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Owners Manual - AP Electric Generators

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1. 6 Verify that the computer is not connected to the same router or local area network as the generator set If it is on the same network you will be able to access the generator set using the local network IP address configured on the generator set The computer used for internet access must be connected to a different internet connection than the generator set 7 Check to see if you can access a standard web page from a computer If not contact the ISP to troubleshoot the internet connection 8 Verify all settings as described in the Network Setup Guide 9 If the previous steps do not correct the problem contact a computer network specialist to diagnose To verify your IP address access whatismyipaddress com from the browser of a computer connected to the internet and on the same network as the generator set This web page displays your current IP address which should match the IP address assigned to you by your ISP Email Alert Troubleshooting Some Generator Set service procedures present hazards that can result in severe personal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform Generator Set service Possible Causes An improper setup the alert level is not set to all events emails cannot be received the outgoing email address is not included in your contact list the email account is not capable of using plain SMTP for the ou
2. A029V089 Issue 8 37 4 Maintenance 9 2013 This page is intentionally blank 38 A029V089 Issue 8 o Troubleshooting By regularly performing the following periodic maintenance and guidelines you greatly reduce the chances of a genset shutdown Maintain an appropriate oil level Keep battery connections clean and tight Do not overload the generator set Keep the air inlet and outlet openings clear 5 1 Troubleshooting With the In Home Operator Panel If a fault shutdown occurs the ACTION REQUIRED lamp on the in home Operator Panel will come on and the LCD screen will display the a description of the Fault the Fault Number and the hour in total generator set running time when the Fault occurred The shutdown codes are listed below in numerical order along with step by step corrective actions 52 Fault Code Blinking At fault shutdown the status indicator light will repeatedly blink sets of 1 2 3 or 4 blinks One blink indicates shutdown due to high engine temperature Two blinks indicate shutdown due to a loss of engine oil pressure Three blinks indicate a service fault Press Stop once to cause the two digit second level shutdown code to blink Pressing Stop again will stop the blinking The two digit code consists of 1 2 3 4 or 5 blinks a brief pause and then 1 to 9 blinks The first set of blinks represents the tens digit and the second set of blinks the units digit of the shutdown code number
3. Four blinks indicate that cranking time exceeded 35 seconds e Fault Code Nos 1 2 3 and 4 are first level faults Pay close attention to the pause sequence to avoid interpreting first level faults as second level Fault Codes Nos 11 22 33 or 44 To avoid the possibility of anyone misinterpreting Code Nos 3 and 4 as Code Nos 33 and 44 the latter have not been assigned faults 5 3 Restoring Fault Code Blinking The fault code stops blinking after five minutes Press Stop three times within three seconds to restore fault code blinking NOTICE The last fault logged will blink even though the condition that caused the shutdown may have been corrected A029V089 Issue 8 39 5 Troubleshooting 9 2013 9 4 9 4 1 9 4 2 9 4 3 40 Some Generator Set service procedures present hazards that can result in severe personal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform Generator Set service Troubleshooting with the Flashing Indicator Light The status indicator light on the Control Switch inside the generator set flashes the diagnostic fault code when a fault shutdown occurs For a single digit fault code 2 or 4 the light will flash 2 or 4 times and after a short pause will repeat For a two digit fault code the light will flash the tens digit pause and flash the units digit and repeat after a longer pause Fault 36 w
4. The Network Setup Parameters screen allows dynamic addresses to be changed to static addresses This screen allows the user to configure the static address for the in home network See the Network Setup Parameters screen shown below Gensel Exercise Load Time 1 Date Schedule Control Network Setup Click here to start Network Setup MAC address 00 1C EB 23 00 01 Saltware Part Number 3267344 Software Version 0 56 FIGURE 34 NETWORK SETUP SCREEN Network Setup DHCP O Off On IP Humbe ni Subnet Mask Gateway Static DNS 4 Static ONS 2 FIGURE 35 NETWORK SETUP PARAMETERS 6 2 7 Email Setup Screen Descriptions The user must determine what events will trigger an email notification of the event e Never All Events A029V089 Issue 8 55 6 Optional Internet Email Interface Descriptions 9 2013 Maintenance and Attention Required or Attention Required Only This screen is also used to set up e mail configuration The user may enter up to three email addresses for receiving notifications of the home standby generator set status See the Email Addresses figure below Network Setup Email Setup Alert Level Maintenance and Attention Requirad Outgoing Server SMTP Sorvar Name max 47 chars User Name max 45 chars Password max 16 chars FIGURE 36 EMAIL SETUP PARAMETERS Network Setup Destination Email Addresses max 48 chars each Address 1 Address p Address 3
5. FIGURE 37 EMAIL ADDRESSES 6 2 8 Saving Changes After the email addresses are added and Done is selected this screen will appear verifying that all changes have been saved FIGURE 38 SAVE SCREEN 6 3 Ethernet Connections Optional Wiring connections to the Ethernet RJ 45 plug are shown in the Ethernet RJ 45 Connector Wiring illustration Utilize an appropriate Ethernet stripping and crimping tool for these connections 56 A029V089 Issue 8 9 2013 6 Optional Internet Email Interface Descriptions AU LANA FOV LEA g Green and White G Green o Orange and White Q Orange b Blue and White B Blue br Brown and White BR Brown FIGURE 40 ETHERNET RJ 45 CONNECTOR WIRING A029V089 Issue 8 57 6 Optional Internet Email Interface Descriptions 9 2013 58 UPS RECOMMENDED INTERNET WORLD WIDE WEB Puklic IP 176 196 052 094 Forward Port 80 to 192 168 000 001 Forward Port 80 to y 192 168 000 150 v CAT 5 CABLE E NOTE IP tionedin th Static IP 192 168 000 150 EA HH SERE instructions are samples only P Dynamic IP 192 168 000 003 GENERATOR SET GENERATOR SET CONTROL BOARD PERSONAL COMPUTER FIGURE 41 NETWORK CONNECTIONS A029V089 Issue 8 Cummins Power Generation 1400 73rd Ave NE Minneapolis MN 55432 USA Phone 1 763 574 5000 Toll free 1 800 888 6626 Fax 1 763 574 5298 Copyright O 2013 Cummins Power Generation Inc All r
6. Press the NEXT button on the Exerciser Clock screen to select the field to change 3 Press the up or down arrow button to increase or decrease the frequency of exercise and the day of the week and time of day for exercise 28 A029V089 Issue 8 9 2013 3 Operation Frequency selections are Weekly Bimonthly Monthly Never 4 Press the BACK button to save the settings and return to the home screen 5 If you want to exercise the generator set now select Exercise Now and press either the up or down arrow NOTICE Scheduled or prompted exercise does not transfer the house loads to the generator set Sun 10 35 AM Battery l Genset Load LIW 12M _ Exerciser Clock Exercise Weekly Mon FIGURE 20 EXERCISE CLOCK SCREEN 3 13 Time Setup To set up the generator set clock for the current date and time 1 Press the CLOCK button on the home screen 2 Press the NEXT button on the Time Setup screen to select the field to change 3 Press the up or down arrow button to increase or decrease or change the date or time 4 Press the BACK button to save the settings and return to the home screen A029V089 Issue 8 29 3 Operation 9 2013 Sun 10 35 AM Battery 12 2 Genset Load LIW LUL EXCERICLOCK LOAD MENU Uu Time Setup Date MEMN Time FIGURE 21 TIME SETUP SCREEN 30 A029V089 Issue 8 4 Maintenance 4 1 Periodic Maintenance Schedule Periodic maintenance is essential for top gene
7. 21 Connnected AUTOMATIC MODE Mode K 22 Load Management 12 Disconnected Connnected When running 2 Connected Connect Load 1 MANUAL MODE FIGURE 16 LOAD MANAGEMENT SCREEN 3 9 Display Setup and Software Info 3 9 1 Brightness and Contrast To change the Brightness and Contrast of the display screen 1 Press the up or down arrow button on the menu screen to select Display Setup NO oO KO N 24 Press the MENU button on the home screen Press the ENTER button on the menu screen Press the NEXT button to select Brightness or Contrast Change Contrast the same way as Brightness Disconnected Disconnect Load 2 9 2013 Press the increase or decrease arrow button to increase or decrease brightness Press the BACK button to save the settings and return to the home screen A029V089 Issue 8 9 2013 3 Operation Sun 10 35 AM Battery 12 2 Genset Load LIW 12M Genset Status Event Log Fault Log Ethernet Setup Display Setup B ee Contrast Software Info GEN SW P N 3261234 SW VERSION 12 34 Dis SW P N 3261234 SW VERSION 10 23 FIGURE 17 DISPLAY SETUP AND SOFTWARE INFO SCREENS 3 9 2 Software Info To check on the generator set and display software 1 Press the MENU button on the home screen 2 Press the up or down arrow button on the menu screen to select Display Setup 3 Press the ENTER button on the menu
