QSK60 (DQKH) Control System

PowerCommand®Control 3201
Publication No. 3549(GB) Issue 1 - April ‘04
QSK60 (DQKH) Control System Publication 3549(GB)
PowerCommand®Control 3201 Issue 1 - April ‘04

FOREWORD
The purpose of this manual is to provide the users with sound, general information. It is for guidance and
assistance with recommendations for correct and safe procedures. Cummins Power Generation Limited
cannot accept any liability whatsoever for problems arising as a result of following recommendations in this
manual.

The information contained within the manual is based on information available at the time of going to print. In
line with Cummins Power Generation Limited policy of continual development and improvement, information
may change at any time without notice. The users should therefore ensure that before commencing any
work, they have the latest information available.

Users are respectfully advised that it is their responsibility to employ competent persons to carry out any
installation work in the interests of good practice and safety. Consult your Authorised Distributor for further
installation information. It is essential that the utmost care is taken with the application, installation and
operation of any diesel engine due to their potentially dangerous nature. Careful reference should also be
made to other Cummins Power Generation Limited literature, in particular the Health and Safety Manual
(3553) and the Engine Operation and Maintenance Manual.

Should you require further assistance contact: -

Cummins Power Generation Limited

Columbus Avenue
Manston Park
Manston
Ramsgate
Kent CT12 5BF
Tel. No.: +44 (0) 1843 255000
Fax. No.: +44 (0) 1843 255902

e-mail: [Link]@[Link]

Web Site: [Link]

Publication 3549(GB) QSK60 (DQKH) Control System
Issue 1 - April ‘04 PowerCommand®Control 3201
QSK60 (DQKH) Control System Publication 3549(GB)
PowerCommand®Control 3201 Issue 1 - April ‘04

CONTENTS
Section Title Page

Schedule of Abbreviations............................................................................................................................ i

1 Safety ..................................................................................................................................... 1-1

1.1 Warning, Caution and Note Styles Used In This Manual .......................................................... 1-1
1.2 Warnings .................................................................................................................................. 1-1
1.3 General Information .................................................................................................................. 1-1
1.4 Generator Plant Safety Code.................................................................................................... 1-1

2 Introduction ................................................................................................................................... 2-1

2.1 General ..................................................................................................................................... 2-1
2.2 Generating Set Identification..................................................................................................... 2-1
2.3 After Sales Services ................................................................................................................. 2-2
2.3.1 Maintenance....................................................................................................................... 2-2
2.3.2 Warranty............................................................................................................................. 2-2
2.3.3 Spares................................................................................................................................ 2-2
2.3.4 Overseas............................................................................................................................ 2-2

3 System Overview .......................................................................................................................... 3-1

3.1 Generator Components – Typical Genset................................................................................. 3-1
3.1.1 Control System................................................................................................................... 3-2
3.1.2 Engine ................................................................................................................................ 3-2
3.1.3 Alternator............................................................................................................................ 3-2
3.1.4 Generator Rating................................................................................................................ 3-2
3.1.5 Generator Construction ...................................................................................................... 3-2
3.1.6 Fuel System ....................................................................................................................... 3-2
3.1.7 Cooling System .................................................................................................................. 3-3
3.1.8 Engine Exhaust (Option) .................................................................................................... 3-3
3.1.9 DC Electrical System.......................................................................................................... 3-3
3.1.10 Alarm Module (Option) ....................................................................................................... 3-4
3.1.11 Sensors/Senders................................................................................................................ 3-4
3.2 Heaters ..................................................................................................................................... 3-5
3.2.1 Engine Heater (Option)....................................................................................................... 3-5
3.2.2 Alternator Heater (Option) .................................................................................................. 3-5
3.2.3 Control Panel Heater (Option) ............................................................................................ 3-5
3.3 Mains Powered Battery Charger (Option) ................................................................................. 3-6
3.3.1 Operation ........................................................................................................................... 3-6
3.3.2 Boost Charge (Option)........................................................................................................ 3-6

4 Control System.............................................................................................................................. 4-1

4.1 Control System Description ...................................................................................................... 4-1
4.1.1 Control Panel Power ON/OFF Modes ................................................................................ 4-2
4.1.2 Control Panel - Front Panel ................................................................................................ 4-3
4.1.3 Control Panel - Operator Panel .......................................................................................... 4-4
4.1.4 Control Panel - Switch Panel .............................................................................................. 4-4
4.2 Menu Display and Switches...................................................................................................... 4-6
4.2.1 Graphical Display ............................................................................................................... 4-6
4.2.2 Menu Buttons ..................................................................................................................... 4-7
4.3 Menu Units Selection ................................................................................................................ 4-7
4.3.1 Local/Remote Field ............................................................................................................ 4-7

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Publication 3549(GB) QSK60 (DQKH) Control System
Issue 1 - April ‘04 PowerCommand®Control 3201

CONTENTS (continued)
Section Title ........................................................................................................................... Page

4.4 Main Menu ................................................................................................................................ 4-8

4.4.1 Adjust Button ...................................................................................................................... 4-8
4.4.2 Set-up Button ..................................................................................................................... 4-8
4.4.3 _\_ Button (Paralleling applications only)............................................................................ 4-9
4.4.4 Power Trans Button (PTC applications only) ...................................................................... 4-9
4.5 Engine Data Submenus .......................................................................................................... 4-10
4.6 Alternator Data Submenus...................................................................................................... 4-11
4.6.1 Voltage L–L and L–N........................................................................................................ 4-11
4.6.2 Amps ................................................................................................................................ 4-11
4.6.3 Frequency ........................................................................................................................ 4-11
4.6.4 AVR Duty Cycle................................................................................................................ 4-11
4.6.5 kW, kVA and PF ............................................................................................................... 4-11
4.7 Control Submenu .................................................................................................................... 4-12
4.7.1 Local Control Submenu Function ..................................................................................... 4-12
4.7.2 Remote Control Submenu Functions................................................................................ 4-13
4.7.3 Local/Remote Control Submenu Function ........................................................................ 4-13
4.8 History/About Submenus ........................................................................................................ 4-14
4.8.1 History .............................................................................................................................. 4-14
4.8.2 About ................................................................................................................................ 4-14
4.8.3 Fault History ..................................................................................................................... 4-14
4.9 Adjust Sub-menu .................................................................................................................... 4-16
4.10 Parallel Data Submenu ........................................................................................................... 4-17
4.10.1 Parallel Data Status Line .................................................................................................. 4-17
4.11 Password Menu ...................................................................................................................... 4-18
4.12 Power Transfer Main Menu..................................................................................................... 4-19
4.12.1 PTC Status Line ............................................................................................................... 4-20
4.12.2 Utility (PWR TRAN) Submenus ........................................................................................ 4-21
4.12.3 Status (PWR TRAN) Submenus ....................................................................................... 4-22
4.12.4 Transfer Control (PWR TRAN) Submenu ......................................................................... 4-23
4.12.5 Genset (PWR TRAN) Submenus ..................................................................................... 4-24

5 Operation ..................................................................................................................................... 5-1

5.1 Safety ..................................................................................................................................... 5-1
5.2 Introduction ............................................................................................................................... 5-1
5.3 Maintenance ............................................................................................................................. 5-1
5.4 Operating Recommendations ................................................................................................... 5-2
5.4.1 Running-in .......................................................................................................................... 5-2
5.4.2 No Load Operation ............................................................................................................. 5-2
5.4.3 Exercise Period .................................................................................................................. 5-2
5.4.4 Low Operating Temperatures ............................................................................................. 5-2
5.4.5 High Operating Temperatures ............................................................................................ 5-2
5.4.6 Genset Standby Rating ...................................................................................................... 5-2
5.4.7 De-rating Factors................................................................................................................ 5-3
5.5 Genset Operation...................................................................................................................... 5-4
5.5.1 Sequence of Operation....................................................................................................... 5-4
5.6 Starting ..................................................................................................................................... 5-4
5.6.1 Pre-start Checks................................................................................................................. 5-5
5.6.2 Starting at Switch Panel (Manual Mode)............................................................................. 5-7
5.6.3 Starting at Remote Operator Panel (Auto Mode) ................................................................ 5-9
5.6.4 Starting from Remote Location (Switch or Device) (Auto Mode)......................................... 5-9
5.6.5 Exercise Start ................................................................................................................... 5-10
5.6.6 Cold Starting with Loads................................................................................................... 5-10

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QSK60 (DQKH) Control System Publication 3549(GB)
PowerCommand®Control 3201 Issue 1 - April ‘04

CONTENTS (continued)
Section Title ........................................................................................................................... Page

5.7 Running at Idle (Manual)......................................................................................................... 5-11

5.8 Stopping ................................................................................................................................. 5-12
5.8.1 Emergency Stop (Code 1434) .......................................................................................... 5-12
5.8.2 Stopping at Switch Panel (Manual Mode)......................................................................... 5-12
5.8.3 Stopping at Remote Operator Panel (Auto Mode) ............................................................ 5-12
5.8.4 Stopping from Remote Location (Switch or Device) (Auto Mode) ..................................... 5-13
5.9 Optional Power Transfer Control (PTC) Operation.................................................................. 5-14
5.9.1 PCC3201/PTC – Normal Operation Sequences ............................................................... 5-14
5.9.2 Test Switch....................................................................................................................... 5-14

6 Maintenance .................................................................................................................................. 6-1

6.1 General ..................................................................................................................................... 6-2
6.2 Genset Specifications ............................................................................................................... 6-3
6.3 Maintenance Schedules............................................................................................................ 6-4
6.4 Locking the Genset Out of Service ........................................................................................... 6-6
6.4.1 Introduction ........................................................................................................................ 6-6
6.4.2 Immobilising the Plant for Safe Working ............................................................................. 6-6
6.5 General Inspection.................................................................................................................... 6-7
6.5.1 Exhaust System ................................................................................................................. 6-7
6.5.2 Fuel System ....................................................................................................................... 6-7
6.5.3 AC Electric System............................................................................................................. 6-7
6.5.4 DC Electrical System.......................................................................................................... 6-8
6.5.5 Engine ................................................................................................................................ 6-8
6.5.6 Mechanical ......................................................................................................................... 6-8
6.6 Lubrication System ................................................................................................................... 6-9
6.6.1 Oil API Classification .......................................................................................................... 6-9
6.6.2 Oil Viscosity........................................................................................................................ 6-9
6.6.3 Engine Oil Level ................................................................................................................. 6-9
6.6.4 Oil and Filter Change ......................................................................................................... 6-9
6.6.5 Starting Procedure After Extended Shutdown or Oil Change ........................................... 6-10
6.7 Coolant System ...................................................................................................................... 6-11
6.7.1 Anti-freeze Concentration................................................................................................. 6-11
6.7.2 Coolant Level ................................................................................................................... 6-12
6.7.3 Cooling System Maintenance ........................................................................................... 6-13
6.7.4 Radiator............................................................................................................................ 6-14
6.7.5 Fan Bearings Re-lubrication ............................................................................................. 6-14
6.7.6 Coolant Heater ................................................................................................................. 6-15
6.8 Heat Exchanger Cooling System (Optional)............................................................................ 6-15
6.9 Fuel System............................................................................................................................ 6-16
6.9.1 Fuel Handling Precautions ............................................................................................... 6-16
6.10 Air Cleaner.............................................................................................................................. 6-16
6.11 AC Generator Bearing Re-lubrication ..................................................................................... 6-17
6.11.1 Lubrication........................................................................................................................ 6-17
6.11.2 Re–Lubrication Procedure................................................................................................ 6-18

Contents Page iii

Publication 3549(GB) QSK60 (DQKH) Control System
Issue 1 - April ‘04 PowerCommand®Control 3201

CONTENTS (continued)
Section Title ........................................................................................................................... Page

7 Troubleshooting ............................................................................................................................ 7-1

7.1 Introduction ............................................................................................................................... 7-1
7.2 Control Unit DC Power Supply.................................................................................................. 7-1
7.3 Safety Considerations............................................................................................................... 7-2
7.4 Fault Finding ............................................................................................................................. 7-3
7.5 Status Indicators ....................................................................................................................... 7-3
7.5.1 Not In Auto Indicator........................................................................................................... 7-3
7.5.2 Shutdown Status Indicator.................................................................................................. 7-3
7.5.3 Warning Status Indicator .................................................................................................... 7-3
7.6 Reading Fault Codes ................................................................................................................ 7-4
7.6.1 Reading Fault Codes Using Graphical Display (Optional) .................................................. 7-4
7.6.2 Reading Fault Codes Using Warning/Shutdown Indicators ................................................ 7-4
7.7 Line Circuit Breaker (Optional).................................................................................................. 7-6
7.8 Control and Diagnostics Via Network or PC (Laptop) ............................................................... 7-6
7.9 Fault Codes .............................................................................................................................. 7-6
7.9.1 Category A Fault Codes ..................................................................................................... 7-6
7.9.2 Category B Fault Codes ..................................................................................................... 7-6
7.9.3 Category C Fault Codes ..................................................................................................... 7-6
7.9.4 Category D Fault Codes ..................................................................................................... 7-6
7.9.5 Category E Fault Codes ..................................................................................................... 7-6

Page iv Contents
QSK60 (DQKH) Control System Publication 3549(GB)
PowerCommand®Control 3201 Issue 1 - April ‘04

Illustrations
Figure Title Page

Figure 2-1 Typical Genset Rating Plate........................................................................................ 2-1

Figure 3-1 Typical Genset ............................................................................................................ 3-1
Figure 3-2 Alarm Module Front Panel .......................................................................................... 3-4
Figure 4-1 Control Panel Assembly (Full Featured)...................................................................... 4-3
Figure 4-2 Graphical Display and Menu Selection Buttons .......................................................... 4-6
Figure 4-3 Units Submenu ........................................................................................................... 4-7
Figure 4-4 System Control Main Menus A and B ......................................................................... 4-8
Figure 4-5 Engine Data Sub-menus ........................................................................................... 4-10
Figure 4-6 Alternator Data Sub-menus....................................................................................... 4-11
Figure 4-7 Local Control Sub-menu ........................................................................................... 4-12
Figure 4-8 Control Sub-menu..................................................................................................... 4-13
Figure 4-9 History/About Sub-menus ......................................................................................... 4-15
Figure 4-10 Adjust Sub-menu ...................................................................................................... 4-16
Figure 4-11 Bus Data Sub-menu.................................................................................................. 4-17
Figure 4-12 Password Menu ........................................................................................................ 4-18
Figure 4-13 Power Transfer Main Menu....................................................................................... 4-19
Figure 4-14 Utility Sub-menu........................................................................................................ 4-21
Figure 4-15 Status (PWR TRANS) Submenus ............................................................................. 4-22
Figure 4-16 Transfer Control Submenus ...................................................................................... 4-23
Figure 4-17 Genset Submenus .................................................................................................... 4-24
Figure 5-1 Normal Start/Run/Stop Sequences ............................................................................. 5-8
Figure 6-1 After Cooler/Water Jacket Coolant Drain Locations .................................................. 6-13
Figure 6-2 Fan Bearing Grease Fittings ..................................................................................... 6-14
Figure 6-3 Coolant Heater.......................................................................................................... 6-15
Figure 7-1 Front Control Panel (Full-Featured) ............................................................................ 7-5

Tables
Table No. Title Page

Table 5-1 Manual Run.............................................................................................................. 5-15

Table 5-2 Utility Power Fail ...................................................................................................... 5-16
Table 5-3 Exercise with load .................................................................................................... 5-17
Table 6-1 Periodic Maintenance Schedule................................................................................. 6-4
Table 6-2 Additional Maintenance Schedule .............................................................................. 6-5
Table 6-3 Maintenance Chart for Re–Grease .......................................................................... 6-17
Table 7-1 Warning and Shutdown Fault Codes........................................................................... 7-7
Table 7-2 Troubleshooting Procedures for Fault Codes ........................................................... 7-10

Contents Page v
Publication 3549(GB) QSK60 (DQKH) Control System
Issue 1 - April ‘04 PowerCommand®Control 3201

Supplementary Publications

The Supplementary Publications appropriate to your system will also be supplied with the system. Where
appropriate the corresponding Instruction Manual(s) will also be supplied with any accessory that you order.

Title Publication No

Lead Acid Battery .................................................................................................................................. 3330

Battery Charger .................................................................................................................................. 3393
Health and Safety (Diesel Gensets) .......................................................................................................... 3553
Radiator Information.................................................................................................................................. 3554

Page vi Contents
QSK60 (DQKH) Control System Publication 3549(GB)
PowerCommand®Control 3201 Issue 1 - April ‘04

Schedule of Abbreviations
AC Alternating Current MCB Miniature Circuit Breaker
ACB Air Circuit Breaker MCCB Moulded Case Circuit Breaker
ACH Anti-Condensation Heaters MF Mains Failed
ATS Automatic Transfer Switch MFSS Master First Start Sensor
AVR Automatic Voltage Regulator MR Mains Returned
MST Mains Sensing Transformer
BHP Brake Horsepower MSU Mains Sensing Unit
BMS Building Management System MV Medium Voltage
BST Busbar Sensing Transformer
NEC Neutral Earthing Contact
CB Circuit Breaker
CCA Cold Cranking Amps PCC3201 PowerCommand® Control System
CHP Combined Heat and Power PF Power Factor
COP Continuous Power Rating PFC Power Factor Controller
CT Current Transformer PLC Programmable Logic Controller
PMG Permanent Magnet Generator
dB(A) Unit of noise level PRP Prime Power Rating
DC Direct Current PSU Power Supply Unit
DIP Dual In-line Package PT/CT Potential Transformer /Current Transformer
DMC Digital Master Control PTC Power Transfer Control
DMSU Demand Load Standby Unit

EMCU Engine Monitoring and Control Unit QCC Quadrature Current Control
EMF Electromotive Force
EPU Engine Protection Unit RFI Radio Frequency Interference
RMS Root Mean Square
FSS First Start Sensor RPM Revolutions Per Minute
RTD Resistance Temperature Detector
GCP Generator Control Panel
Genset Generator Set V Volts
GKWT Global Kilowatt Transducer VAC Volts, Alternating Current
VCB Vacuum Circuit Breaker
HV High Voltage VDC Volts, Direct Current
VF Volt-free
IC Integrated Circuit VT Voltage Transformer
I/O Input / Output

kVA Apparent Power

kVAR Reactive Power
kW Active / Real Power
kWh Unit of electrical energy or work

LED Light-Emitting Diode

LTA Low Temperature Aftercooling
LTP Limited Time Power Rating
LV Low Voltage

Schedule of Abbreviations Page i

Publication 3549(GB) QSK60 (DQKH) Control System
Issue 1 - April ‘04 PowerCommand®Control 3201

Page ii Schedule of Abbreviations

QSK60 (DQKH) Control System Publication 3549(GB)
PowerCommand®Control 3201 Issue 1 - April ‘04

SECTION 1 – PRELIMINARY AND SAFETY

1 Safety
1.1 Warning, Caution and Note Styles Used In This Manual
The following safety styles found throughout this manual indicate potentially hazardous conditions
to the operator, service personnel or the equipment.

