
lamp is automatically shut off when the warning condition no longer exists.
• Remote Start (Green) is lit when the control is receiving a remote run signal.
• Auto (Green) is lit when the control is in Auto mode.
• Manual Run (Green) is lit when the gen set (DG) is running after being
started in Manual mode.
 Symbols Used
 Symbols used with soft push buttons
The soft buttons change function depending on what the status is of the control, gen set
(DG), etc. The control indicates the function of the soft pushbutton by displaying a
symbol above it on the graphical display.
Hand-Manual mode
AUTO Auto-Auto mode
Down Arrow-Next menu Up Arrow-Previous menu
Left Arrow – Abort the auto

or manual run mode and
return to the operator menu
ADJUST Right Arrow – Navigate to an
Display an adjustable menu editable field within an

adjustable menu
Minus Sign – Decrease
a parameter or value shown Plus Sign-Increase a parameter or
value shown
14
 Symbols used in fault messages and menus

The PCC1302 control with the HMI 211 conveys messages and menus by using as little
text as possible. These are some common symbols.
Warning Shutdown Coolant Temperature
Oil Pressure V AC Voltage V DC Voltage
A AC Current Hz Frequency Battery
Out of range High Low
Annunciator Over speed
Fail to Crank Emergency stop
 Operating Modes
The PCC 1302 control is operated by the HMI 211 front panel buttons. There are 5
modes used regularly by gen set (DG) operators:
 Off Mode
 Manual Mode
 Auto Mode
 Sleep Mode
15
 Sleep Mode
The PCC 1302 enters a low power
Sleep mode when the current draw
from the battery is less than 60 mA.
Sleep mode is automatically enabled
and the display will turn itself off after
five minutes of keypad inactivity in Off
or Auto mode.
Sleep mode can only be disabled be
installing a jumper between TB15-1
and TB15-5. The control will not enter
Sleep mode if there are any active,
unacknowledged faults or if the control
is in Manual Run mode.
Once in sleep mode, these signals can wake up the control:

• Local E-Stop – Active when switch is open
• Remote E-Stop – Active when switch is open
• Manual Start
• PCC Net System Wakeup
• Remote Start
• Auto Mode
• Configurable Input #3
• Configurable Input #4
 Off Mode
Pressing the Off button on the HMI 211

