CUMMINS C1750 N5C, C1400 N5C, C1200 N5C, C1160 N5C, C1000 N6C Owner's Manual

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OwnersOwners ManualManual

Generator Set

QSK60G and QSV91 Engines 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 C1000 N6 C1250 N6 C1350 N6 C1700 N6

English Original Instructions

3-2016 0908-0209 (Issue 6)

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Page 3

1. IMPORTANT SAFETY INSTRUCTIONS.................................................................................. 1

1.1 Warning, Caution, and Note Styles Used in This Manual ................................................ 1

1.2 General Information........................................................................................................... 1

1.2.1 General Safety Precautions.................................................................................... 1

1.3 Generator Set Safety Code............................................................................................... 4

1.3.1 Moving Parts Can Cause Severe Personal Injury or Death................................... 4

1.3.2 Positioning of Generator Set - Open Sets .............................................................. 4

1.3.3 Moving the Generator Set ...................................................................................... 4

1.3.4 Alternator Operating Areas..................................................................................... 6

1.4 Electrical Shocks and Arc Flashes Can Cause Severe Personal Injury or Death ............ 6

1.4.1 AC Supply and Isolation ......................................................................................... 7

1.4.2 Medium Voltage Equipment (601 V to 15 kV - North America).............................. 7

1.5 Fuel and Fumes Are Flammable ....................................................................................... 7

1.5.1 Natural Gas ............................................................................................................ 7

1.5.2 Spillage.................................................................................................................. 8

1.5.3 Fluid Containment ................................................................................................. 8

1.5.4 Do Not Operate in Flammable and Explosive Environments ................................. 8

1.6 Exhaust Gases Are Deadly ............................................................................................... 8

1.6.1 Exhaust Precautions.............................................................................................. 9

1.7 Decommissioning and Disassembly.................................................................................. 9

2. INTRODUCTION .................................................................................................................... 11

2.1 About This Manual .......................................................................................................... 11

2.2 Schedule of Abbreviations............................................................................................... 11

2.3 Related Literature ............................................................................................................ 13

2.3.1 Further Information - Literature............................................................................. 13

2.4 After Sales Services ........................................................................................................ 14

2.4.1 Maintenance........................................................................................................ 14

2.4.2 Warranty ............................................................................................................... 14

2.4.3 How to Obtain Service ......................................................................................... 14

2.5 Project Details ................................................................................................................. 15

3. SYSTEM OVERVIEW............................................................................................................. 17

3.1 Generator Set Identification............................................................................................. 17

3.1.1 Generator Set Rating............................................................................................ 17

3.1.2 Nameplate - Open Generator Set ........................................................................ 17

3.2 Generator Set Components ............................................................................................ 17

3.3 Air Cleaner....................................................................................................................... 19

3.3.1 Air Cleaner System............................................................................................... 19

3.4 Coolant Specification....................................................................................................... 20

3.5 Gas Train......................................................................................................................... 21

3.6 Heaters ............................................................................................................................ 21

3.6.1 Heater Supply and Isolation ................................................................................. 21

3.7 Mains (Utility) Powered Battery Charger ......................................................................... 22

3.8 Oil Specification............................................................................................................... 22

3.8.1 Low BTU Gas Engines ......................................................................................... 23

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Table of Contents 3-2016

3.9 Sensors ........................................................................................................................... 24

3.10 System Options ............................................................................................................. 24

3.10.1 PowerCommand Universal Annunciator............................................................. 24

3.10.2 Mains (Utility) Powered Battery Charger ............................................................ 25

3.10.3 Coolant Heater ................................................................................................... 26

4. CONTROL SYSTEM - POWERCOMMAND 3.3 .................................................................... 27

4.1 Control System Description............................................................................................. 27

4.1.1 Control System Panel........................................................................................... 27

4.1.2 Operating Modes .................................................................................................. 28

4.1.3 Power On and Sleep Modes ................................................................................ 30

4.2 Operator Panel ................................................................................................................ 30

4.2.1 Selection Buttons.................................................................................................. 31

4.2.2 Default Settings .................................................................................................... 32

4.2.3 Lamp Indicators .................................................................................................... 32

4.2.4 Lamp (LED) Test Button ...................................................................................... 32

4.2.5 Reset Button ........................................................................................................ 32

4.2.6 CB Open Button .................................................................................................. 32

4.2.7 CB Closed Button ................................................................................................ 33

4.2.8 Graphical Display and Buttons ............................................................................. 33

4.3 Operator Panel - Initial Operator Menu ........................................................................... 35

4.3.1 Initial Menu Data................................................................................................... 35

4.4 Operator Panel - Generator Set Data Operator Menu .................................................... 37

4.4.1 Generator Set Data .............................................................................................. 37

4.5 Operator Panel - Engine Data Operator Menu................................................................ 39

4.5.1 Engine Data.......................................................................................................... 39

4.5.2 History/About Menu .............................................................................................. 41

4.6 Operator Panel - Alternator Data Operator Menu ........................................................... 43

4.6.1 Alternator Data ..................................................................................................... 44

4.7 Operator Panel - Faults and Warnings Menus................................................................ 46

4.7.1 Fault Menu............................................................................................................ 46

4.7.2 Fault Messages .................................................................................................... 48

4.7.3 Fault Acknowledgement ....................................................................................... 48

4.7.4 Warning Fault Menu ............................................................................................. 48

4.7.5 Faults History Data Operator Menu...................................................................... 50

4.8 Operator Panel - Adjust Menu......................................................................................... 52

4.9 Operator Panel - Genset Setup Data Operator Menu..................................................... 53

4.10 Operator Panel - Paralleling Status Menu..................................................................... 54

4.11 Operator Panel - Paralleling/Basic Setup Menu............................................................ 61

4.12 Selecting Operating Modes ........................................................................................... 64

4.12.1 Passwords and Mode Change Access............................................................... 64

4.12.2 Selecting Manual Run Mode .............................................................................. 65

4.12.3 Selecting Auto Mode .......................................................................................... 66

4.12.4 Selecting Off Mode............................................................................................. 67

5. OPERATION - POWERCOMMAND 3.3................................................................................. 69

5.1 Safety .............................................................................................................................. 69

5.2 Introduction ...................................................................................................................... 69

5.3 Maintenance .................................................................................................................... 69

5.4 Operating Recommendations.......................................................................................... 70

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Table of Contents3-2016

5.4.1 Running-in ............................................................................................................ 70

5.4.2 No Load Operation ............................................................................................... 70

5.4.3 Exercise Period .................................................................................................... 70

5.4.4 Low Operating Temperatures............................................................................... 70

5.4.5 High Operating Temperatures.............................................................................. 70

5.4.6 Operating Conditions............................................................................................ 70

5.4.7 De-Rating Factors ............................................................................................... 72

5.5 Generator Set Operation ................................................................................................. 72

5.5.1 Sequence of Operation......................................................................................... 72

5.6 Starting ............................................................................................................................ 73

5.6.1 Operator’s Pre-start Checks ................................................................................. 73

5.6.2 Starting at Operator Panel (Manual Run Mode)................................................... 74

5.6.3 Starting from Remote Location (Auto Mode)........................................................ 75

5.6.4 Cold Starting with Loads ...................................................................................... 76

5.7 Stopping .......................................................................................................................... 76

5.7.1 Stopping at Operator Panel (Manual Mode)......................................................... 77

5.7.2 Stopping from Operator Panel (Auto Mode) ......................................................... 77

5.7.3 Stopping from Remote Location (Auto Mode)...................................................... 77

5.7.4 Emergency Stop (Code 1433 or 1434) ............................................................... 78

5.8 Paralleling Operation ....................................................................................................... 79

5.8.1 Speed and Voltage Matching ............................................................................... 79

5.8.2 Operation When in Parallel ................................................................................. 79

5.8.3 Generator Set Application Type ........................................................................... 79

5.8.4 Standalone Application......................................................................................... 80

5.8.5 Synchronize Only ................................................................................................. 81

5.8.6 Isolated Bus Only ................................................................................................. 82

5.8.7 Power Transfer Control ........................................................................................ 83

5.8.8 Conditions for Each Paralleling State................................................................... 87

6. MAINTENANCE...................................................................................................................... 97

6.1 Locking the Generator Set Out of Service ...................................................................... 98

6.1.1 Immobilizing for Safe Working.............................................................................. 98

6.2 Periodic Maintenance ...................................................................................................... 99

6.2.1 Periodic Maintenance Schedule........................................................................... 99

6.3 Maintenance Procedures - Daily ................................................................................... 100

6.3.1 General Information............................................................................................ 101

6.3.2 Engine Operation Report................................................................................... 101

6.4 Air Intake System .......................................................................................................... 101

6.4.1 Air Cleaner Service Indicator.............................................................................. 102

6.4.2 Air Cleaner System............................................................................................. 102

6.4.3 Air Cleaner System............................................................................................. 103

6.4.4 Air Cleaner System............................................................................................. 103

6.4.5 Air Cleaner Element Replacement ..................................................................... 104

6.5 Batteries ........................................................................................................................ 105

6.5.1 Storage ............................................................................................................... 105

6.5.2 Safety Precautions ............................................................................................. 105

6.5.3 Battery Maintenance........................................................................................... 106

6.5.4 Electrolyte - Specific Gravity and Temperature.................................................. 108

6.5.5 Electrolyte Levels and Bench Charging Rates................................................... 110

6.5.6 Battery Fault Finding .......................................................................................... 112

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Table of Contents 3-2016

6.6 Cooling System ............................................................................................................. 113

6.6.1 Water Quality Check........................................................................................... 113

6.6.2 Radiator - Check................................................................................................. 113

6.6.3 Cooling Fan - Inspection .................................................................................... 114

6.7 DC Electrical System..................................................................................................... 114

6.8 Engine Oil ...................................................................................................................... 115

6.8.1 Oil Maintainer - Level Check and Fill ................................................................. 115

6.8.2 Crankcase Ventilation Re-circulator ................................................................... 116

6.9 Exhaust System............................................................................................................. 117

6.10 Fuel System................................................................................................................. 118

6.10.1 Fuel consumption ............................................................................................. 118

6.10.2 Methane Index.................................................................................................. 118

6.10.3 De-rate.............................................................................................................. 118

6.11 Gearbox Inspection ..................................................................................................... 119

