Power _ Generation Operator’s Manual GenSet Model DQKB, DQKC, DQKD, DQKH with PowerCommand® Control PCC3201 Printed in U.S.A. 961-0108 11-2004Table of Contents SECTION TITLE PAGE IMPORTANT SAFETY INSTRUCTIONS ... it 1 INTRODUCTION General ceseeseeeeeeaety ‘ How to Obtain Service .. 2 SPECIFICATIONS .. 3 OPERATION General ... Prestart Checks ........022.245 Control Panel Power On/Off Modes . Control Panel Assembly Gating eee Running At Idle (Manual) Stopping ....... ‘ 39 | Optional Power Transfer Control (PTC) Operation att Menu Display and Switches . . i 315 Language/Units Selection Menu 316 Main Menu ........eeeeee 347 ENGINE DATA Submenus 3-19 ALTERNATOR DATA Submenus . 3-20 CONTROL Submenu 13-21 HISTORY/ABOUT Submenus 3-22 | ADJUST Submenu 2 B24 | PARALLEL DATA Submenu 3-25 | PASSWORD Menu ..... 3-26 | Power Transfer Main/Submenus 3-27 ' UTILITY (PWR TRAN) Submenus . 3-29 | STATUS (PWR TRAN) Submenus . 3:80 TRANSFER CONTROL (PWR TRAN) Submenus -331 | ee . 3-32 GENSET (PWR TRAN) Submenus 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.SECTION TITLE PAGE 4 ‘TROUBLESHOOTING General Safety Considerations Status Indicators ... Reading Fault Codes Line Circuit Breaker (Optional). Control and Diagnostics VIA Network or PC (Laptop) Fault Codes ... Fault Code Table Troubleshooting Table . 48 5 MAINTENANCE General 2A Perodie Maintenance Schedule General Inspection .. Generator Set Maintenance (Battery Disconnected) Fuel System .. Lubrication System . Cooling System . Air Cleaner... Batteries . Fan Bearing Relubrication 511 Fan Belt Replacement 512 Generator Bearing Re-lubrication . 513 6 OPERATING RECOMMENDATIONS No-Load Operation . Exercise Period . Low Operating Temperature High Operating Temperature . Generator Set Standby Rating .IMPORTANT SAFETY INSTRUCTIONS ‘SAVE THESE INSTRUCTIONS - This manual contains important instructions that should be followed during installation and maintenance of the generator and batter- jes. Before operating the generator set (genset), read the Operator's Manual and become familiar with it and the equipment. Safe and efficient operation can be achieved only if the equipment is properly operated and maintained. Many eccidents are caused by failure to follow fundamental rules and precautions. The following symbols, found throughout this manual, alert you to potently dargerous conditions to the oper- ator, service personnel, or the equipment. This symbol warns of immediate hazards which will result in severe personal in- jury or death. (AWABNING] This symbol refers to a hazard or un- ‘safe practice which can result in severe person- al injury or death. [CAUTION] This symbol refers to a hazard or un- ‘safe practice which can result in personal injury or product or property damage. FUEL AND FUMES ARE FLAMMABLE Fire, explosion, and persoval injury or death can result from improper practices. * DONOT fill fel tanks while engine is running, un- less tanks are outside the engine compartment. Fuel contact with hot engine or exhaust isa potential fire hazard. * DO NOT permit any flame, cigarette, pifot light, spark, arcing equipment, or other ignition source rear the generator sel or fuel tank. ‘* Fuel lines must be adequately secured and free of leaks. Fuel connection at the engine should be made with an approved flexible line. Do not use zine coated or copper fuel Ines with diesel fuel. * Be sure all fue! supplies have a positive shutott valve. * Be sure battery area has been well-ventilated prior to servicing near it. Lead-acid batteries emita highly ‘explosive hydrogen gas that can be Ignited by arc- ing, sparking, smoking te. EXHAUST GASES ARE DEADLY * Provide an adequate exhaust system to properly expel discharged gases away from enclosed or sheltered areas and areas where individuals are likely to congregate. Visually and audibly inspect, the exhaust daily for leaks per the maintenance schedule. Make sure that exhaust manifolds are se- Cured and not warped. Do not use exhaust gases to heat a compartment. © Be sure the unit is well ventilated. ‘* Engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm. MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH ‘© Keep your hands, clothing, and jewelry away from moving parts. ‘* Before starting work on the generator set, discon- rect battery charger from its AC source, then dis- connect starting batteries, negative (-) cable first. Thie will provent accidental starting. ‘* ‘Make sure that fasteners on the generator set are ‘secure. Tighten supports and clamps, keep guards in position over fans, drive telts, etc. '* Do not wear loose clothing or jewelry in the vicinity of moving parts, oF while working on electrical equip- ‘ment. Loose clothing and jewelry can become ‘caught in moving parts. © If adjustment must be made while the unit is run- ning, use extreme caution around hot manifolds, ‘moving parts, etc. DO NOT OPERATE IN FLAMMABLE AND. EXPLOSIVE ENVIRONMENTS Flammable vapor can cause an engine to overspeed and ‘become dificult to stop, resulting in possible fire, explo- sion, severe personal injury and death, Do not operate a genset where a flammable vapor environment can be created by fuel spil, leak, etc., unless the genset is ‘equipped with an automatic safety device to block the air intake and stop the engine. The owners and operators of the genset are solely responsible for operating the gen- set safely. Contact your authorized Cummins Power Generation distributor for more information. Ls-14MELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH ‘¢ Remove electric power before removing protective shields or touching electrical equipment. Use rub- ber insulative mats placed on dry wood platforms ‘ver floors that are metal or concrete when around ‘electrical equipment. Do not wear damp clothing (patticularly wet shoes) or allow skin surface to be damp when handling electrical equipment. Do not wear jewelry. Jewelry can short out electrical con- tacts and cause shock or buming, ‘© Use extreme caution when working on electrical components. High voltages can cause injury or death. DO NOT tamper with interlocks. ‘© Follow all applicable state and local electrical codes. Have all electrical installations performed by a qualified licensed electrician. Tag and lock open ‘switches to avoid accidental closure. * DO NOT CONNECT GENERATOR SET DIRECT- Ly TO ANY BUILDING ELECTRICAL SYSTEM. Hazardous voltages can flow from the generator set, into the utilty ine. Ttis creates a potential for eleo- Connect only through an approved isolation switch or an ap- trocution or property damage. proved paralleling device. MEDIUM VOLTAGE GENERATOR SETS (601V to 15kV) ‘¢ Medium voltage acts differently than low voltage. ‘Special equipment and training is required to work (on or around medium voltage equipment. Operation and maintenance must be done only by persons trained and qualified to work on such devices. Im- proper use or procedures will result in severe per- ‘sonal injury or death, * Donot work on energzed equipment. Unauthorized Personnel must not be permitted near energized equipment. Due to the nature of medium voltage electrical equipment, induced voltage remains even after the equipment is disconnected from the power source. Plan the time for maintenance with autho- rized personnel so that the equipment can be de-en- ergized and safely grounded. GENERAL SAFETY PRECAUTIONS Coolants under pressure have a higher boiling poi than water. DO NOT open a radiator or heat ex- changer pressure cap while the engine is running. ‘Allow the generator set to cool and bleed the system, pressure first. Used engine oils have been identified by some state or federal agencies as causing cancer or reproduc- tive toxicity. When checking or changing engine cil, take care not to ingest, breathe the fumes, or con- tact used oi Keep multiclass ABC fire extinguishers handy. Class A fires involve ordinary combustible materials such as wood and cloth; Class B fires, combustible and flammable liquid fuels end gaseous fuels; Class C fires, lve electrical equipment. (ref. NFPA No. 10). ‘Make sure that rags are nat left on or near the en- gine. Make sure generator set is mounted in a manner to, prevent combustible matetials from accumulating Under the unit. Remove all unnecessary crease and oil from the unit. Accumulated grease and oil can cause over- heating and engine damage which present a poten- tial fire hazard Keep the generator set and the surrounding area clean and free from obstructions. Remove any de- brs from the set and keep the floor clean and dy. Do not work on this equipment when mentally or physically fatigued, or after consuming any alcohol or drug that makes the operation of equipment un- safe. © Substances in exhaust gasas have been identified by some state or federal agencies as causing can- cer of reproductive toxicity. Take care not to breath ‘or ingest or come into contact with exhaust gases. © Do not store any flammable liquids, such as fuel, cleaners, ol, etc., near the generator set. A fire or explosion could result, ‘© Wear hearing protection when going near an oper- ating generator set. To prevent serious bums, avoid contact with hot metal parts such as radiator, turbo charger and ex- hhaust system. KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE1. Introduction ee ee EEE Cee GEEE GENERAL Each operator should read this manual before oper- ating the set for the firs time. A generator set (gen- set) must be operated and maintained properly if you are to expect safe, “liable and quiet operation. ‘The manual includes a troubleshooting guide and a maintenance schedule. The engine manual is included with the set. Where there is conflicting information, this manual takes precedence over the engine manual. Improper operation and mainte- nance can lead to severe personal injury or loss of life and property by fire, electrocution, me- chanical breakdown or exhaust gas asphyxi- ation. Read Important Safety Instructions pages and carefully observe all instructions and precautions in this manual, HOW TO OBTAIN SERVICE When the generator set requires servicing, contact your nearest Cummins Power Generation distribu- WARNING tor. Factory-trained Parts and Service representa- tives are ready to handle all your service needs. To contact your local Cummins Power Generation distributor in the United States or Canada, call 1-800-888-6626 (this automated service utilizes touch-tone phones only). By selecting Option 1 (press 1), you will be automatically connected to the distributor nearest you. Hf you are unable to contact a distributor using the automated service, consult the Yellow Pages. Typi- cally, our distributors are listed under: GENERATORS-ELECTRIC or ELECTRICAL PRODUCTS For outside North America, call Cummins Power Generation, 1-763-574-5000, 7:30 AM to 4:00 PM, Central Standard Time, Monday through Friday. Or, ‘send a fax to Cummins Power Generation using the fax number 1-763-528-7229, ‘When contacting your distributor, always supply the complete Model, Specification, and Serial Number as shown on the generator set nameplate. 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© 2008 Cummins Power Generation Al ights reserved, (Currmins and PowerCommand ar registered trademarks of Cummins lac, 1-1THIS PAGE LEFT INTENTIONALLY BLANK 1-22. Specifications Heid hc kl See MODEL DQKB/DQKC DQKD DQKH Cummins Diesel Series QSK60 (50/60 Hz) I QSK60 (50 Hz) QSK6O (50/60 Hz) ‘Generator kW Rating ‘See Genset Nameplate for rating linformation. Cooling System Radiator-Cooled Models 40°C Jacket Water Cooling System. 