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Service Manual
GenSet Model
GGDB
MS-4
Redistribution or publication of this document,
iii by any means, is strictly prohibited.
ELECTRICAL SHOCK CAN CAUSE Used engine oils have been identified by some state
SEVERE PERSONAL INJURY OR DEATH or federal agencies as causing cancer or reproduc-
tive toxicity. When checking or changing engine oil,
take care not to ingest, breathe the fumes, or con-
Remove electric power before removing protective tact used oil.
shields or touching electrical equipment. Use rub-
ber insulative mats placed on dry wood platforms Keep multi-class ABC fire extinguishers handy.
over floors that are metal or concrete when around Class A fires involve ordinary combustible materials
electrical equipment. Do not wear damp clothing such as wood and cloth; Class B fires, combustible
(particularly wet shoes) or allow skin surface to be and flammable liquid fuels and gaseous fuels; Class
damp when handling electrical equipment. C fires, live electrical equipment. (ref. NFPA No. 10).
Make sure that rags are not left on or near the en-
Use extreme caution when working on electrical gine.
components. High voltages can cause injury or
death. DO NOT tamper with interlocks. Make sure generator set is mounted in a manner to
prevent combustible materials from accumulating
Follow all applicable state and local electrical under the unit.
codes. Have all electrical installations performed by Remove all unnecessary grease and oil from the
a qualified licensed electrician. Tag and lock open unit. Accumulated grease and oil can cause over-
switches to avoid accidental closure. heating and engine damage which present a poten-
tial fire hazard.
DO NOT CONNECT GENERATOR SET DI-
RECTLY TO ANY BUILDING ELECTRICAL SYS- Keep the generator set and the surrounding area
TEM. Hazardous voltages can flow from the gen- clean and free from obstructions. Remove any de-
erator set into the utility line. This creates a potential bris from the set and keep the floor clean and dry.
for electrocution or property damage. Connect only Do not work on this equipment when mentally or
through an approved isolation switch or an ap- physically fatigued, or after consuming any alcohol
proved paralleling device. or drug that makes the operation of equipment un-
safe.
GENERAL SAFETY PRECAUTIONS Substances in exhaust gases have been identified
by some state or federal agencies as causing can-
Coolants under pressure have a higher boiling point cer or reproductive toxicity. Take care not to breath
than water. DO NOT open a radiator or heat ex- or ingest or come into contact with exhaust gases.
changer pressure cap while the engine is running. Do not store any flammable liquids, such as fuel,
Allow the generator set to cool and bleed the system cleaners, oil, etc., near the generator set. A fire or
pressure first. explosion could result.
Benzene and lead, found in some gasoline, have Wear hearing protection when going near an oper-
been identified by some state and federal agencies ating generator set.
as causing cancer or reproductive toxicity. When To prevent serious burns, avoid contact with hot
checking, draining or adding gasoline, take care not metal parts such as radiator, turbo charger and ex-
to ingest, breathe the fumes, or contact gasoline. haust system.
THREE POSITION
ROCKER SWITCH
HOUR
METER
S1 SLEEP
MODE
SELECTION
SWITCH
J1-3
(B+) J2
J1
J1-4
OFF MODE
BUTTON
The function of the four selection buttons varies with When the symbol is displayed, the selec-
each menu. tion button is used to navigate to an editable
field within a menu.
When the symbol is displayed, the When the + and symbols are displayed, the
selection button can be used to switch to selection buttons are used to increase or de-
Auto mode. crease a parameter or value shown on the
When the symbol is displayed, the selec- screen.
tion button can be used to switch to Manual When changing values, pressing the button be-
Run mode. low the + symbol increase the value and press-
When the up and down triangles ( and ) ing the button below the symbol decreases
are displayed, the selection buttons are used the value.
to navigate between a series of submenus. When SAVE is displayed, the selection but-
ton is used to save changes made in a sub-
NOTE: When any Operator menu (Figure 3-12
menu. If the Previous Menu button is
is displayed, a series of Service menus
pressed before pressing SAVE, the
can be viewed by simultaneously
changes are not saved.
pressing the and selection but-
tons for two seconds. Some menus include a list of numbered sub-
jects. These menus include numbers in pa-
NOTE: When a fault is displayed, it can be renthesis (for example, (1)) displayed above
cleared from the front panel by press- the selection buttons. The selection buttons
ing the or button. are then used to display submenus of the
subjects included in the list.