will put the control in Off mode. When in
Off mode, the control does not allow the
gen set(DG) to start. If the genset(DG)
is already running and the control is set
to Off, it initiates a normal shutdown
sequence. When in Off mode, all active
faults are reset.
16
 Manual Run Mode
Pressing the Manual soft button while the control is in Off mode will put the PCC 1302
control in Manual mode. In Manual mode, the genset starting and stopping is controlled
manually by the front panel buttons. When the Man soft button is pushed, the control is
put into Manual mode with a new screen showing on the graphical display. This screen
has an arrow actively pointing at a second Man soft button, in a different location than
the previous. Pressing the soft button below the new Man indication will initiate a normal
start sequence. A remote start signal has no effect while the control is in Manual mode.
If the second Man button is not pressed within ten seconds of entering Manual mode,
the control will revert to Stop mode.
 Auto Mode
17
Pressing the Auto soft buttons while the control is in Off mode will put the PCC 1302
control in Auto mode. In Auto mode, the genset(DG) starting and stopping is controlled
automatically by a remote run signal.
When the Auto soft button is pushed, a new screen shows on the graphical display.
This screen has an arrow actively pointing at a second Auto soft button, in a different
location than the previous. Pressing the soft button below the new Auto indication will
put the control into Auto mode. The green Auto LED will light and the red Not in Auto
LED will no longer be lit. When the control senses a remote start signal, the green
Remote Start LED will light and the genset (DG) will begin a normal start sequence.
The genset(DG) can start at any time while in Auto mode. Never service the genset(DG)
while it is in Auto mode. Accidental starting of the genset(DG) during troubleshooting
can cause severe personal injury or death. Disable the genset(DG) before
troubleshooting.
18
 Connecting HMI 211
This is the rear view of the HMI 211. It has two connections, J1 and J2. These are
essentially identical. J1 or J2 is the connection between the HMI 211 and the PCC 1302
control board. The other connection can be used to “daisy chain” to other PCC Net
devices such as gauges, annunciators, etc.
19
 PCC 1302 Control Board
The PCC 1302 control board is made up of a single control board in a large potting
shell. There are several connection points on the board. TB1, at the bottom, is where all
customer connections are made.
The other connections on the board go to the engine, alternator, current transformers,
and communications cables.
20
 PCC 1302 Connectors
All connectors use a tension or mechanical latch to hold the harness jack in place. All
connectors are keyed so the harness jack cannot easily be inserted incorrectly.
DS1 flashes to let you know the control board is operating properly. This is the
“heartbeat” of the control and will blink once a second when the control is awake and
operating. The heartbeat will stop blinking when the control is asleep. If the control
board has failed, the LED will cease blinking or blink more rapidly than one beat per
second.
21
 TB1 Customer Connections
There are two different ground signals into the PCC 1302 Control. Battery Ground is a
battery negative connection for battery return. Signal Ground is a signal return for
customer inputs. All grounds on TB1 are signal return only. They are not the same
potential as Battery Ground. Using Battery Ground for one of these inputs can
contribute to control board failure.
22
 J20 Gen Set Inputs and Outputs
J20 is the connection to the PCC1302 board that has inputs and outputs for various
items and drivers relevant to the gen set operation.
23
 J11 Engine Inputs and Outputs
J11 is another connection to the PCC1302 board that has inputs and outputs for various
items and drivers relevant to the engine/ECM operation. These connections include
both analog signals and PGI CAN Link, which is the network connection between the
PCC1302 board and the ECM. PGI CAN Link is a proprietary communication protocol
(Cummins owned) that is used to communicate with Cummins ECMs.
24
 J12 Genset CT Connections
J12 is the connection between the PCC1302 board and the current transformers (CTs)
that monitor the current output of the generator. CTs are polarity sensitive, and have a
dot on one side of them which must face the source (generator output). In that sense,
the secondary’s (wires) are polarity sensitive as well. Flipping the secondary’s is the
same as physically installing the CT backwards.
25
• J22 Voltage Sensing Inputs
J22 is the connection between the PCC 1302 and the generator output. It is used
for generator output sensing (voltage and frequency).
The PCC 1302 can be used on single phase or three phase applications.
The maximum input voltage is 600 V AC, not to be confused with the regulator
power input, which is limited to 240 V AC.
26
 J17 and J18 Excitation Output and Input
J17 is the output from the PCC1302 board to the alternator excitation system.
J18 is the input from the voltage regulation power supply. The PCC 1302 will operate
in either a self-excited (shunt excitation) mode or in PMG excitation mode.
J18 can receive input from either the alternator output, or from phase 1 and 2 of a PMG.
There are three connector pins; however, only two of them are used. The J18-1 and 2
inputs are limited to a maximum input of 240 VAC.
27
 J25 Display Connections
J25 is the connection between the PCC1302 board and the display. The display
includes the HMI, gauges, and E-Stop switch.
28
 TB15 Modbus Connection
TB15 is used as a service tool connection point and for Modbus monitoring. Plugging a service
tool harness into TB15 will wake up the control because the service tool harness has a jumper
from TB15-1 to TB15-5.
29
2.2 Automatic Transfer Switch(ATS)