80 Gal (303 L) 80 Gal (303 L) 110 Gal (417 L) 40 Gal (152 L) 40 Gal (152 L) 40 Gal (152 L) Low-Temp Aftercooling System 60°C Jacket Water Cooling System 110 Gal (417 L) 410 Gal (417 Ly Low-Temp Aftercooiing System 40 Gal (152 L) 40 Gal (182 L) Oil Capacity, Maximum (see Figure 2-1) Oil Pan Only ‘Standard Capacity 69 Gal (261 L) 69 Gal (261 L) 46.5 Gal (176 L) High Capacity 100 Gal (979 L) 100 Gal (379 L) NA ‘System (w/Std. Filters) ‘Standard Capacity 74 Gal (280 L) 74 Gal (280 L) 51.5 Gal (195 L) High Capacity 105@al(998L) | 105 Gal (398 L) NA *Oll Type **Fuel Consumption ‘Standby/Full Load/60Hz — GPH(LHR) 117 (443) 115.3 (437) 180 (569) Electrical System Starting Voltage 24 Volts DC Battory Four, 12 Volt Group Number Es) CCA (minimum) Cold Soak @ 0° F (-18°C) 1800 recommendations/specifcations. ** Refer to Data Sheet for other applications. * Refer to Cummins QSK60 Series Engine Operation and Maintenance Manual for lbricating oll a4STANDARD CAPACITY (0QKB, DAKC, DaKD) HIGH CAPACITY (DQKB, DAKC, DAKD) FIGURE 2-1. OIL PAN TYPES 223. Operation eee GENERAL The following describes the function and operation of the PowerCommand® Control 3201 (PCC). All in- dicators, control switches/buttons and graphical display are located on the face of the control panel as illustrated in Figure 3-1. This section covers prestatt checks, starting and stopping and operating the generator set. Each op- erator should read through this entire section before they attempt to start the generator sot. Itis essential that the operator be completely familiar with the generator set and the control panel. Refer to Sec- tion 6 for operating recommendations, PRESTART CHECKS. Before starting, be sure the following checks have been made and the unit is ready for operation. Lubrication Check the engine oil level. Keep the oil level near as Possible to the dipstick high mark without overfiling, Coolant Check the engine coolant level. Refer to Section 5. Fuel Make sure the fuel tanks have sufficient fuel and that fuel system is primed. Check to make sure there are no leaks and that all fittings are tight. Exhaust Check to make sure entire exhaust system is tight, that no combustible materials are near system, and gases are discharged away from building openings. EXHAUST GAS IS DEADLY! Exhaust yases contain carbon monoxide, an odorless and colorless gas. Carbon ‘monoxide is poisonous and can cause unconsciousness and death. Symptoms of carbon monoxide poisoning can include: © Dizziness * Nausea © Headache * Weakness and Sleepiness © Throbbing in Temples © Muscular Twitching © Vomiting © Inability to Think Coherentiy IF YOU GR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GETOUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist, seek medical atten- tion. Shut down the unit and do not operate until it has been inspected and repeired. Protection against carbon monoxide inhalation includes proper installation and ‘regular, frequent visual and audible inspections of the complete exhaust system. 34CONTROL PANEL POWER ON/OFF MODES: ‘The power on/off modes of the control panel and op- erating software are Power On, Screen Saver and Sleep/Awake. Power On Mode: In this mode, power is continu- ously supplied to the control panel. The controls operating software and control panel LEDs/graphi- cal display will remain active until the Screen Saver mode is activated. ‘Screen Saver Made: Power to the graphical dis- play will be removed after 10 minutes (generator set not running or running). The 10 minute timer resets and begins after each control panel action (any but- ton or switch selection) or signal received by the op- erating software. The bottom LEDs of the Analog AC Metering Panel (bar graphs) may remain on dur- ing Screen Saver mode, indicating that the operat- ing software is active (Awake mode). When a ‘Waming” signel is sensed by the PCC (for example, low coolant temp), the control will display the waming message. The control will remain active until the Fault Acknowledge button is pressed to clear the waming message and start the 10 minute timer. ‘Sleep/Awake Mode: In the Sleep mode, the con- trol's operating software is inactive and the LEDs and the graphical display on the control panel are all 3-2 off. Sleep mode is a feature that is used to reduce battery power consumption when the control is in the Auto mode and is not being used. When all conditions are met (i.., no unacknow!- ‘edged faults, Screen Saver Mode is active, and O/ Manual/Auto switch is in the Auto position) the ‘Sleep mode will be activated. ‘The operating software is initialized and the control panel LEDs and graphical display is turned on in re- sponse to one of the following: ‘* moving/pressing any control panel switch/but- ton. ‘© a remote start input signal (generator set in Auto mode), or ‘© customer fault 2 or 8 only (shutdown or waming indicator is on). To activate the control and view the menu display without starting the generator set, press any button ‘on the control panel. The InPower service tool is required to enable or disable the Sleep mode. When shipped from the factory, the Sleep mode is disabled, When disabled, the operating software will always temain active (Awake modo) when tho control ic in Auto modo. InPower service tool is required to select desired mode. Contact an authorized service center for as- sistance.OPERATOR PANEL REMOTE START, NOT IN AUTO, SHUTDOWN, WARNING STATUS INDICATORS. ‘SWITCH PANEL ANALOG AC PANEL LAMP/ FAULT EMERGENCY METERING LAMPTEST ACKNOWLEDGE STOP PUSH PANEL BUTTON BUTTON BUTTON 0 VG On py | DISPLAY MENU EXERCISE MANUAL AUNT SELECTIONBUTTONS — BUTTON& STOP BUTTON (toFe) INDICATOR ‘& INDICATOR GRAPHICAL OMANUAL/AUTO. DISPLAY ‘SWITCH FIGURE 3-1. CONTROL PANEL ASSEMBLY (FULL-FEATURED)CONTROL PANEL ASSEMBLY The control panel assembly (Figure 3-1) consist of two panels, the Operator Panel and the Switch Pan- el. Dependent on site requirements, the Operator Pan- @/ can be mounted on the control panel assembly (full-featured) as shown in Figure 3-1 or contained in a separate enclosure and mounted remotely of the control panel assembly. ‘The function of several buttons on the operator pan- el will vary dependent on the location of the operator panel (remote ot local of the control panel assem- bly). If the function differs, it is noted as either “re- mote” or “local operator panel” in the button de- scription. Operator Panel The operator panel contains the following compo- nents: Analog AC Metering Panel: This panel simulta- neously displays 3-phase line to line AC volts and current, kW, power factor and frequency. ‘The meter panel is composed of a series of LEDs, that are configured in bar graphs for each function. The LEDs are color ccded, with green indicating normal range values, amber for warming levels and red for shutdown conditions, ‘Scales for each function are in % of nominal values. Resolution is 1% for values close to nominal, and in- creases at values further from nominal. Graphical Display: The graphical display is capa- ble of displaying up to S-lines of data with approxi- mately 27 characters per line. The display is used to view the menus of the menu-driven operating sys- tem. Refer to the menu trees later in this section. ‘The display is also used to show waming and shut- down messages/error codes, modes of operation (Figure 3-3) and systerr actions, such as Waming, Derate, Shutdown, etc. Display Menu Selection Buttons: Six momentary buttons—three on eact side of the graphical dis- play window—are used to navigate through the sys- tem control menus and to adjust generator set pa- rameters. The button is active when the message adjacent to the button is highlighted (displayed in in- verse video). ‘Switch Panel The switch panel contains the following compo- nents: Emergency Stop Button: Push the button in for emergency shutdown of the engine. If the engine is not running, pushing the button in will prevent the starting of the engine, regardless of the start signal source (local or remote). To res 1. Pull the button out. 2. Move the O/Manual/Auto switch to 0. 8. Press the front panel Fault Acknowledge button. 4, Return 0/Manual/Auto switch to desired position. Remote Start Indicator: This green lamp is lit whenever the control is receiving a remote run sig- nal. When flashing, indicates a load demand stop mode. Not in Auto Indicator: Thie red lamp flachee con- tinuously when the O/Manual/Auto switch is not in the Auto position. (if in Auto position and lamp is flashing, service is required.) ‘Shutdown Status Indicator: This red lamp is tit whenever the control detects a shutdown condition. ‘The generator set can not be started when this lamp is on. After the condition is corrected, shutdown in- dicators can be reset by turing the O/Manual/Auto switch to the 0 position, and pressing the Fault Ac- knowledge button. Dependent upon the specific fault that occurs, the engine may or may not shut down immediately. A fault that could cause engine damage, causes an immediate engine shutdown (bypasses engine cool-down sequence). All other faults would allow the engine to run during the cool-down sequence before engine shutdown. In this case, the Shutdown Status Indicator blinks during the cooldown period.Warning Status indicator: This yellow lamp is it whenever the control detects a warning condition. After the condition is corrected, waming indicators can be reset by pressing the Fault Acknowledge button. (Itis not necessary to stop the generator set if the fault becomes inactive during genset opera- tion.) Fault Acknowledge: Press this button to acknowl ‘edge waming and shutdown messages after the fault has been corrected, To acknowledge a Warning message, the O/Manu- al/Auto switch can be in any position. (itis not nec- essary to stop the generator set to acknowledge an inactive Warming condition.) To acknowledge a shutdown message with this button, the 0/Manual/ Auto switch must be in the 0 (off) position. This bution is also used to blink a fault code if the ‘Shutdown or Waming Status Indicator is lit. (This function is used when the control does not contain a graphical display.) Refer to Reading Fault Codes in this section, which describes how to use this button for interpreting fault codes, Panel Lamp/Lamp Test Button: Press this button to tum on or off the panel lamp, Press and hold down this button for three seconds or more to turn all. contro! panel LEDs on to make sure all lamps ilu- minate. The illumination will shut off after releasing button. Exercise Button: Press this button to initiate a pre- programmed exercise sequence. The O/Manual/ ‘Auto switch is used in conjunction with this button to enable this funotion (refer to Exercise Start in this section). Manual Run/Stop Button: This button starts and stops the set locally and will bypass Time Delay to Start and Stop sequences. The O/Manual/Auto switch must be in the Manual position to enable this button. OManual/Auto Switch: The Manual position en- abies the use of the switch panel Manual Run/Stop button, Auto position enables start/stop control of the en- gine from a remote location. (It disables the use of the switch panel Manual Run'Stop button.) 0 (off) position. prevents the starting of the genera- tor set (local or remote). If moved to 0 during gener- ator set operation, will cause an immediate engine ‘shutdown (bypasses cool-down timers). This hot ‘shutdown should be avoided, if possible, to help prolong the life of the generator set. Hot shutdowns are logged by the system software.STARTING The following headings cover the systems used to start the generator set. Figure 3-2 provides a flow chart for each of the three startrun/stop sequences. With the optional Power Transter Control (PTC) fea- ture installed, the function and sequence of opera- tion for the Start command differs due to the transfer and retranster of load. Refer to “Optional Power Transfer Control (PTC) Operation” in this section for the startirun/stop PTC sequences. Before starting the generator set, make sure that exhaust and fuel fitings are tight and that proper maintenance has been performed. See Prestart Checks in this section. Starting at Switch Panel (Manual Mode) Move the 0/Manual/Auto switch to the Manual pos! tion and press the Manual Run/Stop button. This will activate the engine control system and the start- ing system. The starter will begin cranking, and af- ter a few seconds the engine will start and the start- er will disconnect. in the Manual position, the control will not complete the time delay to start or time delay to stop (Figure 3-2), but will complete the warm-up at idle and cool- down at rated/idle. (See Table 3-4 for PTC se- quence of operation.) When the coolant reaches operating temperature or the warm-up at idle time delay is reached (0 to 300 seconds), whichever occurs first, the generator set will ramp to rated speed and voltage. 