6.12 Generator Set Output - AC Electric System ................................................................ 119

6.13 Hoses and Fuel Lines - Check .................................................................................... 120

6.14 Lubricating Oil Analysis ............................................................................................... 120

6.15 Storage and Lay-up of Generator Set ......................................................................... 121

7. TROUBLESHOOTING.......................................................................................................... 123

7.1 Control System .............................................................................................................. 123

7.2 Safety Considerations ................................................................................................... 123

7.3 Fault Finding.................................................................................................................. 124

7.4 Status Indicators - PowerCommand 3.3........................................................................ 125

7.4.1 Not in Auto ......................................................................................................... 125

7.4.2 Remote Start ..................................................................................................... 125

7.4.3 Warning ............................................................................................................. 125

7.4.4 Shutdown Status ............................................................................................... 125

7.4.5 Generator Set Running Lamp ........................................................................... 125

7.5 Fault/Status Codes - PowerCommand 3.3.................................................................... 125

7.5.1 Fault Messages .................................................................................................. 126

7.5.2 Fault Acknowledgement ..................................................................................... 126

7.5.3 Fault Codes - PowerCommand 3.3 .................................................................... 126

7.5.4 Troubleshooting Procedure for Fault Codes ...................................................... 161

7.6 Line Circuit Breaker....................................................................................................... 165

8. BATTERY CHARGER .......................................................................................................... 167

8.1 Mains (Utility) Powered Battery Charger - Wall-Mounted (24 VDC - 30 Amp) ............. 167

8.1.1 Boost................................................................................................................... 167

8.1.2 Specifications - 30 Amp...................................................................................... 168

8.2 Circuits........................................................................................................................... 168

9. MANUFACTURING FACILITIES .......................................................................................... 169

iv 0908-0209 (Issue 6)

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1 Important Safety Instructions

Save these instructions. This manual contains important instructions that should be followed during installation and maintenance of the generator set.

Safe and efficient operation can be achieved only if the equipment is properly operated and maintained. Many accidents are caused by failure to follow fundamental rules and precautions.

1.1 Warning, Caution, and Note Styles Used in This Manual

The following safety styles and symbols found throughout this manual indicate potentially hazardous conditions to the operator, service personnel, or equipment.

DANGER

Indicates a hazardous situation that, if not avoided, will result in death or serious injury.

WARNING

Indicates a hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION

Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

NOTICE

Indicates information considered important, but not hazard-related (e.g., messages relating to property damage).

1.2 General Information

This manual should form part of the documentation package supplied by Cummins Power Generation with specific generator sets. In the event that this manual has been supplied in isolation please contact your authorized distributor.

NOTICE

It is in the operator’s interest to read and understand all warnings and cautions contained within the documentation relevant to the generator set, its operation and daily maintenance.

1.2.1 General Safety Precautions

WARNING

Hot Pressurized Liquid Contact with hot liquid can cause severe burns. Do not open the pressure cap while the engine is running. Let the engine cool down before

removing the cap. Turn the cap slowly and do not open it fully until the pressure has been relieved.

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1. Important Safety Instructions 3-2016

WARNING

Moving Parts Moving parts can cause severe personal injury. Use extreme caution around moving parts. All guards must be properly fastened to prevent

unintended contact.

WARNING

Toxic Hazard Used engine oils have been identified by some state and federal agencies to cause cancer or

reproductive toxicity. Do not ingest, breathe the fumes, or contact used oil when checking or changing engine oil.

Wear protective gloves and face guard.

WARNING

Electrical Generating Equipment Incorrect operation can cause severe personal injury or death. Do not operate equipment when fatigued, or after consuming any alcohol or drug.

WARNING

Toxic Gases Substances in exhaust gases have been identified by some state and federal agencies to

cause cancer or reproductive toxicity. Do not breathe in or come into contact with exhaust gases.

WARNING

Combustible Liquid Ignition of combustible liquids is a fire or explosion hazard which can cause severe burns or

death. Do not store fuel, cleaners, oil, etc., near the generator set.

WARNING

High Noise Level Generator sets in operation emit noise, which can cause hearing damage. Wear appropriate ear protection at all times.

WARNING

Hot Surfaces Contact with hot surfaces can cause severe burns. Wear appropriate PPE when working on hot equipment and avoid contact with hot surfaces.

Electrical Generating Equipment Incorrect operation and maintenance can result in severe personal injury or death Make sure that only suitably trained and experienced service personnel perform electrical

and/or mechanical service.

WARNING

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1. Important Safety Instructions3-2016

WARNING

Toxic Hazard Ethylene glycol, used as an engine coolant, is toxic to humans and animals. Wear appropriate PPE. Clean up coolant spills and dispose of used coolant in accordance

with local environmental regulations.

WARNING

Combustible Liquid Ignition of combustible liquids is a fire or explosion hazard which can cause severe burns or

death. Do not use combustible liquids like ether.

WARNING

Automated Machinery Accidental or remote starting of the generator set can cause severe personal injury or death. Isolate all auxiliary supplies and use an insulated wrench to disconnect the starting battery

cables (negative [–] first).

WARNING

Fire Hazard Materials drawn into the generator set are a fire hazard. Fire can cause severe burns or death. Make sure the generator set is mounted in a manner to prevent combustible materials from

accumulating under the unit.

WARNING

Fire Hazard Accumulated grease and oil are a fire hazard. Fire can cause severe burns or death. Keep the generator set and the surrounding area clean and free from obstructions. Repair oil

leaks promptly.

WARNING

Fire Hazard Materials drawn into the generator set are a fire hazard. Fire can cause severe burns or death. Keep the generator set and the surrounding area clean and free from obstructions.

NOTICE

Keep multi-class ABC fire extinguishers handy. Class A fires involve ordinary combustible materials such as wood and cloth. Class B fires involve combustible and flammable liquid fuels and gaseous fuels. Class C fires involve live electrical equipment. (Refer to NFPA No. 10 in applicable region.)

NOTICE

Before performing maintenance and service procedures on enclosed generator sets, make sure the service access doors are secured open.

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1. Important Safety Instructions 3-2016

NOTICE

Stepping on the generator set can cause parts to bend or break, leading to electrical shorts, or to fuel, coolant, or exhaust leaks. Do not step on the generator set when entering or leaving the generator set room.

1.3 Generator Set 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

Electrical Generating Equipment Incorrect operation and maintenance can result in severe personal injury or death. Read and follow all Safety Precautions, Warnings, and Cautions throughout this manual and

the documentation supplied with the generator set.

1.3.1 Moving Parts Can Cause Severe Personal Injury or Death

• Keep hands, clothing, and jewelry away from moving parts.

• Before starting work on the generator set, disconnect the battery charger from its AC source,

then disconnect the starting batteries using an insulated wrench, negative (–) cable first. This will prevent accidental starting.

• Make sure that fasteners on the generator set are secure. Tighten supports and clamps; keep guards in position over fans, drive belts, etc.

• Do not wear loose clothing or jewelry in the vicinity of moving parts or while working on electrical equipment. Loose clothing and jewelry can become caught in moving parts.

• If any adjustments must be made while the unit is running, use extreme caution around hot manifolds, moving parts, etc.

1.3.2 Positioning of Generator Set - Open Sets

The area for positioning the set should be adequate and level, and the area immediately around the set must be free of any flammable material.

1.3.3 Moving the Generator Set

WARNING

Heavy Load Incorrect lifting or repositioning can cause severe personal injury or death. Make sure that only suitably trained and experienced personnel transport and handle

generator sets and associated components.

Heavy Load Incorrect lifting or repositioning can cause severe personal injury or death. Do not lift the generator set by attaching to the engine or alternator lifting points. Do not

stand under or near the generator set when lifting.

WARNING

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1. Important Safety Instructions3-2016

WARNING

Mechanical Hazard Failed components may be ejected or operate incorrectly which can cause severe personal

injury or death. Do not climb the generator set; this may damage critical parts.

NOTICE

Access or service doors must be closed and locked before repositioning, and they must remain locked during transportation and siting.

It is essential that there are sufficient trained and experienced personnel in attendance to make sure the lifting and transportation of the generator set is undertaken in a safe and appropriate manner, and in accordance to local guidelines and legislation.

Before lifting the generator set, lifting points, angle of slings, mass, access to intended site, and the distance of movement should all be taken into account when organizing a suitable crane/hoist. Consult the generator set information supplied with the generator set for details of dimensions and mass.

• Make sure that the crane operating area is able to support the mass of the crane and the generator set.

• Make sure the equipment used for lifting is adequate to support the weight of the generator set.

• Attach the lifting device to the lifting points only using suitable shackles, chains, and spreader bars.

• Slowly tighten the slings. Inspect the lifting attachments before commencing a full lift to make sure they are attached correctly.

• Hoist the generator set slowly using the indicated lifting points only.

• Guide the generator set with ropes at a safe distance to prevent uncontrolled rotation when positioning the generator set.

• Move the generator set to the desired location and place in position, bringing the set down slowly.

• Loosen the slings; unhook and remove the shackles.

1.3.3.1 Positioning a Generator Set Using a Forklift Truck

WARNING

Heavy Load Incorrect lifting or repositioning can cause severe personal injury or death. Make sure that only suitably trained and experienced personnel transport and handle

generator sets and associated components.

WARNING

Heavy Load Incorrect lifting or repositioning can cause severe personal injury or death. Do not attempt to lift a generator set with an undersized forklift truck.

NOTICE

Access or service doors must be closed and locked before repositioning, and they must remain locked during transportation and siting.

When using a forklift truck to transport/position the generator set, the dimensions, mass, and route must be taken into account when selecting an appropriate lifting truck.

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1. Important Safety Instructions 3-2016

1. Insert the arms of the forklift into the forklift pockets. Make sure the generator set completely rests on the forklift arms.

2. Lift and handle the equipment slowly.

3. Lower the generator set in position.

1.3.4 Alternator Operating Areas

WARNING

Ejected Debris Debris ejected during catastrophic failure can cause serious injury or death by impact,

severing or stabbing. To prevent injury:

• Keep away from the air inlet and air outlet when the alternator is running.

• Do not put operator controls near the air inlet and air outlet.

• Do not cause overheating by running the alternator outside rating plate parameters.

• Do not overload the alternator.

• Do not run an alternator with excessive vibration.

