Manual PCS 3300 - Gas

Owners Manual
Gas Generator Set

with PowerCommand 3.3 Control
C995 N5C
C1160 N5C
C1200 N5C
C1400 N5C
C1540 N5C
C1750 N5C
C2000 N5C
C1000 N6C
C1100 N6C
C1250 N6C
C1400 N6C
C1540 N6C
C1750 N6C
C2000 N6C
English Original Instructions 4-2012 0908-0209 (Issue3)

ii
Generator Set Owners Manual Publication 0908-0209
PowerCommand 3.3 Control Issue 3 4-2012
FOREWORD
The purpose of this manual is to provide guidance and assistance with recommendations for correct and
safe procedures to the Generator Set Operator for the use and basic maintenance of the Generator Set.
Refer to the Generator set's specific Operator's Manual for additional information which must also be read
before operating the generator set. 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 continuous development and improvement,
information may change at any time without notice. The Operator should therefore ensure that before
commencing any work, they have the latest information available.
Operators 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. Consult your Authorised Distributor for further
installation information. It is essential that the utmost care is taken with the application, installation and
operation of any engine due to their potentially dangerous nature. Careful reference should also be made to
other Cummins Power Generation Limited literature, in particular the Health and Safety Manual 0908-0110.
Should you require further assistance contact: -
Cummins Power Generation Cummins Power Generation Cummins Power Generation

rd
1400 73 Avenue NE Columbus Avenue 10 Toh Guan Road #07-01
Minneapolis Manston Park TT International Tradepark
MN 55432 Manston Singapore 608838
USA Ramsgate
Kent CT12 5BF
United Kingdom
Tel:+1 (763) 574-5000 Tel:+44 (0) 1843 255000 Tel: (65) 6417 2388
Fax:+1 (763) 574-5298 Fax:+44 (0) 1843 255902 Fax:(65) 6417 2399
e-mail: pgamail@cummins.com e-mail: cpgk.uk@cummins.com e-mail: cpg.apmktg@cummins.com
Web: www.cumminspower.com Web: www.cumminspower.com Web: www.cumminspower.com
Cummins Power Generation Cummins Power Generation

35A/1/2, Erandawana Rua Jati, 310 - Cumbica
Pune 411 038 Guarulhos SP
India Brazil
CEP: 07180-900
Tel.: (91 020) 3024 8600 Tel.: (55 11) 2186 4195
Fax: (91 020) 6602 8090 Fax: (55 11) 2186 4729
e-mail: e-mail: falecom@cumminspower.com.br

cpgiservicesupport@cummins.com
Web: www.cumminspower.com Web: www.cumminspower.com
iii
Publication 0908-0209 Generator Set Owners Manual
Issue 3 4-2012 PowerCommand 3.3 Control
Supplementary Publications
There are publications appropriate to your system that supplement the content of this manual
which are listed below.
Publications delivered with the generator set are include the Engine Operation and Maintenance
Manual, Alternator Manual, Engine Parts Catalogue, Engine Alternator Coupling, Gearbox
Operator Manual, Installation Manual, Inspection and Test Certificates .
Contact your authorised distributor if you require further generator set publications/documentation.
Engine Specific Publications Operator Level

Caution: Important, additional engine specific information is contained within the Engine
Operators Manual. This information must be read before attempting to run the
generator set.
The relevant engine specific manual for the engine model employed in your generator set must be
read in conjunction with this manual for the safe operation and maintenance of this generator set.
Refer to Section 2.2 for information on how to identify your generator set engine model and rating.
Title Publication No
Health and Safety 0908-0110
Storage, Commissioning and Maintenance of Lead Acid Batteries 0908-0101
PowerCommand 3.x Controller Service Manual 900-0670
QSV81/91 Operation and Maintenance Manual 4021313
QSK60 Operation and Maintenance Manual 4021395
QSV81/91 Generator Set Troubleshooting & Repair Manual 4021314
QSK60 Generator Set Troubleshooting & Repair Manual 4021396
Owners Manual QSV81G and QSV91G Series Engines 4915546
Owners Manual QSK60G Series Engine 4915558
Gas Warranty Statement 3624642
Installation Manual A029R140
If further information is required contact your authorised distributor.
iv
CONTENTS
Section Title Page
Schedule of Abbreviations .............................................................................................. ix
1. Safety ....................................................................................................................... 1
1.1 Warning, Caution and Note Styles Used In This Manual ................................................................1
1.2 General Information ........................................................................................................................1
1.3 Generator Plant Safety Code ..........................................................................................................1
1.3.1 Spillage .....................................................................................................................................2
1.3.2 Electrical Equipment .................................................................................................................2
1.3.3 Engine Exhaust.........................................................................................................................2
1.3.4 Natural Gas...............................................................................................................................3
1.3.5 Maintenance .............................................................................................................................3
1.3.6 Moving Components .................................................................................................................3
1.3.7 General Safety ..........................................................................................................................4
2. Introduction ............................................................................................................. 5
2.1 General............................................................................................................................................5
2.2 Generator Set Identification ............................................................................................................5
2.3 After Sales Services ........................................................................................................................7
2.3.1 Maintenance .............................................................................................................................7
2.3.2 Warranty ...................................................................................................................................7
2.3.3 Service Parts ............................................................................................................................7
2.3.4 International Support ................................................................................................................7
2.4 Project Details .................................................................................................................................8
3. Generator Set Components ................................................................................... 9

3.1 Generator rating ............................................................................................................................10
3.1.1 Gas Train (Option) ..................................................................................................................10
3.2 Heaters ..........................................................................................................................................10
3.2.1 Heater Supply and Isolation ...................................................................................................10
3.3 Oil Specification ............................................................................................................................10
3.4 Coolant Specification ....................................................................................................................12
4. Control System ..................................................................................................... 13

4.1 Control System Description...........................................................................................................13
4.1.1 Power On/Off Modes ..............................................................................................................14
4.1.2 Operating Modes ....................................................................................................................14
4.2 Display Module - Front Panel ........................................................................................................15
4.2.1 Lamp Indicators ......................................................................................................................16
4.2.2 Lamp (LED) Test Button .........................................................................................................16
4.2.3 Reset Button ...........................................................................................................................16
4.2.4 Manual Button.........................................................................................................................16
4.2.5 Start Button .............................................................................................................................17
4.2.6 Auto Button` ............................................................................................................................17
4.2.7 Stop Button .............................................................................................................................17
4.2.8 CB Closed...............................................................................................................................17
4.2.9 CB Open .................................................................................................................................17
4.2.10 Graphical Display and Buttons ...............................................................................................18
4.2.11 Selection Buttons ....................................................................................................................20
4.2.12 Default Settings ......................................................................................................................20
4.3 Display Module Initial Operator Menu ........................................................................................21
4.3.1 Initial Menu Data .....................................................................................................................21
4.4 Display Module Genset Data Operator Menu ............................................................................23
4.4.1 Generator Data .......................................................................................................................23
4.5 Display Module Alternator Data Operator Menu ........................................................................25
Contents Page v
4.5.1 Alternator Data ....................................................................................................................... 25

4.6 Display Module Engine Data Operator Menu............................................................................ 27
4.6.1 Engine Data ........................................................................................................................... 27
4.6.2 History/About Menu ............................................................................................................... 29
4.7 Display Module Faults and Warnings Menus ............................................................................. 31
4.7.1 Fault Messages...................................................................................................................... 31
4.7.2 Fault Acknowledgement......................................................................................................... 31
4.7.3 Shutdown Fault Menu ............................................................................................................ 31
4.7.4 Warning Fault Menu............................................................................................................... 33
4.7.5 Faults History Data Operator Menu ....................................................................................... 35
4.8 Display Module - Adjust Menu...................................................................................................... 37
4.9 Display Module Genset Setup Data Operator Menu ................................................................. 39
4.10 Display Module Paralleling Status Menu................................................................................... 41
4.11 Display Module Paralleling/Basic Setup Menu.......................................................................... 44
4.12 Selecting Operating Modes .......................................................................................................... 47
4.12.1 Entering the Mode Change Access Code.............................................................................. 47
4.12.2 Selecting Manual Run Mode .................................................................................................. 48
4.12.3 Selecting Auto Mode .............................................................................................................. 49
4.12.4 Selecting Off Mode ................................................................................................................ 50
5. Operation ............................................................................................................... 51
5.1 Safety ........................................................................................................................................... 51
5.2 Introduction ................................................................................................................................... 51
5.3 Maintenance ................................................................................................................................. 51
5.4 Operating Recommendations....................................................................................................... 52
5.4.1 Running in ............................................................................................................................ 52
5.4.2 No Load Operation................................................................................................................. 52
5.4.3 Exercise Period ...................................................................................................................... 52
5.4.4 Low Operating Temperatures ................................................................................................ 52
5.4.5 High Operating Temperatures ............................................................................................... 52
5.4.6 Operating Conditions for Prime, Standby and Continuous Power Ratings ........................... 53
5.4.7 De-Rating Factors .................................................................................................................. 54
5.5 Generator Set Operation .............................................................................................................. 55
5.5.1 Sequence of Operation .......................................................................................................... 56
5.6 Starting ......................................................................................................................................... 57
5.6.1 Initial Pre-Start Checks .......................................................................................................... 58
5.6.2 Operators Pre-Start Checks .................................................................................................. 59
5.6.3 Starting at Display Panel (Manual Run Mode) ...................................................................... 60
5.6.4 Starting from Remote Location (Auto Mode) ......................................................................... 61
5.6.5 Cold Starting with Loads ........................................................................................................ 61
5.7 Stopping ....................................................................................................................................... 62
5.7.1 Stopping at Display Panel (Manual Mode) ............................................................................ 62
5.7.2 Stopping from Display Panel (Auto Mode) ............................................................................ 62
5.7.3 Stopping from Remote Location (Auto Mode) ....................................................................... 62
5.7.4 Emergency Stop (Code 1433) ............................................................................................... 63
Paralleling Operation ....................................................................................................................................... 64
5.7.5 Speed and Voltage Matching ................................................................................................. 64
5.7.6 Operation When in Parallel .................................................................................................... 64
5.7.7 Generator Set Application Type............................................................................................. 65
5.7.8 Standalone Application .......................................................................................................... 66
5.7.9 Synchronise Only ................................................................................................................... 67
5.7.10 Isolated Bus Only ................................................................................................................... 68
5.7.11 Power Transfer Control (Option)......................................................................................... 70
5.7.12 Conditions for Each Paralleling State .................................................................................... 75
5.7.13 Multiple Utility ......................................................................................................................... 80
6. Maintenance .......................................................................................................... 85
6.1 General ......................................................................................................................................... 86
6.2 Locking the Generator Set Out of Service ................................................................................... 88
Page vi Contents
6.2.1 Introduction .............................................................................................................................88

6.2.2 Precautions with Natural Gas .................................................................................................88
6.2.3 Immobilising the Plant for Safe Working.................................................................................89
6.3 Daily Maintenance Procedures .....................................................................................................89
6.3.1 General Information ................................................................................................................89
6.3.2 Engine Operation Report ........................................................................................................90
6.4 Cooling System .............................................................................................................................90
6.4.1 Coolant Level - Check ............................................................................................................91
6.4.2 Plant Cooling Fan - Inspect ....................................................................................................92
6.4.3 Plant Radiator - Check ...........................................................................................................92
6.5 Air Cleaner Restriction Indicator Check .....................................................................................92
6.6 Gearbox Inspection .......................................................................................................................93
6.7 Engine Oil ......................................................................................................................................93
6.7.1 Engine Oil Level Check .......................................................................................................93
6.8 Lubricating Oil Analysis .................................................................................................................94
6.9 Fuel System ..................................................................................................................................95
6.9.1 Fuel consumption ...................................................................................................................95
6.9.2 Methane Index ........................................................................................................................96
6.9.3 De-rate ....................................................................................................................................96
6.10 Hoses - Check ...............................................................................................................................96
6.11 Exhaust System ............................................................................................................................97
6.12 Generator Set Output - AC Electrical System ...............................................................................97
6.13 DC Electrical System ....................................................................................................................97
6.14 Storage and Lay-up of Generator Set ...........................................................................................97
7. Troubleshooting ................................................................................................... 99
7.1 Introduction....................................................................................................................................99
7.2 Control Unit ...................................................................................................................................99
7.3 Safety Considerations .................................................................................................................100
7.4 Fault Finding................................................................................................................................101
7.5 Status Indicators .........................................................................................................................102
7.6 Fault/Status Codes ......................................................................................................................103
7.6.1 Fault Messages ....................................................................................................................103
7.6.2 Fault Acknowledgement .......................................................................................................103
7.6.3 Customer Input Faults ..........................................................................................................111
Contents Page vii

This Page Has Been Left Intentionally Blank
Page viii Contents

Schedule of Abbreviations
AC Alternating Current kVA Apparent Power
ACB Air Circuit Breaker kVAR Reactive Power
ACH Anti-Condensation Heaters kW Active / Real Power
Ah Ampere Hour kWh Unit of electrical energy or work
AMU Analog Monitoring Unit l Litres
ATS Automatic Transfer Switch LCD Liquid Crystal Display
AVR Automatic Voltage Regulator LED Light-Emitting Diode
bar Kilograms per square centimetre LT Low Temperature
BHP Brake Horsepower LTA Low Temperature Aftercooling
BMS Building Management System LTP Limited Time Power Rating
BS British Standard LV Low Voltage
BSI British Standard Institute m Metres
BST Busbar Sensing Transformer mbar Millibars
o
C DEGREES CENTIGRADE MCB Miniature Circuit Breaker
CB Circuit Breaker MCC Motor Control Centre
CCA Cold Cranking Amps MCCB Moulded Case Circuit Breaker
CCD Capacity Coil Driver MCM Master Control Module
CCW Counter Clockwise MF Mains Failed
CEC Cummins Engine Company MFSS Master First Start Sensor
CENSE Cummins Engine Sensor Equipment Min Minute
CHP Combined Heat and Power MR Mains Returned
CM Command Module MST Mains Sensing Transformer
COP Continuous Power Rating MSU Mains Sensing Unit
COSHH Control of Substances Hazardous to Health MV Medium Voltage
CPG Cummins Power Generation NEC Neutral Earthing Contact
CT Current Transformer PCC PowerCommandTM Control
dB(A) Unit of noise level PCL A low cost power system
DBVV Double Block & Vent Valve PCS PowerCommandTM Supervisor
DC Direct Current PDM Prognostic Diagnostic Module
DIP Dual In-line Package PF Power Factor
DMC Digital Master Control PFC Power Factor Controll
DMSU Demand Load Standby Unit PLC Programmable Logic Controller
EEC European Economic Community PMG Permanent Magnet Generator
e.g For Example PRP Prime Power Rating
EMCU Engine Monitoring and Control Unit PRV Pressure Relief Valve
EMF Electromotive Force PSI Pounds per Square Inch
EMI Electromagnetic Interference PSU Power Supply Unit
EPU Engine Protection Unit PT/CT Potential Transformer / Current Transformer
Etc. Etcetera Quad Quadrature
o
F Degrees Fahrenheit QCC Quadrature Current Control
FCA Fuel Control Assembly RFI Radio Frequency Interference
FSS First Start Sensor RMS Root Mean Square
GCM Generator Control Module RMS Remote Monitoring System
GCP Generator Control Panel RPM Revolutions Per Minute
Genset Generator Set RTD Resistance Temperature Detector
GIB Generator Interface Box Secs Seconds
GKWT Global Kilowatt Transducer SSM Sub-System Module
GSOV Gas Shut-off Valve TBD To Be Defined
HMI Human-Machine Interface TBN Total Base Number
HT High Temperature V Volts
HV High Voltage VAC Volts, Alternating Current
Hz Hertz VCB Vacuum Circuit Breaker
IC Integrated Circuit VDC Volts, Direct Current
IEC International Electro-technical Commission VF Volt-free
IEE Institute of Electrical Engineers Vol Volume
I/O Input / Output VT Voltage Transformer
ISO International Standards Organisation
Schedule of Abbreviations Page ix

Page x Schedule of Abbreviations

PowerCommand 3.3 Issue 3 4 2012
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
for 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: A short piece of text giving information that augments the current text.
1.2 General Information

This manual should form part of the documentation package supplied by Cummins Power
Generation Limited with specific generator sets. In the event that this manual has been supplied in
isolation please contact your authorized Cummins Distributor for referral to key associated
materials, in particular the Health and Safety Manual (0908-0110).
Note: It is in the Operators interest to read and understand all Health and Safety
information together with all Warnings and Cautions contained within the
documentation relevant to the generator set, its operation and daily maintenance.
1.3 Generator Plant Safety Code

Before operating the generator set, read the manuals and become familiar with them 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.
WARNING: IMPROPER OPERATION AND MAINTENANCE CAN LEAD TO SEVERE
PERSONAL INJURY OR LOSS OF LIFE AND PROPERTY BY FIRE,
ELECTROCUTION, MECHANICAL BREAKDOWN OR GAS AND EXHAUST GAS
ASPHYXIATION. READ AND FOLLOW ALL SAFETY PRECAUTIONS,
WARNINGS AND CAUTIONS THROUGHOUT THIS MANUAL AND THE HEALTH
AND SAFETY MANUAL 0908-0110.
CAUTION: Failure to follow recommended procedures when welding on or around the
generator set may result in serious, irreversible damage to one or more of the
electronic modules or sensors. Consult your authorised distributor for recommended
procedures to protect ECMs prior to welding
CAUTION: Disconnect both the positive (+) and negative (-) battery cables from the battery
before welding on the set. Disconnect all Electronic Devices, such as Electronic
Control Modules (ECM's), Ignition Modules, Electronic Throttles and Pressure
Sensors, etc. Isolate the Generator Set Control Panel. Attach the welder ground
cable no more than 0.61 meters [2 feet] from the part being welded. Do not connect
the ground cable of the welder to the ECM cooling plate or ECM. Welding on the
engine or engine mounted components is not recommended.
Section 1 Preliminary and Safety Page 1

WARNING: LIFTING AND REPOSITIONING ON THE GENERATOR SET MUST ONLY BE

CARRIED OUT USING SUITABLE LIFTING EQUIPMENT, SHACKLES AND
SPREADER BARS IN ACCORDANCE WITH LOCAL GUIDELINES AND
LEGISLATION BY SUITABLY TRAINED AND EXPERIENCED PERSONNEL.
INCORRECT LIFTING CAN RESULT IN SEVERE PERSONAL INJURY, DEATH
AND/OR EQUIPMENT DAMAGE. FOR MORE INFORMATION CONTACT YOUR
AUTHORISED DISTRIBUTOR.
1.3.1 Spillage
Any spillage that occurs during oil top-up or oil change must be cleaned up before starting the
generator set.
Note: Where spillage containment is not part of Cummins supply, it is the responsibility of
the installer to provide the necessary containment to prevent contamination of the
environment, especially water courses/sources.
1.3.2 Electrical Equipment

WARNING: ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH.
Remove electrical power before removing protective shields or touching electrical equipment.
Use rubber insulating mats placed on dry wood platforms over floors that are metal or
concrete when around electrical equipment. Do not wear damp clothing (particularly wet
shoes) or allow skin surface to be damp when handling electrical equipment. Do not wear
jewelry; jewelry can short out electrical contacts and cause shock or burning.
Do not tamper with interlocks.
Follow all applicable state and local electrical codes. Tag and lock open switches to avoid
accidental closure.
Medium Voltage (601V to 15kV) behaves differently than low voltage. Special equipment and
training is required to work on or around medium voltage equipment. Operation and
maintenance must be done only by persons trained and qualified to work on such devices.
Do not work on energized equipment. Unauthorized personnel must not be permitted near
energized equipment. Due to the nature of medium voltage electrical equipment, induced
voltage remains even after the equipment is disconnected from the power source. Plan the
time for maintenance with authorized personnel so that the equipment can be de-energized
and safely grounded.
1.3.3 Engine Exhaust

WARNING: EXHAUST PIPES AND CHARGE AIR PIPES ARE VERY HOT AND THEY CAN
CAUSE SEVERE PERSONAL INJURY OR DEATH FROM DIRECT CONTACT
OR FROM FIRE HAZARD.
WARNING: HOT EXHAUST GAS CAN CAUSE BURNS RESULTING IN SEVERE PERSONAL
INJURY.
The exhaust outlet may be sited at the top of the set, make sure that the exhaust outlet is not
obstructed. Personnel using this equipment must be made aware of the exhaust position.
WARNING: CONTAMINATED INSULATION IS A FIRE RISK WHICH CAN RESULT IN
SEVERE PERSONAL INJURY.
The exhaust pipes may have some insulating covers fitted. If these covers become contaminated
by oil they must be replaced before the generator set is run.
To minimise the risk of fire ensure the following steps are observed:
Ensure that the engine is allowed to cool thoroughly before topping up the oil.
Page 2 Section 1 Preliminary and Safety

PowerCommand 3.3 Issue 3 4 2012
Clean the exhaust pipe thoroughly. - Visually and audibly inspect the exhaust system daily for
leaks per the maintenance schedule. Make sure the exhaust manifolds are secured and not
warped.
Ensure the unit is well ventilated.
WARNING: ENGINE EXHAUST AND SOME OF ITS CONSTITUENTS ARE KNOWN TO THE
STATE OF CALIFORNIA, USA, TO CAUSE CANCER, BIRTH DEFECTS AND
OTHER REPRODUCTIVE HARM.
1.3.4 Natural Gas

