Gen control not in auto warning ошибка

Owners Manual

Operator/Installation

Controller

PowerCommand1302

English

Original Instructions 6-2014 900−0661 (Issue 10)

58

“Intentionally Left Blank”

i

Table of Contents

SECTION TITLE PAGE

Foreword viii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warranty viii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Important Safety Instructions ix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

About This Manual 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Certifications 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connector Seal Standards 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to Obtain Service 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Description 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Kit Description 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Additional Equipment 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1302 Control Features 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Current Requirements 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1302 Control System 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Module 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Run/Off/Auto Switch 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Panel 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Panel Connections 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Inputs and Outputs 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Inputs 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Outputs 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Protection and Faults 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault Codes 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Genset Protective Functions 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Protection 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator Protection 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Current Draw 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Running Mode 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parade Rest Mode 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sleep Mode 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Installation 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting Guidelines 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Environmental Capability 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1302 Main Control Board 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ii

SECTION TITLE PAGE

1302 Operator Panel 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Wiring Information 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Guidelines for Current Transformers 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Current Transformer Selection 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Example of CT Sizing − Two Lead CT 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Example of CT Sizing − Three Lead CT 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Current Transformer Setup 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Two Lead CT Setup Example: 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three Lead CT Setup Example 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Charging Alternator Connections 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Denso Type Charging Alternators 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bosch Type Charging Alternators 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator Connections 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Series Star 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Series Delta 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parallel Star 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Double Delta 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Single Phase 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Guidelines for Engine Sensors 3-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coolant Temperature Sensors 3-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pressure Sensors 3-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lube Oil Pressure Switch 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Board Connections 3-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electronic Governor Connections 3-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Kit Installation 3-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setup, Trims, and Adjustments 3-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator Control Adjustments 3-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AVR Enable/Disable Feature 3-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Digital Output Voltage Regulation 3-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torque-Matched Volts/Hz Overload Control 3-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battleshort Mode 3-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Genset Tuning 3-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V/Hz Curve 3-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Governor 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Governor Tuning 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Startup 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator Startup 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setup for Gain Tuning 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gain Tuning Parameters 3-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controller Calibration 3-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1302 Control Functions 3-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Start Mode 3-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Emergency Stop 3-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Local Emergency Stop 3-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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SECTION TITLE PAGE

Emergency Stop 3-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12/24V Battery 3-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Starting 3-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cycle Cranking 3-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spark Ignition Power/Glow Plug Control 3-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Glow Plug Control 3-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preheat Processing 3-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Glow Plug Output Logic 3-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start and Stop Time Delays (Cool Down) 3-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electronic Governor 3-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Speed Sensing 3-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Speed Governor Algorithm and Adjustment 3-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Real Time Clock 3-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Excerise Scheduler 3-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ATS Control 3-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dual Fuel 3-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battle Short Mode Option 3-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installations With an Operator Panel 3-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installations Without an Operator Panel 3-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battle Short Mode 3-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installations with an Operator Panel 3-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installations without an Operator Panel 3-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Operator Panel Operation 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Local Status Output Indicator 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Modes 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Off Mode 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Run Mode 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auto Mode 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emergency Stop Mode 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sleep Mode 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installations with an Operator Panel 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installations with a Manual Run/Off/Auto Switch 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Panel 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graphical Display 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display Text / Symbolic Versions 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display Menu Selection Buttons 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Previous Main Menu Button 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Off Button 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Not In Auto Indicator 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shutdown Indicator 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warning Indicator 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Start Indicator 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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SECTION TITLE PAGE

Auto Indicator 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Run Indicator 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Panel System Messages 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Communication Messages 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Event Messages 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Status Messages 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault Messages 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault Reset / Acknowledgement 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault/Status Codes 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting Default Settings 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Saving Your Changes 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Menus 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Status Menu 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator Status Menu 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator Line-to-Line Voltage Menu 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator Line-to-Neutral Voltage Menu 4-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator Single Phase Voltage Menu 4-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator Amperage Menu 4-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting Auto, Manual Run, and Off Modes 4-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Entering the Mode Change Access Code 4-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting Auto Mode 4-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting Manual Run Mode 4-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Aborting the Transition to Auto or Manual Run Mode 4-23. . . . . . . . . . . . . . . . . . . . . .

Selecting Off Mode 4-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Menus 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Status Menu 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Network Status Menus 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

History / About Menus 4-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

History Submenu 4-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About Genset Submenus 4-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About Control Submenu 4-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About Display Submenu 4-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault History Menu 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Screen Adjust Menu 4-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting Values/Parameters 4-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Screen Adjust Menu 4-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. 1302 Control Panel Service Menus 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Menus 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setup Menus 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Genset Service Menus 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Viewing Only 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Menu Navigation 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Viewing and Adjusting 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

v

SECTION TITLE PAGE

Setup Password Submenu 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting Values/Parameters 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Genset Service Submenus 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Genset Menu, Part 1 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Genset Menu, Part 2 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel System 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start/Stop Delay Menu 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cycle Crank Menu 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battle Short Menu 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AVR Setup Menu 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electronic Governer Menu, Part 1 5-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electronic Governer Menu, Part 2 5-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Genset Number Menu 5-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display Setup Menu 5-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Volts and Hertz Menu 5-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Voltage Regular Submenus 5-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Volts/Hz Rolloff Menu 5-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Regulator Gains Menu 5-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Regulator Gains Menu 5-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electronic Governor Submenus 5-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Governor Crank Fuel Menu 5-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electronic Governor Regulator Menu 5-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electronic Governor Menu 5-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electronic Governor Enable Speed Menu 5-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Customer I/O Submenus 5-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault Input Function Selection 5-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Customer Inputs 5-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault Input Active State Selection 5-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Customer Outputs 5-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Metering Submenus 5-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Meter Calib Menu 5-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Freq. Adjust Menu 5-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Metering Voltage Adjust Menu 5-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Metering Current Adjust Menu 5-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Annunciator Submenus 5-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Annunciator Inputs 5-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Annunciator Outputs 5-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ModBus Submenus 5-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ModBus Enable 5-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ModBus Setup 5-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Genset Setup Submenus 5-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Viewing Only 5-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Menu Navigation 5-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Viewing and Adjusting 5-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

vi

SECTION TITLE PAGE

Genset Setup Password Submenu 5-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting Values/Parameters 5-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Genset Menus 5-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Genset Menu 1 5-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Genset Menu 2 5-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Application Rating Select Menu 5-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standby kVA Rating Menu 5-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prime kVA Rating Menu 5-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Select Menu 5-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Threshold Menu 5-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Delay Setup Menu 5-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pressure Setup Menus 5-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Select Menu 5-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Thresholds Menu 5-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Delay Setup Menu 5-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pressure Setup Menus 5-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage Protection Submenus 5-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High AC Voltage Menu 5-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low AC Voltage Menu 5-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overfrequency Menu 5-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Underfrequency Menu 5-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator Protection 5-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Current Protection Submenus 5-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High AC Current Menu 5-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Protection Submenus 5-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Protection Overspeed Menu 5-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Protection Speed/Frequency Menu 5-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low Oil Pressure Warning Menu 5-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low Oil Pressure Shutdown Menu 5-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Coolant Temperature Warning Menu 5-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Coolant Temperature Shutdown Menu 5-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Protection Low Coolant Temperature and Battery Charger Menus 5-53. . . .

6. Troubleshooting 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PC Based Service Tool 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Network Applications and Configurable Inputs 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Considerations 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reading Fault Codes 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reading Fault Codes Using Optional Operator Panel 6-2. . . . . . . . . . . . . . . . . . . . . . .

Reading Fault Codes Using the Control Switch Indicator 6-2. . . . . . . . . . . . . . . . . . . .

Troubleshooting Procedures 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage/Continuity Testing 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

vii

7. Wiring Diagrams 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A. 1302 Menu System Maps A-1

Appendix B. Index B-1

General Information B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

viii

Foreword

The purpose of this manual is to provide the users with general control operation and fault code information.

Refer to the equipment manufacturer’s product support manuals for important safety precautions.

Manufacturers applying this control are respectfully advised that it is their responsibility to employ compe-

tent persons to carry out any installation work in the interests of good practice and safety. It is essential that

the utmost care is taken with the application of this control device.

Warranty

Warranty: This manual is published solely for information purposes and should not be considered all inclu-

sive. Sale of product shown or described in this literature is subject to terms and conditions outlined in ap-

propriate Cummins Power Generation selling policies or other contractual agreement between the parties.

This literature is not intended to and does not enlarge or add to any such contract. The sole source govern-

ing the rights and remedies of any purchaser of this equipment is the contract between the purchaser and

Cummins Power Generation.

NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PAR-

TICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEAL-

ING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS,

AND DESCRIPTIONS CONTAINED HEREIN.

In no event will Cummins Power Generation be responsible to the purchaser or user in contract, in tort (in-

cluding negligence), strict liability or otherwise for any special, indirect, incidental, or consequential damage

or loss whatsoever, including but not limited to damage or loss of use of equipment, plant or power system,

cost of capital, loss of power, additional expenses in the use of existing power facilities, or claims against the

purchaser or user by its customers resulting from the use of the information, recommendations, and de-

scriptions contained herein.

ix

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS − This manual contains

important instructions that should be followed during

installation and maintenance of the generator and bat-

teries.

Before operating the generator set (genset), read the

Operator’s Manual and become familiar with it and the

equipment. Safe and efficient operation can be

achieved only if the equipment is properly operated

and maintained. Many accidents are caused by failure

to follow fundamental rules and precautions.

The following symbols, found throughout this manual,

alert you to potentially dangerous conditions to the oper-

ator, service personnel, or the equipment.

DANGER This symbol warns of immediate

hazards which will result in severe personal in-

jury or death.

WARNING This symbol refers to a hazard or

unsafe practice which can result in severe per-

sonal injury or death.

CAUTION This symbol refers to a hazard or

unsafe practice which can result in personal in-

jury or product or property damage.

FUEL AND FUMES ARE FLAMMABLE

Fire, explosion, and personal injury or death can result

from improper practices.

DO NOT fill fuel tanks while engine is running, un-

less tanks are outside the engine compartment.

Fuel contact with hot engine or exhaust is a poten-

tial fire hazard.

DO NOT permit any flame, cigarette, pilot light,

spark, arcing equipment, or other ignition source

near the generator set or fuel tank.

Fuel lines must be adequately secured and free of

leaks. Fuel connection at the engine should be

made with an approved flexible line. Do not use

zinc coated or copper fuel lines with diesel fuel.

Be sure all fuel supplies have a positive shutoff

valve.

Be sure battery area has been well-ventilated prior

to servicing near it. Lead-acid batteries emit a high-

ly explosive hydrogen gas that can be ignited by

arcing, sparking, smoking, etc.

EXHAUST GASES ARE DEADLY

Provide an adequate exhaust system to properly

expel discharged gases away from enclosed or

sheltered areas and areas where individuals are

likely to congregate. Visually and audibly inspect

the exhaust daily for leaks per the maintenance

schedule. Make sure that exhaust manifolds are

secured and not warped. Do not use exhaust

gases to heat a compartment.

Be sure the unit is well ventilated.

Engine exhaust and some of its constituents are

known to the state of California to cause cancer,

birth defects, and other reproductive harm.

MOVING PARTS CAN CAUSE SEVERE

PERSONAL INJURY OR DEATH

Keep your hands, clothing, and jewelry away from

moving parts.

Before starting work on the generator set, discon-

nect battery charger from its AC source, then dis-

connect starting batteries, negative (−) cable first.

This will prevent accidental starting.

Make sure that fasteners on the generator set are

secure. Tighten supports and clamps, keep guards

in position over fans, drive belts, etc.

Do not wear loose clothing or jewelry in the vicinity

of moving parts, or while working on electrical

equipment. Loose clothing and jewelry can be-

come caught in moving parts.

If adjustment must be made while the unit is run-

ning, use extreme caution around hot manifolds,

moving parts, etc.

DO NOT OPERATE IN FLAMMABLE AND

EXPLOSIVE ENVIRONMENTS

Flammable vapor can cause an engine to overspeed

and become difficult to stop, resulting in possible fire, ex-

plosion, severe personal injury and death. Do not oper-

ate a genset where a flammable vapor environment can

be created by fuel spill, leak, etc., unless the genset is

equipped with an automatic safety device to block the air

intake and stop the engine. The owners and operators of

the genset are solely responsible for operating the gen-

set safely. Contact your authorized Cummins Power

Generation distributor for more information.

LS-14L

x

ELECTRICAL SHOCK CAN CAUSE

SEVERE PERSONAL INJURY OR DEATH

Remove electric power before removing protective

shields or touching electrical equipment. Use rub-

ber insulative mats placed on dry wood platforms

over floors that are metal or concrete when around

electrical equipment. Do not wear damp clothing

(particularly wet shoes) or allow skin surface to be

damp when handling electrical equipment. Do not

wear jewelry. Jewelry can short out electrical con-

tacts and cause shock or burning.

Use extreme caution when working on electrical

components. High voltages can cause injury or

death. DO NOT tamper with interlocks.

Follow all applicable state and local electrical

codes. Have all electrical installations performed

by a qualified licensed electrician. Tag and lock

open switches to avoid accidental closure.

DO NOT CONNECT GENERATOR SET DIRECT-

LY TO ANY BUILDING ELECTRICAL SYSTEM.

