Operator Manual
Generator Set
Ford V-10 6.8L Engine with PowerCommand® 2100 Control
GGHG (Spec L)
GGHH (Spec L)
English
Original Instructions
9-2011
A034G614 (Issue 3)
Table of Contents
1. IMPORTANT SAFETY INSTRUCTIONS .......................................................................................
1.1 Warning, Caution and Note Styles Used In This Manual .......................................................
1.2 General Information ................................................................................................................
1.2.1 General Safety Precautions ........................................................................................
1.3 Generator Set Safety Code ....................................................................................................
1.3.1 Moving Parts Can Cause Severe Personal Injury Or Death........................................
1.3.2 Positioning of Generator Set.......................................................................................
1.3.3 Positioning of Generator Set - Open Sets ...................................................................
1.4 Electrical Shocks and Arc Flashes Can Cause Severe Personal Injury or Death..................
1.4.1 AC Supply and Isolation...............................................................................................
1.5 Fuel And Fumes Are Flammable ............................................................................................
1.5.1 Gaseous Fuels .............................................................................................................
1.5.2 Spillage .......................................................................................................................
1.5.3 Fluid Containment.......................................................................................................
1.5.4 Do Not Operate in Flammable and Explosive Environments ......................................
1.6 Exhaust Gases Are Deadly.....................................................................................................
1.6.1 Exhaust Precautions ...................................................................................................
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2. INTRODUCTION............................................................................................................................
2.1 About This Manual..................................................................................................................
2.2 Schedule of Abbreviations ......................................................................................................
2.3 Related Literature ...................................................................................................................
2.3.1 Further Information - Literature ....................................................................................
2.4 After Sales Services................................................................................................................
2.4.1 Maintenance................................................................................................................
2.4.2 Warranty.......................................................................................................................
2.4.3 How to Obtain Service .................................................................................................
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3. SYSTEM OVERVIEW ..................................................................................................................
3.1 Generator Set Identification ..................................................................................................
3.1.1 Nameplate..................................................................................................................
3.2 Generator Set Components..................................................................................................
3.3 Generator Set Rating ............................................................................................................
3.4 Engine...................................................................................................................................
3.4.1 Engine Data ...............................................................................................................
3.5 Sensors.................................................................................................................................
3.6 Heaters .................................................................................................................................
3.6.1 Heater Supply and Isolation......................................................................................
3.7 Mains (Utility) Powered Battery Charger ..............................................................................
3.8 Alarm Module........................................................................................................................
3.9 Coolant Heater......................................................................................................................
3.10 System Options...................................................................................................................
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3.10.1 Normal Duty Air Cleaner ..........................................................................................
3.10.2 PowerCommand Universal Annunciator ..................................................................
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4. CONTROL SYSTEM - PCC 2100 ................................................................................................
4.1 Control System Description ..................................................................................................
4.2 Control Panel Power On/Off Modes .....................................................................................
4.2.1 Power On Mode .........................................................................................................
4.2.2 Screen Saver Mode ...................................................................................................
4.2.3 Sleep/Awake Mode ....................................................................................................
4.3 Battle Short Mode ................................................................................................................
4.4 Front Panel ...........................................................................................................................
4.4.1 Digital Display ............................................................................................................
4.4.2 Display Menu Selection Button ..................................................................................
4.4.3 Home Button ..............................................................................................................
4.4.4 Previous Main Menu Button.......................................................................................
4.4.5 Emergency Stop Button .............................................................................................
4.4.6 Running Indicator .......................................................................................................
4.4.7 Remote Start Indicator ..............................................................................................
4.4.8 Not in Auto ................................................................................................................
4.4.9 Analog AC Metering Panel.........................................................................................
4.4.10 Shutdown Status .....................................................................................................
4.4.11 Warning Status Indicator..........................................................................................
4.4.12 Fault Acknowledgement/Reset Button.....................................................................
4.4.13 Panel Lamp and Lamp (LED) Test Button...............................................................
4.4.14 Manual Run/Stop Button..........................................................................................
4.4.15 O/Manual/Auto Switch..............................................................................................
4.4.16 Configurable Indicators ............................................................................................
4.5 Control Menus.......................................................................................................................
4.5.1 Main Menus................................................................................................................
4.5.2 Adjusting Default Settings..........................................................................................
4.5.3 System Messages......................................................................................................
4.5.4 Controller Configuration Menu ...................................................................................
4.5.5 Engine Menu ..............................................................................................................
4.5.6 Alternator Menu..........................................................................................................
4.5.7 Adjust Menu ...............................................................................................................
4.5.8 Faults Menu ...............................................................................................................
4.5.9 System Menu .............................................................................................................
4.5.10 History Menu ............................................................................................................
4.5.11 About Menu..............................................................................................................
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5. OPERATION - PCC 2100 ............................................................................................................
5.1 Safety....................................................................................................................................
5.2 Introduction ...........................................................................................................................
5.3 Maintenance .........................................................................................................................
5.4 Starting .................................................................................................................................
5.4.1 Starting - Safety Consideration ..................................................................................
5.4.2 Operator’s Pre-start Checks ......................................................................................
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Table of Contents
5.4.3 Starting at the Control Panel (Manual Mode) ............................................................
5.4.4 Starting From a Remote Location (PTC or Remote Start Signal) - Auto Mode.........
5.4.5 Cold Starting With Loads ...........................................................................................
5.5 Stopping................................................................................................................................
5.5.1 Emergency Stop.........................................................................................................
5.5.2 Stopping at Control Panel (Manual Mode).................................................................
5.5.3 Stopping from Remote Location (Remote Stop Signal) - Auto Mode ........................
5.6 Operating Recommendations ...............................................................................................
5.6.1 Running-in..................................................................................................................
5.6.2 No Load Operation....................................................................................................
5.6.3 Exercise Period ..........................................................................................................
5.6.4 Low Operating Temperature ......................................................................................
5.6.5 High Operating Temperature .....................................................................................
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6. MAINTENANCE ...........................................................................................................................
6.1 Locking the Generator Set Out of Service............................................................................
6.1.1 Immobilizing for Safe Working ...................................................................................
6.1.2 Periodic Maintenance.................................................................................................
6.2 Daily or Refueling Maintenance Procedures ........................................................................
6.2.1 General Information ...................................................................................................
6.2.2 Engine Operation Report ..........................................................................................
6.3 Cooling System.....................................................................................................................
6.3.1 Coolant Level - Check ..............................................................................................
6.3.2 Cooling Fan - Inspect................................................................................................
6.3.3 Drive Belt - Inspection................................................................................................
6.3.4 Radiator - Check ........................................................................................................
6.4 Engine Oil – Level Check .....................................................................................................
6.5 Fluid Containment.................................................................................................................
6.6 Hoses and Fuel Lines - Check .............................................................................................
6.7 Normal Duty Air Cleaner.......................................................................................................
6.7.1 Air Cleaner Element Removal....................................................................................
6.7.2 Air Cleaner Element Installation.................................................................................
6.8 Exhaust System ....................................................................................................................
6.9 Generator Set Output - AC Electric System .........................................................................
6.10 DC Electrical System ..........................................................................................................
6.11 Lead Acid Batteries.............................................................................................................
6.11.1 Storage.....................................................................................................................
6.11.2 Safety Precautions ...................................................................................................
6.11.3 Battery Commissioning ............................................................................................
6.11.4 Battery Maintenance ................................................................................................
6.11.5 Electrolyte - Specific Gravity and Temperature .......................................................
6.11.6 Battery Replacement................................................................................................
6.11.7 Electrolyte Levels and Bench Charging Rates ........................................................
6.11.8 Battery Fault Finding................................................................................................
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7. TROUBLESHOOTING .................................................................................................................
7.1 Control System .....................................................................................................................
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7.2 Safety Considerations...........................................................................................................
7.3 Fault Finding .........................................................................................................................
7.4 Status Indicators - PCC 2100 ...............................................................................................
7.4.1 Running Indicator .......................................................................................................
7.4.2 Remote Start Indicator ..............................................................................................
7.4.3 Not in Auto ................................................................................................................
7.4.4 Configurable Indicators ..............................................................................................
7.4.5 Shutdown Status .......................................................................................................
7.4.6 Warning Status Indicator............................................................................................
7.5 Fault/Status Codes - PCC 2100 ...........................................................................................
7.5.1 Fault/Status Codes.....................................................................................................
7.5.2 Fault Messages..........................................................................................................
7.5.3 Fault Acknowledgement.............................................................................................
7.5.4 Category A Fault Codes.............................................................................................
7.5.5 Category B Fault Codes.............................................................................................
7.5.6 Category C Fault Codes ............................................................................................
7.5.7 Category D Fault Codes ............................................................................................
7.5.8 Category E Fault Codes.............................................................................................
7.5.9 PCC 2100 Fault Codes Table....................................................................................
7.5.10 Warning and Shutdown Codes ................................................................................
7.6 Line Circuit Breaker ..............................................................................................................
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8. BATTERY CHARGER..................................................................................................................
8.1 Battery Charger - 15 Amp @ 12 Volt and 12 Amp @ 24 Volt ..............................................
8.1.1 Control Panel .............................................................................................................
8.1.2 Battery Charger Configuration ...................................................................................
8.1.3 Battery Temperature Sensor......................................................................................
8.2 Circuits ..................................................................................................................................
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9. MANUFACTURING FACILITIES..................................................................................................
9.1 How to Obtain Service ..........................................................................................................
9.1.1 Locating Your Distributor ...........................................................................................
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A034G614 (Issue 3)
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Important Safety Instructions
SAVE THESE INSTRUCTIONS - This manual contains important instructions that should be
followed during installation and maintenance of the generator set and batteries.
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.
1.1
Warning, Caution and Note Styles Used In This
Manual
The following safety styles and symbols found throughout this manual indicate potentially
hazardous conditions to the operator, service personnel or the equipment.
DANGER: Warns of a hazard that will result in severe personal injury or death.
WARNING: Warns of a hazard that may result in severe personal injury or death.
CAUTION: Warns of a hazard or an unsafe practice that can result in product or property
damage.
NOTE:
1.2
A short piece of text giving information that augments the current text.
General Information
This manual should form part of the documentation package supplied by Cummins Power
Generation with specific generator sets. In the event that this manual has been supplied in
isolation please contact your authorized distributor.
NOTE:
1.2.1
It is in the Operator’s interest to read and understand all Warnings and
Cautions contained within the documentation relevant to the generator set,
its operation and daily maintenance.
General Safety Precautions
WARNING: Coolants under pressure have a higher boiling point than water. DO NOT
open a radiator or heat exchanger pressure cap while the engine is
running. Allow the generator set to cool and bleed the system pressure first.
To prevent severe scalding, let the engine cool down before removing the
coolant pressure cap. Turn the cap slowly, and do not open it fully until the
pressure has been relieved.
WARNING: Used engine oils have been identified by some state or federal agencies as
causing cancer or reproductive toxicity. When checking or changing engine
oil, take care not to ingest, breathe the fumes, or contact used oil.
NOTE:
Keep multi-class ABC fire extinguishers handy. Class A fires involve ordinary
combustible materials such as wood and cloth; Class B fires involve
combustible and flammable liquid fuels and gaseous fuels; Class C fires
involve live electrical equipment. (ref. NFPA No. 10 in applicable region)
CAUTION: Make sure that rags are not left on or near the engine.
A034G614 (Issue 3)
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1. Important Safety Instructions
9-2011
CAUTION: Make sure the generator set is mounted in a manner to prevent combustible
materials from accumulating under the unit.
CAUTION: Remove all unnecessary grease and oil from the unit. Accumulated grease and oil
can cause overheating and engine damage which present a potential fire hazard.
CAUTION: Keep the generator set and the surrounding area clean and free from obstructions.
Remove any debris from the set and keep the floor clean and dry.
WARNING: Do not work on this equipment when mentally or physically fatigued, or after
consuming any alcohol or drug that makes the operation of equipment
unsafe.
WARNING: Substances in exhaust gases have been identified by some state or federal
agencies as causing cancer or reproductive toxicity. Take care not to breath,
ingest, or come into contact with exhaust gases.
WARNING: Do not store any flammable liquids, such as fuel, cleaners, oil, etc., near the
generator set. A fire or explosion could result.
WARNING: Wear hearing protection when going near an operating generator set.
WARNING: To prevent serious burns, avoid contact with hot metal parts such as the
radiator, the turbo charger, and the exhaust system.
WARNING: Use personal protective equipment when maintaining or installing the
generator set. Examples of personal protective equipment include but are not
limited to: safety glasses, protective gloves, hard hats, steel-toed boots, and
protective clothing.
WARNING: Do not use starting fluids that evaporate. They are highly explosive.
CAUTION: Do not step on the generator set when entering or leaving the generator room.
Parts can bend or break leading to electrical shorts, or to fuel, coolant, or exhaust
leaks.
CAUTION: To prevent accidental or remote starting while working on the generator set,
disconnect the negative (-) battery cable at the battery.
WARNING: Ethylene glycol, used as engine coolant, is toxic to humans and animals.
Clean up spills and dispose of used engine coolant in accordance with local
environmental regulations.
WARNING: Moving parts can cause severe personal injury or death. Hot exhaust parts
can cause severe burns. Make sure all protective guards are properly in
place before starting the generator set.
1.3
Generator Set Safety Code
Before operating the generator set, read the manuals and become familiar with them 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.
WARNING: Improper operation and maintenance can lead to severe personal injury or
loss of life and property by fire, electrocution, mechanical breakdown, or
exhaust gas asphyxiation. Read and follow all Safety Precautions, Warnings
and Cautions throughout this manual and the documentation supplied with
your generator set.
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A034G614 (Issue 3)
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1. Important Safety Instructions
WARNING: Lifting and repositioning of the generator set must only be carried out using
suitable lifting equipment, shackles, and spreader bars, in accordance with
local guidelines and legislation, by suitably trained and experienced
personnel. Incorrect lifting can result in severe personal injury, death and/or
equipment damage. For more information, contact your authorized
distributor.
1.3.1
Moving Parts Can Cause Severe Personal Injury Or Death
· Keep your hands, clothing, and jewelry away from moving parts.
· Before starting work on the generator set, disconnect the battery charger from its AC
source, then disconnect the starting batteries, negative (–) cable first. This will prevent
accidental starting.
· Make sure that fasteners on the generator set are secure. Tighten supports and clamps;
keep guards in position over fans, drive belts, etc.
· Do not wear loose clothing or jewelry in the vicinity of moving parts or while working on
electrical equipment. Loose clothing and jewelry can become caught in moving parts.
· If any adjustments must be made while the unit is running, use extreme caution around hot
manifolds, moving parts, etc.
1.3.2
Positioning of Generator Set
The area for positioning the set should be adequate and level and the area immediately around
the set must be free of any flammable material.
WARNING: On an enclosed generator set, the canopy doors must be locked before repositioning and they must remain locked during transportation and sitting.
1.3.3
Positioning of Generator Set - Open Sets
The area for positioning the set should be adequate and level and the area immediately around
the set must be free of any flammable material.
1.4
Electrical Shocks and Arc Flashes Can Cause
Severe Personal Injury or Death
WARNING: Any work with exposed energized circuits with potentials of 50 Volts AC or
75 Volts DC or higher poses a significant risk of electrical shock and
electrical arc flash. These silent hazards can cause severe injuries or death.
Refer to standard NFPA 70E or equivalent safety standards in corresponding
regions for details of the dangers involved and for the safety requirements.
Guidelines to follow when working on de-energized electrical systems:
· Use proper PPE. Do not wear jewelry and ensure that any conductive items are removed
from pockets as these items can fall into equipment and the resulting short circuit can
cause shock or burning. Refer to standard NFPA 70E for PPE standards.
· De-energize and lockout/tagout electrical systems prior to working on them.
Lockout/Tagout is intended to prevent injury due to unexpected start-up of equipment or
the release of stored energy. Please refer to the lockout/tagout section for more
information.
A034G614 (Issue 3)
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1. Important Safety Instructions
9-2011
· De-energize and lockout/tagout all circuits and devices before removing any protective
shields or making any measurements on electrical equipment.
· Follow all applicable regional electrical and safety codes.
Guidelines to follow when working on energized electrical systems:
NOTE:
It is the policy of Cummins Inc. to perform all electrical work in a deenergized state. However, employees or suppliers may be permitted to
occasionally perform work on energized electrical equipment only when
qualified and authorized to do so and when troubleshooting, or if deenergizing the equipment would create a greater risk or make the task
impossible and all other alternatives have been exhausted.
NOTE:
Exposed energized electrical work is only allowed as per the relevant
procedures and must be undertaken by a Cummins authorized person with
any appropriate energized work permit for the work to be performed while
using proper PPE, tools and equipment. In summary:
· Do not tamper with or bypass interlocks unless you are authorized to do
so.
· Understand and assess the risks - use proper PPE. Do not wear jewelry
and ensure that any conductive items are removed from pockets as
these items can fall into equipment and the resulting short circuit can
cause shock or burning. Refer to standard NFPA 70E for PPE standards.
· Ensure that an accompanying person who can undertake a rescue is
nearby.
1.4.1
AC Supply and Isolation
It is the sole responsibility of the customer to provide AC power conductors for connection to
load devices and the means to isolate the AC input to the terminal box; these must comply to
local electrical codes and regulations. Refer to the wiring diagram supplied with the generator
set.
NOTE:
Local electrical codes and regulations (for example BS EN 12601:2001) may
require the installation of a disconnect means for the generator set, either on
the generator set or where the generator set conductors enter a facility.
