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Operator Manual Generator Set DFLB (Spec ET) DFLC (Spec EW) DFLE (Spec AF) with PowerCommand R 2100 Controller English 122009 9600170 (Issue 4)
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Operator Manual...Operator Manual Generator Set DFLB (Spec E−T) DFLC (Spec E−W) DFLE (Spec A−F) with PowerCommand 2100 Controller English 12−2009 960−0170 (Issue 4) i Table

Jan 24, 2021

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  • Operator Manual

    Generator Set

    DFLB (Spec E−T)DFLC (Spec E−W)DFLE (Spec A−F)

    with PowerCommand� 2100 Controller

    English 12−2009 960−0170 (Issue 4)

  • i

    Table of Contents

    SECTION TITLE PAGE

    IMPORTANT SAFETY INSTRUCTIONS iii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    1 INTRODUCTION

    General 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How to Obtain Service 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    2 SPECIFICATIONS 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    3 CONTROL OPERATION

    General 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prestart Checks 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel Power On/Off Modes 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battle Short Mode (Optional) 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Panel 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stopping 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Menu Display and Buttons 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Menus 3-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting Default Settings 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Messages 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controller Configuration Menu 3-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Menu 3-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Menu 3-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust Menu 3-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Faults Menu 3-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Menu 3-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . History Menu 3-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . About Menu 3-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Transfer Menu 3-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    -

    California

    Proposition 65 WarningDiesel engine exhaust and some of its constituents are knownto the State of California to cause cancer, birth defects, andother reproductive harm.

  • ii

    SECTION TITLE PAGE4 TROUBLESHOOTING

    General 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Safety Considerations 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Status Indicators 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Line Circuit Breaker (Optional) 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Control and Diagnostics VIA Network or PC (Laptop) 4-2. . . . . . . . . . . . . . . . .

    Fault Codes 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Fault Code Table 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Troubleshooting Table 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    5 MAINTENANCE

    General 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Maintenance Schedule 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Generator Set Inspection 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Generator Set Maintenance (Battery Disconnected) 5-4. . . . . . . . . . . . . . . . . .

    Lubrication System 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Cooling System 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Air Cleaner 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Batteries 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Fan Belt Replacement (Model DFLC) 5-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    P7 Generator Bearing Re-Lubrication 5-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    6 OPERATING RECOMMENDATIONS

    No-Load Operation 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Exercise Period 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Low Operating Temperature 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    High Operating Temperature 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

  • LS-14Liii

    IMPORTANT SAFETY INSTRUCTIONS

    SAVE THESE INSTRUCTIONS − This manual containsimportant instructions that should be followed duringinstallation and maintenance of the generator and batter-ies.

    Before operating the generator set (genset), read theOperator’s Manual and become familiar with it and theequipment. Safe and efficient operation can beachieved only if the equipment is properly operatedand maintained. Many accidents are caused by failureto follow fundamental rules and precautions.

    The following symbols, found throughout this manual,alert you to potentially dangerous conditions to the op-erator, service personnel, or the equipment.

    This symbol warns of immediatehazards which will result in severe personal in-jury or death.

    WARNING This symbol refers to a hazard or un-safe practice which can result in severe per-sonal injury or death.

    CAUTION This symbol refers to a hazard or un-safe practice which can result in personal injuryor product or property damage.

    FUEL AND FUMES ARE FLAMMABLE

    Fire, explosion, and personal injury or death can resultfrom improper practices.

    • DO NOT fill fuel tanks while engine is running, un-less tanks are outside the engine compartment.Fuel contact with hot engine or exhaust is a potentialfire hazard.

    • DO NOT permit any flame, cigarette, pilot light,spark, arcing equipment, or other ignition sourcenear the generator set or fuel tank.

    • Fuel lines must be adequately secured and free ofleaks. Fuel connection at the engine should bemade with an approved flexible line. Do not use zinccoated or copper fuel lines with diesel fuel.

    • Be sure all fuel supplies have a positive shutoffvalve.

    • Be sure battery area has been well-ventilated priorto servicing near it. Lead-acid batteries emit a highlyexplosive hydrogen gas that can be ignited by arc-ing, sparking, smoking, etc.

    EXHAUST GASES ARE DEADLY

    • Provide an adequate exhaust system to properlyexpel discharged gases away from enclosed orsheltered areas and areas where individuals arelikely to congregate. Visually and audibly inspectthe exhaust daily for leaks per the maintenanceschedule. Make sure that exhaust manifolds are se-cured and not warped. Do not use exhaust gases toheat 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 SEVEREPERSONAL INJURY OR DEATH

    • Keep your hands, clothing, and jewelry away frommoving parts.

    • Before starting work on the generator set, discon-nect battery charger from its AC source, then dis-connect starting batteries, negative (−) cable first.This will prevent accidental starting.

    • Make sure that fasteners on the generator set aresecure. Tighten supports and clamps, keep guardsin position over fans, drive belts, etc.

    • Do not wear loose clothing or jewelry in the vicinity ofmoving parts, or while working on electrical equip-ment. Loose clothing and jewelry can becomecaught 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 ANDEXPLOSIVE ENVIRONMENTS

    Flammable vapor can cause an engine to overspeed andbecome difficult to stop, resulting in possible fire, explo-sion, severe personal injury and death. Do not operate agenset where a flammable vapor environment can becreated by fuel spill, leak, etc., unless the genset isequipped with an automatic safety device to block the airintake and stop the engine. The owners and operators ofthe genset are solely responsible for operating the gen-set safely. Contact your authorized Cummins PowerGeneration distributor for more information.

  • iv

    ELECTRICAL SHOCK CAN CAUSESEVERE PERSONAL INJURY OR DEATH

    • Remove electric power before removing protectiveshields or touching electrical equipment. Use rub-ber insulative mats placed on dry wood platformsover floors that are metal or concrete when aroundelectrical equipment. Do not wear damp clothing(particularly wet shoes) or allow skin surface to bedamp when handling electrical equipment. Do notwear jewelry. Jewelry can short out electrical con-tacts and cause shock or burning.

    • Use extreme caution when working on electricalcomponents. High voltages can cause injury ordeath. DO NOT tamper with interlocks.

    • Follow all applicable state and local electricalcodes. Have all electrical installations performed bya qualified licensed electrician. Tag and lock openswitches to avoid accidental closure.

    • DO NOT CONNECT GENERATOR SET DI-RECTLY TO ANY BUILDING ELECTRICAL SYS-TEM. Hazardous voltages can flow from the gen-erator set into the utility line. This creates a potentialfor electrocution or property damage. Connect onlythrough an approved isolation switch or an ap-proved paralleling device.

    GENERAL SAFETY PRECAUTIONS

    • Coolants under pressure have a higher boiling pointthan 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 systempressure first.

    • Used engine oils have been identified by some stateor federal agencies as causing cancer or reproduc-tive toxicity. When checking or changing engine oil,take care not to ingest, breathe the fumes, or con-tact used oil.

    • Keep multi-class ABC fire extinguishers handy.Class A fires involve ordinary combustible materialssuch as wood and cloth; Class B fires, combustibleand flammable liquid fuels and gaseous fuels; ClassC fires, live electrical equipment. (ref. NFPA No. 10).

    • Make sure that rags are not left on or near the en-gine.

    • Make sure generator set is mounted in a manner toprevent combustible materials from accumulatingunder the unit.

    • Remove all unnecessary grease and oil from theunit. 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 areaclean and free from obstructions. Remove any de-bris from the set and keep the floor clean and dry.

    • Do not work on this equipment when mentally orphysically fatigued, or after consuming any alcoholor drug that makes the operation of equipment un-safe.

    • Substances in exhaust gases have been identifiedby some state or federal agencies as causing can-cer or reproductive toxicity. Take care not to breathor ingest or come into contact with exhaust gases.

    • Do not store any flammable liquids, such as fuel,cleaners, oil, etc., near the generator set. A fire orexplosion could result.

    • Wear hearing protection when going near an oper-ating generator set.

    • To prevent serious burns, avoid contact with hotmetal parts such as radiator, turbo charger and ex-haust system.

  • LS-14Liii

    CONTAINERIZED RENTAL UNITSPOTENTIAL TIPPING PROBLEM

    On all containerized rental equipment, there is a potentialproblem of having the container tip forward over the land-ing legs, pulling the axles off the ground when the con-

    tainer is fully fueled without a semi-tractor under the kingpin. Jack stands for the front of the container are requiredto mitigate this potential problem.

    Note: The figure below shows the jack stands andtheir placement at the nose of the container.

    Jack Stands at Nose of Container

    KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

  • 1-1

    1. Introduction

    GENERAL

    Each operator should read this manual before oper-ating the generator set (genset) for the first time. Agenset must be operated and maintained properly ifyou are to expect safe and reliable operation. Thismanual includes a troubleshooting guide and amaintenance schedule.

    The engine manual is included with the set. Wherethere is conflicting information, this manual takesprecedence over the engine manual.