WARNING: WARNS OF A HAZARD THAT MAY RESULT IN SEVERE PERSONAL

INJURY OR DEATH.

Caution: Warns of a hazard or an unsafe practice that can result in product or property
damage.

Note: A short piece of text giving information that augments the current text.

1.2 Warnings
WARNING: IT IS IMPORTANT TO READ AND UNDERSTAND ALL SAFETY NOTICES
PROVIDED IN THIS MANUAL. IMPROPER OPERATION OR MAINTENANCE
COULD RESULT IN A SERIOUS ACCIDENT, OR DAMAGE TO THE
EQUIPMENT, CAUSING INJURY OR DEATH.

1.3 General Information

This manual should form part of the documentation package supplied by Cummins Power
Generation Limited with specific generator sets. In the event that this manual has been supplied in
isolation please refer to the other Cummins Power Generation Limited literature, in particular the
Health and Safety Manual (3553) and the other Operation and Maintenance manuals relevant to
your genset.
Note: It is in the user’s interest to read and understand all Health and Safety information
together with all Warnings and Cautions contained within the documentation relevant to
the genset and its operation and maintenance.

1.4 Generator Plant Safety Code

Before operating the genset, read the Operation and Maintenance 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.

Section 1 – Preliminary and Safety Page 1-1

Publication 3549(GB) QSK60 (DQKH) Control System
Issue 1 - April ‘04 PowerCommand®Control 3201

Page 1-2 Section 1– Preliminary and Safety

QSK60 (DQKH) Control System Publication 3549(GB)
PowerCommand®Control 3201 Issue 1 - April ‘04

SECTION 2 - INTRODUCTION
2 Introduction
2.1 General
Before any attempt is made to operate the generator, the user should take time to read this
manual and to familiarise him or herself with the Warnings and Operating Procedures.
A genset must be operated and maintained properly if you are to expect safe and reliable
operation. The manual includes a maintenance schedule and a troubleshooting guide.
The engine manual is included with the set. Where there is conflicting information, this manual
takes precedence over the engine manual.

2.2 Generating Set Identification

Each generating set is provided with a Generating Set Rating Plate as shown below. This provides
information unique to the generator.

Figure 2-1 Typical Genset Rating Plate

Section 2 – Introduction Page 2-1

Publication 3549(GB) QSK60 (DQKH) Control System
Issue 1 - April ‘04 PowerCommand®Control 3201

2.3 After Sales Services

We offer a full range of after sales services as follows:

2.3.1 Maintenance
WARNING: INCORRECT SERVICE OR PARTS REPLACEMENT CAN RESULT IN
SEVERE PERSONAL INJURY, DEATH, AND/OR EQUIPMENT DAMAGE.
SERVICE PERSONNEL MUST BE TRAINED AND EXPERIENCED TO
PERFORM ELECTRICAL AND/OR MECHANICAL SERVICE.

For customers who wish to have their gensets expertly serviced at regular intervals the Customer
Service Department offers a complete maintenance contract package. This covers all items
subject to routine maintenance and includes a detailed report on the condition of the genset. In
addition, this can be linked to a 24-hour call-out arrangement, providing assistance 365 days a
year if necessary. Specialist engineers are available to maintain optimum performance levels from
customer’s gensets, and it is recommended that maintenance tasks are only undertaken by trained
and experienced engineers provided by the Customer Service Department

2.3.2 Warranty
All gensets have a twelve months warranty from the commissioning date as standard. Extended
warranty coverage is also available. In the event of a breakdown prompt assistance can normally
be given by factory trained service engineers with facilities to undertake all minor and many major
repairs to equipment on site.
For further warranty details contact your authorised distributor.

2.3.3 Spares
An extensive Spare Parts Department is available for any emergency breakdown and for the
engineer who carries out his own routine maintenance. Please contact your authorised Cummins
Distributor.
Please quote Plant Nos., Serial Nos., and Part Nos. when ordering spares.

2.3.4 Overseas
Agents and representatives in almost 100 countries throughout the world offer installation and after
sales service for the equipment provided. We can provide the name and address of the agent for
your specific location.
For details on any of the above services contact your distributor.

Page 2-2 Section 2– Introduction

QSK60 (DQKH) Control System Publication 3549(GB)
PowerCommand®Control 3201 Issue 1 - April ‘04

SECTION 3 – SYSTEM OVERVIEW

3 System Overview
3.1 Generator Components – Typical Genset
The main components of a typical Generator System are shown below. Refer to the Engine and
Alternator Manuals for location of other components, e.g. oil filler, dipstick, etc. Various options are
available although they may not be available for all models.

1 2 3 4

8 7 6 5

Figure 3-1 Typical Genset

KEY OPTIONS
1. Radiator Batteries and tray
2. Exhaust Outlets Circuit breaker entrance box
3. Air Cleaners Engine coolant heater
4. Control Housing - Alternator Electric fuel transfer pump
5. Alternator Fuel transfer hand pump
6. Bedframe Sump drain pump
7. PowerCommand® Control Panel
8. Engine

Section 3 – System Overview Page 3-1

Publication 3549(GB) QSK60 (DQKH) Control System
Issue 1 - April ‘04 PowerCommand®Control 3201

3.1.1 Control System

The control system is a micro-processor based control unit for monitoring and protecting the
genset (see Section 4) and can provide automatic paralleling. All indicators, control
switches/buttons and the digital display are on the face of the control panel as illustrated in
Figure 4-1.
The control system provides fuel control and engine speed governing, main alternator voltage
output regulation, and complete genset control and monitoring. The control also monitors the
health of the engine, alternator and auxiliary systems continuously, via an array of sensors and
senders located on the genset, and will affect an Automatic Shutdown if a serious fault occurs.

3.1.2 Engine
All generators employ a 4-stroke, water-cooled engine and incorporate a governor control and full
engine protection system. Refer to the Generating Set Rating Plate for engine type and rating
details.
For further information refer to the Engine manufacturer’s Operation and Maintenance Manual
supplied with this manual.

3.1.3 Alternator
All generator types use AC alternators of a brushless, rotating field design, which eliminates the
maintenance associated with slip rings and brushes. Refer to the Generating Set Rating Plate for
alternator type and rating details.
For further information refer to the Alternator manufacturer’s Installation, Service and Maintenance
Manual supplied with this manual.

3.1.4 Generator Rating

For details of your generator rating refer to the Generating Set Rating Plate.

3.1.5 Generator Construction

Most generators are constructed as a single module with the engine and alternator connected
through a coupling chamber with resilient mountings to form one unit. The QSK60 driven gensets
have the engine and alternator solidly mounted to the bedframe with the resilient mounts on the
underside of the bedframe. This results in one unit of immense strength and rigidity, with accurate
alignment between the engine and alternator, and effective damping of engine vibration.

3.1.6 Fuel System

Free standing main tanks with stands providing 450, 900 and 1350 litre capacity are available as
options for the QSK60 gensets.
[Link] Fuel Transfer Pumps (Option)
Free standing fuel tanks can be filled manually using an optional hand fuel transfer pump.
Alternatively, fuel tanks can be filled automatically using an electrical fuel transfer pump. This
pump, which is supplied complete with starter, operates under the control of Low and High Fuel
Level switches fitted to the tank.
On automatically filled systems, the tank filler cap is replaced with an overflow/breather connection
to allow piping to a safe area or return to a bulk tank.
[Link] Fuel / Water Separators
Set-mounted fuel/water separators are fitted as standard to provide protection for the engine fuel
injection system as water-free fuel supplies cannot be guaranteed.

Page 3-2 Section 3 – System Overview

QSK60 (DQKH) Control System Publication 3549(GB)
PowerCommand®Control 3201 Issue 1 - April ‘04

3.1.7 Cooling System

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

3.1.8 Engine Exhaust (Option)

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

3.1.9 DC Electrical System

A 24 volt battery system provides multi-attempt engine starting and DC power for the generator
control system.
[Link] Battery System
Battery type, size and voltage are selected to suit the genset capacity and application on ordering.
[Link] Charge Alternator
An engine driven charge alternator is provided as standard to maintain the battery in a charged
condition when the engine is running.
[Link] Mains Powered Battery Charger (Option)
Optional single phase, mains powered battery chargers, which can be panel or wall mounted, are
available to maintain the battery in a charged condition when the generator is not running.

Section 3 – System Overview Page 3-3

Publication 3549(GB) QSK60 (DQKH) Control System
Issue 1 - April ‘04 PowerCommand®Control 3201

3.1.10 Alarm Module (Option)

The front panel comprises a warning horn, three indicator lights, and one toggle-switch, and has
the ability to provide warnings audibly and/or visually.

Red Lens

Horn

Green Lens

Toggle Switch

Amber Lens

Figure 3-2 Alarm Module Front Panel

The toggle-switch provides the user with the ability to enable or silence the horn. The green or the
amber LED will illuminate to indicate the active mode of the toggle-switch, whilst the red LED will
illuminate if the alarm has been activated.
The three indicator lights provide the following information:

LED Label Text English

Red Alarm Actuated Alarm Actuated
Green Enabled Enabled
Amber Silenced Silenced

3.1.11 Sensors/Senders
Various genset parameters are measured by sensors, senders, RTDs etc. and the resulting
signals are received by the control.
Engine mounted sensors are able to monitor the following systems:
• Cooling system
• Fuel
• Lube oil
• Miscellaneous areas
Alternator mounted sensors are able to monitor the following parameter:
• Winding temps

Page 3-4 Section 3 – System Overview

QSK60 (DQKH) Control System Publication 3549(GB)
PowerCommand®Control 3201 Issue 1 - April ‘04

3.2 Heaters
Caution: Heater(s) must not be energised if the coolant system has been drained.

Caution: Remove AC power to the heater before disconnecting battery leads. Heater will
run continuously without DC power and can overheat and damage heater.

3.2.1 Engine Heater (Option)

The engine heater is designed to keep the engine coolant warm when the engine is shut down. It
heats and circulates the coolant within the engine, reducing start-up time and engine wear caused
by cold starts.
The engine mounted engine heater isolator switch should normally be left in the On position. When
the engine is running, heater operation is controlled automatically by a relay and thermostat.

WARNING: ALWAYS ISOLATE THE SUPPLY TO THE ENGINE HEATER / THERMOSTAT

BEFORE CARRYING OUT ANY MAINTENANCE ON THE ENGINE. ALWAYS
ISOLATE THE GENSET PRIOR TO ANY MAINTENANCE.

Caution: The engine heater is in no way intended to protect the engine and cooling
system from freezing in sub zero conditions. If there is any danger from freezing,
then a suitable antifreeze agent must be added to the cooling system.

3.2.2 Alternator Heater (Option)

The alternator heater is designed to keep the alternator free of condensation when the genset is
not running. During cool and humid conditions, condensation can form within the alternator, which
can create flashing and a shock hazard.
The alternator heater is supplied with power via the engine heater isolator switch, which should
normally be left in the On position as heater operation is controlled automatically by a relay and
thermostat.

WARNING: ALWAYS ISOLATE THE ALTERNATOR HEATER FROM THE AC SUPPLY

BEFORE WORKING ON THE ALTERNATOR OR HEATER.

3.2.3 Control Panel Heater (Option)

The control panel heater provides a means of humidity/temperature control within the control box
interior. It protects the components and ensures their effectiveness when the genset is subjected
to varying ambient air conditions during extended periods of non-use.
The control panel heater is supplied with power via the engine heater isolator switch, which should
normally be left in the On position as heater operation is controlled automatically by a relay and
thermostat.

WARNING: ALWAYS ISOLATE THE CONTROL PANEL HEATER FROM THE AC

SUPPLY BEFORE WORKING ON THE CONTROL PANEL OR HEATER.

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Issue 1 - April ‘04 PowerCommand®Control 3201

3.3 Mains Powered Battery Charger (Option)

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

3.3.2 Boost Charge (Option)

During trickle charging, not all cells in the battery receive the same charge and over a period of
several months this may affect battery performance. It is therefore normal to give batteries a
regular charge at their full rate to return all cells to full capacity. This is referred to as Boost
Charging (also known as equalise charging).
If the charger is fitted with a Boost Charge switch, the Boost position should be selected at
intervals detailed by the battery manufacturer (normally around every six months).
Caution: Batteries should not be left on Boost Charge for extended periods as this will
result in excessive water consumption and gassing and may impair battery
performance.

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SECTION 4 – CONTROL SYSTEM

4 Control System
4.1 Control System Description
The main control panel is mounted on a framework towards the rear of the genset and consists of
two panels, the Operator Panel and the Switch Panel. Vibration isolators are located on the top
and bottom of the control housing to help protect the control from any dangerous or damaging
vibration levels.
Dependent on site requirements the Operator Panel may be mounted in the control panel
assembly (full- featured) as shown in Figure 4-1, or it may be contained in a separate enclosure
and mounted remotely of the control panel assembly. In this latter case, the panel may be situated
up to 1.2km (4,000ft) away from the genset.
Note: The function of several buttons on the Operator Panel will vary dependent on the
location of the Operator Panel (remote or local of the Control Panel assembly). If the
function differs, it is noted as either Remote or Local Operator Panel in the description.
The control system is a micro-processor based control unit for monitoring and protecting the
genset and can provide automatic paralleling. All indicators, control switches/buttons and the
digital display are on the face of the control panel as illustrated in Figure 4-1.
The control system provides fuel control and engine speed governing, main alternator voltage
output regulation, and complete genset control and monitoring. The control also monitors the
health of the engine, alternator and auxiliary systems continuously, via an array of sensors and
senders located on the genset, and will affect an Automatic Shutdown if a serious fault occurs.
There are two fault level signals generated by the control system as follows:
1. Warning: signals an imminent or non-fatal fault for the engine. The control provides
an indication only for this condition.
2. Shutdown: signals a potentially fatal fault for the engine. The control will automatically
take the engine off-load and shut it down immediately, without a cooling down run.
The control system operates on 24V DC battery power. The auxiliary equipment operates on LV
AC power. The history data is stored in non-volatile memory and will not be deleted due to loss of
battery power.
In addition to the many control and annunciation functions, the PCC 3201 can be easily upgraded
to communicate over a PowerCommand® Network, or to work as part of a paralleling system.

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4.1.1 Control Panel Power ON/OFF Modes

The power on/off modes of the control panel and operating software are Power On, Screen Saver
and Sleep/Awake.
Power On Mode
In this mode, power is continuously supplied to the control panel. The control’s operating software
and control panel LEDs/graphical display will remain active until the Screen Saver mode is
activated.
Screen Saver Mode
Power to the graphical display will be removed after ten minutes (genset not running or running).
The ten minute timer resets and begins after each control panel action (any button or switch
selection) or signal received by the operating software. The bottom LEDs of the Analogue AC
Metering Panel (bar graphs) may remain on during Screen Saver mode, indicating that the
operating software is active (Awake mode).
When a Warning signal is sensed by the control, (for example, Low Coolant Temp), a warning
message will be displayed. The control will remain active until the Fault Acknowledge button is
pressed to clear the warning message and start the ten minute timer.
Sleep/Awake Mode
In the Sleep mode, the control’s operating software is inactive and the LEDs and the graphical
display on the control panel are all off. Sleep mode is a feature that is used to reduce battery
power consumption when the control is in the Auto mode and is not being used.
When all conditions are met (i.e., no unacknowledged faults, Screen Saver Mode is active, and
Off/Manual/Auto switch is in the Auto position) the Sleep mode will be activated.
The operating software is initialised and the control panel LEDs and graphical display are turned
on in response to one of the following:
• Moving/pressing any control panel switch/button
• A remote start input signal (genset in Auto mode)
• Customer fault 2 or 3 only (Shutdown or Warning indicator is on)
To activate the control and view the menu display without starting the genset, press any button on
the control panel.
The InPower service tool is required to enable or disable the Sleep mode. When shipped from the
factory, the Sleep mode is disabled. When disabled, the operating software will always remain
active (Awake mode) when the control is in Auto mode.
Note: The InPower service tool is required in order to select the desired mode.
Contact an authorised Service Centre for assistance.

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4.1.2 Control Panel - Front Panel

OPERATOR PANEL SWITCH PANEL

1 2

10 9 8 7

Figure 4-1 Control Panel Assembly (Full Featured)

1. Analogue AC Metering Panel 7. Off/Manual/Auto Switch (mode switch)

2. Emergency Stop Push Switch (This may be a Key Switch)

3. Status Indicators 8. Manual Run/Stop Button & Indicator

4. Fault Acknowledge Button 9. Graphical Display
5. Panel Lamp/Lamp Test Button 10. Display Menu Selection Buttons (1 of 6)
6. Exercise Button & Indicator

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4.1.3 Control Panel - Operator Panel

The operator panel contains the following components:
Analogue AC Metering Panel:
This panel simultaneously displays 3–phase line to line AC volts and current, kW, power factor and
frequency.
The meter panel is composed of a series of LEDs that are configured in bar graphs for each
function. The LEDs are colour coded, with green indicating normal range values, amber for
Warning levels and red for Shutdown conditions.
Scales for each function are in % of nominal values. Resolution is 1% for values close to nominal,
and increases at values further from nominal.
Graphical Display:
The graphical display is capable of displaying up to nine lines of data with approximately 27
characters per line. The display is used to view the menus of the menu–driven operating system.
(Refer to the menu trees later in this section). The display is also used to show Warning and
Shutdown messages/error codes, modes of operation (Figure 4-2) and system actions, such as
Warning, De-rate, Shutdown, etc.
Display Menu Selection Buttons:
Six momentary buttons—three on each side of the graphical display window—are used to navigate
through the system control menus and to adjust genset parameters. The button is active when the
message adjacent to the button is highlighted (displayed in inverse video).

4.1.4 Control Panel - Switch Panel

WARNING: SOME PANEL INTERNAL COMPONENTS MAY HAVE LIVE EXPOSED
TERMINATIONS EVEN IF THE GENSET IS NOT RUNNING. ISOLATE ALL
EXTERNAL ELECTRICAL SUPPLIES PRIOR TO ACCESS OF THE
CONTROL PANEL.

The switch panel contains the following components:

Emergency Stop Button:
Push the button in for Emergency Shutdown of the engine. If the engine is not running, pushing
the button in will prevent the starting of the engine, regardless of the start signal source (local or
remote).
To reset:
• Pull, or twist and pull, the button out.
• Turn the Off/Manual/Auto switch to Off (O).
• Press the front panel Fault Acknowledge button.
• Select Manual or Auto, as required.
Remote Start Indicator:
This green lamp is lit whenever the control is receiving a Remote Run signal. When this lamp is
flashing, it indicates a load demand stop mode.
Not in Auto Indicator:
This red lamp flashes continuously when the Off/Manual/Auto switch is not in the Auto position. (If
it is in the Auto position and the lamp is flashing, this indicates that a service is required.)