NOTE:
The AC supply must have the correct over current and earth fault protection
according to local electrical codes and regulations. This equipment must be
earthed (grounded).
The disconnecting device is not provided as part of the generator set, and Cummins Power
Generation accepts no responsibility for providing the means of isolation.
1.5
Fuel And Fumes Are Flammable
Fire, explosion, and personal injury or death can result from improper practices.
· DO NOT fill fuel tanks while the engine is running, unless the tanks are outside the engine
compartment. Fuel contact with hot engine or exhaust is a potential fire hazard.
· DO NOT permit any flame, cigarette, pilot light, spark, arcing equipment, or other ignition
source near the generator set or fuel tank.
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A034G614 (Issue 3)
9-2011
1. Important Safety Instructions
· 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 copper piping on flexible lines
as copper will become brittle if continuously vibrated or repeatedly bent.
· Be sure all fuel supplies have a positive shutoff valve.
· Be sure the battery area has been well-ventilated prior to servicing near it. Lead-acid
batteries emit a highly explosive hydrogen gas that can be ignited by arcing, sparking,
smoking, etc.
1.5.1
Gaseous Fuels
· Natural gas is lighter than air, and will tend to gather under hoods. Propane is heavier than
air, and will tend to gather in sumps or low areas. NFPA code requires all persons handling
propane to be trained and qualified.
1.5.2
Spillage
Any spillage that occurs during fueling or during oil top-off or oil change must be cleaned up
before starting the generator set.
1.5.3
Fluid Containment
If fluid containment is incorporated into the bedframe, it must be inspected at regular intervals.
Any liquid present should be drained out and disposed of in line with local health and safety
regulations. Failure to perform this action may result in spillage of liquids which could
contaminate the surrounding area.
Any other fluid containment area must also be checked and emptied, as described above.
NOTE:
1.5.4
Where spillage containment is not part of a Cummins supply, it is the
responsibility of the installer to provide the necessary containment to
prevent contamination of the environment, especially water courses/sources.
Do Not Operate in Flammable and Explosive Environments
Flammable vapor can cause an engine to overspeed and become difficult to stop, resulting in
possible fire, explosion, severe personal injury and death. Do not operate a generator set where
a flammable vapor environment can be created by fuel spill, leak, etc., unless the generator set
is equipped with an automatic safety device to block the air intake and stop the engine. The
owners and operators of the generator set are solely responsible for operating the generator set
safely. Contact your authorized Cummins Power Generation distributor for more information.
1.6
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.
WARNING: Engine exhaust and some of its constituents are known to the state of
California to cause cancer, birth defects, and other reproductive harm.
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1. Important Safety Instructions
1.6.1
9-2011
Exhaust Precautions
WARNING: Exhaust pipes and charge air pipes are very hot and they can cause severe
personal injury or death from direct contact or from fire hazard.
WARNING: Hot exhaust gas can cause burns resulting in severe personal injury.
The exhaust outlet may be sited at the top or bottom of the generator set. Make sure that the
exhaust outlet is not obstructed. Personnel using this equipment must be made aware of the
exhaust position. Position the exhaust away from flammable materials - in the case of exhaust
outlets at the bottom, make sure that vegetation is removed from the vicinity of the exhaust.
WARNING: Inhalation of exhaust gases can result in serious personal injury or death. Be
sure deadly exhaust gas is piped outside and away from windows, doors, or
other inlets to buildings. Do not allow to accumulate in habitable areas.
WARNING: Contaminated insulation is a fire risk which can result in severe personal
injury.
The exhaust pipes may have some insulating covers fitted. If these covers become
contaminated by fuel or oil, they must be replaced before the generator set is run.
To minimize the risk of fire, make sure the following steps are observed:
· Make sure that the engine is allowed to cool thoroughly before topping off the oil or
draining the fuel filters.
· Clean the exhaust pipe thoroughly.
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Introduction
2.1
About This Manual
The purpose of this manual is to provide the users with sound, general information. It is for
guidance and assistance with recommendations for correct and safe procedures. Cummins
Power Generation (CPG) cannot accept any liability whatsoever for problems arising as a result
of following recommendations in this manual.
The information contained within the manual is based on information available at the time of
going to print. In line with Cummins Power Generation policy of continuous development and
improvement, information may change at any time without notice. The users should therefore
make sure that before commencing any work, they have the latest information available.
Users are respectfully advised that, in the interests of good practice and safety, it is their
responsibility to employ competent persons to carry out any installation work. Consult your
authorized distributor for further installation information. It is essential that the utmost care is
taken with the application, installation, and operation of any engine due to their potentially
hazardous nature. Careful reference should also be made to other Cummins Power Generation
literature. A generator set must be operated and maintained properly if you are to expect safe
and reliable operation.
Should you require further assistance, contact your authorized distributor.
2.2
Schedule of Abbreviations
This list is not exhaustive. For example, it does not identify units of measure or acronyms that
appear only in parameters, event/fault names, or part/accessory names.
AmpSentry and InPower are trademarks of Cummins Inc. PowerCommand is a registered
trademark of Cummins Inc.
ACRONYM
AC
AMP
ASTM
DESCRIPTION
Alternating Current
ACRONYM
LED
DESCRIPTION
Light-emitting Diode
AMP, Inc., part of Tyco Electronics
Mil Std
Military Standard
American Society for Testing and
Materials (ASTM International)
MMHG
Millimeters of Mercury
ATS
Automatic Transfer Switch
NC
Not Connected
AVR
Automatic Voltage Regulator
NC
Normally Closed
AWG
American Wire Gauge
CAN
Controlled Area Network
NFPA
National Fire Protection Agency
NO
Normally Open
CB
Circuit Breaker
NWF
Network Failure
CE
Conformité Européenne
OEM
Original Equipment Manufacturer
CFM
Cubic Feet per Minute
OOR
Out of Range
CGT
Cummins Generator Technologies
OORH / ORH
Out of Range High
CMM
Cubic Meters per Minute
OORL / ORL
Out of Range Low
CT
Current Transformer
A034G614 (Issue 3)
PSI
Pounds per square inch
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2. Introduction
9-2011
ACRONYM
DC
DESCRIPTION
ACRONYM
DESCRIPTION
Direct Current
PB
Push Button
ECM
Engine Control Module
PC
Personal Computer
ECS
Engine Control System
PCC
PowerCommand® Control
EMI
Electromagnetic interference
PGI
Power Generation Interface
EN
European Standard
PGN
Parameter Group Number
EPS
E-Stop
Engine Protection System
PI
Proportional/Integral
Emergency Stop
PID
Proportional/Integral/Derivative
FAE
Full Authority Electronic
PLC
Programmable Logic Controller
FMI
Failure Mode Identifier
PMG
Permanent Magnet Generator
FSO
Fuel Shutoff
Genset
PT
Potential Transformer
Generator Set
PTC
Power Transfer Control
GCP
Generator Control Panel
PWM
Pulse-width Modulation
GND
Ground
RFI
Radio Frequency Interference
HMI
Human-machine Interface
RH
Relative Humidity
IC
Integrated Circuit
RMS
Root Mean Square
INHG
Inches of Mercury
RTU
Remote Terminal Unit
ISO
International Organization for
Standardization
SAE
Society of Automotive Engineers
kPA
kilo-Pascal
SPN
Suspect Parameter Number
LBNG
Lean-burn Natural Gas
SW_B+
LCD
Liquid Crystal Display
UL
LCL
Low Coolant Level
LCT
Low Coolant Temperature
2.3
UPS
Switched B+
Underwriters Laboratories
Uninterruptible Power Supply
Related Literature
Before any attempt is made to operate the generator set, the operator should take time to read
all of the manuals supplied with the generator set, and to familiarize themselves with the
warnings and operating procedures.
CAUTION: A generator set must be operated and maintained properly if you are to expect safe
and reliable operation. The Operator manual includes a maintenance schedule and
a troubleshooting guide.
The relevant manuals appropriate to your generator set are also available:
· Operator Manual for GGHG/GGHH (A034G614)
· Installation Manual for GGHG/GGHH (A034G612)
· Specification and Data Sheet (For engineering data specific to the generator set)
· Application Manual T-030, Liquid Cooled Generator Sets (For application information)
· Parts Manual for GGHG/GGHH (0928-0242)
· Recommended Spares List (RSL) for GGHG/GGHH (RSL_458)
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2. Introduction
· Warranty Manual (F1117-0002)
· Global Commercial Warranty Statement (A028U870)
· Ford V10 Wiring Diagram (WH-0000-15)
2.3.1
Further Information - Literature
Contact your authorized distributor for more information regarding related literature for this
product.
2.4
After Sales Services
We offer a full range of maintenance and warranty services.
2.4.1
Maintenance
WARNING: Incorrect service or parts replacement can result in severe personal injury,
death, and/or equipment damage. Service personnel must be trained and
experienced to perform electrical and/or mechanical service.
For customers who wish to have their generator sets expertly serviced at regular intervals your
local distributor offers a complete maintenance contract package. This covers all items subject
to routine maintenance and includes a detailed report on the condition of the generator set. In
addition, this can be linked to a 24-hour call-out arrangement, providing year-round assistance if
necessary. Specialist engineers are available to maintain optimum performance levels from
customer’s generator sets, and it is recommended that maintenance tasks are only undertaken
by trained and experienced technicians provided by your authorized distributor.
2.4.2
Warranty
For details of the warranty coverage for your generator set, refer to the Global Commercial
Warranty Statement (A028U870).
Extended warranty coverage is also available. In the event of a breakdown, prompt assistance
can normally be given by factory trained service technicians with facilities to undertake all minor
and many major repairs to equipment on site.
For further warranty details, contact your authorized distributor.
NOTE:
Damage caused by failure to follow the correct coolant recommendations will
not be covered by the warranty. Please contact your authorized distributor.
2.4.2.1 Warranty Limitations
For details of the warranty limitations for your generator set, refer to the Warranty Statement
applicable to the generator set application.
2.4.3
How to Obtain Service
When a product requires servicing, contact your nearest Cummins Power Generation distributor.
To locate your local Cummins Power Generation distributor, refer to www.cumminspower.com
and select Distributor Locator. When contacting your distributor, always supply the complete
Model, Specification, and Serial Number as shown on the nameplate.
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2. Introduction
9-2011
2.4.3.1 Locating Your Distributor
In North America
Telephone +1-800-888-6626 (this is an automated service for touch-tone phones only) to
contact the nearest Cummins Power Generation distributor in the United States or Canada. By
selecting Option 1 (press 1), you will be automatically connected to the distributor nearest you.
If you are unable to contact a distributor using the automated service, consult the Yellow Pages.
Typically, our distributors are listed under:
GENERATORS – ELECTRIC or
ENGINES – GASOLINE OR DIESEL
If you have difficulty arranging service or resolving an issue, please contact the Service
Manager at the nearest Cummins Power Generation distributor for assistance.
When contacting your distributor, always supply the complete Model, Specification, and Serial
Number as shown on the product nameplate.
Outside North America
If you are outside North America, telephone Cummins Power Generation at +1-763-574-5000
from 7:30 am to 4:00 pm, Central Standard Time, Monday through Friday, or fax +1-763-5287229.
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A034G614 (Issue 3)
3
System Overview
This section provides an overview of the Generator Set.
3.1
Generator Set Identification
Each generator set is provided with a nameplate similar to that shown below. This provides
information unique to each generator set.
3.1.1
Nameplate
FIGURE 1.
3.2
TYPICAL GENERATOR SET NAMEPLATE
Generator Set Components
The main components of a typical Ford V-10 6.8L engine generator set are shown below, and
referred to within this section.
There are various options are listed although they may not be available for all models.
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3. System Overview
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1
Radiator
(Not indicated)
2
Engine
Battery and Tray
3
Controller
Alarm Module
4
Battery
Battery Charger
5
Alternator
Engine Coolant Heater
6
Bed Frame
Alternator Heater
FIGURE 2.
3.3
TYPICAL FORD V-10 6.8L ENGINE GENERATOR SET
Generator Set Rating
For details of your generator set rating, refer to the Generator Set nameplate. Refer to Section
5.6 on page 53 for operation at temperatures or altitudes above those stated on the nameplate.
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A034G614 (Issue 3)
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3.4
3. System Overview
Engine
For additional engine specific information, refer to the relevant engine manual for your generator
set.
1
Oil filler cap
2
Fan belt
3
Dipstick
FIGURE 3.
A034G614 (Issue 3)
TYPICAL ENGINE COMPONENTS (FORD V-10 6.8L)
13
3. System Overview
3.4.1
9-2011
Engine Data
3.4.1.1 Engine Fuel Consumption
TABLE 1.
FUEL CONSUMPTION (L/HR) AT 1500 RPM (50 HZ)
Model
Engine
Engine Performance Data at 60Hz
1
GGHH
GGHH
NG
LP
30.1
11.3
1. Standby/Full Load
Refer to Data Sheets for other applications. In line with the CPG policy of continuous improvement, these figures are
subject to change.
TABLE 2.
FUEL CONSUMPTION (STANDBY/PRIME/50 HZ)
Model
GGHH
Standby
cfh (m3/hr)
LPG (Vapor or Liquid)
Natural Gas
399.4 (11.3)
1062.5 (30.1)
TABLE 3.
FUEL CONSUMPTION (L/HR) AT 1800 RPM (60 HZ)
Model
GGHG
GGHG
GGHH
GGHH
Engine
NG
LP
NG
LP
Engine
Performance
Data at 60Hz1
33.2
12.4
30.9
13.2
1. Standby/Full Load
Refer to Data Sheets for other applications. In line with the CPG policy of continuous improvement, these figures are
subject to change.
TABLE 4.
FUEL CONSUMPTION (STANDBY/PRIME/60 HZ)
Model
GGHG
GGHH
Standby
cfh (m3/hr)
LPG (Vapor or Liquid)
Natural Gas
439.7 (12.4)
1173 (33.2)
467 (13.2)
1090 (30.9)
3.5
Sensors
Various generator set parameters are measured by sensors, and the resulting signals are
processed by the control board.
Engine-mounted sensors monitor a number of different systems, including:
· Lube Oil Pressure
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3. System Overview
· Cooling System Temperature
3.6
Heaters
CAUTION: Energizing heater(s) when the coolant system has been drained or if there is a
suspicion that the coolant is frozen can result in equipment damage. Always make
sure the radiator is filled to the recommended level before energizing the heater(s).
3.6.1
Heater Supply and Isolation
A heater supply is required for the operation of the engine and alternator heaters (if fitted).
3.7
NOTE:
It is the sole responsibility of the customer to provide the power supply and
the means to isolate the AC input to the terminal box. Cummins Power
Generation accepts no responsibility for providing the means of isolation.
NOTE:
This disconnecting device is not provided as part of the generator set.
Mains (Utility) Powered Battery Charger
This unit maintains the battery in a fully charged condition without over-charging. The unit also
provides rapid charging, when necessary, at a current up to the rated output.
The charger’s electronic control circuit allows the charger to be left in circuit during engine
cranking and to operate in parallel with the charge alternator.
The charger will supply current to the battery system until the battery terminal voltage becomes
equal to the set float voltage, at which point only a trickle charge current is present. When the
battery becomes discharged due to a load being present and the terminal voltage falls, the
charger will again supply current to restore the voltage of the battery to the float voltage.
CAUTION: Disconnect the battery charger before isolating the battery. Failure to do so can
result in voltage spikes high enough to cause equipment damage and personal
injury.
For more information on Battery Chargers see Chapter 8 on page 89.
3.8
Alarm Module
The Alarm Module provides audible warnings. It includes a push button switch to silence the
horn. It also includes a red LED to announce an active alarm and an amber LED that indicates
when the horn is silenced.
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3. System Overview
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FIGURE 4.
3.9
ALARM MODULE
Coolant Heater
A coolant heater keeps the engine coolant warm when the engine is shut down. It heats and
circulates the coolant within the engine. This reduces start-up time and lessens engine wear
caused by cold starts. It is electrically operated and thermostatically controlled.
Make sure the coolant heater is plugged into a grounded outlet. If an extension cord is used, it
must be a grounded type.
3.10
System Options
3.10.1 Normal Duty Air Cleaner
The standard air cleaner assembly includes two air cleaner cannisters.
FIGURE 5.
16
NORMAL AIR CLEANER ASSEMBLY
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3. System Overview
3.10.2 PowerCommand Universal Annunciator
A universal annunciator provides lamps and a horn to annunciate the operating status and fault
conditions of an emergency power system. It is designed for connection to either a 12 VDC or a
24 VDC control system. It can be configured to be either a positive or negative signal device.
Two versions of the PowerCommand universal annunciator are available.
· Panel Mounted
· Panel with Enclosure
The universal annunciator can communicate using either a PCCNet or a Modbus network.
Refer to the annunciator owner's manual for more information.
No.
Description
No
Description
1
System Status Lamps
4
Silence/Lamp Test Button
2
Insert Card
5
Network Status Lamp
3
Horn
FIGURE 6.
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ANNUNCIATOR COMPONENTS
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This page is intentionally blank.
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4
Control System - PCC 2100
4.1
Control System Description
This manual covers the PowerCommand® Control 2100 (PCC2100) control module for single
generator sets. All indicators, control switches/buttons and digital display are located on the face
of the control panel as illustrated in the figure below.
The main control panel and its associated equipment are located in the Control Housing, which
is mounted at the rear of the generator set. A Load Terminal Box may be mounted on either the
left or right side of the housing, as required for the site.