WARNING: NATURAL GAS IS DANGEROUS IF LEAKAGE OCCURS. RELATIVELY LOW
LEVELS OF GAS LEAKAGE IN CONFINED AREAS CAN CAUSE EXPLOSIONS
AND FIRES IF A SPARK OCCURS TO IGNITE IT. INHALATION OF LARGE
VOLUMES OF NATURAL GAS CAN CAUSE ASPHYXIATION AND DEATH.
Pipeline Natural Gas is lighter than air. If leakage occurs the gas will first accumulate at high
levels, including ceiling voids. Gas detection equipment should be installed at high level to be
effective. If leakage occurs isolate the gas supply, do not operate any equipment (electrical or
otherwise) that may cause a spark or may be a source of ignition, evacuate the building and
completely ventilate the area. Only suitable qualified personnel who are adequately trained to
manage natural gas emergencies are to be allowed near the plant room or generator set(s) in such
emergencies.
Non-Pipeline Gas Generator Sets are designated by Cummins, Inc. as Low Btu Generator Sets.
Non-Pipeline Gas classification includes Landfill Gas, Digester Gas, Well Head Gas and Coal Bed
Methane. Non-pipeline gas, depending on its properties, can be lighter than air, neutral, or heavier
than air. If leakage occurs the gas can accumulate either at high level, mid-level or low level. Gas
detection equipment siting is dependant upon the properties of the gas.
Non-pipeline gases may also contain other substances which may be harmful and can cause
personal injury or death. Analysis of the non-pipeline gas available at site should be performed to
identify the gases properties and consistencies.
Shut down the generator set by following the shut down procedure as described in Section 5
Operation. Fully shut the gas train shut-off valve(s). Fully shut all external gas supply valves to the
generator set. Alert the emergency services and local gas supplier.
1.3.5 Maintenance
Note: Maintenance work, particularly in confined areas, should be carried out by two
engineers working together
Caution: Installation, maintenance and testing of gas pipe work system should be carried out
by suitably qualified personnel.
1.3.6 Moving Components

WARNING: MOVING COMPONENTS OF THE GENERATOR SET CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH.
Follow all health and safety guidelines associated with safe operation and maintenance of the
generator set.
Keep your hands, clothing and jewellery away from moving parts. Before starting work on the
generator set, be sure to properly lock and tag out the equipment and immobilise the plant for safe
working. Make sure fasteners on the generator set are secure. Tighten supports and clamps and
keep guards in position. If adjustments must be made while the generator set is running, use
extreme caution around the hot exhaust manifolds and other moving parts.
Section 1 Preliminary and Safety Page 3

1.3.7 General Safety

WARNING: COOLANTS UNDER PRESSURE HAVE A HIGHER BOILING POINT THAN
WATER. DO NOT OPEN A RADIATOR OR HEAT EXCHANGER PRESSURE
CAP WHILE THE ENGINE IS RUNNING. ALLOW THE ENGINE TO COOL AND
BLEED THE SYSTEM PRESSURE FIRST.
WARNING: USED ENGINE OILS HAVE BEEN IDENTIFIED BY SOME STATE OR FEDERAL
AGENCIES AS CAUSING CANCER OR REPRODUCTIVE TOXICITY. WHEN
CHECKING OR CHANGING ENGINE OIL, TAKE CARE NOT TO INGEST,
BREATHE THE FUMES OR CONTACT USED OIL.
Keep multi-class ABC fire extinguishers near generator set.
Make sure rags are not left on or near the engine and that combustible materials cannot
accumulate under the generator set.
Remove all unnecessary grease and oil from the unit. Accumulated grease and oil can cause
engine overheating and present a potential fire hazard.
Keep the generator set and the surrounding area clean and free from obstructions. Remove
any debris from the set and keep the floor clean and dry.
Do not work on the equipment when mentally or physically fatigued, or after consuming any
alcohol or drug.
Wear hearing protection when going near an operating generator set. For noise levels at the
operating position on the generator set refer to your authorised distributor.
For information on lifting and transportation on the generator set refer to the Installation
manual accompanying your set.
Page 4 Section 1 Preliminary and Safety

SECTION 2 - INTRODUCTION
2. Introduction
2.1 General
Before any attempt is made to operate the generator set, the Operator should take time to read all
of the manuals supplied with the generator set, and to familiarise themselves with the Warnings
and Operating Procedures.
A generator set must be operated and maintained properly if you are to expect safe and reliable
operation. This manual includes a maintenance schedule and a troubleshooting guide.
2.2 Generator Set Identification

Each generator set is provided with a Generator Set Rating Plate similar to that shown below. This
provides information unique to the generator set. The generator set dataplate is attached to the
alternator terminal box. The dataplate contains the model number, serial number, and options
used to build the generator set. These numbers must be referenced when ordering parts.
Generator set rating plate (Figure 1) and engine dataplate (Figure 2) mounting positions are
indicated in section 3.1 Generator Components
Figure 1 Typical Generator Set Rating Plate
Section 2 Introduction Page 5

The engine dataplate shows specific information about your engine. The engine serial number
(ESN) (1), Critical Parts List (CPL) (2), Model (3), provide information for ordering parts and
service needs.
The engine dataplate is located on the right side of the engine as view from the alternator end.
NOTE: The engine dataplate must not be changed unless approved by Cummins Inc.
Figure 2 Typical Engine Data Plate
Page 6 Section 2 Introduction

2.3 After Sales Services

Cummins offer a full range of after sales services as follows:
2.3.1 Maintenance
WARNING: INCORRECT SERVICE OR PARTS REPLACEMENT CAN RESULT IN SEVERE
PERSONAL INJURY, DEATH, AND/OR EQUIPMENT DAMAGE. SERVICE
PERSONNEL MUST BE TRAINED AND EXPERIENCED TO PERFORM
ELECTRICAL AND/OR MECHANICAL SERVICE.
If you wish to have your generator set(s) serviced and maintained by qualified experts, contact
your authorized Cummins distributor for complete maintenance contract packages. Contract
packages may cover all items subject to routine maintenance and includes a detailed report on the
condition of the generator set. Additionally, maintenance contracts may provide access to a means
for 24-hour technical support and specialized engineers who can ensure your generator set
maintains optimum performance.
2.3.2 Warranty
Standard Warranty for this generator set is 12 months from the commissioning date; extended
warranty coverage is also available. For more warranty details, refer to the warranty administration
manual (4021290) or contact your authorized distributor.
For further warranty details contact your authorised distributor.
Note: Damage to any component will be rejected if the incorrect mix of anti-freeze has
been used. Please contact your authorised Cummins distributor.
2.3.3 Service Parts

Service parts for your generator set may be obtained by contacting your authorized Cummins
distributor. Be prepared to provide Plan Numbers, Serial Numbers, and Part Numbers when
ordering. Complete section 2.4 Project Details to assist in identifying these numbers
2.3.4 International Support

Agents and representatives throughout the world offer installation and after sales support for the
equipment provided. Contact your authorized distributor for more detail.
Section 2 Introduction Page 7

2.4 Project Details

It is important when contacting your authorised distributor to have project information at hand.
Complete this form in order to assist you and the distributor when referencing the installation.
(Make duplicate copies of this page as required)
BALANCE OF PLANT DETAILS
Project Title
Company Name
Address
Contact Name
Phone Numbers Tel: Mobile:

Email
SITE DETAILS
Customer Order
Number
Site Name
Address
Contact Name
Phone Numbers Tel: Mobile:

Email
EQUIPMENT DETAILS
Generator
Model(s)
Number of Sets
Generator Set
Serial Number
Engine Serial
Number
Alternator Serial
Number
Date of
Commissioning
Additional
Information
Page 8 Section 2 Introduction

SECTION 3 SYSTEM OVERVIEW
3. Generator Set Components

The locations of mechanical and electrical ancillary equipment for a typical Natural Gas generator
set referred to in this manual are shown in below. Refer to the Engine Manual for more detailed
information.
Figure 3 Typical Generator Set Ancillary Equipment
1 Gas Mass Flow Valve 14 Lube-oil Make-up Valve 27 CENSE Module

2 Air Filter 15 DSSOV Solenoid Shut Off Valve 28 Governor Actuator Module
3 Turbocharger 16 Gas Pipe 29 Low Temp Water Coolant pipe
4 Fuel/Air Mixer 17 Vent Valve 30 Steel Bedframe
5 Gas Mass Flow Valve 18 Centrifugal Oil Filter 31 Electric Starter Motor (Option)
6 Crankcase Breather Filter 19 AVR/Controls Box 32 AC Auxiliaries Box
7 Alternator 20 Lube Oil Filters 33 Exhaust Bellows
8 Genset Terminal Box 21 Coolant Water Pump 34 Gearbox
9 Generator Set Dataplate 22 Spark Plugs & Ignition Coils 35 Lifting Point
10 Dirty Fuel Leak-off Tank 23 Multihousing Cover 36 Jacking Point
11 Engine Dataplate 24 Lube Oil Cooler Coolant Return Pipe 37 High Temp Water Coolant pipe
12 Aftercooler 25 Flotech Gas Valve
13 Lube-oil Dipstick 26 Governor Driver Modules
Section 3 System Overview Page 9

3.1 Generator rating

For details of your generator set rating refer to the Generator Set Rating Plate. Refer to Section
5.4 for operation at temperatures or altitudes above those stated on the Rating Plate.
3.1.1 Gas Train (Option)

Natural Gas is supplied to the engines fuel management system through a flexible pipe attached
to a gas train. The gas train includes a main shut-off valve and other gas control components.
Control equipment for the fuel/air ratio and engine speed, are provided on the generator set.
A typical gas train, starting at the gas main supply point, includes the components shown below:
Figure 4- Typical Gas Train
1 Gas Shut-off Valve (GSOV) 5 Pressure Relief Valve (PRV)

2 Filter 6 Flexible Pipe
3 Flowmeter (optional) 7 Double Block & Double Solenoid Shut Off Valve
4 Pressure Regulator (DSSOV) (Mounted off-genset - Option)
3.2 Heaters
Caution: Coolant heater(s) must not be energised if the coolant system has been drained.
Engine coolant heaters are intended to be used when preparing the generator set for operation by
maintaining the engine's coolant and oil temperature near or above the engine's threshold for
minimum temperature during operation. Engine oil heaters (optional) are intended to supplement
engine coolant heater where they are not capable of maintaining the engine's coolant temperature
near or above the engine's threshold for minimum operating temperature.
Alternator heaters are intended to be used prior to generator set startup to heat the alternator
stator and expel any moisture accumulation.
3.2.1 Heater Supply and Isolation

A heater supply is required for the operation of the engine and alternator heaters (if fitted). These
are powered from the utility auxiliary VAC supply in the GIB (Generator set Interface Box).
3.3 Oil Specification

Caution: High quality engine oil, approved by Cummins should be used only. The use of
unapproved oil may cause severe damage to the engine.
Selecting and using the correct grade of engine oil is critical for achieving engine service life,
engine reliability and performance.
Page 10 Section 3 System Overview

It is important to understand that the generator set must be operated and maintained in
accordance to Cummins published recommendations. Failure to follow applicable service intervals
and recommendations in the Operation and Maintenance Manual applicable to the engine can
result in severe engine damage. Consult your authorised distributor for more information.
Use high-quality SAE40 (mono-grade) NG engine oils, such as Valvoline Premium Blue GEO LA
or its equivalent. The use of the Premium Grade Long Change Interval oils are strongly
recommended. The SAE40 oils approved for use in Cummins HHP natural gas fuelled engines are
as follows:
QSV 91G 2MWe Engine (18.2Bar BMEP Models): C2000 N5C, C2000 N6C
Manufacturer Oil Names Grade TBN Sulphated Ash %
Mobil Pegasus 805* SAE40 6.2 0.54
Valvoline Premium Blue GEO LA* SAE40 5.5 0.44
Shell Mysella XL* SAE40 4.5 0.48
*Premium grade oil
QSV 81/91G Engine (14 & 16Bar BMEP Models): C1540 N5C, C1750 N5C, C1250 N6C, C1540
N6C, C1750 N6C
Mobil Pegasus 705 SAE40 5.6 0.52
Elf Nateria MH40 SAE40 5.2 0.45
Shell Mysella LA SAE40 5.0 0.45
Caltex Geostar LA SAE40 5.2 0.49
* Premium grade oil
QSK 60G Engine (Multi and Single-Turbocharger Models): C995 N5C, C1160 N5C, C1200 N5C,
C1400 N5C, C1000 N6C, C1100 N6C, C1400 N6C
Valvoline Premium Blue GEO MA* SAE40 7.2 0.7
*Premium grade oil

Cummins strongly recommends regular oil sampling and analysis. If regular oil analysis is not
performed, then the oil change interval is reduced and oil analysis must be carried out
immediately prior to the oil change to determine that the oil contamination was within acceptable
limits at the time of the oil change. Refer to the engine specific Operation and Maintenance manual
for guidance on intervals and procedures.
3.3.1 Low BTU Gas Engines

Cummins Inc., recommends the use of a high quality SAE40 lubricating oil specifically formulated
for use in Low BTU and aggressive gaseous fueled engines.
Various lubricating oil brands are available worldwide and careful selection is required to match the
product with the type of fuel in use. Cummins Inc. has Low BTU engines operating experience with
ChevronTexaco and ExxonMobil who offer a wide range of products for the various categories of
fuel.
Section 3 System Overview Page 11

The more acidic fuel sources require oil with a higher Total Base Number (TBN) to protect the
engine.
Supplier Product Fuel

Chevron Texaco (Caltex) Geotex LA Pipeline Natural Gas

Geotex HD Non-Pipeline Natural Gas
Geotex LF Non-Pipeline Natural Gas

Geotex HDAX LA Natural Gas
Geotex HDAX LFG Non-Pipeline Natural Gas

ExxonMobil Pegasus 805 Natural Gas
Pegasus 605 Non-Pipeline Natural Gas

Pegasus 610 Non-Pipeline Natural Gas
3.4 Coolant Specification

Caution: Incorrect coolant concentration or level may allow an engine to overheat without
protection of shutdown device, and cause severe damage to the engine. Maintain
coolant level for proper operation of high engine temperature shutdown system.
It is important that the quality of coolant used in Cummins engines meets the Cummins
recommended specifications (Consult your authorised distributor). A premixed fully formulated
coolant or a 50/50 mixture of high quality water and fully formulated concentrated anti-freeze must
meet Cummins Engineering Standard 14603.
Cummins recommend the use of Fleetguard Antifreeze Coolant ES Compleat containing DCA4
Plus.
For filling and maintenance of Cooling Systems refer to the Operation and Maintenance Manual, or
consult your authorised distributor.
Page 12 Section 3 System Overview

SECTION 4 CONTROL SYSTEM

4. Control System
4.1 Control System Description
The control system is used to start and stop the generator set from the display screen in either
Manual or Auto mode. It is suitable for stand alone or paralleling generator sets in both standby
and prime-power applications, providing full generator set monitoring capability and protection. It
monitors the engine for temperature, oil pressure and speed, and provides voltage and current
metering. In the event of a fault the unit will indicate the fault type and automatically shut down the
generator set on critical faults.
All indicators, control buttons and the display screen are on the face of the display module as
illustrated in Figure 6.
There are two fault level signals generated by the control system as follows:
Warning: - signals an imminent or non-critical fault for the engine. The control provides an
indication only for this condition.
Shutdown: - signals a potentially critical fault for the engine. The control will immediately take
the engine off-load and automatically shut it down.
The standard control system operates on 12 or 24VDC battery power. The auxiliary equipment
operates on LV AC power. The history data is stored in non-volatile memory and will not be
deleted due to loss of battery power.
Figure 5 Typical Control System Panel
KEY
1. Display Module
2. Emergency Stop Button
Section 4 Control System Page 13

4.1.1 Power On/Off Modes

The Power On/Off modes of the control panel and operating software are Power On and Sleep.
Power On Mode
In this mode, power is continuously supplied to the control panel. The controls operating software
and control panel lamps/graphical display will remain active until the Sleep mode is activated.
Sleep Mode
Sleep mode is used to reduce battery power consumption when the control is not being used and it
is in the Off or Auto mode. In this mode, the controls operating software is inactive and the lamps
and graphical display on the control panel are all off.
When all conditions are met (i.e. no unacknowledged faults and the control is in the Off/Auto
mode) the sleep mode is activated after five minutes of keypad inactivity. This length of time is
configurable.
To activate the control and view the menu display without starting the generator set, press any
control button.
Note: Sleep mode can be enabled/disabled, contact your authorised distributor for
options.
4.1.2 Operating Modes

The operating modes of the generator set are Auto, Manual or Off, and may be in stand alone or
paralleling configuration. The required mode is determined by pressing the appropriate button(s)
on the display panel. Refer to Figure 6.
Note: If Mode Change access code feature is enabled, a password is required to use
these buttons to change the mode of operation. Contact you authorised distributor
for options.
Page 14 Section 4 Control System

4.2 Display Module - Front Panel

Figure 6 shows the features of the front panel. It includes ten lamp indicators; the graphical display
with eleven buttons used to navigate through the menus; and eight control mode buttons. This
display panel enables the Operator to look at the status, adjust the settings (optional), and start
and stop the generator set.
Figure 6 Display Module Front Panel
KEY
1. Indicator Lamp Warning 11. Stop Button
2. Indicator Lamp Shutdown 12. Circuit Breaker Close button
3. Indicator Lamp Genset Running 13. Circuit Breaker Open button
4. Indicator Lamp Remote Start 14. Previous Menu Button

Four Change Selection Buttons
5. Indicator Lamp Not in Auto 15.
(Up, Down, Left, Right)
6. Lamp Test Button 16. Item Select Button
7. Reset Button 17. Home Button
8. Manual Button 18. Four Soft-key Buttons(for use with Item 19)
9. Start Button 19. Graphical Display
10. Auto Mode Button

4.2.1 Lamp Indicators

Figure 6 shows the front panel of the Display Module with the following five lamp indicators:
Warning
This yellow lamp is lit whenever the control detects a Warning condition. This lamp is automatically
shut off when the Warning condition no longer exists.
Shutdown Status
This red lamp is lit when the control detects a Shutdown condition. The generator set cannot be
started when this lamp is on. After the condition has been corrected, the lamp can be reset by first
pressing the Stop button and then the Reset button.
Not in Auto
This red lamp will flash when the control is NOT in Auto.
Remote Start
This green lamp indicates the control is receiving a remote run signal. The remote run signal has
no effect unless the generator set is in Auto.
Genset Running
This green lamp is lit when the generator set is running at, or near, rated speed and voltage. This
is not lit while the generator set is warming up or cooling down.
4.2.2 Lamp (LED) Test Button

Press this button to test the lamps (LEDs). All of the lamps should turn on for five
seconds.
Press and hold this for three seconds to turn on or off (to toggle) an external panel
lamp.
4.2.3 Reset Button

Press this to generate a fault reset signal.
If the condition(s) that caused an existing shutdown fault still exists, the generator
set generates the fault again. The Operator Panel always displays any active
shutdown faults, even if the Reset button has been pressed.
If the condition(s) that caused an existing warning fault still exists, the generator set
generates the fault again, but the Operator Panel stops displaying it in the graphical
display.
4.2.4 Manual Button

Press this button to put the generator set into the Manual mode. The Start button
must then be pressed within ten seconds. Failure to do this will result in the
PowerCommand 3.3 control putting the generator set into the Off mode.
The green lamp above this button is lit when the generator set is in Manual mode.
Note: If Mode Change access code feature is enabled, the password must be entered
before pressing the Start button. Refer to Section 4.12.

4.2.5 Start Button

When the Manual button has been pressed, this Start button must be pressed within
ten seconds to start the generator set. The generator set will start up normally but
without the Time Delay to Start.
In other modes, this button has no effect.
Note: If the Start button is not pressed within the ten seconds of pressing the Manual
button, the generator set will change to the Off mode automatically.
4.2.6 Auto Button`

Press this button to put the generator set into the Auto mode. In this mode the
generator is controlled by a remote switch or device (e.g. transfer switch).
The green lamp above this button is lit when the generator set is in Auto mode.
4.2.7 Stop Button

Press this button to put the generator set into the Off mode. This will disable Auto
and Manual modes. The green lamp above this button is lit when the generator set
is in the Off mode.
If the generator set is running, in either Manual or Auto mode, and the Stop button is
pressed, the engine will shut down.
Refer to Sections 4.12.4 and 5.7 for more information on stopping in Auto or Manual
mode.
Note: If possible, hot shutdown under load should be avoided to help prolong the reliability
of the generator set.
4.2.8 CB Closed
This button is for use in Manual mode only. When pressed it will enable the
generator set circuit breaker to close when the set is up to speed and voltage and
therefore ready to accept the load.
Note: This button has no effect unless the bus is dead, or the generator set is
synchronised with the other source. Refer to Section 5.9.5 for further information.
4.2.9 CB Open
This button is for use in Manual mode only. When pressed it will enable the
generator set circuit breaker to open and disconnect from the load.

4.2.10 Graphical Display and Buttons

Figure 7 shows the graphical display and the relevant menu selection buttons.
The graphical display is used to view menus of the menu-driven operating system. System
messages (communication, event, and fault) are also shown on the display.
Four momentary soft-key buttons (item 5) are used to change menus, or pages within each
screen. These selection buttons are active when any text or the up and down triangles ( and
in Area 4) are displayed in the graphical display. Some sub-menus do not include any active
buttons.
Use the graphical display to view event/fault information, status, screens, and parameters.
KEY
DISPLAY PANEL DESCRIPTION
Area 1. Control status
Area 2. Active fault or screen name
Area 3. Relevant data to section 2
Area 4. Additional functions and page up or
down availability
Buttons 5. Selection buttons relevant to Section 4
Buttons 6. Selection change or accept buttons
Figure 7 Graphical Display with Typical Screenshot
Area 1 Control Status

Area 1 displays the status of the controller.
STATUS DESCRIPTION
Ready This is the default state. The controller is ready to start the generator set, or it
has started one of the start sequences but has not started the engine yet.
Starting The controller is starting the engine in one of the start sequences, and the
engine speed is greater than zero.
Idle Warmup The controller is raising the engine speed to idle speed, or the engine is
running at idle speed in one of the start sequences.
Rated Freq and Voltage The controller is raising the engine speed to rated speed; the generator set is
running at rated speed and voltage; or the controller has started one of the
stop sequences but has not started reducing the engine speed yet.
Idle Cooldown The controller is reducing the engine speed to idle speed, or the engine is
running at idle speed in one of the stop sequences.
Stopping The controller is stopping the engine, and the engine speed is still greater than
zero.
Emergency Stop There is an active shutdown fault.
Setup Mode The controller is in Setup mode.
Wait to Powerdown The controller is ready to enter Powerdown mode, but another device is
sending a System Wakeup signal.
Off The controller is in the process of entering power-down mode. The controller is
performing some last-second checks.
Demo Mode The controller is running a demonstration. Every screen is available in the
demonstration, and any changes you make in the demonstration will have no
effect on the controller. To end the demonstration, the Operator Panel must be
powered down.

