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22

MDC CONTROLLER INFORMATION DISPLAYS, FUNCTIONS AND RESET

The Magnum Digital Controller (MDC) constantly monitors vital generator and engine functions for a number of 
operation, alarm and fault conditions. When a fault condition occurs, the engine will shut down automatically and the 
Liquid Crystal Display (LCD) window will show the fault that has caused the shut down. To resume operation, the 
fault condition must be resolved. To reset the controller and resume operation, press the “FAULT RESET” button. 

The operation of the Magnum Digital Controller (MDC) is divided into the following sections:
 

MAGNUM DIGITAL CONTROLLER (MDC) – GENERATOR OPERATIONAL STATUS

The Magnum Digital Controller (MDC) displays the operational status of the generator using the following codes:

MAGNUM DIGITAL CONTROLLER (MDC) - ALARM MANAGEMENT

The Magnum Digital Controller (MDC) is capable of displaying the following alarms:

No. Engine 

State 

Machine

Description

1

AfterCool

Engine aftercooling, Cooling Pump output is closed.

2

Cooling

The generator is cooling before stop. 

3

Cranking

Engine is cranking. 

4

EmergMan

Emergency Manual gen-set operation.  

5

Init

Autotest during controller power on.

6

Loaded

The generator is running at nominal speed and GCB OPEN/CLOSE is 
closed. 

7

Not Ready

The generator is not ready to start. 

8

Pause

Pause between start attempts. 

9

Prestart

Prestart sequence in process, Prestart output is closed.

10

Ready

The generator is ready to run. 

11

Running

The generator is running at nominal speed. 

12

Shutdown

Shut-down alarm is activated.

13

Starting

Starting speed is reached and the 

Idle timer

 is running. 

14

Stop

Stop

No. Electrical 

State 

Machine

Description

1

StabilTO

Stabilization Timeout

No. Type

Description

1

Sensor fail (FLS)

Sensor fail is detected when measured value is 6% out of the selected 
characteristic. Sensor fail indicated by ##### symbol instead measured 
value.

2

Warning (WRN)

When warning comes up, see list of possible alarms.

3

Shut down (SD)

When the shut-down alarm comes up the Magnum Digital Controller opens 
outputs GCB CLOSE/OPEN, FUEL, SOLENOID, STARTER AND 
PRESTART to stop the engine immediately.

Summary of Contents for MMG25FHZ

Page 1: ...25 www m p llc com GASOLINE POWERED GENERATOR MMG25FHZ OPERATING MANUAL ...

Page 2: ... copies of the engine operators manual are available from the engine manufacturer MAGNUM PRODUCTS LLC 215 Power Drive Berlin WI 54923 U S A Phone 920 361 4442 FAX 920 361 4416 Toll Free 1 800 926 9768 www m p llc com For technical or parts QUESTIONS please contact Magnum Products Customer Support or Technical Support team at 920 361 4442 Please have your serial number available To ORDER SERVICE PA...

Page 3: ...GITAL CONTROLLER MDC ALARM MANAGEMENT 22 MAGNUM DIGITAL CONTROLLER MDC LIST OF POSSIBLE ALARMS DESCRIPTIONS 23 ENGINE CONTROLLER 24 ADJUSTING THE DISPLAY BACK LIGHTING 24 MAGNUM DIGITAL CONTROLLER MDC HISTORY 25 RESETTING OF THE TIME TO SERVICE REMINDER 26 CHECK ENGINE LIGHT 26 TROUBLESHOOTING AUTOMATIC SHUTDOWN CONDITIONS 26 GENERATOR OUTPUT CONNECTION LUGS 28 GENERATOR CAM LOCK CONNECTIONS OPTIO...

Page 4: ...ications DO NOT modify or use this equipment for any application other than which it was designed for Equipment operated improperly or by untrained personnel can be dangerous Read the operating instructions and familiarize yourself with the location and proper use of all instruments and controls Inexperienced operators should receive instruction from someone familiar with the equipment before bein...