When a symbol is displayed, the selection
button can be used to abort the Auto or When a black box is displayed, the
Manual Run mode and return to the Operator selection button has no function.
Press the button to view the previous main Press the button to switch to the Off mode. The
menu. Off mode will disable the control Auto or Manual
modes.
NOTE: In the Screen Adjust menu, settings are not If the button is pressed during generator set op-
saved when the button is pressed. eration (manual or remote start), the engine will im-
mediately shut down. If possible, hot shutdown un-
The button is also used to acknowledge warn- der load should be avoided to help prolong the reli-
ing and shutdown messages after the fault has ability of the generator set.
been corrected. Pressing this button clears the fault
from the front panel display and the previous menu The button is also used to acknowledge warn-
is redisplayed. ing and shutdown messages after the fault has
been corrected. Pressing this button clears the fault
NOTE: Pressing the or button also clears the from the front panel and resets the control.
fault from the front panel display. Not in Auto Indicator
This red lamp is lit when the control is not in the Auto
mode.
Warning Indicator
OFF
This yellow lamp is lit whenever the control detects
BUTTON a warning condition. This lamp is automatically shut
off when the warning condition no longer exists.
Auto Indicator
PREVIOUS MAIN
MENU BUTTON This green lamp indicates the control is in Auto
mode. Auto mode can be selected by pressing the
selection button from any of the Operator me-
nus (see Figure 3-12).
EXAMPLE OF
A SYMBOLIC
SHUTDOWN 1
FAULT
AUTO MODE
SELECTED
Engine Status This menu displays genset power (in kVA), frequen-
cy, and engine speed (RPM). (In applications with-
Alternator Status out current transformers, the kVA is not shown.)
Line-to-Line Voltage Alternator Line-to-Line Voltage Menu
Line-to-Neutral Voltage
This menu displays L1-L2, L2-L3, and L3-L1 line-to-
Alternator Amperage line voltages for three phase applications only.
To navigate between the Operator menus, press Alternator Line-to-Neutral Voltage Menu
the buttons next to the and symbols in the
graphical display. This menu displays line-to-neutral voltages for L1,
L2, and L3 for three phase wye configurations only.
The Operator menus can be used to select Auto or (In delta configurations, this menu is not shown.)
Manual Run modes.
Alternator Single Phase Voltage Menu
Appendix A provides a block diagram that illustrates
This menu displays L1-N, L2-N, and L1-L2 voltages
the sequence of how the Operator Menus are dis-
played.
for single phase applications only.
Alternator Amperage Menu
Engine Status Menu
This menu displays L1, L2, and L3 amperage. (In
This menu displays the engine starting battery volt- applications without current transformers, this
age, engine coolant temperature, engine oil pres- menu is not shown.)
THREE PHASE
ONLY SINGLE
PHASE
ONLY
THREE PHASE
WYE ONLY
CURRENT
SENSE ONLY
THREE PHASE
ONLY SINGLE
PHASE
ONLY
THREE PHASE
WYE ONLY
CURRENT
SENSE ONLY
The first Service Menu can be viewed from any of Status Menu
the Operator menus by simultaneously pressing the
The Status menu is displayed when the (5) button is
and selection buttons for two seconds. The
pressed on the second Service Menu. The Status
first Service Menu provides access to the following
menu shows the following:
menus:
Voltage regulator (drive) level, in percentage
Setup Menus Used by Service personnel. of duty cycle
Adjusting the Setup menus is restricted by a
password and is described in Section 6. To Governor regulator (drive) level, in percent-
view the Setup menus only, press the VIEW age of duty cycle. This value is only dis-
button on the Setup password menu. played if the governor is enabled.
