CUMMINS | GSBB | Service manual | CUMMINS GSBB Service manual

Service Manual
Home Standby Generator Set
GSBB (Spec A-B)
GSBC (Spec B)
English
Original Instructions
9-2013
A030A239 (Issue 10)
Table of Contents
1. IMPORTANT SAFETY INSTRUCTIONS ......................................................................................
1.1 Save These Instructions ........................................................................................................
1.2 General Precautions ..............................................................................................................
1.3 Generator Voltage is Deadly ..................................................................................................
1.4 Engine Exhaust is Deadly ......................................................................................................
1.5 Fuel is Flammable and Explosive ..........................................................................................
1.6 Batteries Can Explode ............................................................................................................
1.7 Moving Parts Can Cause Severe Personal Injury or Death ..................................................
1.8 The Hazards of Carbon Monoxide..........................................................................................
1.8.1 What Is Carbon Monoxide Poisoning? ........................................................................
1.8.2 What Are the Special Risks of CO Near the Home? ...................................................
1.8.3 Only You Can Protect Yourself From CO Poisoning! ..................................................
1
1
1
2
2
2
2
3
3
3
3
4
2. INTRODUCTION............................................................................................................................
2.1 About this Manual ...................................................................................................................
2.2 About the Generator Set.........................................................................................................
2.2.1 Model Specifications ....................................................................................................
2.3 Generator Set Nameplate ......................................................................................................
5
5
5
6
8
3. MAINTENANCE ..........................................................................................................................
3.1 Periodic Maintenance Schedule ..........................................................................................
3.2 Cleaning the Housing Top ...................................................................................................
3.3 Exercising the Generator Set ...............................................................................................
3.4 Complete System Test ........................................................................................................
3.5 Engine Oil Maintenance........................................................................................................
3.5.1 Recommended Engine Oil ........................................................................................
3.5.2 Checking Engine Oil Level ........................................................................................
3.5.3 Add or Drain Oil .........................................................................................................
3.5.4 Changing Engine Oil and Oil Filter ...........................................................................
3.6 Replacing the Air Filter Element ..........................................................................................
3.7 Battery Maintenance ............................................................................................................
3.8 Spark Plugs ..........................................................................................................................
3.9 Accessory Heater Kits .........................................................................................................
3.10 Maintenance Record ..........................................................................................................
11
11
12
12
12
13
13
13
13
14
15
16
16
17
17
4. SERVICE ....................................................................................................................................
4.1 Placing the Generator Set Back in Service .........................................................................
4.2 Transfer Switch .....................................................................................................................
4.3 Engine ..................................................................................................................................
4.4 Engine - Generator Assembly ..............................................................................................
4.4.1 Engine - Alternator Removal .....................................................................................
4.4.2 Engine-Alternator Installation ....................................................................................
4.5 Fuel System Components Testing........................................................................................
19
19
19
20
20
20
21
23
A030A239 (Issue 10)
i
Table of Contents
9-2013
4.5.1 Fuel Pressure.............................................................................................................
4.5.2 Gas-Air Mixer ............................................................................................................
4.5.3 Governor Actuator......................................................................................................
4.5.4 Governor Linkage Adjustment (50 Hz LP Only).........................................................
4.5.5 Gas Demand Regulator ............................................................................................
4.5.6 Fuel Solenoid ............................................................................................................
4.5.7 Low Gas Pressure Switch (If Equipped) ....................................................................
4.5.8 Testing the Fuel System for Leaks ............................................................................
4.6 Control .................................................................................................................................
4.6.1 Generator Control .....................................................................................................
4.6.2 START/STOP Switch S2 ..........................................................................................
4.6.3 Line Circuit Breaker CB1/CB2 ...................................................................................
4.6.4 Current Transformers CT1/CT2 .................................................................................
4.6.5 Alternator Temperature Switch .................................................................................
4.7 Generator .............................................................................................................................
4.7.1 Operation ..................................................................................................................
4.8 Alternator Temperature Switch ............................................................................................
4.9 Brush Block/Slip Ring Service .............................................................................................
4.10 Stator Service ....................................................................................................................
4.11 Rotor Service .....................................................................................................................
4.12 Testing the Generator ........................................................................................................
24
24
25
27
28
29
29
29
31
32
32
32
32
33
33
33
35
35
35
35
36
5. OPERATION ...............................................................................................................................
5.1 In-Home Operator Panel ......................................................................................................
5.1.1 BACK Button ..............................................................................................................
5.1.2 Standby ON/OFF Button............................................................................................
5.1.3 START STOP Button .................................................................................................
5.2 Typical Operation..................................................................................................................
5.2.1 Normal Operation: Utility Power Available and Connected .......................................
5.2.2 Emergency Operation: Utility Power Interrupted .......................................................
5.3 To Enable/Disable Standby .................................................................................................
5.4 To Manually Start/Stop Generator Set ................................................................................
5.5 Fault, Maintenance and New Event Screens .......................................................................
5.5.1 Fault Screen...............................................................................................................
5.5.2 Maintenance Due Screen ..........................................................................................
5.5.3 New Event Screen .....................................................................................................
5.6 Genset Status ......................................................................................................................
5.7 Display Setup and Software Info ..........................................................................................
5.7.1 Brightness and Contrast ............................................................................................
5.7.2 Software Info ..............................................................................................................
5.8 Event Log..............................................................................................................................
5.8.1 To Check Log of Last 20 Events................................................................................
5.8.2 List of Recordable Events ..........................................................................................
5.9 Fault Log ...............................................................................................................................
5.10 Ethernet Settings ...............................................................................................................
5.11 Exercise Settings ...............................................................................................................
39
39
39
39
40
40
43
44
45
45
46
46
47
47
48
49
49
50
51
51
51
52
53
55
ii
A030A239 (Issue 10)
9-2013
Table of Contents
5.12 Time Setup .........................................................................................................................
5.13 Load Management ..............................................................................................................
5.13.1 Automatic Load Management ..................................................................................
5.13.2 Manual Load Management ......................................................................................
56
57
57
58
6. STARTUP AND CONFIGURATION.............................................................................................
6.1 Pre-startup Inspection...........................................................................................................
6.2 Startup .................................................................................................................................
6.3 Generator Set Configuration ................................................................................................
6.4 Generator Adjustments .........................................................................................................
6.4.1 To Adjust the Output Voltage.....................................................................................
6.4.2 To Calibrate the Display Meter .................................................................................
6.5 Transfer Switch Configuration .............................................................................................
6.6 Transfer Switch Parameter Adjustments .............................................................................
59
59
59
60
62
62
62
62
63
7. OPTIONAL INTERNET/EMAIL INTERFACE DESCRIPTIONS...................................................
7.1 Introduction ..........................................................................................................................
7.2 Screen Descriptions .............................................................................................................
7.2.1 Setting Time and Date ..............................................................................................
7.2.2 Set Exercise Schedule ..............................................................................................
7.2.3 Load Control (Management) .....................................................................................
7.2.4 Event Log ..................................................................................................................
7.2.5 Fault Log ...................................................................................................................
7.2.6 Network Setup Screen Descriptions ..........................................................................
7.2.7 Email Setup Screen Descriptions ..............................................................................
7.2.8 Saving Changes.........................................................................................................
65
65
66
66
67
67
68
68
69
69
70
8. OPTIONAL INTERNET/EMAIL INTERFACE SETUP..................................................................
8.1 Network Connectivity Options...............................................................................................
8.2 Material/Cable Routing .........................................................................................................
8.3 Network Information Needed For Setup ...............................................................................
8.3.1 Network Router ..........................................................................................................
8.3.2 Email/Internet Service Provider (ISP) ........................................................................
8.4 In-Home Network Access to the Generator Set ..................................................................
8.5 Setting Up Internet Access and E-mail Alerts.......................................................................
8.6 Port Forwarding ...................................................................................................................
8.7 Remote Viewing IP Options Static IP ..................................................................................
8.8 Dynamic IP Monitoring .........................................................................................................
8.9 Email Setup Parameters.......................................................................................................
8.9.1 Outgoing Server (SMTP) Settings .............................................................................
8.9.2 Email Addresses .......................................................................................................
8.10 Remote Internet Access to the Generator Set....................................................................
8.11 Help Hotline .......................................................................................................................
8.12 Frequently Asked Questions ..............................................................................................
71
71
71
71
71
71
72
75
77
77
78
78
78
79
80
81
81
9. TROUBLESHOOTING ................................................................................................................
9.1 Troubleshooting With the In-Home Operator Panel ............................................................
85
85
A030A239 (Issue 10)
iii
Table of Contents
9-2013
9.2 Troubleshooting with the Flashing Indicator Light ...............................................................
9.3 Fault Code Blinking ..............................................................................................................
9.4 Restoring Fault Code Blinking .............................................................................................
9.5 Generator Set Starts or Stops Without Command - No Fault Code ....................................
9.6 No Response - Status Indicator Light Dead ........................................................................
9.7 Starting Battery Runs Down ................................................................................................
9.8 Starter Engages - Disengages .............................................................................................
9.9 No AC Power - Generator Set Running, Status LED On Steady or Flashing Rapidly .........
9.10 Generator Set Cranks But Does Not Start - No Fault Code ..............................................
9.11 Genset Warning - Transfer Switch Failed to Transfer Back to Utility When Utility is
Restored - No Fault Code ....................................................................................................
9.12 Low Oil Pressure Fault - Fault Code 2 ..............................................................................
9.13 Service Check Fault - Fault Code 3 ...................................................................................
9.14 Overcrank - Fault Code 4 ..................................................................................................
9.15 Overvoltage - Fault Code 12 .............................................................................................
9.16 Undervoltage - Fault Code 13 ...........................................................................................
9.17 Overfrequency - Fault Code 14 .........................................................................................
9.18 Underfrequency - Fault Code 15 .......................................................................................
9.19 Governor Actuator Shutdown- Fault Code 19 ...................................................................
9.20 Governor Actuator Overload - Fault Code 22 ....................................................................
9.21 Voltage Sense Lost - Fault Code 27 ..................................................................................
9.22 High Battery Voltage - Fault Code 29 ................................................................................
9.23 Low Cranking Speed Sense - Fault Code 32 ..................................................................
9.24 Control Card Failure - Fault Code 35 ..............................................................................
9.25 Generator Set Stopped Without Fault Condition - Fault Code 36 ...................................
9.26 Invalid Set Configuration - Fault Code 37 ........................................................................
9.27 Processor Fault - Fault Code 43 ......................................................................................
9.28 Speed Sense Fault - Fault Code 45 ................................................................................
9.29 Generator Set Overload - Fault Code 46 .........................................................................
9.30 Alternator Over Temp - Fault Code 76 ............................................................................
9.31 Low Fuel Pressure - Fault Code 78 .................................................................................
9.32 Failure To Transfer To Generator Set - Fault Code 79 ...................................................
85
85
86
86
87
88
88
89
89
90
90
91
91
92
93
94
95
97
97
99
99
100
101
102
103
103
103
104
105
106
106
10. COMMUNICATION TROUBLESHOOTING .............................................................................
10.1 In-Home Network Access to Generator Set Troubleshooting ..........................................
10.2 Remote Internet Access to Generator Set Troubleshooting ............................................
10.3 Email Alert Troubleshooting .............................................................................................
109
109
110
111
APPENDIX A. OUTLINE AND SYSTEM DRAWINGS....................................................................
115
iv
A030A239 (Issue 10)
1
IMPORTANT SAFETY INSTRUCTIONS
1.1
Save These Instructions
This manual contains important instructions for the generator set that should be followed during
installation, operation and maintenance of the generator and batteries.
Thoroughly read the Operator Manual before operating the generator set. Safe operation and
top performance can only be obtained when equipment is properly operated and maintained.
The following symbols in this manual alert you to potential hazards to the operator, service
person and equipment.
DANGER
Alerts you to an immediate hazard that will result in severe personal injury or
death.
WARNING
Alerts you to a hazard or unsafe practice that can result in severe personal injury or
death.
CAUTION
Alerts you to a hazard or unsafe practice that can result in personal injury or equipment
damage.
1.2
General Precautions
• Keep ABC fire extinguishers handy.
• Make sure all fasteners are secure and torqued properly.
• Keep the generator set and its compartment clean. Do not store any items in the genset
compartment.
• Excess oil, oily rags (etc.) can catch fire.
• Dirt and gear stowed in the compartment will restrict cooling air flow.
• Before working on the generator set, move the Stop Switch (S2) to the Stop position,
disconnect the remote harness (P7) to disable the ATS mounted charger and then remove
the negative (-) battery cable to prevent starting.
• Use caution when making adjustments while the generator set is running, hot, moving or
when parts are electrically live, as all situations may cause personal injury or death.
• Used engine oil has been identified by some state and federal agencies as causing cancer
or reproductive toxicity. Do not ingest, inhale or come into contact with used oil or it's
vapors.
• Do not work on the generator set when mentally or physically fatigued or after consuming
alcohol or drugs.
A030A239 (Issue 10)
1
1. IMPORTANT SAFETY INSTRUCTIONS
1.3
9-2013
Generator Voltage is Deadly
• Generator output connections must be made by a trained and experienced electrician in
accordance with all applicable codes.
• This standby generator set and the public utility may only be connected to the house
circuits by means of the automatic transfer switch.
• Improper connections can lead to electrocution of utility workers and damage to
equipment.
• Use caution when working on live electrical equipment. Remove jewelry, make sure
clothing and shoes are dry and stand on a dry wooden platform.
1.4
Engine Exhaust is Deadly
• See What Is Carbon Monoxide Poisoning? to learn the symptoms of Carbon Monoxide
poisoning.
• This generator set is for outdoor installation only.
• It must be located well away from doors, windows, other openings into the house and
where the exhaust gases will disperse away from the house.
1.5
Fuel is Flammable and Explosive
• Keep flames, cigarettes, sparks, pilot lights, electrical arc-producing equipment, switches
and all other sources of ignition well away from areas where fuel fumes are present and
areas sharing ventilation.
• Fuel lines must be secured, free of leaks and separated or shielded from electrical wiring.
• Leaks can lead to explosive accumulations of gas. Prevent leaks and the accumulation of
gas.
• A "rotten egg" smell indicates a possible Natural Gas or Propane leak:
• Natural Gas rises when released and can accumulate under hoods and inside
housings and buildings.
• Propane sinks when released and can accumulate inside housings and
basements and other below-grade spaces.
1.6
Batteries Can Explode
Batteries can explode, causing severe skin and eye burns and can release toxic electrolytes.
• Wear safety glasses.
• Do not smoke.
• Do not dispose of the battery in a fire.
• The battery is capable of exploding.
2
A030A239 (Issue 10)
9-2013
1. IMPORTANT SAFETY INSTRUCTIONS
• Do not open or mutilate the battery.
• Released electrolytes have been known to be harmful to the skin and eyes and to be
toxic.
• Batteries present the risk to high short circuit current:
• Remove watches, rings or other metal objects and use tools with insulated handles.
• To prevent arcing when disconnecting the battery:
• Move the Stop Switch (S2) to the Stop position, disconnect the remote harness (P7)
to disable the ATS mounted charger and then remove the negative (-) battery cable to
prevent starting.
• To prevent arcing when reconnecting the battery:
• First, reconnect the positive (+) cable, then the negative (-) cable, and finally
reconnect the battery charger.
• When replacing the generator set battery, always replace it with a battery as specified in
the Model Specifications section of this manual.
1.7
Moving Parts Can Cause Severe Personal Injury or
Death
• Do not wear loose clothing or jewelry near moving parts such as fans.
• Keep hands away from moving parts.
• Keep guards in place, over fans.
1.8
The Hazards of Carbon Monoxide
Engine-driven generators can produce harmful levels of carbon monoxide that can injure or kill
you.
1.8.1
What Is Carbon Monoxide Poisoning?
Carbon Monoxide (CO) is an odorless, colorless, tasteless and non-irritating gas. You cannot
see it or smell it. Red blood cells, however, have a greater affinity for CO than for Oxygen.
Therefore, exposure even to low levels of CO for a prolonged period can lead to asphyxiation
(lack of Oxygen) resulting in death. Mild effects of CO poisoning include eye irritation, dizziness,
headaches, fatigue and the inability to think clearly. More extreme symptoms include vomiting,
seizures and collapse.
1.8.2
What Are the Special Risks of CO Near the Home?
Residents can be exposed to lethal levels of CO when the genset is running. Depending on air
temperature and wind, CO can accumulate in or near the home.
To protect yourself and others from the dangers of CO poisoning, it is recommended that
reliable and approved CO detector alarms be installed in the home.
WARNING
Carbon Monoxide (CO) gas can cause nausea, fainting or death.
A030A239 (Issue 10)
3
1. IMPORTANT SAFETY INSTRUCTIONS
1.8.3
9-2013
Only You Can Protect Yourself From CO Poisoning!
• Locate the generator in an area where there are no windows, doors or other access points
into the home.
• Make sure all CO detectors are working properly.
• Pay attention to the signs of CO poisoning.
• Check the exhaust system for corrosion, obstruction and leaks each time you start the
generator set and every eight hours if you run it continuously.
4
A030A239 (Issue 10)
2
Introduction
This generator set application is intended for stationary emergency use.
Important note for Brazil applications: The manufacturer warns that the installation, operation
and maintenance of equipment by the user must fully comply with the Manual's guidelines and
current Brazilian laws, including those of the Brazilian Agency of Petroleum, Natural Gas and
Fuels (ANP) and the Brazilian Energy Agency (ANEEL).
2.1
About this Manual
This is the Service Manual for the Model GSBB generator set. Read and carefully observe all of
the instructions and precautions in this manual.
Refer to the Maintenance chapter of this manual for instructions and guidelines for performing
periodic maintenance. The operator is responsible for generator set maintenance in accordance
with the Periodic Maintenance Schedule.
Refer to the Troubleshooting chapter for steps to be taken to diagnose and correct situations
that cause a generator set to shutdown.
WARNING
This generator set is not for life support. It can stop without warning. Children, persons
with physical or mental limitations, and pets could suffer personal injury or death. A
personal attendant, redundant power or an alarm system must be used if power system
operation is critical.
2.2
About the Generator Set
The model GSBB generator set is an engine-powered generator set fueled by Natural Gas or
Propane.
See the Specifications section of this manual for specific information about the generator set.
The generator set is intended as a back-up to utility power. Whenever utility power is
interrupted, the house electrical loads are automatically switched by the transfer switch from the
utility (normal power source) to the generator set (emergency power source). When utility power
is restored, the loads are automatically switched back to the utility. To do this, the generator set
and transfer switch perform the following functions together:
1. Senses an interruption of utility power.
2. Starts the generator set.
3. Transfers the load to the generator set when operation has stabilized.
4. Senses the return of utility power.
5. Retransfers the load to the utility.
6. Stops the generator set.
A more in-depth illustration of the operation of the generator set and transfer switch can be
found in the Timing Charts, located in the Typical Operation chapter of this manual.
A030A239 (Issue 10)
5
2. Introduction
2.2.1
9-2013
Model Specifications
TABLE 1.
GSBB AND GSBC MODEL VARIATIONS
Product
Description
20GSBB-6713A\B
60 Hz Warm
20GSBB-6714A\B
60 Hz Cold *
14GSBB-6716A\B
50 Hz (AU/NZ)
20GSBB-6717A\20GSBC-6927B
60 Hz CSA Cold *
* Includes an engine oil heater.
NOTICE
See the Cold Weather Specifications Table for recommendations.
TABLE 2.
COLD WEATHER SPECIFICATIONS TABLE
60 Hz
Propane Vapor
50 Hz
Natural Gas
Propane Vapor
Natural Gas
Operating Temperature Range
Above 32 °F (0 °C) and low
humidity
No dryers or starting aids required.
High humidity
Alternator drying heater recommended.
Below 20 °F (-7 °C)
Additional oil heater recommended for starting. Factory-installed model available.
Below 0 °F (-18 °C)
Additional accessory breather shield/shroud required to avoid possible engine
damage. See warranty statement.
Below -10 °F (-23 °C)
Additional accessory battery blanket recommended for starting.
Below -20 °F (-29 °C)
Not warranted. See warranty statement.
TABLE 3.