Area 2 Active Fault or Screen Name

Area 2 displays the screen name and information about the last active shutdown fault. If there are
no active shutdown faults, it displays the last active warning fault.
If there is an active fault, the Operator Panel displays the following information about it:
Fault type
Event/fault code
Name of the controller that detected the fault e.g. the engine ECM unit. This is blank if the
controller detected the fault
Fault name.
If you press the Reset button the Operator Panel stops displaying active warning faults, even if the
condition(s) that caused the fault(s) has not been corrected. The Warning LED remains on,
however.
The Operator Panel always displays any active shutdown faults, even if the Reset button is
pressed.
FAULT TYPE DESCRIPTION

Warning This is a warning fault. (See Section 7 Troubleshooting)
Derate This is a derate fault. (See Section 7 Troubleshooting)
Shutdown This is a shutdown fault that initiates a Shutdown Without Cooldown
sequence. (See Section 7 Troubleshooting)
Shutdown with Cooldown This is a shutdown fault that initiates a Shutdown With Cooldown sequence.
Area 3 Interactive Screen or Menu

Area 3 shows information relevant to Area 2. You can view the operating values for the generator
set, navigate through screens and adjust parameters (if permitted).
The default screen is the Genset Data screen.
The following table explains how the Operator Panel displays when the value of a specific
parameter is missing, unexpected, or outside the range allowed for the parameter.
OPERATOR PANEL DESCRIPTION

NWF Network Failure. There is a PCCNet network failure or a CAN (ECM) failure.
NWF of ECM values will occur just after the engine stops. This is normal
since the ECM keyswitch will not maintain the CAN datalink when the engine
is stopped.
OORL Out of Range Low.
The value is less that the lowest allowed value for this parameter.
OORH Out of Range High.
The value is greater that the highest allowed value for this parameter.
-- -- -- This value is not applicable.
Area 4 Additional Functions Indicators

Area 4 indicates the availability of other menus, additional information, and if further sub-menus
are available (indicated by up or down arrows [ and ]). If that particular page or menu has no
additional information, then no arrow will be visible at this time.
For example if the graphical display is not big enough to display the screen at one time an up
and/or down arrow ( and ) will be visible. Press the appropriate selection button beneath the
graphical display to look at the previous or next page of information in that screen.

4.2.10.1 Menu Navigation Buttons
Home Button
Press this to return to the main menu at any time.
Previous Menu Button
Press this button to return to the previous menu.
Note: If you have not pressed the button before pressing the button, any
changes made will not be saved.
4.2.11 Selection Buttons

Four momentary (soft-key) buttons are used to change the
selection in the graphical display.
Press the button to select the item that is currently

highlighted in the graphical display:
If the selected item is a menu item, this opens the sub-menu
or screen.
If the selected item is a parameter, this lets you adjust the parameter (if possible) or prompts
you for a password.
If the selected item is a value you have just adjusted, this saves the change.
If the selected item is an action, the graphical display runs the action or prompts you for a
password.
4.2.12 Default Settings

The control panel can display SAE or Metric units of measurement and should be set during the
initial setup of the generator set. Qualified service personnel are required to change the default
settings. Contact your authorised distributor.

4.3 Display Module Initial Operator Menu

Figure 8 shows the initial menu which is displayed over two pages. Use the soft-key buttons below
the up and down arrows ( and ) to toggle between the two pages.
Use the soft-key buttons below Genset, Alternator, or Engine to short-cut to those menus.
Pressing the Home button from any screen will return the display to the main menu
screens.
4.3.1 Initial Menu Data

This menu displays the information available through the menus.
NAME DESCRIPTION
History/About Use this screen to view historical information about your
generator set.
Faults: If there are no active Faults, these screens will not be
available.
Active Shutdowns Use this screen to view active Shutdown faults
Active Warning Use this screen to view active Warning faults
History Use this screen to view faults that have been cleared.
Paralleling Status Use this screen to view the bus, circuit breakers, and
paralleling states.
Genset Data Use this screen to view the status of the generator set.
Alternator Data Use this screen to view the status of the alternator.
Engine Data Use this screen to view the status of the engine.
Advanced Status:
Genset Use this screen to view power, energy, phase
difference, and other detailed generator set information.
Controller Use this screen to view sequences of operation,
configurable inputs and outputs, and other detailed
controller information.
Engine Use this screen to view pressures, voltages,
temperatures, and other detailed engine information.
Help Use this screen to obtain more information regarding the
Operator Panel.
Adjust
Genset Setup
Paralleling Setup
OEM Setup
PCCnet Setup
The use of these screens is restricted to authorised
Modbus Setup
personnel only.
Display Options
Clock Setup
Configurable IO
Calibration
Save/Reserve

Figure 8 Initial Operator Menu

4.4 Display Module Genset Data Operator Menu

Figure 9 shows a block representation of a typical Genset Data menu. To navigate from the Home
menu (HOME [1/2]), press the soft-key button below the function button indicating Genset. This will
take you directly to the Genset menu.
The Genset Data menu is displayed on two pages. Use the two soft-key buttons below the up and
down arrows ( and ) to toggle between the pages.
4.4.1 Generator Data

Use this menu to look at the status of the generator set.
NAME DESCRIPTION
Alternator
Avg Voltage Genset Line-to-Line average voltage.
Avg Current Genset average current.
Total kW Genset total kW.
Total PF Genset power factor.
Frequency Genset frequency.
Engine
Engine Hrs Total engine run time.
Coolant Temp Monitor point for the Coolant Temperature.
Oil Pressure Monitor point for the Oil Pressure.
Allowed values: 0~993 kPA (0~145 psi).
Batt Voltage Battery voltage value.
% Torq/Duty Monitor point for the percent engine torque output and the governor
percent duty cycle output when used with the HM ECM.
Allowed values: -125~125%.
Fuel Rate Monitor point for Fuel Rate.
Allowed values: 0~3199 L/hr (0~845 gal/hr).
Fuel Cons. Fuel consumption since last reset.
Total Fuel C. Total fuel consumption since start of engine.
Genset Application Rating
kW rating The genset kW rating.
kVA Rating The genset kVA Rating.
Rated Current The value of the genset application nominal current.
Genset Standby Rating
kW rating kW rating for the genset in Standby configuration.
kVA Rating kVA rating for the genset in Standby configuration.
Rated Current The value of the genset Standby nominal current.

Figure 9 Genset Data Menu Typical Data

4.5 Display Module Alternator Data Operator Menu

Figure 10 shows a block representation of a typical Alternator Data menu. To navigate from the
Home menu (HOME [1/2]), press the soft-key button below the function button indicating
Alternator. This will take you directly to the Alternator menu.
The Alternator Data menu is displayed on one page.
4.5.1 Alternator Data

Use this menu to look at the status of the alternator. This menu displays line-to-line voltage, line-
to-neutral voltage, current, and generator set power (in kVA). Some values are not available,
dependent on the number of phases (one or three) and whether or not the application has current
transformers.
NAME DESCRIPTION
L1 Alternator terminals.
L2
L3
LL(Vac) Genset L1L2 voltage.
Genset L2L3 voltage.
Genset L3L1 voltage.
LN(Vac) Genset L1N voltage.
Genset L2N voltage.
Genset L3N voltage.
Amps Monitors the current value:
Genset L1
Genset L2
Genset L3
kW Genset L1 kW.
Genset L2 kW.
Genset L3 kW.
kVA Genset L1 kVA.
Genset L2 kVA.
Genset L3 kVA.
PF* Genset L1 power factor.
Genset L2 power factor.
Genset L3 power factor.
Total kW Genset total kW.
Total kVA Genset total kVA.
Total PF* Genset power factor.
Frequency Genset frequency.
AVR Duty Cycle The AVR PWM software command. Linear relationship between counts
and % duty cycle with 10000 counts = 100% duty cycle.
* A negative (-) value indicates a leading power factor; a positive (+) value indicates a lagging power factor.

Figure 10 Alternator Data Menu Typical Data

4.6 Display Module Engine Data Operator Menu

Figure 11 shows a block representation of a typical Engine Data menu. To navigate from the
Home menu (HOME [1/2]), press the soft-key button below the function button indicating Engine.
This will take you directly to the Engine menu.
The Engine Data menu is displayed on one page.
4.6.1 Engine Data

Use this menu to look at the status of the engine.
NAME DESCRIPTION
Pressure
Oil Monitor point for the Oil Pressure.
Allowed values: 0~993 kPA (0~145 psi)
Boost Monitor point for the Boost Absolute Pressure.
Fuel Rail Monitor point for the Fuel Outlet Pressure.
Fuel Inlet Monitor point for the Fuel Supply Pressure.
Coolant Monitor point for the Coolant Pressure.
Crankcase Monitor point for the Crankcase Pressure.
Allowed values: -244~260 kPA (-35.67~38 psi)
Ambient Monitor point for the Barometric Absolute Pressure.
Temperature
Coolant Monitor point for the Coolant Temperature.
Oil Monitor point for the Oil Temperature.
Allowed values: -40~210 oC (-40~410oF)
Manifold Monitor point for the Intake Manifold Temperature
Allowed values: -40~210 oC (-40~410oF)
Fuel Inlet Monitor point for the Fuel Temperature.
o o
Allowed values: -40~210 C (-40~410 F)
Aftercooler Monitor point for the Aftercooler Temperature.
o o
Allowed values: -40~210 C (-40~410 F)
Engine Hrs Total engine run time.

Engine Speed Monitor point for the Average Engine Speed.
Batt Voltage Battery voltage value.

Figure 11 Engine Data Menu Typical Data

4.6.2 History/About Menu

Figure 12 shows a block representation of a typical History/About menu.
To navigate from the Home menu, toggle down until the History/About line of text
is highlighted, and press the OK button. This information is displayed over three
pages. Use the two soft-key buttons below the up and down arrows ( and ) to
toggle between the pages.
This screen displays the historical information about the generator set.
NAME DESCRIPTION
Starts Total number of start attempts.
Runs Total number of generator set runs.
Engine Hours Total engine run time.
Control Hours Controller ON time in seconds. Upper limit is 136 years.
Kw Hours Generator set total net kWh accumulation.
Gen Mod # Number identifying the model of the generator set. (Password level:2)
Gen Ser # Serial number identifying the generator set.
Nominal Voltage Generator set nominal line-line voltage.
Wye/Delta Delta or Wye for Generator set connection.
Rating Select Selects Standby/Prime/Base application rating.
Contr Type Used by the PC Tool.
Firmware Ver Version of software loaded into the control.
Obtained from PowerCommand3.3 Filename.
Calib Part The unique calibration part number loaded into the control.
Calib Date The revision date of the calibration part number loaded into the control.
ECM Code The calibration coded the ECM is sending.
HMI Firm Ver Parameter:HMI Local Parameter.
HMI Boot Ver Parameter:HMI Local Parameter.
50 Hz Load Profile* This shows how long the generator set has been running (50Hz operation) at
various percentages of its rated load.
60 Hz Load Profile* This shows how long the generator set has been running (60Hz operation) at
various percentages of its rated load.
* When using the Load Profile Graph table (for 50 Hz or 60 Hz) the upper lines value indicates 100% of table.

Figure 12 History/About Menu Typical Data

4.7 Display Module Faults and Warnings Menus

The Faults and Warnings menu is divided into three main sub-sections; Shutdown Faults (Active
Shutdowns); Warning Faults (Active Warnings); and Faults History (showing up to thirty-two faults
that have been cleared).
4.7.1 Fault Messages

A Fault message is an indicator of a Warning or Shutdown
condition. It includes the fault number, and a short
description. It also includes where the fault occurred if the
generator set control did not detect the fault and is simply
reporting the fault. Table 5 (Section 7.6) provides a list of
the fault codes, types, and message displayed.
Active and acknowledged faults may be viewed in the
Faults menu.
4.7.2 Fault Acknowledgement

Shutdown faults must be acknowledged after the fault has been corrected. If in Auto or Manual
mode, the control must be set to Stop mode (Off). Faults are cleared from the control panel display
by pressing the Reset button.
Faults are re-announced if they are detected again after being acknowledged. Refer to Section
4.2.3 Reset Button.
Note: Faults may also be acknowledged when in Auto mode and the Remote Start
command is removed. Contact you authorised distributor for this option.
4.7.3 Shutdown Fault Menu

Figure 13 shows a block representation of a typical Shutdown Fault menu.
To navigate from the Home menu, toggle down until the Faults-Active Shutdowns
line of text is highlighted, and press the OK button.
This will display information regarding the Shutdown fault(s). Use the two soft-key
buttons below the up and down arrows ( and ) to toggle between the pages.
This screen displays up to five faults. The same event/fault code may appear multiple times if
detected by different sources.
NAME DESCRIPTION
Index This is the index number of the fault.
Fault This is the Fault code.
SA This is the controller that identified the fault.
It is blank if the PowerCommand3.3 identified the fault.
Eng Hrs This is how many hours the engine had run (not necessarily continuously)
when the fault was generated.
HH/MM/SS This is the time the fault was generated.
Response This is the type of fault that was generated.
The name of the fault appears below the rest of the information.

Figure 13 Shutdown Faults menu Typical Data

4.7.4 Warning Fault Menu

Figure 14 shows a block representation of a typical Warning Fault menu.
To navigate from the Home menu, toggle down until the Faults - Warning Fault line
of text is highlighted and press the OK button. This will then display information
regarding the current fault. Use the two soft-key buttons below the up and down
arrows ( and ) to toggle between the pages.
This menu displays up to thirty-two faults. The same event/fault code may appear multiple times if
detected by different sources.
NAME DESCRIPTION
It is blank if the PowerCommand3.3 identified the fault.
Eng Hrs This is how many hours the engine had run (not necessarily continuously)
Response This is the type of fault that was generated.

Figure 14 Warning Fault Menu Typical Data

4.7.5 Faults History Data Operator Menu

Figure 15 shows a block representation of a typical Fault History menu.
To navigate from the Home menu, toggle down until the Faults -History line of text
is highlighted and press the OK button. This will then display information regarding
the fault(s) history. Use the two soft-key buttons below the up and down arrows
( and ) to toggle between the pages.
This menu displays up to thirty-two faults. The same event/fault code may appear
multiple times if detected by different sources.
NAME DESCRIPTION
It is blank if the PowerCmmand3.3 identified the fault.
Engine Hrs This is how many hours the engine had run (not necessarily continuously)
MM/DD/YY This is the date the fault was generated.

Figure 15 History Fault Menu Typical Data

4.8 Display Module - Adjust Menu

Figure 16 shows a block representation of a typical Adjust menu. To navigate from the Home
menu (HOME [1/2]), press the soft-key button below the down arrow in the display window. This
will show the second page of the Home menu (HOME [2/2]). With the Adjust line of text
highlighted, press the O.K. button to display the information.
The Adjust menu is displayed on one page.
Note: Should any of these settings require amendment or change, please contact your
authorised service centre.
Note: You cannot adjust Frequency Adjust or Voltage Adjust if Paralleling Speed Control
Mode is set to Synchronise, Load Share, or Load Govern.
NAME DESCRIPTION
Voltage Adjust
Genset LL Average Voltage Genset Line to Line average voltage.
Voltage Adjust A trim that allows the user to add/subtract an offset to the nominal voltage
when calculating the voltage setpoint.
Allowed values: -5~5%. Default value: 0%
Rated/Idle Sw Allowed values: Rated, Idle. Default value: Rated.
Exer Switch Allowed values: Inactive, Active. Default value: Inactive.
Man Warm Byp Allowed values: Normal, Bypass Warmup.
Keyswitch
Keyswitch Status Allowed values: Inactive, Active.
Frequency Adjust
Final Frequency Reference The frequency scaled version of the final speed reference.
Allowed values: 0~100Hz.
Frequency Adjust A method of adding in a frequency offset to the base frequency subject to
high and low limit calibrations.
Allowed values: -6~6Hz. Default value: 0Hz.
Avr Gain A trim that allows the user to modify the overall gains of the AVR.
Allowed values: 0.05~10. Default value: 1
Governor Gain A trim that allows the user to modify the overall gain of the governor.
Allowed values: 0.05~10. Default value: 1
Start Delay Allowed values: 0~300 seconds. Default value: 0 seconds.
Stop Delay Allowed values: 0~600 seconds. Default value: 0 seconds.

Figure 16 Adjust Menu Typical Data

4.9 Display Module Genset Setup Data Operator Menu

Figure 17 shows block representations of the Genset Setup Data menu.
Page down to the second page of the Home menu (using the two soft-key buttons below the up
and down arrows [ and ]). See Section 4.3.
In the HOME (2/2) menu, using the up and down arrows, toggle down again until the Genset Setup
text is highlighted.
With the Genset Setup line of text highlighted, press the OK button. This will display the Setup
Menu.
Use the two soft-key buttons below the up and down arrows
[ and ]) to page through the five
pages of the generator Setup data.

Figure 17 Setup Data Menu Typical Data

4.10 Display Module Paralleling Status Menu

Figures 18 and 19 show block representations of a typical Paralleling Status menu.
In the HOME (1/2) menu, using the up and down arrows, toggle down until the
Paralleling Status text is highlighted.
With the Paralleling Status line of text highlighted, press the OK button. This
will display then display the Paralleling Status Menu.
Use the two soft-key buttons below the up and down arrows
[ and ]) to page through the six
pages of the Paralleling Status menu.

Figure 18 Paralleling Status Data Sheet 1 Typical Data

Figure 19 Paralleling Status Data Sheet 2 Typical Data

4.11 Display Module Paralleling/Basic Setup Menu

Figures 20 and 21 show block representations of a typical Paralleling/Basic Setup menu.
To navigate from the HOME (1/2) menu, press the soft-key button below the
down arrow in the display window. This will show the second page of the
home menu (HOME 2/2). Using the up and down arrows, toggle down until
the Paralleling/Basic Setup text is highlighted.
With the Paralleling/Basic Setup line of text highlighted, press the OK button. This will then display
the Paralleling/Basic Setup Menu.
Note; It is also possible to short-cut to this menu by pressing the soft-key button below the
function button indicating Basic within the Paralleling Status menu.
Use the two soft-key buttons below the up and down arrows [ and ]) to page through the six
pages of the Paralleling/Basic Setup menu.
The adjustment of these submenus is intended for qualified service personnel and site personnel
only and may require a USER password for this operation. If a password is required the USER
password menu will appear when you try to modify the menu. (Refer to Password Menu in
Section 4.12).

Figure 20 Paralleling/Basic Data Sheet 1 Typical Data

Figure 21 Paralleling/Basic Data Sheet 2 Typical Data

4.12 Selecting Operating Modes

4.12.1 Entering the Mode Change Access Code
The Mode Change submenus are intended for qualified service personnel and site personnel only,
and by default will require an Access password. If a password is required the Mode Change
Access Code menu will appear when you try to switch between Auto, Manual Run, or Stop modes.
To enter the mode access code:
1. With the first character highlighted, press the up and down arrow buttons until the required
value is displayed.
2. Press the left arrow button to move to the next numeric character.
3. Repeat steps 1 and 2 until all characters of the Access Code are correct.
4. After you have completed entering the password, press the OK button.
Note: If an incorrect password is entered, the Operator menu that was displayed before
Auto, Manual Run, or Stop mode was selected is re-displayed.
4.12.1.1 Passwords
It is possible for the Operator to view every parameter in the graphical display, however a
password may be required before adjustment of a parameter is permitted. The generator set will
prompt you if a password is required, and inform you of the level of password required.
LEVEL DESCRIPTION COMMENT

0 No password None required
1 Operator password Restricted
2 Service password Restricted
3 Engineering password Restricted

4.12.2 Selecting Manual Run Mode

WARNING: WHEN CHANGING MODES, THE GENERATOR SET MAY START OR STOP
WITHOUT WARNING. ENSURE THERE IS NO DANGER TO PERSONNEL OR
EQUIPMENT SHOULD THE GENERATOR SET START OR STOP WHEN
CHANGING MODES.
Caution: Ensure that it is safe to do so before proceeding to change the mode.
Press the Manual button and then the Start button (within ten seconds).This will
bypass the Time Delay to Start; activate the engine control system and the starting system.
If the engine does not start, the starter will disengage after a specified period of time, and the
control will indicate a Fail to Start shutdown.
The generator set can be configured for one to seven starting cycles with set times for crank and
rest periods for all starting modes (Manual/Auto-Remote). The default setting is for three start
cycles, composed of fifteen seconds of cranking and thirty seconds of rest.
Note: The InPower service tool or access to the Setup menu is required to change the
cycle number, and the crank and rest times. Contact an authorised service centre
for assistance.
To clear a Fail to Start shutdown, press the Stop button and then press the
Reset button.
Before attempting to restart, wait 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 the Troubleshooting
section.
Note: In Manual mode, the remote start signal will have no effect.