2ND 3RD
SERVICE SERVICE
MENU MENU
OR
Fault 2
Oldest Fault
(Maximum of 5)
GRAPHICAL DISPLAY
PANEL ASSEMBLY
(MEMBRANE BUTTONS)
OR
SWITCH PANEL CONTROL
ASSEMBLY BOX
BASE
BOARD
SLEEP MODE
RS-485 SELECTION CUSTOMER
COMMUNICATIONS CONNECTIONS
S1
TB2 TB1
DS1 STATUS
INDICATOR
J11
J13
VOLTAGE/
FIELD
ENGINE
HARNESS
K8 K7 J12
FUEL STARTER
SHUTOFF RELAY CTS
RELAY
BASE K5
BOARD (SWITCHED B+)
K10, K11
(OPTIONAL
RUN RELAYS)
TB10
(OPTIONAL
RUN RELAY
CONNECTION
K8 TERMINAL)
(FUEL CONTROL)
T26 (CONTROL
SWITCHED B+)
TB BAT+ RECONNECTION
TERMINAL BLOCK LOAD CONNECTION
TERMINAL BLOCK
8. Engine misfires on LPG or NG or back- a. Air fuel ratio too lean. Adjust main fuel valve. Refer to Gaseous
fires on LPG at high loads. Fuel Adjustment in Section 8.
b. Inspect spark plugs/gap, .042 to .046 (1.07 to 1.17 mm).
c. Check spark plug wires (6,000 ohms/foot).
d. Check ignition coil primary (0.5 to 1.3 ohms).
e. LPG liquid withdrawal defective LPL converter.
9. Engine has preignition on LPG at high Check fuel time relay K99 should be energized. Check for ground
loads. on lead between terminal K99-87 and Ford engine harness P8-K.
10. Gaseous fuel delivery (vapor withdraw- Check the gas supply pressure at the regulator input. Refer to Sec-
al) t o the set is inadequate or fuel pres- tion 8.
sure is to high at light loads.
11. Excessive crank time (seven seconds or a. See step 10 in this table.
more) before starting (NG or LPG va- b. Regulator may require adjustment. Refer to Initial Secondary Reg-
por). ulator Adjustment in Section 8.
12. The engine is worn. Service the engine according to the engine service manual.
1 Indicates engine has overheated (coolant temperature has risen above the shut-
HIGH COOLANT TEMP down trip point).
Lamp: Shutdown Allow engine to cool down completely before proceeding with the following checks:
a. Check coolant level and replenish if low. Look for possible coolant leakage points
and repair if necessary.
b. Check for obstructions to cooling airflow and correct as necessary.
c. Check fan belt and repair or tighten if necessary.
d. Check blower fan and circulation pumps on remote radiator installations.
e. Reset control and restart after locating and correcting problem.
2 Indicates engine oil pressure has dropped below the shutdown trip point. Check oil
LOW OIL PRESSURE level. If oil level is low, replenish. Reset control and restart.
Lamp: Shutdown
12 Indicates that one or more of the phase voltages has exceeded 130% of nominal
HIGH AC VOLTAGE for 1.0 second, or has exceeded 110% of nominal for 10 seconds.
Lamp: Shutdown
13 Indicates that one or more of the phase voltages has dropped below 85% of nomi-
LOW AC VOLTAGE nal for 10 seconds.
Lamp: Shutdown
14 Indicates frequency is 10% above base frequency for 10 seconds.
OVER FREQUENCY
Lamp: Shutdown
15 Indicates that engine speed has dropped below 90% of nominal for 10 seconds.
UNDER FREQUENCY Check fuel supply pressure, intake air supply and load.
Lamp: Shutdown
27 Indicates a loss of all three voltage sense leads or failure in excitation circuit.
EXCITATION FAULT Check field wiring (X1 and X2) for shorts or opens. (Refer to Section 7.)
Lamp: Shutdown
31 Indicates engine has exceeded normal operating speed. The threshold is 1725
OVERSPEED RPM (50 Hz) or 2075 RPM (60 Hz).
Lamp: Shutdown Possible cause single step large block load removal. Reset control and restart.
38 Indicates that the Field AVR Duty Cycle has been at the maximum for at least 15
FIELD OVERLOAD seconds.
Lamp: Shutdown
45 Indicates that no magnetic pickup pulses are sensed for a Loss of Speed delay.
SPEED SIGNAL LOST
Lamp: Shutdown
46 Indicates that an individual phase of alternator output current has exceeded 150%
HIGH AC CURRENT of the rated output current continuously for more than 10 seconds.
Lamp: Shutdown Check load and load lead connections.
