Operator'S Manual: Genset Model

Operator’s Manual
GenSet Model
DFEG, DFEH, DFEJ, DFEK
with PowerCommand Control

PCC2100
Printed in U.S.A. 961-0101 03-2004

Table of Contents
SECTION TITLE PAGE
IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
1 INTRODUCTION
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
How to Obtain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
3 CONTROL OPERATION
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Control Panel Power On/Off Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Menu Display and Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Main Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Adjusting Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
System Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Controller Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Engine Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Alternator Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Faults Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
System Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
History Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
About Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Power Transfer Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
i
SECTION TITLE PAGE
4 TROUBLESHOOTING
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Line Circuit Breaker (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Control and Diagnostics VIA Network or PC (Laptop) . . . . . . . . . . . . . . . . . 4-2
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Fault Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
5 MAINTENANCE
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Generator Set Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Generator Set Maintenance (Battery Disconnected) . . . . . . . . . . . . . . . . . . 5-4
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
6 OPERATING RECOMMENDATIONS
No-Load Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Exercise Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Low Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
High Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
7 OPTIONAL ENCLOSURE FEATURES
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
External Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Overfill Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
External Emergency Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
AC Distribution Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Fuel Transfer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
External Alarm Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
External Fuel Fill Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
ii
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS − This manual contains EXHAUST GASES ARE DEADLY
important instructions that should be followed during
installation and maintenance of the generator and batter- • Provide an adequate exhaust system to properly
ies. expel discharged gases away from enclosed or
sheltered areas and areas where individuals are
Before operating the generator set (genset), read the likely to congregate. Visually and audibly inspect
Operator’s Manual and become familiar with it and the the exhaust daily for leaks per the maintenance
equipment. Safe and efficient operation can be schedule. Make sure that exhaust manifolds are se-
achieved only if the equipment is properly operated cured and not warped. Do not use exhaust gases to
and maintained. Many accidents are caused by failure heat a compartment.
to follow fundamental rules and precautions.
• Be sure the unit is well ventilated.
The following symbols, found throughout this manual,
alert you to potentially dangerous conditions to the oper-
• Engine exhaust and some of its constituents are
known to the state of California to cause cancer,
ator, service personnel, or the equipment.
birth defects, and other reproductive harm.
This symbol warns of immediate
MOVING PARTS CAN CAUSE SEVERE
hazards which will result in severe personal in-
jury or death. PERSONAL INJURY OR DEATH
• Keep your hands, clothing, and jewelry away from
WARNING This symbol refers to a hazard or un- moving parts.
safe practice which can result in severe person-
al injury or death. • Before starting work on the generator set, discon-
nect battery charger from its AC source, then dis-
CAUTION This symbol refers to a hazard or un- connect starting batteries, negative (−) cable first.
safe practice which can result in personal injury This will prevent accidental starting.
or product or property damage. • Make sure that fasteners on the generator set are
secure. Tighten supports and clamps, keep guards
FUEL AND FUMES ARE FLAMMABLE in position over fans, drive belts, etc.
Fire, explosion, and personal injury or death can result • Do not wear loose clothing or jewelry in the vicinity of
from improper practices. moving parts, or while working on electrical equip-
ment. Loose clothing and jewelry can become
• DO NOT fill fuel tanks while engine is running, un- caught in moving parts.
less tanks are outside the engine compartment.
Fuel contact with hot engine or exhaust is a potential • If adjustment must be made while the unit is run-
fire hazard. ning, use extreme caution around hot manifolds,
moving parts, etc.
• DO NOT permit any flame, cigarette, pilot light,
spark, arcing equipment, or other ignition source DO NOT OPERATE IN FLAMMABLE AND
near the generator set or fuel tank.
EXPLOSIVE ENVIRONMENTS
• Fuel lines must be adequately secured and free of
leaks. Fuel connection at the engine should be Flammable vapor can cause an engine to overspeed and
made with an approved flexible line. Do not use zinc become difficult to stop, resulting in possible fire, explo-
coated or copper fuel lines with diesel fuel. sion, severe personal injury and death. Do not operate a
genset where a flammable vapor environment can be
• Be sure all fuel supplies have a positive shutoff created by fuel spill, leak, etc., unless the genset is
valve. equipped with an automatic safety device to block the air
• Be sure battery area has been well-ventilated prior intake and stop the engine. The owners and operators of
to servicing near it. Lead-acid batteries emit a highly the genset are solely responsible for operating the gen-
explosive hydrogen gas that can be ignited by arc- set safely. Contact your authorized Cummins Power
ing, sparking, smoking, etc. Generation distributor for more information.
LS-14L
iii
ELECTRICAL SHOCK CAN CAUSE • Keep multi-class ABC fire extinguishers handy.
SEVERE PERSONAL INJURY OR DEATH Class A fires involve ordinary combustible materials
such as wood and cloth; Class B fires, combustible
• Remove electric power before removing protective and flammable liquid fuels and gaseous fuels; Class
shields or touching electrical equipment. Use rub- C fires, live electrical equipment. (ref. NFPA No. 10).
ber insulative mats placed on dry wood platforms
over floors that are metal or concrete when around • Make sure that rags are not left on or near the en-
electrical equipment. Do not wear damp clothing gine.
(particularly wet shoes) or allow skin surface to be
damp when handling electrical equipment. Do not • Make sure generator set is mounted in a manner to
wear jewelry. Jewelry can short out electrical con- prevent combustible materials from accumulating
tacts and cause shock or burning. under the unit.
• Use extreme caution when working on electrical • Remove all unnecessary grease and oil from the
components. High voltages can cause injury or unit. Accumulated grease and oil can cause over-
death. DO NOT tamper with interlocks. heating and engine damage which present a poten-
• Follow all applicable state and local electrical tial fire hazard.
codes. Have all electrical installations performed by • Keep the generator set and the surrounding area
a qualified licensed electrician. Tag and lock open clean and free from obstructions. Remove any de-
switches to avoid accidental closure. bris from the set and keep the floor clean and dry.
• DO NOT CONNECT GENERATOR SET DIRECT-
LY TO ANY BUILDING ELECTRICAL SYSTEM. • Do not work on this equipment when mentally or
Hazardous voltages can flow from the generator set physically fatigued, or after consuming any alcohol
into the utility line. This creates a potential for elec- or drug that makes the operation of equipment un-
trocution or property damage. Connect only safe.
through an approved isolation switch or an ap-
• Substances in exhaust gases have been identified
proved paralleling device.
by some state or federal agencies as causing can-
GENERAL SAFETY PRECAUTIONS cer or reproductive toxicity. Take care not to breath
or ingest or come into contact with exhaust gases.
• Coolants under pressure have a higher boiling point
than water. DO NOT open a radiator or heat ex- • Do not store any flammable liquids, such as fuel,
changer pressure cap while the engine is running. cleaners, oil, etc., near the generator set. A fire or
Allow the generator set to cool and bleed the system explosion could result.
pressure first.
• Wear hearing protection when going near an oper-
• Used engine oils have been identified by some state ating generator set.
or federal agencies as causing cancer or reproduc-
tive toxicity. When checking or changing engine oil, • To prevent serious burns, avoid contact with hot
take care not to ingest, breathe the fumes, or con- metal parts such as radiator, turbo charger and ex-
tact used oil. haust system.
KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE
iv
1. Introduction
GENERAL tor. Factory-trained Parts and Service representa-

tives are ready to handle all your service needs.
Each operator should read this manual before oper-
ating the set for the first time. A generator set (gen- To contact your local Cummins Power Generation
set) must be operated and maintained properly if distributor in the United States or Canada, call
you are to expect safe and reliable operation. The 1-800-888-6626 (this automated service utilizes
manual includes a troubleshooting guide and a touch-tone phones only). By selecting Option 1
maintenance schedule. (press 1), you will be automatically connected to the
distributor nearest you.
The engine manual is included with the set. Where
there is conflicting information, this manual takes If you are unable to contact a distributor using the
precedence over the engine manual. automated service, consult the Yellow Pages. Typi-
cally, our distributors are listed under:
WARNING Improper operation and mainte-
nance can lead to severe personal injury or loss GENERATORS-ELECTRIC or
of life and property by fire, electrocution, me- ELECTRICAL PRODUCTS
chanical breakdown or exhaust gas asphyxi-
ation. Read and follow the safety precautions For outside North America, call Cummins Power
on page iii and carefully observe all instructions Generation, 1-763-574-5000, 7:30 AM to 4:00 PM,
and precautions in this manual. Central Standard Time, Monday through Friday. Or,
send a fax to Cummins Power Generation using the
fax number 1-763-528-7229.
HOW TO OBTAIN SERVICE
When contacting your distributor, always supply the
When the generator set requires servicing, contact complete Model, Specification, and Serial Number
your nearest Cummins Power Generation distribu- as shown on the generator set nameplate.
WARNING
INCORRECT SERVICE OR PARTS REPLACEMENT CAN RESULT IN SEVERE PERSONAL IN-

JURY, DEATH, AND/OR EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST BE TRAINED
AND EXPERIENCED TO PERFORM ELECTRICAL AND/OR MECHANICAL SERVICE.
Copyright 2004 Cummins Power Generation. All rights reserved.

Cummins and PowerCommand are registered trademarks of Cummins Inc.
1-1
THIS PAGE LEFT INTENTIONALLY BLANK
1-2
2. Specifications
MODEL DFEG, DFEH, DFEJ, DFEK

Engine
Cummins Series QSX15 (50/60 Hz)
Generator Kw Rating See Genset Nameplate for rating information.
Electrical System
Starting Voltage 24 Volts DC
Battery Two, 12 Volt
Group Number 8D
CCA (minimum)
Cold Soak @ 0° F (-18° C) 1400
Cooling System
(Capacity Std. Raidiator) − Gal (L) 15.3 (58)
Lubricating System
Oil Cap. w/Filters 26 Gallons (58 L)
Oil Type*
* Refer to Cummins QSX15 Series Engine Operation and Maintenance Manual for lubricating oil
recommendations/specifications.
FUEL CONSUMPTION (STANDBY/FULL LOAD/60HZ)