GENERATOR SET SPECIFICATIONS TABLE
60 Hz
Propane Vapor
50 Hz
Natural Gas
Propane Vapor
Natural Gas
Dimensions
Weight (With Oil)
540 lbs (245 kg)
Size (L x W x H)
48 x 43 x 34.6 in (1219 x 864 x 880 mm)
Noise
62 dB(A) at 23 ft (7 m) at normal load. (Normal load is equal to the typical
household consumption of 3 KW.)
6
A030A239 (Issue 10)
9-2013
2. Introduction
TABLE 4.
FUEL SPECIFICATIONS TABLE (SPEC A AND CANADIAN GSBB SPEC B)
60 Hz
Propane Vapor
50 Hz
Natural Gas
Propane Vapor
Natural Gas
Fueling
1/2 Load
132,500 Btu/Hr
53 ft3/Hr
135,000 Btu/Hr
135 ft3/Hr
122,000 Btu/Hr
48 ft3/Hr
114,000 Btu/Hr
111 ft3/Hr
Full Load
275,000 Btu/Hr
109 ft3/Hr
240,000 Btu/Hr
233 ft3/Hr
229,000 Btu/Hr
91 ft3/Hr
213,000 Btu/Hr
207 ft3/Hr
Fuel Pressure (all loads)
As measured at genset fuel
regulator service port
7-11 inches WC
5-11 inches WC
7-11 inches WC
5-11 inches WC
Tank Size
Contact your local gas company to verify the tank size required for your application.
TABLE 5.
FUEL SPECIFICATIONS TABLE (US GSBB SPEC B AND CANADIAN GSBC SPEC B)
60 Hz
Propane Vapor
50 Hz
Natural Gas
Propane Vapor
Natural Gas
Fueling
1/2 Load
195,000 Btu/Hr
78 ft3/Hr
177,000 Btu/Hr
172 ft3/Hr
165,000 Btu/Hr
66 ft3/Hr
150,000 Btu/Hr
146 ft3/Hr
Full Load
310,000 Btu/Hr
123 ft3/Hr
255,000 Btu/Hr
248 ft3/Hr
262,500 Btu/Hr
104 ft3/Hr
217,000 Btu/Hr
211 ft3/Hr
Fuel Pressure (all loads)
As measured at genset fuel
regulator service port
12-14 inches WC
5-7 inches WC
12-14 inches WC
5-7 inches WC
Tank Size
Contact your local gas company to verify the tank size required for your application.
TABLE 6.
ENGINE SPECIFICATIONS TABLE
60 Hz
Propane Vapor
50 Hz
Natural Gas
Propane Vapor
Natural Gas
Engine
2 Cylinder-V Twin, OHV, Air-Cooled, 4-Stroke, Spark Ignited, 3600 RPM
Displacement
60.59 in3 (993 cc)
Spark Plug Gap
.020 inch (.51 mm)
Spark Plug Torque
15 ft-lb (20 N-m)
Intake and Exhaust Cold Valve
Lash
(Measure at 0.25" (6.35mm)
past top dead center)
0.004-0.006 inch (0.10 - 0.15 mm)
Oil Capacity
Approximately 80 oz (2.3 Liters)
Oil Recommendation
(See Operator Manual)
5W-30 Synthetic Engine Oil
A030A239 (Issue 10)
7
2. Introduction
9-2013
TABLE 7.
GENERATOR SPECIFICATIONS TABLE
60 Hz
Propane Vapor
50 Hz
Natural Gas
Propane Vapor
Natural Gas
Generator
Brush-Type, 2-Pole Rotating Field, Single Bearing
Power (kVA)
---
---
13.5
13.5
Rated Voltage (V)
120/240
120/240
115/230
115/230
Rated Current (Amps)
162/81.25
144/72
117.4/58.7
117.4/58.7
Phase Type
Single Phase
Circuit Breaker (Amps)
100
100
60
60
De-rating Guidelines: Maximum wattage or maximum current are subject to and limited by such factors as fuel Btu
content, ambient temperature, altitude, engine power and condition, etc. Full rated power is available at 60 °F (15.5
°C) at sea level. De-rate 3.5% for each 1000 ft (304.8 m) above sea level and 3% for each 10 °F (5.5 °C) increase in
ambient temperature above 60 °F (15.5 °C).This generator is rated in accordance with UL 2200 (Stationary Engine
Generator Assemblies) or CSA C22.2 No. 100-04 (Motors and Generators). The maximum continuous current values
that are listed on the generator set nameplate and specification tables occur at the lower limit of acceptable voltage.
Maximum current occurs at 108 and 216 volts, 10% below nominal voltage 120/240. The voltage set point of this
generator set can be adjusted from the operator panel if desired. Refer to the Operator manual procedure To Adjust
the Output Voltage.
TABLE 8.
CONTROL SPECIFICATIONS TABLE
60 Hz
Propane Vapor
Controller
50 Hz
Natural Gas
Propane Vapor
Natural Gas
Integrated Microprocessor-Based Engine, Generator, Transfer Switch Controller
TABLE 9.
DC SYSTEM SPECIFICATIONS TABLE
60 Hz
Propane Vapor
50 Hz
Natural Gas
Propane Vapor
Natural Gas
DC System
Nominal Battery Voltage
12 Volts DC
Battery Group
26 R
Battery Type
Maintenance Free
Minimum Cold Crank Amps
545
2.3
Generator Set Nameplate
WARNING
Improper service or replacement of parts can lead to severe personal injury or death and to
damage to equipment and property. Service personnel must be qualified to perform electrical and
mechanical service.
8
A030A239 (Issue 10)
9-2013
2. Introduction
CAUTION
Unauthorized modifications or replacement of fuel, exhaust, air intake or speed control system
components that affect engine emissions are prohibited by law in the State of California.
Model, Spec and Serial Numbers: Be ready to provide the model, spec and serial numbers on
the generator set nameplate when contacting Cummins Onan for information, parts and service.
Record these numbers so that they are easy to find when needed. Each character in these
numbers is significant for obtaining the right parts listed in the Parts Catalog. Genuine Cummins
Onan replacement parts are recommended for best results.
My Generator Set Information
Model
Spec
Serial Number
FIGURE 1.
A030A239 (Issue 10)
NAMEPLATE
9
2. Introduction
9-2013
This page is intentionally blank.
10
A030A239 (Issue 10)
3
Maintenance
3.1
Periodic Maintenance Schedule
Periodic maintenance is essential for top generator set performance. Use the Maintenance
Frequency table as a guide for normal periodic maintenance.
• In hot and dusty environments some maintenance procedures should be performed more
frequently, as indicated by the footnotes in the table.
• Maintenance, replacement or repair of emission control devices and systems may be
performed by any engine repair establishment or individual.
• Warranty work MUST be completed by an authorized Cummins dealer.
WARNING
Accidental or remote starting of the generator set can cause severe personal injury or death.
Before working on the generator set, move the switch (S2) to the Stop position, disconnect the
remote harness (P7) to disable the ATS mounted charger and remove the negative (-) battery
cable from the battery to prevent starting.
TABLE 10.
Maintenance Task
MAINTENANCE FREQUENCY
Maintenance Frequency
First Startup
Check Engine Oil Level
Daily or Every Every 3
Every 250
24 Hours
Months or 100 Hours
Hours
Every 400
Hours
X2, 5
Change Engine Oil and Oil Filter After first 8
hours
X1
Adjust Engine Valve Clearance
X4
After first 50
hours4
Replace Engine Air Filter
X1
Clean and Check Starting
Battery
X
Replace Spark Plugs and Wires
X3
Clean Engine Cooling Fins
X3
Complete System Test
1.
2.
3.
4.
5.
6.
X6
Perform more often when operating in dusty conditions.
Perform more often when operating in high temperature conditions.
Perform sooner if engine performance deteriorates.
Must be performed by a qualified mechanic (authorized Cummins Onan dealer).
Check daily during power outages, or monthly without power outages.
See automatic transfer switch manual for testing of load transfer.
A030A239 (Issue 10)
11
3. Maintenance
3.2
9-2013
Cleaning the Housing Top
The top surface of the generator set housing can be damaged by pressure washing or solvents
and other cleaning agents. Only use soap and water or an “all citrus degreaser" to clean the top.
3.3
Exercising the Generator Set
NOTICE
Audible engine RPM variation may be heard while there is no load applied. This is
normal and does not affect genset performance.
Exercising the generator set drives off moisture, re-lubricates the engine and removes oxides
from electrical contacts. The result is better starting, more reliable operation and longer engine
life.
The generator set exerciser is capable of automatically starting the generator set and letting it
run for 20 minutes, once every 28 days, or more often, if desired.
Refer to the Exercise Settings section of this manual for more information on setting up the
exerciser.
3.4
Complete System Test
A complete system test is recommended to verify that the electrical system is working properly.
Testing the system once every three months is required to make sure the transfer switch will
transfer the load to the generator set, should there be a utility power failure. For more
information, see the automatic transfer switch Operator Manual.
To initiate a complete system test:
1. Switch the main utility disconnect from the ON to the OFF position.
2. Make sure the following occurs:
a. The generator control starts the generator set.
b. After the generator set starts and stabilizes, the load is transferred from the utility to
the generator set.
3. Switch the main utility disconnect from the OFF to the ON position.
4. Make sure the following occurs:
a. After a time delay, the load is transferred back to the utility.
b. Once the transfer switch is connected to utility power, after a time delay, the generator
set stops.
NOTICE
If the test fails, call an authorized Cummins dealer to perform the testing.
12
A030A239 (Issue 10)
9-2013
3. Maintenance
3.5
Engine Oil Maintenance
3.5.1
Recommended Engine Oil
Check the oil level prior to starting the generator set to verify that the oil level is between the
FULL and ADD marks.
• The generator set is shipped with engine oil
• 5W-30 synthetic engine oil is recommended
3.5.2
Checking Engine Oil Level
WARNING
State and federal agencies have determined that contact with used engine oil can cause cancer
or reproductive toxicity. Avoid skin contact and breathing of vapors. Use rubber gloves and
wash exposed skin. Accidental or remote starting of the generator set can cause severe personal
injury or death. Disconnect the negative (-) battery cable and place the control switch in its OFF
position before starting work.
1. Pull out the dip stick and wipe it clean
2. Reinsert the dip stick
3. Remove the dipstick one final time and check the oil level
NOTICE
The engine oil level indicated on the dipstick should be between the FULL and ADD
marks.
4. Reinsert the dipstick
If the engine oil level check shows excessive or insufficient levels of oil (oil level line above the
FULL mark or below the ADD mark), oil must be drained or added. Refer to the following
sections (Drain Oil or Add Oil - as needed) for instructions and guidelines for draining and
adding oil.
3.5.3
Add or Drain Oil
CAUTION
Too much oil can cause high oil consumption. Too little oil can cause severe engine
damage. Keep the oil level between the FULL and ADD marks on the dipstick.
3.5.3.1 Drain Oil
If the oil level is found to be excessive (see Checking Engine Oil Level), oil must be drained
from the engine.
1. Attach one end of the drain hose (shipped loose with the genset) to the oil drain valve
2. Place the other end of the drain hose into an appropriate container.
Refer to local/state regulations to determine the appropriate container for used oil.
A030A239 (Issue 10)
13
3. Maintenance
9-2013
3. Open the oil drain valve to release oil from the engine into the appropriate container.
4. Re-check the engine oil level (Checking Engine Oil Level)
Based on the results, add or drain oil.
5. When a sufficient amount of oil has been drained from the system:
a. Close the oil drain valve
b. Remove the drain hose
c. Wipe the oil drain valve clean
d. Dispose of the used oil in accordance with local/state regulations.
3.5.3.2 Add Oil
If the oil level is found to be insufficient (see Checking Engine Oil Level), oil must be added.
1. Add the appropriate amount of oil, based on the engine oil level check performed
beforehand.
2. Re-check the engine oil level (see Checking Engine Oil Level).
Based on the results, add or drain oil.
3. Clean up and dispose of any oil in accordance with local/state regulations.
3.5.4
Changing Engine Oil and Oil Filter
Refer to the Periodic Maintenance Schedule for scheduled engine oil changes and to the
control panel for the oil filter part number. Change oil more often in hot and dusty environments.
1. Run the generator set until warm, shut down and place pan under the end of the oil drain
hose attached to the drain valve.
2. Make sure the oil drain hose is connected to the oil drain valve and open the drain valve.
Reclose the valve when oil stops draining.
3. Spin off the oil filter canister and clean the filter mounting surface on the engine block.
Remove the old gasket if it remains.
4. Make sure the gasket is in place on the new filter and apply a thin film of clean oil to the
gasket. Spin the new filter on until the gasket just touches the block. Turn it an additional
1/2 to 3/4 turn. Do not over tighten.
5. Refill with 67 oz (2 liters) of oil.
CAUTION
Too much oil can cause high oil consumption. Too little oil can cause severe engine
damage. Keep the oil level between the Full and Add marks.
6. Start and run for 30 seconds.
7. Shut the engine off and wait 5 minutes.
8. Add more oil slowly, to bring the oil level to the FULL mark on the dipstick.
9. Dispose of the used oil and oil filter according to local environmental regulations.
14
A030A239 (Issue 10)
9-2013
3.6
3. Maintenance
Replacing the Air Filter Element
WARNING
Before working on the generator set, move the Switch (S2) to the Stop Position, disconnect the
remote harness (P7) to disable the ATS mounted charger, and remove the negative (-) battery
cable from the battery to prevent starting.
Refer to the Periodic Maintenance Table for scheduled air filter replacements. Replace it more
often in dusty environments.
To change the filter element:
1. Remove the outer and inner cover and reassemble with a new air filter element.
2. Make sure the outer cover is seated before tightening its wing nut.
No.
Description
No.
Description
1
Dipstick
2
Air Filter
3
Oil Filter
4
Oil Drain
5
Battery
6
Circuit Breaker
7
Control Switch
FIGURE 2.
A030A239 (Issue 10)
MAINTENANCE POINTS
15
3. Maintenance
3.7
9-2013
Battery Maintenance
WARNING
Arcing at battery terminals or in light switches or other equipment, and flames or sparks, can
ignite battery gas causing severe personal injury—Ventilate battery area before working on or
near battery—Wear safety glasses—Do not smoke—Switch work light ON or OFF away from
battery—Stop the generator set—Disconnect the negative (-) battery cable first and reconnect it
last.
WARNING
Before working on the generator set, move the Switch (S2) to the Stop Position,
disconnect the remote harness (P7) to disable the ATS mounted charger, and remove
the negative (-) battery cable from the battery to prevent starting.
Refer to the Periodic Maintenance Table for scheduled battery maintenance, and follow the
battery manufacturer's instructions. Have the battery charger in the transfer switch replaced if
the battery keeps running down.
Always:
1. Keep the battery case and terminals clean and dry and the terminals tight.
2. Remove battery cables with a battery terminal puller. Torque threaded stud battery
terminals as recommended by the battery manufacturer.
3. Make sure which terminal is positive (+) and which is negative (-) before making battery
connections, always removing the negative (-) cable first and reconnecting it last to reduce
arcing.
NOTICE
If the battery needs to be replaced, be sure that the replacement battery specs match
those found in the Specifications Table in this manual.
3.8
Spark Plugs
WARNING
Before working on the generator set, move the Switch (S2) to the Stop Position, disconnect the
remote harness (P7) to disable the ATS mounted charger, and remove the negative (-) battery
cable from the battery to prevent starting.
Set the genset control to the Off position before checking the spark plugs.
Refer to the Periodic Maintenance Table for scheduled spark plug replacement.
The genset has two spark plugs: one on each side of the engine. The spark plugs must be in
good condition for proper engine starting and performance. A spark plug that fouls frequently or
has heavy soot deposits indicates the need for engine service.
To prevent cross threading a spark plug, always thread it in by hand until it seats. Torque the
spark plug to 15 lb-ft (20 N-m).
Return the genset control to Auto when finished performing maintenance.
16
A030A239 (Issue 10)
9-2013
3.9
3. Maintenance
Accessory Heater Kits
WARNING
Electrical connections must be made by a trained and experienced electrician. Improper
installation can lead to electrocution and damage to property. Automatic startup of the generator
set during installation can cause severe personal injury or death. Push the control switch Off and
disconnect the negative (–) cable from the battery to keep the generator set from starting.
An optional thermostatically controlled battery heater is available for more reliable starting in
ambient temperatures down to -20 °F (-28.8 °C). The heater wraps around the battery. The
heater cord is connected in the 120V junction box.
An optional thermostatically controlled oil and alternator heater assembly is also available for
more reliable generator starting at low ambient temperatures. The heater cord is connected in
the 120V junction box.
TABLE 11.
HEATER KITS AND PARTS
Part Description
Model/Part Number (included in product unless otherwise noted)
Heater Assembly (Spec A and
Canadian GSBB Spec B)
20GSBB-6714A
Heater Assembly (US GSBB
Spec B and Canadian GSBC
Spec B)
20GSBB-6714B, 20GSBC-6727B, 15GSBB-6720B
Harness, Interface (Spec A and
Canadian GSBB Spec B)
A030B021
Harness, Interface (US GSBB
Spec B and Canadian GSBC
Spec B)
A041U952
Harness, Heater (Oil Heater)
(Spec A and Canadian GSBB
Spec B)
A030B021
Harness, Heater (Alternator
Heater) (Spec A and Canadian
GSBB Spec B)
A030B021
Harness, Heater (Alternator
Heater) (US GSBB Spec B and
Canadian GSBC Spec B)
Accessory Only
Battery Heater Kit
Accessory Only
Breather Shroud
Accessory Only
3.10
Maintenance Record
Record all periodic and unscheduled maintenance and service. See the Periodic Maintenance
Schedule for a list of scheduled maintenance frequency.
A030A239 (Issue 10)
17
3. Maintenance
DATE
HOUR
METER
READING
9-2013
MAINTENANCE OR SERVICE PERFORMED
Record the name, address, and phone number of your authorized Cummins Onan service
center.
18
A030A239 (Issue 10)
4
Service
WARNING
Some Generator Set service 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 Generator Set service.
WARNING
Accidental or remote starting of the generator set can cause severe personal injury or death.
Disconnect the negative (–) battery cable and place the control switch in its OFF position before
starting work. Hazardous Voltage. Before starting work disconnect the source that supplies 120 V
for the generator set accessory heaters and GFCI outlet
WARNING
Gaseous fuels are flammable and explosive and can cause severe personal injury or death. Do
not smoke if you smell gas or are near fuel tanks or fuel-burning equipment or are in an area
sharing ventilation with such equipment. Keep flames, sparks, pilot lights, electrical arcs and
arc-producing equipment and all other sources of ignition well away. Keep a type ABC fire
extinguisher handy.
4.1
Placing the Generator Set Back in Service
Before leaving the site, if the generator set is ready to be placed in service, set the control
switch to the REMOTE position to provide automatic standby power.
NOTICE
If the generator set is not in Remote mode, the generator set control goes to sleep and
needs to be reconfigured each time it wakes up.
If the control board is replaced, it will be necessary to configure the replacement control board.
NOTICE
Before placing the genset back in service, review the Startup and Configuration chapter of this
manual.
4.2
Transfer Switch
WARNING
Interconnecting the generator set and the public utility can lead to the electrocution of
personnel working on the utility lines, damage to equipment and fire. An approved
switching device must be used to prevent interconnections.
For information regarding servicing the transfer switch, see the manual that was shipped with
your transfer switch.
A030A239 (Issue 10)
19
4. Service
4.3
9-2013
Engine
This generator set is powered by a Briggs & Stratton Vanguard M61 Engine.
Engine
Part Number
Spec A and Canadian GSBB
Spec B
A026L548
US GSBB Spec B and
Canadian GSBC Spec B
A040R203
For engine-specific service, refer to the Engine Service Manual.
4.4
Engine - Generator Assembly
4.4.1
Engine - Alternator Removal
1. Shut down the generator set and disconnect all power from the house to the generator set.
WARNING
Hazardous Voltage. Before starting work disconnect the source that supplies 120 V for the
generator set accessory heaters and GFCI outlet
2. Turn off the fuel supply.
3. Remove the negative (–) cable from the battery.
WARNING
Accidental or remote starting can cause severe personal injury or death. Disconnect the
negative (–) cable at the battery to prevent the engine from starting before installing the kit.
4. Disconnect the battery charger from the transfer switch by disconnecting connector P7.
WARNING
Even though the battery is disconnected, the wires may still be live from the
battery charger in the transfer switch (trickle charger).
