Power _ Generation Operator’s Manual PowerCommand® Control 2100 Series Generator Sets Models DFAB, DFAC Printed in U.S.A, 960-0175C 02-2004Table of Contents SECTION TITLE IMPORTANT SAFETY INSTRUCTIONS ...... eoceeeee sai INTRODUCTION General How to Obtain Service SPECIFICATIONS CONTROL OPERATION General Prestart Checks a. Control Panel Power On/Off Modes Front Panel Starting . Stopping . : Menu Display and Buttons Main Menus. : Adjusting Default Settings ... System Messages ...... Controller Configuration Menu Engine Menu. Alternator Menu Adjust Menu . Faults Menu System Menu History Menu About Menu Power Transfer Menu 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. 14 ott at 31 3-13 345 345 316 348 + 3:20 3:22 3.24 + 3-26 +. 3-28 3-30 +332SECTION TITLE PAGE 4 TROUBLESHOOTING General Safety Considerations . . Status Indicators oe Line Circuit Breaker (Optional) oe Control and Diagnostics VIA Network or PC (Laptop) 42 Fault Codes . 2 Fault Code Table ....... Troubleshooting TAbIe esc eccccceseesseeneesseeeseseereee AT 5 MAINTENANCE General .........6.5 BA Maintenance Schedule 152 Generator Set Inspection... 53 Generator Set Maintenance (Batlery Disconnected) 54 Lubrication System ......... vette teeeeteeeeees 55 Cooling System... ee ce ceeeeeeeeeeee 56 Change Air Piping .... 56 Fuel System ...... 56 Air Cleaner . ee, Electronic Governor ........20.++ 57 Exhaust Condensation Trap 5-7 Batteries .. 6 OPERATING RECOMMENDATIONS No-Load Operation ............. 64 Exercise Period .... Low Operating Temperature ...... wo OF High Operating Temperature ..... 64 7 OPTIONAL ENCLOSURE FEATURES Geeal Extemal Receptacle ......... Overiill Alarm ...... External Emergency Stop Switch AC Distribution Panel ..... Fuel Transfer Pump ....... Extemal Alarm Panel External Fuel Fill Box1. Introduction GENERAL Each operator should read this manual before oper- ating the set for the first time. A generator set (gen- set) must be operated and maintained properly if you are to expect safe and reliable 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 and follow the safety precautions (on page iii 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- 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. Ifyou 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. [A WARNING] INCORRECT SERVICE OR PARTS REPLACEMENT CAN RESULT IN SEVERE PERSONAL IN- JURY, DEATH, AND/OR EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST BE TRAINED AND EXPERIENCED TO PERFORM ELECTRICAL AND/OR MECHANICAL SERVICE. Copyright© 2008 Cummins Power Generation. All rights reserved. ‘Cummins and PowerCommand are registered trademarks of Curnmin Inc. 1THIS PAGE LEFT INTENTIONALLY BLANK 4-22. Specifications MODEL DFAB, DFAC Engine ‘Cummins Diesel Series LTato Generator (Standby Rating) ‘See Genset Nameplate for rating information, Electrical System Starting Voltage 24 Volts DC Battery Two, 12 Volt Group Number ‘8D CCA (minimum) Cold Soak @ 0° F (-18° C) 1400 Cooling System Capacity with Standard Radiator 18 Gal (49 L) Lubricating System Oil Capacity with Fiters 9.5 Gal (96 L) Oil Type* * Refer to Cummins engine Operation and Maintenance Manual for Wrleting oll recommendatonslepectcations. FUEL CONSUMPTION (STANDBY/FULL LOAD/60HZ) MODEL DFAB DFAG US gph (Uhr) 15.6 (59) 16.8 (64) SHUTDOWN LIMITS ‘OIL PRESSURE WARNING AND Normal Oil Pressure ‘Warning Limit Shutdown Limit ‘30-50 psi (207-345 kPa) 25 psi (172 kPa) 20 psi (138 kPa) Idle Oil Pressure ‘Warning Limit Shutdown Limit 15 psi (104 kPa) 12 psi (83 kPa) 8 psi (55 kPa) 24THIS PAGE LEFT INTENTIONALLY BLANK 2-23. Control Operation GENERAL The following describes the function and operation of the PowerCommand™ 2100 Control (PCC). All in- dicators, control switches/buttons and digital dis- play are located on the face of the control panel as illustrated in Figure 3-1. This section covers prestart checks, starting and stopping and operating the generator set. Each op- erator should read through this entire section before attempting to start the set. itis essential that the op- erator be completely familiar with the set and the PCC control. Refer to Section 6 for operating rec- ommendations, Before starting, be sure the following checks have been made and the unit is ready for operation. PRESTART CHECKS. 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 “Cooling Systems" in the Maintenance section of this manu- als for proper procedure. 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. Ventilation Make sure the generator set cooling inleVoutlet and exhaust ventilation openings are clear (not blocked) and operational Remove all loose debris from surrounding area of generator set. Air flow from the radiator fan can blow loose items around and into ventilation open- ings. 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 gases 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 Coherently oes IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GET OUT 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 repaired. Protection against carbon monoxide inhalation includes proper installation and regular, frequent visual and audible inspections of the complete exhaust system.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 contro! panel LEDs/digital display will remain active until the Screen Saver mode is activated. Screen Saver Mode: Power to the digital display is removed after 30 minutes (generator set not run- ning or running). The 30 minute timer resets and be- gins after each control panel action (any button or switch selection) or signal received by the operating software. All LEDs on the control panel operate nor- mally during Screen Saver mode, indicating that the operating software is active (Awake mode) When a "Warning" signal is sensed by the PCC (for example, low coolant temp), the control displays the warming message Sleep/Awake Mode: In the Sleep mode, the con- trol's operating software is inactive and the LEDs and the digital display on the control panel are all of. Sleep mode is a feature used to reduce battery power consumption when the control is not being 32 used and the O/Manual/Auto switch is in the O posi- tion. When all conditions are met (i.e., no unacknowl- edged faults and O/Manual/Auto switch is in the O position) the Sleep mode is activated. The operating software is initialized and the digital display and control panel LEDs are tumed on in re- sponse to moving/pressing the following control panel switch/buttons: * Off/Manual/Auto switch ‘+ Emergency Stop button ‘+ Fault Acknowledge/Reset button * Panel Lamp/Lamp lest button To activate the control and view the menu display without starting the generator set, press Fault Ac- knowledge or Panel Lamp button or move mode switch from O to Manual The InPower service tool is required to enable or disable the Sleep mode. When shipped from the factory, Sleep mode is disabled. When disabled, the operating software will always remain active (Awake mode). If network and/or power transfer control (PTC) feature is installed, the sleep mode is not available. The InPower service tool is required to select the de- sired mode. Contact an authorized service center for assistance.MENU ‘SHUTDOWN SELECTION AND WARNING BUTTON Previous trots) MAINMENU — STATUS | pane. BUTTON FUNNINGIREMOTE STARTINOT IN AUTO EMERGENCY INDICATORS. DIGITAL ‘STOP PUSH SPAY BUTTON CONFIGURABLE (Pullto reset) Peele LAMP (1 of 3) HOME BUTTON ANALOG AC OFF/MANUAL/ METERING AUTO SWITCH PANEL (OPTIONAL) FAULT ACKNOWLEDGEMENT/ MANUAL RESET BUTTON RUN'STOP BUTTON PANEL LAMP AND LAMP Test BUTTON FIGURE 3-1. FRONT PANEL, 33FRONT PANEL, Figure 3-1 shows the features of the front panel. Digital Display: This two-line, 20-characters per line alphanumeric display is used to view menus of the menu-driven operating system. Refer to the menu trees later in this section. The display is also used to show warning and shutdown messages. Display Menu Selection Buttons: Four momen- tary buttons—two on each side of the digital display window—are used to step through the various menu options and to adjust generator set parame- ters. A green triangle (¢ orp), arrow (/',), ¢, oF 9), >>, or plus/minus sign (+ or -) in the digital display adjacent to the button is shown when the button can be used (button is “active’). Refer to Menu Display And Buttons later in this section Home Button: Press this button (44) to view the Home Menu. Refer to the menu trees later in this section. Previous Main Menu Button: Press this button (4) to view the previous Main Menu. All main menus in- clude both types of green triangles (¢ and). Refer to the menu trees later in this section. NOTE: The up and down arrows (|' and.) are used to navigate between submenus. Emergency Stop Button: Push this button in for emergency shutdown of the generator set. This will stop the generator eet immediately and provent starting of the set from any location (local and re- mote). To reset: 1, Pull the button and allow it to pop out. 2. Tum the O/Manual/Auto switch to © (Off). 