An Automatic Transfer Switch(ATS) is a device that switches an electrical load between
two different sources of power.
Automatic Transfer Switch (ATS):
• A – Automatic: The operations of the ATS, when configured properly, happen
without intervention by a service technician or operator.
• T – Transfer: The ATS is an electrical device designed to “transfer” a customer’s
load between two power sources.
• S – Switch: At its most basic, the ATS is essentially a combination of a shared
bus and two switches. A shared bus is simply a collection point for one or more
power sources. One switch is there to open and close from Source 1, the
other is there to open and close from Source 2. The load is powered by a
connection to the shared bus in the middle.
• Basic Transfer Switch Construction
30
If the Utility(mains) power is available

(represented by a green “U”), the Source
1 Switch is closed, the Source 2 Switch is
open, the customer’s Load (represented
by a yellow “L”) will be powered by
Utility(mains)
If the Genset(DG) power is available

(represented by a green “G”), the Source 2
Switch is closed, the Source 1 Switch is
open, the customer’s Load (represented by
a yellow “L”) will be powered by
Genset(DG).
31
The EC control is mounted to the outside of the

• EC Control Panel cabinet door of the ATS.
The EC control comes in two different versions:
• TS1311 – Line-to-Line sensing
• TS1310 – Line- to-Line sensing
The TS1311 uses Line-to-Neutral sensing, while the
TS1310 uses Line-to-Line.
The EC control panel is made up of several LEDs
and Pushbuttons. This is accessible from the outside
of the ATS cabinet.
Configuration LEDs are used in configuration mode
to determine the parameter and value being
configured.
Indicator LEDs let the operator know which source
is available and which source the ATS is connected
to without having to open the cabinet door.
Pushbuttons allow the operator to configure the EC
control, Test and Exercise the system and override
certain Time Delays.
• ATS Status LEDs
The ATS status LEDs are lit to show what source(s)

are available, which source the ATS is connected to
and what mode the control is in.
Utility(Mains) Power Available LED (Green) is lit
when the utility(mains) is of acceptable voltage.
Utility(mains) Connected LED (Green) is lit when the
ATS is physically connected to the Utility(mains)
side of the switch, regardless of the availability of
utility(mains). This LED will flash as a result of a
failure to connect or disconnect from the
Utility(mains) side of the switch.
32
• Pushbuttons
The test pushbutton is used to set or cancel a

test period, as well as navigate the
configuration function codes.
The override pushbutton is used to bypass
some time delays, cancel an active exercise
period, or stop the Utility(mains) or
Genset(DG) Connected LEDs from flashing
after a failure to disconnect or connect. It is
also used to scroll through the value codes in
configuration mode.
The Set Exercise pushbutton is used to set a
delayed repeat exercise period, start an
immediate exercise period, or cancel the
exercising schedules.
• Rear View of EC Control Panel
On the rear side of the door of the ATS is

the back side of the EC control. This is
where all of the inputs and outputs are
made.
The EC control has 3 terminal blocks:
P3 – Voltage Sensing
P4 – Inputs
P5 – Outputs
33
• P3 – Voltage Sensor Inputs