5. Remove the roof, service doors, finger guards and panels as necessary.
6. Disconnect all fuel and electrical lines and muffler from the engine and alternator.
7. Secure a hoist to the two lifting eyes on the engine and either strap around the alternator or
use the labeled lifting points to achieve a 4-point lift on the engine-alternator assembly.
NOTICE
Only the engine and alternator may be lifted using the four lifting points, the rest of
the generator set must be lifted utilizing the pockets under the skid.
8. Remove the nuts that secure the four vibration isolators to the engine or generator.
9. Lift the engine-alternator assembly away as a unit for service.
20
A030A239 (Issue 10)
9-2013
4.4.2
4. Service
Engine-Alternator Installation
Reference the image below for installation of the engine-alternator assembly.
See the Testing The Fuel System for Leaks section of this manual for appropriate fuel testing
methods.
A030A239 (Issue 10)
21
4. Service
No.
Description
1
Fan housing
2
Fan guard
3
Wound armature
4
Generator stator
5
Alternator brush block
6
Generator end bell
7
Alternator adapter
8
Alternator fan
9-2013
FIGURE 3.
22
ALTERNATOR ASSEMBLY
A030A239 (Issue 10)
9-2013
4.5
4. Service
Fuel System Components Testing
WARNING
Fuel systems must be installed by qualified service technicians. Improper installation
presents hazards of fire and improper operation, resulting in severe personal injury or
property damage.
WARNING
Gaseous fuels are flammable and explosive and can cause severe personal injury or death. Do
not smoke if you smell gas or are near fuel tanks or fuel-burning equipment or are in an area
sharing ventilation with such equipment. Keep flames, sparks, pilot lights, electrical arcs and
arc-producing equipment and all other sources of ignition well away. Keep a type ABC fire
extinguisher handy.
CAUTION
Unauthorized modifications or replacement of fuel, exhaust, air intake or speed control system
components that affect engine emissions are prohibited by law in the State of California.
The following image illustrates the fuel system components. The gas demand regulator meters
fuel to the engine gas-air mixer. It is usually not the cause of fuel system problems. All other
possible fuel system problems should first be checked out.
No.
Description
No.
Description
1
Hose Adapter
3
Solenoid
2
Fuel Regulator
4
Nipple Fitting
Note: The test port (thread size 3/8 NPT) is located on the back side of this image.
FIGURE 4.
A030A239 (Issue 10)
FUEL SYSTEM COMPONENTS (SPEC A AND CANADIAN GSBB SPEC B)
23
4. Service
9-2013
No.
Description
1
Fuel Regulator
2
Solenoid
FIGURE 5.
4.5.1
No.
3
Description
Nipple Fitting
FUEL SYSTEM COMPONENTS (US GSBB SPEC B AND CANADIAN GSBC SPEC B)
Fuel Pressure
WARNING
High gas supply pressure can cause gas leaks which can lead to fire and severe
personal injury or death. Gas supply pressure must be adjusted to specifications by
trained and experienced personnel.
Satisfactory performance requires that the propane vapor be supplied at the appropriate WC
(water column). See the Specifications section of this manual.
When measuring supply pressure, the most accurate reading would be on the input side of the
demand regulator.
4.5.2
Gas-Air Mixer
Gas-Air Mixer: When reinstalling the gas-air mixer make sure to assemble the components in
the appropriate order, with three new flange gaskets. Torque the flange bolts to 13 ft-lbs (17.5
N-m).
24
A030A239 (Issue 10)
9-2013
4.5.3
4. Service
Governor Actuator
Governor Actuator Testing: Disconnect the two actuator leads and apply 12 VDC. Replace
the actuator if the actuator arm does not move smoothly and without binding to the wide open
throttle position (rotation of approximately 35 degrees).
Governor Actuator Replacement:
NOTICE
It is beneficial to remove the air cleaner including the base for this procedure and to
place a clean rag in the "V" between the cylinders to catch any small fasteners that may
drop.
1. Mount the actuator on its bracket with the lever pointing down (approximately 8 o'clock). Do
not tighten the screws at this time.
2. Connect one end of the ball end throttle link to the mixer arm, using a washer on both
faces of the arm and one end to the actuator lever, tightening both screws to 6 in/lb-f.
3. Hold a 3/32" diameter rod (a drill bit works well) at the wide open throttle slot. Pushing the
governor actuator arm counter-clockwise to wide-open the throttle, slide the actuator in its
slots until the throttle lever just touches the rod. Tighten the two actuator mounting screws
to 6 in/lb-f.
4. When the linkage assembly is released, the throttle lever arm should rest against the low
idle screw.
5. Push the link to check that the throttle arm can open fully to the 3/32" diameter rod and
touch the low idle screw. If not, readjust the position of the actuator. The throttle should
open fully and close fully.
A030A239 (Issue 10)
25
4. Service
No.
9-2013
Description
1
Rotate arm counter-clockwise to fully open slide until the lever just touches the rod. Tighten the fasteners.
2
3/32" rod
3
Lever just touches the rod
FIGURE 6.
26
GOVERNOR ACTUATOR - OPEN
A030A239 (Issue 10)
9-2013
No.
4. Service
Description
1
Fully closed actuator
2
Lever touches set screw
FIGURE 7.
4.5.4
GOVERNOR ACTUATOR - CLOSED
Governor Linkage Adjustment (50 Hz LP Only)
NOTICE
It is beneficial to remove the air cleaner including the base for this procedure and to
place a clean rag in the "V" between the cylinders to catch any small fasteners that may
drop.
Due to inconsistencies in fuels, operating temperatures and engine variation, it may be
necessary to adjust the linkage in order to achieve the proper no load frequency (primarily in 50
Hertz LP applications).
1. Loosen the fasteners that hold the actuator.
2. Slide the actuator to its furthest point away from the butterfly.
3. Tighten both fasteners to 6 in-lb-f.
A030A239 (Issue 10)
27
4. Service
No.
1
9-2013
Description
Fasteners
FIGURE 8.
4.5.5
GOVERNOR ACTUATOR - FASTENERS
Gas Demand Regulator
Conduct a lock-off pressure test as follows before replacing a demand regulator. Replace the
demand regulator only if lock-off pressure is not within the range of 0.20–0.35 inches (5.1–8.9
mm) WC (Spec A and Canadian GSBB Spec B) or 0.075 ± 0.025 inches (19 ± 6.35 mm) WC
(US GSBB Spec B and Canadian GSBC Spec B).
Lock-Off Pressure Test: Lock-off pressure is determined by pressurizing the back (vent) side
of the regulator diaphragm to simulate gas-air mixer venturi vacuum. Conduct the test as
follows:
1. Connect the regulator inlet to a source of air pressure regulated to 11 inches (28 cm) WC.
2. Disconnect the hose from the engine gas-air mixer at the regulator outlet. The soap bubble
will be placed on the hose barb at the regulator.
3. “T" in two hoses to the end of the regulator vent hose (3/8 inch I. D.). Use one hose to
measure pressure by connecting it to an inclined manometer that reads 0–2 inches (0–50
mm) WC and the other to provide the test pressure.
4. Attach a soap bubble to the hose barb at the regulator outlet. While reading the pressure
indicated by a manometer and watching the soap bubble, blow lightly into the hose being
used to pressurize the regulator. Regulator lock-off pressure is the minimum pressure that
will cause air to flow through the regulator, as indicated by the expanding soap bubble. (At
first the soap bubble may expand due to diaphragm movement but will stop expanding if air
is not flowing through the regulator.)
28
A030A239 (Issue 10)
9-2013
4. Service
NOTICE
Make sure the diaphragm is in a vertical plane (as in the genset) when performing a bench
test, otherwise the weight of the diaphragm will cause erroneous readings of lock-off
pressure.
Vent Hose: Make sure to reconnect the regulator vent hose to the vent insect screen as
required.
4.5.6
Fuel Solenoid
Test for Leakage: If there is a smell of gas when the genset is not running, or any other reason
to suspect that the valve is leaking, connect the inlet of the valve to a source of air pressure
regulated to not more than 14 inches WC (35 cm) and disconnect the outlet hose. Replace the
solenoid if it leaks. Use a soap bubble to check for leakage.
Test for Operation: Disconnect the solenoid from the generator set wiring harness and connect
it to a 12 volt battery while the source of air pressure is still connected. Replace the solenoid if it
does not open.
First Start: Upon the first connection of the fuel, especially in LP systems, it is possible for a
spike of pressure greater than the operating strength of the fuel solenoid to pass through the
main regulator and to lock the solenoid into an inoperable position. This issue can be reduced
by using a two-stage regulator at the tank.
If the situation occurs:
1. Close the main valve at the tank and vent the fuel from the line at the tank.
2. Start the crank cycle at the genset and then turn on the fuel at the tank while the engine is
cranking.
NOTICE
Multiple crank attempts may be required to purge the fuel line, depending on the
length of the run.
4.5.7
Low Gas Pressure Switch (If Equipped)
Disconnect the pressure switch from the generator set wiring harness and check for electrical
continuity across its terminals while connected to a source of air pressure regulated to not more
than 14 inches WC (35 cm). Replace the switch if it does not close when air pressure is applied
or open when pressure is released.
4.5.8
Testing the Fuel System for Leaks
WARNING
Fuel presents the hazard of explosion or fire which can result in severe personal injury
or death. Do not smoke or allow any flame, spark, pilot light, arc-producing equipment,
switch or other ignition sources around fuel or fuel components.
Before operating the generator set, test the fuel system for leaks.
• Energize the fuel solenoid from a separate 12-volt DC source before testing the fuel
system
A030A239 (Issue 10)
29
4. Service
9-2013
NOTICE
Testing for gas leaks with a flame can cause a fire or explosion that can lead to severe
personal injury or death. Use approved methods only.
After assembly, and before initial operation, all fuel system connections, hose valves, regulators
and fittings must be tested and proven free of leaks using a soap-and-water (or equivalent)
solution while the system is under gas or air pressure of at least 1.5 times the supply pressure
or 3 psi (20.7 kPa) minimum.
• Apply the soap-and-water solution to all fuel system connections, hose valves, regulators
and fittings.
• When the system is running, bubbles will form where air/pressure is leaking from the
system.
Other approved methods of detecting leaks can be used if appropriate. DO NOT use a flame to
test for gas leaks.
30
A030A239 (Issue 10)
9-2013
4.6
No.
4. Service
Control
Description
1
Circuit breaker
2
Rocker switch
3
Insulation boot
4
Sensor bracket
5
Temperature switch
6
Battery lead
7
Electrical strap
8
Control card
9
Engine harness
10
Single pole dual relay
FIGURE 9.
A030A239 (Issue 10)
CONTROL COMPONENTS
31
4. Service
4.6.1
9-2013
Generator Control
General: The generator control is an integrated microcontroller-based engine, generator and
transfer switch control. It provides all the control, monitoring and diagnostic functions required to
operate a standby generator set.
Transfer Switch Control: When a transfer switch without a built-in controller is used, all
transfer and retransfer signals come from the generator control. Transfer times are pre-set and
not adjustable. Power transfer from the utility to the genset is set at five seconds. Retransfer to
the utility is set for ten minutes. After retransfer, there is a generator cool down period of ten
minutes.
Connections: All DC control connections to the control are through connector J1. Utility sense
and control connections are through connector P7. Optional Ethernet connections are through a
Cat 5 Ethernet cable connector. Refer to the appropriate wiring diagrams and wiring harness
drawings.
Mounting: The control is mounted on the left inner panel, under the finger guard. The finger
guard and control panel each have 4 screws for mounting.
Configuration: Perform Generator Set Configuration when replacing the control board.
Software Updates: To update the control software:
1. Disconnect the harness to the in-home display at J4 before updating the control software.
Refer to the appropriate wiring diagrams for more information.
2. Connect the InPower Onan service tool harness (PN 0338-4840) to remote connector J5.
3. Hold the stop button to wake up the control.
4. Connect InPower Onan and update the software.
5. Disconnect the service tool harness and reconnect the in-home display to J4.
4.6.2
START/STOP Switch S2
Unsnap the connector from the back of the switch for access to its terminals. Replace the switch
if it does not:
• close across terminals 2 and 3 when the switch is held in the Start position
• close across terminals 1 and 2 when held in the Stop position
• the status indicator light does not light when 12 VDC is connected across terminals 7 (-)
and 8 (+)
4.6.3
Line Circuit Breaker CB1/CB2
Disconnect all wiring and check electrical continuity across the terminals of each circuit breaker.
Replace a circuit breaker that does not reset or that does not close or open as the handle is
turned ON and OFF.
4.6.4
Current Transformers CT1/CT2
The current transformers are tied to the line side of the circuit breakers with polarity dot toward
the generator.
32
A030A239 (Issue 10)
9-2013
4.6.5
4. Service
Alternator Temperature Switch
The alternator temperature switch contacts are normally closed. The switch contacts open at
170 °F ± 5°.
4.7
Generator
4.7.1
Operation
This is a single-bearing, two-pole, revolving field generator with brushes and slip rings. Output
voltage is regulated by the generator set control.
Stator: The stator consists of steel laminations with two sets of windings in the lamination slots.
The main windings (L1-L2, Neutral) power the connected loads and the quadrature windings
(Q1-Q2) supply power for the generator field.
See Testing the Generator.
Rotor: The rotor consists of a shaft with steel laminations wrapped with field windings. A
molded slip ring assembly is pressed on to supply field current to the rotor windings through the
brush block assembly. The rotor shaft is supported in the end bell by a sealed ball bearing. The
rotor is centered on and driven by the taper on the end of the engine crankshaft.
Brush Block: Field current passes through the brush block which has two spring-loaded carbon
brushes that make contact with the rotor slip rings.
Voltage Regulator: The generator set control maintains constant output voltage under varying
load conditions by varying field current. Power for field excitation is supplied by the quadrature
winding (Q1-Q2).
A030A239 (Issue 10)
33
4. Service
No.
Description
1
Fan housing
2
Fan guard
3
Wound armature
4
Generator stator
5
Alternator brush block
6
Generator end bell
7
Alternator adapter
8
Alternator fan
9-2013
FIGURE 10.
34
GENERATOR (ALTERNATOR)
A030A239 (Issue 10)
9-2013
4.8
4. Service
Alternator Temperature Switch
The alternator temperature switch contacts are normally closed. The switch contacts open at
170 °F ± 5°.
4.9
Brush Block/Slip Ring Service
Disconnect the field leads from the brush block (F1, F2), remove the two mounting screw and
withdraw the brush block from the generator end bell. Replace the brush block assembly if
either brush is shorter than 7/16 inch (11 mm), binds in the brush block or is damaged in any
way.
Remove the brush block and inspect the slip rings for grooves, pits, or other damage. Use a
Scotch Brite pad or commutator stone to remove light wear or corrosion.
4.10
Stator Service
Removal:
1. Remove roof, service doors, finger guards and panels as necessary.
NOTICE
The back panel must be removed to remove the stator.
2. Remove the engine-generator assembly.
3. Remove the brush block.
CAUTION
The brushes can be damaged if the brush block is not removed before removing the end
bell.
4. Remove the nuts and lock washers on the four stator through studs.
5. Remove the end bell.
6. Pull the stator straight out and away from the engine, leaving the rotor and through studs in
place, taking care not to damage rotor or stator windings.
Reassembly: Reassembly is the reverse of removal. Re-lubricate the bearing bore in the end
bell with molybdenum disulfide paste or equivalent and make sure the O-ring is placed in the
bearing bore. Torque the nuts on the through studs to 31 ft-lbs (42 N-m).
4.11
Rotor Service
Removal:
1. Remove roof, service doors, finger guards and panels as necessary.
NOTICE
The back panel must be removed to remove the rotor.
A030A239 (Issue 10)
35
4. Service
9-2013
2. Remove the stator and stator through studs.
3. Remove the nut and flat washer on the rotor through stud and remove the through stud.
(Use two nuts locked together at the end of the rotor through stud to loosen and remove
the stud from the crankshaft.)
4. Thread in a rotor removal rod (shortened rotor through stud or 7/16-14 UNC-2A threaded
rod) and turn it with a screwdriver until it bottoms in the crankshaft. Thread in and tighten a
9/16-12 UNC-2B bolt against the rod until the rotor breaks loose from the crankshaft.
Reassembly: Reassembly is the reverse of removal. Torque the nut on the through stud to 49
ft-lbs (67 N-m). If it is necessary to reinstall the engine-generator adaptor, torque the four
mounting bolts to 49 ft-lbs (67 N-m).
4.12
Testing the Generator
Rotor Winding Continuity: Test the rotor for grounded, open and shorted windings using an
ohmmeter. First test at the brush block terminals. If the resistance is high, remove the brush
block and test directly on the slip rings. Replace the brush block if a high resistance is due to
the brushes.
Rotor Ground Resistance Test: Set the ohmmeter to the highest resistance scale, or use a
megger. Touch one test probe to the rotor shaft and the other to one of the slip rings. Refer to
the Rotor and Stator Resistance Tests table for resistance values and any corrective action.
Rotor Winding Resistance: Touch the slip rings with the meter test probes. Refer to the Rotor
and Stator Resistance Tests table for resistance values and any corrective action.
Main Winding to Quad Winding: Test for short between main windings and quad windings.
Stator Ground Resistance Test: Set the ohmmeter to the highest resistance scale, or use a
megger. Set the ohmmeter to the highest resistance scale and then touch one test probe to the
stack and, in turn, the other to each stator lead. Refer to the Rotor and Stator Resistance Tests
table for measurement values.
Stator Winding Resistance: Use a meter (Wheatstone Bridge) having a precision down to
0.001 ohms to measure stator winding resistance values as shown in the Rotor and Stator
Resistance Tests table.
Stator Winding for Grounds: With an ohmmeter, measure each winding to the stator
laminations to check for bad insulation. Refer to the Rotor and Stator Resistance Tests table for
measurement values.
TABLE 12.
ROTOR AND STATOR RESISTANCE TESTS
Tests
Measurement Values
Rotor Ground Resistance
Reading > 1 megohm (one million ohms) on megger, or
infinity on an ohmmeter
Rotor Winding Resistance F1 to F2 (at 75° F - room
temperature)
27.59 ohms ± 10%.
Main Winding to Quad Winding
Open (infinity) for any winding
Stator Ground Resistance
Reading > 1 megohm (one million ohms) on megger, or
infinity on an ohmmeter.
Stator Winding Resistance (at 75° F - room temperature):
L1 to N
36
0.094 ohms ± 10%
A030A239 (Issue 10)
9-2013
4. Service
Tests
Measurement Values
L2 to N
0.094 ohms ± 10%
L1 to L2
(Equal to sum of L1 to N and L2 to N) ± 1%
Q1 to Q2
1.11 ohms ± 10%
L1 and N to Q1 and Q2
Infinity
L2 and N to Q1 and Q2
Infinity
L1 to Gnd
L2 to Gnd
Infinity
Infinity
L1 and N to laminations
Infinity
L2 and N to laminations
Infinity
Q1-Q2 to laminations
Infinity
*If a stator or rotor fails the initial test, repeat the test to check the validity of the initial measurement before replacing
the stator or the rotor.
This generator is rated in accordance with UL 2200 (Stationary Engine Generator Assemblies)
or CSA C22.2 No. 100-04 (Motors and Generators). The maximum continuous current values
that are listed on the generator set nameplate and specification tables occur at the lower limit of
acceptable voltage. Maximum current occurs at 108 and 216 volts. The voltage set point of this
generator set can be adjusted from the operator panel if desired.
The operator panel allows the service voltage to be changed to 7.5% below the nominal 240 volt
set point. The entire 10% voltage adjustment is not allowed by the end user in order to ensure
that the utilization voltage is not too low at the end devices. Additional voltage drop across the
supply conductors may cause rick of damage or improper function of the devices if the voltage
at the genset is set too low.
Derating Guidelines: Maximum wattage or maximum current are subject to and limited by such
factors as fuel Btu content, ambient temperature, altitude, engine power and condition, etc. Full
rated power is available at 60 °F (15.5 °C) at sea level. Derate 3.5% for each 1000 ft (304.8 m)
above sea level and 3% for each 10 °F (5.5 °C) increase in ambient temperature above 60 °F
(15.5 °C).