MODEL DFEG DFEH DFEJ DFEK
US gph (L/hr) 24.6 (93.2) 27.1 (102.7) 30.0 (113.7) 34.8 (131.9)
2-1
2-2
3. Control Operation
GENERAL Coolant
The following describes the function and operation Check the engine coolant level. Refer to “Cooling
of the PowerCommand 2100 Control (PCC). All in- Systems” in the Maintenance section of this manu-
dicators, control switches/buttons and digital dis- als for proper procedure.
play are located on the face of the control panel as Fuel
illustrated in Figure 3-1.
Make sure the fuel tanks have sufficient fuel and
This section covers prestart checks, starting and that fuel system is primed. Check to make sure
stopping and operating the generator set. Each op- there are no leaks and that all fittings are tight.
erator should read through this entire section before
attempting to start the set. It is essential that the op- Ventilation
erator be completely familiar with the set and the Make sure the generator set cooling inlet/outlet and
PCC control. Refer to Section 6 for operating rec- exhaust ventilation openings are clear (not blocked)
ommendations. and operational.
Before starting, be sure the following checks have Remove all loose debris from surrounding area of
been made and the unit is ready for operation. generator set. Air flow from the radiator fan can
blow loose items around and into ventilation open-
PRESTART CHECKS ings.
Exhaust
Lubrication
Check to make sure entire exhaust system is tight,
Check the engine oil level. Keep the oil level near as that no combustible materials are near system, and
possible to the dipstick high mark without overfilling. gases are discharged away from building openings.
3-1
CONTROL PANEL POWER ON/OFF used and the O/Manual/Auto switch is in the O posi-
MODES tion.
When all conditions are met (i.e., no unacknowl-
The power on/off modes of the control panel and op- edged faults and O/Manual/Auto switch is in the O
erating software are Power On, Screen Saver and position) the Sleep mode is activated.
Sleep/Awake.
The operating software is initialized and the digital
Power On Mode: In this mode, power is continu- display and control panel LEDs are turned on in re-
ously supplied to the control panel. The control’s sponse to moving/pressing the following control
operating software and control panel LEDs/digital panel switch/buttons:
display will remain active until the Screen Saver • Off/Manual/Auto switch
mode is activated.
• Emergency Stop button
Screen Saver Mode: Power to the digital display is • Fault Acknowledge/Reset button
removed after 30 minutes (generator set not run- • Panel Lamp/Lamp Test button
ning or running). The 30 minute timer resets and be-
gins after each control panel action (any button or To activate the control and view the menu display
switch selection) or signal received by the operating without starting the generator set, press Fault Ac-
software. All LEDs on the control panel operate nor- knowledge or Panel Lamp button or move mode
mally during Screen Saver mode, indicating that the switch from O to Manual.
operating software is active (Awake mode).
The InPower service tool is required to enable or
When a “Warning” signal is sensed by the PCC (for disable the Sleep mode. When shipped from the
example, low coolant temp), the control displays the factory, Sleep mode is disabled. When disabled, the
warning message. operating software will always remain active
(Awake mode). If network and/or power transfer
Sleep/Awake Mode: In the Sleep mode, the con- control (PTC) feature is installed, the sleep mode is
trol’s operating software is inactive and the LEDs not available.
and the digital display on the control panel are all off. The InPower service tool is required to select the de-
Sleep mode is a feature used to reduce battery sired mode. Contact an authorized service center for
power consumption when the control is not being assistance.
3-2
MENU SHUTDOWN
SELECTION AND WARNING
BUTTON PREVIOUS
STATUS
(1 of 4) MAIN MENU
INDICATORS RUNNING/REMOTE
PANEL BUTTON
START/NOT IN AUTO
HOME LAMP
EMERGENCY INDICATORS
BUTTON (1 of 3)
DIGITAL STOP PUSH
DISPLAY BUTTON CONFIGURABLE
(Pull to reset) INDICATORS
ANALOG AC OFF/MANUAL/
METERING AUTO SWITCH
PANEL
(OPTIONAL) FAULT
ACKNOWLEDGEMENT/ MANUAL
RESET BUTTON RUN/STOP
BUTTON
PANEL LAMP
AND LAMP
TEST
BUTTON
FIGURE 3-1. FRONT PANEL
3-3
FRONT PANEL Remote Start Indicator: This green lamp is lit
whenever the control is receiving a remote start sig-
Figure 3-1 shows the features of the front panel. nal.
Digital Display: This two-line, 20-characters per Not in Auto Indicator: This red lamp flashes con-
line alphanumeric display is used to view menus of tinuously when the O/Manual/Auto switch is not in
the menu-driven operating system. Refer to the the Auto position.
menu trees later in this section. The display is also
used to show warning and shutdown messages. Analog AC Metering Panel (Optional): This panel
simultaneously displays (in percent of genset rated
Display Menu Selection Buttons: Four momen- output):
tary buttons—two on each side of the digital display • 3-phase line-to-line AC current (A~)
window—are used to step through the various
menu options and to adjust generator set parame- • Kilowatts (kW)
ters. A green triangle ( or ), arrow ( , , , or ), • Generator output frequency in hertz (Hz)
>>, or plus/minus sign (+ or −) in the digital display
• 3-phase line-to-line AC volts (V~)
adjacent to the button is shown when the button can
be used (button is “active”). Refer to Menu Display • Power Factor (PF) (shown in 0.2 increments)
And Buttons later in this section.
Shutdown Status Indicator: This red lamp is lit
Home Button: Press this button ( ) to view the whenever the control detects a shutdown condition.
Home Menu. Refer to the menu trees later in this The generator set cannot be started when this lamp
section. is on. After the condition is corrected, shutdown in-
dicators can be reset by turning the O/Manual/Auto
Previous Main Menu Button: Press this button ( ) switch to the O position and pressing the Fault Ac-
to view the previous Main Menu. All main menus in- knowledge/Reset button.
clude both types of green triangles ( and ). Refer
Warning Status Indicator: This yellow lamp is lit
to the menu trees later in this section.
whenever the control detects a warning condition.
NOTE: The up and down arrows ( and ) are used After the condition is corrected, warning indicators
can be reset by pressing the Fault Acknowledge/
to navigate between submenus.
Reset button. (It is not necessary to stop the gener-
Emergency Stop Button: Push this button in for ator set.) In auto mode, warning indicators can also
emergency shutdown of the generator set. This will be reset by cycling the remote reset input after the
stop the generator set immediately and prevent condition is corrected.
starting of the set from any location (local and re-
Some warnings remain active after the condition is
mote). corrected and the control reset button is pressed.
To reset: This will require the genset to be shutdown to reset
the warning indicator.
1. Pull the button and allow it to pop out.
2. Turn the O/Manual/Auto switch to O (Off). Fault Acknowledge/Reset Button: Press this but-
ton to acknowledge warning and shutdown mes-
3. Press the front panel Fault Acknowledge/Re- sages after the fault has been corrected. Pressing
set button. this button clears the fault from the current fault list.
4. Select Manual or Auto, as required.
To acknowledge a Warning message, the O/Manu-
Emergency Stop shutdown can be reset only at the al/Auto switch can be in any position. (It is not nec-
PCC front panel. essary to stop the generator set to acknowledge an
inactive Warning condition.) To acknowledge a
Running Indicator: This green lamp is lit whenever shutdown message with this button, the O/Manual/
the generator (local or remote) is running. Auto switch must be in the O position.
3-4
Panel Lamp and Lamp Test Button: Press this Configurable Indicators
button to turn the control panel lamps on or off. The
lights will shut off after about ten minutes. Press and The following configurable indicators (default val-
hold this button to test all front panel LEDs and me- ues shown) can be changed with the InPower ser-
ters. The meters will light one bar at a time. vice tool. The configurable items are: change gen-
erator event and LED color (green, yellow or red),
and enable/disable indicator.
Manual Run/Stop Button: This button starts and
stops the set locally and will bypass Time Delay to The InPower service tool is required to select the de-
Start and Stop sequences. The O/Manual/Auto sired settings. Contact an authorized service center
for assistance.
switch must be in the Manual position to enable this
button. Low Oil Pressure Warning Indicator: This yellow
lamp indicates the oil pressure is lower than the nor-
O/Manual/Auto Switch: The Manual position en- mal range of operation.
ables the use of the Manual Run/Stop button. High Engine Temperature Warning Indicator:
This yellow lamp indicates the engine temperature
The Auto position enables start/stop control of the is higher than the normal range of operation.
engine from a remote location. (It disables the use Low Oil Pressure Shutdown Indicator: This red
of the Manual Run/Stop button.) lamp indicates the engine has shut down because
of low oil pressure.
The O (Off) position prevents the starting of the set
Overspeed Shutdown Indicator: This red lamp in-
(local or remote). If the switch is set to O during set
dicates the engine has shut down because of ex-
operation, the engine will immediately shut down
cessive speed.
(cool-down timers are bypassed). This hot shut-
down should be avoided, if possible, to help prolong Fail to Start Indicator: This red lamp indicates the
the life of the engine. engine failed to start.
3-5
STARTING If the engine does not start, the starter will disen-
gage after a specified period of time and the control
The following headings cover the systems used to will indicate an overcrank shutdown.
start the generator set. Figures 3-2, 3-3 and 3-4 pro-
vide a flow chart for all start/run/stop sequences. The generator can be configured for a number of
starting cycles (1−7) with set times for crank and
Before starting the generator set, make sure that rest periods for all starting modes (manual/remote).
exhaust and fuel fittings are tight and properly posi- The default setting is for 3 start cycles, composed of
tioned and that proper maintenance has been per- 15 seconds of cranking and 15 seconds of rest.
formed. See Prestart Checks in this section.
To change the cycle number, and the crank and rest
With the optional Power Transfer Control (PTC) mod- times, contact an authorized service center for assis-
ule installed, the function and sequence of operation tance.
of the Start command can differ and is noted as
“PTC” in the following paragraphs. Refer to the Pow- To clear a Fail to Start shutdown, place the O/Manu-
er Transfer Menu in this section, which describes the al/Auto switch in the O position and press the Fault
operation of the PTC feature. Acknowledge/Reset button. Wait two minutes for
the starter motor to cool and then repeat the starting
Starting at the Control Panel (Manual
procedure. If the engine does not run after a second
Mode) attempt, refer to the Troubleshooting section.
Turn the O/Manual/Auto switch to the Manual posi-
tion and press the Manual Run/Stop button. This Starting from a Remote Location (PTC or
will activate the engine control system and the start- Remote Start Signal) (Auto Mode)
ing system. The starter will begin cranking and, af-
ter a few seconds, the engine will start and the start- Place the O/Manual/Auto switch in the Auto posi-
er will disconnect. tion. This allows the generator set to be started from
a remote switch or device (e.g., transfer switch or
The InPower service tool is required to enable/dis- optional PTC module).
able the warm-up at idle feature and to adjust the
time-out. When shipped from the factory, this feature PTC − If a switch is connected to the remote start in-
is disabled. put of the control and the PTC module is installed,
this switch will function as a Test switch. The PTC
When the switch is in the Manual position, the con- Test sequence is shown in Figure 3-4.
trol will complete the warm-up at idle feature if en-
abled. When the coolant reaches operating temper- In response to the Remote Start or the control de-
ature or the warm-up time at idle time delay (0−300 tects the loss of S1 voltage (PTC option installed),
seconds) is reached, whichever occurs first, the the control lights the Remote Start indicator and ini-
generator set will ramp to the rated speed and volt- tiates the starting sequence as shown in Figure 3-3.
age.
When the switch is in the Auto position, the control
When the switch is in the Manual position, the gener- will complete the time delay to start.
ator set can be operated in the idle mode (used for
maintenance, troubleshooting, etc.). Refer to Adjust Refer to the Adjust submenu in this section to enable
menu (Figure 3-11) to enable/disable the idle feature. and change the time delay start/stop settings.
3-6
Cold Starting with Loads 2. Turn the O/Manual/Auto switch to O.
3. Press the front panel Fault Acknowledge/
In accordance with NFPA 110, Cummins Power Reset button.
Generation recommends installing standby gener- 4. Select Manual or Auto, as required.
ator sets (life safety systems) equipped with engine
jacket water coolant heaters in locations where the Emergency Stop shutdown status can be reset only
minimum ambient temperature is above 40°F at the operator control panel.
(4°C). NFPA also requires that the engine jacket
Stopping at Control Panel (Manual Mode)
water coolant be maintained at a minimum of 90°F
(32°C) and, for most applications, accept the emer- If the set was started at the control panel (O/Manu-
gency load in 10 seconds or less. Although most al/Auto switch in the Manual position), pressing the
Cummins Power Generation generator sets will Manual Run/Stop button causes the set to complete
start in temperatures down to −25°F (−32°C) when its normal (Local Start) shutdown sequence (Figure
equipped with engine jacket water coolant heaters, 3-2).
it might take more than 10 seconds to warm the en-
The set stops after the cool-down at idle timer (0 to
gine up before a load can be applied when ambient
30 minutes) has timed out.
temperatures are below 40°F (4°C).
The InPower service tool is required to enable/dis-
The Engine Cold (Code 1435) message, in con-
able the Cool-down At Idle feature. Contact an autho-
junction with illumination of the Warning LED, is pro- rized service center for assistance.
vided to meet the requirements of NFPA 110. The
engine cold sensing logic initiates a warning when Turning the O/Manual/Auto switch to the O position
the engine jacket water coolant temperature falls causes an immediate engine shutdown (bypasses
below 70°F (21°C). In applications where the ambi- Cool-down At Idle). If possible, this hot shutdown
ent temperature falls below 40°F (4°C), a cold en- should be avoided to help prolong the reliability of
gine may be indicated even though the coolant the engine.
heaters are connected. Under these conditions, al-
though the generator set may start, it may not be Stopping from Remote Location (PTC or
able to accept load within 10 seconds. When this Remote Stop Signal) (Auto Mode)
condition occurs, check the coolant heaters for
If the control receives a remote stop signal or the
proper operation. If the coolant heaters are operat-
control detects the return of S1 voltage (PTC option
ing properly, other precautions may be necessary to
installed), the set completes its normal shutdown
warm the engine before applying a load.
sequence (Figure 3-3). (The remote stop signal is
STOPPING actually the removal of the remote start signal to the
control.)
Emergency Stop
The set stops after completing the Time Delay To
The emergency stop button is located near the cen- Stop (0 to 600 seconds) and the cool-down at idle
ter of the upper part of the control panel (Figure (0-30 minutes).
3-1). Push the button in for an emergency stop. The
red Shutdown status LED is lit and the emergency Refer to the Adjust submenu in this section to enable
stop message is displayed. and change the Time Delay To Stop setting. The In-
Power service tool is required to enable/disable the
To reset: Cool-down At Idle feature. Contact an authorized
1. Pull the emergency stop button out. service center for assistance.
3-7
LOCAL START
(Manual Mode)
CONTROL RUN
BUTTON
WARM-UP @ IDLE
(0-300 sec) 1
2
Engine Temperature
EMERGENCY greater than 100° F go
STOP BUTTON to Rated
RATED SPEED
&VOLTAGE
CONTROL STOP
BUTTON
3 RATED TO IDLE
DELAY (0−10 sec)
2
COOL-DOWN
@ IDLE
(0−30 min) 1
2
STOP
NOTES:
1. Warm-up/cool-down idle adjusted time-out with InPower.
2. Timer expires.
3, Beginning Version 2.303
FIGURE 3-2. STARTING AT THE CONTROL PANEL (MANUAL MODE)
3-8
PTC DETECTS REMOTE START
S1 FAILURE 1 CUST. CONNECT 2
EMERGENCY
START
TIME DELAY TO
START (0−300 sec)
3
RATED SPEED
&VOLTAGE
OPEN S1
CLOSE S2
PTC Module sees