• Do not synchronize parallel alternators outside the specified parameters.

Always wear suitable PPE when working in the hatched areas shown in the diagram or directly in-line with any air inlet/outlet.

Make sure this consideration is captured in your risk assessment.

1.4 Electrical Shocks and Arc Flashes Can Cause Severe Personal Injury or Death

• Only qualified service personnel certified and authorized to work on power circuits should work on exposed energized power circuits.

• All relevant service material must be available for any electrical work performed by certified service personnel.

• Exposure to energized power circuits with potentials of 50 VAC or 75 VDC or higher poses a significant risk of electrical shock and electrical arc flash.

• Refer to standard NFPA 70E, or equivalent safety standards in corresponding regions, for details of the dangers involved and for safety requirements.

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1. Important Safety Instructions3-2016

1.4.1 AC Supply and Isolation

NOTICE

Local electrical codes and regulations (for example, BS EN 12601:2010 Reciprocating internal combustion engine driven generating sets) may require the installation of a disconnect

means for the generator set, either on the generator set or where the generator set conductors enter a facility.

NOTICE

The AC supply must have the correct over current and earth fault protection according to local electrical codes and regulations. This equipment must be earthed (grounded).

It is the sole responsibility of the customer to provide AC power conductors for connection to load devices and the means to isolate the AC input to the terminal box; these must comply with local electrical codes and regulations. Refer to the wiring diagram supplied with the generator set.

The disconnecting device is not provided as part of the generator set, and Cummins Power Generation accepts no responsibility for providing the means of isolation.

1.4.2 Medium Voltage Equipment (601 V to 15 kV - North America)

• Medium voltage acts 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 experienced to work on such devices. Improper use or procedures will result in severe personal injury or death.

• 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.

1.5 Fuel and Fumes Are Flammable

Fire, explosion, and personal injury or death can result from improper practices.

• Do not fill fuel tanks while the engine is running unless the tanks are outside the engine compartment. Fuel contact with hot engine or exhaust is a potential fire hazard.

• Do not permit any flame, cigarette, pilot light, spark, arcing equipment, or other ignition source near the generator set or fuel tank.

• Fuel lines must be adequately secured and free of leaks. Fuel connection at the engine should be made with an approved flexible line. Do not use copper piping on flexible lines as copper will become brittle if continuously vibrated or repeatedly bent.

• Make sure all fuel supplies have a positive shutoff valve.

• Make sure the battery area has been well-ventilated prior to servicing near it. Lead-acid batteries emit a highly explosive hydrogen gas that can be ignited by arcing, sparking, smoking, etc.

1.5.1 Natural Gas

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.

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1. Important Safety Instructions 3-2016

Non-Pipeline Gas Generator Sets are designated by Cummins, Inc. as Low Btu Generator Sets. NonPipeline 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 this manual. 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.

1.5.2 Spillage

Any spillage that occurs during fueling or during oil top-off or oil change must be cleaned up before starting the generator set.

1.5.3 Fluid Containment

NOTICE

Where spillage containment is not part of a Cummins supply, it is the responsibility of the installer to provide the necessary containment to prevent contamination of the environment, especially water courses and sources.

If fluid containment is incorporated into the bedframe, it must be inspected at regular intervals. Any liquid present should be drained out and disposed of in line with local health and safety regulations. Failure to perform this action may result in spillage of liquids which could contaminate the surrounding area.

Any other fluid containment area must also be checked and emptied, as described above.

1.5.4 Do Not Operate in Flammable and Explosive Environments

Flammable vapor can cause an engine to over speed and become difficult to stop, resulting in possible fire, explosion, severe personal injury, and death. Do not operate a generator set where a flammable vapor environment can be created, unless the generator set is equipped with an automatic safety device to block the air intake and stop the engine. The owners and operators of the generator set are solely responsible for operating the generator set safely. Contact your authorized Cummins Power Generation distributor for more information.

1.6 Exhaust Gases Are Deadly

• Provide an adequate exhaust system to properly expel discharged gases away from enclosed or sheltered areas, and areas where individuals are likely to congregate. Visually and audibly inspect the exhaust system daily for leaks per the maintenance schedule. Make sure that exhaust manifolds are secured and not warped. Do not use exhaust gases to heat a compartment.

• Make sure the unit is well ventilated.

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1.6.1 Exhaust Precautions

Hot Exhaust Gases Contact with hot exhaust gases can cause severe burns. Wear personal protective equipment when working on equipment.

Hot Surfaces Contact with hot surfaces can cause severe burns. Wear appropriate PPE when working on hot equipment and avoid contact with hot surfaces.

Toxic Gases Inhalation of exhaust gases can cause asphyxiation and death. Pipe exhaust gas outside and away from windows, doors, or other inlets to buildings. Do not

allow exhaust gas to accumulate in habitable areas.

1. Important Safety Instructions3-2016

WARNING

Fire Hazard Contaminated insulation is a fire hazard. Fire can cause severe burns or death. Remove any contaminated insulation and dispose of it in accordance with local regulations.

The exhaust outlet may be sited at the top or bottom of the generator set. Make sure that the exhaust outlet is not obstructed. Personnel using this equipment must be made aware of the exhaust position. Position the exhaust away from flammable materials - in the case of exhaust outlets at the bottom, make sure that vegetation is removed from the vicinity of the exhaust.

The exhaust pipes may have some insulating covers fitted. If these covers become contaminated they must be replaced before the generator set is run.

To minimize the risk of fire, make sure the following steps are observed:

• Make sure that the engine is allowed to cool thoroughly before performing maintenance or operation tasks.

• Clean the exhaust pipe thoroughly.

1.7 Decommissioning and Disassembly

NOTICE

Decommissioning and disassembly of the generator set at the end of its working life must comply with local guidelines and legislation for disposal/recycling of components and contaminated fluids. This procedure must only be carried out by suitably trained and experienced service personnel. For more information contact your authorized distributor.

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10 0908-0209 (Issue 6)

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2 Introduction

Hazardous Voltage Contact with high voltages can cause severe electrical shock, burns, or death. Make sure that only a trained and experienced electrician makes generator set electrical

output connections, in accordance with the installation instructions and all applicable codes.

Electrical Generating Equipment Faulty electrical generating equipment can cause severe personal injury or death. Generator sets must be installed, certified, and operated by trained and experienced person

in accordance with the installation instructions and all applicable codes.

2.1 About This Manual

The purpose of this manual is to provide the users with sound, general information. It is for guidance and assistance with recommendations for correct and safe procedures. Cummins Power Generation (CPG) cannot accept any liability whatsoever for problems arising as a result of following recommendations in this manual.

WARNING

The information contained within the manual is based on information available at the time of going to print. In line with Cummins Power Generation policy of continuous development and improvement, information may change at any time without notice. The users should therefore make sure that before commencing any work, they have the latest information available. The latest version of this manual is available on QuickServe Online (https://quickserve.cummins.com).

Users are respectfully advised that, in the interests of good practice and safety, it is their responsibility to employ competent persons to carry out any installation work. Consult your authorized 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 hazardous nature. Careful reference should also be made to other Cummins Power Generation literature. A generator set must be operated and maintained properly for safe and reliable operation.

For further assistance, contact your authorized distributor.

2.2 Schedule of Abbreviations

This list is not exhaustive. For example, it does not identify units of measure or acronyms that appear only in parameters, event/fault names, or part/accessory names.

AmpSentry, INSITE, and InPower are trademarks of Cummins Inc. PowerCommand is a registered trademark of Cummins Inc.

ABBR. DESCRIPTION ABBR. DESCRIPTION

AC Alternating Current LED Light-emitting Diode

AMP AMP, Inc., part of Tyco

Electronics

ANSI American National Standards

Institute

ASOV Automatic Shut Off Valve MFM Multifunction Monitor

110908-0209 (Issue 6)

LTS Long Term Storage

LVRT Low Voltage Ride Through

Page 18

2. Introduction 3-2016

ABBR. DESCRIPTION ABBR. DESCRIPTION

ASTM American Society for Testing

and Materials (ASTM International)

ATS Automatic Transfer Switch MLD Masterless Load Demand

AVR Automatic Voltage Regulator NC Normally Closed

AWG American Wire Gauge NC Not Connected

CAN Controlled Area Network NFPA National Fire Protection Agency

CB Circuit Breaker NO Normally Open

CE Conformité Européenne NWF Network Failure

CFM Cubic Feet per Minute OEM Original Equipment

CGT Cummins Generator

Technologies

CMM Cubic Meters per Minute OORH / ORH Out of Range High

CT Current Transformer OORL / ORL Out of Range Low

D-AVR Digital Automatic Voltage

Regulator

DC Direct Current PCC PowerCommand®Control

Mil Std Military Standard

Manufacturer

OOR Out of Range

PB Push Button

DEF Diesel Exhaust Fluid PGI Power Generation Interface

DPF Diesel Particulate Filter PGN Parameter Group Number

ECM Engine Control Module PI Proportional/Integral

ECS Engine Control System PID Proportional/Integral/Derivative

EMI Electromagnetic interference PLC Programmable Logic Controller

EN European Standard PMG Permanent Magnet Generator

EPS Engine Protection System PPE Personal Protective Equipment

E-Stop Emergency Stop PT Potential Transformer

FAE Full Authority Electronic PTC Power Transfer Control

FMI Failure Mode Identifier PWM Pulse-width Modulation

FRT Fault Ride Through RFI Radio Frequency Interference

FSO Fuel Shutoff RH Relative Humidity

Genset Generator Set RMS Root Mean Square

GCP Generator Control Panel RTU Remote Terminal Unit

GND Ground SAE Society of Automotive Engineers

LCT Low Coolant Temperature SCR Selective Catalytic Reduction

HMI Human-machine Interface SPN Suspect Parameter Number

IC Integrated Circuit SWL Safe Working Load

ISO International Organization for

Standardization

LBNG Lean-burn Natural Gas UL Underwriters Laboratories

SW_B+ Switched B+

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ABBR. DESCRIPTION ABBR. DESCRIPTION

LCD Liquid Crystal Display UPS Uninterruptible Power Supply

2.3 Related Literature

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 familiarize 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. The Operator manual includes a maintenance schedule and a troubleshooting guide.