2. Move the rocker switch to the OFF position or press the OFF button.
204, 205 The nature of the fault is an optional customer selection. Example inputs: Low
CUSTOMER INPUT #1, #2 Coolant Level, Low Fuel Pressure, Ground Fault, etc.
Lamp: Warning Each of the fault functions can be programmed (using service tool), as follows:
Warning or Shutdown (Default: Warning) (See fault code 75/76 for Shutdown)
Change display name using up to 32 characters.
212 Indicates that the control has sensed that the engine coolant temperature sensor
COOL SENSOR OUT OF output is out of range (high or low). Check sender/connectors/wires.
RANGE
Lamp: Warning
213 Indicates battery voltage supply to the control is approaching a low level at which
LOW BATTERY unpredictable operation will occur.
Lamp: Warning 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 battery wiring/calibration.
d. Check engine DC alternator. Replace engine DC alternator if normal battery
charging voltage is not obtained.
e. Check battery charge voltage float level if applicable (raise float level).
214 Indicates battery voltage supply to the control is approaching a high level at which
HIGH BATTERY damage to the control can occur. Check float level on battery charger if applicable
Lamp: Warning (lower float level). Check battery wiring/calibration.
215 Indicates engine oil pressure has dropped below the warning trip point. If genera-
PRE-LOW OIL PRESSURE tor is powering critical loads and cannot be shut down, wait until next shutdown
Lamp: Warning period and then follow code 2 procedure.
216 Indicates that one or more of the phase currents has exceeded 110% of nominal
HIGH AC CURRENT for 60 seconds.
Lamp: Warning Check load and load lead connections.
217 Indicates that the control has sensed that the engine oil pressure sensor output is
OIL PRESS SENSOR OUT out of range (high or low). Check sender/connectors/wires.
OF RANGE
Lamp: Warning
219 Indicates the battery charging alternator has not reached an acceptable voltage
CHARGER FAILURE range within the selected period (default = 120 seconds).
Lamp: Warning a. Fault threshold is not set correctly. Refer to Engine Protection Submenus in Sec-
tion 6.
b. Charging alternator is defective. Refer to engine service manual.
221 Indicates that during cranking, the battery voltage is at or below the weak battery
WEAK BATTERY warning trip point for a time greater than or equal to the weak battery set time. See
Lamp: Warning code 213 for corrective action.
222, 223, 224 The nature of the annunciator fault is an optional customer selection.
ANNUNCIATOR FAULT 1, 2,
3
Lamp: Warning
225 Indicates a mismatch in the configuration of one of the annunciator relay outputs.
ANNUNCIATOR OUTPUT
CONFIGURATION ERROR
Lamp: Warning
1ST
GENSET
SERVICE
MENU
2ND
GENSET
SERVICE
MENU
Volts AC: Displays the AC voltage (190, 200, Start: The genset start time delay can be ad-
208, 220, 230, 240, 380, 400, 416, 440, 460, justed from 0 to 300 seconds.
or 480 VAC).
Stop: The genset stop time delay can be ad-
Hertz: Displays the genset frequency (50 or
justed from 0 to 600 seconds.
60 Hz). The control selects limits, gains, and
frequency values based upon this selection.
Cycle Crank Menu
No. of Phases: Displays the number of
phases (1 or 3). The Cycle Crank menu allows for configuring the
Phase: Displays the phase type (Delta or generator for all starting modes (manual and re-
Wye). mote), as follows:
Genset Menu, Part 2 Crank: The cranking period can be set from 3
to 30 seconds. This time limit is used to de-
The second genset menu allows for enabling or dis- termine a Fail to Start status.
abling glow plugs and charging alternators.
Rest: The minimum amount of time between
Glow Plug: Allows control of Glow Plugs for crank attempts can be set from 0 to 60 sec-
a particular genset (Yes or No) onds.
Charging Alt. Enable:
Attempts: The maximum number of times the
A starter disconnect will occur whenever any starter can be engaged when attempting to
one of the following three possible signals start the engine with cycle cranking can be
reaches its disconnect setpoint. set from 1 to 7 attempts.