3. Press the front panel Fault Acknowledge/Re- set button. 4. Select Manual or Auto, as required. Emergency Stop shutdown can be reset only at the PCC front panel. Running Indicator: This green lamp is lit whenever, the generator (local or remote) is running. 3-4 Remote Start Indicator: This green lamp is it whenever the control is receiving a remote start sig- nal. Not in Auto Indicator: This red lamp flashes con- tinuously when the O/Manual/Auto switch is not in the Auto position. Analog AC Metering Panel (Optional): This panel simultaneously displays (in percent of genset rated output): 3-phase line-to-line AC current (A~) Kilowatts (kW) Generator output frequency in hertz (Hz) S-phase line-to-line AC volts (V~) * Power Factor (PF) (shown in 0.2 increments) Shutdown Status Indicator: This red lamp is lit whenever the control detects a shutdown condition ‘The generator set cannot 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 © position and pressing the Fault Ac- knowledge/Reset button. Warning Status Indicator: This yellow lamp is lit whenever the control detects a warning condition. After the condition is corrected, waming indicators can be reset by pressing the Fault Acknowledge/ Reset button. (It is not necessary to stop the gener- ator set.) In auto mode, warning indicators can also be reset by cycling the remote reset input after the condition is corrected. Some warnings remain active after the condition is corrected and the control reset button is presse This will require the genset to be shutdown to reset the warning indicator. Fault Acknowledge/Reset Button: Press this but- ton to acknowledge waming and shutdown mes- sages after the fault has been corrected. Pressing this button clears the fault from the current fault list. To acknowledge a Warning message, the O/Manu- al/Auto switch can be in any position. (It is not nec- essary to stop the generator set to acknowledge an inactive Warning condition.) To acknowledge a shutdown message with this button, the O/Manual/ Auto switch must be in the O position.Panel Lamp and Lamp Test Button: Press this button to turn the control pane! lamps on or off. The lights will shut off after about ten minutes. Press and hold this button to test all front panel LEDs and me- ters. The meters will ight one bar at a time. 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. O/Manual/Auto Switch: The Manual position en- ables the use of the Manual Run/Stop button, The Auto position enables start/stop control of the engine from a remote location. (It disables the use of the Manual Run/Stop button.) ‘The O (Off) position prevents the starting of the set (local or remote). If the switch is set to O during set operation, the engine will immediately shut down (cool-down timers are bypassed). This hot shut- down should be avoided, if possible, to help prolong the life of the engine. Configurable Indicators The following configurable indicators (default val- ues shown) can be changed with the InPower ser- vice tool. The configurable items are: change gen- erator event and LED color (green, yellow or red), and enable/disable indicator. The InPower service tool is required to select the de- sired settings. Contact an authorized service center for assistance. Low Oil Pressure Warning Indicator: This yellow lamp indicates the oil pressure is lower than the nor- mal range of operation. High Engine Temperature Warning Indicator: This yellow lamp indicates the engine temperature is higher than the normal range of operation. Low Oil Pressure Shutdown Indicator: This red lamp indicates the engine has shut down because of low oil pressure. Overspeed Shutdown Indicator: This red lamp in- dicates the engine has shut down because of ex- cessive speed. Fail to Start Indicator: This red lamp indicates the engine failed to start.STARTING The following headings cover the systems used to start the generator set. Figures 3-2, 3-3 and 3-4 pro- vide a flow chart for all start/run/stop sequences, Before starting the generator set, make sure that exhaust and fuel fittings are tight and properly posi- tioned and that proper maintenance has been per- formed. See Prestart Checks in this section. With the optional Power Transfer Control (PTC) mod- tle installed, the function and sequence of operation of the Start command can differ and is noted as “PTC” in the following paragraphs. Refer to the Pow- er Transfer Menu in this section, which describes the operation of the PTC feature, Starting at the Control Panel (Manual Mode) Tum the O/Manual/Auto switch to the Manual posi- 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. The InPower service tool is required to enable/dis- able the warm-up at idle feature and to adjust the time-out. When shipped from the factory, this feature is disabled. When the switch is in the Manual position, the con- trol will complete the warm-up at idle feature if en- abled. When the coolant reaches operating tomper- ature or the warm-up time at idle time delay (0-300 seconds) is reached, whichever occurs first, the generator set will ramp to the rated speed and volt- age. ‘When the switch is in the Manual position, the gener- ator set can be operated in the idle mode (used for maintenance, troubleshooting, etc.). Refer to Adjust menu (Figure 3-11) to enable/disable the idle feature. 3-6 If the engine does not start, the starter will disen- gage after a specified period of time and the control will indicate an overorank shutdown. The generator can be configured for a number of, starting cycles (1-7) with set times for crank and rest periods for all starting modes (manual/remote). The default setting is for 3 start cycles, composed of 15 seconds of cranking and 15 seconds of rest. To change the cycle number, and the crank and rest times, contact an authorized service center for assis- tance. To clear a Fail to Start shutdown, place the O/Manu- al/Auto switch in the © position and press the Fault Acknowledge/Reset button. Wait two minutes for the starter motor to cool and then repeat the starting procedure. If the engine does not run after a second attempt, refer to the Troubleshooting section. Starting from a Remote Location (PTC or Remote Start Signal) (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 optional PTC module). PTC - Ifa switch is connected to the remote start in- put of the control and the PTC module is installed, this switch will function as a Test switch. The PTC Test sequence is shown in Figure 3-4. In response to the Remote Start or the control de- tects the loss of S1 voltage (PTC option installed), the control lights the Remote Start indicator and ini tiates the starting sequence as shown in Figure 3-3. When the switch is in the Auto position, the control will complete the time delay to start Refer to the Adjust submenu in this section to enable and change the time delay start/stop settings.Cold Starting with Loads In accordance with NFPA 110, Cummins Power Generation recommends installing standby gener- ator 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 jacket water coolant be maintained at a