8. 25 6 35mm past top dead center Oil Capacity Approximately 80 oz 2 3 Liters Oil Recommendation 5W 30 Synthetic Engine Oil See Operator Manual 8 A029V089 Issue 8 9 2013 2 Introduction TABLE 7 GENERATOR SPECIFICATIONS TABLE O TA TT Propane Vapor Natural Gas Propane Vapor Natural Gas Power kVA E ESO CECI EC Single Pras O M Phase Type Single Phase Circuit Breaker Amps Hoo ho fof De rating Guidelines Maximum wattage or maximum current are subject to and limited by such factors as fuel Btu content ambient temperature altitude engine power and condition etc Full rated power is available at 60 F 15 5 C at sea level De rate 3 5 for each 1000 ft 304 8 m above sea level and 3 for each 10 F 5 5 C increase in ambient temperature above 60 F 15 5 C This generator is rated in accordance with UL 2200 Stationary Engine Generator Assemblies or CSA C22 2 No 100 04 Motors and Generators The maximum continuous current values that are listed on the generator set nameplate and specification tables occur at the lower limit of acceptable voltage Maximum current occurs at 108 and 216 volts 10 below nominal voltage 120 240 The voltage set point of this generator set can be adjusted from the operator panel if desired Refer to the Operator manual procedure To Adjust the Output Voltage TABLE 8 CONTROL SPECIFICATIONS TABLE Propane Vapor _ NaturalGas PropaneVapor NaturalGas Cont
9. GENERATOR RUNNING lamp will turn on 3 The UTILITY CONNECTED light will go out when the generator set is connected to supply power The LCD screen will provide a visual indication of Genset Load bar graphs The bar graphs indicate how much of the available power is being used in each supply line L1 and L2 If the red ACTION REQUIRED light comes on either the generator shut down or periodic maintenance has come due The LCD screen will indicate what maintenance is due or which fault occurred Cummins Onan UTILITY PRESENT CONNECTED Sun 10 35 AM GENERATOR Battery 12 5 RUNNING Genset Load STANDBY OFF a ct ACTION REQUIRED EXCER CLOCK LOAD MENU d FIGURE 9 GENERATOR SET RUNNING ACTION REQUIRED LAMP ON A029V089 Issue 8 17 3 Operation 9 2013 3 3 3 To Adjust the Output Voltage 3 4 18 Use the follovving procedure 1 Connect an accurate AC volt meter across L1 and L2 while the generator set is running 2 With Output Volts selected on the Adjustments Menu screen press the up or down arrow button to adjust the voltage to the desired setting 3 The control allows an adjustment of 240 VAC 7 17 VAC 4 Press the BACK button to save the settings and return to the home screen To Enable Disable Standby Normally you should not have to disable generator set STANDBY e STANDBY should always be enabled ON except during maintenance service e STANDBY will have to be re enabled STANDBY
10. Gener S e e 20 E 32 ass nene SIN E eT seosueeeseceedeboceses 32 sis E im 32 AA 2 Checkin ENNE S ONE VE e 0 tne seen OE 32 AA daton QI 0999 o 9999 0 90 9 90 9 ere 0 90 040 acre RE 33 da acenansimgimgine Oil and Oil Filter dee 33 4 5 Replacing the Air riltestelement A ia 34 Mo Battery Maintenance S 94 a E I A EET ITEE 35 4 Seuk EU A e T E EEEIERIR 36 ae Wisin Me RE ERES coccion 36 s a0 moti INC EINE iuueni nn nnne ren nnn nnn nnn nnne nnne nnne 39 5 1 Troubleshooting With the In Home Operator Panel aa nana aaa aaa anen an ea na aeke kape eee rene eren ecen 39 AR AS A 39 elo a A 39 5 4 Troubleshooting with the Flashing Indicator Light occoooccoccoconccocccocnconncnnnonanonaconannnos 40 5 4 1 No Response Status Indicator Light Dead oocccoccccoccccccnccnnncconnconncnonononcncnnnoss 40 54 2 SENG eterne NUS LO AAA 40 549 Starter Engages DisengageS r re ca set nee aes Sree he a et Omens a D 40 5 4 4 No AC Power generator set Running Status LED On Steady or Flashing O so cue EUM ULM el ec 41 5 4 5 Generator Set Cranks But Does Not Start No Fault Code 41 5 4 6 Genset Warning Transfer Switch Failed to Transfer to Utility No Fault Code 41 547 Low Oll Pressure Fall Fal Ode o DELETE 41 ouo Overerank Fault Code Aaa a omoes cu ure ub cl UM 41 54 9 Overvoltage FAMA ccc om c
11. OFF light on if the generator set is started or stopped manually normally a maintenance service function or a fault shutdown has occurred When STANDBY is disabled the generator set will NOT automatically start to supply power if utility power is interrupted To enable or disable generator set standby 1 Press the STANDBY ON OFF button on the operator panel which takes you to the Standby ON OFF screen 2 Press the up or down arrow button to select ON or OFF 3 To enable STANDBY select ON and press the BACK button The STANDBY OFF lamp will go out and the display will state Standby ready enabled by user 4 To disable STANDBY select OFF and press the BACK button The STANDBY OFF lamp will come on and the display will state Standby ready disabled by user Standby required for automatic start stop Standby Oi OFF FIGURE 10 ENABLE DISABLE STANDBY SCREEN A029V089 Issue 8 9 2013 3 9 3 6 3 Operation To Manually Startistop Generator Set Normally only the maintenance service technician has to manually start and stop the generator set e Starting the generator set will result in the generator powering the house loads Manually starting or stopping the generator set disables generator set STANDBY The generator set will not automatically start to supply power if utility power is interrupted Manually start and stop the generator set once every 3 months to test that these functions ar
12. TIMING DIAGRAM A029V089 Issue 8 13 3 Operation Exercise Utility Present SH Green Utility Connected Dipay S Generator Running Green I see d RU 2 Generator Standby Off or t a HUU EAST e Available Senerator Transfer Switch Load Control 1 or sa Load Control 2 i Time Duration 2 19 20 min 5min seconds i i Engine Starts Generator Engine Cook Generator up lime Exerase Down OHT FIGURE 5 EXERCISE TIMING DIAGRAM 14 9 2013 A029V089 Issue 8 9 2013 3 Operation Manual Start Stop pr 1 Green Utility Connected OF Generator Running Generator Standby Of YY AF Not Available Generator n____ H EA ESA Transter uiy Switch xi Load Control 1 i Load Control 2 a Time Duration seconds i i i i i Sian SIOP Engine Start Transfer Load ControkLoad Control poete aa Pressed l Up TIRE Ue I Loey l DE ATS x fer l l Pressed Slandby Enabled FIGURE 6 MANUAL START STOP TIMING DIAGRAM A029V089 Issue 8 15 3 Operation 9 2013 3 3 1 16 Load Management LNiliby Green Generator Running Generator Standby OF lon EE MIENNE z Available Utility Power N
13. The Internet Email Interface can make the same fault maintenance and event notices available to you and to your generator set service contract agency with appropriate Internet Service and email account NOTICE Technical support for setup and troubleshooting of the hardware used for in home network access to the generator set is available through the selling Cummins Onan dealer distributor The owner may be required to contact their ISP and or email provider for technical support of the email notification feature setup and troubleshooting Due to the variations in network equipment network configurations and ISPs the owner is responsible for acquiring the needed support service from a qualified network specialist to properly and securely set up the owner s network for remote monitoring of the generator set Cummins Onan does not provide technical support for setup and troubleshooting of the owner s network and email service A029V089 Issue 8 51 6 Optional Internet Email Interface Descriptions 9 2013 6 2 Screen Descriptions E Standby Power by Cummins Microsoft Internet Explorer File Edit View Favorites Tools Help O O DAA Puma dr E E n j Nu E ae address http 92 168 000 002 Google wj IG Search amp E E m Cummins Onan Genset Exercise Load Time Date Schedule Control Home Genset Status Running Battery Voltage 11 7 VDC Genset Clock Genset Load 8 12 AM Line 1 MEN Sept
14. Transfer To Generator Set Fault Code 79 aak nenes 5 5 Communication Troubleshooting 5 5 1 In Home Network Access to Generator Set Troubleshooting 5 5 2 Remote Internet Access to Generator Set Troubleshooting OSM EMAa lA enebeudoiesneohmgeem o o o im too 6 OPTIONAL INTERNET EMAIL INTERFACE DESCRIPTIONS eee oT Introductions cec err EO EE 6 2 Screen Descriptions 6 2 1 Setting Time and Date 6 2 2 Set Exercise Schedule 6i2 Sikoad Control Management A EE Cree elie OQ A E Rault Las TE 6 2 6 Network Setup Screen Descriptions oocccocccocccocnconncoonoconocorocnnnoncnnorononnnonnnonnnnnnos 6 2 7 Email Setup Screen Descriptions oocccocncccncoonnconncocnnocnconnnncnnncnnonnnonnncnnnnnnnnncnnnonos 6 2 8 Saving Changes 6 3 Ethernet Connections Optional A029V089 Issue 8 44 44 44 44 44 45 45 45 45 46 47 91 91 92 92 99 99 94 94 99 99 96 96 Table of Contents 9 2013 This page is intentionally blank iv A029V089 Issue 8 1 IMPORTANT SAFETY INSTRUCTIONS 1 1 Save These Instructions This manual contains important instructions for the generator set that should be followed during the operation and maintenance of the generator and batteries Thoroughly read this manual before operating the generator set Safe operation and to
15. end of the drain hose into an appropriate container Refer to local state regulations to determine the appropriate container for used oil 3 Open the oil drain valve to release oil from the engine into the appropriate container 4 Re check the engine oil level Checking Engine Oil Level Based on the results add or drain oil 5 When a sufficient amount of oil has been drained from the system a Close the oil drain valve b Remove the drain hose c Wipe the oil drain valve clean d Dispose of the used oil in accordance with local state regulations 4 4 3 2 Add Oil If the oil level is found to be insufficient see Checking Engine Oil Level oil must be added 1 Add the appropriate amount of oil based on the engine oil level check performed beforehand 2 Re check the engine oil level see Checking Engine Oil Level Based on the results add or drain oil 3 Clean up and dispose of any oil in accordance with local state regulations 4 4 4 Changing Engine Oil and Oil Filter Refer to the Periodic Maintenance Schedule for scheduled engine oil changes and to the control panel for the oil filter part number Change oil more often in hot and dusty environments 1 Run the generator set until warm shut down and place pan under the end of the oil drain hose attached to the drain valve A029V089 Issue 8 33 4 Maintenance 9 2013 2 Make sure the oil drain hose is connected to the oil drain valve and open the drain valve Reclose