PART 2
A
CONTINUED ON
PAGE 6-9
BATTLE SHORT:
ACTIVE/INACTIVE IS ONLY
DISPLAYED IF THE SWITCH
INPUT IS SET TO
OPERATOR PANEL
YES NO
K
OR
G
C
GO TO AVR
SETUP MENUS
ON PAGE 6-13 IF AVR IS NOT
ENABLED
OR
YES NO IF AVR IS
ENABLED
OR
H
GO TO
E PAGE 6-13
CONTINUED
D ON PAGE 6-11
GO TO
GOVERNOR
SETUP MENUS
ON PAGE 6-15
RETURN TO
PAGE 6-9
G
Volts/Hz Rolloff Menu V/Hz Knee: The Knee Frequency can be ad-
justed from 0.0 to 10.0 Hertz in 0.1 Hz incre-
The Volts/Hz Rolloff function helps optimize the ments. When generator set speed decreases
gensets response to added load. If the engine by more than the value of the knee frequency,
speed drops below nominal frequency, the control the generator set voltage decreases by the
automatically drops the voltage until the engine %/Hz value.
speed starts to recover. V/Hz Rolloff: The Rolloff setting can be ad-
This menu allows for adjusting the knee frequency justed from 0.0 to 5.0 percent of rated volt-
and voltage setpoint slope parameters. The knee age, in 0.1% increments.
frequency is the value below nominal frequency at
which the rolloff function begins. For example, if the Regulator Gains Menu
knee frequency is set to 5 Hz on a 60 Hz genset, this The Regulator menu allows for setting proportional
function begins when the frequency drops below 55 Gain, Integral Gain, and Damping values.
Hz.
Slope refers to how fast the voltage is rolled off be- Gain: The proportional Gain (K1) multiplier
low the knee frequency. The voltage is rolled off the can be set from 5 to 1000%. This allows for a
slope percent setting for every 1 Hz below the knee. scale factor of 0.05 to 10.0.
For example, on a 60 Hz genset, if the slope is set to Int: The Integral Gain (K2) multiplier can be
5% and the knee frequency is set to 5 Hz, then if the set from 5 to 1000%.
frequency drops to 54 Hz, the voltage set point is re-
duced 5%. If the frequency drops to 53 Hz, the volt- D: The Damping adjustment can be set from
age set point is reduced 10%, etc. 95 to 105%.
RETURN TO
PAGE 6-9
RETURN TO
PAGE 6-11
The Meter Calib menu allows for adjusting the actu- Metering Current Adjust Menu
al output voltage of the genset. The percentage can
be set from 90 to 110%. The alternator voltage is The Metering Current Adjust menu allows for ad-
also shown on this menu. justing metered amps.
1. With the genset OFF, attach a calibrated am-
Freq. Adjust Menu meter to L1.
The Frequency Adjust menu allows for adjusting 2. Start the genset and allow it to reach normal
the genset frequency. The frequency can be adjust operating speed.
from 6.0 to +6.0 Hz. The actual frequency is also 3. Display the Metering Current Adjust menu.
shown on this menu. 4. Load the genset to maximum rated kVA at
rated voltage.
Metering Voltage Adjust Menu
5. Calibrate the reading for L1 current so that the
The Metering Voltage Adjust menu allows for ad- reading on the display agrees with calibrated
justing metered genset line voltage. ammeter.
1. With the genset OFF, attach a calibrated volt- 6. After adjusting, press the SAVE button to save
meter to the AC output from L1 to L2. (L1 to the setting.
Neutral for single phase alternators.)
7. Shut the generator set OFF.
2. Start the genset and allow it to reach normal
8. Repeat steps 1 through 7 for L2 and L3. (In step
operating speed.
1, attach meter to L2 to calibrate L2 current,
3. Display the Metering Voltage Adjust menu. and L3 to calibrate L3 current.)
The Annunciator submenus are available by press- The annunciator has three possible customer-de-
ing the (4) button on the second Genset Service fined fault conditions that can be shown on the PCC
menu (see Figure 6-3). 1301 display. The Annunciator Fault Text message
menus are used to enter an event type and descrip-
Seven annunciator submenus (see Figure 6-10) tion for those three customer-defined annunciator
can be used to define three Annunciator Fault Text faults.
messages and four Annunciator Output Maps. Type: Enter the event type (Warning, Shut-
down or Event.