The PCC2100 is a microprocessor-based control for generator sets. It provides fuel control and
engine speed governing, main alternator voltage output regulation, and complete generator set
control and monitoring. The control also monitors the health of the engine, alternator, and
auxiliary systems continuously, and will affect an Automatic Shutdown if a serious fault occurs.
The PCC2100 operates in conjunction with an array of sensors and senders located on the
engine, alternator and auxiliary systems. Data is passed between components over a digital
data link.
An important function of the control system is to continuously monitor the generator set for
faults. If a fault occurs during engine running, the control will provide an indication for the
operator and, if the fault is serious, affect an automatic, fully programmed, shutdown. There are
two fault level signals generated by the PCC2100. These two fault levels are:
1. Warning: signals an imminent or non-critical engine fault. The PCC2100 provides an
indication only for this condition.
2. Shutdown: signals a potentially critical fault for the engine. The PCC2100 will
automatically take the engine off-load and shut it down immediately, without a cooldown
run.
The control systems operate on 12 or 24VDC battery power. Data backup is taken care of by a
small rechargeable battery installed within the PCC2100 enclosure. Auxiliary equipment
operates on low voltage AC power.
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4. Control System - PCC 2100
NO
9-2011
DESCRIPTION
NO DESCRIPTION
1
Home Button
8
Configurable Indicators
2
Menu Selection Button (1 of 4)
9
Shutdown & Warning Status Indicators
3
Digital Display
10 Fault Acknowledgement/Reset Button
4
Panel Lamp
11 Panel Lamp & Lamp Test Button
5
Previous Main Menu Button
12 O/Manual/Auto Key Switch (Mode Switch)
6
Emergency Stop Push Button
13 Manual Run/Stop Button
7
Running/Remote Start/Not in Auto Indicators
14 Analog AC Metering Panel (Optional)
FIGURE 7.
4.2
FRONT PANEL
Control Panel Power On/Off Modes
The power on/off modes of the control panel and operating software are Power On, Screen
Saver, and Sleep/Awake.
4.2.1
Power On Mode
In this mode, power is continuously supplied to the control panel. The control's operating
software and control panel LEDs/graphical display will remain active until the Screen Saver
mode is activated.
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4.2.2
4. Control System - PCC 2100
Screen Saver Mode
Power to the graphical display will be removed after 10 minutes (generator set not running or
running). The 10 minute timer resets and begins after each control panel action (any button or
switch selection) or signal received by the operating software. The bottom LEDs of the Analog
AC Metering Panel (bar graphs) may stay On during Screen Saver mode, indicating that the
operating software is active (Awake mode).
When a "Warning" signal (for example, low coolant temp) is sensed by the control will display
the warning message. The control will remain active until the Fault Acknowledge button is
pressed to clear the warning message and start the 10 minute timer.
4.2.3
Sleep/Awake Mode
In the Sleep mode, the control's operating software is inactive and the LEDs and the digital
display on the control panel are all off. Sleep mode is a feature used to reduce battery power
consumption when the control is not being used and the O/Manual/Auto switch is in the O
position.
When all conditions are met (i.e., no unacknowledged faults and O/Manual/Auto switch is in the
O position), the Sleep mode is activated.
The operating software is initialized and the digital display and control panel LEDs are turned on
in response to moving/pressing the following control panel switch/buttons:
· Off/Manual/Auto switch
· Emergency Stop button
· Fault Acknowledge/Reset button
· Panel Lamp/Lamp Test button
To activate the control and view the menu display without starting the generator set, press the
Fault Acknowledge or Panel Lamp button or move the mode switch from O to Manual.
The InPowerTM service tool is required to enable or disable the Sleep mode. When shipped from
the factory, Sleep mode is disabled. When disabled, the operating software will always remain
active (Awake mode). If network and/or power transfer control (PTC) feature is installed, the
sleep mode is not available.
NOTE:
4.3
The InPower service tool is required to select the desired mode. Contact an
authorized service center for assistance.
Battle Short Mode
Battle Short mode is not a distinct mode of operation. The PowerCommand® control is still in the
Off, Manual, or Auto mode while Battle Short mode is active. The PowerCommand® control still
follows the appropriate sequence of operation to start and stop the generator set. Battle Short
mode is a generator set mode of operation that prevents the generator set from being shutdown
by all but a few, select, critical shutdown faults.
The purpose of Battle Short mode is to satisfy local code requirements, where necessary. To
use this feature, the necessary software must be installed at the factory when the
PowerCommand® control is purchased. Only authorized service personnel can enable this
feature. When shipped from the factory, this feature is disabled.
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4. Control System - PCC 2100
NOTE:
9-2011
The Battle Short feature must be enabled or disabled using the InPower
service tool.
WARNING: Use of the Battle Short mode feature can cause a fire or electrical hazard,
resulting in severe personal injury or death and/or property and equipment
damage. Operation of the set must be supervised during Battle Short
operation.
This feature must only be used during supervised, temporary operation of the generator set.
The faults that are overridden when in Battle Short mode can affect generator set performance,
or cause permanent engine, alternator or connected equipment damage.
CAUTION: If this mode of operation is selected, the protection of load devices will be disabled.
Cummins Power Generation will not be responsible for any claim resulting from the
use of this mode.
CAUTION: All shutdown faults, including those overridden by Battle Short, must be acted upon
immediately to ensure the safety and well being of the operator and the generator
set.
Battle Short is turned on or off with an external switch connected to one of the two customer
configured inputs or a soft switch on the operator panel.
When enabled, Battle Short switch input can be set using a Setup menu. To turn Battle Short
mode on using the soft switch in the operator panel, Battle Short must be set to Operator Panel
and enabled using the InPower service tool (default is Inactive).
When Battle Short mode is enabled, the Warning status indicator lights and code 1131 – Battle
Short Active – is displayed.
When Battle Short mode is enabled and an overridden shutdown fault occurs, the shutdown
lamp remains lit even though the set continues to run. Fault code 1416 – Fail to Shutdown – is
displayed. If the fault is acknowledge, the fault message is cleared from the display but remains
in the Fault History file as long as Battle Short mode is enabled.
Battle Short is suspended and a shutdown occurs immediately if any of the following critical
shutdown faults occur:
· Speed Signal Lost (Loss of Speed Sense) - Fault code 121
· Overspeed - Fault code 234
· Local Emergency Stop - Fault code 1433
· Remote Emergency Stop - Fault code 1434
· Excitation Fault (Loss of Voltage Sense) - Fault code 2335
Or
The Battle Short feature is disabled after an overridden shutdown fault occurred while in Battle
Short mode. Fault code 1123 – Shutdown After Battle Short – is then displayed.
4.4
Front Panel
The front panel contains the following components:
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4.4.1
4. Control System - PCC 2100
Digital Display
This two-line, 20-characters per line alphanumeric display is used to view menus of the menudriven operating system. Refer to the menu trees later in this section. The display is also used
to show warning and shutdown messages.
NO
Description
1
Home Button
2
Digital Display
3
Previous Main Menu Button
FIGURE 8.
4.4.2
DIGITAL DISPLAY AND MENU SELECTION BUTTON
Display Menu Selection Button
Four momentary buttons-two on each side of the digital display window-are used to step
through the various menu options and to adjust generator set parameters. A green triangle (◄
or ►), arrow (↑, ↓, ←, or →), >>, or plus/minus sign (+ or –) in the digital display adjacent to the
button is shown when the button can be used (button is "active").
· In the digital display for main menus, the ◄ or ► symbols indicate that pressing the
adjacent button causes the operating program to go to the selected submenu (e.g., Engine
Menu).
· In the digital display, the More>> symbol indicates that pressing the adjacent button
causes the operating program to go to the next main menu.
· In the digital display, the ↑ or ↓ symbols indicate that pressing the adjacent button causes
the operating program to go to the next or previous submenu, as shown in the menu
diagrams. Only the ↓ symbol is displayed in the first submenu. Only the ↑ is displayed in
the last submenu. Both symbols are displayed in the rest of the submenus.
· In the digital display, the plus or minus symbols (+ or –) indicate that pressing the adjacent
button can be used to change a parameter or value shown on the display.
When there is a choice of two parameters, one parameter is associated with the + symbol
and the other is associated with the – symbol.
When changing values, pressing the button adjacent to the + symbol increases the value
and pressing the button adjacent to the – symbol decreases the value. Only one numeric
character of a field can be changed at a time.
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· In the digital display, the ← or → symbol indicates that pressing the adjacent button
causes the operating program to move the cursor to the next numeric character. The
selected numeric character can then be changed by pressing the buttons adjacent to the +
and – symbols. Only the → symbol is displayed when the cursor is on the first character of
a field that can be changed. Only the ← is displayed when the cursor is on the last
character. Both symbols are displayed when the cursor is on any other character.
· After adjusting values/parameters, pressing the ► symbol results in the changes being
saved. If the Home button or Previous Main Menu button is pressed before pressing
the ► symbol, the changes are not saved.
4.4.3
Home Button
Press this button (◄◄) to view the Home Menu. Refer to the menu trees that appear later in
the manual.
4.4.4
Previous Main Menu Button
Press this button (◄) to view the previous Main Menu. All main menus include both types of
green triangles ( ◄ and ►). Refer to the menu trees later in this manual.
NOTE:
4.4.5
The up and down arrows (↑ and ↓) are used to navigate between the
submenus.
Emergency Stop Button
Push this button in for emergency shutdown of the generator set. This will stop the generator set
immediately and prevent starting of the set from any location (local and remote).
CAUTION: To avoid equipment damage, the Emergency Stop button must not be used for a
normal shutdown, as this will prevent a cooling run in which the lubricating oil and
engine coolant carry heat away from the engine combustion chamber and bearings
in a safe manner.
If the generator set is not running, pushing the button in will prevent the starting of the engine,
regardless of the Start signal source.
CAUTION: Ensure the remote start control is not active when the Emergency Stop is reset.
The generator set may start after the Emergency Stop is reset upon receiving a
remote start signal.
To reset:
1. Pull the button and allow it to pop out.
2. Turn the O/Manual/Auto switch to O.
3. Press the front panel Fault Acknowledge/Reset button.
4. Select Manual or Auto, as required.
NOTE:
Emergency Stop shutdown can be reset only at the operator panel.
CAUTION: Ensure that the cause of the emergency stop is fully investigated and remedied
before a fault Reset and generator Start are attempted.
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4. Control System - PCC 2100
NOTE:
4.4.6
On enclosed sets, an external Emergency Stop button is situated in close
proximity to the control panel viewing window. For open generator sets, it is
recommended that an additional Emergency Stop button be situated in close
proximity to the plant room exit.
Running Indicator
This green lamp is lit whenever the generator (local or remote) is running.
4.4.7
Remote Start Indicator
This green lamp indicates the control is receiving a remote run signal. When flashing, it
indicates a load demand stop mode.
4.4.8
Not in Auto
This red lamp flashes continuously when the O/Manual/Auto switch is not in the Auto position.
NOTE:
4.4.9
If the switch is in the Auto position and the lamp is still flashing, service is
required.
Analog AC Metering Panel
This panel simultaneously displays 3-phase line to line AC volts and current, kW, power factor
and frequency.
The meter panel is composed of a series of LEDs, that are configured in bar graphs for each
function. The LEDs are color coded, with green indicating normal range values, amber for
warning levels, and red for shutdown conditions.
Scales for each function are in % of nominal values. Resolution is 1% for values close to
nominal, and increases at values further from nominal.
4.4.10 Shutdown Status
This red lamp is lit when the control detects a Shutdown condition. The generator set cannot be
started when this lamp is on. After the condition has been corrected, the lamp can be reset by
turning the O/Manual/Auto switch to the O position, and pressing the Fault Acknowledge button.
The generator set cannot be started when this lamp is on.
Dependent upon the specific fault that occurs, the engine may or may not shut down
immediately. A fault that could cause engine damage, causes an immediate engine shutdown
(bypasses engine cooldown sequence). All other faults would allow the engine to run during the
cooldown sequence before engine shutdown. In this case, the Shutdown Status indicator blinks
during the cooldown period.
4.4.11 Warning Status Indicator
This yellow lamp is lit whenever the control detects a warning condition. After the condition is
corrected, warning indicators can be reset by pressing the Fault Acknowledge button. (It is not
necessary to stop the generator set if the fault becomes inactive during generator set
operation.) In auto mode, warning indicators can also be reset by cycling the remote reset input
after the condition is corrected.
A034G614 (Issue 3)
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4. Control System - PCC 2100
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Some warnings remain active after the condition is corrected and the control reset button
is pressed. This will require the generator set to be shut down to reset the warning
indicator.
4.4.12 Fault Acknowledgement/Reset Button
Press this button to acknowledge warning and shutdown messages after the fault has been
corrected. Pressing this button clears the fault from the current fault list.
To acknowledge a Warning message, the O/Manual/Auto switch can be in any position. (It is not
necessary to stop the generator set to acknowledge an inactive Warning condition.) To
acknowledge a shutdown message with this button, the O/Manual/Auto switch must be in the O
position.
4.4.13 Panel Lamp and Lamp (LED) Test Button
Press this button to turn the control panel lamps on or off. The lights will shut off after about ten
minutes. Press and hold this button to test all front panel LEDs and meters. The meters will light
one bar at a time.
4.4.14 Manual Run/Stop Button
This button starts and stops the generator set locally and will bypass the Time Delay to Start
and Stop sequences. The O/Manual/Auto switch must be in the Manual position to enable this
button.
4.4.15 O/Manual/Auto Switch
Manual position enables the use of the switch panel Manual Run/Stop button.
Auto position enables start/stop control of the engine from a remote location. (Disable the use of
the switch panel Manual Run/Stop button.)
O (off) position prevents the starting of the set (local or remote).
CAUTION: If moved to the O position during set operation, this will cause an immediate engine
shutdown (bypasses cooldown timers). Hot shutdowns should be avoided to
prolong the reliability of the generator set. Hot shutdowns are logged by the system
software.
NOTE:
When the generator set is operating in the Remote Start Mode, removing the
Remote Start Command does not shut off the engine if the load is more than
10 percent, the cooldown timer is set to zero, and the control is configured
for a single unit (not in parallel). The generator set continues to operate until
it runs out of fuel, the E-stop button is used, or the load is removed.
4.4.16 Configurable Indicators
The following configurable indicators (default values shown) can be changed with the InPower
service tool. The configurable items are: change generator event and LED color (green, yellow
or red), and enable/disable indicator.
The InPower service tool is required to select the desired settings. Contact an authorized
service center for assistance.
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4. Control System - PCC 2100
4.4.16.1 Low Oil Pressure Warning Indicator
This yellow lamp indicates the oil pressure is lower than the normal range of operation.
4.4.16.2 High Engine Temperature Warning Indicator
This yellow lamp indicates the engine temperature is higher than the normal range of operation.
4.4.16.3 Low Oil Pressure Shutdown Indicator
This red lamp indicates the engine has shut down because of low oil pressure.
4.4.16.4 Overspeed Shutdown Indicator
This red lamp indicates the engine has shut down because of excessive speed.
4.4.16.5 Fail to Start Indicator
This red lamp indicates the engine failed to start.
4.5
Control Menus
4.5.1
Main Menus
The figure below shows the three major main menus available to the user. When viewing a
submenu, you can press the previous main menu button at any time to view its main menu.
As shown in the illustration, each main menu can branch into one of four directions. Press the
button next to "More>>" in the display to view the next Main menu. Main Menu 1 is redisplayed
when you press the button next to "More>>" in the Main Menu 3 display.
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4. Control System - PCC 2100
NO
9-2011
DESCRIPTION
1
Main Menu 1
2
Main Menu 2
NO
3
FIGURE 9.
DESCRIPTION
Main Menu 3
MAIN MENUS
4.5.1.1 Main Menu 1
Main Menu 1 is also the Home menu. When viewing any of the other main menus or any
submenu, you can press the home button to view this menu.
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4. Control System - PCC 2100
To display engine parameters, such as coolant temperature, oil pressure, oil temperature, etc.,
press the button next to the word "Engine" in the display. Refer to the Engine menu diagram.
To display alternator parameters, such as line-to-line voltage, line-to-neutral voltage, amperage,
frequency, etc., press the button next to the word "Alternator" in the display. Turn to the
Alternator menu diagram.
To adjust generator parameters, such as idle start, voltage, frequency, start delay, and stop
delay, press the button next to the word "Adjust" in the display. Turn to the Adjust menu
diagram.
To view one of the other main menus, press the button next to "More>>" in the display.
4.5.1.2 Main Menu 2
To display system faults, press the button next to the word "Faults" in the display. Up to 20 of
the most recent/current faults can be displayed. Refer to the Faults menu diagram.
To view network system parameters, such as on the automatic transfer switch (ATS), Master, or
Genset system, press the button next to the word "System" in the display. Refer to the System
menu diagram.
To display historical engine parameters such as number of starts, engine hours, control hours,
kilowatt hours, and genset duty cycle, press the button next to the word "History" in the display.
Refer to the History menu diagram.
To view one of the other main menus, press the button next to "More>>" in the display.
4.5.1.3 Main Menu 3
To view parameters on the generator, such as model, standby rating, and software version,
press the button next to the word "About" in the display. Refer to the About menu diagram.
To view power transfer parameters, such as source power, frequency, generator, utility, and
active transfer timer, press the button next to the word "Pwr Tran" in the display. Refer to the
Power Transfer Menu
Main Menu 3 also includes a link to the Setup menus. These menus can be viewed but changes
to these menus are restricted to service personnel with the appropriate access code.
To view one of the other main menus, press the button next to "More>>" in the display.
