PCC 3200 PDF

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
2
2.1
2.2
2.3
2.3.1
2.3.2
2.3.3
2.3.4
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
Contents
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
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
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
Page i
CONTENTS (continued)
Section
3.3
3.3.1
3.3.2
3.3.3
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
Page ii
Title
Page
Heaters....................................................................................................................... 3-4
Engine Heater (Option) ......................................................................................... 3-4
Alternator Heater (Option)..................................................................................... 3-4
Control Panel Heater (Option)............................................................................... 3-4
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
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
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
Contents
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
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
Page iii
Section
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
Title
Page
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
Page iv
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
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
Contents
Publication No
.....................................................................................................................3330
.....................................................................................................................3331
.....................................................................................................................3334
.....................................................................................................................3393
Page v
Page vi
Contents
Schedule of Abbreviations
AC
ACB
ACH
ATS
AVR
Alternating Current
Air Circuit Breaker
Anti-Condensation Heaters
Automatic Transfer Switch
Automatic Voltage Regulator
BHP
BMS
BST
Brake Horsepower
Building Management System
Busbar Sensing Transformer
CB
CCA
CHP
COP
CT
Circuit Breaker
Cold Cranking Amps
Combined Heat and Power
Continuous Power Rating
Current Transformer
dB(A)
DC
DIP
DMC
DMSU
Unit of noise level

Direct Current
Dual In-line Package
Digital Master Control
Demand Load Standby Unit
EMCU
EMF
EPU
Engine Monitoring and Control Unit

Electromotive Force
Engine Protection Unit
FSS
First Start Sensor
GCP
Genset
GKWT
Generator Control Panel

Generator Set
Global Kilowatt Transducer
HV
High Voltage
IC
I/O
Integrated Circuit
Input / Output
kVA
kVAR
kW
kWh
Apparent Power
Reactive Power
Active / Real Power
Unit of electrical energy or work
LED
LTA
LTP
LV
Light-Emitting Diode
Low Temperature Aftercooling
Limited Time Power Rating
Low Voltage
MCB
MCCB
MF
MFSS
MR
MST
MSU
MV
Miniature Circuit Breaker

Moulded Case Circuit Breaker
Mains Failed
Master First Start Sensor
Mains Returned
Mains Sensing Transformer
Mains Sensing Unit
Medium Voltage
NEC
Neutral Earthing Contact
PCC II
PCL
PF
PFC
PLC
PMG
PRP
PSU
PT/CT
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
QCC
Quadrature Current Control
RFI
RMS
RPM
RTD
Radio Frequency Interference

Root Mean Square
Revolutions Per Minute
Resistance Temperature Detector
V
VAC
VCB
VDC
VF
VT
Volts
Volts, Alternating Current
Vacuum Circuit Breaker
Volts, Direct Current
Volt-free
Voltage Transformer
TM
Potential Transformer / Current Transformer
Page i
Page ii
SECTION 1 PRELIMINARY AND SAFETY

1
Safety
1.1
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.
Caution:
Warns of a hazard or an unsafe practice that can result in product or

property damage.
Note:
1.2
A short piece of text giving information that augments the current text.
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.
WARNING:
DEPENDENT UPON THE CONTROL SYSTEM FITTED, THIS UNIT

MAY OPERATE AUTOMATICALLY AND COULD START WITHOUT
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.
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.
1.
Turn the Mode switch on the control panel to Off (O)

Manual
Auto
2.
Isolate and lock off the supply to the battery charger, where fitted.
3.
Disconnect the starting batteries and control system batteries, (if separate).
4.
Isolate and lock off the heater control box, where fitted.
5.
Isolate the fuel supply to the engine.
6.
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
1.5
Radio Frequency Warning
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:
Page 1-4
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
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)
General requirements for rotating electrical machines
BS 5000
(IEC 600341)
Rotating electrical machines of particular types or for

particular applications
BS 5514
(ISO 30462)
Reciprocating internal combustion engines: performance
BS 7671
Requirements for electrical installations

IEE Wiring Regulations (16th Edition)
BS 7698
(ISO 85282)
Reciprocating internal combustion engine driven alternating

current generating sets
BS EN 50081
(EN 500812)
Electromagnetic compatibility. Generic emission standard
BS EN 61000-6-2: 1999
(IEC 61000-6-2: 19992)
Electromagnetic compatibility. Generic immunity standard
BS EN 60439
(IEC 604392)
(EN 604392)
Specification for low-voltage switchgear and control gear

assemblies
BS EN 60947
(IEC 9471)
(EN 609472)
Specification for low voltage switchgear and control gear
BS EN 60204-1
Safety of Machinery Electrical Equipment of Machines
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.
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
Introduction
2.1
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
Section 2 Introduction
Typical Genset Rating Plate
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
System Description
3.1
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)
9.
10.
11.
12.
13.
14.
15.
Load Terminal Box (LH/RH)