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Shutdown Status Indicator:

This red lamp is lit whenever the control detects a Shutdown condition. The genset cannot be
started when this lamp is on. After the condition is corrected, Shutdown indicators can be reset by
turning the Off/Manual/Auto switch to the Off (O) position, and pressing the Fault Acknowledge
button.
Dependent upon the specific fault that occurs, the engine may or may not shut down immediately.
A fault that could cause engine damage causes an immediate engine shutdown (bypasses engine
cool–down sequence). All other faults would allow the engine to run during the cool–down
sequence before engine shutdown. In this case, the Shutdown Status Indicator blinks during the
cooldown period.
Warning Status Indicator:
This yellow lamp is lit whenever the control detects a Warning condition. After the condition is
corrected, warning indicators can be reset by pressing the Fault Acknowledge button. (It is not
necessary to stop the genset if the fault becomes inactive during genset operation).
Fault Acknowledge:
Press this button to acknowledge Warning and Shutdown messages after the fault has been
corrected.
To acknowledge a Warning message, the Off/Manual/Auto switch can be in any position. (It is not
necessary to stop the genset to acknowledge an inactive Warning condition). To acknowledge a
Shutdown message with this button, the Off/Manual/Auto switch must be in the Off (O) position.
This button is also used to blink a fault code if the Shutdown or Warning Status Indicator is lit.
(This function is used when the control does not contain a graphical display). Refer to Reading
Fault Codes in Section 7 -Troubleshooting, which describes how to use this button for interpreting
fault codes.
Panel Lamp/Lamp Test Button:
Press this button to turn the panel lamp on or off.
Press and hold down this button for a minimum of three seconds to turn all control panel LEDs on,
to make sure all lamps illuminate. The illumination will shut off after releasing the button.
Exercise Button:
Press this button to initiate a pre-programmed exercise sequence. The Off/Manual/Auto switch is
used in conjunction with this button to enable this function (refer to Section 5.6.5 Exercise Start).
Manual Run/Stop Button:
This button starts and stops the set locally and will bypass Time Delay to Start and Stop
sequences. The Off/Manual/Auto switch must be in the Manual position to enable this button.
Off/Manual/Auto Switch:
Manual position enables the use of the switch panel Manual Run/Stop button.
Auto position enables start/stop control of the engine from a remote location. (Disables the use of
the switch panel Manual Run/Stop button).
Off (O) position prevents the starting of the set (local or remote). If moved to Off (O) during set
operation, an immediate engine shutdown will be initiated (bypasses cool–down timers). This hot
shutdown should be avoided, if possible, to help reduce unnecessary engine wear. Hot shutdowns
are logged by the system software.
An optional key function may be provided to prevent unauthorised operation of the switch.

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4.2 Menu Display and Switches

Figure 4-2 shows the graphical display and the menu selection buttons.

4.2.1 Graphical Display

The graphical display is capable of displaying up to nine lines of data with approximately 27
characters per line. The display is used to view the menus of the menu–driven operating system.
(Refer to the menu trees later in this section). The display is also used to show the following
system information:
• State Line - modes of operation, such as Stopped, Time Delay to Start, Warm Up at Idle, etc.
(see Figure 4-1), and paralleling operations, such as Standby, Dead BUS Close, Synchronise,
etc.
• Action Line - system actions, such as Warning, De-rate, Shutdown Cool–down and
Shutdown, and fault codes.
• Description Line - Fault code/status messages.

STATE LINE
ACTION LINE
DESCRIPTION LINE

MENU DISPLAY
AREA

GRAPHICAL
DISPLAY

MENU MENU
BUTTONS BUTTONS

Figure 4-2 Graphical Display and Menu Selection Buttons

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4.2.2 Menu Buttons

Six momentary buttons - three on each side of the graphical display window - are used to navigate
through the system control menus and to adjust genset parameters. The button is active when the
message or symbol adjacent to the switch is highlighted (displayed in inverse video). The
displayed message or symbol indicates the function of the button.
Note: In the graphical display, the symbol indicates that selecting the adjacent button
causes the operating program to go to the next menu display—as shown in the menu
diagrams.
In the graphical display, the symbol indicates that selecting the adjacent button
causes the operating program to go back to the previous menu display.

In the graphical display, the symbol indicates that selecting the adjacent button
causes the operating program to go back to Main Menu A (Figure 4-4).

4.3 Menu Units Selection

During any control panel operation, you can change how units are displayed by pressing the two
lower menu buttons (one on each side of display). When pressing these two buttons
simultaneously, the unit’s submenus will appear (Figure 4-3). After selecting the desired units,
press the ENTER button in this submenu to change and save the selections.
Note: Use the + button to select the desired option for each field. Use the arrow (→) button to
move to the next field. Selected field is highlighted.

LOCATION LOCAL
+ TEMP EF
PRESS FLD PSI
PRESS GAS INHG ENTER
→ FLOW AIR CFM

Figure 4-3 Units Submenu

4.3.1 Local/Remote Field

This selection must be set to Local, when the graphical display is mounted on the genset front
control panel, or Remote when mounted remotely from the genset.
The Local/Remote selection determines which buttons in the Control submenu (Section 4.7) are
active (displayed).

Temp: Used to select °F or °C for temperature readings.

Pressure Fluid: Used to select PSI, KPa, BAR or IN for pressure readings.
Pressure Gas: Used to select INHG or MMHG for pressure readings.
Flow Air: Used to select CFM or CMM for airflow readings.

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4.4 Main Menu

Figure 4-4 shows the main menus (Menu A and Menu B) of the system control. The two main
menus are used to divide the system submenus into major categories, such as, Engine Data,
Alternator Data, Control, etc.
To view system data, simply press the appropriate menu button to select the category. After
pressing the desired menu button, refer to the following pages for detailed information related to
the selected category.

MENU A
MENU MENU MENU
BUTTONS B BUTTONS

ENGINE MORE>
ALTERNATOR POWER TRAN or_\_
CONTROL HISTORY/ABOUT

MENU B

ADJUST
BUS DATA
SETUP BACK <<

Service GRAPHICAL MENU

Manual DISPLAY A

Figure 4-4 System Control Main Menus A and B

Note: In the following figures, the boxed/highlighted field indicates that the adjacent menu
button is active. Also, the submenus are shown in the order in which they are displayed
when scrolling up , or down .

4.4.1 Adjust Button

The Adjust submenu is intended for competent site personnel only. Note that a password may be
assigned to allow only authorised operators to modify this data.

4.4.2 Set-up Button

The Set-up submenu is described in the Service manual and is intended for competent service
personnel only. For this reason, a password must be entered before this data can be modified.
Note: PTC – The PTC Setup submenu is intended for qualified service and site personnel
only. Password is provided, but can be changed after installation to prevent un-
authorised modifications,
Note: The Adjust and Set-up submenus can be viewed, but not modified without entering the
correct passwords.

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4.4.3 _\_ Button (Paralleling applications only)

When displayed, indicates that the feature for genset paralleling applications is enabled. This
button is used to open and close the genset circuit breaker (CB). The symbol indicates if the CB is
opened or closed.
Opened _\_, push to close.
Closed _-_, push to open.
With the control panel Off/Manual/Auto switch in the Auto position, the opening and closing of the
CB is controlled by the control system software. The CB symbol will indicate an open or closed
CB, but the button will be inactive when the control is in Auto.
In the Manual position, the CB can only be closed by using this button. When manually closed and
the CB opens, it must be closed again by using this button. To close the CB, press and hold the
button until the symbol indicates a closed CB. (CB close will occur only when set-up conditions
allow - dead bus or genset synchronised with bus).

4.4.4 Power Trans Button (PTC applications only)

When displayed, indicates that the Power Transfer Control feature is enabled.
Refer to Section 4-12 for submenu description.

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4.5 Engine Data Submenus

If you press the Engine Data button in Menu A, the Engine Data submenus will appear
(Figure 4-5).
The first submenu displays general information that applies to all gensets (coolant temp, oil
pressure, etc.) The data in the remaining submenu(s) will vary according to the type and number of
sensors provided with the engine.

ENGINE DATA

COOLANT TEMP 180EF

ENGINE SPEED 1800 RPM
BATTERY 29.1 VDC
OIL PRESSURE 75 PSI
OIL TEMP 210EF

MANF TEMP 75EF

MANF PRESS ABS 180 INHG
OUT PRESS ABS 180 PSI
AMBIENT PRESS 88 INHG

Figure 4-5 Engine Data Sub-menus

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4.6 Alternator Data Submenus

If the Alternator Data button in Menu A is pressed, the Alternator Data submenus will appear
(Figure 4-6).

4.6.1 Voltage L–L and L–N

Indicates voltage Line–to Line, and Line–to–Neutral. Note that the Line–to–Neutral column will not
be displayed for a 3-phase/3-wire system. Accuracy 1%.
The voltages Line–to–Line (L1, L2 and L3) are measured between L1 to L2, L2 to L3 and L3 to L1,
respectively.

ALTERNATOR DATA

V L-L L-N AMPS

L1 480 277 1340
L2 480 277 1290
L3 480 277 1260
FREQUENCY 60.0HZ
AVR DUTY CYCLE 10.3%

kW kVA PF
L1 350 500 .80
L2 350 500 .80
L3 350 500 .80
TOT 1050 1500 .80

Figure 4-6 Alternator Data Sub-menus

4.6.2 Amps
All phases. Accuracy 1%.

4.6.3 Frequency
Genset output frequency.

4.6.4 AVR Duty Cycle

Displays voltage regulator (drive) level in percentage of maximum.

4.6.5 kW, kVA and PF

Displays genset kW and kVA output (average and individual phase, and direction of flow) and
power factor with leading/lagging indication. Accuracy 5%.
Note: The PF reading will contain an asterisk if the power factor is leading (e.g., *.30).

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4.7 Control Submenu

If the Control button in Menu A is pressed, the Control submenu will appear
(Figure 4-7).

4.7.1 Local Control Submenu Function

When the Operator panel (Figure 4-1) is mounted on the control panel assembly, the Run Mode
Idle/Rated button is active (displayed).
Note: In remote applications (Figure 4-8) this button is not displayed.
The shaded area in Figure 4-7 displays the selected/active mode of operation, (Idle or Rated).
Note: Run Mode Idle/Run at Rated Button: Refer to Section 5.7 for a complete description of
the Run at Idle mode.

CONTROL
(Local)

+ RUN MODE IDLE

ENABLE SYNC

BARGRAPH TEST

Figure 4-7 Local Control Sub-menu

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4.7.2 Remote Control Submenu Functions

When the Operator panel is mounted remotely of the control panel assembly, the menu buttons in
the Control submenu are used to perform the following remote operations. (To activate these
menu buttons for Remote/Local use, refer to Section 4.3.1).
Note: The Off/Manual/Auto switch must be in the Auto position to activate the Remote Menu
Buttons of the Control submenu.

CONTROL
(Remote)

START GENSET
FAULT ACKNOWLEDGE
ENABLE SYNC

BARGRAPH TEST

Figure 4-8 Control Sub-menu

[Link] Remote Start or Stop Button:

This button is used to Start and Stop the genset when the operator panel is mounted in a remote
location. For additional information refer to the Starting at Remote Operator Panel (Section 5.6.3)
and Stopping at Remote Operator Panel (Section 5.8.3).
When the genset is operating, Stop will be displayed for this button and Start will be displayed
when not operating.
[Link] Fault Acknowledge Button:
Used to reset inactive Warning messages, not Shutdown messages.

4.7.3 Local/Remote Control Submenu Function

[Link] Bargraph Test:
The function of this button remains the same and is not dependent on operator panel location. This
button sequentially lights the LEDs to test the bar graph display.
[Link] Enable Sync:
Displayed in paralleling applications only. Intended for service personnel to turn off the
synchroniser for troubleshooting/testing purposes.

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4.8 History/About Submenus

Pressing the History/About button in Menu A will reveal the History/About submenus (Figure 4-9).

4.8.1 History
The control maintains a data log of the number of engine starts and number of operating hours for
the engine and control, and the megawatt and maximum torque hours of the genset. This
information is stored in non-volatile memory and will not be deleted due to loss of battery power.

4.8.2 About
The About submenus provide the following genset information:
• Genset model and wattage (kW/MW)
• Output voltage and WYE, DELTA or SINGLE
• Frequency 50 or 60 Hz
• Rating: Standby, Prime or Base
• Version level of the controller and panel operating software

4.8.3 Fault History

The control maintains a data log of all fault conditions as they occur, and time stamps them with
the control and engine operating hours.
Up to 32 (unacknowledged) fault codes can be stored in control panel memory. Following Fault
acknowledgement and correction, it is deleted from the control panel memory. However, it remains
in a data log that maintains the fault code history. (The InPower service tool is required to view this
data log).
The Fault History display line: 1 of 24 indicates that 24 faults are recorded and that the most
recent fault (1) detected by the controller is displayed.
The Occurrences display line: In this example, 5 indicates that this is the fifth occurrence of this
fault. (The InPower service tool is required to review the last four faults of this code).
Note: The Occurrences number is incremented for each new occurrence of the same fault.
The controller must detect that the original sensed fault is corrected before it will
increment the occurrence number for that fault.
For example, when a Low Oil Pressure fault is detected, the controller will increment
the Occurrences number by 1. This fault will remain active until the controller detects
that the fault is corrected. An active fault will prevent the controller from incrementing
the Occurrences number each time the engine is started. When the controller detects
that the oil pressure is normal the fault will become inactive, allowing the occurrences
number to be incremented for the next detected Low Oil Pressure fault.

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HISTORY/ABOUT

STARTS 533
ENGINE HOURS 1236
CONTROL HOURS 7879
KWHRS 890

HRS@%MAX TORQUE
12345@0-9 23455@50-59
12345@10-19 12345@60-69
12345@20-29 12345@70-79
12345@30-39 12345@80-89

MODEL 1750DQKB
VOLTAGE 416 WYE
FREQUENCY 60
RATING STANDBY

CONTROLLER VERSION
RTOP [Link]
BATS FEB 15 1999
OT PANEL VERSION
RTOP 1.12
BATS 1.04

FAULT HISTORY 1 OF 24
+ CNTL HOURS 459
OCCURRENCES 5
ENGINE HOURS 334
FAULT CODE 1437
(FAULT DESCRIPTION)

Figure 4-9 History/About Sub-menus

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4.9 Adjust Sub-menu

If the Adjust button in Menu B is pressed, the Adjust submenu will appear
(Figure 4-10).
The Adjust submenu is intended for qualified service personnel and site personnel only and may
require a USER password. If a password is required, the USER password menu will appear when
you try to modify the Adjust submenu. (Refer to Password Menu in Section 4.11 to enter
password).
Changes are automatically saved when you exit this menu.
Note: Use the + and - buttons to increase or decrease the values in the following fields. Use
the arrow (→) button to move the cursor within a field or to the next field. Selected field
is highlighted.
• START DELAY: This delay applies only to remote starting in the Auto mode.
The Start Delay adjustment range is 0 to 300 seconds.
• STOP DELAY: This delay applies only to remote stopping in the Auto
mode. The Stop Delay adjustment range is 0 to 600
seconds.
• VOLTAGE: Used to adjust the output voltage ±5%.
• FREQUENCY: Used to adjust the frequency ±3 Hz.
• VOLTAGE/SPEED DROOP: These two sub-menus apply to a genset that has the
paralleling option enabled and is configured to operate in
droop mode. These adjustments must be performed by
technically qualified personnel only.

ADJUST

ADJUST:
+ START DELAY 5 SEC
STOP DELAY 11 SEC
-
VOLTAGE 208 1.2 %
FREQ 60.0 HZ -0.0 HZ
6

ADJUST:
+ STANDBY
VOLTAGE DROOP OFF
-
BUS L1 480 V
POWER FACTOR 0.80
6 VOLT 4.99 %

ADJUST:
+ STANDBY
SPEED DROOP OFF
-
BUS FREQ 60.0 HZ
TOTAL KW 300 HZ
6 FREQ 60.0 0.40 HZ

Figure 4-10 Adjust Sub-menu

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4.10 Parallel Data Submenu

If the Parallel Data button in Menu B is pressed, the Parallel Data submenu will appear
(Figure 4-11). This menu is displayed in paralleling applications only.

4.10.1 Parallel Data Status Line

The top line of the graphical display is used to indicate the following Parallel Data status:
• STANDBY: Indicates no paralleling activity is occurring.
• DEAD BUS CLOSE: Indicates first genset in system to close to bus.
• SYNCHRONISE: Genset is synchronising to bus.
• LOAD SHARE: Genset has closed to bus and is sharing load with other gensets in
system.
• LOAD GOVERN: Genset closed to bus in parallel with utility (mains).

PARALLEL DATA

LOAD GOVERN
V BUS GEN
L1 480 480
L2 480 480
L3 480 480
_\_
HZ 60.1 60.1
DEG – 122 NOT SYNCHRONIZING

Figure 4-11 Bus Data Sub-menu

BUS Voltage L–L: The BUS voltage Line–to–Line (L1, L2 and L3) is measured between L1 to L2,
L2 to L3 and L3 to L1, respectively.
BUS/GEN HZ: BUS/GEN hertz.
BUS/GEN SYNC STATUS: The bottom line of the graphical display is used to indicate the
following BUS/GEN Sync status:
• NOT SYNCHRONIZING: Genset is in service mode that does not allow auto sync feature.
• SYNCHRONIZING: Genset is synchronising to bus.
• READY TO CLOSE: In manual mode, push circuit breaker close button to close
breaker.
• _\_ Button: (Paralleling applications only). Used to open and close the
genset circuit breaker (CB). The symbol indicates if the CB is
opened or closed.
Opened _\_, push to close.
Closed _-_, push to open.
With the control panel Off/Manual/Auto switch in the Auto position, the opening and closing of the
CB is controlled by the control system software. The CB symbol will indicate an open or closed
CB, but the button will be inactive when the control is in Auto.
In the Manual position, the CB must be closed by this button. When manually closed and the CB
opens, it must be closed again by using this button. To close the CB, press and hold the button
until the symbol indicates a closed CB. (CB close will occur only when set-up conditions allow -
dead bus or generator synchronised with bus).