Enter a brief description of the event (up to
32 characters).
CONTINUED ON
PAGE 6-23
SETUP
In the following menu entry descriptions, the default
PASSWORD
parameter/value is not shown because the default MENU
value is subject to change by model. Always create
and refer to the initial capture file for factory default
settings of system parameters/values.
To enter the Genset Setup password 1209: NOTE: If the button is pressed before
1. With the first character highlighted, press the pressing the SAVE button, the
button below to the + or symbols until the val- changes are not saved.
ue reads 1.
6. Press the button to return to the genset
2. Press the arrow selection button to move Setup Menus menu.
to the next numeric character.
3. Press the button below the + or symbols until 7. To return to the Service Menu from the genset
the value reads 2. Setup Menus menu, press the button.
1ST
GENSET
SETUP
MENU
2ND
GENSET
SETUP
MENU
The Genset submenus are available by pressing The kVA Rating menu displays the kVA rating of
the (1) button on the first Genset Setup menu (see single-phase or three-phase, 50 or 60 hertz standby
Figure 6-12). genset systems. These value are used by the con-
trol to determine what is 100% load. The values
Appendix A provides a block diagram that illustrates must match the kVA rating of the genset application
the sequence of how the Genset Setup Submenus and cannot be more than 2000 kVA.
are displayed.
3Ph/50Hz: The three phase, 50 Hertz rating
Figure 6-13 (3 sheets) is a block representation of can be set from 0 to 2000 kVA.
the Genset Submenus.
3Ph/60Hz: The three phase, 60 Hertz rating
Genset Menu can be set from 0 to 2000 kVA.
1Ph/50Hz: The single phase, 50 Hertz rating
The Genset menu is used to set the CT Ratio, en- can be set from 0 to 2000 kVA.
able the Magnetic Pickup Unit (MPU), set the num-
ber of teeth pulses per revolution on the Flywheel, 1Ph/60Hz: The single phase, 60 Hertz rating
and set the Speed/Frequency Ratio. can be set from 0 to 2000 kVA.
CT Ratio: The CT Ratio value must be set to Prime kVA Rating Menu
match the CT Ratio of the current transform-
ers on the genset. The kVA Rating menu displays the kVA rating of
single-phase or three-phase, 50 or 60 hertz prime
MPU Enable: Displays whether or not the genset systems. These value are used by the con-
Magnetic Pickup Unit is installed (Yes or No). trol to determine what is 100% load. The values
must match the kVA rating of the genset application
Fly. Teeth: The total number of teeth pulses and cannot be more than 2000 kVA.
per revolution on the flywheel (used for elec-
tronic governed systems) can be set from 0 3Ph/50Hz: The three phase, 50 Hertz rating
to 256. can be set from 0 to 2000 kVA.
RPM/Hz Ratio: Allows for setting the Speed/ 3Ph/60Hz: The three phase, 60 Hertz rating
Frequency Ratio to 20, 30, or 60 RPM/Hz. can be set from 0 to 2000 kVA.
1Ph/50Hz: The single phase, 50 Hertz rating
Application Rating Select Menu can be set from 0 to 2000 kVA.
The genset application rating can be set to either 1Ph/60Hz: The single phase, 60 Hertz rating
Standby or Prime. can be set from 0 to 2000 kVA.
CONTINUED ON
PAGE 6-31
12V 24V
OR
D D
C
CONTINUED ON
PAGE 6-33
SWITCH SENDER
OR
CONTINUED ON
PAGE 6-41
CONTINUED ON
PAGE 6-43
The PCC Base board (Figure 6-17) provides con- Enter a brief description of the event (up to 32
nection points (TB1) for remote control and monitor characters).
options. The InPower service tool or access to the Genset
Service Menus is required to modify the customer
TB1 Customer Inputs fault inputs.