Example Derate Calculation:
Customer location is at 2000 ft (x m) elevation and the ambient air temperature is 90 °F (x °C).
De-rate for Elevation:
2000 ÷ 1000 = 2
2 x 3.5% = 7% de-rate for elevation
De-rate for Temperature:
90° - 60° = 30°
30° ÷ 10° = 3
3 x 3% = 9% de-rate for temperature
Total De-rate:
9% + 7% = 16% total de-rate %
Amp x (total de-rate ÷ 100) = de-rate in amps
73.2 x (16 ÷ 100) = 11.7 amps
A030A239 (Issue 10)
37
4. Service
9-2013
Expected output will be 73.2 amp - 11.7 amp = 61.5 amp
To verify generator set performance:
1. Follow de-rate guidelines above and determine % reduction in generator set output due to
temperature and elevation. See example calculation.
2. While the generator set is running, determine the output voltage at the customer
connection block TB2.
3. Use the table below to find the expected current value for the measured voltage and apply
the de-rate calculated in step 1.
4. Measure current at the customer connection wires at TB2.
5. Turn on household devices or increase the load setting of the load bank until the current is
equal to the de-rated current calculated in step 3. Approximate load bank setting required
to achieve the expected amperage output can be estimated by multiplying the expected
amperage output by the voltage measured in step 2.
TABLE 13.
EXPECTED CURRENT VALUE FOR MEASURED VOLTAGE
Generator Voltage at
TB2
Minimum Amps
Available Before
Derate LP
Minimum Amps
Available Before
Derate NG
Generator Voltage at
TB2
Minimum Amps
Available Before
Derate NG
252
69.7
61.5
241.5
55.9
249.6
70.4
62.1
239.2
56.4
247.2
71
62.7
236.9
57
244.8
71.7
63.4
234.6
57.5
242.4
72.4
64
232.3
58.1
240
73.2
64.6
230
58.7
237.6
73.9
65.3
227.7
59.3
235.2
74.7
65.9
225.4
59.9
232.8
75.4
66.6
223.1
60.5
230.4
76.2
67.3
220.8
61.1
228
77
68
218.5
61.8
225.6
77.8
68.7
216.2
62.4
223.2
78.7
69.5
213.9
63.1
*220.8
79.5
70.2
*211.6
63.8
*218.4
80.4
71
*209.3
64.5
*216
81.3
71.8
*207
65.2
*These voltage settings are not allowed by the generator control.
38
A030A239 (Issue 10)
5
Operation
5.1
In-Home Operator Panel
The operator panel must be hard-wired to the generator set in order for the generator system to
operate.
NOTICE
The in-home operator panel and Internet/Email interface can be used simultaneously
The operator panel consists of two UTILITY status lamps, three GENERATOR status lamps,
three action buttons and an LCD display screen with four navigation buttons.
No.
Description
1
Back Button - When navigating through the LCD menus, press this button to return to the main operating
screen.
2
Standby On/Off Button - See the To Enable/Disable Standby section of this manual.
3
Start Stop Button - See the To Manually Start/Stop Generator Set section of this manual.
4
Navigation Buttons - The function of these buttons change as different screens appear.
FIGURE 11.
5.1.1
IN-HOME OPERATOR PANEL
BACK Button
When navigating through the LCD menus, press the BACK button to return to the main
operating screen.
5.1.2
Standby ON/OFF Button
See To Enable/Disable Standby.
A030A239 (Issue 10)
39
5. Operation
5.1.3
9-2013
START STOP Button
See To Manually Start/Stop Generator Set.
5.2
Typical Operation
NOTICE
The following diagrams are based on an APPROXIMATE time duration. Your genset may
vary slightly from the timing diagrams in this manual.
FIGURE 12.
40
TYPICAL POWER OUTAGE CYCLE TIMING DIAGRAM
A030A239 (Issue 10)
9-2013
5. Operation
FIGURE 13.
A030A239 (Issue 10)
EXERCISE TIMING DIAGRAM
41
5. Operation
9-2013
FIGURE 14.
42
MANUAL START/STOP TIMING DIAGRAM
A030A239 (Issue 10)
9-2013
5. Operation
FIGURE 15.
5.2.1
LOAD MANAGEMENT TIMING DIAGRAM
Normal Operation: Utility Power Available and Connected
As long as utility power is available and connected, both of the green UTILITY lamps
(PRESENT and CONNECTED) will stay on and the LCD screen will indicate “Genset Stopped".
If the red GENERATOR STANDBY OFF light is on, the generator set will not start up
automatically if utility power is interrupted. See the To Enable/Disable Standby section of this
manual to enable STANDBY so that the generator set will automatically supply power if utility
power is interrupted.
A030A239 (Issue 10)
43
5. Operation
9-2013
FIGURE 16.
5.2.2
UTILITY PRESENT AND CONNECTED—STANDBY OFF LAMP ON
Emergency Operation: Utility Power Interrupted
If utility power is interrupted,
1. The green UTILITY PRESENT lamp will go out
2. The generator set will start automatically and the green GENERATOR RUNNING lamp will
turn on.
3. The UTILITY CONNECTED light will go out when the generator set is connected to supply
power.
The LCD screen will provide a visual indication of “Genset Load" (bar graphs). The bar graphs
indicate how much of the available power is being used in each supply line (L1 and L2).
If the red ACTION REQUIRED light comes on, either the generator shut down or periodic
maintenance has come due. The LCD screen will indicate what maintenance is due or which
fault occurred.
FIGURE 17.
44
GENERATOR SET RUNNING—ACTION REQUIRED LAMP ON
A030A239 (Issue 10)
9-2013
5.3
5. Operation
To Enable/Disable Standby
Normally, you should not have to disable generator set STANDBY.
• STANDBY should always be enabled (ON) except during maintenance/service.
• STANDBY will have to be re-enabled (STANDBY OFF light on) if the generator set is
started or stopped manually (normally a maintenance/service function) or a fault shutdown
has occurred.
CAUTION
When STANDBY is disabled the generator set will NOT automatically start to supply power if
utility power is interrupted.
To enable or disable generator set standby:
1. Press the STANDBY ON/OFF button on the operator panel, which takes you to the
Standby ON/OFF screen.
2. Press the up or down arrow button to select ON or OFF.
3. To enable STANDBY select ON and press the BACK button. The STANDBY OFF lamp
will go out and the display will state: “Standby ready enabled by user."
4. To disable STANDBY select OFF and press the BACK button. The STANDBY OFF lamp
will come on and the display will state: “Standby ready disabled by user."
FIGURE 18.
5.4
ENABLE/DISABLE STANDBY SCREEN
To Manually Start/Stop Generator Set
Normally, only the maintenance/service technician has to manually start and stop the generator
set.
• Starting the generator set will result in the generator powering the house loads.
CAUTION
Manually starting or stopping the generator set disables generator set STANDBY. The generator
set will not automatically start to supply power if utility power is interrupted.
Manually start and stop the generator set once every 3 months to test that these
functions are working properly.
A030A239 (Issue 10)
45
5. Operation
9-2013
To manually start or stop the generator set:
1. Press the START STOP button on the operator panel, which takes you to the Genset
START/STOP screen.
• The screen will display “Genset Stopped" or “Genset Running," as appropriate.
2. Press START to manually start the generator set and connect it to supply power to the
house. The STANDBY OFF lamp will come on and the display will state: “Genset started
manually (Standby Ready Disabled)."
3. Press STOP to manually stop the generator set and disconnect it. The STANDBY OFF
lamp will come on and the display will state: “Genset stopped manually (Standby Ready
Disabled)."
NOTICE
To start the generator set without connecting loads pick Exercise Now on the Exerciser
Clock screen.
FIGURE 19.
5.5
GENSET START/STOP SCREEN
Fault, Maintenance and New Event Screens
Various warning and event screens may appear on the operator panel during Normal or
Emergency Operation.
5.5.1
Fault Screen
If a generator set shutdown fault occurs, a FAULT warning appears with the following
information:
• Brief description of the warning or fault
• The two-digit Fault Code Number
• The time of occurrence of the fault
Press the BACK button to reset the fault and return to the home screen.
See the Fault Log section of this manual to review the log of the last 5 faults.
46
A030A239 (Issue 10)
9-2013
5. Operation
FIGURE 20.
5.5.2
TYPICAL FAULT SCREEN
Maintenance Due Screen
A Maintenance Due screen appears when a scheduled maintenance operation is due.
• The warning does not time out.
• Perform the maintenance.
Press the BACK button to return to the home screen.
FIGURE 21.
5.5.3
TYPICAL MAINTENANCE DUE SCREEN
New Event Screen
A New Event screen appears whenever system status changes, such as when there is an
interruption of utility power. The screen provides a brief description of the event along with the
time and date of the event.
• The message does not time out, unless superseded by a new event.
• Press the BACK button to return to the home screen.
A030A239 (Issue 10)
47
5. Operation
9-2013
FIGURE 22.
5.6
TYPICAL NEW EVENT SCREEN
Genset Status
To check generator set output voltage and frequency and the total numbers of hours run:
1. Press the MENU button on the home screen.
2. Press the up or down arrow button on the menu screen to select Genset Status.
3. Press the ENTER button on the menu screen and note the values displayed on the Genset
Status screen.
4. Press the BACK button to return to the home screen.
48
A030A239 (Issue 10)
9-2013
5. Operation
FIGURE 23.
GENERATOR SET STATUS SCREEN
5.7
Display Setup and Software Info
5.7.1
Brightness and Contrast
To change the Brightness and Contrast of the display screen:
1. Press the MENU button on the home screen.
2. Press the up or down arrow button on the menu screen to select Display Setup.
3. Press the ENTER button on the menu screen.
4. Press the NEXT button to select Brightness or Contrast.
5. Press the increase or decrease arrow button to increase or decrease brightness.
6. Change Contrast the same way as Brightness.
7. Press the BACK button to save the settings and return to the home screen.
A030A239 (Issue 10)
49
5. Operation
9-2013
FIGURE 24.
5.7.2
DISPLAY SETUP AND SOFTWARE INFO SCREENS
Software Info
To check on the generator set and display software:
1. Press the MENU button on the home screen.
2. Press the up or down arrow button on the menu screen to select Display Setup.
3. Press the ENTER button on the menu screen.
4. Press the INFO button on the Display Setup screen and note the values displayed on the
Software Info screen.
5. Press the BACK button to return to the home screen.
50
A030A239 (Issue 10)
9-2013
5. Operation
5.8
Event Log
5.8.1
To Check Log of Last 20 Events
1. Press the MENU button on the home screen.
2. Press the up or down arrow button on the menu screen to select Event Log.
3. Press the ENTER button on the menu screen.
4. Scroll through the event log with the up and down double-arrow buttons. Each screen
provides a brief description of the event along with the time and date of the event.
5. Press the BACK button to return to the home screen.
FIGURE 25.
5.8.2
EVENT LOG SCREEN
List of Recordable Events
• "Genset started manually (Standby Ready Disabled)"
• "Genset stopped manually (Standby Ready Disabled)"
• "Genset exercise started"
• "Genset exercise completed"
• "Genset started due to loss of utility"
A030A239 (Issue 10)
51
5. Operation
9-2013
• "Genset stopped with return of utility"
• "Switch on genset moved to remote position"
• "Switch on genset moved to run position"
• "Switch on genset moved to off position"
• "Standby ready disabled by user"
• "Standby ready enabled by user"
• "Utility lost - not in Standby Ready"
• "Utility returned - not in Standby Ready"
• "Maintenance reminder - Change oil and check valve lash"
• "Maintenance reminder - Change oil & filter, air filter, adjust valve lash, clean and check
battery & engine cooling fins"
• "Genset fault - (Fault description appended)"
• "Genset warning - Transfer Switch Signal Failure"
• "Genset warning - Transfer Switch Failed to Transfer to Utility"
• "Genset warning - Low Battery or Battery Charger Failure"
5.9
Fault Log
To check the log of the last 5 faults:
1. Press the MENU button on the home screen.
2. Press the up or down arrow button on the menu screen to select Fault Log.
3. Press the ENTER button on the menu screen.
4. Scroll through the fault log with the up and down double-arrow buttons. Each screen
provides a brief description of the fault, the fault code number and the time and date of the
fault.
5. Press the BACK button to return to the home screen
NOTICE
If there are no faults recorded, the “No Stored Faults" screen will appear.
52
A030A239 (Issue 10)
9-2013
5. Operation
FIGURE 26.
5.10
FAULT LOG SCREEN
Ethernet Settings
This feature allows for in-home or remote access to your generator set through a web page.
• On this web page, you can:
• start or stop your generator set
• adjust the exerciser day and time
A030A239 (Issue 10)
53
5. Operation
9-2013
• determine if utility power is available
• view the last 20 events/faults on the generator set
This feature is useful for homeowners who travel or have a second home and want to be able to
remotely interface with their generator set. This feature can also help to reduce troubleshooting
time and service calls when the service technician has access to the same web page.
Use of the Ethernet is not required if you do not use web access. To set up your generator set
for web access, complete installation instructions.
NOTICE
Ethernet setup must be done at the generator set location. It cannot be done via the web from a
different location. An available Ethernet port and a high-speed Internet are required for
functionality.
To reset the Internet and email interface IP address and password:
1. Press the MENU button on the home screen.
2. Press the up or down arrow button on the menu screen to select Ethernet Setup.
3. Press the ENTER button on the menu screen.
4. Press the NEXT button to select the field to change.
5. To Reset Password - If you have forgotten your password, select the Reset Password
field and press an up or down arrow. The password will be reset to “cummins". Press the
BACK button to go back to the home screen.
6. IP Address - If DHCP is ON (factory setting), the modem/router will assign the generator
set IP Address displayed here. This is the address you enter in your internet browser
address bar. The address assigned to the generator set may change over time. If, for
example, the modem/router is unplugged, it will probably re-assign new addresses to all of
the devices in the home that it serves. If the IP Address you have been using does not
work any longer, copy down the new address and enter it on the browser page.
7. DHCP ON/OFF - DHCP leaves the factory ON. If more advanced features are desired, the
modem/router probably can be configured for DHCP to be OFF. Refer to the Generator
Set Network Setup Guide regarding the permanent generator set IP Address to assign.
8. Manually Enter IP Address—DHCP OFF - If DHCP is OFF, it will be necessary to
manually enter the IP Address, which consists of four three-digit numbers. To enter a
number, select the hundreds, tens or units field in each three digit number field by pressing
the NEXT and PREV buttons. Push the up or down arrow to increase or decrease the
number in the selected field. Numbers in the units fields will increase by one, in the tens
fields by ten and in the hundreds field by one hundred. Refer to the Generator Set
Network Setup Guide to make sure setup is complete.
NOTICE
If utilizing a remote internet access to the generator set, it is recommended that a UPS
battery backup be connected to your router and/or modem.
54
A030A239 (Issue 10)
9-2013
5. Operation
FIGURE 27.
5.11
NETWORK SETUP SCREEN
Exercise Settings
To set the generator set exercise schedule:
1. Press the EXCER button on the home screen.
2. Press the NEXT button on the Exerciser Clock screen to select the field to change.
3. Press the up or down arrow button to increase or decrease the frequency of exercise and
the day of the week and time of day for exercise.
Frequency selections are:
Weekly
Bimonthly
Monthly
Never
4. Press the BACK button to save the settings and return to the home screen.
5. If you want to exercise the generator set now, select Exercise Now, and press either the up
or down arrow.
A030A239 (Issue 10)
55
5. Operation
9-2013
NOTICE
Scheduled or prompted exercise does not transfer the house loads to the generator set.
FIGURE 28.
5.12
EXERCISE CLOCK SCREEN
Time Setup
To set up the generator set clock for the current date and time:
1. Press the CLOCK button on the home screen.
2. Press the NEXT button on the Time Setup screen to select the field to change.
3. Press the up or down arrow button to increase or decrease or change the date or time.
4. Press the BACK button to save the settings and return to the home screen.
56
A030A239 (Issue 10)
9-2013
5. Operation
FIGURE 29.
5.13
TIME SETUP SCREEN
Load Management
The generator set may have been set up at installation to connect and disconnect certain large
loads, such as air conditioners, to manage the total load so as not to overload the generator set.
This requires the installation of relays to the load management signals which allow for the
disconnection of loads. Load management can be set to operate in automatic or manual mode.
Whether in automatic or manual mode, there is a delayed start. Load 1 is enabled three minutes
after the generator set is connected to the house loads, and Load 2 is enabled six minutes after
the generator set is connected to the house loads.
5.13.1 Automatic Load Management
When set to automatic mode, the user takes no action and can only view which loads are
connected. Three minutes after the generator starts, the load that is connected to genset load
L1 is connected. After a delay of three more minutes, the load that is connected to genset load
L2 is connected. If the connection of loads L1 and L2 exceeds 95% of the generator's load
capacity, they are disconnected by the generator. Following another three minute delay, the
control reconnects both loads following the same connection sequence used in the first attempt
(three minutes apart). If generator load capacity is exceeded again, both loads are disconnected
and no further reconnection is tried.
To select automatic load management and view whether the selected loads are connected while
the generator set is running:
1. Press the LOAD button on the home screen.
2. Press the up or down arrow button to select Automatic.
3. Note which loads are connected or disconnected.
4. Press the BACK button to return to the home screen.
Adjust percent load to match the de-rate.
A030A239 (Issue 10)
57
5. Operation
9-2013
5.13.2 Manual Load Management
CAUTION
To reduce unnecessary loss of service, it is highly recommended that manual load
management be undertaken only by an authorized Cummins Onan dealer.
When set to manual mode, the user is able to view, connect, and disconnect loads. If the
connection of loads L1 and L2 exceeds generator capacity, the AC circuit breaker trips.
To select manual load management when the generator is running:
1. Press the LOAD button on the home screen.
2. Press the up or down arrow button to select Manual.
3. Note which loads are connected or disconnected.
4. Press the double-down arrow button to go the load connect/disconnect screen.
5. Connect or disconnect Load 1 or Load 2 as necessary by pressing either button under
Load 1 or Load 2.
6. Press the BACK button to save the setting and return to the home screen.
FIGURE 30.
58
LOAD MANAGEMENT SCREEN
A030A239 (Issue 10)
6
Startup and Configuration
6.1
Pre-startup Inspection
Before starting the genset inspect the installation and check off each of the following questions if
it can be answered “YES". If a question cannot be checked off, review the appropriate section in
the manual.
• [ ] Can the top, maintenance and service access doors be swung fully open for operation,
maintenance and service?
• [ ] Are the cooling air inlet and outlet openings free of obstructions?
• [ ] Have the AC output connections been made properly?
• [ ] Has the transfer switch been installed properly to prevent connecting the generator set
to the utility?
• [ ] Has a properly sized battery been installed?
• [ ] Are all fuel connections tight?
• [ ] Is fuel supply pressure correct?
• [ ] Are electrical and fuel lines properly separated?
• [ ] Does engine exhaust disperse away from buildings?
• [ ] Have all fuel connections been checked for leaks?
• [ ] Is the fuel supply pressure to the inlet of the generator set appropriately set for the fuel
being used?
• [ ] Does the installation meet all applicable local, state, and federal codes?
• [ ] Is the fuel regulator vent screen free of obstructions?
• [ ] Is the manual fuel selector set to proper fuel?
6.2
Startup
When all installation requirements have been met, connect the battery cables to the battery,
positive (+) cable first.
WARNING
Automatic startup of the generator set during installation can cause severe personal injury or
death. Push the control switch OFF and disconnect the negative (–) cable from the battery to
keep the generator set from starting.
Read through the Operator's Manual and perform the maintenance and pre-start checks
instructed. The genset is shipped from the factory with the proper level of engine oil, but should
be checked before the genset is started. Start and operate the genset, following all the
instructions and precautions in the Operator Manual.
Perform Generator Set Configuration.
A030A239 (Issue 10)
59
6. Startup and Configuration
9-2013
NOTICE
Before leaving the site, if the genset is ready to be placed in service, set the control switch to the
REMOTE position to provide automatic standby power.
6.3
Generator Set Configuration
The operator panel has a menu with four generator set/transfer switch parameters that must be
configured for the installation.
To configure the generator set:
1. Press the MENU button on the home screen.
2. Press and hold the blank (far left, solid black) button on the menu screen for at least 5
seconds to go to the Config Menu.