4.12.3 Selecting Auto Mode

WARNING: WHEN CHANGING MODES, THE GENERATOR SET MAY START OR STOP
WITHOUT WARNING. ENSURE THERE IS NO DANGER TO PERSONNEL OR
EQUIPMENT SHOULD THE GENERATOR SET START OR STOP WHEN
CHANGING MODES.
Caution: Ensure that it is safe to do so before proceeding to change the mode.
Press the Auto button. This allows the generator set to be started from a remote switch or
device (e.g. transfer switch).
In response to the Remote Start, the control lights the Remote Start indicator and initiates the
starting sequence as shown in Figure 22. This start will incorporate the Time Delay to Start
function.
Note: The InPower service tool or access to the Setup menu is required to change the
cycle number, and the crank and rest times. Contact an authorised service centre
for assistance.
WARNING: SHOULD A REMOTE START SIGNAL BE RECEIVED, THE GENERATOR SET

WILL START AUTOMATICALLY. ENSURE THERE IS NO DANGER TO
PERSONNEL OR EQUIPMENT SHOULD THE GENERATOR SET START
WITHOUT WARNING.
Figure 22 Starting in Auto Mode

4.12.4 Selecting Off Mode

WARNING: WHEN CHANGING MODES, THE GENERATOR SET MAY STOP WITHOUT
WARNING. ENSURE THERE IS NO DANGER TO PERSONNEL OR EQUIPMENT
SHOULD THE GENERATOR SET STOP WHEN CHANGING MODES.
Caution: Ensure that there is no danger to personnel or equipment if the generator set is
stopped.
Press the Stop button to put the generator set into the Off mode. This will disable Auto
and Manual modes.
If the generator set is running, in either Manual or Auto mode, and the Stop button is pressed, the
engine will shut down. This action may include a Cooldown run. Refer to Section 5.7.
of the generator set.

SECTION 5 SYSTEM OPERATION

5. Operation
5.1 Safety
Personnel must be suitably qualified and experienced before operating a generator set. Before
operating the system, the operator must become familiar with Section 1 of this manual
Preliminary and Safety Instructions, together with the Health and Safety Manual (0908-0110).
Observe all of the WARNINGS and CAUTIONS at all times.
WARNING: BEFORE OPERATING THE PLANT BECOME FAMILIAR WITH THE
EQUIPMENT AND HOW IT IS OPERATED (INCLUDING ALL CONTROLS,
MANUALLY OPERATED VALVES AND ALARM DEVICES). SAFE AND
EFFICIENT OPERATION CAN ONLY BE ACHIEVED IF THE PLANT IS
OPERATED CORRECTLY.
WARNING: CONTACTING HIGH VOLTAGE COMPONENTS CAN CAUSE SEVERE

PERSONAL INJURY OR DEATH BY ELECTROCUTION. DO NOT OPEN THE
GENERATOR OUTPUT BOX WHILE THE GENERATOR SET IS RUNNING.
READ AND OBSERVE ALL WARNINGS AND CAUTIONS IN YOUR
GENERATOR SET MANUALS.
Caution: Personnel must be technically qualified before opening the control housing.
Voltages are present which can cause electrical shock, resulting in personal injury.
Even with the power removed, improper handling of components can cause
electrostatic discharge and damage circuit board components.
5.2 Introduction
This section describes the operation of the generator set. The text must be read in conjunction with
Section 3 the System Overview, and Section 4 the Control System sections of this manual,
together with the Operators specific engine manual supplied as part of the documentation pack.
This latter manual will contain further information regarding the running and care of the generator
set and also specific equipment instructions that may differ from the standard generator set.
All indicators, control switches/buttons, and graphical display are located on the face of the Control
Panel as illustrated in Figure 6.
5.3 Maintenance
To ensure maximum performance and reliability from your generator set it is essential that certain
components are inspected periodically and, where necessary, maintenance procedures carried out
as detailed in Section 6 Maintenance.
Section 5 System Operation Page 51

5.4 Operating Recommendations

5.4.1 Running in
Special running-in oils are not recommended for new or rebuilt Cummins engines. Use the same
type of oil during running-in as is used in normal operation.
5.4.2 No Load Operation

Periods of off-load operation must 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.
5.4.3 Exercise Period

Generator sets 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 set for a minimum of ten minutes off-load at least once a week, and for a minimum of
30 minutes with load at least once each month so the engine reaches normal operating
temperatures.
5.4.4 Low Operating Temperatures

Use a coolant heater if a separate source of power is available. The optional heater available from
Cummins Power Generation Limited 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.
5.4.5 High Operating Temperatures

Refer to the generator set nameplate for the maximum operating temperature, if applicable.
Page 52 Section 5 System Operation

5.4.6 Operating Conditions for Prime, Standby and Continuous Power

Ratings
Note: All generator sets supplied by Cummins Power Generation Limited must be run
under the following operating conditions, and in accordance with the operating
information contained within the manuals documentation package supplied with
each generator set.
5.4.6.1 Continuous Power Rating (COP) for Constant Load Applications

The Continuous Power Rating is applicable to Utility parallel and other non-variable load
applications for supplying power continuously to a load of up to 100% of the continuous rating for
an unlimited number of hours per year between the stated maintenance intervals and under stated
ambient conditions. All maintenance must be carried out as prescribed in the generator set
operating manuals. No sustained overload capability is available at this rating. This rating is
applicable for Utility base load operation. In these applications, generator sets are operated in
parallel with a Utility source and run under constant loads for extended periods of time.
5.4.6.2 Prime Power Rating

The Prime Power Rating is the maximum power available during a variable load sequence which
may be run for an unlimited number of hours per year, between the stated maintenance intervals
and under the stated ambient conditions. All maintenance must be carried out as prescribed in the
generator set operating manuals. Prime power applications fall into one of the following two
categories:
Unlimited time prime power (for variable load applications)
Prime power is available for an unlimited number of annual operating hours in variable load
applications. The permissible average power output under variable load shall not exceed a
70% average of the prime power rating during any operation of 250 hours. The total operating
time at 100% prime power shall not exceed 500 hours per year. A 10% overload capability is
available for a period of one hour within a twelve-hour period of operation, in accordance with
ISO 3046-3:2006. Total operating time at the 10% overload power shall not exceed 25 hours
per year.
Limited running time prime power (for constant load applications)
Prime power is available for a limited number of hours in a non-variable load application. It is
intended for use in situations where power outages are contracted, such as Utility power
curtailment. Generators may be operated in parallel with the public Utility up to 750 hours per
year at power levels never to exceed the prime power rating. No sustained overload capability
is available at this rating. The customer should be aware, however, that the life of any
generator will be reduced by constant high load operation. Any operation exceeding 750
hours per year at the Prime Power Rating should use the Continuous Power Rating.

5.4.6.3 Standby Power Rating (for variable load applications)

The Standby Power Rating is applicable for supplying emergency power for the duration of a Utility
power interruption, between the stated maintenance intervals and under the stated ambient
conditions. All maintenance must be carried out as prescribed in the generator set operating
manuals. No overload capability is available for this rating and Utility parallel operation is not
permitted at the Standby Power Rating. For applications requiring sustained Utility parallel
operation the Limited Time Prime Power Rating or Continuous Power Rating must be utilised as
applicable.
This rating is applicable to installations served by a reliable normal Utility source. Generators
should be sized for a maximum average load factor of 80% of the Standby Power Rating with a
maximum of 200 hours of operation per year, which includes less than 25 hours per year at the
Standby Power Rating. In installations served by unreliable Utility sources (where outages last
longer or occur more frequently), where operation is likely to exceed 200 hours per year, the Prime
Power Rating should be applied. The Standby Rating is only applicable for emergency and
standby applications where the generator set serves as the back up to the normal Utility source.
Negotiated power outages are not considered as emergencies.
5.4.6.4 Notes applicable to all ratings

The following notes are applicable to all ratings, unless otherwise agreed by the Regional Sales
Manager of Cummins Power Generation Limited in writing:
When determining the actual average power output of a variable power sequence in any of
the ratings above, powers of less than 30% of the emergency standby power shall be taken
as 30% and time at standstill shall not be counted.
Variable load is calculated in accordance with methods and formulae given in ISO 8528-1-
2005.
All three-phase generators are rated for 0.8 power factor lag. Single-phase generators are
rated for 1.0 power factor.
All ratings are based on the following reference conditions:
a) Ambient temperature 27C (80oF)
b) Altitude above sea level 150 metres (500 feet)
c) Relative humidity 60%
d) Output power may be subject to de-rate if the above conditions are exceeded.
If any of the above conditions are not satisfied, the operational life of the generating set may
be reduced.
Short term parallel operation with the Utility for load transfer purposes only is permitted with
all ratings.
5.4.7 De-Rating Factors

For de-rating factors applicable at specific sites please contact your authorised distributor.

5.5 Generator Set Operation

Correct care of your engine will result in longer life, better performance, and more economical
operation.
WARNING: DO NOT OPERATE AN 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, AN EXPLOSION, AND
EXTENSIVE PROPERTY DAMAGE. NUMEROUS SAFETY DEVICES ARE
AVAILABLE, SUCH AS AIR INTAKE SHUTOFF DEVICES, TO MINIMIZE THE
RISK OF OVERSPEEDING IN WHICH AN ENGINE, BECAUSE OF
APPLICATION, MIGHT OPERATE IN A COMBUSTIBLE ENVIRONMENT (FROM
A FUEL SPILL OR GAS LEAK, FOR EXAMPLE). CUMMINS POWER
GENERATION DOES NOT KNOW HOW YOU WILL USE YOUR ENGINE. THE
EQUIPMENT OWNER AND OPERATOR, THEREFORE, IS RESPONSIBLE FOR
SAFE OPERATION IN A HOSTILE ENVIRONMENT. CONSULT YOUR CUMMINS
AUTHORISED DISTRIBUTOR FOR FURTHER INFORMATION.
Note: Cummins Power Generation recommends the installation of an air intake shutoff
device or a similar safety device to minimise the risk of overspeeding where an
engine will be operated in a combustible environment.

5.5.1 Sequence of Operation

The generator set is run Automatically using a Remote Start signal, or Manually using the
generator set control panel buttons. LEDs are provided on the display module front panel to
indicate the operating run mode of the generator set. The PowerCommand 3.3 initiates a starter
cranking signal and will perform an automatically sequenced manual start, under a complete
engine protection system combined with full monitoring capability. If a fault is sensed at Start-up,
the engine is locked out and will not start.
The choice of Auto or Manual run mode is decided by authorised personnel during the generator
set initial setup. An access code is required to switch between the Auto, Manual, or Stop modes,
and this facility may be permitted or denied by the authorised personnel during the initial setup of
the generator set.

5.6 Starting
Caution: One operator must 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 set installation may become electrically charged.
Ensure that only authorised and competent personnel carry out this work.
Caution: Do not use the Emergency Stop button to shut down an engine unless a serious
fault develops. The Emergency Stop button 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 the 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. The engine must be shut down as soon as possible after the
appropriate functions have been checked.
Before attempting to start the generator set, the operator must read through this entire manual,
together with the Health and Safety manual and the Operators engine specific manual provided as
part of the documentation pack supplied with the generator set. It is essential that the operator be
completely familiar with the generator set and the PowerCommand 3.3 control.
The following sub-sections cover the systems used to start and stop the generator set.
Before starting the generator set, make sure that exhaust and fuel fittings are tight and properly
positioned, and that proper maintenance and pre-start checks have been performed.
During starting, automatic checks are carried out for the integrity of various protection systems.
The PowerCommand 3.3 control will not allow the generator set to continue the starting
sequence if the integrity of a sensor is considered to be in doubt.
The generator set can be configured for a number of starting cycles (one to seven) with set times
for crank and rest periods for all starting modes (manual/remote). The default setting is for three
start cycles, composed of fifteen seconds of cranking and thirty seconds of rest.
Note: The number of starting cycles, and the crank and rest times are set from within the
Setup menu. Qualified service personnel are required to change the default setting.
Contact your authorised distributor.

5.6.1 Initial Pre-Start Checks

WARNING: VOLTAGE PRESENTS SPECIAL HAZARDS OF SEVERE PERSONAL INJURY
OR DEATH. EVEN AFTER GENERATOR SET SHUTDOWN AN ELECTRICAL
SHOCK HAZARD MAY STILL EXIST, CAUSED BY INDUCED OR RESIDUAL
VOLTAGE WITHIN THE ALTERNATOR OR CABLES. SERVICE PERSONNEL
MUST BE WELL TRAINED/QUALIFIED TO WORK WITH DISTRIBUTION
VOLTAGES.
Before starting, be sure competent personnel have made the following checks to ensure that the
unit is ready for operation:
Generator Set Grounding Procedure This must be followed prior to performing service or
inspection procedures that may expose personnel to conductors normally energized with
voltages greater than 600 volts. Contact your authorised distributor.
Megger and Insulation Testing This must be performed on all generator sets before initial
start-up and after the generator set Grounding Procedure has been completed. Insulation
testing for low voltage (less than 600 volts) generator sets is recommended by Cummins
Power Generation Limited. These tests are used to verify that the windings are dry before the
generator set is operated, and to develop a base line for future test comparisons. Contact
your authorised distributor.
Caution: When Megger testing an alternator, failure to protect the voltage regulator, control,
and diodes could result in permanent damage to one or more of the electronic
components.
Lubrication - Check the engine lubrication oil level and ensure that the correct level is always
maintained.
Note: Generator sets may be shipped dry. They must be filled with the correct type and
quantity of oil before use. Be sure to check oil level before initial start.
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: Generator sets may be shipped dry. They must be filled with the correct type and
quantity of coolant before use. Be sure to check coolant level(s) before initial start.
Caution: It is essential that Cummins Power Generation recommendations for the correct
type and concentration of anti-freeze and DCA inhibitor are complied with. Warranty
claims for damage will be rejected if the incorrect mix has been used. Consult your
authorised distributor for the correct anti-freeze specifications and concentration for
your operating conditions.
Note: Some radiators have two fill necks, both of which must be filled when the cooling
system has been drained.
Caution: Do not attempt to remove a radiator pressure cap while the generator is running, or
is stationary but hot. Always allow the engine to cool before removing the radiator
cap.

5.6.2 Operators Pre-Start Checks

WARNINGS: WINDINGS OF HIGH VOLTAGE GENERATOR SETS, 601 TO 15,000 VOLTS,
MUST BE DRY BEFORE THE GENERATOR SET IS OPERATED. FAILURE TO
ENSURE DRY WINDINGS BEFORE START-UP MAY RESULT IN
CATASTROPHIC FAILURE, SEVERE PERSONAL INJURY OR DEATH.
Before starting, be sure competent personnel have made the following checks to ensure that the
unit is ready for operation:
Earthing Check the earthing for the gas supply pipework.
Ensure leakage free joints, fittings and connections.
Check and ensure gas pressure suitability for the supplied gas train.
Lubrication - Check the engine lubrication oil level and ensure that the correct level is always
maintained.
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 has been drained.
Caution: Do not attempt to remove a radiator pressure cap while the generator is running, or
is stationary but hot. Always allow the engine to cool before removing the radiator
cap.
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.
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
customers supply.
Emergency Stop/Fire Detection Equipment - Ensure that all related equipment is fully
operational.

5.6.3 Starting at Display Panel (Manual Run Mode)

WARNING: ENSURE THAT ALL PRE-START CHECKS ARE CARRIED OUT BEFORE
STARTING THE GENERATOR SET. 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.
To start the generator set in the Manual Run mode, press the Manual button on the display
module front panel, and then press the Start button within ten seconds. Failure to press the
Start button within this time will result in the generator set changing to the Off mode. (Refer also to
Section 4.12.2)
Note: If the mode change access code feature has been enabled, enter the access code
when prompted. (See Section 4.12.1).
The PowerCommand 3.3 control will initiate a starter cranking signal and will perform an
automatically sequenced manual start, under a complete engine protection system combined with
full monitoring capability. This will activate the engine control system and the starting procedure.
The starter will begin cranking, and after a few seconds the engine will start and the starter will
disconnect.
Should the engine fail to start, the starter will disengage after a specified period of time and the
control will indicate a Fail to Start shutdown.
To clear a Fail to Start shutdown, press the Stop button and then press the
Reset button. Before attempting to re-start 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 7 Troubleshooting.
To disable Manual mode, change to Auto or Stop mode. If the generator set is running when it
leaves Manual mode, it will continue to run if Auto mode has been selected and the remote start
signal is active. If there is no active remote start signal, the generator set will stop.
Caution: In Auto mode the generator set will re-start should a remote start signal be received.

5.6.4 Starting from Remote Location (Auto Mode)

Select the Auto button from the display module front panel to allow the generator set to be
started from a remote switch or device. (Refer also to Section 4.12.3).
There are two start modes that are selectable for the Remote Start input; one for non-emergency
start and the other for emergency start. In the non-emergency start, the control will complete the
warm-up at idle. In the emergency mode, the generator set will omit the warm-up stage and
proceed directly to rated speed and voltage.
In response to the Remote Start signal, or the control detects the loss of the Utility voltage, the
control lights the Remote Start indicator and initiates the starting sequence as described in Section
5.6.3 (Starting at Display Panel), except for the following:
In Auto position, the control will complete the Time Delay to Start (0 to 300 seconds) for a
non-emergency start signal only.
Note: If the mode change access code feature has been enabled, enter the access code
when prompted. (See Section 4.12.1).
To disable Auto mode, change to Manual or Stop mode. Refer to Section 5.7 Stopping.
5.6.5 Cold Starting with Loads

Use a coolant heater if a separate source of power is available. The optional heater available from
Cummins Power Generation Limited 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.
Cummins Power Generation Limited recommends equipping standby generator sets (life safety
systems) with engine water jacket coolant heaters to maintain the coolant at a minimum of 40C
(90F) and, for most applications, accept the emergency load in ten seconds or less. Although
most Cummins Power Generation Limited generator sets will start in temperatures down to -32C
(-25F) when equipped with engine water jacket coolant heaters, it might take more than ten
seconds to warm the engine up before a load can be applied when ambient temperatures are
below 4C (40F).
To advise the Operator of a possible delay in accepting the load, the Low Coolant Temp (code
1435) message, in conjunction with illumination of the Warning LED, is provided. The engine cold
sensing logic initiates a warning when the engine water jacket coolant temperature falls below
21C (70F). In applications where the ambient temperature falls below 4C (40F), a cold engine
may be indicated even though the coolant heaters are connected and functioning correctly. Under
these conditions, although the generator set may start, it may not be able to accept load within ten
seconds. When this condition occurs, check the coolant heaters for correct operation. If the coolant
heaters are operating correctly, other precautions may be necessary to warm the engine before
applying a load.

5.7 Stopping
Note: The access code may be required before initiating the Stop button sequence to put
the generator set into the Off mode. Refer to Section 4.12.4.
Caution: Run the generator set at no load for three to five minutes before stopping. This
allows the lubricating oil and engine coolant to carry heat away from the combustion
chamber and bearings.
5.7.1 Stopping at Display Panel (Manual Mode)

If the generator set was started at the control panel in Manual mode, press the
Stop button once to put the generator set into a Cooldown run after which the set will enter
the Off mode.
Pressing the Stop button twice will stop the generator set immediately, without a Cooldown
run, after which the set will enter the Off mode.
of the set. A hot shutdown may result in a Hot Shutdown Warning.
5.7.2 Stopping from Display Panel (Auto Mode)
If the generator set was started in Auto mode, press the Stop button once to stop the
generator set immediately, without a Cooldown run, after which the set will enter the Off mode.
If possible re-start the generator set in Manual mode with the circuit breaker open, and allow to
stop with a Cooldown run.
of the set. A hot shutdown may result in a Hot Shutdown Warning.
5.7.3 Stopping from Remote Location (Auto Mode)

If the control receives a Remote Stop signal, or the control detects the return of the Utility voltage,
the generator set completes its normal shutdown sequence incorporating a Cooldown run (Refer to
Figure 22). (The remote stop signal is actually the removal of the remote start signal to the
control).
The generator set will stop after completing the following Cooldown sequence:
Time Delay to Stop function (zero to 600 seconds)
Cooldown at Idle (zero to ten minutes) or longer, if necessary to obtain normal operating
temperature before shutdown.
The set will remain in the Auto mode, and subject to a remote start signal, unless the Stop button
is pressed. If this button is pressed the set will enter the Off mode.
Note: The InPower service tool or access to the Setup menus is required to enable and
change the time delay start/stop settings. Contact an authorised service centre for
assistance.

5.7.4 Emergency Stop (Code 1433)

The Local Emergency Stop Button is situated on the front of the Control Panel. This is a
mechanically latched switch that will unconditionally stop the engine when pressed, bypassing any
time delay to stop. Push this button in for Emergency Shutdown of the engine.
Note: If the engine is not running, pushing this button in will prevent the starting of the
engine, regardless of the start signal source (Manual or Auto - remote).
When the Emergency Stop Button is pressed the display panel will indicate the Shutdown
condition by illuminating the red Shutdown status LED and displaying the following message
on the graphical LCD display:
Fault Number: 1433
EMERGENCY STOP
A Remote Emergency Stop Button may be incorporated within the installation. If this Stop Button is
activated the following message will be displayed;
Fault Number: 1434
REMOTE EMERGENCY STOP
To reset:
1. Pull, or twist and pull, the button out.
2. Press the Stop button on the Display Module to acknowledge this action.
3. Press the Reset button.
4. Press the Auto or Manual Run Button, as previously determined. (See Section 4.12).
Caution: Do not use an Emergency Stop button to shut down an engine unless a serious
fault develops.
Note: Ensure the remote start control is not active or when the Emergency Stop is reset
the generator set could start running.
Caution: Ensure that the cause of the emergency stop is fully investigated and remedied
before a fault Reset and generator Start are attempted.

Paralleling Operation
5.7.5 Speed and Voltage Matching
Once the generator set has achieved nominal voltage and frequency, the set is ready to be
paralleled with the busbar supply. Each generator set is paralleled completely independently of
any others.
The PowerCommand3.3 control unit monitors both the incoming supply and the busbar voltage
and frequency and adjusts the incoming supply to match the busbar supply over a wide span of
busbar parameters. Synchronisation is achieved under full control, and at the correct phase
coincidence.
In Automatic mode, the PowerCommand3.3 control receives a breaker close signal when
synchronisation has been achieved, and signals the main breaker to close. In Manual mode, the
main breaker is closed to connect the generator set to the busbars by using the breaker Close
button.
Note: The PowerCommand3.3 control performs a synchronisation check in both Manual
and Auto modes before allowing the generator set circuit breaker to close.
5.7.6 Operation When in Parallel

When in parallel with the busbar supply, the generator set voltage and frequency are dependent
upon the busbar parameters, and control is changed to kW and kVAR load management.
Each generator set is individually controlled by separate PowerCommand3.3 controls.
Apart from the protection systems, there is no common coupling between generator sets. This
allows for any set, or its relevant controls, to be under maintenance without affect ting the others.
When the control system detects that the generator set is up to speed and voltage, the load will be
ramped from the mains to the generator set, the engine governor control system keeping the
electrical output within the correct parameters.