minimum of 90°F (82°C) and, for most applications, accept the emer- gency load in 10 seconds or less. Although most Cummins Power Generation generator sets will start in temperatures down to -25°F (32°C) when equipped with engine jacket water coolant heaters, it might take more than 10 seconds to warm the en- gine up 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 Waming LED, is pro- vided to meet the requirements of NFPA 110. The engine cold sensing logic initiates a warning 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. Under these conditions, al- though the generator set may start, it may not be able to accept load within 10 seconds. When this condition occurs, check the coolant heaters for proper operation. If the coolant heaters are operat- ing property, other precautions may be necessary to warm the engine before applying a load. STOPPING Emergency Stop The emergency stop button is located near the cen- ter of the upper part of the control pane! (Figure 3-1). Push the button in for an emergency stop. The red Shutdown status LED is lit and the emergency stop message is displayed. To reset: 1. Pull the emergency stop button out. 2. Turn the O/Manual/Auto switch to O. 3, Press the front panel Fault Acknowledge/ Reset button. 4. Select Manual or Auto, as required. Emergency Stop shutdown status can be reset only at the operator control panel. Stopping at Control Panel (Manual Mode) If the set was started at the control panel (O/Manu- al/Auto switch in the Manual position), pressing the Manual Run/Stop button causes the set to complete its normal (Local Start) shutdown sequence (Figure 3-2). The set stops after the cool-down at idle timer (0 to 30 minutes) has timed out. The InPower service tool is required to enable/dis- able the Cool-down At Idle feature. Contact an autho- rized service center for assistance. Turing the O/Manual/Auto switch to the O position causes an immediate engine shutdown (bypasses Cool-down At Idle). If possible, this hot shutdown should be avoided to help prolong the reliability of the engine. Stopping from Remote Location (PTC or Remote Stop Signal) (Auto Mode) If the control receives a remote stop signal or the control detects the return of St voltage (PTC option installed), the set completes its normal shutdown sequence (Figure 3-3). (The remote stop signal is actually the removal of the remote start signal to the control.) The set stops after completing the Time Delay To ‘Stop (0 to 600 seconds) and the cool-down at idle (0-30 minutes) Refer to the Adjust submenu in this section to enable and change the Time Delay To Stop setting. The In- Power service tool is required to enable/disable the Cool-down At Idle feature. Contact an authorized service center for assistance.TOGAL START (Manual Mode) | CONTROL AUN BUTTON, ¥ WARW-UP @ DLE (0-300 sec) 1 1 2 + Engine Tempera ingine Temperalure EMERGENCY, ‘greater than 100° F go } to Rated RATED SPEED VOLTAGE: CONTROL STOP BUTTON ¥ SRATED TO IDLE DELAY (0-10 sec) 2 COOL-DOWN @ IDLE {0-30 min) 4 2 STOP NoTES: 1. Warmup/cookdown idle adjusted time-out with InPower. 2. Timer expires. 3, Beginning Version 2.303, FIGURE 3-2. STARTING AT THE CONTROL PANEL (MANUAL MODE) 3-8PTC DETECTS REMOTE START St FAILURE 1 CUST. CONNECT 2 | EMERGENCY START | TIM DELAY TO START (0-300 sec} | 3 RATED SPEED VOLTAGE | PTC Module sees 1 Voltage OK et OPEN ST CLOSE $2 CLOSE St REMOTE START OPEN s2 Removed 1 TIE DELAY TO EMERGENCY STOP (0-600 sec) STOP BUTTON 3 BS RATED TO IDLE DELAY (0-10 sec) 3 ‘COOLDOWN @ IDLE (0-30 min) 4 I] 3 STOP NOTES: 1. PTC feature installed 2. PTC feature not installed (input from transfer switch, remote start switch, etc) 3. Timer expires. 4. Cool-down adjusted time-out with InPower. 5. Beginning Version 2.303, FIGURE 3-3. STARTING WITH CONTROL IN AUTO MODE (PTC OR REMOTE START SIGNAL)REMOTE START (est)4 | PTC Module sees 81 Voltage OK ¥ TIME DELAY TO START (0-300 sec) 2 1 WARM-UP @ TOLE {0-300 sec) 3 + Engine Temporature EMERGENCY 2 iyeater than 100° F go STOP BUTTON to Rated ¥ RATED SPEED}! ‘& VOLTAGE (Selectable ~ with’ without load) EMOTE START (TEST) Removed + TIME DELAY TO STOP (0-600 sec) 2 + TRATED TOTOLE DELAY (0-10 sec) 2 COOL-DOWN @ IDLE (0-30 min) 3 2 STOP NoTEs: 41. Remote (exercise) start sequence with PTC feature installed. 2. Timer expires. 3. Warm-upicool-down idle adjusted time-out with InPower. 4. Beginning Version 2.308 FIGURE 3-4. PTC FEATURE REMOTE START TEST/EXERCISE SWITCH (IN AUTO MODE) 3-10MENU DISPLAY AND BUTTONS, Figure 3-5 shows the digital display and the menu selection buttons. Digital Display: The two-line, 20 characters per line, digital display is used to view the menus of the menu-driven operating system. Refer to the menu trees later in this section. The display is also used to show fault messages. Display Menu Selection Buttons: Four momen- tary buttons—two on each side of the digital display window—are used to step through the various menu options and to adjust generator set parame- ters. The button is active when a symbol adjacent to the button is displayed. The displayed symbol indi: cates the function of the button. * In the digital display for main menus (Figure 3-6), the 4 and} symbols indicate that pressing the adjacent button causes the operating pro- gram to go to the selected submenu (e.g., En- gine Menu in Figure 3-9). In the digital display, the More>> symbol indi- cates that pressing the adjacent button causes the operating program to go to the next main menu, as shown in Figure 3-6. In the digital display, the | or / symbols indi- cate that pressing the adjacent button causes the operating program to go to the next or pre- vious submenu, as shown in the menu dia grams. Only the |, symbol is displayed in the first submenu. Only the “\ is displayed in the last submenu. Both symbols are displayed in the rest of the submenus. 311 * In the digital display, the plus or minus symbols (+ or -) indicate that pressing the adjacent but- ton can be used to change a parameter or val- ue shown on the display. When there is a choice of two parameters, one parameter is associated with the + symbol and the other is associated with the ~ symbol. ‘When changing values, pressing the button ad- jacent to the + symbol increase the value and pressing the button adjacent to the — symbol decreases the value. Only one numeric char- acter of a field can be changed at a time. In the digital display, the > or< symbol indicates that pressing the adjacent bullon causes the operating program to move the cursor to the next numeric character. The selected numeric character can then be changed by pressing the buttons adjacent to the + and - symbols. Only the > symbol is displayed when the cursor is on the first character of a field that can be changed. Only the < is displayed when the cur- sor is on the last character. Both symbols are displayed when the cursor is on any other char- acter. After adjusting values/parameters, pressing the } symbol results in the changes being saved. If the Home button or Previous Main Menu button is pressed before pressing the ) symbol, the changes are not saved. Home Button: Pressing this button causes the op- erating system to show Main Menu 1 (Figure 3-6) in, the digital display. Previous Main Menu Button: Pressing this button causes the operating system to show the previous Main Menu in the digital display. All main menus in- clude both types of green triangles (4 and).2 LINE, 20 CHARACTERS PER LINE MENU DISPLAY DIGITAL DISPLAY HOME PREVIOUS MAIN BUTTON MENU BUTTON FIGURE 3-5. DIGITAL DISPLAY AND MENU SELECTION BUTTONS. 3412MAIN MENUS ‘As shown in the illustration, each main menu can Figure 3-6 shows the three major main menus avail: __ branch into one of four directions. Press the button able to the user. Figure 3-6 also includes references next to “More>>” in the display to view the next Main to pages in this section where you can find addition- menu. Main Menu 1 is redisplayed when you press al information on submenus. When viewing a sub. ‘he button next to*More>>" in the Main Menu 8 dis- menu, you can press the previous main menu but- Pla. ton at any time to view its main menu. Main Menu 1 4 Engine 4 Alternator Main Menu 2 (Faults History? 