36 PTC - To manually transfer load between the utility and the genset during genset operation, refer to Transfer Control (PWR TRAN} Submenu in this sec- tion. If the engine does not start, the starter will disen- gage after a specified period of time and the control will indicate an overcrank shutdown, The generator set can be coniigured for a number of starting cycles (1 to 7) with sat times for crank and rest periods. Default setting is for 3 start cycles ‘composed of 15 seconds of cranking, and 15 seo- onds of rest. ‘The InPower service tool is required to change the number of crank cycles, and the crank and rest ‘times. Contact an authorized service center for as- sistance. To clear a Fail To Start shutdown, place the O/Manu- al/Auto switch in the 0 position and press the Fault Acknowledge button. Before attempting to restart, wait two or more minutes for the starter motor to 00! and then repeat the starting procedure. If the engine does not run after a second attempt, refer to the Troubleshooting section. Starting at Remote Operator Panel (Auto Mode) When the operator panel is mounted remotely of the control panel assembly, the Slart button of the Con- trol submenu can also be used to start the generator set. The function of this Start button is identical to the following Starting from Remote Location de- scription. Refer to page 3-21 for Control Submenu description. ‘The O/Manual/Auto switch must be in the Auto posi- tion to activate the Remote Menu Buttons of the Con- trol submenu,Starting from Remote Location (Switch or Device) (Auto Mode) Place the O/Manual/Auto switch in the Auto posi- tion. This allows the generator set to be started from a remote switch or device (e.g., transfer switch or the optional Power Transfer Control feature). With the PTC feature installed, the Remote Start in- put (TB8-4/5) will function as a Test mode switch for the PTC. The PTC Test sequence is shown in Table 3-3 (Exercise). The installation manual describes how to enable test “with load” or “without load”, There are two start modes that are selectable for the remote start input, one for non-emergency start and the other for emergency start. In the non-emer- gency mode, the contro’ will complete the warm-up at idle. In the Emergency mode, the genset will skip 37 the warm-up and go directly to rated speed and volt- age. Emergency start feature is controlled by connecting a remote contact between TB8-3 and TB8-5. Open the contact for emergency start and close the con- tact for non-emergency start. In response to the remote run signal or the control detects the loss of utility voltage detected through the PTC, the control lights the Remote Start indica- tor and initiates the starting sequence described in the previous heading (Starting at Switch Pane), ex- cept for the following: In the Auto position, the contro! will complete the Time Delay To Start (0 to 300 seconds) and the ‘Time Delay To Stop (0 to 600 seconds). Refer to Adjust submenu in this section to change the time dolay settings.Exercise Start Move the 0/Manual/Auto switch to the Auto position and press and hold the Exercise button. Move the control switch from Auto to Manual and back to Auto. This will activate the engine control system to com- plete a pre-programmed exercise sequence. The sequence (Figure 3-2) will vary accordingly to the settings/selections of the system control parame- ters. PTC - The installation manual describes how to en- able exercise “with load” or “without load”. (See Table 3-3 for PTC Exercise sequence.) The InPower service tool is required to modify the following exercise parameters. Contact an autho- rized service center for assistance. The exercise sequence may include running at idle speed, ramping to rated speed, running for a prede- termined period of time and timed shutdown. During the exercise operation, the LED lamp adjacent to the Exercise button will ight. To manually stop the exercise operation before completion, press the Ex- ercise button. The set will complete its normal cool- down sequence. The control will indicate that the ‘set is in a cool-down mode by tlashing the exercise LED. PTC - If exercising with load, cool-down mode is ac- tivated after retransfer cf load to utility. (See Table 3-3 for PTC Exercise sequence.) All exercise functions ate disabled when a remote start signal is received ty the control. Cold Starting with Loads In accordance with NFPA 110, Cummins Power Generation recommends installing diese! standby generator sets (life safety systems) equipped with engine jacket water coolant heaters in locations where the minimum ambient temperature is above 40°F (4°C). NFPA also requires that the engine be heated as necessary to maintain the water jacket temperature determined by the manufacturer for cold start and load acceptance for the type of sys- tem. Although most Cummins Power Generation 38 generator sets will start in temperatures down to ~25°F (32°C) when equippad with engine jacket water coolant heaters, it might take more than 10 seconds to warm the engine before a load can be applied when ambient temperatures are below 40°F (4°C). ‘The Engine Cold (Code 1435) message, in con- junction with illumination of the Waring LED, is pro- vided to meet the requirements of NFPA 110. The engine cold sensing logic initiates a warming when the engine jacket water coolant temperature falls below 70°F (21°C). In applications where the ambi- ent temperature falls below 40°F (4°C), a cold en- gine may be indicated even though the coolant heaters are connected and operating correctly. Un- der these conditions, although the generator set may star, it may not be able to accept load within 10 seconds. When this condition occurs, check the coolant heaters for proper operation. If the coolant heaters are operating propeily, other precautions may be necessary to warm the engine before apply- ing a load. RUNNING AT IDLE (MANUAL) ‘The Run At Idle mode is selectable only when the op- ‘orator panel ie mounted on the control panol assom- bly. ‘The run mode can be set to Reted or Idle with the sot running or not running. To manually select the en- gine idle function, the O/Manual/Auto switch must be in the Manual position. Once selected and the ‘set is manually started, the control will imit the en- gine idle time to 10 minutes. When the 10 minute idle cycle is complete, the genset will ramp to rated speed. To activate the idle function, refer to page 3-21. ‘When the engine idle function is enabled, the con- tol automatically sets lower oll pressure warning and shutdown trip points to reflect the lower operat- ing speed. When the engine idle function is re- moved and the set reverts to normal operating speed, the control automatically resets oil pressure warning and shutdown trip points to the normal set- tings.STOPPING Emergency Stop (Code 1433/1434) The emergency stop button is located on the upper right side of control panel (Figure 3-1). Push the but- ton in for emergency stop. The red Shutdown status LED will light, and the graphical display message willbe: "EMERGENCY STOP 1434 ~ SHUTDOWN” To reset 1, Pull the button out. 2. Move the O/ManuaV/Auto switch to 0. 3. Press the front penel Fault Acknowledge button, 4, Retum the O/Manwal/Auto switch to the desired position. Emergency Stop shutdown status can be reset only at the operator control panel. Stopping at Switch Panel (Manual Mode) Ifthe set was started at the switch panel (/Manual/ Auto switch in the Manual position), pressing the Manual RurvStop button will cause the set to com- plete its normal (Local Start) shutdown sequence (Figure 3-2). (See Table 3-4 for PTC sequence of operation.) ‘The preset cool-down time (at rated speed) can vary dependent on the KW output. Thats, if prior to shutdown, the kW is 10% or less of rated, the control ‘software considers this output as cool-down and will subtract this time from the preset cool-down tim- er. ‘The set will stop after the Cool-down At Idle Timer (0 to 10 minutes) has timed out. (If necessary, the set will continue to run after time-out until coolant reaches normal operating temperature.) Moving the O/Manual/Auto switch to the 0 position will cause an immediate engine shutdown (bypass 39 Cool-down At Idle) and display a Cool-down Inter- rupted Waming message. This hot shutdown should be avoided, if possible, to help prolong the reliability of the generator set. Hot shutdowns are logged in the system software. Stopping at Remote Operator Panel (Auto Mode) ‘When the operator panel is mounted remotely of the control panel assembly, the Stop button of the Con- trol submenu can also be used to stop the generator set (O/Manual/Auto switch in the Auto position). The function of this Stop button is identical to the Stopping from Remote Location (non-emergency sequence, Figure 3-2). Referto page 3-21 for Con- trol Submenu description. ‘The O/Manual/Auto switch must be in the Auto pos!- tion to activate the Remote Menu Buttons of the Con- trol submenu, ‘Stopping from Remote Location (Switch or Device) (Auto Mode) If the control receives a remete stop signal or the contro! detects the return of utility voltage through the PTC. the set will complete its normal shutdown sequence. (The remote stop signal is actually the removal of the remote start signal to the control.) The set will stop after completing the following cook down sequence: ‘* Time Delay To Stop (0 to 300 seconds) * Cool-down At Idle (0 to 10 minutes) or longer, if necessary, to obtain normal operating temper- ature before shutdown, Refer to Adjust submenu in this section to change the Time Delay To Stop setting. The InPower service tool is required to modify the Cooldown At Idle. Con- tact an authorized service center for assistance.REMOTE START LOCAL START LOCAL START ‘CUST. CONNECT SWITCH PANEL ‘SWITCH PANEL (Auto Mode) (Manual Mode) (Auto Mode) + RUN EXERCISE BUTTON BUTTON, ¥ TIME DELAY TO TIME DELAY TO START ‘START 1 1 ¥ ¥ 7 WARMUP 7 WARMUP WARMUP @ @ @ ILE IDLE IDLE Tor? Tord Tore +. ¥. RATED SPEED RATED SPEED RATED SPEED & & VOLTAGE, VOLTAGE VOLTAGE 4. + £ REMOTE START CONTROL STOP EXERCISE TIME REMOVED BUTTON EXPIR: ¥ TIME DELAY TO TIME DELAY TO STOP, ‘STOP ii 7 + COOL-DOWN COOLDOWN COOL e @ @ RATEDIOLES RATEDADLES RATEDMIDLE® I 7 i 1 7 ¥ STOP, ‘STOP STOP, NOTES: 1. Timer expires. 2. Coolant temperature reaches operating level 8, Cooldown can be at reted speed and/or iale with different time-outs for each. 4, Only when non-emergency feature enabled (18-3 closed). FIGURE 3-2, NORMAL START/RUN/STOP SEQUENCES 3-10OPTIONAL POWER TRANSFER CONTROL ‘two functions: genset operation and transfer of load (PTC) OPERATION between utility and genset. The following describes the function and operation Table 3-1 describes how the gense/PTC operates of the PCC with the optional PTC feature installed. when the PCC control switch is in the Off, Manual With the PTC feature installed, the PCC performs —_and Auto position. TABLE 3-1. GENSET/PTC OPERATION ~ OFF/MANUAL/AUTO CONTROL SWITCH POSITION Reet OFF * PCC/PTC Not In Auto (1222) waming fault active. * Genset will not start. + Loads will not transfer/retranster. MANUAL (Sequence |« POGIPTC Not In Auto (1222) waming fault active. gt Pperation, Table | Genset can oniy be started manual trol panel Manual Rur/Stop butt ea jenset can only be started manually via control panel Manual Run/Stop button. * Load must be transterred manually (see Figure 3-17) + Synchronizing and load ramping will occur automatically + Enforcement of maximum paralel ime will occur automatically ‘AUTO (Sequences of | *POG/PTC In automatio mode. Operation, Table 3-2) |. Genset wil start automaticaly as required. + Loads willtransfer/retransfer automatically as required. 11PCC/PTC - Normal Operation Sequences The following tables show the normal operating se- quence of events for ezch of the four possible run- ning modes (utility power failure, exercise, test, or manual run). The sequences are further defined by what the Genset Application Type is (ie., Open Transition, Closed Transition-Momentary, or Closed Transition-Soft Loading). The previous Start, Exercise and Stop information also applies/remains the same, other than the addi- tion of the PTC transfer and retransfer of load after ‘The PCC/PTC Exercise With Load is shown in Table 3-3, The PCC/PTC Exercise Without Load is identical to the standard PCC Exercise sequence shown in Figure 3-2. TEST Switch — With the PTC feature installed, the Re- mote Start input (TB8-4/5) will function as a Test mode switch for the PTC. The PTC Test sequence is identical to the Exercise sequence (with or without load), except that the genset will continue to run until the TEST switch is deactivated. The installation manual describes how to enable test “with load” or the genset or utility voltage/frequency stabilize. “without load”, TABLE 9-2. UTILITY POWER FAIL ‘CLOSED TRANSITION ‘CLOSED TRANSITION eer ~ MOMENTARY ~ SOFT LOADING Utity Failure Utity Failure Utity Failure Time Delay to Start Time Delay to Start Time Delay to Start Genset Starts (Genset Starts Genset Starts Gensat Available ‘Genset Available Gonset Avaliable Time Delay to Transfer Time Delay to Transfer Utiity Circuit Breaker Opens Utiity Circuit Breaker Opens Uitlity Circuit Breaker Opens Time Delay Programmed Transition Time Delay Programmed Transition Tine Delay Programmed Transiion 1 2 3 a 5 _| Time Delay to Transfer 6 7 & e Gonset Circuit Breaker Closes __| Genset Circuit Breaker Closes __| Genset Circut Breaker Closes GENSET SUPPLYING LOAD ‘GENSET SUPPLYING LOAD ‘GENSET SUPPLYING LOAD 10 | Uilty Available Uitiity Available Utility Available 11 | Time Delay Retransfer Time Delay Retranster Time Delay Retransfer 21 [Genset Stopped 2 ‘Synchronizes to Utility ‘Synehronizes to Utiity 3 Ualty Circuit Breaker Closes Uiiity Circuit Breaker Closes 4 ~. —— [ALTERNATOR] [POWER TRAN or _\_ HISTORY/ABOUT [ ‘CONTROL GRAPHICAL DISPLAY FIGURE 3-5. SYSTEM CONTROL MAIN MENUS A AND B 318ENGINE DATA If you press the “ENGINE DATA’ button in Menu A, the Engine Data submenus will appear (Figure 3-6). The first submenu displays general information that applies to all gensets (coolant temp, oil pressure, etc.) The data in the remaining submenu(s) will vary according to the type end number of sensors pro- vided with the engine, 319 ‘SUBMENUS ENGINE DATA COOLANT TEMP 180 °F ENGINE SPEED 1800 RPM BATTERY 29.1 VDC OIL PRESSURE "75 PSI Ol TEMP 210 °F <> MANE TEMP 75 °F MANF PRESS ABS 130 INH [a OUTPRESSABS 130 PS! AMBIENT PRESS «38 INHG. FIGURE 3-6. ENGINE SUBMENUSALTERNATOR DATA SUBMENUS, if you press the "ALTERNATOR DATA” button in Menu A, the Altemator Data submenus will appear (Figure 3-7). Voltage L-L and L-N: indicates voltage Line-to Line and Line-to-Neutral. Note that the Line-to-Neu- tral column will not be displayed for a 3 phase/S wire system. Accuracy 1%, The voltage Line-to-Line (L1, L2 and L3) are mea- sured between Li to L2, L2 to L3 and L3 to L1, re- spectively. ‘Amps: All phases. Accuracy 1%. Frequency: Generator set output frequency. AVR DUTY CYCLE: Displays voltage regulator (drive) level in percentage of maximum. kW, kVA and PF: Displays generator set KW and KVA output (average and individual phase, and rection of flow) and power factor with leading/lag- ging indication. Accuracy 5%. ‘The PF reading will contain an asterisk if the power factor is leading (for example, *.30). 