4.5.2
Adjusting Default Settings
The Controller Configuration Menu can be used to adjust the following default settings:
· Language - Select from available loaded languages
· Temperature Units - Fahrenheit or Centigrade
· Fluid Pressure Units - kPA or PSI
For more information on adjusting these settings, turn to the Controller Configuration menu
diagram.
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System Messages
A system message pop-up screen is displayed when the event it is displaying becomes active.
These pop-up screens remain displayed until pre-empted by another pop-up screen or until any
display button is pressed. Once a button is pressed, the previous menu is redisplayed. To return
to an active pop-up screen from the previous menu, select the following menu:
· Engine to redisplay Time Delay Idle
· Faults to redisplay Faults
Pop-up screens are displayed for the following:
· Faults
· Power Transfer Control timer
· Time Delay - Start, Stop, and Idle
An example of a Time Delay Idle pop-up screen is shown below. A countdown, in seconds, is
included in the display.
FIGURE 10.
4.5.4
TIME DELAY IDLE POP-UP SCREEN
Controller Configuration Menu
Figure 11 on page 31 shows a block representation of the Controller Configuration menus.
These menus are used to change the default language, temperature units, and pressure units to
be displayed in menus.
To view the first Controller Configuration menu, make sure Main Menu 1 is displayed and
simultaneously press the Home Menu and Previous Main Menu buttons.
As shown in the diagram, the Controller Configuration menu has three submenus.
· Language Selected submenu: Used to select desired language (default = English).
· Temperature Units submenu: Used to select Fahrenheit or Centigrade for temperature
readings.
· Fluid Pressure Units submenu: Used to select PSI or kPA for pressure readings.
Press the buttons next to the up and down arrows in the digital display to navigate between the
menus.
Press the button next to the ► symbol in the display until the + and - symbols are displayed.
Press the button next to the + or – symbol to select the desired option.
After selecting option, pressing the ► symbol results in the changes being saved. If the Home
button or Previous Main Menu button is pressed before pressing the ► symbol, the changes are
not saved.
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FIGURE 11.
4.5.5
CONTROLLER CONFIGURATION MENU
Engine Menu
Figure 12 on page 33 shows a block representation of the Engine menu. If you press the
button next to the word "Engine" in the display, the first Engine submenu is displayed.
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As shown in the diagram, the Engine menu has seven submenus. The data in the submenus
will vary according to the type and number of sensors provided with the engine.
· Coolant Temperature submenu: This submenu displays the engine coolant temperature
which can be viewed in degrees Fahrenheit or Centigrade (see the Section 4.5.4).
· Oil Pressure submenu: This submenu displays the engine oil pressure which can be
viewed in PSI or kPA (see Section 4.5.4 on page 30).
· Oil Temperature submenu (Only available on some models): This submenu displays
the engine oil temperature which can be viewed in degrees Fahrenheit or Centigrade (see
Section 4.5.4 on page 30).
· Engine Speed submenu: This submenu displays the engine RPM.
· Battery Voltage submenu: This submenu displays the engine battery voltage.
· Governor Duty Cycle submenu: This submenu displays the governor duty cycle (drive)
levels in percentage of maximum.
· Active Time Delay submenu: This submenu displays the time delay that is currently
active: warm-up, cooldown, start, or stop delays.
Press the buttons next to the ↓ and ↑ symbols in the digital display to navigate between the
menus. Press the Home button or the Previous Main Menu button to return to Main Menu 1.
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FIGURE 12.
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ENGINE MENU
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Alternator Menu
Figure 13 on page 35 shows a block representation of the Alternator menu. If you press the
button next to the word "Alternator" in the display, the first Alternator submenu is displayed.
As shown in the diagram, the Alternator menu has eleven submenus.
· Line-to-Line Voltage submenu: The voltages Line-to-Line (L1, L2 and L3) are measured
between L1 to L2, L2 to L3 and L3 to L1, respectively. (Single phase - L1 to L2 only.)
· Line-to-Neutral Voltage submenu: Note that the Line-to -Neutral menu will not be
displayed for a 3 phase/3 wire system. Single phase - L1 to N and L2 to N.
· Amps submenu: All phases. (Single phase - L1 and L2 only.)
· Frequency submenu: Generator set output frequency.
· Total Real Power submenu: This submenu displays the total amount of real power
output, in kilowatts (kW).
· Real Power submenu: This submenu displays the amount of real power output for L1,
L2, and L3, in kilowatts (kW). (Single phase - L1 and L2 only.)
· Total Apparent Power submenu: This submenu displays the total amount of apparent
power output, in kilovolt amps (kVA).
· Apparent Power submenu: This submenu displays the amount of apparent power output
for L1, L2, and L3, in kilovolt amps (kVA). (Single phase - L1 and L2 only.)
· Total Power Factor submenu: This submenu displays the power factor with
leading/lagging indication.
The PF reading will contain an asterisk if the power factor is leading (for example, Total PF
0.9*).
· Power Factor submenu: This submenu displays a power factor value for L1, L2, and L3.
(Single phase - L1 and L2 only.)
The PF reading will contain an asterisk if the power factor is leading (for example, PF L1
0.9*).
· AVR Duty Cycle submenu: This submenu displays the voltage regulator (drive) level in
percentage of maximum. (Where maximum is 100% Duty Cycle, software clamps Duty
Cycle maximum to 60% for PMG and 90% for shunt.)
Press the buttons next to the ↑ and ↓ arrows in the digital display to navigate between the
menus. Press the Home button or the Previous Main Menu button to return to Main Menu 1.
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FIGURE 13.
4.5.7
ALTERNATOR MENU
Adjust Menu
Figure 14 on page 37 shows a block representation of the Adjust menu. If you press the button
next to the word "Adjust" in the display, the first Adjust submenu is displayed.
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As shown in the diagram, the Adjust menu has six submenus. Each submenu includes a
parameter or value that can be changed.
· Voltage Adjust submenu: Voltage can be adjusted to 5 percent of the nominal voltage.
For example, if generator set output voltage is 208 volts, the voltage can be adjusted from
198 to 218 volts.
If the displayed value is greater or less than the allowed (5%) range, the control will not
except the entry and will return to the previous setting. Retry by entering a smaller change
in one volt increments.
· Frequency Adjust submenu: Frequency can be adjusted to 5 percent of the nominal
frequency. For example, if the generator set frequency is 60.0 Hz, the frequency can be
adjusted from 57.0 to 63.0 Hz.
· Start Delay submenu: Start Delay can be set from 0 to 300 seconds (default = 0). (Enter
1 or more to enable.) This function is bypassed during a manual start/stop sequence.
· Stop Delay submenu: Stop Delay can be set from 0 to 600 seconds (default = 0). (Enter
1 or more to enable.) This function is bypassed during a manual start/stop sequence and
engine shutdown faults.
· Rated To Idle (Beginning Version 2.303): Rated To Idle delay can be set from 0 to 10
seconds (default = 0). (Enter 1 or more to enable.) Entering a non-zero delay will cause the
generator set to delay the transition to Cooldown At Idle.
· Idle Start submenu (Only available on some models): Idle Start can be enabled or
disabled (default = Disable). This function is only enabled when the generator set is started
in manual mode. Idle Start can also be enabled while the generator set is running in
manual mode. (Auto/remote start is not affected by this setting.)
Press the buttons next to the ↑ and ↓ arrows in the digital display to navigate between the
menus. Press the Home button or the Previous Main Menu button to return to Main Menu 1.
Adjusting Values/Parameters:
1. Press the button next to the ► symbol in the display until the + and - symbols are
displayed.
2. If necessary, press the button next to the symbols to move to the numeric character you
wish to change.
3. Press the button next to the + symbol to increase the value or select parameter; press the
button next to the – symbol to decrease the value or select parameter.
4. After adjusting values/selecting parameters, pressing the ► symbol results in the changes
being saved. (When adjusting values, make sure the cursor is on the last numeric
character before pressing the ► symbol).
If the Home button or Previous Main Menu button is pressed before pressing the ►
symbol, the changes are not saved.
Enabling Idle Start will cause the genset to run in idle mode until Idle Start is disabled. A
warning is displayed if genset is left in idle more than 10 minutes. Long periods of engine idling
can eventually affect engine performance and may void engine warranty.
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FIGURE 14.
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ADJUST MENU
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Faults Menu
Figure 15 shows a block representation of the Faults menu. Up to 20 of the most recent faults
can be viewed. An example of how a fault code is displayed is shown in Figure 16 on page 39.
FIGURE 15.
38
FAULTS MENU
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The available menus are dependent on the number of faults that have occurred.
· History submenu: From the Faults Main Menu, press the button next to the word "History"
in the display to view up to twenty of the most recent acknowledged faults. Press the
buttons next to the ↑ and ↓ symbols in the digital display to navigate between the menus.
Press the Previous Main Menu button to return to the Faults Main Menu.
· Current Fault submenu: From the Faults Main Menu, press the button next to the word
"Current" in the display to view up to twenty of the most recent unacknowledged faults.
Press the Previous Main Menu button to return to the Faults Main Menu.
If there are no faults, the ◄ symbol next to the word "Faults" is not displayed and no Fault
menus are available.
If more than one fault has occurred, press the button next to the word "Fault" in the screen
display to view the Faults Main Menu. As shown in the diagram, the Faults Main Menu has two
submenus. Press the Previous Main Menu button to return to the Faults Main Menu. Press the
Previous Main Menu button a second time to return to Main Menu 2.
Press the Home button at any time to return to Main Menu 1.
NO
DESCRIPTION
NO
DESCRIPTION
1
Asterisk = Active Fault
4
W=Warning
S=Shutdown
2
Fault Code
5
Fault Description
3
Hour Fault Occurred
FIGURE 16.
4.5.9
HISTORY/CURRENT FAULT SUBMENU
System Menu
Figure 17 on page 40 shows a block representation of the System menu. If you press the
button next to the word "System" in the display, the System Main Menu is displayed. This menu
is displayed only if the network communications module (NCM) feature is installed. The System
Main Menu allows you to view the status and load of other PCC equipment connected on a
common network with the PCC 2100 control.
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As shown in the diagram, the System Main Menu has one set of submenus.
· Genset System submenus: From the System Main Menu, press the button next to the
word "Genset" in the display to view the first of up to 16 Genset System submenus. One
generator set must be available in the network to display this submenu.
The genset submenu allows viewing of the generator set name (configured with InPower),
kW load and operational state.
FIGURE 17.
SYSTEM MENU
4.5.10 History Menu
Figure 18 on page 42 shows a block representation of the History menu. If you press the
button next to the word "History" in the display, the first History submenu is displayed.
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As shown in the diagram, the History menu has five submenus. This information is stored in
non-volatile memory and will not be deleted due to loss of battery power.
· Number of Starts submenu: This submenu shows the number of engine starts.
· Engine Hours submenu: This submenu shows the number of operating hours for the
engine.
· Control Hours submenu: This submenu shows the number of operating hours for the
control.
· Kilowatt Hours submenu: This submenu shows the number of kilowatt (kW) or megawatt
(MW) hours.
· Genset Duty Cycle submenu: This submenu shows the percent of genset operating
hours that are less than 30 percent of rated load and percent of hours that are greater than
90 percent.
Press the buttons next to the ↑ and ↓ symbols in the digital display to navigate between the
menus. Press the Previous Main Menu button to return to Main Menu 2. Press the Home button
to return to Main Menu 1.
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FIGURE 18.
HISTORY MENU
4.5.11 About Menu
Figure 19 on page 43 shows a block representation of the About menu. If you press the button
next to the word "About" in the display, the first About submenu is displayed.
As shown in the diagram, the About menu has three submenus.
· Model submenu: This submenu shows the generator set model.
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· Rating submenu: This submenu shows the rating (Standby or Prime and number of
kilowatts (kW)).
· Software Version submenu: This submenu shows the software version level. This
information is required to service the generator set.
Press the buttons next to the ↑ and ↓ symbols in the digital display to navigate between the
menus. Press the Previous Main Menu button to return to Main Menu 3. Press the Home button
to return to Main Menu 1.
FIGURE 19.
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ABOUT MENU
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Operation - PCC 2100
5.1
Safety
Only trained and experienced personnel should carry out generator set operations. Before
operating the system, the operator should become familiar with all the safety instructions, see
Chapter 1 on page 1, together with the Health and Safety manual. Observe all of the
WARNINGS and CAUTIONS at all times.
WARNING: Before operating the generator set become familiar with the equipment and
how it is operated (including all controls, manually operated valves and alarm
devices). Safe and efficient operation can ONLY BE achieved if the plant is
operated correctly.
WARNING: Contacting high voltage components can cause severe personal injury or
death by electrocution. Do not open the generator output box while the
generator set is running. Read and observe all warnings and cautions in your
generator set manuals.
CAUTION: Only technically qualified personnel should open the control housing. Voltages are
present which can cause electrical shock, resulting in personal injury. Even with the
power removed, improper handling of components can cause electrostatic
discharge and damage circuit board components.
WARNING: Exhaust gases contain carbon monoxide, an odorless and colorless gas.
Carbon monoxide is poisonous and can cause unconsciousness and death.
Symptoms of carbon monoxide poisoning include:
· Dizziness
· Nausea
· Headache
· Weakness and sleepiness
· Throbbing in temples
· Muscular twitching
· Vomiting
· Inability to think coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GET
OUT INTO FRESH AIR IMMEDIATELY. If symptoms persist, seek medical
attention. Shut down the unit and do not operate until it has been inspected
and repaired.
Protection against carbon monoxide inhalation includes proper installation
and regular, frequent visual and audible inspections of the complete exhaust
system.
5.2
Introduction
This section describes the operation of the generator set. The text should be read in conjunction
with the System Overview and the Control System Sections of this manual, together with the
Operator’s specific engine manual. This latter manual will contain further information regarding
the running and care of the generator set and also specific equipment instructions that may
differ from the standard generator set.
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All indicators, control switches/buttons, and graphical display are located on the face of the
Operator Panel.
5.3
Maintenance
To ensure maximum performance and reliability from your generator set, it is essential that
certain components are inspected periodically and, where necessary, maintenance procedures
are carried out, as detailed in Chapter 6 on page 55.
5.4
Starting
The following headings cover the systems used to start the generator set.
Before starting the generator set, make sure that the exhaust and fuel fittings are tight and
properly positioned and that proper maintenance has been performed.
5.4.1
Starting - Safety Consideration
CAUTION: One operator should be in complete charge, or working under the direction of
someone who is in charge. Remember that, upon starting the engine, cables and
switchgear will become energized, possibly for the first time. Furthermore,
equipment that does not form part of the generator set installation may become
electrically charged. Only authorized and competent personnel should carry out this
work.
CAUTION: Do not use the Emergency Stop switch to shut down an engine unless a serious
fault develops. The Emergency Stop push-switch must not be used for a normal
shut-down as this will prevent a cooling down run in which the lubricating oil and
engine coolant carry the heat away from the engine combustion chamber and
bearings in a safe manner.
CAUTION: Avoid off-load running for other than short periods. A minimum loading of 30% is
recommended. This loading will help to prevent the build up of carbon deposits in
the injectors, due to unburnt fuel, and reduce the risk of fuel dilution of the engine
lubricating oil. The engine must be shut down as soon as possible after the
appropriate functions have been checked.
5.4.2
Operator’s Pre-start Checks
WARNING: Windings of high voltage, 601 to 15,000 volts, generator sets must be dry
before the generator set is operated. Failure to make sure dry windings
before start-up may result in catastrophic failure, severe personal injury and
death.
· Fuel Supply - Make sure that the fuel tank is filled to the normal level and that all the
valves required for operation are open. Make sure that there are no leaks and that all
fittings are tight.
· Lubrication - Check the engine lubrication oil level and ensure that the correct level is
always maintained.
· Coolant - Check the engine coolant level and ensure that the level is always maintained at
the coolant expansion tank. Fill the cooling system to the bottom of the fill neck in the
radiator fill or expansion tank. Do not check while the engine is hot.
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NOTE:
Some radiators have two fill necks, both of which must be filled when the
cooling system has been drained.
CAUTION: Do not attempt to remove a radiator pressure cap while the generator set is
running, or is stationary but hot. Hot coolant is under pressure in the radiator
system. Contact with hot coolant can result in severe burns. Always allow it to cool
before releasing the pressure and removing the cap.
CAUTION: It is essential that Cummins Power Generation’s recommendations for the correct
type and concentration of anti-freeze and DCA inhibitor are complied with.
Warranty claims for damage will be rejected if the incorrect mix has been used.
Consult your authorized distributor for the correct anti-freeze specifications and
concentration for your operating conditions.
NOTE:
Generator sets may be shipped dry. They must be filled with the correct type
and quantity of coolant before use. Be sure to check coolant level(s) before
initial start.
· Cooling Air Inlet / Outlets - Make sure that the cooling air inlets/outlets are unobstructed.
· Exhaust Outlet - Make sure that exhaust components are secured and not warped; that the
exhaust outlet is unobstructed; that no combustible materials are near the system; and
gases are discharged away from building openings. Make sure that there are no leaks and
that all fittings are tight.
· Batteries - Make sure that the batteries are charged, that the electrolyte is at the correct
level and that all connections are correct.
· Auxiliary AC Supplies - Make sure that all auxiliary equipment is receiving power from the
customer’s supply.
· Emergency Stop/Fire Detection Equipment - Make sure that all related equipment is fully
operational.
5.4.3
Starting at the Control Panel (Manual Mode)
Turn the O/Manual/Auto switch to the Manual position and press the Manual Run/Stop button.