4System_ More>> Main Menu 3 PAGE| iserwce! 331 | nce 4 About Setup? (PwrTran More>> PAGE| FIGURE 3-6. MAIN MENUS. 3-13Main Menu 1 Main Menu 1 is also the Home menu. When viewing any of the other main menus or any submenu, you can press the home button to view this menu. To display engine parameters, such as coolant tem- perature, oil pressure, oil temperature, etc., press the button next to the word “Engine” in the display. Tum to the Engine menu diagram on page 3-19. To display alternator parameters, such as line-to- voltage, line-to-neutral voltage, amperage, fre- quency, etc., press the button next to the word “Al- temator’ in the display. Turn to the Alternator menu diagram on page 3-21 To adjust generator parameters, such as idle start, voltage, frequency, start delay, and stop delay, press the button next to the word “Adjust” in the display. Tum to the Adjust menu diagram on page 3-23. To view one of the other main menus, press the but- ton next to “More>>” in the display. Main Menu 2 To display system faults, press the button next to the word “Faults” in the display. Up to 20 of the most, recent/current faults can be displayed. Tur to the Faults menu diagram on page 3-25. To view network system parameters, such as on the automatic transfer switch (ATS), Master, or Genset, 314 system, press the button next to the word "System’ in the display. Tum to the System menu diagram on page 3-27, To display historical engine parameters such as number of starts, engine hours, control hours, kilo- watt hours, and genset duty cycle, press the button next to the word “History” in the display. Turn to the History menu diagram on page 3-29. To view one of the other main menus, press the but- ton next to “More>>” in the display. Main Menu 3 To view parameters on the generator, such as mod- el, standby rating, and software version, press the button next to the word “About” in the display. Turn to the About menu diagram on page 3-31 To view power transfer parameters, such as source power, frequency, generator, utility, and active transfer timer, press the button next to the word “Pwr Tran’ in the display, Turn to the Power Transfer Menu on page 3-33. Main Menu 3 also includes a link to the Setup me- nus. These menus can be viewed but changes to these menus are restricted to service personnel with the appropriate access code. To view one of the other main menus, press the but- ton next to “More>>” in the display.ADJUSTING DEFAULT SETTINGS The Controller Configuration Menu can be used to adjust the following default settings: * Language - Select from available loaded lan- guages + Temperature Units ~ Fahrenheit or Centigrade ‘+ Fluid Pressure Units ~ KPA or PSI For more information on adjusting these settings, turn to the Controller Configuration menu diagram on page 3-17. SYSTEM MESSAGES A system message pop-up screen is displayed when the event itis displaying becomes active, These pop-up screens remain displayed until pre- empted by another pop-up screen or until any dis- play button is pressed. Once a button is pressed, the previous menu is redisplayed. To return to an active pop-up screen from the previous menu, se- lect the following menu: * Engine to redisplay Time Delay Idle * Faults to redisplay Faults * Power Transfer to redisplay PTC Timer 3-15 Pop-up screens are displayed for the following: + Faults * Power Transfer Control timer * Time Delay - Start, Stop, and Idle ‘An example of a Time Delay Idle pop-up screen is shown in Figure 3-7. A countdown, in seconds, is in- cluded in the display. ana See FIGURE 3-7. TIME DELAY IDLE POP-UP SCREENCONTROLLER CONFIGURATION MENU Figure 3-8 shows a block representation of the Con- troller Configuration menus. These menus are used to change the default language, temperature units, and pressure units to be displayed in menus. To view the first Controller Configuration menu, make sure Main Menu 1 is displayed and simuita- neously press the Home Menu and Previous Main Menu buttons. ‘As shown in the diagram, the Controller Configura- tion menu has three submenus. Press the buttons next to the | and symbols in the digital display to navigate between the menus. 3-16 Press the button next to the} symbol in the display Until the + and — symbols are displayed. Press the button next to the + or — symbol to select the desired option. After selecting option, pressing the} symbol results in the changes being saved. If the Home button or Previous Main Menu button is pressed before pressing the } symbol, the changes are not saved. Language Selected submenu: Used to select de- sired language (default = English). Temperature Units submenu: Used to select Fahrenheit or Centigrade for temperature readings. Fluid Pressure Units submenu: Used to select PSI or KPA for pressure readings.CONTROLLER CONFIGURATION MENU Main Menu 1 Language Selected + English ‘Language Selected = English ‘Temperature Units 4 Deg F —— | Temperature Unite c ‘Fluid Pressure Units — Fat “Fluid Pressure Units a kea FIGURE 3-8. CONTROLLER CONFIGURATION MENU 3-17 BackENGINE MENU Figure 3-9 shows a block representation of the En- gine menu. If you press the button next to the word “Engine” in the display, the first Engine submenu is displayed. ‘As shown in the diagram, the Engine menu has seven submenus. The data in the submenus will vary according to the type and number of sensors provided with the engine. Press the buttons next to the |, and! symbols in the digital display to navigate between the menus. Press the Home button or the Previous Main Menu button to return to Main Menu 1. 3-18 Coolant Temperature submenu: This submenu displays the engine coolant temperature which can be viewed in degrees Fahrenheit or Centigrade (see Controller Configuration Menu in this section). Oil Pressure submenu: This submenu displays the engine oil pressure which can be viewed in PSI or KPA (see Controller Configuration Menu in this section). Oi! Temperature submenu (Only available on some models): This submenu displays the engine cil temperature which can be viewed in degrees Fahrenheit or Centigrade (see Controller Configu- ration Menu in this section). Engine Speed submenu: This submenu displays the engine RPM. Battery Voltage submenu: This submenu dis- plays the engine battery voltage. Governor Duty Cycle submenu: This submenu displays the governor duty cycle (drive) levels in percentage of maximum. Active Time Delay submenu: This submenu dis- plays the time delay that is currently active: warm— up, cool down, start or stop delays.Main Menu 1 «Engine ‘Alternator Coolant Temperature J “nnn Deg F "Engine Speed nnn Rent ‘Battery Voltage + nnnvoe ‘NGovernor Duty Cycle Joann 9% *Aetive Time Delay None nnn See FIGURE 3-9. ENGINE MENU 3-19ALTERNATOR MENU Figure 3-10 shows a block representation of the Al- termator menu. If you press the button next to the word “Altemator” in the display, the first Alternator submenu is displayed. ‘As shown in the diagram, the Alternator menu has eleven submenus. Press the buttons next to the | and symbols in the digital display to navigate between the menus. Press the Home button or the Previous Main Menu button to return to Main Menu 1. 