Hazardous voltages can flow from the generator

set into the utility line. This creates a potential for

electrocution or property damage. Connect only

through an approved isolation switch or an ap-

proved paralleling device.

GENERAL SAFETY PRECAUTIONS

Coolants under pressure have a higher boiling

point than water. DO NOT open a radiator or heat

exchanger pressure cap while the engine is run-

ning. Allow the generator set to cool and bleed the

system pressure first.

Used engine oils have been identified by some

state or federal agencies as causing cancer or re-

productive toxicity. When checking or changing

engine oil, take care not to ingest, breathe the

fumes, or contact used oil.

Keep multi-class ABC fire extinguishers handy.

Class A fires involve ordinary combustible materi-

als such as wood and cloth; Class B fires, combus-

tible and flammable liquid fuels and gaseous fuels;

Class C fires, live electrical equipment. (ref. NFPA

No. 10).

Make sure that rags are not left on or near the gen-

erator.

Make sure generator set is mounted in a manner to

prevent combustible materials from accumulating

under the unit.

Remove all unnecessary grease and oil from the

unit. Accumulated grease and oil can cause over-

heating and engine damage which present a po-

tential fire hazard.

Keep the generator set and the surrounding area

clean and free from obstructions. Remove any de-

bris from the set and keep the floor clean and dry.

Do not work on this equipment when mentally or

physically fatigued, or after consuming any alcohol

or drug that makes the operation of equipment un-

safe.

Substances in exhaust gases have been identified

by some state or federal agencies as causing can-

cer or reproductive toxicity. Take care not to breath

or ingest or come into contact with exhaust gases.

Do not store any flammable liquids, such as fuel,

cleaners, oil, etc., near the generator set. A fire or

explosion could result.

Wear hearing protection when going near an oper-

ating generator set.

To prevent serious burns, avoid contact with hot

metal parts such as radiator, turbo charger and ex-

haust system.

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

LS-14L

1-1

1. Introduction

ABOUT THIS MANUAL

This manual provides installation and operation in-

formation regarding the 1302 series control. This

manual includes information for the following types

of installations.

Kit 541−1414−01 is for Hydro Mechanical

(HM) engines.

Kit 541−1414−02 is for Full Authority Elec-

tronic (FAE) engines. FAE engines have an

external Electronic Control Module (ECM).

This manual does not have instructions for servic-

ing printed circuit board assemblies. After deter-

mining that a printed circuit board assembly is

faulty, replace it. Do not repair it. Attempts to repair

a printed circuit board can lead to costly equipment

damage.

This manual contains basic (generic) wiring dia-

grams and schematics that are included to help in

troubleshooting. Service personnel must use the

actual wiring diagram and schematic shipped with

each unit. The wiring diagrams and schematics

that are maintained with the unit should be updated

when modifications are made to the unit.

Read Important Safety Precautions and careful-

ly observe all instructions and precautions in this

manual.

SYSTEM OVERVIEW

The 1302 series control is a microprocessor-based

control. All generator set control functions are con-

tained on one circuit board. The circuit board pro-

vides engine speed governing (optional, when the

governor output module and appropriate engine

equipment is provided), main alternator voltage

output regulation, and complete generator set con-

trol protection and monitoring.

The operating software provides control of the gen-

erator set and its performance characteristics, and

displays performance information on an optional

operator panel. It accepts menu-driven control and

setup input from the push button switches on the

operator panel.

CERTIFICATIONS

The 1302 series control meets or exceeds the re-

quirements of the following codes and standards.

NFPA110 for level 2 or 3 systems

ISO 8528−4: 1993 Compliance, Controls

and Switchgear

CE Marking: The control system is suitable

for use on generator sets to be CE−marked

EN 50081−1,2 Residential/Light Industrial

emissions or Industrial Emissions

EN 50082−1,2 Residential/light industrial or

Industrial susceptibility

ISO 7637−2, level 2; DC supply surge volt-

age test

Mil Std 202C, Method 101 and ASTM B117:

Salt Fog test

This control is suitable for use on generator sets

that are UL2200 listed.

Connector Seal Standards

The following standards apply to the connector

seals used with the 1302 series control.

J11, J25, and J20 − AMP 794758-1

J12 − AMP 794275−1 Interface seal and

AMP 794276−1 Wire seal (both are re-

quired)

J17 − AMP 794269−1 Interface seal and

AMP 794276−1 Wire seal (both are re-

quired)

J18 − AMP 794271−1 Interface seal and

AMP 794276−1 Wire seal (both are re-

quired)

HOW TO OBTAIN SERVICE

Contact your generator set manufacturer when

seeking additional service information or replace-

ment parts. Provide model and serial number infor-

mation.

WARNING Incorrect service or replacement of

parts can result in severe personal injury or

death, and/or equipment damage. Service per-

sonnel must be qualified to perform electrical

and mechanical service. Read and follow Im-

portant Safety Precautions, on pages v and vi.

1-2

THIS PAGE LEFT INTENTIONALLY BLANK

2-1

2. Description

FIGURE 2-1. 1302 MAIN CONTROL BOARD AND OPERATOR PANEL (HMI211)

OVERVIEW

The PCC1302 controller is a microprocessor−

based generator set (genset) monitoring, meter-

ing, and control system. The control provides a

simple operator interface to the genset’s digital

voltage regulation, engine speed governing, re-

mote start / stop control, and protective functions.

The PCC1302 control is suitable for use on hydro

mechanical or FAE engines. It can be used in non-

paralleling applications and it is compatible with re-

connectable alternators up to 600VAC. The control

can also be configured for various frequency (50 /

60 Hz operation), voltage, and power connection

configurations from 190−600 VAC L-L.

The control is designed for mounting on the gener-

ator set. The 1302 series control is usually pow-

ered from the generator set starting batteries and

works over a voltage range from 8 to 30 VDC.

The 1302 series control meets NFPA 110 require-

ments (with appropriate accessories) and is de-

signed for connection to a 12 or 24 VDC control

system.

An optional operator panel can be used as a user

interface.

KIT DESCRIPTION

The 1302 genset control kits include the 1302 con-

trol board (12/24V control assembly with run and

start relay drivers) and the operator panel shown in

Figure 2-1. Also included in these kits are the fol-

lowing sensors and harnesses.

Quantity

Description HM Kit

541−1414−01

FAE Kit

541−1414−02

Oil Pressure Sensor 1 —

Temperature Sensor 1 —

Coolant Temperature

Sensor Harness 1 —

Oil Pressure Sensor

Harness 1 —

Control Panel to

PCC1302 Harness 1 1

Engine Harness 1 1

Genset AC Harness 1 1

2-2

ADDITIONAL EQUIPMENT

Figure 2-1 shows the 1302 control module (327−

1617−01) and the optional HMI211 digital display

panel (300−6014). If your installation is to include

any additional equipment (see Figure 2-2), the ap-

propriate kit(s) must be purchased separately.

HMI112 LED Bargraph − Kit 541−1319 (In-

cludes Instruction Sheet C697)

HMI113 Universal Annunciator − Kit

300−5929 (Includes Operator’s Manual

900−0301)

AUX101 System I/O Module − Kit 541−1291

(Includes Instruction Sheet C693)

AUX104 External Governor Power Module −

Kit 541−1231 (Includes Instruction Sheet

C689)

HMI113 UNIVERSAL ANNUNCIATOR

(300−5929)

HMI112 LED BARGRAPH

(300−6050−02)

AUX104 EXTERNAL GOVERNOR

POWER MODULE (327−1507)

AUX101 SYSTEM I/O MODULE

(327−1536)

FIGURE 2-2. ADDITIONAL EQUIPMENT

2-3

1302 CONTROL FEATURES

The 1302 series controller includes the following

features.

Operates on 12 or 24 VDC.

Electronic Governor Enable/Disable (via an

external Governor Power Module).

FAE Engine support utilizing partial PGI CAN

protocol support.

Automatic Voltage Regulator (AVR) Enable/

Disable.

PMG or Shunt Excitation methods supported.

PCCNet Communications.

ModBus Communications.

Digital speed governing.

Digital voltage regulation.

Low power sleep mode, with configurable

Wake-In-Auto mode.

Phase voltage and current sensing. Wye and

Delta voltage sensing single phase. Current

sensing with an external 0−5 amp current

transformers.

Engine relay drivers.

Generator set monitoring. Display status of all

critical engine and alternator generator set

functions.

Genset protection – Engine and Alternator

protection features.

Operator Panel Display (optional). Provides

easy to use operator display of critical genset

parameters and operating history.

Advanced serviceability using a PC based

software service tool.

Environmental protection. The control system

is designed for reliable operation in harsh en-

vironments. The core control board is potted

module that is fully protected from the ele-

ments.

Configurable Inputs and Outputs. Four dis-

crete configurable inputs and two dry contact

relay outputs.

Relay driver output for glow plug or spark igniter

controller, switched B+, FSO, Starter, Ready to

Load, Local Status, and Keyswitch control.

Current Requirements

The 1302 series control consumes 0.150 Amps of

current while in idle mode. While in the running

mode, it consumes 0.75 Amps of current. This

doesn’t include other application specific devices

such as the optional operator panel, external

actuators, relay coils, or display lamps.

1302 CONTROL SYSTEM

Control Module

The basic control system for the generator set

consists of a single control board with an external

control switch and status indicator.

The control board includes all the functions

necessary to locally or remotely start and stop the

Genset, provide digital voltage regulation, and

protect the Genset.

To use the electronic governor feature, an external

governor power stage may be required to drive the

fuel actuator.

Control Run/Off/Auto Switch

Off Mode − If the control is in the OFF mode, the

generator set is immediately shut down (if running)

and can’t be started. When in OFF mode, all active

faults are reset.

Run Mode − If the control is in the RUN mode, the

generator set will execute its start sequence and

operate at rated speed and voltage.

Auto Mode − If the control is in AUTO mode, the

generator set can be started with a start signal from

a remote device, such as an automatic transfer

switch by accepting a ground signal.

Fault Reset − Placing the switch in the OFF posi-

tion also resets the active/inactive faults in the con-

trol.

2-4

OPERATOR PANEL

The 1302 series control is provided with an optional

operator panel that may be either locally or

remotely mounted. The operator menus are made

up of English or internationally accepted symbols

so translations are not required. The display is

composed of an adjustable contrast backlit LCD

display, with a series of 6 generator status LED

lamps. The display is accompanied by a set of six

tactile feel membrane switches that are used by the

operator to navigate through control menus, and to

make control adjustments. It is configurable for

units of measurement.

The Run/Off/Auto switch function is integrated into

the operator panel; therefore an external switch is

not required when a operator panel is installed. The

operator panel displays current active faults, and a

time-ordered history of previous faults.

Operator Panel Connections

Two connectors (J1 and J2) are located on the

back of the operator panel (see Figure 2-3).

Connections are listed in Table 2-1.

NOTE: J1 and J2 are identical. Either one can be

used for the harness connection between

the main control board and the operator

panel.

J1

J2

J1-4

PIN 1 J1 or J2

1

2

3

4

5

6

7

8

FIGURE 2-3. 1302 OPERATOR PANEL

TABLE 2-1. OPERATOR PANEL CONNECTIONS

Connector Pin Signal Name Connect To / Comments

J1-1 RS-485 Data A Network Data A

J1-2 RS-485 Data B Network Data B

J1-3 B+ Network Supply

J1-4 PCCNet System Wake Up System Wakeup

J1-5 Return Network Supply Return

J1-6 Run Output

J1-7 Auto Output

J1-8

2-5

CONTROL INPUTS AND OUTPUTS

Control Inputs

Input signals to the main control board are:

Run/Off/Auto switch

Remote start signal

Remote emergency stop

Local emergency stop

Coolant temperature signal

Lube oil pressure signal

Battery voltage signal

PCCNet System Wake Up Input

Magnetic pick up signal

Starter disconnect signal

Single or three-phase current transformers

(CTs)

Single or three phase line-to-neutral voltage

Configurable inputs – The control includes

four inputs that have configurable functions.

Once mapped, each configurable input can be

used as a fault input, remote fault reset input,

battleshort input, or disabled.

Control Outputs

Output signals from the control are:

Control status lamp.

Configurable relay outputs (OUT1_NO and

OUT2_NO) − The control includes two relay

outputs rated at two amps. These outputs can

be configured to activate on any control warn-

ing or shutdown fault as well as ready to load,

not in auto, common alarm, common warning,

and common shutdown.

Ready to load (generator set running) signal –

This output pin goes low when the genset is

capable of supporting a load. The genset

speed and voltage output are what determines

the state of this pin.

Communications connections − The control

includes two RS-485 ports.

−PC Tool Interface – This communication

port (TB15) allows the control to com-

municate with a personal computer run-

ning a PC based service tool. This port

also allows the control to communicate

with external devices, such as a Pro-

grammable Logic Controller (PLC) via

the ModBus protocol.

−PCCNet − This communications port

(TB1) allows for connection from the

control to the optional operator panel,

universal annunciator, LED bargraph,

and system I/O module.

Local status – Refer to “Local Status Output In—

dicator” on page 4-1.

Battery charging alternator – Alternator flash

connection

Fuel shut-off relay driver

Starter relay driver

Keyswitch relay driver

Glow plug relay driver

Governor drive PWM command

Field coil − AVR PWM command

Excitation source − Input power for field coil

Alternator line voltage sensing − 600 VAC

RMS max

Switched B+ driver

2-6

PROTECTION AND FAULTS

The 1302 series control features genset protection

functions and fault detection.