S1 Voltage OK
CLOSE S1 REMOTE START

OPEN S2 Removed
TIME DELAY TO EMERGENCY

STOP (0−600 sec) STOP BUTTON
3
5 RATED TO IDLE
DELAY (0−10 sec)
3
COOL-DOWN
@ IDLE
(0−30 min) 4
3
STOP
NOTES:
1. PTC feature installed.
2. PTC feature not installed (input from transfer switch, remote start switch, etc).
3. Timer expires.
4. Cool-down adjusted time-out with InPower.
5. Beginning Version 2.303
FIGURE 3-3. STARTING WITH CONTROL IN AUTO MODE (PTC OR REMOTE START SIGNAL)
3-9
REMOTE START
(TEST) 1
PTC Module sees

S1 Voltage OK
TIME DELAY TO
START (0−300 sec)
2
WARM-UP @ IDLE
(0-300 sec) 3
Engine Temperature
EMERGENCY greater than 100° F go
STOP BUTTON 2
to Rated
RATED SPEED
& VOLTAGE
(Selectable − with/
without load)
REMOTE START
(TEST) Removed
TIME DELAY TO
STOP (0−600 sec)
2
4 RATED TO IDLE
DELAY (0−10 sec)
2
COOL-DOWN
@ IDLE
(0−30 min) 3
2
STOP
NOTES:
1. Remote (exercise) start sequence with PTC feature installed.
2. Timer expires.
3. Warm-up/cool-down idle adjusted time-out with InPower.
4. Beginning Version 2.303
FIGURE 3-4. PTC FEATURE REMOTE START TEST/EXERCISE SWITCH (IN AUTO MODE)
3-10
MENU DISPLAY AND BUTTONS • In the digital display, the plus or minus symbols
(+ or −) indicate that pressing the adjacent but-
ton can be used to change a parameter or val-
Figure 3-5 shows the digital display and the menu
ue shown on the display.
selection buttons.
When there is a choice of two parameters, one
Digital Display: The two-line, 20 characters per parameter is associated with the + symbol and
line, digital display is used to view the menus of the the other is associated with the − symbol.
menu-driven operating system. Refer to the menu When changing values, pressing the button ad-
trees later in this section. The display is also used to jacent to the + symbol increase the value and
show fault messages. pressing the button adjacent to the − symbol
decreases the value. Only one numeric char-
Display Menu Selection Buttons: Four momen- acter of a field can be changed at a time.
tary buttons—two on each side of the digital display • In the digital display, the or symbol indicates
window—are used to step through the various that pressing the adjacent button causes the
menu options and to adjust generator set parame- operating program to move the cursor to the
ters. The button is active when a symbol adjacent to next numeric character. The selected numeric
the button is displayed. The displayed symbol indi- character can then be changed by pressing the
cates the function of the button. buttons adjacent to the + and − symbols. Only
the symbol is displayed when the cursor is on
• In the digital display for main menus (Figure
the first character of a field that can be
3-6), the and symbols indicate that pressing changed. Only the is displayed when the cur-
the adjacent button causes the operating pro- sor is on the last character. Both symbols are
gram to go to the selected submenu (e.g., En- displayed when the cursor is on any other char-
gine Menu in Figure 3-9). acter.
• In the digital display, the More>> symbol indi- • After adjusting values/parameters, pressing
cates that pressing the adjacent button causes the symbol results in the changes being
the operating program to go to the next main saved. If the Home button or Previous Main
menu, as shown in Figure 3-6. Menu button is pressed before pressing the
symbol, the changes are not saved.
• In the digital display, the or symbols indi-
Home Button: Pressing this button causes the op-
cate that pressing the adjacent button causes
erating system to show Main Menu 1 (Figure 3-6) in
the operating program to go to the next or pre-
the digital display.
vious submenu, as shown in the menu dia-
grams. Only the symbol is displayed in the Previous Main Menu Button: Pressing this button
first submenu. Only the is displayed in the causes the operating system to show the previous
last submenu. Both symbols are displayed in Main Menu in the digital display. All main menus in-
the rest of the submenus. clude both types of green triangles ( and ).
3-11
2 LINE, 20 CHARACTERS PER LINE
MENU DISPLAY
DIGITAL DISPLAY
HOME PREVIOUS MAIN

BUTTON MENU BUTTON
FIGURE 3-5. DIGITAL DISPLAY AND MENU SELECTION BUTTONS
3-12
MAIN MENUS As shown in the illustration, each main menu can
Figure 3-6 shows the three major main menus avail- branch into one of four directions. Press the button
able to the user. Figure 3-6 also includes references next to “More>>” in the display to view the next Main
to pages in this section where you can find addition- menu. Main Menu 1 is redisplayed when you press
al information on submenus. When viewing a sub- the button next to “More>>” in the Main Menu 3 dis-
menu, you can press the previous main menu but- play.
ton at any time to view its main menu.
Main Menu 1
PAGE PAGE
3-19 3-23
Engine Adjust
Alternator More>>
PAGE
3-21
Main Menu 2
PAGE PAGE
3-25 3-29
Faults History
System More>>
PAGE
3-27
Main Menu 3
PAGE SERVICE
3-31 REP
About Setup
Pwr Tran More>>
PAGE
3-33
FIGURE 3-6. MAIN MENUS
3-13
Main Menu 1 system, press the button next to the word “System”
in the display. Turn to the System menu diagram on
Main Menu 1 is also the Home menu. When viewing page 3-27.
any of the other main menus or any submenu, you
can press the home button to view this menu. To display historical engine parameters such as
number of starts, engine hours, control hours, kilo-
To display engine parameters, such as coolant tem- watt hours, and genset duty cycle, press the button
perature, oil pressure, oil temperature, etc., press next to the word “History” in the display. Turn to the
the button next to the word “Engine” in the display. History menu diagram on page 3-29.
Turn to the Engine menu diagram on page 3-19.
To view one of the other main menus, press the but-
To display alternator parameters, such as line-to-
ton next to “More>>” in the display.
line voltage, line-to-neutral voltage, amperage, fre-
quency, etc., press the button next to the word “Al- Main Menu 3
ternator” in the display. Turn to the Alternator menu
diagram on page 3-21. To view parameters on the generator, such as mod-
el, standby rating, and software version, press the
To adjust generator parameters, such as idle start,
button next to the word “About” in the display. Turn
voltage, frequency, start delay, and stop delay, press
to the About menu diagram on page 3-31.
the button next to the word “Adjust” in the display.
Turn to the Adjust menu diagram on page 3-23. To view power transfer parameters, such as source
To view one of the other main menus, press the but- power, frequency, generator, utility, and active
ton next to “More>>” in the display. transfer timer, press the button next to the word
“Pwr Tran” in the display. Turn to the Power Transfer
Main Menu 2 Menu on page 3-33.
To display system faults, press the button next to Main Menu 3 also includes a link to the Setup me-
the word “Faults” in the display. Up to 20 of the most nus. These menus can be viewed but changes to
recent/current faults can be displayed. Turn to the these menus are restricted to service personnel
Faults menu diagram on page 3-25. with the appropriate access code.
To view network system parameters, such as on the To view one of the other main menus, press the but-
automatic transfer switch (ATS), Master, or Genset ton next to “More>>” in the display.
3-14
ADJUSTING DEFAULT SETTINGS Pop-up screens are displayed for the following:
The Controller Configuration Menu can be used to
• Faults
adjust the following default settings:
• Power Transfer Control timer
• Language − Select from available loaded lan-
guages • Time Delay − Start, Stop, and Idle
• Temperature Units − Fahrenheit or Centigrade
• Fluid Pressure Units − kPA or PSI An example of a Time Delay Idle pop-up screen is
shown in Figure 3-7. A countdown, in seconds, is in-
For more information on adjusting these settings,
turn to the Controller Configuration menu diagram cluded in the display.
on page 3-17.
SYSTEM MESSAGES
A system message pop-up screen is displayed
when the event it is displaying becomes active.
These pop-up screens remain displayed until pre- TD Idle nnn Sec
empted by another pop-up screen or until any dis-
play button is pressed. Once a button is pressed,
the previous menu is redisplayed. To return to an
active pop-up screen from the previous menu, se-
lect the following menu:
• Engine to redisplay Time Delay Idle
• Faults to redisplay Faults
• Power Transfer to redisplay PTC Timer FIGURE 3-7. TIME DELAY IDLE POP-UP SCREEN
3-15
CONTROLLER CONFIGURATION MENU Press the button next to the symbol in the display
until the + and − symbols are displayed.
Figure 3-8 shows a block representation of the Con-
troller Configuration menus. These menus are used Press the button next to the + or − symbol to select
to change the default language, temperature units, the desired option.
and pressure units to be displayed in menus. After selecting option, pressing the symbol results
in the changes being saved. If the Home button or
To view the first Controller Configuration menu, Previous Main Menu button is pressed before
make sure Main Menu 1 is displayed and simulta- pressing the symbol, the changes are not saved.
neously press the Home Menu and Previous Main
Menu buttons. Language Selected submenu: Used to select de-
sired language (default = English).
As shown in the diagram, the Controller Configura-
Temperature Units submenu: Used to select
tion menu has three submenus.
Fahrenheit or Centigrade for temperature readings.
Press the buttons next to the and symbols in the Fluid Pressure Units submenu: Used to select
digital display to navigate between the menus. PSI or kPA for pressure readings.
3-16
CONTROLLER CONFIGURATION MENU
Main Menu 1
Engine Adjust
Alternator More>>
Language Selected
English
+Language Selected
− English
Back
Temperature Units
Deg F
+Temperature Units
− Deg C
Back
Fluid Pressure Units

PSI
+Fluid Pressure Units
− kPa
Back
FIGURE 3-8. CONTROLLER CONFIGURATION MENU
3-17
ENGINE MENU Coolant Temperature submenu: This submenu
displays the engine coolant temperature which can
Figure 3-9 shows a block representation of the En- be viewed in degrees Fahrenheit or Centigrade
gine menu. If you press the button next to the word (see Controller Configuration Menu in this section).
“Engine” in the display, the first Engine submenu is
displayed. Oil Pressure submenu: This submenu displays
the engine oil pressure which can be viewed in PSI
As shown in the diagram, the Engine menu has or kPA (see Controller Configuration Menu in this
seven submenus. The data in the submenus will section).
vary according to the type and number of sensors Oil Temperature submenu (Only available on
provided with the engine. some models): This submenu displays the engine
Press the buttons next to the and symbols in the oil temperature which can be viewed in degrees
digital display to navigate between the menus. Fahrenheit or Centigrade (see Controller Configu-
Press the Home button or the Previous Main Menu ration Menu in this section).
button to return to Main Menu 1. Engine Speed submenu: This submenu displays
the engine RPM.
Battery Voltage submenu: This submenu dis-
plays the engine battery voltage.
Governor Duty Cycle submenu: This submenu
displays the governor duty cycle (drive) levels in
percentage of maximum.
3-18
ENGINE MENU
Main Menu 1
Engine Adjust
Alternator More>>
Coolant Temperature
nnn Deg F
Oil Pressure
nnn PSI
Oil Temperature
nnn Deg F
Engine Speed
nnnn RPM
Battery Voltage
nn.n VDC
Governor Duty Cycle

nnn %
CONTINUED
FIGURE 3-9. ENGINE MENU
3-19
ENGINE MENU (CONT.) Barometric Pressure submenu: This submenu
displays the barometric pressure which can be
Governor Torque submenu: This submenu dis- viewed in InHg or kPa (see Controller Configuration
plays the governor torque levels in percentage of Menu in this section).
maximum value. Boost Pressure submenu: This submenu dis-
plays the boost pressure which can be viewed in
Fuel Temperature submenu: This submenu dis- InHg or kPa (see Controller Configuration Menu in
plays the fuel temperature which can be viewed in this section).
degrees Fahrenheit or Centigrade (see Controller
Intake Manifold submenu: This submenu dis-
Configuration Menu in this section).
plays the intake manifold temperature which can be
viewed in degrees Fahrenheit or Centigrade (see
Fuel Rate submenu: This submenu displays the Controller Configuration Menu in this section).
fuel rate which can be displayed in gallons per hour
or liters per hour (see Controller Configuration Fuel Outlet Pressure submenu: This submenu
Menu in this section). displays the fuel outlet pressure which can be
viewed in PSI or kPA (see Controller Configuration
Menu in this section).
Coolant Pressure submenu: This submenu dis-
plays the coolant pressure which can be viewed in Active Time Delay submenu: This submenu dis-
PSI or kPA (see Controller Configuration Menu in plays the time delay that is currently active: warm−
this section). up, cool down, start or stop delays.
3-20
ENGINE MENU (Cont.)
CONTINUED
Governor Trq Intk Manifold Temp