3-20 “ALTERNATOR DATA vooLL LN AMPS L480 27 1340 (2 480 277 1290 Ls 4802771260 v FREQUENCY 60.0 HZ AVRDUTY CYCLE 103% kW VA PE L350 500.80 x 2% 500 ig 350500 Tor 1060 1800 0 oH FIGURE 3-7. ALTERNATOR DATA SUBMENUSCONTROL SUBMENU If you press the “CONTROL” button in Menu A, the Control submenu will appear (Figure 3-8). Local CONTROL Submenu Function When the operator panel is mounted on the control panel assembly, the Run Mode Idle/Rated button is active (displayed). Note in Figure 3-8 that this but- ton is not displayed in remote applications, The shaded area in Figure 3-8 displays the se- lected/active mode of operation, either IDLE or RATED. Run Mode Idie/Run At Rated Button: Refer to Page 3-8 for a complete description of the Run At Idle mode. Remote CONTROL Submenu Functions ‘When the operator panel (Figure 3-1) is mounted remotely of the control panel assembly, the menu buttons in the Control submenu are used to perform the following remote operations. (To activate these menu buttons for remote/local use, refer to page 346.) The 0/Manual/Auto switch must be in the Auto posi- tion to activate the Remote Menu Buttons of the Con- trol submenu. Remote START or STOP Button: This bution is used to start and stop the generator set when the ‘operator panel is mounted in a remote location. For additional information refer to Starting at Remote Operator Panel (page 3-6) and Stopping at Remote Operator Panel (page 3-9). When the generator set is operating, Stop will be displayed for this button and Start will be displayed when not operating. Fault Acknowledge Button: Used to reset inactive Warning messages, not Shutdown messages. Local/Remote CONTROL Submenu Functions Bargraph Test: The function of this button remains the same and is not dependent on operator panel location. This button sequentially lights the LEDs to test the bar graph display. Enable Syne: Displayed in paralleling applications only. Intended for service personnel to turn off the ‘synchronizer for troubleshooting/testing purposes. 3-21 CONTROL (Local) + RUN MoDEgIBEEH [ENABLE SYNC | <|)>| [BARGRAPH TEST | ‘START GENSET FAULT ACKNOWLEDGE l<|>| BARGRAPH TEST. a, FIGURE 3-8. CONTROL SUBMENUHISTORY/ABOUT SUBMENUS It you press the "HISTORY/ABOUT” button in Menu A, the History/About susmenus will appear (Figure 39). HISTORY: The control maintains a data log of the number of engine starts and number of operating hours for the engine and control, and the megawatt and maximum torque hours of the generator set. This information is stored in non-volatile memory and will not be deleted due to loss of battery power. ABOUT: The About submenus provide the follow- ing generator set information. * Genset model and wattage (KW/MW) Output voltage and WYE, DELTA or SINGLE Frequency 50 or 60 Hz Rating: Standby, Prime or Base Version level of the controller and panel operat- ing software. HISTORVIABOUT STARTS ENGINE HOURS CONTROL HOURS: KWHRS 533 1235 7873 890 |<|>} HOURS@ % MAX TORQUE: 1234500-9 23465@50-59 12345@10-10 12345@60-69 12345@20.29 12345 423453039 12345@40-89 Oy MODEL 1750D0K8 VOLTAGE 416 WE FREQUENCY 60 RATING STANDBY CONTROLLER VERSION RTOP DN30008 DFA BATS FEB 15 1909 OP PANEL VERSION RTOP 1.12 BATS 1104 bl] CONTINUED TO NEXT PAGE FIGURE 3-9. HISTORY/ABOUT SUBMENUS. 3-22HISTORY/ABOUT SUBMENUS (CONT.) FAULT HISTORY: The control maintains a data log of all fault conditions as they occur, and time stamps them with the control and engine operating hours. Up to 32 (unacknowledged) fault codes can be stored in control panel memory. After the fault is ac- knowledged and corrected, the recorded fault will be deleted from the control panel memory, but will remain in a data log that maintains a fault code his- tory. (The InPower service tool is required to view this data log.) The Fault History display line: 1 of 24 indicates that 24 faults are recorded and that the most recent fault (1) detected by the controller is displayed. The Occurrences display line: In this example, 5 in- dicates that this is the fith occurrence of this fault. (The InPower service tcol is required to review the last four faults of this code.) The Occurrences number is incremented for each new occurrence of the same fault. The controller must detect that the original sensed fault is cor- rected before it will increment the occurrence num- ber for that fault. For example, when a Low Oil Pressure fault is de- tected, the controller will increment the Occurrences number by 1. This fault will remain active until the controller detects that the fault is corrected. An ac- tive fault will prevent the controller from increment- ing the Occurrences number each time the engine is started, When the controller detects that the oil pres- sure is normal the fault will become inactive, allow- ing the occurrences number to be incremented for the next detected Low Oil Pressure fault. 3-23 HISTORVIABOUT (CONT) FAULTHISTORY: 1 0F 24 =] one wours ‘450° Og occunrences 5 LAY ENGINE HOURS S04 FAULTCODE14a7 CE] (FAULT DESCRIPTION, FIGURE 3-10. HISTORY/ABOUT SUBMENUS (CONT)ADJUST SUBMENUS If you press the “ADJUST” button in Menu B, the Ad- just submenus will appear (Figure 3-11). The Adjust submenus are intended for qualified service personnel and site personnel only and may require a USER password. If a password is re quired, the USER password menu will appear when you try to modify the Adjust submenus. (Refer to PASSWORD Menu in this section to enter pass- word. Changes are automatically saved when you exit this menu. Use the + and ~ buttons to increase or decrease the values in the following fields. Use the arrow (>) but- ton to move the cursor within a field or to the next field, Selected field is highlighted. ‘START DELAY: This delay applies only to remote starting in the Auto mode. The Start Delay adjust- ‘ment range is 0 to 300 seconds. STOP DELAY: This delay applies only to remote stopping in the Auto mode. The Stop Delay adjust- ment range is 0 to 600 seconds. VOLTAGE: Used to adjust the output voltage +5%. FREQUENCY: Used to adjust the frequency #3 Hz. VOLTAGE/SPEED DROOP: These two submenus apply to a genset that hes the paralleling option and is configured to operate in droop mode. These ad- justments must be performed by technically quali- fied personnel only. 324 ‘ADJUST ADUUST, START DELAY ‘STOP DELAY VOLTAGE 208 FREQ 60.0 HZ ADJUST. F] STANDBY x F=| VOLTAGE DROOP OFF $=] BUS Lt ago v LY. >] POWER FACTOR 0.80 vour 499% ‘ADJUST. ‘STANDBY x SPEEDDROOP OFF [=] Bus FREQ 600 Hz TOTAL KW 300 KW FREQ 60.0 040 HZ FIGURE 3-11. ADJUST SUBMENUS.PARALLEL If you press the “PARALLEL DATA” button in Menu B, the Parallel Data submenu will appear (Figure 3-12). This menu is disolayed in paralleling applica- tions only. PARALLEL DATA STATUS LINE: The top line of the graphical display is used to indicate the follow- ing PARALLEL DATA status: - STANDBY: Indicates no paralleling activity is ‘occurring at present. DEAD BUS CLOSE: Indicates first genset in system to close to bus. SYNCHRONIZE: Genset is synchronizing to bus. LOAD SHARE: Genset has closed to bus and is sharing load with other gensets in system. LOAD GOVERN: Genset closed to bus in par- allel with utility (mains). BUS Voltage L-L: The BUS voltage Line-to-Line (L1, L2 and L3) are meesured between Lt to L2, L2 to L8 and L3 to L1, respectively. BUS/GEN HZ: BUS/GEN hertz. BUS/GEN SYNC STATUS: The bottom line of the graphical display is used to indicate the following BUS/GEN Sync status: — NOT SYNCHRONIZING: Genset is in service mode that does not allow auto syne feature. — SYNCHRONIZING: Genset is synchronizing to bus. - READY TO CLOSE: In manual mode, push cir- cuit breaker close button to close breaker. _\_ Button: (Paralleling applications only). Used to open and close the generator set circuit breaker (CB). The symbol indicetes if the CB is opened or closed. Opened _\_, push to close. Closed _- , push to open. With the control panel 0/Manual/Auto switch in the ‘Auto position, the opening and closing of the CB is controlled by the control system software. The CB symbol will indicate an open or closed CB, but the button will be inactive when the control is in Auto, In the Manual position, the CB must be closed by this button. When manually closed and the CB opens, it must be closed again by using this button. ‘To close the CB, press and hold the button until the ‘symbol indicates a closed CB. (CB close will occur only when setup conditions allow — dead bus or generator synchronized with bus.) DATA SUBMENU [PARALLEL DATA] LOAD GOVERN v Bus GEN Lt 480480 x 2 480 4a0 13 480480 a HZ 601 oa DEG -122 NOT SYNCHRONIZING FIGURE 3-12. BUS DATA SUBMENU 3-25PASSWORD Menu ‘When viewing the Adjust submenu, pressing either the + or — button will dsplay the Password menu (Figure 3-19) if a User password is assigned to this, field. After entering the correct password, the sys- tem will allow you to modify the submenu. To pre- vent unauthorized adjustment, the entered pass- word is valid for only 10 minutes after the last button Is pressed. Application Password is intended only for qualified service personnel to allow adjustment of Setup sub- menu parameters. To enter the password: 1. Display Adjust submenu. 2. Press either the + or = button within the dis- played submenu. The Password menu ap- pears. (Adjustment is allowed if Password menu does not appear.) 3. Press the + and — button to select the first char- acter of the User password (A~Z or 0-9). 4. Press the ~ button to select the next character field. Selected character field is highlighted. 5. Repeat steps 3 and 4 to enter remaining pass- word characters, 6. Press the Enter button after entering the pass- word. The Adjust submenu will reappear. 7. Exit Adjust submenu to save changes. 3-26 ENTER USER PASSWORD (OR) ENTER APPLICATION PASSWORD Booo000% FIGURE 3-13, PASSWORD MENUPOWER TRANSFER MAIN/SUBMENUS If you press the “POWER TRANS" button in Menu A, the Power Transfer main menu will appear (Fig- ure 3-14). The Power Transfer Control (PTC) fea- ture must be installed to display this menu. The PTC feature enables the PCC to monitor the utility voltage (mains) and frequency for failure and Control the opening and closing of the contacts (cir- cuit breakers) for the utility (S1) and the genset (2). If utility fails, the control will initiate the starting se- quence (Figure 3-2), o2en S1 and close $2 to the load. When utility retums, the load is retransferred to the utility (S1 closes/S2 opens) and the contro! initiates the genset shutdown sequence. 