3-20 Line-to-Line Voltage submenu: The voltages Line-to-Line (L1, L2 and L3) are measured between Lt to L2, L2 to L3 and L3 to L1, respectively, (Single phase ~ L1 to L2 only.) Line-to-Neutral Voltage submenu: Note that the Line-to -Neutral menu will not be displayed for a 3 phase/8 wire system. Single phase - L1 to N and L2 toN. Amps submenu: All phases. (Single phase ~ L1 and L2 only.) Frequency submenu: Generator set output fre- quency. Total Real Power submenu: This submenu dis- plays the total amount of real power output, in kilo- watts (kW). Real Power submenu: This submenu displays the amount of real power output for L1, L2, and L3, in kilowatts (kW). (Single phase - L1 and L2 only.) Total Apparent Power submenu: This submenu displays the total amount of apparent power output, in kilovolt amps (kVA). Apparent Power submenu: This submenu dis- plays the amount of apparent power output for L1, L2, and L3, in kilovolt amps (kVA). (Single phase - Lt and L2 only.) Total Power Factor submenu: This submenu dis- plays the power factor with leading/lagging indica- tion. The PF reading will contain an asterisk if the power factor is leading (for example, Total PF 0.9 *). Power Factor submenu: This submenu displays a power factor value for Li, L2, and L3. (Single phase ~ Lt and L2 only.) The PF reading will contain an asterisk if the power factor is leading (for example, PF L1 0.9"). AVR Duty Cycle submenu: This submenu dis- plays the voltage regulator (drive) level in percent- age of maximum. (Where maximum is 100% Duty Cycle, software clamps Duty Cycle maximum to 60% for PMG and 90% for shunt.)ALTERNATOR MENU Main Menu 1 Vos Liz 23 Lat 4 nnn_nnn nnn ‘tVolts LiN L2N ‘Total Power ov nnn nn kv, Amps U1 2 13 ioe “Frequency Jann Hz "Total Power vr nnn kW 4 shan ‘nnn "Power Li 12 U3 ‘SAV Duty Cycle J dW nn nnn nnn ‘nnn FIGURE 3-10. ALTERNATOR MENU 3-21ADJUST MENU Figure 3-11 shows a block representation of the Ad- just menu. If you press the button next to the word “Adjust” in the display, the first Adjust submenu is displayed. ‘As shown in the diagram, the Adjust menu has five submenus. Each submenu includes a parameter or value that can be changed. Press the buttons next to the |, and! symbols in the digital display to navigate between the menus. Press the Home button or the Previous Main Menu button to return to Main Menu 1. Adjusting Values/Parameters: 1. Press the button next to the symbol in the dis- play until the + and — symbols are displayed. If necessary, press the button next to the ¢ or> symbols to move to the numeric character you wish to change. Press the button next to the + symbol to in- ctease the value or select parameter; press the button next to the - symbol to decrease the val- ue or select parameter. After adjusting values/selecting parameters, pressing the } symbol results in the changes being saved. (When adjusting values, make sure the cursor is on the last numeric character before pressing the } symbol). If the Home button or Previous Main Menu but- ton is pressed before pressing the » symbol, the changes are not saved. 3-22 Voltage Adjust submenu: Voltage can be ad- justed to -E5 percent of the nominal voltage. For ex- ample, if genset output voltage is 208 volts, the volt- age can be adjusted from 198 to 218 volts. If the displayed value is greater or less than the al- lowed (5%) range, the contro! will not except the try and will return to the previous setting. Retry by entering a smaller change in one volt increments. Frequency Adjust submenu: Frequency can be adjusted to -5 percent of the nominal frequency. For example, if the genset frequency is 60.0 Hz, the frequency can be adjusted from 57.0 to 63.0 Hz. Start Delay submenu: Start Delay can be set from 0 to 300 seconds (default = 0). (Enter 1 or more to enable.) This function is bypassed during a manual start/stop sequence. Stop Delay submenu: Stop Delay can be set from 0 to 600 seconds (default = 0). (Enter 1 or more to enable.) This function is bypassed during a manual start/stop sequence and engine shutdown faults. Rated To Idle (Beginning Version 2.303): Rated To Idle delay can be set from 0 to 10 seconds (de- fault = 0). (Enter 1 or more to enable.) Entering a non-zero delay will cause the genset to delay the transition to Cooldown At Idle. Idle Start submenu (Only available on some models): Idle Start can be enabled or disabled (de- fault = Disable). This function is only enabled when the genset is started in manual mode. Idle Start can also be enabled while the set is running in manual mode. (Auto/remote start is not affected by this set- ting.) Enabling Idle Start will cause the genset to run in idle mode until Idle Start is disabled. A warning is displayed if genset is left in idle more than 10 mit utes. Long periods of engine idling can eventually affect engine performance and may void engine warranty.ADJUST MENU Main Menu 1 “Alternator Voltage Adjust nna oy LJ | | wottage aajust el (Dna | (Frequency Adjust vonmiz WJ “Frequency Adjust ' a "onn ie ’ { L 1 Start Delay | nnn Sec > J “Siar Delay Tana See "Stop a nnn See > : —¥8tep Delay Bin see “Rated To Idle Delay. wong) J eater Daay oimSee , 7idle Start sat ») Disable : WJ side Start a cnable FIGURE 3-11. ADJUST MENU 3-23 Back Back Back Back BackFAULTS MENU Figure 3-13 shows a block representation of the Faults menu. Up to 20 of the most recent faults can be viewed. An example of how a fault code is dis- played is shown in Figure 3-12. The available menus are dependent on the number of faults that have occurred. * If there are no faults, the ¢ symbol next to the word “Faults” is not displayed and no Fault me- nus are available. If more than one fault has occurred, press the button next to the word “Fault” in the screen dis- play to view the Faults Main Menu. As shown in the diagram, the Faults Main Menu has two submenus. Press the Previous Main Menu but- ton to retum to the Faults Main Menu. Press the Previous Main Menu button a second time to retum to Main Menu 2. Press the Home button at any time to retum to Main Menu 1 History submenu: From the Faults Main Menu, press the button next to the word “History” in the dis- play to view up to twenty of the most recent ac- knowledged faults. Press the buttons next to the | and |’ symbols in the digital display to navigate be- ‘tween the menus. Press the Previous Main Menu button to return to the Faults Main Menu. Current Fault submenu: From the Faults Main Menu, press the button next to the word “Current” in the display to view up to twenty of the most recent unacknowledged faults. Press the Previous Main Menu button to retum to the Faults Main Menu, ASTERISK = ACTIVE FAULT FAULT CODE ge | = W= WARNING HUTDOWN CO eannfin @Hr nnnrin.n W1000000000030000000X HOUR FAULT OCCURRED . FAULT DESCRIPTION FIGURE 3-12. HISTORY/CURRENT FAULT SUBMENU. 3-24FAULTS MENU Main Menu 2 «Faults History >| «System, More>> Faults Main Menu “History «Curent fanann @Hr nnann.n ‘anann @Hr nnana.n EW ronooocoo oan .a%.c0K fi 418 9909000000000 Fault 4 Fault 1 (fnnnnn @Hr nnnnnn = ‘annnn @Hr nnnnn.n |S opa.00009000000000% “LW 39900009000200000000% Fault 2 Fault 2 (Fannin @Hr mannan - ‘Tanne @Hrnnnna.n |_W renoncn aca \W sonoenonoa 0A. Fault 20 Fault 20 FIGURE 3-13. FAULTS MENU 3-25SYSTEM MENU Figure 3-14 shows a block representation of the ‘System menu. If you press the button next to the word “System” in the display, the System Main Menu is displayed. This menu is displayed only if the network communications module (NCM) fea- ture is installed. The System Main Menu allows you to view the status and load of other PCC equipment connected on a common network with the PCC 2100 control As shown in the diagram, the System Main Menu has three submenus. When viewing ATS and Genset System submenus, press the buttons next to the | and “ symbols in the digital display to navigate between the menus. Press the Previous Main Menu button to retum to the System Main Menu. Press the Previous Main Menu button a second time to retum to Main Menu 2. Press the Home button to return to Main Menu 1. 