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4.11 Password Menu

When viewing the Adjust submenu, pressing either the + or - button will display the Password
menu (Figure 4-12) if a User password is assigned to this field. After entering the correct
password, the system will allow you to modify the submenu. To prevent unauthorised adjustment,
the entered password is valid for only ten minutes after the last button is pressed.
Note: Application Password is intended only for competent service personnel to allow
adjustment of Set-up submenu parameters.
To enter the password:
1. Display Adjust submenu.
2. Press either the + or - button within the displayed submenu. The Password menu appears.
(Adjustment is allowed if Password menu does not appear).
3. Press the + and - button to select the first character of the User password (A-Z or 0-9).
4. Press the → button to select the next character field. Selected character field is highlighted.
5. Repeat steps 3 and 4 to enter remaining password characters.
6. Press the Enter button after entering the password. The Adjust submenu will re-appear.
7. Exit Adjust submenu to save changes.

+ OR - BUTTON

ENTER USER PASSWORD

(OR)
ENTER APPLICATION
+ PASSWORD
ENTER
- xxxxxxxx

Figure 4-12 Password Menu

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QSK60 (DQKH) Control System Publication 3549(GB)
PowerCommand®Control 3201 Issue 1 - April ‘04

4.12 Power Transfer Main Menu

If you press the Power Trans button in Menu A, the Power Transfer main menu will appear
(Figure 4–13).
Note: The Power Transfer Control (PTC) feature must be enabled to display this menu.
The PTC feature enables the PCC3201 to monitor the utility voltage (mains) and frequency for
failure, and control the opening and closing of the contacts (circuit breakers) for the utility (S1) and
the genset (S2).
If utility fails, the control will initiate the starting sequence (Figure 5–1), open S1 and close S2 to
the load. When utility returns, the load is retransferred to the utility (S1 closes and S2 opens) and
the control initiates the genset shutdown sequence.
The symbol displayed in the middle of the Power Transfer main menu indicates which
breaker (utility or genset) is closed/opened to the load. The symbol shown in Figure 4-13 indicates
that the utility breaker is closed and supplying power to the load.
The Power Transfer main menu also indicates if the utility and the genset are available to accept
load. When the control detects that either source is ready to accept load, Utility and/or Genset will
be displayed in inverse video.
The Power Transfer main menu has four submenu groups:
• Utility
• Status
• Transfer Control
• Genset
To view system data, simply press the appropriate menu button to select the category. After
pressing the desired menu button, refer to the following pages for detailed information related to
the selected category.

MENU PTC STATUS LINE MENU

BUTTONS BUTTONS
UTILITY GENSET

STATUS

TRANSFER CONTROL

DEG – 123 SYNCHRONIZING

Figure 4-13 Power Transfer Main Menu

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4.12.1 PTC Status Line

The top line of the graphical display is used to indicate the following PTC status:
• NOT ENABLED: PTC is not enabled. Control panel switch in O (Off) position.
• MANUAL: Control panel switch is in Manual position. All PTC actions or genset start/stop
actions are manually controlled.
• NORMAL UTIL: Load is connected to the utility.
• RETRAN: Retransfer of load to utility.
• RETRAN OVRD: Immediate retransfer of load to utility due to genset fault (e.g., warning,
derate, or shutdown with cooldown fault). The retransfer timer is ignored as is the retransfer
inhibit.
• EMERG TEST: Emergency Test sequence initiated through Remote Start switch with
emergency start sequence enabled (TB8–3 terminal opened). Emergency test mode means
that the genset will continue to run even if a genset warning or derate fault occurs. This test
can be performed with or without load (refer to Section 5.9). See Table 5–3 for sequence of
operation.
• TEST: Test sequence initiated through Remote Start switch with emergency start sequence
disabled (TB8–3 terminal closed). Test mode is non–emergency, which means that a
retransfer to utility will occur if any problems occur with the genset while testing with load.
This test can be performed with or without load (refer to Section 5.9). See Table 5–3 for
sequence of operation.
• EXERCISE: Exercise sequence initiated through control panel. This test can be performed
with or without load (refer to Section 5.9). A retransfer to utility will occur if any problems
occur with the genset during the exercise sequence. See Table 5–3 for sequence of
operation.
• UTILITY FAIL: Utility has failed. (Initiates transfer of load to genset if Off/Manual/Auto switch
is in Auto.)

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4.12.2 Utility (PWR TRAN) Submenus

If the Utility button in the Power Transfer Main menu is pressed, the Utility submenu will appear
(Figure 4–14).
• Voltage L–L and L–N: Indicates utility voltage Line–to Line and Line–to–Neutral. Note that
the Line–to–Neutral column will not be displayed for a 3 phase/3 wire system. Accuracy 1%.
The voltage Line–to–Line (L1, L2 and L3) are measured between L1 to L2, L2 to L3 and L3 to
L1, respectively.
• Amps: L2 only. Accuracy 1%.
• Frequency: Utility frequency.
• kW, kVA and PF: Displays (L2 only) utility kW and kVA output (average and direction of flow)
and power factor with leading/lagging indication. Accuracy 5%.
Note: The PF reading will contain an asterisk if the power factor is leading (for example,
*.30).

UTILITY

UTILITY:
V L-L L-N AMPS
L1 480 277
L2 480 277 1320
L3 480 277
FREQUENCY 60.0HZ

UTILITY:
kWL kVA PF
L1
L2 125 175 .96
L3
TOT

Figure 4-14 Utility Sub-menu

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4.12.3 Status (PWR TRAN) Submenus

If the Status button in the Power Transfer Main menu is pressed, the Status submenus will appear
(Figure 4–15).
• Connected: Indicates which source(s) is connected to the load.
• Available: Indicates when the corresponding sources have acceptable output voltage and
frequency. Both can be available simultaneously.
• Volt L12: Indicates utility and genset Line 1 to Line 2 voltage.
• HZ: Utility and genset output frequency.
• KW L2: Utility and genset Phase B (L2) kW output.
• Transfer Inhibit: This feature is used to control load transfer to the genset. When activated,
load transfer to the genset will not take place if the utility fails.
Transfer inhibit is controlled by connecting a remote contact between TB3–57 and TB3–58.
Closing the contact enables the feature and opening the contact disables it. When enabled,
the event is displayed on the graphical display.
• Retransfer Inhibit: This feature is used to prevent the PTC from automatically transferring
the load back to the utility. When activated, load transfer will not take place unless the genset
fails (Retransfer Inhibit is ignored if the genset fails).
Retransfer inhibit is controlled by connecting a remote contact between TB3–64 and TB3–65.
Closing the contact enables the feature and opening the contact disables it. When enabled,
the event is displayed on the graphical display.

STATUS

UTIL GEN
CONNECTED YES NO
AVAILABLE YES NO
VOLT L12 480 0
HZ 60.0 0.0
KW L2 456 0

TRAN INH OFF

RETRAN INH ON

Figure 4-15 Status (PWR TRANS) Submenus

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QSK60 (DQKH) Control System Publication 3549(GB)
PowerCommand®Control 3201 Issue 1 - April ‘04

4.12.4 Transfer Control (PWR TRAN) Submenu

If the Transfer Control button in the Power Transfer Main menu is pressed, the Transfer Control
submenu will appear (Figure 4–16).
The symbol displayed in the middle of the
Transfer Control submenu indicates which
breaker (utility or genset) is closed/opened TRANSFER CONTROL

to the load. The symbol shown in Figure 4-

16 indicates that the utility breaker is closed
and supplying power to the load.
UTILITY GENSET
During genset operation in the manual
mode, you can manually transfer/retransfer CB ENABLE CB ENABLE
load between the utility and the genset. To
transfer load, press the appropriate CB << BACK
Enable button (Utility or Genset).
Example (Figure 4–16)
In the example in Figure 4–16, the CB
Enable button for Utility was pressed. (If the
CB Enable button for the Genset was ENABLE UTIL CB
pressed, Enable Gen CB would be displayed
in the second submenu, allowing you to CANCEL

open or close the genset circuit breaker.)

After pressing the Utility CB Enable button,
the second submenu will be displayed
allowing you to either Cancel or Enable the
entered selection. UTILITY GENSET

Pressing the Cancel button will return the OPEN UTIL CB ENABLE
display to the previous menu.
<< BACK
Pressing the Enable button will display the
third submenu. With this submenu displayed
you can return to the second submenu
without opening the utility circuit breaker
(press <<Back) or you can press the Open
UTILITY GENSET
Util button.
Pressing the Open Util button will display the CLOSE UTIL CB ENABLE

fourth submenu, indicating that the utility << BACK

circuit breaker is now opened.
Note that the fourth submenu displays Close
Util. Pressing this button will close the utility
circuit breaker and redisplay the third
submenu.
Figure 4-16 Transfer Control Submenus

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4.12.5 Genset (PWR TRAN) Submenus

If the Genset button in the Power Transfer Main menu is pressed, the Genset submenus will
appear (Figure 4–17).
• Voltage L–L and L–N: Indicates voltage Line–to Line and Line–to–Neutral. Accuracy 1%.
The voltage Line–to–Line (L1, L2 and L3) is measured between L1 to L2, L2 to L3 and L3 to
L1, respectively.
Note: Note that the Line–to–Neutral column will not be displayed for a 3 phase/3 wire system.
• Amps: All phases. Accuracy 1%.
• Frequency: Genset output frequency.
• kW, kVA and PF: Displays genset kW and kVA output (average and individual phase, and
direction of flow) and power factor with leading/lagging indication. Accuracy 5%.
Note: The PF reading will contain an asterisk if the power factor is leading (for example,
*.30).

GENSET

GENSET:
V L-L L-N AMPS
L2 480 277 1320
L2 480 277 1320
L3 480 277 1320
FREQUENCY 60.0HZ

GENSET:
kW kVA PF
L2 100 150 .97
L2 125 175 .96
L3 150 200 .95
TOT 375 525 .96

Figure 4-17 Genset Submenus

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QSK60 (DQKH) Control System Publication 3549(GB)
PowerCommand®Control 3201 Issue 1 - April ‘04

SECTION 5 – SYSTEM OPERATION

5 Operation
5.1 Safety
Only suitably qualified and experienced personnel should carry out genset operations. Before
operating the system, the operator should become familiar with Section 1 of this manual –
Preliminary and Safety instructions together with the Health and Safety Manual (3553). Observe all
of the WARNINGS and CAUTIONS at all times.

WARNING: BEFORE OPERATING THE PLANT BECOME FAMILIAR WITH THE

EQUIPMENT AND HOW IT IS OPERATED (INCLUDING ALL CONTROLS,
MANUALLY OPERATED VALVES AND ALARM DEVICES). SAFE AND
EFFICIENT OPERATION CAN ONLY BE ACHIEVED IF THE PLANT IS
OPERATED CORRECTLY.

WARNING: CONTACTING HIGH VOLTAGE COMPONENTS CAN CAUSE SEVERE

PERSONAL INJURY OR DEATH BY ELECTROCUTION. DO NOT OPEN THE
GENERATOR OUTPUT BOX WHILE THE GENSET IS RUNNING. READ AND
OBSERVE ALL WARNINGS AND CAUTIONS IN YOUR GENSET MANUALS.

Caution: Only technically qualified personnel should open the PCC 3201 front panel.
Voltages are present which can cause electrical shock, resulting in personal
injury.
Even with power removed, improper handling of components can cause
electrostatic discharge and damage circuit board components.

5.2 Introduction
This section describes the operation of the genset. The text should be read in conjunction with the
System Description, Control System Operation, and the Engine and Alternator Operating Manuals.
All indicators, control switches/buttons and graphical display are located on the face of the Control
Panel as illustrated in Figure 4-1.

5.3 Maintenance
To secure maximum performance and reliability from your genset it is essential that certain
components are inspected periodically and, where necessary, maintenance procedures carried out
as detailed in Section 6 - Maintenance.

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5.4 Operating Recommendations

5.4.1 Running-in
Drain and replace the crankcase oil after the first 50 hours of operation on new gensets. Refer to
the Maintenance section of this manual for the recommended procedures.

5.4.2 No Load Operation

Periods of off-load operation should be held to a minimum. If it is necessary to keep the engine
running for long periods of time when no electric output is required, best engine performance will
be obtained by connecting a load of at least 30% rated load, but not to exceed rated load. Such a
load could consist of heater element or load bank.

5.4.3 Exercise Period

Gensets on continuous standby must be able to go from a cold start to being fully operational in a
matter of seconds. This can impose a severe burden on engine parts.
Regular exercising keeps engine parts lubricated, prevents oxidation of electrical contacts, and in
general helps provide reliable engine starting.
Exercise the genset at least once a week, for a minimum of 30 minutes with load, so the engine
reaches normal operating temperatures.

5.4.4 Low Operating Temperatures

Use a coolant heater if a separate source of power is available. The optional heater available from
Cummins will help provide reliable starting under adverse weather conditions. Be sure the voltage
of the separate power source is correct for the heater element rating.

5.4.5 High Operating Temperatures

Refer to the genset nameplate for the maximum ambient operating temperature, if applicable.

5.4.6 Genset Standby Rating

Applicable for supplying emergency power for the duration of normal power interruption. No
sustained overload capability is available for this rating. This rating is applicable to installations
served by a reliable normal utility source. This rating is only applicable to variable loads with an
average load factor of 70% of the standby rating for a max of 200 hours of operation per year, and
a maximum of 5 hours per year at 100% of its standby rating. The standby rating is only applicable
to emergency and standby applications where the genset serves as the back-up to the normal
utility source. No sustained utility parallel operation is permitted with this rating. (Equivalent to Fuel
Stop Power in accordance with ISO3046, AS2789, DIN6271 and BS5514). Nominally Rated.

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5.4.7 De-rating Factors

Power De-rate Curve @ 1500RPM

1500RPM –Above these conditions de-rate by an additional 3% per 300m (1000ft) and 10.9% per
10oC (50oF)

Power De-rate Curve @ 1800RPM

1800RPM - Above these elevations, de-rate by an additional 3.3% per 300m (1000ft) and 8.4%
per 10oC (50oF).

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5.5 Genset Operation

5.5.1 Sequence of Operation
The genset is run Automatically using a Remote Start signal, or Manually using the genset switch
panel controls. Genset indications are provided on the control panels. If a fault is sensed at Start-
up, the engine is locked out and will not start.
When the PCC 3201 is put in the Manual mode and the Manual Run button is pressed, the genset
performs an automatically sequenced manual start. First, the PCC 3201 initiates a starter cranking
signal and verifies that the engine is rotating. Then it provides sufficient fuel for the engine to
accelerate up to start-disconnect speed.
After the initial start procedure, the control system ramps the genset to rated speed and voltage.
The Ready to Load output is activated when the AC voltage and frequency exceeds 90% of
nominal.

5.6 Starting
Caution: One operator should be in complete charge, or working under the direction of
someone who is. Remember that, upon starting the engine, cables and
switchgear will become energised, possibly for the first time. Furthermore,
equipment that does not form part of the genset installation may become
electrically charged. Only authorised and competent personnel should carry out
this work.

Caution: Do not use an Emergency Stop switch to shut down an engine unless a serious
fault develops. The Emergency Stop push-switch must not be used for a normal
shut-down, as this will prevent a cooling down run in which the lubricating oil and
engine coolant carry heat away from the engine combustion chamber and
bearings in a safe manner.

Caution: Avoid off-load running for other than short periods. A minimum loading of 30% is
recommended. This loading will help to prevent the build up of carbon deposits
in the injectors, due to unburnt fuel, and reduce the risk of fuel dilution of the
engine lubricating oil. The engine must be shut down as soon as possible after
the appropriate functions have been checked.

Before attempting to start the genset, the operator should read through this entire section and
become familiar with the Engine and Alternator Operating Manuals. It is essential that the operator
be completely familiar with the genset and the PCC 3201 control.
The following headings cover the systems used to start the genset. Figure 5-1 provides a flow
chart for each of the three Start/Run/Stop sequences.
Before starting the genset, make sure that exhaust and fuel fittings are tight and properly
positioned, and that proper maintenance and pre-start checks have been performed.
During starting automatic checks are carried out for the integrity of various protection systems. The
PCC 3201 will not allow the genset to continue the starting sequence if the integrity of a sensor is
considered to be in doubt.
The genset can be configured for a number of starting cycles (one to seven) with set times for
crank and rest periods for all starting modes (manual/remote). The default setting is for three start
cycles, composed of fifteen seconds of cranking and fifteen seconds of rest.
Note: The InPower service tool is required to change the number of starting cycles, and the
crank and rest times. Contact an authorized service centre for assistance.

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5.6.1 Pre-start Checks

WARNING: HIGH VOLTAGE, 601 TO 15,000 VOLTS, PRESENTS SPECIAL HAZARDS
OF SEVERE PERSONAL INJURY OR DEATH. EVEN AFTER GENSET
SHUTDOWN AN ELECTRICAL SHOCK HAZARD MAY STILL EXIST,
CAUSED BY INDUCED OR RESIDUAL VOLTAGE WITHIN THE
ALTERNATOR OR CABLES. SERVICE PERSONNEL MUST BE WELL-
TRAINED/QUALIFIED TO WORK WITH DISTRIBUTION VOLTAGES.

WARNING: WINDINGS OF HIGH VOLTAGE, 601 TO 15,000 VOLTS, GENSETS MUST BE

DRY BEFORE THE GENSET IS OPERATED. FAILURE TO ENSURE DRY
WINDINGS BEFORE START-UP MAY RESULT IN CATASTROPHIC
FAILURE, SEVERE PERSONAL INJURY AND DEATH.

Before starting, be sure competent personnel have made the following checks to ensure that the
unit is ready for operation:
• Genset Grounding Procedure – This must be followed prior to performing service or
inspection procedures that may expose personnel to conductors normally energized with
voltages greater than 600 volts. Refer to the genset Installation Manual.
• Megger and Insulation Testing – This must be performed on all high voltage (601 to 15,000
volts) gensets before initial start-up and after the genset Grounding Procedure has been
completed. Insulation testing for low voltage (less than 600 volts) gensets is recommended by
Cummins Power Generation Limited.
Note: These tests are used to verify that the windings are dry before the genset is operated,
and to develop a base line for future test comparisons.

Caution: When Megger testing an alternator, failure to protect the voltage regulator, control
and diodes could result in permanent damage to one or more of the electronic
components.
• Lubrication - Check the engine lubrication oil level and ensure that the level is always
maintained as detailed in the engine Operation and Maintenance Manual.
Note: Gensets may be shipped dry. They must be filled with the correct type and quantity of
oil before use. Be sure to check oil level before initial start.
• Coolant - Check the engine coolant level and ensure that the level is always maintained at the
coolant expansion tank. Fill the cooling system to the bottom of the fill neck in the radiator fill
or expansion tank. Do not check while the engine is hot.
Note: Some radiators have two fill necks, both of which must be filled when the cooling
system is drained

Caution: Do not attempt to remove a radiator pressure cap while the generator is running,
or is stationary but hot. Always allow it to cool before removing.

Note: Gensets may be shipped dry. They must be filled with the correct type and quantity of
coolant before use. Be sure to check coolant level(s) before initial start.