327 ‘The“T™ symbol displayed in the middle of the Pow- er Transfer main menu indicates which breaker (utility or genset) is closed/opened to the load. The symbol presently shown indicates that the utility breaker is closed and supplying power to the load. ‘The Power Transfer main menu also indicates if the utility and the generator set are available to accept load. When the control detects that either souroe is. ready to accept load, UTILITY and/or GENSET will be displayed in inverse video. ‘The Power Transfer main menu has four submenu gtoups. Refer to the page numbers shown in Figure 3-14 for the Power Transfer submenu descriptions.PTC Status Line The top line of the graphical display is used to indi- ate the following PTC status: NOT ENABLED: PTC is not enabled. Control panel switch in © (Off) position. MANUAL: Control panel switch is in Manual position. All PTC ections or genset start/stop actions are manually controlled. NORMAL UTIL: Load is connected to the util- ity. RETRAN: Retransier of load to utility. RETRAN OVRD: Immediate retransfer of load to utility due to genset fault (e.g., warming, der- ate, or shutdown w/cooldown fault). The re- transfer timer is ignored as is the retransfer in- hibit. EMERG TEST: Emergency Test sequence ini- tiated through Remote Start switch with emer- gency start sequence enabled (TB8-3 terminal ‘opened). Emergency test mode means that the genset will continue to run even if a genset, warning or derate fault occurs. This test can be performed with or without load (refer to TEST/ EXERCISE submenu ~ installation manual). ‘See Table 3-3 for sequence of operation, TEST: Test sequence initiated through Remote Start switch with emergency start sequence disabled (TB8-3 terminal closed). Test mode is non-emergency, which means that a retransfer to utility will occur if any problems occur with the genset while testing with load. This test can be performed with or without load (refer to TEST/EXERCISE submenu - installation manual). See Table 3-3 for sequence of opera- tion. EXERCISE: Exercise sequence initiated through control panel. This test can be per- formed with or without load (refer to TEST/EX- ERCISE submenu ~ installation manual). A re- transfer to utility will occur if any problems oo- cur with the genset duting the exercise se- quence. See Table 3-3 for sequence of opera- tion. UTILITY FAIL: Utility has failed. (Initiates transfer of load to genset if OMANUAL/AUTO- switch is in AUTO.) MENU BUTTONS, PTC STATUS LINE ‘MENU BUTTONS vorury GENSET a ‘STATUS, a TRANSFER CONTROL 7 DEG —123 SYNCHRONIZING FIGURE 3-14, POWER TRANSFER MAIN MENU 3-28UTILITY (PWR TRAN) SUBMENUS If you press the ‘Utiity’ button in the Power Transfor Main menu, the Utility submenus will appear (Fig- ure 3-15). Voltage L-L and L-N: ‘ndicates utility voltage Line- to Line and Line-to-Neutral. Note that the Line-to- Neutral column will not be displayed for a 3 phase/3 wire system. Accuracy 1%. umiiry: —_| vo LL LN oaAMPS x Li 480277 (2 480 277 1320 v (3480277 FREQUENCY 60.0HZ The voltage Line-to-Lire (L1, L2 and L3) are mea- sured between Lt toL2, L2 to L3 and L3 to Lt, re- spectively. Amps: L2 only. Acouragy 1%. umiuiry: Frequency: Utility frequency. KW RVA PF x u 1 125 17596 b Ea Tor KW, KVA and PF: Displays (L2 only) utility KW and KVA output (average and direction of flow) and pow- ef factor with leading/lagging indication. Accuracy 5%. FIGURE 3-15. UTILITY SUBMENUS ‘The PF reading will contain an aeteriok if the power factor is leading (for example, *.30). 3-29GENSET (PWR TRAN) SUBMENUS. Ifyou press the "Gensef’ button in the Power Trans- fer Main menu, the Genset submenus will appear (Figure 3-18). Voltage L+L and L-N: Indicates voltage Line-to Line and Line-to-Neutral. Note that the Line-to-Neu- tral column will not be displayed for a 3 phase/S wire system. Accuracy 1%, The voltage Line-to-Lins (L1, L2 and L3) are mea- sured between Lt to L2, L2 to L3 and LS to Lt, re~ spectively. ‘Amps: All phases. Accuracy 1%. Frequency: Generator set output frequency. KW, kVA and PF: Displays generator set KW and kVA output (average and individual phase, and di- rection of flow) and power factor with leading/lag- ging indication, Accuracy 5%. ‘The PF reading will contain an asterisk if the power factor is leading (for example, *.20). GENSET, GENSET: vo LL OLN AMPS Li 4802771820 12 480 © 2771320 134802771320 FREQUENCY B.0HZ GENSET SUBMENUS4. Troubleshooting GENERAL The genset control continuously monitors engine sensors for abnormal conditions, such as low oil pressure and high coolant temperature. If any of these conditions occur, the control will light a yellow Warning lamp or a red Shutdown lamp and display a message on the graphical display panel. In the event of an engine shutdown fault (red Shut- down lamp), the control will stop the engine immedi- ately; an altemator shu:down fault, the engine will stop after the cool-down timer has timed out. If the generator set is stopped for this reason, the opera- tor can restart the set a'ter making adjustments or corrections. This section lists the waming and shut- down codes/messages (Table 4-1), and suggests troubleshooting procedures (Table 4-2). 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- ter for aeeistance. ‘SAFETY CONSIDERATIONS Contacting high voltage compo- nents can cause electrocution, resulting in se- vere personal injury or death. Keep the output box covers in place during troubleshooting. High voltages are present when the set is running. Do not open the generator output box while the set is running. (AWABNING] /gnition of explosive battery gases can cause severe personal injury or death. Arc- ing at battery terminals, light switch or other equipment, flame, pilot lights and sparks can ig- nite battery gas. Do not smoke, or switch trouble light ON or OFF near battery. Discharge static electricity from body before touching bat- teries by first touching a grounded metal sur- face. Ventilate battery area before working on or near battery—Wear goggles—Stop genset and dis- conneet charger before disconnecting battery cables—Disconnect negative (-) cable first and reconnect last. 44 Disconnect battery charger from AC source before disconnecting battery cables. Otherwise, disconnecting cables can result in voltage spikes damaging to DC control circuits of the set. (WARNING) Accidental starting of the generator Set can cause severe personal injury or death. Prevent accidental starting by disconnecting the negative (-) cable from the battery terminal. When troubleshooting a set that is shut down, make certain the generator set cannot be accidentally re- started as follows: 1, Move the O/Manual/Auto switch on the contro! panel to the O (off) position. 2, Tum off or remove AC power from the battery charger. 8. Remove the negative (-) battery cable from the generator set starting battery. STATUS INDICATORS Not In Auto Indicator: This red lamp flashes con- tinuously when the 0/Manual/Auto switch is not in the Auto position (Figure 4-1). Shutdown Status Indicator: This red lamp is lit whenever the contro! detects a shutdown cor Aiter the condition is corrected, the shutdown indi cator can be reset by turning the O/Manual/Auto ‘switch to the 0 position, and pressing the Fault Ac- knowledge button. The generator set can not be started when this lamp is on. Warning Status Indicator: This yellow lamp is lit whenever the control detects a waming condition. After the condition is corrected, the warming indica- tor can be reset by pressing the Fault Acknowledge button. (Itis not necessary to stop the generator set if the fault becomes inactive during genset opera~ tion.)READING FAULT CODES If the genset contains the optional graphical display and a fault occurs, the fault code/message will be displayed in the display Description Line (Figure 4-1). If the control does not contain the graphical display, the fault code is reed from the Waming and ‘Shutdown status indicators. After the fault is acknowledged and corrected, the recorded fault will be deleted from the control panel memory, but will remain in a data log to maintain a fault code history. The InPower service tool is re- quired to view this data log, Reading Fault Codes Using Graphical Display (Optional): The top three lines of the graphical dis- play contain the followirg control information in the order described: * State Line - modes of operation, such as Stopped, Time Delay To Start, Warm Up At Idle, etc. (see Figu’e 3-2), and paralleling op- erations, such as Standby, Dead BUS Close, ‘Synchronize, ete. * Action Line - system actions, such as Waming, Derate, Shutdown Cool-down and Shutdown, and fault codes. * Description Line - Fault code messages. Refer to History/About Submenus in Section 3, which describes how to view fault codes using graphical display. Reading Fault Codes Using Warning/Shutdown Indicators: If the Waming or Shutdown status indi- cator is lit, press and hold the Fault Acknowledge button and release after ten seconds or more. After ten seconds, the Shutdown lamp will begin to blink the active fault code(s) as follows. The Waming lamp is used to indicate the start of a new code. The Warning lamp will remain on for 2 seconds, followed by the Shutdown lamp blinking the fault code. This sequence occurs three times for 42 ‘each code. The fourth flash of the Waming lamp in- dicates the beginning of the second fault code. There are distinct pauses between repetitions of the code blink transmissions of the Shutdown lamp. A three digit fault code is indicated by three sets of blinks separated by a two second pause. The first set corresponds to the hundreds position, the sec- ‘ond to the tens position and the third to the ones dig- it, Example for Code No. 213: ‘Shutdown LEI blink-blink-pause-blink-pause-blink-blink-blink Warning LED: blink (2 seconds) ‘The light will display the fault codes (active or inac- tive) in succession, starting with the most recent. Up to 32 (unacknowledged) faull codes can be stored in control panel memory. To retum the control to the most recent fault code, press and release the Fault Acknowledge button (less than one second) and repeat procedure. ‘When the fault code is acknowledged and the fault condition is corrected, the fault code will be re- moved from the LED fault log. LINE CIRCUIT BREAKER (OPTIONAL) Optional line circuit breakers mount in the generator output box. If the load exceeds the circuit breaker current rating, the line circuit breaker will open, pre~ venting the generator from being overloaded. If the circuit breaker trips, locate the source of the over- load and correct as necessary. Manually reset the breaker to reconnect the load to the generator. CONTROL AND DIAGNOSTICS VIA NETWORK OR PERSONAL COMPUTER (LAPTOP) See your authorized Cummins dealer regarding software, hardware and network requirements for control and diagnostics via network or personal ‘computer.‘SHUTDOWN, ‘WARNING STATUS INDICATORS. FAULT ACKNOWLEDGE BUTTON ‘OPERATOR PANEL GRAPHICAL, DISPLAY ooo 1 Reino eee ‘SWITCH PANEL FIGURE 4-1. FRONT CONTROL PANEL (FULL-FEATURED) a3FAULT CODES ‘The fault codes have been divided into five catego- rigs to help you determine what corrective action to take for safe operation of the generator set. Use Table 4-1 to find the category (CTG) and fault de- scription for all codes. Gaps in the code numbers are for codes that do not apply to this genset model, Also, some of the codes listed are fea- ture dependent, and will not be displayed by this genset control. Category A Fault Codes: Pertain to engine or al- temator shutdown faults that require immediate re- pair by qualified service personnel (generator set non-operational). The cantrol prevents the genera- tor set from being restarted if the shutdown fault is not corrected. Category B Fault Codes: Consist of faults that can affect genset performance or cause engine, alter- nator, or connected equipment damage. Oper- ate genset only when it is powering critical loads and cannot be shut down. Requires repair by quali- fied service personnel. Category C Fault Codes: Consist of faults that do not affect generator set performance but require ‘qualified service personnel torepair. These code in- dicate a defective hamess or wiring problem. These codes can also indicate a defective engine sensor, leaving no engine protection. (Engine dam- age can occur without detection.) Continued op- eration may void generator set warranty if dam- ‘age occurs that relates to fault condition, Category D Fault Codes: Consist of faults that are repairable by site personnel. Service will be re- quited by qualified service personnel if site person- nel cannot resolve the problem after taking the cor- tective actions suggested in Table 4-2. Category E Fault Codes: Incicates non-critical op- erational status of generator set, external faults, or customer fault inputs. May require repair by quali- fied service personnel.TABLE 4-1. FAULT CODES ‘CODE [LAMP | DISPLAYED MESSAGE ‘CTG | CODE | LAMP | DISPLAYED MESSAGE Tit_| Shan Internal ECM error 254 | Shton | Fuel shutofl valve 412 _| Shida [Actuator not responding 258 _| Wing [Fuel shutoff vave 713 | Wing [Actuator sensor fault 261_| Wing [Fuel temperature sensor 775_| Shtan [No speed signal 263_| Wing_| Fuel temperature sensor 416 | Shtdn | Time press sensor high 265 | Wig | Fuel temperature sensor 7i7_| Shan Time press sensor low 266_| Shidn [Fuel tomperatare 718_| Wing [Pump press sensor high 316 _| Wing [Fuel supply pump 718_| Wing [Pump press sensor low 318_| Wing [Fuel supply pump 72i_| Wing” [No engine speed signal 326 | Wing [Oillovel waming 122__| Wing | Manifold air press sensor 343_| Wing [Internal ECM error 723_| Wing |Wanifold air press sensor 359__| Wing [Engine falledto stat 736 | Wing [Dilpressure sensor 378_| Wing [Fueling actuator #1 141_| Wing [Oilpressure sensor 379_| Wing [Fueling actuator #1 143_[ Wing [Low oll pressure 384] Wing | Fueling actuator #7 144_| Wing [Coolant temperature sensor Fusling actuator #1 145__| Wing | Coolant temporature sensor 396_| Wing | Fueling actuator #2 146__[ Wing [igh coolant temp warning 387_| Wing | Fueling actuator #2 71_| Shc [High coolant temp alarm 