    WARNING Improper operation and mainte-nance can lead to severe personal injury or lossof life and property by fire, electrocution, me-chanical breakdown or exhaust gas asphyxi-ation. Read Important Safety Instructions andprecautions in this manual.

    HOW TO OBTAIN SERVICE

    When the generator set requires servicing, contactyour 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 Generationdistributor in the United States or Canada, call1-800-888-6626 (this automated service utilizestouch-tone phones only). By selecting Option 1(press 1), you will be automatically connected to thedistributor nearest you.

    If you are unable to contact a distributor using theautomated service, consult the Yellow Pages. Typi-cally, our distributors are listed under:

    GENERATORS-ELECTRIC orELECTRICAL PRODUCTS

    For outside North America, call Cummins PowerGeneration, 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 thefax number 1-763-528-7229.

    When contacting your distributor, always supply thecomplete Model, Specification, and Serial Numberas shown on the generator set nameplate.

    WARNING

    INCORRECT SERVICE OR PARTS REPLACEMENT CAN RESULT IN SEVERE PERSONAL IN-JURY, DEATH, AND/OR EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST BE TRAINEDAND EXPERIENCED TO PERFORM ELECTRICAL AND/OR MECHANICAL SERVICE.

    Copyright© 2003 Cummins Power Generation. All rights reserved.

    Cummins and PowerCommand are registered trademarks of Cummins Inc.

  • 1-2

    THIS PAGE LEFT INTENTIONALLY BLANK

  • 2-1

    2. Specifications

    MODEL DFLB DFLC, DFLE

    EngineCummins Diesel Series KTA50

    Generator kW Rating See Genset Nameplate for rating information.

    Electrical SystemStarting VoltageBattery Charging CurrentBattery

    Group NumberCCA (minimum)

    Cold Soak @ 0° F (-18° C)

    24 Volts DC45 Amps

    Four, 12 Volt8D

    1400

    Cooling SystemCapacity with Standard Radiator 92.0 Gal (348 L) 102.0 Gal (386 L)

    Lubricating SystemOil Capacity with Filters

    StandbyPrime

    Oil Type*

    44.7 Gal (169 L)58.7 Gal (222 L)

    * Refer to Cummins engine Operation and Maintenance Manual for lubricating oil recommendations/specifications.

    FUEL CONSUMPTION (STANDBY/FULL LOAD/60HZ)

    MODEL DFLB DFLC DFLE

    US gph (L/hr) 77.2 (292.6) 87.3 (330.9) 103.6 (392.6)

    OIL PRESSURE WARNING ANDSHUTDOWN LIMITS

    Normal Oil PressureWarning LimitShutdown Limit

    50-70 psi (345-482 kPa)40 psi (276 kPa)35 psi (241 kPa)

    Idle Oil PressureWarning LimitShutdown Limit

    20 psi (138 kPa)15 psi (103 kPa)10 psi (69 kPa)

  • 2-2

    THIS PAGE LEFT INTENTIONALLY BLANK

  • 3-1

    3. Control Operation

    GENERAL

    The following describes the function and operationof the PowerCommand® 2100 Control (PCC). All in-dicators, control switches/buttons and digital dis-play are located on the face of the control panel asillustrated in Figure 3-1.

    This section covers prestart checks, starting andstopping and operating the generator set (genset).Each operator should read through this entire sec-tion before they attempt to start the generator set. Itis essential that the operator be completely familiarwith the generator set and the PCC control. Refer toSection 6 for operating recommendations.

    Before starting, be sure the following checks havebeen made and the unit is ready for operation.

    PRESTART CHECKS

    Lubrication

    Check the engine oil level. Keep the oil level as nearas possible to the dipstick high mark without overfil-ling.

    Coolant

    Check the engine coolant level. Refer to “CoolingSystems” in the Maintenance section of this manu-als for proper procedure.

    Fuel

    Make sure the fuel tanks have sufficient fuel andthat fuel system is primed. Check to make surethere are no leaks and that all fittings are tight.

    Ventilation

    Make sure the generator set cooling inlet/outlet andexhaust ventilation openings are clear (not blocked)and operational.

    Remove all loose debris from surrounding area ofgenerator set. Air flow from the radiator fan canblow 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, andgases are discharged away from building openings.

  • 3-2

    CONTROL PANEL POWER ON/OFFMODES

    The power on/off modes of the control panel and op-erating software are Power On, Screen Saver andSleep/Awake.

    Power On Mode: In this mode, power is continu-ously supplied to the control panel. The control’soperating software and control panel LEDs/digitaldisplay will remain active until the Screen Savermode is activated.

    Screen Saver Mode: Power to the digital display isremoved 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 orswitch selection) or signal received by the operatingsoftware. All LEDs on the control panel operate nor-mally during Screen Saver mode, indicating that theoperating software is active (Awake mode).

    When a “Warning” signal is sensed by the PCC (forexample, low coolant temp), the control displays thewarning message.

    Sleep/Awake Mode: In the Sleep mode, the con-trol’s operating software is inactive and the LEDsand the digital display on the control panel are all off.Sleep mode is a feature used to reduce batterypower consumption when the control is not being

    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 Oposition) the Sleep mode is activated.

    The operating software is initialized and the digitaldisplay and control panel LEDs are turned on in re-sponse to moving/pressing the following controlpanel switch/buttons:

    • Off/Manual/Auto switch

    • Emergency Stop button

    • Fault Acknowledge/Reset button

    • Panel Lamp/Lamp Test button

    To activate the control and view the menu displaywithout starting the generator set, press Fault Ac-knowledge or Panel Lamp button or move modeswitch from O to Manual.

    The InPower service tool is required to enable ordisable the Sleep mode. When shipped from thefactory, Sleep mode is disabled. When disabled, theoperating software will always remain active(Awake mode). If network and/or power transfercontrol (PTC) feature is installed, the sleep mode isnot available.

    The InPower service tool is required to select the de-sired mode. Contact an authorized service center forassistance.

  • 3-3

    BATTLE SHORT MODE (OPTIONAL)The purpose of Battle Short mode is to satisfy localcode requirements where necessary.

    The Battle Short mode prevents the genset from be-ing shutdown by all but a select few critical shutdownfaults. All shutdown faults, including those over-ridden by Battle Short, must be acted upon im-mediately to ensure the safety and well being ofthe operator and the genset.

    WARNING Use of the Battle Short mode cancause a fire or electrical hazard, resulting in se-vere personal injury or death and/or propertyand equipment damage. Operation of the gen-set must be supervised during Battle Shortmode operation.This feature must only be used during supervised,temporary operation of the genset. The faults thatare overridden during Battle Short mode consist offaults that can affect genset performance or causepermanent engine, alternator, or connectedequipment damage. Operation may void genera-tor set warranty if damage occurs that relates tofault condition.When Battle Short mode is enabled, the Warningstatus indicator is lit, along with displayed fault code1131 − Battle Short Active.With Battle Short mode enabled and an overriddenshutdown fault occurs, the shutdown fault is an-nounced but the genset does not shut down, andfault code 1416 − Fail To Shut Down is displayed.The Fault Acknowledgement/Reset button will clearthe fault message, but will remain in the Fault/Histo-ry file with an asterisk sign (* equals active fault) aslong as Battle Short mode is enabled.

    Battle Short is suspended and a shutdown occursimmediately if:

    • Any of the following critical shutdown faultsoccurs:

    − Overspeed − Fault code 234− Emergency Stop − Fault code 1433− Remote Emergency Stop − Fault code

    1434− Speed Signal Lost − Fault code 121− Excitation Fault − Fault code 2335

    • Moving the customer installed Battle Shortswitch to OFF with an active but overriddenshutdown fault or a shutdown fault that wasoverridden at any time. (Fault code 1123 −Shutdown After Battle Short will be dis-played for this type of shutdown.)

    The software for the Battle Short feature must beinstalled at the factory or ordered and installed byan authorized service representative. Wheninstalled, the InPower service tool is required to en-able the Battle Short mode feature and to configurea Customer Input for an external switch input. Thisswitch (customer supplied) allows the operator toenable/disable the Battle Short mode. Contact anauthorized service center for assistance.

  • 3-4

    PANELLAMP(1 of 3)

    CONFIGURABLEINDICATORS

    MANUALRUN/STOPBUTTON

    OFF/MANUAL/AUTO SWITCH

    SHUTDOWNAND WARNING

    STATUSINDICATORS

    EMERGENCYSTOP PUSH

    BUTTON(Pull to reset)

    HOMEBUTTON

    ANALOG ACMETERING

    PANEL(OPTIONAL)

    DIGITALDISPLAY

    MENUSELECTION

    BUTTON (1 of 4)

    PREVIOUSMAIN MENU

    BUTTON

    FAULTACKNOWLEDGEMENT/

    RESET BUTTON

    RUNNING/REMOTESTART/NOT IN AUTO

    INDICATORS

    PANEL LAMPAND LAMP

    TESTBUTTON

    FIGURE 3-1. FRONT PANEL

  • 3-5

    FRONT PANEL

    Figure 3-1 shows the features of the front panel.

