Operator Manual
Contents
1. Power om Generation Operator Manual Standby Power Generator Set PowerCommand Controller C20 N6 Spec A C22 N6 Spec A C25 N6 Spec A C30 N6 Spec A C36 N6 Spec A C40 N6 Spec A C30 N6H Spec A C36 N6H Spec A C40 N6H Spec A C45 N6H Spec A C50 N6H Spec A C60 N6H Spec A English Original Instructions 10 2013 A045R242 Issue 2 Table of Contents 1 IMPORTANT SAFETY INSTRUCTIONS 1 1 Warning Caution and Note Styles Used In This Manual cccccceeeccceeeeessssnneeeeeeseeees 1 2 General Information 1 3 General Precautions see 1 4 Generator Voltage is Deadly eee 1 5 Engine Exhaust is Deadly 1 6 Fuel is Flammable and Explosive 1 7 Batteries Can Explode 1 8 Moving Parts Can Cause Severe Personal Injury or Death 0 0 0 ecceeeeeeeeeeeeeeeeeeeeeeeeeeneeees 1 9 The Hazards of Carbon Monoxide ZAINTRODUGiIO NBs o 2 1 About this Manual 2 2 CONS scvesscsosa a a A E oca 2 3 Schedule of Abbreviations ccccceee 2 4 Related Literature 2 5 About the Generator Set 2 6 Model SpecificatiG meme ese 2 7 How to Obtain Service ccceeeeeeeeeeees ERG ONT ROP S VSR aaeain air 3 1 Operator Panel HMI211 3 2 In Home Operator Panel Accessory 3 3 Sequence of O2. 10 2013 2 Introduction TABLE 3 FUEL SPECIFICATIONS 60 HZ 1800 RPM C22 N6 C25 N6 C30 N6 C36 N6 C40 N6 Full load 105 1 scfh 112 7 scfh 125 4 scfh 164 1 scfh 182 7 scfh 193 6 scfh propane 265 000 285 000 315 000 410 000 460 000 490 000 BTU hr BTU hr BTU hr BTU hr BTU hr BTU hr Full load 259 6 scfh 278 8 scfh 1309 5 scfh 380 9 scfh 472 3 scfh 519 scfh natural gas 270 000 290 000 320 000 395 000 490 000 540 000 BTU hr BTU hr BTU hr BTU hr BTU hr BTU hr 6 14 inch water column TABLE 4 FUEL SPECIFICATIONS 60 HZ 3600 RPM C30 N6H C36N6H C40N6H C45N6H C5ON6H C60 N6H Full load 195 5 scfh 219 6 scfh 236 2 scfh 256 9 scfh 289 5 scfh 324 6 scfh propane 490 000 550 000 595 000 645 000 725 000 820 000 BTU hr BTU hr BTU hr BTU hr BTU hr BTU hr Full load 476 1 scfh 533 3 scfh 573 2 scfh 623 0 scfh 704 7 scfh 814 2 scfh natural gas 495 000 555 000 595 000 645 000 730 000 840 000 BTU hr BTU hr BTU hr BTU hr BTU hr BTU hr 6 14 inch water column TABLE 5 ENGINE SPECIFICATIONS All Models 4 Cylinder in line SOHC liquid cooled 4 stroke spark ignited Displacement 144 in 2351 cc Spark plug gap 0 040 inch 1 0 mm NA 0 030 inch 0 76 mm T TAA Spark plug torque 15 ft lb 20 N m Oil capacity Approximately 4 5 quarts 4 3L il O 5W30 API SM recommendation A045R242 Issue 2 15 2 Introduction 10 2013 TABLE 6 GENERATOR SET SIZE SPECIFICATIONS 20 25 kW 1800 RPM and 30 kW 30
3. 68 FIGURE 25 HISTORY ABOUT MENU A045R242 Issue 2 37 3 Control System 10 2013 3 Fault Log 38 To check the fault log 1 From any Information Menu hold down the up and down arrows simultaneously for two seconds The Service Menu appears 2 Select Fault History NOTICE The active faults are displayed first If there are no active faults this screen is skipped Following the Active Faults Menu are the Fault History screens These screens display the faults in chronological order from newest to oldest NOTICE The following screens represent the standard operator panel HMI211 If using an in home operator panel which may be additionally purchased as an option the screens may look slightly different This procedure applies to both operator panels A045R242 Issue 2 10 2013 3 Control System Battery 12 4 VDC Eng Temp 180 F Oil Press 75 PSI Eng Hours 2222 h AUTO a RES SERVICE MENU 4 Fault History 5 Status 6 Lamp Test 7 More Options 4 5 6 z ACTIVE FAULT At 123456 0 Hrs Fault No 34 Low Oil Pressure E FAULT HISTORY At 123456 0 Hrs Fault No 29 Loss of AC Voltage Sense FAULT HISTORY At 123456 0 Hrs Fault No 34 High Engine Temperature FIGURE 26 FAULT LOG SCREEN A045R242 Issue 2 39 3 Control System 3 8 Time Setup 40 NOTICE When battery power is lost these settings must be reset To set up the generator se
4. Temp 180 F Oil Press 75 PSI ENG Home genta Aa aod 5 a mo Zz Battery 12 4 VDC Eng Temp 180 F Oil Press 75 PSI Eng Hours 2222 h v 2 FIGURE 17 MANUAL START SCREEN IN HOME OPERATOR PANEL 4 The generator set starts and provides voltage to the transfer switch but the transfer switch does not switch allowing the voltage to go to the building until after a delay Time Remaining Until Transfer 5 Seconds FIGURE 18 TIME REMAINING UNTIL TRANSFER SCREEN 5 Five seconds after starting the generator set provides a signal to the transfer switch to transfer the building load to the generator set A045R242 Issue 2 31 3 Control System 10 2013 eng Utility rer ee In TS Process TT MAN v ra FIGURE 19 BUILDING LOAD TRANSFER IN PROCESS 6 The transfer switch switches the generator set power to the building load The building is now running on generator power 6 Utility nn 4e Genset MAN Vv a FIGURE 20 GENERATOR SET POWERING BUILDING LOAD 7 When the Stop button is pressed the transfer switch switches back to utility power eo Utility TS Genset RXfer In Process MAN v a FIGURE 21 BUILDING LOAD TRANSFER IN PROCESS UCILLEY FIGURE 22 UTILITY POWERING BUILDING LOAD 8 The generator set runs for a 5 minute cooldown and shuts off 32 A045R242 Issue 2 10 2013 3 4 3 5 3 Control System Time Remaining Unti
5. house and where exhaust gases will disperse away from the house 1 6 Fuel is Flammable and Explosive e Keep flames cigarettes sparks pilot lights electrical arc producing equipment switches and all other sources of ignition away from areas where fuel fumes are present and areas sharing ventilation e Fuel lines must be secured free of leaks and separated or shielded from electrical wiring e Leaks can lead to explosive accumulations of gas Prevent leaks and the accumulation of gas A rotten egg smell indicates a possible natural gas or propane leak o Natural gas rises when released and can accumulate under hoods and inside housings and buildings o Propane sinks when released and can accumulate inside housings and basements and other below grade spaces 1 7 Batteries Can Explode Batteries can explode causing severe skin and eye burns and can release toxic electrolytes A045R242 Issue 2 5 1 IMPORTANT SAFETY INSTRUCTIONS 10 2013 1 8 1 9 Do not dispose of the battery in a fire because it is capable of exploding Do not open or mutilate the battery Released electrolytes have been known to be harmful to the skin and eyes and to be toxic Batteries present the risk to high short circuit current Remove watches rings or other metal objects and use tools with insulated handles e Wear safety glasses e Do not smoke e To prevent arcing when disconnecting the battery 1 Press the Stop Switch 2 Disc
6. 40 kW 1800 RPM and 36 60 kW 3600 RPM 3600 RPM Propane Vapor Natural Gas Propane Vapor Natural Gas Size with L x W x H 72 x 34 x 45 2 in L x W x H 94 x 34 x 45 2 in sound level 1 1830 x 864 x 1152 mm 2384 x 864 x 1152 mm enclosure TABLE 7 GENERATOR SET WEIGHT POUNDS 60 HZ 1800 RPM C20 N6 C22 N6 C25 N6 C30 N6 C36 N6 C40 N6 Sound level 1 1109 1109 1147 1279 1356 1424 wet TABLE 8 GENERATOR SET WEIGHT POUNDS 60 HZ 3600 RPM C30 N6H C36N6H C40N6H C45N6H C50 N6H C60 N6H Sound level 1 1134 1249 1399 1399 1399 1429 wet TABLE 9 GENERATOR SPECIFICATIONS 60 HZ 1800 RPM C20 N6 C22 N6 C25 N6 C30 N6 C36 N6 C40 N6 Brushless 2 pole rotating field single bearing Power kVA 20 25 22 27 5 25 31 3 30 37 5 36 45 40 50 1phase 3 phase Rated voltages 120 240 120 240 120 240 120 240 120 240 120 240 V 1 Ph 1 Ph 1 Ph 1 Ph 1 Ph 1 Ph 120 240 120 240 120 240 120 240 120 240 120 240 3 Ph 3 Ph 3 Ph 3 Ph 3 Ph 3 Ph 120 208 120 208 120 208 120 208 120 208 120 208 3 Ph 3 Ph 3 Ph 3 Ph 3 Ph 3 Ph 277 480 277 480 277 480 277 480 277 480 277 480 3 Ph 3 Ph 3 Ph 3 Ph 3 Ph 3 Ph 347 600 347 600 347 600 347 600 347 600 347 600 3 Ph 3 Ph 3 Ph 3 Ph 3 Ph 3 Ph 16 A045R242 Issue 2 10 2013 2 Introduction TABLE 10 GENERATOR SPECIFICATIONS 60 HZ 3600 RPM C30 N6H C36N6H C40N6H C45N6H C5ON6H C60 N6H Brushless 2 pole rotating field single bearing Power kVA 30 37 5 36 45 40 50 45 56 3 50 62 5 60
7. 75 1Phase 3 Phase Rated Voltages 120 240 120 240 120 240 120 240 120 240 120 240 V 1 Ph 1 Ph 1 Ph 1 Ph 1 Ph 1 Ph 120 240 120 240 120 240 120 240 120 240 120 240 3 Ph 3 Ph 3 Ph 3 Ph 3 Ph 3 Ph 120 208 120 208 120 208 120 208 120 208 120 208 3 Ph 3 Ph 3 Ph 3 Ph 3 Ph 3 Ph 277 480 277 480 277 480 277 480 277 480 277 480 3 Ph 3 Ph 3 Ph 3 Ph 3 Ph 3 Ph NOTICE Maximum I 8 TABLE 11 GENERATOR SET DERATING GUIDELINES Model NG LP Guidelines C20 N6 NG LP Engine power available up to 1005 m 3300 ft at ambient C22 NG temperatures up to 40 C 104 F Above these elevations derate at 4 per 305m 1000 ft and 2 per 10 C above 40 C 104 P C45 N6H C22 N6 NG Engine power available up to 670 5 m 2200 ft at ambient temperatures up to 40 C 104 F Above these elevations derate at 4 per 305 m 1000 ft and 2 per 10 C above 40 C 104 F C40 N6 NG LP Engine power available up to 114 m 375 ft at ambient temperatures up to 40 C 104 F Above these elevations C60 NGH NG LP derate at 4 per 305 m 1000 ft and 2 per 10 C above 40 104 F A045R242 Issue 2 17 2 Introduction 10 2013 Guidelines Engine power available up to 0 m 0 ft at ambient temperatures up to 25 C 77 F Above these elevations derate at 4 per 305 m 1000 ft and 2 per 10 C above 40 C 104 F Engine power available up to 114 m 375 ft at ambient temperatures up to 25 C 77 F
8. Above these elevations C50 NGH NG LP derate at 4 per 305 m 1000 ft and 2 per 10 C above 25 G77 FF C30 N6 Engine power available up to 762 m 2500 ft at ambient temperatures up to 40 C 104 F Above these elevations derate at 4 per 305 m 1000 ft and 2 per 10 C above 40 C 104 F C30 N6H NG LP Engine power available up to 945 m 3100 ft at ambient temperatures up to 40 C 104 F Above these elevations derate at 4 per 305 m 1000 ft and 2 per 10 C above 40 C 104 F C45 N6H NG LP Engine power available up to 914 m 3000 ft at ambient temperatures up to 40 C 104 F Above these elevations derate at 4 per 305 m 1000 ft and 2 per 10 C above 40 104 F TABLE 12 CONTROL SPECIFICATIONS All Models Integrated microprocessor based engine generator transfer switch control TABLE 13 DC SYSTEM SPECIFICATIONS All Models Nominal 12 VDC battery voltage Battery group 26 standard 24 high capacity high capacity battery require an accessory battery tray Battery Type Maintenance free Minimum cold 545 standard 850 high capacity high capacity battery require an accessory crank amps battery tray 18 A045R242 Issue 2 10 2013 2 Introduction 2 7 How to Obtain Service For parts service and product information such as the Service Manual contact the nearest authorized Cummins Power Generation dealer To easily locate the nearest certified distributor dealer for
9. After the inital 50 hour interval and every 200 hours thereafter A045R242 Issue 2 51 4 Maintenance 10 2013 TABLE 22 EXHAUST MAINTENANCE MAINTENANCE ITEMS Perform maintenance tasks as specified using Daily or Hourly periods of operation whichever Daily Weekly or After occurs first 24 or After Hours 50 Hours Check all exhaust components and hardware fittings clamps fasteners etc Visually inspect the exhaust system for signs of wear or damage Check audibly when the generator set is running TABLE 23 GENERATOR SET MAINTENANCE MAINTENANCE ITEMS Perform maintenance tasks as specified using Daily or 12 Months or Hourly periods of operation Daily or After Weekly or After After whichever occurs first 24 Hours 50 Hours 200 Hours Check generator set enclosure Visually check enclosure walk around inspection of generator set Make sure no inlets outlets are covered restricted service access doors are operational and safety systems are in place and operational Check batteries Check connections are secure and battery area is free from en con and other items Check Check battery condition condition Check electrical connections battery starter motor and alternator connections 4 3 Exercising the Generator Set NOTICE Audible engine RPM variation may be heard when there is no load applied This is normal and does not affect the generator set performance 52 A045R242
10. Cummins generators in your area or for more information contact us at 1 800 344 0039 or visit power cummins com A045R242 Issue 2 19 2 Introduction 10 2013 This page is intentionally blank 20 A045R242 Issue 2 3 Control System 3 1 Operator Panel HMI211 The operator panel includes indicator lights LEDs display buttons used to navigate through the menus control mode buttons and an LCD display The display enables the operator to check the status adjust the settings and start and stop the generator set The standard operator panel show below is located on every generator set An optional operator panelis also available for location inside the home For more information about the optional in home display see the In Home Operator Panel section FIGURE 1 STANDARD OPERATOR PANEL HMI211 Standard Key Functions HMI211 The user interface includes two fixed action buttons and four soft key buttons The action of the soft key buttons changes to meet the requirements of each screen TABLE 14 KEY FUNCTIONS Key Symbol Action On Gun Switches to Off mode fixed action button Switches to Auto mode A045R242 Issue 2 21 3 Control System 10 2013 Key Symbol Action Navigates to the previous menu level fixed action button _ Up Arrow Navigates to the previous screen menu in alist Down Arrow Navigates to the next screen menu in alist aand Hold the up and down arrows simul
11. External leak a Inspect the engine and surrounding area for external oil leaks b Contact your local dealer if a leak is present Code 421 Engine Oil Temperature High Warning Logic The control has detected the engine oil temperature has exceeded the warning threshold Possible Cause 1 High ambient temperature 2 Enclosure air intake blocked 3 Coolant level is below specification A045R242 Issue 2 10 2013 5 Troubleshooting Diagnosis and Repair 1 High ambient temperature a Reduce loads or recirculation of discharge air to generator in elevated ambient 2 Enclosure air intake blocked a Inspect for dirt debris or obstructions b Remove blockage or snow ice buildup as applicable 3 Coolant level is below specification a Check coolant level b Add coolant as necessary 5 10 Code 441 Battery Voltage Low Warning Logic Battery voltage low Possible Causes 1 Loose or damaged battery cable connections Diagnosis and Repair 1 Loose or damaged battery cable connections a Inspect the battery cable connections i Inspect connections for corrosion ii Inspect connections for loose connections 5 11 Code 488 Intake Manifold Temperature High Warning Logic Engine intake manifold temperature has exceeded 185 F 85 C for more than 90 seconds Possible Cause 1 High ambient temperature Enclosure air intake blocked Coolant level is below specification Radiator core
12. Parameter Number International Organization SW_B Switched B ECB Standardization LBNG Lean burn Natural Gas oa Underwriters Laboratories LCD Liquid Crystal Display UPS Uninterruptible Power Supply 2 4 Related Literature The literature provided with the generator set is as follows e Installation Manual A045R241 e Operator Manual A045R242 A generator set must be operated and maintained properly if you are to expect safe and reliable operation The Operator Manual includes a maintenance schedule and a troubleshooting guide The Health and Safety Manual must be read in conjunction with this manual for the safe operation of the generator set e Health and Safety Manual 0908 0110 e Warranty Statement A028U870 e Emissions Component Defect Warranty Statement A028X278 The relevant manuals appropriate to your generator set are also available The documents below are in English e Service Manual A045R243 e Parts Manual A046Z674 e E Controls Inc Service Manual A035C596 12 A045R242 Issue 2 10 2013 2 Introduction Global Control Platform GCP Engine Display Interface Software EDIS Training Manual A035C608 RA Series Transfer Switch Owner s Manual A046S594 if applicable PowerCommand 1302 Controller Owner s Manual 900 0661 Standard Repair Times SRT Manual A046Z094 Application Manual T 030 for application information A040S369 Service Tool Manual A043D529 2 5 About the Gen
13. cleaner elements and reset the air cleaner service indicator Check air intake system for leaks Visually inspect the air intake system for signs of wear or damage Check audibly when the generator set is running Replace worn or damaged components TABLE 19 CONTROL MAINTENANCE MAINTENANCE ITEMS Perform maintenance tasks as specified using Daily or Hourly periods of operation whichever Daily or After Weekly or After occurs first 24 Hours 50 Hours Check operation of operator panel Check display the system will perform a control panel test on initial activation Replace component if not functioning properly Check operation of Emergency Stop Button where fitted With the generator set running press the Emergency Stop button Check all systems before resetting the fault A045R242 Issue 2 49 4 Maintenance TABLE 20 MAINTENANCE ITEMS Perform maintenance tasks as specified using Daily or Hourly periods of operation whichever occurs first 10 2013 COOLING MAINTENANCE 12 Months or After 200 Hours Daily or After 24 Hours Weekly or After 50 Hours 2 Years Check coolant level of radiator s water jacket amp LTA If low top up to coolant system specifications level with Cummins recommended coolant mix Check cooling fan blades Visually inspect the fan blades through the guarding for signs of wear or damage Check drive belt condition and tension Vi
14. e This device must accept any interference received including interference that may cause undesired operation 2 2 Icons The following symbols may have been used in this manual to help communicate the intent of the instructions They are defined below A045R242 Issue 2 9 2 Introduction 10 2013 Description Clean the part or assembly Indicates an electrical measurement Indicates that an inspection is required Indicates an installation or assembly procedure Lubricate the part or assembly Indicates a mechanical or time measurement Refer to another publication for additional information Indicates a removal or disassembly step Tighten to a specific torque Indicates parts or tools required Indicates that the component is heavy 50 Ib or 23 kg or more To reduce the possibility of personal injury use a hoist or get assistance to lift eS RI D 2 3 Schedule of Abbreviations This list is not exhaustive For example it does not identify units of measure or acronyms that appear only in parameters event fault names or part accessory names AmpSentry INSITE and InPower are trademarks of Cummins Inc PowerCommand is a registered trademark of Cummins Inc 10 A045R242 Issue 2 10 2013 2 Introduction DESCRIPTION ABBR DESCRIPTION Alternating Current Low Coolant Temperature AMP Inc part of Tyco LED Light emitting Diode Electronics American National MFM Multifunction Monitor Standar
15. fouled Enclosure air discharge blocked O O1 BB WwW D Broken fan belt A045R242 Issue 2 69 5 Troubleshooting 10 2013 Diagnosis and Repair 1 High ambient temperature a Reduce loads or recirculation of discharge air to generator in elevated ambient 2 Enclosure air intake blocked a Inspect for dirt debris or obstructions b Remove blockage or snow ice buildup as applicable 3 Coolant level is below specification a Check coolant level b Add coolant as necessary 4 Radiator core fouled a Inspect for dirt debris or obstruction on core b Remove obstructions or debris and clean the radiator core 5 Enclosure air discharge blocked a Inspect for dirt debris or obstructions b Remove blockage or snow ice buildup as applicable 6 Broken fan belt a Inspect fan belt b Replace fan belt 5 12 Code 1438 Fail to Crank Shutdown Logic The engine failed to crank after the generator control received a start signal Possible Cause 1 Dead or weak battery Diagnosis and Repair 1 Dead or weak battery a Verify battery voltage is at least 12 VDC b Charge or replace the battery as necessary 5 13 Code 1472 High AC Current Shutdown Logic The generator output current has exceeded at least 150 of rated current 70 A045R242 Issue 2 10 2013 5 Troubleshooting Possible Causes 1 Generator set overload Diagnosis and Repair 1 Generator set overload a Reduce the gene
16. near an operating generator set Hot metal parts can cause severe burns Avoid contact with the radiator turbo charger and exhaust system Maintaining or installing a generator set can cause severe personal injury Wear personal protective equipment such as safety glasses protective gloves hard hats steel toed boots and protective clothing when working on equipment Ethylene glycol used as engine coolant is toxic to humans and animals Clean up coolant spills and dispose of used antifreeze in accordance with local environmental regulations A045R242 Issue 2 3 1 IMPORTANT SAFETY INSTRUCTIONS 10 2013 Starting fluids such as ether can cause explosion and generator set engine damage Do not use Stepping on the generator set can cause parts to bend or break leading to electrical shorts or to fuel coolant or exhaust leaks Do not step on the generator set when entering or leaving the generator room To prevent accidental or remote starting while working on the generator set disconnect the negative battery cable at the battery using an insulated wrench Make sure that rags are not left on or near the engine Make sure the generator set is mounted in a manner to prevent combustible materials from accumulating under the unit Accumulated grease and oil can cause overheating and engine damage presenting a potential fire hazard Keep the generator set clean and repair any oil leaks promptly Before
17. 1 Battery Voltage Low Warning 69 5 11 Code 488 Intake Manifold Temperature High Warning 69 Ae Cne ea ENONCE SAONE Jenene 70 5 13 Code 1472 High A GCUrEeNASNMEAMNNIEES Ne CE AR nne 70 5 14 Code 5134 Unknown Shutdown at Idle eee ceeccceeeeseeeeeeeeeeeeeensseeeseeeeaeeeeeneeeeneeneenes 71 5 15 Code 5569 Engine Combustion Shutdown eececeeeeseeeeeeeneceeeeeeeeeeeeeeeeeeetssaaeeeeeeeees 71 ii A045R242 Issue 2 1 1 1 1 2 IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions for the generator set Follow these instructions during installation operation and maintenance of the generator set and batteries Thoroughly read the Operator Manual before operating the generator set Safe operation and top performance can only be obtained when the equipment is properly operated and maintained Warning Caution and Note Styles Used In This Manual The following safety styles and symbols found throughout this manual indicate potentially hazardous conditions to the operator service personnel or the equipment DANGER Indicates a hazardous situation that if not avoided will result in death or serious injury Indicates a hazardous situation that if not avoided could result in death or serious injury Indicates a hazardous situation that if not avoided could result in minor or moderate injury NOTICE Indicates information conside
18. 242 Issue 2 10 2013 3 Control System Daylight Saving Adjust End Mth Wk Day Hr 0 1 Sun O AM ADJUST SE 2 Daylight Saving Adjust End Mth Wk Day Hr ON SR On SAVE m FIGURE 30 DAYLIGHT SAVING ADJUST END MENU 3 9 Exercise Settings NOTICE When the battery power is lost these settings must be reset To access the Clock Exerciser Menu 1 From any Information Menu hold down the up and down arrows simultaneously for two seconds The Service Menu appears 2 Navigate through the screens to find and select Clock Excr in the Service Menu NOTICE The following screens represent the standard operator panel HMI211 If using an in home operator panel which may be additionally purchased as an option the screens may look slightly different This procedure applies to both operator panels A045R242 Issue 2 43 3 Control System 44 10 2013 Battery 12 4 VDC Eng Temp 180 F Oil Press 75 PSI Eng Hours 2222 h AUTO MAN ni SERVICE MENU 1 Setup Menus 2 History About 3 Screen Adjust 7 More Options 1 2 3 v SERVICE MENU 4 Fault History 5 Status 6 Lamp Test 7 More Options 4 5 6 v SERVICE MENU 7 Network Status 8 Clock Excr 7 More Options 7 8 v TIME SETUP Date 00 00 00 mm dd yy Time 00 00 AM ADJUST ees ha Fi CLOCK EXERCISER MENU NAVIGATION A045R242 Issue 2 10 2013 3 Control System Updating E
19. 3 3 Sequence of Operation NOTICE The following sequences are based on an approximate time duration Your generator set may vary slightly from the timing diagrams in this manual All referenced times are based on default control settings Power Outage Sequence The sequence of operation after a power outage the generator set is in Auto Mode is as follows 1 In normal operation the utility power is running to the transfer switch and then to the building load and the generator set is off 2 The utility power turns off power outage 3 One second after the power outage the transfer switch sends the command to the generator set to start 4 The generator set starts and provides voltage to the transfer switch but the transfer switch does not switch allowing the voltage to go to the building until after a delay 24 A045R242 Issue 2 10 2013 3 Control System Time Remaining Until Transfer 5 Seconds FIGURE 3 TIME REMAINING UNTIL TRANSFER SCREEN 5 Five seconds after starting the generator set provides a signal to the transfer switch to transfer the building load to the generator set Genset P til n er IT In TS Process Ven MAN v FT FIGURE 4 BUILDING LOAD TRANSFER IN PROCESS 6 The transfer switch switches the generator set power to the building load The building is now running on generator power 8 Utility T rs MAN v a FIGURE 5 GENERATOR SET POWERING BUILDING LOAD
20. 7 When the utility power is back and providing voltage to the transfer switch the transfer switch waits for utility power stability Genset Time Remaining Until Re Trans 300 Seconds FIGURE 6 TIME REMAINING UNTIL TRANSFER 8 When the utility power is stable for 5 minutes the transfer switch switches back to utility power A045R242 Issue 2 25 10 2013 3 Control System Genset RXfer In Process 8 Utility i TS MAN Me a FIGURE 7 BUILDING LOAD TRANSFER IN PROCESS Genset p 1 Utility TS MAN Y a FIGURE 8 UTILITY POWERING BUILDING LOAD 9 The generator set runs for a 5 minute cooldown and shuts off Time Remaining Until Stop 300 Seconds FIGURE 9 TIME REMAINING UNTIL STOP 10 Normal operation resumes Exercise Sequence The exercise sequence when the programmed exercise time is realized the generator set is in Auto Mode is as follows 1 The generator set starts and runs 2 The Exerciser Scheduler On screen displays every 3 seconds and toggles between the existing Information screen that is displayed for 1 second A045R242 Issue 2 26 10 2013 3 Control System Battery 12 4 VDC Exercise Scheduler Eng Temp 180 F 38sec Oil Press 75PSI ON Eng Hrs 2222 RES T1 FIGURE 10 EXERCISER SCHEDULER SCREEN AND INFORMATION SCREEN TOGGLE EXAMPLE 3 The transfer switch is not commanded to switch the building load to t
21. 9 4 Maintenance 10 2013 4 Remove the media 2 from the housing 1 Air Cleaner Element Installation No Description No Description Housing End cover S End cover FIGURE 40 HEAVY DUTY AIR CLEANER 1 Ensure that no debris enters the filter element or connection point on the air cleaner housing 2 Insert the media 2 into the housing 1 3 Install the end cover 4 onto the housing 1 4 Turn the end cover 4 clockwise until latch 3 snaps into place 60 A045R242 Issue 2 10 2013 4 6 4 7 4 Maintenance Battery Maintenance Accidental or remote starting of the generator set can cause severe personal injury or death Before working on the generator set make sure that the generator set is in Off mode disable the battery charger and remove the negative battery cable from the battery to prevent starting 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 Replace the battery charger if the battery keeps running down Always e Keep the battery case and terminals clean and dry and the terminals tight e Remove battery cables with a battery terminal puller e Make sur
22. Issue 2 10 2013 4 4 4 Maintenance Exercising the generator set drives off moisture relubricates the engine and removes oxides from electrical contacts The result is better starting more reliable operation and longer engine life The generator set exerciser mode defaults are as follows e Day Tuesday e Time 2 00 pm e Period Monthly e Run Time 5 minutes 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 High and Low marks The generator set is shipped with engine oil 5W30 API SM engine oil is recommended Checking Engine Oil Level NOTICE Check the engine oil level when the engine is not running and is out of Auto mode Crankcase pressure can blow out hot oil and cause severe burns Do NOT check oil while the engine is operating Overfilling can cause foaming or aeration of the oil while operation below the low mark may cause loss of oil pressure Do not operate the engine with the oil level below the low mark or above the high mark 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 pers
23. RATOR PANEL Key Functions In Home Operator Panel The user interface includes two fixed action buttons and four soft key buttons The action of the soft key buttons changes to meet the requirements of each screen TABLE 16 KEY FUNCTIONS Key Symbol Action Stop Switches to Off mode This key works from any screen fixed action button aaa Up Arrow Navigates to the previous screen menu in a list Fw Down Arrow Navigates to the next screen menu in a list and Hold the up and down arrows simultaneously for two seconds from any Info Menu to navigate to the Service Menu Back Navigates to the previous screen menu in a list fixed action button In Adjust screens settings are not saved Decreases value of the highlighted editable field A045R242 Issue 2 23 3 Control System 10 2013 LED Indicators In Home Operator Panel The operator panel has five LED indicators Colors flashing frequency and conditions to turn them on off blink are included in the table below TABLE 17 LED INDICATORS Color Action Shutdown Red Indicates a Shutdown Fault has occurred Indicates a Warning Fault has occurred Auto Start Green Indicates that the generator set has received an Remote Start Command Auto Green Indicates that the generator set is in Auto Mode The generator starts when it receives a Remote Start Command Manual Run Green Indicates that the generator set has received a Manual Run Command
24. carcinogenic and cause reproductive toxicity Avoid inhalation of vapors ingestion and prolonged contact with used engine oil If not reused dispose of in accordance with local environmental regulations To reduce the possibility of personal injury avoid direct contact of hot oil with your skin NOTICE Change the engine oil and filter when the engine is not running and is out of Auto mode 1 Before changing the oil the engine should be operated until the water temperature is approximately 60 C 140 F 2 Shut down the engine 3 Drain the oil 4 Remove the oil filter and clean the filter mounting surface on the engine block Remove the old gasket if it remains 56 A045R242 Issue 2 10 2013 4 Maintenance 5 Make sure the gasket is in place on the new filter and apply a thin film of clean oil to the gasket Install the new filter until the gasket just touches the block Turn it an additional 1 2 to 3 4 turn Do not over tighten 6 Refill with oil until full Too much oil can cause high oil consumption Too little oil can cause severe engine damage Keep the oil level between the High and Low marks 7 Start and run for 30 seconds 8 Shut the engine off and wait 5 minutes 9 Check the engine oil level 10 Dispose of the used oil and oil filter according to local environmental regulations 4 5 Air Intake System Normal Duty Air Cleaner Air Cleaner Removal Holes loose end seals dented sealin
25. chdr Exercise Duration ADJUST 5 MIN Exercise Schdr Exercise A MIN Duration Lal SAVE FIGURE 33 EXERCISE DURATION NAVIGATION 46 A045R242 Issue 2 4 Maintenance Regularly performing the following periodic maintenance and guidelines greatly reduce the chances of a generator set shutdown e Maintain an appropriate oil level e Keep battery connections clean and tight e Do not overload the generator set e Keep the air inlet and outlet openings clear 4 1 General Operating Conditions The area surrounding the generator set is critical for safety and its performance Follow the guidelines below e Do not stack anything on top of the generator set e Do not store anything inside of the generator set e Keep areas clear in front of the cool air in and hot air out free of obstructions debris plants etc Win Asa No Description No Description Cool Air In Hot Air Out FIGURE 34 GENERATOR SET LOCATION NOTICE All maintenance procedures must be performed or supervised by authorized and trained service personnel only A045R242 Issue 2 47 4 Maintenance 10 2013 4 2 Periodic Maintenance 48 The periodic maintenance procedures should be performed at whichever interval occurs first calendar time or hours of operation At each scheduled maintenance interval perform all previous maintenance checks that are due for scheduled maintenance The tabular data that follows giv
26. core fouled a A N Enclosure air discharge blocked 6 Broken fan belt Diagnosis and Repair 1 High ambient temperature a Reduce loads or recirculation of discharge air to generator in elevated ambient 2 Enclosure air intake blocked a Inspect for dirt debris or obstructions b Remove blockage or snow ice buildup as applicable 3 Coolant level is below specification a Check coolant level b Add coolant as necessary 4 Radiator core fouled a Inspect for dirt debris or obstruction on core b Remove obstructions or debris and clean the radiator core 5 Enclosure air discharge blocked a Inspect for dirt debris or obstructions b Remove blockage or snow ice buildup as applicable 6 Broken fan belt a Inspect fan belt b Replace fan belt A045R242 Issue 2 67 5 Troubleshooting 10 2013 9 7 9 8 5 9 68 Code 197 Coolant Level Low Warning Logic Coolant level sensor signal is showing a low coolant level for greater 10 seconds Possible Causes 1 Low coolant Diagnosis and Repair 1 Low coolant a Remove radiator cap and check that coolant is up to the required level Code 415 Engine Oil Pressure Low Shutdown Logic Engine oil pressure is below 26 psig 180 kpa for greater than 10 seconds Possible Cause 1 Lubricating oil level is low 2 External leak Diagnosis and Repair 1 Lubricating oil level is low a Check the oil level Add oil if necessary 2
27. ds Institute American Society for Mil Std Military Standard Testing and Materials ASTM International Automatic Transfer Switch Normally Closed Automatic Voltage NC Not Connected Regulator American Wire Gauge NFPA National Fire Protection Agency Controlled Area Network Normally Open Network Failure Conformit Europ enne OEM Original Equipment Manufacturer Cubic Feet per Minute OOR Out of Range Cummins Generator OORH Out of Range High Technologies ORH Cubic Meters per Minute OORL Out of Range Low ORL Current Transformer Push Button Direct Current PowerCommand Control Diesel Particulate Filter Engine Control Module Parameter Group Number Engine Control System Proportional Integral PGI Power Generation Interface Electromagnetic Proportional Integral Deriva interference tive European Standard Programmable Logic Controller Engine Protection System Permanent Magnet Generator Emergency Stop Potential Transformer Full Authority Electronic Power Transfer Control A045R242 Issue 2 11 2 Introduction 10 2013 ABBR DESCRIPTION ABBR DESCRIPTION Failure Mode Identifier Pulse width Modulation FSO Fuel Shutoff RFI Radio Frequency Interference Generator Set Relative Humidity ES ane Contei Pane Generator Control Panel as Root Mean te PE GND Ground sd RTU Remote Terminal Unit Terminal Unit Human machine Interface Society of Automotive Engineers Integrated Circuit Suspect
28. e transfer switch switches the generator set power to the building load The building is now running on generator power 28 A045R242 Issue 2 10 2013 3 Control System 8 Utility Ei ps Genset MAN hd FIGURE 13 GENERATOR SET POWERING BUILDING LOAD 6 Press the Off Mode fixed action button to switch the load back to the utility RXfer power 8 Utility In TS PeOCeCSSaam a Genset MAN v a FIGURE 14 BUILDING LOAD TRANSFER IN PROCESS Genset P Utility A TS zx MAN v a FIGURE 15 UTILITY POWERING BUILDING LOAD 7 Normal operation resumes Remote Starting the Generator Set Sequence The sequence if the generator set is remote started with the in home operator panel accessory if equipped the generator set is in Auto Mode is as follows 1 In a normal operation the utility power is running to the transfer switch and then to the building load and the generator set is off 2 The generator set mounted control HMI211 is set in Auto Mode A045R242 Issue 2 29 3 Control System 10 2013 Battery 12 4 VDC Eng Temp 180 F Oil Press 75 PSI EngsHourer 2222 h AUTO MAN zx X Battery 12 4 VDC Eng Temp 180 F Oil Press 75 PSI Eng Hours 2222 h mn 7 a FIGURE 16 HMI211 SET IN AUTO MODE 3 Manually start the generator set via the in home operator panel 30 A045R242 Issue 2 10 2013 3 Control System Battery 12 4 VDC Eng
29. e which terminal is positive and which is negative before making battery connections always removing the negative cable first and reconnecting it last to reduce arcing NOTICE If the battery needs to be replaced be sure that the replacement battery specs match those found in the Model Specifications in this manual Spark Plugs Set the generator set control to the Off position before checking the spark plugs The generator set 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 lb ft 20 N m Return the generator set control to the desired setting when finished performing maintenance A045R242 Issue 2 61 4 Maintenance 10 2013 This page is intentionally blank 62 A045R242 Issue 2 5 1 Troubleshooting The following list of codes is not an all inclusive list For more information about the fault codes listed or for additional codes contact your local dealer NOTICE Only trained and authorized personnel shall maintain or service the generator set Display Text or Symbolic Version The operator panel graphical display can be set to show text English only or symbols for fault messages some o
30. erator Set The generator set is an engine powered generator set fueled by natural gas or propane See the Model 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 O1 WwW ND Stops the generator set A more in depth illustration of the operation of the generator set and transfer switch can be found in the Sequence of Operation section of this manual 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
31. es the recommended service intervals for a generator set on Standby service If the generator set will be subjected to extreme operating conditions the service intervals should be reduced accordingly Some of the factors that can affect the maintenance schedule are e Extremes in ambient temperature e Exposure to elements e Exposure to salt water e Exposure to windblown dust or sand Consult with an authorized dealer if the generator set will be subjected to any extreme operating conditions and determine if extra protection or a reduction in service intervals is needed Use the running time meter to keep an accurate log of all service performed for warranty support Perform all service at the time period indicated or after the number of operating hours indicated whichever comes first Accidental or remote starting of the generator set can cause severe personal injury or death Before working on the generator set make sure that the generator set is in Off mode disable the battery charger and remove the negative battery cable from the battery to prevent starting A045R242 Issue 2 10 2013 4 Maintenance Periodic Maintenance Schedule TABLE 18 AIR INTAKE MAINTENANCE MAINTENANCE ITEMS Perform maintenance tasks as specified using Daily or Hourly periods of operation whichever Daily or After occurs first 100 Hours Check air cleaner restriction indicator where fitted If the service indicator shows red replace air
32. for high coolant temperature Possible Cause 1 O OA D High ambient temperature Enclosure air intake blocked Coolant level is below specification Radiator core fouled Enclosure air discharge blocked Broken fan belt 7 Coolant level is below specification Diagnosis and Repair Le High ambient temperature a Reduce loads or recirculation of discharge air to generator in elevated ambient Enclosure air intake blocked a Inspect for dirt debris or obstructions b Remove blockage or snow ice buildup as applicable Coolant level is below specification a Check coolant level b Add coolant as necessary Radiator core fouled a Inspect for dirt debris or obstruction on core b Remove obstructions or debris and clean the radiator core Enclosure air discharge blocked a Inspect for dirt debris or obstructions b Remove blockage or snow ice buildup as applicable Broken fan belt a Inspect fan belt b Replace fan belt Coolant level is below specification a Check coolant level A045R242 Issue 2 10 2013 5 Troubleshooting b Add coolant as necessary 5 6 Code 155 Intake Manifold Temperature High Shutdown Logic Engine intake manifold temperature has exceeded 203 F 95 C for greater than 10 seconds Possible Cause 1 High ambient temperature Enclosure air intake blocked Coolant level is below specification Radiator
33. for two seconds to gain access to the Service Menu screen 2 Select Screen Adjust A045R242 Issue 2 33 3 Control System 10 2013 To adjust the contrast brightness or units from the Screen Adjust screen 1 From the Screen Adjust Menu select Adjust to access the screen variables 2 Press the right arrow to move between the variables 3 Adjust settings and press Save to save any changes When updating these settings the function of the keys are as follows e The horizontal right arrow key is used to select successive blocks for editing settings on the screen e Select the left arrow to return to the previous screen e Adjust values by using the or keys on the Adjust Menu of the Display Setup Menu e Press Save to save any changes After savings the Save button changes to the Adjust button NOTICE The following screens represent the standard operator panel HMI211 If using an in home operator panel which may be additionally purchased as an option the screens may look slightly different This procedure applies to both operator panels 34 A045R242 Issue 2 10 2013 3 Control System Battery 12 4 VDC Eng Temp 180 F Oil Press 75 PSI Eng Hoursses2222 h AUTO MAN MM SERVICE MENU 1 Setup Menus 2 History About 3 Screen Adjust 7 More Options 1 2 3 id ADJUST SCREEN Contrast Sa Brightness Units F PSI ADJUST ADJUST SCREEN COntr ast i Brightnes
34. g surfaces corrosion of pipes and other forms of damage render the air cleaner inoperative and require immediate element replacement or engine damage can occur NOTICE Cummins Inc does not recommend cleaning paper type air cleaner elements A045R242 Issue 2 57 4 Maintenance 10 2013 No Description No Description Strap clamp FIGURE 37 NORMAL DUTY AIR CLEANER 1 Loosen the strap clamp 2 2 Wipe away any debris accumulated around the air cleaner connection to the engine Ensure that no debris is allowed to enter the body of the air cleaner or the connection on the engine 3 Remove the dirty cleaner 1 Dispose of the dirty element in accordance with local environmental agency requirements Air Cleaner Installation No Description No Description 1 Air cleaner Strap clamp FIGURE 38 NORMAL DUTY AIR CLEANER Cal Install the air cleaner 1 as follows 1 Install the air cleaner 1 2 Tighten strap clamp 2 58 A045R242 Issue 2 10 2013 4 Maintenance Heavy Duty Air Cleaner Air Cleaner Element Removal No Description No Description FIGURE 39 HEAVY DUTY AIR CLEANER NOTICE Cummins Inc does not recommend cleaning paper type air cleaner elements 1 Before disassembly wipe dirt from the cover and the upper portion of the air cleaner 2 Lift tab 3 and turn end cover 4 counter clockwise 3 Pull the end cover 4 away from the housing 1 A045R242 Issue 2 5
35. he generator set NOTICE The user may navigate to other screens from the Information screens during this duration No functional keys are active on the Exerciser Scheduler On screen 4 The generator set stops after programmed exercise run time Manually Starting the Generator Set Sequence The sequence if the generator set is manually started with the standard operator panel HMI211 the generator set is in Man Mode is as follows NOTICE Open the generator set main line circuit breaker to prevent the transfer switch from transferring building load to the generator set 1 In normal operation the utility power is running to the transfer switch and then to the building load and the generator set is off 2 Manually start the generator set via the standard control HMI211 mounted on the generator set A045R242 Issue 2 27 3 Control System 10 2013 Battery 12 4 VDC Eng Temp 180 F Oil Press 75 PSI Eng Hours 2222 h AUTO naa ES y BR Battery 12 4 VDC Eng Temp 180 F Oil Press 75 PSI Eng Hours 2222 h AUTO v a FIGURE 11 MANUAL START SCREEN STANDARD OPERATOR PANEL 3 The generator set starts and provides voltage to the transfer switch 4 The generator set provides a signal to the transfer switch to transfer the building load to the generator set Genset z Utility rer hrs In TS Procesa pa MAN n a FIGURE 12 BUILDING LOAD TRANSFER IN PROCESS 5 Th
36. in the State of California A045R242 Issue 2 13 2 Introduction 10 2013 Model Spec and Serial Numbers Be ready to provide the model spec and serial numbers on the generator set nameplate when contacting Cummins Power Generation for information parts and service The nameplate is located on the inside of the customer service door on enclosed generator sets 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 Power Generation replacement parts are recommended for best results My Generator Set Information O ee si _ SF 49 2 6 Model Specifications TABLE 1 2 4L MODEL VARIATIONS Model Description C20 N6 C22 N6 C25 N6 C30 N6 C36 N6 60 Hz 1800 RPM C40 N6 C30 N6H C36 N6H C40 N6H C45 N6H 60 Hz 3600 RPM C50 N6H C60 N6H TABLE 2 COLD WEATHER SPECIFICATIONS All Models For NFPA 110 applications a coolant heater is required Factory option is available Ca 40 F 4 No starting aids required Standard battery group 26 0 to 40 F 17 Additional coolant heater and battery charger recommended for starting to 4 C Factory options available Standard battery group 26 Below 0 F 17 All starting aides battery heater coolant heater battery charger recommended Factory options available Larger battery group 24 14 A045R242 Issue 2
37. l Stop 300 Seconds a D FIGURE 23 TIME REMAINING UNTIL STOP 9 Normal operation resumes Operating Modes The generator set control works with a Manual Run Off Auto switch used to control generator set operating modes Off Mode When in Off mode the control does not allow the generator set to start If the generator set is already running and the control is set to Off it initiates a normal shutdown sequence Manual Run Mode When in Manual Run mode the generator set starts and continues to run until the control is put into the Off mode While in Manual Run mode the remote start signal is ignored Auto Mode When in Auto mode the control allows the generator set to be started with a remote start signal only When in Auto mode the generator set can start at any time When a remote start signal is received the genset starts after a time delay preheat if programmed and time delay start if programmed is completed If the generator set is running in Auto mode and the Off button is pressed the control immediately stops the genset and the control transitions to the Off mode When all remote start signals are removed the control performs a normal shutdown sequence which may include a time delay stop Brightness and Contrast The Screen Adjust Menu allows the contrast brightness and units to be set To access the Screen Adjust Menu 1 From any Information screen hold down the up and down arrows simultaneously
38. onal injury or death Disconnect the negative battery cable and place the control switch in its OFF position before starting work A045R242 Issue 2 53 4 Maintenance 10 2013 No Description No Description Fill Cap Dipstick Oil Filter Oil Drain Hose FIGURE 35 ENGINE OIL COMPONENTS To check the engine oil level 1 Pull out the dipstick and wipe it clean 2 Clean off the area surrounding the dipstick port to prevent entry of debris into the oil pan 3 Make sure that the engine has not been running for approximately five minutes 4 Reinsert and fully seat the dipstick 5 Remove the dipstick and check the oil level NOTICE The engine oil level indicated on the dipstick should be between the High 4 3 L or 4 5 qt and Low 3 8 L or 4 0 qt marks 6 Reinsert and fully seat the dipstick 54 A045R242 Issue 2 10 2013 4 Maintenance High Oil Level 4 3 L or 4 5 qt 2 Low Oil Level 3 8 L or 4 0 at FIGURE 36 ENGINE OIL DIPSTICK If the engine oil level check shows excessive or insufficient levels of oil oil level line above the High mark or below the Low mark oil must be drained or added Refer to the following sections for instructions and guidelines for draining and adding oil Adding or Draining Oil Too much oil can cause high oil consumption Too little oil can cause severe engine damage Keep the oil level between the High and Low marks on the dipstick A CAUTION Hot engines can bu
39. onnect AC power from any battery chargers 3 Remove the negative battery cable to prevent starting e To prevent arcing when reconnecting the battery 1 Reconnect the positive cable 2 Reconnect the negative cable 3 Reconnect the battery charger to AC power supply e When replacing the generator set battery always replace it with a battery as specified in the Model Specifications section of this manual Moving Parts Can Cause Severe Personal Injury or Death e Do not wear loose clothing or jewelry near moving parts such as fans e Keep hands away from moving parts e Keep guards in place over fans The Hazards of Carbon Monoxide Carbon Monoxide CO is an odorless colorless tasteless and non irritating gas you cannot see it or smell it 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 Engine driven generators produce harmful levels of carbon monoxide that can injure or kill you A045R242 Issue 2 10 2013 1 IMPORTANT SAFETY INSTRUCTIONS 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 The
40. pect the engine and surrounding area for external oil leaks b Contact your local dealer if a leak is present 64 A045R242 Issue 2 10 2013 5 Troubleshooting 5 4 Code 146 Engine Coolant Temperature Above Normal Warning Logic Engine coolant temperature has exceeded 225 F 107 2 C for greater than 5 seconds Possible Cause 1 High ambient temperature Enclosure air intake blocked Coolant level is below specification Radiator core fouled oa A N Enclosure air discharge blocked 6 Broken fan belt Diagnosis and Repair 1 High ambient temperature a Reduce loads or recirculation of discharge air to generator in elevated ambient 2 Enclosure air intake blocked a Inspect for dirt debris or obstructions b Remove blockage or snow ice buildup as applicable 3 Coolant level is below specification a Check coolant level b Add coolant as necessary 4 Radiator core fouled a Inspect for dirt debris or obstruction on core b Remove obstructions or debris and clean the radiator core 5 Enclosure air discharge blocked a Inspect for dirt debris or obstructions b Remove blockage or snow ice buildup as applicable 6 Broken fan belt a Inspect fan belt b Replace fan belt A045R242 Issue 2 65 5 Troubleshooting 10 2013 9 5 66 Code 151 Engine Coolant Temperature High Shutdown Logic Engine coolant temperature has exceeded the alarm shutdown threshold
41. peration 3 4 Operating Modes a n ee eee eee rene 3 5 Brightness and Contrast cc secreeeeees 3 6 History and About Menu 37 Fault Logi renee ce ee ee SOc TMG SOUPE TNT em 3 9 EXenciSe SCUINGS ctu neat terete E de MAINTENANCE SR nn ete un 4 1 General Operating Conditions 4 2 Periodic Maintenance 4 3 Exercising the Generator Set 0 00e 4 4 Engine Oil Maintenance 4 5 Air IntaKPS SBME neers eee 4 6 Battery Maintenance 4 7 Spark Plugs 0 5 TROUBLESHOOTING animes 5 1 Display Text or Symbolic Version 5 2 Engine is Difficult to Start or Does Not Start A045R242 Issue 2 OO O O1 O1 O1 O1 D 10 12 13 14 19 21 21 22 24 33 33 36 38 40 43 47 47 48 92 53 97 61 61 63 63 64 Table of Contents 10 2013 5 3 Code 143 Engine Oil Pressure Low Warning 64 5 4 Code 146 Engine Coolant Temperature Above Normal Warning 65 5 5 Code 151 Engine Coolant Temperature High Shutdown eeeceeeeeeeeeeeeeeeeeeeeteeeeeeeees 66 5 6 Code 155 Intake Manifold Temperature High Shutdown cceeeeeeeeeeeeeeeeeeteteeeeeeees 67 5 7 Code 197 Coolant Level Low Ora ea EEE nappe epee 68 5 8 Code 415 Engine Oil Pressure Low Shutdown 68 5 9 Code 421 Engine Oil Temperature High Warning 68 5 10 Code 44
42. perator menus and the Mode Change Menu Descriptions of commonly used symbols are included in the following table Combinations of symbols are used to display some fault conditions Additional specialized symbols are also used for some faults When shipped from the factory the display is set to display symbols Qualified service personnel are required to change the default setting TABLE 24 SYMBOLS Symbol Text mt Generator Warning Fault Generator Shutdown Fault AA Coolant Temperature Oil Pressure Voltage Alternating Current VAC VDC Voltage Direct Current VDC AC Current Battery Out of Range High or Pre High A045R242 Issue 2 63 5 Troubleshooting 10 2013 Symbol Text Emergency Stop 5 2 Engine is Difficult to Start or Does Not Start Possible Cause 1 Battery voltage 2 Fuel system issue s Diagnosis and Repair 1 Battery voltage e Battery voltage is low interrupted or open o Check the batteries connections unswitched battery supply circuit and fuses 2 Fuel system issue s e Manual fuel shutoff valve is closed o Check the manual fuel shutoff valves 5 3 Code 143 Engine Oil Pressure Low Warning Logic Engine oil pressure is below the low oil pressure warning threshold Possible Cause 1 Lubricating oil level is low 2 External leak Diagnosis and Repair 1 Lubricating oil level is low a Check the oil level Add oil if necessary 2 External leak a Ins
43. performing maintenance and service procedures on enclosed generator sets make sure the service access doors are secured open Keep the generator set and the surrounding area clean and free from obstructions Remove any debris from the set and keep the floor clean and dry NOTICE Keep multi class ABC fire extinguishers handy Class A fires involve ordinary combustible materials such as wood and cloth Class B fires involve combustible and flammable liquid fuels and gaseous fuels Class C fires involve live electrical equipment Refer to NFPA No 10 in applicable region 4 A045R242 Issue 2 10 2013 1 IMPORTANT SAFETY INSTRUCTIONS 1 4 Generator Voltage is Deadly e Generator output connections must be made by a trained and experienced electrician in accordance with all applicable codes e This generator set and the public utility may only be connected to house circuits by means of the automatic transfer switch Improper connections can lead to electrocution of utility workers and damage to equipment Make sure that the connections are installed properly by a trained technician e Use caution when working on live electrical equipment Remove jewelry and make sure clothing and shoes are dry Stand on a dry wooden platform 1 5 Engine Exhaust is Deadly e See The Hazards of Carbon Monoxide to learn the symptoms of Carbon Monoxide poisoning e Locate the generator set away from doors windows other openings into the
44. rator set load by powering off to unneccessary household appliances examples washer dryer air conditioning etc 5 14 Code 5134 Unknown Shutdown at Idle Logic The generator set failed to start Possible Causes 1 Fuel supply issue Diagnosis and Repair 1 Fuel supply issue a Check that the manual shutoff valves are open 5 15 Code 5569 Engine Combustion Shutdown Logic Rapid rate of increase of intake manifold temperature detected Possible Causes 1 Intake manifold overpressurization event 2 Faulty TMAP sensor 3 Faulty engine harness Diagnosis and Repair 1 Intake manifold overpressurization event a Inspect the hose couplings between the compressor outlet and intake manifold i Inspect the hose couplings for damage ii Inspect the clamps for damage b Inspect the turbocharger i Externally inspect the turbocharger for damage ii Inspect for loose or missing bolts on the compressor housing c Inspect the mixer i Remove the air cleaner and confirm there are no loose pieces within the mixer A045R242 Issue 2 71 5 Troubleshooting 10 2013 2 Faulty TMAP sensor a Check the intake air temperature with the GCP Display service tool or the intake manifold temperature with InPower Confirm that the value is reasonable 3 Faulty engine harness a Inspect the engine harness and the connector pins b Disconnect the engine harness connector from the extension harness c Inspect for cor
45. red important but not hazard related e g messages relating to property damage General Information This manual should form part of the documentation package supplied by Cummins Power Generation with specific generator sets In the event that this manual has been supplied in isolation please contact your authorized dealer A045R242 Issue 2 1 1 IMPORTANT SAFETY INSTRUCTIONS 10 2013 1 3 NOTICE Its is in the operator s interest to read and understand all warnings and cautions contained in the documentation relevant to the generator set operation and daily mainteance General Precautions e Keep ABC fire extinguishers accessible e Make sure that all fasteners are secure and torqued properly e Keep the generator set and its compartment clean Do not store any items in the generator set compartment e Before working on the generator set 1 Press the Stop Switch and disable AUTO mode 2 Disconnect AC power from any battery chargers 3 Remove the negative battery cable from the battery to prevent it from contacting the battery terminal post e Use caution when making adjustments when the generator set is running hot or when parts are electrically live as all situations may cause personal injury or death e 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 its vapors e Do not
46. refore 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 Special Risks of CO Near the Home Residents can be exposed to lethal levels of CO when the generator set 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 approved and operable CO detector alarms are installed in proper locations in the home as specified by their manufacturer Carbon Monoxide CO gas can cause nausea fainting or death Protecting Yourself From CO Poisoning e Locate the generator in an area where there are no windows doors or other access points into the home e Make sure all CO detectors are installed and working properly e Pay attention for signs of CO poisoning e Check the exhaust system for corrosion obstruction and leaks every time you start the generator set and every eight hours when you run it continuously A045R242 Issue 2 7 1 IMPORTANT SAFETY INSTRUCTIONS 10 2013 This page is intentionally blank 8 A045R242 Issue 2 2 Introduction This generator set is intended for stationary installation for emergency use only 2 1 About this Manual This man
47. rn you Ensure that the generator set engine has cooled down before adding or draining the oil Adding Oil If the oil level is found to be insufficient oil must be added 1 Ensure that the oil fill cap area is clean and prevent debris from entering the engine 2 Add the appropriate amount of oil based on the engine oil level check performed beforehand 3 Recheck the engine oil level Based on the results add or drain oil A045R242 Issue 2 55 4 Maintenance 10 2013 4 Clean up and dispose of any oil in accordance with local state regulations Draining Oil If the oil level is found to be excessive oil must be drained from the engine 1 Detach the oil drain hose from the side of the engine 2 Place the end of the drain hose into an appropriate container Refer to local regulations to determine the appropriate container for used oil e Open the oil drain valve to release oil from the engine into the appropriate container e Recheck the engine oil level Based on the results add or drain oil e When a sufficient amount of oil has been drained from the system 1 Close the oil drain valve 2 Wipe the oil drain valve clean 3 Re attach the drain hose to the side of the engine 4 Dispose of the used oil in accordance with local state regulations Changing Engine Oil and Oil Filter Change the oil more often in hot and dusty environments Some state and federal agencies have determined that used engine oil can be
48. roded pins bent or broken pins pushed back or expanded pins Inspect for evidence of moisture in or on the connector Inspect for missing or damaged connector seals Inspect for dirt or debris in or on the connector pin Disconnect harness from ECM and sensor r ey fe eb Measure the resistance in each pin from ECM to sensor Resistance should be 5 ohms or less i Repair or replace harness as necessary 72 A045R242 Issue 2 www cumminspower com Cummins the C logo and Our energy working for you are trademarks of Cummins Inc Copyright 2013 Cummins Power Generation Inc All rights reserved
49. s EN Units ITS FIGURE 24 BRIGHTNESS AND CONTRAST MENU NAVIGATION NOTICE Adjusting the brightness on the Operator Panel adjusts the brightness of both the LCD backlight and the LEDs on the display The contrast should never be 0 or 100 on any of the screens The default value for Brightness is 50 A045R242 Issue 2 35 3 Control System 10 2013 3 6 History and About Menu To access the History About Menu 1 From any Information Menu hold down the up and down arrows simultaneously for two seconds The Service Menu appears 2 Select History About 3 Advance through the screens to view information about the generator set control and display NOTICE The following screens represent the standard operator panel HMI211 If using an in home operator panel which may be additionally purchased as an option the screens may look slightly different This procedure applies to both operator panels 36 A045R242 Issue 2 10 2013 3 Control System SERVICE MENU 1 Setup Menus 2 History About 3 Screen Adjust 7 More Options 1 2 3 Y HISTORY Starts 1234567 Hours 123456 7 Control Hours 123456 7 B ABOUT GENSET Model Number ABCDEZS ASG ere Control PCC1302 ABOUT GENSET KVA Standby Rating 1200 kVA ABOUT CONTROL P N 3260000 S N A0123456789 SW P N 3260000 SW Version 0 24 ABOUT DISPLAY SW P N 3260000 SCRNE Ver PEA Pah SCRN VER 1 50 DISP DEVICE ID
50. sually check belt for evidence of wear or slippage Check coolant lines and radiator hoses for leaks wear and cracks Visually check for leaks worn or damaged hoses Check radiator air flow Visually inspect the radiator through the guarding for blockage build up of debris signs of wear or damage Clean radiator core S o f Check aftercooler core where fite J o J f Check water pump do o o Check coolant heater has power and is l ae running viele fitted Replace cooling system coolant m Cleaning schedule may be reduced depending on operating See 50 A045R242 Issue 2 10 2013 4 Maintenance TABLE 21 ENGINE MAINTENANCE MAINTENANCE ITEMS Perform maintenance tasks as specified using Daily or 12 Months or Hourly periods of operation Daily or After Weekly or After After whichever occurs first 24 Hours 50 Hours 200 Hours Check engine oil level If low top up to engine specifications level with recommended oil Check fuel lines and hoses Visually check for leaks worn or damaged hoses Check charge alternator Check visually and audibly when the generator set is E o Mec al Replace engine oil and filters engine oil and filters Check engine ground Clean as necessary Check engine mounts Check starting motor Check turbocharger where fitted Check timing belt condition Visually inspect Inspect spark plugs Replace as necessary m
51. t clock for the current date and time 1 Access the Time Setup Menu by selecting Clock Exerciser on the Genset Service Menu 2 Select Adjust When updating these settings the function of the keys are as follows settings on the screen Select the left arrow to return to the previous screen Menu the Adjust button TIME SETUP Date 00 00 00 mm dd yy Time 00 00 AM ADJUST Li bd EL TIME SETUP Date M 00 00 mm dd yy Time 00 00 AM SAVE FIGURE 27 TIME SETUP SCREEN Updating Daylight Saving Adjust Menu To update the Savings Time and Adjustment on the Daylight Saving Adjust Menu 1 Press the down key on the Time Setup Menu to access the Daylight Saving Adjust Menu 2 Select Adjust The horizontal right arrow key is used to select successive blocks for editing Adjust values by using the or keys on the Adjust Menu of the Time Setup Press Save to save any changes After savings the Save button changes to A045R242 Issue 2 10 2013 3 Control System When updating these settings the functions of the keys are as follows e The horizontal right arrow key is used to select successive blocks for editing settings on the screen Select the left arrow to return to the previous screen Adjust values by using the or keys on the Adjust Menu of the Daylight Saving Adjust Menu Press Save to save any changes After savings the Save button changes to the Adjust button Daylight Sa
52. taneously for two seconds from any Info Menu to navigate to the Menu screen Save Saves changes and navigates to the associated screen Adjust Navigates to the Adjust Menu of a specific menu Right Arrow Advances the hightlighted field to the next editable field Decreases value of the highlighted editable field Increases value of highlighted editable field Standard LED Indicators HMI211 The operator panel has six LED indicators Colors flashing frequency and conditions to turn them on off blink are included in the table below TABLE 15 LED INDICATORS Color Action LED Not in Auto Red sd Indicates the generator set is in Manual or Off Mode Shutdown Red sd Indicates a Shutdown Fault has occurred Indicates a Warning Fault has occurred Remote Start Green Indicates that the generator set has received a Remote Start Command Auto Green Indicates that the generator set is in Auto Mode The generator starts when it receives a Remote Start Command Manual Run Green Indicates that the generator set has received a Manual Run Command 3 2 In Home Operator Panel Accessory The in home operator panel kit part number A046K103 is an optional display that may be purchased This panel is intended to serve as a convenient option to the standard operator panel mounted on the generator set 22 A045R242 Issue 2 10 2013 3 Control System O O Oo O Oo BACK STOP O FIGURE 2 IN HOME OPE
53. ual is a guide for the operation of the generator set models listed on the front cover Each operator of this generator set should become familiar with the information in this manual and observe all of the instructions and precautions The purpose of this manual is to provide the user with general operating information This manual provides guidance and assistance with recommendations for correct and safe procedures Cummins Power Generation CPG cannot accept any liability whatsoever for problems arising as a result of following recommendations in this manual The information contained within the manual is based on information available at the time of issue In line with Cummins Power Generation policy of continuous development and improvement information may change at any time without notice The users should therefore make sure that before commencing any work they have the latest information available Consult your authorized dealer for further installation information It is essential that the utmost care is taken with the application installation and operation of any generator set due to their potentially hazardous nature Careful reference should also be made to other Cummins Power Generation literature Should you require further assistance contact your authorized dealer NOTICE This device complies with part 15 of the FCC rules Operation is subject to the following two conditions e This device may not cause harmful interferences
54. ving Adjust Saving Time Disabled Adjust 60 MIN ADJUST d a Daylight Saving Adjust Saving Time Disabled Adjust 60 MIN SAVE F FIGURE 28 DAYLIGHT SAVING ADJUST MENU NAVIGATION To access and update the Daylight Saving Adjust Start Menu 1 Press the down key on the Daylight Saving Adjust Menu 2 Press Adjust When updating these settings the functions of the keys are as follows e The horizontal right arrow key is used to select successive blocks for editing settings on the screen e Use the or keys to edit the following settings Month o Week Day Hour e Press Save to save any changes After savings the Save button changes to the Adjust button A045R242 Issue 2 41 3 Control System 10 2013 Daylight Saving Adjust Start Mth Wk Day Hr O 1 Sun O AM ADJUST v Daylight Saving Adjust Start Mth Wk Day Hr Os Steir SAVE 5 FIGURE 29 DAYLIGHT SAVING ADJUST START MENU To access and update the Daylight Saving Adjust End Menu 1 Press the down key on the Daylight Saving Adjust Start Menu 2 Press Adjust When updating these settings the functions of the keys are as follows e The horizontal right arrow key is used to select successive blocks for editing settings on the screen e Use the or keys to edit the following settings Month o Week Day Hour e Press Save to save any changes After savings the Save button changes to the Adjust button 42 A045R
55. work on the generator set when mentally or physically fatigued or after consuming alcohol or drugs NOTICE Only trained and authorized personnell shall maintain or service the generator set General Safety Precautions Coolants under pressure can cause severe scalding Do not open a radiator or heat exchanger pressure cap while the engine is running Let the engine cool down before removing the coolant pressure cap Turn the cap slowly and do not open it fully until the pressure has been relieved A045R242 Issue 2 10 2013 1 IMPORTANT SAFETY INSTRUCTIONS Moving parts can cause severe personal injury or death and hot exhaust parts can cause severe burns Make sure all protective guards are properly in place before starting the generator set Used engine oils have been identified by some state and federal agencies to cause cancer or reproductive toxicity Do not ingest breathe the fumes or contact used oil when checking or changing engine oil Operation of equipment is unsafe when mentally or physically fatigued Do not operate equipment in this condition or after consuming any alcohol or drug Substances in exhaust gases have been identified by some state and federal agencies to cause cancer or reproductive toxicity Do not breathe in or come into contact with exhaust gases Flammable liquids can cause fire or explosion Do not store fuel cleaners oil etc near the generator set Wear hearing protection when going
56. xercise Frequency To update the exercise frequency and dates on the Clock Exerciser Menu 1 Press Exercise Schdr on the Daylight Saving Adjust End Menu 2 Press Adjust When updating these settings the functions of the keys are as follows e The horizontal right arrow key is used to select successive blocks for editing settings on the screen e Use the or keys to edit the following settings o Schdr Enable Enable or Disable o Exercise Schedule Semi Annual every six months Quarterly Monthly Bi Weekly every two weeks or Weekly o Exercise Schedule Day Hours Minutes AM PM e Press Save to save any changes After savings the Save button changes to the Adjust button Exercise Schdr Schdr Enable Dis Exrc Monthly Tue 02 00 PM ADJUST v 2 Exercise Schdr Schdr Enable Exre 2 Moncey Tue 02 00 PM SAVE FIGURE 32 EXERCISE FREQUENCY NAVIGATION Updating Exercise Duration To update the exercise duration on the Clock Exerciser Menu 1 Press the down key on the Exercise Schdr Menu 2 Press Adjust When updating these settings the functions of the keys are as follows e The horizontal right arrow key is used to select the duration block for editing exercise duration A045R242 Issue 2 45 3 Control System 10 2013 Use the or keys to edit the exercise duration minutes e Press Save to save any changes After savings the Save button changes to the Adjust button Exercise S
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