Available options will vary between PCC1301 control
models (PCC with or without display). TB1 Customer Outputs
Refer to Page 9-6 for typical connections to TB1. Available options will vary between PCC1300 control
Remote Start: When the control is in Auto/Remote models (PCC with or without display).
mode, grounding this input initiates the engine
cranking and start sequence. This circuit must be Refer to Page 9-6 for typical connections to TB1.
opened to permit resetting a shutdown condition
Customer Outputs 1 and 2: One set of normally
with the Reset input. (The remote stop is actually
open (NO) contacts, rated for 2 amps at 30 VDC for
the removal of the remote start signal to the control.)
each of the two output signals. The relays can be
Local/Remote Emergency Stop: Grounding this used to control small devices and indicator lamps.
input causes an immediate shutdown. Emergency
stop must be reset at the front panel. The nature of the customer output signal (contacts
closed) is an optional customer selection. Example
Customer Fault Inputs 1 and 2: Grounding any outputs: Genset running (event), common warning,
one of these inputs activates the corresponding common shutdown, etc. (Refer to Table 5-3 for the
warning or shutdown sequence. warning and shutdown code listing and page 5-3 for
the event code listing.)
External sensing equipment must be connected to
the designated digital input. Each relay can be independently programmed to
The nature of the fault is an optional customer energize by entering the a code number (0 through
selection. Example inputs: Low Coolant Level, Low 255, default = 0) for the desired event.
Fuel Pressure, Ground Fault, etc.
The InPower service tool or access to the Genset
Each of the two fault functions can be programmed Service Menus is required to modify the customer
as follows: outputs.
BASE
BOARD
(TB1)
COOLANT TEMPERATURE
SENDER (E2)
ENGINE
FLYWHEEL
RING GEAR
Refer to the Reconnection Diagram to identify the B. Route the load lead (U, V or W) through the ap-
generator output leads/phase that must be routed propriate CT (refer to Reconnection Diagram).
through each CT, and also appropriate transformer C. The CTs have dual secondaries (3 pins). The
post selection for control sensing leads. The trans- CT secondary wire marked 1 is connected to
formers are labeled CT1, CT2 and CT3 on the re- pin 1 of the CT. CT secondary wire marked 2/3
connection wiring diagram. (The Reconnection Dia- is connected to pin 3 for low voltage gensets.
gram is located on the control box cover.) (Refer to Reconnection Diagram.)
STATOR ROTOR
STATOR
COOLING LEADS
BLADES
END
BELL
DRIVE
DISC
ROTOR
SHAFT
BEARING
AIR
BAFFLE O-RING
EXCITER STATOR
LEADS F1 AND F2
STATOR CONNECTION
BOARD
BEARING
BORE O-RING
+
F1
DIODE
12 VDC EXCITER DISCONNECT BASE
BATTERY BASE BOARD LEADS TO
STATOR BOARD EXCITER STATOR
F2
The rotating rectifier assembly is mounted on the Replacing Diode Assembly: Make sure the re-
back face of the exciter rotor. It consists of one posi- placement diode assembly is of the correct polarity,
tive (+) and one negative () diode assembly. Each positive (+) or negative (). Then disconnect all
assembly carries three diodes in an epoxy potting. leads from the defective diode assembly and re-
Each diode has a terminal for connecting the ap- move the two mounting screws. Mount the new
propriate lead from the exciter rotor (CR1 through diode assembly, reconnect all leads and torque the
CR6). Each assembly has a field terminal (F1+ or terminal screws to 24 lb-in (2.6 N-m).
ONE OF SIX DIODE TERMINALS FOR CONNECTING THE POSITIVE (+) DIODE AS- NEGATIVE () DIODE AS-
EXCITER WINDING LEADS. TORQUE THE TERMINAL SEMBLYMOUNT ON SEMBLYMOUNT ON
NUTS TO 24 LB-IN (2.6 N-M) AND USE A FLAT WASHER TO LEFT-HAND SIDE WHEN RIGHT-HAND SIDE
PROTECT THE LEAD CONNECTOR ROTOR KEY IS UP WHEN ROTOR KEY IS UP
ONE OF TWO
MOUNTING
SCREWS FOR
EACH DIODE
ASSEMBLY
THE MAIN ROTOR LEADS PASS THROUGH THE EXCITER ROTOR AND ARE CONNECTED TO
F1+ AND F2 TERMINALS ON THE ROTATING RECTIFIER ASSEMBLY. DISCONNECT THE
LEADS FROM THE TERMINALS WHEN TESTING THE MAIN ROTOR WINDINGS.