    Digital Display: This two-line, 20-characters perline alphanumeric display is used to view menus ofthe menu-driven operating system. Refer to themenu trees later in this section. The display is alsoused to show warning and shutdown messages.

    Display Menu Selection Buttons: Four momen-tary buttons—two on each side of the digital displaywindow—are used to step through the variousmenu options and to adjust generator set parame-ters. A green triangle ( or ), arrow ( , , , or ),>>, or plus/minus sign (+ or −) in the digital displayadjacent to the button is shown when the button canbe used (button is “active”). Refer to Menu DisplayAnd Buttons later in this section.

    Home Button: Press this button ( ) to view theHome Menu. Refer to the menu trees later in thissection.

    Previous Main Menu Button: Press this button ( )to view the previous Main Menu. All main menus in-clude both types of green triangles ( and ). Referto the menu trees later in this section.

    NOTE: The up and down arrows ( and ) are usedto navigate between submenus.

    Emergency Stop Button: Push this button in foremergency shutdown of the generator set. This willstop the generator set immediately and preventstarting of the generator set from any location (localand remote).

    To reset:1. Pull the button and allow it to pop out.

    2. Turn the O/Manual/Auto switch to O (Off).

    3. Press the front panel Fault Acknowledge/Re-set button.

    4. Return O/Manual/Auto switch to desired posi-tion.

    Emergency Stop shutdown can be reset only at thePCC front panel.

    Running Indicator: This green lamp is lit wheneverthe generator set is running.

    Remote Start Indicator: This green lamp is litwhenever 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 inthe Auto position.

    Analog AC Metering Panel (Optional): This panelsimultaneously displays (in percent of genset ratedoutput):

    • 3-phase line-to-line AC current (A~) (L1, L2and L3); Single phase line-to-line (L1 and L2)

    • Kilowatts (kW)

    • Generator output frequency in hertz (Hz)

    • 3-phase line-to-line AC volts (V~) (L1, L2 andL3); Single phase line-to-neutral (L1)

    • Power Factor (PF) (shown in 0.2 increments)

    Shutdown Status Indicator: This red lamp is litwhenever the control detects a shutdown condition.The generator set cannot be started when this lampis on. After the condition is corrected, shutdown in-dicators can be reset by turning the O/Manual/Autoswitch to the O position and pressing the Fault Ac-knowledge/Reset button.

    Warning Status Indicator: This yellow lamp is litwhenever the control detects a warning condition.After the condition is corrected, the warning indica-tors can be reset by pressing the Fault Acknowl-edge/Reset button. (The majority of faults can bereset without stopping the generator set.) In automode, the warning indicators can also be reset bycycling the remote reset input after the condition iscorrected.

    This lamp is also lit when Battle Short mode is en-abled and an overridden shutdown fault occurs.

    Some warnings remain active after the condition iscorrected and the control reset button is pressed.This will require the genset to be shutdown to resetthe warning indicator.

    Fault Acknowledge/Reset Button: Press this but-ton to acknowledge warning and shutdown mes-sages after the fault has been corrected. Pressingthis 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 aninactive Warning condition.) To acknowledge ashutdown message with this button, the O/Manual/Auto switch must be in the O position.

  • 3-6

    Panel Lamp and Lamp Test Button: Press thisbutton to turn the control panel lamps on or off. Thelights will shut off after about ten minutes. Press andhold this button to test all front panel LEDs and me-ters. The meters will light one bar at a time. (Test canbe enabled during genset operation.)

    Manual Run/Stop Button: This button starts andstops the generator set locally and will bypass TimeDelay to Start and Stop sequences. The O/Manual/Auto switch must be in the Manual position to en-able 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 theengine from a remote location. (It disables the useof the Manual Run/Stop button.)

    The O (Off) position prevents the starting of the gen-erator set (local or remote). If the switch is set to Oduring generator set operation, the engine will im-mediately shut down (cool-down timers are by-passed). If possible, hot shutdown under loadshould be avoidedto help prolong the life of the gen-erator set.

    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 centerfor assistance.

    Low Oil Pressure Warning Indicator: This yellowlamp indicates the oil pressure is lower than the nor-mal range of operation.

    High Engine Temperature Warning Indicator:This yellow lamp indicates the engine temperatureis higher than the normal range of operation.

    Low Oil Pressure Shutdown Indicator: This redlamp indicates the engine has shut down becauseof 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 theengine failed to start.

  • 3-7

    STARTING

    The following headings cover the systems used tostart 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 thatexhaust 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-ule installed, the function and sequence of operationof 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 theoperation of the PTC feature.

    Starting at the Control Panel (ManualMode)

    Turn the O/Manual/Auto switch to the Manual posi-tion and press the Manual Run/Stop button. Thiswill 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 thetime-out. When shipped from the factory, this featureis 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 temper-ature or the warm-up time at idle time delay (0−300seconds) is reached, whichever occurs first, thegenerator 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 formaintenance, troubleshooting, etc.). Refer to Adjustmenu (Figure 3-11) to enable/disable the idle feature.

    If the engine does not start, the starter will disen-gage after a specified period of time and the controlwill indicate an overcrank shutdown.

    The generator can be configured for a number ofstarting cycles (1 to 7 cycles) with set times for crankand rest periods for all starting modes (manual/re-mote). The default setting is for 3 start cycles, com-posed of 15 seconds of cranking and 15 seconds ofrest.

    To change the cycle number, and the crank and resttimes, contact an authorized service center for assis-tance.

    To clear a Fail to Start shutdown, place the O/Manu-al/Auto switch in the O position and press the FaultAcknowledge/Reset button. Before attempting torestart, wait two minutes for the starter motor to cooland then repeat the starting procedure. If the enginedoes not run after a second attempt, refer to theTroubleshooting section.

    Starting from a Remote Location (PTC orRemote Start Signal) (Auto Mode)

    Place the O/Manual/Auto switch in the Auto posi-tion. This allows the generator set to be started froma remote switch or device (e.g., transfer switch oroptional PTC module).

    PTC − If a 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 PTCTest 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 controlwill complete the Time Delay To Start function.

    Refer to the Adjust submenu in this section to enableand change the time delay start/stop settings.

  • 3-8

    Cold Starting with Loads

    In accordance with NFPA 110, Cummins PowerGeneration recommends installing diesel standbygenerator sets (life safety systems) equipped withengine jacket water coolant heaters in locationswhere the minimum ambient temperature is above40°F (4°C). NFPA also requires that the engine beheated as necessary to maintain the water jackettemperature determined by the manufacturer forcold start and load acceptance for the type of sys-tem. Although most Cummins Power Generationgenerator sets will start in temperatures down to−25°F (−32°C) when equipped with engine jacketwater coolant heaters, it might take more than 10seconds to warm the engine before a load can be

    applied when ambient temperatures are below40°F (4°C).

    The Engine Cold (Code 1435) message, is pro-vided to meet the requirements of NFPA 110. Theengine cold sensing logic initiates a warning whenthe engine jacket water coolant temperature fallsbelow 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 coolantheaters are connected and operating correctly. Un-der these conditions, although the generator setmay start, it may not be able to accept load within 10seconds. When this condition occurs, check thecoolant heaters for proper operation. If the coolantheaters are operating properly, other precautionsmay be necessary to warm the engine before apply-ing a load.

  • 3-9

    STOPPING

    Before Stopping

    Run the generator set at no load for three to fiveminutes before stopping. This allows the lubricatingoil and engine coolant to carry heat away from thecombustion chamber and bearings.

    Emergency Stop

    The emergency stop button is located near the cen-ter of the upper part of the control panel (Figure3-1). Push the button in for an emergency stop. Thered Shutdown status LED is lit and the emergencystop 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. Return O/Manual/Auto switch to desired

    position.

    Emergency Stop shutdown status can be reset onlyat the operator control panel.

    Stopping at Control Panel (Manual Mode)

    If the generator set was started at the control panel(O/Manual/Auto switch in the Manual position),pressing the Manual Run/Stop button causes the

    generator set to complete its normal (Local Start)shutdown sequence (Figure 3-2).

    The generator set stops after the cool-down at idletimer (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.

    Turning the O/Manual/Auto switch to the O positioncauses an immediate engine shutdown (bypassesCool-down At Idle). If possible, hot shutdown underload should be avoided to help prolong the reliabilityof the generator set.

    Stopping from Remote Location (PTC orRemote Stop Signal) (Auto Mode)

    If the control receives a remote stop signal or thecontrol detects the return of S1 voltage (PTC optioninstalled), the generator set completes its normalshutdown sequence (Figure 3-3). (The remote stopsignal is actually the removal of the remote start sig-nal to the control.)

    The generator set stops after completing the TimeDelay To Stop (0 to 600 seconds) and the cool-down at idle (0 to 30 minutes).

    Refer to the Adjust submenu in this section to enableand change the Time Delay To Stop setting. The In-Power service tool is required to enable/disable theCool-down At Idle feature. Contact an authorizedservice center for assistance.