Page 5: ...ic acid can cause eye damage burn flesh or eat holes in clothing Protective eye wear and clothing are necessary when working on or around the battery Always disconnect the NEGATIVE battery cable from the corresponding terminal before performing any service on the engine or other components ELECTRICAL SAFETY The unit is powered by a generator driven by a gasoline powered engine While the engine is ...

Page 6: ... trailer and tow vehicle will cause more weight to be carried by one axle which could cause premature wear on the tires and axles and cause potentially unsafe operating conditions The trailer is equipped with hydraulic surge brakes or electric surge brakes Check the operation of the brakes by braking the vehicle at a slow speed before entering traffic Both the trailer and the vehicle should brake ...

Page 7: ...ed steam Fan hazard Keep body parts clear of this area Pinch crush hazard Keep body parts clear of this area Isolate generator to prevent electrocution hazard Belt entanglement hazard Keep body parts clear of this area Safety alert symbol Used to alert you to potential personal injury hazards Stop engine before fueling Engine running SAFETY SYMBOL SUMMARY This equipment has been supplied with nume...

Page 8: ...enerator 3Ø Standby kW kVA 32 40 Amps 3Ø Standby 480V 208V A 30 69 3Ø Prime kW kVA 28 35 Amps 3Ø Prime 480V 208V A 28 64 1Ø Standby kW kVA 30 30 Amps 1Ø Standby 240V A 67 1Ø Prime kW kVA 26 26 Amps 1Ø Prime 240V A 63 Frequency Hz 60 Power Factor 1 1Ø 0 8 3Ø Sound dB A 23 ft prime 66 Weights Dry Weight Skid Mounted lbs kg 1966 892 Operating Weight Skid Mounted lbs kg 2349 1065 Dry Weight Trailer Mo...

Page 9: ...CTS LLC 215 Power Drive Berlin WI 54923 1 800 926 9768 TM Mfg Code V A KW Located on control panel UNIT ID Tag Trailer ID Tag V I N Tag UNIT DIMENSIONS Read this manual carefully before attempting to use this generator The potential for property damage personal injury or death exists if this equipment is misused or installed incorrectly Read all of the manuals included with this unit Each manual d...

Page 10: ...10 COMPONENT LOCATIONS ...

Page 11: ...e hood latch located on the upper corner of the left hood side see Figure A Tilt the hood open until it contacts the bulkhead panel CAUTION Generator hoods are heavy Use caution when opening or closing To close the front hood 1 Make sure the skid is free of debris and all personnel are clear of unit 2 Slowly push hood forward and allow it to close firmly to ensure the hood latch is engaged 3 Verif...

Page 12: ...Figure B A With your right hand grip the lip of the emergency stop panel on the right side of the unit B With your left hand pull the hood latch located on the upper corner of the left hood side see FigureC Tilt the hood completely open travel is limited by two metal guide straps CAUTION Generator hoods are heavy Use caution when opening or closing 5 Verify the red safety link is engaged and undam...

Page 13: ...ly closed and secure 3 Release the red safety link located on the left side metal guide strap by rotating the link counterclockwise CAUTION Generator hoods are heavy Use caution when opening or closing 4 Slowly push hood forward and allow it to close firmly to ensure the hood latches have engaged 5 Verify the hood is securely closed by attempting to open without releasing the hood latches NOTICE F...

Page 14: ...location with a dry contact closure switch when the generator is used for standby or remote power 10 ENGINE ACCESSORY CONNECTION Connection for battery charger and other engine accessories 11 GENERATOR GROUND CONNECTION LUG This lug is for connecting a good earthen ground per any local state or National Electric Code NEC guidelines before starting the generator 12 GENERATOR OUTPUT CONNECTION LUGS ...

Page 15: ...Fine Voltage Adjustment Screw the OPERATION keypad the LCD window the DIAGNOSTICS keypad and the STATUS Light Emitting Diodes LED s The following is a brief summary of the operation of each section of the control panel DIGITAL CONTROLLER FEATURES AND FUNCTIONS 1 The CONTROL ON CONTROL OFF Toggle Switch and Fine Voltage Adjustment Screw Control On Off Toggle Switch This toggle switch powers up the ...