Upon operation of a protective function, the control

will indicate a fault by flashing the fault code on the

local status lamp driver (J25−1). On systems with

an optional operator panel, the warning or

shutdown LED lights and the fault symbol and code

is displayed on the display. The nature of the fault

and time of occurrence is logged in the control. The

service manual and PC based service tool provide

service keys and procedures based upon the

service codes provided.

Fault Codes

A list of fault/status codes is included in Section 4.

Shutdown faults will shutdown the genset. Warning

faults are issued to notify the genset operator of the

problem but the 1302 series control will not shut-

down the genset when they occur.

Genset Protective Functions

The control provides the following system protec-

tive functions:

Configurable Alarm and Status Inputs – The

1302 series control accepts up to four alarm or

status inputs (configurable contact closed to

ground or open) to indicate customer-speci-

fied conditions. The control is programmable

for warning, shutdown, or status indication,

and for labeling the input.

Emergency Stop − Annunciated whenever the

emergency stop signal is received from an ex-

ternal switch.

Engine Protection

Overspeed Shutdown – The engine over-

speed default setting is 115% of the rated en-

gine speed nominal. The control includes time

delays to prevent nuisance shutdown signals.

Low Lube Oil Pressure Warning/Shutdown

− The level is preset (configurable with a PC

based service tool or through the display panel

menus) to match the capabilities of the engine

used. The control includes time delays to pre-

vent nuisance warning/shutdown signals.

High Engine Temperature Warning/Shut—

down − The level is preset (configurable with

PC based service tool or through the display

panel menus) to match the capabilities of the

engine used. The control includes time delays

to prevent nuisance warning/shutdown sig-

nals.

Low Coolant Temperature Warning − This

warning indicates that the engine temperature

may not be high enough for a 10-second start

or proper load pickup. The level is preset (con-

figurable with a PC based service tool or

through the display panel menus) to match the

capabilities of the engine used. The control in-

cludes time delays to prevent nuisance warn-

ing signals.

Low Battery Voltage Warning − This warning

indicates a battery charging system failure by

continuously monitoring battery voltage. The

control includes time delays to prevent nui-

sance warning signals.

High Battery Voltage Warning – This warn-

ing indicates that the battery charging system

is of a high level by continuously monitoring

battery voltage. The control includes time de-

lays to prevent nuisance warning signals.

Weak Battery Voltage Warning − The control

system tests the battery bank each time the

generator set is signaled to start. A warning is

announced if the generator set battery indi-

cates impending failure. The control includes

time delays to prevent nuisance warning sig-

nals.

Dead Battery Voltage Shutdown −Indicates

battery voltage drop during cranking which re-

sets control for three consecutive times (This

feature is available in 1302 calibration version

3.0 onwards )

Fail to Start (Overcrank) Shutdown.

Fail to Crank Shutdown − This shutdown in-

dicates that the control signaled the starter to

crank the engine but the engine did not rotate.

Cranking Lockout − The control will not allow

the starter to attempt to engage or to crank the

engine when the engine is rotating (when the

control senses the valid engine RPM above

the noise threshold value.)

Sensor Failure Indication – An out-of-range

high or low diagnostic logic is provided on the

base control to detect analog sensor or inter-

connecting wiring failures.

2-7

Alternator Protection

High/Low AC Voltage Shutdown − The high

voltage default setting is 110% of the rated

voltage with a 10 second time delay. The

instantaneous voltage default setting is 130%

of the rated voltage. The low AC voltage de-

fault setting is 85% of the rated voltage with a

10 second time delay.

Overcurrent Warning/Shutdown − Imple-

mentation of the thermal damage curve with

an instantaneous trip level is calculated based

on the Current Transformer Ratio and the Ap—

plication Power Rating (see Figure 2-4).

10

1

0.03

101

Seconds

Amps (x rated)

Instantaneous

Trip Point

Overcurrent

Protection

Curve

Alternator

Thermal

Damage Curve

FIGURE 2-4. ALTERNATOR PROTECTION

THERMAL DAMAGE CURVE

Under/Overfrequency − The underfrequen-

cy default is − 6Hz of the 50 Hz / 60 Hz frequen-

cy with a 10 second time delay. The overfre-

quency default is + 6Hz of the 50 Hz / 60 Hz fre-

quency with a 10 second time delay.

Loss Of Sensing AC Voltage Shutdown –

Loss of sensing AC voltage detects the loss of

voltage sensing or senses the loss of zero

crosses. This fault will also be the primary way

to detect short circuit conditions.

Overexcitation Shutdown – Overexcitation

is used to detect short circuit alternator faults.

CURRENT DRAW

The current draw information below is for the 1302

series control only. It does not include current draw

for other application specific devices, such as the

optional operator panel, external actuators, relay

coils, or display lamps.

Running Mode

When in Running mode, the 1302 series control

consumes .750 amps of current.

Parade Rest Mode

Parade Rest mode is when the 1302 series control

is waiting for a start command (for example, the

genset is not running). During Parade Rest mode,

the control consumes 150 milliamps of current.

Sleep Mode

The 1302 series control enters Sleep mode after

five minutes in the Off or Auto mode. During Sleep

mode, the control consumes 60 milliamps of cur-

rent.

2-8

THIS PAGE INTENTIONALLY LEFT BLANK

3-1

3. Installation

Read these instructions completely and become

familiar with safety warnings, cautions, and proce-

dures before starting the installation.

WARNING Incorrect installation, service, or

replacement of parts can result in severe per-

sonal injury or death and/or equipment dam-

age. Only trained and experienced personnel

are to perform the following procedures.

CAUTION A generator set control must be

serviced only by technically qualified person-

nel. High voltages are present. These voltages

can cause electrical shock, resulting in person-

al injury.

Even with power removed, improper handling

of components can cause electrostatic dis-

charge and damage to circuit components.

WARNING AC voltages and currents present

an electrical shock hazard that can cause se-

vere personal injury or death. Incorrect instal-

lation, service, or parts replacement can result

in severe personal injury, death, and/or equip-

ment damage.

Turn off or remove AC power from the battery char-

ger (if present) and then remove the negative (−)

battery cable from the set starting battery. This is to

make sure the genset will not start while working on

it and to avoid circuit board damage, caused by

voltage spikes when removing and replacing circuit

board connectors.

CAUTION If present, always disconnect a bat-

tery charger from its AC source before discon-

necting the battery cables. Otherwise, discon-

necting the cables can result in voltage spikes

high enough to damage the DC control circuits

of the generator set.

WARNING Accidental starting of the genera-

tor set while working on it can cause severe

personal injury or death. Prevent accidental

starting by disconnecting the starting battery

cables (negative [−] first).

Make certain the battery area has been well-

ventilated before servicing the battery—Wear

goggles—Stop the genset and disconnect the

charger before disconnecting battery cables.

Arcing can ignite explosive hydrogen gas giv-

en off by batteries, causing severe personal in-

jury. Arcing can occur when a cable is removed

or re-attached, or when the negative (−) battery

cable is connected and a tool used to connect

or disconnect the positive (+) battery cable

touches the frame or other grounded metal part

of the generator set. Always remove the nega-

tive (−) cable first, and reconnect it last. Make

certain 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.

WARNING Ignition of explosive battery gases

can cause severe personal injury or death. Arc-

ing 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 a battery. Dis-

charge static electricity from body before

touching batteries by first touching a grounded

metal surface.

MOUNTING GUIDELINES

The main control board and the optional operator

panel are suitable for non-engine mounting. As

such, they should not be directly mounted on the

engine.

The control and operator panel may be mounted on

one of the following.

A suitable frame on top of the alternator

A frame supported from the genset base rail

A stand-alone mounting frame isolated from

the vibration of the genset

Appropriate vibration isolators should be used to

make sure that neither the main control board, the

operator panel, nor customer wiring are subjected

to vibration levels beyond their capability.

To prevent the control board and the optional oper-

ator panel from being exposed to conditions be-

yond their specifications, care should be taken not

to mount them close to the engine exhaust pipes.

Mounting them in a manner that would expose

3-2

them to direct sunlight or rain/snow should also be

avoided.

It is recommended that the control board be

mounted with the longer side horizontal and the

shorter side vertical so as to allow air to move freely

upwards through the heat sink channels. Mounting

the control board with the short side horizontal and

the longer side vertical should be avoided.

ENVIRONMENTAL CAPABILITY

The control system is specifically designed and

tested for resistance to RFI / EMI and to resist the

effects of vibration to provide a long reliable life

when mounted on a generator set. The control in-

cludes transient voltage surge suppression to pro-

vide compliance to referenced standards.

1302 Main Control Board

The main control board is designed to withstand

vibration levels of 50 mm / sec in the 20−100 Hz

range and of 3.3 G in the 100−2000 Hz range.

The main control board is designed for proper op-

eration without recalibration in ambient tempera-

tures from –40 to +70 Deg C, and for storage from

–55 to +80 Deg C. The control is designed to oper-

ate with humidity up to 95%, non-condensing, and

at an altitude up to 13,000 feet (5000 meters).

The main control board is fully encapsulated to pro-

vide resistance to the effects of dust and moisture.

1302 Operator Panel

The optional operator panel is designed to with-

stand vibration levels of 40 mm / sec in the 4−100

Hz range and the engine vibration levels shown in

Figure 3-1.

The operator panel is designed for proper opera-

tion in ambient temperatures from −4 to 158 Deg F

(–20 to +70 Deg C) and for storage, from −22 to 176

Deg F (–30 to +80 Deg C).

The operator panel has a single membrane sur-

face, which is impervious to the effects of dust,

moisture, oil, and exhaust fumes.

0.1

1

10

0 50 100 150 200 250

Frequency (Hz)

Amplitude (Gs) LCD Vibration Profile

FIGURE 3-1. OPERATOR PANEL VIBRATION

LIMITS

CONTROL WIRING INFORMATION

For connecting the Magnetic Pickup, use mini-

mum 0.8 sq. mm (18 gage), 2 conductors,

twisted shielded cable. Connect the shield at

J11—8 and leave the shield un-connected at the

magnetic pickup side of the cable.

For connection the ECM CAN, use minimum

0.8 sq. mm (18 gage), 2 conductors, twisted

shielded cable. Connect the shield at

J11-17and leave the shield un-connected at

the ECM side of the cable.

For connecting the PCCNet, use minimum 0.8

sq. mm (18 gage), 2 conductors, twisted

cable.

For connecting the battery supply, use two

twisted pair wires (16 AWG).

For connecting current transformers, use

three twisted pair wires minimum (16 AWG).

For all other connections, use minimum 0.8 sq

mm (18 gauge) wires.

The Electronic Governor feature typically re-

quires an external Governor Output Module

Kit. Governor PWM output from the 1302 se-

ries control board is connected as input to the

Governor Power Module by a minimum 0.8 sq.

mm (18 gage), 2 conductors, twisted shielded

cable.

3-3

GUIDELINES FOR CURRENT

TRANSFORMERS

All current transformers (CTs) used with a 1302 se-

ries control must conform to the following specifica-

tions.

Continuous rated full load secondary output

current: 5 amps at 50 or 60Hz

Total burden VA rating: at least 2.5 VA

Output terminals between which current is

drawn in high and low ranges on tapped CTs.

Maximum allowable ratio error at rated output:

+/−1%

Maximum allowable phase error at rated out-

put: +/−1

10-second overload output current in rated

metering load: 10 Amps

Maximum allowable ratio error at overload

output: +/−1%

Ambient temperature rating: −40 to 176 Deg F

(−40 to +80 Deg C)

System voltage rating − 600VAC

NOTE: in PCC1302,if trim parameter

Current Multiplier 2X Enable is

enabled and only one of the two

alternator winding phase cables

is routed through CT, then the cur-

rent measurement calculation will

be multiplied by 2 to show the cor-

rect reading of the load current.

Current Transformer Selection

Current transformers (CTs) used in 1302 control

applications are ideally sized to produce rated CT

secondary amps at twice rated generator (full

200% range) output amperes. In other words,

when the generator is producing 100% output am—

peres, the secondary current of the CTs is 2.5 am-

peres per phase. This requirement determines a

lower bound of the CT ratio. An upper bound is de-

termined by requiring that, at 100% rated output

current, the CTs secondary current is at least 1 am-

pere. The purpose of this is to maintain sufficient

metering resolution. The lower and upper bound of

the CT limits are prescribed by the following two

formulas.

Minimum CT Ratio = 2 * Max_Rated_Current

5

Maximum CT Ratio = 5 * Min_Rated_Current

5

In non-reconnectable genset applications, the

Max_Rated_Current and Min_Rated_Current are

the same. In reconnectable genset applications,

they are different.

Example of CT Sizing − Two Lead CT

A 250kVA rated genset application at 240V pro-

duces rated output current of 602 amps/phase.

This yields a Minimum CT Ratio of 1204:5 and a

Maximum CT Ratio of 3010:5. Any CT with a ratio

between these two values would be sufficient for

this application.

3-4

Example of CT Sizing − Three Lead CT

A reconnectable generator capable of 208−240/

416−480V outputs with a 125 kVA 3-phase only rat-

ing.

You first need to find the current in each phase for

each output voltage. This is done using the follow-

ing formula:

Voltage

VAPower

Current

*3

)(



or

VoltageFactorPower

WPower

Current

*_*3

)(



Using the above equation, the current in each

phase is computed as shown below.