  • 3-10

    CONTROL RUNBUTTON

    LOCAL START(Manual Mode)

    RATED SPEED&VOLTAGE

    STOP

    2

    NOTES:1. Warm-up/cool-down idle adjusted time-out with InPower.2. Timer expires.3, Beginning Version 2.303

    CONTROL STOPBUTTON

    COOL-DOWN@ IDLE

    (0−30 min) 1

    EMERGENCYSTOP BUTTON

    WARM-UP @ IDLE(0-300 sec) 1

    Engine Temperaturegreater than 100° F go

    to Rated

    2

    3 RATED TO IDLEDELAY (0−10 sec)

    2

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

  • 3-11

    EMERGENCYSTART

    PTC DETECTSS1 FAILURE 1

    RATED SPEED&VOLTAGE

    STOP

    3

    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

    TIME DELAY TOSTOP (0−600 sec)

    COOL-DOWN@ IDLE

    (0−30 min) 4

    EMERGENCYSTOP BUTTON

    REMOTE STARTCUST. CONNECT 2

    TIME DELAY TOSTART (0−300 sec)

    3

    CLOSE S1OPEN S2

    REMOTE STARTRemoved

    3

    OPEN S1CLOSE S2

    PTC Module seesS1 Voltage OK

    5 RATED TO IDLEDELAY (0−10 sec)

    3

    FIGURE 3-3. STARTING WITH CONTROL IN AUTO MODE (PTC OR REMOTE START SIGNAL)

  • 3-12

    PTC Module seesS1 Voltage OK

    RATED SPEED& VOLTAGE

    (Selectable − with/without load)

    STOP

    2

    NOTES:1. Remote (exercise) start sequence with PTC feature installed.2. Timer expires.3. Warm-up/cool-down idle adjusted time-out with InPower.4. Beginning Version 2.303

    TIME DELAY TOSTOP (0−600 sec)

    COOL-DOWN@ IDLE

    (0−30 min) 3

    REMOTE START(TEST) 1

    TIME DELAY TOSTART (0−300 sec)

    2

    REMOTE START(TEST) Removed

    2

    WARM-UP @ IDLE(0-300 sec) 3

    Engine Temperaturegreater than 100° F go

    to Rated2

    4 RATED TO IDLEDELAY (0−10 sec)

    2

    EMERGENCYSTOP BUTTON

    FIGURE 3-4. PTC FEATURE REMOTE START TEST/EXERCISE SWITCH (IN AUTO MODE)

  • 3-13

    MENU DISPLAY AND BUTTONS

    Figure 3-5 shows the digital display and the menuselection buttons.

    Digital Display: The two-line, 20 characters perline, digital display is used to view the menus of themenu-driven operating system. Refer to the menutrees later in this section. The display is also used toshow fault messages.

    Display Menu Selection Buttons: Four momen-tary buttons—two on each side of the digital displaywindow—are used to step through the variousmenu options and to adjust generator set parame-ters. The button is active when a symbol adjacent tothe button is displayed. The displayed symbol indi-cates the function of the button.

    • In the digital display for main menus (Figure3-6), the and symbols indicate that pressingthe 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 causesthe operating program to go to the next mainmenu, as shown in Figure 3-6.

    • In the digital display, the or symbols indi-cate that pressing the adjacent button causesthe operating program to go to the next or pre-vious submenu, as shown in the menu dia-grams. Only the symbol is displayed in thefirst submenu. Only the is displayed in thelast submenu. Both symbols are displayed inthe rest of the submenus.

    • 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, oneparameter is associated with the + symbol andthe other is associated with the − symbol.

    When changing values, pressing the button ad-jacent to the + symbol increase the value andpressing the button adjacent to the − symboldecreases the value. Only one numeric char-acter of a field can be changed at a time.

    • In the digital display, the or symbol indicatesthat pressing the adjacent button causes theoperating program to move the cursor to thenext numeric character. The selected numericcharacter can then be changed by pressing thebuttons adjacent to the + and − symbols. Onlythe symbol is displayed when the cursor is onthe first character of a field that can bechanged. Only the is displayed when the cur-sor is on the last character. Both symbols aredisplayed when the cursor is on any other char-acter.

    • After adjusting values/parameters, pressingthe symbol results in the changes beingsaved. If the Home button or Previous MainMenu 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) inthe digital display.

    Previous Main Menu Button: Pressing this buttoncauses the operating system to show the previousMain Menu in the digital display. All main menus in-clude both types of green triangles ( and ).

  • 3-14

    HOMEBUTTON

    PREVIOUS MAINMENU BUTTON

    2 LINE, 20 CHARACTERS PER LINE

    MENU DISPLAY

    DIGITAL DISPLAY

    FIGURE 3-5. DIGITAL DISPLAY AND MENU SELECTION BUTTONS

  • 3-15

    MAIN MENUSFigure 3-6 shows the three major main menus avail-able to the user. Figure 3-6 also includes referencesto pages in this section where you can find addition-al information on submenus. When viewing a sub-menu, you can press the previous main menu but-ton at any time to view its main menu.

    As shown in the illustration, each main menu canbranch into one of four directions. Press the buttonnext to “More>>” in the display to view the next Mainmenu. Main Menu 1 is redisplayed when you pressthe button next to “More>>” in the Main Menu 3 dis-play.

    AboutPwr Tran

    SetupMore>>

    FaultsSystem

    HistoryMore>>

    EngineAlternator

    AdjustMore>>

    Main Menu 1

    Main Menu 2

    Main Menu 3

    PAGE3-21

    PAGE3-23

    PAGE3-25

    PAGE3-27

    PAGE3-29

    PAGE3-31

    SERVICEREP

    PAGE3-33

    PAGE3-35

    FIGURE 3-6. MAIN MENUS

  • 3-16

    Main Menu 1

    Main Menu 1 is also the Home menu. When viewingany of the other main menus or any submenu, youcan press the home button to view this menu.

    To display engine parameters, such as coolant tem-perature, oil pressure, oil temperature, etc., pressthe button next to the word “Engine” in the display.Turn to the Engine menu diagram on page 3-21.

    To display alternator parameters, such as line-to-line voltage, line-to-neutral voltage, amperage, fre-quency, etc., press the button next to the word “Al-ternator” in the display. Turn to the Alternator menudiagram on page 3-23.

    To adjust generator parameters, such as idle start,voltage, frequency, start delay, and stop delay, pressthe button next to the word “Adjust” in the display.Turn to the Adjust menu diagram on page 3-25.

    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 tothe word “Faults” in the display. Up to 20 of the mostrecent/current faults can be displayed. Turn to theFaults menu diagram on page 3-27.

    To view network system parameters, such as on theautomatic transfer switch (ATS), Master, or Genset

    system, press the button next to the word “System”in the display. Turn to the System menu diagram onpage 3-29.

    To display historical engine parameters such asnumber of starts, engine hours, control hours, kilo-watt hours, and genset duty cycle, press the buttonnext to the word “History” in the display. Turn to theHistory menu diagram on page 3-31.

    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 thebutton next to the word “About” in the display. Turnto the About menu diagram on page 3-33.

    To view power transfer parameters, such as sourcepower, frequency, generator, utility, and activetransfer timer, press the button next to the word“Pwr Tran” in the display. Turn to the Power TransferMenu on page 3-35.

    Main Menu 3 also includes a link to the Setup me-nus. These menus can be viewed but changes tothese menus are restricted to service personnelwith the appropriate access code.

    To view one of the other main menus, press the but-ton next to “More>>” in the display.

  • 3-17

    ADJUSTING DEFAULT SETTINGS

    The Controller Configuration Menu can be used toadjust 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 diagramon page 3-19.

    SYSTEM MESSAGES

    A system message pop-up screen is displayedwhen the event it is 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 anactive 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

    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 isshown in Figure 3-7. A countdown, in seconds, is in-cluded in the display.

    TD Idle nnn Sec

    FIGURE 3-7. TIME DELAY IDLE POP-UP SCREEN

  • 3-18

    CONTROLLER CONFIGURATION MENU

    Figure 3-8 shows a block representation of the Con-troller Configuration menus. These menus are usedto 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 simulta-neously press the Home Menu and Previous MainMenu buttons.

    As shown in the diagram, the Controller Configura-tion menu has three submenus.

    Press the buttons next to the and symbols in thedigital display to navigate between the menus.

    Press the button next to the symbol in the displayuntil the + and − symbols are displayed.

    Press the button next to the + or − symbol to selectthe desired option.

    After selecting option, pressing the symbol resultsin the changes being saved. If the Home button orPrevious Main Menu button is pressed beforepressing the symbol, the changes are not saved.

    Language Selected submenu: Used to select de-sired language (default = English).

    Temperature Units submenu: Used to selectFahrenheit or Centigrade for temperature readings.

    Fluid Pressure Units submenu: Used to selectPSI or kPA for pressure readings.