P3 – Voltage Sensing (TS1311 Line-to-Neutral):
• P3-1 N Genset(DG) Sensing Voltage
• P3-3 L1 Genset (DG)Sensing Voltage
• P3-5 N Utility (mains)Sensing Voltage
• P3-7 L3 Utility (mains) Sensing Voltage
• P3-9 L2 Utility (mains)Sensing Voltage
• P3-11 L1 Utility (mains)Sensing Voltage
• P4 - Inputs
P4 is used for inputs in to the EC control.
These inputs are coming from the transfer switch mechanism from the Auxiliary Contacts and Customer
Connections.
P4 – Inputs:
• P4-1 Functional Earth Ground. Used as the common for the ATS position switches.
• P4-2 Remote Override (optional). Grounded to activate using P4-1 common. The remote
override acts exactly like the override pushbutton on the front of the control
• P4-3 Remote Test. Grounded to activate using P4-1 common. The remote test input will initiate a
test sequence similar to the pushbutton on the front of the control.
• P4-4 External Exerciser Clock. Grounded to activate, this is the input to the EC control that the
optional exerciser clock will use to force the switch into exercise periods without the use of the
integrated exercise clock
• P4-5 Transfer Inhibit. Grounded to activate. Prevents the switch from transferring
• P4-6 ReTransfer Inhibit. Grounded to activate. Prevents the switch from retransferring
• P4-7 Connected to Utility(mains) signal from ATS position switches. Grounded to activate. Tells
the EC control that the ATS mechanism is connected to Utility(mains)
• P4-8 Connected to Genset(DG) signal from ATS position switches. Grounded to activate. Tells
the EC control that the ATS mechanism is connected to Genset(DG)
34
• Terminal Block P5 - Outputs
P5 is used primarily for outputs going from the EC control to the ATS mechanism. It is also where control
power comes into the EC control.
These outputs controlling the transfer switch mechanism, genset(DG), and the Elevator Pretransfer relay
by grounding (and opening) connection points on P5.
P5 – Outputs:
• P5-1 Open Utility (mains). The control grounds this point to energize the power relays to open
from Utility (mains).
• P5-2 Close Utility (mains). The control grounds this point to energize the power relays to close
to Utility (mains).
• P5-3 Open Genset (DG). The control grounds this point to energize the power relays to open
from Genset (DG).
• P5-4 Close Genset(DG). The control grounds this point to energize the power relays to close
to Genset (DG).
• P5-5 Elevator Pretransfer. Grounded to energize elevator pretransfer relay, to send signal to
elevator controller to stop and open doors at nearest floor
• P5-6 Genset (DG)Start Relay. Dry contact outputs for starting the genset(DG)
• P5-7 Genset (DG)Start Relay. Dry contact outputs for starting the genset(DG)
• P5-8 Ground Input. Negative genset(DG) battery connection for EC power supply
• P5-9 B+ Input (+). Positive genset(DG) battery connection for EC power Supply
35
• Source/Load Connections
Utility (mains) power is installed into
the GT mechanism at the top of the
mechanism.
Genset (DG) power is installed into the
GT mechanism at the bottom of the
mechanism.
The customer’s load is installed into
the GT mechanism at the bottom,
behind the Genset (DG) connection
lugs.
Follow the instructions in the
Installation Manual for guides on
power cable size and number of
conductors per phase.
36
2.3 The typical wiring diagram of TS1311And Sequence of events
TYPICAL CONDITIONAL SCHEMATIC – LOSS OF UTILITY(MAINS) POWER

OCCURS, TRANSFER FROM UTILITY (MAINS OR SOURCE 1) TO NEUTRAL
37
TYPICAL CONDITIONAL SCHEMATIC – GENSET (DG or SOURCE 2) AVAILABLE,

TRANSFER FROM NEUTRAL TO THE GENSE(DG)
38
TYPICAL CONDITIONAL SCHEMATIC – UTILITY(MAINS) POWER RETURNS,

TRANSFER FROM GENSET (DG OR SOURCE 2) TO NEUTRAL
39
TYPICAL CONDITIONAL SCHEMATIC – UTILITY(MAINS) POWER AVAILABLE,

TRANSFER FROM NEUTRAL TO UTILITY (MAINS OR SOURCE 1)
40
3. GU320B Controller Operation Manual Brief Introduction
GU320B Genset intelligent controller is adopted high performance computer chip, can
modify the control procedure and protection parameters of generator, which
incorporated kinds of functions, such as measure, control, protection, three remote, and
programmable managements.
The controller measure and display all output electric parameters for generator, and
rpm, oil pressure, coolant temperature, DC source voltage and running hours for
engine, and the voltage and current adopted true RMS measure to make sure data
accuracy.
 The Outline Image Drawings and Wirings of Controller










LED
Panel display
LED
Front view Panel Buttons
41
Back view
42
3.1 Connecting Terminals:

Pin No Function Description Signal
A1 L1-phase voltage input 0-300VAC
A4 Neutral zero line
B5 L1-phase current input {S1} 0-5A(AC)
B8 Current input com. port {S2} 0-5A(AC)
C9 Relay output com. Port
C10 Fuel solenoid relay output N.O. dry contact, 10A/30VDC
C11 Start relay output N.O. dry contact, 10A/30VDC
C12 Charger excitation source If not use, do not connect to
output cathode
C13 Genset(DG) running output N.O. dry contact, 3A/30VDC
C14 Custom output 1# N.O. dry contact, 3A/30VDC
D17 Oil pressure test P-sensor (<2KΩ)
D18 Coolant temperature detect T-sensor (<2KΩ)
D19 Fuel level detect Fuel level sensor (
D20 Oil pressure signal Low potential is active
D21 Coolant temperature signal Low potential is active
D22 Emergency stop signal Low potential is active
D23 Start {external control }signal Low potential is active
D24 Auxiliary switch signal input Low potential is active
D25 Magnetic sensor signal {＋} 1~70Vac Internal connect to
D26 Magnetic sensor signal {－} the cathode of DC source
D27 Working power source {+} 12V/24V (8~35VDC
D28 Working power source {-} continued)
D29 Grounded
43
3.2 Typical Wiring Diagram:
44
 Operation Panel
The operation panel covers three sections: measuring parameters displayed by
LCD, operation switches and running states displayed by LED.
 Panel Buttons and
The button is used for setting “auto-operation mode”. When controller is

running in AUTO mode, LED above the button lights up. According to the “remote start
signals” is active or not, to control generator start and stop.
The button is used for setting “manual-operation mode”. When controller is

running in MAN mode, LED above the button lights up. The controller controls generator
starts and stop by pressing “START” and “STOP” buttons...
The button is used for setting “test-operation mode”. When controller is

running in test mode, LED above the button lights up. At that time, controller analogs
the “remote start input signal” is active to control generator start. When switch to “Auto
operation mode” and the “remote start input signal” is inactive, generator stop.
The button is used for MAN start Genet(DG). When controller is setting in
MAN-operation mode, press this button can start generator. During the period from
controller performs start procedure to Genset(DG) is normal running, the normal running
LED above the button flash, and LED keep on when the Genset(DG) is normal running.
45
The button is used for manual stop generator, when controller is set in
“MAN” mode, this button can stop Genset(DG). Continuously press this button over 2s
can release from failure shutdown locked if occurs failure output. (When controller
performs stop procedure, LED above the button on, when fail to stop, LED flash.)
It is alarm silence and lamp test button. Continuously press the button
more than 2S, all LED on the panel will illuminate. This function is used for testing all
LED on the panel. When warning or fault alarm occur, press this button can mute the
buzzer and LED above the button illuminate at that time. Press it again will cancel mute
function, if controller holding on failure status, the alarm buzzer keeping sound.
Entering submenu/ modify/ confirming modification
Scroll up menu /value ascend
Scroll down menu/ value descend
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 Control and Operation Instruction

The controller has 3 control modes: AUTO operation mode, MAN operation mode and
test-operation mode.
Continuously press “AUTO” button (2s above), the LED above the button
lights up, controller then running in “AUTO” mode.
Continuously press “MAN” button (2s above), the LED above the button lights
up, controller then running in MAN” mode.
Continuously press “TEST” button (2s above), the LED above the button lights
up, controller then running in “TEST” mode.
When controller running in AUTO status and remote start input signal is
active, or in MAN status press “START” button, controller begins start procedure,
START LED flash.
When Genset(DG) in normal running, in “MAN” mode continuously press

“STOP/RESET” button one time, controller begins cooling delay stop process, which
same as auto stop. Press “STOP/RESET” button again, controller switch off fuel
solenoid valve immediately, Genset(DG) start stop.
47
4.TU510A Auto Transfer Controller(ATS)
TU510A controller is an auto transfer controller, which incorporating the functions such
as measuring display, control, and three remote. It has following functions:
• Micro-computer control, complete digital technology.