3. Press the up or down arrow button on the Config Menu screen to select Generator Config.
4. Press Enter on the Config Menu to go to the Generator Config screen.
5. Press the NEXT button on the Generator Config Menu screen to select the Config,
Frequency or Rating field.
6. Press the up or down arrow button to increase or decrease the configuration parameter.
a. Config: Select appropriate configuration (depending on model and fuel) from the table
shown below.
b. Frequency: Select 60 Hz or 50 Hz.
c. Rating: Rating will be filled in, based on the configuration selected. This value can be
lowered in order to correctly de-rate for high altitude or hot climates. (Selecting the
correct Amps value will also allow the correct genset load to be displayed on the
Operator Panel.
d. Press the BACK button to save the setting and return to the home screen.
TABLE 14.
CONFIGURATIONS, BASED ON MODEL AND FUEL TYPE
Model (Spec)
Fuel
Configuration
GSBB Spec A and Canadian GSBB
Spec B
Natural Gas
14
GSBB Spec A and Canadian GSBB
Spec B
Propane
15
US GSBB Spec B and Canadian
GSBC Spec B
Natural Gas
18
US GSBB Spec B and Canadian
GSBC Spec B
Propane
19
60
A030A239 (Issue 10)
9-2013
6. Startup and Configuration
FIGURE 31.
A030A239 (Issue 10)
GENERATOR CONFIGURATION
61
6. Startup and Configuration
9-2013
6.4
Generator Adjustments
6.4.1
To Adjust the Output Voltage
Use the following procedure:
1. Connect an accurate AC volt meter across L1 and L2 while the generator set is running.
2. With Output Volts selected on the Adjustments Menu screen, press the up or down arrow
button to adjust the voltage to the desired setting
3. The control allows an adjustment of 240 VAC ± 7% (17 VAC).
4. Press the BACK button to save the settings and return to the home screen.
6.4.2
To Calibrate the Display Meter
Use the following procedure:
1. Connect an accurate AC volt meter across L1 and L2 while the generator set is running.
2. Press the NEXT button to select the Display Cal field (screen not shown).
3. Press the up or down arrow to adjust the voltage reading on the screen until it matches the
meter reading.
4. Press the BACK button to save the settings and return to the home screen.
FIGURE 32.
6.5
ADJUSTMENT MENU SCREEN
Transfer Switch Configuration
To configure the generator set for the transfer switch being used:
1. Press the MENU button on the home screen.
2. Press and hold the blank button on the menu screen for at least 5 seconds to go to the
Config Menu.
3. Press the up or down arrow button on the Config Menu screen to select TS Config.
4. Press Enter on the Config Menu to go to the Transfer Switch screen.
5. Press the up or down arrow button to select between two choices: “RSS100-6868 and
RSS200-6869" or “RSS100-6634 and RSS200-6635," which must match the model number
of the transfer switch being used.
NOTICE
For non-Cummins Onan transfer switches, select RSS100-6634 and RSS100-6635.
62
A030A239 (Issue 10)
9-2013
6. Startup and Configuration
6. Press the BACK button to save the setting and return to the home screen.
FIGURE 33.
6.6
TRANSFER SWITCH CONFIGURATION
Transfer Switch Parameter Adjustments
Model RSS100-6634 and RSS200-6635 Transfer Switches: Refer to Transfer Switch
Installation Manual 962-0620 to set the parameters inside the transfer switch.
Model RSS100-6868 and RSS200-6869 Transfer Switches: To make transfer switch
parameter adjustments:
1. Press the MENU button on the home screen.
2. Press and hold the blank button on the menu screen for at least 5 seconds to go to the
Config Menu.
3. Press the up or down arrow button on the Config Menu screen to select TS Adjustments.
A030A239 (Issue 10)
63
6. Startup and Configuration
9-2013
4. Press Enter on the Config Menu to go to the Transfer Switch screen.
5. Press the NEXT button on the Generator Config Menu screen to select the Pickup, Dropout
or Nominal field.
6. To set Nominal - Press the up or down double-arrow button to increase or decrease the
nominal utility voltage parameter to match actual (Present) utility voltage. The Pickup and
Dropout parameters are percentages of the nominal voltage parameter.
7. To set Pickup- Press the up or down double-arrow button to increase or decrease the
minimum utility voltage to which the transfer switch will connect. Default is 90% of nominal.
It can be increased to 95% of nominal.
8. To set Dropout- Press the up or down double-arrow button to increase or decrease the
minimum utility voltage at which the transfer switch will disconnect. Default is 85% of
nominal. It can be decreased to 80/75/70% of nominal.
9. Press the BACK button to save the setting and return to the home screen.
FIGURE 34.
64
TRANSFER SWITCH ADJUSTMENTS
A030A239 (Issue 10)
7
Optional Internet/Email Interface
Descriptions
7.1
Introduction
This feature allows for in-home or remote access to your generator set through a web page.
NOTICE
An Internet browser (i.e., Internet Explorer) is required for this option.
On this web page, you can start or stop the generator set, adjust the exerciser day and time,
determine if utility power is available and view the last 20 events/faults on the generator set.
This feature is useful for homeowners who travel or have a second home and want to be able to
remotely interface with their generator set. This feature can also help to reduce troubleshooting
time and service calls when the service technician has access to the same web page.
Use of the Ethernet is not required if you do not use web access. To set up your generator set
for web access, complete installation instructions are included in the Network Setup Guide
instruction sheet, included with your generator set literature package.
The Internet/Email Interface can make the same fault, maintenance and event notices available
to you and to your generator set service contract agency with appropriate Internet Service and
email account.
NOTICE
Technical support for setup and troubleshooting of the hardware used for in-home
network access to the generator set is available through the selling Cummins Onan
dealer/distributor.
The owner may be required to contact their ISP and/or email provider for technical support of the
email notification feature setup and troubleshooting.
Due to the variations in network equipment, network configurations and ISPs, the owner is
responsible for acquiring the needed support/service from a qualified network specialist to
properly and securely set up the owner's network for remote monitoring of the generator set.
Cummins Onan does not provide technical support for setup and troubleshooting of the owner's
network and email service.
A030A239 (Issue 10)
65
7. Optional Internet/Email Interface Descriptions
7.2
Screen Descriptions
FIGURE 35.
7.2.1
9-2013
HOME PAGE
Setting Time and Date
Select the Genset Time/Date Tab on the Home Screen to set the time and date for the
generator set control.
66
A030A239 (Issue 10)
9-2013
7. Optional Internet/Email Interface Descriptions
FIGURE 36.
7.2.2
SET GENSET TIME AND DATE
Set Exercise Schedule
Select the Exercise Schedule Tab on the Home Screen to set the generator set exercise
schedule.
NOTICE
The generator set will exercise on the first scheduled day for which it is programmed. After that it
exercises on that day at the scheduled interval. For example, if the generator set is scheduled on
a Wednesday for Saturdays with a monthly interval, the generator set starts on the next available
Saturday. After that it exercises on Saturdays one month apart.
FIGURE 37.
7.2.3
SET EXERCISE SCHEDULE
Load Control (Management)
Select the Load Control Tab on the Home Screen to enable Automatic or Manual Load Control.
In Automatic mode, the user can only view which loads are connected. In Manual mode, the
user can view loads and also connect or disconnect them. See Load Management for details.
A030A239 (Issue 10)
67
7. Optional Internet/Email Interface Descriptions
FIGURE 38.
7.2.4
9-2013
GENSET LOAD MANAGEMENT
Event Log
Select the Event Log Tab on the Home Screen to review the last 20 events. See the Event Log
screen capture below for a list of all of the recordable events.
FIGURE 39.
7.2.5
EVENT LOG
Fault Log
Select the Fault Log Tab on the Home Screen to review the last 5 faults.
68
A030A239 (Issue 10)
9-2013
7. Optional Internet/Email Interface Descriptions
FIGURE 40.
7.2.6
FAULT LOG
Network Setup Screen Descriptions
An owner-custom password can be defined in the Network Setup screen shown below. The
user will be prompted to enter the User Name and Password to access this screen.
The Network Setup Parameters screen allows dynamic addresses to be changed to static
addresses. This screen allows the user to configure the static address for the in-home network.
See the Network Setup Parameters screen shown below.
FIGURE 41.
FIGURE 42.
7.2.7
NETWORK SETUP SCREEN
NETWORK SETUP PARAMETERS
Email Setup Screen Descriptions
The user must determine what events will trigger an email notification of the event:
• Never
• All Events
A030A239 (Issue 10)
69
7. Optional Internet/Email Interface Descriptions
9-2013
• Maintenance and Attention Required or Attention Required Only
This screen is also used to set up e-mail configuration.
The user may enter up to three email addresses for receiving notifications of the home-standby
generator set status. See the Email Addresses figure below.
FIGURE 43.
EMAIL SETUP PARAMETERS
FIGURE 44.
7.2.8
EMAIL ADDRESSES
Saving Changes
After the email addresses are added and Done is selected, this screen will appear, verifying that
all changes have been saved.
FIGURE 45.
70
SAVE SCREEN
A030A239 (Issue 10)
8
Optional Internet/Email Interface Setup
8.1
Network Connectivity Options
Network connectivity includes in-home Network access to the generator set, e-mail notification,
and remote access to the generator set.
8.2
Material/Cable Routing
Route the category 5 Ethernet cable from the generator in the same conduit as the control lines
and display cable (for in-home mounted displays) to the transfer switch and into the house.
Ensure the cable is long enough to reach the network router. Attach the cable end connectors at
each end.
8.3
Network Information Needed For Setup
The following sections will help with gathering information required for a successful installation.
8.3.1
Network Router
The following information is needed to configure the generator set with a static IP address.
• Router User Name:_______________________________
• Router Password:________________________________
• Available Static IP Address:________________________
8.3.2
Email/Internet Service Provider (ISP)
This information is used when configuring email notifications. The internet service provider (ISP)
may need to be contacted for this information.
NOTICE
If these items cannot be verified or provided, email communication and/or remote
Internet access may not work. If the service provider will not verify or provide the
installer with this information, it is the responsibility of the customer to provide this
information.
Email Account Provider (May Be ISP):____________________________________________
Email Account Provider Contact Number:__________________________________________
Email Provider Allows SMTP Communications Via Port: ___
Email Provider Supports Authenticated and Unauthenticated Email: Yes/No (circle one)
A030A239 (Issue 10)
71
8. Optional Internet/Email Interface Setup
9-2013
NOTICE
Some email accounts will not accept unauthenticated emails and will not work with the
system. Ensure the email account and SMTP port accept non-SSL and TLS
connections.
Email Server Static IP Address:_________________________________________
Email Server Name (SMTP):____________________________________________
(Example: smtp.hughes.net)
Email Account User Name: _____________________________________________
(Example: include@emailprovider.com)
Email Account Password:_________________________________________
Email Notification Preferences
Email Address 1:________________________________________________
Email Address 2:________________________________________________
Email Address 3:________________________________________________
NOTICE
The ISP may take several days to establish the IP address and an additional service
cost may be incurred.
8.4
In-Home Network Access to the Generator Set
1. Connect a category 5 (Ethernet) cable from the generator set control board to the
modem/router. Make sure the modem/router has sufficient ports available for connections
for both the generator set and the computer connections.
NOTICE
The router will assign an IP address to the generator set control.
2. Write down the IP Address (shown on the Network Setup screen below) on the generator
set's in-home operator panel.
IP Address _____________________
72
A030A239 (Issue 10)
9-2013
8. Optional Internet/Email Interface Setup
FIGURE 46.
NETWORK SETUP SCREEN ON THE IN-HOME OPERATOR PANEL
NOTICE
Leave the DHCP (Dynamic Host Configuration Protocol) on, as it assigns a dynamic
IP adress to your internet connection.
3. Type the IP address in the address bar of the web browser of a computer established on
the same in-home network as the generator set. The computer’s web browser will display
the generator set’s web page.
4. Enter the User Name and Password. The default User Name and Password is as follows.
User Name: admin
Password: cummins
5. To change your password, click the Network Setup tab. Enter a new password, and click
Save Password.
A030A239 (Issue 10)
73
8. Optional Internet/Email Interface Setup
FIGURE 47.
FIGURE 48.
74
9-2013
GENERATOR SET HOME PAGE
NETWORK SETUP SCREEN
A030A239 (Issue 10)
9-2013
8. Optional Internet/Email Interface Setup
FIGURE 49.
8.5
NETWORK SETUP (PAGE 1)
Setting Up Internet Access and E-mail Alerts
1. Set up the in-home computer access to the generator set. See Section 8.4.
NOTICE
For the following steps, refer to the figures below.
A030A239 (Issue 10)
FIGURE 50.
NETWORK SETUP SCREEN
FIGURE 51.
NETWORK SETUP PAGE 1
75
8. Optional Internet/Email Interface Setup
9-2013
FIGURE 52.
NETWORK SETUP PAGE 2
FIGURE 53.
NETWORK SETUP PAGE 3
2. Click Network Setup on the home page.
3. Click Click here to start Network Setup.
4. Click Off to turn off the generator set DHCP.
NOTICE
Skip step 5 is a unique IP address was already provided by the router.
5. In the IP Number field, enter a unique in-home network address for the generator set by
changing the field of IP address number to a number between 001 and 256 (one that is not
in use by another device on the same network).
6. The Subnet Mask, Static DNS #1 and #2, and Gateway numbers establish the
connections between the modem/router and the generator set and do not need to be
changed.
7. Press Next to continue to the e-mail setup screen.
8. Select the Alert Level to choose the type of e-mail message that the customer would like
to receive.
9. Enter the SMTP Port Number provided by your ISP or e-mail service provider.
10. Enter your e-mail Server Name.
NOTICE
An e-mail server name may be obtained from the customer's ISP or e-mail service
provider (example: smtp.cummins).
11. Enter the User Name and Password for the provided e-mail server.
76
A030A239 (Issue 10)
9-2013
8. Optional Internet/Email Interface Setup
12. Click Next to enter the destination e-mail addresses.
13. Enter up to three different e-mail addresses which will receive generator set e-mail alerts.
E-mail Address 1:___________________________________________
E-mail Address 2:___________________________________________
E-mail Address 3:___________________________________________
14. Press Done to complete the e-mail confirmation.
NOTICE
If the IP address was changed in step 5, type the new address into the Internet
browser's address bar in order to return to the home screen.
15. To complete the remote viewing process, see Section 8.6 and Section 8.7.
FIGURE 54.
8.6
NETWORK SETUP SCREEN
Port Forwarding
NOTICE
Opening ports in a firewall can pose network security risks. The following instructions
require forwarding port 80.
1. Access the customer’s modem/router user manual.
2. Using the operator manual, determine how to gain access to the modem/router’s setup
screen.
3. Locate the port forwarding section of the modem/router’s setup menu.
4. Configure port 80 to be forwarded to the IP address created inSection 8.5.
NOTICE
To maintain connections to all devices connected to the modem/router, do not turn
off the modem/router DHCP.
5. To complete the remote viewing process, see Section 8.7.
8.7
Remote Viewing IP Options Static IP
1. Acquire a static IP address.
A030A239 (Issue 10)
77
8. Optional Internet/Email Interface Setup
9-2013
NOTICE
Acquiring a static IP may incur additional service charges from your ISP.
2. Use the provided static IP address to access the generator set webpage from any location
with Internet access.
8.8
Dynamic IP Monitoring
NOTICE
If a static IP address has been authorized from your ISP, the following steps are not
required. Some services may require software to be installed on a home computer.
1. Determine the home network's public/external IP address using an online tool (such as,
www.whatismyip.com).
2. Locate a dynamic IP host online and register for services.
NOTICE
Online dynamic hosting service can often be provided at no cost.
3. Configure the modem/router to update the dynamic IP host each time its external/public IP
address changes.
NOTICE
Instructions for completing the above step should be provided by the dynamic IP
monitoring host and the router user manual.
4. Use the URL provided by the dynamic IP host service to access the generator set webpage
from any location with Internet access.
8.9
Email Setup Parameters
8.9.1
Outgoing Server (SMTP) Settings
Ask your Internet Service Provider (ISP) and/or e-mail provider for the Server Name, User
Name and Password to enter.
Server Name:__________________________________
User Name:____________________________________
Password:_____________________________________
NOTICE
An Email account capable of SMTP authentication via port 25 is required. The User
Name must include the domain name. Example: username@domainname
78
A030A239 (Issue 10)
9-2013
8.9.2
8. Optional Internet/Email Interface Setup
Email Addresses
You may enter up to three Email addresses to whom to send generator set status and event
messages.
FIGURE 55.
FIGURE 56.
NETWORK SETUP PARAMETERS
FIGURE 57.
A030A239 (Issue 10)
NETWORK SETUP SCREEN
EMAIL SETUP PARAMETERS
79
8. Optional Internet/Email Interface Setup
9-2013
FIGURE 58.
FIGURE 59.
8.10
EMAIL ADDRESSES
RETURN TO HOME PAGE
Remote Internet Access to the Generator Set
See the network connection information, provided in Appendix A of this manual. Be sure
to read through the procedure and collect all needed information before attempting this
procedure.
WARNING
Opening ports in your firewall can pose network security risks. The following
instructions require forwarding port 80.
NOTICE
It is highly recommended that a professional computer and network support specialist
be hired to complete this part of the setup for proper connections and proper firewall
protection to the in-home network.
1. Follow the modem and router setup instructions to forward port 80 to the IP address that
was previously assigned to the generator set. Typically, this is done on a Port Forwarding
or Virtual Server setup screen.
NOTICE
To maintain connections to all devices connected to the modem/router, do not turn
off modem/router DHCP.
NOTICE
If the router is capable of being set up as a switch, plug the input from the modem
into one of the open router outputs instead of accomplishing this step.
80
A030A239 (Issue 10)
9-2013
8. Optional Internet/Email Interface Setup
2. To access the generator set's web page on any computer or wireless device not connected
to the same modem/router as the generator set, type in the owner's public IP address and
enter the user name and password.
3. To access the generator set's web page on any computer or wireless device connected to
the same modem/router as the generator set, type in the unique in-home network address
of the generator set and enter the username and password.
8.11
Help Hotline
1-800-888-6626 option 1
Technical support for setup and troubleshooting of the hardware used for in-home network
access to the generator set is available through the selling Cummins Onan dealer/distributor.
The owner may be required to contact their ISP and/or email provider for technical support of
the e-mail notification feature setup and troubleshooting.
Due to the variations in network equipment, network configurations and ISPs, the owner is
responsible for acquiring the needed support/service from a qualified network specialist to
properly and securely set up the owner's network for remote monitoring of the generator set.
Cummins Onan does not provide technical support for setup and troubleshooting of the owner's
network and email service.
• If you can't remember your password, reset it to “cummins" by selecting Reset Password
on the Network Setup screen on the in-home Operator Panel and pressing the up or down
arrow.
• The customer's public IP Address must be a static IP Address. If the customer's public IP
Address is dynamic, the customer must either obtain a static IP Address from their service
provider or set up a domain name that manages the dynamic IP Address.
8.12
Frequently Asked Questions
Question: Do I need a router?
Answer: Yes, a router or switch is required to allow for the connection of more than one device
(computer, generator set, etc.) with each other and the Internet.
• Typically, your Internet modem also serves as a router.
• If you have an available Ethernet connection on your router-enabled modem, you may not
need to add an additional router.
Question: Do I need a modem?
Answer: A modem is required if you want to utilize the email and remote Internet access
features of the generator set.
• Only one modem is required.
• If you already have an Internet connection, you have a modem.
Question: What is an IP Address?
Answer: An IP Address, or Internet Protocol Address, is a unique address that devices such as
a computer or your home generator set use to communicate with each other, both on your inhome network (LAN network) or with the World Wide Web.
A030A239 (Issue 10)
81
8. Optional Internet/Email Interface Setup
9-2013
Question: What is the difference between Static and Dynamic IP Addresses?
Answer:
Dynamic IP Address - On your in-home network, the router (with DHCP enabled) will assign a
dynamic IP Address to all devices (computer, home generator set, etc.) connected to the router.
As devices are added and removed from the router, the devices are automatically updated with
new IP Addresses. This means that your computer and generator set IP Addresses will not
always be the same unless static IP Addresses are assigned.