  • 3-19

    CONTROLLER CONFIGURATION MENU

    EngineAlternator

    AdjustMore>>

    +Language Selected− English

    Language SelectedEnglish

    Temperature UnitsDeg F +Temperature Units

    − Deg C

    Fluid Pressure UnitsPSI +Fluid Pressure Units

    − kPa

    Back

    Back

    Back

    Main Menu 1

    FIGURE 3-8. CONTROLLER CONFIGURATION MENU

  • 3-20

    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 isdisplayed.

    As shown in the diagram, the Engine menu hasseven submenus. The data in the submenus willvary according to the type and number of sensorsprovided with the engine.

    Press the buttons next to the and symbols in thedigital display to navigate between the menus.Press the Home button or the Previous Main Menubutton to return to Main Menu 1.

    Coolant Temperature submenu: This submenudisplays the engine coolant temperature which canbe viewed in degrees Fahrenheit or Centigrade(see Controller Configuration Menu in this section).

    Oil Pressure submenu: This submenu displaysthe engine oil pressure which can be viewed in PSIor kPA (see Controller Configuration Menu in thissection).

    Oil Temperature submenu (Only available onsome models): This submenu displays the engineoil temperature which can be viewed in degreesFahrenheit or Centigrade (see Controller Configu-ration Menu in this section).

    Engine Speed submenu: This submenu displaysthe engine RPM.

    Battery Voltage submenu: This submenu dis-plays the engine battery voltage.

    Governor Duty Cycle submenu: This submenudisplays the governor duty cycle (drive) levels inpercentage 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.

  • 3-21

    ENGINE MENU

    EngineAlternator

    AdjustMore>>

    Coolant Temperaturennn Deg F

    Oil Pressurennn PSI

    Engine Speednnnn RPM

    Battery Voltagenn.n VDC

    Governor Duty Cyclennn %

    Active Time DelayNone nnnn Sec

    Main Menu 1

    Oil Temperaturennn Deg F

    FIGURE 3-9. ENGINE MENU

  • 3-22

    ALTERNATOR MENU

    Figure 3-10 shows a block representation of the Al-ternator menu. If you press the button next to theword “Alternator” in the display, the first Alternatorsubmenu is displayed.

    As shown in the diagram, the Alternator menu haseleven submenus.

    Press the buttons next to the and symbols in thedigital display to navigate between the menus.Press the Home button or the Previous Main Menubutton to return to Main Menu 1.

    Line-to-Line Voltage submenu: The voltagesLine-to-Line (L1, L2 and L3) are measured betweenL1 to L2, L2 to L3 and L3 to L1, respectively. (Singlephase − L1 to L2 only.)

    Line-to-Neutral Voltage submenu: Note that theLine-to -Neutral menu will not be displayed for a 3phase/3 wire system. Single phase − L1 to N and L2to N.

    Amps submenu: All phases. (Single phase − L1and 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 theamount of real power output for L1, L2, and L3, inkilowatts (kW). (Single phase − L1 and L2 only.)

    Total Apparent Power submenu: This submenudisplays the total amount of apparent power output,in kilovolt amps (kVA).

    Apparent Power submenu: This submenu dis-plays the amount of apparent power output for L1,L2, and L3, in kilovolt amps (kVA). (Single phase −L1 and L2 only.)

    Total Power Factor submenu: This submenu dis-plays the power factor with leading/lagging indica-tion.

    The PF reading will contain an asterisk if the powerfactor is leading (for example, Total PF 0.9 * ).

    Power Factor submenu: This submenu displays apower factor value for L1, L2, and L3. (Singlephase − L1 and L2 only.)

    The PF reading will contain an asterisk if the powerfactor 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% DutyCycle, software clamps Duty Cycle maximum to60% for PMG and 90% for shunt.)

  • 3-23

    ALTERNATOR MENU

    EngineAlternator

    AdjustMore>>

    Volts L12 L23 L31 V nnn nnn nnn

    Volts L1N L2N V nnn nnn

    Amps L1 L2 L3 nnn nnn nnn

    Frequency nn.n Hz

    Power L1 L2 L3kW nn.n nn.n nn.n

    Total Power nnn kW

    Total Power nn.n kVA

    Power L1 L2 L3 kVA nn.n nn.n nn.n

    Total PF n.nn*

    PF L1 L2 L3 *n.nn *n.nn *n.nn

    AVR Duty Cyclennn %

    Main Menu 1

    FIGURE 3-10. ALTERNATOR MENU

  • 3-24

    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 isdisplayed.

    As shown in the diagram, the Adjust menu has fivesubmenus. Each submenu includes a parameter orvalue that can be changed.

    Press the buttons next to the and symbols in thedigital display to navigate between the menus.Press the Home button or the Previous Main Menubutton 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.

    2. If necessary, press the button next to the or symbols to move to the numeric character youwish to change.

    3. Press the button next to the + symbol to in-crease the value or select parameter; press thebutton next to the − symbol to decrease the val-ue or select parameter.

    4. After adjusting values/selecting parameters,pressing the symbol results in the changesbeing saved. (When adjusting values, makesure the cursor is on the last numeric characterbefore pressing the symbol).

    If the Home button or Previous Main Menu but-ton is pressed before pressing the symbol,the changes are not saved.

    Voltage Adjust submenu: Voltage can be ad-justed to �5 percent of the nominal voltage. For ex-ample, if genset output voltage is 208 volts, the volt-age can be adjusted from 198 to 218 volts.

    If the displayed value is greater or less than the al-lowed (5%) range, the control will not accept theentry and will return to the previous setting. Retry byentering a smaller change in one volt increments.

    Frequency Adjust submenu: Frequency can beadjusted to �5 percent of the nominal frequency.For example, if the genset frequency is 60.0 Hz, thefrequency can be adjusted from 57.0 to 63.0 Hz.

    Start Delay submenu: Start Delay can be set from0 to 300 seconds (default = 0). (Enter 1 or more toenable.) This function is bypassed during a manualstart/stop sequence.

    Stop Delay submenu: Stop Delay can be set from0 to 600 seconds (default = 0). (Enter 1 or more toenable.) This function is bypassed during a manualstart/stop sequence and engine shutdown faults.

    Rated To Idle (Beginning Version 2.303): RatedTo Idle delay can be set from 0 to 10 seconds (de-fault = 0). (Enter 1 or more to enable.) Entering anon-zero delay will cause the genset to delay thetransition to Cooldown At Idle.

    Idle Start submenu (Only available on somemodels): Idle Start can be enabled or disabled (de-fault = Disable). This function is only enabled whenthe genset is started in manual mode. Idle Start canalso be enabled while the generator set is running inmanual mode. (Auto/remote start is not affected bythis setting.)

    Enabling Idle Start will cause the genset to run inidle mode until Idle Start is disabled. A warning isdisplayed if genset is left in idle more than 10 min-utes. Long periods of engine idling can eventuallyaffect engine performance and may void enginewarranty.

  • 3-25

    Voltage Adjustnnn V

    Frequency Adjustnn.n Hz

    Start Delaynnn Sec

    +Voltage Adjust− nnn V

    +Frequency Adjust− nn.n Hz

    +Start Delay− nnn Sec

    Back

    Back

    Back

    ADJUST MENU

    EngineAlternator

    AdjustMore>>

    Main Menu 1

    Idle Start Disable

    +Idle Start− Enable

    Back

    Stop Delaynnn Sec +Stop Delay

    − nnn SecBack

    Rated To Idle Delaynn Sec +Rated To Idle Delay

    − nn SecBack

    FIGURE 3-11. ADJUST MENU

  • 3-26

    FAULTS MENUFigure 3-13 shows a block representation of theFaults menu. Up to 20 of the most recent faults canbe viewed. An example of how a fault code is dis-played is shown in Figure 3-12.

    The available menus are dependent on the numberof 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 thebutton next to the word “Fault” in the screen dis-play to view the Faults Main Menu. As shownin the diagram, the Faults Main Menu has twosubmenus. Press the Previous Main Menu but-ton to return to the Faults Main Menu. Press thePrevious Main Menu button a second time toreturn to Main Menu 2.

    Press the Home button at any time to return to MainMenu 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 Menubutton to return to the Faults Main Menu.

    Current Fault submenu: From the Faults MainMenu, press the button next to the word “Current” inthe display to view up to twenty of the most recentunacknowledged faults. Press the Previous MainMenu button to return to the Faults Main Menu.

    FAULTDESCRIPTION

    W = WARNINGS = SHUTDOWN

    ASTERISK =ACTIVE FAULT

    HOUR FAULTOCCURRED

    FAULTCODE

    FIGURE 3-12. HISTORY/CURRENT FAULT SUBMENU

  • 3-27

    FaultsSystem

    HistoryMore>>

    FAULTS MENU

    Main Menu 2

    History

    nnnnn @Hr nnnnn.nW xxxxxxxxxxxxxxxxxxxx

    nnnnn @Hr nnnnn.nW xxxxxxxxxxxxxxxxxxxx

    nnnnn @Hr nnnnn.nS xxxxxxxxxxxxxxxxxxxx

    Fault 1

    Fault 2

    Fault 20

    Faults Main Menu

    Current

    nnnnn @Hr nnnnn.nW xxxxxxxxxxxxxxxxxxxx

    nnnnn @Hr nnnnn.nW xxxxxxxxxxxxxxxxxxxx

    Fault 2

    Fault 20

    nnnnn @Hr nnnnn.nS xxxxxxxxxxxxxxxxxxxx

    Fault 1

    FIGURE 3-13. FAULTS MENU

  • 3-28

    SYSTEM MENU

    Figure 3-14 shows a block representation of theSystem menu. If you press the button next to theword “System” in the display, the System MainMenu is displayed. This menu is displayed only ifthe network communications module (NCM) fea-ture is installed. The System Main Menu allows youto view the status and load of other PCC equipmentconnected on a common network with the PCC2100 control.