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• Cooling Air Inlet / Outlets - Ensure that the cooling air inlets/outlets are unobstructed.
• Exhaust Outlet - Ensure that exhaust components are secured and not warped; that the
exhaust outlet is unobstructed; that no combustible materials are near the system, and gases
are discharged away from building openings. Ensure that there are no leaks and that all
fittings are tight.
• Fuel Supply - Ensure that the fuel tank is filled to the normal level and that the fuel system is
primed and all the valves required for operation are open. Ensure that there are no leaks and
that all fittings are tight.
• Batteries – Ensure that the batteries are charged, that the electrolyte is at the correct level
and that all connections are correct.
• Auxiliary AC Supplies - Ensure that all auxiliary equipment is receiving power from the Load
Terminal Box.
• Emergency Stop/Fire Detection Equipment - Ensure that all related equipment is fully
operational.

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5.6.2 Starting at Switch Panel (Manual Mode)

WARNING: ENSURE THAT ALL PRE-START CHECKS ARE CARRIED OUT BEFORE
STARTING THE GENSET. DO NOT ATTEMPT TO START THE GENERATOR
UNTIL IT IS SAFE TO DO SO. WARN ALL OTHERS IN THE VICINITY THAT
THE SET IS ABOUT TO START.

Caution: One operator should be in complete charge, or working under the direction of
someone who is. Remember that, upon starting the engine, cables and
switchgear will become energised, possibly for the first time. Furthermore,
equipment that does not form part of the generator installation may become
electrically charged. Only authorised and competent personnel should carry out
this work.

Caution: Do not use an Emergency Stop switch to shut down an engine unless a serious
fault develops. The Emergency Stop push-switch must not be used for a normal
shut-down, as this will prevent a cooling down run in which the lubricating oil and
engine coolant carry heat away from the engine combustion chamber and
bearings in a safe manner.

Caution: Avoid off-load running for other than short periods. A minimum loading of 30% is
recommended. This loading will help to prevent the build up of carbon deposits
in the injectors, due to unburnt fuel, and reduce the risk of fuel dilution of the
engine lubricating oil. The engine must be shutdown as soon as possible after
the appropriate functions have been checked.

Note: PTC: With the Optional Power Transfer Control (PTC) feature enabled, the function
and sequence of operation for the Start command differs due to the transfer and re-
transfer of load. Refer to Power Transfer Control Operation, later in this section, for the
Start/Run/Stop PTC sequences.
Turn the Off/Manual/Auto switch to the Manual position and press the Manual Run/Stop button.
This will activate the engine control system and the starting system. The starter will begin cranking,
and after a few seconds the engine will start and the starter will disconnect.
In the Manual position, the control will not complete the Time Delay to Start or Time Delay to Stop
(Figure 5-1), but will complete the Warm–up at Idle and Cool–down at Rated/Idle. (See Table 5-1
for the PTC sequence of operation).
When the coolant reaches operating temperature or the Warm–up at Idle Time Delay is reached (0
to 300 seconds), whichever occurs first, the genset will ramp to rated speed and voltage.
Note: PTC: To manually transfer the load between the utility and the genset during genset
operation, refer to Transfer Control (PWR TRAN) Submenu in this section.
If the engine does not start, the starter will disengage after a specified period of time and the
control will indicate an Overcrank Shutdown.
To clear a Fail to Start Shutdown, place the Off/Manual/Auto switch in the Off (O) position and
press the Fault Acknowledge button. Wait a minimum of two minutes for the starter motor to cool
and then repeat the starting procedure. If the engine does not run after a second attempt, refer to
Section 7 -Troubleshooting.
When the switch is in the Manual position, the genset can be operated in the Idle mode (used for
maintenance, troubleshooting etc.).

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REMOTE START LOCAL START LOCAL START

CUST CONNECT SWITCH PANEL SWITCH PANEL
(Auto Mode) (Manual Mode) (Auto Mode)

RUN EXERCISE BUTTON

BUTTON

TIME DELAY to TIME DELAY to

START START
1 1

4 4 WARM-UP
WARM-UP WARM-UP
at IDLE at IDLE at IDLE
1 OR 2 1 OR 2 1 OR 2

RATED SPEED and RATED SPEED and RATED SPEED and

VOLTAGE VOLTAGE VOLTAGE

REMOTE START CONTROL STOP EXERCISE TIME

REMOVED BUTTON EXPIRES

TIME DELAY to STOP TIME DELAY to STOP

1 1

COOL-DOWN at COOL-DOWN at COOL-DOWN at

3 3 3
RATED/IDLE RATED/IDLE RATED/IDLE
1 1 1

STOP STOP STOP

Notes:
1. Timer expires.
2. Coolant temperature reaches operating level.
3. Cool-down can be at rated speed and/or idle with
different time-outs for each.
4. Only when non-emergency feature enabled (TB8-3 closed).

Figure 5-1 Normal Start/Run/Stop Sequences

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5.6.3 Starting at Remote Operator Panel (Auto Mode)

WARNING: ENSURE THAT ALL PRE-START CHECKS ARE CARRIED OUT BEFORE
STARTING THE GENSET. DO NOT ATTEMPT TO START THE GENSET
UNTIL IT IS SAFE TO DO SO. WARN ALL OTHERS IN THE VICINITY THAT
THE SET IS ABOUT TO START.

When the operator panel is mounted remotely of the control panel assembly, the Start button of
the Control submenu can also be used to start the genset. The function of this Start button is
identical to the following section, Starting from Remote Location. Refer to Control Submenu
(Section 4.7) for additional information.
Note: The Off/Manual/Auto switch must be in the Auto position to activate the Remote Menu
Buttons of the Control submenu.

5.6.4 Starting from Remote Location (Switch or Device) (Auto Mode)

WARNING: ENSURE THAT ALL PRE-START CHECKS ARE CARRIED OUT BEFORE
STARTING THE GENSET. DO NOT ATTEMPT TO START THE GENSET
UNTIL IT IS SAFE TO DO SO. WARN ALL OTHERS IN THE VICINITY THAT
THE SET IS ABOUT TO START.

Place the Off/Manual/Auto switch in the Auto position. This allows the genset to be started from a
remote switch or device (e.g., transfer switch or the optional Power Transfer Control feature).
Note: With the PTC feature activated, the Remote Start input (TB8-4/5) will function as a Test
mode switch for the PTC. Refer to Section 5.9.
There are two Start modes that are selectable for the Remote Start input, one for non-emergency
start and the other for emergency start. In the non-emergency mode, the control will complete the
warm-up at Idle. In the Emergency mode, the genset will omit the Warm-up stage and will proceed
directly to rated speed and voltage.
The Emergency start feature is controlled by connecting a remote contact between TB8-3 and
TB8-5. Open the contact for emergency start and close the contact for non-emergency start.
In response to the Remote Run signal, or the control detects the loss of the utility voltage detected
through the PTC, the control lights the Remote Start indicator and initiates the starting sequence
described in the previous heading (Starting at Switch Panel), except for the following:
• In the Auto position, the control will complete the Time Delay to Start (0 to 300 seconds) and
the Time Delay to Stop (0 to 600 seconds).
Note: Refer to Adjust submenu (Section 4.9) to change the Time Delay settings.

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5.6.5 Exercise Start

WARNING: ENSURE THAT ALL PRE-START CHECKS ARE CARRIED OUT BEFORE
STARTING THE GENSET. DO NOT ATTEMPT TO START THE GENERATOR
UNTIL IT IS SAFE TO DO SO. WARN ALL OTHERS IN THE VICINITY THAT
THE SET IS ABOUT TO START.

Turn the Off/Manual/Auto switch to the Auto position and press and hold down the Exercise
button. Turn the Off/Manual/Auto switch from Auto to Manual and back to Auto.
This will activate the engine control system to complete a pre–programmed exercise sequence.
The sequence (Figure 5-1) will vary according to the settings/selections of the system control
parameters. The default setting is for Exercise Without Load.
Note: The InPower service tool is required to modify these parameters. Contact an
authorised service centre for assistance.
Note: PTC – for PTC Exercise sequence refer to Section 5.9.
The exercise sequence may include running at idle speed, ramping to rated speed, running for a
predetermined period of time and timed shutdown. During the exercise operation, the LED lamp
adjacent to the Exercise button will light. To manually stop the exercise operation before
completion, press the Exercise button. The set will complete its normal cool–down sequence. The
control will indicate that the set is in a cool–down mode by flashing the exercise LED.
Note: PTC – If exercising with load, cool-down mode is activated after retransfer of load to
utility. (See Table 5-3 for PTC Exercise sequence).

Note: All exercise functions are disabled when a remote start signal is received by the
control.

5.6.6 Cold Starting with Loads

WARNING: ENSURE THAT ALL PRE-START CHECKS ARE CARRIED OUT BEFORE
STARTING THE GENSET. DO NOT ATTEMPT TO START THE GENSET
UNTIL IT IS SAFE TO DO SO. WARN ALL OTHERS IN THE VICINITY THAT
THE SET IS ABOUT TO START.

Use a coolant heater if a separate source of power is available. The optional heater available from
Cummins will help provide reliable starting under adverse weather conditions. Be sure the voltage
of the separate power source is correct for the heater element rating.
Cummins Power Generation recommends equipping diesel standby gensets (life safety systems)
with engine water jacket coolant heaters to maintain the coolant at a minimum of 32°C (90°F) and,
for most applications, accept the emergency load in ten seconds or less. Although most Cummins
Power Generation gensets will start in temperatures down to -32°C (-25°F) when equipped with
engine water jacket coolant heaters, it might take more than ten seconds to warm the engine up
before a load can be applied when ambient temperatures are below 4°C (40°F).
To advise the user of a possible delay in accepting the load, the Engine Cold (Code 1435)
message, in conjunction with illumination of the Warning LED, is provided. The engine cold
sensing logic initiates a warning when the engine water jacket coolant temperature falls below
21°C (70°F). In applications where the ambient temperature falls below 4°C (40°F), a cold engine
may be indicated even though the coolant heaters are connected and functioning correctly. Under
these conditions, although the genset may start, it may not be able to accept load within ten
seconds. When this condition occurs, check the coolant heaters for correct operation. If the
coolant heaters are operating correctly, other precautions may be necessary to warm the engine
before applying a load.

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5.7 Running at Idle (Manual)

Caution: Avoid off-load running for other than short periods. A minimum loading of 30% is
recommended. This loading will help to prevent the build up of carbon deposits
in the injectors, due to unburnt fuel, and reduce the risk of fuel dilution of the
engine lubricating oil. The engine must be shutdown as soon as possible after
the appropriate functions have been checked.

Caution: If the engine coolant temperature becomes too low, 60°C (140°F), raw fuel from
incomplete combustion will wash the lubricating oil off the cylinder walls and
dilute the crankcase oil. Under these conditions, not all the moving parts of the
engine will receive the correct amount of lubrication.

Note: The Run at Idle mode is selectable only when the Operator Panel is mounted on the
control panel assembly.
The Run Mode can be set to Rated or Idle with the set running or not running. To manually select
the engine Idle function, the Off/Manual/Auto switch must be in the Manual position. Once selected
and the set is manually started, the control will limit the engine idle time to ten minutes. When the
ten-minute Idle cycle is complete, the genset will ramp to rated speed.
To activate the Idle function, refer to Section 4.7.1-Local Control Submenu Function.
When the engine Idle function is enabled, the control automatically sets lower oil pressure Warning
and Shutdown trip points to reflect the lower operating speed. When the engine Idle function is
removed and the set reverts to normal operating speed, the control automatically resets oil
pressure Warning and Shutdown trip points to the normal settings.

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5.8 Stopping
5.8.1 Emergency Stop (Code 1434)
The emergency stop button is located on the upper right side of control panel
(Figure 4-1). Push the button in for emergency stop. The red Shutdown status LED will light and
the graphical display message will be:
EMERGENCY STOP
1434 - SHUTDOWN
To reset:
1. Pull, or twist and pull, the button out.
2. Turn the Off/Manual/Auto switch to Off (O).
3. Press the front panel Fault Acknowledge button.
4. Select Manual or Auto, as required.
Note: Emergency Stop shutdown status can be reset only at the operator control panel.

5.8.2 Stopping at Switch Panel (Manual Mode)

If the set was started at the switch panel (Off/Manual/Auto switch in the Manual position), pressing
the Manual Run/Stop button will cause the set to complete its normal (Local Start) shutdown
sequence (Figure 5-1).
Note: PTC: See Table 5-1 for PTC sequence of operation.
The pre-set Cool–down time (at rated speed) can vary dependent on the kW output. That is if, prior
to shutdown, the kW is 10% or less of rated, the control software considers this output as Cool–
down and will subtract this time from the pre-set Cool–down Timer.
The set will stop after the Cool–down at Idle Timer (zero to ten minutes) has timed out. (If
necessary, the set will continue to run after time–out until coolant reaches normal operating
temperature).
Moving the Off/Manual/Auto switch to the Off (O) position will cause an immediate engine
shutdown (bypass Cool–down At Idle) and display a Cool–down Interrupted Warning message.
This hot shutdown should be avoided, if possible, to help prolong the reliability of the engine.
Hot shutdowns are logged in the system software.

5.8.3 Stopping at Remote Operator Panel (Auto Mode)

When the Operator Panel is mounted remotely of the control panel assembly, the Stop button of
the Control submenu can also be used to stop the genset (Off/Manual/Auto switch in the Auto
position).
The function of this Stop button is identical to the Stopping from Remote Location (non-emergency
sequence, Figure 5-1). Refer to Control Submenu for additional information.
Note: The Off/Manual/Auto switch must be in the Auto position to activate the Remote Menu
Buttons of the Control submenu.

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QSK60 (DQKH) Control System Publication 3549(GB)
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5.8.4 Stopping from Remote Location (Switch or Device) (Auto Mode)

If the control receives a Remote Stop signal or the control detects the return of the utility voltage
through the PTC, the set will complete its normal shutdown sequence. (The remote Stop signal is
actually the removal of the remote Start signal to the control).
The set will stop after completing the following Cool–down sequence:
• Time Delay To Stop (zero to 300 seconds)
• Cool–down At Idle (zero to ten minutes) or longer, if necessary, to obtain normal operating
temperature before shutdown.
Note: Refer to Section 4.9 Adjust Submenu to change the Time Delay to Stop setting. The
InPower service tool is required to modify the Cool–down At Idle setting. If necessary,
contact an authorised service centre for assistance.

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5.9 Optional Power Transfer Control (PTC) Operation

The following table describes the function and operation of the PCC3201 with the optional PTC
feature enabled. With the PTC feature enabled, the control performs two functions: genset
operation and transfer of load between utility and genset.
The following table describes how the genset/PTC operates when the control switch is in the Off,
Manual and Auto positions.

Control Switch
Result
Position
Off • PCC3201/PTC Not in Auto (1222) warning fault active.
• Genset will not start
• Loads will not transfer/retransfer
Manual • PCC3201/PTC Not in Auto (1222) warning fault active
(see also Table 5-1 • Genset can only be started manually via control panel Manual Run/Stop
for sequence of button
operation) • Load must be transferred manually (see Figure 4-16)
• Synchronizing and load ramping will occur automatically
• Enforcement of max parallel time will occur automatically
Auto • PCC3201/PTC in auto mode
(see also Table 5-2 • Genset will start automatically as required
for sequence of • Loads will transfer/retransfer automatically as required
operation)

5.9.1 PCC3201/PTC – Normal Operation Sequences

The following tables show the normal operating sequence of events for each of the four possible
running modes (utility power failure, exercise, test or manual run). The sequences are further
defined by genset application type i.e. Open transition, Closed transition-momentary, or Closed
transition-soft loading.
The previous Start, Exercise and Stop information (Figure 5-1) also applies/remains the same with
the exception of the PTC transfer and re-transfer of load after the genset or utility
voltage/frequency stabilize.
The PCC3201/PTC Exercise Without Load is identical to the standard PCC3201 exercise
sequence shown in Figure 5-1. The PCC3201/PTC Exercise With Load is shown in Table 5-3. The
default setting is without load. Contact an authorised service centre to change this parameter.

5.9.2 Test Switch

With the PTC featured enabled, the Remote Start input (TB8-4/5) will function as a Test mode
switch for the PTC. The PTC Test sequence is identical to the Exercise sequence (with or without
load), except that the genset will continue to run until the Test switch is de-activated. The default is
without load. Contact an authorised service centre to change this parameter.

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QSK60 (DQKH) Control System Publication 3549(GB)
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Table 5-1 Manual Run

CLOSED TRANSITION – CLOSED TRANSITION –

OPEN TRANSITION
MOMENTARY SOFT LOADING
1 Manual Run switch activated Manual Run switch activated Manual Run switch activated
2 Genset starts Genset starts Genset starts
3 Warm-up at Idle Warm-up at Idle Warm-up at Idle
4 Genset available Genset available Genset available
5 Synchronises to Utility Synchronises to Utility
6 Open Utility CB (Operator)
7 Time Delay programmed
transition
8 Close genset CB (Operator) Close genset CB (Operator) Close genset CB (Operator)
9 <100msec overlap Genset ramp loads
10 Utility unloaded
11 Utility CB opens (Auto by Open Utility CB (*Operator)
control)
12 GENSET SUPPLYING LOAD GENSET SUPPLYING LOAD GENSET SUPPLYING LOAD
13 Open genset CB (Operator)
14 Time Delay programmed Synchronises to Utility Synchronises to Utility
transition
15 Close Utility CB (Operator) Close Utility CB (Operator) Close Utility CB (Operator)
16 <100msec overlap Genset ramp unloads
17 Genset unloaded
18 Genset CB opens (by control) Open genset CB (*Operator)
19 UTILITY SUPPLYING LOAD UTILITY SUPPLYING LOAD UTILITY SUPPLYING LOAD
20 Manual Run switch de-activated Manual Run switch de- Manual Run switch de-
activated activated
21 Cool down Cool down Cool down
22 Genset stopped Genset stopped Genset stopped
* Maximum parallel time is enforced in Manual mode. Breaker operation will be automatic if maximum parallel time is exceeded.