Static IP Address - A static IP Address is an unique address that is permanently assigned to a
device. On the World Wide Web, your typical ISP (Internet Service Provider) assigns a dynamic
IP Address to your Internet connection. This is the IP Address you type into your Internet
browser to access your generator set from the World Wide Web. A static IP Address is required
for you to establish a constant address you can always access from the World Wide Web.
Contact your ISP to set up a static IP Address for your Internet connection.
Question: What is DHCP?
Answer: DCHP, or Dynamic Host Configuration Protocol, automatically assigns IP Addresses,
subnet masks, and gateways to devices, allowing them to communicate with each other.
• Your router and generator set are equipped with DHCP.
• Default is for DHCP to be on.
Question: What is a UPS device and why is it recommended?
Answer: A UPS (Uninterruptible Power Supply) device is battery backup to keep devices such
as computers and modems powered during short-term power outages.
• We recommend that the modem/router be powered through a UPS device to ensure that
your generator set is able to send emails and be remotely accessed at all times.
• For example, if your generator set shuts down during a utility power outage, the
generator set can still send you an email letting you know that the power has failed
and that the generator set shut down.
Question: When do I need to use a Static IP Address?
Answer: Static IP addresses are required if you plan to access your generator set remotely via
the Internet.
Question: I used the IP Addresses shown on the front of this guide, but why was I not able to
access the generator set?
Answer: The IP Addresses shown in this guide are only examples and are not likely to be the
ones that will work on your network setup.
Question: The IP Address consists of four numbers ranging from 0 to 255 which are separated
by dots; 179.168.052.094, for example. Are leading zeros necessary?
Answer: No, the IP Address, 192.168.0.1, for example, is equivalent to 192.168.000.001. The
address can be entered either way.
Question: How do I get my IP Number, Subnet Mask and Gateway?
Answer:
On a PC:
1. Disable the PC's wireless function.
82
A030A239 (Issue 10)
9-2013
8. Optional Internet/Email Interface Setup
2. Establish an Ethernet connection between the computer and generator set via a common
modem.
3. On the computer, Click Start>Run.
4. On the run menu that appears type “cmd " and click OK.
5. Type “ipconfig " on the DOS window that appears.
Question: Why do I need two IP Addresses to access my generator set?
Answer: You can access your generator set from two networks, your in-home or local network,
and from the World Wide Web, thus requiring two addresses.
• Your local IP Address is different from your World Wide Web IP Address.
• From your in-home network you use the generator set's Static IP Address.
• From the World Wide Web you first need to access your modem, which is
accomplished by typing in the Static IP Address of your Internet connection.
Your modem will then automatically forward you to your generator set on the local network.
A030A239 (Issue 10)
83
8. Optional Internet/Email Interface Setup
9-2013
This page is intentionally blank.
84
A030A239 (Issue 10)
9
Troubleshooting
By regularly performing the following periodic maintenance and guidelines, you greatly reduce
the chances of a genset shutdown.
• Maintain an appropriate oil level
• Keep battery connections clean and tight
• Do not overload the generator set
• Keep the air inlet and outlet openings clear
9.1
Troubleshooting With the In-Home Operator Panel
If a fault shutdown occurs the ACTION REQUIRED lamp on the in-home Operator Panel will
come on and the LCD screen will display the a description of the Fault, the Fault Number, and
the hour in total generator set running time when the Fault occurred.
The shutdown codes are listed below in numerical order along with step-by-step corrective
actions.
9.2
Troubleshooting with the Flashing Indicator Light
The status indicator light on the Control Switch inside the generator set flashes the diagnostic
fault code when a fault shutdown occurs. For a single-digit fault code (2 or 4), the light will flash
2 or 4 times and after a short pause will repeat.
For a two-digit fault code the light will flash the tens digit, pause and flash the units digit and
repeat after a longer pause. Fault 36 would be flashed as follows:
flash-flash-flash—pause —flash-flash-flash-flash-flash-flash—long pause —repeat
NOTICE
For fault history, go to the in-home Operator Panel.
9.3
Fault Code Blinking
At fault shutdown, the status indicator light will repeatedly blink sets of 1, 2, 3 or 4 blinks.
• One blink indicates shutdown due to high engine temperature.
• Two blinks indicate shutdown due to a loss of engine oil pressure.
• Three blinks indicate a service fault. Press Stop once to cause the two-digit, second-level
shutdown code to blink. (Pressing Stop again will stop the blinking.) The two-digit code
consists of 1, 2, 3, 4 or 5 blinks, a brief pause, and then 1 to 9 blinks. The first set of blinks
represents the tens digit and the second set of blinks the units digit of the shutdown code
number.
• Four blinks indicate that cranking time exceeded 35 seconds.
A030A239 (Issue 10)
85
9. Troubleshooting
9-2013
• Fault Code Nos. 1, 2, 3, and 4 are first level faults. Pay close attention to the pause
sequence to avoid interpreting first level faults as second-level Fault Codes Nos. 11, 22, 33
or 44.
• To avoid the possibility of anyone misinterpreting Code Nos. 3 and 4 as Code Nos. 33 and
44, the latter have not been assigned faults.
9.4
Restoring Fault Code Blinking
The fault code stops blinking after five minutes. Press Stop three times within three seconds to
restore fault code blinking.
NOTICE
The last fault logged will blink even though the condition that caused the shutdown may have
been corrected.
WARNING
Some Generator Set service 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 Generator Set service.
9.5
Generator Set Starts or Stops Without Command No Fault Code
Logic: To start or stop - control receives ground at start or stop input on control, DC voltage
drops below 8V and controller de-energizes (shuts down in sleep mode)
Possible Causes: Low battery voltage, shorted harness connection, faulty start/stop switch,
“Standby Ready" is enabled, faulty or incorrect spark plugs.
Diagnosis and Repair:
1. Check last fault and record.
2. Measure battery voltage at battery and generator set.
3. Inspect battery connections and cables for cleanliness, tightness and damage: clean,
tighten and repair connections and cables as necessary.
4. Check electrolyte level and hydrometer reading in maintenance type batteries: replace
electrolyte and recharge or replace battery as necessary.
5. Disconnect generator set control J1 connector. Verify that the J1 pins are fully inserted and
inspect pin condition, using one of the processes listed below. Then insert, repair or
replace pins as necessary.
Pin Inspection Processes (use one of the following to inspect the pins):
Use the test points of the tester tool #420-0603
Use a mating pin connector
Use a pin gauge the same size (.045") as the mating control connector pin
Use any suitable device that will not damage the inside contact wipers of the pin socket
86
A030A239 (Issue 10)
9-2013
9. Troubleshooting
6. Reconnect J1 connector and test run generator set for symptom: repair or replace pins in
connector as necessary.
7. Measure battery voltage at generator set while attempting to start from local or remote
switch: recharge or replace battery if voltage drops below 8 VDC, test and service
generator set battery charger.
8. Measure battery voltage and check for voltage increase while generator set is running.
9. Measure for continuity change across start/stop switch between neutral and start position
and neutral and stop position at switches and at connector J1: reconnect or repair
connections, replace switches as necessary.
10. Measure for continuity from start and stop inputs to ground at switches and at connector
J1: Repair or replace damaged harness.
11. Determine if “Standby Ready" is enabled (Control will command start and stop based on its
own settings): disable “Standby Ready" or explain “Standby Ready" function to customer.
12. Verify the condition of the spark plugs and whether they are Cummins Onan branded
plug(s). Non-resistive type plugs sold through non-Cummins Onan channels can cause this
condition. Replace the spark plug(s) if questionable or of non-Cummins Onan origin.
Please see field flash for more information.
9.6
No Response - Status Indicator Light Dead
Logic: To start - the control receives ground via the start/stop switch to start or stop input on
control
Possible Causes: Low/No battery voltage, poor battery connection, faulty battery, open
harness connection, faulty start/stop switch, faulty LED, F3 fuse open
Diagnosis and Repair:
1. Measure the battery voltage at the battery, at the generator set, and at connector J1:
reconnect, clean, repair, and replace connections as necessary.
2. Measure battery voltage at the generator set while attempting to start or prime from the
local or remote switch: recharge or replace the battery if voltage drops below 8 VDC, test
and service the generator set battery charger if so equipped, increase battery cable size or
run parallel cables.
3. Check F3 fuse for open circuit.
4. Measure for continuity change across start/stop switch between neutral and start position
and neutral and stop position at switches and at connector J1: reconnect or repair
connections; replace switches as necessary.
5. Test switches LED by energizing with 12 VDC: replace switches as necessary.
6. Disconnect the generator set control J1 connector. Verify that the J1 pins are fully inserted
and inspect pin condition, using one of the processes listed below. Then insert, repair, or
replace pins as necessary.
Pin Inspection Processes (use one of the following to inspect the pins):
• Use the test points of the tester tool #420-0603
• Use a mating pin connector
• Use a pin gauge the same size (.045") as the mating control connector pin
A030A239 (Issue 10)
87
9. Troubleshooting
9-2013
• Use any suitable device that will not damage the inside contact wipers of the pin
socket
7. Reconnect the J1 connector and test run the generator set for start operation.
9.7
Starting Battery Runs Down
Logic: Low/No battery voltage
Possible Causes: Marginal battery connections, battery, charging system, excessive cranking
Diagnosis and Repair:
1. Measure battery voltage at the battery and the generator set.
2. Inspect battery connections and cables for cleanliness, tightness, and damage: clean,
tighten, and repair connections and cables as necessary.
3. Check electrolyte level and hydrometer reading in maintenance type batteries: replace
electrolyte and recharge or replace the battery as necessary.
4. Verify the battery charger is on and check operation.
5. Measure battery voltage and check for voltage increase while the generator set is running.
6. Check last fault and record: troubleshoot as necessary.
7. Disconnect the generator set control J1 connector. Verify that the J1 pins are fully inserted
and inspect pin condition, using one of the processes listed below. Then insert, repair, or
replace pins as necessary.
Pin Inspection Processes (use one of the following to inspect the pins):
• Use the test points of the tester tool #420-0603
• Use a mating pin connector
• Use a pin gauge the same size (.045") as the mating control connector pin
• Use any suitable device that will not damage the inside contact wipers of the pin
socket
8. Reconnect the J1 connector and test run the generator set for fault occurrence: repair or
replace pins in the connector as necessary.
9. Measure for continuity change across the start/stop switch between the neutral and stop
position at the switches and the J1 connector: replace switches as necessary or disconnect
the external stop device if so equipped.
10. Measure for voltage at the fuel solenoid while the generator set is not running.
9.8
Starter Engages - Disengages
Logic: Cranking voltage dips below 8 VDC: microprocessor aborts start attempt
Possible Causes: Battery connections, battery, charging system, start/stop switches, engine
compression, faulty or incorrect spark plugs.
Diagnosis and Repair:
1. Measure battery voltage at the battery and the generator set.
88
A030A239 (Issue 10)
9-2013
9. Troubleshooting
2. Inspect the battery connections and cables for cleanliness, tightness, and damage: clean,
tighten, and repair connections and cables as necessary.
3. Check electrolyte level and hydrometer reading in maintenance type batteries: replace
electrolyte and recharge or replace the battery as necessary.
4. Disconnect the generator set control J1 connector. Verify that the J1 pins are fully inserted
and inspect pin condition, using one of the processes listed below. Then insert, repair, or
replace pins as necessary.
Pin Inspection Processes (use one of the following to inspect the pins):
• Use the test points of the tester tool #420-0603
• Use a mating pin connector
• Use a pin gauge the same size (.045") as the mating control connector pin
• Use any suitable device that will not damage the inside contact wipers of the pin
socket
5. Reconnect the J1 connector and test run the generator set for fault occurrence: repair or
replace pins in the connector as necessary.
6. Measure battery voltage at the generator set while attempting to start from a local or
remote switch: recharge or replace the battery if voltage drops below 8 VDC, test and
service the generator set battery charger if so equipped, increase the battery cable size or
run parallel cables.
7. Verify the condition of the spark plugs and whether they are Cummins Onan branded
plugs. Non-resistive type plugs sold through non-Cummins Onan channels can cause this
condition. Replace the spark plug(s) if questionable or of non-Cummins Onan origin.
8. Measure battery voltage and check for voltage increase while the generator set is running.
9.9
No AC Power - Generator Set Running, Status LED
On Steady or Flashing Rapidly
Logic: Circuit Breakers have tripped due to overload or short.
Possible Causes: Circuit breakers, customer loads
Diagnosis and Repair:
1. Status light on - Measure AC output at generator set circuit breaker: reset or turn on the
generator set circuit breaker; diagnose faulty loads as necessary.
9.10
Generator Set Cranks But Does Not Start - No Fault
Code
Logic: Fault codes are based on time lapse between events
Possible Causes: Faulty or incorrect spark plugs, low battery output, low fuel pressure
Diagnosis and Repair:
1. Check and record last fault code.
2. Measure battery voltage at the battery and the generator set.
A030A239 (Issue 10)
89
9. Troubleshooting
9-2013
3. Inspect the battery connections and cables for cleanliness, tightness, and damage: clean,
tighten, and repair connections and cables as necessary.
4. Check electrolyte level and hedrometer reading in maintenance type batteries: replace
electrolyte and recharge or replace the battery as necessary.
5. Check the fuel supply pressure coming into the generator regulator and ensure it is within
specification.
6. Verify the condition of the spark plugs and whether they are Cummins Onan branded
plug(s). Non-resistive type plugs sold through non-Cummins Onan channels can cause this
condition. Replace the spark plug(s) if questionable or of non-Cummins Onan origin.
9.11
Genset Warning - Transfer Switch Failed to Transfer
Back to Utility When Utility is Restored - No Fault
Code
Logic: The control does not sense the grounded, utility switch-position wire.
Possible Causes: Transfer switch is faulty, or wire is disconnected or broken.
Diagnosis and Repair:
1. Fix wire connection.
2. Replace a broken wire.
3. Replace a faulty transfer switch.
9.12
Low Oil Pressure Fault - Fault Code 2
Logic: Continuous ground (>= 3 seconds) at control for oil pressure input. The switch opens
with pressure.
Possible Causes: Low/high oil level, faulty switch, faulty oil pressure relief valve, faulty oil
pump
Diagnosis and Repair:
1. Verify that Last Fault is FC 2: Yes, continue diagnosis; No, troubleshoot actual last fault.
2. Measure oil level: add or drain oil as necessary.
3. Disconnect the generator set control J1 connector. Verify that the J1 pins are fully inserted
and inspect pin condition, using one of the processes listed below. Then insert, repair, or
replace pins as necessary.
Pin Inspection Processes (use one of the following to inspect the pins):
• Use the test points of the tester tool #420-0603
• Use a mating pin connector
• Use a pin gauge the same size (.045") as the mating control connector pin
• Use any suitable device that will not damage the inside contact wipers of the pin
socket
4. Reconnect the J1 connector and test run the generator set for fault occurrence: repair or
replace pins in the connector as necessary.
90
A030A239 (Issue 10)
9-2013
9. Troubleshooting
5. Measure continuity change across the start/stop switch between rest and under simulated
pressure: replace the switch as necessary.
6. Measure continuity between ground and J1-6: repair or replace the harness as necessary.
7. Measure oil pressure with a mechanical gauge: repair or replace the relief valve and oil
pump as necessary.
9.13
Service Check Fault - Fault Code 3
Logic: Single–Digit Fault to indicate shutdown due to a Two–Digit Fault
Possible Causes: Any Two–Digit Fault Code
Diagnosis and Repair:
1. Verify that Last Fault is FC 3: Yes, continue diagnosis; No, troubleshoot actual last fault.
2. While LED is flashing three times press stop once (1 second duration): trouble shoot
Two–Digit Fault Code.
3. You can read the fault code from the in-home Operator Panel if access is granted.
9.14
Overcrank - Fault Code 4
Logic: Controller unable to sense generator set quad frequency after cycle crank (30 seconds
of cranking / 30 seconds between each crank attempt for a total of 3 crank attempts) and Low
Fuel Pressure switch is closed (pressure switch circuit open = low pressure).
Possible Causes: Faulty switch, faulty external start command, fuel supply, air fuel mixture,
exhaust system, wire connections, starter, ignition system
Diagnosis and Repair:
1. Verify that Last Fault is FC 4: Yes, continue diagnosis; No, troubleshoot actual last fault.
2. Measure for continuity change across the start/stop switch between the neutral and start
position at the switches and the J1 connector: replace switches as necessary or disconnect
the external start device if so equipped.
3. Disconnect the generator set control J1 connector, verify the J1 pins are fully inserted, and
inspect pin condition using the steps below:
• Use the test points of the tester tool #420-0603
• Use a mating pin connector, a pin gauge of the same size (.045") as the mating
control connector pin, or any suitable device that will not damage the inside contact
wipers of the pin socket
• Insert, repair, or replace pins as necessary.
4. Reconnect the J1 connector and test run the generator set for fault occurrence: repair or
replace pins in the connector as necessary.
5. Verify engine rotation manually: repair engine damage as necessary.
6. Measure DC voltage at the starter during start attempt: repair wire connections, replace the
start solenoid and starter as necessary.
7. Check air filter cleanliness; replace the air filter as necessary.
A030A239 (Issue 10)
91
9. Troubleshooting
9-2013
8. Check for blocked or damaged exhaust system: repair or replace exhaust components as
necessary.
9. Propane Models
a. When ambient temperatures are less than 40°F vapor – withdrawal Propane tanks
should be at least half full to provide proper vaporization rate.
b. Propane having more than 2.5 percent Butane will not vaporize in ambients at less
than 32°F; use HD-5 grade Propane.
c. Run the generator set on shop fuel supply; verify tank level and fuel line condition.
10. Measure steady DC voltage at the fuel solenoid while the generator set is running; repair
wiring as necessary.
11. Verify clear vent hose.
12. Check the generator set fuel lines for damage: replace the fuel line as required.
13. Measure the fuel supply and regulator lock-off pressures.
14. Check the governor, actuator, linkage, and spring for debris, damage, and looseness:
readjust and repair as necessary.
15. Verify that the spark plug cables are secure on the spark plugs: reconnect or replace as
necessary.
16. Inspect the ignition kill lead (J1-12) in the harness and at connector J1: repair or replace
the lead, terminal, or pins as necessary.
17. Measure the spark plug gap: set the gap or replace the spark plugs as necessary.
18. Verify the ignition spark condition.
19. Inspect the spark plug leads, kill lead terminals at magnetos, and measure magneto air
gap: replace the terminals, set the gap, or replace the magnetos as necessary.
20. Measure field, quadrature, and main winding resistance: clean the slip rings, replace the
brushes, repair the harness, and replace the rotor or stator as necessary.
21. Measure field, quadrature, and main winding resistance to ground: clean the slip rings,
replace the brushes, repair the harness, and replace the rotor or stator as necessary.
22. Measure field, quadrature, and main winding resistance to each other: clean the slip rings,
replace the brushes, repair the harness, and replace the rotor or stator as necessary.
23. Check the alignment of the brushes to the slip rings.
9.15
Overvoltage - Fault Code 12
Logic: Instantaneous Fault - AC voltage S1-S2 greater than 300 VAC Delayed Fault - AC
voltage line-to-line greater than 278 VAC, but less than 150 VAC for 3 continuous seconds.
Possible Causes: Generator set loads, wire connections, windings
Diagnosis & Repair:
1. Verify that Last Fault is FC 12: Yes, continue diagnosis; No, troubleshoot actual last fault.
2. Measure and verify AC voltage at the customer connection block and at pins J1-34 and J135.
92
A030A239 (Issue 10)
9-2013
9. Troubleshooting
3. Measure and verify AC frequency while changing engine rpm to determine if frequency
response matches engine rpm response.
4. Cycle loads to determine if a particular load causes fault: diagnose faulty load as
necessary.
5. Verify balanced loads in 120/240 VAC applications: balance loads within 10 percent line-toline as required.
6. Remove connector J1 from the control and re–install, and try to start the generator set:
inspect, repair, or replace the J1 connector pins as necessary.
7. Measure field, quadrature, and main winding resistance: clean the slip rings, replace the
brushes, repair the harness, and replace the rotor or stator as necessary.
8. Measure field, quadrature, and main winding resistance to ground: clean the slip rings,
replace the brushes, repair the harness, and replace the rotor or stator as necessary.
9. Measure field, quadrature, and main winding resistance to each other: clean the slip rings,
replace the brushes, repair the harness, and replace the rotor or stator as necessary.