3-26 ATS System submenus: From the System Main Menu, press the button next to the word “ATS" in the display to view the first of up to 16 ATS System sub- menus. An ATS system must be available in the net- work to display this submenu. The ATS submenu allows viewing of the transfer switch name (configured with InPower), KW load (if monitored by the ATS system), status (e.g., not in auto), and source connected and availabilty (ON source connected, OK = source available, or NA = source not available). Master System submenu: From the System Main Menu, press the button next to the word “Master” in the display to view the Master System submenu. A. master controller must be available in the network to display this submenu. The master submenu allows viewing of the master controller name (configured with InPower), KW load and operational state. Genset System submenus: From the System Main Menu, press the button next to the word "Gen- set” in the display to view the first of up to 16 Genset System submenus. One genset must be available in the network to display this submenu. The genset submenu allows viewing of the genset name (configured with InPower), kW load and op- erational state. It a PCC 2100 contro! genset, in the network, con- tains the Power Transfer Control (PTC) feature, a genset system submenu will be displayed for the genset and the ATS System submenu will be dis- Played for the PTC feature.SYSTEM MENU Main Menu 2 “Faults «System {ATSnameTagOi=nnnniW Gonsettvamedt>nnnnkW Non Auto $1=0n, S2=0n —\ Waring Fail2start ATS Menu 1 Genset Menu 1 | a | /FATSnameTago2>nnnnkW ‘*GensetNamed2>nnnnkW | sNonAut 0 S1=0k, S2=NA_ JNonAuto Alarm a ATS Menu 2 = Genset Menu 2 = 4 { . , 1 . "TATSnameTagié>nnnniW 7GensetNametésnnnakW | NonAuto St=Ok, S2=NA NonAuto Alarm ATS Menu 16 Genset Menu 16 Masiersnnnn kW Shutdwn N-On.E=NA FIGURE 3-14. SYSTEM MENU 3-27HISTORY MENU Figure 3-15 shows a block representation of the History menu. If you press the button next to the word “History” in the display, the first History subme- nu is displayed. ‘As shown in the diagram, the History menu has five submenus. This information is stored in non-volatile. memory and will not be deleted due to loss of bat- tery power. Press the buttons next to the |, and’) symbols in the digital display to navigate between the menus. Press the the Previous Main Menu button to retum to Main Menu 2. Press the Home button to retum to Main Menu 1. 3-28 Number of Starts submenu: This submenu shows the number of engine starts. Engine Hours submenu: This submenu shows the number of operating hours for the engine. Control Hours submenu: This submenu shows the number of operating hours for the control. Kilowatt Hours submenu: This submenu shows the number of kilowatt (kW) or megawatt (MW) hours. Genset Duty Cycle submenu: This submenu shows the percent of genset operating hours that are less than 30 percent of rated load and percent of hours that are greater than 90 percent.| HISTORY MENU Main Menu 2 ‘Faults History > «system More>> Number Starts: ~ anna naive Hours ‘Control Hours \ nnnan Hours (RW Hours: nnn kW Hee — 7Genset Duty Cycle He <30:nnts >90:nnee FIGURE 3-15. HISTORY MENU 3-29ABOUT MENU Figure 3-16 shows a block representation of the About menu. If you press the button next to the word “About” in the display, the first About submenu is displayed As shown in the diagram, the About menu has three submenus. Press the buttons next to the |, and’ symbols in the digital display to navigate between the menus. Press the the Previous Main Menu button to return to Main Menu 3. Press the Home button to retum to Main Menu 1. 3-30 Model submenu: This submenu shows the genset model. Rating submenu: This submenu shows the rating (Standby or Prime and number of kilowatts (kW)). Software Version submenu: This submenu shows the software version level. This information is required to service the generator set.ABOUT MENU Main Menu 3 ‘About ‘Setup ) «Pw Tran More>> Wodel ‘Rating + Standby _nn.n kW, Software Version FIGURE 3-16. ABOUT MENU 3-31POWER TRANSFER MENU Figure 3-17 shows a block representation of the Power Transfer menu. If you press the button next to the word “Pwr Tran” in the display, the first Power Transfer submenu is displayed. The Power Trans- fer Control (PTC) feature must be installed to dis- play this submenu. The PTC module enables the PCC to monitor the utility voltage (mains) and frequency for failure and control the opening and closing of the contacts (cir- cuit breakers) for Source 1 (St utility) and Source 2 (S2 genset) If S1 power fails, the control will initiate the starting sequence (Figure 3-3), open S1 and close S2 to the load. When S1 returns, the load is retransferred to ‘S1 and the control initiates the genset shutdown se- quence. ‘As shown in the diagram, the Power Transfer menu has five submenus. Press the buttons next to the |, and symbols in the digital display to navigate between the menus. Press the the Previous Main Menu button to retum to Main Menu 3. Press the Home button to return to Main Menu 1. 3-32 $1 (Source 1) submenu: This submenu shows power transfer source voltage. The voltages Line- to-Line (L1, L2 and L3) are measured between L1 to L2, L2 to L3 and L3 to L1, respectively. (Single phase - L1 to L2 only.) $1 (L-N Source) submenu: This submenu is dis- played only if the control system is configured for line-to-neutral voltage sensing of source 1. Single phase only - L1 to Nand L2 to N. Frequency submenu: This menu shows power tranefer cource frequency. Source 1 submenu: This submenu shows utility status (On, Ok, or NA). “On means Source 1 is con- nected and available. “Ok” means Source 1 is avail- able but not connected. “NA” means Source 1 is not available, Genset submenu: This submenu shows generator status (On, Ok, or NA). “On" means the genset is connected and available. “Ok’ means the genset is available but not connected. “NA” means the gen- set is not available. Active Transfer Timer submenu: This submenu shows the time delay, in seconds.POWER TRANSFER MENU Main Menu 3 St LA 123 Lat Vv _nnn_nnn_nnn 181 Lin LN | 4 OV _pnn_nnn__ “Active Tran Timer "TD Re-Trans nnn See FIGURE 3-17. POWER TRANSFER MENU 3-33THIS PAGE LEFT INTENTIONALLY BLANK 3-34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 ight a yellow ‘Warning lamp or a red Shutdown lamp and display a message on the digital display. This section lists the warming and shutdown codes/ messages (Table 4-1), and suggests troubleshoot- ing 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 assistance. 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, Ignition of explosive battery gases an cause severe pereonal injury or death, Arc- jing 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. 44 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 contro! 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 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 control panel to the O (off) position, 2. Tum off or remove AC power from the battery charger. 3, Remove the negative (-) battery cable from the generator set starting battery.STATUS INDICATORS Running Indicator: This green lamp is lit whenever the generator (local or remote) is running (Figure 4-1). Remote Start Indicator: This green lamp is lit whenever the control is receiving a remote run sig- nal. Not in Auto Indicator: This red lamp flashes con- tinuously when the O/Manual/Auto switch is not in the Auto position. (if in Auto position and the lamp is flashing, service is required.) Configurable Indicators: Defaults for the confi- gurable indicators shown in Figure 4-1 can be changed with the InPower service tool. ‘Shutdown Status Indicator: This red lamp is lit whenever the control detects a shutdown condition. ‘The generator set cannot 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 O position and pressing the Fault Ac- knowledge/Reset button Warning Status Indicator: This yellow lamp is lit whenever the control detects a warning condition. After the condition is corrected, waming indicators ‘can be reset by pressing the Fault Acknowledge/ Reset button. (It may not be necessary to stop the 4-2 generator set.) In auto mode, warning indicators can also be reset by cycling the remote reset input after the condition is corrected. ‘Some warnings remain active after the condition is corrected and the control reset button is pressed. This will require the genset to be shutdown to reset the warning indicator. Digital Display: This two-line, 20-characters per line alphanumeric display is used to view menus of the menu-driven operating system and to show warning and shutdown messages. LINE CIRCUIT BREAKER (OPTIONAL) The optional line cirouit breaker mounts on the gen- erator output box. If the load exceeds the generator 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 PC (LAPTOP) See your authorized Cummins Power Generation dealer regarding software, hardware and network Tequirements for control and diagnostics via net- work or PC.MENU ‘SHUTDOWN rT SSUTTONT previous AND. WARNING (tot) MANMEND STATUS, PANEL, BUTTON ee RUNNING/REMOTE ia ue STARTINOT IN AUTO ust (rof3) EMERGENCY INDICATORS. BUTTON ora. | ‘Stop PusH DISPLAY BUTTON ConFicuraaLe peal INDICATORS ANALOG AC OFF/MANUAL) METERING AUTO SWITCH PANEL FAULT ACKNOWLEDGEMENT/ MANUAL, RESET BUTTON, RUNISTOP, BUTTON PANEL LAMP AND LAMP TEST BUTTON FIGURE 4-1. FRONT PANEL (FULL FEATURED) 4-3FAULT CODES The fault codes have been divided into five catego- ries 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. 