The Health and Safety manual must be read in conjunction with this manual for the safe operation of the generator set:

• Health and Safety Manual (0908-0110)

The relevant manuals appropriate to your generator set are also available, the documents below are in English:

2. Introduction3-2016

NOTICE

• Operator Manual for QSV91 & QSK60G Generator Sets with PowerCommand 3.3 control (0908-

0209)

• Installation Manual for QSV91 & QSK60G Generator Sets with PowerCommand 3.3 control (A029R140)

• Recommended Spares List (RSL) for QSK60G (A046W059)

• Recommended Spares List (RSL) for QSK60G (A046W060)

• Recommended Spares List (RSL) for QSV91 (<2MW) (A046W061)

• Recommended Spares List (RSL) for QSV91 (>2MW) (A046W064)

• Service Manual for PowerCommand 3.3 Control (0900-0670_

• Parts Manual for QSK60G (A029C810)

• Parts Manual for QSV91 (A029B383)

• Service Tool Manual (A043D529)

• Failure Code Manual (F1115C)

• Application Manual T-030, Liquid Cooled Generator Sets - for application information (A040S369)

• Engine Operation & Maintenance Manual for QSV81/91 (4021313)

• Engine Operation & Maintenance Manual for QSK60G (4021395)

• Engine Owners Manual for QSV81/91 (4915546)

• Engine Owners Manual for QSK60G (4915558)

• Warranty Manual (A040W374)

• ESB Warranty Statement - Lean-Burn Gaseous Fuel Generating Set (A050L829)

2.3.1 Further Information - Literature

Contact your authorized distributor for more information regarding related literature for this product.

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2. Introduction 3-2016

2.4 After Sales Services

Cummins Power Generation offers a full range of maintenance and warranty services.

2.4.1 Maintenance

WARNING

and/or mechanical service.

For expert generator set service at regular intervals, contact your local distributor. Each local distributor offers a complete maintenance contract package covering all items subject to routine maintenance, including a detailed report on the condition of the generator set. In addition, this can be linked to a 24-hour call-out arrangement, providing year-round assistance if necessary. Specialist engineers are available to maintain optimum performance levels from generator sets. Maintenance tasks should only be undertaken by trained and experienced technicians provided by your authorized distributor.

2.4.2 Warranty

For details of the warranty coverage for your generator set, refer to the Global Commercial Warranty Statement listed in the Related Literature section.

In the event of a breakdown, prompt assistance can normally be given by factory trained service technicians with facilities to undertake all minor and many major repairs to equipment on site.

Extended warranty coverage is also available.

For further warranty details, contact your authorized distributor.

Damage caused by failure to follow the manufacturer's recommendations will not be covered by the warranty. Please contact your authorized distributor.

2.4.2.1 Warranty Limitations

For details of the warranty limitations for your generator set, refer to the warranty statement applicable to the generator set.

2.4.3 How to Obtain Service

When a product requires servicing, contact the nearest Cummins Power Generation distributor. To locate the distributor, refer to power.cummins.com and select Distributor Locator. When contacting the distributor, always supply the complete model, specification, and serial number as shown on the nameplate.

NOTICE

2.4.3.1 Locating a Distributor

In North America

To easily locate the nearest certified distributor/dealer for Cummins generator sets in your area, or for more information, contact us at 1-800-344-0039 or visit power.cummins.com.

If unable to contact a distributor using the automated service, consult the Internet.

If unable to arrange a service or resolve an issue, contact the Service Manager at the nearest Cummins Power Generation distributor for assistance.

14 0908-0209 (Issue 6)

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When contacting the distributor, always supply the complete Model, Specification, and Serial Number as shown on the product nameplate.

Outside North America

Refer to power.cummins.com and select Distributor Locator, or send an email to ask.powergen@cummins.com.

2.5 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.)

2. Introduction3-2016

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2. Introduction 3-2016

Balance of Plant Details

Project Title

Company Name

Address

Contact Name

Phone Numbers Tel: Mobile:

Site Details

Customer Order Number

Site Name

Address

Contact Name

Phone Numbers Tel: Mobile:

Equipment Details

Generator Model(s)

Number of Sets

Generator Set Serial Number(s)

Engine Serial Number(s)

Alternator Serial Number(s)

Date of Commissioning

Additional Information

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3 System Overview

This section provides an overview of the generator set.

3.1 Generator Set Identification

Each generator set is provided with a nameplate similar to that shown below. The nameplate provides information unique to the generator set.

3.1.1 Generator Set Rating

Refer to the generator set nameplate for generator set rating. Refer to Section 5.4 on page 70 for operation at temperatures or altitudes above those stated on the nameplate.

3.1.2 Nameplate - Open Generator Set

FIGURE 1. TYPICAL OPEN GENERATOR SET NAMEPLATE

3.2 Generator Set Components

The main components of a typical QSV91G engine generator set are shown below, and referred to within this section.

There are various options listed although they may not be available for all models.

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3. System Overview 3-2016

No Description No Description No Description

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

2 Air Filter 15 DSSOV Solenoid Shut Off

Valve

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

6 Crankcase Breather Filter 19 AVR/Controls Box 32 AC Auxiliaries Box

7 Alternator 20 Lube Oil Filters 33 Exhaust Bellows

8 Generator Set Terminal Box 21 Coolant Water Pump 34 Gearbox

9 Generator Set Dataplate 22 Spark Plugs & Ignition Coils 35 Lifting Point

10 Dirty Oil Leak-off Tank 23 Multihousing Cover 36 Jacking Point

11 Engine Dataplate 24 Lube Oil Cooler Coolant Return

Pipe

12 Aftercooler 25 Flotech Gas Valve

13 Lube-oil Dipstick 26 Governor Driver Modules

FIGURE 2. TYPICAL QSV91G ENGINE GENERATOR SET

28 Governor Actuator Module

37 High Temp Water Coolant pipe

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3.3 Air Cleaner

An air cleaner includes an element that must be replaced periodically. Some air cleaners include a service indicator that indicates when an air cleaner element is dirty and must be replaced.

3.3.1 Air Cleaner System

An air cleaner is used to filter particles from the air supply to the engine. Regular maintenace is critical in achieving optimum performance of the generator set.

Depending on the requirements, one of the following air cleaner systems will be fitted on the generator set.

3. System Overview3-2016

FIGURE 3. AIR CLEANER ASSEMBLY

FIGURE 4. AIR CLEANER ASSEMBLY

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3. System Overview 3-2016

FIGURE 5. AIR CLEANER ASSEMBLY

FIGURE 6. AIR CLEANER ASSEMBLY

3.4 Coolant Specification

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.

NOTICE

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For filling and maintenance of Cooling Systems refer to the Operation and Maintenance Manual, or consult your authorised distributor.

3.5 Gas Train

Installation, maintenance and testing of gas pipe work system must be carried out by suitably trained and experienced personnel.

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.

3. System Overview3-2016

NOTICE

No Description No Description

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

(DSSOV) (Mounted off-genset - Option)

4 Pressure Regulator

FIGURE 7. TYPICAL GAS TRAIN

3.6 Heaters

3.6.1 Heater Supply and Isolation

A power supply is required for the operation of the engine, coolant, and alternator heaters (if fitted).

NOTICE

It is the sole responsibility of the customer to provide the power supply and the means to isolate the AC input to the terminal box. Cummins Power Generation accepts no responsibility for providing the means of isolation. Contact your distributor for more information.

NOTICE

This disconnecting device is not provided as part of the generator set.

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3. System Overview 3-2016

3.7 Mains (Utility) Powered Battery Charger

CAUTION

Hazardous Voltage Contact with high voltages can cause severe electrical shock, burns, or death. Disconnect the battery charger before isolating the battery.

This unit maintains the battery in a fully charged condition without over-charging. The unit also provides rapid charging, when necessary, at a current up to the rated output.

The charger’s electronic control circuit allows the charger to be left in circuit during engine cranking and to operate in parallel with the charge alternator.

The charger will supply current to the battery system until the battery terminal voltage becomes equal to the set float voltage, at which point only a trickle charge current is present. When the battery becomes discharged due to a load being present and the terminal voltage falls, the charger will again supply current to restore the voltage of the battery to the float voltage.

3.8 Oil Specification

NOTICE

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.

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:

TABLE 1. QSV91G 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

Valvoline Premium Blue GEO

MA*

Shell Mysella XL* SAE40 4.5 0.48

*Premium grade oil

SAE40 7.2 0.7

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3. System Overview3-2016

TABLE 2. QSV81/91G ENGINE (14 & 16BAR BMEP MODELS): C1540 N5C, C1750 N5C, C1250 N6C, C1540

N6C, C1750 N6C, C1700 N6

Manufacturer Oil Names Grade TBN Sulphated Ash %

Mobil Pegasus 805* SAE40 6.2 0.54

Mobil Pegasus 705 SAE40 5.6 0.52

Elf Nateria MH40 SAE40 5.2 0.45

Shell Mysella LA SAE40 5.0 0.45

Shell Mysella XL* SAE40 4.5 0.48

Caltex Geostar LA SAE40 5.2 0.49

Valvoline Premium Blue GEO

SAE40 5.5 0.44

LA*

*Premium grade oil

TABLE 3. QSK60G ENGINE (MULTI AND SINGLE-TURBOCHARGER MODELS): C995 N5C, C1160 N5C,

C1200 N5C, C1400 N5C, C1000 N6C, C1100 N6C, C1400 N6C, C1000 N6, C1250 N6, C1350 N6

Manufacturer Oil Names Grade TBN Sulphated Ash %

Mobil Pegasus 805* SAE40 6.2 0.54

Valvoline Premium Blue GEO

SAE40 5.5 0.44

LA*

Shell Mysella XL* SAE40 4.5 0.48

*Premium grade oil

Regularly sample the oil and perform oil 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.

3.8.1 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.

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

Geotex HD

Geotex LF

Geotex HDAX LA

Geotex HDAX LFG

ExxonMobil Pegasus 805

Pegasus 605

Pipeline Natural Gas

Non-Pipeline Natural Gas

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Natural Gas

Non-Pipeline Natural Gas

Natural Gas

Non-Pipeline Natural Gas

Page 30

3. System Overview 3-2016

Supplier Product Fuel

Pegasus 610

Non-Pipeline Natural Gas

3.9 Sensors

Various generator set parameters are measured by sensors, and the resulting signals are processed by the control board.