10. Check the alignment of the brushes to the slip rings.
9.16
Undervoltage - Fault Code 13
Logic: AC voltage 240 line-to-line less than 216 VAC for 5 continuous seconds
Possible Causes: generator set loads, wire connections, windings
Diagnosis & Repair:
1. Verify that the Last Fault is FC 13: Yes, continue diagnosis; No, troubleshoot actual last
fault.
2. Measure and verify AC voltage at the customer connection block and at pins J1-34 and J135.
3. Measure and verify AC frequency while changing engine rpm to determine if frequency
response matches engine rpm response.
4. Cycle loads to determine if a particular load will cause fault: diagnose faulty load as
necessary.
5. Verify balanced loads in 120/240 VAC applications: balance loads within 10 percent line-toline as required.
6. Remove connector J1 from the control and re–install it, and try to start the generator set:
inspect, repair, or replace J1 connector pins as necessary.
7. Measure field, quadrature and main winding resistance: clean the slip rings, replace the
brushes, repair the harness, and replace the rotor or stator as necessary.
8. Measure field, quadrature, and main winding resistance to ground: clean the slip rings,
replace the brushes, repair the harness, and replace the rotor or stator as necessary.
9. Measure field, quadrature, and main winding resistance to each other: clean the slip rings,
replace the brushes, repair the harness, and replace the rotor or stator as necessary.
10. Check brush alignment:
a. Inspect brush wear on the slip rings and verify brush misalignment is toward the
windings.
A030A239 (Issue 10)
93
9. Troubleshooting
9-2013
b. If misalignment is toward the bearing, the cause is not from this tolerance issue and is
likely the result of the end bell not being seated properly during assembly. Inspect for
cause and repair as necessary.
9.17
Overfrequency - Fault Code 14
Logic: Instantaneous Fault - Frequency greater than 72Hz Delayed Fault - Frequency greater
than 66Hz, but less than 72Hz, for 6 continuous seconds
NOTICE
This fault code is for both the 50 Hz and 60 Hz models.
Possible Causes: Generator set loads, engine governor function, fuel supply, air fuel mixture,
exhaust system, choke, demand regulator, carburetor, generator windings, wire connections
Diagnosis & Repair:
1. Verify that the Last Fault is FC 14: Yes, continue diagnosis; No, troubleshoot actual last
fault.
2. Measure AC current while running the generator set with loads: identify faulty or short
cycling loads.
3. Measure generator set load capability with load bank (de-rate for altitude and temperature
as necessary).
4. Measure AC frequency while running.
5. Measure AC frequency while changing engine rpm to determine if frequency response
matches engine rpm response.
6. Disconnect the generator set control J1 connector, verify the J1 pins are fully inserted, and
inspect pin condition using the steps below:
• Use the test points of the tester tool #420-0603
• Use mating pin connector, a pin gauge of the same size (.045") as the mating control
connector pin, or any suitable device that will not damage the inside contact wipers of
the pin socket
• Insert, repair, or replace pins as necessary.
7. Reconnect J1 connector and test run the generator set for fault occurrence: repair or
replace pins in the connector as necessary.
8. Check all grounds and neutral leads for looseness at the battery and the generator set; run
the generator set on a separate battery: tighten or replace terminals and leads as
necessary.
9. Check for air filter cleanliness; replace air filter as necessary.
10. Check for blocked or damaged exhaust system: repair or replace exhaust components as
necessary.
11. Propane Models
a. When ambient temperatures are less than 40°F vapor – withdrawal Propane tanks
should be at least half full to provide proper vaporization rate.
94
A030A239 (Issue 10)
9-2013
9. Troubleshooting
b. Propane having more than 2.5 percent Butane will not vaporize in ambients at less
than 32°F; use HD-5 grade Propane.
c. Run the generator set on shop fuel supply; verify the tank level and fuel line condition.
12. Measure steady DC voltage at the fuel solenoid while the generator set is running; repair
wiring as necessary.
13. Verify clear vent hose.
14. Check the generator set fuel lines for damage: replace the fuel line as required.
15. Measure fuel supply and regulator lock off pressures.
16. Check the governor, actuator, linkage, and spring for debris, damage, and looseness:
readjust and repair as necessary.
17. Measure field, quadrature, and main winding resistance: clean the slip rings, replace the
brushes, repair the harness, and replace the rotor or stator as necessary.
18. Measure field, quadrature and main winding resistance to ground: clean slip rings, replace
brushes, repair harness and replace rotor or stator as necessary.
19. Measure field, quadrature, and main winding resistance to each other: clean the slip rings,
replace the brushes, repair the harness, and replace the rotor or stator as necessary.
20. Check brush alignment:
Inspect brush wear on the slip rings and verify brush misalignment is toward the windings.
If misalignment is toward the bearing, the cause is not from this tolerance issue and is
likely the result of the end bell not being seated properly during assembly. Inspect for
cause and repair as necessary.
21. Verify that spark plug cables are secure on spark plugs: reconnect or replace as
necessary.
22. Inspect ignition kill lead (J1-12) in harness and at connector J1: repair or replace lead,
terminal or pins as necessary.
23. Measure spark plug gap: set the gap or replace the spark plugs as necessary.
24. Verify ignition spark condition.
25. Inspect the spark plug leads, kill lead terminals at magnetos, and measure magneto air
gap: replace the terminals, set the gap, or replace magnetos as necessary.
9.18
Underfrequency - Fault Code 15
Logic: Frequency less than 54 Hz (for the 60 Hz model) or 45 Hz (for the 50 Hz model) for 8
continuous seconds.
Possible Causes: Generator set loads, engine governor function, fuel supply, air fuel mixture,
exhaust system, choke, demand regulator, carburetor, generator windings, ignition, wire
connections
Diagnosis & Repair:
1. Verify that the Last Fault is FC 15: Yes, continue diagnosis; No, troubleshoot actual last
fault.
2. Measure AC current while running the generator set with loads: identify faulty or short
cycling loads.
A030A239 (Issue 10)
95
9. Troubleshooting
9-2013
3. Measure generator set load capability with shop load bank (de-rate for altitude and
temperature as necessary).
4. Measure AC frequency while running.
5. Measure AC frequency while changing engine rpm to determine if frequency response
matches engine rpm response.
6. Disconnect the generator set control J1 connector, verify the J1 pins are fully inserted, and
inspect pin condition using the steps below:
• Use the test points of the tester tool #420-0603
• Use a mating pin connector, a pin gauge of the same size (.045") as the mating
control connector pin, or any suitable device that will not damage the inside contact
wipers of the pin socket
• Insert, repair, or replace the pins as necessary.
7. Reconnect the J1 connector and test run the generator set for fault occurrence: repair or
replace pins in the connector as necessary.
8. Check air filter cleanliness; replace the air filter as necessary.
9. Check for blocked or damaged exhaust system: repair or replace exhaust components as
necessary.
10. Propane Models
a. When ambient temperatures are less than 40°F vapor–withdrawal, Propane tanks
should be at least half full to provide proper vaporization rate.
b. Propane having more than 2.5 percent Butane will not vaporize in ambients at less
than 32°F; use HD-5 grade Propane.
c. Run the generator set on shop fuel supply; verify the tank level and fuel line condition.
11. Measure steady DC voltage at fuel solenoid while the generator set is running; repair wiring
as necessary.
12. Verify clear vent hose.
13. Check the generator set fuel lines for damage: replace fuel line as required.
14. Measure the fuel supply and regulator lock off pressures.
15. Check the governor, actuator, linkage, and spring for debris, damage, and looseness:
readjust and repair as necessary.
16. Measure field, quadrature, and main winding resistance: clean the slip rings, replace the
brushes, repair the harness, and the replace rotor or stator as necessary.
17. Measure field, quadrature, and main winding resistance to ground: clean the slip rings,
replace the brushes, repair the harness, and replace the rotor or stator as necessary.
18. Measure field, quadrature, and main winding resistance to each other: clean the slip rings,
replace the brushes, repair the harness, and replace the rotor or stator as necessary.
19. Check brush alignment:
Inspect brush wear on the slip rings and verify brush misalignment is toward the windings.
If misalignment is toward the bearing, the cause is not from this tolerance issue and likely
the result of the end bell not being seated properly during assembly. Inspect for cause and
repair as necessary.
96
A030A239 (Issue 10)
9-2013
9. Troubleshooting
20. Verify that the spark plug cables are secure on the spark plugs: reconnect or replace as
necessary.
21. Inspect ignition kill lead (J1-12) in the harness and at connector J1: repair or replace the
lead, terminal, or pins as necessary.
22. Measure the spark plug gap: set the gap or replace the spark plugs as necessary.
23. Verify ignition spark condition.
24. Inspect the spark plug leads, kill lead terminals at magnetos, and measure magneto air
gap: replace the terminals, set the gap, or replace the magnetos as necessary.
25. Measure temperature of the air intake and temperature rise across the generator set;
remove blockage or prevent air recirculation.
9.19
Governor Actuator Shutdown- Fault Code 19
Logic: Controller sensed governor actuator circuit open or shorted.
Possible Causes: Wire connections, governor actuator
Diagnosis & Repair:
1. Verify that the Last Fault is FC 19: Yes, continue diagnosis; No, troubleshoot actual last
fault.
2. Measure and verify governor actuator resistance. Replace as necessary.
3. Measure and verify governor wiring to the control. Replace or repair as necessary.
4. Disconnect the generator set control J1 connector, verify the J1 pins are fully inserted, and
inspect pin condition using the steps below:
• Use the test points of the tester tool #420-0603
• Use a mating pin connector, a pin gauge of the same size (.045") as the mating
control connector pin, or any suitable device that will not damage the inside contact
wipers of the pin socket
• Insert, repair, or replace the pins as necessary.
5. Reconnect the J1 connector and test run the generator set for fault occurrence: repair or
replace pins in the connector as necessary.
9.20
Governor Actuator Overload - Fault Code 22
Logic: Maximum governor output (PWM) for 10 continuous seconds while fuel pressure switch
open and current at 100%
Possible Causes: Generator set loads, wire connections, fuel supply, air fuel mixture, exhaust
system, governor actuator, ignition system
Diagnosis & Repair:
1. Verify that the Last Fault is FC 22: Yes, continue diagnosis; No, troubleshoot actual last
fault.
2. Measure AC current while running the generator set with loads: identify faulty or short
cycling loads or reduce loads as necessary.
A030A239 (Issue 10)
97
9. Troubleshooting
9-2013
3. Measure the generator set load capability with a shop load bank (de-rate for altitude and
temperature as necessary).
4. Measure AC frequency and droop while the generator set is running.
5. Measure AC frequency while changing engine rpm to determine if frequency response
matches engine rpm response.
6. Disconnect the generator set control J1 connector, verify J1 pins are fully inserted, and
inspect pin condition using the steps below:
• Use the test points of the tester tool #420-0603
• Use a mating pin connector, a pin gauge of the same size (.045") as the mating
control connector pin, or any suitable device that will not damage the inside contact
wipers of the pin socket
• Insert, repair, or replace pins as necessary.
7. Reconnect the J1 connector and test run the generator set for fault occurrence: repair or
replace pins in the connector as necessary.
8. Check air filter cleanliness; replace the air filter as necessary.
9. Measure steady DC voltage at the fuel solenoid while the generator set is running; repair
wiring as necessary.
10. Propane Models
a. When ambient temperatures are less than 40°F vapor – withdrawal Propane tanks
should be at least half full to provide proper vaporization rate.
b. Propane having more than 2.5 percent Butane will not vaporize in ambients at less
than 32°F; use HD-5 grade Propane.
c. Run generator set on shop fuel supply; verify tank level and fuel line condition.
11. Verify clear vent hose.
12. Check the generator set fuel lines for damage: replace the fuel line as required.
13. Measure the regulator lock off pressure.
14. Check the intake manifold and gaskets for air leaks: tighten fasteners and replace the
gaskets and manifold as necessary.
15. Check for a blocked or damaged exhaust system: repair or replace the exhaust
components as necessary.
16. Verify actuator function by applying DC voltage to the terminals: replace the actuator as
necessary.
17. Check the carburetor for binding; inspect the spring for dirt and debris: clean the spring,
replace the carburetor as necessary.
18. Verify that spark plug cables are secure on the spark plugs: reconnect or replace as
necessary.
19. Inspect the ignition kill lead (J1-12) in the harness and at connector J1: repair or replace
the lead, terminal, or pins as necessary.
20. Measure spark plug gap: set gap or replace spark plugs as necessary.
21. Verify ignition spark condition.
98
A030A239 (Issue 10)
9-2013
9. Troubleshooting
22. Inspect the spark plug leads, kill lead terminals at magnetos, and measure the magneto air
gap: replace the terminals, set the gap, or replace the magnetos as necessary.
9.21
Voltage Sense Lost - Fault Code 27
Logic: generator set frequency is greater than 40 Hz and voltage sensed less than 5 VAC on
one or both lines. (The control senses if one line is lost or disconnected).
Possible Causes: generator set loads, generator windings, ignition, wire connections,
Diagnosis & Repair:
1. Verify that the Last Fault is FC 27: Yes, continue diagnosis; No, troubleshoot actual last
fault.
2. Measure AC voltage.
3. Disconnect the generator set control J1 connector, verify the J1 pins are fully inserted, and
inspect pin condition using the steps below:
• Use the test points of the tester tool #420-0603
• Use a mating pin connector, a pin gauge of the same size (.045") as the mating
control connector pin, or any suitable device that will not damage the inside contact
wipers of the pin socket
• Insert, repair, or replace pins as necessary.
4. Reconnect the J1 connector and test run the generator set for fault occurrence: repair or
replace pins in the connector as necessary.
5. Measure field, quadrature, and main winding resistance: clean the slip rings, replace the
brushes, repair the harness, and replace the rotor or stator as necessary.
6. Measure field, quadrature, and main winding resistance to ground: clean the slip rings,
replace the brushes, repair the harness, and replace the rotor or stator as necessary.
7. Measure field, quadrature, and main winding resistance to each other: clean the slip rings,
replace the brushes, repair the harness, and replace the rotor or stator as necessary.
8. Check brush alignment.
9. Verify that the spark plug cables are secure on the spark plugs: reconnect or replace as
necessary.
10. Inspect the ignition kill lead (J1-12) in the harness and at connector J1: repair or replace
the lead, the terminal, or the pins as necessary.
11. Measure the spark plug gap: set the gap or replace the spark plugs as necessary.
12. Verify ignition spark condition.
13. Inspect the spark plug leads, kill lead terminals at magnetos, and measure the magneto air
gap: replace the terminals, set the gap, or replace the magnetos as necessary.
14. Measure temperature of the air intake and temperature rise across the generator set;
remove blockage or prevent air recirculation.
9.22
High Battery Voltage - Fault Code 29
Logic: DC voltage to controller greater than 19 VDC.
A030A239 (Issue 10)
99
9. Troubleshooting
9-2013
Possible Causes: Incorrect battery configuration, wire damage, faulty charger, control
Diagnosis & Repair:
1. Verify that the Last Fault is FC 29: Yes, continue diagnosis; No, troubleshoot actual last
fault.
2. Measure DC voltage at the battery, at the generator set, and at connector J1: reconnect
the battery or repair wiring as necessary.
3. Measure DC voltage with the battery charger on: reduce the boost charge rate or diagnose
the faulty charger as necessary.
4. Disconnect the generator set control J1 connector, verify that the J1 pins are fully inserted,
and inspect pin condition using the steps below:
• Use the test points of the tester tool #420-0603
• Use mating pin connector, a pin gauge of the same size (.045") as the mating control
connector pin, or any suitable device that will not damage the inside contact wipers of
the pin socket
• Insert, repair, or replace pins as necessary.
5. Reconnect the J1 connector and test run the generator set for fault occurrence.
9.23
Low Cranking Speed Sense - Fault Code 32
Logic: Quadrature frequency less than 1Hz (Engine RPM less than 180) for 3 continuous
seconds after pressing start
Possible Causes: Starter, engine components, air intake system, exhaust system, generator
windings, wire connections, battery, battery connections, oil viscosity
Diagnosis & Repair:
1. Verify that the Last Fault is FC 32: Yes, continue diagnosis; No, troubleshoot actual last
fault.
2. Measure battery voltage at the battery and the generator set: recharge or replace the
battery as necessary.
3. Verify engine rotation manually: repair engine damage as necessary.
4. Verify generator rotation manually: repair generator damage as necessary.
5. Disconnect the generator set control J1 connector, verify that the J1 pins are fully inserted,
and inspect pin condition using the steps below:
• Use the test points of the tester tool #420-0603
• Use a mating pin connector, a pin gauge of the same size (.045") as the mating
control connector pin, or any suitable device that will not damage the inside contact
wipers of the pin socket
• Insert, repair, or replace pins as necessary.
6. Reconnect the J1 connector and test run the generator set for fault occurrence: repair or
replace pins in the connector as necessary.
7. Measure DC voltage at the starter during a start attempt: repair wire connections, replace
the start solenoid and starter as necessary.
100
A030A239 (Issue 10)
9-2013
9. Troubleshooting
8. Check air filter cleanliness; replace the air filter as necessary.
9. Check for a blocked or damaged exhaust system: repair or replace exhaust components as
necessary.
10. Measure AC frequency while changing engine rpm to determine if frequency response
matches engine rpm response.
11. Propane Models
a. When ambient temperatures are less than 40°F vapor – withdrawal Propane tanks
should be at least half full to provide proper vaporization rate.
b. Propane having more than 2.5 percent Butane will not vaporize in ambients at less
than 32°F; use HD-5 grade Propane.
c. Run the generator set on shop fuel supply; verify tank level and fuel line condition.
12. Measure steady DC voltage at the fuel solenoid while the generator set is running; repair
wiring as necessary.
13. Verify clear vent hose.
14. Check the generator set fuel lines for damage: replace fuel line as required.
15. Measure fuel supply and regulator lock off pressures.
16. Check the governor, actuator, linkage, and spring for debris, damage, and looseness:
readjust and repair as necessary.
17. Verify that the spark plug cables are secure on the spark plugs: reconnect or replace as
necessary.
18. Inspect the ignition kill lead (J1-12) in the harness and at connector J1: repair or replace
the lead, terminal, or pins as necessary.
19. Measure the spark plug gap: set the gap or replace the spark plugs as necessary.
20. Verify ignition spark condition.
21. Inspect the spark plug leads, kill lead terminals at magnetos, and measure the magneto air
gap: replace the terminals, set the gap, or replace the magnetos as necessary.
22. Measure the temperature of the air intake and temperature rise across the generator set;
remove blockage or prevent air recirculation.
9.24
Control Card Failure - Fault Code 35
Logic: EEPROM (programming variables) error during self test
Possible Causes: Faulty program
Diagnosis & Solution:
1. Verify that the Last Fault is FC 35: Yes, continue diagnosis; No, troubleshoot actual last
fault.
2. Replace the control.
A030A239 (Issue 10)
101
9. Troubleshooting
9.25
9-2013
Generator Set Stopped Without Fault Condition Fault Code 36
Logic: RPM less than 500 and Sense Voltage S1-S2 at 0 VAC while fuel pressure switch open
and no other fault condition occurred
Possible Causes: Fuel supply, air fuel mixture, exhaust system, choke, demand regulator,
carburetor, generator windings, ignition, wire connections
Diagnosis & Repair:
1. Verify that the Last Fault is FC 36: Yes, continue diagnosis; No, troubleshoot actual last
fault.
2. Verify engine rotation manually: repair engine damage as necessary.
3. Verify generator rotation manually: repair generator damage as necessary.
4. Disconnect the generator set control J1 connector, verify that the J1 pins are fully inserted,
and inspect pin condition using the steps below:
• Use the test points of the tester tool #420-0603
• Use a mating pin connector, a pin gauge of the same size (.045") as the mating
control connector pin, or any suitable device that will not damage the inside contact
wipers of the pin socket
• Insert, repair, or replace pins as necessary.
5. Reconnect the J1 connector and test run the generator set for fault occurrence: repair or
replace pins in the connector as necessary.
6. Check the air filter for cleanliness; replace air filter as necessary.
7. Check for a blocked or damaged exhaust system: repair or replace exhaust components as
necessary.
8. Measure the generator set load capability with a shop load bank.
9. Measure AC frequency while changing engine rpm to determine if frequency response
matches engine rpm response.