Voltage (V) Output Current (A)

208 346.376

240 300.192

416 173.188

480 150.096

The next step is to use the equations on page 3-3

to find the lower and upper bound for the CT ratios

for each voltage configuration.

For a 208−240 voltage configuration:

96.1500192.300*5 

Maximum CT Ratio

752.692376.346*2 

Minimum CT Ratio

For a 416−480 voltage configuration:

8.754096.150*5 

Maximum CT Ratio

376.346188.173*2 

Minimum CT Ratio

For three-tap CTs, it would be advisable to choose

a CT with a 1500/750:5 ratio.

For the 208−240 voltage configuration, connect

the CT leads to the 1st and 3rd CT connections,

leaving the center tap disconnected.

For the 416−480 voltage configuration, use the

same 1500/750:5 ratio CT, but this time connect

the CT leads to the first and second (center-tap)

connections on the CT, leaving the third tap uncon-

nected.

Current Transformer Setup

After the 1302 series control kit has been installed,

the controller must be programmed to use the CT

by one of the following methods.

1. Enter an appropriate value in the CT ratio pa-

rameter on the operator panel.

2. Select a feature to be downloaded using the

Manufacturing Tool.

3. Program an appropriate value in the Primary

CT Current parameter using a PC-based ser-

vice tool (for example, InPower).

NOTE: To check the actual genset output, True

(calibrated) RMS meter should be

usedThe 1302 series control automatically

doubles the entered CT ratio when switch-

ing from high nominal voltage (above

300V) to lower nominal voltage (below

300V).

When entering a CT ratio the following rules apply:

Two Lead CT, above 300V application − Enter

CT ratio as read from the CT.

Two Lead CT, below 300V applications − Enter

HALF of the CT Ratio as read from the CT.

Three Lead CT (Center Tapped) – Enter the

SMALLER of the two ratios as read from the

CT.

Two Lead CT Setup Example:

For this example, assume a CT with a 1500:5 ratio

is being used.

Operator Panel

Above 300V applications − Enter 1500 into the

CT ratio parameter on the operator panel.

Below 300 V applications − Enter 750 into the

CR ratio parameter on the operator panel.

Manufacturing Tool

Above 300V applications − Select a feature

corresponding to 1500:5 to download using

the Manufacturing Tool.

Below 300 V applications − Select a feature

corresponding to 750:5 to download using the

Manufacturing Tool.

PC-Based Service Tool

Above 300V applications − Enter 1500 into the

Primary CT Current parameter, using the PC-

based service tool (e.g. InPower).

Below 300V applications − Enter 750 into the

Primary CT Current parameter, using the PC-

based service tool (e.g. InPower).

3-5

In PCC1302 Control, Voltage Calibration

procedure is divided into three processes

as described below:

1. Meter Calibration: There are two sets of AC in-

puts on the 1302: L1−N, L2−N, and L3−N (or

L1−2, L2−3, L3−1 for delta) AND 3 phase aver-

age voltage. The metering calibration will cali-

brate L1−N, L2−N, L3−N., which is used for

display and diagnostic purposes. Method:

Verify each phase on PCC matches external

calibrated meter. This calibration should be

done first.

2. Regulation Calibration: This calibrates the 3

phase average voltage, which is used for reg-

ulation. Method: Verify the 3 phase average

voltage of the genset matches an external me-

ter’s voltage. Special note: When changing

the regulation feedback calibration, the PCC’s

feedback will appear to say the same, and the

external meter’s value will change. This is be-

cause the PCC regulator is active, and is mak-

ing what the PCC sees be the PCC’s Setpoint.

3. Voltage Adjust: Once both the metering and

voltage calibration is done, you use the volt-

age adjust to modify the PCC’s voltage Set-

point ( i.e. for example: If the user wants the

PCC to output 215VAC instead of 220VAC)

Procedure of calibrating the Alternator

Voltages is as follows:

Safety Precautions:

1. Contacting high voltage components can

cause electrocution, resulting in severe per-

sonal injury or death. Calibration and adjust-

ment must be performed by technically quali-

fied personnel only. Read and observe all the

Warnings and Cautions in your generator set

manuals.

2. Improper calibration and adjustment of the

PCC can cause equipment malfunction or

damage. Calibration and adjustment must be

performed by technically qualified personnel

only.

One or more of the PCC’s internal circuits may

need to be calibrated, in which case you should cal-

ibrate the internal circuits in the following order

listed in the table shown below:

NOTE: To check the actual genset output, True

(calibrated) RMS meter should be used.

3-6

TABLE 3-1. CALIBRATION

Component to be calibrated Calibration method

PC based service tool Operating panel

Meter Calibration or Voltage mea-

surement for display

1. Connect to the control with your

PC based service tool.

2. Verify the nominal voltage trim is

set to the desired value. The trim Al-

ternator Nominal Voltage is available

at Adjustments −> AC Measurement

Calibrations −> Voltage Measure-

ment for Regulation. Set the Alterna-

tor Nominal Voltage to the voltage

that the genset will generate.

3. With the genset OFF, attach a cali-

brated Voltmeter to the AC Output

from L1 to L2. (L1 to Neutral for

single phase alternators).

4. Start the genset and allow it to

reach normal operating speed.

5. Calibrate voltage reading for L1 by

adjusting the trim Alternator L1−N

50Hz Voltage Display Adjust or Alter-

nator L1−N 60Hz Voltage Display

Adjust trim for your application, so

that the reading on the display

agrees with the calibrated voltmeter.

6. Shut the generator set OFF.

7. Repeat Step 3 to Step 6 for L2

and L3 (In Step 3 attach meter to the

AC output from L2 to L3 to calibrate

L2 and L3 to L1 to calibrate L3) by

adjusting the trims Alternator L2−N

50Hz Voltage Display Adjust or Alter-

nator L2−N 60Hz Voltage Display

Adjust trim and Alternator L3−N

50Hz Voltage Display Adjust or Alter-

nator L3−N 60Hz Voltage Display

Adjust trim respectively.

8. Save the adjustments by doing a

Save Trims with your PC based ser-

vice tool.

1. View the service menu by holding

down the ”up” and ”down” arrow keys

on any of the operating menus.

2. Select item 1, ”Setup Menu”.

3. Enter Setup menu password

”574”.

4. Select item 1, ”Genset Service”.

5. Select item 1, and verify the ”Volts

AC” setting is correct for your ap-

plication. If necessary press the ”Ad-

just” button and change the setting,

and press the ”Save” button.

6. Press the back button to return to

service menu.

7. With the genset OFF, attach a cali-

brated Voltmeter to the AC Output

from L1 to L2. (L1 to Neutral for

single phase alternators).

8. Start the genset and allow it to

reach normal operating speed.

9. Select item 3, ”Meter Calib”.

10. Press the down arrow twice to

scroll down to the ”Metering Voltage

Adjust”

11. Adjust the three parameters one

by one listed so that the reading on

the display agrees with the calibrated

voltmeter.

12. Shut the generator set OFF.

13. Repeat Step 7 to Step 12 for L2

and L3 (In Step 3 attach meter to the

AC output from L2 to L3 to calibrate

L2 and L3 to L1 to calibrate L3) by

adjusting the trims Alternator L2−N

50Hz Voltage Display Adjust or Alter-

nator L2−N 60Hz Voltage Display

Adjust trim and Alternator L3−N

50Hz Voltage Display Adjust or Alter-

nator L3−N 60Hz Voltage Display

Adjust trim respectively.

14. Save the adjustment by pressing

the ”Save” button.

3-7

Regulation Calibration or Voltage

measurement for regulation

1. Connect to the control with your

PC based service tool.

2. Verify the nominal voltage trim is

set to the desired value.

3. With the genset OFF, attach a cali-

brated Voltmeter to the AC Output

from L1 to L2.

4. Start the genset and allow it to

reach normal operating speed.

5. Adjust the trim Voltage Regulation

Calibration 50Hz or Voltage Regula-

tion Calibration 60Hz for your desired

application. The effect of this trim is

Inverse on the regulated voltage. In-

creasing the trim will lower the regu-

lated voltage, and decreasing the

trim will raise the regulated voltage.

The monitored Regulated Voltage

will match with the reading on the at-

tached external calibrated meter and

the Regulated Feedback Voltage (Al-

ternator Voltage) matches the de-

sired Nominal voltage.

6. Shut the generator set OFF.

7. Save the adjustments by doing a

Save Trims with your PC based ser-

vice tool.

1. View the service menu by holding

down the ”up” and ”down” arrow keys

on any of the operating menus.

2. Select item 1, ”Setup Menu”.

3. Enter Setup menu password

”574”.

4. Select item 1, ”Genset Service”.

5. Select item 1, and verify the ”Volts

AC” setting is correct for your ap-

plication. If necessary press the ”Ad-

just” button and change the setting,

and press the ”Save” button.

6. Press the back button to return to

service menu.

7. Start the genset and allow it to

reach normal operating speed.

8. Select item 3, ”Meter Calib”.

9. Press the ”Adjust” button and

change the ”Reg Volt Adj” value. The

effect of this trim is Inverse on the

regulated voltage. Increasing the trim

will decrease the regulated voltage.

Decreasing the trim will increase the

regulated voltage.

10. Save the adjustment by pressing

the ”Save” button.

Voltage Setpoint Adjustment 1. Connect to the control with your

PC based service tool.

2. Verify the nominal voltage trim is

set to the desired value.

3. With the genset OFF, attach a cali-

brated Voltmeter to the AC Output

from L1 to L2.

4. Start the genset and allow it to

reach normal operating speed.

5. Adjust the trim Voltage Adjust

which shall move the voltage Set-

point either in positive direction or in

negative direction as per your re-

quirement.

Not Applicable.

NOTE:

1. Meter Calibration is what all the diagnostics use and the display shows, while Regulator Calibration it the

feedback going to the AVR. Thus Meter Calibration and the Regulator calibration shall be done when the

PCC1302 control is initially calibrated or if the boards are swapped / replaced with the new ones.

2.Voltage Setpoint adjustment shall be carried out as and when required to move the voltage Setpoint.

3-8

Three Lead CT Setup Example

For this example, assume that a CT with a

1500/750:5 ratio is being used.

Operator Panel

Enter 750 into the CT Ratio parameter on the

Operator Panel.

Manufacturing Tool

Select a feature corresponding to 750:5 to

download using the Manufacturing Tool.

PC-Based Service Tool

Enter 750 into the Primary CT Current param-

eter using a PC based service tool (e.g. In-

Power).

BATTERY CHARGING ALTERNATOR

CONNECTIONS

The 1302 series control currently supports the fol-

lowing charging alternator types.

Denso Type Charging Alternators

A Denso charging alternator with IG and L (failure

lamp) connection points is shown in Figure 3-2.

This configuration is used to produce a start dis-

connect signal and to indicate a failed battery

charging alternator.

Bosch Type Charging Alternators

A Bosch charging alternator with D+ (flash input)

connection point is shown in Figure 3-3. This con-

figuration is used to produce a start disconnect sig-

nal and to indicate a failed charging alternator.

Battery Charging

Alternator Input

Denso Type

Charging Alternator

L

IG

RUN

1302 Series Control

B+

J20−22

J20−11

FIGURE 3-2. DENSO CHARGING ALTERNATOR WIRING DIAGRAM

Bosch Type

Charging Alternator

D+

RUN

1302 Series Control

B+

J20−22

J20−11

Battery Charging

Alternator Input

Approx, 5 Ohm

input impedance

FIGURE 3-3. BOSCH CHARGING ALTERNATOR WIRING DIAGRAM

3-9

ALTERNATOR CONNECTIONS

A fast acting UL certified ceramic fuse with a rating

of ten amperes shall be placed inline with the Ex-

citation Inputs J18-1 and J18-2.

Series Star

Series star connection yields an output voltage of

220−277/380−480 volts. Figure 3-4 shows the cor-

rect series−star alternator connections.

CT3

CT1 CT2

J12-1 J12-4 J12-2 J12-5

V2: J22-2

VN: J22-4

V3: J22-3

V5 (T8)

W6 (T12)

W5 (T9)

W2 (T6)

W1 (T3)

V2 (T5)

V1 (T2)

V6 (T11)

U1 (T1)

U2 (T4)

U5 (T7)

U6 (T10)

J12-3 J12-6

V1: J22-1

FIGURE 3-4. SERIES STAR CONNECTIONS

Series Delta

Series delta provides for an output voltage of

110−120/220−240 volts. Figure 3-5 shows the cor-

rect series delta connections.

NOTE: To check the actual genset output, True

(calibrated) RMS meter should be

usedSense N must not be connected in

three phase delta connections.

Parallel Star

Parallel star alternator configuration yields an out-

put voltage of 110−139/190−240 volts. Figure 3-6

illustrates the correct parallel star connections.

CT3

CT1

CT2

VN: J22-4

V2: J22-2

V3: J22-3

V1: J22-1

J12-1 J12-4

J12-2 J12-5

J12-3 J12-6

W6 (T12)

W5 (T9)

W2 (T6)

W1 (T3)

U6 (T10)

V5 (T8)

V2 (T5)

V1 (T2)

V6 (T11)

U1 (T1)

U2 (T4)

U5 (T7)

FIGURE 3-5. SERIES DELTA CONNECTIONS

CT3

CT1

CT2

J12-2 J12-5

J12-3 J12-6

J12-1 J12-4

V1: J22-1

V2: J22-2

V3: J22-3

U6 (T10)

V1 (T2)

VN: J22-4

V5 (T8)

V2 (T5)

W1 (T3)

V6 (T11)

U2 (T4)

U5 (T7)

W5 (T9)

W2 (T6)W6 (T12)

U1 (T1)

FIGURE 3-6. PARALLEL STAR CONNECTIONS

3-10

Double Delta

The double delta alternator configuration yields an

output voltage of 110−120/220−240 volts. Correct

double delta connections are illustrate in Figure

3-7.