• Select the running mode of controller by buttons on panel.
• LED directly displays the running status of ATS and the running mode of
controller.
• Configure the running parameters by LED and buttons on panel.
• Display measuring data by LED, including voltage and frequency.
• By connecting RS485 communication port to PC (required for
RS485/RS232 interface converter) all setting values and data can be read
and wrote, and modified.
• The Outline Image Drawings and wirings of Controller
DG side
Mains Indicter
display
side
display
LED
display
Front view
Operating Buttons
and LED
48
Back view
49
4.1 The Connecting Terminals of MG Model:

Pin No
A1 Mains Ph-L1 voltage input 0-300VAC
A2 Mains Ph-L2 voltage input 0-300VAC
A3 Mains Ph-L3voltage input 0-300VAC
A4 Mains neutral
A5 Relay N. O. contact control outputs of transfer
A6 Relay COM switch at Mains side
A7 Relay N. C. contact 10A/250VAC
B8 Working power +B (optional)12V/24V(8-
B9 Working power –B 35VDC continuous)
C10 DG Ph-L1 voltage input 0-300VAC
C13 DG neutral
C14 Relay N. O. contact Control outputs of Transfer
C15 Relay COM switch at DG side
C16 Relay N. C. contact 10A/250VAC
D17 Com. port for status input Low potential output
signal
D18 Mains aux contact signal Low potential is active
D19 Gen aux contact signal Low potential is active
D20 Reserve Low potential is active
D21 Generator failure input Low potential is active
D22 Reserve Low potential is active
D23 Start output {COM} Control generator start
D24 Start output {N/O} output 5A/30VDC
D25 Reserve output {COM}
D26 Reserve output {N/O} Reserve output 5A/30VDC
D27 externally grounded
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4.2 The typical wiring diagram of MG Model
51
 Operation panel
The operation panel covers three sections: measuring parameters displayed by LED,
operating buttons and running states displayed by LED.
• LED display and control buttons

3- digit LED in 2 rows at the both sides respectively display one phase voltage and
frequency of either power in the dual power system, and scroll page can review other
phase voltage. LED combined with control buttons provide a friendly operation interface
for operator to set operating parameters.
Enter into submenu/modify/confirm modification
Scroll up menu/ value ascend
Scroll down menu/ value descend
• The Operating Buttons and LED of MG Mode
This button is used for AUTO mode setting, when controller in this mode,
the LED above the button lights up. Mains is prior, when Mains is normal, power supply
by Mains; when Mains failure occurs, power supply by DG.
This button is used for MAN mode setting. When controller in this mode,
the LED above the button lights up. Controller will choose power supply by Mains or DG
by pressing “TO MAINS” or “TO GENSET(DG)” button.
This button is used for testing mode setting. When controller in this mode,
the LED above the button lights up. In this mode, controller simulates Mains failure.
52
When controller in MAN mode and Mains voltage is normal, press this
button can switch to Mains supply, the LED above the button lights up.
When controller in MAN mode and DG voltage is normal, press this button
can switch to DG supply, the LED above the button lights up.
Lamp testing button, when press this button all lamps on panel should light
up, otherwise, failure occurred.
53
5. InteliLiteNT AMF20/25
InteliLiteNT AMF20/25 is a comprehensive AMF-controller for single generating sets

operating in stand-by mode. IL-NT AMF25 features extended support of electronic
engines and extension modules.
InteliLiteNT controllers are equipped with a powerful graphic display showing icons,
symbols and bar-graphs for intuitive operation, which sets, together with high
functionality, new standards in Gen-set controls.
InteliLiteNT automatically starts the Gen-set, closes the Gen-set C.B. when all
conditions are met, then stops the engine on external signal or by pressing push
buttons.
InteliLiteNT provides gas engine support without ventilation.
The key feature of InteliLiteNT is its easy-to-use operation and installation. Predefined
configurations for typical applications are available as well as user-defined
configurations for special applications.
• The Outline Image Drawings and wirings of Controller
Front view
54
 Front panel elements
Use this button to move left or to change the mode. The