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Table 5-2 Utility Power Fail

CLOSED TRANSITION – CLOSED TRANSITION –

OPEN TRANSITION
MOMENTARY SOFT LOADING
1 Utility failure Utility failure Utility failure
2 Time Delay to Start Time Delay to Start Time Delay to Start
3 Genset starts Genset starts Genset starts
4 Genset available Genset available Genset available
5 Time Delay to Transfer Time Delay to Transfer Time Delay to Transfer
6 Utility CB opens Utility CB opens Utility CB opens
7 Time Delay programmed transition Time Delay programmed Time Delay programmed
transition transition
8 Genset CB closes Genset CB closes Genset CB closes
9 GENSET SUPPLYING LOAD GENSET SUPPLYING LOAD GENSET SUPPLYING LOAD
10 Utility available Utility available Utility available
11 Time Delay retransfer Time Delay retransfer Time Delay retransfer
12 Synchronises to Utility Synchronises to Utility
13 Utility CB Closes Utility CB Closes
14 <100msec overlap Genset ramp unloads
15 Genset unloaded
16 Genset CB opens Genset CB opens Genset CB opens
17 Time Delay programmed transition
18 Utility CB closes
19 UTILITY SUPPLYING LOAD UTILITY SUPPLYING LOAD UTILITY SUPPLYING LOAD
20 Time Delay to Stop/Cooldown Time Delay to Stop/Cooldown Time Delay to Stop/Cooldown
21 Genset stopped Genset stopped Genset stopped

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Table 5-3 Exercise with load

CLOSED TRANSITION – CLOSED TRANSITION –
OPEN TRANSITION
MOMENTARY SOFT LOADING
1 Exercise start activated Exercise start activated Exercise start activated
2 Time Delay to Start Time Delay to Start Time Delay to Start
3 Genset starts Genset starts Genset starts
4 Warm-up at Idle Warm-up at Idle Warm-up at Idle
5 Genset available Genset available Genset available
6 Time Delay to transfer Time Delay to transfer Time Delay to transfer
7 Utility CB opens Synchronises to Utility Synchronises to Utility

8 Time Delay programmed

transition
9 Genset CB closes Genset CB closes Genset CB closes
10 <100msec overlap Genset ramp loads
11 Utility unloaded
12 Utility CB opens Utility CB opens
13 GENSET SUPPLYING LOAD GENSET SUPPLYING LOAD GENSET SUPPLYING LOAD
14 Exercise timer expires Exercise timer expires Exercise timer expires
15 Time Delay retransfer Time Delay retransfer Time Delay retransfer
16 Genset CB opens Synchronises to Utility Synchronises to Utility
17 Time Delay programmed transition
18 Utility CB closes Utility CB closes Utility CB closes
19 <100msec overlap Genset ramp unloads
20 Genset unloaded
21 Genset CB opens Genset CB opens
22 UTILITY SUPPLYING LOAD UTILITY SUPPLYING LOAD UTILITY SUPPLYING LOAD
23 Time Delay to Stop/Cooldown Time Delay to Stop/Cooldown Time Delay to Stop/Cooldown
24 Genset stopped Genset stopped Genset stopped

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QSK60 (DQKH) Control System Publication 3549(GB)
PowerCommand®Control 3201 Issue 1 - April ‘04

SECTION 6 – MAINTENANCE
6 Maintenance
Maintenance work, particularly in confined areas, should be carried out by two engineers working
together.
Read, understand and comply with all Caution and Warning notes in this section, those contained
within Section 1 – Preliminary and Safety, and those contained within the Health and Safety
Manual (3553).
Ensure that adequate lighting and staging (where required) are installed.

Caution: Only authorised and qualified maintenance engineers, who are familiar with the
equipment and its operation, should carry out maintenance.

WARNING: DEPENDENT UPON THE CONTROL SYSTEM FITTED, THIS UNIT MAY
OPERATE AUTOMATICALLY AND COULD START WITHOUT WARNING.

Caution: Before carrying out any maintenance work, become familiar with the Generator
Plant Safety Code given in Section 1 of this manual, together with the Health
and Safety Manual (3553).

Caution: Remove AC power to the cooling system heaters before disconnecting battery
leads. Heater will run continuously without DC power and can overheat and
damage heater.

Caution: Always disconnect a battery charger from its AC source before disconnecting the
battery leads. Failure to do so can result in voltage spikes high enough to
damage the DC control circuits of the genset.

WARNING: ACCIDENTAL STARTING OF THE GENSET WHILE WORKING ON IT CAN

CAUSE SEVERE PERSONAL INJURY OR DEATH. PREVENT ACCIDENTAL
STARTING BY DISCONNECTING THE STARTING BATTERY LEADS
(NEGATIVE [-] FIRST).

ENSURE BATTERY AREA HAS BEEN WELL-VENTILATED BEFORE

SERVICING THE BATTERY. ARCING CAN IGNITE EXPLOSIVE HYDROGEN
GAS GIVEN OFF BY BATTERIES, CAUSING SEVERE PERSONAL INJURY.
ARCING CAN OCCUR WHEN LEADS ARE REMOVED OR REPLACED, OR
WHEN THE NEGATIVE (-) BATTERY LEAD IS CONNECTED AND A TOOL
USED TO CONNECT OR DISCONNECT THE POSITIVE (+) BATTERY LEAD
TOUCHES THE FRAME OR OTHER GROUNDED METAL PART OF THE
GENSET.

INSULATED TOOLS MUST BE USED WHEN WORKING IN THE VICINITY OF

THE BATTERIES.
ALWAYS REMOVE THE NEGATIVE (-) LEAD FIRST AND RECONNECT
LAST.

ENSURE HYDROGEN FROM THE BATTERY, ENGINE FUEL AND OTHER

EXPLOSIVE FUMES ARE FULLY DISSIPATED. THIS IS ESPECIALLY
IMPORTANT IF THE BATTERY HAS BEEN CONNECTED TO A BATTERY
CHARGER.

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WARNING: BEFORE CARRYING OUT ANY MAINTENANCE WORK, LOCK OFF FOR
SAFE WORKING:
1. SELECT THE MODE SWITCH ON THE GENSET CONTROL PANEL TO
OFF.
2. REMOVE, AND ACCOUNT FOR, THE KEY(S) IF THE MODE SWITCH
IS OF THE KEY SWITCH TYPE.
3. ISOLATE ALL SUPPLIES TO THE GENSET.
4. ISOLATE THE BATTERY CHARGER.
5. DISCONNECT THE BATTERY.
6. REMOVE THE STARTER CONTROL WIRES.
7. A SUITABLE WARNING PLATE STATING ‘MAINTENANCE IN
PROGRESS’ SHOULD BE DISPLAYED PROMINENTLY.

WARNING: SOME PANEL INTERNAL COMPONENTS MAY HAVE LIVE EXPOSED

TERMINATIONS EVEN IF THE GENSET IS NOT RUNNING. ISOLATE ALL
EXTERNAL ELECTRICAL SUPPLIES PRIOR TO ACCESS OF THE
CONTROL PANEL.

6.1 General
Establish and adhere to a definite schedule for maintenance and service based on the application
and severity of the environment. Table 6-1 covers the recommended service intervals for a genset
on Standby service. If the genset will be subjected to extreme operating conditions, the service
intervals should be reduced accordingly. Some of the factors that can affect the maintenance
schedule are:
• Use for continuous duty (prime power)
• Extremes in ambient temperature
• Exposure to elements
• Exposure to salt water
• Exposure to windblown dust or sand.
Consult with an authorised distributor if the genset will be subjected to any extreme operating
conditions and determine a suitable schedule of maintenance. Use the running time meter to keep
an accurate log of all service performed for warranty support. Perform all service at the time period
indicated, or after the number of operating hours indicated, whichever comes first. Use Tables 6–1
and 6-2 to determine the maintenance required and then refer to the sections that follow for the
correct service procedures.
Refer also to the Engine Operation and Maintenance Manuals, and the Alternator Operation and
Maintenance Manuals.

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6.2 Genset Specifications

MODEL DQKH
Cummins Diesel Series QSK60 (50/60Hz)
Generator kW Rating See Genset Nameplate
Electrical System
Starting Voltage 24 Volts DC
Battery Four, 12 Volt
Cold Cranking Amps(minimum)
Cold Soak @ 0°F (–18°C)and above
1800CCA
Cooling System Radiator-Cooled Capacity
Set Mounted 108 Imp Gallons (492 Litres)
Remote Radiator (Optional) 42.5 Imp Gallons (193 Litres) (engine only)
**Fuel Consumption
Standby/Full Load/60Hz 125 Imp Gallons (569 Litres) per Hour
Oil Capacity Max. with Combo Filter 43 Imp Gallons (196Litres)

*Oil Type
* Refer to the QSK60 Series Engine Operation and Maintenance Manual for lubricating oil
recommendations and specifications.
** Refer to Data Sheet for other applications

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6.3 Maintenance Schedules

Table 6-1 Periodic Maintenance Schedule
MAINTENANCE ITEMS SERVICE TIME
See Daily Monthly 6 Months Yearly 1000 4000
Specific or after or after or after or after Hours Hours
Engine 8 Hours 100 250 500
Manual Hours Hours Hours
General set inspection X1 X2
Check engine oil level X
Check coolant level of radiator(s)
X
(water jacket & LTA)
Check coolant heater(s) X
Check battery charging system X
Check all hardware (fittings, clamps,
X
fasteners, etc.)
3
Check drive belt X
Check battery electrolyte level X
Drain exhaust condensate trap X
Check generator air outlet X
Check radiator hoses for wear and
X
cracks
Grease fan bearings (two) X6
Test generator insulation resistance X4
5
Grease generator bearing (Frame 8) X
5
Grease generator bearing (Frame 7) X
Check air cleaner (replace as
X1
necessary)
Drain fuel filter(s) X1
Check anti–freeze and DCA
X1
concentration
Change engine oil and filter X1
Change water jacket coolant filters X1
Clean crankcase breather X1
Change fuel filters X1
Clean water jacket & LTA cooling
X1
systems

X1–Refer to the Engine Operation and Maintenance Manual for maintenance intervals and/or procedures.
X2–Check for oil, fuel, cooling and exhaust system leaks. Check exhaust system audibly and visually with genset running
and repair any leaks immediately.
X3–Visually check belt for evidence of wear or slippage. Replace if hard or brittle.
X4–This procedure should be followed periodically throughout the life of the genset, or if the generator has sat idle for a
period of time with no generator heaters used. Contact your authorised service centre.
5
X –Lubricate the bearing(s) according to the alternator manufacturer’s instructions. These instructions are contained
within the Alternator Manufacturer’s Operation & Maintenance Manual provided with the genset.
Frame 7 outside casing is round, Frame 8 outside casing is octagonal (flat-sided).
Refer also to Section 6.11 of this manual.
X6–Check radiator(s) and their bearings. Refer to Section 6.7 of this manual and to the Radiator Manual 3554 provided
with this genset.

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Table 6-2 Additional Maintenance Schedule

Weekly / Monthly / 100 Yearly / 200

ITEM TASK
10 hours hours hours
Set Electrics Clean battery terminals and re-grease z
Check fuel solenoid and linkage z
Check all electrical connections z
Clean all apertures (with vacuum cleaner) z
2
Alternator Grease bearings if required z
Check all ventilation points z
Perform any maintenance tasks specified in
the Alternator Installation, Service and z2
Maintenance Manual
Clean the alternator z
Control Panel Check circuit breaker contacts and check
z
power cable connections for security
Carry out a Lamp Test z
Check all fuses and tripping devices z
Clean the control panel z
Check security of all fixings as required z
General Check plant room for cleanliness z
Have set / panel inspected by manufacturer z
Check air inlets / outlets for freedom from
z
obstruction
Test Run Test generator insulation resistance z1
Run the set on-load — at least 30% load z
Check anti-vibration mounts z
Check all systems functioning z
Check operation of Emergency Stop z

z1–This procedure should be followed periodically throughout the life of the genset, or if the generator has sat idle for a
period of time with no generator heaters used. Contact your authorised service centre.
z2– Lubricate the bearing(s) according to the alternator manufacturer’s instructions. These instructions are contained
within the Alternator Manufacturer’s Operation & Maintenance Manual provided with the genset.
Refer also to Section 6.11 of this manual.

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6.4 Locking the Genset Out of Service

6.4.1 Introduction
Before any work is carried out for maintenance, etc., the plant must be immobilised. Even if the
plant is put out of service using the Mode switch in the Off position on the control panel, the plant
cannot be considered safe to work on until the engine is properly immobilised as detailed in the
following procedures.

WARNING: BEFORE CARRYING OUT ANY MAINTENANCE, ISOLATE ALL SUPPLIES

TO THE GENSET AND ANY CONTROL PANELS. RENDER THE SET
INOPERATIVE BY DISCONNECTING THE PLANT BATTERY.

Caution: Remove AC power to the cooling system heaters before disconnecting battery
leads. Heaters will run continuously without DC power and can overheat and
damage heater.

Caution: If the engine has been running recently explosive gases (given off during battery
charging) may be present in the vicinity of the batteries. Ensure the area is well
ventilated before disconnecting batteries.

6.4.2 Immobilising the Plant for Safe Working

Note: Shutdown the engine first, as described in Section 5.8 - Stopping.
To immobilise the engine:
1. Turn the Mode switch on the control panel to Off (O).

Manual Auto

2. Remove the key from the Mode switch and account for all other keys for safekeeping, (if
applicable).
3. As an additional precaution, thoroughly ventilate the plant room before disconnecting any
leads.
4. Isolate and lock off the heater control box, where fitted.
5. Isolate and lock off the supply to the battery charger, where fitted.
6. Isolate the fuel supply to the engine.
7. Disconnect the starting batteries and control system batteries, (if separate). Disconnect
the negative (-) lead first.
8. Fit warning notices at each of the above points to indicate Maintenance in Progress -
Plant Immobilised for Safe Working.

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QSK60 (DQKH) Control System Publication 3549(GB)
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6.5 General Inspection

During operation, be alert for mechanical problems that could create unsafe or hazardous
conditions. The following sections cover several areas that should be frequently inspected for
continued safe operation.

6.5.1 Exhaust System

With the genset operating, inspect the entire exhaust system visually and audibly including the
exhaust manifold, muffler, and exhaust pipe. Check for leaks at all connections, welds, gaskets
and joints, and ensure that exhaust pipes are not heating surrounding areas excessively. If any
leaks are detected, shut down the genset and have the leaks corrected immediately.

WARNING: INHALATION OF EXHAUST GASES CAN RESULT IN SERIOUS PERSONAL

INJURY OR DEATH. BE SURE DEADLY EXHAUST GAS IS PIPED OUTSIDE
AND AWAY FROM WINDOWS, DOORS OR OTHER INLETS TO BUILDINGS.
DO NOT ALLOW TO ACCUMULATE IN HABITABLE AREAS.

6.5.2 Fuel System

With the genset operating, inspect the fuel supply lines, return lines, filters, and fittings for leaks.
Check any flexible sections for cuts, cracks and abrasions and ensure they are not rubbing against
anything that could cause breakage. If any leaks are detected, have them corrected immediately.

WARNING: IGNITION OF FUEL CAN CAUSE SERIOUS PERSONAL INJURY OR DEATH

BY FIRE OR EXPLOSION. DO NOT PERMIT ANY FLAME, CIGARETTE, OR
OTHER IGNITER NEAR THE FUEL SYSTEM, OR IN AREAS SHARING
VENTILATION.

WARNING: ENGINE FUEL ACTUATORS CAN OPERATE AT VOLTAGES UP TO

140 VOLTS DC.

6.5.3 AC Electric System

Check the following while the genset is operating:
• Frequency: The genset frequency should be stable and the reading should be the
same as the genset nameplate rating. (50Hz/1500RPM or
60Hz/1800RPM).
• AC Voltage: At no load, the line–to–line voltage(s) should be the same as the genset
nameplate rating.
• AC Ammeter: At no load, the current readings should be zero. With a load applied,
each line current should be similar.
• Panel Lamps: Press and hold down the Panel Lamp/Lamp Test button on the control
panel. All indicator lamps should light. Verify that all lamps are on and
then release the button. Contact an authorised service centre if any
lamps are burnt out.

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Publication 3549(GB) QSK60 (DQKH) Control System
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6.5.4 DC Electrical System

Check the terminals on the batteries for clean and tight connections. Loose or corroded
connections create resistance, which can hinder starting. Clean and reconnect the battery cables if
loose. Always disconnect both ends of the negative battery cable. Reconnect one end of the cable
to the negative battery terminal and the other end to ground. This will ensure that any arcing will
be away from the battery and least likely to ignite explosive battery gases.

WARNING: IGNITION OF EXPLOSIVE BATTERY GASES CAN CAUSE SEVERE

PERSONAL INJURY. DO NOT SMOKE WHILE SERVICING BATTERIES.

Refer to Supplementary Publication 3330 for cleaning and safety precautions of the battery.

6.5.5 Engine
Monitor fluid levels, oil pressure, and coolant temperatures frequently. Refer to the Engine
Operation and Maintenance Manual for recommended operating pressures and temperatures.
Most engine problems give an early warning. Look and listen for changes in engine performance,
sound, or appearance that can indicate service or repair is needed. Some engine changes to look
for are as follows:
• Misfire
• Vibration
• Unusual noises
• Sudden changes in engine operating temperatures or pressures
• Excessive exhaust smoke
• Loss of power
• An increase in oil consumption
• An increase in fuel consumption
• Fuel, oil, or coolant leaks.

6.5.6 Mechanical
WARNING: ACCIDENTAL STARTING OF THE GENSET CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH. TURN THE CONTROL SWITCH TO THE
STOP POSITION AND DISCONNECT THE NEGATIVE (-) BATTERY CABLE
BEFORE INSPECTING THE GENSET.

With the genset stopped, check for loose belts and fittings, leaking gaskets and hoses, or any
signs of mechanical damage. If any problems are found, have them corrected immediately.
With the set running, listen for any unusual noises that may indicate mechanical problems and
check the oil pressure frequently. Investigate anything that indicates possible mechanical
problems.

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QSK60 (DQKH) Control System Publication 3549(GB)
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6.6 Lubrication System

Note: Gensets may be shipped dry. They must be filled with the correct type and quantity of
oil before use. Be sure to check the oil level before initial start.

6.6.1 Oil API Classification

Refer to the Engine Operation and Maintenance Manual for lubricating oil classification.

6.6.2 Oil Viscosity

Refer to the Engine Operation and Maintenance Manual for lubricating oil
recommendations/specifications.

6.6.3 Engine Oil Level

Check the engine oil level during engine shutdown periods at the intervals specified in the
Maintenance Table 6-1. The dipstick is stamped with high and low marks to indicate the level of oil
in the crankcase. For accurate readings, shut off the engine and wait approximately fifteen minutes
before checking the oil level. This allows oil in the upper portion of the engine to drain back into the
crankcase.

WARNING: CRANKCASE PRESSURE CAN BLOW OUT HOT OIL AND CAUSE SEVERE
BURNS. DO NOT CHECK OIL WHILE THE GENSET IS OPERATING.

Keep the oil level as near as possible to the high mark on the dipstick but never above it. Remove
the oil fill cap and add oil of the same API viscosity and brand when necessary. Replace the oil fill
cap after adding oil. Refer to the Engine Operation and Maintenance manual for the position of the
oil dipstick and oil filler.

Caution: Do not operate the engine with the oil level below the low mark or above the high
mark. Overfilling can cause foaming or aeration of the oil while operation below
the low mark may cause loss of oil pressure.