nnn % nnnn Deg F
Fuel Temperature Fuel Outlet Press

nnnn Deg F nnn PSI
Fuel Rate Active Time Delay

nnn.nn Gal/hr None nnnn Sec
Coolant Pressure
nnn PSI
Barometric Press
nnn InHg
Boost Press
nnn InHg
FIGURE 3-9. ENGINE MENU (CONT.)
3-21
ALTERNATOR MENU Line-to-Line Voltage submenu: The voltages
Line-to-Line (L1, L2 and L3) are measured between
Figure 3-10 shows a block representation of the Al- L1 to L2, L2 to L3 and L3 to L1, respectively. (Single
ternator menu. If you press the button next to the phase − L1 to L2 only.)
word “Alternator” in the display, the first Alternator
submenu is displayed. Line-to-Neutral Voltage submenu: Note that the
Line-to -Neutral menu will not be displayed for a 3
As shown in the diagram, the Alternator menu has phase/3 wire system. Single phase − L1 to N and L2
eleven submenus. to N.
Press the buttons next to the and symbols in the Amps submenu: All phases. (Single phase − L1
digital display to navigate between the menus. and L2 only.)
Press the Home button or the Previous Main Menu Frequency submenu: Generator set output fre-
button to return to Main Menu 1. quency.
Total Real Power submenu: This submenu dis-
plays the total amount of real power output, in kilo-
watts (kW).
Real Power submenu: This submenu displays the
amount of real power output for L1, L2, and L3, in
kilowatts (kW). (Single phase − L1 and L2 only.)
Total Apparent Power submenu: This submenu
displays the total amount of apparent power output,
in kilovolt amps (kVA).
Apparent Power submenu: This submenu dis-
plays the amount of apparent power output for L1,
L2, and L3, in kilovolt amps (kVA). (Single phase −
L1 and L2 only.)
Total Power Factor submenu: This submenu dis-
plays the power factor with leading/lagging indica-
tion.
The PF reading will contain an asterisk if the power
factor is leading (for example, Total PF 0.9 * ).
Power Factor submenu: This submenu displays a
power factor value for L1, L2, and L3. (Single
phase − L1 and L2 only.)
The PF reading will contain an asterisk if the power
factor is leading (for example, PF L1 0.9*).
AVR Duty Cycle submenu: This submenu dis-
plays the voltage regulator (drive) level in percent-
age of maximum. (Where maximum is 100% Duty
Cycle, software clamps Duty Cycle maximum to
60% for PMG and 90% for shunt.)
3-22
ALTERNATOR MENU
Main Menu 1
Engine Adjust
Alternator More>>
Volts L12 L23 L31

V nnn nnn nnn
Volts L1N L2N Total Power

V nnn nnn nn.n kVA
Amps L1 L2 L3 Power L1 L2 L3
nnn nnn nnn kVA nn.n nn.n nn.n
Frequency Total PF
nn.n Hz n.nn*
Total Power PF L1 L2 L3
nnn kW *n.nn *n.nn *n.nn
Power L1 L2 L3 AVR Duty Cycle

kW nn.n nn.n nn.n nnn %
FIGURE 3-10. ALTERNATOR MENU
3-23
ADJUST MENU Voltage Adjust submenu: Voltage can be ad-
justed to 5 percent of the nominal voltage. For ex-
ample, if genset output voltage is 208 volts, the volt-
Figure 3-11 shows a block representation of the Ad-
age can be adjusted from 198 to 218 volts.
just menu. If you press the button next to the word
“Adjust” in the display, the first Adjust submenu is If the displayed value is greater or less than the al-
displayed. lowed (5%) range, the control will not except the
entry and will return to the previous setting. Retry by
entering a smaller change in one volt increments.
As shown in the diagram, the Adjust menu has five
submenus. Each submenu includes a parameter or Frequency Adjust submenu: Frequency can be
value that can be changed. adjusted to 5 percent of the nominal frequency.
For example, if the genset frequency is 60.0 Hz, the
frequency can be adjusted from 57.0 to 63.0 Hz.
Press the buttons next to the and symbols in the
digital display to navigate between the menus. Start Delay submenu: Start Delay can be set from
Press the Home button or the Previous Main Menu 0 to 300 seconds (default = 0). (Enter 1 or more to
button to return to Main Menu 1. enable.) This function is bypassed during a manual
start/stop sequence.
Adjusting Values/Parameters: Stop Delay submenu: Stop Delay can be set from
0 to 600 seconds (default = 0). (Enter 1 or more to
1. Press the button next to the symbol in the dis- enable.) This function is bypassed during a manual
play until the + and − symbols are displayed. start/stop sequence and engine shutdown faults.
2. If necessary, press the button next to the or Rated To Idle (Beginning Version 2.303): Rated
symbols to move to the numeric character you To Idle delay can be set from 0 to 10 seconds (de-
wish to change. fault = 0). (Enter 1 or more to enable.) Entering a
non-zero delay will cause the genset to delay the
3. Press the button next to the + symbol to in- transition to Cooldown At Idle.
crease the value or select parameter; press the
button next to the − symbol to decrease the val- Idle Start submenu (Only available on some
models): Idle Start can be enabled or disabled (de-
ue or select parameter.
fault = Disable). This function is only enabled when
the genset is started in manual mode. Idle Start can
4. After adjusting values/selecting parameters,
also be enabled while the set is running in manual
pressing the symbol results in the changes mode. (Auto/remote start is not affected by this set-
being saved. (When adjusting values, make ting.)
sure the cursor is on the last numeric character
before pressing the symbol). Enabling Idle Start will cause the genset to run in
idle mode until Idle Start is disabled. A warning is
displayed if genset is left in idle more than 10 min-
If the Home button or Previous Main Menu but- utes. Long periods of engine idling can eventually
ton is pressed before pressing the symbol, affect engine performance and may void engine
the changes are not saved. warranty.
3-24
ADJUST MENU
Main Menu 1
Engine Adjust
Alternator More>>
Voltage Adjust
nnn V
+Voltage Adjust
− nnn V
Back
Frequency Adjust
nn.n Hz
+Frequency Adjust
− nn.n Hz
Back
Start Delay
nnn Sec
+Start Delay
− nnn Sec
Back
Stop Delay
nnn Sec
+Stop Delay
− nnn Sec
Back
Rated To Idle Delay

nn Sec
+Rated To Idle Delay
− nn Sec
Back
Idle Start
Disable
+Idle Start
− Enable
Back
FIGURE 3-11. ADJUST MENU
3-25
FAULTS MENU History submenu: From the Faults Main Menu,
Figure 3-13 shows a block representation of the press the button next to the word “History” in the dis-
Faults menu. Up to 20 of the most recent faults can play to view up to twenty of the most recent ac-
be viewed. An example of how a fault code is dis- knowledged faults. Press the buttons next to the
played is shown in Figure 3-12. and symbols in the digital display to navigate be-
The available menus are dependent on the number tween the menus. Press the Previous Main Menu
of faults that have occurred. button to return to the Faults Main Menu.
• If there are no faults, the symbol next to the
word “Faults” is not displayed and no Fault me-
nus are available. Current Fault submenu: From the Faults Main
Menu, press the button next to the word “Current” in
• If more than one fault has occurred, press the the display to view up to twenty of the most recent
button next to the word “Fault” in the screen dis- unacknowledged faults. Press the Previous Main
play to view the Faults Main Menu. As shown Menu button to return to the Faults Main Menu.
in the diagram, the Faults Main Menu has two
submenus. Press the Previous Main Menu but-
ton to return to the Faults Main Menu. Press the
Previous Main Menu button a second time to
return to Main Menu 2.
Press the Home button at any time to return to Main
Menu 1.
ASTERISK = FAULT HOUR FAULT

ACTIVE FAULT CODE OCCURRED
W = WARNING FAULT
S = SHUTDOWN DESCRIPTION
FIGURE 3-12. HISTORY/CURRENT FAULT SUBMENU
3-26
FAULTS MENU
Main Menu 2
Faults History
System More>>
Faults Main Menu
History
Current
nnnnn @Hr nnnnn.n nnnnn @Hr nnnnn.n

W xxxxxxxxxxxxxxxxxxxx S xxxxxxxxxxxxxxxxxxxx
Fault 1 Fault 1

S xxxxxxxxxxxxxxxxxxxx W xxxxxxxxxxxxxxxxxxxx
Fault 2 Fault 2

W xxxxxxxxxxxxxxxxxxxx W xxxxxxxxxxxxxxxxxxxx
Fault 20 Fault 20
FIGURE 3-13. FAULTS MENU
3-27
SYSTEM MENU ATS System submenus: From the System Main
Menu, press the button next to the word “ATS” in the
Figure 3-14 shows a block representation of the display to view the first of up to 16 ATS System sub-
System menu. If you press the button next to the menus. An ATS system must be available in the net-
word “System” in the display, the System Main work to display this submenu.
Menu is displayed. This menu is displayed only if
the network communications module (NCM) fea-
The ATS submenu allows viewing of the transfer
ture is installed. The System Main Menu allows you
switch name (configured with InPower), kW load (if
to view the status and load of other PCC equipment
monitored by the ATS system), status (e.g., not in
connected on a common network with the PCC
auto), and source connected and availability (ON =
2100 control.
source connected, OK = source available, or NA =
As shown in the diagram, the System Main Menu source not available).
has three submenus.
Master System submenu: From the System Main
When viewing ATS and Genset System submenus,
Menu, press the button next to the word “Master” in
press the buttons next to the and symbols in the the display to view the Master System submenu. A
digital display to navigate between the menus. master controller must be available in the network
Press the Previous Main Menu button to return to to display this submenu.
the System Main Menu. Press the Previous Main
Menu button a second time to return to Main
The master submenu allows viewing of the master
Menu 2. Press the Home button to return to Main
controller name (configured with InPower), kW load
Menu 1.
and operational state.
Genset System submenus: From the System

Main Menu, press the button next to the word “Gen-
set” in the display to view the first of up to 16 Genset
System submenus. One genset must be available
in the network to display this submenu.
The genset submenu allows viewing of the genset

name (configured with InPower), kW load and op-
erational state.
If a PCC 2100 control genset, in the network, con-

tains the Power Transfer Control (PTC) feature, a
genset system submenu will be displayed for the
genset and the ATS System submenu will be dis-
played for the PTC feature.
3-28
SYSTEM MENU
Main Menu 2
Faults History
System More>>
System Main Menu
ATS Genset
Master
ATSnameTag01>nnnnkW GensetName01>nnnnkW
Non Auto S1=On, S2=On Warning Fail2Start
ATS Menu 1 Genset Menu 1
NonAut o S1=Ok, S2=NA NonAuto Alarm
NonAuto S1=Ok, S2=NA NonAuto Alarm
Master>nnnn kW
Shutdwn N=On,E=NA
FIGURE 3-14. SYSTEM MENU
3-29
HISTORY MENU Number of Starts submenu: This submenu shows
the number of engine starts.
Figure 3-15 shows a block representation of the
History menu. If you press the button next to the Engine Hours submenu: This submenu shows
word “History” in the display, the first History subme- the number of operating hours for the engine.
nu is displayed.
Control Hours submenu: This submenu shows
As shown in the diagram, the History menu has five the number of operating hours for the control.
submenus. This information is stored in non-volatile
memory and will not be deleted due to loss of bat-
Kilowatt Hours submenu: This submenu shows
tery power. the number of kilowatt (kW) or megawatt (MW)
hours.
digital display to navigate between the menus. Genset Duty Cycle submenu: This submenu
Press the the Previous Main Menu button to return shows the percent of genset operating hours that
to Main Menu 2. Press the Home button to return to are less than 30 percent of rated load and percent of
Main Menu 1. hours that are greater than 90 percent.
3-30
HISTORY MENU
Main Menu 2
Faults History
System More>>
Number Starts
nnnnn
Engine Hours
nnnnn Hours
Control Hours
nnnnn Hours
kW Hours
nnnnn kW Hrs
Genset Duty Cycle