    As shown in the diagram, the System Main Menuhas three submenus.

    When viewing ATS and Genset System submenus,press the buttons next to the and symbols in thedigital display to navigate between the menus.Press the Previous Main Menu button to return tothe System Main Menu. Press the Previous MainMenu button a second time to return to MainMenu 2. Press the Home button to return to MainMenu 1.

    ATS System submenus: From the System MainMenu, press the button next to the word “ATS” in thedisplay 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 transferswitch name (configured with InPower), kW load (ifmonitored by the ATS system), status (e.g., not inauto), and source connected and availability (ON =source connected, OK = source available, or NA =source not available).

    Master System submenu: From the System MainMenu, press the button next to the word “Master” inthe display to view the Master System submenu. Amaster controller must be available in the networkto display this submenu.

    The master submenu allows viewing of the mastercontroller name (configured with InPower), kW loadand operational state.

    Genset System submenus: From the SystemMain Menu, press the button next to the word “Gen-set” in the display to view the first of up to 16 GensetSystem submenus. One genset must be availablein the network to display this submenu.

    The genset submenu allows viewing of the gensetname (configured with InPower), kW load and op-erational state.

    If a PCC 2100 control genset, in the network, con-tains the Power Transfer Control (PTC) feature, agenset system submenu will be displayed for thegenset and the ATS System submenu will be dis-played for the PTC feature.

  • 3-29

    ATSMaster

    Genset

    FaultsSystem

    HistoryMore>>

    SYSTEM MENU

    Main Menu 2

    System Main Menu

    ATSnameTag01>nnnnkWNon Auto S1=On, S2=On

    ATSnameTag02>nnnnkWNonAut o S1=Ok, S2=NA

    GensetName01>nnnnkWWarning Fail2Start

    GensetName02>nnnnkWNonAuto Alarm

    ATSnameTag16>nnnnkWNonAuto S1=Ok, S2=NA

    ATS Menu 1

    ATS Menu 2

    ATS Menu 16

    GensetName16>nnnnkWNonAuto Alarm

    Genset Menu 1

    Genset Menu 2

    Genset Menu 16

    Master>nnnn kWShutdwn N=On,E=NA

    FIGURE 3-14. SYSTEM MENU

  • 3-30

    HISTORY MENU

    Figure 3-15 shows a block representation of theHistory menu. If you press the button next to theword “History” in the display, the first History subme-nu is displayed.

    As shown in the diagram, the History menu has fivesubmenus. This information is stored in non-volatilememory and will not be deleted due to loss of bat-tery power.

    Press the buttons next to the and symbols in thedigital display to navigate between the menus.Press the the Previous Main Menu button to returnto Main Menu 2. Press the Home button to return toMain Menu 1.

    Number of Starts submenu: This submenu showsthe number of engine starts.

    Engine Hours submenu: This submenu showsthe number of operating hours for the engine.

    Control Hours submenu: This submenu showsthe number of operating hours for the control.

    Kilowatt Hours submenu: This submenu showsthe number of kilowatt (kW) or megawatt (MW)hours.

    Genset Duty Cycle submenu: This submenushows the percent of genset operating hours thatare less than 30 percent of rated load and percent ofhours that are greater than 90 percent.

  • 3-31

    FaultsSystem

    HistoryMore>>

    HISTORY MENU

    Main Menu 2

    Number Startsnnnnn

    Engine Hours nnnnn Hours

    Control Hours nnnnn Hours

    kW Hours nnnnn kW Hrs

    Genset Duty Cycle Hr 90:nn%

    FIGURE 3-15. HISTORY MENU

  • 3-32

    ABOUT MENU

    Figure 3-16 shows a block representation of theAbout menu. If you press the button next to the word“About” in the display, the first About submenu isdisplayed.

    As shown in the diagram, the About menu has threesubmenus.

    Press the buttons next to the and symbols in thedigital display to navigate between the menus.Press the the Previous Main Menu button to returnto Main Menu 3. Press the Home button to return toMain Menu 1.

    Model submenu: This submenu shows the gensetmodel.

    Rating submenu: This submenu shows the rating(Standby or Prime and number of kilowatts (kW)).

    Software Version submenu: This submenushows the software version level. This informationis required to service the generator set.

  • 3-33

    AboutPwr Tran

    SetupMore>>

    ABOUT MENU

    Main Menu 3

    Modelxxxxxxxxxxxxxxx

    RatingStandby nn.n kW

    Software Versionnn.nnn

    FIGURE 3-16. ABOUT MENU

  • 3-34

    POWER TRANSFER MENU

    Figure 3-17 shows a block representation of thePower Transfer menu. If you press the button nextto the word “Pwr Tran” in the display, the first PowerTransfer 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 theutility voltage (mains) and frequency for failure andcontrol the opening and closing of the contacts (cir-cuit breakers) for Source 1 (S1 utility) and Source 2(S2 genset).

    If S1 power fails, the control will initiate the startingsequence (Figure 3-3), open S1 and close S2 to theload. When S1 returns, the load is retransferred toS1 and the control initiates the genset shutdown se-quence.

    As shown in the diagram, the Power Transfer menuhas five submenus.

    Press the buttons next to the and symbols in thedigital display to navigate between the menus.Press the the Previous Main Menu button to returnto Main Menu 3. Press the Home button to return toMain Menu 1.

    S1 (Source 1) submenu: This submenu showspower transfer source voltage. The voltages Line-to-Line (L1, L2 and L3) are measured between L1 toL2, L2 to L3 and L3 to L1, respectively. (Singlephase − L1 to L2 only.)

    S1 (L-N Source) submenu: This submenu is dis-played only if the control system is configured forline−to−neutral voltage sensing of source 1. Singlephase only − L1 to N and L2 to N.

    Frequency submenu: This menu shows powertransfer source frequency.

    Source 1 submenu: This submenu shows utilitystatus (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 notavailable.

    Genset submenu: This submenu shows generatorstatus (On, Ok, or NA). “On” means the genset isconnected and available. “Ok” means the genset isavailable but not connected. “NA” means the gen-set is not available.

    Active Transfer Timer submenu: This submenushows the time delay, in seconds.

  • 3-35

    S1On

    AboutPwr Tran

    SetupMore>>

    POWER TRANSFER MENU

    Main Menu 3

    S1 L12 L23 L31V nnn nnn nnn

    Frequencynn.n Hz

    GensetOn

    Active Tran TimerTD Re-Trans nnn Sec

    S1 L1N L2NV nnn nnn

    FIGURE 3-17. POWER TRANSFER MENU

  • 3-36

    THIS PAGE LEFT INTENTIONALLY BLANK

  • 4-1

    4. Troubleshooting

    GENERAL

    The genset control continuously monitors enginesensors for abnormal conditions, such as low oilpressure and high coolant temperature. If any ofthese conditions occur, the control will light a yellowWarning lamp or a red Shutdown lamp and display amessage on the digital display.

    This section lists the warning and shutdown codes/messages (Table 4-1), and suggests troubleshoot-ing procedures (Table 4-2).

    Displayed error codes that are not listed in Table 4-2will require an authorized service representative tocorrect the fault. Contact an authorized service cen-ter for assistance.

    SAFETY CONSIDERATIONS

    WARNING Contacting high voltage compo-nents can result in severe personal injury ordeath. Keep the output box covers in place dur-ing troubleshooting.

    High voltages are present when the set is running.Do not open the generator output box while the setis running.

    WARNING Ignition of explosive battery gasescan cause severe personal injury or death. Arc-ing at battery terminals, light switch or otherequipment, flame, pilot lights and sparks can ig-nite battery gas. Do not smoke, or switchtrouble light ON or OFF near battery. Dischargestatic electricity from body before touching bat-teries by first touching a grounded metal sur-face.

    Ventilate battery area before working on or nearbattery—Wear goggles—Stop genset and dis-connect charger before disconnecting batterycables—Disconnect negative (−) cable first andreconnect last.

    CAUTION Disconnect battery charger from ACsource before disconnecting battery cables.Otherwise, disconnecting cables can result involtage spikes damaging to DC control circuitsof the generator set.

    WARNING Accidental starting of the generatorset can cause severe personal injury or death.Prevent accidental starting by disconnectingthe negative (−) cable from the battery terminal.