6.6.4 Oil and Filter Change

Change the oil and filter at the intervals specified in the Maintenance Table 6-1. Refer to, Section
6-2 for information regarding oil capacity. Use oil that meets Cummins
recommendations/specifications, or its equivalent.
Refer to the Engine Operation and Maintenance Manual for maintenance intervals and
procedures.

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6.6.5 Starting Procedure After Extended Shutdown or Oil Change

After each oil change or if the genset has not been exercised within the past seven days, the
lubricating system must be primed to be sure that the engine receives the correct oil flow through
the lubricating system to minimise engine wear. To prime the lubricating system:
• Disconnect the electrical wire from the fuel injection pump solenoid valve.
• Rotate the crankshaft, using the starter motor, until oil pressure appears on the gauge or the
warning lamp is extinguished.
• Reconnect the electrical wire to the fuel injection pump solenoid valve.
• Start the engine in idle mode using the Manual Run button on the switch panel to start the
engine (refer to Starting at the Switch Panel [manual mode], Section 5.6.2). Using the Manual
Run button, the engine will start in idle mode, but note that the engine will go to rated speed
after warm–up. Run the engine for five to ten minutes at idle, but no more than ten minutes.
Note: If the engine is allowed to run out of fuel, air is pulled into the fuel lines. Refer to the
Engine Operation and Maintenance Manual for instructions to vent the fuel system.
Refer to Running at Idle procedure in Section 5.7 of this manual.
Note: If the control panel is mounted remotely, the Running at Idle mode cannot be selected.
Use the Manual Run button on the switch panel to start the engine in idle mode (refer
to Starting at Switch Panel in Section 5.6.2). Using the Manual Run button, the engine
will start in idle mode, but note that the engine will go to rated speed after warm–up.

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6.7 Coolant System

Note: Gensets may be shipped dry. They must be filled with the correct type and quantity of
oil before use. Be sure to check the oil level before initial start.

Caution: The heaters must not be operated while the cooling system is empty, or when
the engine is running, or damage to the heater will occur.
Isolate AC power to the heaters before disconnecting battery cables. Heaters will
run continuously without DC power and can overheat and become damaged.

Caution: Do not add cold coolant to a hot engine. Engine castings can be damaged. Allow
the engine to cool to below 50oC (122°F) before adding coolant.

6.7.1 Anti-freeze Concentration

The standard coolant mixture for the QSK60 (DQKH) genset is 50% Ethylene Glycol and 50%
water for protection down to -36oC (-33oF). Warranty claims for damage caused by freezing to any
component will be rejected if the incorrect mix of anti-freeze has been used. Consult your
distributor for other options.

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6.7.2 Coolant Level

WARNING: CONTACT WITH HOT COOLANT CAN RESULT IN SERIOUS BURNS.
ALLOW COOLING SYSTEM TO COOL BEFORE RELEASING PRESSURE
AND REMOVING WATER JACKET RADIATOR CAP OR LTA EXPANSION
TANK CAP.

Caution: Loss of coolant can allow engine to overheat without protection of shutdown
device, and cause severe damage to the engine. Maintain coolant level for
proper operation of high engine temperature shutdown system.

Check the coolant level during shutdown periods at the intervals specified in the Maintenance
Table 6-1.
The coolant level should be approximately in the middle of the sight glass, with the coolant
temperature at 50°C (122oF) or lower. Refer to the Engine Operation and Maintenance Manual for
further, general information.

COOLANT SIGHT
GLASS 3
JACKET WATER COOLING
2 SYSTEM FILL CAP

11LTA COOLING
SYSTEM FILL CAP

1. LTA Cooling System Fill Cap

2. Water Jacket Cooling System Fill Cap
3. Coolant Sight Glass

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QSK60 (DQKH) Control System Publication 3549(GB)
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6.7.3 Cooling System Maintenance

Caution: Failure to use the correct type of coolant, maintain the correct level and bleed
the system of air can result in severe engine damage.

Refer to the Engine Operation and Maintenance Manual for all cooling system maintenance, such
as coolant requirements, filling of the engine water jacket and LTA cooling systems, coolant filter
replacement, and flushing and cleaning. Refer to Figure 6-1 for the coolant drain locations of the
aftercooler and water jacket systems.
If engine coolant heater(s) is installed in the water jacket cooling system, disconnect heater(s) from
power source before performing cooling system maintenance.

Caution: The heater element will burn out if the engine coolant is removed with the heater
connected to power source.

Caution: The heater element will burn out if the power is connected before it is filled with
coolant, or if straight antifreeze solution is used for coolant. Before connecting
the power, fill the engine with coolant and run it for a minimum of ten minutes to
circulate coolant through the heater.

Figure 6-1 After Cooler/Water Jacket Coolant Drain Locations

1. After Cooler Coolant Drain

2. Water jacket Coolant Drain (Both Sides)
3. After Cooler Coolant Drain (Both Sides)

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6.7.4 Radiator
Inspect the exterior of the radiator for obstructions. During the service life of a radiator a build up of
foreign matter can obstruct the flow of air through the radiator cores, reducing the cooling
capability. To ensure the continued efficiency of the radiator, the core will require cleaning.
Refer to the Radiator Information Manual 3554 for further details on cleaning the radiator and
greasing the bearings.

WARNING: LITHIUM AND POLYUREA GREASES ARE NOT COMPATIBLE AND MUST
NOT BE MIXED.

6.7.5 Fan Bearings Re-lubrication

Re–lubricate the fan bearings at the interval specified in the Maintenance Table 6-1. A grease
fitting is provided for the bearings to allow the use of a grease gun to re–lubricate the bearings with
the following quantities:

Fan side bearing 6 Grams

Pulley side bearing 8 grams
The recommended lubricant is a lithium based grease, such as, Mobilux EP 2, Mobilith AW 2, or
Shell Alvania R3.
1

Figure 6-2 Fan Bearing Grease Fittings

1. Bearings
2. Grease Fittings

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6.7.6 Coolant Heater

WARNING: CONTACT WITH COOLING SYSTEM OR ENGINE CAN RESULT IN SERIOUS
BURNS. DO NOT TOUCH COOLING SYSTEM OR ENGINE DURING GENSET
MAINTENANCE UNTIL THEY ARE COOL.

Check the operation of the coolant heater by verifying that hot coolant is being discharged from the
outlet hose (see Figure 6–3). Do not touch the outlet hose – if heater is operational, radiant heat
should be felt with hand held close to outlet hose.

3 2

Figure 6-3 Coolant Heater

1. Outlet
2. Inlet
3. Drain

6.8 Heat Exchanger Cooling System (Optional)

Various optional heat exchangers are available. Please refer to your authorised distributor for
further information.

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6.9 Fuel System

Refer to the Engine Operation and Maintenance Manual for fuel recommendations and fuel system
maintenance, such as draining of the fuel–water separators and fuel filter replacement interval and
procedure.

6.9.1 Fuel Handling Precautions

WARNING: IGNITION OF FUEL CAN CAUSE SERIOUS PERSONAL INJURY OR DEATH
BY FIRE OR EXPLOSION. DO NOT PERMIT ANY FLAME, CIGARETTE, OR
OTHER IGNITER NEAR THE FUEL SYSTEM.

To avoid condensation problems, keep fuel supply tanks as full as possible by filling up each time
the engine is used. In cold weather, warm fuel returning from the injectors heats the fuel in the
supply tank. If the fuel level is low, the upper portion of the tank tends to form condensation. In
warm weather, both the fuel and the tank will be warm during the daytime. At night, cool air tends
to lower the temperature of the tank more rapidly than the temperature of the fuel. If the fuel level
is low, the upper portion of the tank will cool more rapidly and tend to form condensation.
Condensation (water) can cause clogging of fuel filters when the sulphur in the fuel forms acid,
which can corrode and damage engine parts.

6.10 Air Cleaner

Refer to the Engine Operation and Maintenance Manual for air-cleaner filter element replacement,
interval and procedure.

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6.11 AC Generator Bearing Re-lubrication

Caution: The bearing must be filled with the same type of grease used when the
alternator was manufactured. This grease, Kluber type ASONIC GHY72, was
chosen to provide optimum lubrication and MUST NOT be mixed with any other
type of grease.
To locate the nearest Kluber distributor please refer to the Kluber Web site at:
[Link]

6.11.1 Lubrication
It is important that the correct type and quantity of grease is used for periodic re-lubrication with a
grease gun during planned maintenance. Refer to the label located adjacent to the end bearing of
the alternator (if provided) or Table 6-3, which specifies the grease fill quantity. (Refer also to
Maintenance Tables 6-1 and 6-2).
Table 6-3 Maintenance Chart for Re–Grease

Frame Bearing Grease Qty Re–Lubrication

Part Number** Grams Ounces Period
7* Non-Drive End 18.75 0.66 1000
7* Drive End 22.25 .79 1000
8* 6324 C3 37.75 1.33 1000
8* 6232 C3 30.25 1.07 1000
8* 6236 C3 43.25 1.52 1000
* Frame 7 outside casing is round, Frame 8 outside casing is octagonal (flat sided)
** Refer to label located at bearing end of alternator for bearing part no.

To determine how much grease is supplied with each pump (stroke) of the device, weigh the
quantity required (e.g., 37.75 grams or 1.33 ounces), against the number of pump strokes taken to
inject that amount onto a small weighing scale. Also, note in practice:
• If the pump hits an airlock, (i.e., no pressure when pumping) these strokes cannot be
counted.
• For greater accuracy, the grease fitting can be unscrewed, and a flexible grease–pipe
screwed directly to the fitting adapter. This will make sure that no grease is expelled outside
of the fitting.
• If too much grease is applied, any excess will be exhausted out of the bearing cartridge via
the grease escape. (Any exhausted grease should be cleaned out of the PMG cover.
• Always extend the grease gun pump arm out to its full extent with each pump, failure to do
this could mean little or no grease is going into the bearing.
Note: It is very important that these lubrication instructions are strictly adhered to.

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6.11.2 Re–Lubrication Procedure

Re–lubricate the bearing(s) at the intervals specified in the Maintenance Tables 6-1 and
6-2 and 6-3. These intervals may differ from those specified on the label located adjacent to the
end bearing of the alternator. Use the information provided in this manual for these values.
Lubricate the bearing according to the instructions contained within the Alternator Manufacturer’s
Operation & Maintenance Manual supplied with the genset. A grease fitting is provided to allow the
use of a grease gun to re-lubricate the bearing.
1. Make sure grease gun nozzle and re–lubricating fitting are free from contaminants or abrasive
material.
2. With the genset running, apply the specified re–lubrication grease fill quantity through the
grease fitting.
3. Run the genset for at a minimum of ten minutes to allow excess grease to exhaust.
4. Check inside the PMG cover for expelled grease. Clean out as necessary.

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QSK60 (DQKH) Control System Publication 3549(GB)
PowerCommand®Control 3201 Issue 1 - April ‘04

SECTION 7 – TROUBLESHOOTING
7 Troubleshooting
7.1 Introduction
Fault code tables together with Warning and Shutdown code tables are provided in this section to
assist in locating and identifying the possible causes of faults in the genset system.
The Engine Operation and Maintenance Manual and the Alternator Installation, Service and
Maintenance Manual contain their own fault finding charts which identify the possible causes of
their respective faults.

7.2 Control Unit DC Power Supply

The genset 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 graphical display
panel.
In the event of an engine shutdown fault (red Shutdown lamp), the control will stop the engine
immediately; for an alternator shutdown fault, the engine will stop after the Cool–down Timer has
timed out. If the genset is stopped for this reason, the operator can restart the set after making the
necessary adjustments or corrections. This section lists the Warning and Shutdown
codes/messages (Table 7–1), and suggests troubleshooting procedures (Table 7–2).
Note: Displayed error codes that are not listed in Table 7–2 will require an authorised service
representative to correct the fault. Contact an authorised service centre for assistance.

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7.3 Safety Considerations

Fault finding work, particularly in confined areas, should be carried out by two engineers working
together. Read, understand and comply with all safety precautions listed within Section 1 –
Preliminary and Safety – and observe all instructions and precautions throughout this manual and
the Health and Safety Manual (3553).
The installation of a genset can be designed for remote starting. When troubleshooting a genset
that is shutdown ensure that the set cannot be accidentally re-started. Refer to Section 6.4 –
Locking the Genset out of Service.

WARNING: HIGH VOLTAGES ARE PRESENT WHEN THE GENSET IS RUNNING. DO

NOT OPEN THE OUTPUT BOX WHILE THE GENSET IS RUNNING.

WARNING: SOME PANEL INTERNAL COMPONENTS MAY HAVE LIVE EXPOSED

TERMINATIONS EVEN IF THE GENSET IS NOT RUNNING. ISOLATE ALL
EXTERNAL ELECTRICAL SUPPLIES PRIOR TO ACCESS OF THE
CONTROL PANEL.

WARNING: CONTACTING HIGH VOLTAGE COMPONENTS CAN CAUSE SEVERE

PERSONAL INJURY OR DEATH BY ELECTROCUTION. KEEP THE OUTPUT
BOX COVERS IN PLACE DURING TROUBLESHOOTING. ONLY
PERSONNEL QUALIFIED TO PERFORM ELECTRICAL SERVICING SHOULD
CARRY OUT TESTING AND/OR ADJUSTMENTS.

Caution: Always disconnect a battery charger from its AC source before disconnecting the
battery leads. Failure to do so can result in voltage spikes high enough to
damage the DC control circuits of the genset.

WARNING: 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

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.

WARNING: ACCIDENTAL STARTING OF THE GENSET WHILE WORKING ON IT CAN

CAUSE SEVERE PERSONAL INJURY OR DEATH. PREVENT ACCIDENTAL
STARTING BY DISCONNECTING THE STARTING BATTERY LEADS
(NEGATIVE [-] FIRST).

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7.4 Fault Finding

Should a fault condition occur during operation follow the procedures in the following tables to
locate and correct the problem. For any symptom not listed, contact an authorised service centre
for assistance.
Before starting any fault finding, ensure that the following basic checks are carried out:
• All switches and controls are in their correct positions
• The fuel oil level is correct
• The lubricating oil level is correct
• The coolant level is correct
• The radiator matrix is free from obstruction
• The battery charge condition is satisfactory and the connections are secure
• The genset electrics and alternator connections are secure
• The panel connections are secure
• The protection circuits have been reset
• Blown fuses have been replaced
• Tripped contactors or circuit breakers have been reset

WARNING: MANY TROUBLESHOOTING PROCEDURES PRESENT HAZARDS THAT

CAN RESULT IN SEVERE PERSONAL INJURY OR DEATH. ONLY
QUALIFIED SERVICE PERSONNEL WITH KNOWLEDGE OF FUELS,
ELECTRICITY, AND MACHINERY HAZARDS SHOULD PERFORM SERVICE
PROCEDURES.
REVIEW SAFETY PRECAUTIONS LISTED WITHIN SECTION 1 -
PRELIMINARY AND SAFETY SECTION - OF THIS MANUAL TOGETHER
WITH THE HEALTH AND SAFETY MANUAL (3553).

7.5 Status Indicators

7.5.1 Not In Auto Indicator
This red lamp flashes continuously when the Off/Manual/Auto switch is not in the Auto position
(Figure 7–1).

7.5.2 Shutdown Status Indicator

This red lamp is lit whenever the control detects a Shutdown condition. After the condition has
been corrected, the Shutdown indicator can be reset by turning the Off/Manual/Auto switch to the
Off (O) position, and pressing the Fault Acknowledge button. The genset cannot be started when
this lamp is on.

7.5.3 Warning Status Indicator

This yellow lamp is lit whenever the control detects a Warning condition. After the condition has
been corrected, the Warning indicator can be reset by pressing the Fault Acknowledge button. (It
is not necessary to stop the genset if the fault becomes inactive during genset operation).

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7.6 Reading Fault Codes

If the genset contains the optional graphical display and a fault occurs, the fault code/message will
be displayed in the graphical display Description Line (Figure 7–1). If the control does not contain
the graphical display, the fault code is read from the Warning and Shutdown status indicators.
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.
Note: The InPower service tool is required to view this data log.

7.6.1 Reading Fault Codes Using Graphical Display (Optional)

The top three lines of the graphical display contain the following control information in the order
described:
• State Line: Modes of operation, such as Stopped, Time Delay to Start, Warm Up
at Idle, etc. (see Figure 7–1), and paralleling operations, such as
Standby, Dead BUS Close, Synchronise, etc.
• Action Line: System actions, such as Warning, De-rate, Shutdown Cool–down and
Shutdown, and Fault codes.
• Description Line: Fault code messages.
Refer to History/About Submenus in Section 4.8, which describes how to view fault codes using
graphical display.

7.6.2 Reading Fault Codes Using Warning/Shutdown Indicators

If the Warning or Shutdown status indicator is lit, press and hold the Fault Acknowledge button for
a minimum of ten seconds. After ten seconds, the Shutdown lamp will begin to blink the active fault
code(s) as follows:
The Warning lamp is used to indicate the start of a new code. The Warning lamp will remain on for
two seconds, followed by the Shutdown lamp blinking the fault code. This sequence occurs three
times for each code. The fourth flash of the Warning lamp indicates the beginning of the second
fault code.
There are distinct pauses between repetitions of the code blink transmissions of the Shutdown
lamp.
A three-digit fault code is indicated by three sets of blinks separated by a two-second pause. The
first set corresponds to the hundreds position, the second to the tens position, and the third to the
ones digit. Example for Code No. 213:
Shutdown LED: blink–blink–pause–blink–pause–blink–blink–blink
Warning LED: blink (two seconds)
The light will display the fault codes (active or inactive) in succession, starting with the most recent.
Up to 32 (unacknowledged) fault codes can be stored in control panel memory.
To return the control to the most recent fault code, press and release the Fault Acknowledge
button (less than one second) and repeat procedure.
When the fault code is acknowledged and the fault condition is corrected, the fault code will be
removed from the LED fault log.

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OPERATOR PANEL SWITCH PANEL

STATE LINE
ACTION LINE
DESCRIPTION LINE

MENU DISPLAY
AREA

Figure 7-1 Front Control Panel (Full-Featured)

1. Shutdown, Warning Status Indicators

2. Fault Acknowledge Button
3. Graphical Display
4. Not in Auto Indicator

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7.7 Line Circuit Breaker (Optional)

The optional line circuit breaker mounts on the genset output box. If the load exceeds the
generator current rating, the line circuit breaker will open, preventing the genset from being
overloaded. If the circuit breaker trips, locate the source of the overload and correct as necessary.
Manually reset the breaker to reconnect the load to the genset.

7.8 Control and Diagnostics Via Network or PC (Laptop)

See your authorised Cummins dealer regarding software, hardware and network requirements for
control and diagnostics via network or PC.