5.7.7 Generator Set Application Type

Generator set application type is the primary setting for configuring the paralleling features of the
PowerCommand 3.3 control. Table 1 provides more information about each generator set
application type. It indicates how the generator set can run in parallel and what paralleling states or
processes are available together with how much control the PowerCommand 3.3 control has
over the circuit breakers.
Table 1 Overview of Generator Set Application Types; Paralleling States and Processes
Power
Synchroniser Isolated Utility Utility Transfer
Standalone
Only Bus Only Single Multiple
Control*
Parallel with
Yes Yes Yes
Utility
Parallel with
other generator Yes Yes
sets
Paralleling
States:
Standby Yes Yes Yes Yes Yes Yes
Dead Bus/First
Yes Yes Yes
Start
Synchronise Yes Yes Yes Yes Yes
Load Share Yes Yes
Load Govern Yes Yes Yes
Generator Set
Yes Yes
CB trip
Generator Set
Yes Yes Yes Yes
CB Control
Utility CB
Yes
Control
* Power Transfer Control is an option and may not be applicable to your generator set.
In general, generator set application types are distinguished by what may be run in parallel with
the generator set. Synchroniser Only and Power Transfer Control are further distinguished by
other characteristics as follows:
Synchroniser Only: The generator set is not running in parallel with other generator sets or
with the Utility, but the PowerCommand 3.3 control can synchronise its voltage, frequency
and phase with one other power source. This is typically for use in applications with transfer
switches which use fast-close transitions but do not have a built in synchroniser.
Power Transfer Control (Option): The PowerCommand 3.3 controls the generator sets
circuit breaker and Utility circuit breaker to ensure the load has power. The
PowerCommand3.3 control does not control the Utility circuit breaker in any other generator
set application type.
Note: The PowerCommand 3.3 control does not support paralleling in a Single-Phase
configuration. If Single/3-Phase Configuration is set to Single-Phase, the generator
set application type is Standalone.

5.7.8 Standalone Application

In the generator set application shown in Figure 23, the generator set is not running in parallel with
other sets or with the Utility. The controller is always in the Standby state and may be in either the
Power On or Sleep mode.
Figure 23 Standalone
KEY
1. PowerCommand3.3 Controller 3. Generator Set Circuit Breaker
2. Generator Set (Shown Open)
When the generator set is required to accept a load, the generator set must be started in either
Manual or Auto mode. When the set has run up to speed, the circuit breaker must be closed in
either the Manual or Auto mode to accept the load.

5.7.9 Synchronise Only

In the generator set application shown in Figure 24, the generator set is not running in parallel with
other sets or with the Utility, but the PowerCommand3.3 control can synchronise the voltage,
frequency and phase with one other power source. This is typically used in applications with
transfer switches that use fast-close transitions but do not have a built in synchroniser.
Figure 24 Synchronised Only
The PowerCommand3.3 control is in the Standby paralleling state until event 1465 (Ready to
Load) is active, then the PowerCommand3.3 control synchronises if all of the following conditions
are met:
The Sync Enable signal is active
The synchroniser conditions are met.
If any of these conditions are not met the PowerCommand3.3 control remains in the Standby
paralleling state.
The Sync Enable Signal may come from the PowerCommand3.3 controls Sync Enable
connection or Modbus networks. This signal becomes active when any of these sources are
present and remains active until any of these conditions are changed. When this signal becomes
active the PowerCommand3.3 control synchronises with the live bus.

5.7.10 Isolated Bus Only

In the generator set application shown in Figure 25, the generator set is running in parallel with
other generator sets.
Figure 25 Isolated Bus Only Sequence 1
The generator set is in the Standby paralleling state until event 1465 (Ready to Load) is active.
The PowerCommand3.3 controller then considers the current position of the generator set circuit
breaker.
Before the PowerCommand3.3 closes the generator set circuit breaker all of the following
conditions must be met:
Initially the First Start process determines whether or not to close the generator set circuit
breaker onto a dead bus when it is in parallel with other generator sets (provided the sets are
in Auto setup).
The generator set circuit breaker is then closed if the following conditions are met:
a) There are no generator set circuit breaker Open requests
b) There is a generator set circuit breaker Close request
If the PowerCommand3.3 is in Manual mode, the CB Close button must be pressed.
Note: The PowerCommand3.3 control inhibits closure of the paralleling breaker outside
the sync-check window. Therefore the breaker close button can be operated even
before synchronisation, although the breaker will not close until a signal is sent from
the PowerCommand3.3 control to allow it.
When all the above conditions are met and the generator set circuit breaker is Closed, the
generator set will parallel with the other generator sets to share the load.

In Figure 26 the PowerCommand3.3 is now in the Load Share paralleling state, all of the
generator sets circuit breakers are closed, so the load is now receiving power from all sources.
Figure 26 Isolated Bus Only Sequence 2
Open the generator set circuit breaker if there are any generator set circuit breaker Open requests.
This will place the generator set back into the Standby paralleling state and therefore will no longer
supply power to the load.

5.7.11 Power Transfer Control (Option)

In the generator set application shown in Figure 27 (Utility circuit breaker closed and taking the
load) a single generator runs in parallel with the Utility; no other generators are connected. This is
the only application whereby the PowerCommand3.3 controls the Utility circuit breaker as well as
the generator to ensure the load has continuous power.
Figure 27 Power Transfer Control
The PowerCommand3.3 controls the generator set, the generator set circuit breaker and the
Utility circuit breaker to make sure the load has power. For example, the PowerCommand3.3
monitors the Utility; if the Utility fails, the PowerCommand3.3 starts the generator and transfers
the load to the generator set. When the Utility is available again the PowerCommand3.3 transfers
the load to the Utility and shuts down the generator. In this Power Transfer Control (PTC) you can
also test the generator set, exercise the generator set and run the generator set in parallel with the
Utility.
Note: In this generator set application type, Utility Single Mode verify/configurable input
#29 function pointer must be set to Default if the PowerCommand3.3 is allowed to
close the generator circuit breaker onto a dead bus.
The PTC operating mode determines the conditions under which the PowerCommand3.3 opens
and closes the generator set circuit breaker and the Utility circuit breaker, as well as conditions
under which the PowerCommand3.3 starts and stops the generator set.
The PTC operating mode is related to the mode of operation. Table 2 provides a summary of the
relationships between the mode of operation and the PTC operating mode.
Table 2 Summary of Relationships Between Modes of Operation and PTC Operating Modes.
MODE OF OPERATION CONDITION PTC OPERATING MODE

Off Default Mode Off
Default Mode Normal
PTC Mode Switch Signal Manual
Exercise Signal Exercise
Auto Remote Start Signal Test
Extended Parallel Signal Extended Parallel
Generator Set is Unavailable Normal Override
Utility is Unavailable Utility Fail
Manual Default Mode Manual

5.7.11.1 Exercise Mode

In this PTC operating mode the PowerCommand3.3 responds to the exercise signal. This
operating mode is similar to the test PTC operating mode with the following exceptions:
The exercise signal replaces the remote start signal and the remote start signal must be
inactive.
If the exercise scheduler is active, Scheduler Program Run Mode replaces Test With Load
Enable.
5.7.11.2 Extended Parallel Mode

In this PTC operating mode, the PowerCommand3.3 responds to the extended parallel signal.
The generator set and the Utility are supposed to run in parallel. The PowerCommand3.3 is in
the PTC operating mode when all the following conditions are met:
Single/3-phase connection is set to 3-phase
The PTC mode switch signal is inactive
The PowerCommand3.3 is in Auto mode
The extended parallel signal is active
Extended Parallel Enable is set to enable
Utility circuit breaker Position Status is set to Closed, or the generator set is available and the
generator circuit breaker position status is set to Closed.

5.7.11.3 Manual Mode

This is the default PTC operating mode when Single/3-Phase Connection is set to 3- Phase and
one of these conditions is met:
The PTC mode switch signal is active
The PowerCommand3.3 is in manual mode.
When the PowerCommand3.3 enters this PTC operating mode, it considers the current position
of both the generators and the Utilitys circuit breaker. However the generator set must be started
manually and the generator sets circuit breaker will not close to accept the load until the generator
set is up to speed and voltage.
Note: In the following sequences the PowerCommand3.3 must be in the Standby
Paralleling State unless otherwise stated and assumes that the
PowerCommand3.3 menus have been set for the correct paralleling parameters.
Figures 28 -31 illustrate the various conditions which may be set manually while in a paralleling
state. In this instance an operator controls how the load is shared by operating the circuit breakers
on both the generator and the Utility for the desired mode.
In Figure 31 the Utility has become unavailable while the generator set is in the Standby paralleling
state.
KEY
1. Generator Set
2. PowerCommand3.3 Controller
3. Utility
Utility Circuit Breaker
4.
(shown Open)
5. Load
Generator Set Circuit Breaker
6.
(shown Open)
Figure 28 Manual Mode Circuit Breaker Control Sequence 1
Start the generator set in Manual mode (Refer to Section 5.6.3). When the generator set is up to
speed and voltage press the circuit breaker Close button to enable the generator set to accept the
load.

In Figure 29 the generator sets circuit breaker is open while the Utility circuit breaker is closed and
is therefore accepting the load.
The generators circuit breaker remains open while the Utility circuit breaker is closed, the
generator is running and the load is receiving power from the Utility only. In this condition the
Transition Type must be set to hard or soft closed and the generator and Utility must be fully
synchronised.
Note: Synchronisation requires the Sync Enable signal to be present otherwise the
PowerCommand3.3 does not automatically synchronise the generator and the
Utility together.
To progress further the generator set circuit breaker closed button must be pressed. This will
enable the generator set to load share with the Utility.

In Figure 30 the generator sets circuit breaker is closed and the Utility circuit breaker is open, the
load in this instance is receiving power from the generator set only.
When the Utility is again providing power the Utility circuit breaker can be closed.
In Figure 31, both generator set and Utility are providing power for the load.
In this condition the PowerCommand3.3 is in the Load Govern paralleling state; both the
generator and Utility circuit breakers are closed, so the load is now receiving power from both
sources. In this condition Transition Type is set to open transition and the Maximum Parallel Time
(TDMO) has expired.
The Power Transfer menu also indicates if either/both Utility and the generator set are available to
accept a load, this will only be allowed if both sources are fully synchronised.

5.7.12 Conditions for Each Paralleling State

5.7.12.1 Utility Single
In this application, the generator is running in parallel with the Utility; there are no other generators
employed in this type of system.
Figure 32 Utility - Single Mode
The generator set is in the Standby paralleling state until event 1465 (Ready to Load) is active.
The controller then considers the current position of both the generator set and the Utility circuit
breakers as illustrated in Figure 32.
Figures 33 36 illustrate the various conditions for each paralleling state.


In Figure 33 the circuit breakers on both the generator and Utility are open; the generator is
running and power from the Utility is available; in this condition the load is receiving no power from
either source.
Figure 33 Utility Single Sequence 1
There is a generator set circuit breaker Close request
There are no generator set circuit breaker Open requests
Utility Single Mode Verify/Configurable Input #29 Function Pointer is set to Default
Configurable Input #29 is active
If the PowerCommand3.3 is in Manual mode, the circuit breaker Close button must be pressed.
The generator set will then provide power for the load.

In Figure 34 the generator set is running with the circuit breaker Open and the Utility circuit breaker
closed, providing power for the load.
The PowerCommand3.3 will automatically initiate the Synchronise procedure since it is

synchronising to the Utility.
Before the PowerCommand3.3 closes the generator set circuit breaker both of the following
There is a generator set circuit breaker Close request.
The generator set will then load share with the Utility.

In Figure 35 the Utility circuit breaker is Open and the generator set is running with the circuit
breaker Closed, providing power for the load.
When the Utility is available, its circuit breaker may be closed and therefore available to supply the
load. The generator set circuit breaker may then be opened returning the generator set to the
Standby paralleling state. The generator set will therefore no longer supply power to the load.-
The Sync Enable input must be closed to enable the synchroniser, thereby allowing a re-transfer of
load back to the Utility.
Note: Utility CB sync check and Utility breaker controls are not part of the
PowerCommand3.3 control system.
Note: In Manual mode it will be necessary to press the CB Open button on the control
panel.

Figure 36 in this condition the PowerCommand3.3 is now in the Load Govern paralleling state,
both the generator and Utility circuit breakers are closed, so the load is now receiving power from
both sources.

5.7.13 Multiple Utility

In the generator set application shown in Figure 37 the generator set is running in parallel with
other generator sets which in turn are running in parallel with the Utility.
Figure 37 Utility Multiple
The PowerCommand3.3 is in the Standby paralleling state until Event 1465 (Ready to Load) is
active. The PowerCommand3.3 then considers the current position of the generator set circuit
breaker and the Utility circuit breaker as illustrated in Figure 37. To ensure a seamless transfer of
the load between the Utility and generator set(s) a closed transition transfer switch is incorporated.
The generator sets may be in Auto or Manual setup. If in Auto setup, the First Start process will be
available to enable a generator set to close the circuit breaker onto a dead bus. The remaining
generator sets then wait for the bus to go live before synchronising to it.
Figures 38-41 illustrate the various conditions for each paralleling state.


In Figure 38 the circuit breakers on both the generator and Utility are open; the generator is
running and power from the Utility is available; in this condition the load is receiving no power from
either source.
Figure 38 Utility Multiple Sequence 1
Initially the First Start process determines whether or not to close the generator set circuit
breaker onto a dead bus when it is in parallel with other generator sets (provided the sets are
in Auto setup).
The generator set circuit breaker is then closed if the following conditions are met:
When all the above conditions are met and the generator set circuit breaker is Closed, the
generator set will parallel with the other generator sets and/or the Utility to share the load.

In Figure 39 the generator set is running with the circuit breaker Open and the Utility circuit breaker
Closed, providing power for the load.
The PowerCommand3.3 will automatically initiate the Synchronise procedure since it is

synchronising to the Utility.
The generator set will then load share with the Utility.

In Figure 40 the Utility circuit breaker is Open and a generator set is running with the circuit
breaker Closed, providing power for the load.
When the Utility is again available to supply the load open the generator set circuit breaker if there
are any generator set circuit breaker Open requests. This will place the generator set back into the
Standby paralleling state and therefore will no longer supply power to the load.

Figure 41 in this condition the PowerCommand3.3 is now in the Load Govern paralleling state,
both the generator and Utility circuit breakers are closed, so the load is now receiving power from
both sources.
This will place the generator set back into the Standby paralleling state and therefore will no longer
supply power to the load.

SECTION 6 - MAINTENANCE
6. Maintenance
All maintenance tasks must be assessed for health and safety risks, the preventative measures
identified must be actioned. Accompaniment is required for tasks where the presence of someone
else will add significantly to the safety of the task.
Read, understand and comply with all Caution and Warning notes in this section, those contained
within Section 1 - Preliminary and Safety, and those contained within the Health and Safety
Manual (0908-0110). Refer also to the Operators engine specific manual supplied as part of the
generator set documentation pack. The Health and Safety Manual will contain further information
regarding the running and care of the generator set and also specific equipment instructions that
may differ from the standard generator set. Maintenance work, particularly in confined areas,
should be carried out by two engineers working together.
Complete a risk assessment and LO/TO (Lockout/Tagout: key-controlled locks and identifying tags
are used to shut down and lockout sources of hazardous energy that could otherwise result in
personal injury if energy were unintentionally released during maintenance or service) of the
generator set before conducting maintenance.
Ensure adequate lighting and staging (where required) are installed to be understood post risk
assessment.
Caution: Only authorised and qualified maintenance engineers, 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.
Caution: Before carrying out any maintenance work, become familiar with the Generator
Plant Safety Code given in Section 1 of this manual, together with the Health and
Safety Manual (0908-0110).
Caution: Welding equipment, blowlamps and any other source of ignition that may cause
natural gas to ignite are not TO BE used in the Plant Room unless all gas pipes
have been purged.
Caution: Ensure incomplete gasways are sealed, and never left unattended without all
reasonable precautions being taken to inform others of the disconnection and
potential danger i.e. Warning Signs etc. Metal pipes should always be sealed with
metal pipe fittings.
Caution: Ensure electrical earth bonding on all gas pipes and gas components is regularly
checked for security and good electrical contact.
Refer to the Warnings and Cautions provided in Section 6.2 when working on natural gas
generator sets and installations.
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 generator set.
Section 6 Maintenance Page 85

WARNING: ACCIDENTAL STARTING OF THE GENERATOR SET 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 PERSONAL 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
GENERATOR SET.
INSULATED TOOLS MUST BE USED WHEN WORKING IN THE VICINITY OF

THE BATTERIES.
ALWAYS REMOVE THE NEGATIVE (-) LEAD FIRST AND RECONNECT LAST.
ENSURE 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: DO NOT USE THE SKID (BEDFRAME) OR ANY PART OF THE GENERATOR
SET AS A MEANS OF ACCESS. USE OF THE GENERATOR SET AS ACCESS
MAY RESULT IN SEVERE PERSONAL INJURY OR DEATH AND/OR
PROPERTY AND EQUIPMENT DAMAGE.
WARNING: BEFORE CARRYING OUT ANY MAINTENANCE WORK, LOCK OFF FOR SAFE
WORKING
1. Press the off mode switch on the generator set control panel.
2. As an additional precaution, press the Emergency Stop button, and hold in for 30 seconds.
3. Isolate all supplies to the generator set.
4. Isolate the battery charger.
5. Disconnect the starting battery.
6. Remove the starter control wires.
7. A suitable warning plate stating maintenance in progress should be displayed prominently.
WARNING: TO COMPLETE MAINTENANCE TASKS AT HEIGHT REFER TO LOCAL
LEGISLATIVE REQUIREMENTS. SUITABLE EQUIPMENT FOR PERFORMING
THESE TASKS MUST BE USED IN ACCORDANCE WITH THE LOCAL
GUIDELINES AND LEGISLATION. FAILURE TO FOLLOW THESE
INSTRUCTIONS CAN RESULT IN SEVERE PERSONAL INJURY OR DEATH.
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.
6.1 General
The maintenance procedures covered in this manual are intended for Operator-level service only.
At each scheduled maintenance interval, perform all previous maintenance checks that are due for
scheduled maintenance.
Table 3 lists recommended service procedures for a generator set on automatic, unattended
service. It is essential, however, that certain components are inspected periodically and, where
necessary, maintenance procedures carried out.
Some of the factors that can affect the maintenance schedule are:
Extremes in ambient temperature
Page 86 Section 6 Maintenance

Exposure to elements
Exposure to salt water
Exposure to windblown dust or sand.
Consult with an authorised distributor if the generator set 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.
Note: For a detailed maintenance schedule refer to the Operation and Maintenance
manual for your generator set.
Table 3 Typical Maintenance Schedule Procedures
MAINTENANCE ITEMS
Daily Check Lubricating Oil Level
Daily Check Coolant Level
Daily Check Air Filter(s) Restriction
Daily General Inspection
Daily Check Control Panel Assembly
Daily Check Gearbox Lubricating Oil Level, Pressure & Filer (If fitted)
Daily Check Gearbox Breather (If fitted)
Early Life Test Exhaust Emission (O2 & Nox)2
Early Life Change Lubricating Filters1
Early Life Adjust Valve Overhead Sets2
Early Life Check Spark Plugs1
Early Life Clean Lubricating Oil Centrifugal Filter1
14 day/250hr Conduct Lubricating Oil Analysis
14 day/250hr Check Waste Lubricating Oil Reservoir1
14 day/250hr Check DC Batteries
14 day/250hr Clean Control Panel Assemby
1
Refer to the generator set Operation and Maintenance manual for procedure.
2
Must be carried out by an authorised service engineer..
Note: Maintenance procedures carried out by an authorised service engineer
according to the recommended maintenance schedule will depend on the
model of generator set. For more details refer to the Operation and
Maintenance manual for your generator set.

6.2 Locking the Generator Set Out of Service

6.2.1 Introduction
Before any work is carried out for maintenance, etc., the plant must be immobilised. Even if the
plant is put out of service by pressing the Off switch 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.
Caution: Refer also to the Operators engine specific manual included in the documentation
package supplied with the generator set. This manual will contain specific
equipment instructions that may differ from the standard generator set.
WARNING: BEFORE CARRYING OUT ANY MAINTENANCE, ISOLATE ALL SUPPLIES TO
THE GENERATOR SET AND ANY CONTROL PANELS. RENDER THE SET
INOPERATIVE BY DISCONNECTING THE PLANT BATTERY.
Caution: If the engine has been running recently explosive gases may be present. Ensure
the area is well ventilated before disconnecting batteries.
WARNING: NATURAL GAS IS DANGEROUS IF A LEAKAGE OCCURS. RELATIVELY LOW
LEVELS OF GAS LEAKAGE IN CONFINED AREAS CAN CAUSE EXPLOSIONS
AND FIRES IF A SPARK OCCURS TO IGNITE IT.
INHALATION OF LARGE VOLUMES OF NATURAL GAS CAN CAUSE
ASPHYXIATION AND DEATH.
IF A LEAKAGE OCCURS, IMMEDIATELY ISOLATE THE GAS SUPPLY, DO NOT
OPERATE ANY EQUIPMENT (ELECTRICAL OR OTHERWISE) THAT MAY
CAUSE A SPARK OR MAY BE A SOURCE OF IGNITION, FULLY VENTILATE
THE AREA, AND EVACUATE BUILDING.
ONLY SUITABLY QUALIFIED PERSONNEL WHO ARE FULLY TRAINED TO
HANDLE NATURAL GAS EMERGENCIES ARE TO BE ALLOWED NEAR THE
PLANT ROOM OR GENSET(S) IN SUCH EMERGENCIES.
6.2.2 Precautions with Natural Gas

Particular precautions are required when servicing or maintaining natural gas equipment. Only
competent persons, trained and certified by all generator set local and national gas regulations,
are to work on natural gas equipment.
Contact your authorised distributor if you require details of the regulations for your location.