This will activate the engine control system and the starting system. The starter will begin
cranking and, after a few seconds, the engine will start and the starter will disconnect.
NOTE:
The InPower service tool is required to enable/disable the warm-up at idle
feature and to adjust the time-out. When shipped from the factory, this
feature is disabled.
When the switch is in the Manual position, the control will complete the warm-up at idle feature
if enabled. When the coolant reaches operating temperature or the warm-up time at idle time
delay (0–300 seconds) is reached, whichever occurs first, the generator set will ramp to the
rated speed and voltage.
When the switch is in the Manual position, the generator set can be operated in the idle
mode (used for maintenance, troubleshooting, etc.). Refer to Section 4.5.7 on page 35 to
enable/disable the idle feature.
If the engine does not start, the starter will disengage after a specified period of time and the
control will indicate an overcrank shutdown.
The generator can be configured for a number of starting cycles (1–7) with set times for crank
and rest periods for all starting modes (manual/remote). The default setting is for 3 start cycles,
composed of 15 seconds of cranking and 15 seconds of rest.
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To change the cycle number, and the crank and rest times, contact an authorized service
center for assistance.
To clear a Fail to Start shutdown, place the O/Manual/Auto switch in the O position and press
the Fault Acknowledge/Reset button. Wait two minutes for the starter motor to cool and then
repeat the starting procedure. If the engine does not run after a second attempt, refer to the
Troubleshooting section.
Note:
1. Warm-up/cooldown idle adjusted timeout with InPower
2. Timer expires
3. Beginning Version 2.303
FIGURE 20.
5.4.4
STARTING AT THE CONTROL PANEL (MANUAL MODE)
Starting From a Remote Location (PTC or Remote Start
Signal) - Auto Mode
Place the O/Manual/Auto switch in the Auto position. This allows the generator set to be started
from a remote switch or device (e.g., transfer switch or optional PTC module).
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In response to the Remote Start or the control detects the loss of S1 voltage (PTC option
installed), the control lights the Remote Start indicator and initiates the starting sequence,
shown in Figure 21.
If a switch is connected to the remote start input of the control and the PTC module is installed,
this switch will function as a test switch. The PTC test sequence is shown in Figure 22.
When the switch is in the Auto position, the control will complete the time delay to start.
Refer to the Section 4.5.7 on page 35 in this section to enable and change the time delay
start/stop settings.
When the generator set is operating in the Remote Start Mode, removing the Remote Start
Command does not shut off the engine if the load is more than 10%, the cooldown timer is set
to zero, and the control is configured for a single unit (not in parallel). The generator set
continues to operate until it runs out of fuel, the E-stop button is used, or the load is removed.
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Note:
1. PTC feature installed only.
2. PTC feature not installed.
3. Timer exercise.
4. Cooldown adjusted timeout with InPower.
5. Beginning Version 2.303
FIGURE 21.
50
STARTING FROM A REMOTE LOCATION (PTC OR REMOTE START SIGNAL) - AUTO
MODE
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Note:
1. Remote (exercise) start sequence with PTC feature installed.
2. Timer expires.
3. Warm-up/cool-down idle adjustment time-out with InPower.
4. Beginning Version 2.303
FIGURE 22.
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PTC FEATURE REMOTE START TEST/EXERCISE SWITCH - AUTO MODE
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Cold Starting With Loads
In accordance with NFPA 110, Cummins Power Generation recommends installing standby
generator sets (life safety systems) equipped with engine jacket water coolant heaters in
locations where the minimum ambient temperature is above 40o F (4o C). NFPA also requires
that the engine jacket water coolant be maintained at a minimum of 90o F (32o C) and, for most
applications, accept the emergency load in 10 seconds or less. Although most Cummins Power
Generation generator sets will start in temperatures down to –25o F (–32o C) when equipped
with engine jacket water coolant heaters, it might take more than 10 seconds to warm the
engine up before a load can be applied when ambient temperatures are below 40o F (4o C).
The Engine Cold (Code 1435) message, in conjunction with illumination of the Warning LED, is
provided to meet the requirements of NFPA 110. The engine cold sensing logic initiates a
warning when the engine jacket water coolant temperature falls below 70o F (21o C). In
applications where the ambient temperature falls below 40o F (4o C), a cold engine may be
indicated even though the coolant heaters are connected. Under these conditions, although the
generator set may start, it may not be able to accept load within 10 seconds. When this
condition occurs, check the coolant heaters for proper operation. If the coolant heaters are
operating properly, other precautions may be necessary to warm the engine before applying a
load.
5.4.5.1 Checking Coolant Heater Operation
WARNING: Contact with the cooling system or engine can cause serious burns. Do not
touch the cooling system or engine until they are cool.
Do not touch the cooling system outlet hose. The coolant heater is operating if radiant heat can
be felt with your hand held close to the outlet hose and the engine is not running.
5.5
Stopping
5.5.1
Emergency Stop
The emergency stop button is located near the center of the upper part of the control panel.
Push the button in for an emergency stop. The red Shutdown status LED is lit and the
emergency stop message is displayed.
To reset:
1. Pull the emergency stop button out.
2. Turn the O/Manual/Auto switch to O.
3. Press the front panel Fault Acknowledge/ Reset button.
4. Select Manual or Auto, as required.
Emergency Stop shutdown status can be reset only at the operator control panel.
5.5.2
Stopping at Control Panel (Manual Mode)
If the set was started at the control panel (O/Manual/Auto switch in the Manual position),
pressing the Manual Run/Stop button causes the set to complete its normal (Local Start)
shutdown sequence.
The set stops after the cooldown at idle timer (0 to 30 minutes) has timed out.
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NOTE:
The InPower service tool is required to enable/disable the Cooldown At Idle
feature. Contact an authorized service center for assistance.
Turning the O/Manual/Auto switch to the O position causes an immediate engine shutdown
(bypasses Cooldown At Idle). If possible, this hot shutdown should be avoided to help prolong
the reliability of the engine.
5.5.3
Stopping from Remote Location (Remote Stop Signal) Auto Mode
If the control receives a remote stop signal or the control detects the return of S1 voltage (PTC
option installed), the set completes its normal shutdown sequence. (The remote stop signal is
actually the removal of the remote start signal to the control.)
The set stops after completing the Time Delay To Stop (0 to 600 seconds) and the cooldown at
idle (0-30 minutes).
Refer to the Adjust submenu in on page 35 to enable and change the Time Delay To Stop
setting. The InPower service tool is required to enable/disable the Cooldown At Idle
feature. Contact an authorized service center for assistance.
5.6
Operating Recommendations
5.6.1
Running-in
Refer to the Maintenance section of this manual Chapter 6 on page 55. Special ‘running-in’ oils
are not recommended for new or rebuilt Cummins engines. Use the same type of oil during
‘running-in’ as is used in normal operation.
The engine should be run at varying loads during the first few hours of operation to allow the
components to 'bed in.' Avoid long periods of light load or full load running particularly during the
early life of the engine.
5.6.2
No Load Operation
Periods of no-load operation should be held to a minimum. If it is necessary to keep the engine
running for long periods of time when no electric output is required, best engine performance
will be obtained by connecting a load of at least 30% rated load, but not to exceed rated load.
Such a load could consist of a heater element or load bank.
5.6.3
Exercise Period
Generator sets on standby duty must be able to go from a cold start to being fully operational in
a matter of seconds. This can impose a severe burden on engine parts.
Regular exercising keeps engine parts lubricated, prevents oxidation of electrical contacts and
in general helps provide reliable engine starting.
Exercise the generator set at least once a month for a minimum of 30 minutes, under not less
than 30 percent of the nameplate rating.
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Low Operating Temperature
Use a coolant heater if a separate source of power is available. The optional heater will help
provide reliable starting under adverse weather conditions. Be sure the voltage of the separate
power source is correct for the heater element rating.
CAUTION: To avoid damage to the heater, be sure the cooling system is full before applying
power to the heater.
5.6.5
High Operating Temperature
Refer to the generator set nameplate or the Specification/Data Sheet for the maximum ambient
operating temperature, if applicable.
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Maintenance
All maintenance tasks must be assessed for health and safety risks, the preventative measures
identified must be actioned. Accompaniment is required for tasks where the presence of
someone else will add significantly to the safety of the task.
Read, understand, and comply with all Caution and Warning notes in this section, those
contained within Chapter 1 on page 1, and those contained within the documentation supplied
with the generator set.
Ensure adequate lighting and staging (where required) are installed.
CAUTION: Only authorized and qualified maintenance technicians, who are familiar with the
equipment and its operation, should carry out maintenance.
WARNING: Dependent upon the control system fitted, this unit may operate
automatically and could start without warning.
CAUTION: Before carrying out any maintenance work, become familiar with Section 1.3 on
page 2, together with all the documentation supplied with the generator set.
CAUTION: Always disconnect a battery charger from its AC source before disconnecting the
battery cables. Failure to do so can result in voltage spikes high enough to damage
the DC control circuits of the generator set.
WARNING: Accidental starting of the generator set while working on it can cause severe
personal injury or death. Prevent accidental starting by disconnecting the
starting battery cables (negative [–] first).
Ensure battery area has been well-ventilated before servicing the battery.
Arcing can ignite explosive hydrogen gas given off by batteries, causing
severe personal injury. Arcing can occur when cables are removed or
replaced, 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.
Insulated tools must be used when working in the vicinity of the batteries.
Always remove the negative (–) cable first and reconnect last.
Make sure 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: To complete maintenance tasks at height refer to local legislative
requirements. Suitable equipment for performing these tasks must be used in
accordance with the local guidelines and legislation. Failure to follow these
instructions can result in severe personal injury or death.
WARNING: Do not use the skid (bedframe) or any part of the generator set as a means of
access. Use of the generator set as access may result in severe personal
injury or death and/or property and equipment damage.
WARNING: Before carrying out any maintenance work, lock off for safe working:
1. Press the off mode switch on the generator set control panel.
2. As an additional precaution, press the Emergency Stop Button, and hold
in for 30 seconds.
3. Isolate all supplies to the generator set.
4. Isolate the battery charger.
5. Disconnect the battery.
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6. Remove the starter control wires.
7. A suitable warning plate stating ‘Maintenance in Progress’ should be
displayed prominently.
WARNING: Some panel internal components may have live exposed terminations even if
the generator set is not running. Isolate all external electrical supplies prior
to access of the control panel. Voltages are present which can cause
electrical shock, resulting in personal injury. Even with the power removed,
improper handling of components can cause electrostatic discharge and
damage circuit board components.
6.1
Locking the Generator Set Out of Service
Before any work is carried out for maintenance, etc., the generator set must be immobilized.
Even if the generator set is put out of service by pressing the Off switch on the Operator Panel,
the generator set cannot be considered safe to work on until the engine is properly immobilized
as detailed in the following procedures.
NOTE:
Refer also to the Operator’s engine specific manual. This manual contains
specific equipment instructions that may differ from the standard generator
set.
WARNING: Before carrying out any maintenance, isolate all supplies to the generator set
and any control panels. Render the set inoperative by disconnecting the
plant battery.
WARNING: If the engine has been running recently, explosive gases (given off during
battery charging) may be present in the vicinity of the batteries. Ignition of
battery gases can cause severe personal injury. Make sure the area is well
ventilated before disconnecting batteries.
6.1.1
Immobilizing for Safe Working
NOTE:
Shut down the engine first.
To immobilize the engine:
1. Press the Off mode switch on the Operator Panel.
2. Press the Emergency Stop button. This will prevent the starting of the generator set
regardless of the Start signal source and will therefore provide an additional safety step for
immobilizing the generator set.
NOTE:
When this Stop button is pressed, the Operator Panel will indicate the
Shutdown condition by illuminating the red Shutdown status LED
displaying a message on the graphical LCD display.
NOTE:
and
This fault will affect the Fault History memory bank.
3. As an additional precaution, thoroughly ventilate the plant room before disconnecting any
leads.
4. Isolate and lock off the supply to the heater, where fitted.
5. Isolate and lock off the supply to the battery charger, where fitted.
6. Isolate the fuel supply to the engine.
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7. Disconnect the starting batteries and control system batteries, (if separate). Disconnect the
negative (–) cable first.
8. Fit warning notices at each of the above points to indicate Maintenance in Progress - Plant
Immobilized for Safe Working.
6.1.2
Periodic Maintenance
The periodic maintenance procedures should be performed at whichever interval occurs first. At
each scheduled maintenance interval, perform all previous maintenance checks that are due for
scheduled maintenance.
The tabular data that follows give the recommended service intervals for a generator set on
Standby service. If the generator set will be subjected to Prime usage or extreme operating
conditions, the service intervals should be reduced accordingly. Consult your authorized
distributor.
Some of the factors that can affect the maintenance schedule are:
· Use for continuous duty (prime power)
· Extremes in ambient temperature
· Exposure to elements
· Exposure to salt water
· Exposure to windblown dust or sand.
Consult with an authorized distributor if the generator set will be subjected to any extreme
operating conditions and determine a suitable schedule of maintenance. Use the running time
meter to keep an accurate log of all service performed for warranty support. Perform all service
at the time period indicated, or after the number of operating hours indicated, whichever comes
first.
6.1.2.1 Periodic Maintenance Schedule
TABLE 5.
PERIODIC MAINTENANCE SCHEDULE - ONE DAY TO TWO YEARS
MAINTENANCE ITEMS
Daily Weekly
or
or after
after 8
50
Hours Hours 6
3
12
12
Months Months
Months
or after or after
or after
250
500
1000
1500
Hours4,6 Hours4,6 Hours4,6 Hours 4,6
2000
Hours
2 Years
4,6
4,6
Perform maintenance tasks as specified using Daily or Hourly periods – whichever is the sooner
Check fuel level in tank
■
Check Fuel lines and hoses
■1
Check bedframe fluid containment
(where fitted), drain if necessary
■7
Check engine oil level
■1
Check coolant level of radiator(s)
(water jacket & LTA)
■4
Check cooling fan blades
Check all exhaust components, and
hardware (fittings, clamps, fasteners,
etc.)
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■1
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MAINTENANCE ITEMS
9-2011
Daily Weekly
or
or after
after 8
50
Hours Hours 6
Check drive belt, condition and
tension
■2
Check air cleaner restriction
indicator (where fitted)
■
Check air intake system for leaks
■
Check trailer equipment
■7
Check alternator
■11
Check operation of Emergency Stop
Button
3
12
12
Months Months
Months
or after or after
or after
250
500
1000
1500
Hours4,6 Hours4,6 Hours4,6 Hours 4,6
■12
2000
Hours
2 Years
4,6
4,6
■
■
Check battery electrolyte level
■
Check coolant lines and radiator
hoses for wear and cracks
■8
Check electrical connections
(battery, starter motor and alternator
connections)
■8,9
Check engine ground
■9
■10
Check engine valve lash
Check alternator stator winding
insulation resistance
■13
Check alternator Bearings
■8
Check connections in alternator
terminal box
■
Check aftercooler core
■
Check engine mounts
■
Check starting motor
■
Check turbocharger
■
Check water pump
Drain water from fuel system
primary filter/water separator
Drain fuel tank water and sediment
■
3
■
■3
Clean radiator matrix
■
■8
Clean air cleaner element
Replace engine oil and filter
■5
■
Replace water separator element
■
Replace fuel system secondary filter
■
Replace cooling system coolant
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6. Maintenance
Daily Weekly
or
or after
after 8
50
Hours Hours 6
MAINTENANCE ITEMS
3
12
12
Months Months
Months
or after or after
or after
250
500
1000
1500
Hours4,6 Hours4,6 Hours4,6 Hours 4,6
2000
Hours
2 Years
4,6
4,6
■1 – Check for oil, fuel, coolant, and exhaust system leaks. Check exhaust system audibly and visually with the
generator set running.
■2 – Visually check belt for evidence of wear or slippage. Replace if hard or brittle (to be undertaken by a Service
Engineer).
■3 – Drain one cup, or more, of fuel to remove water and sediment.
■4 – To be undertaken by a Service Technician.
■5 – Engine oil and filter should be replaced after the initial running-in period of 50 hours. Contact your authorized
distributor.
■6 – All maintenance checks and inspections listed at lesser maintenance intervals must be carried out at this time.
■7 – Visually check trailer equipment/walk around inspection of generator set.
■8 – Replace as necessary.
■9 – Clean as necessary.
■10 – Adjust as necessary.
■11 – Visual inspection.
■12 – Visual inspection and running audible check.
■13 – Record resistance value.
TABLE 6.
PERIODIC MAINTENANCE SCHEDULE - 3000 HOURS TO SIX YEARS
Maintenance Items
Check fuel injectors
Check aftercooler core
3000
2 Years
Hours3,4 or 3000
Hours3,4
4000
Hours
3 Years 3 Years 6 Years
or 4500 or 6000
or
Hours3,4 Hours3,4 12000
Hours3,4
■1
■2
■2
Check alternator vibration levels
Check alternator bearing housings
■
Check alternator winding condition
■
Check alternator rotating diode assembly
■
Replace cooling system coolant (commercial heavy
duty)
■
Replace cooling system coolant (ELC)
■
Replace alternator bearings
■
Replace alternator NDE o-ring
■
Add cooling system coolant extender (ELC)
Clean and regrease alternator bearings
■
■
■1 – Replace as necessary.
■2 – Clean as necessary.
■3 – To be undertaken by a Service Technician.
■4 – All maintenance checks and inspections listed at lesser maintenance intervals must be carried out at this time.