CT1

CT2

VN: J22-4

V2: J22-2

V1: J22-1

J12-1 J12-4

J12-2 J12-5

V1 (T2)

W6 (T12)

W5 (T9)

W1 (T3)

V2 (T5)

U2 (T4)

U5 (T7)

U6 (T10)

V6 (T11) U1 (T1)

V5 (T8)

W2 (T6)

FIGURE 3-7. DOUBLE DELTA CONNECTIONS

Single Phase

Single phase provides for an output voltage of

110−120/220−240 volts. Single phase alternator

connections are shown in Figure 3-8.

CT2

J12-2 J12-5

CT1

J12-1 J12-4

VN: J22-4

V2: J22-2

V1: J22-1

U2 (T4)

U1 (T1)

U5 (T7)

U6 (T10)

FIGURE 3-8. SINGLE PHASE CONNECTIONS

3-11

GUIDELINES FOR ENGINE SENSORS

The engine sensors included in this kit are:

Coolant Temperature Sensor 193−0529−01

Oil Pressure Sensor 193−0444

This section provides information on these plus

additional engine sensors that can be used with

1302 series controllers.

Coolant Temperature Sensors

The coolant temperature sensors that are avail-

able from Cummins Power Generation (CPG) are

listed in Table 3-1.

The coolant temperature sensor connectors that

are available from CPG are listed in Table 3-2.

Oil Pressure Sensors

The 1302 series control can be programmed for ei-

ther oil pressure sensors or switches. The trim pa-

rameter for this is: Lube Oil Pressure Sensor Type

= Sensor, Switch. If the type is set to Sensor, the

control can also be programmed for either 3-wire or

2-wire sensors. The trim parameter for this is Oil

Pressure Sender Type = 3-wire, 2-wire. Available

switch and sensors are listed in Table 3-3.

For information on setting the oil pressure sender

type using the display panel, see page 5-43.

FIGURE 3-9. THREE-WIRE PRESSURE SENSOR

CONNECTIONS

FIGURE 3-10. TWO-WIRE PRESSURE SENSOR

CONNECTIONS

TABLE 3-1. COOLANT TEMPERATURE SENSORS

CPG P/N Manufacturer / P/N Resistive Temp Range Threading

0193−0529−01 AirPax / 5024−0250 −40 to +230 F 3/8 “NPTF

0193−0529−02 AirPax / 5024−0274 −40 to +230 F M14 X 1.5 with “O” Ring

TABLE 3-2. TEMPERATURE SENSOR CONNECTORS

CPG P/N Manufacturer Manufacturer P/N Comments

0323−1755 Packard 121621893 Plastic shell with seal

0323−1818 Delphi 12124075 Socket Connector

3-12

TABLE 3-3. OIL PRESSURE SENSORS AND SWITCH

CPG P/N Manufacturer /

P/N Sensor Type Range /

Unit

Resistance /

Voltage Comments

193−0430−02 F.W. Murphy

ED2P-100

2-Wire Standard

Resistive Sender

0−100 PSIG 240−33

Ohms

Includes 10-32 hex nut

connectors, 1/8” NPTF dry

sealing threading, and a

diaphragm operated resis-

tive sensing element

193−0444 Kavlico

P165−5110

3-Wire Active

Sender

(Capacitive)

0−100 PSIG 0−5 VDC Mating Connector

326−1666 (Packard

12065287) includes

323−1667 socket termi-

nals (Packard 12103881)

309−0641−XX Stewart Warner Pressure Switch (See the following page)

A028X493 Kavlico

P4055−5001−1

3-Wire Active

Sender

(Capacitive)

0−100 PSIG 0−5 VDC Mating Connector

326−1666 (Packard

12065287) includes

323−1667 socket termi-

nals (Packard 12103881)

Lube Oil Pressure Switch

The part number for the Lube Oil Pressure Switch

is 309−0641−XX. The XX portion of the number is

dependent the trip pressure point. Refer to Table

3-4 to select an appropriate lube oil pressure

switch.

If an oil pressure switch is used, the active state

(active high or active low) of the switch must be

configured using a PC based service tool or

through the menus available with the operator pan-

el. A software setting allows for selection of the ac-

tive state of the switch. The Lube Oil Pressure

Switch Polarity can be set to Active High or Active

Low.

For information on setting the oil pressure switch

polarity using the display panel, see page 5-43.

FIGURE 3-11. PRESSURE SWITCH

TABLE 3-4. AVAILABLE PRESSURE SWITCHES (309−0641)

Part No. Set Point Contact (At Rest) No. of Terminals

309−0641−01 14 2.0 PSI Closed 1

309−0641−02 14 2.0 PSI Open 2

309−0641−03 14 2.0 PSI Closed 2

309−0641−04 9 1.5 PSI Open 2

309−0641−05 9 1.5 PSI Closed 1

309−0641−06 10 1.5 PSI Open 2

309−0641−07 20 2.0 PSI Closed 1

309−0641−08 20 2.0 PSI Closed 2

309−0641−10 20 3.0 PSI Closed 2

3-13

309−0641−13 30 3.0 PSI Closed 1

309−0641−14 4 1.0 PSI Open 2

309−0641−15 5 1.0 PSI Open/Closed 3

309−0641−16 5 1.0 PSI Closed 1

309−0641−17 5 1.0 PSI Open 1

309−0641−18 5 1.0 PSI Open 2

309−0641−19 14 2.0 PSI Closed 2

309−0641−20 20 2.0 PSI Closed 1

All pressure switches have steel base and nipple construction.

3-14

CONTROL BOARD CONNECTIONS

The 1302 control board includes the following

connectors (see Figure 3-12).

CAUTION Reversing the power supply con-

nections on TB1 and/or TB15 can permanently

damage the control. Refer to drawing 630−3270

for proper connections.

TB1 − Customer connections (see Table 3-5

and sheet 3 of Figure 7-1)

TB15 − Tools interface connections (see Table

3-6 and sheet 3 of Figure 7-1)

J11 − Engine connections (see Table 3-7)

J12 − Genset CT connections (see Table 3-8)

J17 − Field winding connections (see Table

3-9)

J18 − Field power connections (see Table

3-10)

J20 − Genset connections (see Table 3-11)

J22 − Alternator voltage sense connections

(see Table 3-12)

J25 − Display connections (see Table 3-13)

Mating connector and connector pin part numbers

for the control board are listed in Table 3-14.

J25 (DISPLAY

CONNECTIONS)

TB1 (CUSTOMER

CONNECTIONS)

J12 (CT

CONNECTIONS)

J11 (ENGINE

CONNECTIONS)

J18 (FIELD

POWER)

J20 (GENSET

CONNECTIONS)

TB15 (PC BASED

SERVICE TOOL)

J17 (FIELD

POWER)

J22 (ALTERNATOR

VOLTAGE SENSE)

FIGURE 3-12. CONTROL BOARD CONNECTIONS

3-15

TABLE 3-5. TB1 − CUSTOMER CONNECTIONS

Pin Signal Name Connect To

TB1-1 PCCNet A Network Data A

TB1-2 PCCNet B Network Data B

TB1-3 PCCNet Shield / B+ Return

TB1-4 Ready to Load 20ma Low Side Relay Driver

TB1-5 B+ Output (5A)

TB1-6 Configurable Relay 1 − A

TB1-7 Configurable Relay 1 − B

TB1-8 Configurable Relay 2 − A

TB1-9 Configurable Relay 2 − B

TB1-10 Remote Start Return

TB1-11 Remote Start

TB1-12 Configurable Input 1 Pull to TB1-13 to activate input. Remove from TB1-13 to

deactivate input.

TB1-13 Configurable Input − Common Common for the two fault inputs

TB1-14 Configurable Input 2 Pull to TB1-13 to activate input. Remove from TB1-13 to

deactivate input.

TB1-15 Remote E-STOP Return Remote normally closed E-STOP switch

TB1-16 Remote E-STOP Remote normally closed E-STOP switch

TABLE 3-6. TB15 − TOOLS INTERFACE CONNECTIONS

Connector

Pin

Signal Name Connect To

TB15-1 Return Network Power Supply Return

TB15-2

TB15-3 RS-485 Data A Network Data A

TB15-4 RS-495 Data B Network Data B

TB15-5 PCCNet System Wakeup

3-16

TABLE 3-7. J11 − ENGINE CONNECTIONS

Connector Pin Signal Name Connect To

J11-1 Oil Pressure Sender (Active) +5V

J11-2 Oil Pressure Sender or Switch Re-

turn

J11-3 Oil Pressure Sender

J11-4 Governor Drive −Governor PWM low side driver

J11-5 Governor Drive + Governor drive + (for low side driver)

J11-6 Relay Coil B+ Coil for glow plug relay

J11-7 Glow Plug / Ignition Control Relay

Driver

Low side of the relay coil

J11-8 Magnetic Pickup Shield

J11-9 Magnetic Pickup Supply

J11-10 Magnetic Pickup Return

J11-11 Coolant Temperature Sender

J11-12 Coolant Temperature Sender Re-

turn

J11-13 NA

J11-14 NA

J11-15 NA

J11-16 NA

J11-17 ECM CAN Shield

J11-18 B+ Return for ECM

J11-19 ECM CAN Low

J11-20 ECM CAN High

J11-21 Keyswitch Low Side Driver Low side of keyswitch relay coil

J11-22 Keyswitch Relay Coil B+ High side of keyswitch relay coil

J11-23 NA

J11-24 NA

TABLE 3-8. J12 − GENSET CT CONNECTIONS

Connector Pin Signal Name Connect To

J12-1 CT1

J12-2 CT2

J12-3 CT3

J12-4 CT1 Common

J12-5 CT2 Common

J12-6 CT3 Common

3-17

TABLE 3-9. J17 − FIELD WINDING CONNECTIONS

Connector Pin Signal Name Connect To

J17-1 Field + X+ (F1)

J17-2 Field −XX− (F2)

TABLE 3-10. J18 − FIELD POWER CONNECTIONS

Connector Pin Signal Name Connect To

J18-1 PMG 1 / Shunt L1 240 Vmax Excitation Source

J18-2 PMG 2 / Shunt L2 240 Vmax Excitation Source

J18-3 NC

TABLE 3-11. J20 − GENSET CONNECTIONS

Connector Pin Signal Name Connect To

J20-1 Chassis ground

J20-2 B+ Return

J20-3 Switched B+ Low Side Driver

J20-4 B+ Return

J20-5 Discrete Input Return

J20-6 Discrete Input Return

J20-7 B+ Return

J20-8 Discrete Input Return

J20-9 B+ Input

J20-10 B+ Input

J20-11 Starter Disconnect Input Charging alternator

J20-12 B+ Return

J20-13 Relay Coil B+ Supply Switched B+ (Switched B+ might be connected to

E−Stop B+ instead)

J20-14 FSO Relay Driver Low Side of FSO Relay Coil

J20-15 Starter Relay Driver Low Side of Starter Relay Coil

J20-16 NA

J20-17 Configurable Input #3 Defaulted to Low Coolant Level Switch

J20-18 Configurable Input #4 Defaulted to Low Fuel Level Switch

J20-19 NA

J20-20 B+ Input

J20-21 B+ Input

J20-22 Alt Flash Input

TABLE 3-12. J22 − GENSET VOLTAGE SENSING CONNECTIONS

Connector Pin Signal Name Connect To

J22-1 L1 600 Vmax L1 Source

J22-2 L2 600 Vmax L2 Source

J22-3 L3 600 Vmax L3 Source

J22-4 LN 600 Vmax LN Source

3-18

TABLE 3-13. J25 − DISPLAY CONNECTIONS

Connector Pin Signal Name Connect To

J25-1 Local Status Low side of local status lamp

J25-2 Local E-Stop Normally closed local E-Stop switch

J25-3 PCCNet B Network Data B

J25-4 PCCNet A Network Data A

J25-5 System wakeup

J25-6 Discrete Input Return

J25-7 Discrete Input Return

J25-8 B+ Return

J25-9 B+ Return / PCCNet

J25-10 Manual

J25-11 Auto

J25-12 B+

TABLE 3-14. CONNECTOR PART NUMBERS

Connector Housing Connector Pins

onnector CPG P/N Man/Man P/N CPG P/N Man/Man P/N

J11 323−2161 Amp/Tyco / 790587−1 323−2466 Amp/Tyco / 770904−1/

770988−1/171637−1

J12 323−1932 Amp/Tyco / 1−480704−0 323−1200 Amp/Tyco / 350536−1/350550−1

J17 323−2098 Amp/Tyco / 1−480698−0 323−1200 Amp/Tyco / 350536−1/350550−1

J18 323−2444 Amp/Tyco / 1−480700−0 323−1200 Amp/Tyco / 350536−1/350550−1

J25 323−2445 Amp/Tyco / 770581−1 323−2466 Amp/Tyco / 770904−1/

770988−1/171637−1

J22 323−2226−03 Amp/Tyco / 282809−4

J20 323−2466 Amp/Tyco / 770586−1 323−2466 Amp/Tyco / 770904−1/

770988−1/171637−1

3-19

ELECTRONIC GOVERNOR

CONNECTIONS

This section describes the installation of the option-

al Electronic Governor Power Module.