Engine-mounted sensors monitor a number of different systems, such as:

• Lube Oil Pressure

• Cooling System Temperature

3.10 System Options

3.10.1 PowerCommand Universal Annunciator

A universal annunciator provides lamps and a horn to annunciate the operating status and fault conditions of an emergency power system. It is designed for connection to either a 12 VDC or a 24 VDC control system. It can be configured to be either a positive or negative signal device.

Two versions of the PowerCommand universal annunciator are available.

• Panel Mounted

• Panel with Enclosure

The universal annunciator can communicate using either a PCCNet or a Modbus network.

Refer to the annunciator owner's manual for more information.

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3. System Overview3-2016

No. Description No. Description

1 System Status Lamps 4 Silence/Lamp Test Button

2 Insert Card 5 Network Status Lamp

3 Horn

FIGURE 8. ANNUNCIATOR COMPONENTS

3.10.2 Mains (Utility) Powered Battery Charger

CAUTION

Hazardous Voltage Contact with high voltages can cause severe electrical shock, burns, or death. Disconnect the battery charger before isolating the battery.

This unit maintains the battery in a fully charged condition without over-charging. The unit also provides rapid charging, when necessary, at a current up to the rated output.

The charger’s electronic control circuit allows the charger to be left in circuit during engine cranking and to operate in parallel with the charge alternator.

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3. System Overview 3-2016

3.10.3 Coolant Heater

NOTICE

Operating the heater or heaters when the coolant system has been drained, or there is a suspicion that the coolant is frozen, can result in equipment damage.

Always make sure the coolant is not frozen and the radiator is filled to the recommended level before energizing the heater, or heaters.

A coolant heater keeps the engine coolant warm when the engine is shut down. It heats and circulates the coolant within the engine. This reduces start-up time and lessens engine wear caused by cold starts. It is electrically operated and thermostatically controlled.

FIGURE 9. TYPICAL COOLANT HEATER

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4 Control System - PowerCommand 3.3

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 primepower 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 indicates the fault type and automatically shuts down the generator set on critical faults.

All indicators, control buttons and the display screen are on the face of the operator panel as illustrated in the following figure.

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 immediately takes the engine off-load and automatically shuts it down.

The standard control system operates on 12 or 24 VDC battery power. The auxiliary equipment operates on LV AC power. The history data is stored in non-volatile memory and is not deleted if battery power is lost.

4.1.1 Control System Panel

No Description

1 Operator Panel

2 Bargraph Meter Panel

3 Alarm Module

4 Emergency Stop Button

5 Isolator Switch

FIGURE 10. TYPICAL CONTROL SYSTEM PANEL

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4. Control System - PowerCommand 3.3 3-2016

4.1.2 Operating Modes

The PowerCommand®3.3 control is operated by the Start/Stop/Manual/Auto buttons on the Operator Panel. Refer to Figure 11 on page 31.

NOTICE

If the Mode Change access feature is enabled, a password is required to use these buttons to change the mode of operation. Contact your authorized distributor for options.

4.1.2.1 Stop Button

Press this button to put the generator set into the Off mode. This disables Auto and Manual modes. The green lamp above this button lights 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 shuts down.

Refer to Section 4.12 on page 64 for more information on stopping in Auto or Manual mode.

NOTICE

If possible, hot shutdown under load should be avoided to help prolong the reliability of the generator set.

4.1.2.2 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 results in the control mode defaulting, putting the generator set into the Off mode.

The green lamp above this button is lit when the generator set is in Manual mode.

If Mode Change access password feature is enabled, the password must be entered before pressing the Start button. See Section 4.12.1.

4.1.2.3 Start Button

NOTICE

When the Manual button is pressed, this Start button must be pressed within ten seconds to start the generator set. The generator set starts up normally but without the Time Delay to Start.

In other modes, this button has no effect.

If the Start button is not pressed within the ten seconds of pressing the Manual button, the generator set mode changes to the Off mode automatically.

NOTICE

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4.1.2.4 Auto Button

Press this button to put the generator set into the Auto mode. In this mode, the generator set is controlled by a remote switch or device (e.g. transfer switch).

The green lamp above this button lights when the generator set is in Auto mode.

4.1.2.5 Battle Short Mode

Automated Machinery Battle Short mode overrides some parameters of generator set control. Unmonitored

generator sets can cause a fire or electrical hazard, resulting in severe personal injury or death.

Make sure that the operation of the set is supervised during Battle Short operation.

Battle Short mode is not a distinct mode of operation. The PowerCommand®control is still in the Off, Manual, or Auto mode while Battle Short mode is active. The PowerCommand®control still follows the appropriate sequence of operation to start and stop the generator set. Battle Short mode is a generator set mode of operation that prevents the generator set from being shutdown by all but a few, select, critical shutdown faults.

4. Control System - PowerCommand 3.33-2016

WARNING

The purpose of Battle Short mode is to satisfy local code requirements, where necessary. To use this feature, the necessary software must be installed at the factory when the PowerCommand®control is purchased. Only authorized service personnel can enable this feature. When shipped from the factory, this feature is disabled.

NOTICE

The Battle Short feature must be enabled or disabled using the InPower service tool.

This feature must only be used during supervised, temporary operation of the generator set. The faults that are overridden when in Battle Short mode can affect generator set performance, or cause permanent engine, alternator or connected equipment damage.

NOTICE

If this mode of operation is selected, the protection of load devices will be disabled. Cummins Power Generation will not be responsible for any claim resulting from the use of this mode.

NOTICE

All shutdown faults, including those overridden by Battle Short, must be acted upon immediately to ensure the safety and well being of the operator and the generator set.

Battle Short is turned on or off with an external switch connected to one of the two customer configured inputs or a soft switch on the operator panel.

When enabled, Battle Short switch input can be set using a Setup menu. To turn Battle Short mode on using the soft switch in the operator panel, Battle Short must be set to Operator Panel and enabled using the InPower service tool (default is Inactive).

When Battle Short mode is enabled, the Warning status indicator lights and code "1131 – Battle Short Active" is displayed.

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4. Control System - PowerCommand 3.3 3-2016

When Battle Short mode is enabled and an overridden shutdown fault occurs, the shutdown lamp remains lit even though the set continues to run. "Fault code 1416 – Fail to Shutdown" is displayed. If the fault is acknowledge, the fault message is cleared from the display but remains in the Fault History file as long as Battle Short mode is enabled.

Battle Short is suspended and a shutdown occurs immediately if any of the following critical shutdown faults occur:

• Speed Signal Lost (Loss of Speed Sense) - Fault code 121

• Overspeed - Fault code 234

• Local Emergency Stop - Fault code 1433

• Remote Emergency Stop - Fault code 1434

• Excitation Fault (Loss of Voltage Sense) - Fault code 2335

The Battle Short feature is disabled after an overridden shutdown fault occurred while in Battle Short mode. Fault code "1123 – Shutdown After Battle Short" is then displayed.

4.1.3 Power On and Sleep Modes

The operating 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 control’s operating software and control panel lamps/graphical display 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 control’s 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 activates 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.

Sleep mode can be enabled/disabled, contact your authorized distributor for options.

4.2 Operator Panel

Figure 11 shows the features of the front panel. It includes five lamp indicators; the graphical display

with four menu select and seven menu navigation buttons; and six control mode buttons. This display panel enables the operator to look at the status, adjust the settings, and start and stop the generator set.

NOTICE

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4. Control System - PowerCommand 3.33-2016

No. Description No. Description

1 Indicator Lamp – Warning 11 Circuit Breaker – Closed Button

2 Indicator Lamp – Shutdown 12 Circuit Breaker – Open Button

3 Indicator Lamp – Genset Running 13 Manual Button

4 Indicator Lamp – Remote Start 14 Previous Menu Button (or Clear)

5 Indicator Lamp – Not in Auto 15 Item Select Button (OK)

6 Lamp Test Button 16 Menu Navigation Buttons (Up, Down, Left, Right)

7 Reset Button 17 Home Button

8 Auto Mode Button 18 Menu Select Buttons (for use with Item 19)

9 Start Button 19 Graphical Display

10 Stop Button

FIGURE 11. OPERATOR PANEL

4.2.1 Selection Buttons

Four momentary buttons are used to navigate and change the selection in the graphical display.

Press the OK 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.

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4. Control System - PowerCommand 3.3 3-2016

4.2.2 Default Settings

The Operator Panel can display SAE or Metric units of measurement and should be set during the initial setup of the generator set. Only trained and experienced personnel are allowed to change the default setting. Contact your authorized distributor.

4.2.3 Lamp Indicators

Figure 11 on page 31 shows the front panel of the Operator Panel with the five lamp indicators.

4.2.3.1 Warning

This amber lamp is lit whenever the control detects a Warning condition. This lamp is automatically shut off when the Warning condition no longer exists.

4.2.3.2 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.

4.2.3.3 Not in Auto

This red lamp is lit when the control is not in Auto.

4.2.3.4 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.

4.2.3.5 Generator Set Running Lamp

The 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.

4.2.4 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.

4.2.5 Reset Button

Press this to reset any active faults.

If the condition(s) that caused an existing shutdown fault still exists, the generator set generates the fault again.

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.

4.2.6 CB Open Button

The circuit breaker open button is used in Manual mode only. When pressed, it enables the generator set circuit breaker to open and disconnect from the load.

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4.2.7 CB Closed Button

The circuit breaker closed button is used in Manual mode only. When pressed it enables the generator set circuit breaker to close when the set is up to speed and voltage and therefore, ready to accept the load.

NOTICE

This button has no effect unless the bus is dead, or the generator set is synchronized with the other source.

4.2.8 Graphical Display and Buttons

Figure 12 on page 33 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 Section

4) are displayed in the graphical display. Some sub-menus do not include any active buttons.

4. Control System - PowerCommand 3.33-2016

Use the graphical display to view event/fault information, status, screens, and parameters.

Display Panel Description

Section 1 Control status

Section 2 Active fault or screen name

Section 3 Relevant data to Section 2

Section 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 12. GRAPHICAL DISPLAY WITH TYPICAL SCREENSHOT

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4.2.8.1 Section 1 - Control Status

Section 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

Idle Cooldown The controller is reducing the engine speed to idle speed, or the engine is running at idle

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

Off The controller is in the process of entering power-down mode. The controller is performing

Demo Mode The controller is running a demonstration. Every screen is available in the demonstration,

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.

speed in one of the stop sequences.