16. reduce arcing NOTICE If the battery needs to be replaced be sure that the replacement battery specs match those found in the Specifications Table in this manual Spark Plugs Before working on the generator set move the Switch S2 to the Stop Position disconnect the remote harness P7 to disable the ATS mounted charger and remove the negative battery cable from the battery to prevent starting Set the genset control to the Off position before checking the spark plugs Refer to the Periodic Maintenance Table for scheduled spark plug replacement The genset has two spark plugs one on each side of the engine The spark plugs must be in good condition for proper engine starting and performance A spark plug that fouls frequently or has heavy soot deposits indicates the need for engine service To prevent cross threading a spark plug always thread it in by hand until it seats Torque the spark plug to 15 Ib ft 20 N m Return the genset control to Auto when finished performing maintenance Maintenance Record Record all periodic and unscheduled maintenance and service See the Periodic Maintenance Schedule for a list of scheduled maintenance frequency HOUR MAINTENANCE OR SERVICE PERFORMED METER READING 36 A029V089 Issue 8 9 2013 4 Maintenance DATE HOUR MAINTENANCE OR SERVICE PERFORMED METER READING Record the name address and phone number of your authorized Cummins Onan service center
17. screen 4 Press the INFO button on the Display Setup screen and note the values displayed on the Software Info screen 5 Press the BACK button to return to the home screen A029V089 Issue 8 25 3 Operation 9 2013 3 10 Event Log 3 10 1 To Check Log of Last 20 Events 1 Press the MENU button on the home screen 2 Press the up or down arrow button on the menu screen to select Event Log 3 Press the ENTER button on the menu screen 4 Scroll through the event log with the up and down double arrow buttons Each screen provides a brief description of the event along with the time and date of the event 5 Press the BACK button to return to the home screen Sun 10 35 AM Battery 1243 Genset Load LIN L2M Genset Status Display Setup Fault Log Ethernet Setup Standby Enabled 05 04 2007 1 18PM Y 12 FIGURE 18 EVENT LOG SCREEN 3 10 2 List of Recordable Events e Genset started manually Standby Ready Disabled e Genset stopped manually Standby Ready Disabled e Genset exercise started e Genset exercise completed Genset started due to loss of utility 26 A029V089 Issue 8 9 2013 3 Operation Genset stopped with return of utility Switch on genset moved to remote position Switch on genset moved to run position Switch on genset moved to off position Standby ready disabled by user Standby ready enabled by user Utility lost not in Standby Ready Uti
18. stas led manually Slandby Heady Disabled Svilteh on genzer maved ro remote positlan n E n 5 A ist E EN eT Sore SHE Ti FEE ym pU a eS 3 Thanet HE A O PO TAE CO ST ELO SN RSS Pa e E SEL TI e cue A dese Vt da mu A A AA e tana DERE iata Jaen CR S a a P UA ag Peut 2 ZI nA an n td Moe das trm A E i rs Event Log Said acm leer C fazor niami clone unha Dach lanuary 1 2006 12 00 AM TimejDate september 13 00 Gol PM September 14 2000 2 21 PM Epprrmbor 14 2007 1 04 PM Sepiember 14 9007 2 2 PM September 14 2007 2 08 PM september 14 2007 2 02 PM September 14 2000 1 36 PM iqiiimlus 14 2077 4238 PM amp npremher 14 2007 1 37 PM September 14 2057 1 27 PM January d 2036 4 50 AM January 2 2336 1 14 EM January 2 2006 14 FM hacia y 3 2006 12 23 PM January 1 2396 474 PM January 1 2336 4 23 PM January 1 2006 4 21 FM January 1 2385 4 71 PM January 1 2006 4 22 FM FIGURE 32 EVENT LOG 6 2 5 Fault Log 94 Select the Fault Log Tab on the Home Screen to review the last 5 faults A029V089 Issue 8 9 2013 6 Optional Internet Email Interface Descriptions Cent Ezeh Everti Lead Timn i Nate beh mili nwl Lan Fault Log Engine Howa FIGURE 33 FAULT LOG 6 2 6 Network Setup Screen Descriptions An owner custom password can be defined in the Network Setup screen shown below The user will be prompted to enter the User Name and Password to access this screen
19. that the domain name is included in the user name field of the Network Setup screen i e username domainname 8 Verify with your ISP that the Static DNS Domain Name Server 1 and 2 are correct 9 If the previous steps do not correct the problem contact a computer network specialist to diagnose No authentication is possible on some systems by leaving the username and password fields blank IMPORTANT NOTE Changes are not saved unless you navigate through all three Network Setup screens and click on Done The message Settings Saved Successfully is then displayed Network Setup DHCP Off C On IPNumber 192 18 0 iso SubnetMask 255 255 255 0 Gateway 192 63 Jo 14 Static DNS 1 192 168 Do 1 Static DNS 2 134 Lari om Lan Next FIGURE 24 NETVVORK SETUP PAGE 1 A029V089 Issue 8 9 2013 5 Troubleshooting Home Genset Exercise Load Event Fault Network Time Date Schedule Control Log Log Setup Genset Status Stopped Genset Clock 6 11 PM March 10 2008 Battery Voltage 13 8 Voc Genset Load Line 21 Utility Present 0 25 50 75 100 Utility Connected enerator Output Voltage Frequency Q Running x Dios pibe O Standby Off Engine Hours 389 Hours Action Required Enable Standby Disable Standby FIGURE 25 GENERATOR SET HOME PAGE Network Setup Email Setup Alert Level All Events Outgoing Server SMTP Server Name max
20. to shutdown This generator set is not for life support It can stop without warning Children persons with physical or mental limitations and pets could suffer personal injury or death A personal attendant redundant power or an alarm system must be used if power system operation is critical 2 2 About the Generator Set The model GSBB generator set is an engine powered generator set fueled by Natural Gas or Propane See the Specifications section of this manual for specific information about the generator set The generator set is intended as a back up to utility power Whenever utility power is interrupted the house electrical loads are automatically switched by the transfer switch from the utility normal power source to the generator set emergency power source When utility power is restored the loads are automatically switched back to the utility To do this the generator set and transfer switch perform the following functions together 1 Senses an interruption of utility power Starts the generator set Transfers the load to the generator set when operation has stabilized Senses the return of utility power Retransfers the load to the utility o oO K CO N Stops the generator set A029V089 Issue 8 5 2 Introduction 9 2013 A more in depth illustration of the operation of the generator set and transfer switch can be found in the Timing Charts located in the Typical Operation chapter of this man
21. 2494 AD ona FIGURE 1 NAMEPLATE 6 A029V089 Issue 8 9 2013 2 Introduction 2 2 2 Model Specifications TABLE1 GSBB AND GSBC MODEL VARIATIONS Prdut Deserintion 20GSBB 6717A 20GSBC 6927B 60 Hz CSA Cold Includes an engine oil heater NOTICE See the Cold Weather Specifications Table for recommendations TABLE 2 COLD WEATHER SPECIFICATIONS TABLE Propane Vapor Natural Gas Propane Vapor Natural Gas Operating Temperature Range Above 32 F 0 C and low No dryers or starting aids required humidity High humidity Alternator drying heater recommended Below 20 F 7 C Additional oil heater recommended for starting Factory installed model available Below 0 F 18 C Additional accessory breather shield shroud required to avoid possible engine damage See warranty statement Below 10 F 23 C Additional accessory battery blanket recommended for starting Below 20 F 29 C Not warranted See warranty statement TABLE 3 GENERATOR SET SPECIFICATIONS TABLE BEEN Propane Vapor Natural Gas Propane Vapor Natural Gas Weight With Oil 540 lbs 245 kg Size Lx W x H 48 x 43 x 34 6 in 1219 x 864 x 880 mm 62 dB A at 23 ft 7 m at normal load Normal load is equal to the typical household consumption of 3 KW A029V089 Issue 8 7 2 Introduction 9 2013 TABLE4 FUEL SPECIFICATIONS TABLE SPEC A AND CANADIAN GSBB SPEC B Propane Vapor N
22. 25 Low Fuel Pressure Fault Code 78 Possible Causes Wire connections fuel system fuel pressure switch Corrective Actions 1 Open any closed fuel valves 2 Have unit serviced by an authorized Cummins Onan dealer 5 4 26 Failure To Transfer To Generator Set Fault Code 79 Possible Causes Wire connections faulty positional switch faulty transfer switch component s Diagnosis amp Solution 1 Verify that the main AC circuit breaker on the generator set is to On 2 Have unit serviced by an authorized Cummins Onan dealer 5 5 Communication Troubleshooting 5 5 1 In Home Network Access to Generator Set Troubleshooting Some generator set service procedures present hazards that can result in severe personal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform generator set service Possible Causes Bad connections or bad communications Corrective Actions 1 Check connections a Verify that the Ethernet cable is plugged into the generator set control and the router b Verify that the computer that is attempting to access the generator set is connected to the same router as the generator set via an Ethernet cable on the same local area network c Verify that the wireless card on the computer is turned off d Check to see if both ends of the Ethernet cable are assembled and crimped as described in the installation instructions
23. 42 chars yourservemame User Name max 48 chars yourusernamed domainname Password max 16 chars yourpassword FIGURE 26 NETWORK SETUP PAGE 2 A029V089 Issue 8 49 5 Troubleshooting 9 2013 Network Setup Destination Email Addresses max 48 chars each Address 1 yo uremallzyouremail com Address 2 yourCumminsOnanDealeraitheiremail com Address 3 yourCumminsOnanServiceTech rtheiremail com FIGURE 27 NETWORK SETUP PAGE 3 50 A029V089 Issue 8 6 Optional Internet Email Interface Descriptions 6 1 Introduction This feature allows for in home or remote access to your generator set through a web page NOTICE An Internet browser i e Internet Explorer is required for this option On this web page you can start or stop the generator set adjust the exerciser day and time determine if utility power is available and view the last 20 events faults on the generator set This feature is useful for homeowners who travel or have a second home and want to be able to remotely interface with their generator set This feature can also help to reduce troubleshooting time and service calls when the service technician has access to the same web page Use of the Ethernet is not required if you do not use web access To set up your generator set for web access complete installation instructions are included in the Network Setup Guide instruction sheet included with your generator set literature package
24. Cummins Onan e Operator Manual Home Standby Generator Set GSBB Spec A B GSBC Spec B English Original Instructions 9 2013 A029V089 Issue 8 Table of Contents 1 IMPORTANT SAFETY INSTRUC NS aT a 1 1 Save These Instructions 1 2 General Precautions 1 3 Generate itadessibead A A JA 1 4 Engine Exhaust is Deadly UE SAMA San OS TA o O o cee eo es 1 6 Batteries Can Explode 1 7 Moving Parts Can Cause Severe Personal Injury or Death eee Salime Mn azalas oe bono ode e 32 29 007777 77 7777 een oes eee 1 8 1 What Is Carbon Monoxide Poisoni ND 2 aaa aaauaaaaa aa ana aa ananas eren eee ner rene eres er ees eren e eee nnns 1 8 2 What Are the Special Risks of CO Near the Home aaa aaa aaa nana nana anen e eren arena eee ee cese 1 8 3 Only You Can Protect Yourself From CO Poisoning ooocccoccccccnccncnconcncncnnnncnnnnnoss 2 INTRODUCTION 2 1 About this Manual 2 2 About the Generator Set 2 2 1 Generator Set Nameplate 1 aaa aaaa aa ane nena ke need air ese pese kene r enet ek etike eee ne nennen eee emen 2 AAA e eese mnn rn rn n rr n nr nr reis 2 3 How to Obtain Service See RATION 489m 3 1 3 Position Switch 3 2 In Home Operator Panel 3 2 1 BACK Button e 9 2 959tandbys e NIOEIBUttOm E Beater ci 3 3 Typical Operation 3 3 1 Normal Operation
25. Ethernet Setup Genset Status Voltage 240V Frequency 60Hz Hr Meter 1234 0 FIGURE 15 GENERATOR SET STATUS SCREEN 3 8 Load Management The generator set may have been set up at installation to connect and disconnect certain large loads such as air conditioners to manage the total load so as not to overload the generator set This requires the installation of relays to the load management signals which allow for the disconnection of loads Load management can be set to operate in automatic or manual mode Whether in automatic or manual mode there is a delayed start Load 1 is enabled three minutes after the generator set is connected to the house loads and Load 2 is enabled six minutes after the generator set is connected to the house loads 22 A029V089 Issue 8 9 2013 3 Operation 3 8 1 Automatic Load Management When set to automatic mode the user takes no action and can only view which loads are connected Three minutes after the generator starts the load that is connected to genset load L1 is connected After a delay of three more minutes the load that is connected to genset load L2 is connected If the connection of loads L1 and L2 exceeds 95 of the generator s load capacity they are disconnected by the generator Following another three minute delay the control reconnects both loads following the same connection sequence used in the first attempt three minutes apart If generator load capacity is exceeded again bot
26. If not reassemble and crimp as described in the installation instructions e Verify that the Ethernet cable connections between the generator set and the router are solid and correct f Proceed to Check communications A029V089 Issue 8 45 5 Troubleshooting 9 2013 2 Check communications a If the router is also connected to an incoming connection from an ISP check to see if you can access a standard web page with the computer connected to the same router as the generator set If not contact your router manufacturer for troubleshooting information b Check to see if the green and orange lights are illuminated at the Ethernet connection port on the generator set control board If the lights are not illuminated this indicates that no information is being transmitted or received Test the cable by disconnecting the Ethernet cable from the generator control board and connecting it to the computer swap the cable with the exisiting Ethernet cable With the router connected to the ISP check to see if you can access a standard web page a If you can access a standard web page call Cummins Support at 1 800 888 6626 and select option 1 b If you cannot access a standard web page go to the Check connections step above c Check to see if the correct generator IP address has been entered If not enter the correct IP address in the address bar of the web browser Be sure to not enter www or other text prior to the IP add
27. Maintenance No Description No Description 5 Batey Circuit Breaker o 3 MARTE O poo FIGURE 22 MAINTENANCE POINTS 46 Battery Maintenance Arcing at battery terminals or in light switches or other equipment and flames or sparks can ignite battery gas causing severe personal injury Ventilate battery area before working on or near battery Wear safety glasses Do not smoke Switch work light ON or OFF away from battery Stop the generator set Disconnect the negative battery cable first and reconnect it last Before working on the generator set move the Switch S2 to the Stop Position disconnect the remote harness P7 to disable the ATS mounted charger and remove the negative battery cable from the battery to prevent starting A029V089 Issue 8 35 4 Maintenance 9 2013 4 7 Refer to the Periodic Maintenance Table for scheduled battery maintenance and follow the battery manufacturer s instructions Have the battery charger in the transfer switch replaced if the battery keeps running down Always 1 Keep the battery case and terminals clean and dry and the terminals tight 2 Remove battery cables with a battery terminal puller Torque threaded stud battery terminals as recommended by the battery manufacturer 3 Make sure which terminal is positive and which is negative before making battery connections always removing the negative cable first and reconnecting it last to
28. Utility Power Available and Connected 3 3 2 Emergency Operation Utility Power Interrupted cooccccoccccccnccccncccnnconnncconoconnnnns 9913 MO AUS trie Ou utpultoVollagece ew eee ee e ee I e e 3 4 Ove Mable DIS able STAN dy ese e m emo RCM EET 3 5 TO Manually start Stop Generator Set ad do cout onde cesse ee 3 6 Fault Maintenance and New Event Screens sssssssssee em I eee remet temere 3 6 1 Fault Screen 3 56 27 Maintenance Dler screen eR RES MERI UE NE 3 6 3 New Event Screen 3 7 Genset Status 3 8 Load Management 3 8 1 Automatic Load Manager 3 0 2 Manual Load Management ua sues adi dd Ter a Pet equae tete rto teu dU mE wee 3 9 Display S lup and Sofware INO asin eer E eu PA ER eL do 39T BOTA S Sa no CON AS Lc A029V089 Issue 8 0 00 0N yNNN a iN NOOO CI 11 11 12 12 12 12 13 16 17 18 18 19 19 20 20 20 21 22 23 23 24 24 Table of Contents 9 2013 SEPATU ane mem e e e e 25 Se e E e E EE EErEE A S EEEE wee 26 3 10 1 To Check Log Of East 20 EVENIS utili 26 3 10 2 ListOf Recordable EVenls sai ke bee A as 26 SA FULL A O 21 3 12 Exercise Settings A 28 3 13 Time Setup m TUS cnet ilt 29 4 MAINT EG eee eee nme osse NE AES 31 4 1 Periodic Maintenance Schedule aaa a aaa nana aaa ane anen aanne eanan pe ee teme nene eee eee eee eee 31 AAC ICARUS not op P E 32 e ev G INS
29. arts Can Cause Severe Personal Injury or Death Do not wear loose clothing or jewelry near moving parts such as fans Keep hands away from moving parts Keep guards in place over fans The Hazards of Carbon Monoxide Engine driven generators can produce harmful levels of carbon monoxide that can injure or kill you What Is Carbon Monoxide Poisoning Carbon Monoxide CO is an odorless colorless tasteless and non irritating gas You cannot see it or smell it Red blood cells however have a greater affinity for CO than for Oxygen Therefore exposure even to low levels of CO for a prolonged period can lead to asphyxiation lack of Oxygen resulting in death Mild effects of CO poisoning include eye irritation dizziness headaches fatigue and the inability to think clearly More extreme symptoms include vomiting seizures and collapse What Are the Special Risks of CO Near the Home Residents can be exposed to lethal levels of CO when the genset is running Depending on air temperature and wind CO can accumulate in or near the home To protect yourself and others from the dangers of CO poisoning it is recommended that reliable and approved CO detector alarms be installed in the home Carbon Monoxide CO gas can cause nausea fainting or death A029V089 Issue 8 3 1 IMPORTANT SAFETY INSTRUCTIONS 9 2013 1 8 3 Only You Can Protect Yourself From CO Poisoning Locate the generator in an area where there are no wind
30. atural Gas Propane Vapor Natural Gas 1 2 Load 132 500 Btu Hr 135 000 Btu Hr 122 000 Btu Hr 114 000 Btu Hr 53 ft Hr 135 ft Hr 48 ft Hr 111 ft Hr Full Load 2 5 000 Btu Hr 240 000 Btu Hr 229 000 Btu Hr 213 000 Btu Hr 109 ft Hr 233 ft Hr 91 ft Hr 207 ft Hr Fuel Pressure all loads As measured at genset fuel 7 11 inches WC 5 11 inches WC 7 11 inches WC 5 11 inches WC regulator service port Contact your local gas company to verify the tank size required for your application TABLE 5 FUEL SPECIFICATIONS TABLE US GSBB SPEC B AND CANADIAN GSBC SPEC B Propane Vapor Natural Gas Propane Vapor Natural Gas 1 2 Load 195 000 Btu Hr 177 000 Btu Hr 165 000 Btu Hr 150 000 Btu Hr 78 ft Hr 172 ft Hr 66 ft Hr 146 ft Hr Full Load 310 000 Btu Hr 255 000 Btu Hr 262 500 Btu Hr 217 000 Btu Hr 123 ft Hr 248 ft Hr 104 ft Hr 211 ft Hr Fuel Pressure all loads As measured at genset fuel 12 14 inches WC 5 7 inches WC 12 14 inches WC 5 7 inches WC regulator service port Contact your local gas company to verify the tank size required for your application TABLE 6 ENGINE SPECIFICATIONS TABLE Propane Vapor NaturalGas Propane Vapor NaturalGas Engne 2 Oylinder V Twin OHV Air Cooled 4 Stroke Spark Ignited 3600 RPM Displacement 60 59 in 993 cc Spark Plug Gap 020 inch 51 mm Spark Plug Torque 15 ft Ib 20 N m Intake and Exhaust Cold Valve 0 004 0 006 inch 0 10 0 15 mm Lash Measure at 0
31. ced by an authorized Cummins Onan dealer Underfrequency Fault Code 15 Possible causes Generator set loads engine governor function fuel supply air fuel mixture exhaust system choke demand regulator carburetor generator windings ignition wire connections Corrective Actions 1 Reduce the number of connected loads especially loads that require higher starting current such as air conditioners 2 Have unit serviced by an authorized Cummins Onan dealer Governor Actuator shutdown Fault Code 19 Possible causes Wire connections governor actuator Corrective Actions 1 Have unit serviced by an authorized Cummins Onan dealer A029V089 Issue 8 9 2013 5 Troubleshooting 5 4 14 Governor Actuator Overload Fault Code 22 Possible causes Generator set loads wire connections fuel supply air fuel mixture exhaust system governor actuator ignition system Corrective Actions 1 Reduce the number of connected loads especially loads that require higher starting current such as air conditioners 2 Check and service air filter as necessary 3 Have unit serviced by an authorized Cummins Onan dealer 5 4 15 Voltage Sense Lost Fault Code 27 Possible Causes Generator set loads generator windings ignition wire connections Corrective Actions 1 Have unit serviced by an authorized Cummins Onan dealer Some Generator Set service procedures present hazards that can result in severe personal injury or dea
32. ctions Diagnosis amp Repair 1 Check the fuel source Open any closed fuel valves Secure spark plug leads to spark plugs Check and service air filter as necessary Replace spark plugs ME ECTS Check for mechanical damage Invalid Set Configuration Fault Code 37 Possible Causes Generator set configuration control Diagnosis amp Repair 1 Have unit serviced by an authorized Cummins Onan dealer Processor Fault Fault Code 43 Possible Causes Faulty program Corrective Actions 1 Have unit serviced by an authorized Cummins Onan dealer Speed Sense Fault Fault Code 45 Possible Causes Loads generator windings wire connections Corrective Actions 1 Have unit serviced by an authorized Cummins Onan dealer Generator Set Overload Fault Code 46 Possible causes Loads wire connections windings Corrective Actions 1 Reduce the number of connected loads especially loads that require higher starting current such as air conditioners 2 Check and service air filter as necessary 3 Have unit serviced by an authorized Cummins Onan dealer Alternator Over Temp Fault Code 76 Possible Causes Wire connections faulty temperature sensor faulty DC fan blocked intake or exhaust openings A029V089 Issue 8 9 2013 5 Troubleshooting Corrective Actions 1 Verify the generator set enclosure for clear intake and exhaust openings 2 Have unit serviced by an authorized Cummins Onan dealer 5 4
33. e 8 3 Operation 3 1 3 Position Switch A three position Start Stop switch is located at the genset control panel Switch positions available e Manual Start Normally only the maintenance service technician has occasion to manually start and stop the generator set Push the switch down at the thick end to start the set immediately e Stop middle position This switch disables the set e Remote For automatic operation the Start Stop switch must be in the Remote position and Standby On must be activated on the In Home Display Push the switch down at the thin end to put into the Remote position No Description No Description Manual Start Position Remote Position Stop Position a UO FIGURE 2 3 POSITION SWITCH STOP SWITCH A029V089 Issue 8 11 3 Operation 9 2013 3 2 In Home Operator Panel The operator panel must be hard wired to the generator set in order for the generator system to operate NOTICE The in home operator panel and Internet Email interface can be used simultaneously The operator panel consists of two UTILITY status lamps three GENERATOR status lamps three action buttons and an LCD display screen with four navigation buttons Cummins Onan UTILITY PRESENT CONNECTED sun 10 35 AM GENERATOR Battery 12 5 RUNNING Genset Stopped STANDBY OFF ACTION REQUIRED EXCER CLOCK LOAD MENU STANDBY ON OFF BACK START STOP CU No Description Back Button When navi
34. e Oil Level State and federal agencies have determined that contact with used engine oil can cause cancer or reproductive toxicity Avoid skin contact and breathing of vapors Use rubber gloves and wash exposed skin Accidental or remote starting of the generator set can cause severe personal injury or death Disconnect the negative battery cable and place the control switch in its OFF position before starting work 1 Pull out the dip stick and wipe it clean 2 Reinsert the dip stick 3 Remove the dipstick one final time and check the oil level NOTICE The engine oil level indicated on the dipstick should be between the FULL and ADD marks A029V089 Issue 8 9 2013 4 Maintenance 4 Reinsert the dipstick If the engine oil level check shows excessive or insufficient levels of oil oil level line above the FULL mark or belovv the ADD mark oil must be drained or added Refer to the follovving sections Drain Oil or Add Oil as needed for instructions and guidelines for draining and adding oil 4 4 3 Add or Drain Oil Too much oil can cause high oil consumption Too little oil can cause severe engine damage Keep the oil level between the FULL and ADD marks on the dipstick 4 4 3 1 Drain Oil If the oil level is found to be excessive see Checking Engine Oil Level oil must be drained from the engine 1 Attach one end of the drain hose shipped loose with the genset to the oil drain valve 2 Place the other
35. e working properly To manually start or stop the generator set 1 Press the START STOP button on the operator panel which takes you to the Genset START STOP screen e The screen will display Genset Stopped or Genset Running as appropriate 2 Press START to manually start the generator set and connect it to supply power to the house The STANDBY OFF lamp will come on and the display will state Genset started manually Standby Ready Disabled 3 Press STOP to manually stop the generator set and disconnect it The STANDBY OFF lamp will come on and the display will state Genset stopped manually Standby Ready Disabled NOTICE To start the generator set without connecting loads pick Exercise Now on the Exerciser Clock screen Manual Operation Disables Standby Genset Stopped FIGURE 11 GENSET START STOP SCREEN Fault Maintenance and New Event Screens Various warning and event screens may appear on the operator panel during Normal or Emergency Operation A029V089 Issue 8 19 3 Operation 3 6 1 3 6 2 3 6 3 20 9 2013 Fault Screen If a generator set shutdown fault occurs a FAULT warning appears with the following information Brief description of the warning or fault e The two digit Fault Code Number The time of occurrence of the fault Press the BACK button to reset the fault and return to the home screen See the Fault Log section of this manual to review the log of the
36. ember 16 2007 Line 2 MEN 0 25 50 75 100 si Proson Utility Connected Output Voltage Frequency snerator 240VAC 60Hz Running Standby Off Engine Hours 105 4 Hours Action Required FIGURE 28 HOME PAGE 6 2 1 Setting Time and Date Select the Genset Time Date Tab on the Home Screen to set the time and date for the generator set control 52 A029V089 Issue 8 9 2013 6 2 2 6 2 3 6 Optional Internet Email Interface Descriptions ExutrciEu Nebwork schedule Setup Genset Time Date Duis September v 15 v oT Time 2 Yi 20 v AM v FIGURE 29 SET GENSET TIME AND DATE Set Exercise Schedule Select the Exercise Schedule Tab on the Home Screen to set the generator set exercise schedule NOTICE The generator set will exercise on the first scheduled day for which it is programmed After that it exercises on that day at the scheduled interval For example if the generator set is scheduled on a Wednesday for Saturdays with a monthly interval the generator set starts on the next available Saturday After that it exercises on Saturdays one month apart Exercise Schedule Frequency Meun M Sunday 12v 06 v AM Apply Lxercise Now FIGURE 30 SET EXERCISE SCHEDULE Load Control Management Select the Load Control Tab on the Home Screen to enable Automatic or Manual Load Control In Automatic mode the user can only view which loads are connected In Manual mode the user can view
37. en egg smell indicates a possible Natural Gas or Propane leak e Natural Gas rises when released and can accumulate under hoods and inside housings and buildings Propane sinks when released and can accumulate inside housings and basements and other below grade spaces 1 6 Batteries Can Explode Batteries can explode causing severe skin and eye burns and can release toxic electrolytes e Wear safety glasses e Do not smoke Do not dispose of the battery in a fire e The battery is capable of exploding 2 A029V089 Issue 8 9 2013 1 1 1 8 1 8 1 1 8 2 1 IMPORTANT SAFETY INSTRUCTIONS e Do not open or mutilate the battery Released electrolytes have been known to be harmful to the skin and eyes and to be toxic e Batteries present the risk to high short circuit current e Remove watches rings or other metal objects and use tools with insulated handles To prevent arcing when disconnecting the battery e Move the Stop Switch S2 to the Stop position disconnect the remote harness P7 to disable the ATS mounted charger and then remove the negative battery cable to prevent starting To prevent arcing when reconnecting the battery First reconnect the positive cable then the negative cable and finally reconnect the battery charger e When replacing the generator set battery always replace it with a battery as specified in the Model Specifications section of this manual Moving P
38. gating through the LCD menus press this button to return to the main operating screen Standby On Off Button See the To Enable Disable Standby section of this manual Start Stop Button See the To Manually Start Stop Generator Set section of this manual Navigation Buttons The function of these buttons change as different screens appear FIGURE 3 IN HOME OPERATOR PANEL 3 2 1 BACK Button When navigating through the LCD menus press the BACK button to return to the main operating screen 3 2 2 START STOP Button See To Manually Start Stop Generator Set 3 2 3 Standby ON OFF Button See To Enable Disable Standby 12 A029V089 Issue 8 9 2013 3 Operation 3 3 Typical Operation NOTICE The following diagrams are based on an APPROXIMATE time duration Your genset may vary slightly from the timing diagrams in this manual Utility Connected Generator Running Transfer Utility Switch Generator On Load Control 1 Off TET L d C tr 2 O E u 1 oa onto OR 1 Time Duration i 2 194 5 3min 3min 5min 5min seconds i i i l Engine Start Engine Start Transfer Load Controlj Lo ad Control Transfer En gine C ool Generator i tt L tity etur Uptime Lely Delay Uels Delay Dm s Oni 1 l I Utility Failure FIGURE 4 TYPICAL POWER OUTAGE CYCLE
39. h loads are disconnected and no further reconnection is tried To select automatic load management and view whether the selected loads are connected while the generator set is running 1 Press the LOAD button on the home screen 2 Press the up or down arrow button to select Automatic 3 Note which loads are connected or disconnected 4 Press the BACK button to return to the home screen Adjust percent load to match the de rate 3 8 2 Manual Load Management To reduce unnecessary loss of service it is highly recommended that manual load management be undertaken only by an authorized Cummins Onan dealer When set to manual mode the user is able to view connect and disconnect loads If the connection of loads L1 and L2 exceeds generator capacity the AC circuit breaker trips To select manual load management when the generator is running 1 Press the LOAD button on the home screen 2 Press the up or down arrow button to select Manual 3 Note which loads are connected or disconnected 4 Press the double down arrow button to go the load connect disconnect screen 5 Connect or disconnect Load 1 or Load 2 as necessary by pressing either button under Load 1 or Load 2 6 Press the BACK button to save the setting and return to the home screen A029V089 Issue 8 23 3 Operation Sun 10 35 AM Battery 12 5 Genset Load Lim L28N 7j EXCER CLOCK LOAD Load Management Mode Makoma l Disconnected
40. horized Cummins Onan dealer A029V089 Issue 8 9 2013 9 4 4 9 4 5 9 4 6 9 4 7 9 4 8 5 Troubleshooting No AC Power generator set Running Status LED On Steady or Flashing Rapidly Possible Cause Circuit breakers tripped due to short circuit or overloading Corrective Actions 1 Reduce number of loads 2 Reset or turn on generator set circuit breaker 3 Reset or turn on circuit breaker in the distribution panel 4 Have the circuits from the generator set and distribution panel verified by an authorized electrician Generator Set Cranks But Does Not Start No Fault Code Possible Cause Faulty or incorrect spark plugs Corrective Actions 1 Check and record last fault code 2 Crank generator set and troubleshoot fault code and reference last fault code recorded above if necessary Some Generator Set service procedures present hazards that can result in severe personal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform Generator Set service Genset Warning Transfer Switch Failed to Transfer to Utility No Fault Code Possible Cause Transfer switch is faulty or wire is disconnected or broken Corrective Actions 1 Have the utility switch position wire wire connections and transfer switch checked by an authorized electrician Low Oil Pressure Fault Fault Code 2 Possible Cause Oil Level too low high fa
41. ights reserved Cummins Onan the C logo and Performance you rely on are trademarks of Cummins Inc
42. iorates Must be performed by a qualified mechanic authorized Cummins Onan dealer Check daily during power outages or monthly without power outages See automatic transfer switch manual for testing of load transfer A029V089 Issue 8 31 4 Maintenance 9 2013 4 2 4 3 4 4 4 4 1 4 4 2 32 Cleaning the Housing Top The top surface of the generator set housing can be damaged by pressure washing or solvents and other cleaning agents Only use soap and water or an all citrus degreaser to clean the top Exercising the Generator Set NOTICE Audible engine RPM variation may be heard while there is no load applied This is normal and does not affect genset performance Exercising the generator set drives off moisture re lubricates the engine and removes oxides from electrical contacts The result is better starting more reliable operation and longer engine life The generator set exerciser is capable of automatically starting the generator set and letting it run for 20 minutes once every 28 days or more often if desired Refer to the Exercise Settings section of this manual for more information on setting up the exerciser Engine Oil Maintenance Recommended Engine Oil Check the oil level prior to starting the generator set to verify that the oil level is between the FULL and ADD marks The generator set is shipped with engine oil e 5W 30 synthetic engine oil is recommended Checking Engin
43. last 5 faults Starting Fault Fault Number 32 Hour 10000 1 FIGURE 12 TYPICAL FAULT SCREEN Maintenance Due Screen A Maintenance Due screen appears when a scheduled maintenance operation is due he warning does not time out Perform the maintenance Press the BACK button to return to the home screen Maintenance Due Air Filter FIGURE 13 TYPICAL MAINTENANCE DUE SCREEN New Event Screen A New Event screen appears whenever system status changes such as when there is an interruption of utility power The screen provides a brief description of the event along with the time and date of the event e The message does not time out unless superseded by a new event A029V089 Issue 8 9 2013 3 Operation e Press the BACK button to return to the home screen New Event Auto Start Loss of Utility 07 10 2007 4 08PM FIGURE 14 TYPICAL NEW EVENT SCREEN 3 1 Genset Status To check generator set output voltage and frequency and the total numbers of hours run 1 Press the MENU button on the home screen 2 Press the up or down arrow button on the menu screen to select Genset Status 3 Press the ENTER button on the menu screen and note the values displayed on the Genset otatus screen 4 Press the BACK button to return to the home screen A029V089 Issue 8 21 3 Operation 9 2013 Sun 10 35 AM Battery l242 Genset Load LIW 12M Genset Status Display Setup Event Log Fault Log
44. lity returned not in Standby Ready Maintenance reminder Change oil and check valve lash Maintenance reminder Change oil 4 filter air filter adjust valve lash clean and check battery amp engine cooling fins Genset fault Fault description appended Genset warning Transfer Switch Signal Failure Genset warning Transfer Switch Failed to Transfer to Utility Genset warning Low Battery or Battery Charger Failure 3 11 Fault Log To check the log of the last 5 faults 1 Press the MENU button on the home screen 2 Press the up or down arrow button on the menu screen to select Fault Log 3 4 Scroll through the fault log with the up and down double arrow buttons Each screen Press the ENTER button on the menu screen provides a brief description of the fault the fault code number and the time and date of the fault Press the BACK button to return to the home screen NOTICE If there are no faults recorded the No Stored Faults screen will appear A029V089 Issue 8 27 3 Operation 9 2013 Sun 10 35 AM Battery LL Genset Load LIB LH EXCERICLOCKI LOAD MENU Genset Status Display Setup Event Lo Ethernet Setup Cw 4 ENTER Fault Log 1of 5 Speed Sense Lost Fault No 27 Hour 10000 1 Fault History No Stored Faults FIGURE 19 FAULT LOG SCREEN 3 12 Exercise Settings To set the generator set exercise schedule 1 Press the EXCER button on the home screen 2
45. loads and also connect or disconnect them See Load Management for details A029V089 Issue 8 53 6 Optional Internet Email Interface Descriptions Exercise Erhe cule Genset Load Management amas d isset oed Load 2 Connected Vinee lande aen aa diesnenerra fre n nro paria whan nho qencemnr emn vum whaa n Mano Macs Lucus urz deh ec ut o Dame welt delay Unswocn dur Mode Automate v 9 2013 6 2 4 EventLog FIGURE 31 GENSET LOAD MANAGEMENT Select the Event Log Tab on the Home Screen to review the last 20 events See the Event Log screen capture below for a list of all of the recordable events Geti Emi limes Dat schacule Dvent Description f Genset started manually Standby Ready Disabled Standby ready enabled by user l SGeneer stopped manially Standby Roary Pablire Genser stared manually Standby Ready Disabled 8 Standby ready enabled by user BGencet stopped manu ally Standby Ready Disabled SGurcut ela led manually San ly Heady Licabludj S Seca A ad biy eunt 5 Standby ready enabled by user Genser stopped manually Standby Ready Disabled Genset started manually Standby Ready Disabled Stan by ready enabled by usar 0 SGunsvl slapped manually Standby Heady Disabled O Genser started manually Standby Ready Disabled Genset stopped manually Standby Ready Disabled 1 Genset stopped with return of utility E B Standby ready enabled by usai Gurit
46. nerator set when mentally or physically fatigued or after consuming alcohol or drugs A029V089 Issue 8 1 1 IMPORTANT SAFETY INSTRUCTIONS 9 2013 13 Generator Voltage is Deadly Generator output connections must be made by a trained and experienced electrician in accordance with all applicable codes This standby generator set and the public utility may only be connected to the house circuits by means of the automatic transfer switch Improper connections can lead to electrocution of utility workers and damage to equipment Use caution when working on live electrical equipment Remove jewelry make sure clothing and shoes are dry and stand on a dry wooden platform 14 Engine Exhaust is Deadly e See What Is Carbon Monoxide Poisoning to learn the symptoms of Carbon Monoxide poisoning This generator set is for outdoor installation only e t must be located well away from doors windows other openings into the house and where the exhaust gases will disperse away from the house 1 5 Fuel is Flammable and Explosive Keep flames cigarettes sparks pilot lights electrical arc producing equipment switches and all other sources of ignition well away from areas where fuel fumes are present and areas sharing ventilation Fuel lines must be secured free of leaks and separated or shielded from electrical wiring Leaks can lead to explosive accumulations of gas Prevent leaks and the accumulation of gas e A rott
47. oat pa ke Ue eee a 42 5 4 TO ndervoltage s Kall Godelli 42 5 4 11 Overfrequency Fault Code 14 aaa aaa anen eee ene k ren ee pe ee epe a ek bee e eee eke nnn nnns 42 5 442 Underreguenc yv Eat terere NU MI E 42 5 4 13 Governor Actuator shutdown Fault Code 19 occcocccccccccoccncconncconononononcnconcncnnnnnos 42 5 4 14 Governor Actuator Overload Fault Code 22 ocooccccocccccccnccccnccocnconnncnonononnnonnnonannos 43 5 4 15 Voltage Sense Costra OGOIZI secre re ee ae rn arn ener ne 43 5 4 16 High Battery Voltage Fault Code 29 oo cece ceecccesceseeeeseeeeseeeesaeeseeeseeeeseeeens 43 5 4 17 Low Cranking Speed Sense Fault Code 32 00 aaa aaa anen aa ee ea aeke kek e eee k ene eee ee eenas 43 5 4 18 Control Card Failure Fault Code 35 oo ene kena eee eee kene kren eren e ipen pe eee 43 5 4 19 Generator Set Stopped Without Fault Condition Fault Code 36 44 i A029V089 Issue 8 9 2013 Table of Contents 5 4 20 Invalid Set Configuration Fault Code 37 aaa aaa ena e eke eee dek e peer eke kene ke 5 4 21 Processor Fault Fault Code 43 na aaa aaa aa aaa aa aa enen e ane deres ee teres mmn 5 4 22 Speed Sense Fault Fault Code 45 na aaa aaa ana ane e ane nep ea ee dete ner ete pere ee pere ere see ee eesi 5 4 23 Generator Set Overload KANE OGG AD x25 ne ale m cns 5 4 24 Alternator Over Temp Fault Code 76 eaaa E ere kek a ner e nennen 5 4 25 Low Fuel Presse oder e S A 5 4 26 Failure To
48. ot Available On E n Transfer Switch i Time Duration _ BE i i s gas 5 1 3min 3min I 3min 3min l I 19 seconds 0 1 Po P Po P P t8 pog Iransfer Loed ControliLoad Contro Load Control Load Control Lead Control I ie Gane Eo a Control Coy Delay Doldr 1862 HaHa 1Doliy day H Y H 182 Enat ei I I I Load lt 0 707 lt 95 2959 lt 50 lt 50 lt 95 gt 95 FIGURE 7 LOAD MANAGEMENT TIMING DIAGRAM Normal Operation Utility Power Available and Connected As long as utility power is available and connected both of the green UTILITY lamps PRESENT and CONNECTED will stay on and the LCD screen will indicate Genset Stopped If the red GENERATOR STANDBY OFF light is on the generator set will not start up automatically if utility power is interrupted See the To Enable Disable Standby section of this manual to enable STANDBY so that the generator set will automatically supply power if utility power is interrupted A029V089 Issue 8 9 2013 3 Operation Cummins Onan UTILITY PRESENT CONNECTED GENERATOR RUNNING STANDBY OFF ACTION REQUIRED FIGURE 8 UTILITY PRESENT AND CONNECTED STANDBY OFF LAMP ON 3 3 2 Emergency Operation Utility Power Interrupted If utility power is interrupted 1 The green UTILITY PRESENT lamp will go out 2 The generator set will start automatically and the green
49. ould be flashed as follows flash flash flash pause flash flash flash flash flash flash long pause repeat NOTICE For fault history go to the in home Operator Panel No Response Status Indicator Light Dead Possible Cause Low No battery voltage poor battery connection faulty battery open harness connection faulty start stop switch faulty LED Corrective Actions 1 Try generator set Start Switch if the remote display Start Switch does not respond and vice versa 2 Clean and tighten positive and negative battery cable connections at the battery 3 Recharge or replace battery Refer to the battery manufacturer s recommendations Starting Battery Runs Down Possible Cause Marginal battery connections battery charging system excessive cranking Corrective Actions 1 Clean and tighten positive t and negative battery cable connections at the battery 2 Recharge or replace battery Refer to the battery manufacturer s recommendations 3 Have battery charger serviced by an authorized Cummins Onan dealer Starter Engages Disengages Possible Cause Cranking voltage dips below 8 VDC Battery connections battery charging system start stop switches Corrective Actions 1 Clean and tighten positive t and negative battery cable connections at the battery 2 Recharge or replace battery Refer to the battery manufacturer s recommendations 3 Have the battery charger serviced by an aut
50. ows doors or other access points into the home Make sure all CO detectors are working properly e Pay attention to the signs of CO poisoning e Check the exhaust system for corrosion obstruction and leaks each time you start the generator set and every eight hours if you run it continuously 4 A029V089 Issue 8 2 Introduction This generator set application is intended for stationary emergency use Important note for Brazil applications The manufacturer vvarns that the installation operation and maintenance of equipment by the user must fully comply with the Manual s guidelines and current Brazilian laws including those of the Brazilian Agency of Petroleum Natural Gas and Fuels ANP and the Brazilian Energy Agency ANEEL 2 1 About this Manual This is the Operator Manual for the Model GSBB generator set Each operator of this generator set should become thoroughly familiar with the information in this manual and observe all of it s instructions and precautions Refer to the Operation chapter of this manual for instructions and guidelines for operating and monitoring the genset Refer to the Maintenance chapter of this manual for instructions and guidelines for performing periodic maintenance The operator is responsible for generator set maintenance in accordance with the Periodic Maintenance Schedule Refer to the Troubleshooting chapter for steps to be taken to diagnose and correct situations that cause a generator set
51. p performance can only be obtained when equipment is properly operated and maintained The following symbols in this manual alert you to potential hazards to the operator service person and equipment DANGER Alerts you to an immediate hazard that will result in severe personal injury or death Alerts you to a hazard or unsafe practice that can result in severe personal injury or death Alerts you to a hazard or unsafe practice that can result in personal injury or equipment damage 12 General Precautions Keep ABC fire extinguishers handy Make sure all fasteners are secure and torqued properly Keep the generator set and its compartment clean Do not store any items in the genset compartment Excess oil oily rags etc can catch fire Dirt and gear stowed in the compartment will restrict cooling air flow e Before working on the generator set move the Stop Switch S2 to the Stop position disconnect the remote harness P7 to disable the ATS mounted charger and then remove the negative battery cable to prevent starting Use caution when making adjustments while the generator set is running hot moving or when parts are electrically live as all situations may cause personal injury or death Used engine oil has been identified by some state and federal agencies as causing cancer or reproductive toxicity Do not ingest inhale or come into contact with used oil or it s vapors Do not work on the ge
52. rator set performance Use the Maintenance Frequency table as a guide for normal periodic maintenance n hot and dusty environments some maintenance procedures should be performed more frequently as indicated by the footnotes in the table Maintenance replacement or repair of emission control devices and systems may be performed by any engine repair establishment or individual e Warranty work MUST be completed by an authorized Cummins dealer Accidental or remote starting of the generator set can cause severe personal injury or death Before working on the generator set move the switch S2 to the Stop position disconnect the remote harness P7 to disable the ATS mounted charger and remove the negative battery cable from the battery to prevent starting TABLE 10 MAINTENANCE FREQUENCY Maintenance Task Maintenance Frequency First Startup Daily or Every Every 3 Every 250 Every 400 24 Hours Months or 100 Hours Hours J Check Check Engine Oil Level Oil Level Change Engine Oil and Oil Filter E first 8 hours Adjust Engine Valve Clearance ENE first 50 BD Replace Replace Engine Air Filter Air Filter Clean and Check Starting Battery Replace Spark Plugs and Wires E Clean Engine Cooling Fins Jo O e Complete System Test lA a Perform more often when operating in dusty conditions Perform more often when operating in high temperature conditions Perform sooner if engine performance deter
53. ress d If none of the above troubleshooting techniques help call Cummins Support at 1 800 888 6626 and select option 1 FIGURE 23 NETWORK CONNECTIONS CONTROL BOARD AND ETHERNET CONNECTION 5 5 2 Remote Internet Access to Generator Set Troubleshooting Some generator set service procedures present hazards that can result in severe personal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform generator set service 46 A029V089 Issue 8 9 2013 9 9 3 5 Troubleshooting Possible Causes Improper setup no high speed internet connection public IP address is not active or properly set up incorrect IP address is entered computer is connected to the same router or network as the generator set or the internet connection is faulty Corrective Actions 1 Check to see if you are able to access the generator set with your in home computer If not refer to the In Home Network Access Troubleshooting procedures 2 Verify that you followed the network setup procedures Refer to the Network Setup Guide 3 Verify that you are using a high speed internet connection 4 Verify that the public IP address is active and set up properly with the ISP Internet Service Provider If necessary contact the ISP to verify your setup 5 Verify that the correct public IP address is entered into the web browser of the computer i e XXX XXX XXX XXX
54. roller Integrated Microprocessor Based Engine Generator Transfer Switch Controller TABLE 9 DC SYSTEM SPECIFICATIONS TABLE Propane Vapor NaturalGas Propane Vapor Natural Gas DC System AS Nominal Battery Voltage 12 Volts DC Battery Group Battery Type Minimum Cold Crank Amps 2 3 How to Obtain Service For parts service and product information such as the Service Manual contact the nearest authorized Cummins Onan distributor You may go to Web site www cumminsonan com for information on contacting our distributors worldwide In North America Call 1 800 888 6626 to contact the nearest Cummins Onan distributor in the United States or Canada If you are unable to contact a distributor using the automated service consult the Yellow Pages Typically our distributors are listed under A029V089 Issue 8 9 2 Introduction 9 2013 10 GENERATORS ELECTRIC ENGINES GASOLINE OR DIESEL If you have difficulty arranging service or resolving a problem please contact the Service Manager at the nearest Cummins Onan distributor for assistance Outside North America If you are outside North America call Cummins Onan at 1 763 574 5000 from 7 30 AM to 4 00 PM Central Standard Time Monday through Friday or fax 1 763 528 7229 Information to Have Ready Before calling for service have the following information available 1 Complete model number and serial number 2 Date of purchase 3 Nature of problem A029V089 Issu
55. tgoing SMTP server setup the domain name is not included in the user name filed of the Network Setup screen or the DNS 1 and 2 values are incorrect on the Network Setup screen Corrective Actions 1 Check to see if you are able to access the generator set with your in home computer If not refer to In Home Computer Access Troubleshooting 2 Verify that you followed the network setup instructions Refer to the Network Setup Guide A029V089 Issue 8 47 5 Troubleshooting 9 2013 48 3 Verify that the alert level is set to All Events a To verify that your generator set can send emails select Disable Standby and wait several minutes to verify that you did receive an email b Select Enable Standby and wait a few more minutes to verify that you did receive a second email 4 Send an email to the destination email address and check to see if you received this email If not contact your email service provider or your ISP Internet service provider to diagnose 5 Check to see if the destination email accounts have spam filtering a If spam filtering is present add the outgoing email address to your contact list b If spam filtering is not present proceed to step 6 6 Ensure that the SMTP server in use is capable of distributing non SSL certified emails If the SMTP server is not capable of sending non SSL certified emails or the status is unknown please contact your ISP technical support for information 7 Verify
56. th Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform Generator Set service 5 4 16 High Battery Voltage Fault Code 29 Possible Causes Incorrect battery configuration wire damage faulty charger control Corrective Actions 1 Have battery charger serviced by an authorized Cummins Onan dealer 5 4 17 Low Cranking Speed Sense Fault Code 32 Possible Causes Starter engine components air intake system exhaust system generator windings wire connections battery battery connections oil viscosity Corrective Actions 1 Clean and tighten positive and negative battery cable connections at the battery 2 Recharge or replace battery Refer to the battery manufacturer s recommendations 3 Verify engine oil viscosity is correct for the ambient temperature If not refill and replace engine oil with correct viscosity 4 Have unit serviced by an authorized Cummins Onan dealer 5 4 18 Control Card Failure Fault Code 35 Possible Causes Faulty program Corrective Actions 1 Have unit serviced by an authorized Cummins Onan dealer A029V089 Issue 8 43 5 Troubleshooting 9 2013 5 4 19 Generator Set Stopped Without Fault Condition Fault 9 4 20 9 4 21 9 4 22 9 4 23 9 4 24 44 Code 36 Possible Causes Fuel supply air fuel mixture exhaust system choke demand regulator carburetor generator windings ignition wire conne
57. the valve when oil stops draining 3 Spin off the oil filter canister and clean the filter mounting surface on the engine block Remove the old gasket if it remains 4 Make sure the gasket is in place on the new filter and apply a thin film of clean oil to the gasket Spin the new filter on until the gasket just touches the block Turn it an additional 1 2 to 3 4 turn Do not over tighten 5 Refill with 67 oz 2 liters of oil Too much oil can cause high oil consumption Too little oil can cause severe engine damage Keep the oil level between the Full and Add marks Start and run for 30 seconds Shut the engine off and wait 5 minutes Add more oil slowly to bring the oil level to the FULL mark on the dipstick Oo CO N O Dispose of the used oil and oil filter according to local environmental regulations 4 5 Replacing the Air Filter Element Before working on the generator set move the Switch S2 to the Stop Position disconnect the remote harness P7 to disable the ATS mounted charger and remove the negative battery cable from the battery to prevent starting Refer to the Periodic Maintenance Table for scheduled air filter replacements Replace it more often in dusty environments To change the filter element 1 Remove the outer and inner cover and reassemble with a new air filter element 2 Make sure the outer cover is seated before tightening its wing nut 34 A029V089 Issue 8 9 2013 4
58. ual 2 2 1 Generator Set Nameplate Improper service or replacement of parts can lead to severe personal injury or death and to damage to equipment and property Service personnel must be qualified to perform electrical and mechanical service Unauthorized modifications or replacement of fuel exhaust air intake or speed control system components that affect engine emissions are prohibited by law in the State of California Model Spec and Serial Numbers Be ready to provide the model spec and serial numbers on the generator set nameplate when contacting Cummins Onan for information parts and service Record these numbers so that they are easy to find when needed Each character in these numbers is significant for obtaining the right parts listed in the Parts Catalog Genuine Cummins Onan replacement parts are recommended for best results AA Sooo spec TJ Serial Number EE m ves Sasi ISHA E D Lx i IMPORTANT EMISSIONS CONTROL INFORMATION EI TS CUMMINS POWER GENERATION SL EIS eT 1400 73d Ave NE a ih d i Minneapolis MA 55432 XI Mote te 20GSBB 67138 Spec H 5 un 120383176 PH 4 AE Volta TRIN Amps TI Pi 4 RPM Nd Fuel MGRLPV He B Ba UM Opa 220580 8271 2 nit Win Dingnum SFEIC B ADSL TZ RATED AMBIENT 256 MAX 280K BTUUHA x HEMA CLASS H IMSULATION amp BC MAK OPERATING TEMP Y REFER TO OPERATOR S MANUAL PON MAINTENANCE SPECIFICATIONS AND ADJUSTHENTE 28
59. ulty switch faulty oil pressure relief valve faulty oil pump Corrective Actions 1 Check oil level add or drain oil as necessary Overcrank Fault Code 4 Possible Cause Faulty switch faulty external start command fuel supply air fuel mixture exhaust system wire connections starter ignition system Corrective Actions 1 Open any closed fuel valves A029V089 Issue 8 41 5 Troubleshooting 9 2013 9 4 9 9 4 10 9 4 11 9 4 12 9 4 13 42 2 Secure spark plug leads to spark plugs 3 Check and service air filter as necessary 4 Replace spark plugs Some Generator Set service procedures present hazards that can result in severe personal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform Generator Set service Overvoltage Fault Code 12 Possible Causes Generator set loads wire connections windings Corrective Actions 1 Have unit serviced by an authorized Cummins Onan dealer Undervoltage Fault Code 13 Possible Causes Generator set loads wire connections windings Corrective Actions 1 Have unit serviced by an authorized Cummins Onan dealer Overfrequency Fault Code 14 Possible Causes Generator set loads engine governor function fuel supply air fuel mixture exhaust system choke demand regulator carburetor generator windings wire connections Corrective Actions 1 Have unit servi

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