386__| Wing” | Fueling actuator #2 752__| Wing [Tow coolant temp 398 __| Wing | Fueling actuator #2 | 153_[ Wing_| Manifoia air temp sensor 4is__| Shtan [Low alipressure alarm 164__[ Wing | Manifold air tomp sensor 421__| Wing [High ol temperature 765 _[ Shtan | Manifold air temp alarm 423_| Wing [Fuel tring 167 | Wing [Coolant level waming 447__| Wing | Low battery vohage 2i2_| Wing [Oiltemperature sensor 442_| Wing | High batlory volage 213 _| Wing |Oiltemperature sensor 449__| Wing [High fuel suppiy pressure 2i4_| Shidn [High oll temperature 451_| Wing [Fuel ral pressure sensor 221__| Wing [Air pressure sensor 452_| Wing | Fuel rai pressure sensor 223_| Wing [Air pressure sensor 455_| Shidn’ [Fuel contol valve sensor 228_| Shidn [Low coolant pressure 467_| Wing | Timing ral act senor 2a1__| Wing_| Coolant pressure sensor 468_| Wing | Fuel al actuator sensor 238__| Wing_| Coolant pressure sensor “471_| Wing [Low olievel 233_| Wing [Coolant pressure waming 482_| Wing [High fuel supply pressure 2a4_| Shin |Gverspeed 488__| Wing [High intake manifold temp 235_| Shan | Coolant fovel alarm 498__| Wing [Oilleve! sensor | 236_| Stan | Position sensor 498__| Wing [Oilleve’ sensor 253__| Shtan [Ollevel alam 514_| Shin [Fuel control valve a 3 9| >} OF] >| >] o} of >] of of >| of 0} 9] >] of 0 Of of | of 0 @] 0] 0 @] | of | wl >] >] >] ol >] > >} >}>] >] >=] >] >[>]>] >] >] 5] =] =] >] >] >] >>] >) lela] ola] o]o]o]o]ol ola 3 45TABLE 4-1. FAULT CODES (CONT) (TG | CODE | LAMP | DISPLAYED MESSAGE CFG] CODE [LAMP | DISPLAYED MESSAGE B | 546 _| Wing | Fuel pressure sensor | tai? | Shtan’ [Castomer input #3 B | 847 | Wing | Fuel pressure sensor ‘Wmg 3 | 864] wing | Fuel rail pressure sensor B | 1819 | Wing [High altemator temp B | 585} Wing |Stowby pressure [1821 [ Wing |Comrron waming driver *T 656 | Shin | Stowby pressure A | 1822| Shidn [Load gov KW selpoint oor Ar _ | 386_| Shan |Run/Stop switch ‘®_ | 1923,_| Shtan [Load gov RW setpoint cor lo A_|587_| Shin [Run/Stop switch B_[ 1824 | Wing [Load gov VAR oor hi D_| it] Wing [Engine hot B_| 125 | Wing [Load gov KVAR oor o D_ | 688 _| Shicin [igh of level alarm B_| 1926 | Wing [Backup starier disconnect B_| 689_| Wing | rank shaft sensor ‘A | 1827 | Shin | Load gov RW analog oor B | 719 _| Wmg |Blowby pressure sensor D | 1328 | Wg |Genset CB tripped B | 729 | Wig [Blowby pressure sensor B | 1329 [Wg [AVR DC power failure B | 731_| Wing |Cam/Grank misalignment A | 1951 | Shtan” [AVA diver shorted B_|_778_| Wing [Camshaft sensor 7K [7332 | Shan | Manual swith corto [118 [Wing [Pretube relay drver A] 1686] Shtan | Manual switch oor hi ®_| 121] Shtan [Failed to Disconnect AT taaa} Stan | Gitical scaler oor C | 1219 | Wing [Ublty CB tripped B_| 1885 | Wing |Non critical scaler cor | 1222 | Wing | Power wansfor notin auto Ea Gookacan compets © _| 1223 | Wing |Uility frequency sensor [CE [ ear Rone Rat wi [erg [ooraervoage sansa] [=| 19 St [tnt sents % | 1942 | Shan | Sioto card | 1226 | Wing _| genset frequency sensor tee bone fae E [i311 | Shtan’ [Castomer input #1 wig | 1345 | Shicn | Siot3 card E | tate | Shan’ Customer input #2 A_| 1946 | Shidn [Slot neorect Wing © _| 7351 | Wing [Slot 4 /network enabled Eels: io. Network Fault 1 © | 1414 | Wing [Run reay contact E | 1314 | Shida’ [Network Fautt2 C | 1415 | Wing [Run reiay driver wing D_| 1416 | Wing [Fall to shutdown E_| 1816 | Shtan’ [Network Faults D_| 1417 | Wing [Power down error Wing B | 1419 | Wing | Fuel rail driver eater: pied Reon an 4: B | 1421 | Wing | Timing rail driver #1 17318 Sra | Oastomer Ppa B_ | 1422 | Wing | Timing rail diver #2 wing [1424 [Wing [High side diver‘TABLE 4-1, FAULT CODES (CONT) cre LAMP | DISPLAYED MESSAGE ‘CODE [LAMP | DISPLAYED MESSAGE c Wing |Overspeed relay driver ©_| 1468_| Wing | Network error c ‘Wing_|COP shutdown relay driver B_| 1471_| Wing [High current D Shtdn_ | Emergency stop — local ‘A_| 1472_| Shtan [Overcurrent D Shtan_ [Emergency stop - remote ‘A_| 1473 | Shtan | Watchdog faiture o ‘Wing | Engine cold ‘A | 1474 | Shtdn | Software version mismatch B Wing [PT fuel system drivers © | 1475 | Wing | First cart backup a ‘Shidn_ | E-stop path fuse blown © | 1a76 | Wing | LonWorks card 2 Wing [Fall to crank ©_[1477_| Wing | Grankrelay contact 7 Wing | Fuel level low in day ©_[ 4478 | Wing |Crankrelay driver D Wing_| Fuel level fow in main K] iaar_ | Shtan- AVR diver open 7 ira | (Eaiery 18 weet E_[/ 1485 | None [Common alarm status ei imo | Batley 6 teed ‘A_| 1485. | Shtdn’ [EFC diver shorted . uno oven ‘A_| 1486_| Shtan [EFC diver open é Sieh Neer snot aaa _| 7487 | Wing [Auto acknowledge driver A — oe — = rh [7488 [ Wing | Warning LED driver ©_| 4489" | Wing [Shutdewn LED driver a ‘Shtdn_ [AC output frequency low © _| 7497 | Wing [Ready to load relay driver 4 deni ial ©_| 1492 | Wing [Load dimp relay driver B Wing | Gen/Bus voltage afer A ‘Shtan [Gen CB falled to close STE ae Lee | Dieta cooled ee x Shida Gen GB Taiod to open ©_| 1494 | Wing | Modem power relay driver t ‘ing [en CB postion contact ©_[ 1495 | Wing [Common shutdowna driver x Wing ai CB contact ©_| 1496 | Wing [Auto mode relay driver = Wing Eus out of range ©_[1497_| Wing |Manual run LED driver 7 Wing | Fai'to synchronize ©_| 1498 | Wing [Exercise rin LED driver = Wing | Fhase rotation ©_| 1499 | Wing [Remote start LED diver R Ghtdn |Feverse KW © _| 2111 | Wing [Aftercosler tomp sensor K Ghidn |Loss of eld © _| 2112 [| Wing |Aftercooler temp sensor EJ Wing |Figh ground current B_| 2173 | Wing [High aftercooler temp = None [Notin Auto A_| 2174 _| Shtan [High aftercooler temp E None | Load dump ©_| 2331 | Wing |Utity under volt sensor E None [Ready toload © [2868 | Wing | Utility over vot sensor c Wing [Woden failure [2806 | Wing [Utility CB failed to close € ‘Wing [Unable to connect modem _| 2897 _[ Wing [Utility OB failed to openTABLE 4-2. WARNING AND SHUTDOWN CODES. Many troubleshooting procedures present hazards which can result in severe per- ‘sonal injury or death. Only qualified service personnel with knowledge of fuels, electricity, and ‘mechanical hazards should perform service procedures. Review safety precautions. ‘SYMPTOM CORRECTIVE ACTION CODE: 146 Indicates engine is operating near cooling system capacity. Increase in LAMP: Warming load or higher ambient temperature may cause High Coolant Temp (151) MESSAGE: shutdown. Review 151 correction list for other possible causes. HIGH COOLANT TEMP WARNING CODE: 151 Indicates engine has overheated (engine coolant temperature has risen LAMP: Shutdown, above the shutdown trip point. Allow engine to cool down completely be- MESSAGE: fore proceeding with the following checks: HGH COOLANT Teme tan a. Check coolant level and replenish repair if necessary. '. Check for obstructions to cooling airflow and correct as necessary. ©. Check fan belt and repair if necessary. 4. Reset control and restart after locating and correcting problem. fow. Look for coolant leaks and CODE: 152 Indicates engine coolant heater is not operating or is not circulating cool- LAMP: Warning ant. Setis in standby mode but is not operating. Waning occurs when en- MESSAGE: gine jacket water coolant temperature is 70° F (21°C) or lower. LOW COOLANT TEMP NOTE: in applications where the ambient temperature falls below 40° F (4° C), Low Coolant Temp may be indicated even though the coolant heaters are operating, (Check for the following conditions: ‘a. Check that both ball valves in coolant heater system are both open. . Coolant heater not connected to power supply. Check for blown fuse or disconnected heater cord and correct as required. ‘e, Check for low jacket water coolant level and replenish if required. Look for possible coolant leaks and repair as required. Indicates engine coolant level has fallen to an unaceeptable level. If gen- erator is powering critical loads and cannot be shut down, walt until next = Warning MESSAGE: shutdown period, then follow 235 Coolant Level Alarm procedure. If en- COOLANT LEVEL WARNING gine can be stopped, follow 235 procedure. CODE: 235 Indicates engine coolant level has fallen below the elarm tip point. Alow i LAMP: Shutdown engine to cool down completely before proceeding. MESSAGE: i | ‘a, Check jacket water coolant level and replenish if low. Look for pos- Soot env en Ara sible coolant leakage points and repair if necessary. . Reset control and restart after locating and correcting problem.TABLE 4-2. WARNING AND SHUTDOWN CODES (CONT) [AQWARNING] Many troubleshooting procedures present hazards which can result in severe per- sonal injury or death. Only qualified service personnel with knowledge of fuels, electricity, and ‘mechanical hazards should perform service procedures. Review safety precautions. ‘SYMPTOM CORRECTIVE ACTION CODE: 358 Indicates possible fuel system or air induction problem. (Engine cranks LAMP: Warning but fils to start) MESSAGE: ‘a. Check for empty fuel tank, fuel leaks, or pluggad fuel lines and cor- ENGINE FAILED TO START rect as requitod. . Check for dirty fuel filter and replace if necessar . Check for ditty or plugged air fiter and replace if necessary. d. Reset the control and restart after correcting the problem, CODE: 441 Indicates battery voltage is below 24 VDC. esceee a. Discharged or defective battery. Check the battery charger fuse. Recharge or replace the battery. acta acta b. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. ©. Check engine DC eltemator. Replace engine DC altemator it normal battery charging voltage (24 to 26 VDC) is not obtained. 4. Check float level if applicable (raise float level). CODE: 442 Indicates battery voltage exceeds 82 VDC. ue ening Check float level on battery charger if applicable (lower oat level). HIGH BATTERY VOLTAGE Check engine DC alternator. Replace engine DC altemator if normal bat- ‘ery charging voltage (24 to 26 VDC) is not obtained. CODE: 611 Indicates that an engine hot shut down has occurred (cool-down timers. LAMP: Warning ‘were bypassed). This condition wil occur when the operator presses the MESSAGE: Emergency Switch or moves the O/Manual/Auto switch to the 0 (Off) posi- ENGINE HOT tion before the genset completes the cooidown operation. (Genset should 1un at 10% oF less load for 3 minutes before engine shutdown.) This type Cf shutdown should be avoided. Can cause possible loss of performance and engine damage. CODE: 1311 through 1318 ‘When any one of these customer defined inputs is detected by the control, LAMP: Shutdown/Warning the corresponding fault message is displayed. The nature ofthe fauitis an MESSAGE: optional customer selection. These fault functions can be programmed to Customer Defined Fault initiate a shutdown or waming as indicated by the Waring or Shutdown lamp. "Note: Customer fault messages are editable. The message displayed for the code shown (1811 through 1318) is determined ay the customer. CODE: 1416 Status ~ indicates that the “Fault Bypass" mode Is enabled. This mode is LAMP: Warning primarily used by service personnel for troubleshooting purposes. In this MESSAGE: mode the generator set ignores the majority of system shutdown faults. FAIL TO SHUTDOWNTABLE 4-2. WARNING AND SHUTDOWN CODES (CONT) [WARNING] Many troubleshooting procedures present hazards which can result in severe per- ‘sonal injury or death. Only qualified service personnel with knowledge of fuels, electricity, and mechanical hazards should perform service procedures. Review safety precautions. SYMPTOM CORRECTIVE ACTION CODE: 1417 Indicates that the control can not power down due to some unknown con- LAMP: Warning ‘ition. Possible drain on battery. Contact an authorized service center for MESSAGE: service. POWER DOWN ERROR CODE: 1433/1434 Indicates local or remote Emergency Stop. Emergency Stop shutdown LAMP: Shutdown status can be reset only at the local control panel. MESSAGE: To reset the local/remote Emergency Stop button: EMERGENCY STOP - LOCAL / ull the button out, EMERGENCY STOP - REMOTE Move the O/Manual/Auto switch to © (Off. Press the front panel Fault Acknowledge button. Select Manual or Auto, as required. CODE: 1438 Indicates possible fault with control or starting system. Check for the fok LAMP: Warning lowing conditions: MESSAGE: a. Poor battery cable connections. Clean the bettery cable terminals Paes caer and tighten all connections. b. Lischarged or detective battery. Hecharge or replace the battery. CODE: 1439 Indicates fuel supply is running low. Check fuel supply and replenish as LAMP: Warming required. MESSAGE: FUEL LEVEL LOW IN DAY CODE: 1441 Indicates fuel supply is running low. Check fuel supply and replenish as LAMP: Warning required. MESSAGE: FUEL LEVEL LOW IN MAIN CODE: 1442 Indicates battery voltage drops below 14.4 volts for two seconds during LAMP: Warning starting. MESSAGE: Discharged or defective battery. BATTERY IS WEAK See Waring message 441 Low Battery Voltage. CODE: 1443 Indicates battery has dropped below genset operating range (3.5 volts LAMP: Warning when cranking) to power the starter and the control circuitry. MESSAGE: ‘See Warning message 441 Low Battery Voltage. BATTERY IS DEAD 4-105. Maintenance GENERAL Establish and adhere to a definite schedule for maintenance and servise based on the application and severity of the environment. Table 5-1 covers the recommended sence intervals for a generator set on STANDBY service. If the set will be subjected to extreme operating conditions, the service inter- vals should be reduced accordingly. Some of the factors that can affect the maintenance schedule are the followin. * Use for continuous duty (prime power) + Extremes in ambient temperature + Exposure to weather 51 + Exposure to salt water ‘* Exposure to dust, sand or other airborne con- taminates Consult with your local Cummins Power Generation distributor if the generator set will be subjected to any extreme operating conditions and determine a suitable schedule of maintenance. Use the running time meter to keep an accurate log of all service per- formed for warranty support. Perform all service at the time period indicated or atter the number of op- erating hours indicated, whichever comes first. Use Table 5-1 to determine the maintenance required and then refer to the sections that follow for the cor- rect service procedures.