Wakeup signal.

some last-second checks.

and any changes you make in the demonstration will have no effect on the controller. To end the demonstration, the Operator Panel must be turned off.

4.2.8.2 Section 2 - Active Fault or Screen Name

Section 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 Chapter 7 on page 123)

Derate This is a derate fault. (See Chapter 7 on page 123)

Shutdown This is a shutdown fault that initiates a Shutdown Without Cooldown sequence. (See

Chapter 7 on page 123)

Shutdown with Cooldown

This is a shutdown fault that initiates a Shutdown With Cooldown sequence

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4.2.8.3 Section 3 - Interactive Screen or Menu

Section 3 shows information relevant to Section 2. You can view the operating values for the generator set, navigate through screen 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

OORL Out Of Range Low - The value is less that the lowest allowed value for this parameter

OORH Out Of Range High - This value is greater that the highest allowed value for this parameter

-- -- -- This value is not applicable

4.2.8.4 Section 4 - Additional Functions Indicators

Section 4 indicates if additional information or further sub-menus are available 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.

4.2.8.5 Menu Navigation Buttons

Four momentary buttons are used to navigate and change the selection in the graphical display.

Press the OK 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.

4.3 Operator Panel - Initial Operator Menu

Figure 13 on page 37 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.

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TABLE 4. INITIAL MENU DATA

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.

Setup Menus:

Adjust The use of these screens is restricted to authorized personnel only.

Genset Setup

Paralleling Setup

OEM Setup

PCCnet Setup

Modbus Setup

Display Options

Clock Setup

Configurable IO

Calibration

Save/Reserve

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Press the Home Button to return to the main menu at any time.

Press the C Button to return to the previous menus. Settings will not be saved when this button is pressed.

FIGURE 13. INITIAL OPERATOR MENU

4.4 Operator Panel - Generator Set Data Operator Menu

Figure 14 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 Set Data

Use this menu to look at the status of the generator set.

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TABLE 5. GENERATOR SET DATA

PARAMETER DESCRIPTION

Alternator

Genset LL Average Voltage Generator Set Line to Line average voltage

Genset Average Current Generator Set average current

Genset Total kW Generator Set total kW

Genset Total Power Factor Generator Set L1 power factor

Genset Frequency Generator Set frequency

Engine

Engine Running Time Total engine run time

Coolant Temperature Monitor point for the Coolant Temperature

Oil Pressure Monitor point for the Oil Pressure

Allowed values: 0~145 PSI.

Battery Voltage Battery voltage value.

Percent Engine Torque/Duty Cycle 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 the Fuel Rate

Allowed values: 0~845 liters/hr (223.2 gal/hr)

Fuel Consumption Since Reset Fuel consumption since last reset.

Total Fuel Consumption Total fuel consumption since start of engine.

Genset Application

Genset Application kW rating The Generator Set KW rating.

Genset Application kVA rating The Generator Set KVA rating.

Genset Application Nominal Current The value of the Generator Set application nominal

current.

Genset Standby

Genset Standby kW rating KW rating for the Generator Set in Standby

configuration.

Genset Standby kVA rating KVA rating for the Generator Set in Standby

configuration.

Genset Standby Nominal Current The value of the Generator Set standby nominal

current.

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Press the Home Button to return to the main menu at any time.

Press the C Button to return to the previous menus. Settings will not be saved when this button is pressed.

FIGURE 14. GENERATOR SET DATA MENU - TYPICAL DATA

4.5 Operator Panel - Engine Data Operator Menu

Figure 15 on page 41 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.

4.5.1 Engine Data

Use this menu to look at the status of the engine.

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TABLE 6. ENGINE DATA (LBNG GENSET ENABLE IS SET TO DISABLE)

Name Description

Oil Pressure Monitor point for the Oil Pressure

Allowed values: 0~145 PSI.

Boost Pressure Monitor point for the Boost Absolute Pressure

Allowed values: 0~148 PSI.

Coolant Pressure Monitor point for the Coolant Pressure

Allowed values: 0~145 PSI.

Fuel Supply Pressure Monitor point for the Fuel Supply Pressure

Allowed values: 0~145 PSI.

Fuel Outlet Pressure Monitor point for the Fuel Outlet Pressure

Allowed values: 0~36404 PSI.

Crankcase Pressure Monitor point for the Crankcase Pressure

Allowed values: -35.67~38 PSI.

Barometric Absolute Pressure Monitor point for the Barometric Absolute Pressure

Allowed values: 0~37 PSI.

Coolant Temperature Monitor point for the Coolant Temperature

Oil Temperature Monitor point for the Oil Temperature

Allowed values: -40~410 °F.

Intake Manifold Temperature Monitor point for the Intake Manifold Temperature

Allowed values: -40~410 °F.

Fuel Temperature Monitor point for the Fuel Temperature

Allowed values: -40~410 °F.

Aftercooler Temperature Monitor point for the Aftercooler Temperature

Allowed values: -40~410 °F.

Battery Voltage Battery voltage value

Average Engine Speed Monitor point for the Average Engine Speed

Engine Running Time Total engine run time

Glow Plug Command Output of glow plug logic

Allowed values: Driver Off, Driver On.

Oil Pressure Switch Status Low or Not Low.

Allowed values: Not Low, Low.

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Press the Home Button to return to the main menu at any time.

Press the C Button to return to the previous menus. Settings will not be saved when this button is pressed.

FIGURE 15. ENGINE DATA MENU - TYPICAL DATA

4.5.2 History/About Menu

Figure 16 on page 43 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.

TABLE 7. HISTORY/ABOUT

Name Description

Start Attempts (Starts) Total number of start attempts

Allowed values: 0~65535

Total Number of Runs (Runs) Total number of generator set runs

Allowed values: 0~65535

Engine Running Time (Engine Hours)

Controller On Time (Control Hours)

Total engine run time in hours

Controller ON time in hours, Upper limit is 136 years Allowed values: 0~4294967291 hours

Generator Set Total Net (Kw Hours)

Generator Set Model Number (Gen Mod #)

Generator Set Serial Number (Gen Ser #)

Generator set total net kWh accumulation Allowed values: -2147483648~2147483643 kWh

Number identifying the model of this generator set (Password level: 2)

Serial number identifying this generator set

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Name Description

Generator Set Nominal Voltage (Nominal Voltage)

Generator Set Delta/Wye Connection (Wye/Delta)

Application Rating Select (Rating Select)

Controller Device Type (Contr Type)

Calibration Part Number (Calib Part)

Calibration Revision Date (Calib Date)

Firmware Version Number (Contr H/ ver)

Generator set nominal line-line voltage (Password level: 1) Allowed values: 1~45000 Vac (Default: 1 VAC)

Delta or Wye for generator set connection (Password level: 1) Allowed values: Delta, Wye (Default: Wye)

Selects generator set's standby/prime/base application rating (Password level: 1) Allowed values: Standby, Prime, Base (Default: Standby)

Used by the PC Tool Allowed values: PCC3300, PCC3300 with Masterless Load Demand (MLD)

The unique calibration part number loaded into this control (Password level: 3)

The revision date of the calibration part number loaded into this control (Password level: 3)

Version of S/W loaded into this control, obtained from PCC Filename

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Press the Home Button to return to the main menu at any time.

Press the C Button to return to the previous menus. Settings will not be saved when this button is pressed.

FIGURE 16. HISTORY/ABOUT MENU - TYPICAL DATA

4.6 Operator Panel - Alternator Data Operator Menu

Figure 17 on page 46 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.

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4.6.1 Alternator Data

Use this menu to look at the status of the alternator. This menu displays line-to-line voltage, line-toneutral 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.

TABLE 8. ALTERNATOR DATA

Parameter Description

Genset L1L2 Voltage Generator Set L1L2 voltage

Genset L1N Voltage Generator Set L1N voltage

Genset L1 Current Monitors the genset L1 current value

Genset L1 kW Generator Set L1 kW

Genset L1 KVA Generator Set L1 kVA

Genset L1 Power Factor Generator Set L2 power factor

Allowed values: -1.28~1.27 PF

Genset L2L3 Voltage Generator Set L2L3 voltage

Genset L2N Voltage Generator Set L2N voltage

Genset L2 Current Generator Set L2 current

Genset L2 kW Generator Set L2 kW

Allowed values: -32768~32762 kW

Genset L2 KVA Generator Set L2 kVA

Genset L2 Power Factor Generator Set L2 power factor

Allowed values: -1.28~1.27 PF

Genset L3L1 Voltage Generator Set L3L1 voltage

Genset L3N Voltage Generator Set L3N voltage

Genset L3 Current Generator Set L3 current

Genset L3 kW Generator Set L3 kW

Allowed values: -32768~32762 kW

Genset L3 KVA Generator Set L3 kVA

Allowed values: 0~4294967.29 kVA

Genset L3 Power Factor Generator Set L3 power factor

Allowed values: -1.28~1.22 PF

Genset Total kW Generator Set total kW

Genset Total KVA Generator Set total kVA

Genset Total Power Factor Generator Set L1 power factor

Genset Frequency Generator Set frequency

AVR PWM Command The AVR PWM software command. Linear relationship between

counts and % duty cycle with 10000 counts=100% duty cycle

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Parameter Description

Genset Neutral Current Generator Set neutral current

This is not displayed if the neutral current is not available.

Ground Current Ground current

Alternator Temperatures

NOTICE

Non-Drive End Bearing Temperature (Aux101)

Drive End Bearing Temperature (Aux101) Monitor point for the Drive End Bearing Temp input from the I/O

Alternator Temperature 1 (Aux101) Monitor point for the Alternator Temp 1 input from the Aux 101 I/O

Alternator Temperature 2 (Aux101) Monitor point for the Alternator Temp 2 input from the Aux 101 I/O

Alternator Temperature 3 (Aux101) Monitor point for the Alternator Temp 3 input from the Aux 101 I/O

Monitor point for the Non-Drive End Bearing Temp input from the I/O Module.

Allowed values: -65534~65535 °F

Module. Allowed values: -32767~32762 °F

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Press the Home Button to return to the main menu at any time.

Press the C Button to return to the previous menus. Settings will not be saved when this button is pressed.