Hr <30:nn% >90:nn%
FIGURE 3-15. HISTORY MENU
3-31
ABOUT MENU Model submenu: This submenu shows the genset
model.
Figure 3-16 shows a block representation of the
About menu. If you press the button next to the word
“About” in the display, the first About submenu is
displayed.
Rating submenu: This submenu shows the rating
As shown in the diagram, the About menu has three (Standby or Prime and number of kilowatts (kW)).
submenus.
digital display to navigate between the menus.
Press the the Previous Main Menu button to return Software Version submenu: This submenu
to Main Menu 3. Press the Home button to return to shows the software version level. This information
Main Menu 1. is required to service the generator set.
3-32
ABOUT MENU
Main Menu 3
About Setup
Pwr Tran More>>
Model
xxxxxxxxxxxxxxx
Rating
Standby nn.n kW
Software Version
nn.nnn
FIGURE 3-16. ABOUT MENU
3-33
POWER TRANSFER MENU S1 (Source 1) submenu: This submenu shows
power transfer source voltage. The voltages Line-
to-Line (L1, L2 and L3) are measured between L1 to
Figure 3-17 shows a block representation of the L2, L2 to L3 and L3 to L1, respectively. (Single
Power Transfer menu. If you press the button next phase − L1 to L2 only.)
to the word “Pwr Tran” in the display, the first Power
Transfer submenu is displayed. The Power Trans-
fer Control (PTC) feature must be installed to dis- S1 (L-N Source) submenu: This submenu is dis-
play this submenu. played only if the control system is configured for
line−to−neutral voltage sensing of source 1. Single
phase only − L1 to N and L2 to N.
The PTC module enables the PCC to monitor the
utility voltage (mains) and frequency for failure and
control the opening and closing of the contacts (cir- Frequency submenu: This menu shows power
cuit breakers) for Source 1 (S1 utility) and Source 2 transfer source frequency.
(S2 genset).
If S1 power fails, the control will initiate the starting Source 1 submenu: This submenu shows utility
sequence (Figure 3-3), open S1 and close S2 to the status (On, Ok, or NA). “On” means Source 1 is con-
load. When S1 returns, the load is retransferred to nected and available. “Ok” means Source 1 is avail-
able but not connected. “NA” means Source 1 is not
S1 and the control initiates the genset shutdown se-
available.
quence.
As shown in the diagram, the Power Transfer menu Genset submenu: This submenu shows generator
has five submenus. status (On, Ok, or NA). “On” means the genset is
connected and available. “Ok” means the genset is
available but not connected. “NA” means the gen-
Press the buttons next to the and symbols in the set is not available.
digital display to navigate between the menus.
Press the the Previous Main Menu button to return
to Main Menu 3. Press the Home button to return to Active Transfer Timer submenu: This submenu
Main Menu 1. shows the time delay, in seconds.
3-34
POWER TRANSFER MENU
Main Menu 3
About Setup
Pwr Tran More>>
S1 L12 L23 L31

V nnn nnn nnn
S1 L1N L2N
V nnn nnn
Frequency
nn.n Hz
S1
On
Genset
On
Active Tran Timer

TD Re-Trans nnn Sec
FIGURE 3-17. POWER TRANSFER MENU
3-35
3-36
4. Troubleshooting
GENERAL Ventilate battery area before working on or near
battery—Wear goggles—Stop genset and dis-
The genset control continuously monitors engine
connect charger before disconnecting battery
sensors for abnormal conditions, such as low oil
pressure and high coolant temperature. If any of cables—Disconnect negative (−) cable first and
these conditions occur, the control will light a yellow reconnect last.
Warning lamp or a red Shutdown lamp and display a
message on the digital display. CAUTION Disconnect battery charger from AC
This section lists the warning and shutdown codes/ source before disconnecting battery cables.
messages (Table 4-1), and suggests troubleshoot- Otherwise, disconnecting cables can result in
ing procedures (Table 4-2). voltage spikes damaging to DC control circuits
of the set.
Displayed error codes that are not listed in Table 4-2
will require an authorized service representative to
correct the fault. Contact an authorized service cen- WARNING Accidental starting of the generator
ter for assistance.
set can cause severe personal injury or death.
SAFETY CONSIDERATIONS Prevent accidental starting by disconnecting
the negative (−) cable from the battery terminal.
WARNING Contacting high voltage compo-
nents can cause electrocution, resulting in se-
vere personal injury or death. Keep the output When troubleshooting a set that is shut down, make
box covers in place during troubleshooting. certain the generator set cannot be accidentally re-
started as follows:
High voltages are present when the set is running.
Do not open the generator output box while the set
is running. 1. Move the O/Manual/Auto switch on the control
WARNING Ignition of explosive battery gases panel to the O (off) position.
can cause severe personal injury or death. Arc-
ing at battery terminals, light switch or other
equipment, flame, pilot lights and sparks can ig- 2. Turn off or remove AC power from the battery
nite battery gas. Do not smoke, or switch charger.
trouble light ON or OFF near battery. Discharge
static electricity from body before touching bat-
teries by first touching a grounded metal sur- 3. Remove the negative (−) battery cable from the
face. generator set starting battery.
4-1
STATUS INDICATORS generator set.) In auto mode, warning indicators
can also be reset by cycling the remote reset input
Running Indicator: This green lamp is lit whenever after the condition is corrected.
the generator (local or remote) is running (Figure
4-1). Some warnings remain active after the condition is
corrected and the control reset button is pressed.
Remote Start Indicator: This green lamp is lit This will require the genset to be shutdown to reset
whenever the control is receiving a remote run sig- the warning indicator.
nal.
Digital Display: This two-line, 20-characters per
Not in Auto Indicator: This red lamp flashes con-
line alphanumeric display is used to view menus of
tinuously when the O/Manual/Auto switch is not in
the menu-driven operating system and to show
the Auto position. (if in Auto position and the lamp is
warning and shutdown messages.
flashing, service is required.)
Configurable Indicators: Defaults for the confi- LINE CIRCUIT BREAKER (OPTIONAL)
gurable indicators shown in Figure 4-1 can be
The optional line circuit breaker mounts on the gen-
changed with the InPower service tool.
erator output box. If the load exceeds the generator
Shutdown Status Indicator: This red lamp is lit current rating, the line circuit breaker will open, pre-
whenever the control detects a shutdown condition. venting the generator from being overloaded. If the
The generator set cannot be started when this lamp circuit breaker trips, locate the source of the over-
is on. After the condition is corrected, shutdown in- load and correct as necessary. Manually reset the
dicators can be reset by turning the O/Manual/Auto breaker to reconnect the load to the generator.
switch to the O position and pressing the Fault Ac-
knowledge/Reset button. CONTROL AND DIAGNOSTICS VIA
NETWORK OR PC (LAPTOP)
Warning Status Indicator: This yellow lamp is lit
whenever the control detects a warning condition. See your authorized Cummins Power Generation
After the condition is corrected, warning indicators dealer regarding software, hardware and network
can be reset by pressing the Fault Acknowledge/ requirements for control and diagnostics via net-
Reset button. (It may not be necessary to stop the work or PC.
4-2
MENU SHUTDOWN
SELECTION AND WARNING
BUTTON PREVIOUS
STATUS
(1 of 4) MAIN MENU
INDICATORS RUNNING/REMOTE
PANEL BUTTON
START/NOT IN AUTO
HOME LAMP
EMERGENCY INDICATORS
BUTTON (1 of 3)
DIGITAL STOP PUSH
DISPLAY BUTTON CONFIGURABLE
(Pull to reset) INDICATORS
ANALOG AC OFF/MANUAL/
METERING AUTO SWITCH
PANEL
FAULT
ACKNOWLEDGEMENT/ MANUAL
RESET BUTTON RUN/STOP
BUTTON
PANEL LAMP
AND LAMP
TEST BUTTON
FIGURE 4-1. FRONT PANEL (FULL FEATURED)
4-3
FAULT CODES Category C Fault Codes: Consist of faults that do
not affect generator set performance but require
The fault codes have been divided into five catego- qualified service personnel to repair. These codes
ries to help you determine what corrective action to indicate a defective harness or wiring problem.
take for safe operation of the generator set. Use
Table 4-1 to find the category (CTG) and fault de- These codes can also indicate a defective engine
scription for all codes. Gaps in the code numbers sensor, leaving no engine protection. (Engine dam-
are for codes that do not apply to this genset. age can occur without detection.) Continued op-
eration may void generator set warranty if dam-
Category A Fault Codes: Pertain to engine or al- age occurs that relates to fault condition.
ternator shutdown faults that require immediate re-
pair by qualified service personnel (generator set Category D Fault Codes: Consist of faults that are
non-operational). Control prevents the generator repairable by site personnel. Service will be re-
set from being restarted. quired by qualified service personnel if site person-
nel cannot resolve the problem after taking the cor-
Category B Fault Codes: Consist of faults that can rective actions suggested in Table 4-2.
affect genset performance or cause engine, alter-
nator, or connected equipment damage. Oper- Category E Fault Codes: Indicates non-critical op-
ate only when generator set is powering critical erational status of generator set, external faults, or
loads and cannot be shut down. Requires repair by customer fault inputs. May require repair by quali-
qualified service personnel. fied service personnel.
TABLE 4-1. FAULT CODES
CTG CODE LAMP FAULT DESCRIPTION CTG CODE LAMP FAULT DESCRIPTION
A 111 Shtdn Internal ECM error A 214 Shtdn High oil temperature
C 122 Wrng Manifold air press sensor H D 219 Wrng Oil tank level low
C 123 Wrng Manifold air press sensor L C 221 Wrng Air pressure sensor H
C 135 Wrng Oil pressure sensor H C 222 Wrng Air pressure sensor L
C 141 Wrng Oil pressure sensor L C 223 Wrng Cors val driver shorted L
B 143 Wrng Low oil pressure
C 227 Wrng Sensor supply 2 H
C 144 Wrng Coolant temp sensor H
A 234 Shtdn Overspeed
C 145 Wrng Coolant temp sensor L
D 235 Shtdn Coolant level alarm
D 146 Wrng High coolant temp warning
A 236 Shtdn Position sensor
C 151 Shtdn High coolant temp alarm
A 254 Shtdn Fuel shutoff valve
D 152 Wrng Low coolant temp
C 255 Wrng High FSO voltage
C 153 Wrng Manifold air temp sensor H
C 154 Wrng Manifold air temp sensor L C 259 Wrng Fuel shutoff valve
A 155 Shtdn Manifold air temp alarm C 284 Wrng Crankshaft sensor supply L
C 187 Wrng Sensor supply 2 L C 295 Wrng Air pressure sensor error
D 197 Wrng Coolant level warning C 341 Wrng ECM data lost
C 212 Wrng Oil temperature sensor H B 343 Wrng Internal ECM error
C 213 Wrng Oil temperature sensor L C 352 Wrng Sensor supply 1 L
4-4
TABLE 4-1. FAULT CODES (CONT.)
A 378 Shtdn Frt fueling act undercurrent E 1124 Wrng Delayed Shutdown
A 379 Shtdn Frt fueling act overcurrent E 1131 Wrng Battle Sh Active
C 386 Wrng Sensor supply 1 H B 1244 Shtdn CAN - Eng normal shtdn
A 394 Shtdn Frt timing act undercurrent B 1245 Shtdn CAN - Engine shutdown
A 395 Shtdn Frt timing act overcurrent C 1246 Wrng CAN - Unknown eng fault
A 396 Shtdn R fueling act undercurrent B 1247 Shtdn CAN - Eng unannounced flt
A 397 Shtdn R fueling act overcurrent C 1248 Wrng CAN - Engine warning cond
A 398 Shtdn R timing act undercurrent E 1311 Shtdn/ Customer Input #1
A 399 Shtdn R timing act overcurrent Wrng/
None
B 415 Shtdn Low oil pressure alarm
E 1312 Shtdn/ Customer Input #2
B 419 Wrng Intake mfld pres imbalance
Wrng/
B 421 Wrng High oil temperature None
C 422 Wrng Coolant level sen data error E 1313− Shtdn/ Network Fault 1 thru 4
C 426 None CAN datalink error 1316 Wrng/
None
C 427 Wrng CAN datalink lost messages
E 1317 Shtdn/ Customer Input #3
C 433 Wrng Intake mfld data error Wrng/
B 434 Wrng Power lost with ignition None
C 435 Wrng Oil pressure data error E 1318 Shtdn/ Customer Input #4
Wrng/
B 449 Wrng High fuel supply pressure None
B 482 Wrng High fuel supply pressure A 1334 Shtdn Crit Scaler OR
B 488 Wrng High intake manifold temp B 1335 Wrng Noncrit Scaler OR
C 496 Wrng Camshaft speed sensor
E 1337 None No Message
supply voltage problem
C 1416 Wrng Fail To Shutdown
B 546 Wrng Fuel pressure sensor H
D 1417 Wrng Powr Down Error
B 547 Wrng Fuel pressure sensor L
B 689 Wrng Crankshaft sensor error D 1433 Shtdn Emergency Stop
C 697 Wrng ECM internal temp sen H D 1434 Shtdn Remote E-Stop
C 698 Wrng ECM internal temp sen L D 1435 Wrng Low Coolant Temp
B 731 Wrng Cam/Crank misalignment D 1438 Shtdn Fail To Crank
B 778 Wrng Camshaft sensor D 1442 Wrng Weak Battery
A 781 Shtdn CAN datalink failed D 1443 Shtdn Battery Failed
A 782 Shtdn CAN - no data received B 1444 Wrng KW Overload
E 1122 None Rated/Idle Trans A 1445 Shtdn Short Circuit
A 1123 Shtdn Shutdown After BS A 1446 Shtdn High AC Voltage
4-5
TABLE 4-1. FAULT CODES (CONT.)
A 1447 Shtdn Low AC Voltage E 2331 Wrng Low S1 Voltage
A 1448 Shtdn Under Frequency A 2335 Shtdn Excitation Fault
A 1449 Wrng Over Frequency A 2336 Shtdn Memory Error
A 1452 Wrng Gen CB Not Close C 2337 Wrng Pwr Tran Disabled
A 1453 Wrng Gen CB Not Open C 2338 Wrng Pwr Tran Failure
A 1459 Shtdn Reverse Power E 2339 Wrng Pwr Down Enabled
A 1461 Shtdn Loss Of Field B 2341 Wrng High Control Temp
C 1466 Wrng Modem Failure E 2342 Wrng Too Long In Idle (10 min.)
C 1468 Wrng Network Error E 2358 Wrng High S1 Voltage
A 1469 Shtdn Speed/Hz Match E 2396 Wrng S1 CB Not Close
B 1471 Wrng Over Current E 2397 Wrng S1 CB Not Open
A 1472 Shtdn Over Current C 2966 Wrng PTC Timeout
E 2323− Shtdn/ Network Fault 5 thru 8 C 2967 Wrng Governor Fault
2326 Wrng/
None C 2968 Wrng AVR Fault
B 2327 Wrng PTC Fault C 2969 Wrng LON Failure
E 2329 Wrng Low S1 Frequency A 2972 Shtdn Field Overload
4-6
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform service procedures. Read Safety Precautions page
and observe all instructions and precautions in this manual.
TABLE 4-2. WARNING AND SHUTDOWN CODES
FAULT CODE CORRECTIVE ACTION
143 Indicates engine oil pressure has dropped to an unacceptable level. If generator is
PRE-LOW OIL PRES powering critical loads and cannot be shut down, wait until next shutdown period
Lamp: Warning and then follow code 415 procedure.
146 Indicates engine has begun to overheat (coolant temperature has risen to an un-
PRE-HIGH COOL TMP acceptable level. If generator is powering non-critical and critical loads and cannot
Lamp: Warning be shut down, use the following:
a. Reduce load if possible by turning off non-critical loads.
b. Check air inlets and outlets and remove any obstructions to airflow.
If engine can be stopped, follow code 151 procedure.
151 Indicates engine has overheated (coolant temperature has risen above the shut-
HIGH COOLANT TEMP down trip point). Allow engine to cool down completely before proceeding with the
Lamp: Shutdown following checks:
a. Check coolant level and replenish if low. Look for possible coolant leakage
points and repair if necessary.
b. Check for obstructions to cooling airflow and correct as necessary.
c. Check fan belt and repair or tighten if necessary.
d. Check blower fan and circulation pumps on remote radiator installations.
e. Reset control and restart after locating and correcting problem.
197 Indicates engine coolant level has fallen below the warning trip point. If generator
LOW COOLANT LEVEL is powering critical loads and cannot be shut down, wait until next shutdown peri-
Lamp: Warning od, then follow code 235 procedure. If engine can be stopped, follow code 235
(Optional) procedure.
235 Indicates engine coolant level has fallen below the shutdown trip point. Allow en-
LOW COOLANT LEVEL gine to cool down completely before proceeding.
Lamp: Shutdown a. Check coolant level and replenish if low. Look for possible coolant leakage
(Optional) points and repair if necessary.
b. Reset control and restart after locating and correcting problem.
359 Indicates possible fuel system problem. (Engine cranks but fails to start)
FAIL TO START a. Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as re-
Lamp: Shutdown quired.
b. Check for dirty fuel filter and replace if necessary.
c. Check for dirty or plugged air filter and replace if necessary.
d. Reset the control and restart after correcting the problem.
415 Indicates engine oil pressure has dropped below the shutdown trip point. Check
LOW OIL PRESSURE oil level, lines and filters. If oil system is OK but oil level is low, replenish. Reset
Lamp: Shutdown control and restart.
4-7
TABLE 4-2. WARNING AND SHUTDOWN CODES (CONT.)
421 Indicates engine has begun to overheat (oil temperature has risen to an unac-
OIL TEMP ceptable level). If generator is powering non-critical and critical loads and cannot
Lamp; Warning be shut down, use the following:
(Optional)
a. Reduce load if possible by turning off non-critical loads.
b. Check air inlets and outlets and remove any obstructions to airflow.
If engine can be stopped, follow code 151 procedure and also check engine oil
level.
441 Indicates battery voltage supply to the control is approaching a low level at which
LOW BAT VOLTAGE unpredictable operation will occur.
Lamp: Warning a. Discharged or defective battery.
Check the battery charger fuse.
Recharge or replace the battery.
b. Poor battery cable connections. Clean the battery cable terminals and tighten all
connections.
c. Check battery charge voltage float level if applicable (raise float level).
442 Indicates battery voltage supply to the control is approaching a high level at which
HIGH BAT VOLTAGE damage to the control can occur. Check float level on battery charger if applicable
Lamp: Warning (lower float level).
1311, 1312, 1317, 1318 The nature of the fault is an optional customer selection. Example inputs: Low
CUSTOMER INPUT #1 − #4 Fuel Day Tank, Water In Fuel, Ground Fault, Low Starting Hydraulic Pressure,
Lamp: Warning/Shutdown or Low Starting Air Pressure, etc.
none for status message. Each of the fault functions can be programmed (using service tool), as follows:
• Enable/disable input (Default: enable)
• Status, Warning or Shutdown (Default: #1−None, #2 thru #4−Warning)
• Active closed or open (Default: closed [ground])
• Change display name using up to 19 characters (Default: #1− Customer Fault 1,
#2−Ground Fault, #3−Low Fuel, #4−Rupture Basin Fault)
1417 Indicates that the controller can not power down because of some unknown condi-
POWER DOWN ERROR tion. Possible drain on battery. Contact an authorized service center for service.
Lamp: Warning
1433 Indicates local Emergency Stop. To reset the local/remote Emergency Stop button:
EMERGENCY STOP
Lamp: Shutdown 4. Pull the button out.
5. Move the O/Manual/Auto switch to O.
6. Press the front panel Fault Acknowledge/Reset button.
7. Select Manual or Auto, as required.
4-8
TABLE 4-2. WARNING AND SHUTDOWN CODES (CONT.)
1434 Indicates remote Emergency Stop. See code 1433 to reset.