Page 16: ... operational status of the generator Alarm Fault Indicates active or inactive alarms but not reset shutdown alarms Warning Indicates an active or inactive alarm or a warning alarm that has not been reset Ready Manual Indicates the controller is ready to start and in the manual mode Ready Auto Indicates the unit is in the AUTO mode ready for the remote start signal Running Indicates the unit is run...

Page 17: ...ng is 13 14V on 12 volt systems and 24 26 on 24 volt systems with the engine running Additional information may be viewed while the unit is in MANUAL or AUTO mode By pressing the Page Select button the operator will select one of the following screens Running screen Password screen or History screen In each of these page selections the operator may press the S or T buttons on the DIAGNOSTICS keypa...

Page 18: ... screw turns a rheostat that will provide an increase or a decrease in the generator output voltage as displayed on the Power Display Screen on the control panel When making this adjustment if the voltage is increased or decreased too fast or too slow the unit will automatically shut down This adjustment needs to be made within the 45 second delay and countdown to 0 Zero period To adjust the outpu...

Page 19: ...generator sitting level Thoroughly check for any water inside the unit on or near the generator Dry the unit before starting Check oil coolant and fuel levels and engine battery connections Check engine fan belt tension and condition Check engine fan belt guard Check engine exhaust system for loose or rusted components Check radiator and surrounding shroud for debris Are any of the generator cover...

Page 20: ...or Display Screen and then to the Engine Display Screen 8 If the engine does not start after the first cranking attempt the engine will pause for 15 seconds to allow the starter to cool The LCD window will show PAUSE The engine will make two more attempts to start for a total of three crank cycles 9 Should the engine not start and run within 3 starting cycles the LCD window will show SD Start fail...

Page 21: ...e generator with a transfer switch if the unit is to be used as a standby power supply see page 34 Then continue with the steps described below 1 Perform a manual start of the generator at least once to verify that the engine is operating correctly 2 If a check of the remote start circuit is desired remove the wires from the remote start terminal block Press the AUTO button the Liquid Crystal Disp...

Page 22: ...tercooling Cooling Pump output is closed 2 Cooling The generator is cooling before stop 3 Cranking Engine is cranking 4 EmergMan Emergency Manual gen set operation 5 Init Autotest during controller power on 6 Loaded The generator is running at nominal speed and GCB OPEN CLOSE is closed 7 Not Ready The generator is not ready to start 8 Pause Pause between start attempts 9 Prestart Prestart sequence...

Page 23: ...of the generator circuit breaker 13 Igen unbl SD NO The generator current is unbalanced 14 Low BackupBatt WRN NO RTC backup battery is flat 15 Oil Press Sd SD NO Oil pressure is less than Sd Oil press setpoint 16 Oil Press Wrn WRN YES Oil pressure is less than Wrn Oil press setpoint 17 Overload SD YES The load is greater than the value given by Overload setpoint 18 Overspeed SD YES The protection ...

Page 24: ...y the operator whenever the Magnum Digital Controller MDC is powered up 1 Press and hold Enter and press S or T on the Diagnostics keypad to increase or decrease the display contrast as needed 2 Release the Enter button and the S or T buttons when the desired backlighting is attained Note Anytime an is displayed on the LCD the text or set point cannot be changed with out the use of a password Cont...

Page 25: ... IG IOM IGS PTM 6 BIN Binary inputs IL NT 7 BOM IG IOM IGS PTM Binary outputs when configured IG IOM IGS PTM 8 BOUT Binary inputs IL NT 9 Date Date of historical event in format DD MM YY 10 EngT IL NT Analog input 2 value default Water temperature 11 FC ECU alarm FailureCode 12 FLvl IL NT Analog input 3 value default Fuel level 13 FMI ECUalarm Failure Mode Identifier 14 Gfrg Generator frequency 15...