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). Control prevents the generator set from being restarted, Category B Fault Codes: Consist of faults that can affect genset performance or cause engine, alter- nator, or connected equipment damage. Oper- ate only when generator set is powering critical loads and cannot be shut down. Requires repair by qualified service personnel. Category C Fault Codes: Consist of faults that do not affect generator set performance but require qualified service personnel to repair. 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- quired by qualified service personnel if site person- nel cannot resolve the problem after taking the cor- rective actions suggested in Table 4-2. Category E Fault Codes: Indicates non-critical op- erational status of generator set, extemal faults, or customer fault inputs. May require repair by quali- fied service personnel. TABLE 4-1. FAULT CODES CTG| CODE [LAMP | DISPLAYED MESSAGE ‘CTG| CODE | LAMP | DISPLAYED MESSAGE 121_| Shtcn [Speed Signal Lost 234 _| Shtén | Overspeed 135__[ Wing [Oil Pressure SensorH 235 _| Shtdn [Low Coolant Level 147_| Wing [Oil Pressure Sensor ‘359. | Shtdn |Fail To Start 143 | Wing |Pre-Low Oil Pres 415__| Shtdn [Low Oil Pressure 144 | Wing _| Coolant Sensor High 421_| Wing [Oi Temp 7145 | Wing | Coolant Sensor Low 441 | Wing |Low Bat Voltage 146 | Wig | Pre-High Coolant Temp 442_| Wig [High Bat Voltage 151 _| Shtdn [High Coolant Temp 1122 | None |Ratediidie Trans 197__| Wing [Low Coolant Level 1723 | Shtdn | Shutdown After BS 212_| Wing [Oil Temp Sensor H 1124 | Wrng [Delayed Shutdown 9} of 9} o} of of of of of of >| 2i3_| Wing [Oil Temp SensorL mm] >| m| of of of o} of of >| 1131_| Wrng [Battle Sh ActiveTABLE 4-1, FAULT CODES (CONT.) CTG]| CODE | LAMP | DISPLAYED MESSAGE TG] CODE | LAMP | DISPLAYED MESSAGE | 1811 | Shtan/ [Customer input #1 A_| 1452 | Wing [Gen CB Not Close Wing/ ®_| 1453 | Wing |Gen GB Not Open None E | 1312 | Shtdn/ [Customer Input #2 aa 8 Sn | teres a Wrng! ‘A_| 1461 _| Shtdn [Loss OF Field None _| 1466 | Wing [Modem Failure | 1313 | Shtcn’ [Network Fault 1 thru 4 S| 1468] Wing [Network Error 1316 | Wing’ None ‘A_| 1469 _| Shtdn [Speedie Match E | 1317 | Shtda’ [Customer Input #3 B [1471 | Wig [Over Current wing! ‘A_| 1472 _| Shtdn | Over Current one E_ | 2323- | Shtdn/ [Network Fault 5 thru @ = | 1318 | Shtdn’ [Customer Input #4 2326 | Wing! Wmg/ None None 2327 | Wing [PTC Fault 1384 | Shtdn [Crt Scaler OR 2329_| Wing [Low St Frequency 1335 | Wing [Nonorit Scaler OR 2331 _| Wing [Low St Voltage Peat shone: | Ne Message 2335 | Shtdn | Excitation Fault 7416 | Wing [Fail To Shutdown 2336 | Shion [Memory Error 1417 | Wrng | Powr Down Error 2337 | Wmg [Pwr Tran Disabled 1483. | Shtdn_[ Emergency Stop 2338_| Wig | Pwr Tran Failure 1484 | Shtdn [Remote E-Stop 2339 | Wing | Pwr Down Enabled 1435 [ Wmg [Low Coolant Temp 2347_| Wing [High Control Temp ‘Shien | Fail To Crank 2342_| Wing [Too Long in lale (10 min) 1442 | Wmg [Weak Battery 2358 | Wmg [High Si Voltage 7443_| Shicn [Battery Failed 2306 | Wing [81 GB Not Close 1444 [ Wing [KW Overload 2397 | Wig [Si CB Not Open 1445_| Shtdn | Short Circuit 2966 | Wing [PTC Timeout 7446 _| Shtdn [High AC Voltage 2967 | Wing [Govemor Fault 7447_[ Shtdn [Low AC Voltage 2968 | Wig [AVR Fault 7448 | Shtdn [Under Frequency 2969 | Wing [LON Failure >| >] >] >] >] &| of of of 0} of of of of m} | >| z >| of of of of m] mm] mo] m] of of >] >] mm] ml ow 7449 | Wig [Over Frequency 2972 | Shidn | Field Overioad 45Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electric- ity, and machinery hazards should perform service procedures. Read Safety Precautions page and observe all instructions and precautions in this manual. TABLE 4-2. WARNING AND SHUTDOWN CODES FAULT CODE CORRECTIVE ACTION 143 Indicates engine off pressure has dropped to an unacceptable level. i generator is PRE-LOW OIL PRES powering critical loads and cannot be shut down, wait until next shutdown period Lamp: Warning and then follow code 415 procedure. 146 Indicates engine has begun to overheat (coolant temperature has risen to an un- PRE-HIGH COOL TMP acceptable level. If generator is powering non-critical and critical loads and cannot Lamp: Waming be shut down, use the following: a. Reduce load if possible by turning off non-critical loads. . Check air inlets and outlets and remove any obstructions to airfiow. lfengine can be stopped, follow code 151 procedure. 151 Indicates engine has overheated (coolant temperature has risen above the shut- HIGH COOLANT TEMP down trip point). Allow engine to cool down completely before proceeding with the Lamp: Shutdown following checks: ‘a. Check coolant level and replenish if low. Look for possible coolant leakage Points and repair if necessary. , Check for obstructions to cooling airflow and correct as necessary. ©. Check fan belt and repair or tighten if necessary. d. Check blower fan and circulation pumps on remote radiator installations. @. Reset control and reetart after locating and correcting problom. 197 Indicates engine coolant level has fallen below the warning trip point. f generator LOW COOLANT LEVEL is powering critical loads and cannot be shut down, wait until next shutdown peri- Lamp: Waring 0d, then follow code 235 procedure. If engine can be stopped, follow code 235 (Optional) procedure. 235 Indicates engine coolant level has fallen below the shutdown trip point. Allow en- LOW COOLANT LEVEL gine to cool down completely before proceeding Lamp: Shutdown a. Check coolant level and replenish if low. Look for possible coolant leakage (Optional) points and repair if necessary. b, Reset control and restart after locating and correcting problem 359 Indicates possible fuel system problem. (Engine cranks but fails to start) FAIL TO START ‘a, Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as re- Lamp: Shutdown aired b. Check for dirty fuel filter and replace if necessary. ©. Check for dirty or plugged air filter and replace if necessary. 4d. Reset the control and restart atter correcting the problem. a5 Indicates engine oll pressure has dropped below the shutdown trip point. Check LOW OIL PRESSURE oil level, lines and filters. If oil system is OK but oil level is low, replenish, Reset Lamp: Shutdown control and restart. 4-6Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electric- ity, and machinery hazards should perform service procedures. Read Safety Precautions page and observe alll instructions and precautions in this manual. TABLE 4-2. WARNING AND SHUTDOWN CODES (CONT.) FAULT CODE CORRECTIVE ACTION at Indicates engine has begun to overheat (oll temperature has risen to an unac- OIL TEMP ‘ceptable level). If generator is powering non-critical and critical loads and cannot Lamp; Warning be shut down, use the following (Optional) a, Reduce load if possible by turning off non-critical loads. b. Check air inlets and outlets and remove any obstructions to airflow. IF engine can be stopped, follow code 151 procedure and also check engine oil level aa Indicates battery voltage supply to the control is approaching a low level at which LOW BAT VOLTAGE Unpredictable operation will occur. Lamp: Waming a. Discharged or defective battery. Check the battery charger fuse. Recharge or replace the battery. b. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. . Check battery charge voltage float level if applicable (raise float level) a2 Indicates battery voltage supply to the control is approaching a high level at which HIGH BAT VOLTAGE damage to the control can occur. Check float level on battery charger if applicable Lamp: Waming (lower float level) 1311, 1312, 1317, 1318 CUSTOMER INPUT #1 - #4 Lamp: Warning/Shutdown or none for status message. ‘The nature of the faultis an optional customer selection. Example inputs: Low Fuel Day Tank, Water In Fuel, Ground Fault, Low Starting Hydraulic Pressure, Low Starting Air Pressure, etc. Each of the fault functions can be programmed (using service tool), as follows: © Enable/disable input (Default: enable) * Status, Waming or Shutdown (Default: #1-None, #2 thru #4—-Warning) * Active closed or open (Default: closed [ground]) * Change display name using up to 19 characters (Default: #1 Customer Fault 1, +#2-Ground Fault, #3-Low Fuel, #4—Rupture Basin Fault) Ta7 Indicates that the controller can not power down because of some unknown condi POWER DOWN ERROR tion. Possible drain on battery. Contact an authorized service center for service. Lamp: Waring 1433 Indicates local Emergency Stop. To reset the local/remote Emergency Stop button EMERGENCY STOP Lamp: Shutdown 4, Pull the button out. 5. Move the O/Manual/Auto switch to O. 6. Press the front panel Fault Acknowledge/Reset button. 7. Select Manual or Auto, as required. 47(A.WARNING] Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electric- ity, and machinery hazards should perform service procedures. Read Safety Precautions page and observe all instructions and precautions in this manual. TABLE 4-2. WARNING AND SHUTDOWN CODES (CONT.) FAULT CODE CORRECTIVE ACTION 1434 REMOTE E-STOP Lamp: Shutdown Indicates remote Emergency Stop. See code 1433 to reset 1435 LOW COOLANT TEMP Lamp: Waring Set is not operating. Waring ‘occurs when engine coolant temperature is 70° F (21°C) or lower. NOTE: In applica- tions where the ambient ‘temperature falls below 40° F (4° C), Low Coolant Temp may be indicated even ‘though the coolant heaters are operating. Indicates engine coolant heater is not operating or is not circulating coolant. Check for the following conditions: . Coolant heater not connected to power supply. Check for blown fuse or discon- nected heater cord and correct as required. b. Check for low coolant level and replenish if required. Look for possible coolant leakage points and repair as required 1438 FAIL TO CRANK Lamp: Shutdown Indicates possible fault with control, speed sensing or starling system. See code 441 for corrective action. 1442 Indicates that during cranking, the battery voltage is at or below the weak battery WEAK BATTERY warning trip point for a time greater than or equal to the weak battery set time. See Lamp: Warning code 441 for corrective action 1443, Dead battery — engine will not start. Sae cade 4a for corrective action BATTERY FAILED Lamp: Shutdown 2342 ‘TOO LONG IN IDLE Lamp: Warning Indicates genset has been in Idle mode too long (10 minutes maximum) 485. Maintenance GENERAL Establish and adhere to a definite schedule for maintenance and service based on the application and severity of the environment. Table 5-1 covers the recommended service 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 following: + Use for continuous duty (prime power) + Extremes in ambient temperature + Exposure to weather + Exposure to salt water + Exposure to dust, sand or other airborne contam inates. 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 after 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. MAINTENANCE SCHEDULE SERVICE TIME MAINTENANCE Daily | Weekly | Monthly | 6Months | Yearly ae orafter | orafter | orafter | orafter | oratter SHours_| 50 Hours | 100 Hours | 250 Hours | 500 Hours Inspect Genset x Check Coolant Heater Check Oil Level Check Coolant Level (Check Fuel Level ‘Check Charge Air Piping x] x] > >< ‘Check Air Cleaner (Clean i required) x2 Check Battery Charging System x Drain Fuel Filter(s) xas Drain Water and Sediment from Fuel Tank x# Check Anti-freeze and DCA Concentration xe Check Drive Belt Tension Xe8 Drain Exhaust Condensate Trap x Check Starting Batteries x ‘Change Crankcase Oil and Filter xe Change Coolant Filter x Clean Crankcase Breather xe Change Air Cleaner Element xe Check Radiator Hoses for Wear & Cracks x Change Fuel Filters xe Clean Cooling System x ‘Test Generator Insulation Resistance x7 ‘Test Rupture Basin Leak Detect Switch xe X! Check forcil, uel, cooling and exhaust system leaks. Check exhaust system audibly and visually with set running and repair any leaks immediately. X2 Perform more often in dusty conditions, X®_ Visually check belt for evidence of wear or slippage. Replace it hard or brite, X# Drain 1 cup or more of fuel to remove water and sediment X®_ Refer to engine operation and maintenance manual for procedure. X°_ It genset is used for prime power applications, change ll and fiter every 6 months or 250 hours, if used for standby applications, change oll every 12 months or 250 hours, whichever comes fist. X7 This procedure should be followed periodically throughout the Ife of the generator set, orf the generator has set idle for a period of time with no generator heaters used. Contact your authorized service center, X® Check leak detect switch in sub-base fuel tank of optional enclosure, once a year or as required by safety code. Contact your authorized sarvice center. 5-2GENERATOR SET INSPECTION During operation, be alert for mechanical problems that could create unsafe or hazardous conditions. The following sections cover several areas that should be frequently inspected for continued safe operation. 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 delecied, shut down the genset 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 trom 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, return lines, filters and fittings for ‘racks and abrasions and make sure they are not rubbing against anything that could cause break- age. If any leaks are detected, have them corrected immediately. 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 genset is operating, Frequency/RPM (Alternator/Engine Menu): The generator frequency should be stable and the read- 5-3 ing should be the same as the genset nameplate rating (50 or 60 Hz/1500 or 1800 RPM). AC Voltmeter (Alternator Menu): At no load, the line-to-line or line-to-neutral voltage(s) should be the same as the genset nameplate rating. AC Ammeter (Alternator Menu): At no load the current ratings should be zero. With a load applied, each line current should be about the same. Panel Lamp/Lamp Test Button: Press and hold this button to test all front panel LEDs and meters. The meters will ight one bar at a time. Make sure that all LEDs and meters are OK and then release the button, 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 warning. Look and listen for changes in engine performance, sound, or appearance that can indicate service or repair is needed. Some en- gine changes to look for are as follows: Misfire Vibration Unusual noises Sudden changes in engine operating tempera- tutes or pressures Excessive exhaust smoke Loss of power An increase in oil consumption An increase in fuel consumption Fuel, oil, 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. 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. 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. 5-4 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 before beginning maintenance procedures. When performing the following maintenance proce- dures, make certain the generator set cannot be ac- cidentally restarted as follows: 1. Move the O/Manual/Auto switch on the control panel to the O (off) position, 2. Turn off or remove AC power from the battery charger. 3. Remove the negative (-) battery cable from the generator set starting battery. Mechanical Inspection With the generator set stopped, 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.