A description of the Governor Power Module con-

nections are listed in Table 3-15. Module connector

pat numbers are listed in Table 3-16.

The electronic fuel actuator is driven by the output

of the Governor Power Module. Use twisted pair

wires minimum 1 sq mm (16 Gage). Power to the

Governor Power Module is derived from the genset

starting battery but should be connected to the

Governor Power Module as indicated in the dia-

grams “Applications without FSO” (see Figure

3-13) and “Applications with FSO” (see Figure

3-14) as appropriate.

TABLE 3-15. GOVERNOR MODULE CONNECTIONS

Connector Pin Signal Name Comments

P1-1 Gov drive −

P1-2 Gov drive +

P1-3 B+ Battery +

P1-4 Actuator Low side of actuator

P1-5 Return GND

TABLE 3-16. CONNECTOR PART NUMBERS FOR THE GOVERNOR MODULE CONNECTIONS

Connector Housing Connector Pins

Ref Internal P/N Man / P/N Internal P/N Man / P/N

P1 0323−2216 Amp/Tyco /

1−480763−0

0323−1200 Amp/Tyco /

770008−3

1302 Series

Control

FSO

PWM

Fuel

Actuator

B+

GND

Governor

Power Stage

Relay

J20−14

J11−5

J11−4

Fuse

E−Stop B+

FIGURE 3-13. ELECTRONIC GOVERNOR CONNECTIONS FOR APPLICATIONS WITHOUT FSO

3-20

1302 Series

Control

FSO

PWM

B+

GND

Governor

Power Stage

Relay

J20−14

J11−5

J11−4

E−Stop B+

FSO

FIGURE 3-14. ELECTRONIC GOVERNOR CONNECTIONS FOR APPLICATIONS WITH FSO

KIT INSTALLATION

Refer to the control wiring diagram included in

Section 7 when installing the items included in this

kit. This wiring diagram also includes information

on wiring items (annunciator, I/O module, and gov-

ernor power module) not included in this kit.

While the harnesses included in this kit should be

long enough for all types of installations, it is a good

idea to make sure that the distance between two

connecting parts does not exceed the length of the

harness. Excess wiring may be trimmed if it inter-

feres with your installation.

NOTE: To check the actual genset output, True

(calibrated) RMS meter should be

usedMounting hardware for the 1302 con-

trol and the operator panel is not included

in this kit. The instructions below include

suggested hardware sizes.

1. Make sure the generator set is shut down and

disabled:

a. The generator set Run/Off/Auto switch is

in the Off position and the generator is

cool (to the touch).

b. The battery charger (if equipped) is

turned off and disconnected.

c. The negative (−) cable from the battery is

disconnected to prevent accidental start-

ing.

2. Select a suitable location (see “Mounting

Guidelines” on page 3-1) and mount the

1302 control board using M4 hardware. Figure

3-15 shows the control board dimensions. The

outside dimensions do not include necessary

clearance for wire connections.

DIMENSIONS ARE IN MILLIMETERS

FIGURE 3-15. 1302 CONTROL FOOTPRINT

3-21

3. Install the operator panel and operator panel

harness.

a. Select a suitable location and mount the

panel using #6−32 hardware. Figure 3-16

shows the operator panel dimensions.

The operator panel must be mounted

within 72 inches (1828.8 mm) of the con-

trol board.

b. Install the operator panel harness (see

Figure 3-17). Plug the P1 connector into

the display (either J1 or J2) and plug the

P25 connector into the J25 connector on

the control board.

DIMENSIONS ARE IN MILLIMETERS

FIGURE 3-16. OPERATOR PANEL FOOTPRINT

DIMENSIONS ARE IN FEET

FIGURE 3-17. OPERATOR PANEL HARNESS

3-22

4. Install the genset harness (see Figure 3-18).

a. Make sure the current transformers in-

stalled are appropriate for use with a 1302

series control. Refer to the “Guidelines for

Current Transformers” subsection, start-

ing on page 3-3.

b. Make sure the battery charging alternator

installed is one of the types listed in the

“Battery Charger Alternator Connec-

tions” subsection, starting on page 3-8.

c. Make sure the alternator connections are

appropriate for your installation (see “Al-

ternator Connections” on page 3-9).

d. Connect the six harness CT wires to the

current transformers.

e. Connect the four harness sense wires to

the alternator.

f. Connect the harness X+ and XX− wires to

the generator field windings.

g. Make the connections for the excitiation

source (shunt or PMG). For shunt ap-

plications, connect J18-1 and J18-2 to the

low side of L1 and L2. For PMG applica-

tions, connect J18-1, J18-2, and 18-3 to

P2, P3, and P4 on the permanent magnet.

J18-1 and J18-2 are 240V maximum in-

puts.

CAUTION Do not connect J18-1 di-

rectly to L1 in 480V applications. Mak-

ing this connection will blow up the

1302 control board.

h. Connect the harness P12, P17, P18, and

P22 connectors to the mating connectors

on the 1302 control board.

DIMENSIONS ARE IN INCHES

FIGURE 3-18. GENSET HARNESS

3-23

5. Install the engine harness.

a. Connect the engine harness wires

marked P11-2 and P11-3 to the oil pres-

sure harness wires marked J11-5, J11-6,

and J11-17 (see Figure 3-20).

b. Connect the engine harness wires

marked P11-11 and P11-12 to the coolant

temperature sensor harness wires

marked P11-11 and P11-12 (see Figure

3-21).

c. If installed, connect the engine harness

wires marked P11-8, P11-9, and P11-10

to the magnetic pickup sensor on the en-

gine. If not installed, tie the wires back.

d. Connect the remaining engine harness

wires to the appropriate locations indi-

cated in Figure 3-19.

NOTE: If your installation does not in-

clude an electronic governor, tie

back the wires marked P11-4 and

P11-5.

e. Connect the engine harness P11 and P20

connectors to the 1302 control board J11

and J20 connectors.

6. Install the oil pressure sensor and harness.

a. Install the sensor on the engine.

b. Connect the harness connector to the oil

pressure sensor.

FIGURE 3-19. ENGINE HARNESS

3-24

DIMENSIONS ARE IN FEET

FIGURE 3-20. OIL PRESSURE SENSOR HARNESS

DIMENSIONS ARE IN FEET

FIGURE 3-21. COOLANT TEMPERATURE SENSOR HARNESS

FIGURE 3-22. OIL PRESSURE SENSOR

7. Install the coolant temperature sensor and

harness.

a. Install the sensor on the radiator.

b. Connect the harness connector to the

temperature sensor.

8. Reconnect the generator starting battery

cables (positive [+] cable first).

9. Connect the battery charger (If equipped).

10. Press any button on the operator panel to

“wake up” the control.

FIGURE 3-23. COOLANT TEMPERATURE SENSOR

11. Use the operator panel to access the Service

menus (see Section 5) and/or a PC service

tool to adjust the appropriate control parame-

ters.

a. For general information on all available

parameters that can be adjusted, see

“Setup, Trims, and Adjustments” on page

3-26.

3-25

b. Follow the setup procedures for current

transformers listed on page 3-4.

c. For information on alternator control ad-

justments, see page 3-36.

d. For information on genset tuning, see

page 3-36.

e. For information on other control functions,

see page 3-46. These include:

−Remote start mode

−Remote emergency stop

−12V/24V batteries

−Engine starting

−Cycle cranking

−Spark ignition power/Glow plug

control

−Genset cooldown start and stop

time delays

f. For information on the Battle Short option,

see page 3-55.

12. Place the generator set Run/Off/Auto switch in

the desired position.

3-26

SETUP, TRIMS, AND ADJUSTMENTS

While applying a 1302 series control to a new ap-

plication, make sure the parameters listed in Table

3-17 have appropriate values. Many of these can

be adjusted using the operator panel but some re-

quire use of a genset Manufacturing Tool or a PC

based service tool.

NOTE: To check the actual genset output, True

(calibrated) RMS meter should be

usedSection 5 includes information on all

of the Service menus that are used to ad-

just parameters using the 1302 operator

panel. The last column in Table 3-17 lists

the page references in Section 5 where you

can find information on how to adjust each

parameter.

Configurable / Model Specific features like nominal

voltage, frequency, KVA rating, Engine protection

values Alternator Protection values, AVR and Gov-

ernor Gains, CT Ratio, etc have to be assigned ap-

propriate values at manufacturing time.

TABLE 3-17. 1302 CONTROL PARAMETERS

Adjusted Using Limits

Group Parameter Name PC Based

Service Tool

Operator

Panel Lower Limit Upper

Limit

Units

g

Ref

Adjust- Voltage Adjust X−5 5 % —

ment Start Time Delay (V2.79

and prior with HMI211 7.10

or prior)

X X 0 300 Sec 5-8

Start Time Delay (V2.80

and later with HMI211 7.20

or later)

X X 0 3600 Sec 5−8

Adjust- Stop Time Delay X X 0 600 Sec 5-8

ment V/Hz Knee Frequency X X 0 10 Hz 5-17

V/Hz Rolloff Slope X X 0 5 % 5-17

3-27

TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.)

Group Pg

Ref

Units

LimitsAdjusted Using

Parameter Name

Group Pg

Ref

Units

Upper

Limit

Lower Limit

Operator

Panel

PC Based

Service Tool

Parameter Name

Setup –

Nominal Battery Voltage X X 12 24 VDC 5-41

Genset AVR Enable X X Enable or

Disable

NA NA 5-11

Excitation Source X X Shunt or PMG 5-39

Excitation / Line Frequency

Gain

X X 1,2,4 5-39

Nominal Voltage X X 190 480 V AC 5-8

Alternator Nominal

Frequency

X X 50 or 60 N/A Hz 5-8

Single Phase 60Hz Standby

kVA Rating

X X 0 2000 KVA 5-39

Three Phase 60Hz Standby

kVA Rating

X X 0 2000 KVA 5-39

Single Phase 50Hz Standby

kVA Rating

X X 0 2000 KVA 5-39

Three Phase 50Hz Standby

kVA Rating

X X 0 2000 KVA 5-39

Single Phase 60Hz Prime

kVA Rating

X X 0 2000 KVA 5-41

Three Phase 60Hz Prime

kVA Rating

X X 0 2000 KVA 5-41

Single Phase 50Hz Prime

kVA Rating

X X 0 2000 KVA 5-41

Three Phase 50Hz Prime

kVA Rating

X X 0 2000 KVA 5-41

Frequency to Speed Gain

Select

X X 20, 30, or 60 N/A RPM/Hz 5-39

Oil Pressure Switch Polarity X Active Low or

Active High

N/A N/A 5-43

3-28

TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.)

Group Pg

Ref

Units

LimitsAdjusted Using

Parameter Name

Group Pg

Ref

Units

Upper

Limit

Lower Limit

Operator

Panel

PC Based

Service Tool

Parameter Name

Setup –

Oil Pressure Sensor Type X X 2 or 3 wire N/A N/A 5-43

Genset

(Contin-

Electronic Governor Enable XEnable or

Disable

NA NA —

ue

XYes or No N/A N/A 5-11

Glow Plug Enable XEnable or

Disable

N/A N/A —

XYes or No N/A N/A 5-8

Fuel System X X Diesel or Gas N/A N/A 5-8

Fuel Burn Time Delay X X 0 10 Sec 5-8

Magnetic Pickup Enable XEnable or

Disable

None N/A —

XYes or No None N/A 5-13

Flywheel Teeth X X 0 255 Teeth 5-39

Dither Factor X X 0 30 % 5-19

Maximum Governor Duty

Cycle

X X 0 100 % 5-19

AVR Gain Adjust X X 5 1000 % 5-17

AVR K2 Gain Adjust X X 5 1000 % 5-17

AVR D Gain Adjust X X 95 105 % 5-17

K1 (Regulator Gain 50Hz) X 0 65535 NA —

K1 (Regulator Gain 60Hz) X 0 65535 NA —

K2 (Regulator Integral

50Hz)

X 0 65535 NA —

K2 (Regulator Integral

60Hz)

X 0 65535 NA —

K3 (Regulator K3 Gain

50Hz)

X 0 65535 NA —

K3 (Regulator K3 Gain

60Hz)

X 0 65535 NA —

Damping Effect (60Hz) X 0.2 0.99 NA —

Damping Effect (50Hz) X 0.2 0.99 NA —

Cycle Crank Attempts X X 1 7 Attempts 5-11

Cycle Crank Engage Time X X 3 30 Sec 5-11

Cycle Crank Rest Time X X 0 60 Sec 5-11

Remote / Local Display N/A X Remote or

Local

N/A N/A 5-15

Battle Short Enable XEnable or

Disable

NA NA 5-11

Battle Short Switch Input X X Configurable

input 1−4 or

operator panel

N/A N/A 5-11

Governor Ramp Time X X 0 30 Sec 5-19

3-29

TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.)