    When troubleshooting a set that is shut down, makecertain the generator set cannot be accidentally re-started as follows:

    1. Move the O/Manual/Auto switch on the controlpanel to the O (off) position.

    2. Turn off or remove AC power from the batterycharger.

    3. Remove the negative (−) battery cable from thegenerator set starting battery.

  • 4-2

    STATUS INDICATORS

    Running Indicator: This green lamp is lit wheneverthe generator set is running (Figure 4-1).

    Remote Start Indicator: This green lamp is litwhenever 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 inthe Auto position. (if in Auto position and the lamp isflashing, service is required.)

    Configurable Indicators: Defaults for the confi-gurable indicators shown in Figure 4-1 can bechanged with the InPower service tool.

    Shutdown Status Indicator: This red lamp is litwhenever the control detects a shutdown condition.The generator set cannot be started when this lampis on. After the condition is corrected, shutdown in-dicators can be reset by turning the O/Manual/Autoswitch to the O position and pressing the Fault Ac-knowledge/Reset button.

    Warning Status Indicator: This yellow lamp is litwhenever the control detects a warning condition.After the condition is corrected, warning indicatorscan be reset by pressing the Fault Acknowledge/Reset button. (It may not be necessary to stop thegenerator set.) In auto mode, warning indicators

    can also be reset by cycling the remote reset inputafter the condition is corrected.

    Some warnings remain active after the condition iscorrected and the control reset button is pressed.This will require the genset to be shutdown to resetthe warning indicator.

    Digital Display: This two-line, 20-characters perline alphanumeric display is used to view menus ofthe menu-driven operating system and to showwarning and shutdown messages.

    LINE CIRCUIT BREAKER (OPTIONAL)

    Optional line circuit breakers mount in the generatoroutput box. If the load exceeds the circuit breakercurrent rating, the line circuit breaker will open, pre-venting the generator from being overloaded. If thecircuit breaker trips, locate the source of the over-load and correct as necessary. Manually reset thebreaker to reconnect the load to the generator.

    CONTROL AND DIAGNOSTICS VIANETWORK OR PERSONAL COMPUTER

    (LAPTOP)

    See your authorized Cummins Power Generationdealer regarding software, hardware and networkrequirements for control and diagnostics via net-work or personal computer.

  • 4-3

    PANELLAMP(1 of 3)

    CONFIGURABLEINDICATORS

    MANUALRUN/STOPBUTTON

    OFF/MANUAL/AUTO SWITCH

    SHUTDOWNAND WARNING

    STATUSINDICATORS

    EMERGENCYSTOP PUSH

    BUTTON(Pull to reset)

    HOMEBUTTON

    ANALOG ACMETERING

    PANEL

    DIGITALDISPLAY

    MENUSELECTION

    BUTTON (1 of 4)

    PREVIOUSMAIN MENU

    BUTTON

    FAULTACKNOWLEDGEMENT/

    RESET BUTTON

    RUNNING/REMOTESTART/NOT IN AUTO

    INDICATORS

    PANEL LAMPAND LAMP

    TEST BUTTON

    FIGURE 4-1. FRONT PANEL (FULL FEATURED)

  • 4-4

    FAULT CODES

    The fault codes have been divided into five catego-ries to help you determine what corrective action totake for safe operation of the generator set. UseTable 4-1 to find the category (CTG) and fault de-scription for all codes. Gaps in the code numbersare for codes that do not apply to this gensetmodel. Also, some of the codes listed are de-pendent on installed options, and will not bedisplayed by this genset control.

    Category A Fault Codes: Pertain to engine or al-ternator shutdown faults that require immediate re-pair by qualified service personnel (generator setnon-operational). The control prevents the genera-tor set from being restarted if the shutdown fault isnot corrected.

    Category B Fault Codes: Consist of faults that canaffect genset performance or can cause engine, al-ternator, or connected equipment damage. Op-erate genset only when it is powering critical loadsand cannot be shut down. Requires repair by quali-fied service personnel.

    Category C Fault Codes: Consist of faults that donot affect generator set performance but require

    qualified service personnel to repair. These codesindicate a defective harness or wiring problem.

    These codes can also indicate a defective enginesensor, 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 arerepairable 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, external faults, orcustomer fault inputs. May require repair by quali-fied service personnel.

    The fault codes have been divided into five catego-ries to help you determine what corrective action totake for safe operation of the generator set. UseTable 4-1 to find the category (CTG) and fault de-scription for all codes. Gaps in the code numbersare for codes that do not apply to this genset.

    TABLE 4-1. FAULT CODES

    CTG CODE LAMP DISPLAYED MESSAGE

    A 121 Shtdn Speed Signal Lost

    C 135 Wrng Oil Pressure Sensor H

    C 141 Wrng Oil Pressure Sensor L

    D 143 Wrng Pre-Low Oil Pres

    C 144 Wrng Coolant Sensor High

    C 145 Wrng Coolant Sensor Low

    D 146 Wrng Pre-High Coolant Temp

    D 151 Shtdn High Coolant Temp

    D 197 Wrng Low Coolant Level

    C 212 Wrng Oil Temp Sensor H

    C 213 Wrng Oil Temp Sensor L

    CTG CODE LAMP DISPLAYED MESSAGE

    A 234 Shtdn Overspeed

    D 235 Shtdn Low Coolant Level

    D 359 Shtdn Fail To Start

    D 415 Shtdn Low Oil Pressure

    D 421 Wrng Oil Temp

    D 441 Wrng Low Bat Voltage

    D 442 Wrng High Bat Voltage

    E 1122 None Rated/Idle Trans

    A 1123 * Shtdn Shutdown After Battle Short

    E 1124 Wrng Delayed Shutdown

    E 1131 * Wrng Battle Sh Active

    * Refer to Battle Short Mode description in Section 3.

  • 4-5

    TABLE 4-1. FAULT CODES (CONT.)

    CTG CODE LAMP DISPLAYED MESSAGE

    E 1311 Shtdn/Wrng/None

    Customer Input #1

    E 1312 Shtdn/Wrng/None

    Customer Input #2

    E 1313−1316

    Shtdn/Wrng/None

    Network Fault 1 thru 4

    E 1317 Shtdn/Wrng/None

    Customer Input #3

    E 1318 Shtdn/Wrng/None

    Customer Input #4

    A 1334 Shtdn Crit Scaler Out Of Range

    B 1335 Wrng Noncrit Scaler Out Of Range

    E 1337 None No Message

    C 1416 * Wrng Fail To Shutdown

    D 1417 Wrng Powr Down Error

    D 1433 Shtdn Emergency Stop

    D 1434 Shtdn Remote E-Stop

    D 1435 Wrng Low Coolant Temp

    D 1438 Shtdn Fail To Crank

    D 1442 Wrng Weak Battery

    D 1443 Shtdn Battery Failed

    B 1444 Wrng KW Overload

    A 1445 Shtdn Short Circuit

    A 1446 Shtdn High AC Voltage

    A 1447 Shtdn Low AC Voltage

    A 1448 Shtdn Under Frequency

    A 1449 Wrng Over Frequency

    CTG CODE LAMP DISPLAYED MESSAGE

    A 1452 Wrng Gen CB Not Close

    A 1453 Wrng Gen CB Not Open

    A 1459 Shtdn Reverse Power

    A 1461 Shtdn Loss Of Field

    C 1466 Wrng Modem Failure

    C 1468 Wrng Network Error

    A 1469 Shtdn Speed/Hz Match

    B 1471 Wrng Over Current

    A 1472 Shtdn Over Current

    E 2323−2326

    Shtdn/Wrng/None

    Network Fault 5 thru 8

    B 2327 Wrng PTC Fault

    E 2329 Wrng Low S1 Frequency

    E 2331 Wrng Low S1 Voltage

    A 2335 Shtdn Excitation Fault

    A 2336 Shtdn Memory Error

    C 2337 Wrng Pwr Tran Disabled

    C 2338 Wrng Pwr Tran Failure

    E 2339 Wrng Pwr Down Enabled

    B 2341 Wrng High Control Temp

    E 2342 Wrng Too Long In Idle (10 min.)

    E 2358 Wrng High S1 Voltage

    E 2396 Wrng S1 CB Not Close

    E 2397 Wrng S1 CB Not Open

    C 2966 Wrng PTC Timeout

    C 2967 Wrng Governor Fault

    C 2968 Wrng AVR Fault

    C 2969 Wrng LON Failure

    A 2972 Shtdn Field Overload

    * Refer to Battle Short Mode description in Section 3.

  • 4-6

    Hazards present in troubleshooting can cause equipment damage, severe personalinjury or death. Only trained and experienced service personnel with knowledge of fuels, electric-ity, and machinery hazards should perform service procedures. Read Safety Precautions pageand observe all instructions and precautions in this manual.

    WARNING

    TABLE 4-2. WARNING AND SHUTDOWN CODES

    FAULT CODE CORRECTIVE ACTION

    143PRE-LOW OIL PRESLamp: Warning

    Indicates engine oil pressure has dropped below the warning trip point.. If genera-tor is powering critical loads and cannot be shut down, wait until next shutdownperiod and then follow code 415 procedure.