6.2.3 Immobilising the Plant for Safe Working

Note: Shutdown the engine first, as described in the accompanying PowerCommand3.3
Controller Manual.
To immobilise the engine:
1. Press the Stop Button on the display panel
2. Press and hold the Emergency Stop Button (and hold for 30 seconds). This will prevent the
starting of the generator set regardless of the Start signal source and will therefore provide an
additional safety step for immobilising the generator set. (See also Section 5.7).
Note: When this Stop Button is pressed the display panel will indicate the Shutdown
condition by illuminating the red Shutdown status LED and displaying the
following message on the graphical LCD display:
Fault Number: 1433

EMERGENCY STOP
or
Fault Number: 1434
REMOTE EMERGENCY STOP
Note: This Fault will affect the Fault History memory bank.
3. At the Gas Train, close the manual Gas Shut Off Valve.
4. As an additional precaution, thoroughly ventilate the plant room before disconnecting any
leads.
5. Disconnect the electrical connection (E) from the starting motor solenoids..
6. At the GIB (Generator Interface Box), turn the Isolator Switch (B) to the O position to isolate
the AC Auxiliary circuit supplies..
7. Fit warning notices at each of the above points to indicate Maintenance in Progress - Plant
Immobilised for Safe Working.
Note: Following Generator Set immobilization, or prolonged shutdown, check the
alternator windings for signs of moisture and ensure that alternator windings are dry
before restarting and applying
6.3 Daily Maintenance Procedures

Monitor fluid levels, oil pressure, and coolant temperature frequently. 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.
6.3.1 General Information

Preventative maintenance begins with day-to-day awareness
of the condition of the generator set.
Before starting the generator set check the oil and coolant
levels and look for:
Leaks
Loose or damaged parts
Any change in engine or generator set appearance.

6.3.2 Engine Operation Report

The engine must be maintained in good mechanical condition if the operator is to obtain optimum
satisfaction from its use. Running reports are necessary to enable programmed or emergency
servicing to be carried out.
Comparison and intelligent interpretation of the running report, together with a practical follow-up
action will eliminate most failures and
emergency repairs.
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 and report on
are:
Low lubricating oil pressure
Low power
Abnormal water or oil temperature
Unusual engine noise
Excessive smoke
Excessive use of coolant or lubricating oil
Any coolant or lubricating oil leaks.
Misfire
Vibration
Excessive exhaust smoke
6.4 Cooling System

WARNING: CONTACT WITH HOT COOLANT CAN RESULT IN SERIOUS SCOLDING.
ALLOW COOLING SYSTEM TO COOL BEFORE RELEASING PRESSURE AND
REMOVING WATER JACKET RADIATOR CAP OR LTA EXPANSION TANK
CAP.
Caution: Loss of coolant can allow engine to overheat without protection of shutdown device,
and cause severe damage to the engine. Maintain coolant level for proper operation
of high engine temperature shutdown system.

6.4.1 Coolant Level - Check

WARNING: HOT COOLANT MAY BE PRESSURIZED; WAIT UNTIL THE TEMPERATURE IS
BELOW 50oC (120oF) BEFORE REMOVING PRESSURE CAP. FAILURE TO DO
SO CAN RESULT IN PERSONAL INJURY FROM HEATED COOLANT SPRAY
OR STEAM.
Caution: Avoid prolonged or repeated skin contact with antifreeze. Refer to the Health and
Safety Manual 0908-0110 for handling and disposal of antifreeze.
Note: Never use a sealing additive to stop leaks in the coolant system. This can result in
coolant system plugging and inadequate coolant flow causing the engine to
overheat.
Coolant level must be checked daily. The standard coolant concentration is either 25% or 50%
Ethylene Glycol and water, this concentration must be maintained. Warranty claims for damage
will be rejected if the incorrect mix of anti-freeze has been used. Consult your authorised
distributor for the correct anti-freeze specifications and concentration for your operating conditions.
The recommended antifreeze is Fleetguard Compleat ES which is a low-silicate antifreeze, or its
equivalent.
Caution: Do not add cold coolant to a hot engine. Engine castings can be damaged. Allow the
o o
engine to cool to below 50 C (120 F) before adding coolant.
Note: On applications that use a coolant recovery system, check to ensure the coolant is
at the appropriate level on the coolant recovery tank dependent on engine
temperature.
Fill the cooling system with coolant to the bottom of the fill neck in the radiator or expansion tank,
with the coolant temperature at 50C (122oF) or lower.

6.4.2 Plant Cooling Fan - Inspect

A visual inspection of the plant cooling fan is required daily. Refer to the plant cooling fan's
operator's manual for inspection details
6.4.3 Plant Radiator - Check

A visual inspection of the plant heat radiators, if equipped, must be conducted. For specific
inspection details, refer to the radiator's operator's manual.
In general, check the radiator(s) for damaged hoses and loose and damaged hose clamps.
Inspect the exterior of the radiator for
obstructions. During the service life of a
radiator a build up of foreign matter can
obstruct the flow of air through the radiator
cores, reducing the cooling capability. To
ensure the continued efficiency of the
radiator, the core will require cleaning.
Refer to the Radiator Information Manual
0908-0107-00 for further details on cleaning
the radiator.
6.5 Air Cleaner Restriction

Indicator Check
The engine air filtration units are equipped with a
mechanical air cleaner restriction gauge.
The red flag gradually rises as the filter becomes
restricted. After changing the filter, reset the indicator
by pressing the reset button.
Note: Do not remove the felt washer from
the indicator. The felt washer absorbs
moisture.
Air restriction indicator in place

6.6 Gearbox Inspection

Check the gearbox (if fitted) for leaks, and loose or missing capscrews, excessive noise, and
vibration. Also check the following components as illustrated in below and refer to the Operation
and Maintenance manual for more detailed information:
1. Lubricating oil pressure gauge
2. Breather cap
3. Lubricating oil level sight glass
4. Lubricating oil filter.
6.7 Engine Oil

6.7.1 Engine Oil Level Check
WARNING: CRANKCASE PRESSURE CAN BLOW HOT OIL OUT OF THE DISPSTICK
SHAFT AND CAUSE SEVERE BURNS. DO NOT CHECK OIL WHILE THE
GENERATOR SET IS OPERATING.
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.
Caution: Prolonged and repeated skin contact with used engine oils can cause skin disorders
or other bodily injury.
Refer to the Health and Safety Manual (0908-0110) supplied with your generator set
for precautions when handling or disposing of used engine oil.

Check the engine oil level during engine shutdown

periods at the intervals specified in the Operation
and Maintenance manual.
Never operate the engine with the oil level below
the L (Low) mark, or above the H (High) mark.
Wait at least fifteen minutes, after shutting off the
engine, before checking the oil level so as to allow
adequate time for the oil to drain back to the oil
pan.
Note: Use high-quality SAE40 (mono-grade) NG engine oils, such as Valvoline Premium
Blue GEO LA or its equivalent. For a list of the approved engine oils see Section
3.3. Consult your authorised distributor for the correct lubricating oil for your
operating conditions.
6.8 Lubricating Oil Analysis

WARNING: TO REDUCE THE POSSIBILITY OF PERSONAL INJURY, AVOID DIRECT
CONTACT OF HOT OIL WITH YOUR SKIN.
Caution: Prolonged and repeated skin contact with used engine oils can cause skin disorders
or other bodily injury.
Refer to the Health and Safety Manual (0908-0110) supplied with your generator set
for precautions when handling or disposing of used engine oil.
A well conducted used engine oil analysis may provide insight to internal engine damage and the
source of cause such as:
Intake air filter malfunction
Coolant leaks
High wear metal content
Suitability of oil for additional service.
NOTE: If regular oil analysis is not performed, the recommended oil change period is
reduced by 50 percent and an oil analysis must be taken immediately prior to
changing the engine oil, to confirm its condition.
For additional oil analysis information, refer to Cummins Engine Oil Recommendations, consult
your authorised distributor.
NOTE: Do not disassemble an engine for repair based only on the results of an oil
analysis. Inspect the oil filters also. If the filters show evidence of internal damage,
find the source of the problem and repair the damage. Refer to the appropriate
section(s) based on findings of the oil filter inspection.

The lubricating oil must be at normal operating temperatures. Oil samples must not be taken
immediately following an oil change or top-off, or immediately after engine start-up or shutdown.
Ideally, the lubricating oil will have been in use for at least 10 hours before sampling.
Wipe the area around the sample fitting to remove any
old oil residue.
With the engine running, remove the sample fitting cap

and insert the needle into the fitting.
Fill the bottle at least 3/4 full.
Remove the needle from the fitting and install the

fitting cap.
6.9 Fuel System

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, OR IN AREAS SHARING VENTILATION.
6.9.1 Fuel consumption

Fuel consumption of gas engines can be affected by the reduction in oxygen mass entering the
cylinders at altitudes, quality of fuel (methane index) and higher/lower temperatures.
Fuel consumption figures will be specified in the project contract. Below is an example of Gas
Quality Requirements.
Gas Formula Value Level

Gas Heat Value MJ/n.m 30 - 40
Gas Density Kg/n.m 0.7 0.9
Methane Number MN >80
Methane Content CH >75%
Ethane Content CH <5%
Hydrogen Sulphide HS <0.01%
Maximum Gas Temperature Degrees Celcius 500C
Table 4 Example of Gas Quality Requirements

6.9.2 Methane Index

For more information on Methane Index and Cummins engine requirements contact your
authorised distributor. For information on Cummins fuel requirements, consult your authorised
distributor.
6.9.3 De-rate
The generator set de-rate is calculated before the set is installed to give clear indication of power
output in the site conditions. Additional on-site adjustments can be made through the controller
software Fluctuations in the operating conditions may affect engine performance. The de-rate
calculation is based upon the several factors:
Quality of fuel The methane number (index) of the gas supply is a factor in engine selection.
Onsite variances in fuel supply quality will affect the engine performance.
Ambient temperature Engines working in higher temperatures must be de-rated otherwise this
may cause the engine to overheat. (Engines operating at lower temperatures will require engine
heaters to maintain
Air quality In a dusty/contaminated environment the use of heavy duty air cleaners for the engine
and filters for the alternator cooling intake will be fitted. These filters will reduce the volume of air
intake thus affecting set performance.
Site Altitude At higher altitude the reduction in air density impedes the air cooling efficiency
which can contribute to engine overheating. This decrease in air density will also affect engine
performance.
Site Humidity High relative humidity can cause condensation to form when the temperature
changes. This condensation can cause malfunctions in control systems and alternators.
Other less common but significant site conditions affecting performance and installation are:
Atmospheric contaminants (Chemicals and gases), Salt water spray, High wind.
6.10 Hoses - Check

WARNING: MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH. USE
EXTREME CAUTION AROUND HOT MANIFOLDS, MOVING PARTS, ETC..
TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT METAL PARTS
SUCH AS RADIATOR, TURBOCHARGER AND EXHAUST SYSTEM.
With the generator set operating, inspect filters,
hoses 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,
shut down the generator set (if possible), contact
your authorised distributor and have the leaks
corrected immediately.

6.11 Exhaust System

WARNING: EXHAUST COMPONENTS BECOME VERY HOT WHEN THE GENERATOR SET
IS IN USE AND REMAIN HOT FOR A PERIOD OF TIME AFTER THE
GENERATOR SET HAS BEEN SHUT DOWN. THESE COMPONENTS CAN
CAUSE SEVERE PERSONAL INJURY OR DEATH FROM CONTACT. ALLOW
THESE COMPONENTS TO COOL COMPLETELY BEFORE PERFORMING ANY
MAINTENANCE TASKS.
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. DO
NOT ALLOW TO ACCUMULATE IN HABITABLE AREAS.
WARNING: MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH. USE
EXTREME CAUTION AROUND HOT MANIFOLDS, MOVING PARTS, ETC..
With the generator set 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 generator set (if possible), contact your authorised distributor
and have the leaks corrected immediately.
6.12 Generator Set Output - AC Electrical System

Check the following while the generator set is operating:
Frequency: The generator set frequency should be stable and the reading should be
the same as the generator set nameplate rating.
AC Voltage: At no load, the linetoline voltage(s) should be the same as the generator
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: When the Operating Panel is first connected to the DC supply, the system
runs a check by illuminating each of the indicator lamps in turn.
6.13 DC Electrical System

Check the terminals on the batteries 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.
Refer to Supplementary Publication 0908-0101-00 for cleaning and safety precautions of the
battery.
6.14 Storage and Lay-up of Generator Set

Proper storage is essential for preserving generator set performance and reliability when the
generator set cannot be exercised regularly and will be idle for more than 30 days. Failure to follow
the proper storage procedure may result in damage to the generator set.
NOTE: Proper storage and lay-up of the generator set must be carried out by a qualified
person. Please contact your authorised Cummins distributor.


SECTION 7 TROUBLESHOOTING
7. Troubleshooting
7.1 Introduction
Fault code information, together with Warning and Shutdown information, is provided in this
section to assist in locating and identifying the possible causes of faults in the generator set
system. Refer also to the Operators engine specific manual supplied as part of the generator set
documentation pack. This latter manual will contain further information regarding the running and
care of the generator set and also specific equipment instructions that may differ from the standard
generator set.
7.2 Control Unit

The generator set control system 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 will display a message on the
graphical display panel. In the event of an engine shutdown fault (red Shutdown LED), the control
will stop the engine immediately.
This section lists the Warning and Shutdown Fault Codes/Messages (Table 5), and suggests
possible causes of the fault.
Note: Displayed error codes that are not listed in Table 5 will require an authorised service
representative to correct the fault. Contact an authorised service centre for
assistance.
Section 7 Troubleshooting Page 99

7.3 Safety Considerations

Fault finding work, particularly in confined areas, must be carried out by two engineers working
together. Read, understand and comply with all safety precautions listed within Section 1
Preliminary and Safety and observe all instructions and precautions throughout this manual, the
Operators engine specific manual, and the Health and Safety Manual (0908-0110).
The installation of a generator set can be designed for remote starting. When troubleshooting a
generator set that is shutdown ensure that the set cannot be accidentally re-started. Refer to
Section 6.2 Locking the Generator Set out of Service.
WARNING: HIGH VOLTAGES ARE PRESENT WHEN THE GENERATOR SET IS RUNNING.
DO NOT OPEN THE OUTPUT BOX WHILE THE GENERATOR SET IS RUNNING.
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.
WARNING: CONTACTING HIGH VOLTAGE COMPONENTS CAN CAUSE SEVERE

PERSONAL INJURY OR DEATH BY ELECTROCUTION. KEEP THE OUTPUT
BOX COVERS IN PLACE DURING TROUBLESHOOTING. TESTING AND/OR
ADJUSTMENTS MUST ONLY BE CARRIED OUT BY PERSONNEL QUALIFIED
TO PERFORM ELECTRICAL SERVICING.
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 generator set.
WARNING: VENTILATE BATTERY AREA BEFORE WORKING ON OR NEAR BATTERY

WEAR GOGGLES STOP GENERATOR SET AND DISCONNECT CHARGER
BEFORE DISCONNECTING BATTERY CABLES DISCONNECT NEGATIVE(-)
CABLE FIRST AND RECONNECT LAST.
WARNING: IGNITION OF EXPLOSIVE BATTERY GASES CAN CAUSE SEVERE

PERSONAL INJURY OR DEATH. ARCING AT BATTERY TERMINALS, LIGHT
SWITCH OR OTHER EQUIPMENT, FLAME, PILOT LIGHTS AND SPARKS, CAN
IGNITE BATTERY GAS. DO NOT SMOKE, OR SWITCH INSPECTION LIGHT ON
OR OFF NEAR BATTERY. DISCHARGE STATIC ELECTRICITY FROM BODY
BEFORE TOUCHING BATTERIES BY FIRST TOUCHING A GROUNDED METAL
SURFACE.
WARNING: ACCIDENTAL STARTING OF THE GENERATOR SET WHILE WORKING ON IT

Page 100 Section 7 Troubleshooting

7.4 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 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 generator set 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: MANY TROUBLESHOOTING PROCEDURES PRESENT HAZARDS THAT CAN
RESULT IN SEVERE PERSONAL INJURY OR DEATH. SERVICE PROCEDURES
MUST ONLY BE CARRIED OUT BY QUALIFIED SERVICE PERSONNEL WITH
KNOWLEDGE OF FUELS, ELECTRICITY AND MACHINERY HAZARDS.
REVIEW SAFETY PRECAUTIONS LISTED WITHIN SECTION 1 - PRELIMINARY
AND SAFETY SECTION - OF THIS MANUAL TOGETHER WITH THE HEALTH
AND SAFETY MANUAL (0908-0110).

7.5 Status Indicators
Figure 42 Display Module Front Panel
Warning
This yellow lamp is lit whenever the control detects a Warning condition. This lamp is automatically
shut off when the Warning condition no longer exists.
Shutdown Status
This red lamp is lit when the control detects a Shutdown condition. The generator set cannot be
started when this lamp is on. After the condition has been corrected, the lamp can be reset by first
pressing the Stop button and then the Reset button.
Not in Auto
This red lamp will flash when the control is NOT in Auto.
Remote Start
This green lamp indicates the control is receiving a remote run signal. The remote run signal has
no effect unless the generator set is in Auto.
Genset Running
This green lamp is lit when the generator set is running at, or near, rated speed and voltage. This
is not lit while the generator set is warming up or cooling down.

7.6 Fault/Status Codes

WARNING: MANY TROUBLESHOOTING PROCEDURES PRESENT HAZARDS THAT CAN
RESULT IN SEVERE PERSONAL INJURY OR DEATH. SERVICE PROCEDURES
MUST ONLY BE CARRIED OUT BY QUALIFIED SERVICE PERSONNEL WITH
KNOWLEDGE OF FUELS, ELECTRICITY AND MACHINERY HAZARDS.
ACCIDENTAL STARTING OF THE GENERATOR SET WHILE WORKING ON IT
7.6.1 Fault Messages

A Fault message is an indicator of a Warning or Shutdown condition. It includes the fault type
(Warning or Shutdown), fault number, and a short description. It also includes where the fault
occurred if the generator set control did not detect the fault and is simply reporting the fault.
Table 5 provides a list of the fault codes, types, and messages displayed.
Active and acknowledged faults may be viewed in the Faults menu.
7.6.2 Fault Acknowledgement

Shutdown faults must be acknowledged after the fault has been corrected. If in Auto or Manual
mode, the control must be set to Stop mode (Off). Faults are cleared from the control panel display
by pressing the Reset button.
Faults are also acknowledged when in Auto mode and the remote start command is removed.
Faults are re-announced if they are detected again after being acknowledged.
Note: Gaps in the code numbers are for codes that do not apply to this generator set.
Some of the codes listed are feature dependent and will not be displayed by this
control.