REMOTE E-STOP
Lamp: Shutdown
1435 Indicates engine coolant heater is not operating or is not circulating coolant.
LOW COOLANT TEMP Check for the following conditions:
Lamp: Warning a. Coolant heater not connected to power supply. Check for blown fuse or discon-
Set is not operating. Warning nected heater cord and correct as required.
occurs when engine coolant b. Check for low coolant level and replenish if required. Look for possible coolant
temperature is 70° F (21° C) leakage points and repair as required.
or lower. NOTE: In applica-
tions where the ambient
temperature falls below 40
F (4 C), Low Coolant Temp
may be indicated even
though the coolant heaters
are operating.
1438 Indicates possible fault with control, speed sensing or starting system. See code
FAIL TO CRANK 441 for corrective action.
Lamp: Shutdown
1442 Indicates that during cranking, the battery voltage is at or below the weak battery
WEAK BATTERY warning trip point for a time greater than or equal to the weak battery set time. See
Lamp: Warning code 441 for corrective action.
1443 Dead battery − engine will not start. See code 441 for corrective action.
BATTERY FAILED
Lamp: Shutdown
2342 Indicates genset has been in Idle mode too long (10 minutes maximum).
TOO LONG IN IDLE
Lamp: Warning
4-9
4-10
5. Maintenance
GENERAL • Exposure to salt water
• Exposure to dust, sand or other airborne con-
Establish and adhere to a definite schedule for
taminates
maintenance and service based on the application
and severity of the environment. The table below Consult with an authorized distributor if the genera-
covers the recommended service intervals for a tor set will be subjected to any extreme operating
generator set on STANDBY service. If the set will be conditions and determine a suitable schedule of
subjected to extreme operating conditions, the ser- maintenance. Use the running time meter to keep
vice intervals should be reduced accordingly. Some an accurate log of all service performed for warranty
of the factors that can affect the maintenance support. Perform all service at the time period indi-
schedule are the following: cated or after the number of operating hours indi-
cated, whichever comes first. Use Table 5-1 to de-
• Use for continuous duty (prime power) termine the maintenance required and then refer to
the sections that follow for the correct service pro-
• Extremes in ambient temperature
cedures. Also refer to Cummins QSX15 Series En-
• Exposure to weather gines Operation and Maintenance Manual.
5-1
TABLE 5-1. PERIODIC MAINTENANCE SCHEDULE
SERVICE TIME
Monthly 6 Months
MAINTENANCE ITEMS See Daily
or after or after
Engine or after 1 Year
100 250
Schedule 8 Hours
Hours Hours
General set inspection X1 X2
Check engine oil level X
Check coolant level X
Check coolant heater(s) X
Check battery charging system X
Check all hardware (fittings, clamps, fasteners, etc.) X
Check battery electrolyte level X
Check generator air outlet X
Check radiator hoses for wear and cracks X
Test rupture basin leak detect switch X3
Check drive belt X1
Check air cleaner (replace as necessary) X1
Drain fuel filter(s) X1
Check anti-freeze and DCA concentration X1
Change engine oil and filter X1
Change water coolant filter X1
Clean crankcase breather X1
Change fuel filter X1
Clean cooling systems X1
X1 - Refer to Cummins QSX15 Series Engine Operation and Maintenance Manual for maintenance interval and/or procedure.
X2 - Check for oil, fuel, cooling and exhaust system leaks. Check exhaust system audibly and visually with set running and repair
any leaks immediately.
X3 - Check leak detect switch in sub-base fuel tank of optional enclosure, once a year or as required by safety code. Contact your
authorized service center.
5-2
GENERATOR SET INSPECTION Frequency/RPM (Alternator/Engine Menu): The
generator frequency should be stable and the read-
During operation, be alert for mechanical problems ing should be the same as the genset nameplate
that could create unsafe or hazardous conditions. rating (50 or 60 Hz/1500 or 1800 RPM).
The following sections cover several areas that
should be frequently inspected for continued safe AC Voltmeter (Alternator Menu): At no load, the
operation. line-to-line or line-to-neutral voltage(s) should be
the same as the genset nameplate rating.
Exhaust System AC Ammeter (Alternator Menu): At no load the
With the generator set operating, inspect the entire current ratings should be zero. With a load applied,
exhaust system visually and audibly including the each line current should be about the same.
exhaust manifold, muffler and exhaust pipe. Check
Panel Lamp/Lamp Test Button: Press and hold
for leaks at all connections, welds, gaskets and
this button to test all front panel LEDs and meters.
joints and also make sure that exhaust pipes are not
The meters will light one bar at a time. Make sure
heating surrounding areas excessively. If any leaks
that all LEDs and meters are OK and then release
are detected, shut down the genset and have leaks
the button.
corrected immediately.
DC Electrical System
WARNING Inhalation of exhaust gases can re-
sult in severe personal injury or death. Be sure Check the terminals on the batteries for clean and
deadly exhaust gas is piped outside and away tight connections. Loose or corroded connections
from any windows, doors, vents or other inlets create resistance which can hinder starting. Refer
to building and not allowed to accumulate in in- to BATTERIES later in this section for cleaning and
habitable areas. safety precautions.
Engine
Fuel System
Monitor fluid levels and oil pressure and coolant
With the generator set operating, inspect the fuel
temperatures frequently. Most engine problems
supply lines, return lines, filters, and fittings for
give an early warning. Look and listen for changes
leaks. Check any flexible sections for cuts, cracks
in engine performance, sound, or appearance that
and abrasions and make sure they are not rubbing
can indicate service or repair is needed. Some en-
against anything that could cause breakage. If any
gine changes to look for are as follows:
leaks are detected, have them corrected immedi-
ately. • Misfire
• Vibration
WARNING Ignition of fuel can cause severe • Unusual noises
personal injury or death by fire or explosion. Do • Sudden changes in engine operating tempera-
not permit any flame, cigarette, arcing switch or tures or pressures
equipment, pilot light, or other igniter near the • Excessive exhaust smoke
fuel system or in areas sharing ventilation. • Loss of power
• An increase in oil consumption
AC Electric System • An increase in fuel consumption
Check the following while the genset is operating. • Fuel, oil, or coolant leaks.
5-3
GENERATOR SET MAINTENANCE WARNING Accidental starting of the generator
(Battery Disconnected) set can cause severe personal injury or death.
Prevent accidental starting by disconnecting
WARNING Ignition of explosive battery gases
the negative (−) cable from the battery terminal
can cause severe personal injury or death. Arc- before beginning maintenance procedures.
ing at battery terminals, light switch or other
equipment, flame, pilot lights and sparks can ig- When performing the following maintenance proce-
nite battery gas. Do not smoke, or switch dures, make certain the generator set cannot be ac-
trouble light ON or OFF near battery. Discharge cidentally restarted as follows:
static electricity from body before touching bat-
teries by first touching a grounded metal sur- 1. Move the O/Manual/Auto switch on the control
face. panel to the O (off) position.
Ventilate battery area before working on or near 2. Turn off or remove AC power from the battery
battery—Wear goggles—Stop genset and dis- charger.
connect charger before disconnecting battery
3. Remove the negative (−) battery cable from the
cables—Disconnect negative (−) cable first and
generator set starting battery.
reconnect last.
CAUTION Disconnect battery charger from AC Mechanical Inspection
source before disconnecting battery cables. With the generator set stopped, check for loose
Otherwise, disconnecting cables can result in belts and fittings, leaking gaskets and hoses, or any
voltage spikes damaging to DC control circuits signs of mechanical damage. If any problems are
of the set. found, have them corrected immediately.
5-4
LUBRICATION SYSTEM WARNING Crankcase pressure can blow out
hot oil and cause severe burns. Do NOT check
Gensets are shipped filled with the correct type and oil while the generator set is operating.
quantity of oil. Be sure to check oil level before initial
start. Keep the oil level as near as possible to the high
mark on the dipstick but never above it. Remove
the oil fill cap and add oil of the same API viscos-
Oil API Classification ity and brand when necessary. Install the oil fill
cap after adding oil.
Refer to the Cummins QSX15 Series Engines Op-
eration and Maintenance Manual for lubricating oil CAUTION Do not operate the engine with the
classification. oil level below the low mark or above the high
mark. Overfilling can cause foaming or aeration
Oil Viscosity of the oil while operation below the low mark
may cause loss of oil pressure.
Refer to the Cummins QSX15 Series Engines Op- Oil and Filter Change
eration and Maintenance Manual for lubricating oil
recommendations/specifications. Refer to the Cummins QSX15 Series Engines Op-
eration and Maintenance Manual for maintenance
Engine Oil Level interval and procedure.
WARNING State or federal agencies have de-
Check the engine oil level during engine shutdown termined that contact with used engine oil can
periods at the intervals specified in the Mainte- cause cancer or reproductive toxicity. Do not
nance Table. The dipstick (Figure 5-1) is stamped contact oil or breath vapors. Use rubber gloves
with high and low marks to indicate the level of oil in and wash exposed skin.
the crankcase. For accurate readings, shut off the
engine and wait approximately 15 minutes before Used oil and filters must be disposed of proper-
checking the oil level. This allows oil in the upper ly to avoid environmental damage and clean-up
portion of the engine to drain back into the crank- liability. Check all federal, state and local regu-
case. lations for disposal requirements.
5-5
FUEL SYSTEM engine is used. In cold weather, warm fuel returning
from the injectors heats the fuel in the supply tank. If
Refer to the Cummins QSX15 Series Engines Op-
the fuel level is low, the upper portion of the tank
eration and Maintenance Manual for fuel recom-
mendations and fuel system maintenance, such as, tends to form condensation. In warm weather, both
draining of the fuel-water separator and fuel filter re- the fuel and the tank will be warm during the day-
placement interval and procedure. time. At night, cool air tends to lower the tempera-
ture of the tank more rapidly than the temperature of
Fuel Handling Precautions the fuel. If the fuel level is low, the upper portion of
WARNING Ignition of fuel can cause serious the tank will cool more rapidly and tend to form con-
personal injury or death by fire or explosion. Do densation.
not permit any flame, cigarette, arc, spark, pilot
light, or other igniter near the fuel system. Condensation (water) can cause clogging of fuel fil-
To avoid condensation problems, keep fuel supply ters with the sulphur in the fuel forms acid which can
tanks as full as possible by filling up each time the corrode and damage engine parts.
OIL FILL
CAP
OIL LEVEL
DIPSTICK
FUEL
FILTER
FUEL-WATER
SEPARATOR
VALVE
OIL DRAIN
HOSE OIL DRAIN FLEX FUEL
VALVE LINE
FIGURE 5-1. LUBRICATION AND FUEL COMPONENTS
5-6
COOLANT SYSTEM Coolant Level
Check the coolant level during shutdown periods at
CAUTION The heater must not be operated the intervals specified in the Maintenance Table. A
while the cooling system is empty or when the sight glass is provided on the radiator of the engine
engine is running or damage to the heater will water cooling system (Figure 5-2).
occur.
The coolant level should be approximately in the
CAUTION Remove AC power to the heater be- middle of the sight glass, with the coolant tempera-
fore disconnecting battery cables. Heater will ture at 120° F (50° C) or lower. Refer to the Cum-
run continuously without DC power and can mins Cummins QSX15 Series Engines Operation
overheat and damage heater. and Maintenance Manual for coolant recommenda-
tions/specifications.
CAUTION Do not add cold coolant to a hot en- WARNING Contact with hot coolant can result
gine. Engine castings can be damaged. Allow in serious burns. Allow cooling system to cool
the engine to cool to below 120° F (50° C) before before releasing pressure and removing jacket
adding coolant. water radiator cap or LTA expansion tank cap.
RADIATOR
CAP
COOLANT SIGHT
GLASS
FIGURE 5-2. COOLING SYSTEM SIGHT GLASS/FILL LOCATIONS
5-7
Cooling System Maintenance If engine coolant heater(s) is installed in the water
cooling system, disconnect heater(s) from power
Refer to the Cummins QSX15 Series Engines Op- source before performing cooling system mainte-
eration and Maintenance Manual for all cooling sys- nance.
tem maintenance, such as, coolant requirements,
filling of the engine cooling system, coolant filter re- CAUTION The heater element will burn out if
placement and flushing and cleaning. engine coolant is removed with heater con-
An on/off valve is provided to prevent coolant leak- nected to power source.
age while changing the coolant filter. With the valve
CAUTION The heater element will burn out if
in the ON position, the coolant flows through the fil-
ter. In the OFF position, the coolant does not flow power is connected before it is filled with cool-
through the filter. ant or if undiluted antifreeze solution is used for
coolant. Before connecting power, fill the en-
Make sure coolant shut off valve is in the ON posi- gine with coolant and run it for a while to circu-
tion before operating the generator set. late coolant through the heater.
OIL
FILTER
ON COOLANT
FILTER
OFF
COOLANT FILTER
SHUTOFF VALVE
FIGURE 5-3. COOLANT AND LUBRICATION COMPONENTS
5-8
Coolant Heater
OUTLET
Check the operation of the coolant heater by verify-
ing that hot coolant is being discharged from the
outlet hose (see Figure 5-4). Do not touch outlet
hose − if heater is operational, radiant heat should
be felt with hand held close to outlet hose.
WARNING Contact with cooling system or en-

gine can result in serious burns. Do not touch
cooling system or engine during genset mainte-
nance until they are cool.
Heat Exchanger Plugs

INLET PETCOCK
DRAIN
Check the zinc plugs in the heat exchanger and re-
place if they are eroded to less than half their origi-
nal length. The frequency of replacement is depen- FIGURE 5-4. COOLANT HEATER
dent on the chemical reaction that occurs when the
plugs are in contact with the raw water.
5-9
BATTERIES Keep the batteries clean by wiping them with a
damp cloth whenever dirt appears excessive.
WARNING Ignition of explosive battery gases
can cause severe personal injury or death. Arc- If corrosion is present around the terminal connec-
ing at battery terminals, light switch or other tions, remove battery cables and wash the termi-
equipment, flame, pilot lights and sparks can ig- nals with a solution consisting of 1/4 pound of bak-
nite battery gas. Do not smoke, or switch ing soda added to 1 quart of water. (This solution is
trouble light ON or OFF near battery. Discharge also used for washing down spilled electrolyte.)
static electricity from body before touching bat- Be sure the vent plugs are tight to prevent cleaning
teries by first touching a grounded metal sur- solution from entering the cells.
face.
After cleaning, flush the outside of the battery and
Ventilate battery area before working on or near surrounding areas with clean water.
battery—Wear goggles—Stop genset and dis-
connect charger before disconnecting battery Keep the battery terminals clean and tight. After
cables—Disconnect negative (−) cable first and making connections, coat the terminals with a light
reconnect last. application of petroleum jelly or non-conductive
grease to retard corrosion.
CAUTION Disconnect battery charger from AC
source before disconnecting battery cables. Checking Specific Gravity
Otherwise, disconnecting cables can result in Use a battery hydrometer to check the specific
voltage spikes damaging to DC control circuits gravity of the electrolyte in each battery cell.
of the set.
Hold the hydrometer vertical and take the reading.
Check the condition of the starting batteries at the Correct the reading by adding four gravity points
interval specified in the Maintenance Table. To pre- (0.004) for every ten degrees the electrolyte tem-
vent dangerous arcing, always disconnect the neg- perature is above 80° F (27° C). A fully charged bat-
ative ground cable from the battery before working tery will have a corrected specific gravity of 1.260.
on any part of the electrical system or the engine. Charge the battery if the reading is below 1.215.
Disregard the sections On Checking Specific Gravi-
ty and Checking Electrolyte Level if using a “mainte- Checking Electrolyte Level
nance-free” battery. CAUTION Do not add water in freezing weather
unless the engine will run long enough (two to
Cleaning Batteries three hours) to assure a thorough mixing of wa-
WARNING Electrolyte is a dilute sulfuric acid ter and electrolyte.
that is harmful to the skin and eyes. Do not get Check the level of the electrolyte (acid and water
the substance in your eyes or contact with skin. solution) in the batteries at least every 200 hours of
Wear goggles and protective, rubber gloves operation.
and apron when servicing batteries.
Fill the battery cells to the bottom of the filler neck. If
In case of contact, immediately wash skin with cells are low on water, add distilled water and re-
soap and water. In case of contact, immediately charge. If one cell is low, check case for leaks. Keep
flood eyes with large amounts of water for a the battery case clean and dry. An accumulation of
minimum of 15 minutes. IMMEDIATELY CALL A moisture will lead to a more rapid discharge and
PHYSICIAN. battery failure.
5-10
Battery Replacement NiCad Batteries
Always replace the starting battery with the same
number and type (vented, lead acid). Properly dis- NiCad (nickel-cadmium) battery systems are often
pose of battery in accordance with local environ- specified where extreme high or low ambient tem-
mental agency requirements. perature is expected because their performance is
less affected by temperature extremes than that of
WARNING Electrolyte or explosion of battery lead-acid batteries.
can cause severe personal injury or death. Do
not mutilate or burn the battery in a fire for dis-
posal. NiCad batteries require special battery chargers in
order to bring them to the full-charge level. These
Damage to case will release electrolyte which is chargers must be provided with filter to reduce
harmful to the skin and eyes and is also toxic. “charge ripple” which can disrupt engine and gener-
Burning of battery may cause an explosion. ator control systems.
5-11
5-12
6. Operating Recommendations
NO-LOAD OPERATION Exercise the generator set at least once a month for
a minimum of 30 minutes, under not less than 30
Periods of no load operation should be held to a percent of the nameplate rating.
minimum. If it is necessary to keep the engine run-
ning for long periods of time when no electric output
is required, best engine performance will be ob- LOW OPERATING TEMPERATURE
tained by connecting a load bank of at least 30 per-
cent of nameplate rating. Use a coolant heater if a separate source of power
is available. The optional heater will help provide re-
EXERCISE PERIOD liable starting under adverse weather conditions.
Generator sets on continuous standby must be able Be sure the voltage of the separate power source is
to go from a cold start to being fully operational in a correct for the heater element rating.
matter of seconds. This can impose a severe bur-
den on engine parts. HIGH OPERATING TEMPERATURE
Regular exercising keeps engine parts lubricated,
prevents oxidation of electrical contacts and in gen- Refer to the genset nameplate for the maximum
eral helps provide reliable engine starting. ambient operating temperature, if applicable.
6-1
6-2
7. Optional Enclosure Features
GENERAL EXTERNAL RECEPTACLE
This section describes the function and operation of This receptacle is located on the outside of the en-
the optional enclosure features. Figure 7-1 shows closure (Figure 7-1) and provides shore power at
the location of the optional features within the enclo- 20A, 120 VAC. With the AC distribution panel pro-
sure. vided, this receptacle is GFCI protected. If power to
the external receptacle is lost, reset the GFCI re-
ceptacle that is mounted to the side of the AC dis-
tribution panel (Figure 7-4).
OVERFILL FUEL FUEL SYSTEM