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Daily or Refueling Maintenance Procedures
Monitor fluid levels, oil pressure, and coolant temperature frequently. During operation, be alert
for mechanical problems that could create unsafe or hazardous conditions. The following
sections cover several areas that should be frequently inspected for continued safe operation.
NOTE:
6.2.1
Components that have guards against inadvertent touching must be visually
inspected only. Do not remove the guards to do the inspection.
General Information
Preventative maintenance begins with day-to-day awareness of the condition of the generator
set.
FIGURE 23.
DAY-TO-DAY AWARENESS
Before starting the generator set, check the oil and coolant levels and look for:
· Leaks
· Loose or damaged parts
· Worn or damaged belts
· Any change in engine or generator set appearance.
6.2.2
Engine Operation Report
The engine must be maintained in good mechanical condition if the operator is to obtain
optimum satisfaction from its use. Running reports are necessary to enable programmed or
emergency servicing to be carried out.
Comparison and intelligent interpretation of the running report, together with a practical followup action will eliminate most failures and emergency repairs.
Most engine problems give an early warning. Look and listen for changes in engine
performance, sound, or appearance that can indicate service or repair is needed. Some engine
changes to look for and report on are:
· Low lubricating oil pressure
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· Low power
· Abnormal water or oil temperature
· Unusual engine noise
· Excessive smoke
· Excessive use of coolant, fuel or lubricating oil
· Any coolant, fuel or lubricating oil leaks
· Misfire
· Vibration
· Excessive exhaust smoke.
FIGURE 24.
6.3
LOOK AND LISTEN FOR CHANGES IN PERFORMANCE
Cooling System
WARNING: Contact with hot coolant can result in serious scolding. Allow cooling system
to cool before releasing pressure and removing water jacket radiator cap or
LTA expansion tank cap.
CAUTION: Loss of coolant can allow engine to overheat without protection of shutdown
device, and cause severe damage to the engine. Maintain coolant level for proper
operation of high engine temperature shutdown system.
6.3.1
Coolant Level - Check
WARNING: Do not remove the radiator cap from a hot engine; wait until the temperature
is below 50 °C (122 °F) before removing pressure cap. Failure to do so can
result in personal injury from heated coolant spray or steam. Remove filler
cap slowly to release coolant system pressure.
CAUTION: Avoid prolonged or repeated skin contact with antifreeze. Comply to all local health
and safety regulations/codes when handling or disposing of antifreeze.
NOTE:
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Never use a sealing additive to stop leaks in the coolant system. This can
result in a blocked coolant system and inadequate coolant flow causing the
engine to overheat.
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FIGURE 25.
COOLANT LEVEL PROCEDURE
Coolant level must be checked daily. The standard coolant concentration is 50% Ethylene
Glycol and water, this concentration must be maintained. Warranty claims for damage will be
rejected if the incorrect mix of anti-freeze has been used. Consult your authorized distributor for
the correct anti-freeze specifications and concentration for your operating conditions. The
recommended antifreeze is Fleetguard® Compleat ES which is a low-silicate antifreeze, or its
equivalent.
CAUTION: Do not add cold coolant to a hot engine. Engine castings can be damaged. Allow
the engine to cool to below 50 °C (122 °F) before adding coolant.
NOTE:
On applications that use a coolant recovery system, check to make sure the
coolant is at the appropriate level on the coolant recovery tank dependent on
engine temperature.
Fill the cooling system with coolant to the bottom of the fill neck in the radiator or expansion
tank, with the coolant temperature at 50 °C (122 °F) or lower.
NOTE:
6.3.2
Some radiators have two fill necks, both of which must be filled. Refer to the
generator set specific drawings supplied with the set.
Cooling Fan - Inspect
WARNING: Personal injury can result from a fan blade failure. Never pull or pry on the
fan, this can damage the fan blade(s) and cause fan failure.
FIGURE 26.
FAN INSPECTION
A visual inspection of the cooling fan is required daily. Check for cracks, loose rivets, and bent
or loose blades.
Contact your authorized distributor if the fan is damaged.
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6. Maintenance
Drive Belt - Inspection
FIGURE 27.
DRIVE BELT INSPECTION
Visually inspect the belt through the guarding.
Check for:
· Intersecting cracks. Small transverse (across the belt width) cracks are acceptable.
Longitudinal (direction of belt length) cracks that intersect with transverse cracks are NOT
acceptable.
· Frays or pieces of material missing.
· Glazed or cracked side walls.
· Uneven wear on sidewalls of belt.
CAUTION: Do not mix old and new V-belts on the same drive.
Contact your authorized distributor to have worn belts replaced.
Visually inspect sheaves through the guarding.
Check for:
· Damaged or worn grooves.
· Breaks on flanges of grooves
· Frays or pieces of material missing.
· Glazed or cracked side walls.
· Uneven wear on sidewalls of belt.
CAUTION: V-Belts should never ride in the bottom of the groove. Damaged or worn grooves
should not be used.
NOTE:
Keep foreign materials away from sheaves and belts as this may cause belt
slip.
Contact your authorized distributor to have worn sheaves replaced.
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6.3.4
9-2011
Radiator - Check
FIGURE 28.
RADIATOR CHECK
Check for damaged hoses and loose and damaged hose clamps.
Inspect the exterior of the radiator (through the guarding) for obstructions. During the service life
of a radiator a build up of foreign matter can obstruct the flow of air through the radiator cores,
reducing the cooling capability. To continue the efficiency of the radiator, the core will require
cleaning.
Cleaning of the radiator core must only be undertaken by suitably trained and experienced
service personnel.
6.4
Engine Oil – Level Check
WARNING: Crankcase pressure can blow out hot oil and cause severe burns. Do NOT
check oil while the generator set is operating.
CAUTION: Do not operate the engine with the oil level below the low mark or above the high
mark. Overfilling can cause foaming or aeration of the oil while operation below the
low mark may cause loss of oil pressure.
CAUTION: Prolonged and repeated skin contact with used engine oils can cause skin
disorders or other bodily injury. Comply to all local health and safety
regulations/codes when handling or disposing of used engine oil.
FIGURE 29.
ENGINE OIL LEVEL CHECK
Check the engine oil level when the generator set is not running.
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Never operate the engine with the oil level below the L (Low) mark, or above the H (High) mark.
Wait at least fifteen minutes, after shutting off the engine, before checking the oil level. This
allows time for the oil to drain back to the oil pan.
NOTE:
6.5
Use high-quality 15W-40 multi-viscosity lubricating oil such as Cummins
Premium Blue® or its equivalent. Consult your authorized distributor for the
correct lubricating oil for your operating conditions.
Fluid Containment
The bedframe fluid containment area (if applicable) must be inspected at regular intervals and
any liquid should be drained off and disposed off in line with local health and safety regulations.
Failure to perform this action may result in spillage of liquids likely to contaminate the
surrounding area.
1
Oil Filler
2
Dip Stick
3
Containment Area
FIGURE 30.
FLUID CONTAINMENT INSPECTION
Any other fluid containment area must also be checked and emptied, as above.
6.6
Hoses and Fuel Lines - Check
WARNING: Moving parts can cause severe personal injury or death. Use extreme caution
around hot manifolds, moving parts, etc.
To prevent serious burns, avoid contact with hot metal parts such as
radiator, turbocharger and exhaust system.
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FIGURE 31.
HOSES AND FUEL LINE INSPECTION
With the generator set operating, inspect the supply lines, return lines, filters, and fittings for
leaks. Check any flexible sections for cuts, cracks and abrasions and ensure they are not
rubbing against anything that could cause breakage. If any leaks are detected, shut down the
generator set (if possible). Contact your authorized distributor and have the leaks corrected
immediately.
6.7
Normal Duty Air Cleaner
6.7.1
Air Cleaner Element Removal
Normal duty air cleaners combine centrifuge cleaning with element filtering before air enters the
engine.
CAUTION: Holes, loose-end seals, dented sealing surfaces, corrosion of pipes, and other
forms of damage render the air cleaner inoperative and require immediate element
replacement or engine damage can occur.
NOTE:
Cummins Inc. does not recommend cleaning paper-type air cleaner elements.
Elements that have been cleaned will clog, and airflow to the engine will be
restricted.
1. Before disassembly, wipe dirt from the cover and the upper portion of the air cleaner.
2. Loosen the wing bolt (2) and remove the band clamp securing the dust pan (1).
3. Remove the dust shield (3) from the dust pan (1).
4. Clean the dust pan and shield.
5. Remove the wing nut (5) that secures the air cleaner element (4) in the air cleaner housing.
6. Inspect the rubber sealing washer on the wing nut.
7. Remove the dirty cleaner element (4). Dispose of the dirty element in accordance with local
environmental agency requirements.
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No.
Description
No.
Description
1
Dust Pan
4
Air Cleaner Element
2
Wing Bolt
5
Wing Nut
3
Dust Shield
FIGURE 32.
6.7.2
NORMAL DUTY AIR CLEANER
Air Cleaner Element Installation
1. Install the air cleaner element (4) in the air cleaner housing.
2. Inspect the rubber sealing washer and make sure it is in place under the wing nut (5).
3. Tighten the wing nut (5) that secures the element (4) in the air cleaner housing.
4. Assemble the dust shield (3) and the dust pan (1).
5. Position the dust shield (3) and dust pan (1) on the air cleaner housing and secure them
with the band clamp wing bolt (2).
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9-2011
Description
No.
Description
1
Dust Pan
4
Air Cleaner Element
2
Wing Bolt
5
Wing Nut
3
Dust Shield
FIGURE 33.
6.8
NORMAL DUTY AIR CLEANER
Exhaust System
WARNING: Exhaust components become very hot when the generator set is in use and
remain hot for a period of time after the generator set has been shut down.
These components can cause severe personal injury or death from contact.
Allow these components to cool completely before performing any
maintenance tasks.
WARNING: Inhalation of exhaust gases can result in serious personal injury or death. Be
sure deadly exhaust gas is piped outside and away from windows, doors or
other inlets to buildings. Do not allow to accumulate in habitable areas.
WARNING: Moving parts can cause severe personal injury or death. Use extreme caution
around hot manifolds, moving parts, etc.
With the generator set operating, inspect the entire exhaust system visually and audibly
including the exhaust manifold, muffler, and exhaust pipe without removing guarding and
panels. Check for leaks at all connections, welds, gaskets and joints, and ensure that exhaust
pipes are not heating surrounding areas excessively. If any leaks are detected, shut down the
generator set (if possible). Contact your authorized distributor and have the leaks corrected
immediately.
6.9
Generator Set Output - AC Electric System
Check the following while the generator set is operating:
· Frequency: The generator set frequency should be stable and the reading should be the
same as the generator set nameplate rating (50 Hz / 1500 RPM or 60 Hz / 1800 RPM).
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· AC Voltage: At no load, the line-to-line voltage(s) should be the same as the generator set
nameplate rating.
· AC Ammeter: At no load, the current readings should be zero. With a load applied, each
line current should be similar.
· Panel Lamps: When the Operating Panel is first connected to the DC supply, the system
runs a check by illuminating each of the indicator lamps in turn.
6.10
DC Electrical System
FIGURE 34.
CHECK HARNESS CONNECTIONS
Check the terminals on the batteries for clean and tight connections. Loose or corroded
connections create resistance, which can hinder starting. Clean and reconnect the battery
cables if loose. Always disconnect both ends of the negative battery cable. Reconnect one end
of the cable to the negative battery terminal and the other end to ground. This will ensure that
any arcing will be away from the battery and least likely to ignite explosive battery gases.
WARNING: Ignition of explosive battery gases can cause severe personal injury. Do not
use naked flames, smoke or cause sparks while servicing batteries.
6.11
Lead Acid Batteries
Batteries are an essential part of any standby generator system and some 90% of all generator
failures are due to batteries.
It is therefore vital that batteries are stored, commissioned, and maintained as detailed here.
Reference should also be made to the Battery Manufacturer’s instructions.
Batteries are usually supplied with the generator in ‘dry-charged’ form. In order to commission
dry-charged lead-acid batteries, pre-mixed electrolyte of the correct type and specific gravity
must be added to the cells of the battery.
6.11.1 Storage
Dry-charged batteries should be stored in a cool, dry place, upright and with the vent caps
securely in place.
Filled and charged batteries must be stored in a cool, dry, well ventilated place. Make sure that
the vent caps are securely screwed down, or pushed home.
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Batteries must never be stacked one on top of another and must be protected from the floor by
a wooden pallet or suitably thick cardboard sheet
6.11.2 Safety Precautions
The handling and proper use of lead-acid batteries is not hazardous providing the correct
precautions are observed and personnel are trained in their use.
6.11.2.1 General Precautions
CAUTION: Never lay tools or metal objects across the top of the battery. This can cause
arcing that may ignite battery gases causing explosions resulting in personal injury.
CAUTION: Keep batteries upright to prevent spillage. Electrolyte is a dilute sulphuric acid that
is harmful to the skin and eyes.
CAUTION: Use tools with insulated handles to prevent the risk of electric shock.
6.11.2.2 Fire Hazard
WARNING: Make sure that batteries are charged in a well ventilated area, away from
naked flames and sparks.
WARNING: Before disconnecting the battery, always remove power from the mains
powered battery charger (where fitted).
CAUTION: During the charging of a battery, explosive gases are given off. Keep the battery
well ventilated and away from naked flames and sparks. NO SMOKING.
Before disconnecting a battery, always remove power from the mains powered
battery charger (where fitted) BEFORE disconnecting the charger leads.
When putting a battery into service on a generator set, connect the earth lead
LAST; when removing the battery, disconnect the earth lead FIRST.
6.11.2.3 Fluid Hazard
CAUTION: Take care when filling batteries with electrolyte and always wear personal
protective equipment.
WARNING: Never add undiluted sulfuric acid to a battery.
WARNING: Always wear an acid-proof protective apron, goggles and gloves when
handling electrolyte. If electrolyte is splashed on the skin or in the eyes, flush
the affected areas immediately with water and seek medical advice.
6.11.3 Battery Commissioning
NOTE:
Commissioning is to be undertaken by suitably trained and qualified service
personnel only.
Lead-acid batteries supplied in dry-charged form are commissioned using the following steps:
· Pre-Commissioning Procedure
· Filling the Electrolyte
· Charging
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· Fitting the Battery to the Generator Set
6.11.3.1 Pre-Commissioning Procedure
1. Check for any mechanical damage to the battery case or terminals, and make sure that the
battery is clean and dry.
2. Smear the battery terminals with petroleum jelly to prevent corrosion.
3. Remove the vent plugs and break any seals (if present), taking care not to damage the
plates or separators. The broken seal will fall into the bottom of the chamber and do no
harm.
6.11.3.2 Filling the Battery with Electrolyte
1. Fill each cell of the battery with dilute sulphuric acid (electrolyte) of the correct specific
gravity (SG) as shown in Table 7 on page 75, and according to the levels given in Table 8
on page 76 (8.2 liters (2.2 gallons) per standard battery).
2. The filling operation must be completed in one operation.
3. Allow the battery to soak for ten to fifteen minutes. If the electrolyte level has fallen, it
should be restored by adding electrolyte of the correct SG to the levels given in Table 8 on
page 76.
4. After filling, the battery must be placed on a commissioning charge within one hour.
Charging must take place before any load is placed on the battery.
CAUTION: Failure to give this commissioning charge may impair the charge capacity and life
of the battery.
6.11.3.3 Charging - Commissioning
1. Charge the battery at the current rating given in Table 8 on page 76 for a minimum of four
hours in order to ensure that the acid is sufficiently mixed within the battery. The charging
period may need to be extended if the battery has been in storage.
2. At the end of the charging process, the electrolyte levels must be checked and restored if
necessary by the addition of electrolyte of the correct SG. The vent caps must then be
replaced.
NOTE:
Any further topping-up of the electrolyte must be made using distilled or deionized water.
3. When the generator set is running, check the charge alternator output using an induction
ammeter.
6.11.3.4 Fitting the Battery to the Generator Set
1. A battery must not be fitted to a generator set without charge if the SG of the electrolyte
has fallen below 1.240 during storage.
2. Battery hold-down bolts must be tight but not over tight.
3. Re-smear the terminals with petroleum jelly, if necessary.
4. Fit the vents firmly in position and ensure that the battery is clean and dry.
5. Verify correct polarity when connecting the battery to the set. Even momentary incorrect
connection can cause damage to the electrical system. Connect the positive generator
cable FIRST, followed by the negative ground.
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6. Terminal connections must be tight but not over tight.
6.11.4 Battery Maintenance
NOTE:
Maintenance-free batteries are sealed and do not require the addition of
electrolyte. Some manufacturers of maintenance-free batteries provide an
‘eye’ or some visible means of telling when the battery is discharged or
approaching the end of its useful life.
Batteries require attention at all times, even when not working. A battery will not last if it is
neglected. Maintenance is carried out as follows:
1. Keep the battery, and the battery area, clean and dry. Ensure that the vent caps are
securely screwed down, or pushed home.
2. To avoid contamination of the battery, only clean it when the vent plugs are in place.
3. Keep the battery terminals and connections free from corrosion by lightly coating them with
petroleum jelly.
4. Check the condition of the starting batteries every month or after 100 hours use whichever
occurs first.