FIGURE 17. ALTERNATOR DATA MENU - TYPICAL DATA

4.7 Operator Panel - Faults and Warnings Menus

The Faults and Warning 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 Menu

Figure 18 shows a block representation of a typical Fault menu.

To navigate from the Home menu, select the Fault menu from the Home screen.

The fault menu home screen displays, which is divided into three main sub-sections: Active Faults (Active Shutdowns), Active Warnings, and Faults History. The Faults History screen shows up to thirty-two faults that have been cleared.

Use the two soft-key buttons below the up and down arrows (▲ and ▼) to toggle between the pages.

TABLE 9. ACTIVE SHUTDOWN FAULTS

Name Description

Index This is the index number of the fault

Fault This is the fault code

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Name Description

SA Source Address

This is the controller that identified the fault, it is blank if the PCC identified the fault

Eng Hrs This is how many hours the engine had run (not necessarily continuously) when

the fault was generated

YY/MM/DD This is the date 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

Press the Home Button to return to the main menu at any time.

Press the C Button to return to the previous menus. Settings will not be saved when this button is pressed.

FIGURE 18. FAULTS MENU

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4.7.2 Fault Messages

FIGURE 19. FAULT MESSAGE DISPLAY SCREEN

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. Chapter 7 on page 123 provides a list of the fault codes, types, and message displayed.

Active and acknowledged faults may be viewed in the Faults menu.

4.7.3 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 4.2.5

on page 32.

Faults may also be acknowledged when in Auto mode and the Remote Start command is removed. Contact you authorized distributor for this option.

4.7.4 Warning Fault Menu

Figure 20 shows a block representation of a typical Warning Fault menu.

NOTICE

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.

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TABLE 10. ACTIVE WARNING FAULTS

Name Description

Index This is the index number of the fault

Fault This is the Fault code

SA Source Address

This is the controller that identified the fault, it is blank if the PCC 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

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Press the Home Button to return to the main menu at any time.

Press the C Button to return to the previous menus. Settings will not be saved when this button is pressed.

FIGURE 20. WARNING FAULT MENU - TYPICAL DATA

4.7.5 Faults History Data Operator Menu

Figure 21 on page 51 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 softkey 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.

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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 PowerCommand®3.3 control

identified the fault.

Engine Hrs This is how many hours the engine had run (not necessarily continuously) when the fault

was generated.

MM/DD/YY This is the date the fault was generated.

HH/MM/SS This is the time the fault was generated.

The name of the fault appears below the rest of the information.

Press the Home Button to return to the main menu at any time.

Press the C Button to return to the previous menus. Settings will not be saved when this button is pressed.

FIGURE 21. HISTORY FAULT MENU - TYPICAL DATA

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4.8 Operator Panel - Adjust Menu

Figure 22 on page 53 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 OK button to display the information.

The Adjust menu is displayed on one page.

NOTICE

Should any of these settings require amendment or change, please contact your authorized service center.

NOTICE

You cannot adjust Frequency Adjust or Voltage Adjust if Paralleling Speed Control Mode is set to Synchronize, Load Share, or Load Govern.

Name Description

Voltage Adjust

Genset LL Average Voltage

Voltage Adjust A trim that allows the user to add/subtract an offset to the nominal voltage when

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

Frequency Adjust A method of adding in a frequency offset to the base frequency subject to high and low

Avr Gain A trim that allows the user to modify the overall gains of the AVR. Allowed values:

Generator set Line-to-Line average voltage.

calculating the voltage setpoint. Allowed values: -5~5%. Default value: 0%

The frequency scaled version of the final speed reference. Allowed values: 0~100 Hz.

limit calibrations. Allowed values: -6~6 Hz. Default value: 0 Hz.

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.

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Press the Home Button to return to the main menu at any time.

Press the C Button to return to the previous menus. Settings will not be saved when this button is pressed.

FIGURE 22. ADJUST MENU - TYPICAL DATA

4.9 Operator Panel - Genset Setup Data Operator Menu

Figure 23 on page 54 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 on page 35

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 Setup data.

NOTICE

Should any of these settings require amendment or change, please contact your authorized service center.

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Press the Home Button to return to the main menu at any time.

Press the C Button to return to the previous menus. Settings will not be saved when this button is pressed.

FIGURE 23. SETUP DATA MENU - TYPICAL DATA

4.10 Operator Panel - Paralleling Status Menu

Figure 24 on page 60 and Figure 25 on page 61 show block representations of a typical Paralleling

Status menu. This screen varies according to the application type. See Section 5.8.3 on page 79.

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 then display the Paralleling Status Menu (if the generator set application type is not Standalone).

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Use the two soft-key buttons below the up and down arrows [▲ and ▼] to page through the six pages of the Paralleling Status menu.

TABLE 11. PARALLELING STATUS

Parameter Description

ES State Internal paralleling status variable

Allowed values: Standby, Dead Bus, Synchronize, Load Share, Load Govern

Genset LL Average Voltage Generator set line-to-line average voltage

Genset Frequency Generator set frequency

Genset Total kW Generator set total kW

Genset Total kVAR Generator set total kVAR

Genset Total Power Factor Generator set L1 power factor

Genset CB Position Status Indicates generator set breaker position

Allowed values: Open, Closed, Not Available

Phase Match Error Phase error signal for the synchronizer control algorithm

Load Demand Stop Command Indicates status of the final load demand stop command to generator set start

stop control function Allowed values: Don't Stop, Stop

Genset Bus LL Average Voltage

Genset Bus Frequency Generator set bus line frequency

Genset Bus Total kW Generator set bus total kW

Genset Bus Total kVAR Generator set bus total kVAR

Genset Bus Total Power Factor

Synchronizer Status Indicates whether synchronizer is on or off

Bus Status Indicates status of the bus

Permissive Close Allowed Indicates when permissive sync check conditions have been met

Phase Matched Sync check phase match status

Voltage Matched Sync check voltage match status

Frequency Matched Sync check frequency match status

Generator set bus line-to-line average voltage

Generator set bus total power factor

Allowed values: Synchronizer Off, Synchronizer On

Allowed values: Unavailable, Dead, Live

Allowed values: Not Allowed, Allowed

Allowed values: Inactive, Active

Phase Match Error Phase error signal for the synchronizer control algorithm

Frequency Match Error Frequency match error value used by frequency match PI loop

Voltage Match Error Voltage match error value used by voltage match PI loop

Load Govern kW Target Indicates the final target set point for generator set kW output when paralleled to

utility

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Parameter Description

Load Govern kVAR Target Indicates the final target set point for generator set kVAR output when paralleled

to utility

Power Factor Setpoint Indicates analog input power factor set point derived from kVAR analog input

Paralleling Speed Control Mode

Paralleling Voltage Control Mode

Genset CB Tripped Command Generator set CB tripped command

Genset CB Inhibit Command Generator set CB inhibit command

Load Share %kW Error Indicates %kW error for load sharing control algorithm

Utility CB Tripped Command Utility CB tripped command

Load Share %kVAR Error Indicates %kVAR error for load sharing control algorithm

Utility CB Inhibit Command Utility CB inhibit command

Utility Current Based Breaker Position

Genset Bus L1L2 Voltage Generator set bus L1L2 voltage

Genset Bus L2L3 Voltage Generator set bus L2L3 voltage

Indicates which speed control algorithm is in effect Allowed values: Isochronous, Droop, Synchronize, Load Share, Load Govern

Indicates which voltage control algorithm is in effect Allowed values: Isochronous, Droop, Synchronize, Load Share, Load Govern

Allowed values: Inactive, Active (Default: Inactive)

Indicates utility breaker position based on current

Genset Bus L3L1 Voltage Generator set bus L3L1 voltage

Genset Bus L1N Voltage Generator set bus L1N voltage

Genset Bus L2N Voltage Generator set bus L2N voltage

Genset Bus L3N Voltage Generator set bus L3N voltage

Genset Bus L1 Current Generator set bus L1 current

Allowed values: 0~65530 amps

Genset Bus L2 Current Generator set bus L2 current

Allowed values: 0~65530 amps

Genset Bus L3 Current Generator set bus L3 current

Allowed values: 0~65530 amps

Genset Bus L1 kW Generator set bus L1 kW

Allowed values: -32768~32762 kW

Genset Bus L2 kW Generator set bus L2 kW

Allowed values: -32768~32762 kW

Genset Bus L3 kW Generator set bus L3 kW

Allowed values: -32768~32762 kW

Genset Bus Total kW Generator set bus total kW

Genset Bus L1 kVA Generator set bus L1 kVA

Genset Bus L2 kVA Generator set bus L2 kVA

Genset Bus L3 kVA Generator set bus L3 kVA

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Parameter Description

Genset Bus Total kVA Generator set bus total kVA

Genset Bus L1 Power Factor Generator set bus L1 power factor

Allowed values: -1.28~1.22 PF

Genset Bus L2 Power Factor Generator set bus L2 power factor

Allowed values: -1.28~1.22 PF

Genset Bus L3 Power Factor Generator set bus L3 power factor

Allowed values: -1.28~1.22 PF

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Genset Bus Total Power Factor

Genset Bus Frequency Generator set bus line frequency

Genset Bus L1 Positive kWh Generator set bus L1 positive kWh accumulation

Genset Bus L2 Positive kWh Generator set bus L2 positive kWh accumulation

Genset Bus L3 Positive kWh Generator set bus L3 positive kWh accumulation

Genset Bus Total Positive kWh

Genset Bus L1 Negative kWh Generator set bus L1 negative kWh accumulation

Genset Bus L2 Negative kWh Generator set bus L2 negative kWh accumulation

Genset Bus L3 Negative kWh Generator set bus L3 negative kWh accumulation

Genset Bus Total Negative kWh

Generator set bus total power factor

Allowed values: 0~4294967290 kWh (Default: 0 kWh)

Generator set bus total positive kWh accumulation

Allowed values: 0~4294967290 kWh (Default: 0 kWh)

Generator set bus total negative kWh accumulation

Genset Bus Total Net kWh Generator set bus total net kWh accumulation

Genset Bus L1 Positive kVARh

Genset Bus L2 Positive kVARh

Genset Bus L3 Positive kVARh

Genset Bus Total Positive kVARh

Genset Bus L1 Negative kVARh

Genset Bus L2 Negative kVARh

Genset Bus L3 Negative kVARh

Generator set bus L1 positive kVARh accumulation Allowed values: 0~4294967290 kVARh (Default: 0 kVARh)