Table 5 Fault Codes

Code Response Displayed Message Code Response Displayed Message
121 Warning Speed/Pos 1 Abnrml Rate 1984 Warning Int Man 2 Tmp Moderate Hi
136 Warning Pre-Filt Oil Pr OOR Hi 1985 Warning Int Man 3 Tmp Moderate Hi
137 Warning Pre-Filt Oil Pr OOR Lo 1986 Warning Int Man 4 Tmp Moderate Hi
142 Warning Oil Rifle Pr Moderate Hi 2111 Warning LT Cool Tmp OOR Hi
156 Warning Int Man 2 Tmp OOR Hi 2112 Warning LT Cool Tmp OOR Lo
157 Warning Int Man 2 Tmp OOR Lo 2113 Warning LT Cool Tmp Moderate Hi
Shutdown
158 Shutdown Int Man 2 Tmp Critical Hi 2114 LT Cool Tmp Critical Hi
w/Cooldown
159 Warning Int Man 3 Tmp OOR Hi 2115 Warning LT Cool Pr OOR Hi
161 Warning Int Man 3 Tmp OOR Lo 2116 Warning LT Cool Pr OOR Lo
162 Shutdown Int Man 3 Tmp Critical Hi 2117 Warning LT Cool Pr Moderate Lo
163 Warning Int Man 4 Tmp OOR Hi 2121 Warning EGT 1 (A1) Moderate Hi
164 Warning Int Man 4 Tmp OOR Lo 2122 Warning EGT 3 (A2) Moderate Hi
165 Shutdown Int Man 4 Tmp Critical Hi 2123 Warning EGT 5 (A3) Moderate Hi
Shutdown
175 Throt Ctrl OOR Hi 2124 Warning EGT 7 (A4) Moderate Hi
w/Cooldown
Shutdown
176 Throt Ctrl OOR Lo 2125 Warning EGT 9 (A5) Moderate Hi
w/Cooldown
Shutdown
177 Throt Ctrl Out of Adj 2126 Warning EGT 11 (A6) Moderate Hi
w/Cooldown
Shutdown
189 HT Cool TMP Root Unknwn 2127 Warning EGT 13 (A7) Moderate Hi
w/Cooldown
219 Warning Low Oil Level 2128 Warning EGT 15 (A8) Moderate Hi
229 Warning HT Cool Pr Incorrect 2129 Warning EGT 17 (A9) Moderate Hi
233 Warning HT Cool Pr Moderate Lo 2131 Warning EGT 2 (B1) Moderate Hi
244 Warning Red Lamp OOR Lo 2132 Warning EGT 4 (B2) Moderate Hi
246 Warning Exh Gas Tmp OOR Hi 2133 Warning EGT 6 (B3) Moderate Hi
247 Warning Exh Gas Tmp OOR Lo 2134 Warning EGT 8 (B4) Moderate Hi
248 Warning Exh Gas Tmp Moderate Hi 2135 Warning EGT 10 (B5) Moderate Hi
Shutdown
253 Eng Oil Level Critical Lo 2136 Warning EGT 12 (B6) Moderate Hi
w/Cooldown
277 Warning Fuel Ctrl Vlv Out of Adj 2137 Warning EGT 14 (B7) Moderate Hi
334 Warning HT Cool Tmp Incorrect 2138 Warning EGT 16 (B8) Moderate Hi
346 Warning Powerdown Data Lost 2139 Warning EGT 18 (B9) Moderate Hi
354 Warning Int Man Pr 1 OOR Hi 2141 Warning Ext Sup Air Pr OOR Hi
355 Warning Int Man Pr 1 OOR Lo 2142 Warning Ext Sup Air Pr OOR Lo
412 NONE J1587 Datalink Incorrect 2143 Warning Ext Sup Air Pr Moderate Hi
Shutdown
414 NONE J1587 Datalink Abnrml Rate 2144 EGT 16 (B8) Critical Hi
w/Cooldown
Shutdown
453 Warning Gas Flow OOR Hi 2145 EGT 18 (B9) Critical Hi
w/Cooldown
454 Warning Gas Flow OOR Lo 2146 Warning EGT 17 (A9) OOR Lo
Shutdown
458 Ign Timing OOR Hi 2147 Warning EGT 18 (B9) OOR Lo
w/Cooldown
Shutdown
459 Ign Timing OOR Lo 2154 Warning Post-Filt Oil Pr OOR Hi
w/Cooldown
Shutdown
461 Ign Ctrl Ref OOR Hi 2155 Warning Post-Filt Oil Pr OOR Lo
w/Cooldown
Shutdown Shutdown
462 Ign Ctrl Ref OOR Lo 2157 Int Man 2 Tmp Abnrml Rate
w/Cooldown w/Cooldown
Shutdown
463 Warning Exh Gas Oxygen OOR Hi 2158 Int Man 3 Tmp Abnrml Rate
w/Cooldown
Shutdown
464 Warning Exh Gas Oxygen OOR Lo 2159 Int Man 4 Tmp Abnrml Rate
w/Cooldown
471 Warning Sump Oil Level Warning 2188 Warning Exh O2 OOR Hi
477 Warning Battery 2 V Moderate Lo 2191 Warning Int Man Pr Cond Exists
478 Warning Battery 2 V Moderate Hi 2192 Warning Exh O2 OOR Lo
512 Warning Throt Pos Fb OOR Hi 2193 Warning HT Cool Level Moderate Hi


513 Warning Throt Pos Fb OOR Lo 2217 Warning ECM Memory Cond Exists
Shutdown
514 Fuel Valve Stuck 2219 Warning Exh O2 Moderate Hi
w/Cooldown
Shutdown
557 Fuel Ctrl Vlv 2 OOR Hi 2221 Warning Exh O2 Moderate Lo
w/Cooldown
558 Warning Fuel Ctrl Vlv 2 OOR Lo 2231 Warning Knock 1 (A1) OOR Hi
Shutdown
561 Knock 1 (A1) Critical Hi 2232 Warning Knock 2 (B1) OOR Hi
w/Cooldown
Shutdown
562 Knock 2 (B1) Critical Hi 2233 Warning Knock 3 (A2) OOR Hi
w/Cooldown
Shutdown
w/Cooldown
Shutdown
w/Cooldown
Shutdown
w/Cooldown
Shutdown
w/Cooldown
Shutdown
w/Cooldown
Shutdown
w/Cooldown
Shutdown
569 Knock 9 (A5) Critical Hi 2279 Warning Knock 11 (A6) Warning Hi
w/Cooldown
Shutdown
571 Warning Knock 1 (A1) OOR Lo 2281 Knock 11 (A6) Moderate Hi
w/Cooldown
Shutdown
572 Warning Knock 2 (B1) OOR Lo 2282 Knock 11 (A6) Critical Hi
w/Cooldown
573 Warning Knock 3 (A2) OOR Lo 2298 Warning Fuel Shutoff 2 OOR Lo
574 Warning Knock 4 (B2) OOR Lo 2313 Warning Fuel Ctrl Vlv 2Cond Exists
575 Warning Knock 5 (A3) OOR Lo 2315 Warning Red Lamp OOR Hi
576 Warning Knock 6 (B3) OOR Lo 2316 Warning Amber Lamp OOR Hi
577 Warning Knock 7 (A4) OOR Lo 2317 Warning Amber Lamp OOR Lo
578 Warning Knock 8 (B4) OOR Lo 2427 Warning FCV Out Pr OOR Hi
579 Warning Knock 9 (A5) OOR Lo 2428 Warning FCV Out Pr OOR Lo
584 Warning Starter Relay OOR Hi 2431 Warning Knock 1 (A1) Warning Hi
585 Warning Starter Relay OOR Lo 2432 Warning Knock 2 (B1) Warning Hi
591 Warning Exh Back Pr OOR Hi 2433 Warning Knock 3 (A2) Warning Hi
592 Warning Exh Back Pr OOR Lo 2434 Warning Knock 4 (B2) Warning Hi
595 Warning Turbo Speed Moderate Hi 2435 Warning Knock 5 (A3) Warning Hi
618 Warning Comp In Pr Moderate Hi 2436 Warning Knock 6 (B3) Warning Hi
619 Warning Comp In 2 Pr Moderate Hi 2437 Warning Knock 7 (A4) Warning Hi
Shutdown
641 EGT 1 (A1) Critical Hi 2438 Warning Knock 8 (B4) Warning Hi
w/Cooldown
Shutdown
642 EGT 3 (A2) Critical Hi 2439 Warning Knock 9 (A5) Warning Hi
w/Cooldown
Shutdown
643 EGT 5 (A3) Critical Hi 2441 Warning Knock 10 (B5) Warning Hi
w/Cooldown
Shutdown
644 EGT 7 (A4) Critical Hi 2453 Warning Gen kW Load OOR Hi
w/Cooldown
Shutdown
645 EGT 9 (A5) Critical Hi 2454 Warning Gen kW Load OOR Lo
w/Cooldown
Shutdown
646 EGT 11 (A6) Critical Hi 2455 Warning Gov Spd Bias OOR Lo
w/Cooldown
Shutdown
647 EGT 13 (A7) Critical Hi 2456 Warning Gov Spd Bias OOR Hi
w/Cooldown
Shutdown Shutdown
648 EGT 15 (A8) Critical Hi 2457 Eng Misfire Cond Exists
Shutdown
651 EGT 17 (A9) Critical Hi 2458 Warning EGT 2 (B1) Moderate Lo
w/Cooldown
Shutdown
652 EGT 2 (B1) Critical Hi 2459 Warning EGT 4 (B2) Moderate Lo
w/Cooldown
Shutdown
w/Cooldown


Shutdown
w/Cooldown
Shutdown
w/Cooldown
Shutdown
w/Cooldown
Shutdown
w/Cooldown
Shutdown
w/Cooldown
671 Warning EGT 1 (A1) OOR Lo 2467 Warning EGT 18 (B9) Moderate Lo
672 Warning EGT 3 (A2) OOR Lo 2469 Warning EGT 1 (A1) Moderate Lo
683 Warning Turbo 2 Speed Moderate Hi 2478 Warning EGT 15 (A8) Moderate Lo
684 Warning Turbo 2 Speed Moderate Lo 2479 Warning EGT 17 (A9) Moderate Lo
Shutdown
685 Warning Turbo 2 Speed Incorrect 2482 Starter Mode Cond Exists
w/Cooldown
Shutdown
687 Warning Turbo Speed Moderate Lo 2483 Starter Mode Out of Adj
w/Cooldown
Shutdown
721 Warning EGT 2 (B1) OOR Lo 2484 EGT 1 (A1) Abnrml Rate
w/Cooldown
Shutdown
w/Cooldown
Shutdown
w/Cooldown
Shutdown
w/Cooldown
Shutdown
w/Cooldown
Shutdown
w/Cooldown
Shutdown
w/Cooldown
Shutdown
w/Cooldown
Shutdown
736 Warning Air Starter Pr OOR Lo 2493 EGT 17 (A9) Abnrml Rate
w/Cooldown
Shutdown
737 Warning Air Starter Pr OOR Hi 2494 EGT 2 (B1) Abnrml Rate
w/Cooldown
Shutdown
738 Warning Starter Air Press Low 2495 EGT 4 (B2) Abnrml Rate
w/Cooldown
Shutdown
741 Warning Comp In Pr OOR Hi 2496 EGT 6 (B3) Abnrml Rate
w/Cooldown
Shutdown
742 Warning Comp In Pr OOR Lo 2497 EGT 8 (B4) Abnrml Rate
w/Cooldown
Shutdown
751 Warning Gas Flow Incorrect 2498 EGT 10 (B5) Abnrml Rate
w/Cooldown
Shutdown
752 Warning Exh O2 Incorrect 2499 EGT 12 (B6) Abnrml Rate
w/Cooldown
Shutdown Shutdown
783 Int Man Tmp Abnrml Rate 2511 EGT 14 (B7) Abnrml Rate
Shutdown
831 Warning Sprk Plg 1 (A1) OOR Lo 2512 EGT 16 (B8) Abnrml Rate
w/Cooldown
Shutdown
832 Warning Sprk Plg 2 (B1) OOR Lo 2513 EGT 18 (B9) Abnrml Rate
w/Cooldown
Shutdown
833 Warning Sprk Plg 3 (A2) OOR Lo 2514 EGT 19 (A10) Abnrml Rate
w/Cooldown
Shutdown
834 Warning Sprk Plg 4 (B2) OOR Lo 2515 EGT 20 (B10) Abnrml Rate
w/Cooldown
835 Warning Sprk Plg 5 (A3) OOR Lo 2517 Warning Comp Out Pr OOR Hi
836 Warning Sprk Plg 6 (B3) OOR Lo 2518 Warning Comp Out Pr OOR Lo


Shutdown
837 Warning Sprk Plg 7 (A4) OOR Lo 2521 Bank_ID SwitchPos
w/Cooldown
Shutdown
838 Warning Sprk Plg 8 (B4) OOR Lo 2522 Knock 1 (A1) Moderate Hi
w/Cooldown
Shutdown
839 Warning Sprk Plg 9 (A5) OOR Lo 2523 Knock 2 (B1) Moderate Hi
w/Cooldown
Shutdown
w/Cooldown
Shutdown
w/Cooldown
Shutdown
w/Cooldown
Shutdown
w/Cooldown
Shutdown
w/Cooldown
Shutdown
w/Cooldown
Shutdown
w/Cooldown
Shutdown
w/Cooldown
Shutdown
849 Warning Sprk Plg 18 (B9) OOR Lo 2544 ECM Int Tmp Critical Hi
w/Cooldown
891 Warning Sprk Plg 1 (A1) Root Unknwn 2553 Warning Eng Oil Level Moderate Lo
892 Warning Sprk Plg 2 (B1) Root Unknwn 2567 Warning Start Air Comp Cond Exists
Shutdown
893 Warning Sprk Plg 3 (A2) Root Unknwn 2568 Gas Supply Pr Critical Hi
w/Cooldown
Shutdown
894 Warning Sprk Plg 4 (B2) Root Unknwn 2569 Gas Supply Pr Critical Lo
w/Cooldown
895 Warning Sprk Plg 5 (A3) Root Unknwn 2586 NONE Sprk Plg 1 (A1) Warning Hi
896 Warning Sprk Plg 6 (B3) Root Unknwn 2587 NONE Sprk Plg 2 (B1) Warning Hi
912 Warning Sprk Plg 11 (A6) Root Unknwn 2593 NONE Sprk Plg 1 (A1) Warning Lo
913 Warning Sprk Plg 12 (B6) Root Unknwn 2594 NONE Sprk Plg 2 (B1) Warning Lo
918 Warning Sprk Plg 17 (A9) Root Unknwn 2643 Warning Throt 2 Pos Fb OOR Hi
919 Warning Sprk Plg 18 (B9) Root Unknwn 2644 Warning Throt 2 Pos Fb OOR Lo
Shutdown
1213 Comp Out Pr Moderate Hi 2646 Warning HT Cool Tmp Cond Exists
w/Cooldown
Shutdown
1274 Knock 10 (B5) Critical Hi 2724 Warning Gas Supply Pr Moderate Hi
w/Cooldown
1275 Warning Knock 10 (B5) OOR Lo 2725 Warning Gas Supply Pr Moderate Lo
Shutdown
1276 Warning Knock 10 (B5) OOR Hi 2737 Exh Gas Tmp Critical Hi
w/Cooldown
Shutdown
1277 Warning Knock 11 (A6) OOR Lo 2752 Throt Ctrl OOR Hi
w/Cooldown
Shutdown
1278 Warning Knock 11 (A6) OOR Hi 2766 Ignition 1 (L) Cond Exists
w/Cooldown
Shutdown
1279 Warning Knock 12 (B6) Warning Hi 2767 Ignition 2 (R) Cond Exists
w/Cooldown
Shutdown Shutdown
1281 Knock 12 (B6) Critical Hi 2768 CAN Par Com Incorrect
Shutdown
1282 Warning Knock 12 (B6) OOR Lo 2769 CAN Chld Com Incorrect
w/Cooldown
1283 Warning Knock 12 (B6) OOR Hi 2789 Warning HT Cool Tmp Moderate Lo
Shutdown
1284 Warning Knock 13 (A7) Warning Hi 2793 HT Cool Tmp Critical Lo
w/Cooldown


Shutdown
1285 Knock 13 (A7) Moderate Hi 2794 Warning Ign Shutd Rly OOR Hi
w/Cooldown
Shutdown
1286 Knock 13 (A7) Critical Hi 2795 Warning Ign Shutd Rly OOR Lo
w/Cooldown
1287 Warning Knock 13 (A7) OOR Lo 2796 Warning Gen kW Load Warning Hi
1288 Warning Knock 13 (A7) OOR Hi 2797 Warning In Gas Diff Pr OOR Hi
1289 Warning Knock 14 (B7) Warning Hi 2798 Warning In Gas Diff Pr OOR Lo
Shutdown Shutdown
1291 Knock 14 (B7) Critical Hi. 2799 Comp Out Pr Abnrml Rate
Shutdown
1292 Warning Knock 14 (B7) OOR Lo 2811 Comp Out Pr Critical Hi
w/Cooldown
Shutdown
1293 Warning Knock 14 (B7) OOR Hi 2812 Throt Ctrl Incorrect
w/Cooldown
1294 Warning Knock 15 (A8) Warning Hi 2837 Warning EGT 1 (A1) Incorrect
Shutdown
1295 Knock 15 (A8) Moderate Hi 2838 Warning EGT 3 (A2) Incorrect
w/Cooldown
Shutdown
1296 Knock 15 (A8) Critical Hi 2839 Warning EGT 5 (A3) Incorrect
w/Cooldown
1297 Warning Knock 15 (A8) OOR Lo 2841 Warning EGT 7 (A4) Incorrect
1298 Warning Knock 15 (A8) OOR Hi 2842 Warning EGT 9 (A5) Incorrect
1299 Warning Knock 16 (B8) Warning Hi 2843 Warning EGT 11 (A6) Incorrect
Shutdown
1311 Knock 18 (B9) Critical Hi. 2844 Warning EGT 13 (A7) Incorrect
w/Cooldown
1338 Warning Knock 18 (B9) OOR Lo 2845 Warning EGT 15 (A8) Incorrect
1339 Warning Knock 18 (B9) OOR Hi 2846 Warning EGT 17 (A9) Incorrect
1352 Warning Knock 20 (B10) Warning Hi 2847 Warning EGT 2 (B1) Incorrect
Shutdown
1353 Knock 20 (B10) Moderate Hi 2848 Warning EGT 4 (B2) Incorrect
w/Cooldown
Shutdown
1354 Knock 20 (B10) Critical Hi. 2849 Warning EGT 6 (B3) Incorrect
w/Cooldown
1355 Warning Knock 20 (B10) OOR Lo 2851 Warning EGT 8 (B4) Incorrect
1356 Warning Knock 20 (B10) OOR Hi 2852 Warning EGT 10 (B5) Incorrect
1362 Warning Oil Filt Rst Pr Moderate Hi 2853 Warning EGT 12 (B6) Incorrect
Shutdown
1474 Software Ver Cond Exists 2854 Warning EGT 14 (B7) Incorrect
w/Cooldown
1521 Warning EGT 3 (A2) OOR Hi 2855 Warning EGT 16 (B8) Incorrect
1522 Warning EGT 5 (A3) OOR Hi 2856 Warning EGT 18 (B9) Incorrect
Shutdown
1523 Warning EGT 7 (A4) OOR Hi 2857 Turbo Speed Critical Hi
w/Cooldown
Shutdown
1524 Warning EGT 9 (A5) OOR Hi 2858 Turbo 2 Speed Critical Hi
w/Cooldown
1525 Warning EGT 11 (A6) OOR Hi 2859 Warning Alt Htr Ctrl OOR Hi
1526 Warning EGT 13 (A7) OOR Hi 2861 Warning Alt Htr Ctrl OOR Lo
1527 Warning EGT 15 (A8) OOR Hi 2862 Warning Gen Alt 1st Str Cond Exists
Shutdown
1528 Warning EGT 17 (A9) OOR Hi 2863 Gen Eng Com Incorrect
w/Cooldown
Shutdown
1529 Warning EGT 2 (B1) OOR Hi 2864 Fuel Shutoff 1 OOR Hi
w/Cooldown
1531 Warning EGT 6 (B3) OOR Hi 2866 Warning FCV Pos Fb OOR Hi
1532 Warning EGT 8 (B4) OOR Hi 2867 Warning FCV Pos Fb OOR Lo
1533 Warning EGT 10 (B5) OOR Hi 2868 Warning Eng Heater Moderate Hi
1534 Warning EGT 12 (B6) OOR Hi 2869 Warning HT Cool T Drvr OOR Hi
1535 Warning EGT 14 (B7) OOR Hi 2871 Warning HT Cool T Drvr OOR Lo
1536 Warning EGT 16 (B8) OOR Hi 2872 Warning HT Cool T Drvr Cond Exists
1537 Warning EGT 18 (B9) OOR Hi 2873 Warning LT Cool T Drvr OOR Hi
1545 Warning Speed / Pos 2 Cond Exists 2874 Warning LT Cool T Drvr OOR Lo
1546 Warning Speed / Pos 1 Cond Exists 2875 Warning LT Cool T Drvr Cond Exists
Shutdown Shutdown
1572 Knock 19 (A10) Moderate Hi 2876 Comp In Tmp Critical Lo
1574 Shutdown Knock 19 (A10) Critical Hi 2877 Warning Comp In Tmp Moderate Lo


w/Cooldown
1575 Warning Knock 19 (A10) OOR Lo 2938 Warning Earth/Ground Fault
1576 Warning Knock 19 (A10) OOR Hi 2951 Warning Alternator 1 Temp Sen Hi
Shutdown
1579 Knock 12 (B6) Moderate Hi 2952 Warning Alternator 1 Temp Sen Lo
w/Cooldown
Shutdown
1581 Knock 14 (B7) Moderate Hi 2953 Warning High Alternator 1 Temp
w/Cooldown
Shutdown
1582 Knock 16 (B8) Moderate Hi 2954 Warning Alternator 2 Temp Sen Hi
w/Cooldown
Shutdown
1583 Knock 16 (B8) Critical Hi 2955 Warning Alternator 2 Temp Sen Lo
w/Cooldown
1584 Warning Knock 16 (B8) OOR Lo 2956 Warning High Alternator 2 Temp
1585 Warning Knock 16 (B8) OOR Hi 2957 Warning Alternator 3 Temp Sen Hi
1586 Warning Knock 17 (A9) Warning Hi 2958 Warning Alternator 3 Temp Sen Lo
Shutdown
1587 Knock 17 (A9) Moderate Hi 2959 Warning High Alternator 3 Temp
w/Cooldown
Shutdown
1588 Knock 17 (A9) Critical Hi 2963 NONE HT Cool Tmp Warning Hi
w/Cooldown
1589 Warning Knock 17 (A9) OOR Lo 2981 Warning Drv Bearing Temp Sen Hi
1591 Warning Knock 17 (A9) OOR Hi 2982 Warning Drv Bearing Temp Sen Lo
1592 Warning Knock 18 (B9) Warning Hi 2983 Warning High Drive Bearing Temp
Shutdown
1593 Knock 18 (B9) Moderate Hi 2984 Warning NonDrv Bearing Sens Hi
w/Cooldown
1594 Warning Knock 19 (A10) Warning Hi 2985 Warning NonDrv Bearing Sens Lo
1618 Warning EGT 1 (A1) OOR Hi 2986 Warning High NonDrv Bearing Tmp
1619 Warning EGT4 (B2) OOR Hi 2994 Warning ECM Special Case
Shutdown
1636 Warning Int Man 2 Pr OOR Hi 2995 Int Man Pr 1 Critical Hi
w/Cooldown
1637 Warning Int Man 2 Pr OOR lo 2996 Warning Int Man Pr 1 Moderate Hi
Shutdown Shutdown
1737 Throt Ctrl Bad Device 2997 Exh O2 Critical Lo
Shutdown
1738 Warning Throt Ctrl InternalFlt 3111 Knock 1 (A1) Special Case
w/Cooldown
Shutdown
1739 Warning Throt Ctrl Cond Exists 3112 Knock 2 (B1) Special Case
w/Cooldown
Shutdown
1741 Warning Throt Ctrl Warning Hi 3113 Knock 3 (A2) Special Case
w/Cooldown
Shutdown
1742 Warning Throt Ctrl Moderate Hi 3114 Knock 4 (B2) Special Case
w/Cooldown
Shutdown Shutdown
1743 Throt Ctrl 2 OOR Hi 3115 Knock 5 (A3) Special Case
Shutdown Shutdown
1744 Throt Ctrl 2 OOR Lo 3116 Knock 6 (B3) Special Case
Shutdown Shutdown
1745 Throt Ctrl 2 Incorrect 3117 Knock 7 (A4) Special Case
Shutdown Shutdown
1746 Throt Ctrl 2 Out of Adj 3118 Knock 8 (B4) Special Case
Shutdown Shutdown
1747 Throt Ctrl 2 Bad Device 3119 Knock 9 (A5) Special Case
Shutdown
1748 Warning Throt Ctrl 2 InternalFlt 3121 Knock 10 (B5) Special Case
w/Cooldown
Shutdown
1749 Warning Throt Ctrl 2 Cond Exists 3122 Knock 11 (A6) Special Case
w/Cooldown
Shutdown
1751 Warning Throt Ctrl 2 Warning Hi 3123 Knock 12 (B6) Special Case
w/Cooldown
Shutdown
1752 Warning Throt Ctrl 2 Moderate Hi 3124 Knock 13 (A7) Special Case
w/Cooldown
Shutdown
1753 Warning Fuel Shutoff 2 OOR Hi 3125 Knock 14 (B7) Special Case
w/Cooldown
Shutdown
1754 Warning Fuel Tmp 2 OOR Hi 3126 Knock 15 (A8) Special Case
w/Cooldown
Shutdown
1755 Warning Fuel Tmp 2 OOR Lo 3127 Knock 16 (B8) Special Case
w/Cooldown
Shutdown
1756 Warning Gas Flow 2 OOR Hi 3128 Knock 17 (A9) Special Case
w/Cooldown