Bedframe
Alternator
Starter Motor
Coolant Heater (Option)
Engine
Oil Filters (RH side)
PowerCommand Control II Panel
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.
Caution:
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.
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:
Page 3-4
ALWAYS ISOLATE THE CONTROL PANEL HEATER FROM THE AC

SUPPLY BEFORE WORKING ON THE CONTROL PANEL OR
HEATER.
SECTION 4 SYSTEM OPERATION

4
Operation
4.1
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.
4.2
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.
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)
EXERCISE
BUTTON &
INDICATOR
MANUAL RUN/
STOP BUTTON
& INDICATOR
GRAPHICAL
DISPLAY
0/MANUAL/AUTO
SWITCH
Figure 4-1
Page 4-2
Control Panel Assembly (Full Featured)
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.
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.
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.
Remove the key from the Mode switch and account for all other keys for safekeeping,
(if applicable).
3.
Isolate and lock off the supply to the battery charger, where fitted.
4.
As an additional precaution, disconnect the starting batteries and control system

batteries, (if separate).
5.
Isolate and lock off the heater control box, where fitted.
6.
Isolate the fuel supply to the engine.
7.
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
Note:
Some radiators have two fill necks, both of which must be filled when the
cooling system is drained
Caution:
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.
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.
Caution:
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.
Caution:
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.
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.
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:
Page 4-10
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.
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:

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)

WARNING:

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

WARNING:

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

WARNING:

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
Caution:
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.
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
Page 4-14
Normal start/run/stop sequences
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:
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
Figure 4-3
Page 4-16
MENU
BUTTONS
Graphical Display and Menu Selection Buttons
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.
button causes the operating program to go back to the previous menu display.
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
Figure 4-4
LOCAL
8F
PSI
INHG
CFM
ENTER
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
MENU
B
PAGE
3-13
ENGINE
MORE>>
ALTERNATOR
PAGE
3-14
MENU
BUTTONS
CONTROL
_\_
HISTORY/ABOUT
PAGE
3-15
See
Above
PAGE
3-16
MENU B
PAGE
3-17
ADJUST
BUS DATA
SETUP
BACK<<
GRAPHICAL
DISPLAY
Service
Manual
Figure 4-5
PAGE
3-18
MENU
A
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
Figure 4-7
kVA
500
500
500
1500
PF
.80
.80
.80
.80
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:
Page 4-20
The PF reading will contain an asterisk if the power factor is leading (e.g., *.30).
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:
CONTROL
(Local)
RUN MODE IDLE

BARGRAPH TEST
CONTROL
(Remote)
START GENSET
BARGRAPH TEST
FAULT ACKNOWLEDGE
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:
Page 4-22
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
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.
VOLTAGE:
Used to adjust the output voltage 5%.
FREQUENCY:
Used to adjust the frequency 3 Hz.
START DELAY:
This delay applies only to remote starting in the Auto mode. The
Start Delay adjustment range is 0 to 300 seconds.
STOP DELAY:
This delay applies only to remote stopping in the Auto mode. The
Stop Delay adjustment range is 0 to 600 seconds.
ADJUST
+
-
ADJUST:
VOLTAGE 208
FREQ 60.0 HZ
START DELAY
STOP DELAY
Figure 4-10
1.2
-0.0
5
11
%
HZ
SEC
SEC
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:
Indicates first genset in system to close to bus.
SYNCHRONIZE:
Genset is synchronising to bus.
LOAD SHARE:
Genset Bus closed and load shared with other gensets in

system.
LOAD GOVERN:
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:
Genset is synchronising to bus.
READY TO CLOSE:
In manual mode, push circuit breaker close button to close

breaker.
_\_ Button:
(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
Page 4-28
Password Menu
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:
Section 5 Maintenance