Group Pg

Ref

Units

LimitsAdjusted Using

Parameter Name

Group Pg

Ref

Units

Upper

Limit

Lower Limit

Operator

Panel

PC Based

Service Tool

Parameter Name

Setup –

ECM CAN

ECM CAN Enabled XDisable, J1939,

PGI

—

Keyswitch Reset Delay X 1 10 Sec —

Keyswitch On Time Delay X 1 10 Sec —

CAN Datalink Failure

Retries

X 0 10 Times —

ECM Datasave Time X 30 60 Sec —

Setup −

Configur-

Configurable Input #1−4

Function

X X Active open or

Active closed

N/A 5-21

able I/O

Configurable I/P #1

AnnActive LED

X NO_ANNUN_M

APPING,

CUSTOMER_F

AULT_1,

CUSTOMER_F

AULT_2,

CUSTOMER_F

AULT_3,

GEN_SUPPLY

_LOAD,

CHARGER_AC

_FAIL,

LOW_COOLAN

T_LEVEL,

LOW_FUEL_L

EVEL

N/A 5-21

Configurable I/P #2

AnnActive LED

X NO_ANNUN_M

APPING,

CUSTOMER_F

AULT_1,

CUSTOMER_F

AULT_2,

CUSTOMER_F

AULT_3,

GEN_SUPPLY

_LOAD,

CHARGER_AC

_FAIL,

LOW_COOLAN

T_LEVEL,

LOW_FUEL_L

EVEL

N/A 5-21

3-30

TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.)

Group Pg

Ref

Units

LimitsAdjusted Using

Parameter Name

Group Pg

Ref

Units

Upper

Limit

Lower Limit

Operator

Panel

PC Based

Service Tool

Parameter Name

Configurable I/P #3

AnnActive LED

X NO_ANNUN_M

APPING,

CUSTOMER_F

AULT_1,

CUSTOMER_F

AULT_2,

CUSTOMER_F

AULT_3,

GEN_SUPPLY

_LOAD,

CHARGER_AC

_FAIL,

LOW_COOLAN

T_LEVEL,

LOW_FUEL_L

EVEL

N/A 5-21

Configurable I/P #4

AnnActive LED

X NO_ANNUN_M

APPING,

CUSTOMER_F

AULT_1,

CUSTOMER_F

AULT_2,

CUSTOMER_F

AULT_3,

GEN_SUPPLY

_LOAD,

CHARGER_AC

_FAIL,

LOW_COOLAN

T_LEVEL,

LOW_FUEL_L

EVEL

N/A 5-21

3-31

TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.)

Group Pg

Ref

Units

LimitsAdjusted Using

Parameter Name

Group Pg

Ref

Units

Upper

Limit

Lower Limit

Operator

Panel

PC Based

Service Tool

Parameter Name

Setup −

Configur-

Configurable Fault Input

#1−4 Active State Select

X X Active open or

Active closed

N/A 5-21

able I/O

Configurable Fault Input

#1−4 Fault Level Response

X X Warning,

Shutdown, or

None

5-21

Configurable #1−4 Input

Text Line 1

X X 5-21

Configurable #1−4 Input

Text Line 2

X X 5-21

Customer Output 1/2 Event X X 0 9999 Fault

Code

Numbers

5-25

Regulated

Voltage

Voltage Regulator

Calibration 50Hz

X X 0.9 1.1 % 5-27

Adjust Voltage Regulator

Calibration 60Hz

X X 0.9 1.1 % 5-27

Alternator L1−N 50Hz

Voltage Display Adjust

X X 0.8 1.1 % 5-27

Alternator L2−N 50Hz

Voltage Display Adjust

X X 0.8 1.1 % 5-27

Alternator L2−N 50Hz

Voltage Display Adjust

X X 0.8 1.1 % 5-27

Alternator L1−N 60Hz

Voltage Display Adjust

X X 0.8 1.1 % 5-27

Alternator L2−N 60Hz

Voltage Display Adjust

X X 0.8 1.1 % 5-27

Alternator L2−N 60Hz

Voltage Display Adjust

X X 0.8 1.1 % 5-27

Alternator L1 50Hz Current

Adjust

X X 0.8 1.2 % 5-27

Alternator L2 50Hz Current

Adjust

X X 0.8 1.2 % 5-27

Alternator L2 50Hz Current

Adjust

X X 0.8 1.2 % 5-27

3-32

TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.)

Group Pg

Ref

Units

LimitsAdjusted Using

Parameter Name

Group Pg

Ref

Units

Upper

Limit

Lower Limit

Operator

Panel

PC Based

Service Tool

Parameter Name

Regulated

Voltage

Alternator L1 60Hz Current

Adjust

X X 0.8 1.2 % 5-27

Adjust

(Contin-

Alternator L2 60Hz Current

Adjust

X X 0.8 1.2 % 5-27

u

Alternator L2 60Hz Current

Adjust

X X 0.8 1.2 % 5-27

High AC Voltage Threshold X X 105 125 % 5-45

High AC Voltage Delay X X 1 10 Sec 5-45

Low AC Voltage Threshold X X 50 95 % 5-45

Low AC Voltage Delay XX 2 20 Sec 5-45

Under Frequency Threshold X X 2 10 Hz 5-45

Under Frequency Delay X X 500 2000 1/2

cycles

5-45

Overfrequency Enable XEnable or

Disable

N/A NA —

Overfrequency Threshold X X 2 10 Hz 5-45

Overfrequency Delay X X 100 2000 1/2

cycles

5-45

High AC Current Shutdown

Delay

X X 2 60 Sec 5-45

Protection

– Engine

Overspeed Shutdown

Threshold 50Hz

X X 0 8192 Rpm 5-49

Overspeed Shutdown

Threshold 60Hz

X X 0 8192 Rpm 5-49

LOP Shutdown Threshold X X 0 100 Psig 5-51

LOP Shutdown Delay X X 2 15 Sec 5-51

LOP Warning Threshold X X 0 100 Psig 5-49

LOP Warning Delay X X 2 15 Sec 5-49

LCT Warning Threshold X X 32 100 deg f 5-53

HCT Shutdown Threshold X X 180 300 deg f 5-51

HCT Shutdown Delay X X 2 10 Sec 5-51

HCT Warning Threshold X X 150 290 deg f 5-51

HCT Warning Delay X X 2 10 sec 5-51

12V Low Battery Threshold X X 11 13 VDC 5-41

24V Low Battery Threshold X X 22 27 VDC 5-41

Low Battery Fault Delay X X 2 60 Sec 5-43

High Battery Fault Delay X X 14 17 VDC 5-41

24V High Battery Threshold X X 28 34 VDC 5-41

12V High Battery Threshold X X 2 60 Sec 5-43

12V Weak Battery

Threshold

X X 6 10 VDC 5-41

3-33

TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.)

Group Pg

Ref

Units

LimitsAdjusted Using

Parameter Name

Group Pg

Ref

Units

Upper

Limit

Lower Limit

Operator

Panel

PC Based

Service Tool

Parameter Name

Protection

– Engine

24V Weak Battery

Threshold

X X 18 21 VDC 5-41

on

n-

ued) Weak Battery Fault Delay X X 1 5 sec 5-43

Fault

Reset Runs X —

History Reset Start Attempts X —

NFPA 110 Status Logical Bits 1−7, Annunciator

Discrete Signals (Configurable via PCC1302

A universal annunciator connected in a network in-

dicates and annunciates the active faults received

from the PCC1302. The NFPA 110 Status Logical

bits 1 to 7 (i.e. LEDs) of an annunciator can be

mapped to indicate and annunciate the active

faults corresponding to each of the four configur-

able inputs of PCC1302 as defined by the user. For

this, the (trim) ”Configurable Input #n Function” (n =

1, 2, 3, or 4) should be set as ”Fault Input” and the

LED should be mapped through (trim) ”Configur-

able I/P# n Ann Active LED” (n = 1,2,3 or 4), where,

”Configurable I/P# 1 Ann Active LED”) is applica-

ble only for ”Configurable Input #1 Function”.

”Configurable I/P# 2 Ann Active LED” is applicable

only for ”Configurable Input #2 Function”.

”Configurable I/P# 3 Ann Active LED” is applicable

only for ”Configurable Input #3 Function”.

”Configurable I/P# 4 Ann Active LED” is applicable

only for ”Configurable Input #4 Trim Function”

Each active fault corresponding to the respective

configurable input of PCC1302 is annunciated and

indicated according to the LEDs mapped by the

user to the ”Configurable Input #n Function” (n = 1,

2, 3, or 4) set as ”Fault Input”:

Refer the table below for more information on setup

and expected observations:

TABLE 3-18. 1302 CONTROL SETUP

Input #

”Configurable I/P# n Ann

Active LED” (n =

1,2,3 or 4) set to one of

the following

Active Condition (LED#

indication) on Annunciator

Active Fault

Condition

Active

FC#

”Configurable In-

NO_ANNUN_MAPPING No bit set = NONE None 1311

put #1 Function” =

Fault Input and

”

CUSTOMER_FAULT_1 Bit 1 set = LED 1 Annunciator

Fault 1

on

gura

e

I/P# 1 Ann Active

LED”

CUSTOMER_FAULT_2 Bit 1 set = LED 2 Annunciator

Fault 2

CUSTOMER_FAULT_3 Bit 1 set = LED 3 Annunciator

Fault 3

GEN_SUPPLY_LOAD Bit 1 set = LED 4 Genset

Supplying

Load

CHARGER_AC_FAIL Bit 1 set = LED 5 Charger AC

Failure

3-34

TABLE 3-18. 1302 CONTROL SETUP (CONT.)

Input # Active

FC#

Active Fault

Condition

Active Condition (LED#

indication) on Annunciator

”Configurable I/P# n Ann

Active LED” (n =

1,2,3 or 4) set to one of

the following

”Configurable In-

NO_ANNUN_MAPPING No bit set = NONE None 1312

put #1 Function” =

Fault Input and

”

CUSTOMER_FAULT_1 Bit 1 set = LED 1 Annunciator

Fault 1

on

gura

e

I/P# 1 Ann Active

LED”

CUSTOMER_FAULT_2 Bit 1 set = LED 2 Annunciator

Fault 2

CUSTOMER_FAULT_3 Bit 1 set = LED 3 Annunciator

Fault 3

GEN_SUPPLY_LOAD Bit 1 set = LED 4 Genset

Supplying

Load

CHARGER_AC_FAIL Bit 1 set = LED 5 Charger AC

Failure

LOW_COOLANT_LEVEL Bit 1 set = LED 6 Low Coolant

Level

LOW_FUEL_LEVEL Bit 1 set = LED 7 Low Fuel

Level

”Configurable In-

NO_ANNUN_MAPPING No bit set = NONE None 1317

put #1 Function” =

Fault Input and

”

CUSTOMER_FAULT_1 Bit 1 set = LED 1 Annunciator

Fault 1

on

gura

e

I/P# 1 Ann Active

LED”

CUSTOMER_FAULT_2 Bit 1 set = LED 2 Annunciator

Fault 2

CUSTOMER_FAULT_3 Bit 1 set = LED 3 Annunciator

Fault 3

GEN_SUPPLY_LOAD Bit 1 set = LED 4 Genset

Supplying

Load

CHARGER_AC_FAIL Bit 1 set = LED 5 Charger AC

Failure

”Configurable In-

NO_ANNUN_MAPPING No bit set = NONE None 1318

put #1 Function” =

Fault Input and

”

CUSTOMER_FAULT_1 Bit 1 set = LED 1 Annunciator

Fault 1

on

gura

e

I/P# 1 Ann Active

LED”

CUSTOMER_FAULT_2 Bit 1 set = LED 2 Annunciator

Fault 2

CUSTOMER_FAULT_3 Bit 1 set = LED 3 Annunciator

Fault 3

GEN_SUPPLY_LOAD Bit 1 set = LED 4 Genset

Supplying

Load

CHARGER_AC_FAIL Bit 1 set = LED 5 Charger AC

Failure

ALTERNATOR CONTROL ADJUSTMENTS

The 1302 series control includes an integrated line-

to-line sensing voltage regulation system that is

compatible with shunt or PMG excitation systems.

The voltage regulation system is SCR type. Excita-

tion power is derived either directly from the genset

terminals or from a PMG stator. Power from either

source is fed into the control thru J18. Positive volt-

3-35

age build up from residual levels is ensured by the

use of efficient semiconductors in the power circuit-

ry.

AVR Enable/Disable Feature

The 1302 series control provides automatic

voltage regulating capability for the generator set

when the AVR feature is enabled on the genset. It

has a field adjustment trim to enable or disable the

AVR feature. The trim parameter for this is AVR

Enable = Enable / Disable.

For information on enabling/disabling the AVR fea-

ture using the operator panel, see page 5-11.

Digital Output Voltage Regulation

The 1302 series control supports digital output

voltage regulation as defined below.

Voltage setpoint algorithm sets the level of the

automatic voltage regulation. It is adjustable.

The maximum allowed rated current for the

field coil for the regulation is 4.0 Amps RMS

and maximum 6.0 Amps for 10 seconds.

The control provides voltage ramping at start-

up if the AVR algorithm is enabled, such that

voltage overshoot can be controlled. AVR boot

enable logic supports the step by step voltage

ramping.

A PC based service tool allows the operator to

adjust the output voltage within plus or minus

5.0% of rated voltage.

Torque-Matched Volts/Hz Overload

Control

A frequency measuring circuitry monitors the

generator output and provides output underspeed

protection of the excitation system, by reducing the

output voltage proportionally with speed.

The voltage rolloff set point and rate of decay (i.e.,

the slope of the volts/hertz curve) is adjustable in

the control.

Major system features include.