ALARM FILL CONTROL
FUEL ALARM EMERGENCY

PANEL STOP SWITCH
EXTERNAL
FUEL FILL BOX
120 VAC
MOTORIZED EXTERNAL
INLET LOUVER RECEPTACLE
AC DISTRIBUTION
PANEL
FIGURE 7-1. OPTIONAL ENCLOSURE FEATURES (WEATHER ENCLOSURE SHOWN)
7-1
OVERFILL ALARM
ALARM
The overfill alarm indicates that the fuel has HORN
reached an abnormally high level (alarm sounds at
approximately 90% of fuel tank capacity). Immedi-
ately stop adding fuel. The horn can be turned off by
pressing the reset button (Figure 7-2).
Note: The automatic shutoff of a fuel truck nozzle is

approximately 95% of fuel tank capacity.
ALARM
RESET
BUTTON
FIGURE 7-2. OVERFILL ALARM PANEL
EXTERNAL EMERGENCY STOP SWITCH

EMERGENCY
Push this button in for emergency shutdown of the STOP SWITCH
generator set. This will stop the generator set imme-
diately and prevent starting of the set from any loca-
tion (local or remote).
Emergency Stop shutdown can be reset only at the

generator set control panel.
To reset:
1. Pull the button (external) and allow it to pop out.
2. Turn the O/Manual/Auto switch to O (Off).
3. Press the front panel Fault Acknowledge/Re-

set button.
FIGURE 7-3. EXTERNAL EMERGENCY STOP
4. Select Manual or Auto, as required. SWITCH
7-2
AC DISTRIBUTION PANEL RECEPTACLES (J1−J4): For internal use only (not
The AC distribution panel provides a centralized GFCI protected). 120VAC/20A outlets for optional
power source (120 VAC) for all optional enclosure enclosure features.
features. Figure 7-4 shows the locations of the cir- WARNING Electrical shock can cause severe
cuit breakers and optional feature connection personal injury or death. Receptacles J1
points. through J4 are not GFCI protected and must not
GFCI RECEPTACLE: 120VAC/20A ground fault be used by service personnel as a power source
protected outlet. For use by service personnel. for tools/lighting.
(GFCI receptacle also supplies power to external
receptacle.)
2
1/3
4
GFCI SERVICE
6 RECEPTACLE
5/7
8
CIRCUIT BREAKERS
1/3: 100A MAIN COOLANT HEATER
2: 20A J1/J2 RECEPTACLES CONTROL AC SUPPLY
4: 20A J3/J4 RECEPTACLES
5/7: 40A COOLANT HEATERS
6: 20A INLET/OUTLET LOUVERS
8: 20A INTERNAL/EXTERNAL J1 J2 J3 J4
SERVICE RECEPTACLES
120VAC RECEPTACLES
FOR OPTIONAL FEATURES
J1: ENGINE OIL HEATER 24 VAC
J2: BATTERY HEATER TRANSFORMERS
J3: ALTERNATOR/CONTROL (LOUVER MOTORS)
CABINET HEATERS
J4: BATTERY CHARGER/TRANS-
FER PUMP CONTROLLER
FIGURE 7-4. AC DISTRIBUTION PANEL FEATURES
7-3
FUEL TRANSFER PUMP the control switches and indicators.
The fuel transfer pump and control are available as

an option when a sub-base fuel tank is provided. Indicators:
The automatic control operates the fuel pump to
• FUEL LEVEL (green): indicates in percent the
maintain a reservoir of fuel in the sub-base tank.
amount of fuel that is contained in the sub-base
This section explains functions of the control panel tank.
lamps, components and operation of the day tank • HIGH FUEL (red): indicates that the fuel has
fuel control system. All red color lamps indicate a reached an abnormally high level (approxi-
fault condition. mately (90%). It indicates a possible failure of
Control Panel Switches and Indicators the ”pump-off” float gauge in the sub-base
tank. The lamp will turn off when the fuel level
The following paragraphs describe the operation of drops to normal.
FIGURE 7-5. TRANSFER PUMP CONTROL FRONT PANEL
7-4
• LOW FUEL (red): indicates that the fuel level the normally closed contact to provide a signal
has dropped below low fuel level (approximate- if a fault does occur.
ly 62%). This warning enables the operator • POWER ON (green): indicates that AC power
time to react to a potential problem before low is available to the control.
fuel shutdown occurs. It indicates a possible
empty main fuel tank, fuel line restriction, pump Switches:
failure, or failure of the float gauge. • ON: This pushbutton activates the control after
• CRITICAL LOW FUEL (red): indicates that the the OFF pushbutton has been pressed.
fuel level has dropped to tank bottom. This • OFF: This pushbutton disables the control for
warning enables the operator time to shut routine maintenance to the tank system without
down generator set before fuel runs out, pre- disrupting the control. NOTE: This also de-ener-
venting loss of prime or engine damage. It indi- gizes the ECM FUNCTIONAL relay which will ac-
cates a possible empty main fuel tank, fuel line tivate a customer alarm wired to this relay.
restriction, pump failure, or failure of the float
gauge. • TEST: This pushbutton will test all front panel
lamps for three seconds and activate pump/
The control should be wired to shut down the motor for as long as the button is pressed. All
genset (optional) as continued operation will al- alarm relays will not activate but will maintain
low air to enter the engine injection pump ne- their original state.
cessitating bleeding to restart the engine. The
control will reset after restoring the tank fuel Operation
level. This will also restore engine operation if The following steps describe how to operate the day
the tank control has been connected to shut tank controller.
down the engine.
NOTE: When power is applied to the control or is re-
CAUTION Continued operation with a stored after a power interruption, the control will au-
CRITICAL LOW FUEL fault can lead to a low tomatically go to the power on mode (functions the
fuel shutdown if the fuel level float switch same as pressing the ON switch). The pump will start
fails. if the control detects low fuel in tank.
• FUEL IN RUPTURE BASIN (red): indicates 1. Press the control ON switch for automatic op-
that the fuel has flooded the safety basin sur- eration. The green PUMP light will come on
rounding the fuel tank. The basin float switch and the pump will fill the tank. The level of fuel in
turns off the fuel pump. The pump cannot func- the tank will be automatically kept between a
tion again until the basin is drained of fuel. Pos- set of pump-on and pump-off float gauge.
sible cause, leak in fuel tank.
When filling an empty tank, the red CRITICAL
• PUMP (green): indicates that the fuel pump is LOW FUEL and LOW FUEL lights will come on
running. It will come on and go off as fuel is when the control switch is pushed to the ON
pumped to maintain the fuel tank level. position. This is normal. The red lights will turn
off as the tank is filled.
• ECM FUNCTIONAL (green): indicates no
faults are detected within the control circuitry 2. The green PUMP light indicates when the
(including float gauge). If a fault occurs, the pump is running. It will come on and off as fuel
lamp will go out and de-energize the control is pumped to maintain the proper level in the
relay. It is suggested that the customer wire to tank.
7-5
EXTERNAL ALARM PANEL Solenoid Override Button
The following paragraphs describe the operation of The Solenoid Override Button is only provided on
the external alarm panel components. the Alarm Panel when the optional overflow preven-
tive valve (Figure 5-7) is provided with the external
Overfill Indicator/Horn/Mute Button fill box feature.
This switch is used to release the delivery hose

The overfill alarm Indicates that the fuel has
pressure caused by the closing of the overflow pre-
reached an abnormally high level (95%). Immedi-
ventive valve. This valve automatically closes dur-
ately stop adding fuel. It also indicates a possible
ing an overfill alarm, stopping the filling of the tank
failure of the “pump-off” float gauge for fuel systems
and creating pressure between the valve and the
that contain the fuel transfer pump.
delivery hose. Before disconnecting the delivery
hose, always press this button after an overfill warn-
The horn can be turned off by pressing the mute but-
ing to release fuel back pressure into the sub-base
ton. The indicator will turn off when the fuel level
tank.
drops to normal.
Test Button
Fuel Gauge
Press the TEST switch to test the indicator light and
Indicates the amount of fuel that is contained in the the horn. The test will remain active for as long as
sub-base tank. the button is pressed.
FUEL
GAUGE
OVERFILL
INDICATOR
SOLENOID OVERRIDE
BUTTON (OPTIONAL) HORN
TEST BUTTON MUTE BUTTON
FIGURE 5-6. EXTERNAL ALARM PANEL
7-6
EXTERNAL FUEL FILL BOX valve will energize (close) when a Critical High fuel
condition (95% full) is detected/displayed by the Ex-
The external fuel fill box plumping may contain the ternal Alarm panel (Figure 5-6). If this valve is
optional overflow preventive valve (OFPV), which is installed, the External Alarm panel will contain the
used to prevent the overfilling of the fuel tank. The Solenoid Override button.
OVERFLOW
PREVENTIVE
VALVE (OFPV)
(OPTIONAL)
EXTERNAL
FUEL FILL BOX
FIGURE 5-7. OPTIONAL FUEL (SPILL) FILL BOX
7-7
7-8
Cummins Power Generation
1400 73rd Avenue N.E.
Minneapolis, MN 55432
1-800-888-6626
763-574-5000 International Use
Fax: 763-528-7229
Cummins is a registered trademark of Cummins Inc.

Operator'S Manual: Genset Model

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Operator’s Manual

with PowerCommand Control

Printed in U.S.A. 961-0101 03-2004

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

GENERAL tor. Factory-trained Parts and Service representa-

INCORRECT SERVICE OR PARTS REPLACEMENT CAN RESULT IN SEVERE PERSONAL IN-

Copyright 2004 Cummins Power Generation. All rights reserved.

MODEL DFEG, DFEH, DFEJ, DFEK

FUEL CONSUMPTION (STANDBY/FULL LOAD/60HZ)

FIGURE 3-1. FRONT PANEL

FIGURE 3-2. STARTING AT THE CONTROL PANEL (MANUAL MODE)

PTC Module sees

CLOSE S1 REMOTE START

TIME DELAY TO EMERGENCY

PTC Module sees

HOME PREVIOUS MAIN

FIGURE 3-5. DIGITAL DISPLAY AND MENU SELECTION BUTTONS

FIGURE 3-6. MAIN MENUS

Fluid Pressure Units

FIGURE 3-8. CONTROLLER CONFIGURATION MENU

Governor Duty Cycle

FIGURE 3-9. ENGINE MENU

Governor Trq Intk Manifold Temp

Fuel Temperature Fuel Outlet Press

Fuel Rate Active Time Delay

FIGURE 3-9. ENGINE MENU (CONT.)

Volts L12 L23 L31

Volts L1N L2N Total Power

Power L1 L2 L3 AVR Duty Cycle

FIGURE 3-10. ALTERNATOR MENU

Rated To Idle Delay

FIGURE 3-11. ADJUST MENU

ASTERISK = FAULT HOUR FAULT

FIGURE 3-12. HISTORY/CURRENT FAULT SUBMENU

Faults Main Menu

nnnnn @Hr nnnnn.n nnnnn @Hr nnnnn.n

nnnnn @Hr nnnnn.n nnnnn @Hr nnnnn.n

nnnnn @Hr nnnnn.n nnnnn @Hr nnnnn.n

FIGURE 3-13. FAULTS MENU

Genset System submenus: From the System

The genset submenu allows viewing of the genset

If a PCC 2100 control genset, in the network, con-

System Main Menu

ATS Menu 1 Genset Menu 1

ATS Menu 2 Genset Menu 2

ATS Menu 16 Genset Menu 16

FIGURE 3-14. SYSTEM MENU

Genset Duty Cycle

FIGURE 3-15. HISTORY MENU

FIGURE 3-16. ABOUT MENU

S1 L12 L23 L31

Active Tran Timer

FIGURE 3-17. POWER TRANSFER MENU

FIGURE 4-1. FRONT PANEL (FULL FEATURED)

TABLE 4-1. FAULT CODES

TABLE 4-2. WARNING AND SHUTDOWN CODES

FAULT CODE CORRECTIVE ACTION

TABLE 4-2. WARNING AND SHUTDOWN CODES (CONT.)

FAULT CODE CORRECTIVE ACTION

5. Move the O/Manual/Auto switch to O.

6. Press the front panel Fault Acknowledge/Reset button.

7. Select Manual or Auto, as required.

TABLE 4-2. WARNING AND SHUTDOWN CODES (CONT.)