Page 26: ...off using the appropriate start stop procedures on pages 19 and 21 If the engine fault has been properly diagnosed and addressed the Check Engine light will be reset turned off on the fourth start stop cycle TROUBLESHOOTING AUTOMATIC SHUTDOWN CONDITIONS LOW FUEL LEVEL SHUTDOWN 1 Check the fuel level on the Liquid Crystal Display LCD window 2 Check for leaks in the fuel tank The fuel tank should no...

Page 27: ...or damage To check for continuity between the sender and the engine controller remove the bolts at the top and bottom of the control panel and open the panel like a door Consult the appropriate DC wiring diagram on page 41 for the proper path between the engine controller and the temperature sender 11 If the sender and wiring are good and no other problems are found remove the load on the generato...

Page 28: ...ble is disconnected Potentially lethal voltages may be present at the generator connection lugs DANGER IMPROPER OR INCORRECT CONNECTIONS TO A BUILDINGS ELECTRICAL SYSTEM CAN CAUSE POTENTIALLY LETHAL VOLTAGE TO BACKFEED ONTO UTILITY LINES THIS MAY RESULT IN INJURY OR ELECTROCUTION TO UTILITY WORKERS NEARBY MAKE SURE THE GENERATOR IS SUPPLYING POWER TO AN ISOLATED OBJECT OR BUILDING THAT IS NOT CONN...

Page 29: ...ges may be present at the generator cam lock receptacles DANGER IMPROPER OR INCORRECT CONNECTIONS TO A BUILDINGS ELECTRICAL SYSTEM CAN CAUSE POTENTIALLY LETHAL VOLTAGE TO BACKFEED ONTO UTILITY LINES THIS MAY RESULT IN INJURY OR ELECTROCUTION TO UTILITY WORKERS NEARBY MAKE SURE THE GENERATOR IS SUPPLYING POWER TO AN ISOLATED OBJECT OR BUILDING THAT IS NOT CONNECTED TO ANY UTILITY LINES Connections ...

Page 30: ...enerator windings The connection lug door is equipped with safety interlock switches that will trip the main circuit breaker and disable the voltage regulator dropping the operator output to residual voltage if the door is opened while the unit is operating WARNING Never attempt to disable or modify the lug door safety switches Equipment damage personal injury or death may result Note When the vol...

Page 31: ...nit is operating WARNING Never attempt to disable or modify the lug door safety switches Equipment damage personal injury or death may result Note The following applies to units without a convenience outlet buck transformer When the voltage selector switch is in position for 480 277V 3Ø voltage at the two GFCI duplex convenience outlets is 139 Volts and the voltage at the two twist lock convenienc...

Page 32: ...nerator has been started and allowed to reach normal operating temperature the breaker may be switched to the ON I position The main circuit breaker will be tripped disconnecting power to the connection lugs if any of the following items occur while the unit is running 1 Overload of the generator circuits to the connection lugs 2 The door covering the customer connection lugs is opened 3 If the em...

Page 33: ...sure that the voltage selector switch is in the proper position and that the output voltage is correct for the equipment that is connected to the outlets Improper voltage may cause equipment damage or malfunction Note When the voltage selector switch is in position for 480 277V 3Ø voltage at the two GFCI duplex convenience outlets is 139 Volts and the voltage at the two twist lock outlets is 240 1...

Page 34: ... NORMAL POWER UTILITY CAN CAUSE POTENTIALLY LETHAL VOLTAGE TO BACKFEED INTO THE UTILITY LINES THIS MAY RESULT IN INJURY OR ELECTROCUTION OF UTILITYWORKERSNEARBY MAKE SURE THAT THE GENERATOR IS ISOLATED BY A TRANSFER SWITCHFROMANYLOCALUTILITY LINES THIS ALSO APPLIES IF THE GENERATOR IS BEING USED AS A BACK UP TO SOME OTHER TYPE OF POWER SUPPLY Installation of a transfer switch or other type of remo...