10. Propane Models
a. When ambient temperatures are less than 40°F vapor – withdrawal Propane tanks
should be at least half full to provide proper vaporization rate.
b. Propane having more than 2.5 percent Butane will not vaporize in ambients at less
than 32°F; use HD-5 grade Propane.
c. Run the generator set on shop fuel supply; verify the tank level and fuel line condition.
11. Measure steady DC voltage at the fuel solenoid while the generator set is running; repair
wiring as necessary.
12. Verify clear vent hose.
13. Check the generator set fuel lines for damage: replace fuel lines as required.
14. Measure the fuel supply and regulator lock off pressures.
15. Check the governor, actuator, linkage, and spring for debris, damage, and looseness:
readjust and repair as necessary.
102
A030A239 (Issue 10)
9-2013
9. Troubleshooting
16. Verify that the spark plug cables are secure on the spark plugs: reconnect or replace as
necessary.
17. Inspect ignition kill lead (J1-12) in harness and at connector J1: repair or replace the lead,
terminal, or pins as necessary.
18. Measure the spark plug gap: set the gap or replace the spark plugs as necessary.
19. Verify ignition spark condition.
20. Inspect the spark plug lead, kill lead terminals at magnetos, and measure the magneto air
gap: replace the terminals, set the gap, or replace the magnetos as necessary.
21. Measure temperature of the air intake and temperature rise across the generator set;
remove blockage or prevent air recirculation.
9.26
Invalid Set Configuration - Fault Code 37
Logic: Generator set control configuration does not meet any valid configuration.
Possible Causes: Generator set configuration, control
Diagnosis & Repair:
1. Verify that the Last Fault is FC 37: Yes, continue diagnosis; No, troubleshoot actual last
fault.
2. Using the remote display, reset and save the generator set configuration.
3. If the generator set configuration is correct and the fault will not clear, replace the control.
9.27
Processor Fault - Fault Code 43
Logic: RAM (programming variables) error during self test
Possible Causes: Faulty program
Diagnosis & Solution:
1. Verify that the Last Fault is FC 43: Yes, continue diagnosis; No, troubleshoot actual last
fault.
2. Disconnect battery power to the generator set control, wait 30 seconds, and reconnect the
battery. Power up control and verify if fault code returns.
3. Replace the control.
9.28
Speed Sense Fault - Fault Code 45
Logic: While running quadrature frequency dropped to 0 Hz for 1 continuous second
Possible Causes: Loads, generator windings, wire connections
Diagnosis & Repair:
1. Verify that the Last Fault is FC 45: Yes, continue diagnosis; No, troubleshoot actual last
fault.
2. Measure quadrature winding resistance at stator leads (J1-2 and J1-3) and at the J1
connector.
A030A239 (Issue 10)
103
9. Troubleshooting
9-2013
3. Disconnect the generator set control J1 connector, verify that the J1 pins are fully inserted,
and inspect pin condition using the steps below:
• Use the test points of the tester tool #420-0603
• Use a mating pin connector, a pin gauge of the same size (.045") as the mating
control connector pin, or any suitable device that will not damage the inside contact
wipers of the pin socket.
• Insert, repair, or replace pins as necessary.
4. Reconnect the J1 connector and test run the generator set for fault occurrence: repair or
replace pins in the connector as necessary.
5. Measure AC current while running the generator set with loads: identify faulty or short
cycling loads.
6. Measure generator set load capability with a shop load bank (de-rate for altitude and
temperature as necessary).
7. Measure generator set frequency and droop while running.
8. Measure AC frequency while changing the engine rpm to determine if the frequency
response matches engine rpm response: repair the damaged generator drive system as
necessary.
9.29
Generator Set Overload - Fault Code 46
Logic: Current is at or above operational design limit and approaching fault declaration: 13, 15,
22, or 36.
Possible Causes: Loads, wire connections, windings,
Diagnosis & Repair:
1. Verify that the Last Fault is FC 46: Yes, continue diagnosis; No, troubleshoot actual last
fault.
2. Measure AC current and voltage while running the generator set with loads: identify faulty
or short cycling loads or reduce loads as necessary.
3. Measure the generator set load capability with a shop load bank (de-rate for altitude and
temperature as necessary).
4. Disconnect the generator set control J1 connector, verify that the J1 pins are fully inserted,
and inspect pin condition using the steps below:
• Use the test points of the tester tool #420-0603
• Use mating pin connector, a pin gauge of the same size (.045") as the mating control
connector pin, or any suitable device that will not damage the inside contact wipers of
the pin socket.
• Insert, repair, or replace pins as necessary.
5. Reconnect the J1 connector and test run the generator set for fault occurrence: repair or
replace pins in the connector as necessary.
6. Check the air filter for cleanliness; replace the air filter as necessary.
7. Measure steady DC voltage at the fuel solenoid while the generator set is running; repair
wiring as necessary.
104
A030A239 (Issue 10)
9-2013
9. Troubleshooting
8. Verify clear vent hose.
9. Run the generator set on shop fuel supply; verify the tank level and fuel line condition.
10. Check the generator set fuel lines for damage: replace the fuel lines as required.
11. Measure regulator lock off pressure.
12. Check the intake manifold and gaskets for air leaks: tighten the fasteners and replace the
gaskets and manifold as necessary.
13. Check for a blocked or damaged exhaust system: repair or replace exhaust components as
necessary.
14. Verify actuator function by applying DC voltage to the terminals: replace the actuator as
necessary.
15. Check the carburetor for binding; inspect the spring for dirt and debris: clean the spring;
replace the carburetor as necessary.
16. Verify that the spark plug cables are secure on the spark plugs: reconnect or replace as
necessary.
17. Inspect ignition kill lead (J1-12) in the harness and at connector J1: repair or replace the
lead, terminal, or pins as necessary.
18. Measure the spark plug gap: set the gap or replace the spark plugs as necessary.
19. Verify ignition spark condition.
20. Inspect the spark plug leads, kill lead terminals at magnetos, and measure the magneto air
gap: replace the terminals, set the gap, or replace the magnetos as necessary.
9.30
Alternator Over Temp - Fault Code 76
Logic: Temperature at alternator is too high (switch at 170 °F).
Possible Causes: Wire connections, faulty temperature sensor, faulty DC fan, blocked intake or
exhaust openings
Diagnosis & Solution:
1. Verify that the Last Fault is FC 76: Yes, continue diagnosis; No, troubleshoot actual last
fault.
2. Verify the generator set enclosure is fully closed and latched during operation to promote
proper air flow.
3. Verify the generator set enclosure for clear intake and exhaust openings.
4. Verify the temperature at the customer connection terminal block within the generator set.
5. Disconnect the generator set control J1 connector, verify that the J1 pins are fully inserted
and inspect pin condition using the steps below:
• Use the test points of the tester tool #420-0603
• Use a mating pin connector, a pin gauge of the same size (.045") as the mating
control connector pin, or any suitable device that will not damage the inside contact
wipers of the pin socket
• Insert, repair, or replace pins as necessary
A030A239 (Issue 10)
105
9. Troubleshooting
9-2013
6. Verify the temperature sensor resistance. Replace as necessary.
7. Measure the temperature sensor wiring (J1-33) for continuity. Repair or replace as
necessary.
8. Visually inspect the alternator fan for missing or damaged fins. Replace the fan if
necessary.
9.31
Low Fuel Pressure - Fault Code 78
Logic: Controller sensed fuel pressure switch open and approaching fault declaration: 14, 15,
22 or 36.
Possible Causes: Wire connections, fuel system, fuel pressure switch,
Diagnosis & Solution:
1. Verify that the Last Fault is FC 78: Yes, continue diagnosis; No, troubleshoot actual last
fault.
2. Verify the fuel supply and regulator lock off pressures.
3. Measure steady DC voltage at the fuel solenoid while the generator set is running; repair
wiring as necessary.
4. Verify the fuel lines are not kinked or broken/cracked.
5. Run the generator set on shop fuel supply; verify the tank level and fuel line condition.
6. Check the generator set fuel lines for damage: replace the fuel line as required.
7. Check for fuel pressure switch continuity to ground while the generator set is running.
8. Check for fuel pressure switch continuity across its terminals while fuel system pressure is
applied.
9. Check the fuel pressure switch wiring for an open circuit.
10. Disconnect the generator set control J1 connector, verify that the J1 pins are fully inserted
and inspect pin condition using the steps below:
• Use the test points of the tester tool #420-0603
• Use a mating pin connector, a pin gauge of the same size (.045") as the mating
control connector pin, or any suitable device that will not damage the inside contact
wipers of the pin socket
• Insert, repair, or replace pins as necessary.
9.32
Failure To Transfer To Generator Set - Fault Code
79
NOTICE
Only with 6634 and 6635 (to be performed by a Cummins Technician only)
Only with 6868 and 6869
Logic: Controller commanded transfer switch to standby position but standby position feedback
not received after the 5 second transfer time delay.
106
A030A239 (Issue 10)
9-2013
9. Troubleshooting
Possible Causes: Wire connections, faulty positional switch, faulty transfer switch
component(s)
Diagnosis & Solution:
1. Verify that the main AC circuit breaker on generator set is to “On".
2. Verify that the Last Fault is FC 79: Yes, continue diagnosis; No, troubleshoot actual last
fault.
3. Manually start an exercise session and verify the transfer switch position during the
exercise.
4. Disable the generator by placing the generator local start switch in the “Off" position.
5. Manually operate the transfer switch via lever to the generator position; check for generator
position switch continuity to ground at the transfer switch.
6. Check for continuity from the transfer terminal block position (TB4-6) to the generator
position terminal (J2-5).
7. Check for a ground signal at the generator position terminal (J2-5) at the control connector;
repair wiring as necessary.
8. Disconnect the generator set control J1 connector, verify that the J1 pins are fully inserted
and inspect pin condition using the steps below:
• Use the test points of the tester tool #420-0603
• Use mating pin connector, a pin gauge of the same size (.045") as the mating control
connector pin, or any suitable device that will not damage the inside contact wipers of
the pin socket
• Insert, repair, or replace pins as necessary.
A030A239 (Issue 10)
107
9. Troubleshooting
9-2013
This page is intentionally blank.
108
A030A239 (Issue 10)
10
Communication Troubleshooting
10.1
In-Home Network Access to Generator Set
Troubleshooting
WARNING
Some generator set service 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 generator set service.
Possible Causes: Bad connections or bad communications
Corrective Actions:
1. Check connections.
a. Verify that the Ethernet cable is plugged into the generator set control and the router.
b. Verify that the computer that is attempting to access the generator set is connected to
the same router as the generator set via an Ethernet cable (on the same local area
network).
c. Verify that the wireless card on the computer is turned off.
d. Check to see if both ends of the Ethernet cable are assembled and crimped as
described in the installation instructions. If not, reassemble and crimp as described in
the installation instructions.
e. Verify that the Ethernet cable connections between the generator set and the router
are solid and correct.
f. Proceed to "Check communications."
2. Check communications.
a. If the router is also connected to an incoming connection from an ISP, check to see if
you can access a standard web page with the computer connected to the same router
as the generator set. If not, contact your router manufacturer for troubleshooting
information.
b. Check to see if the green and orange lights are illuminated at the Ethernet connection
port on the generator set control board. If the lights are not illuminated, this indicates
that no information is being transmitted or received. Test the cable by disconnecting
the Ethernet cable from the generator control board and connecting it to the computer
(swap the cable with the exisiting Ethernet cable). With the router connected to the
ISP, check to see if you can access a standard web page.
a. If you can access a standard web page, call Cummins Support at 1-800-8886626 and select option 1.
b. If you cannot access a standard web page, go to the “Check connections" step
above.
c. Check to see if the correct generator IP address has been entered. If not, enter the
correct IP address in the address bar of the web browser. Be sure to not enter "www"
or other text prior to the IP address.
A030A239 (Issue 10)
109
10. Communication Troubleshooting
9-2013
d. If none of the above troubleshooting techniques help, call Cummins Support at 1-800888-6626 and select option 1.
FIGURE 60.
10.2
NETWORK CONNECTIONS (CONTROL BOARD AND ETHERNET CONNECTION)
Remote Internet Access to Generator Set
Troubleshooting
WARNING
Some generator set service 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 generator set service.
Possible Causes: Improper setup, no high-speed internet connection, public IP address is not
active or properly set up, incorrect IP address is entered, computer is connected to the same
router or network as the generator set, or the internet connection is faulty.
Corrective Actions:
1. Check to see if you are able to access the generator set with your in-home computer.
If not, refer to the In-Home Network Access Troubleshooting procedures.
2. Verify that you followed the network setup procedures.
Refer to the Network Setup Guide.
3. Verify that you are using a high-speed internet connection.
4. Verify that the public IP address is active and set up properly with the ISP (Internet Service
Provider). If necessary, contact the ISP to verify your setup.*
5. Verify that the correct public IP address is entered into the web browser of the computer
(i.e. xxx.xxx.xxx.xxx).
110
A030A239 (Issue 10)
9-2013
10. Communication Troubleshooting
6. Verify that the computer is not connected to the same router or local area network as the
generator set. If it is on the same network, you will be able to access the generator set
using the local network IP address configured on the generator set. The computer used for
internet access must be connected to a different internet connection than the generator set.
7. Check to see if you can access a standard web page from a computer. If not, contact the
ISP to troubleshoot the internet connection.
8. Verify all settings, as described in the Network Setup Guide.
9. If the previous steps do not correct the problem, contact a computer network specialist to
diagnose.
* To verify your IP address, access “whatismyipaddress.com" from the browser of a
computer connected to the internet and on the same network as the generator set. This
web page displays your current IP address which should match the IP address assigned to
you by your ISP.
10.3
Email Alert Troubleshooting
WARNING
Some Generator Set service 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 Generator Set service.
Possible Causes: An improper setup, the alert level is not set to “all events," emails cannot be
received, the outgoing email address is not included in your contact list, the email account is not
capable of using plain SMTP for the outgoing SMTP server setup, the domain name is not
included in the user name filed of the Network Setup screen, or the DNS #1 and #2 values are
incorrect on the Network Setup screen.
Corrective Actions:
1. Check to see if you are able to access the generator set with your in-home computer. If
not, refer to In-Home Computer Access Troubleshooting.
2. Verify that you followed the network setup instructions. Refer to the Network Setup Guide.
3. Verify that the alert level is set to All Events.
a. To verify that your generator set can send emails, select Disable Standby and wait
several minutes to verify that you did receive an email.
b. Select Enable Standby and wait a few more minutes to verify that you did receive a
second email.
4. Send an email to the destination email address and check to see if you received this email.
If not, contact your email service provider or your ISP (Internet service provider) to
diagnose.
5. Check to see if the destination email accounts have spam filtering.
a. If spam filtering is present, add the outgoing email address to your contact list.
b. If spam filtering is not present, proceed to step 6.
A030A239 (Issue 10)
111
10. Communication Troubleshooting
9-2013
6. Ensure that the SMTP server in use is capable of distributing non SSL certified emails. If
the SMTP server is not capable of sending non SSL certified emails or the status is
unknown, please contact your ISP technical support for information.
7. Verify that the domain name is included in the user name field of the Network Setup screen
(i.e. username@domainname).**
8. Verify with your ISP that the Static DNS (Domain Name Server) #1 and #2 are correct.
9. If the previous steps do not correct the problem, contact a computer network specialist to
diagnose.
** “No authentication" is possible on some systems by leaving the username and password
fields blank.
IMPORTANT NOTE: Changes are not saved unless you navigate through all three
Network Setup screens and click on “Done". The message “Settings Saved Successfully"
is then displayed.
FIGURE 61.
112
NETWORK SETUP - PAGE 1
A030A239 (Issue 10)
9-2013
10. Communication Troubleshooting
FIGURE 62.
FIGURE 63.
A030A239 (Issue 10)
GENERATOR SET HOME PAGE
NETWORK SETUP - PAGE 2
113
10. Communication Troubleshooting
FIGURE 64.
114
9-2013
NETWORK SETUP - PAGE 3
A030A239 (Issue 10)
Appendix A. Outline and System Drawings
Table of Contents
Figure 65. Ethernet Connections (Optional) ........................................................................................... 116
Figure 66. Ethernet Connector ................................................................................................................ 116
Figure 67. ethernet RJ-45 connector Wiring .......................................................................................... 117
Figure 68. Network Connections .............................................................................................................. 118
Figure 69. Manual Fuel Selection Valve ................................................................................................... 119
Figure 70. Wiring Diagram (Sheet 1 of 3) ................................................................................................. 121
Figure 71. Wiring Diagram (Sheet 2 of 3) ................................................................................................. 122
Figure 72. Wiring Diagram (Sheet 3 of 3) ................................................................................................. 123
Figure 73. Harness Label ........................................................................................................................... 124
Figure 74. Wiring Harness Connections (Sheet 1 of 4) .......................................................................... 125
Figure 75. Wiring Harness Connections (Sheet 2 of 4) .......................................................................... 126
Figure 76. Wiring Harness Connections (Sheet 3 of 4) .......................................................................... 127
Figure 77. Wiring Harness Connections (Sheet 4 of 4) .......................................................................... 128
Figure 78. Outline Drawing ........................................................................................................................ 129
A030A239 (Issue 10)
115
Appendix A.
Outline and System Drawings
9-2013
Wiring connections to the Ethernet RJ-45 plug are shown in the Ethernet RJ-45 Connector Wiring illustration. Utilize
an appropriate Ethernet stripping and crimping tool for these connections.
FIGURE 65.
ETHERNET CONNECTIONS (OPTIONAL)
FIGURE 66.
116
ETHERNET CONNECTOR
A030A239 (Issue 10)
9-2013
Appendix A.
FIGURE 67.
A030A239 (Issue 10)
Outline and System Drawings
ETHERNET RJ-45 CONNECTOR WIRING
117
Appendix A.
Outline and System Drawings
FIGURE 68.
118
9-2013
NETWORK CONNECTIONS
A030A239 (Issue 10)
9-2013
Appendix A.
FIGURE 69.
A030A239 (Issue 10)
Outline and System Drawings
MANUAL FUEL SELECTION VALVE
119
Appendix A.
Outline and System Drawings
9-2013
This page is intentionally blank.
120
A030A239 (Issue 10)
9-2013
Appendix A.
FIGURE 70.
A030A239 (Issue 10)
Outline and System Drawings
WIRING DIAGRAM (SHEET 1 OF 3)
121
Appendix A.
Outline and System Drawings
9-2013
FIGURE 71.
122
WIRING DIAGRAM (SHEET 2 OF 3)
A030A239 (Issue 10)
9-2013
Appendix A.
FIGURE 72.
A030A239 (Issue 10)
Outline and System Drawings
WIRING DIAGRAM (SHEET 3 OF 3)
123
Appendix A.
Outline and System Drawings
9-2013
FIGURE 73.
124
HARNESS LABEL
A030A239 (Issue 10)
9-2013
Appendix A.
FIGURE 74.
A030A239 (Issue 10)
Outline and System Drawings
WIRING HARNESS CONNECTIONS (SHEET 1 OF 4)
125
Appendix A.
Outline and System Drawings
9-2013
FIGURE 75.
126
WIRING HARNESS CONNECTIONS (SHEET 2 OF 4)
A030A239 (Issue 10)
9-2013
Appendix A.
FIGURE 76.
A030A239 (Issue 10)
Outline and System Drawings
WIRING HARNESS CONNECTIONS (SHEET 3 OF 4)
127
Appendix A.
Outline and System Drawings
9-2013
FIGURE 77.
128
WIRING HARNESS CONNECTIONS (SHEET 4 OF 4)
A030A239 (Issue 10)
9-2013
Appendix A.
FIGURE 78.
A030A239 (Issue 10)
Outline and System Drawings
OUTLINE DRAWING
129
Appendix A.
Outline and System Drawings
9-2013
This page is intentionally blank.
130
A030A239 (Issue 10)
Cummins Power Generation
1400 73rd Ave. NE
Minneapolis, MN 55432 USA
Phone 1 763 574 5000
Toll-free 1 800 888 6626
Fax 1 763 574 5298
Copyright © 2013 Cummins Power Generation, Inc. All rights reserved.
Cummins, Onan, the "C" logo, and "Performance you rely on." are
trademarks of Cummins Inc.
Download PDF