    146PRE-HIGH COOL TMPLamp: Warning

    Indicates engine is operating near cooling system capacity. Increase in load orhigher ambient temperature may cause High Coolant Temp (151) shutdown. Re-view 151 correction list for other possible causes.

    151HIGH COOLANT TEMPLamp: Shutdown

    Indicates engine has overheated (coolant temperature has risen above the shut-down trip point). Allow engine to cool down completely before proceeding with thefollowing checks:

    a. Check coolant level and replenish if low. Look for coolant leaks and repair if nec-essary.

    b. Check for obstructions to cooling airflow and correct as necessary.

    c. Check fan belt and repair or tighten if necessary.

    d. Check blower fan and circulation pumps on remote radiator installations.

    e. Reset control and restart after locating and correcting problem.

    197LOW COOLANT LEVELLamp: Warning(Optional)

    Indicates engine coolant level has fallen below the warning trip point. If generatoris powering critical loads and cannot be shut down, wait until next shutdown peri-od, then follow code 235 procedure. If engine can be stopped, follow code 235procedure.

    235LOW COOLANT LEVELLamp: Shutdown(Optional)

    Indicates engine coolant level has fallen below the shutdown trip point. Allow en-gine to cool down completely before proceeding.

    a. Check coolant level and replenish if low. Look for possible coolant leakagepoints and repair if necessary.

    b. Reset control and restart after locating and correcting problem.

    359FAIL TO STARTLamp: Shutdown

    Indicates possible fuel system or air induction problem. (Engine cranks but fails tostart)

    a. Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as re-quired.

    b. Check for dirty fuel filter and replace if necessary.c. Check for dirty or plugged air filter and replace if necessary.d. Reset the control and restart after correcting the problem.

    415LOW OIL PRESSURELamp: Shutdown

    Indicates engine oil pressure has dropped below the shutdown trip point. Checkoil level. If oil level is low, replenish. Reset control and restart.

  • 4-7

    Hazards present in troubleshooting can cause equipment damage, severe personalinjury or death. Only trained and experienced service personnel with knowledge of fuels, electric-ity, and machinery hazards should perform service procedures. Read Safety Precautions pageand observe all instructions and precautions in this manual.

    WARNING

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

    FAULT CODE CORRECTIVE ACTION

    421OIL TEMPLamp; Warning(Optional)

    Indicates engine has begun to overheat (oil temperature has risen to an unac-ceptable level). If generator is powering non-critical and critical loads and cannotbe shut down, use the following:

    a. Reduce load if possible by turning off non-critical loads.

    b. Check air inlets and outlets and remove any obstructions to airflow.If engine can be stopped, follow code 151 procedure and also check engine oillevel.

    441LOW BAT VOLTAGELamp: Warning

    Indicates battery voltage supply to the control is approaching a low level at whichunpredictable operation will occur.

    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 allconnections.

    c. Check battery charge voltage float level if applicable (raise float level).

    442HIGH BAT VOLTAGELamp: Warning

    Indicates battery voltage supply to the control is approaching a high level at whichdamage to the control can occur. Check float level on battery charger if applicable(lower float level).

    1311, 1312, 1317, 1318CUSTOMER INPUT #1 − #4Lamp: Warning/Shutdown ornone for status message.

    The nature of the fault is an optional customer selection. Example inputs: LowFuel 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, Warning or Shutdown (Default: #1−None, #2 thru #4−Warning)• Active closed or open (Default: closed [ground])• Change display name using up to 19 characters (Default: #1− Customer Fault 1,

    #2−Ground Fault, #3−Low Fuel, #4−Rupture Basin Fault)

    1417POWER DOWN ERRORLamp: Warning

    Indicates that the controller can not power down because of some unknown condi-tion. Possible drain on battery. Contact an authorized service center for service.

    1433EMERGENCY STOPLamp: Shutdown

    Indicates local Emergency Stop. To reset the local/remote Emergency Stop button:

    4. Pull the button out.

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

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

    7. Return O/Manual/Auto switch to desired position.

  • 4-8

    Hazards present in troubleshooting can cause equipment damage, severe personalinjury or death. Only trained and experienced service personnel with knowledge of fuels, electric-ity, and machinery hazards should perform service procedures. Read Safety Precautions pageand observe all instructions and precautions in this manual.

    WARNING

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

    FAULT CODE CORRECTIVE ACTION

    1434REMOTE E-STOPLamp: Shutdown

    Indicates remote Emergency Stop. See code 1433 to reset.

    1435LOW COOLANT TEMPLamp: Warning

    Set is not operating. Warningoccurs when engine coolanttemperature is 70° F (21° C)or lower. NOTE: In applica-tions where the ambienttemperature falls below 40�F (4� C), Low Coolant Tempmay be indicated eventhough the coolant heatersare operating.

    Indicates engine coolant heater is not operating or is not circulating coolant.Check for the following conditions:

    a. 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 coolantleaks and repair as required.

    1438FAIL TO CRANKLamp: Shutdown

    Indicates possible fault with control, speed sensing or starting system. See code441 for corrective action.

    1442WEAK BATTERYLamp: Warning

    Indicates that during cranking, the battery voltage is at or below the weak batterywarning trip point for a time greater than or equal to the weak battery set time. Seecode 441 for corrective action.

    1443BATTERY FAILEDLamp: Shutdown

    Dead battery − engine will not start. See code 441 for corrective action.

    2342TOO LONG IN IDLELamp: Warning

    Indicates genset has been in Idle mode too long (10 minutes maximum).

  • 5-1

    5. Maintenance

    GENERAL

    Establish and adhere to a definite schedule formaintenance and service based on the applicationand severity of the environment. Table 5-1 coversthe recommended service intervals for a generatorset on STANDBY service. If the set will be subjectedto extreme operating conditions, the service inter-vals should be reduced accordingly. Some of thefactors that can affect the maintenance scheduleare 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 con-taminates

    Consult with your local Cummins Power Generationdistributor if the generator set will be subjected toany extreme operating conditions and determine asuitable schedule of maintenance. Use the runningtime meter to keep an accurate log of all service per-formed for warranty support. Perform all service atthe time period indicated or after the number of op-erating hours indicated, whichever comes first. UseTable 5-1 to determine the maintenance requiredand then refer to the sections that follow for the cor-rect service procedures.

  • 5-2

    TABLE 5-1. MAINTENANCE SCHEDULE

    MAINTENANCE ITEMS

    SERVICE TIME

    SeeEngineSchdl.

    Dailyor after

    8Hours

    Weeklyor after

    50Hours

    Month-ly

    or after100

    Hours

    6Month-s or af-ter 250Hours

    Yearlyor after

    500Hours

    4000 −4500

    Hours

    General Genset Inspection X1 X2

    Check Coolant Heater X

    Check Oil Level X

    Check Coolant Level X

    Check Fuel Level X

    Check Charge Air Piping X

    Check Air Cleaner (Clean if required) X3

    Check Battery Charging System X

    Drain Water and Sediment from Fuel Tank X5

    Drain Exhaust Condensate Trap X

    Check Starting Batteries X

    Change Air Cleaner Element X3

    Check Radiator Hoses for Wear & Cracks X

    Test Generator Insulation Resistance X7

    Grease generator bearing (P7) X

    Drain Fuel Filter(s) X1

    Check Anti-freeze and DCA Concentration X1

    Change Crankcase Oil and Filter X1, 6

    Check Drive Belt Tension X1

    Change Coolant Filter X1

    Clean Crankcase Breather X1

    Change Fuel Filters X1

    Clean Cooling System X1

    X1 Refer to Cummins Engine Operation and Maintenance Manual for maintenance interval and/or procedure.

    X2 Check for oil, fuel, cooling and exhaust system leaks. Check exhaust system audibly and visually with set running and repair anyleaks immediately.

    X3 Perform more often in dusty conditions.

    X4 Visually check belt for evidence of wear or slippage. Replace if hard or brittle.

    X5 Drain 1 cup or more of fuel to remove water and sediment.

    X6 If genset is used for standby applications, change oil every 12 months or 250 hours, whichever comes first.

    X7 This procedure should be followed periodically throughout the life of the generator set, or if the generator has set idle for a periodof time with no generator heaters used. Contact your authorized service center.

  • 5-3

    GENERATOR SET INSPECTION

    During operation, be alert for mechanical problemsthat could create unsafe or hazardous conditions.The following sections cover several areas thatshould be frequently inspected for continued safeoperation.

    Exhaust SystemWith the generator set operating, inspect the entireexhaust system visually and audibly including theexhaust manifold, muffler and exhaust pipe. Checkfor leaks at all connections, welds, gaskets andjoints and also make sure that exhaust pipes are notheating surrounding areas excessively. If any leaksare detected, shut down the genset and have leakscorrected immediately.

    WARNING Inhalation of exhaust gases can re-sult in severe personal injury or death. Be suredeadly exhaust gas is piped outside and awayfrom any windows, doors, vents or other inletsto building and not allowed to accumulate in in-habitable areas.

    Fuel SystemWith the generator set operating, inspect the