7.9 Fault Codes

The fault codes have been divided into five categories to help you determine what corrective
action to take for safe operation of the genset. Use Table 7–1 to find the category (CAT) and fault
description for all codes.
Note: Gaps in the code numbers are for codes that do not apply to this genset. Some of the
codes are feature dependent and will not be displayed by the genset control.

7.9.1 Category A Fault Codes

Relate to engine or alternator Shutdown faults that require immediate repair by competent service
personnel (genset non-operational). The Control unit prevents the genset from being restarted.

7.9.2 Category B Fault Codes

Consist of faults that can affect genset performance or cause engine, alternator, or connected
equipment damage. Continue operation of the genset only when it is powering critical loads and
cannot be shut down. Requires repair by competent service personnel.

7.9.3 Category C Fault Codes

Consist of faults that do not affect genset performance but require competent service personnel to
repair. These codes indicate a defective sensor or harness, leaving no engine protection. (Engine
damage may therefore occur without detection).
Note: Continued operation may void genset warranty if damage occurs that relates to any of
these category faults.

7.9.4 Category D Fault Codes

Consist of faults that are repairable by site personnel. Service will be required by competent
service personnel if site personnel cannot resolve the problem after taking the corrective actions
suggested in Table 7–2.

7.9.5 Category E Fault Codes

Indicates non-critical operational status of genset, external faults, or customer fault inputs. May
require repair by qualified service personnel.

Page 7-6 Section 7 – Troubleshooting

QSK60 (DQKH) Control System Publication 3549(GB)
PowerCommand®Control 3201 Issue 1 - April ‘04

Table 7-1 Warning and Shutdown Fault Codes

CAT CODE LAMP DISPLAYED MESSAGE CAT CODE LAMP DISPLAYED MESSAGE
A 111 Shtdn Internal ECM error A 254 Shtdn Fuel shutoff valve
A 112 Shtdn Actuator not responding C 259 Wrng Fuel shutoff valve
B 113 Wrng Actuator sensor fault C 261 Wrng Fuel temperature sensor
A 115 Shtdn No speed signal C 263 Wrng Fuel temperature sensor
A 116 Shtdn Time press sensor high C 265 Wrng Fuel temperature sensor
A 117 Shtdn Time press sensor low A 266 Shtdn Fuel temperature
B 118 Wrng Pump press sensor high B 316 Wrng Fuel supply pump
B 119 Wrng Pump press sensor low B 318 Wrng Fuel supply pump
C 121 Wrng No engine speed signal D 326 Wrng Oil level warning
B 122 Wrng Manifold air press sensor B 343 Wrng Internal ECM error
B 123 Wrng Manifold air press sensor D 359 Wrng Engine failed to start
C 135 Wrng Oil pressure sensor A 378 Wrng Fuelling actuator #1
C 141 Wrng Oil pressure sensor A 379 Wrng Fuelling actuator #1
B 143 Wrng Low oil pressure A 394 Wrng Fuelling actuator #1
C 144 Wrng Coolant temperature sensor A 395 Wrng Fuelling actuator #1
C 145 Wrng Coolant temperature sensor A 396 Wrng Fuelling actuator #2
D 146 Wrng High coolant temp warning A 397 Wrng Fuelling actuator #2
C 151 Shtdn High coolant temp alarm A 398 Wrng Fuelling actuator #2
D 152 Wrng Low coolant temp A 399 Wrng Fuelling actuator #2
C 153 Wrng Manifold air temp sensor B 415 Shtdn Low oil pressure alarm
C 154 Wrng Manifold air temp sensor B 421 Wrng High oil temperature
A 155 Shtdn Manifold air temp alarm B 423 Wrng Fuel timing
D 197 Wrng Coolant level warning D 441 Wrng Low battery voltage
C 212 Wrng Oil temperature sensor D 442 Wrng High battery voltage
C 213 Wrng Oil temperature sensor B 449 Wrng High fuel supply pressure
A 214 Shtdn High oil temperature B 451 Wrng Fuel rail pressure sensor
C 221 Wrng Air pressure sensor B 452 Wrng Fuel rail pressure sensor
C 222 Wrng Air pressure sensor A 455 Shtdn Fuel control valve sensor
A 228 Shtdn Low coolant pressure B 467 Wrng Timing rail act sensor
C 231 Wrng Coolant pressure sensor B 468 Wrng Fuel rail actuator sensor
C 232 Wrng Coolant pressure sensor D 471 Wrng Low oil level
A 233 Wrng Coolant pressure warning B 482 Wrng High fuel supply pressure
A 234 Shtdn Overspeed B 488 Wrng High intake manifold temp
D 235 Shtdn Coolant level alarm C 498 Wrng Oil level sensor
A 236 Shtdn Position sensor C 499 Wrng Oil level sensor
D 253 Shtdn Oil level alarm A 514 Shtdn Fuel control valve

Section 7 - Troubleshooting Page 7-7

Publication 3549(GB) QSK60 (DQKH) Control System
Issue 1 - April ‘04 PowerCommand®Control 3201

Table 7-1 Warning and Shutdown Fault Codes (continued)

CAT CODE LAMP DISPLAYED MESSAGE CAT CODE LAMP DISPLAYED MESSAGE
B 546 Wrng Fuel pressure sensor B 1319 Wrng High alternator temp
B 547 Wrng Fuel pressure sensor C 1321 Wrng Common warning driver
B 554 Wrng Fuel rail pressure sensor A 1322 Shtdn Load gov kW setpoint oor hi
B 555 Wrng Blowby pressure A 1323 Shtdn Load gov kW setpoint oor lo
A 556 Shtdn Blowby pressure B 1324 Wrng Load gov kVAR oor hi
A 586 Shtdn Run/Stop switch B 1325 Wrng Load gov kVAR oor lo
A 587 Shtdn Run/Stop switch B 1326 Wrng Backup starter disconnect
D 611 Wrng Engine hot A 1327 Shtdn Load gov kW analog oor
D 688 Shtdn High oil level alarm D 1328 Wrng Genset CB tripped
B 689 Wrng Crank shaft sensor B 1329 Wrng AVR DC power failure
B 719 Wrng Blowby pressure sensor A 1331 Shtdn AVR driver shorted
B 729 Wrng Blowby pressure sensor A 1332 Shtdn Manual switch oor lo
B 731 Wrng Cam/Crank misalignment A 1333 Shtdn Manual switch oor hi
B 778 Wrng Camshaft sensor A 1334 Shtdn Critical scaler oor
C 1118 Wrng Prelube relay driver B 1335 Wrng Non critical scaler oor
A 1121 Shtdn Failed to disconnect E 1336 Shtdn Cooldown complete
C 1219 Wrng Utility CB tripped E 1337 None Network wink
C 1222 Wrng Power transfer not in auto E 1341 Shtdn Load demand stop
C 1223 Wrng Utility frequency sensor A 1342 Shtdn Slot 0 card
C 1224 Wrng Gen over voltage sensor A 1343 Shtdn Slot 1 card
C 1225 Wrng Gen under voltage sensor A 1345 Shtdn Slot 3 card
C 1226 Wrng Genset frequency sensor A 1346 Shtdn Slot 4 incorrect
Shtdn/ C 1351 Wrng Slot 4 / network enabled
E 1311 Customer input #1
Wrng C 1414 Wrng Run relay contact
Shtdn/ C 1415 Wrng Run relay driver
E 1312 Customer input #2
Wrng D 1416 Wrng Fail to shutdown
Shtdn/ D 1417 Wrng Power down error
E 1313 Network Fault 1
Wrng B 1419 Wrng Fuel rail driver
Shtdn/ B 1421 Wrng Timing rail driver #1
E 1314 Network Fault 2
Wrng B 1422 Wrng Timing rail driver #2
Shtdn/ C 1424 Wrng High side driver
E 1315 Network Fault 3
Wrng C 1427 Wrng Overspeed relay driver
Shtdn/ C 1428 Wrng LOP shutdown relay driver
E 1316 Network Fault 4
Wrng D 1433 Shtdn Emergency stop - local
Shtdn/
E 1317 Customer input #3
Wrng
Shtdn/
E 1318 Customer input #4
Wrng

Page 7-8 Section 7 – Troubleshooting

QSK60 (DQKH) Control System Publication 3549(GB)
PowerCommand®Control 3201 Issue 1 - April ‘04

Table 7-1 Warning and Shutdown Fault Codes (continued)

CTG CODE LAMP DISPLAYED MESSAGE CTG CODE LAMP DISPLAYED MESSAGE
D 1434 Shtdn Emergency stop - remote B 1471 Wrng High current
D 1435 Wrng Engine cold A 1472 Shtdn Overcurrent
B 1436 Wrng PT fuel system drivers A 1473 Shtdn Watchdog failure
A 1437 Shtdn E–stop path fuse blown A 1474 Shtdn Software version mismatch
D 1438 Wrng Fail to crank C 1475 Wrng First start backup
D 1439 Wrng Fuel level low in day C 1476 Wrng LonWorks card
D 1441 Wrng Fuel level low in main C 1477 Wrng Crank relay contact
D 1442 Wrng Battery is weak C 1478 Wrng Crank relay driver
D 1443 Wrng Battery is dead A 1481 Shtdn AVR driver open
B 1444 Wrng kW overload E 1483 None Common alarm status
A 1445 Shtdn Alternator short circuit A 1485 Shtdn EFC driver shorted
A 1446 Shtdn AC output voltage is high A 1486 Shtdn EFC driver open
A 1447 Shtdn AC output voltage is low C 1487 Wrng Auto acknowledge driver
A 1448 Shtdn AC output frequency low C 1488 Wrng Warning LED driver
A 1449 Wrng AC output frequency high C 1489 Wrng Shutdown LED driver
B 1451 Wrng Gen/Bus voltage differ C 1491 Wrng Ready to load relay driver
A 1452 Shtdn Gen CB failed to close C 1492 Wrng Load dump relay driver
A 1453 Shtdn Gen CB failed to open C 1493 Wrng Display control driver
C 1454 Wrng Gen CB position contact C 1494 Wrng Modem power relay driver
A 1455 Shtdn Util CB contact C 1495 Wrng Common shutdown2 driver
E 1456 Wrng Bus out of range C 1496 Wrng Auto mode relay driver
E 1457 Wrng Fail to synchronise C 1497 Wrng Manual run LED driver
E 1458 Wrng Phase rotation C 1498 Wrng Exercise run LED driver
A 1459 Shtdn Reverse kW C 1499 Wrng Remote start LED driver
A 1461 Shtdn Loss of field C 2111 Wrng Aftercooler temp sensor
B 1462 Wrng High ground current C 2112 Wrng Aftercooler temp sensor
E 1463 None Not in Auto B 2113 Wrng High aftercooler temp
E 1464 None Load dump A 2114 Shtdn High aftercooler temp
E 1465 None Ready to load C 2331 Wrng Utility under volt sensor
C 1466 Wrng Modem failure C 2358 Wrng Utility over volt sensor
C 1467 Wrng Unable to connect modem C 2396 Wrng Utility CB failed to close
C 1468 Wrng Network error C 2397 Wrng Utility CB failed to open

Section 7 - Troubleshooting Page 7-9

Publication 3549(GB) QSK60 (DQKH) Control System
Issue 1 - April ‘04 PowerCommand®Control 3201

WARNING: MANY TROUBLESHOOTING PROCEDURES PRESENT HAZARDS WHICH

CAN RESULT IN SEVERE PERSONAL INJURY OR DEATH. ONLY
COMPETENT SERVICE PERSONNEL WITH KNOWLEDGE OF FUELS,
ELECTRICITY, AND MECHANICAL HAZARDS SHOULD PERFORM
SERVICE PROCEDURES.
REVIEW SAFETY PRECAUTIONS LISTED WITHIN SECTION 1 -
PRELIMINARY AND SAFETY SECTION - OF THIS MANUAL TOGETHER
WITH THE HEALTH AND SAFETY MANUAL(3553).

Table 7-2 Troubleshooting Procedures for Fault Codes

SYMPTOM CORRECTIVE ACTION
CODE: 146 Indicates engine has begun to overheat and engine coolant
LAMP: Warning temperature has risen to an unacceptable level. If genset is
MESSAGE: powering non–critical and critical loads and cannot be shut down,
HIGH COOLANT TEMP WARNING use the following:
a) Reduce load if possible by turning off non-critical loads.
b) Check air inlets and outlets and remove any obstructions to
airflow.
If engine can be stopped, follow 151 High Coolant Temp Alarm
procedure.
CODE: 151 Indicates engine has overheated (water jacket coolant
LAMP: Shutdown temperature has risen above the shutdown trip point or the coolant
MESSAGE: level is low). Allow engine to cool down completely before
HIGH COOLANT TEMP ALARM proceeding with the following checks:
a) Check water jacket coolant level and replenish if low. Look for
coolant leakage and repair if necessary.
b) Check for obstructions to cooling airflow and correct as
necessary.
c) Check fan belt and repair if necessary.
d) Reset control and restart after locating and correcting problem.
CODE: 152 Indicates engine coolant heater is not operating or is not
LAMP: Warning circulating coolant. Set is in standby mode but is not operating.
MESSAGE: Warning occurs when engine water jacket coolant temperature is
LOW COOLANT TEMP 21°C (70°F) or lower.
NOTE: In applications where the ambient temperature falls
below 4°C (40°F, Low Coolant Temp may be indicated even
though the coolant heaters are operating.
Check for the following conditions:
a) Check that both ball valves in coolant heater system are open.
b) Coolant heater not connected to power supply. Check for
blown fuse or disconnected heater cord and correct as
required.
c) Check for low water jacket coolant level and replenish if
required. Look for possible coolant leakage points and repair
as required.
CODE: 197 Indicates engine water jacket coolant level has fallen to an
LAMP: Warning unacceptable level. If genset is powering critical loads and cannot
MESSAGE: be shut down, wait until next shutdown period, then follow 235
COOLANT LEVEL WARNING Coolant Level Alarm procedure. If engine can be stopped, follow
235 procedure.

Page 7-10 Section 7 – Troubleshooting

QSK60 (DQKH) Control System Publication 3549(GB)
PowerCommand®Control 3201 Issue 1 - April ‘04

SYMPTOM CORRECTIVE ACTION

CODE: 235 Indicates engine water jacket coolant level has fallen below the
LAMP: Shutdown alarm trip point. Allow engine to cool down completely before
MESSAGE: proceeding.
COOLANT LEVEL ALARM a) Check water jacket coolant level and replenish if low. Look for
possible coolant leakage points and repair if necessary.
b) Reset control and restart after locating and correcting problem.
CODE: 359 Indicates possible fault with control or starting system. Check for
LAMP: Warning the following conditions:
MESSAGE: a) Poor battery cable connections. Clean the battery cable
ENGINE FAILED TO START terminals and tighten all connections.
b) Discharged or defective battery. Recharge or replace the
battery.
CODE: 441 Indicates battery voltage is below 24 VDC.
LAMP: Warning a) Discharged or defective battery. Check the battery charger
MESSAGE: fuse. Recharge or replace the battery.
LOW BATTERY VOLTAGE
b) Poor battery cable connections. Clean the battery cable
terminals and tighten all connections.
c) Check engine DC alternator. Replace engine DC alternator if
normal battery charging voltage (24 to 26 VDC) is not
obtained.
d) Check float level if applicable (raise float level).
CODE: 442 Indicates battery voltage exceeds 32 VDC.
LAMP: Warning a) Check float level on battery charger if applicable (lower float
MESSAGE: level).
HIGH BATTERY VOLTAGE
b) Check engine DC alternator. Replace engine DC alternator if
normal battery charging voltage (24 to 26 VDC) is not
obtained.
CODE: 611 Indicates that an engine hot shutdown has occurred (cool–down
LAMP: Warning timers were bypassed). This condition will occur when the operator
MESSAGE: presses the Emergency Switch or moves the 0ff/Manual/Auto
ENGINE HOT switch to the 0ff (O) position before the genset completes the
cooldown operation. (Genset should run at 10% or less load for
three minutes before engine shutdown). This type of shutdown
should be avoided; it can cause possible loss of performance and
engine damage.
CODE: 1311 through 1318 When any one of these customer defined inputs is detected by the
LAMP: Shutdown/Warning control, the corresponding fault message is displayed. The nature
MESSAGE: of the fault is an optional customer selection. These fault functions
Customer Defined Fault can be programmed to initiate a shutdown or warning as indicated
by the Warning or Shutdown lamp.
Note: Customer fault messages are editable. The message
displayed for the code shown (1311 through 1318) is
determined by the customer.
CODE: 1416 Status - indicates that the Fault Bypass mode is enabled. This
LAMP: Warning mode is primarily used by service personnel for troubleshooting
MESSAGE: purposes. In this mode the genset ignores the majority of system
FAIL TO SHUTDOWN shutdown faults.
CODE: 1417 Indicates that the control cannot power down due to some
LAMP: Warning unknown condition. Possible drain on battery. Contact an
MESSAGE: authorised service centre for service.
POWER DOWN ERROR

Section 7 - Troubleshooting Page 7-11

Publication 3549(GB) QSK60 (DQKH) Control System
Issue 1 - April ‘04 PowerCommand®Control 3201

SYMPTOM CORRECTIVE ACTION

CODE: 1433 / 1434 Indicates local or remote Emergency Stop. Emergency Stop
LAMP: Shutdown shutdown status can be reset only at the local control panel.
MESSAGE: To reset the local/remote Emergency Stop button:
EMERGENCY STOP - LOCAL / a) Pull, or twist and pull, the button out.
EMERGENCY STOP - REMOTE b) Move the Off/Manual/Auto switch to Off (O).
c) Press the front panel Fault Acknowledge button.
d) Select Manual or Auto, as required.
CODE: 1438 Indicates possible fault with control or starting system. Check for
LAMP: Warning the following conditions:
MESSAGE: a) Poor battery cable connections. Clean the battery cable
FAIL TO CRANK terminals and tighten all connections.
b) Discharged or defective battery. Recharge or replace the
battery.
CODE: 1439 Indicates fuel supply is running low. Check fuel supply and
LAMP: Warning replenish as required.
MESSAGE:
FUEL LEVEL LOW IN DAY
CODE: 1441 Indicates fuel supply is running low. Check fuel supply and
LAMP: Warning replenish as required.
MESSAGE:
FUEL LEVEL LOW IN MAIN
CODE: 1442 Indicates battery voltage drops below 14.4 volts for two seconds,
LAMP: Warning during starting.
MESSAGE: a) Discharged or defective battery.
BATTERY IS WEAK b) See Warning message 441 Low Battery Voltage.
CODE: 1443 Indicates battery has dropped below genset operating range (3.5
LAMP: Warning volts when cranking) to power the starter and the control circuitry.
MESSAGE: a) See Warning message 441 Low Battery Voltage.
BATTERY IS DEAD

Page 7-12 Section 7 – Troubleshooting

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