‘TABLE 5-1. PERIODIC MAINTENANCE SCHEDULE SERVICE TIME Daily [MO | Suny | Yearly MAINTENANCE ITEMS etn [orator other] trie [arate] sono | 28 ‘Schdl. Hours 100 | ter 250 Hours Hours Hours | Hours General setinspection x | Oe Check engine oil level x ‘Check coolant level of radiators (Jacket Water x <A) Check coolant heater(s) x ‘Check battery charging system x Check all hardware (fittings, clamps, fasteners, eto.) x ‘Check drive belts xe Check battery electrolyte level x Drain exhaust condensate trap x Check generator air outlet x Check radiator hoses for wear and cracks x ‘Grease fan bearings (twe) x Test generator insulation resistance: xt Groace gonorator boaring (P80) xe Grease generator beating (P7) % Check air cleaner (replace as necessary) xt Drain fuel filter(s) xt Check anti-freeze and DCA concentration xt [Change engine oil and filler xt Change jacket water coolant filters xt Clean crankoase breather xt Change fuel filters xt Clean Jacket Water & LTA cooling systems x X1 - Refer to Cummins QSK45/OSKE6O Series Engine Operation and Maintenance Manual for maintenance interval and/or procedure. X@ - Check for cil, fuel, cooing and exhaust system leaks. Check exhaust system audibly and visvally with set running and repair any leaks immediately. X® - Visually check bolts for evidence of wear orsippage. Replace it hard orbit X# This procedure shouldbe followed petiocoaly throughout the life ofthe generator so, ort the generaéor has st idle fora period of time with no generator heaters used. Contact your authorized sence center. x8 P7 outside casing is round, PBO outside casing is octagon-shaped (at-sided). 5-2GENERAL INSPECTION During operation, be alert for mechanical problems that could create unsate or hazardous conditions. The following sections cover several areas that should be frequently inspected for continued safe operation. Exhaust System With the generator set operating, inspect the entire exhaust system visually and audibly including the exhaust manifold, muffler, and exhaust pipe. Check for leaks at all connections, welds, gaskets, and joints and also make sure that exhaust pipes are not heating surrounding areas excessively. If any leaks are detected, shut down the generator set and have leaks corrected immediately. (AWABNING) Inhalation of exhaust gases can re- sult In severe personal injury or death. Be sure deadly exhaust gas is piped outside and away from any windows, doors, vents or other inlets to building and not allowed to accumulate in in- habitable areas. Fuel System With the generator set operating, inspect the fuel supply lines, retum lings, tliters, and fittings for leaks. Check any flexible sections for cuts, cracks and abrasions and make sure they are not rubbing against anything that could cause breakage. If any leaks are detected, have them corrected immedi- ately. Ignition of fuel can cause severe personal injury or death by fire or explosion. Do not permit any flame, cigarette, arcing switch or equipment, pilot light, or other igniter near the fuel system or in areas sharing ventilation. AC Electric System Check the following while the generator set is oper- ating. Frequency: The generator frequency should be stable and the reading should be the same as the nameplate. AC Voltage: At no load, the line-to-line voltage(s) should be the same as the set nameplate rating, AC Ammeter: At no load, the current readings ‘should be zero. With a load epplied, each line cur- rent should be about the same. Panel Lamps: Press and hold down the Panel Lamp/Lamp Test button on the control panel. All in- dicator lamps should light. Verify that all lamps are ‘on and then release the button. Contact an autho- rized service center if any lamps are burned out. DC Electrical System Check the terminals on the batteries for clean and tight connections. Loose or corroded connections create resistance which can hinder starting. Refer to BATTERIES later in this section for cleaning and safety precautions. Engine Monitor fluid levels and oil pressure and coolant temperatures frequently. Most engine problems give an early warming. Look and listen for changes in engine performance, sound, or appearance that ‘can indicate service or repairs needed. Some en- gine changes to look for are es follows: © Misfire * Vibration © Unusual noises ‘* Sudden changes in engine operating tempera- tures or pressures: * Excessive exhaust smoke © Loss of power * An increase in oil consumption * An increase in fuel consumption © Fuel, oll, or coolant leaks,GENERATOR SET MAINTENANCE (Battery Disconnected) Ignition of explosive battery gases can cause severe personal injury or death. Arc- ing at battery terminals, light switch or other equipment, flame, pilot lights and sparks can ig nite battery gas. Dc not smoke, or switch trouble light ON or OFF near battery. Discharge static electricity from body before touching bat- pow by first touching a grounded metal sur- ce. Ventilate battery area before working on or near battery—Wear goggles—Stop genset and dis- connect charger before disconnecting battery cables—Disconnect negative (-) cable first and reconnect last. Disconnect battery charger from AC source before disconnecting battery cables. Otherwise, disconnecting cables can result in voltage spikes damaging to DC control circuits of the set. Accidental starting of the generator set can cause severe personal injury or death. Prevent accidental starting by disconnecting the negative (-) cable trom the battery terminal before beginning maintenance procedures. When performing the following maintenance proce- dures, make certain the generator set cannot be ao- cidentally restarted as follows: 1, Move the O/Manual/Auto switch on the control panel to the O (off) cosition. 2. Tum off or remove AC power from the battery charger. 54 3, Remove the negative (~) battery cable from the generator set starting battery. Mechanical Inspection With the generator set stopsed, check for loose belts and fittings, leaking gaskets and hoses, or any signs of mechanical damage. if any problems are found, have them corrected immediately. FUEL SYSTEM Refer to the Cummins QSK45 and QSK60 Series Engines Operation and Maintenance Manual for fuel recommendations and fuel system mainte- nance, such as, draining of the fuel-water separat- ors and fuel filter replacement interval and proce- dure. Fuel Handling Precautions Ignition of fuel can cause serious personal injury or death by fire or explosion. Do not permit any flame, cigarette, arc, spark, pilot light, or other igniter near the fuel system. ‘To avoid condensation problems, keep fuel supply tanks as full as possible by filing up each time the engine is used. In cold weather, warm fuel retuming from the injectors heats the fuel in the supply tank. If the fuel level is low, the upper portion of the tank tends to form condensation. In warm weather, both the fuel and the tank will be warm during the day- time. At night, cool air tends to lower the tempera- ture of the tank more rapidly than the temperature of the fuel. If the fuel level is low, the upper portion of the tank will cool more rapidly and tend to form con- densation. ‘Condensation (water) can cause clogging of fuel fi ters with the sulphur in the fuel forms acid which can corrode and damage engine parts.LUBRICATION SYSTEM Gensets are shipped filled with the correct type and quantity of oll. Be sure to check oil level before initial start. Oil API Classification Refer to the Cummins QSK45 and QSK60 Series Engines Operation and Maintenance Manual or lu- bricating oil classification. Oil Viscosity Refer to the Cummins QSK45 and QSK60 Series Engines Operation and Maintenance Manual forlu- bricating oil recommendations/specifications. il Level Engine Check the engine oil level during engine shutdown Periods at the intervals specified in the Mainte- nance Table. The dipstick is stamped with high and jow marks to indicate the level of oil in the crank- case. For accurate readings, shut off the engine and wait approximately 15 minutes before checking the oil evel. This allows oil in the upper portion of the engine to drain back into the crankcase, Crankease pressure can blow out hot oll and cause severe burns. Do NOT check oil while the generator set is operating. 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 tie same API viscos- ity and brand when necessary, Install the oil fil cap after adding oil. ([ACAUTION) Do not operate the engine with the oil level below the low mark or above the high ‘mark. Overfilling can cause foaming or aeration of the oil while operation below the low mark may cause loss of oil pressure. Oil and Filter Change Refer to the Cummins QSK45 and QSK60 Series Engines Operation and Maintenance Manual for maintenance interval and procedure. State or federal agencies have de- termined that contact with used engine oil can cause cancer or reproductive toxicity. Do not contact oil or breath vapors. Use rubber gloves and wash exposed skin. Used oil and filters must be disposed of proper- ly to avoid environmental damage and clean-up liability. Check all federal, state and local regu- lations for disposal requirements. |COOLING SYSTEM The heater must not be operated while the the cooling system Is empty or when the engine is running or damage to the heater will oceur, (ACAUTION) Remove AC power to the heater be- fore disconnecting battery cables. Heater will run continuously without DC power and can overheat and damage heater. [CAUTION] Do not add cold coolant to a hot en- gine. Engine castings can be damaged. Allow the engine to cool to below 120° F (50° C) before adding coolant. Coolant Level Check the coolant level during shutdown periods at the intervals specified ir the Maintenance Table. A sight glass is provided on both radiators (Figure 5-1). The coolant level should be approximately in the middle of the sight glass, with the coolant tempera- ture at 120° F (60°C) or lower. Refer to the Cum- mins QSK60 Series Engines Operation and Mainte- nance Manual for coolant recommendations/speci- fications. Contact with hot coolant can result in serious burns. Allow cooling system to cool before releasing pressure and removing jacket water radiator cap or LTA expansion tank cap. Cooling System Maintenance Refer to the Cummins QSK60 Series Engines Op- eration and Maintenance Manualtor all cooling sys- tem maintenance, such as, coolant requirements, filing of the engine jacket water and LTA cooling systems, coolant filter replacement and flushing and cleaning. Refer to Figure 5-2 for the coolant drain locations of the aftercooler and water jacket systems. In addition to the cooling system maintenance pro- cedures in the Engine Operation and Maintenance Manual, also refer to the generator set Installation Manual (Section 9). This manual contains additional information which must be followed to properly bleed the air from the cooling system during coolant refill. Hf engine coolant heater(s) is installed in the jacket water cooling system, disconnect heater(s) from Power source before performing cooling system maintenance. (ACAUTION] The heater element will burn out if engine coolant is removed with heater con- nected to power source. The heater clement will burn out if power is connected before it is filled with cool- ant or if straight antifreeze solution is used for coolant. Before connecting power, fill the en- gine with coolant and run itfor a while to circu- late coolant through the heater.COOLANT SIGHT GLASS JACKET WATER COOLING ‘SYSTEM FILL CAP LTA COOLING ‘SYSTEM FILL CAP FIGURE 5-1. COOLING SYSTEM SIGHT GLASSES/FILL LOCATIONS ———_ Phe AFTER COOLER COOLANT DRAIN JACKET WATER AFTER COOLER COOLANT DRAIN COOLANT DRAIN {GOTH SIDES) (GOTH SIDES) FIGURE 5-2. AFTER COOLER/JACKET WATER COOLANT DRAIN LOCATIONS 5-7Coolant Heater Cheek the operation of the coolant heater by verify- ing that hot coolant is being discharged from the outlet hose. Do not touch outlet hose - it heater is operational, radiant heat should be felt with hand held close to outlet hoss. 