button can change the mode only if the main screen with the indicator of currently
selected mode is displayed.
Use this button to move right or to change the mode. The

button can change the mode only if the main screen with the indicator of currently
selected mode is displayed.
. Works in MAN mode only. Press this button to initiate the

start sequence of the engine.
Works in MAN mode only. Press this button to initiate the stop
sequence of the gen-set. Repeated pressing of button will cancel current phase of stop
sequence (like cooling) and next phase will continue.
Use this button to acknowledge alarms and

deactivate the horn output. Inactive alarms will disappear immediately and status of
active alarms will be changed to "confirmed" so they will disappear as soon as their
reasons dismiss.
Use this button to deactivate the horn output without

acknowledging the alarms.
There are two states - Gen-set OK (indicator

is green) and Genset failure (indicator is red). Green LED is on if the generator voltage
is present and within limits. Red LED starts flashing when gen-set failure occurs. After
FAULT RESET button is pressed, goes to steady light (if an alarm is still active) or is off
(if no alarm is active).
55
Green LED is ON if load is supplied by mains or by generator. It

means, that Gen-set or mains is OK and proper circuit breaker is closed.
There are two states - Mains OK (indicator is

green) and Mains failure (indicator is red). Green LED is on, if mains is present and
within limits. Red LED starts blinking when the mains failure is detected and after the
gen-set has started and connected to the load it lights permanently until the mains
failure disappears.
Use this button to switch over display pages.
Use this button to finish editing a set point or moving right in

the history page.
Use this button to move down or decrease value.
Use this button to move up or increase value.
Green LEDs are on if GCB is closed and Gen-set is healthy. If

Gen-set is not healthy and GCB is closed than middle LED is on. It is driven by GCB
CLOSE/OPEN output or by GCB feedback signal.
Works in MAN and TEST modes only. Press this button to

open or close the GCB.
Green LEDs are on if MCB is closed and Mains is healthy. If

Mains is not healthy and MCB is closed than middle LED is on. It is driven by MCB
CLOSE/OPEN output or by MCB feedback signal.
Works in MAN and TEST modes only. Press this button to

open or close the MCB.
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Back view
57
• Inputs and outputs

Generator current inputs
Generator voltage inputs
Mains voltage inputs
Binary inputs
CAN bus and RS485
Analog inputs
Binary outputs
Power sup
USB
58
5.1 Binary inputs

BIs Description Function
BI1 Generator circuit breaker feedback Use this input for indication whether the
generator circuit breaker is open or closed.
BI2 Mains circuit breaker feedback Use this input for Indication whether the
mains circuit breaker is open or closed.
BI3 Emergency stop button The shutdown procedure will start
immediately when this input is activated.
Input is inverted (NC=normally closed)
in
Default configuration.
BI4 Access lock key switch When this input is closed, no set points can
be adjusted from controller’s front panel and
controller mode (OFF/MAN/AUTO/TEST) can
not be changed.
BI5 Switch controller to OFF mode The controller is switched to the OFF mode
(there are four modes
OFF/MAN/AUTO/TEST) when this binary
input is closed. When opens controller is
switched back to previous mode.
BI6 Switch controller to TEST mode The controller is switched to the TEST mode
BI7 Suppression of alarms The controller is switched to the TEST mode
59
• Binary outputs
BOs Description Function
BO1 Starter motor Starter
control
BO2 Fuel solenoid valve This output controls the fuel solenoid
valve. The Fuel Solenoid output has two
different behaviors depending on engine
type–gas or diesel
BO3 Indication of The output controls the generator circuit
breaker state breaker. Its state represents the breaker
position requested by the controller. The
breaker must react within 5 seconds to
a close or open command, otherwise an
alarm is issued.
BO4 Indication of The output controls the generator circuit
breaker state breaker. Its state represents the breaker
position requested by the controller. The
breaker must react within 5 seconds to a
close or open command, otherwise an
alarm is issued.
BO5 Activation of any Prestart
devices before start
BO6 Gen-set can be Ready to load
connected to load
BO7 Indication of The output is designed to be used as
unconfirmed alarm extern alarm indication such as a red
bulb in the control room.
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 Analog inputs
The analog inputs are designed for resistive automotive type sensors like VDO or
DATCON. The sensors are connected either by one wire (the second pole is the sensor
body) or by two wires.
 In the case of grounded sensors, connect the AI COM terminal to the engine
body as near to the sensors as possible.
 In the case of isolated sensors, connect the AI COM terminal to the negative
power supply terminal of the controller as well as one pole of each sensor.
Analog inputs are typically used for: Oil Pressure, Coolant Temperature and Fuel Level. All of
these parameters are connected with relevant protections.
AI Configured sensor Function