EXPOSED TERMINATIONS EVEN IF THE GENSET IS NOT RUNNING.
ISOLATE ALL EXTERNAL ELECTRICAL SUPPLIES PRIOR TO
ACCESS OF THE CONTROL PANEL.
Page 5-1
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
Caution:
Only authorised and qualified maintenance engineers, who are familiar

with the equipment and its operation, should carry out maintenance.
Caution:
Before carrying out any maintenance work, become familiar with the
Generator Plant Safety Code given in Section 1 of this manual.
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
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
Periodic Maintenance Schedule
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
1000
Hours
4000
Hours
X
X
X
X
3
X
X
X
X
X
X
4
X
5
X
1
X
1
X
1
X
1
X Refer to the Cummins Engine Operation and Maintenance Manuals for maintenance interval and/or procedure.
2
X Check for oil, fuel, cooling and exhaust system leaks. Check exhaust system audibly and visually with set running
and repair any leaks immediately.
3
X Visually check belt for evidence of wear or slippage. Replace if hard or brittle.
4
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.
5
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.
Page 5-3
Table 5-2
ITEM
Set Electrics
Alternator
Control Panel
General
Test Run
Additional Maintenance Schedule
TASK
Clean battery terminals and re-grease
Check fuel solenoid and linkage
Check all electrical connections
Weekly /
10 hours
Monthly /
100 hours
l
l
l
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
Yearly /
200 hours
l
l
l
l
l
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
l
l
l
Run the set on-load at least 30% load

Check anti-vibration mounts
Check all systems functioning
Check operation of Emergency Stop
X
l
l
l
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.
5
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.
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:
The generator frequency should be stable and the reading should

be the same as the set nameplate rating.
AC Voltage:
At no load, the linetoline voltage(s) should be the same as the

set nameplate rating.
AC Ammeter:
At no load, the current readings should be zero. With a load

applied, each line current should be similar.
Panel Lamps:
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:
5.4
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.
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.
Page 5-8
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.
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.
WARNING:
IGNITION OF EXPLOSIVE BATTERY GASES CAN CAUSE SEVERE

PERSONAL INJURY. DO NOT SMOKE WHILE SERVICING
BATTERIES.
SPECIFIC GRAVITY
READING SHOULD BE
1.260 AT 27 C
Figure 5-2
5.7
Battery
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
Troubleshooting
6.1
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:

EXPOSED TERMINATIONS EVEN IF THE GENSET IS NOT RUNNING.
ISOLATE ALL EXTERNAL ELECTRICAL SUPPLIES PRIOR TO
ACCESS OF THE CONTROL PANEL.
WARNING:
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.
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
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.
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
WARNING:
6.5
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.
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.
Action Line:
System actions, such as Warning, De-rate, Shutdown Cool

down and Shutdown, and Fault codes.
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:
blinkblinkpauseblinkpauseblinkblinkblink
Warning LED:
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
Figure 6-1
SWITCH
PANEL
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
A
A
B
A
A
A
B
B
C
B
B
C
C
B
111
112
113
115
116
117
118
119
121
122
123
135
141
143
Shtdn
Shtdn
Wrng
Shtdn
Shtdn
Shtdn
Wrng
Wrng
Wrng
Wrng
Wrng
Wrng
Wrng
Wrng
144
Wrng
145
Wrng
D
C
D
C
C
A
D
C
C
A
C
C
A
C
C
A
A
D
A
D
146
151
152
153
154
155
197
212
213
214
221
222
228
231
232
233
234
235
236
253
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
Fault Codes
CAT CODE
A
C
C
C
C
A
B
B
D
B
D
A
A
A
254
259
261
263
265
266
316
318
326
343
359
378
379
394
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
Fuel supply pump
Fuel supply pump
Oil level warning
Internal ECM error
Engine failed to start
Fuelling actuator #1
395
Wrng Fuelling actuator #1
396
Wrng Fuelling actuator #2
A
A
A
B
B
B
D
D
B
B
B
A
B
B
D
B
B
C
C
A
397
398
399
415
421
423
441
442
449
451
452
455
467
468
471
482
488
498
499
514
Wrng
Wrng
Wrng
Shtdn
Wrng
Wrng
Wrng
Wrng
Wrng
Wrng
Wrng
Shtdn
Wrng
Wrng
Wrng
Wrng
Wrng
Wrng
Wrng
Shtdn
Low oil pressure alarm
High oil temperature
Fuel timing
Low battery voltage
High battery voltage
High fuel supply pressure
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
CAT CODE
Wrng
Wrng
Wrng
Wrng
Shtdn
Shtdn
Shtdn
Wrng
Shtdn
Wrng
Wrng
Wrng
Wrng
Shtdn/
Wrng
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
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
B
B
B
B
A
A
A
D
D
B
B
B
B
546
547
554
555
556
586
587
611
688
689
719
729
778
NA
1311
NA
1312
Shtdn/
Customer input #2
Wrng
NA
1313
Shtdn/
Network Fault 1
Wrng
NA
1314
Shtdn/
Network Fault 2
Wrng
NA
1315
Shtdn/
Network Fault 3
Wrng
NA
1316
Shtdn/
Network Fault 4
Wrng
NA
1317
Shtdn/
Customer input #3
Wrng
NA
1318
Shtdn/
Customer input #4
Wrng
B
C
A
A
B
B
B
A
D
B
1319
1321
1322
1323
1324
1325
1326
1327
1328
1329
Wrng
Wrng
Shtdn
Shtdn
Wrng
Wrng
Wrng
Shtdn
Wrng
Wrng
Note:
Page 6-8
Fault Codes (continued)
Fuel pressure sensor