WARNING: Thoroughly ventilate battery area before working on the battery. Ignition of
explosive battery gases can cause severe personal injury. Do not smoke
while servicing batteries, or cause sparks or arcing that may ignite battery
gases
CAUTION: Always disconnect a battery charger from its AC source before disconnecting the
battery leads. Failure to do so can result in voltage spikes high enough to damage
the DC control circuits of the generator set
WARNING: To prevent dangerous arcing, always disconnect the negative (-) ground
cable from the battery before working on any parts of the electrical system or
the engine. Discharge static electricity from body before touching batteries,
by first touching a grounded metal surface
6.11.4.1 Cleaning Batteries
WARNING: Electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes. Do
not get the substance in your eyes or contact with skin. Wear goggles,
protective rubber gloves, and apron when servicing batteries.
WARNING: In case of skin contact, immediately wash affected area with soap and water.
In case of eye contact, immediately flood eyes with large amounts of water
for a minimum of fifteen minutes. Immediately call a physician.
Prevent a build up of dirt or corrosion by wiping the batteries with a damp cloth. Use a solution
consisting of 1/4 lb (0.11 kg) of baking soda added to 1 quart (0.96 liters) of water to neutralize
any possible acid. Be sure the vent plugs are tight to prevent any cleaning solution from
entering the cells.
After cleaning, make sure the battery and surrounding areas are dry.
After making connections, coat the terminals with a light application of petroleum jelly to retard
corrosion. Keep the battery terminals clean and tight. A loose connection can reduce battery
standby time and cause battery fires.
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6. Maintenance
6.11.4.2 Charging
Where generator sets are used infrequently, battery re-charging must take place when the SG
drops below 1.220 (or 1.180 in tropical climates) until the SG in all cells rises and remains
constant for three hours. In all cases where use is infrequent, batteries must be put on a
monthly re-charge schedule to ensure that a fully charged condition is maintained.
CAUTION: NEVER allow a battery to become completely flat (fully discharged), or to stand in
a discharged condition, or damage will result.
1. Remove the vent caps before carrying out charging.
2. Do not put a filled battery into storage without first giving the battery a commissioning
charge.
3. Batteries must be given a further charge every six months at the normal initial charge rate
until the voltage and SG cease to rise.
4. At the end of the charging process, the electrolyte levels must be checked and restored, if
necessary, by the addition of electrolyte of the correct SG. The vent caps must then be
replaced.
NOTE:
Any further topping-up of the electrolyte must be made using distilled or deionized water.
6.11.4.3 Trickle / Boost Charging (Option)
The battery will automatically receive a ‘trickle-charge’ to prevent the battery becoming
discharged below its optimum charge level by the battery charger (when switched ON).
During trickle-charging, not all cells in the battery receive the same charge; over a period of
several months this may affect battery performance. It is therefore good practice to give
batteries a regular charge at their full rate to return all cells to full capacity. This is referred to as
boost-charging, or equalize-charging.
If the charger is fitted with a Boost Charge switch, the Boost position should be selected at
intervals detailed by the battery manufacturer (normally around every six months).
CAUTION: Batteries should not be left on Boost Charge for extended periods as this will result
in excessive water consumption, gassing, and may impair battery performance.
A Boost Charge not exceeding twice the bench charge rate may be used, providing that:
· The electrolyte temperature does not exceed 109 °F (43 °C).
· The battery volts do not reach 15 V (for a 12 V battery)
If either of these situations should arise, reduce the charge rate to the normal bench rate. For
tropical climates the temperature must not exceed 120 °F (49 °C).
NOTE:
The charge period should be extended:
· To eight hours if the battery has been in storage for three months or
more, at temperatures in excess of 86 °F (30 °C), or if humidity is above
80%.
· To twelve hours if the battery has been in storage for twelve months or
more.
At the end of the charging process, the electrolyte levels must be checked and restored if
necessary by the addition of electrolyte of the correct SG. The vent caps must then be replaced.
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Any further topping-up of the electrolyte must be made using distilled or deionized water.
6.11.5 Electrolyte - Specific Gravity and Temperature
Maintenance-free batteries are sealed and do not require the addition of electrolyte. Some
manufacturers of maintenance-free batteries provide an ‘eye’ or some visible means of telling
when the battery is discharged or approaching the end of its useful life.
6.11.5.1 Checking Electrolyte Level
CAUTION: Never add tap or well water and never allow the battery electrolyte to drop below
the top of the plates otherwise damage will occur.
CAUTION: Do not add water in freezing weather unless the engine will run long enough (two
to three hours) to assure a thorough mixing of water and electrolyte.
Check the level of the electrolyte (acid and water solution) in the batteries at least every month
or 100 hours of operation, whichever occurs first. Maintain the electrolyte to the levels indicated
in Table 8 on page 76 by the addition of distilled water only and recharge. Replace the vent
plugs once filling is completed.
If the cell is low, check case for leaks.
Keep the battery case clean and dry. An accumulation of moisture will lead to a more rapid
discharge and battery failure.
6.11.5.2 Checking Specific Gravity Using a Hydrometer
Use a hydrometer to check the specific gravity (SG) of the electrolyte in each battery cell.
Hold the hydrometer vertical and take the reading.
FIGURE 35.
CHECKING SPECIFIC GRAVITY
6.11.5.3 Checking Specific Gravity Using a Refractometer
Follow the instructions included with the refractometer. Obtain a small drop of liquid and place it
under the clear plastic cover to check the specific gravity (SG) of the electrolyte in each battery
cell.
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6. Maintenance
FIGURE 36.
TYPICAL BATTERY ACID REFRACTOMETER
6.11.5.4 Specific Gravity Values for Batteries
A fully charged battery will have a corrected specific gravity of 1.260 at 77 oF (25 oC). Charge
the battery if the reading is below 1.215.
Hold the hydrometer vertical and take the reading. A fully charged battery will have a corrected
specific gravity of 1.260 at 77 oF (25 oC). Charge the battery if the reading is below 1.215.
TABLE 7.
SPECIFIC GRAVITY
SPECIFIC GRAVITY
TEMPERATURE
For Filling New Cells
At end of Charge
Ambient temperature normally below
32 °C
1.270
1.270 – 1.290
Ambient Temperature frequently
above 32 °C
1.240
1.240 – 1.260
Maximum permissible temperature of
electrolyte during charge
113 °F (45 °C)
113 °F (45 °C)
Table 7 on page 75 shows the specific gravity (SG) of electrolyte, corrected to 77 oF (25 oC).
Correct the SG reading for other temperatures by subtracting seven gravity points (0.007) for
every 18 oF (10 oC) the electrolyte temperature is above 80 oF (27 oC). Apply the correction
formula as follows:
1. For every 18 oF (10 oC) above 77 oF (25 oC), subtract 0.007 (7 points)
2. For every 18 oF (10 oC) below 77 oF (25 oC), add 0.007 (7 points)
For example: if the specific gravity at 77 oF (25 oC) is 1.260, then the specific gravity at 59 oF (15
o
C) is 1.267.
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6.11.6 Battery Replacement
Always replace the starting battery with the same number and type (e.g. vented, lead acid).
Properly dispose of battery in accordance with local environment agency requirements.
WARNING: Do not mutilate or burn the battery in a fire for disposal. Burning the battery
may cause an explosions which can result in severe personal injury or death.
Damage to the case will release electrolyte which is harmful to the skin and
eyes and is also toxic.
6.11.7 Electrolyte Levels and Bench Charging Rates
The following table shows the electrolyte level expected at a range of bench charging rates.
TABLE 8.
76
ELECTROLYTE LEVELS
Battery Type
Electrolyte
Level Above
Plates (mm)
Bench Charging
Rate (A/hour)
Battery Type
Electrolyte
Level Above
Plates (mm)
Bench Charging
Rate (A/hour)
1
8
3
325
8
20
7
8
3.5
327
8
11
15
8
4
328
8
20
16
8
4
329
8
20
17
8
9
332
8
25
35
8
3.5
333
8
11
36
8
3.5
386
8
6
37
8
4
404
8
7
38
8
4
414
8
20
46
8
6
415
8
20
47
8
3
471
8
15
48
8
4
484
8
25
49
8
4
501
8
9
63
8
4
511
8
10
65
8
5
521
8
12
67
8
7
531
8
13
68
8
7
541
8
15
69
8
7
543
8
15
70
8
7
591
8
14
71
8
6
602
8
8
72
8
8
612
8
9
73
8
6
635
16
12
74
8
7
643
16
9
75
8
7
644
16
12
77
8
4
645
16
9
78
12
5
646
16
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8
3.5
647
16
12
84
8
4
648
16
12
85
8
5
649
16
9
90
12
7
655
16
12
91
8
6
656
16
12
92
12
5
663
16
9
93
8
6
664
16
9
97
8
6
665
16
9
154
4
3.5
678
8
6
175
8
7
679
16
9
191
6
6
701
8
16
221
8
8
702
8
20
222
8
12
703
8
25
279
8
6
711
8
16
312
8
14
712
8
20
313
8
14
713
8
25
315
8
14
721
8
15
319
8
14
722
8
20
320
8
14
732
8
15
321
8
14
733
8
20
322
8
14
769
8
45
324
8
20
NOTE:
If not listed in the above table use the bench rate given in the catalog, or
charge at a current equal to 10% of the nominal capacity at the twenty hour
rate (Amperes/hour), or 5% of the reserve capacity in minutes.
NOTE:
Batteries of the 800 series should be prepared in accordance with the
instructions supplied with each battery.
6.11.8 Battery Fault Finding
The following table shows some typical faults, their possible causes and remedies.
TABLE 9.
Symptom
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Possible Fault
FAULT FINDING
Remedy
77
6. Maintenance
Battery completely
discharged
Battery low charge
Battery overcharged
9-2011
Poor battery terminal
connection
Clean connections, replace and tighten
Charge alternator /
alternator connection fault
Contact your nearest Cummins Power Generation
distributor
Mains battery charger /
charger connections fault /
mains supply fault
Check battery charger, charger mains supply and charger
connections
Blown fuse
Replace fuse
Battery fault
Remove and check using specialist equipment
Newly installed battery
shipped dry
Fill with electrolyte and give commissioning charge
Poor battery connection
Clean connections, reconnect and tighten securely
Charge alternator /
alternator connection fault
Contact your nearest Cummins Power Generation
distributor
Mains battery charger /
charger connections fault
Check battery charger and charger connections
Inequality in cell charge
Boost (equalize) charge required; when complete,
recheck voltage and specific gravity
Battery fault
Remove and check using specialist equipment
Charge alternator fault
Contact your nearest Cummins Power Generation
distributor
Mains battery charge fault
Check mains battery charger
Low battery fluid level
Check the charger; it may not be shutting off when the
charge is complete.
Battery terminals getting hot Poor battery connection
Clean connections, reconnect and tighten securely
Check charging mechanism, auto shut-off
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Troubleshooting
Fault code information, together with Warning and Shutdown information, is provided in this
section to assist in locating and identifying the possible causes of faults in the generator set
system. Refer also to the Operator’s engine specific manual. This latter manual contains
additional information regarding the running and care of the generator set and also specific
equipment instructions that may differ from the standard generator set.
7.1
Control System
The generator set control system continuously monitors engine sensors for abnormal conditions,
such as low oil pressure and high coolant temperature. If any of these conditions occur, the
control will light a yellow Warning lamp or a red Shutdown lamp and will display a message on
the graphical display panel. In the event of an engine shutdown fault (red Shutdown LED), the
control will stop the engine immediately.
7.2
Safety Considerations
All maintenance tasks must be assessed for health and safety risks, the preventative measures
identified must be actioned. Accompaniment is required for tasks where the presence of
someone else will add significantly to the safety of the task.
The installation of a generator set can be designed for remote starting. When troubleshooting a
generator set that is shut down, make sure that the generator set cannot be accidentally restarted. Refer to Section 6.1 on page 56.
WARNING: High voltages are present when the generator set is running. Do not open the
output box while the generator set is running.
WARNING: Some panel internal components may have live exposed terminations even if
the generator set is not running. Isolate all external electrical supplies prior
to access of the control panel.
WARNING: Contacting high voltage components can cause severe personal injury or
death by electrocution. Keep the output box covers in place during
troubleshooting. Only personnel trained and experienced in performing
electrical servicing should carry out testing and/or adjustments.
CAUTION: Always disconnect a battery charger from its AC source before disconnecting the
battery cables. Failure to do so can result in voltage spikes high enough to damage
the DC control circuits of the generator set.
WARNING: Ventilate the battery area before working on or near the battery. Wear
goggles. Stop the generator set and disconnect the battery charger before
disconnecting the battery cables. Disconnect the negative (–) cable first and
reconnect it last.
WARNING: Ignition of explosive battery gases can cause severe personal injury or
death. Arcing at battery terminals, light switch or other equipment, flame,
pilot lights and sparks, can ignite battery gas. Do not smoke, or switch
inspection light on or off near battery. Discharge static electricity from body
before touching batteries by first touching a grounded metal surface.
WARNING: Accidental starting of the generator set while working on it can cause severe
personal injury or death. Prevent accidental starting by disconnecting the
starting battery cables (negative (–) first).
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9-2011
Fault Finding
Should a fault condition occur during operation, follow the procedures in the following tables to
locate and correct the problem. For any symptom not listed, contact your authorized distributor
for assistance.
Before starting any fault finding, ensure that the following basic checks are carried out:
· All switches and controls are in their correct positions
· The fuel oil level is correct
· The lubricating oil level is correct
· The coolant level is correct
· The radiator matrix is free from obstruction
· The battery charge condition is satisfactory and the connections are secure
· The generator set electrics and alternator connections are secure
· The panel connections are secure
· The protection circuits have been reset
· Blown fuses have been replaced
· Tripped contactors or circuit breakers have been reset
WARNING: Many troubleshooting procedures present hazards that can result in severe
personal injury or death. Only qualified service personnel with knowledge of
fuels, electricity, and machinery hazards should perform service procedures.
Review safety precautions listed within Chapter 1 on page 1 of this manual
together with the documentation supplied with the generator set.
7.4
Status Indicators - PCC 2100
7.4.1
Running Indicator
This green lamp is lit whenever the generator (local or remote) is running.
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7.4.2
7. Troubleshooting
Remote Start Indicator
This green lamp indicates the control is receiving a remote run signal. When flashing, it
indicates a load demand stop mode.
7.4.3
Not in Auto
This red lamp flashes continuously when the O/Manual/Auto switch is not in the Auto position.
NOTE:
7.4.4
If the switch is in the Auto position and the lamp is still flashing, service is
required.
Configurable Indicators
The following configurable indicators (default values shown) can be changed with the InPower
service tool. The configurable items are: change generator event and LED color (green, yellow
or red), and enable/disable indicator.
The InPower service tool is required to select the desired settings. Contact an authorized
service center for assistance.
7.4.5
Shutdown Status
This red lamp is lit when the control detects a Shutdown condition. The generator set cannot be
started when this lamp is on. After the condition has been corrected, the lamp can be reset by
turning the O/Manual/Auto switch to the O position, and pressing the Fault Acknowledge button.
The generator set cannot be started when this lamp is on.
Dependent upon the specific fault that occurs, the engine may or may not shut down
immediately. A fault that could cause engine damage, causes an immediate engine shutdown
(bypasses engine cooldown sequence). All other faults would allow the engine to run during the
cooldown sequence before engine shutdown. In this case, the Shutdown Status indicator blinks
during the cooldown period.
7.4.6
Warning Status Indicator
This yellow lamp is lit whenever the control detects a warning condition. After the condition is
corrected, warning indicators can be reset by pressing the Fault Acknowledge button. (It is not
necessary to stop the generator set if the fault becomes inactive during generator set
operation.) In auto mode, warning indicators can also be reset by cycling the remote reset input
after the condition is corrected.
Some warnings remain active after the condition is corrected and the control reset button
is pressed. This will require the generator set to be shut down to reset the warning
indicator.
7.5
Fault/Status Codes - PCC 2100
7.5.1
Fault/Status Codes
WARNING: Many troubleshooting procedures present hazards that can result in severe
personal injury or death. Only trained and experienced service personnel
with knowledge of fuels, electricity, and machinery hazards should perform
service procedures.
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Accidental starting of the generator set while working on it can cause severe
personal injury or death. Prevent accidental starting by disconnecting the
starting battery leads (negative [–] first).
The fault codes have been divided into five categories to help you determine what corrective
action to take for safe operation of the generator set. Use the Fault Codes table to find the
category (CTG) and fault description for all codes.
NOTE:
7.5.2
Gaps in the code numbers are for codes that do not apply to this generator
set. Some of the codes listed are feature dependent and will not be displayed
by this control.
Fault Messages
NO.
Description
1
Asterisk indicates Active Fault
2
Fault Code
3
Hour Fault Occurred
4
W = Warning, S = Shutdown
5
Fault Description
FIGURE 37.
FAULT MESSAGE DISPLAY SCREEN
A Fault message is an indicator of a Warning or Shutdown condition. It includes the fault
number, and a short description. It also includes where the fault occurred if the generator set
control did not detect the fault and is simply reporting the fault. Faults/Status Codes on page
81 provides a list of the fault codes, types, and message displayed.
Active and acknowledged faults may be viewed in the Faults menu.
7.5.3
Fault Acknowledgement
Shutdown faults must be acknowledged after the fault has been corrected. If in Auto or Manual
mode, the control must be set to Stop mode (Off). Faults are cleared from the control panel
display by pressing the Reset button.
Faults are re-announced if they are detected again after being acknowledged. Refer to Fault
Acknowledgement/Reset Button on page 82.
NOTE:
82
Faults may also be acknowledged when in Auto mode and the Remote Start
command is removed. Contact you authorized distributor for this option.