Shutdown
1757 Warning Gas Flow 2 OOR Lo 3129 Knock 18 (B9) Special Case
w/Cooldown
1758 Warning Gas Flow 2 Incorrect 3262 NONE Sprk Plg 7 (A4) Warning Hi
Shutdown
1759 FCV 2 Pos Fb Incorrect 3263 NONE Sprk Plg 7 (A4) Warning Lo
w/Cooldown
Shutdown
1761 FCV Pos Fb Incorrect 3264 NONE Sprk Plg 8 (B4) Warning Hi
w/Cooldown
1765 Warning FCV 2 In Pr OOR Hi 3265 NONE Sprk Plg 8 (B4) Warning Lo
1766 Warning FCV 2 In Pr OOR lo 3266 NONE Sprk Plg 9 (A5) Warning Hi
1767 Warning FCV 2 Out Pr OOR Hi 3267 NONE Sprk Plg 9 (A5) Warning Lo
1768 Warning FCV 2 Out Pr OOR lo 3268 NONE Sprk Plg 10 (B5) Warning Hi
1769 Warning E_Shutd Ind OOR Hi 3269 NONE Sprk Plg 10 (B5) Warning Lo
1771 Warning E_Shutd Ind OOR Lo 3271 NONE Sprk Plg 11 (A6) Warning Hi
1772 Warning Derate Req OOR Hi 3272 NONE Sprk Plg 11 (A6) Warning Lo
1773 Warning Derate Req OOR Lo 3273 NONE Sprk Plg 12 (B6) Warning Hi
1774 Warning Oil Pr Pmp Ctrl OOR Hi 3274 NONE Sprk Plg 12 (B6) Warning Lo
1775 Warning Oil Pr Pmp Ctrl OOR Lo 3275 NONE Sprk Plg 13 (A7) Warning Hi
1778 Warning Eng PreHtr Ctrl OOR Hi 3276 NONE Sprk Plg 13 (A7) Warning Lo
1779 Warning Eng PreHtr Ctrl OOR Lo 3277 NONE Sprk Plg 14 (B7) Warning Hi
1781 Warning Shutd Request OOR Hi 3278 NONE Sprk Plg 14 (B7) Warning Lo
1782 Warning Shutd Request OOR Lo 3279 NONE Sprk Plg 15 (A8) Warning Hi
1783 Warning Cool Circ Pmp OOR Hi 3281 NONE Sprk Plg 15 (A8) Warning Lo
1784 Warning Cool Circ Pmp OOR Lo 3282 NONE Sprk Plg 16 (B8) Warning Hi
1785 Warning Oil Pr Pmp Man StuckOn 3283 NONE Sprk Plg 16 (B8) Warning Lo
1786 Warning Oil Pr Pmp Ctrl StuckOn 3284 NONE Sprk Plg 17 (A9) Warning Hi
1787 Warning Oil Pr Pmp Stat Moderate Lo 3285 NONE Sprk Plg 17 (A9) Warning Lo
1788 Warning Oil Pr Pmp Stat Warning Lo 3286 NONE Sprk Plg 18 (B9) Warning Hi
Shutdown
1789 Oil Pr Pmp Stat Critical Lo 3287 NONE Sprk Plg 18 (B9) Warning Lo
w/Cooldown
Shutdown
1791 Load / Speed Cond Exists 3288 Warning Exh Aft Out O2 Rly OOR Hi
w/Cooldown
1792 Warning Idl Brk Close Cond Exists 3289 Warning Exh Aft Out O2 Rly OOR Lo
1793 Warning Speed / Pos 1 Out of Adj 3291 Warning Exh Aft In O2 Rly OOR Hi
Shutdown
1794 Fire Detect Cond Exists 3292 Warning Exh Aft In O2 Rly OOR Lo
w/Cooldown
1795 Warning Comp Byp Pos OOR Hi 3293 Warning Exh O2 Rly OOR Hi
1796 Warning Comp Byp Pos OOR Lo 3294 Warning Exh O2 Rly OOR Lo
1797 Warning Comp Byp Ctrl OOR Hi 3362 Warning Pwr Cons Ctrl OOR Hi
1798 Warning Comp Byp Ctrl OOR Lo 3363 Warning Pwr Cons Ctrl OOR Lo
1799 Warning Comp Byp Ctrl Out of Adj 3364 Warning Pwr Cons Ctrl Cond Exists
1811 Warning FSO VPS Test OOR Hi 3365 Warning Ext Sup Air Pr Moderate Lo
1812 Warning FSO VPS Test OOR Lo 3384 Warning Int Man Pr 2 OOR Hi
1813 Warning FSO VPS Test Moderate Lo 3391 Warning Int Man Pr 2 OOR Lo
Shutdown Shutdown
1814 FSO VPS Test Critical Lo 3392 Int Man Pr 2 Critical Hi
1815 Warning Oil PreHtr Ctrl OOR Hi 3393 Warning Int Man Pr 2 Moderate Hi
Shutdown
1816 Warning Oil PreHtr Ctrl OOR Lo 3397 Low GB Oil Pressure
w/Cooldown
Shutdown
1817 Warning Oil PreHtr Ctrl Cond Exists 3398 High GB Oil Temperature
w/Cooldown
Shutdown
1818 Warning Oil PreHtr Stat DeviceFail 3399 Differential Fault
w/Cooldown
1819 Warning AC Aux Cond Exists 3411 Warning DC Power Supply Fault
Shutdown
1821 Speed / Pos 1 LowSpd 3412 Warning GIB Isolator Open Fault
w/Cooldown
Shutdown
1822 LT Cool Level Critical Lo 3413 Warning Radiator Fan Trip
w/Cooldown


1823 Warning LT Cool Level Warning Lo 3414 Warning Ventilator Fan Trip
1824 Warning Oil Tmp Cond Exists 3415 Warning Louvres Closed
1825 Warning Drty Oil Lvl Warning Hi 3416 Warning Start System
Shutdown
1826 Software Ver Cond Exists 3417 Warning Alternator Heater Trip
w/Cooldown
1827 Warning FCV In Pr OOR Hi 3458 Warning Knock Derate Cond Exists
1828 Warning FCV In Pr OOR Lo 3475 Warning FCV 2 Pos FbOOR Hi
Shutdown
1829 FSO Vent Vlv Opn/Cls 3476 Warning FCV 2 Pos FbOOR Lo
w/Cooldown
Shutdown Start Inhibit Shutdown Fault
1831 Fuel Shutoff 1 Opn/Cls 3479 Shutdown
w/Cooldown for Inputs;
Shutdown
1832 Fuel Shutoff 2 Opn/Cls 3481 Warning Start-Inhibit Warning.
w/Cooldown
1833 Warning Eng PreHtr Ctrl Cond Exists 3482 Shutdown Off Load Running Fault
High Alternator 1 Temp
1834 Warning Cool Circ Pmp Cond Exists 3483 Shutdown
Shutdown
High Alternator 2 Temp
1835 Warning Oil Pr Pmp Ctrl Cond Exists 3484 Shutdown
Shutdown
Shutdown High Alternator 3 Temp
1836 LT Cool Pr Critical Lo 3485 Shutdown
w/Cooldown Shutdown
Shutdown High Drive Bearing Temp
1837 Speed / Pos 2 Incorrect 3486 Shutdown
w/Cooldown Shutdown
Shutdown High NonDrv Bearing Temp
1838 Gen kW Load Critical Hi 3487 Shutdown
w/Cooldown Shutdown
1839 Warning Gas Supply Pr OOR Hi 3489 Warning Comp Byp Ctrl Cond Exists
Shutdown
1841 Warning Gas Supply Pr OOR Lo 3491 Oil Filt Rst PrCritical Hi
w/Cooldown
Shutdown
1842 Warning Radiator Fan Cond Exists 3499 Throt Ctrl 2 Cmd Shutd
w/Cooldown
Shutdown
1858 Warning Exh Aft In O2 OOR Hi 3511 Throt Ctrl 2 OOR Hi
w/Cooldown
Shutdown
1859 Warning Exh Aft In O2 OOR Lo 3512 Throt Ctrl 2 OOR Lo
w/Cooldown
Shutdown
1861 Warning Exh Aft In O2 Incorrect 3514 Throt Ctrl OOR Lo
w/Cooldown
Shutdown
1862 Warning Exh Aft Out O2 OOR Hi 3515 Throt Ctrl Cmd Shutd
w/Cooldown
1863 Warning Exh Aft Out O2 OOR Lo 3521 Warning Throt Ctrl Warning Lo
1864 Warning Exh Aft Out O2 Incorrect 3522 Warning Throt Ctrl 2 Warning Lo
9971 NONE LBNG ECM Derate
7.6.3 Customer Input Faults

Dependent on Customer Options specified, the Customer Input Faults may indicate the following:
ACTUAL TEXT SHOWN TRANSLATION
Earth Fault Earth Fault
Low Fuel Low Fuel
High Fuel High Fuel
High Alternator Temperature High Alternator Temperature
Dependent on the number of Customer Options required, an adjacent display panel may be fitted
where these Faults will be displayed.

Table 6 Troubleshooting Procedures for Fault Codes

CORRECTIVE ACTION (IF IN DOUBT, CALL YOUR
FAULT CODE
AUTHORISED SERVICE ENGINEER)
CODE: 143 Indicates engine oil pressure has dropped below the warning
LAMP: Warning trip point. If generator set is powering critical loads and cannot
MESSAGE: Low Oil Rifle Pressure be shut down, wait until next shutdown period and then follow
the fault code 415 procedure.
CODE: 144 Indicates engine has begun to overheat and engine coolant
LAMP: Warning temperature has risen to an unacceptable level. Increase in
MESSAGE: High Coolant 1 Temp load or higher ambient temperature may cause High Coolant
Temp (151) shutdown. Review fault code 151 correction list for
other possible causes.
CODE: 145 Engine coolant temperature is below the low coolant
LAMP: Warning temperature warning threshold. If generator set is powering
MESSAGE: Low Coolant 1 Temp critical loads and cannot be shut down, wait until next shutdown
period and then follow the fault code 1435 procedure.
CODE: 146 Indicates engine is operating near cooling system capacity.
LAMP: Derate Increase in load or higher ambient temperature may cause High
MESSAGE: Pre-High Engine Coolant Coolant Temp (151) shutdown. Review fault code 151
Temperature correction list for other possible causes.
CODE: 151 Indicates engine has overheated (coolant temperature has risen
LAMP: Shutdown above the shutdown trip point or coolant level is low). Allow
MESSAGE: High Coolant Temp engine to cool down completely before proceeding with the
following checks:
a) Look for possible coolant leakage points and repair if
necessary. Check coolant level and replenish if low.
b) Check for obstructions to cooling airflow and correct as
necessary.
c) Check fan belt and repair or tighten if necessary.
d) Check blower fan and circulation pumps on remote radiator
installations.
e) Reset control and restart after locating and correcting
problem.
CODE: 155 Indicates engine has overheated (intake manifold temperature
LAMP: Shutdown has risen above the shutdown trip point). Large load or high
MESSAGE: High Intake Manf 1 Temp ambient temperature may be the cause. Review fault code 151
correction list for other possible causes.
CODE: 196 Indicates engine coolant level has fallen below the trip point. If
LAMP: Warning generator is powering critical loads and cannot be shut down,
MESSAGE: Low Coolant 1 Level wait until next shutdown period. If engine can be stopped allow
engine to cool down completely before proceeding:
f) Look for possible coolant leakage points and repair if
g) Reset control and restart after locating and correcting
problem.
CODE: 197 Indicates engine coolant level has fallen below the trip point. If
LAMP: Warning generator is powering critical loads and cannot be shut down,
MESSAGE: Low Coolant Level wait until next shutdown period. If engine can be stopped allow
engine to cool down completely before proceeding:
necessary
b) Check coolant level and replenish if low
c) Reset control and restart after locating and correcting
problem.


FAULT CODE
CODE: 235 Low Coolant Level input is active and the threshold response is
LAMP: Shutdown set to Shutdown. Allow engine to cool down completely before
MESSAGE: Low Coolant Level proceeding:
necessary.
b) Check coolant level and replenish if low.
problem.
CODE: 359 Indicates possible fault with control or starting system. (Engine
LAMP: Shutdown cranks but fails to start). Allow engine to cool down completely
MESSAGE: Fail To Start before proceeding with the following checks:
a) Check for empty fuel tank, fuel leaks, or blocked fuel lines
and correct as required.
b) Check for dirty fuel filter and replace if necessary.
c) Check for dirty or blocked air filter and replace if necessary.
d) Clean and tighten all battery cable connections
e) Discharged or defective battery. Recharge or replace
f) Reset control and restart after correcting the problem.
CODE: 415 Indicates engine oil pressure has dropped below the shutdown
LAMP: Shutdown trip point. Allow engine to cool down completely before
MESSAGE: Low Oil Rifle press proceeding with the following checks:
a) Check the oil level, lines and filters.
b) If the oil system is OK but the oil level is low, replenish.
problem.
CODE: 427 Communication between the engine control (ECM) and the
LAMP: Warning PCC is severed. Allow engine to cool down completely before
MESSAGE: CAN Data Link Degraded proceeding:
a) Ensure the E-Stop button is not active. Reset the
Local/Remote Emergency Stop.
CODE: 441 Indicates battery voltage is below 24VDC and is approaching a
LAMP: Warning low level at which unpredictable operation will occur. If engine
MESSAGE: Low Battery 1 Voltage can be stopped allow engine to cool down completely before
proceeding:
a) Clean battery terminals and tighten all connections
b) Check electrolyte level, top up and re-charge (if applicable)
c) Discharged or defective battery. Recharge or replace.
CODE: 442 Indicates battery voltage to the control is approaching a high
LAMP: Warning level (exceeding 32VDC) at which damage to the control can
MESSAGE: High Battery 1 Voltage occur. If engine can be stopped allow engine to cool down
completely before proceeding:
a) Clean battery terminals and tighten all connections
b) Check battery charge float level if applicable (lower float
level).
CODE: 488 Indicates engine has overheated (intake manifold temperature
LAMP: Derate has risen above the shutdown trip point). Large load or high
MESSAGE: High Intake Manf 1 temp ambient temperature may be the cause. Review fault code 151
correction list for other possible causes.
CODE: 611 Indicates that an engine hot shutdown has occurred (cooldown
LAMP: Warning timers were bypassed). This condition will occur when the
MESSAGE: Engine Hot Shut Down operator presses the Emergency Switch or presses the Stop
button before the generator set completes the cooldown
operation. (Generator set should run at 10% or less load for
three minutes before engine shutdown). This type of hot
shutdown should be avoided; it can cause possible loss of
performance and engine damage.


FAULT CODE
CODE: 781 Communication between the engine control (ECM) and the
LAMP: Shutdown PCC has been severed.
MESSAGE: CAN Data Link Failure a) Ensure the E-Stop button is not active. Reset the
Local/Remote Emergency Stop.
CODE: 1433/1434 Indicates local or remote Emergency Stop has been activated.
LAMP: Shutdown Emergency Stop shutdown status can be reset only at the local
MESSAGE: Local Emergency control panel.
Stop/Remote Emergency Stop Allow engine to cool down completely before proceeding with
the following checks:
a) After locating and correcting problem, reset the
local/remote Emergency Stop button as follows:
1) De-activate (disable) emergency stop button
2) Press the Stop button
3) Press the Reset button
4) Select the desired operating mode (manual or
auto).
b) Check the Emergency Stop button is working correctly
CODE: 1435 Indicates engine coolant heater is not operating or is not
LAMP: Warning circulating coolant. If engine can be stopped allow engine to
MESSAGE: Low Coolant cool down completely before proceeding with the following
Temperature checks:
a) The coolant heater is not connected to power supply.
Check for blown fuse or disconnected heater cable and
correct as required.
b) Look for possible coolant leaks and repair as required.
c) Check for low coolant level and replenish if required.
Set is not operating. Warning occurs when engine coolant

o o
temperature is 21 C (70 F) or lower.
NOTE: In applications where the ambient temperature falls
o o
below 4 C (40 F), Low Coolant Temp may be indicated
even though the coolant heaters are operating.
CODE: 1438 Indicates a possible fault with control, speed sensing, or starting
LAMP: Shutdown system. Allow engine to cool down completely before
MESSAGE: Fail To Crank proceeding with the following checks:
a) Indicates a possible fault with control, speed sensing, or
starting system. See code 441 for corrective action
b) Ensure Emergency Stop button is disengaged.
CODE: 1442 Indicates that during cranking, the battery voltage is at, or
LAMP: Warning below, the weak battery warning trip point for a time greater
MESSAGE: Weak Battery than, or equal to, the weak battery set time.
If engine can be stopped allow engine to cool down completely
before proceeding with the following checks:
a) See code 441.
CODE: 1443 During cranking, the battery voltage Has dropped below the
LAMP: Shutdown operating voltage of the PCC, which resets the PCC. After three
MESSAGE: Dead Battery consecutive resets, event/fault code 1443 will become active.
If engine can be stopped allow engine to cool down completely
before proceeding with the following checks:
a) See code 441.
CODE: 1448 Indicates that the generator set frequency has dropped below
LAMP: Shutdown 90% of nominal for approximately ten seconds. Allow engine to
MESSAGE: Under Frequency cool down completely before proceeding with the following
checks:
a) Check the fuel supply
b) Check the air intake supply
c) Check the load and correct any overload.


FAULT CODE
CODE: 1449 Indicates that the generator set frequency has exceeded the
LAMP: Shutdown Over Frequency threshold for the set time parameter. Allow
MESSAGE: Over Frequency engine to cool down completely before proceeding with the
following checks:
a) Check the fuel supply
b) Check the air intake supply
c) Check the load and correct any overload.
CODE: 2977 Indicates engine coolant level, in the second radiator, has fallen
LAMP: Warning below the trip point. If generator is powering critical loads and
MESSAGE: Low Coolant 2 Level cannot be shut down, wait until next shutdown period. If engine
can be stopped allow engine to cool down completely before
proceeding:
b) Reset control and restart after locating and correcting
problem.
CODE: 3416 Refer to fault codes 359 and 1438
LAMP: Warning
MESSAGE: Start System Fault
Condition Exists

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Manual PCS 3300 - Gas

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Manual PCS 3300 - Gas

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Owners Manual

Gas Generator Set

English Original Instructions 4-2012 0908-0209 (Issue3)

Cummins Power Generation Cummins Power Generation Cummins Power Generation

e-mail: pgamail@cummins.com e-mail: cpgk.uk@cummins.com e-mail: cpg.apmktg@cummins.com

Web: www.cumminspower.com Web: www.cumminspower.com Web: www.cumminspower.com

Cummins Power Generation Cummins Power Generation

e-mail: e-mail: falecom@cumminspower.com.br

Web: www.cumminspower.com Web: www.cumminspower.com

Engine Specific Publications Operator Level

If further information is required contact your authorised distributor.

Schedule of Abbreviations .............................................................................................. ix

3. Generator Set Components ................................................................................... 9

4. Control System ..................................................................................................... 13

4.5.1 Alternator Data ....................................................................................................................... 25

6.2.1 Introduction .............................................................................................................................88

Contents Page vii

This Page Has Been Left Intentionally Blank

Page viii Contents

Schedule of Abbreviations Page ix

This Page Has Been Left Intentionally Blank

Page x Schedule of Abbreviations

SECTION 1 PRELIMINARY AND SAFETY

1.2 General Information

1.3 Generator Plant Safety Code

Section 1 Preliminary and Safety Page 1

WARNING: LIFTING AND REPOSITIONING ON THE GENERATOR SET MUST ONLY BE

1.3.2 Electrical Equipment

1.3.3 Engine Exhaust

Page 2 Section 1 Preliminary and Safety

1.3.4 Natural Gas

1.3.6 Moving Components

Section 1 Preliminary and Safety Page 3

1.3.7 General Safety

Page 4 Section 1 Preliminary and Safety

2.2 Generator Set Identification

Figure 1 Typical Generator Set Rating Plate

Section 2 Introduction Page 5

Figure 2 Typical Engine Data Plate

Page 6 Section 2 Introduction

2.3 After Sales Services

2.3.3 Service Parts

2.3.4 International Support

Section 2 Introduction Page 7

2.4 Project Details

Phone Numbers Tel: Mobile:

Phone Numbers Tel: Mobile:

Page 8 Section 2 Introduction

SECTION 3 SYSTEM OVERVIEW

3. Generator Set Components

Figure 3 Typical Generator Set Ancillary Equipment

1 Gas Mass Flow Valve 14 Lube-oil Make-up Valve 27 CENSE Module

Section 3 System Overview Page 9

3.1 Generator rating

3.1.1 Gas Train (Option)

Figure 4- Typical Gas Train

1 Gas Shut-off Valve (GSOV) 5 Pressure Relief Valve (PRV)

3.2.1 Heater Supply and Isolation

3.3 Oil Specification

Page 10 Section 3 System Overview

*Premium grade oil

* Premium grade oil

*Premium grade oil

3.3.1 Low BTU Gas Engines