Fuel 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
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
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
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.
Table 6-1
Fault Codes (continued)
CAT CODE
CAT CODE
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
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
C
C
C
C
A
NA
A
A
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
Wrng
Wrng
Wrng
Wrng
Shtdn
None
Shtdn
Shtdn
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
C
C
C
1498
1499
2111
Wrng
Wrng
Wrng
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
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:
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
Common shutdown2 driver
Auto mode relay driver

Manual run LED driver
Software version mismatch
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.
CODE:
151
LAMP:
Shutdown
MESSAGE:
HIGH COOLANT TEMP ALARM
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.
CODE:
LAMP:
MESSAGE:
LOW COOLANT TEMP
152
Warning
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.
CODE:
197
LAMP:
Warning
MESSAGE:
COOLANT LEVEL WARNING
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.
CODE:
235
LAMP:
Shutdown
MESSAGE:
COOLANT LEVEL ALARM
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.
CODE:
LAMP:
MESSAGE:
OIL LEVEL ALARM
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.
Page 6-10
253
Shutdown
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.
CODE:
359
LAMP:
Warning
MESSAGE:
ENGINE FAILED TO START
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.
CODE:
441
LAMP:
Warning
MESSAGE:
LOW BATTERY VOLTAGE
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
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).
CODE:
442
LAMP:
Warning
MESSAGE:
HIGH BATTERY VOLTAGE
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.
CODE:
LAMP:
MESSAGE:
LOW OIL LEVEL
471
Warning
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.
CODE:
LAMP:
MESSAGE:
ENGINE HOT
611
Warning
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.
CODE:
688
LAMP:
Shutdown
MESSAGE:
HIGH OIL LEVEL ALARM
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.
CODE:
1311
through
1318
LAMP:
Shutdown/Warning
MESSAGE:
Customer Defined Fault
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.
CODE:
1416
LAMP:
Warning
MESSAGE:
FAIL TO SHUTDOWN
CODE:
1417
LAMP:
Warning
MESSAGE:
POWER DOWN ERROR
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.
Page 6-11
SYMPTOM
CODE:
1433 / 1434
LAMP:
Shutdown
MESSAGE:
EMERGENCY STOP - LOCAL /
EMERGENCY STOP - REMOTE
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.
CODE:
LAMP:
MESSAGE:
FAIL TO CRANK
1438
Warning
Indicates possible fault with control or starting system. Check for the
following conditions:
a) Poor battery cable connections. Clean the battery cable terminals and
b) Discharged or defective battery. Recharge or replace the battery.
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
Indicates fuel supply is running low. Check fuel supply and replenish as
required.
CODE:
LAMP:
MESSAGE:
BATTERY IS DEAD
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.
Page 6-12
1443
Warning
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.
SECTION 7 APPENDICES
APPENDIX: A.
Section 7 Appendices
Additional Engine Specific Information
Page A-i
Page A-ii
ENGINE SPECIFIC INFORMATION

1 Engine Specific Information
1.1 QSX15G8
MODEL
ITEM
DATA
Engine
Cummins QSX15G8
DFEK, DFEJ, DFEH (50/60 Hz)
Generator
Power Rating (kW)
See Genset Nameplate for rating information.
Electrical
System
Starting Voltage
Battery
Cold Cranking Amps (CCA) minimum)
cold soak @ 0 F (-18 C) and above.
24 Volts DC
Two x 12 Volts
Cooling
System
Capacity Standard Radiator - Gal (L)
17.2 Imperial Gallons (78.2 Litres)
Lubricating
System
Oil Capacity including Filters