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7.5.4
7. Troubleshooting
Category A Fault Codes
This category pertains to engine or alternator shutdown faults that require immediate repair by
trained and experienced service personnel (generator set non-operational). The control prevents
the generator set from being re-started if a shutdown fault has not been corrected.
7.5.5
Category B Fault Codes
This category consists of faults that can affect generator set performance or can cause engine,
alternator, or connected equipment damage. Operate the generator set only when it is powering
critical loads and cannot be shut down. These faults require repair by trained and experienced
service personnel.
7.5.6
Category C Fault Codes
This category consists of faults that do not affect generator set performance, but require repair
by trained and experienced service personnel. These codes indicate a defective harness or
wiring problem.
These codes can also indicate a defective engine sensor, leaving no engine protection. (Without
this protection, engine damage can occur without detection).
CAUTION: Continued operation may void the generator set warranty if damage occurs that
relates to this type of fault condition.
7.5.7
Category D Fault Codes
This category consists of faults that are repairable by site personnel. Service will be required by
trained and experienced service personnel if site personnel cannot resolve the problem after
taking the corrective actions suggested in the Customer Input Faults section of this chapter.
7.5.8
Category E Fault Codes
This category indicates non-critical operational status of the generator set, external faults, or
customer fault inputs. These faults require repair by trained and experienced service personnel.
7.5.9
PCC 2100 Fault Codes Table
TABLE 10.
FAULT CODES TABLE FOR PCC 2100
CTG
CODE
LAMP
DISPLAYED
A
121
Shtdn
Speed Signal Lost
C
135
Wrng
Oil Pressure Sensor H
C
141
Wrng
Oil Pressure Sensor L
D
143
Wrng
Pre-Low Oil Pres
C
144
Wrng
Coolant Sensor High
C
145
Wrng
Coolant Sensor Low
D
146
Wrng
Pre-High Coolant Temp
D
151
Shtdn
High Coolant Temp
D
197
Wrng
Low Coolant Level
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9-2011
CTG
CODE
LAMP
DISPLAYED
A
234
Shtdn
Overspeed
D
235
Shtdn
Low Coolant Leve
D
359
Shtdn
Fail To Start
D
415
Shtdn
Low Oil Pressure
D
441
Wrng
Low Bat Voltage
D
442
Wrng
High Bat Voltage
A
1123
Shtdn
Shutdown After BS
E
1124
Wrng
Delayed Shutdown
E
1131
Wrng
Battle Sh Active
E
1311
Shtdn/Wrng
Customer Input #1
E
1312
Shtdn/Wrng
Customer Input #2
E
1313-1316
Shtdn/Wrng
Network Fault 1 through 4
E
1317
Shtdn/Wrng
Customer Input #3
B
1318
Wrng
Customer Input #4
A
1334
Shtdn
Crit Scaler OR
B
1335
Wrng
Noncrit Scaler OR
C
1416
Wrng
Failt to Shutdown
D
1417
Wrng
Pwr Down Error
D
1433
Shtdn
Emergency Stop
D
1434
Shtdn
Remote E-stop
D
1435
Wrng
Low Coolant Temp
D
1438
Shtdn
Fail to Crank
D
1442
Wrng
Weak Battery
D
1443
Shtdn
Battery Failed
B
1444
Wrng
kW Overload
A
1445
Shtdn
Short Circuit
A
1446
Shtdn
High AC Voltage
A
1447
Shtdn
Low AC Voltage
D
1448
Shtdn
Under Frequency
A
1449
Wrng
Over Frequency
A
1452
Wrng
Gen CB Not Close
A
1453
Wrng
Gen CB Not Open
A
1459
Shtdn
Reverse Power
A
1461
Shtdn
Loss of Field
C
1466
Wrng
Modem Failure
C
1468
Wrng
Network Error
A
1469
Shtdn
Speed/Hz Match
B
1477
Wrng
Over Current
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7. Troubleshooting
CTG
CODE
LAMP
DISPLAYED
A
1472
Shtdn
Over Current
E
2323-2326
Shtdn/Wrng
Network Fault 5 through 8
B
2327
Wrng
PTC Fault
E
2329
Wrng
Low S1 Frequency
E
2331
Wrng
Low S1 Voltage
A
2335
Shtdn
Excitation Fault
A
2336
Shtdn
Memory Error
C
2337
Wrng
Pwr Tran Disabled
C
2338
Wrng
Pwr Tran Failure
E
2339
Wrng
Pwr Down Enabled
B
2341
Wrng
High Control Temp
E
2342
Wrng
Too Long in Idle (10 min)
E
2358
Wrng
High S1 Voltage
E
2396
Wrng
S1 CB Not Close
E
2397
Wrng
S1 CB Not Open
C
2966
Wrng
PTC Timeout
C
2967
Wrng
Governor Fault
C
2968
Wrng
AVR Fault
C
2969
Wrng
LON Failure
A
2972
Shtdn
Field Overload
7.5.10 Warning and Shutdown Codes
WARNING: Many troubleshooting procedures present hazards which can result in severe
personal injury or death. Only trained and experienced service personnel
with knowledge of fuels, electricity, and mechanical hazards should perform
service procedures. Review safety precautions.
7.5.10.1 Code 143 - Pre-Low Oil Pres
Corrective Action: Indicates the engine oil pressure has dropped to an unacceptable level. If the
generator is powering critical loads and cannot be shut down, wait until the next shutdown
period and then follow code 415 procedure.
7.5.10.2 Code 146 - Pre-High Cool Tmp
Corrective Action: Indicates the engine has begun to overheat (coolant temperature has risen
to an unacceptable level). If the generator is powering non-critical and critical loads and cannot
be shut down, use the following:
1. Reduce the load if possible by turning off non-critical loads.
2. Check air inlets and outlets and remove any obstructions to airflow.
If engine can be stopped, follow code 151 procedure.
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7.5.10.3 Code 151 - High Coolant Temp Alarm
Corrective Action: Indicates the engine has overheated (coolant temperature has risen above
the shutdown trip point). Allow the engine to cool down completely before proceeding with the
following checks:
1. Check the coolant level and replenish if low.
necessary.
Look for coolant leaks and repair if
2. Check for obstructions to cooling airflow and correct as necessary.
3. Check fan belt and repair or tighten if necessary.
4. Check the blower fan and circulation pumps on remote radiator installations.
5. Reset the control and restart after locating and correcting the problem.
7.5.10.4 Code 197 - Low Coolant Level
Corrective Action: Indicates engine coolant level has fallen to an unacceptable level. If the
generator is powering critical loads and cannot be shut down, wait until the next shutdown
period, and then follow 235 Coolant Level Alarm procedure. If the engine can be stopped,
follow 235 procedure.
7.5.10.5 Code 235 - Low Coolant Level
Corrective Action: Indicates engine coolant level has fallen below the alarm trip point. Allow the
engine to cool down completely before proceeding.
1. Check the coolant level sight glass at LTA top tank. Replenish if low.
2. Look for possible coolant leakage points and repair if necessary.
3. Reset the control and restart after locating and correcting the problem.
7.5.10.6 Code 359 - Fail To Start
Corrective Action: Indicates a possible fuel system problem. (Engine cranks but fails to start)
1. Open any closed fuel shutoff valve.
2. Check for dirty or plugged air filter and replace if necessary (see Maintenance section).
3. Fuel delivery to the set is inadequate. Contact an authorized service center for service.
4. Reset the control and restart after correcting the problem.
7.5.10.7 Code 415 - Low Oil Pressure
Corrective Action: Indicates engine oil pressure has dropped below the shutdown trip point.
Check oil level, lines and filters. If the oil system is OK but oil level is low, replenish. Reset the
control and restart.
7.5.10.8 Code 441 - Low Bat Voltage
Corrective Action: Indicates battery voltage supply to the control is approaching a low level at
which unpredictable operation will occur.
1. Discharged or defective battery. Check the battery charger fuse. Recharge or replace the
battery.
2. Poor battery cable connections. Clean the battery cable terminals and tighten all
connections.
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7. Troubleshooting
3. Check battery charge voltage float level if applicable (raise float level).
.
7.5.10.9 Code 442 - High Bat Voltage
Corrective Action: Indicates battery voltage supply to the control is approaching a high level at
which damage to the control can occur. Check the float level on the battery charger if applicable
(lower float level).
7.5.10.10 Code 1311, 1312, 1317, 1318 - Customer Input #1-#4
Corrective Action: The nature of the fault is an optional customer selection. Example inputs: Low
Fuel Day Tank, Water In Fuel, Ground Fault, Low Starting Hydraulic Pressure, Low Starting Air
Pressure, etc.
Each of the fault functions can be programmed (using the InPower service tool), as follows:
· Enable/disable input (Default: enable)
· Status, Warning, or Shutdown (Default: #1-None, #2 and #3-Warning)
· Active closed or open (Default: closed [ground])
· Change the display name using up to 19 characters (Default: #1- Customer Fault 1, #2Ground Fault, #3-Low Fuel)
7.5.10.11 Code 1417 - Power Down Error
Corrective Action: Indicates that the control can not power down due to some unknown
condition. Possible drain on battery. Contact an authorized service center for service.
7.5.10.12 Code 1433 - Emergency Stop
Corrective Action: Indicates local Emergency Stop. To reset the local/remote Emergency Stop
button:
1. Pull the button out.
2. Move the O/Manual/Auto switch to O.
3. Press the front panel Fault Acknowledge/Reset button.
4. Select Manual or Auto, as required.
7.5.10.13 Code 1434 - Remote E-Stop
Corrective Action: Indicates remote Emergency Stop. See code 1433 to reset.
7.5.10.14 Code 1435 - Low Coolant Temp
Generator set is not operating. This warning occurs when the engine coolant temperature is 70o
F (21o C) or lower.
NOTE:
In applications where the ambient temperature falls below 40o F (4o C), Low
Coolant Temp may be indicated even though the coolant heaters are
operating.
Corrective Action: Indicates engine coolant heater is not operating or is not circulating coolant.
Check for the following conditions:
1. Coolant heater not connected to power supply. Check for blown fuse or disconnected
heater cord and correct as required.
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2. Check for low coolant level and replenish if required. Look for possible coolant leakage
points and repair as required.
7.5.10.15 Code 1438 - Fail To Crank
Indicates possible fault with control, speed sensing or starting system. See code 441 for
corrective action.
7.5.10.16 Code 1442 - Weak Battery
Correctice Action: Indicates that during cranking, the battery voltage is at or below the weak
battery warning trip point for a time greater than or equal to the weak battery set time. See code
441 for corrective action.
7.5.10.17 Code 1443 - Battery Failed
Corrective Action: Dead battery - engine will not start. See code 441 for corrective action.
7.5.10.18 Code 1448 - Under Frequency
Corrective Action: Indicates possible fuel system problem or overload condition.
1. Check for dirty or plugged air filter and replace if necessary (see Maintenance section).
2. Check operation by disconnecting load and restarting generator set.
3. Fuel system requires adjustment. Contact an authorized service center for service.
4. Fuel delivery to the set is inadequate. Contact an authorized service center for service.
5. Reset the control and restart after correcting the problem.
7.5.10.19 Code 2342 - Too Long in Idle
Corrective Action: Indicates the generator set has been in Idle mode too long (10 minutes
maximum).
7.6
Line Circuit Breaker
A line circuit breaker is mounted in the generator output box. If the load exceeds the circuit
breaker current rating, the line circuit breaker will open, preventing the generator from being
overloaded. If the circuit breaker trips, locate the source of the overload and correct as
necessary. Manually reset the breaker to reconnect the load to the generator.
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8
Battery Charger
8.1
Battery Charger - 15 Amp @ 12 Volt and 12 Amp @
24 Volt
There are two types of 15/12-amp PowerCommand battery chargers (see Figure 38 on page
90). All 15/12-amp battery chargers have a 20 amp DC circuit breaker switch on the front of the
battery charger. The 120, 208, and 240 VAC battery chargers include two 10 amp AC circuit
breaker switches, while the 277, 380, 416, 480, and 600 VAC battery chargers include two AC
fuse holders.
Refer to the battery charger owner's manual for more information.
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A
120, 208, and 240 VAC Battery Charger
4
20 Amp DC Circuit Breaker Switch (Shown in the
"On" position)
B
277, 380, 416, 480, and 600 VAC Battery Charger
5
10 Amp AC Circuit Breaker Switches (Shown in the
"On" position)
1
Status LED
6
Fault Alarm Output Connector
2
Control Panel
7
10 Amp AC Fuse Holders
3
Reset Button
8
Connector for Optional Battery Temperature Sensor
FIGURE 38.
8.1.1
15/12-AMP POWERCOMMAND BATTERY CHARGERS
Control Panel
The 15/12-amp charger control panel includes a digital display, a Reset button, and an LED
status indicator.
· The 2-line x 16-character digital display displays menus and faults.
· The Reset button is used to select menu options and to clear fault messages.
· The status LED displays the appropriate color for the following conditions.
· Green - On solid indicates unit is charging.
· Amber - On solid indicates equalizing.
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8. Battery Charger
· Red - On solid indicate a fault condition. The fault number is shown on the digital
display.
No.
Description
1
Digital Display
2
LED/Status Indicator
No.
3
FIGURE 39.
8.1.2
Description
Reset Button
CONTROL PANEL
Battery Charger Configuration
The RESET button on the control panel is used to configure the battery charger. More
information on the Setup menus is included in the Battery Charger Operator Manual (901-0107).
· Battery Voltage and Type - The battery charger must be correctly configured, using the
Setup menus, for the correct battery voltage and type before it is connected to the battery.
The battery voltage can be set for 12 or 24 VDC (default = 12 VDC). The battery type can
be set for Lead-Acid, Gel, or AGM batteries (default = Lead-Acid).
NOTE:
A factory installed battery charger is set up for the proper DC battery voltage
requested on the production order, with the Lead-Acid battery type selected
as the default.
· Float Voltage - Various float voltages can be configured using the Setup menus. Consult
your battery datasheet for the best possible choice.
· Battery Equalization - Battery equalization is available for Lead-Acid batteries that are
completely charged, using the Equalize Battery screen in the Setup menus. When battery
equalization is in process, the LED status indicator turns amber.
8.1.3
Battery Temperature Sensor
A connector for the battery temperature sensor option is located on the front on the battery
charger. When used to monitor battery temperature, this sensor is connected from the battery
charger to the positive terminal of the battery. A fault message (fault code 2263) is displayed if
the battery temperature is too high (reaches 131 degrees F [55 degrees C]).
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FIGURE 40.
8.2
TEMPERATURE SENSOR
Circuits
For generator set specific information, refer to the drawings and circuit diagrams provided with
your generator set.
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9
Manufacturing Facilities
NORTH AMERICA
EMEA, CIS
ASIA PACIFIC
Cummins Power Generation Limited
1400 73rd Ave. NE
Minneapolis, MN 55432 USA
Cummins Power Generation Limited
Columbus Avenue
Manston Park
Manston, Ramsgate
Kent CT12 5BF
United Kingdom
Cummins Power Generation Limited
10 Toh Guan Road #07-01
TT International Tradepark
Singapore 608838
Phone +1 763 574 5000
Toll Free +1 800 888 6626
Fax +1 763 574 5298
Phone +44 1843 255000
Fax +44 1843 255902
Phone +65 6417 2388
Fax +65 6417 2399
BRAZIL
CHINA
INDIA
Rua Jati, 310, Cumbica
Guarulhos, SP 07180-900
Brazil
Cummins Power Generation
2 Rongchang East Street,
Beijing Economic – Technological
Development Area
Beijing 100176, P.R.China
35A/1/2, Erandawana
Pune 411 038
India
Phone +55 11 2186 4195
Fax +55 11 2186 4729
Phone +86 10 5902 3000
Fax +86 10 5902 3199
Phone +91 020 6602 7525
Fax +91 020 6602 8090
LATIN AMERICA
MEXICO
3350 Southwest 148th Ave.
Suite 205
Miramar, FL 33027
USA
Eje 122 No. 200 Zona Industrial
San Luis Potosi, S.L.P. 78395
Mexico
Phone +1 954 431 551
Fax +1 954 433 5797
Phone +52 444 870 6700
Fax +52 444 824 0082
9.1
How to Obtain Service
When a product requires servicing, contact your nearest Cummins Power Generation distributor.
To locate your local Cummins Power Generation distributor, refer to www.cumminspower.com
and select Distributor Locator. When contacting your distributor, always supply the complete
Model, Specification, and Serial Number as shown on the nameplate.
9.1.1
Locating Your Distributor
In North America
Telephone +1-800-888-6626 (this is an automated service for touch-tone phones only) to
contact the nearest Cummins Power Generation distributor in the United States or Canada. By
selecting Option 1 (press 1), you will be automatically connected to the distributor nearest you.
If you are unable to contact a distributor using the automated service, consult the Yellow Pages.
Typically, our distributors are listed under:
GENERATORS – ELECTRIC or
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9. Manufacturing Facilities
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ENGINES – GASOLINE OR DIESEL
If you have difficulty arranging service or resolving an issue, please contact the Service
Manager at the nearest Cummins Power Generation distributor for assistance.
When contacting your distributor, always supply the complete Model, Specification, and Serial
Number as shown on the product nameplate.
Outside North America
If you are outside North America, telephone Cummins Power Generation at +1-763-574-5000
from 7:30 am to 4:00 pm, Central Standard Time, Monday through Friday, or fax +1-763-5287229.
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A034G614 (Issue 3)
Copyright © 2011 Cummins Power Generation, Inc. All rights reserved.
Cummins, the "C" logo, and "Our energy working for you." are trademarks of
Cummins Inc.
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