Page 35: ...e 2500 hour 10 month service interval it is recommended that the belt be removed and checked for wear While the belt is removed inspect pulleys and bearings Rotate and feel for hard turning or unusual sounds If pulleys or bearings need replacement contact engine manufacturer ENGINE AND GENERATOR MAINTENANCE Poorly maintained equipment can become a safety hazard In order for the equipment to operat...

Page 36: ...ANUAL for coolant recommendations and proper mixture Check the condition of the air filter by viewing the level of vacuum draw on the filter minder gauge Replace the air filter when the yellow center bar reaches the red section on the gauge 20 in H20 Replace primary air cleaner when restriction indicator shows a vacuum of 25 in H2O Change the oil and oil filter after the first 100 hours then every...

Page 37: ...ng If a tire has been removed for axle service or replaced tighten the lugs in the order shown to the following specifications A Start all lug nuts by hand B First pass tighten to 20 25 Ft Lbs 27 33 Nm C Second pass tighten to 50 60 Ft Lbs 67 81 Nm D Third pass tighten to 90 120 Ft Lbs 122 162 Nm Afterthefirstroaduse re torquethelugnutsinsequence 6 Maximum recommended speed for highway towing is 4...

Page 38: ...38 TRAILER WIRING DIAGRAM ELECTRIC BRAKE WIRING DIAGRAM BLK BLU GREEN YELLOW BROWN WHITE BREAK AWAY SW BATT TO BRAKES RIGHT TURN STOP LEFT TURN STOP TAIL MARKER GROUND ...

Page 39: ... BRK L3 PS 1 BRK L1 PS 13 GB T5 GB T4 GB T6 PS 26 GB T9 GB T8 GB T10 GB T11 PS 7 PS 6 PS 10 PS 2 PS 18 PS 25 GB T12 PB T9 PB T9 PB T7 LO GB T7 BRN WHT YEL WHT ORN WHT BLU BLK BLK BLU BLU RED BLK BLK BLK RED BRN WHT BLK WHT BRN WHT BLK WHT BLK WHT GRN GRN GRN GRN GRN GRN GRN 1 7 6 12 BLK WHT CT1 CT2 CT3 X1 X1 X1 GRN GRN GRN BRN WHT YEL WHT ORN WHT BRN YEL ORN MDC GENERATOR CONTROLLER GENERATOR VOLT...

Page 40: ...ORN BLK BLK GRN RED 3 5 6 4 1 8 7 2 MDC GENERATOR CONTROLLER GENERATOR VOLTAGE N L1 L2 L3 GENERATOR CURRENT COM L1 L2 L3 BRN YEL ORG WHT BRN BRN REMOVED FOR BUCK BOOST OPTION L2 L3 L1 L0 MECHANICAL LUGS GND BLK GENERATOR F F T1 T3 T4 T5 T6 T7 T8 T9 T10 T12 T2 T11 CB L1 CB L2 CB L3 PS 1 PS 43 PS 24 PS 11 PS 7 PS 33 PS 2 PS 21 PS 27 RED BLK 1 7 6 12 BRN ORN 36 40 8 12 16 4 20 24 28 32 34 33 29 37 38...

Page 41: ...ION TOP PLUG LOCATION BOTTOM 7 PIN PLUG BINARY INPUTS PLUG LOCATION TOP ALTERNATOR 4NO 3NO 3NO 4NO REMOTE START MDC CONTROLLER RED W RED W SPLICE 2NC 1NC BLK SHIELD BLK R VIO V YEL SHIELD GRY BLK VIO GRY BLK BLK BLK BLK BLK SEE AC PRINT SEE AC PRINT R YEL R BLK GRY ORN W YEL W BLU W VIO BLK YEL VIO BLK GY OR WHT YEL WHT YEL BLK GRY BLK VIO SHIELD SHIELD BRN WHT YEL WHT ORN WHT WHT SPLICE SHIELD V ...

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Page 44: ...REV ORG WD PART NO 27459 05 12 09 ...

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