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. AIR CLEANER Refer to the Cummins QSK60 Series Engines Op- eration and Maintenance Manual for air cleaner fil- ter element replacement interval and procedure. ourlet DRAIN WLET | FIGURE 5-3. COOLANT HEATERBATTERIES Ignition of explosive battery gases can cause severe personal injury or death. Arc- ing at battery terminals, light switch or other equipment, flame, pilot lights and sparks can ig- nite battery gas. Do not smoke, or switch trouble light ON or OFF near battery. Discharge static electricity from body before touching bat- teries by first touching a grounded metal sur- face. Ventilate battery area before working on or near battery—Wear goggles—Stop genset and dis- connect charger before disconnecting battery cables—Disconnect negative (-) cable first and reconnect last. (ACAUTION] Disconnect battery charger from AC source before disconnecting battery cables. Otherwise, disconnecting cables can result in voltage spikes damaging to DC control circuits of the set. ‘Check the condition of the starting batteries at the interval specified in the Maintenance Table. To pre- vent dangerous arcing, always disconnect the neg- ative ground cable from the battery before working ‘on any part of the electical system or the engine. Disregard the sections On Checking Specific Gravi- ty and Checking Electrolyte Level if using a “mainte- nance-free" battery. Cleaning Batteries Electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes. Do not get the substance in your eyes or contact with skin. Wear goggles and protective, rubber gloves and apron when servicing batteries. In case of contact, immediately wash skin with soap and water. In case of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. IMMEDIATELY CALL A PHYSICIAN. 59 Keep the batteries clean by wiping them with a damp cloth whenever dirt appears excessive. If corrosion is present around the terminal connec- tions, remove battery cables and wash the termi- nals with a solution consisting of 1/4 pound of bak- ing soda added to 1 quart of water. (This solution is, also used for washing down spilled electrolyte.) Be sure the vent plugs are tight to prevent cleaning solution from entering the cells. After cleaning, flush the outside of the battery and ‘surrounding areas with clean water. Keep the battery terminals clean and tight. After making connections, coat the terminals with a light application of petroleum jelly or non-conductive grease to retard corrosion. Checking Specific Gravity Use a battery hydrometer to check the specific gravity of the electrolyte in each battery cell. Hold the hydrometer vertical and take the reading. Correct the reading by adding four gravity points (0.004) for every ten degrees the electrolyte tem- perature is above 80° F (27° C). A fully charged bat- tery will have a corrected specific aravity of 1.260. Charge the battery if the reading is below 1.215. Checking Electrolyte Level [ACAUTION] Do not add water in freezing weather unless the engine will run long enough (two to three hours) fo assure a thorough mixing of wa- ter and electrolyte. ‘Check the level of the electrolyte (acid and water solution) in the batteries at least every 200 hours of operation. Fill the battery cells to the bottom ofthe filer neck. If cells are low on water, add distilled water and re- charge. IFone cell is low, check case for leaks. Keep the battery case clean and dry. An accumulation of moisture will lead to a more rapid discharge and battery failure,Battery Replacement Always replace the starting battery with the same number and type (vented, lead acid). Property dis- pose of battery in accordance with local environ- mental agency requirements. Electrolyte or explosion of battery can cause severe personal injury or death. Do not mutilate or burn the battery in a fire for dis- posal. Damage to case will release electrolyte which is harmful to the skin and eyes and is also toxic. Burning of battery may cause an explosion. 5-10 NiCad Batteries NiCad (nickel-cadmium) battery systems are often ‘specified where extreme high or low ambient tem- perature is expected because their performance is less affected by temperature extremes than that of lead-acid batteries. NiCad batteries require special battery chargers in ‘order to bring them to the ful-charge level. These chargers must be provided with filter to reduce “charge ripple” which can disrupt engine and gener- ator control systems.FAN BEARING RE-LUBRICATION Re-lubricate the fan bearings at the interval speci- fied in the Maintenance Table. A grease fitting is provided for each of ths two bearings to allow the use of a grease gun to re-lubricate the bearings. The grease fittings are located on side of the fan housing pedestal structure (Figure 5-4). The recommended lubricant is a lithium based grease, such as, Mobilix EP 2, Mobilith AW 2, or Shell Alvania R3. Note the following quentities when re-lubricating the bearings. Fan side bearing ~ 39 grams Pulley side beating ~ 31 grams en BEARINGS FITTINGS FIGURE 5-4. FAN BEARING GREASE FITTINGSFAN BELT REPLACEMENT (AWARNING] Arcing at battery terminals, arcing in light switch or other equipment, flame, pilot lights and sparks can ignite battery gas causing ‘severe personal injury. Ventilate battery area before working on or near battery—Wear safety glasses—Do not smoke— ‘Switch trouble light ON or OFF away from bat- tery—Stop genset and disconnect charger be- fore disconnecting battery cables—Disconnect negative (-) cable first and reconnect last. Disconnect battery charger from AC source before disconnecting battery cables. Otherwise, disconnecting cables can result in voltage spikes damaging to DC control circuits of the set. Accidental starting of the generator set while working on it can cause severe per- sonal injury or death, Prevent accidental start- ing by disconnecting the negative (-) cable from the battery terminal. Belt Removal 1. Disconnect the negative (-) cable fron the bat- tery to prevent acctdental starting. 2. Remove fan belt guard (between engine and radiator) to gain access to fan belt. 3. Use an 8-point socket and breaker bar or a large wrench to hold the idler in position against the spring tension. Slowly tum the wrench until the spring tension is relieved (Figure 5-5). Re- move the fan belt. The fan belt idler is under ten- sion. Do not allow your hands to get be- tween the idler and the belt or the fan hub. Personal injury will result. Belt Replacement 1. Slip new fan belt onto the crankshaft and fan hub pulley. The fan belt idler is under ten- sion. Do not allow your hands to get be- tween the idler and the belt or the fan hub. Personal injury will result. 2. Use an 8:point socket and breaker bar or a large wrench to hold the idler in position against the spring tension. Slowly tum the wrench until the spring tension is relieved sufficiently to position the belt in front ofthe idler pulley. Align the grooves of the belt on the ribs of the pulley and shaft and then slowiy release spring ten- sion onto belt. 7 spring-loaded idler used on this design maintains the correct belt tension. 3, Install fan belt guards. 4, Reconnect starting batteries (negative cable last). §. Start genset and visually check belt for proper alignment with engine running. ‘TURN WRENCH IN DIRECTION OF ARROW UNTIL SPRING TENSION 1S RELIEVED. FIGURE 5-5. FAN BELT REPLACEMENTGENERATOR BEARING RE-LUBRICATION Re-lubricate the generator bearing at the interval specified in the Mainterance Table. A grease fitting is provided to allow the use of a grease gun to re-iu- bricate the bearing. The bearing must be filed with the same type of grease used when the generator was manufac- tured. This grease was chosen to provide the bear- ing with optimum lubrizating characteristics, and MUST NOT be mixed with any other type. The grease that must be used is Kluber, type ASONIC GHY72. To locate the nearest Kliber grease distributor, see Kluber Web site at: www.klueber.com Lubrication Itis important that the correct quantity of grease is used for periodic re-lubrication with a grease gun during planned maintenance. Refer to label located at bearing end of generator (if provided) or Table 5-2, which specifies the grease fill quantity. To determine how much grease is supplied with each pump (stroke) of the device, weight the quanti- ty required (e.g,, 75 grams or 2.7 ounces + 1/4 = 19 grams or 0.68 ounces), against the number of pump strokes taken to inject that amount onto a small weighing scale. Also, nete in practice: © If the pump hits an airlock, (i.e., no pressure when pumping) these strokes can not be counted. * For greater accuracy, the grease fitting can be unscrewed, and a flexible grease-pipe sctewed directly to the fiting adapter. This will make sure that no grease is expelled outside of the fiting. ‘ If too much grease is applied, any excess will be exhausted out of the bearing cartridge via the grease escape. (Any exhausted grease ‘should be cleaned out of the PMG cover. * Always extend the grease gun pump arm out to its full extent with each pump, failure to do this could mean little or no grease is going into the bearing. Re-Lubrication Procedure 1. Make sure grease gun nozzle and re-lubricat- ing fitting are free from contaminants or abra- sive material 2. With the generator running, apply the specified rerlubrication grease fill quantity through the grease fitting. 3. Run the generator for at a minimum of 10 min- utes to allow excess grease to exhaust. 4, Check inside the PMG cover for expelled grease. Clean out as necessary. ‘TABLE 5-2. MAINTENANCE CHART FOR RE-GREASE ze GREASE QTY RE-LUBRICATION FRAME BEARING P/N CM GRAMS PERIOD a a 3 75 “4000 - 4500 P80" 6824 03 170 151 000 PaO 6282 C3 196 124 7000 PaO® 6286 03 185 178 7000 * 7 outside casing is round, P80 outside casing is octagon-shaped (lat-sided). “Refer to label located at bearing end of generator for bearing PIN. 5-13THIS PAGE LEFT INTENTIONALLY BLANK 5146. Operating Recommendations NO-LOAD OPERATION Periods of no load operation should be held to a minimum. If itis necessary to keep the engine run- ning for long periods of ime when no electric output is required, best engine performance will be ob- tained by connecting a load bank of at least 30 per- cent of nameplate MW rating, EXERCISE PERIOD Generator sets on continuous standby must be able to go from a cold start to being fully operational in a matter of seconds. This can impose a severe bur- den on engine parts. Regular exercising keeos engine parts lubricated, prevents oxidation of electrical contacts and in gen- eral helps provide reliable engine starting, Exercise the generator set at least once a month for a minimum of 80 minutes, under not less than 30 percent of the nameplate MW rating. LOW OPERATING TEMPERATURE Use a coolant heater if a separate source of power is available. The optional heater available trom Cummins will help provide reliable starting under adverse weather conditions. Be sure the voltage of the separate power source is correct for the heater element rating. 6-1 HIGH OPERATING TEMPERATURE Refer to the genset nameplate for the maximum ambient operating temperature, if applicable. GENERATOR SET STANDBY RATING Applicable for supplying emergency power for the duration of normal power interruption. No sustained overload capability is available for this rating. This rating is applicable to installations served by a reli- able normal utility source. This rating is only appli- Cable to variable loads with an average load factor of 80 percent of the standby rating for a maximum of 200 hours of operation per year and a maximum of 25 hours per year at 100% of ts standby rating. The standby rating is only applicable to emergency and standby applications where the generator set serves as the back up to the normal utility source. No sustained utility parallel operation is permitted with this rating. (Equivalent to Fuel Stop Power in accordance with 1803046, AS2789, DIN6271 and BS5514). Nominally Rated. Derating Factors Engine power available up to 260 m (853 tt) at ambi- ‘ent temperatures up to 40° C (104° F). Above these elevations, derate at 8.9% per 305 m (1000 ft) and 8.4% per 10° C (18° F).THIS PAGE LEFT INTENTIONALLY BLANK 6-2Cummins Power Generation 1400 73rd Avenue N.E. Minneapolis, MIN 55432 1-800-888-6626 763-574-5000 International Use Fax: 763-528-7228 ‘Curmmins i registered trademark of Cummins Inc. Power r Generation (