Oil Type
20 Imperial Gallons (91 Litres)
Oil Type
Refer to Cummins QSX15 Series Engine Operation and Maintenance Manual for
lubricating oil recommendations and specifications.
Fuel System
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)
Exhaust
Outlet Size
6 NPT Male STD. (A299)/ASA Flange (A355)

or Slip-on (A298) Optional
Maximum Allowable Back Pressure

H20
kPa
Hg
Gas Volume (Max) - 50Hz
Gas Temperature (Max) - 50Hz
900CCA
27 in (686 mm)
6.8
2.0 in (51 mm)
Refer to the Exhaust Gas Volumes and
Pressures Table, below.
Exhaust Gas Volumes and Pressures

DFEK
DFEJ
DFEH
3090cfm (1458l/s)
2800cfm (1321l/s)
2550cfm (1203l/s)
3625cfm (1710l/s)
3135cfm (1479l/s)
2875cfm (1356l/s)
945F (507C)
910C (488C)
880C (471C)
925F (496C)
890C (477C)
870C (466C)
Page A-1
1.2 QST30G2
MODEL
ITEM
DATA
Engine
Cummins QST30
DFHA, DFHB, DFHC, DFHD, DFHE, DFHF,

DFHG (50/60 Hz)
Generator
Power Rating (kW)
See Genset Nameplate for rating information.
Electrical
System
Starting Voltage
Battery
Cold Cranking Amps (CCA) minimum)
cold soak @ 0 F (-18 C) and above.
24 Volts DC
Two x 12 Volts
1800CCA
Cooling
System
Capacity
(Engine and
Standard
Radiator)
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

Lubricating
System
Oil Capacity including Filters

75 litre oil pan
132 litre oil pan -
19.8 Imp Gallons (90 Litres)

32.6 Imp Gallons (148 Litres)
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
DQKB/DQKC
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)
o
122 F (50 C) Gal (L)

Oil Capacity
Standard Double Deep Oil Pan
System with Standard Filters
Oil Type
QSK45
QSK60 (50/60 Hz)
(See Genset Nameplate)
(See Genset Nameplate)
24 Volts DC
Four, 12 Volt
24 Volts DC
Four, 12 Volt
1800CCA
1800CCA
N/A
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.
Caution:
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.
WARNING:
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.
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:
Page A-6
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.
1.3.3.2 Belt Replacement

1.
Slip new fan belt onto the crankshaft and fan hub pulley.
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.
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

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Power

Issue 03 March 2002

Standard PCC II Control System

Cummins Power Generation Limited

Standard PCC II Control System

Standard PCC II Control System

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

Warning, Caution and Note Styles Used In This Manual .............................................1-1

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

Standard PCC II Control System

Standard PCC II Control System

Alternator Data Submenus........................................................................................4-20

Standard PCC II Control System

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

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

Standard PCC II Control System

Radio Frequency Warning .............................................................................. 1-4

Periodic Maintenance Schedule ..................................................................... 5-3

Standard PCC II Control System

Standard PCC II Control System

Unit of noise level

Engine Monitoring and Control Unit

First Start Sensor

Generator Control Panel

Miniature Circuit Breaker

Neutral Earthing Contact

PowerCommand Control System II

Quadrature Current Control

Radio Frequency Interference

Potential Transformer / Current Transformer

Standard PCC II Control System

Standard PCC II Control System

SECTION 1 PRELIMINARY AND SAFETY

Warning, Caution and Note Styles Used In This Manual

WARNS OF A HAZARD THAT MAY RESULT IN SEVERE PERSONAL

Warns of a hazard or an unsafe practice that can result in product or

IT IS IMPORTANT TO READ AND UNDERSTAND ALL SAFETY

ELECTRICITY CAN KILL! LETHAL VOLTAGES MAY BE PRESENT

1.2.2 High Pressures

LIQUIDS OR GASES THAT ARE HIGHLY PRESSURISED CAN PASS

Section 1 Preliminary and Safety

Standard PCC II Control System

ONLY AUTHORISED AND COMPETENT PERSONNEL WHO ARE

DEPENDENT UPON THE CONTROL SYSTEM FITTED, THIS UNIT

1.2.4 Supply Isolation

BEFORE CARRYING OUT ANY MAINTENANCE, ISOLATE ALL

Turn the Mode switch on the control panel to Off (O)

Isolate the fuel supply to the engine.

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

Radio Frequency Warning

Standards, Codes & Regulations

The Health & Safety at work Act 1974

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