%Volts/Hz rolloff supports the engine speed

recovery under block loading. The slope set-

ting (%volts/Hz) range is 0.0−5.0% of rated

with 0.1% increment.

The knee frequency range is 0.0−10.0Hz less

than the nominal frequency with 0.1 Hz incre-

ment.

For information on adjusting rolloff and knee fre-

quency settings using the operator panel, see page

5-17.

Battleshort Mode

The 1302 series control can be programmed to

work in battleshort mode by loading the battleshort

feature with a manufacturing tool or PC based ser-

vice tool.

The controller then can accept Configurable Input

1−4 as battle short switch inputs. If an operator

panel is used, it can be also selected as a source of

input by selecting appropriate input source value

for the trim.

Battleshort mode is designed to work only in critical

load circumstances. While in battleshort mode the

1302 series control will ignore most warnings and

shutdowns and will continue to operate as if no fault

or shutdown exists on the system.

For information on enabling/disabling the battle-

short feature using the operator panel, see page

5-11.

3-36

GENSET TUNING

The 1302 series control uses a standard 4 coeffi-

cient PID algorithm running at an execution rate of

once per zero cross of the generator AC waveform.

Standard values for the K1−K4 and damping terms

for both 60 and 50Hz are listed in Table 3-19.

Consider the following before making any adjust-

ments.

The values of K3, K4, and the damping factor

are set for basic stability reasons and should

not need to be adjusted, but they can be ad-

justed if necessary.

The useful range of values for K2 is 200 to

1500. The value of 1500 for K2 can be a little

too high or aggressive for some applications

and cause “ringing” upon recovering from a

load acceptance or offload transient situation.

A value of K2 below 200 can cause the regula-

tor to hit an integrator windup limit and should

be avoided if possible. Set the correct value for

the application.

The value of K1 should be adjusted to meet the

specification for percent off rated voltage dur-

ing a load acceptance, and prevent large volt-

age overshoots during offloads and during en-

gine/alternator startup.

The value of K2 should be adjusted to control

the recovery characteristics of the voltage dur-

ing large load acceptance and rejection tran-

sients. Values of K2 which are too high can

cause unstable voltage performance and val-

ues too low can cause slow performance or

steady state voltage offset errors.

In general, K1 increases and K2 decreases in val-

ue with increasing generator size, but can vary in

different applications.

V/Hz Curve

The 1302 series control uses a simple breakpoint

and slope approach to the V/Hz curve to allow for

the matching of the torque curve of the engine dur-

ing a large transient load acceptance. The two ad-

justment points are the V/Hz Knee Frequency

which set the point at which the V/Hz curve starts,

and the V/Hz Roll−off Slope which sets the roll−off

slope of the voltage setpoint as a function of fre-

quency error.

The default V/Hz settings are:

Parameter Default Value

V/Hz Knee Frequency 0.5 Hz

V/Hz Roll-off Slope 2.2 %V/Hz

The voltage set point command is calculated from

the frequency error between commanded frequen-

cy and the actual frequency. For example, a volt-

age set point of 93.4% of nominal would be com-

manded if there is a frequency error of 3.5Hz under

nominal. There is no offset to voltage for errors

above nominal frequency.

NOTE: To check the actual genset output, True

(calibrated) RMS meter should be

usedNote: There are only one V/Hz set-

tings per calibration so the values must be

used for both 50 and 60Hz operation. If a

particular application requires vastly differ-

ent V/Hz settings for 50Hz and 60Hz op-

eration, it will be required to create sepa-

rate software features for those applica-

tions.

For information on how to adjust the slope and

knee frequency using the operator panel, see page

5-17.

TABLE 3-19. GOVERNOR GAINS FOR SMALL

ENGINES

Newage BC/UC Generators Under 200Kw

60Hz 50Hz

K1 = 1000 K1 = 1000

K2 = 650 K2 = 650

K3 = 10000 K3 = 10000

K4 = 36429 K4 = 36429

Damping = 0.8 Damping = 0.8

3-37

Governor

The 1302 series control’s governor also uses the 4

coefficient PID algorithm. There are gains for use

at 50 and 60Hz operation. Standard values for the

K1−K4 and damping terms for both 60 and 50 Hz

for engines in the Cummins 4B3.9 and 6B5.9 range

are listed in Table 3-20.

TABLE 3-20. GOVERNOR GAINS FOR SMALL

ENGINES

60Hz 50Hz

GK1 = 1696 GK1 = 1200

GK2 = 240 GK2 = 300

GK3 = 28,800 GK3 = 28,800

GK4 (calc) = 7424 GK4 (calc) = 7424

Governor Damping =

0.936

Governor Damping =

0.936

Governor Tuning

A good starting point for any new engine applica-

tion is to start with a set of released gains for an en-

gine of a similar type and size should they already

exist.

If a set of pre−developed gains are not available,

the gains listed above should work well enough to

start most engines and to allow them to run

smoothly.

The value of GK1 should be adjusted to meet the

specification for percent off rated voltage during a

load acceptance, to prevent large voltage over-

shoots during offloads, and during engine/alterna-

tor startup.

The value of GK2 should be adjusted to control the

recovery characteristics of the engine during large

load acceptance and rejection transients. GK2 is a

true integral type gain and is applied to the gover-

nor output as GK2 times the sum of all the previous

governor error. Values of GK2 which are too high

can cause unstable voltage performance and val-

ues too low can cause slow performance or steady

state voltage offset errors.

The values of GK3, GK4 and the Damping factor

are used to set the basic steady state stability of the

engine, but also influence the overall speed of re-

sponse of the governor in transient situations. Ad-

justment of GK3 and the Damping factor is an itera-

tive process started by finding the engine load level

which produces the worst steady state engine per-

formance (note: GK1 and GK2 may have to be ad-

justed first to allow the engine to be transitioned

smoothly into this) and adjusting GK3 until the best

performance is observed, then doing the same for

the Damping factor. Repeat this process at least

once to ensure that the best possible values for

GK3 and the Damping term have been determined.

For information on how to adjust the GK1and GK2

values and the damping factor using the operator

panel, see page 5-17.

Engine Startup

The 1302 series control applies fuel to the engine

as described in the Speed Governor Algorithm and

Adjustment section.

Alternator Startup

The alternator will be started up and brought to

rated voltage when the engine speed reaches

rated speed. The PWM command to the field coil

will now be stepped through an AVR Boot Table un-

til the sensed voltage goes above the value of the

AVR Boot Threshold trim and if AVR feature is en-

abled. The regulator will now bring the voltage up to

rated voltage.

The purpose of the AVR Boot Table is to aid alterna-

tor startup whilst preventing overvoltage condi-

tions. The value of the AVR Boot Table and the AVR

Boot Threshold can be set to bring the voltage up

both as quickly and as smoothly as possible, but

should already be set in the calibration to their ideal

values. The AVR Boot Table has different values

depending on value of the Excitation Source trim.

Setup for Gain Tuning

In order to properly set up engine and alternator

control parameters it is convenient to setup the PC

based service tool to be used to monitor.

The following are step-by-step procedures for de-

termining engine and alternator control parame-

ters.

1. Determine 60Hz governor gains, regulator

gains, and VHz curve values with PMG ex-

citation.

a. Start the genset, bring it to rated speed

and temperature, and adjust the GK3 and

damping factor for 60Hz operation to al-

low the engine to run smoothly in steady

state operation.

NOTE: GK1 and/or GK2 may need to be

adjusted to allow this to happen.

Apply various loads up to 100% rated and

verify the steady state operation at all load

3-38

levels. Most engines have some load lev-

el which is inherently less stable than oth-

ers and must be found to determine the

correct value for GK3 and the damping

factor.

NOTE: It is important to control the

steady state performance of the

engine. Unstable engine perfor-

mance is carried over into the

generator output voltage. Very

fast increases or decreases in en-

gine speed, even if the magnitude

of the increase or decrease is

small, tend to be carried into the

alternator voltage as large in-

creases and decreases in voltage

at the same frequency as the en-

gine speed changes.

b. Do a series of load steps to determine the

transient characteristics of the genset.

Tuning of the governor GK1 and GK2 val-

ues, the settings of the V/Hz curve, and

the values of K1 and K2 (mostly K1) for

the regulator must be done concurrently.

In general, these values should be ad-

justed to achieve the maximum possible

performance from both the engine and

the alternator. A production test spec (if

available) should give the full load step

transient performance levels for any giv-

en genset model. This is a very iterative

process and many require some time to

find the best combination of gains to fit the

application. In general, adjust GK1 to con-

trol the peak frequency during transients

and adjust GK2 to control the recovery

shape of the frequency transient. A V/Hz

slope too steep causes the engine to re-

cover too quickly and recovers to nominal

speed very poorly. A V/Hz curve too shal-

low causes a very slow engine recovery

from a transient.

c. Re-verify steady state voltage and gover-

nor performance.

2. Determine 50Hz governor gains, Regulator

gains, and V/Hz curve values. Follow the

same process as used at 60Hz. The order of

50Hz vs 60Hz testing can be reversed.

3. Determine the correct values for the governor

startup parameters (see “Speed Governor Al-

gorithm and Adjustment” below).

a. Adjust the Initial Crank Fueling Com-

mand, Initial Crank Fueling Period, Crank

Fueling Ramp Rate, and Max Crank Fuel-

ing Command parameters to control the

way the engine transitions through the

cranking stage of the engine startup. The

controls default values should work well.

b. The value of the Crank Exit Fueling Com-

mand parameter should be set to the gov-

ernor duty at which the engine runs when

at rated speed, or to a value slightly high-

er.

Gain Tuning Parameters

This is a list of all of the parameters which affect

genset performance. A correct value should be de-

termined for each of the parameters listed.

NOTE: To check the actual genset output, True

(calibrated) RMS meter should be

usedFor any parameters that have some-

thing listed in the “Value” column, it is

recommended that the parameter stay at

that value during testing. Some parame-

ters should never be changed during test-

ing and are listed as never to be changed.

3-39

TABLE 3-21. GAIN TUNING PARAMETERS

Parameter Value Comments

AVR Parameters

K1 (50Hz) Sets overall AVR gain in 50Hz applications. This is a true

proportional gain which is multiplied against the voltage

error signal.

K2 (50Hz) Controls the recovery shape of voltage transients in 50Hz

applications. This is a true integral gain which is multiplied

against the sum of all previous errors.

K3 (50Hz) Affects high frequency characteristics of the AVR algorithm

in 50Hz applications. Adjust for voltage stability reasons.

Damping Effect (50Hz) Affects high frequency characteristics of the AVR algorithm

in 50Hz applications. Adjust for voltage stability reasons.

K1 (60Hz) Sets overall AVR gain in 60Hz applications. This is a true

proportional gain which is multiplied against the voltage

error signal.

K2 (60Hz) Controls the recovery shape of voltage transients in 60Hz

applications. This is a true integral gain which is multiplied

against the sum of all previous errors.

K3 (60Hz) Affects high frequency characteristics of the AVR algorithm

in 60Hz applications. Adjust for voltage stability reasons.

Damping Effect (60Hz) Affects high frequency characteristics of the AVR algorithm

in 60Hz applications. Adjust for voltage stability reasons.

Engine Governing Parameters

GK1 (50Hz) Sets overall governor gain in 50Hz applications. This is a

true proportional gain which is multiplied against the fre-

quency error signal.

GK2 (50Hz) Controls the recovery shape of speed transients in 50Hz

applications. This is a true integral gain which is multiplied

against the sum of all previous errors.

GK3 (50Hz) Affects high frequency characteristics of the governor algo-

rithm in 50Hz applications. Adjust for frequency stability

reasons.

Governor Damping Effect

(50Hz)

Affects high frequency characteristics of the governor algo-

rithm in 50Hz applications. Adjust for frequency stability

reasons.

GK1 (60Hz) Sets overall governor gain in 60Hz applications. This is a

true proportional gain which is multiplied against the speed

error signal.

GK2 (60Hz) Controls the recovery shape of frequency transients in

60Hz applications. This is a true integral gain which is mul-

tiplied against the sum of all previous errors.

GK3 (60Hz) Affects high frequency characteristics of the governor algo-

rithm in 60Hz applications. Adjust for frequency stability

reasons.

Governor Damping Effect

(60Hz)

Affects high frequency characteristics of the governor algo-

rithm in 60Hz applications. Adjust for frequency stability

reasons.

3-40

TABLE 3-21. GAIN TUNING PARAMETERS (CONT.)

Parameter CommentsValue

Engine Starting Parameters

Initial Crank Fueling Duty

Cycle

The initial value assigned to Governor Duty Cycle at entry

in Crank State

Initial Crank Fueling Period The period for which the value of Initial Crank Fuel Duty

Cycle is assigned to Governor Duty Cycle after entry in

Crank State

Crank Fueling Ramp Rate The Rate at which the value of Governor Duty Cycle is

ramped up by during Crank State after expiration of the

Initial Crank Fueling Period

Maximum Crank Fueling The level to which the Governor Duty Cycle is limited dur-

ing Crank State

Crank Exit Fueling

Command

The Value at which the Governor Duty Cycle is held after

disengaging the starter until the Governor is enabled.

Governor Enable Speed The Value of speed above which the electronic governor

starts controlling the value of Governor Duty Cycle

Governor Ramp Time Sets the minimum governor speed reference ramp rate

3-41

Controller Calibration

The internal circuitry of the 1302 series control may

need to be calibrated. There are three different

components which may need this. They are: