PCC 3200

Power Generation
Issue 03 March 2002
Standard PCC II Control System
Publication 3526(GB)
FOREWORD
The purpose of this manual is to provide the users with sound, general information. It is for guidance and assistance with recommendations for correct and safe procedures. Cummins Power Generation Limited 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 going to print. In line with Cummins Power Generation Limited policy of continual development and improvement, information may change at any time without notice. The users should therefore ensure that before commencing any work, they have the latest information available. Users are respectfully advised that it is their responsibility to employ competent persons to carry out any installation work in the interests of good practice and safety. It is essential that the utmost care is taken with the application, installation and operation of any diesel engine due to their potentially dangerous nature. Careful reference should also be made to other Cummins Power Generation Limited literature, in particular the Engine Operation and Maintenance Manual. Should you require further assistance contact: -
Cummins Power Generation Limited Manston Park Columbus Avenue Manston Ramsgate Kent CT12 5BF Tel. No.: +44 (0) 1843 255000 Fax. No.: +44 (0) 1843 255902
CONTENTS
Section Title Page
Schedule of Abbreviations ................................................................................................ i 1

1.1 1.2 1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.3 1.4 1.5 1.6 1.7 1.7.1 1.8 1.8.1 1.8.2 1.8.3 1.8.4 1.8.5 1.8.6 1.8.7 1.8.8 1.8.9 1.8.10
Safety
.............................................................................................................. 1-1
Warning, Caution and Note Styles Used In This Manual .............................................1-1 Warnings.....................................................................................................................1-1 Electricity...............................................................................................................1-1 High Pressures......................................................................................................1-1 Maintenance .........................................................................................................1-2 Supply Isolation.....................................................................................................1-2 Reinstatement of Supply .......................................................................................1-2 General Information ....................................................................................................1-3 Radio Frequency.........................................................................................................1-4 Standards, Codes & Regulations ................................................................................1-4 Standards ...................................................................................................................1-5 Generator Plant Safety Code ......................................................................................1-6 Genset Warning Labels.........................................................................................1-6 Safety Precautions......................................................................................................1-7 Engine Warning.....................................................................................................1-7 Exhaust Gas Hazards ...........................................................................................1-7 Fire Hazards .........................................................................................................1-8 Moving Part Hazards.............................................................................................1-9 High Temperature Hazards ...................................................................................1-9 Electrical Hazards .................................................................................................1-9 Noise...................................................................................................................1-11 General ...............................................................................................................1-11 Fluids ..................................................................................................................1-11 Disposal of Engine Waste ...................................................................................1-12
2
2.1 2.2 2.3 2.3.1 2.3.2 2.3.3 2.3.4
Introduction.......................................................................................................... 2-1
General.......................................................................................................................2-1 Generating Set Identification .......................................................................................2-1 After Sales Services....................................................................................................2-2 Maintenance .........................................................................................................2-2 Warranty ...............................................................................................................2-2 Spares ..................................................................................................................2-2 Overseas...............................................................................................................2-2
3
3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 3.1.8 3.2
System Description ............................................................................................. 3-1

Generator Components...............................................................................................3-1 Engine...................................................................................................................3-2 Alternator ..............................................................................................................3-2 Generator Rating...................................................................................................3-2 Generator Construction .........................................................................................3-2 Fuel System ..........................................................................................................3-2 Cooling System .....................................................................................................3-3 Engine Exhaust (Option) .......................................................................................3-3 DC Electrical System.............................................................................................3-3 Control System ...........................................................................................................3-3
Contents
Page i
CONTENTS (continued)
Section 3.3 3.3.1 3.3.2 3.3.3 Title Page Heaters....................................................................................................................... 3-4 Engine Heater (Option) ......................................................................................... 3-4 Alternator Heater (Option)..................................................................................... 3-4 Control Panel Heater (Option)............................................................................... 3-4
4
4.1 4.2 4.3 4.4 4.4.1 4.5 4.5.1 4.5.2 4.5.3 4.6 4.6.1 4.6.2 4.7 4.7.1 4.7.2 4.8 4.8.1 4.8.2 4.8.3 4.9 4.9.1 4.9.2 4.9.3 4.9.4 4.9.5 4.9.6 4.10 4.11 4.11.1 4.11.2 4.11.3 4.11.4 4.12 4.12.1 4.12.2 4.13 4.13.1 4.14 4.14.1 1.1.1 4.15
Operation ..............................................................................................................4-1
Safety ........................................................................................................................ 4-1 Introduction................................................................................................................. 4-1 Maintenance............................................................................................................... 4-1 Control Panel.............................................................................................................. 4-2 Front Panel ........................................................................................................... 4-2 Control Panel Power ON/OFF Modes......................................................................... 4-3 Power On Mode.................................................................................................... 4-3 Screen Saver Mode .............................................................................................. 4-3 Sleep/Awake Mode ............................................................................................... 4-3 Control Panel Assembly ............................................................................................. 4-4 Operator Panel ..................................................................................................... 4-4 Switch Panel ......................................................................................................... 4-5 Locking the Genset Out of Service ............................................................................. 4-7 Introduction........................................................................................................... 4-7 Immobilising the Plant for Safe Working................................................................ 4-7 Operating Recommendations ..................................................................................... 4-8 No Load Operation ............................................................................................... 4-8 Exercise Period..................................................................................................... 4-8 High/Low Operating Temperatures ....................................................................... 4-8 Starting ....................................................................................................................... 4-9 Pre-start Checks ................................................................................................... 4-9 Starting at Switch Panel (Manual Mode) ............................................................. 4-10 Starting at Remote Operator Panel (Auto Mode)................................................. 4-11 Starting from Remote Location (Switch or Device) (Auto Mode) ......................... 4-11 Exercise Start ..................................................................................................... 4-12 Cold Starting with Loads ..................................................................................... 4-12 Running at Idle (Manual) .......................................................................................... 4-13 Stopping ................................................................................................................... 4-15 Emergency Stop (Code 1434)............................................................................. 4-15 Stopping at Switch Panel (Manual Mode) ........................................................... 4-15 Stopping at Remote Operator Panel (Auto Mode)............................................... 4-15 Stopping from Remote Location (Switch or Device) (Auto Mode)........................ 4-16 Menu Display and Switches...................................................................................... 4-16 Graphical Display................................................................................................ 4-16 Menu Buttons...................................................................................................... 4-17 Menu Units Selection................................................................................................ 4-17 Local/Remote Field ............................................................................................. 4-17 Main Menu................................................................................................................ 4-18 Adjust Button ...................................................................................................... 4-18 Set-up Button...................................................................................................... 4-18 Engine Data Submenus............................................................................................ 4-19
Page ii
Contents
Section 4.16 4.16.1 4.16.2 4.16.3 4.16.4 4.16.5 4.17 4.17.1 4.17.2 4.17.3 4.18 4.18.1 4.18.2 4.18.3 4.19 4.20 4.20.1 4.21 Title Page Alternator Data Submenus........................................................................................4-20 Voltage LL and LN...........................................................................................4-20 Amps...................................................................................................................4-20 Frequency ...........................................................................................................4-20 AVR Duty Cycle ..................................................................................................4-20 kW, kVA and PF..................................................................................................4-20 Control Submenu ......................................................................................................4-21 Local Control Submenu Function ........................................................................4-21 Remote Control Submenu Functions...................................................................4-21 Local/Remote Control Submenu Function ...........................................................4-22 History/About Submenus ..........................................................................................4-22 History.................................................................................................................4-22 About ..................................................................................................................4-22 Fault History........................................................................................................4-24 Adjust Sub-menu ......................................................................................................4-25 Bus Data Sub-menu..................................................................................................4-26 Bus Data Status Line...........................................................................................4-26 Password Menu ........................................................................................................4-28
5
5.1 5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6 5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.4 5.4.1 5.4.2 5.4.3 5.4.4 5.5 5.5.1 5.6 5.7 5.8 5.9
Maintenance......................................................................................................... 5-1
General.......................................................................................................................5-2 General Inspection......................................................................................................5-5 Exhaust System ....................................................................................................5-5 Fuel System ..........................................................................................................5-5 AC Electric System ...............................................................................................5-5 DC Electrical System.............................................................................................5-6 Engine...................................................................................................................5-6 Mechanical............................................................................................................5-6 Lubrication System .....................................................................................................5-7 Oil API Classification .............................................................................................5-7 Oil Viscosity ..........................................................................................................5-7 Engine Oil Level ....................................................................................................5-7 Oil and Filter Change ............................................................................................5-7 Starting Procedure After Extended Shutdown or Oil Change.................................5-7 Coolant System...........................................................................................................5-8 Coolant Level ........................................................................................................5-8 Cooling System Maintenance................................................................................5-8 Coolant Heater ......................................................................................................5-9 Heat Exchanger Plugs...........................................................................................5-9 Fuel System................................................................................................................5-9 Fuel Handling Precautions ....................................................................................5-9 Batteries ...................................................................................................................5-10 Air Cleaner................................................................................................................5-10 Fan Bearing Re-lubrication .......................................................................................5-11 AC Generator Bearing Re-lubrication........................................................................5-11
Contents
Page iii
Section Title Page
6
6.1 6.2 6.3 6.4 6.5 6.5.1 6.5.2 6.5.3 6.6 6.6.1 6.6.2 6.7 6.8 6.9 6.9.1 6.9.2 6.9.3 6.9.4
Troubleshooting...................................................................................................6-1
Introduction................................................................................................................. 6-1 Control Unit DC Power Supply.................................................................................... 6-1 Safety Considerations................................................................................................. 6-2 Fault Finding............................................................................................................... 6-3 Status Indicators......................................................................................................... 6-3 Not In Auto Indicator ............................................................................................. 6-3 Shutdown Status Indicator .................................................................................... 6-3 Warning Status Indicator....................................................................................... 6-3 Reading Fault Codes .................................................................................................. 6-4 Reading Fault Codes Using Graphical Display (Optional) ..................................... 6-4 Reading Fault Codes Using Warning/Shutdown Indicators ................................... 6-4 Line Circuit Breaker (Optional).................................................................................... 6-6 Control and Diagnostics Via Network or PC (Laptop) ................................................. 6-6 Fault Codes ................................................................................................................ 6-6 Category A Fault Codes........................................................................................ 6-6 Category B Fault Codes........................................................................................ 6-6 Category C Fault Codes ....................................................................................... 6-6 Category D Fault Codes ....................................................................................... 6-6
APPENDIX: A. Additional Engine Specific Information ............................................. A-i 1

1.1 1.2 1.3 1.3.1 1.3.2 1.3.3
Engine Specific Information............................................................................... A-1

QSX15G8 ...................................................................................................................A-1 QST30G2 ...................................................................................................................A-2 QSK45 and QSK60 ....................................................................................................A-3 Cooling System Sight Glass Fill Locations .........................................................A-4 Fan Bearing Grease Fittings .................................................................................A-5 Fan Belt Replacement ..........................................................................................A-6
Page iv
Contents
Illustrations
Figure Figure 1-1 Figure 2-1 Figure 3-1 Figure 4-1 Figure 4-2 Figure 4-3 Figure 4-4 Figure 4-5 Figure 4-6 Figure 4-7 Figure 4-8 Figure 4-9 Figure 4-10 Figure 4-11 Figure 4-12 Figure 5-1 Figure 5-2 Figure 6-1 Title Page Radio Frequency Warning .............................................................................. 1-4 Typical Genset Rating Plate ........................................................................... 2-1 Typical Genset ............................................................................................... 3-1 Control Panel Assembly (Full Featured) ......................................................... 4-2 Normal start/run/stop sequences .................................................................. 4-14 Graphical Display and Menu Selection Buttons ............................................ 4-16 Units Submenu............................................................................................. 4-17 System Control Main Menus A and B ........................................................... 4-18 Engine Data Sub-menus .............................................................................. 4-19 Alternator Data Sub-menus .......................................................................... 4-20 Control Sub-menu ........................................................................................ 4-21 History/About Sub-menus............................................................................. 4-23 Adjust Sub-menu.......................................................................................... 4-25 Bus Data Sub-menu ..................................................................................... 4-26 Password Menu............................................................................................ 4-28 Coolant Heater ............................................................................................... 5-9 Battery.......................................................................................................... 5-10 Front Control Panel (Full-Featured) ................................................................ 6-5
Tables
Table No. Table 5-1 Table 5-2 Table 6-1 Table 6-2 Title Page Periodic Maintenance Schedule ..................................................................... 5-3 Additional Maintenance Schedule.................................................................. 5-4 Fault Codes.................................................................................................... 6-7 Warning and Shutdown Codes ..................................................................... 6-10
Supplementary Publications The Supplementary Publications appropriate to your system will also be supplied with the system. Where appropriate the corresponding Instruction Manual(s) will also be supplied with any accessory that you order. Title Lead Acid Battery NiCad Battery COSHH Battery Charger Publication No .....................................................................................................................3330 .....................................................................................................................3331 .....................................................................................................................3334 .....................................................................................................................3393
Contents
Page v
Page vi
Contents
Schedule of Abbreviations
AC
ACB ACH ATS AVR BHP BMS BST CB CCA CHP COP CT dB(A) DC DIP DMC DMSU EMCU EMF EPU FSS GCP Genset GKWT HV IC I/O kVA kVAR kW kWh LED LTA LTP LV Alternating Current Air Circuit Breaker Anti-Condensation Heaters Automatic Transfer Switch Automatic Voltage Regulator Brake Horsepower Building Management System Busbar Sensing Transformer Circuit Breaker Cold Cranking Amps Combined Heat and Power Continuous Power Rating Current Transformer Unit of noise level Direct Current Dual In-line Package Digital Master Control Demand Load Standby Unit Engine Monitoring and Control Unit Electromotive Force Engine Protection Unit First Start Sensor Generator Control Panel Generator Set Global Kilowatt Transducer High Voltage Integrated Circuit Input / Output Apparent Power Reactive Power Active / Real Power Unit of electrical energy or work Light-Emitting Diode Low Temperature Aftercooling Limited Time Power Rating Low Voltage MCB MCCB MF MFSS MR MST MSU MV NEC PCC II PCL PF PFC PLC PMG PRP PSU PT/CT QCC RFI RMS RPM RTD V VAC VCB VDC VF VT Miniature Circuit Breaker Moulded Case Circuit Breaker Mains Failed Master First Start Sensor Mains Returned Mains Sensing Transformer Mains Sensing Unit Medium Voltage Neutral Earthing Contact PowerCommand Control System II A low cost power system Power Factor Power Factor Controller Programmable Logic Controller Permanent Magnet Generator Prime Power Rating Power Supply Unit
Potential Transformer / Current Transformer
TM
Quadrature Current Control Radio Frequency Interference Root Mean Square Revolutions Per Minute Resistance Temperature Detector Volts Volts, Alternating Current Vacuum Circuit Breaker Volts, Direct Current Volt-free Voltage Transformer
Page i
Page ii
SECTION 1 PRELIMINARY AND SAFETY 1

1.1
Safety
Warning, Caution and Note Styles Used In This Manual
The following safety styles found throughout this manual indicate potentially hazardous conditions to the operator, service personnel or the equipment. WARNING: WARNS OF A HAZARD THAT MAY RESULT IN SEVERE PERSONAL INJURY OR DEATH. Warns of a hazard or an unsafe practice that can result in product or property damage.
Caution:
Note:
A short piece of text giving information that augments the current text.
1.2
Warnings
WARNING: IT IS IMPORTANT TO READ AND UNDERSTAND ALL SAFETY NOTICES PROVIDED IN THIS MANUAL. IMPROPER OPERATION OR MAINTENANCE COULD RESULT IN A SERIOUS ACCIDENT, OR DAMAGE TO THE EQUIPMENT, CAUSING INJURY OR DEATH.
1.2.1 Electricity
WARNING: ELECTRICITY CAN KILL! LETHAL VOLTAGES MAY BE PRESENT IN MUCH OF THE EQUIPMENT REFERRED TO IN THIS MANUAL.
1.2.2 High Pressures

WARNING: LIQUIDS OR GASES THAT ARE HIGHLY PRESSURISED CAN PASS THROUGH THE SKIN AND INTO THE BODY. THEY CAN ALSO CAUSE DAMAGE TO EQUIPMENT.
Section 1 Preliminary and Safety
Page 1-1
1.2.3 Maintenance
WARNING: ONLY AUTHORISED AND COMPETENT PERSONNEL WHO ARE FAMILIAR WITH THE EQUIPMENT AND ITS OPERATION SHOULD CARRY OUT MAINTENANCE. DEPENDENT UPON THE CONTROL SYSTEM FITTED, THIS UNIT MAY OPERATE AUTOMATICALLY AND COULD START WITHOUT WARNING.
WARNING:
1.2.4 Supply Isolation

Caution: If the engine has been running recently, explosive gases (given off during battery charging) may be present in the vicinity of the batteries. Ensure the area is well ventilated before disconnecting batteries. BEFORE CARRYING OUT ANY MAINTENANCE, ISOLATE ALL SUPPLIES TO THE GENERATOR AND ANY CONTROL PANELS. RENDER THE GENERATOR INOPERATIVE BY DISCONNECTING THE PLANT BATTERY.
WARNING:
1.
Turn the Mode switch on the control panel to Off (O) Manual Auto
2. 3. 4. 5. 6.
Isolate and lock off the supply to the battery charger, where fitted. Disconnect the starting batteries and control system batteries, (if separate). Isolate and lock off the heater control box, where fitted. Isolate the fuel supply to the engine. Fit Warning notices at each of the above points to indicate Maintenance in Progress Plant Immobilised for Safe Working.
1.2.5 Reinstatement of Supply

WARNING: REINSTATE ALL PROTECTIVE DEVICES REMOVED OR DISCONNECTED DURING MAINTENANCE OR OVERHAUL, BEFORE PUTTING THE UNIT BACK INTO SERVICE.
The procedure for reinstatement is the reverse of the procedure for isolation.
Page 1-2
1.3
General Information
Personnel engaged in the installation, commissioning, operation and maintenance of this equipment must be competent and experienced in these fields. They must also comply with all relevant and current statutory requirements and regulations, including the provisions of the Health and Safety at Work Act (1974), and any modification and amendment that may subsequently become a legal requirement. Before operating the genset, read this manual and become familiar with the equipment and its operation (including all controls, manually operated valves and shutdown devices). Correct operation and maintenance is essential for safe and efficient operation of this unit. Read and become familiar with the Safety Precautions listed in this section. Many accidents result from a failure to observe fundamental safety rules and precautions. There are many potential hazards that can occur during the operation of a genset, which cannot always be anticipated. Therefore a warning cannot be included in the manual for every possible circumstance that might involve a potential hazard. Should a procedure be used that has not been specifically recommended, then the personnel involved must be satisfied that it is safe and will not damage the genset.
Page 1-3
1.4
Radio Frequency
The apparatus has been tested according to European Standards EN 50081-2 and BS EN 61000-6-2:1999 (IEC 61000-6-2:1999), specifying the limits of radio frequency immunity and emissions to meet the essential requirements of the EMC directive 89/336/EEC as amended by Directive 92/31/EEC. From these tests the manufacturer has established that as a precaution against undue effects, no radio frequency communications equipment should be operated at a distance of less than three metres from any part of the apparatus when the genset could, or is relied upon to, provide power. The effective separation distance should be increased if the radio frequency communications equipment is found to interfere with the apparatus, the onus lies with the customer to effectively test for adverse effects on the apparatus before usage of the equipment.
NO RADIO FREQUENCY COMMUNICATIONS EQUIPMENT MAY BE OPERATED IN THE VICINITY OF THIS APPARATUS
Figure 1-1 Radio Frequency Warning
1.5
Standards, Codes & Regulations

The genset and its control system, are manufactured under a registered quality control system approved to BS EN ISO 9001 (1994). The following regulations are observed where applicable: The Health & Safety at work Act 1974 The Control of Substances Hazardous to Health Directive 1999, (SI 1999 No. 437) IEE Wiring Regulations for Electrical Installations (16th Edition) The Electricity at Work Regulations 1989 The Environmental Protection Act 1990 The Health & Safety at Work Regulations 1992 The EMC Directive 89/336/EEC as amended by Directive 92/31/EEC The LV Directive 73/23/EEC The Machinery Directive 98/37/EC
Page 1-4
1.6
Standards
The genset and its control system has been designed, constructed and tested generally in accordance with the following Standards where applicable: BS 4999 (IEC 600341) BS 5000 (IEC 600341) BS 5514 (ISO 30462) BS 7671 BS 7698 (ISO 85282) BS EN 50081 (EN 500812) BS EN 61000-6-2: 1999 (IEC 61000-6-2: 19992) BS EN 60439 (IEC 604392) (EN 604392) BS EN 60947 (IEC 9471) (EN 609472) BS EN 60204-1 KEY:
1. A related, but not equivalent, standard: A BSI publication, the content of which to any extent at all, short of complete identity or technical equivalence, covers subject matters similar to that covered by a corresponding international standard. 2. An identical standard: A BSI publication identical in every detail with a corresponding international standard.
General requirements for rotating electrical machines Rotating electrical machines of particular types or for particular applications Reciprocating internal combustion engines: performance Requirements for electrical installations IEE Wiring Regulations (16th Edition) Reciprocating internal combustion engine driven alternating current generating sets Electromagnetic compatibility. Generic emission standard Electromagnetic compatibility. Generic immunity standard Specification for low-voltage switchgear and control gear assemblies Specification for low voltage switchgear and control gear
Safety of Machinery Electrical Equipment of Machines
Page 1-5
1.7
Generator Plant Safety Code

Before operating the genset, read the Operation and Maintenance manual and become familiar with it and the equipment. Safe and efficient operation can be achieved only if the equipment is properly operated and maintained. Many accidents are caused by failure to follow fundamental rules and precautions.
1.7.1 Genset Warning Labels

Warning signs are provided on the genset at the point of risk. To avoid injury, always take the necessary precautions - as indicated on the sample signs shown below: Caution / Warning. Indicates a risk of personal injury.
Caution / Warning of Pressure Hazard. Indicates a risk of personal injury from pressurised fluids.
Caution / Warning of Temperature Hazard. Indicates a risk of personal injury from high temperature.
Caution / Warning of Radio Frequency Hazard. Indicates a risk of operating radio frequency communications equipment in the vicinity of the genset. Caution / Warning of High Voltage Hazard. Indicates a risk of personal injury from electric shock.
Caution / Warning of High Voltage Hazard. Indicates that earth leads only must be connected at this point.
Page 1-6
1.8
Safety Precautions
Copy and post these suggestions in potentially hazardous areas.
1.8.1 Engine Warning

WARNING: DO NOT OPERATE A DIESEL ENGINE WHERE THERE ARE, OR CAN BE, COMBUSTIBLE VAPOURS. THESE VAPOURS CAN BE SUCKED THROUGH THE AIR INTAKE SYSTEM AND CAUSE ENGINE ACCELERATION AND OVERSPEEDING, WHICH CAN RESULT IN A FIRE, OR AN EXPLOSION. WHERE AN ENGINE, DUE TO ITS APPLICATION, MIGHT OPERATE IN A COMBUSTIBLE ENVIRONMENT, SUITABLE OVERSPEED SHUTDOWN DEVICES MUST BE FITTED. THE EQUIPMENT OWNER AND OPERATOR ARE RESPONSIBLE FOR SAFE OPERATION IN A HOSTILE ENVIRONMENT. CONSULT YOUR INFORMATION. AUTHORISED DEALER FOR FURTHER
1.8.2 Exhaust Gas Hazards

WARNING: RISK FROM TOXIC FUMES
Exhaust fumes are toxic and all necessary measures must be taken to ensure that they do not escape into, or re-circulate within, the plant room or associated buildings. Visually and audibly inspect the exhaust system as detailed in Section 5 Maintenance Schedule. Ensure that all exhaust components are secured and true (not warped). Do not use exhaust gases to heat a compartment. Ensure that the genset is kept well ventilated. Thoroughly ventilate the genset plant room to remove all fumes and explosive vapours before disconnecting or connecting battery cables thus reducing the possibility of accidental sparks causing an explosion. Ensure that the exhaust outlet is kept free from obstruction. Should repeated attempts to start the engine fail, unburnt fuel gas may build up in the exhaust system creating a potentially dangerous situation. Allow these gases to disperse before carrying out further attempts to start.
Page 1-7
Benzene and lead found in some diesel oils have been identified as causing cancer or reproductive toxicity. When checking, draining or adding diesel, take care not to ingest, breathe the fumes, or contact diesel. Used engine oils have been identified as causing cancer or reproductive toxicity. When checking or changing engine oil, take care not to ingest, breathe the fumes or contact used oil.
1.8.3 Fire Hazards

WARNING: RISK OF FIRE
With the use of fuel, lubricating oils and batteries there is a fire hazard. Naked flames or sparks should not be allowed near the genset, fuel tank and battery. Explosive fuel and oil vapours are always present in the vicinity of a genset, while a battery on charge can produce inflammable hydrogen gas. An area in the vicinity of the genset should be designated a NO SMOKING area and one that is prohibited to unauthorised persons. Ensure that adequate ventilation is maintained within the plant room at all times. Thoroughly ventilate the genset plant room to remove all fumes and explosive vapours before disconnecting or connecting battery cables thus reducing the possibility of accidental sparks causing an explosion. No loose items of equipment or combustible material should be left on or near any part of the genset. Remove all unnecessary oil and grease from the unit and clean up fuel and oil spills immediately. In the event of a fuel or oil leak, the spillage should be absorbed using a proprietary material (e.g. Fullers Earth granules, or similar). Sawdust should not be used, as this will create a fire hazard. Appropriate fire fighting equipment should be readily available - (CO2 or BCF type fire extinguishers are recommended). Inspect the fuel system before each operation and periodically while running. Do not refill the fuel tank while the genset is running. Keep a fire extinguisher available in or near the plant room and in other areas throughout the site. Use the correct extinguisher for the area.
Page 1-8
1.8.4 Moving Part Hazards

WARNING: RISK OF INJURY
Safety guards and covers must be securely fitted and all cubicle doors, coverplates, etc., should be firmly in place while the genset is in operation. Keep hands and loose clothing away from moving parts. Do not wear jewellery while servicing any part of the genset. Never step on the genset. It can stress and break unit components, possibly resulting in dangerous operating conditions from leaking fuel, leaking exhaust fumes, etc. Before performing any maintenance on the genset, disconnect its batteries to prevent accidental starting. Thoroughly ventilate the genset plant room to remove all fumes and explosive vapours before disconnecting or connecting battery cables thus reducing the possibility of accidental sparks causing an explosion. Avoid contact with any moving part.
1.8.5 High Temperature Hazards

WARNING: RISK OF BURNING AND SCALDING
While the genset is running, and for a period following shutdown, avoid contact with exhaust, radiator and other components that are likely to become hot. At all times, avoid contact with hot oil, hot coolant and hot exhaust gases. Hot coolant is under pressure. DO NOT attempt to remove a radiator or heat exchanger pressure cap while the genset is running. Always allow the genset to cool completely before doing so. DO NOT drain coolant or lubricating oil until the genset has cooled completely.
1.8.6 Electrical Hazards

WARNING: RISK FROM ELECTRIC SHOCK
The genset should only be connected to loads compatible with its electrical characteristics and rated output. Only suitably trained and qualified engineers, who are authorised to do so, should connect the genset load. Connection must also be in compliance with relevant codes and standards.
Page 1-9
The metalwork of the generating plant, bed frame and other exposed parts must be bonded to an effective earth point. Do not touch any electrically energised parts of the genset or cables/conductors with any part of the body or with any non-electrically insulated object. Do not operate the genset with any terminal box cover open. Ensure that all connections are insulated. Ensure that all electrical equipment and connections are kept clean and dry. Replace any defective terminal covers and wiring immediately and ensure that all terminations are secure. Reinstate all protective devices removed or disconnected during maintenance or overhaul, before putting the genset back into service. The appropriate neutral earthing requirements must be complied with, or adequate means incorporated to ensure that an isolated neutral system is adequately protected against voltage rises and undetected earth faults. In the situation where the genset is operated in parallel with a network supply, the user must be satisfied that the neutral earthing switch gear (where fitted), is operational and that the associated protection devices are fully functional. Permission must have been obtained from the local electricity supply utility, before parallel operation is considered. Before carrying out any maintenance, isolate all supplies to the genset and any control panels. Render the genset inoperative by disconnecting the plant battery see also Section 4.7 Locking the Genset Out of Service. To prevent irreparable damage to the battery charging system: Never disconnect the battery whilst the plant is running Never disconnect the charging leads whilst the plant is running Disconnect the battery and charge alternator before electric arc welding on the plant
Note: The charge alternator output lead is live at all times. Follow all applicable electrical safety codes. Do not work on this equipment when mentally or physically fatigued, or after consuming any alcohol or drug that makes the operation of equipment unsafe.
Page 1-10
1.8.7 Noise
WARNING: RISK OF DAMAGE TO HEARING
Gensets emit noise. It is recommended that the personnel exposed to noise should wear adequate protection, e.g. ear defenders.
1.8.8 General
WARNING: RISK OF INJURY
On gensets that can be started automatically or from a remote location, a warning plate should be displayed prominently, advising personnel that The Plant may start automatically without warning. Appropriate personal protective equipment should be worn when working on the genset or on any associated equipment. Information on first aid procedures and facilities should be displayed near the plant. The area around the genset should be clear of obstructions and dangerous objects. In addition, the floor should be kept clean, dry and clear of oil deposits. Maintenance work, particularly in confined areas, should be carried out by a minimum of two operators working together. Never lift the genset using the engine or alternator lifting lugs. Refer to the lifting recommendation drawings Lifting Ilus series. Only lifting devices of suitable capacity should be used.
1.8.9 Fluids
WARNING: RISK OF TOXIC CHEMICALS
There is a health risk associated with exposure to fuel, lubricating oils, coolant additives and battery electrolyte. Avoid contact with these fluids and always wear the appropriate personal protective equipment. Reference should be made to the (Control of Substances Hazardous to Health) COSHH Publication No. 3334, supplied with this manual. Avoid fluid spillage and discard clothing contaminated by fuel oil, coolant, lubricants or battery electrolyte. Ensure that remote fuel storage systems are installed in compliance with relevant codes, standards and local requirements.
Page 1-11
The user should also contact their supplier of fluids used in the genset for Manufacturers recommendation on Health & Safety.
1.8.10 Disposal of Engine Waste

WARNING: INCORRECT DISPOSAL OF ENGINE WASTE IS ENVIRONMENTALLY HARMFUL AND PRESENTS A HEALTH RISK. SOME ENGINE WASTE IS COMBUSTIBLE AND IS THEREFORE A FIRE RISK.
Dispose of unwanted or absorbed substances through an authorised contractor who will transport and correctly dispose of the waste to a licensed site. For further information refer to the COSHH Publication No. 3334, supplied with this manual.
Page 1-12
SECTION 2 - INTRODUCTION 2
2.1
Introduction
General
Before any attempt is made to operate the generator, the user should take time to read this manual and to familiarise him or herself with the Warnings and Operating Procedures.
2.2
Generating Set Identification

Each generating set is provided with a Generating Set Rating Plate as shown below. This provides information unique to the generator.
Figure 2-1
Typical Genset Rating Plate
Section 2 Introduction
Page 2-1
2.3
After Sales Services

We offer a full range of after sales services as follows:
2.3.1 Maintenance
For customers who wish to have their gensets expertly serviced at regular intervals the Customer Service Department offers a complete maintenance contract package. This covers all items subject to routine maintenance and includes a detailed report on the condition of the genset. In addition, this can be linked to a 24-hour call-out arrangement, providing assistance 365 days a year if necessary. Specialist engineers are available to maintain optimum performance levels from customers gensets, and it is recommended that maintenance tasks are only undertaken by trained and experienced engineers provided by the Customer Service Department
2.3.2 Warranty
All gensets have a twelve months warranty from the commissioning date as standard. Extended warranty coverage is also available. In the event of a breakdown prompt assistance can normally be given by factory trained service engineers with facilities to undertake all minor and many major repairs to equipment on site.
2.3.3 Spares
An extensive Spare Parts Department is available for any emergency breakdown and for the engineer who carries out his own routine maintenance. Please quote Plant Nos., Serial Nos., and Part Nos. when ordering spares.
2.3.4 Overseas
Agents and representatives in almost 100 countries throughout the world offer installation and after sales service for the equipment provided. We can provide the name and address of the agent for your specific location. For details on any of the above services contact your distributor.
Page 2-2
Section 2 Introduction
SECTION 3 SYSTEM DESCRIPTION 3

3.1
System Description
Generator Components
The main components of a typical Generator System are shown below. Refer to the Engine and Alternator Manuals for location of other components, e.g. oil filler, dipstick, etc. Various options are available although they may not be available for all models. Note that the Load Terminal Box, item 9, is mounted optionally on the left or right side and includes the load connection gland plate (with optional entry point location).
Figure 3-1
Typical Genset
KEY: 1. 2. 3. 4. 5. 6. 7. 8. Radiator Exhaust Outlets Air Cleaners Control Housing Load Output Circuit Breaker (LH/RH) Generating Set Rating Plate (LH/RH) Alarm Module (Option) PowerCommand Control II Panel 9. 10. 11. 12. 13. 14. 15. Load Terminal Box (LH/RH) Bedframe Alternator Starter Motor Coolant Heater (Option) Engine Oil Filters (RH side)
Section 3 System Description
Page 3-1
3.1.1 Engine
All generators employ a 4-stroke, water-cooled engine and incorporate a governor control and full engine protection system. Refer to the Generating Set Rating Plate for engine type and rating details. For further information refer to the Engine manufacturers Operation and Maintenance Manual supplied with this manual.
3.1.2 Alternator
All generator types use AC alternators of a brushless, rotating field design, which eliminates the maintenance associated with slip rings and brushes. Refer to the Generating Set Rating Plate for alternator type and rating details. For further information refer to the Alternator manufacturers Installation, Service and Maintenance Manual supplied with this manual.
3.1.3 Generator Rating

For details of your generator rating refer to the Generating Set Rating Plate.
3.1.4 Generator Construction

Generators are constructed as a single module with the engine and alternator connected through a coupling chamber with resilient mountings to form one unit. The engine and alternator are mounted on a bedframe on resilient mountings. This results in one unit of immense strength and rigidity, with accurate alignment between the engine and alternator, and effective damping of engine vibration.
3.1.5 Fuel System

A base fuel tank formed from fabricated sheet sections can be provided as an option. The tank is fitted with a large filler cap with in-built coarse filter, and provides a minimum of eight hours operation at a nominal 100% load. Free standing main tanks with stands providing 450, 900 and 1350 litre capacity are available as options.
3.1.5.1 Fuel Transfer Pumps (Option)

Free standing fuel tanks can be filled manually using an optional hand fuel transfer pump. Alternatively, fuel tanks (base tank or free standing) can be filled automatically using an electrical fuel transfer pump. This pump, which is supplied complete with starter, operates under the control of Low and High Fuel Level switches fitted to the tank. On automatically filled systems, the base tank filler cap is replaced with an overflow / breather connection to allow piping to a safe area or return to a bulk tank.
3.1.5.2 Fuel / Water Separators (Option)

Optional Set-mounted fuel / water separators are available to provide protection for the engine fuel injection system where water-free fuel supplies cannot be guaranteed.
Page 3-2
3.1.6 Cooling System

The engine cooling system consists of a radiator and pusher fan, mechanically driven water pump and a thermostat. The fan drives air through the radiator and removes surface heat from the engine and alternator. The alternator has its own internal cooling fan.
3.1.7 Engine Exhaust (Option)

Exhaust systems, which are optional and supplied in loose form, reduce engine noise to acceptable levels and pipe exhaust gases to an area where they will not present a hazard. Industrial and residential types are available as options. Flexible bellows are also available as an option.
3.1.8 DC Electrical System

A 12 or 24 volt battery system (determined by generator type) provides multi-attempt engine starting and DC power for the generator control system.
3.1.8.1 Battery System

Battery type, size and voltage are selected to suit the generator capacity and application on ordering and include lead acid and NiCad types. (All types are options). Lead acid batteries are Set-mounted. NiCad batteries are free standing.
3.1.8.2 Charge Alternator

An engine driven charge alternator is provided as standard to maintain the battery in a charged condition when the engine is running.
3.1.8.3 Mains Powered Battery Charger (Option)

Optional single phase, mains powered battery chargers, which can be panel or wall mounted, are available to maintain the battery in a charged condition when the generator is not running.
3.2
Control System
The Control Panel is a micro-processor based control unit for monitoring and protecting the genset. The Control Panel Assembly consists of two panels, the Operator Panel and the Switch Panel. The Switch Panel must be mounted on the genset whilst the Operator Panel may be situated up to 4,000 ft (1.2km) away from the genset. In addition to the many control, annunciation, automatic voltage regulator and governor functions, the PCC II can easily be upgraded to communicate over a PowerCommand Network, or work as part of a paralleling system.
Page 3-3
3.3
Heaters
Caution: Heater(s) must not be energised if the coolant system has been drained.
3.3.1 Engine Heater (Option)

The engine heater is designed to keep the engine coolant warm when the engine is shut down. It heats and circulates the coolant within the engine, reducing start-up time and engine wear caused by cold starts. The engine mounted engine heater isolator switch should normally be left in the On position. When the engine is running, heater operation is controlled automatically by a relay and thermostat. WARNING: ALWAYS ISOLATE THE SUPPLY TO THE ENGINE HEATER / THERMOSTAT BEFORE CARRYING OUT ANY MAINTENANCE ON THE ENGINE. ALWAYS ISOLATE THE GENSET PRIOR TO ANY MAINTENANCE. The engine heater is in no way intended to protect the engine and cooling system from freezing in sub zero conditions. If there is any danger from freezing, then a suitable antifreeze agent must be added to the cooling system.
Caution:
3.3.2 Alternator Heater (Option)

The alternator heater is designed to keep the alternator free of condensation when the genset is not running. During cool and humid conditions, condensation can form within the alternator, which can create flashing and a shock hazard. The alternator heater is supplied with power via the engine heater isolator switch, which should normally be left in the On position as heater operation is controlled automatically by a relay and thermostat. WARNING: ALWAYS ISOLATE THE ALTERNATOR HEATER FROM THE AC SUPPLY BEFORE WORKING ON THE ALTERNATOR OR HEATER.
3.3.3 Control Panel Heater (Option)

The control panel heater provides a means of humidity/temperature control within the control box interior. It protects the components and ensures their effectiveness when the genset is subjected to varying ambient air conditions during extended periods of non-use. The control panel heater is supplied with power via the engine heater isolator switch, which should normally be left in the On position as heater operation is controlled automatically by a relay and thermostat. WARNING: ALWAYS ISOLATE THE CONTROL PANEL HEATER FROM THE AC SUPPLY BEFORE WORKING ON THE CONTROL PANEL OR HEATER.
Page 3-4
SECTION 4 SYSTEM OPERATION 4

4.1
Operation
Safety
Only suitably qualified and experienced personnel should carry out genset operations. Before operating the system, the operator should become familiar with Section 1 of this manual Preliminary and Safety instructions. Observe the following WARNINGS and CAUTIONS at all times. WARNING: BEFORE OPERATING THE PLANT BECOME FAMILIAR WITH THE EQUIPMENT AND HOW IT IS OPERATED (INCLUDING ALL CONTROLS, MANUALLY OPERATED VALVES AND ALARM DEVICES). SAFE AND EFFICIENT OPERATION CAN ONLY BE ACHIEVED IF THE PLANT IS OPERATED CORRECTLY.
WARNING:
CONTACTING HIGH VOLTAGE COMPONENTS CAN CAUSE ELECTROCUTION, RESULTING IN SEVERE PERSONAL INJURY OR DEATH. DO NOT OPEN THE GENERATOR OUTPUT BOX WHILE THE GENSET IS RUNNING. READ AND OBSERVE ALL WARNINGS AND CAUTIONS IN YOUR GENSET MANUALS.
Caution:
Only technically qualified personnel should open the PCC II front panel. Voltages are present which can cause electrical shock, resulting in personnel injury. Even with power removed, improper handling of components can cause electrostatic discharge and damage circuit board components.
4.2
Introduction
This section describes the operation of the PCC II genset control, covering pre-start checks, starting and stopping, and operating the genset. The text should be read in conjunction with the System Description, and the Engine and Alternator Operating Manuals. All indicators, control switches / buttons and graphical display are located on the face of the Control Panel as illustrated in Figure 4-1.
4.3
Maintenance
To secure maximum performance and reliability from your genset it is essential that certain components are inspected periodically and, where necessary, maintenance procedures carried out as detailed in Section 5 - Maintenance.
Section 4 System Operation
Page 4-1
4.4
Control Panel
4.4.1 Front Panel
OPERATOR PANEL
SWITCH PANEL
REMOTE START, NOT IN AUTO, SHUTDOWN, WARNING STATUS INDICATORS ANALOG AC METERING PANEL PANEL LAMP/ LAMP TEST BUTTON FAULT ACKNOWLEDGE BUTTON EMERGENCY STOP PUSH BUTTON
DISPLAY MENU SELECTION BUTTONS (1 of 6) GRAPHICAL DISPLAY
EXERCISE BUTTON & INDICATOR
MANUAL RUN/ STOP BUTTON & INDICATOR 0/MANUAL/AUTO SWITCH
Figure 4-1
Control Panel Assembly (Full Featured)
Page 4-2
4.5
Control Panel Power ON/OFF Modes

The power on/off modes of the control panel and operating software are Power On, Screen Saver and Sleep/Awake.
4.5.1 Power On Mode

In this mode, power is continuously supplied to the control panel. The controls operating software and control panel LEDs/graphical display will remain active until the Screen Saver mode is activated.
4.5.2 Screen Saver Mode

Power to the graphical display will be removed after ten minutes (genset not running or running). The ten minute timer resets and begins after each control panel action (any button or switch selection) or signal received by the operating software. The bottom LEDs of the Analog AC Metering Panel (bar graphs) may remain on during Screen Saver mode, indicating that the operating software is active (Awake mode). When a Warning signal is sensed by the PCC II, (for example, Low Coolant Temp), the control will display the warning message. The control will remain active until the Fault Acknowledge button is pressed to clear the warning message and start the ten minute timer.
4.5.3 Sleep/Awake Mode

In the Sleep mode, the controls operating software is inactive and the LEDs and the graphical display on the control panel are all off. Sleep mode is a feature that is used to reduce battery power consumption when the control is in the Auto mode and is not being used. When all conditions are met (i.e., no unacknowledged faults, Screen Saver Mode is active, and O/Manual/Auto switch is in the Auto position) the Sleep mode will be activated. The operating software is initialised and the control panel LEDs and graphical display are turned on in response to one of the following: Moving / pressing any control panel switch / button A remote start input signal (genset in Auto mode) Customer fault 2 or 3 only (Shutdown or Warning indicator is on)
To activate the control and view the menu display without starting the genset, press any button on the control panel. The InPower service tool is required to enable or disable the Sleep mode. When shipped from the factory, the Sleep mode is disabled. When disabled, the operating software will always remain active (Awake mode) when the control is in Auto mode. Note: The InPower service tool is required in order to select the desired mode. Contact an authorised Service Centre for assistance.
Page 4-3
4.6
Control Panel Assembly

The control panel assembly (Figure 4-1) consists of two panels, the Operator Panel and the Switch Panel. The control panel assembly is a free-standing cabinet and must be located near the Genset. Dependent on site requirements, the Operator Panel may be mounted in the control panel assembly (fullfeatured) as shown in Figure 4-1, or may be contained in a separate enclosure and mounted remotely of the control panel assembly. Note: The function of several buttons on the operator panel will vary dependent on the location of the operator panel (remote or local of the control panel assembly). If the function differs, it is noted as either Remote or Local Operator Panel in the button description.
4.6.1 Operator Panel

The operator panel contains the following components:
4.6.1.1 Analog AC Metering Panel:

This panel simultaneously displays 3phase line to line AC volts and current, kW, power factor and frequency. The meter panel is composed of a series of LEDs that are configured in bar graphs for each function. The LEDs are colour coded, with green indicating normal range values, amber for Warning levels and red for Shutdown conditions. Scales for each function are in % of nominal values. Resolution is 1% for values close to nominal, and increases at values further from nominal.
4.6.1.2 Graphical Display:

The graphical display is capable of displaying up to nine lines of data with approximately 27 characters per line. The display is used to view the menus of the menudriven operating system. (Refer to the menu trees later in this section). The display is also used to show Warning and Shutdown messages/error codes, modes of operation (Figure 4-3) and system actions, such as Warning, De-rate, Shutdown, etc. Display Menu Selection Buttons: Six momentary buttonsthree on each side of the graphical display windoware used to navigate through the system control menus and to adjust genset parameters. The button is active when the message adjacent to the button is highlighted (displayed in inverse video).
Page 4-4
4.6.2 Switch Panel

WARNING: SOME PANEL INTERNAL COMPONENTS MAY HAVE LIVE EXPOSED TERMINATIONS EVEN IF THE GENERATOR SET IS NOT RUNNING. ISOLATE ALL EXTERNAL ELECTRICAL SUPPLIES PRIOR TO ACCESS OF THE CONTROL PANEL.
The switch panel contains the following components:
4.6.2.1 Emergency Stop Button:

Push the button in for Emergency Shutdown of the engine. If the engine is not running, pushing the button in will prevent the starting of the engine, regardless of the start signal source (local or remote). To reset: 1. Pull the button out. 2. Turn the O/Manual/Auto switch to Off (O). 3. Press the front panel Fault Acknowledge button. 4. Select Manual or Auto, as required.
4.6.2.2 Remote Start Indicator:

This green lamp is lit whenever the control is receiving a Remote Run signal. When this lamp is flashing, it indicates a load demand stop mode.
4.6.2.3 Not in Auto Indicator:

This red lamp flashes continuously when the O/Manual/Auto switch is not in the Auto position. (If it is in the Auto position and the lamp is flashing, this indicates that a service is required.)
4.6.2.4 Shutdown Status Indicator:

This red lamp is lit whenever the control detects a Shutdown condition. The genset cannot be started when this lamp is on. After the condition is corrected, Shutdown indicators can be reset by turning the O/Manual/Auto switch to the Off (O) position, and pressing the Fault Acknowledge button. Dependent upon the specific fault that occurs, the engine may or may not shut down immediately. A fault that could cause engine damage, causes an immediate engine shutdown (bypasses engine cooldown sequence). All other faults would allow the engine to run during the cooldown sequence before engine shutdown.
4.6.2.5 Warning Status Indicator:

This yellow lamp is lit whenever the control detects a Warning condition. After the condition is corrected, warning indicators can be reset by pressing the Fault Acknowledge button. (It is not necessary to stop the genset if the fault becomes inactive during genset operation.)
Page 4-5
4.6.2.6 Fault Acknowledge:

Press this button to acknowledge Warning and Shutdown messages after the fault has been corrected. To acknowledge a Warning message, the O/Manual/Auto switch can be in any position. (It is not necessary to stop the generator set to acknowledge an inactive Warning condition.) To acknowledge a Shutdown message with this button, the O/Manual/Auto switch must be in the Off (O) position. This button is also used to blink a fault code if the Shutdown or Warning Status Indicator is lit. (This function is used when the control does not contain a graphical display.) Refer to Reading Fault Codes in Section 6 -Troubleshooting, which describes how to use this button for interpreting fault codes.
4.6.2.7 Panel Lamp/Lamp Test Button:

Press this button to turn the panel lamp on or off. Press and hold down this button for a minimum of three seconds to turn all control panel LEDs on, to make sure all lamps illuminate. The illumination will shut off after releasing the button.
4.6.2.8 Exercise Button:

Press this button to initiate a pre-programmed exercise sequence. The O/Manual/Auto switch is used in conjunction with this button to enable this function (refer to section 4.9.5 Exercise Start).
4.6.2.9 Manual Run/Stop Button:

This button starts and stops the set locally and will bypass Time Delay to Start and Stop sequences. The O/Manual/Auto switch must be in the Manual position to enable this button.
4.6.2.10 O/Manual/Auto Switch:

Manual position enables the use of the switch panel Manual Run/Stop button. Auto position enables start/stop control of the engine from a remote location. (Disables the use of the switch panel Manual Run/Stop button.) Off (O) position prevents the starting of the set (local or remote). If moved to Off (O) during set operation, an immediate engine shutdown will be initiated (bypasses cool down timers). This hot shutdown should be avoided, if possible, to help reduce unnecessary engine wear. Hot shutdowns are logged by the system software. An optional key function may be provided to prevent unauthorised operation of the switch.
Page 4-6
4.7
Locking the Genset Out of Service
4.7.1 Introduction
Before any work is carried out for maintenance, etc., the plant must be immobilised. Even if the plant is put out of service using the Mode switch in the Off position on the control panel, the plant cannot be considered safe to work on until the engine is properly immobilised as detailed in the following procedures. WARNING: BEFORE CARRYING OUT ANY MAINTENANCE, ISOLATE ALL SUPPLIES TO THE GENERATOR AND ANY CONTROL PANELS. RENDER THE GENERATOR INOPERATIVE BY DISCONNECTING THE PLANT BATTERY. If the engine has been running recently explosive gases (given off during battery charging) may be present in the vicinity of the batteries. Ensure the area is well ventilated before disconnecting batteries.
Caution:
4.7.2 Immobilising the Plant for Safe Working

Note: Shutdown the engine first, as described in Section 4.11 Stopping.
To immobilise the engine: 1. Turn the Mode switch on the control panel to Off (O). Manual Auto
2. 3. 4. 5. 6. 7.
Remove the key from the Mode switch and account for all other keys for safekeeping, (if applicable). Isolate and lock off the supply to the battery charger, where fitted. As an additional precaution, disconnect the starting batteries and control system batteries, (if separate). Isolate and lock off the heater control box, where fitted. Isolate the fuel supply to the engine. Fit warning notices at each of the above points to indicate Maintenance in Progress Plant Immobilised for Safe Working.
Page 4-7
4.8
Operating Recommendations
4.8.1 No Load Operation

Periods of off-load operation should be held to a minimum. If it is necessary to keep the engine running for long periods of time when no electric output is required, best engine performance will be obtained by connecting a load of at least 30% rated load, but not to exceed rated load. Such a load could consist of heater element or load bank.
4.8.2 Exercise Period

Gensets on continuous standby must be able to go from a cold start to being fully operational in a matter of seconds. This can impose a severe burden on engine parts. Regular exercising keeps engine parts lubricated, prevents oxidation of electrical contacts and in general helps provide reliable engine starting. Exercise the genset at least once a week for a minimum of 30 minutes with load so the engine reaches normal operating temperatures.
4.8.2.1 Starting Procedure After Extended Shutdown or Oil Change

After each oil change, or if the genset has not been exercised within the past seven days, the lubricating system must be primed to ensure that the engine receives the correct oil flow through the lubricating system to minimise engine wear. To prime the lubricating system, start the engine by selecting the Idle Mode. Allow the engine to run between five to ten minutes at idle, but no more than ten minutes. (Refer to Running at Idle procedure in Section 4.10 of this manual.) Note: If the Operator Panel is mounted remotely, the Running at Idle mode cannot be selected. Use the Manual Run button on the switch panel to start the engine in Idle mode (refer to Starting at Switch Panel in Section 4.9.2). Using the Manual Run button, the engine will start in Idle mode, but note that the engine will go to rated speed after warmup.
4.8.3 High/Low Operating Temperatures

Use a coolant heater if a separate source of power is available. The optional heater available from Cummins will help provide reliable starting under adverse weather conditions. Be sure the voltage of the separate power source is correct for the heater element rating.
Page 4-8
4.9
Starting
The following headings cover the systems used to start the genset. Figure 4-2 provides a flow chart for each of the four Start/Run/Stop sequences.
4.9.1 Pre-start Checks

Before starting, be sure competent personnel have made the following checks to ensure that the unit is ready for operation: Lubrication - Check the engine lubrication oil level and ensure that the level is always maintained as detailed in the engine Operation and Maintenance Manual Coolant - Check the engine coolant level and ensure that the level is always maintained at the coolant expansion tank. Fill the cooling system to the bottom of the fill neck in the radiator fill or expansion tank. Do not check while the engine is hot Some radiators have two fill necks, both of which must be filled when the cooling system is drained Do not attempt to remove a radiator pressure cap while the generator is running, or is stationary but hot. Always allow it to cool before removing.
Note:
Caution:
Cooling Air Inlet / Outlets - Ensure that the cooling air inlets/outlets are unobstructed Exhaust Outlet - Ensure that exhaust components are secured and not warped; that the exhaust outlet is unobstructed; that no combustible materials are near the system, and gases are discharged away from building openings. Ensure that there are no leaks and that all fittings are tight Fuel Supply - Ensure that the fuel tank is filled to the normal level and that the fuel system is primed and all the valves required for operation are open. Ensure that there are no leaks and that all fittings are tight Batteries Ensure that the batteries are charged, that the electrolyte is at the correct level and that all connections are correct Auxiliary AC Supplies - Ensure that all auxiliary equipment is receiving power from the Load Terminal Box Emergency Stop/Fire Detection Equipment - Ensure that all related equipment is fully operational
Page 4-9
4.9.2 Starting at Switch Panel (Manual Mode)

WARNING: ENSURE THAT ALL PRE-START CHECKS ARE CARRIED OUT BEFORE STARTING THE GENSET. DO NOT ATTEMPT TO START THE GENERATOR UNTIL IT IS SAFE TO DO SO. WARN ALL OTHERS IN THE VICINITY THAT THE SET IS ABOUT TO START. One operator should be in complete charge, or working under the direction of someone who is. Remember that, upon starting the engine, cables and switchgear will become energised, possibly for the first time. Furthermore, equipment that does not form part of the generator installation may become electrically charged. Only authorised and competent personnel should carry out this work. Do not use an Emergency Stop switch to shut down an engine unless a serious fault develops. The Emergency Stop push-switch must not be used for a normal shut-down, as this will prevent a cooling down run in which the lubricating oil and engine coolant carry heat away from the engine combustion chamber and bearings in a safe manner. Avoid off-load running for other than short periods. A minimum loading of 30% is recommended. This loading will help to prevent the build up of carbon deposits in the injectors, due to unburned fuel, and reduce the risk of fuel dilution of the engine lubricating oil. The engine must be shutdown as soon as possible after the appropriate functions have been checked.
Caution:
Caution:
Caution:
Turn the O/Manual/Auto switch to the Manual position and press the Manual Run/Stop button. This will activate the engine control system and the starting system. The starter will begin cranking, and after a few seconds the engine will start and the starter will disconnect. In the Manual position, the control will not complete the Time Delay to Start or Time Delay to Stop (Figure 4-2), but will complete the Warmup at Idle and Cooldown at Rated/Idle. When the coolant reaches operating temperature or the Warmup at Idle Time Delay is reached (0 to 300 seconds), whichever occurs first, the genset will ramp to rated speed and voltage. If the engine does not start, the starter will disengage after a specified period of time and the control will indicate an Overcrank Shutdown. The genset can be configured for a number of starting cycles (one to seven) and duration of crank and rest periods. Default setting is for three start cycles composed of fifteen seconds of cranking, and fifteen seconds of rest. Note: The InPower service tool is required to change the number of crank cycles, and the crank and rest times. Contact an authorised service centre for assistance.
Page 4-10
To clear a Fail To Start Shutdown, place the O/Manual/Auto switch in the Off (O) position and press the Fault Acknowledge button. Wait a minimum of two minutes for the starter motor to cool and then repeat the starting procedure. If the engine does not run after a second attempt, refer to Section 6Troubleshooting.
4.9.3 Starting at Remote Operator Panel (Auto Mode)

WARNING: ENSURE THAT ALL PRE-START CHECKS ARE CARRIED OUT BEFORE STARTING THE GENSET. DO NOT ATTEMPT TO START THE GENERATOR UNTIL IT IS SAFE TO DO SO. WARN ALL OTHERS IN THE VICINITY THAT THE SET IS ABOUT TO START.
When the operator panel is mounted remotely of the control panel assembly, the Start button of the Control submenu can also be used to start the genset. The function of this Start button is identical to the Starting from Remote Location (nonemergency sequence, Figure 4-2). Refer to Control Submenu (Section 4.17) for additional information. Note: The O/Manual/Auto switch must be in the Auto position to activate the Remote Menu Buttons of the Control submenu.
4.9.4 Starting from Remote Location (Switch or Device) (Auto Mode)

Place the O/Manual/Auto switch in the Auto position. This allows the genset to be started from a remote switch or device (e.g., transfer switch). There are two Start modes that are selectable for the Remote Start input, one for nonemergency start and the other for emergency start. Figure 4-2 illustrates how the Start/Run/Stop sequence differs between the two modes. In response to the Remote Run signal, the control lights the Remote Start indicator and initiates the starting sequence described in Section 4.9.2 (Starting at Switch Panel), except for the following: In the Auto position, the control will complete the Time Delay To Start (0 to 300 seconds) for a nonemergency start signal and the Time Delay To Stop (0 to 600 seconds) for an emergency or nonemergency start signal (see Figure 4-2). Note: Refer to Adjust submenu (Section 4.13.1) to change the Time Delay settings.
Page 4-11
4.9.5 Exercise Start

Press and hold down the Exercise button and turn the O/Manual/Auto switch from Auto to Manual and back to Auto, or from Manual to Auto. This will activate the engine control system to complete a preprogrammed exercise sequence. The sequence (Figure 4-2) will vary accordingly to the settings/selections of the system control parameters. Note: The InPower service tool is required to modify these parameters. Contact an authorised service centre for assistance.
The exercise sequence may include running at idle speed, ramping to rated speed, running for a predetermined period of time and timed shutdown. During the exercise operation, the LED lamp adjacent to the Exercise button will light. To manually stop the exercise operation before completion, press the Exercise button. The set will complete its normal cooldown sequence. The control will indicate that the set is in a cooldown mode by flashing the exercise LED. All exercise functions are disabled when a remote start signal is received by the control.
4.9.6 Cold Starting with Loads

Use a coolant heater if a separate source of power is available. The optional heater available from Cummins will help provide reliable starting under adverse weather conditions. Be sure the voltage of the separate power source is correct for the heater element rating.
Page 4-12
4.10 Running at Idle (Manual)

Caution: Avoid off-load running for other than short periods. A minimum loading of 30% is recommended. This loading will help to prevent the build up of carbon deposits in the injectors, due to unburned fuel, and reduce the risk of fuel dilution of the engine lubricating oil. The engine must be shutdown as soon as possible after the appropriate functions have been checked If the engine coolant temperature becomes too low, 140 F (60 C), raw fuel from incomplete combustion will wash the lubricating oil off the cylinder walls and dilute the crankcase oil. Under these conditions, not all the moving parts of the engine will receive the correct amount of lubrication.
Caution:
Note:
The Run at Idle mode is selectable only when the operator panel is mounted on the control panel assembly.
The Run Mode can be set to Rated or Idle with the set running or not running. To manually select the engine Idle function, the O/Manual/Auto switch must be in the Manual position. Once selected and the set is manually started, the control will limit the engine idle time to ten minutes. When the ten-minute Idle cycle is complete, the genset will ramp to rated speed. To activate the Idle function, refer to Section 4.16.1-Local Control Submenu Function. When the engine Idle function is enabled, the control automatically sets lower oil pressure Warning and Shutdown trip points to reflect the lower operating speed. When the engine Idle function is removed and the set reverts to normal operating speed, the control automatically resets oil pressure Warning and Shutdown trip points to the normal settings.
Page 4-13
Figure 4-2
Normal start/run/stop sequences
Page 4-14
4.11 Stopping
4.11.1 Emergency Stop (Code 1434)
The emergency stop button is located on the upper right side of control panel (Figure 41). Push the button in for emergency stop. The red Shutdown status LED will light, and the graphical display message will be: EMERGENCY STOP 1434 - SHUTDOWN To reset: 1. Pull the button out. 2. Turn the O/Manual/Auto switch to Off (O). 3. Press the front panel Fault Acknowledge button. 4. Select Manual or Auto, as required. Note: Emergency Stop shutdown status can be reset only at the operator control panel.
4.11.2 Stopping at Switch Panel (Manual Mode)

If the set was started at the switch panel (O/Manual/Auto switch in the Manual position), pressing the Manual Run/Stop button will cause the set to complete its normal (Local Start) shutdown sequence. The pre-set Cooldown time (at rated speed) can vary dependent on the kW output. That is, if prior to shutdown, the kW is 10% or less of rated, the control software considers this output as Cooldown and will subtract this time from the pre-set Cooldown Timer. The set will stop after the Cooldown at Idle Timer (zero to ten minutes) has timed out. (If necessary, the set will continue to run after timeout until coolant reaches normal operating temperature.) Moving the O/Manual/Auto switch to the Off (O) position will cause an immediate engine shutdown (bypass Cooldown At Idle) and display a Cooldown Interrupted Warning message. This hot shutdown should be avoided, if possible, to help prolong the reliability of the engine. Hot shutdowns are logged in the system software.
4.11.3 Stopping at Remote Operator Panel (Auto Mode)

When the operator panel is mounted remotely of the control panel assembly, the Stop button of the Control submenu can also be used to stop the generator set (O/Manual/Auto switch in the Auto position). The function of this Stop button is identical to the Stopping from Remote Location (non-emergency sequence, Figure 4-2). Refer to Control Submenu for additional information. Note: The O/Manual/Auto switch must be in the Auto position to activate the Remote Menu Buttons of the Control submenu.
Page 4-15
4.11.4 Stopping from Remote Location (Switch or Device) (Auto Mode)

If the control receives a Remote Stop signal (O/Manual/Auto switch in the Auto position), the set will complete its normal shutdown sequence. There are two start modes that are selectable for the Remote Start input, one for nonemergency start and the other for emergency start. Figure 4-2 illustrates how the Start/Run/Stop sequence differs between the two modes. Note that the stop sequence is the same for either mode. The set will stop after completing the following Cooldown sequence: Time Delay To Stop (zero to 300 seconds) Cooldown At Idle (zero to ten minutes) or longer, if necessary, to obtain normal operating temperature before shutdown.
Refer to Section 4.19 Adjust Submenu to change the Time Delay To Stop setting. The InPower service tool is required to modify the Cooldown At Idle. If necessary, contact an authorised service centre for assistance.
4.12 Menu Display and Switches

Figure 4-3 shows the graphical display and the menu selection buttons.
4.12.1 Graphical Display

The graphical display is capable of displaying up to nine lines of data with approximately 27 characters per line. The display is used to view the menus of the menudriven operating system. (Refer to the menu trees later in this section). The display is also used to show the following system information: State Line - modes of operation, such as Stopped, Time Delay to Start, Warm Up at Idle, etc. (see Figure 4-2), and paralleling operations, such as Standby, Dead BUS Close, Synchronise, etc. Action Line - system actions, such as Warning, De-rate, Shutdown Cooldown and Shutdown, and fault codes. Description Line - Fault code/status messages.
STATE LINE ACTION LINE DESCRIPTION LINE MENU DISPLAY AREA
GRAPHICAL DISPLAY
MENU BUTTONS
MENU BUTTONS
Figure 4-3
Graphical Display and Menu Selection Buttons
Page 4-16
4.12.2 Menu Buttons

Six momentary buttonsthree on each side of the graphical display windoware used to navigate through the system control menus and to adjust generator set parameters. The button is active when the message or symbol adjacent to the switch is highlighted (displayed in inverse video). The displayed message or symbol indicates the function of the button. Note: In the graphical display, the symbol indicates that selecting the adjacent button causes the operating program to go to the next menu displayas shown in the menu diagrams. In the graphical display, the symbol indicates that selecting the adjacent button causes the operating program to go back to the previous menu display. In the graphical display, the symbol indicates that selecting the adjacent button causes the operating program to go back to Main Menu A (Figure 4-5).
4.13 Menu Units Selection

During any control panel operation, you can change how units are displayed by pressing the two lower menu buttons (one on each side of display). When pressing these two buttons simultaneously, the units submenus will appear (Figure 4-4). After selecting the desired units, press the ENTER button in this submenu to change and save the selections. Note: Use the + button to select the desired option for each field. Use the arrow () button to move to the next field. Selected field is highlighted.
LOCATION TEMP PRESS FLD PRESS GAS FLOW AIR
LOCAL 8F PSI INHG CFM
ENTER
Figure 4-4
Units Submenu
4.13.1 Local/Remote Field

This selection must be set to Local, when the graphical display is mounted on the generator set front control panel, or Remote when mounted remotely of the genset. The Local/Remote selection determines which buttons in the Control submenu (Section 4.17) are active (displayed). Temp: Used to select F or C for temperature readings. Pressure Fluid: Used to select PSI, KPa, BAR or IN for pressure readings. Pressure Gas: Used to select INHG or MMHG for pressure readings. Flow Air: Used to select CFM or CMM for airflow readings.
Page 4-17
4.14 Main Menu

Figure 4-5 shows the main menus (Menu A and Menu B) of the system control. The two main menus are used to divide the system submenus into major categories, such as, Engine Data, Alternator Data, Control, etc. To view system data, simply press the appropriate menu button to select the category. After pressing the desired menu button, refer to the page number shown in Figure 4-5 for detailed information related to the selected category.
MENU A
MENU BUTTONS PAGE 3-13 ENGINE PAGE 3-14 ALTERNATOR CONTROL MORE>> _\_ HISTORY/ABOUT See Above MENU B MENU BUTTONS
PAGE 3-15
PAGE 3-16
MENU B
PAGE 3-17 ADJUST BUS DATA SETUP BACK<< PAGE 3-18
Service Manual
GRAPHICAL DISPLAY
MENU A
Figure 4-5
System Control Main Menus A and B
4.14.1 Adjust Button

The Adjust submenu is intended for competent site personnel only. Note that a password may be assigned to allow only authorised operators to modify this data. (Password is not required if not assigned.)
1.1.1 Set-up Button

The Set-up submenu is described in the Service manual and is intended for competent service personnel only. For this reason, a password must be entered before this data can be modified. Note: The Adjust and Set-up submenus can be viewed, but not modified without entering the correct passwords. _\_ Button: (Paralleling applications only). Used to open and close the generator set circuit breaker (CB). The symbol indicates if the CB is opened or closed. Opened _\_, push to close. Closed _-_, push to open.
Page 4-18
With the control panel O/Manual/Auto switch in the Auto position, the opening and closing of the CB is controlled by the control system software. The CB symbol will indicate an open or closed CB, but the button will be inactive when the control is in Auto. In the Manual position, the CB can only be closed by using this button. When manually closed and the CB opens, it must be closed again by using this button. To close the CB, press and hold the button until the symbol indicates a closed CB. (CB close will occur only when set-up conditions allow - dead bus or generator synchronised with bus.) Note: In the following figures, the boxed/highlighted field indicates that the adjacent menu button is active. Also, the submenus are shown in the order in which they are displayed when scrolling up, or when scrolling down.
4.15 Engine Data Submenus

If you press the ENGINE DATA button in Menu A, the Engine Data submenus will appear (Figure 4-6). The first submenu displays general information that applies to all gensets (coolant temp, oil pressure, etc.) The data in the remaining submenu(s) will vary according to the type and number of sensors provided with the engine.
ENGINE DATA
COOLANTTEMP OIL PRESSURE ENGINE SPEED BATTERY
180 75 1800 29.1
F PSI RPM VDC
MANF TEMP 75 F MANF PRESSABS 180 INHG RAIL PRESSABS 180 PSI PUMP PRESSABS 291 PSI FUEL INLETTEMP 172 F COOLANTPRESSURE 59 PSI
BLOWBY FLOW 25 CFM TIMING PRESS 50 PSI AFTERCOOLERTEMP 76 F AMBIENT PRESS 88 INHG
Figure 4-6
Engine Data Sub-menus
Page 4-19
4.16 Alternator Data Submenus

If the ALTERNATOR DATA button in Menu A is pressed, the Alternator Data submenus appear (Figure 4-7).
4.16.1 Voltage LL and LN

Indicates voltage Lineto Line and LinetoNeutral. Note that the LinetoNeutral column will not be displayed for a 3-phase/3-wire system. Accuracy 1%. The voltage LinetoLine (L1, L2 and L3) are measured between L1 to L2, L2 to L3 and L3 to L1, respectively.
ALTERNATOR DATA
V L-L L-N AMPS L1 480 277 1340 L2 480 277 1290 L3 480 277 1260 FREQUENCY 60.0 HZ AVR DUTY CYCLE 10.3 %
L1 L2 L3 TOT
kW 350 350 350 1050
kVA 500 500 500 1500
PF .80 .80 .80 .80
Figure 4-7
Alternator Data Sub-menus
4.16.2 Amps
All phases. Accuracy 1%.
4.16.3 Frequency
Genset output frequency.
4.16.4 AVR Duty Cycle

Displays voltage regulator (drive) level in percentage of maximum.
4.16.5 kW, kVA and PF

Displays generator set kW and kVA output (average and individual phase, and direction of flow) and power factor with leading/lagging indication. Accuracy 5%. Note: The PF reading will contain an asterisk if the power factor is leading (e.g., *.30).
Page 4-20
4.17 Control Submenu

If the CONTROL button in Menu A is pressed, the Control submenu will appear (Figure 48).
4.17.1 Local Control Submenu Function

When the operator panel is mounted on the control panel assembly, the Run Mode Idle/Rated button is active (displayed). Note in Figure 4-8 that this button is not displayed in remote applications. The shaded area in Figure 4-8 displays the selected/active mode of operation, (Idle or Rated). Note: Run Mode Idle/Run at Rated Button: Refer to Section 4.10 for a complete description of the Run at Idle mode.
4.17.2 Remote Control Submenu Functions

When the operator panel (Figure 4-1) is mounted remotely of the control panel assembly, the menu buttons in the Control submenu are used to perform the following remote operations.(To activate these menu buttons for Remote/Local use, refer to Section 4.13.1). Note: The O/Manual/Auto switch must be in the Auto position to activate the Remote Menu Buttons of the Control submenu.
CONTROL (Local)
RUN MODE IDLE BARGRAPH TEST
CONTROL (Remote)
START GENSET FAULT ACKNOWLEDGE
BARGRAPH TEST
Figure 4-8
Control Sub-menu
Page 4-21
4.17.2.1 Remote Start or Stop Button:

This button is used to Start and Stop the genset when the operator panel is mounted in a remote location. For additional information refer to the Starting at Remote Operator Panel (Section 4.9.3) and Stopping at Remote Operator Panel (Section 4.11.3). When the genset is operating, Stop will be displayed for this button and Start will be displayed when not operating.
4.17.2.2 Fault Acknowledge Button:

Used to reset inactive Warning messages, not Shutdown messages.
4.17.3 Local/Remote Control Submenu Function

4.17.3.1 Bargraph Test:
The function of this button remains the same and is not dependent on operator panel location. This button sequentially lights the LEDs to test the bar graph display.
4.18 History/About Submenus

If the HISTORY/ABOUT button in Menu A is pressed, the History/About submenus will appear (Figure 4-9).
4.18.1 History
The control maintains a data log of the number of engine starts and number of operating hours for the engine and control, and the megawatt and maximum torque hours of the genset. This information is stored in non-volatile memory and will not be deleted due to loss of battery power.
4.18.2 About
The About submenus provide the following genset information: Genset model and wattage (kW/MW) Output voltage and WYE, DELTA or SINGLE Frequency 50 or 60 Hz Rating: Standby, Prime or Base Version level of the controller and panel operating software
Page 4-22
HISTORY/ABOUT
STARTS ENGINE HOURS CONTROL HOURS KWHRS
533 1236 7879 890
HISTORY-HRS@ %MAX TORQUE 12345@0-9 23455@50-59 12345@10-19 12345@60-69 12345@20-29 12345@70-79 12345@30-39 12345@80-89
MODEL 1750DQKB VOLTAGE 416 WYE FREQUENCY 60 RATING STANDBY
CONTROLLER VERSION RTOP DN30008.DFA BATS FEB 15 1999 OP PANEL VERSION RTOP 1.08 JUN 4 1999 BATS 1.02 MAY 6 1999
FAULT HISTORY: 1 OF 24 CNTL HOURS 459 OCCURRENCES 5 ENGINE HOURS 334 FAULT CODE 1437 ( FAULT DESCRIPTION )
Figure 4-9
History/About Sub-menus
Page 4-23
4.18.3 Fault History

The control maintains a data log of all fault conditions as they occur, and time stamps them with the control and engine operating hours. Up to 32 (unacknowledged) fault codes can be stored in control panel memory. Following Fault acknowledgement and correction, it is deleted from the control panel memory. However, it remains in a data log that maintains the fault code history: the InPower service tool is required to view this data log. The Fault History display line: 1 of 24 indicates that 24 faults are recorded and that the most recent fault (1) detected by the controller is displayed. The Occurrences display line: In this example, 5 indicates that this is the fifth occurrence of this fault. (The InPower service tool is required to review the last four faults of this code.) Note: The Occurrences number is incremented for each new occurrence of the same fault. The controller must detect that the original sensed fault is corrected before it will increment the occurrence number for that fault. For example, when a Low Oil Pressure fault is detected, the controller will increment the Occurrences number by 1. This fault will remain active until the controller detects that the fault is corrected. An active fault will prevent the controller from incrementing the Occurrences number each time the engine is started. When the controller detects that the oil pressure is normal the fault will become inactive, allowing the occurrences number to be incremented for the next detected Low Oil Pressure fault.
Page 4-24
4.19 Adjust Sub-menu

If the ADJUST button in Menu B is pressed, the Adjust submenu will appear (Figure 410). The Adjust submenu is intended for competent service personnel and site personnel only and may require a USER password. If a password is required, the USER password menu will appear when you try to modify the Adjust submenu. (Refer to PASSWORD Menu in Section 4.21 to enter password). Changes are automatically saved when you exit this menu. Note: Use the + and - buttons to increase or decrease the values in the following fields. Use the arrow () button to move the cursor within a field or to the next field. Selected field is highlighted. Used to adjust the output voltage 5%. Used to adjust the frequency 3 Hz. This delay applies only to remote starting in the Auto mode. The Start Delay adjustment range is 0 to 300 seconds. This delay applies only to remote stopping in the Auto mode. The Stop Delay adjustment range is 0 to 600 seconds.
VOLTAGE: FREQUENCY: START DELAY: STOP DELAY:
ADJUST
+ -
ADJUST: VOLTAGE 208 FREQ 60.0 HZ START DELAY STOP DELAY
1.2 -0.0 5 11
% HZ SEC SEC
Figure 4-10
Adjust Sub-menu
Page 4-25
4.20 Bus Data Sub-menu

If the ADJUST button in Menu B is pressed, the Bus Data submenu will appear (Figure 411). This menu is displayed in paralleling applications only.
4.20.1 Bus Data Status Line

The top line of the graphical display is used to indicate the following BUS DATA status: STANDBY DEAD BUS CLOSE: SYNCHRONIZE: LOAD SHARE: LOAD GOVERN: Indicates first genset in system to close to bus. Genset is synchronising to bus. Genset Bus closed and load shared with other gensets in system. Genset closed to bus in parallel with utility (mains).
BUS DATA
LOAD GOVERN V BUS GEN L1 480 480 L2 480 480 L3 480 480 HZ 60.1 60.1 DEG -122 NOT SYNCHRONIZING
_\_
Figure 4-11
Bus Data Sub-menu
BUS Voltage LL: The BUS voltage LinetoLine (L1, L2 and L3) are measured between L1 to L2, L2 to L3 and L3 to L1, respectively. BUS/GEN HZ: BUS/GEN hertz. BUS/GEN SYNC STATUS: The bottom line of the graphical display is used to indicate the following BUS/GEN Sync status: NOT SYNCHRONIZING: Genset is in service mode that does not allow auto sync feature. SYNCHRONISE: READY TO CLOSE: _\_ Button: Genset is synchronising to bus. In manual mode, push circuit breaker close button to close breaker. (Paralleling applications only). Used to open and close the genset circuit breaker (CB). The symbol indicates if the CB is opened or closed. Opened _\_, push to close. Closed _-_, push to open.
Page 4-26
With the control panel O/Manual/Auto switch in the Auto position, the opening and closing of the CB is controlled by the control system software. The CB symbol will indicate an open or closed CB, but the button will be inactive when the control is in Auto. In the Manual position, the CB must be closed by this button. When manually closed and the CB opens, it must be closed again by using this button. To close the CB, press and hold the button until the symbol indicates a closed CB. (CB close will occur only when set-up conditions allow - dead bus or generator synchronised with bus).
Page 4-27
4.21 Password Menu

When viewing the Adjust submenu, pressing either the + or - button will display the Password menu (Figure 4-12) if a User password is assigned to this field. After entering the correct password, the system will allow you to modify the submenu. To prevent unauthorised adjustment, the entered password is valid for only ten minutes after the last button is pressed. Note: Application Password is intended only for competent service personnel to allow adjustment of Set-up submenu parameters.
To enter the password: 1. Display Adjust submenu. 2. Press either the + or - button within the displayed submenu. The Password menu appears. (Adjustment is allowed if Password menu does not appear.) 3. Press the + and - button to select the first character of the User password (A-Z or 0-9). 4. Press the button to select the next character field. Selected character field is highlighted. 5. Repeat steps 3 and 4 to enter remaining password characters. 6. Press the Enter button after entering the password. The Adjust submenu will reappear. 7. Exit Adjust submenu to save changes.
+ OR - BUTTON
+ -
ENTER USER PASSWORD (OR) ENTER APPLICATION PASSWORD ENTER XXXXXXXX
Figure 4-12
Password Menu
Page 4-28
SECTION 5 MAINTENANCE 5 Maintenance

Maintenance work, particularly in confined areas, should be carried out by two engineers working together. Ensure that adequate lighting and staging (where required) are installed. WARNING: BEFORE CARRYING OUT ANY MAINTENANCE WORK LOCK OFF FOR SAFE WORKING: 1. SELECT THE MODE SWITCH ON THE SET CONTROL PANEL TO OFF. 2. ISOLATE ALL SUPPLIES TO THE GENERATOR. 3. ISOLATE THE BATTERY CHARGER. 4. DISCONNECT THE BATTERY. 5. REMOVE THE STARTER CONTROL WIRES. 6. A SUITABLE WARNING PLATE STATING MAINTENANCE IN PROGRESS SHOULD BE DISPLAYED PROMINENTLY.
WARNING:
ACCIDENTAL STARTING OF THE GENSET WHILE WORKING ON IT CAN CAUSE SEVERE PERSONAL INJURY OR DEATH. PREVENT ACCIDENTAL STARTING BY DISCONNECTING THE STARTING BATTERY LEADS (NEGATIVE [-] FIRST). ENSURE BATTERY AREA HAS BEEN WELL-VENTILATED BEFORE SERVICING THE BATTERY. ARCING CAN IGNITE EXPLOSIVE HYDROGEN GAS GIVEN OFF BY BATTERIES, CAUSING SEVERE PERSONNEL INJURY. ARCING CAN OCCUR WHEN LEADS ARE REMOVED OR REPLACED, OR WHEN THE NEGATIVE (-) BATTERY LEAD IS CONNECTED AND A TOOL USED TO CONNECT OR DISCONNECT THE POSITIVE (+) BATTERY LEAD TOUCHES THE FRAME OR OTHER GROUNDED METAL PART OF THE GENSET. ALWAYS REMOVE THE NEGATIVE (-) LEAD FIRST AND RECONNECT LAST. MAKE CERTAIN HYDROGEN FROM THE BATTERY, ENGINE FUEL AND OTHER EXPLOSIVE FUMES ARE FULLY DISSIPATED. THIS IS ESPECIALLY IMPORTANT IF THE BATTERY HAS BEEN CONNECTED TO A BATTERY CHARGER.
WARNING:
SOME PANEL INTERNAL COMPONENTS MAY HAVE LIVE EXPOSED TERMINATIONS EVEN IF THE GENSET IS NOT RUNNING. ISOLATE ALL EXTERNAL ELECTRICAL SUPPLIES PRIOR TO ACCESS OF THE CONTROL PANEL.
Section 5 Maintenance
Page 5-1
Caution:
Always disconnect a battery charger from its AC source before disconnecting the battery leads. Failure to do so can result in voltage spikes high enough to damage the DC control circuits of the genset Only authorised and qualified maintenance engineers, who are familiar with the equipment and its operation, should carry out maintenance. Before carrying out any maintenance work, become familiar with the Generator Plant Safety Code given in Section 1 of this manual.
Caution:
Caution:
5.1
General
Establish and adhere to a definite schedule for maintenance and service based on the application and severity of the environment. The table below covers the recommended service intervals for a generator set on STANDBY service. If the 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 the following: Use for continuous duty (prime power) Extremes in ambient temperature Exposure to elements Exposure to salt water Exposure to windblown dust or sand.
Consult with an authorised distributor if the genset will be subjected to any extreme operating conditions and determine a suitable schedule of maintenance. Use the running time meter to keep an accurate log of all service performed for warranty support. Perform all service at the time period indicated or after the number of operating hours indicated, whichever comes first. Use Tables 51 and 5-2 to determine the maintenance required and then refer to the sections that follow for the correct service procedures. Refer also to the Cummins Engine Operation and Maintenance Manuals, and alternator Operation and Maintenance Manuals.
Page 5-2
Table 5-1
Periodic Maintenance Schedule
MAINTENANCE ITEMS
General set inspection Check engine oil level Check coolant level of radiator(s) (water jacket & LTA) Check coolant heater(s) Check battery charging system Check all hardware (fittings, clamps, fasteners, etc.) Check drive belt Check battery electrolyte level Drain exhaust condensate trap Check generator air outlet Check radiator hoses for wear and cracks Grease fan bearing Test generator insulation resistance Grease generator bearing Check air cleaner (replace as necessary) Drain fuel filter(s) Check antifreeze and DCA concentration Change engine oil and filter Change water jacket coolant filters Clean crankcase breather Change fuel filters Clean water jacket & LTA cooling systems
1 2
SERVICE TIME See Daily Monthly 6 Yearly Specific or after or after Months or after Engine 8 Hours 100 or after 500 Manual Hours 250 Hours Hours 1 2 X X X X X X X X X X X
3
1000 Hours
4000 Hours
X X 4 X X X X X
1 1 1 1 5
X 1 X 1 X 1 X X
1
X Refer to the Cummins Engine Operation and Maintenance Manuals for maintenance interval and/or procedure. X Check for oil, fuel, cooling and exhaust system leaks. Check exhaust system audibly and visually with set running and repair any leaks immediately. X Visually check belt for evidence of wear or slippage. Replace if hard or brittle. X This procedure should be followed periodically throughout the life of the generator set, or if the generator has sat idle for a period of time with no generator heaters used. Contact your authorised service centre. X Lubricate the bearing according to the alternator manufacturers instructions. These instructions are contained within the alternator manufacturers Operation & Maintenance Manual provided with the generator.
5 4 3
Page 5-3
Table 5-2
Additional Maintenance Schedule
ITEM
Set Electrics
TASK
Clean battery terminals and re-grease Check fuel solenoid and linkage Check all electrical connections Clean all apertures (with vacuum cleaner) Grease bearings if required Check all ventilation points Perform any maintenance tasks specified in the Alternator Installation, Service and Maintenance Manual Clean the alternator Check circuit breaker contacts and check power cable connections for security Carry out a Lamp Test Check all fuses and tripping devices Clean the control panel Check security of all fixings as required Check plant room for cleanliness Have set / panel inspected by manufacturer Check air inlets / outlets for freedom from obstruction Run the set on-load at least 30% load Check anti-vibration mounts Check all systems functioning Check operation of Emergency Stop
Weekly / 10 hours
Monthly / 100 hours

l
Yearly / 200 hours

l
l l X l X l l l l l l l l l X l l l
4 5 5
Alternator
Control Panel
General
Test Run
X This procedure should be followed periodically throughout the life of the genset, or if the generator has sat idle for a period of time with no generator heaters used. Contact your authorised service centre. X Lubricate the bearing according to the alternator manufacturers instructions. These instructions are contained within the alternator manufacturers Operation & Maintenance Manual provided with the generator.
5
Page 5-4
5.2
General Inspection
During operation, be alert for mechanical problems that could create unsafe or hazardous conditions. The following sections cover several areas that should be frequently inspected for continued safe operation.
5.2.1 Exhaust System

With the genset operating, inspect the entire exhaust system visually and audibly including the exhaust manifold, muffler, and exhaust pipe. Check for leaks at all connections, welds, gaskets and joints, and ensure that exhaust pipes are not heating surrounding areas excessively. If any leaks are detected, shut down the genset and have the leaks corrected immediately. WARNING: INHALATION OF EXHAUST GASES CAN RESULT IN SERIOUS PERSONAL INJURY OR DEATH. BE SURE DEADLY EXHAUST GAS IS PIPED OUTSIDE AND AWAY FROM WINDOWS, DOORS OR OTHER INLETS TO BUILDINGS.
5.2.2 Fuel System

With the genset operating, inspect the fuel supply lines, return lines, filters, and fittings for leaks. Check any flexible sections for cuts, cracks and abrasions and ensure they are not rubbing against anything that could cause breakage. If any leaks are detected, have them corrected immediately. WARNING: IGNITION OF FUEL CAN CAUSE SERIOUS PERSONAL INJURY OR DEATH BY FIRE OR EXPLOSION. DO NOT PERMIT ANY FLAME, CIGARETTE, OR OTHER IGNITER NEAR THE FUEL SYSTEM.
WARNING:
ENGINE FUEL ACTUATORS CAN OPERATE AT VOLTAGES UP TO 140 VOLTS DC.
5.2.3 AC Electric System

Check the following while the genset is operating: Frequency: AC Voltage: AC Ammeter: Panel Lamps: The generator frequency should be stable and the reading should be the same as the set nameplate rating. At no load, the linetoline voltage(s) should be the same as the set nameplate rating. At no load, the current readings should be zero. With a load applied, each line current should be similar. Press and hold down the Panel Lamp/Lamp Test button on the control panel. All indicator lamps should light. Verify that all lamps are on and then release the button. Contact an authorised service centre if any lamps are burnt out.
Page 5-5
5.2.4 DC Electrical System

Check the terminals on the battery for clean and tight connections. Loose or corroded connections create resistance, which can hinder starting. Clean and reconnect the battery cables if loose. Always disconnect both ends of the negative battery cable. Reconnect one end of the cable to the negative battery terminal and the other end to ground. This will ensure that any arcing will be away from the battery and least likely to ignite explosive battery gases. WARNING: IGNITION OF EXPLOSIVE BATTERY GASES CAN CAUSE SEVERE PERSONAL INJURY. DO NOT SMOKE WHILE SERVICING BATTERIES.
5.2.5 Engine
Monitor fluid levels, oil pressure, and coolant temperatures frequently. Refer to the Cummins engine Operation and Maintenance Manual for recommended operating pressures and temperatures. Most engine problems give an early warning. Look and listen for changes in engine performance, sound, or appearance that can indicate service or repair is needed. Some engine changes to look for are as follows: Misfire Vibration Unusual noises Sudden changes in engine operating temperatures or pressures Excessive exhaust smoke Loss of power An increase in oil consumption An increase in fuel consumption Fuel, oil, or coolant leaks.
5.2.6 Mechanical
WARNING: ACCIDENTAL STARTING OF THE GENERATOR SET CAN CAUSE SEVERE PERSONAL INJURY OR DEATH. TURN THE CONTROL SWITCH TO THE STOP POSITION AND DISCONNECT THE NEGATIVE (-) BATTERY CABLE BEFORE INSPECTING THE GENERATOR SET.
With the genset stopped, check for loose belts and fittings, leaking gaskets and hoses, or any signs of mechanical damage. If any problems are found, have them corrected immediately. With the set running, listen for any unusual noises that may indicate mechanical problems and check the oil pressure frequently. Investigate anything that indicates possible mechanical problems.
Page 5-6
5.3
Lubrication System
Note: Gensets are shipped filled with the correct type and quantity of oil. Be sure to check oil level before initial start.
5.3.1 Oil API Classification

Refer to the Cummins Engine Operation and Maintenance Manual for lubricating oil classification.
5.3.2 Oil Viscosity

Refer to the Cummins Engine Operation and Maintenance Manual for lubricating oil recommendations/specifications.
5.3.3 Engine Oil Level

Check the engine oil level during engine shutdown periods at the intervals specified in the Maintenance Table 5-1. The dipstick is stamped with high and low marks to indicate the level of oil in the crankcase. For accurate readings, shut off the engine and wait approximately fifteen minutes before checking the oil level. This allows oil in the upper portion of the engine to drain back into the crankcase. WARNING: CRANKCASE PRESSURE CAN BLOW OUT HOT OIL AND CAUSE SEVERE BURNS. DO NOT CHECK OIL WHILE THE GENERATOR SET IS OPERATING.
Keep the oil level as near as possible to the high mark on the dipstick but never above it. Remove the oil fill cap and add oil of the same API viscosity and brand when necessary. Install the oil fill cap after adding oil. Caution: Do not operate the engine with the oil level below the low mark or above the high mark. Overfilling can cause foaming or aeration of the oil while operation below the low mark may cause loss of oil pressure.
5.3.4 Oil and Filter Change

Refer to the Cummins Engine Operation and Maintenance Manual for maintenance interval and procedure.
5.3.5 Starting Procedure After Extended Shutdown or Oil Change

After each oil change or if the genset has not been exercised within the past seven days, the lubricating system must be primed to be sure that the engine receives the correct oil flow through the lubricating system to minimise engine wear. To prime the lubricating system, start the engine by selecting the Idle Mode. Run the engine for five to ten minutes at idle, but no more than ten minutes. (Refer to Running at Idle procedure in Section 4.10 of this manual.)
Page 5-7
Note:
If the control panel is mounted remotely, the Running At Idle mode cannot be selected. Use the Manual Run button on the switch panel to start the engine in idle mode (refer to Starting at Switch Panel in Section 4.9.2). Using the Manual Run button, the engine will start in idle mode, but note that the engine will go to rated speed after warmup.
5.4
Coolant System
Caution: The heaters must not be operated while the cooling system is empty or when the engine is running or damage to the heater will occur. Isolate AC power to the heaters before disconnecting battery cables. Heaters will both run continuously without DC power and can overheat and damage heaters.
Caution:
Do not add cold coolant to a hot engine. Engine castings can be damaged. Allow the engine to cool to below 50 C before adding coolant
5.4.1 Coolant Level

Check the coolant level during shutdown periods at the intervals specified in the Maintenance Table 5-1. The coolant level should be approximately in the middle of the sight glass, with the coolant temperature at 122oF (50C) or lower. Refer to the Cummins engine Operation and Maintenance Manual for coolant recommendations/specifications. WARNING: CONTACT WITH HOT COOLANT CAN RESULT IN SERIOUS BURNS. ALLOW COOLING SYSTEM TO COOL BEFORE RELEASING PRESSURE AND REMOVING WATER JACKET RADIATOR CAP OR LTA EXPANSION TANK CAP.
5.4.2 Cooling System Maintenance

Refer to the Cummins Engine Operation and Maintenance Manual for all cooling system maintenance, such as coolant requirements, filling of the engine water jacket and LTA cooling systems, coolant filter replacement, and flushing and cleaning. If engine coolant heater(s) is installed in the water jacket cooling system, disconnect heater(s) from power source before performing cooling system maintenance. Caution: The heater element will burn out if the engine coolant is removed with the heater connected to power source.
Caution:
The heater element will burn out if the power is connected before it is filled with coolant, or if straight antifreeze solution is used for coolant. Before connecting the power, fill the engine with coolant and run it for a minimum of ten minutes to circulate coolant through the heater.
Page 5-8
5.4.3 Coolant Heater

Check the operation of the coolant heater by verifying that hot coolant is being discharged from the outlet hose (see Figure 51).
OUTLET
DRAIN
INLET
Figure 5-1
Coolant Heater
5.4.4 Heat Exchanger Plugs

Check the zinc plugs in the heat exchanger and replace if they are eroded to less than half their original length. The frequency of replacement is dependent on the chemical reaction that occurs when the plugs are in contact with the raw water
5.5
Fuel System
Refer to the Cummins Engine Operation and Maintenance Manual for fuel recommendations and fuel system maintenance, such as draining of the fuelwater separators and fuel filter replacement interval and procedure.
5.5.1 Fuel Handling Precautions

WARNING: IGNITION OF FUEL CAN CAUSE SERIOUS PERSONAL INJURY OR DEATH BY FIRE OR EXPLOSION. DO NOT PERMIT ANY FLAME, CIGARETTE, OR OTHER IGNITER NEAR THE FUEL SYSTEM.
To avoid condensation problems, keep fuel supply tanks as full as possible by filling up each time the engine is used. In cold weather, warm fuel returning from the injectors heats the fuel in the supply tank. If the fuel level is low, the upper portion of the tank tends to form condensation. In warm weather, both the fuel and the tank will be warm during the daytime. At night, cool air tends to lower the temperature of the tank more rapidly than the
Page 5-9
temperature of the fuel. If the fuel level is low, the upper portion of the tank will cool more rapidly and tend to form condensation. Condensation (water) can cause clogging of fuel filters when the sulphur in the fuel forms acid, which can corrode and damage engine parts.
5.6
Batteries
Check the condition of the starting batteries (see Figure 52) at the interval specified in the Maintenance Table 5-1. See that connections are clean and tight. A light coating of non-conductive grease will retard corrosion at terminals. Keep the electrolyte at the proper level above the plates by adding distilled water. Check specific gravity using a hydrometer and recharge if below 1.260. Note: Maintenance-free batteries are sealed and do not require the addition of electrolyte. Some manufacturers of maintenance-free batteries provide an eye or some visible means of telling when the battery is discharged or approaching the end of its useful life. IGNITION OF EXPLOSIVE BATTERY GASES CAN CAUSE SEVERE PERSONAL INJURY. DO NOT SMOKE WHILE SERVICING BATTERIES.
WARNING:
SPECIFIC GRAVITY READING SHOULD BE 1.260 AT 27 C
Figure 5-2
Battery
5.7
Air Cleaner
Refer to the Cummins Engine Operation and Maintenance Manual for air-cleaner filter element replacement, interval and procedure.
Page 5-10
5.8
Fan Bearing Re-lubrication

Relubricate the fan bearings at the interval specified in the Maintenance Table 5-1. A grease fitting is provided for the bearings to allow the use of a grease gun to relubricate the bearings. The recommended lubricant is a lithium based grease, such as, Mobilux EP 2, Mobilith AW 2, or Shell Alvania R3.
5.9
AC Generator Bearing Re-lubrication

Lubricate the bearing according to the alternator manufacturers instructions Table 5-2. These instructions are contained within the alternator manufacturers Operation & Maintenance Manual This manual is supplied with the generator. Note: It is very important that these lubrication instructions are strictly adhered to.
Page 5-11
Page 5-12
SECTION 6 TROUBLESHOOTING 6
6.1
Troubleshooting
Introduction
Fault code tables together with Warning and Shutdown code tables are provided in this section to assist in locating and identifying the possible causes of faults in the genset system. The engine Operation and Maintenance Manual contains its own fault finding charts and covers many possible engine faults. Similarly, the alternator Installation, Service and Maintenance manual provides fault finding details.
6.2
Control Unit DC Power Supply

The genset control continuously monitors engine sensors for abnormal conditions, such as low oil pressure and high coolant temperature. If any of these conditions occur, the control will light a yellow Warning lamp or a red Shutdown lamp and display a message on the graphical display panel. In the event of an engine shutdown fault (red Shutdown lamp), the control will stop the engine immediately; for an alternator shutdown fault, the engine will stop after the Cool down Timer has timed out. If the genset is stopped for this reason, the operator can restart the set after making adjustments or corrections. This section lists the Warning and Shutdown codes/messages (Table 61), and suggests troubleshooting procedures (Table 62). Note: Displayed error codes that are not listed in Table 62 will require an authorised service representative to correct the fault. Contact an authorised service centre for assistance.
Section 6 Troubleshooting
Page 6-1
6.3
Safety Considerations
Fault finding work, particularly in confined areas, should be carried out by two engineers working together. High voltages are present within the genset output box when the generator is running. WARNING: SOME PANEL INTERNAL COMPONENTS MAY HAVE LIVE EXPOSED TERMINATIONS EVEN IF THE GENSET IS NOT RUNNING. ISOLATE ALL EXTERNAL ELECTRICAL SUPPLIES PRIOR TO ACCESS OF THE CONTROL PANEL. CONTACTING HIGH VOLTAGE COMPONENTS CAN CAUSE ELECTROCUTION, RESULTING IN SEVERE PERSONAL INJURY OR DEATH. KEEP THE OUTPUT BOX COVERS IN PLACE DURING TROUBLESHOOTING. ONLY PERSONNEL QUALIFIED TO PERFORM ELECTRICAL SERVICING SHOULD CARRY OUT TESTING AND/OR ADJUSTMENTS.
WARNING:
The installation of a genset can be designed for remote starting. When troubleshooting a genset that is shutdown ensure that the set cannot be accidentally re-started. Turn the O/Manual/Auto switch to the Off (O) position. Turn off, or remove, AC power from the battery charger and then remove the negative (-) battery lead from the genset starting battery. Caution: Always disconnect a battery charger from its AC source before disconnecting the battery leads. Failure to do so can result in voltage spikes high enough to damage the DC control circuits of the genset ACCIDENTAL STARTING OF THE GENSET WHILE WORKING ON IT CAN CAUSE SEVERE PERSONAL INJURY OR DEATH. PREVENT ACCIDENTAL STARTING BY DISCONNECTING THE STARTING BATTERY LEADS (NEGATIVE [-] FIRST). ENSURE BATTERY AREA HAS BEEN WELL-VENTILATED BEFORE SERVICING THE BATTERY. ARCING CAN IGNITE EXPLOSIVE HYDROGEN GAS GIVEN OFF BY BATTERIES, CAUSING SEVERE PERSONNEL INJURY. ARCING CAN OCCUR WHEN LEADS ARE REMOVED OR REPLACED, OR WHEN THE NEGATIVE (-) BATTERY LEAD IS CONNECTED AND A TOOL USED TO CONNECT OR DISCONNECT THE POSITIVE (+) BATTERY LEAD TOUCHES THE FRAME OR OTHER GROUNDED METAL PART OF THE GENSET. ALWAYS REMOVE THE NEGATIVE (-) LEAD FIRST AND RECONNECT LAST. MAKE CERTAIN HYDROGEN FROM THE BATTERY, ENGINE FUEL AND OTHER EXPLOSIVE FUMES ARE FULLY DISSIPATED. THIS IS ESPECIALLY IMPORTANT IF THE BATTERY HAS BEEN CONNECTED TO A BATTERY CHARGER.
WARNING:
Page 6-2
6.4
Fault Finding
Should a fault condition occur during operation follow the procedures in the following tables to locate and correct the problem. For any symptom not listed, contact an authorised service centre for assistance. Before starting any fault finding, ensure that the following basic checks are carried out: All switches and controls are in their correct positions The fuel oil level is correct The lubricating oil level is correct The coolant level is correct The radiator matrix is free from obstruction The battery charge condition is satisfactory and the connections are secure The genset electrics and alternator connections are secure The panel connections are secure The protection circuits have been reset Blown fuses have been replaced Tripped contactors or circuit breakers have been reset MANY TROUBLESHOOTING PROCEDURES PRESENT HAZARDS THAT CAN RESULT IN SEVERE PERSONAL INJURY OR DEATH. ONLY QUALIFIED SERVICE PERSONNEL WITH KNOWLEDGE OF FUELS, ELECTRICITY, AND MACHINERY HAZARDS SHOULD PERFORM SERVICE PROCEDURES. REVIEW SAFETY PRECAUTIONS LISTED WITHIN SECTION 1 PRELIMINARY AND SAFETY SECTION - OF THIS MANUAL.
WARNING:
6.5
Status Indicators
6.5.1 Not In Auto Indicator

This red lamp flashes continuously when the O/Manual/Auto switch is not in the Auto position (Figure 61).
6.5.2 Shutdown Status Indicator

This red lamp is lit whenever the control detects a shutdown condition. After the condition has been corrected, the Shutdown indicator can be reset by turning the O/Manual/Auto switch to the Off (O) position, and pressing the Fault Acknowledge button. The genset cannot be started when this lamp is on.
6.5.3 Warning Status Indicator

This yellow lamp is lit whenever the control detects a warning condition. After the condition has been corrected, the Warning indicator can be reset by pressing the Fault Acknowledge button. (It is not necessary to stop the genset if the fault becomes inactive during genset operation.)
Page 6-3
6.6
Reading Fault Codes

If the genset contains the optional graphical display and a fault occurs, the fault code/message will be displayed in the display Description Line (Figure 61). If the control does not contain the graphical display, the fault code is read from the Warning and Shutdown status indicators. After the fault is acknowledged and corrected, the recorded fault will be deleted from the control panel memory, but will remain in a data log to maintain a fault code history. The InPower service tool is required to view this data log.
6.6.1 Reading Fault Codes Using Graphical Display (Optional)

The top three lines of the graphical display contain the following control information in the order described: State Line: Modes of operation, such as Stopped, Time Delay To Start, Warm Up At Idle, etc. (see Figure 42), and paralleling operations, such as Standby, Dead BUS Close, Synchronise, etc. System actions, such as Warning, De-rate, Shutdown Cool down and Shutdown, and Fault codes.
Action Line:
Description Line: Fault code messages.
Refer to History/About Submenus in Section 4.18, which describes how to view fault codes using graphical display.
6.6.2 Reading Fault Codes Using Warning/Shutdown Indicators

If the Warning or Shutdown status indicator is lit, press and hold the Fault Acknowledge button for a minimum of one second. After one second, the Shutdown lamp will begin to blink the active fault code(s). The Warning lamp is used to indicate the start of a new code. The Warning lamp will remain on for two seconds, followed by the Shutdown lamp blinking the fault code. This sequence occurs three times for each code. The fourth flash of the Warning lamp indicates the beginning of the second fault code. There are distinct pauses between repetitions of the code blink transmissions of the Shutdown lamp. A three-digit fault code is indicated by three sets of blinks separated by a two-second pause. The first set corresponds to the hundreds position, the second to the tens position, and the third to the ones digit. Example for Code No. 213: Shutdown LED: Warning LED: blinkblinkpauseblinkpauseblinkblinkblink blink (two seconds)
The light will display the fault codes (active or inactive) in succession, starting with the most recent. Up to 32 (unacknowledged) fault codes can be stored in control panel memory.
Page 6-4
To return the control to the most recent fault code, press and release the Fault Acknowledge button (less than one second) and repeat procedure. When the fault code is acknowledged and the fault condition is corrected, the fault code will be removed from the LED fault log.
SHUTDOWN, WARNING STATUS INDICATORS
FAULT ACKNOWLEDGE BUTTON
STATE LINE ACTION LINE DESCRIPTION LINE MENU DISPLAY AREA

0
OPERATOR PANEL
GRAPHICAL DISPLAY
SWITCH PANEL
Figure 6-1
Front Control Panel (Full-Featured)
Page 6-5
6.7
Line Circuit Breaker (Optional)

The optional line circuit breaker mounts on the generator output box. If the load exceeds the generator current rating, the line circuit breaker will open, preventing the generator from being overloaded. If the circuit breaker trips, locate the source of the overload and correct as necessary. Manually reset the breaker to reconnect the load to the generator.
6.8
Control and Diagnostics Via Network or PC (Laptop)

See your authorised Cummins dealer regarding software, hardware and network requirements for control and diagnostics via network or PC.
6.9
Fault Codes
The fault codes have been divided into four categories to help you determine what corrective action to take for safe operation of the generator set. Use Table 61 to find the category (CAT) and fault description for all codes. Note: Gaps in the code numbers are for codes that do not apply to this genset.
6.9.1 Category A Fault Codes

Relate to engine or alternator Shutdown faults that require immediate repair by competent service personnel (genset non-operational). The Control unit prevents the genset from being restarted.
6.9.2 Category B Fault Codes

Consist of faults that can affect genset performance or cause engine, alternator, or connected equipment damage. Continue operation of the genset only when it is powering critical loads and cannot be shut down. Requires repair by competent service personnel.
6.9.3 Category C Fault Codes

Consist of faults that do not affect genset performance but require competent service personnel to repair. These codes indicate a defective sensor or harness, leaving no engine protection. (Engine damage may therefore occur without detection). Note: Continued operation may void genset warranty if damage occurs that relates to any of these category faults.
6.9.4 Category D Fault Codes

Consist of faults that are repairable by site personnel. Service will be required by competent service personnel if site personnel cannot resolve the problem after taking the corrective actions suggested in Table 62.
Page 6-6
Table 6-1
CAT CODE LAMP DISPLAYED MESSAGE
Fault Codes
A A B A A A B B C B B C C B C C D C D C C A D C C A C C A C C A A D A D
111 112 113 115 116 117 118 119 121 122 123 135 141 143 144 145 146 151 152 153 154 155 197 212 213 214 221 222 228 231 232 233 234 235 236 253
Shtdn Shtdn Wrng Shtdn Shtdn Shtdn Wrng Wrng Wrng Wrng Wrng Wrng Wrng Wrng Wrng Wrng Wrng Shtdn Wrng Wrng Wrng Shtdn Wrng Wrng Wrng Shtdn Wrng Wrng Shtdn Wrng Wrng Wrng Shtdn Shtdn Shtdn Shtdn
Internal ECM error Actuator not responding Actuator sensor fault No speed signal Time press sensor high Time press sensor low Pump press sensor high Pump press sensor low No engine speed signal Manifold air press sensor Manifold air press sensor Oil pressure sensor Oil pressure sensor Low oil pressure Coolant temperature sensor Coolant temperature sensor High coolant temp warning High coolant temp alarm Low coolant temp Manifold air temp sensor Manifold air temp sensor Manifold air temp alarm Coolant level warning Oil temperature sensor Oil temperature sensor High oil temperature Air pressure sensor Air pressure sensor Low coolant pressure Coolant pressure sensor Coolant pressure sensor Coolant pressure warning Overspeed Coolant level alarm Position sensor Oil level alarm
A C C C C A B B D B D A A A A A A A A B B B D D B B B A B B D B B C C A
254 259 261 263 265 266 316 318 326 343 359 378 379 394 395 396 397 398 399 415 421 423 441 442 449 451 452 455 467 468 471 482 488 498 499 514
Shtdn Wrng Wrng Wrng Wrng Shtdn Wrng Wrng Wrng Wrng Wrng Wrng Wrng Wrng
Fuel shutoff valve Fuel shutoff valve Fuel temperature sensor Fuel temperature sensor Fuel temperature sensor Fuel temperature Fuel supply pump Fuel supply pump Oil level warning Internal ECM error Engine failed to start Fuelling actuator #1 Fuelling actuator #1 Fuelling actuator #1
Wrng Fuelling actuator #1 Wrng Fuelling actuator #2 Wrng Wrng Wrng Shtdn Wrng Wrng Wrng Wrng Wrng Wrng Wrng Shtdn Wrng Wrng Wrng Wrng Wrng Wrng Wrng Shtdn Fuelling actuator #2 Fuelling actuator #2 Fuelling actuator #2 Low oil pressure alarm High oil temperature Fuel timing Low battery voltage High battery voltage High fuel supply pressure Fuel rail pressure sensor Fuel rail pressure sensor Fuel control valve sensor Timing rail act sensor Fuel rail actuator sensor Low oil level High fuel supply pressure High intake manifold temp Oil level sensor Oil level sensor Fuel control valve
Page 6-7
Table 6-1
CAT CODE
Fault Codes (continued)

LAMP DISPLAYED MESSAGE
B B B B A A A D D B B B B NA NA NA NA NA NA NA NA B C A A B B B A D B
546 547 554 555 556 586 587 611 688 689 719 729 778 1311 1312 1313 1314 1315 1316 1317 1318 1319 1321 1322 1323 1324 1325 1326 1327 1328 1329 Note:
Wrng Wrng Wrng Wrng Shtdn Shtdn Shtdn Wrng Shtdn Wrng Wrng Wrng Wrng Shtdn/ Wrng
Fuel pressure sensor Fuel pressure sensor Fuel rail pressure sensor Blowby pressure Blowby pressure Run/Stop switch Run/Stop switch Engine hot High oil level alarm Crank shaft sensor Blowby pressure sensor Blowby pressure sensor Camshaft sensor Customer input #1
Shtdn/ Customer input #2 Wrng Shtdn/ Network Fault 1 Wrng Shtdn/ Network Fault 2 Wrng Shtdn/ Network Fault 3 Wrng Shtdn/ Network Fault 4 Wrng Shtdn/ Customer input #3 Wrng Shtdn/ Customer input #4 Wrng Wrng Wrng Shtdn Shtdn Wrng Wrng Wrng Shtdn Wrng Wrng High alternator temp Common warning driver
Load gov kW setpoint oor hi Load gov kW setpoint oor lo
Load gov kVAR oor hi Load gov kVAR oor lo Backup starter disconnect Load gov kW analog oor Genset CB tripped AVR DC power failure
A A A A B NA NA NA A A A A A A A A C C C D D B B B C C C D D D B A D D D D D B A
1331 1332 1333 1334 1335 1336 1337 1341 1342 1343 1344 1345 1346 1347 1348 1349 1351 1414 1415 1416 1417 1419 1421 1422 1424 1427 1428 1433 1434 1435 1436 1437 1438 1439 1441 1442 1443 1444 1445
Shtdn Shtdn Shtdn Shtdn Wrng Shtdn None Shtdn Shtdn Shtdn Shtdn Shtdn Shtdn Shtdn Shtdn Shtdn Wrng Wrng Wrng Wrng Wrng Wrng Wrng Wrng Wrng Wrng Wrng Shtdn Shtdn Wrng Wrng Shtdn Wrng Wrng Wrng Wrng Wrng Wrng Shtdn
AVR driver shorted Manual switch oor lo Manual switch oor hi Critical scaler oor Non critical scaler oor Cooldown complete Network wink Load demand stop Slot 0 card Slot 1 card Slot 2 card Slot 3 card Slot 4 incorrect Slot 5 card Slot 6 card Slot 7 card Slot 4 / network enabled Run relay contact Run relay driver Fail to shutdown Power down error Fuel rail driver Timing rail driver #1 Timing rail driver #2 High side driver Overspeed relay driver LOP shutdown relay driver Emergency stop - local Emergency stop - remote Engine cold PT fuel system drivers Estop path fuse blown Fail to crank Fuel level low in day Fuel level low in main Battery is weak Battery is dead kW overload Alternator short circuit
NA Indicates non-critical operational status of genset, external faults, or customer fault inputs. May require repair by competent service personnel.
Page 6-8
Table 6-1
CAT CODE
Fault Codes (continued)

LAMP DISPLAYED MESSAGE
A A A A B A A C A NA NA NA A A B NA NA NA C C C B A A A
1446 1447 1448 1449 1451 1452 1453 1454 1455 1456 1457 1458 1459 1461 1462 1463 1464 1465 1466 1467 1468 1471 1472 1473 1474 Note:
Shtdn Shtdn Shtdn Wrng Wrng Shtdn Shtdn Wrng Shtdn Wrng Wrng Wrng Shtdn Shtdn Wrng None None None Wrng Wrng Wrng Wrng Shtdn Shtdn Shtdn
AC output voltage is high AC output voltage is low AC output frequency low AC output frequency high Gen/Bus voltage differ Gen CB failed to close Gen CB failed to open Gen CB position contact Util CB contact Bus out of range Fail to synchronize Phase rotation Reverse kW Loss of field High ground current Not in Auto Load dump Ready to load Modem failure Unable to connect modem Network erorr High current Overcurrent Watchdog failure
Software version mismatch
C C C C A NA A A C C C C C C C C C C
C C C
1475 1476 1477 1478 1481 1483 1485 1486 1487 1488 1489 1491 1492 1493 1494 1495 1496 1497
1498 1499 2111
Wrng Wrng Wrng Wrng Shtdn None Shtdn Shtdn Wrng Wrng Wrng Wrng Wrng Wrng Wrng Wrng Wrng Wrng
Wrng Wrng Wrng
First start backup LonWorks card Crank relay contact Crank relay driver AVR driver open Common alarm status EFC driver shorted EFC driver open Auto acknowledge driver Warning LED driver Shutdown LED driver Ready to load relay driver Load dump relay driver Display control driver Modem power relay driver
Common shutdown2 driver
Auto mode relay driver Manual run LED driver

Exercise run LED driver Remote start LED driver Aftercooler temp sensor
C B A
2112 2113 2114
Wrng Aftercooler temp sensor Wrng High aftercooler temp Shtdn High aftercooler temp
NA Indicates non-critical operational status of genset, external faults, or customer fault inputs. May require repair by competent service personnel.
Page 6-9
WARNING:
MANY TROUBLESHOOTING PROCEDURES PRESENT HAZARDS WHICH CAN RESULT IN SEVERE PERSONAL INJURY OR DEATH. ONLY COMPETENT SERVICE PERSONNEL WITH KNOWLEDGE OF FUELS, ELECTRICITY, AND MECHANICAL HAZARDS SHOULD PERFORM SERVICE PROCEDURES. REVIEW SAFETY PRECAUTIONS LISTED WITHIN SECTION 1 PRELIMINARY AND SAFETY SECTION - OF THIS MANUAL.
Table 6-2
SYMPTOM CODE: 146 LAMP: Warning MESSAGE: HIGH COOLANT TEMP WARNING
Warning and Shutdown Codes

CORRECTIVE ACTION Indicates engine has begun to overheat and water jacket coolant temperature has risen to an unacceptable level. If generator is powering noncritical and critical loads and cannot be shut down, use the following: a) Reduce load if possible by turning off non-critical loads. b) Check air inlets and outlets and remove any obstructions to airflow. If engine can be stopped, follow 151 High Coolant Temp Alarm procedure. Indicates engine has overheated (water jacket coolant temperature has risen above the shutdown trip point or the coolant level is low). Allow engine to cool down completely before proceeding with the following checks: a) Check water jacket coolant level and replenish if low. Look for coolant leakage and repair if necessary. b) Check for obstructions to cooling airflow and correct as necessary. c) Check fan belt and repair if necessary. d) Reset control and restart after locating and correcting problem. Indicates engine coolant heater is not operating or is not circulating coolant. Set is in standby mode but is not operating. Warning occurs when engine water jacket coolant temperature is 70 F (21 C) or lower. NOTE: In applications where the ambient temperature falls below 40F (4C), Low Coolant Temp may be indicated even though the coolant heaters are operating. Check for the following conditions: a) Coolant heater not connected to power supply. Check for blown fuse or disconnected heater cord and correct as required. b) Check for low water jacket coolant level and replenish if required. Look for possible coolant leakage points and repair as required. Indicates engine water jacket coolant level has fallen to an unacceptable level. If generator is powering critical loads and cannot be shut down, wait until next shutdown period, then follow 235 Coolant Level Alarm procedure. If engine can be stopped, follow 235 procedure. Indicates engine water jacket coolant level has fallen below the alarm trip point. Allow engine to cool down completely before proceeding. a) Check water jacket coolant level and replenish if low. Look for possible coolant leakage points and repair if necessary. b) Reset control and restart after locating and correcting problem. Indicates engine oil level has dropped below the shutdown trip point. Check oil level, lines and filters. If oil system is OK but oil level is low, replenish. Reset control and restart.
CODE: 151 LAMP: Shutdown MESSAGE: HIGH COOLANT TEMP ALARM
CODE: LAMP: MESSAGE: LOW COOLANT TEMP
152 Warning
CODE: 197 LAMP: Warning MESSAGE: COOLANT LEVEL WARNING CODE: 235 LAMP: Shutdown MESSAGE: COOLANT LEVEL ALARM CODE: LAMP: MESSAGE: OIL LEVEL ALARM 253 Shutdown
Page 6-10
SYMPTOM CODE: LAMP: MESSAGE: OIL LEVEL WARNING
CORRECTIVE ACTION 326 Warning Indicates that the engine oil level has exceeded the warning trip point for high oil level. If generator is powering critical loads and cannot be shut down, wait until next shutdown period, then follow 688 High Oil Level Alarm procedure. If engine can be stopped follow 688 procedure. Indicates possible fault with control or starting system. Check for the following conditions: a) Poor battery cable connections. Clean the battery cable terminals and tighten all connections. b) Discharged or defective battery. Recharge or replace the battery. Indicates battery voltage is below 24 VDC. a) Discharged or defective battery. Check the battery charger fuse. Recharge or replace the battery. b) Poor battery cable connections. Clean the battery cable terminals and tighten all connections. c) Check engine DC alternator. Replace engine DC alternator if normal battery charging voltage (24 to 26 VDC) is not obtained. d) Check float level if applicable (raise float level). Indicates battery voltage exceeds 32 VDC. a) Check float level on battery charger if applicable (lower float level). b) Check engine DC alternator. Replace engine DC alternator if normal battery charging voltage (24 to 26 VDC) is not obtained. Indicates engine oil has dropped to an unacceptable level. If generator is powering critical loads and cannot be shut down, wait until next shutdown period, then follow 253 Oil Level Alarm procedure. If engine can be stopped follow 253 procedure. Indicates that an engine hot shutdown has occurred (cooldown timers were bypassed). This condition will occur when the engine coolant temperature is above the normal operating level and the operator presses the Emergency Switch or moves the 0/Manual/Auto switch to the 0ff (O) position. This type of shutdown should be avoided. Can cause possible loss of performance and engine damage. Indicates that the engine oil level has exceeded the alarm trip point for high oil level. a) Check oil level. b) Drain oil to operating level. When any one of these customer defined inputs is detected by the control, the corresponding fault message is displayed. The nature of the fault is an optional customer selection. These fault functions can be programmed to initiate a shutdown or warning as indicated by the Warning or Shutdown lamp. Note: Customer fault messages are editable. The message displayed for the code shown (1311 through 1318) is determined by the customer. Status - indicates that the Fault Bypass mode is enabled. This mode is primarily used by service personnel for troubleshooting purposes. In this mode the generator set ignores the majority of system shutdown faults. Indicates that the control can not power down due to some unknown condition. Possible drain on battery. Contact an authorised service centre for service.
CODE: 359 LAMP: Warning MESSAGE: ENGINE FAILED TO START CODE: 441 LAMP: Warning MESSAGE: LOW BATTERY VOLTAGE
CODE: 442 LAMP: Warning MESSAGE: HIGH BATTERY VOLTAGE CODE: LAMP: MESSAGE: LOW OIL LEVEL CODE: LAMP: MESSAGE: ENGINE HOT 471 Warning
611 Warning
CODE: 688 LAMP: Shutdown MESSAGE: HIGH OIL LEVEL ALARM CODE: 1311 through 1318 LAMP: Shutdown/Warning MESSAGE: Customer Defined Fault
CODE: 1416 LAMP: Warning MESSAGE: FAIL TO SHUTDOWN CODE: 1417 LAMP: Warning MESSAGE: POWER DOWN ERROR
Page 6-11
SYMPTOM CODE: 1433 / 1434 LAMP: Shutdown MESSAGE: EMERGENCY STOP - LOCAL / EMERGENCY STOP - REMOTE CODE: LAMP: MESSAGE: FAIL TO CRANK 1438 Warning
CORRECTIVE ACTION Indicates local or remote Emergency Stop. Emergency Stop shutdown status can be reset only at the local control panel. To reset the local/remote Emergency Stop button: a) Pull the button out. b) Move the Off/Manual/Auto switch to Off (O). c) Press the front panel Fault Acknowledge button. d) Select Manual or Auto, as required. Indicates possible fault with control or starting system. Check for the following conditions: a) Poor battery cable connections. Clean the battery cable terminals and tighten all connections. b) Discharged or defective battery. Recharge or replace the battery. Indicates fuel supply is running low. Check fuel supply and replenish as required. Indicates fuel supply is running low. Check fuel supply and replenish as required. Indicates battery voltage drops below 14.4 volts for two seconds, during starting. a) Discharged or defective battery. b) See Warning message 441 Low Battery Voltage. Indicates battery has dropped below genset operating range (3.5 volts when cranking) to power the starter and the control circuitry. a) See Warning message 441 Low Battery Voltage.
CODE: 1439 LAMP: Warning MESSAGE: FUEL LEVEL LOW IN DAY CODE: 1441 LAMP: Warning MESSAGE: FUEL LEVEL LOW IN MAIN CODE: 1442 LAMP: Warning MESSAGE: BATTERY IS WEAK CODE: LAMP: MESSAGE: BATTERY IS DEAD 1443 Warning
Page 6-12
SECTION 7 APPENDICES APPENDIX: A. Additional Engine Specific Information
Section 7 Appendices
Page A-i
Page A-ii
ENGINE SPECIFIC INFORMATION 1 Engine Specific Information

1.1 QSX15G8
MODEL Engine Generator Electrical System ITEM Cummins QSX15G8 Power Rating (kW) Starting Voltage Battery Cold Cranking Amps (CCA) minimum) cold soak @ 0 F (-18 C) and above. Capacity Standard Radiator - Gal (L) Oil Capacity including Filters Oil Type DATA DFEK, DFEJ, DFEH (50/60 Hz) See Genset Nameplate for rating information. 24 Volts DC Two x 12 Volts 900CCA 17.2 Imperial Gallons (78.2 Litres) 20 Imperial Gallons (91 Litres)
Cooling System Lubricating System Oil Type Fuel System
Refer to Cummins QSX15 Series Engine Operation and Maintenance Manual for lubricating oil recommendations and specifications. Inlet Thread Size - Flex Fuel Hose Outlet Thread Size Fuel Lift (Max) Fuel Head (Max) 7/814 UNF 2Ax45 7/814 UNF 2Ax45 5 ft (1524 mm) 7ft (2100mm) Check Valve limit is 3psi. A pressure greater than 3psi, may cause fuel to leak into the engine. (Refer to AEB70.28) 6 NPT Male STD. (A299)/ASA Flange (A355) or Slip-on (A298) Optional 27 in (686 mm) 6.8 2.0 in (51 mm) Refer to the Exhaust Gas Volumes and Pressures Table, below.
Exhaust
Outlet Size Maximum Allowable Back Pressure H20 kPa Hg Gas Volume (Max) - 50Hz Gas Volume (Max) - 60Hz Gas Temperature (Max) - 50Hz Gas Temperature (Max) - 60Hz
Exhaust Gas Volumes and Pressures DFEK Gas Volume (Max) - 50Hz Gas Volume (Max) - 60Hz Gas Temperature (Max) - 50Hz Gas Temperature (Max) - 60Hz 3090cfm (1458l/s) 3625cfm (1710l/s) 945F (507C) 925F (496C) DFEJ 2800cfm (1321l/s) 3135cfm (1479l/s) 910C (488C) 890C (477C) DFEH 2550cfm (1203l/s) 2875cfm (1356l/s) 880C (471C) 870C (466C)
Page A-1
1.2 QST30G2
MODEL Engine Generator Electrical System ITEM Cummins QST30 Power Rating (kW) Starting Voltage Battery Cold Cranking Amps (CCA) minimum) cold soak @ 0 F (-18 C) and above. 104 F (40 C) Gal (L) QST30-G1, G2 or G3 QST30-G4 122 F (50 C) Gal (L) QST30-G1, G2 or G3 QST30-G4 Oil Capacity including Filters 75 litre oil pan 132 litre oil pan o o o o
DATA DFHA, DFHB, DFHC, DFHD, DFHE, DFHF, DFHG (50/60 Hz) See Genset Nameplate for rating information. 24 Volts DC Two x 12 Volts 1800CCA 37 Imperial Gallons (169 Litres) 66 Imperial Gallons (302 Litres) 38 Imperial Gallons (175 Litres) 75 Imperial Gallons (342 Litres) 19.8 Imp Gallons (90 Litres) 32.6 Imp Gallons (148 Litres)
Cooling System Capacity (Engine and Standard Radiator) Lubricating System Oil Type
Refer to Cummins QST30 Series Engine Operation and Maintenance Manual for lubricating oil recommendations and specifications.
Page A-2
1.3 QSK45 and QSK60

MODEL Cummins Diesel Series Generator kW Rating Electrical System Starting Voltage Battery Cold Cranking Amps(minimum) Cold Soak @ 0F (18C) and above Cooling System Capacity Engine and Standard Radiator Imp Gal(Litres) o o 104 F (40 C) Gal (L) 122 F (50 C) Gal (L) Oil Capacity Standard Double Deep Oil Pan System with Standard Filters Oil Type
o o
DQKB/DQKC QSK45 (See Genset Nameplate) 24 Volts DC Four, 12 Volt 1800CCA QSK60 (50/60 Hz) (See Genset Nameplate) 24 Volts DC Four, 12 Volt 1800CCA
90 Imperial Gallons (410 Litres) N/A
90 Imperial Gallons (410 Litres) 115 Imperial Gallons (525 Litres)
49 Imperial Gallons (226 Litres)
60 Imperial Gallons (272 Litres)
Refer to Cummins QSK45 & QSK60 Series Engine Operation and Maintenance Manual for lubricating oil recommendations and specifications.
Page A-3
1.3.1 Cooling System Sight Glass Fill Locations
COOLANT SIGHT GLASS
JACKET WATER COOLING SYSTEM FILL CAP
LTA COOLING SYSTEM FILL CAP
LTA EXPANSION TANK
SPEC A COOLING SYSTEM
COOLANT SIGHT GLASS JACKET WATER COOLING SYSTEM FILL CAP
LTA COOLING SYSTEM FILL CAP
SPEC B COOLING SYSTEM
Page A-4
1.3.2 Fan Bearing Grease Fittings
BEARING
Spec. A - Cooling System. Quantity: Apply slowly until grease can be seen escaping from side of bearing. Clean expelled grease from side of bearing.
GREASE FITTINGS
SPEC A COOLING SYSTEM
BEARINGS
Spec. B - Cooling System. Quantity: Fan side bearing 39 grams Pulley side bearing 31 grams
GREASE FITTINGS
SPEC B COOLING SYSTEM
Page A-5
1.3.3 Fan Belt Replacement

WARNING: ARCING AT BATTERY TERMINALS, ARCING IN LIGHT SWITCHES OR OTHER EQUIPMENT, FLAME, PILOT LIGHTS AND SPARKS CAN IGNITE BATTERY GAS CAUSING SEVERE PERSONAL INJURY OR DEATH. VENTILATE BATTERY AREA BEFORE WORKING ON OR NEAR BATTERYWEAR SAFETY GLASSESDO NOT SMOKESWITCH TROUBLE LIGHT ON OR OFF AWAY FROM BATTERYSTOP GENSET AND DISCONNECT CHARGER BEFORE DISCONNECTING BATTERY CABLESDISCONNECT NEGATIVE (-) CABLE FIRST AND RECONNECT LAST. Disconnect battery charger from AC source before disconnecting battery cables. Otherwise, disconnecting cables can result in voltage spikes damaging to DC control circuits of the set. ACCIDENTAL STARTING OF THE GENERATOR SET WHILE WORKING ON IT CAN CAUSE SEVERE PERSONAL INJURY OR DEATH. PREVENT ACCIDENTAL STARTING BY TURNING THE CONTROL SWITCH TO THE OFF (O) POSITION AND DISCONNECTING THE NEGATIVE (-) CABLE FROM THE BATTERY TERMINAL.
Caution:
WARNING:
1.3.3.1 Belt Removal

1. Observe Section 4.7 of this manual Locking the Genset Out of Service. 2. Turn the control switch to the Off (O) position. 3. Disconnect the negative (-) cable from the battery to prevent accidental starting. 4. Remove fan belt guard (between engine and radiator) to gain access to fan belt. 5. Use an 8point socket and breaker bar or a large wrench to hold the idler in position against the spring tension. Slowly turn the wrench until the spring tension is relieved. Remove the fan belt.
TURN WRENCH IN DIRECTION OF ARROW UNTIL SPRING TENSION IS RELIEVED
WARNING:
THE FAN BELT IDLER IS UNDER TENSION. DO NOT ALLOW YOUR HANDS TO GET BETWEEN THE BELT AND IDLER / FAN HUB OR CRANKSHAFT PULLEY. PERSONAL INJURY WILL RESULT.
Page A-6
1.3.3.2 Belt Replacement

1. Slip new fan belt onto the crankshaft and fan hub pulley. THE FAN BELT IDLER IS UNDER TENSION. DO NOT ALLOW YOUR HANDS TO GET BETWEEN THE BELT AND IDLER / FAN HUB OR CRANKSHAFT PULLEY. PERSONAL INJURY WILL RESULT.
WARNING:
2. Use an 8point socket and breaker bar or a large wrench to hold the idler in position against the spring tension. Slowly turn the wrench until the spring tension is relieved sufficiently to position the belt in front of the idler pulley. Align the grooves of the belt on the ribs of the pulley and shaft and then slowly release spring tension onto belt. Note: The springloaded idler used on this design maintains the correct belt tension.
3. Install fan belt guards. 4. Reconnect starting batteries (negative cable last). 5. Start genset and visually check belt for proper alignment with engine running.
Page A-7
Page A-8

PCC 3200

Încărcat de

Informații document

Descriere originală:

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

PCC 3200

Încărcat de

Drepturi de autor:

Formate disponibile

Power Generation

Issue 03 March 2002

Standard PCC II Control System

Standard PCC II Control System

Standard PCC II Control System

Schedule of Abbreviations ................................................................................................ i 1

System Description ............................................................................................. 3-1

Standard PCC II Control System

Standard PCC II Control System

Standard PCC II Control System

APPENDIX: A. Additional Engine Specific Information ............................................. A-i 1

Engine Specific Information............................................................................... A-1

Standard PCC II Control System

Standard PCC II Control System

Standard PCC II Control System

Standard PCC II Control System

Standard PCC II Control System

SECTION 1 PRELIMINARY AND SAFETY 1

1.2.2 High Pressures

Section 1 Preliminary and Safety

Standard PCC II Control System

1.2.4 Supply Isolation

1.2.5 Reinstatement of Supply

Section 1 Preliminary and Safety

Standard PCC II Control System

Section 1 Preliminary and Safety

Standard PCC II Control System

Standards, Codes & Regulations

Section 1 Preliminary and Safety

Standard PCC II Control System

Safety of Machinery Electrical Equipment of Machines

Section 1 Preliminary and Safety

Standard PCC II Control System

Generator Plant Safety Code

1.7.1 Genset Warning Labels

Section 1 Preliminary and Safety

Standard PCC II Control System

1.8.1 Engine Warning

1.8.2 Exhaust Gas Hazards

Section 1 Preliminary and Safety

Standard PCC II Control System

1.8.3 Fire Hazards

Section 1 Preliminary and Safety

Standard PCC II Control System

1.8.4 Moving Part Hazards

1.8.5 High Temperature Hazards

1.8.6 Electrical Hazards

Section 1 Preliminary and Safety

Standard PCC II Control System

Section 1 Preliminary and Safety

Standard PCC II Control System

Section 1 Preliminary and Safety

Standard PCC II Control System

1.8.10 Disposal of Engine Waste

Section 1 Preliminary and Safety

Standard PCC II Control System

Generating Set Identification

Typical Genset Rating Plate

Standard PCC II Control System

After Sales Services

Standard PCC II Control System

SECTION 3 SYSTEM DESCRIPTION 3