AI1 VDO 10 Bar Oil pressure sensor-Logical analog input designed for oil pressure
value received from analog sensor
AI2 VDO40-120°C Coolant temperature sensor-Logical analog input designed for coolant
temperature value received from analog sensor
AI3 VDO Level % Fuel level sensor-Logical analog input designed for fuel level value
received from analog sensor.
AI4 -------- -------------------
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5.2 AMF 25 wiring diagram
62
6.Conclusion
This guide use for all new coming staff, related employee like IP, run, TX
etc. And also to initiative everyone to read others working manual. when
technicians are on task and suddenly need how to handle different types of
faults within short period of time and wants to installation a new device.
63

DG and ATS

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DG and ATS troubleshooting within solutions

1.1 If DG hold alarm over coolant temperature

Add coolant as necessary and repair any

Inspect radiator fans clean or repair if

Inspect radiator tube(hose) or repair if

If the incorrect oil level Add or drain engine oil.

Check the belt and replace it if

Check the radiator cap and replace it

Check the thermostat and replace it if

Remove injection pump check

Check hose clamps for leaks on the

Contact to power team.

1.2 If DG hold low coolant temperature

Check the cooling rate and add if

Check the fan is working and replace if

Check and clean sensor and coolant

Check the gauge and replace if

If the thermostats are faulty Check the thermostats and replace if

Contact to power team. 3

1.3 If DG hold alarm over speed shutdown

Check the generator rotor and replace if

Check the speed sensor and replace if

Check the DG controller and replace if

Check load and load share.

Contact to power team.

1.4 If DG hold alarm under speed (under freq.) shutdown or pickup

Check the governor and replace if

Check the air filter and replace if

Check the fuel filter and replace if

Inspect the fuel line for the engine and

If there is a wrong message Check the governor, DG

Contact to power team.

1.5 If the Engine (DG) Stops after starting (not running)

If the fuel filter is dirty or

If the engine output frequency

Check the DC connection suitable and

Contact to power team.

1.6 If the engine does not crank or crank slowly

The emergency stop button is Check the emergency stop button

Check the starter motor and replace if

Check the AUTO mode

Check the DG controller(module) and

Check the crank relay and lines

Check and tighten connections.

If no DC voltage reaches Check that the DC voltage reaches the

If the DG output fuse or Check the DG output fuse and breaker

Contact to power team.

Check the fuel solenoid and replace if

If the DG controller(module) Check the DG controller(module) and

Check that the DC voltage reaches the

Check and tighten connections.

Check the fuel relay and replace if

Contact to power team.

1.8 If DG hold alarm low oil pressure shutdown

Check the condition of the oil and

Check the DG controller(module) if

Contact to power team. 10

1.9 If DG hold low or high BV.

If the batter cable connection

If the battery charge is faulty

If the DG belt is damage

If the DG dynamo is damage

If the battery is dead

Check the condition of the battery and