REFERENCE
STACK
LENGTH
REFERENCE
LENGTH
(1) . These are approximate reference dimensions for aiding generator identification. The corresponding rotor stack lengths are slightly greater than
the stator stack lengths.
(2) . Stator resistances are 5% of nominal at 77 F (25 C) and rotor resistance are 10%.
Ventilate battery area before working on or near 10. Before separating the generator stator from the
batteryWear gogglesStop genset and dis- flywheel housing and end bell, scribe lines to
connect charger before disconnecting battery register the parts for easier reassembly.
cablesDisconnect negative () cable first and
reconnect last. 11. Remove the remaining two nuts and washers
on the generator through-studs and tap the end
CAUTION Disconnect battery charger from AC
bell free of the stator assembly.
source before disconnecting battery cables.
Otherwise, disconnecting cables can result in
12. Tap the generator stator free of the adaptor
voltage spikes damaging to DC control circuits
housing and carefully draw the stator straight
of the set.
back until it clears the ends of the through-
WARNING Accidental starting of the generator
studs.
set can cause severe personal injury or death.
Prevent accidental starting by disconnecting 13. Remove the generator through-studs.
the negative () cable from the battery terminal.
14. If it is necessary to remove the rotor, first re-
1. Remove connector from Ignition Control Mod- move the air baffle. Cinch a hoisting strap
ule and hardware that secures the relay. Both around the middle of the main rotor laminations
items are located on right side of saddle brack- and then remove the bolts securing the genera-
et when facing PCC control. tor drive disc to the flywheel.
2. Remove the top cover of the control box. 15. Remove the two mounting screws if it is neces-
sary to remove the exciter stator from the gen-
3. Disconnect all power output and remote control erator end bell.
connections and conduit at the generator. For
easier reconnections later, make sure each 16. Use a gear puller if it is necessary to remove
lead is clearly marked. the rotor bearing.
GAS
NATURAL GAS
MIXER
PRESSURE
SWITCH
PROPANE
ADJUSTMENT
VALVE
LPG
REGULATOR
NATURAL GAS/
LPG REGULATOR
SOLENOID
VALVE
GAS
MIXER
MANUAL MAIN
FUEL VALVE
ACTUATOR
After completing the following adjustments, it will be If the factory setting has been changed/lost, set the
necessary to start the generator set and fine tune adjustment screw as indicated in Table 8-1. If the
these adjustments. Refer to Actuator/Fuel System factory setting has not been changed, refer to Table
Adjustments in this section. 8-2 to adjust regulator for desired fuel.
THROTTLE
BODY
COVER
ACTUATOR
No. 630-2796 sh 1 of 1
Rev. C
Modified 12-04
No. 630-2936 sh 1 of 3
Rev. C
Modified 01-05
No. 630-2936 sh 2 of 3
Rev. C
Modified 01-05
No. 630-2936 sh 3 of 3
Rev. C
Modified 01-05
No. 338-4521 sh 1 of 2
Rev. C
Modified 01-05
No. 338-4521 sh 2 of 2
Rev. C
Modified 01-05
No. 620-0277 sh 1 of 1
Rev. B
Modified 01-05
CUSTOMER CONNECTIONS
THREE
PHASE
ONLY
SINGLE
PHASE
ONLY
THREE
PHASE
WYE ONLY
CURRENT
SENSE
AMPERAGE
MANUAL
RUN MODE
SELECTED
AUTO MODE
SELECTED
VIEWING AND
VIEWING ONLY ADJUSTING
GO TO GENSET
OR
SETUP AND
SERVICE MENUS
ON PAGE A-4
YES NO
OR
Redistribution or publication of this document,
by any means, is strictly prohibited.
IF AVR IS
NOT
ENABLED
OR
IF AVR IS
YES NO ENABLED
OR
GENSET SETUP AND SERVICE MENUS
OR
GO TO GENSET
SERVICE MENUS
ON PAGE A-3
VIEWING AND
VIEWING ONLY ADJUSTING
OR
12V 24V
OR
OR
A-4
SWITCH SENDER
OR
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1400 73rd Avenue N.E.
Minneapolis, MN 55432
1-800-888-6626
763-574-5000 International Use
Fax: 763-528-7229
Cummins is a registered trademark of Cummins Inc.