Generator set bus L2 positive kVARh accumulation Allowed values: 0~4294967290 kVARh (Default: 0 kVARh)

Generator set bus L3 positive kVARh accumulation Allowed values: 0~4294967290 kVARh (Default: 0 kVARh)

Generator set bus total positive kVARh accumulation

Generator set bus L1 negative kVARh accumulation Allowed values: 0~4294967290 kVARh (Default: 0 kVARh)

Generator set bus L2 negative kVARh accumulation Allowed values: 0~4294967290 kVARh (Default: 0 kVARh)

Generator set bus L3 negative kVARh accumulation Allowed values: 0~4294967290 kVARh (Default: 0 kVARh)

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Parameter Description

Genset Bus Total Negative kVARh

Genset Bus Total Net kVARh Generator set bus total net kVARh accumulation

Genset Bus Reset All Energy Meters Timestamp - Hour

Genset Bus Reset All Energy Meters Timestamp - Minute

Genset Bus Reset All Energy Meters Timestamp - Second

Genset Bus Reset All Energy Meters Timestamp - Day

Genset Bus Reset All Energy Meters Timestamp - Month

Genset Bus Reset All Energy Meters Timestamp - Year

Genset Bus L1 kVAR Generator set bus L1 kVAR

Genset Bus L2 kVAR Generator set bus L2 kVAR

Generator set bus total negative kVARh accumulation

Time stamp of when energy meters were last reset Allowed values: 0~23 (Default: 0)

Time stamp of when energy meters were last reset Allowed values: 0~59 (Default: 0)

Time stamp of when energy meters were last reset Allowed values: 1~31 (Default: 1)

Time stamp of when energy meters were last reset Allowed values: 1~12 (Default: 1)

Time stamp of when energy meters were last reset Allowed values: 0~99 (Default: 0)

Allowed values: -32678~32672 kVAR

Allowed values: -32768~32762 kVAR

Genset Bus L3 kVAR Generator set bus L3 kVAR

Allowed values: -32768~32762 kVAR

Genset Bus L1L2 Phase Difference

Genset Bus L2L3 Phase Difference

Genset Bus L3L1 Phase Difference

Genset Bus L1 kVAh Generator set bus L1 kVAh accumulation

Genset Bus L2 kVAh Generator set bus L2 kVAh accumulation

Genset Bus L3 kVAh Generator set bus L3 kVAh accumulation

Genset Bus Total kVAh Generator set bus total kVAh accumulation

Genset Bus Phase Rotation Generator set bus phase rotation

System Network Termination Resistor Switch Status

Generator set bus L1L2 voltage phase angle

Generator set bus L2L3 voltage phase angle

Generator set bus L3L1 voltage phase angle

Allowed values: 0~4294967290 kVAh (Default: 0 kVAh)

Allowed values: 0~4294967295 kVAh (Default: 0 kVAh)

Allowed values: L1-L2-L3, L1-L3-L2, Not Available

Indicates the status of the on-board CAN termination resistor switch (S1)

Load Demand State Indicates the status of load demand operation

PCC3300 MLD controls only

Load Demand Online Capacity Indicates the total amount of online kW bus capacity for load demand

Only generator sets which are eligible for load demand count PCC3300 MLD controls only

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Parameter Description

Load Demand Genset Bus Total kW

Load Demand Surplus Capacity

Load Demand Total Spare Capacity Requested

Load Demand Spare Capacity Available

Load Demand Next Stop Threshold (kW)

Load Demand Next Start Threshold (kW)

Load Demand Next Gen to Start

Load Demand Next Gen to Stop

Load Demand Initial Delay Timer

Indicates the total load of system network connected generator sets PCC3300 MLD controls only

Indicates the amount of unused online kW bus capacity (spinning reserve) PCC3300 MLD controls only

Indicates the total kW value of all currently active spare capacity requests in the system

PCC3300 MLD controls only

Indicates when the current load and spare capacity requirements are satisfied PCC3300 MLD controls only

The kW load at which the next generator set will be stopped PCC3300 MLD controls only

The kW load at which the next generator set will be started PCC3300 MLD controls only

Indicates Genset ID of the next generator set to start PCC3300 MLD controls only

Indicates Genset ID of the next generator set to stop PCC3300 MLD controls only

Indicates the time remaining before generator sets are allowed to stop after initial start or after resuming from halted load demand

This timer is set by Load Demand Initial Delay PCC3300 MLD controls only

Load Demand Start Delay Timer

Load Demand Stop Delay Timer

Load Demand Inhibit Local Indicates the status of the Load Demand Inhibit input

Load Demand Genset Status Table

Genset ID Generator set identifier. All load demand generator sets must have a unique

Load Demand Genset Run Hours

System Network Datalink Status

Indicates the time remaining before next generator set is allowed to start This timer is set by Load Demand Start Delay PCC3300 MLD controls only

Indicates the time remaining before next generator set is allowed to stop This timer is set by Load Demand Stop Delay PCC3300 MLD controls only

When Active all the generator sets will start PCC3300 MLD controls only

Indicates the load demand priorities and status of all load demand system network connected generator sets

PCC3300 MLD controls only

Genset ID PCC3300 MLD controls only

Run hour accumulator used for load demand run hour equalization This is writable Allowed Values: 0~999999.9 hours (Default: 0 hours) PCC3300 MLD controls only

Indicates communication status of the local generator set on system network (used for load demand)

PCC3300 MLD controls only

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Parameter Description

Load Demand Spare Capacity Request Status

Indicates the status of the spare capacity request input When Active additional spare capacity (set by Load Demand Spare Capacity

Request Value) is requested PCC3300 MLD controls only

Press the Home Button to return to the main menu at any time.

Press the C Button to return to the previous menus. Settings will not be saved when this button is pressed.

FIGURE 24. PARALLELING STATUS DATA SHEET 1 - TYPICAL DATA

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Press the Home Button to return to the main menu at any time.

Press the C Button to return to the previous menus. Settings will not be saved when this button is pressed.

FIGURE 25. PARALLELING STATUS DATA SHEET 2 - TYPICAL DATA

4.11 Operator Panel - Paralleling/Basic Setup Menu

Figure 26 on page 63 and Figure 27 on page 64 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.

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NOTICE

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 4.12.1.1 on

page 64)

NOTICE

Should any of these settings require amendment or change, please contact your authorized service center.

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Press the Home Button to return to the main menu at any time.

Press the C Button to return to the previous menus. Settings will not be saved when this button is pressed.

FIGURE 26. PARALLELING/BASIC DATA (SHEET 1 OF 2) - TYPICAL DATA

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Press the Home Button to return to the main menu at any time.

Press the C Button to return to the previous menus. Settings will not be saved when this button is pressed.

FIGURE 27. PARALLELING/BASIC DATA (SHEET 2 OF 2) - TYPICAL DATA

4.12 Selecting Operating Modes

4.12.1 Passwords and Mode Change Access

4.12.1.1 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.

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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.

FIGURE 28. MODE CHANGE ACCESS CODE DISPLAY SCREEN

NOTICE

If an incorrect password is entered, the Operator menu that was displayed before Auto, Manual Run, or Stop mode was selected is re-displayed.

4.12.1.1.1 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

NOTICE

When changing modes, the generator set may start or stop without warning. Make sure there is no danger to personnel or equipment should the generator set unexpectedly start or stop.

Press the Manual button and then (within ten seconds) the Start button . This bypasses the 'Time Delay to Start' function and activates the engine control system and the starting system.

If the engine does not start, the starter disengages after a specified period of time and the controller indicates a 'Fail to Start' shutdown.

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The generator set can be configured for 1–7 starting cycles with set times for crank and rest periods for all starting modes (manual/remote). The default setting is 3 start cycles, composed of 15 seconds of cranking and 30 seconds of rest.

NOTICE

The InPower service tool or access to the setup menu is required to change the cycle number, and crank and rest times. Contact your authorized distributor for assistance.

To clear a Fail to Start shutdown, press the Stop button and then press the Reset button

Before attempting to restart, wait 2 minutes for the starter motor to cool and repeat the starting procedure. If the engine does not run after a second attempt, refer to Chapter 7 on page 123.

4.12.3 Selecting Auto Mode

NOTICE

When changing modes, the generator set can start or stop without warning. Make sure there is no danger to personnel or equipment should the generator set start or stop.

NOTICE

Make sure 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. This start incorporates a Time Delay to Start function.

NOTICE

The InPower service tool or access to the setup menu is required to change the cycle number, and crank and rest times. Contact your authorized distributor for assistance.

NOTICE

Should a remote start signal be received, the generator set starts automatically. Make sure there is no danger to personnel or equipment should the generator set start without warning.

The starting/stopping sequence for a remote start is as follows:

1. A remote start signal is received at the customer connection on the generator set. This input signal is received from a transfer switch, a remote start switch, etc.

2. The Time Delay to Start (0–300 seconds) begins.

3. When the Time Delay to Start has expired, the engine starts. Once it has reached its rated speed and voltage, the generator set is available for use.

4. When the remote start signal is removed, a Time Delay to Stop (0–600 seconds) begins. This time delay is used to transfer the load (if connected to another power source) and let the engine cool down.

5. When the Time Delay to Stop has expired, the engine stops.

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If the emergency stop or control off button is pressed at any time during the starting/stopping sequence, the engine immediately stops, bypassing the cooldown sequence.

4.12.4 Selecting Off Mode

When changing modes, the generator set can stop without warning. Make sure there is no danger to personnel or equipment should the generator set stop.

Press the Stop button to put the generator set into the Off mode. This disables 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 cool down run.

4. Control System - PowerCommand 3.33-2016

NOTICE

Do not perform a hot shutdown under load; a hot shutdown may result in engine damage.

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5 Operation - PowerCommand 3.3

5.1 Safety

WARNING

Toxic Gases Inhalation of exhaust gases can cause asphyxiation and death. Use extreme care during installation to provide a tight exhaust system. Terminate exhaust

pipes away from enclosed or sheltered areas, windows, doors, and vents. Do not use exhaust heat to warm a room, compartment, or storage area.

WARNING

Hazardous Voltage Contact with high voltages can cause severe electrical shock, burns, or death. Do not open the generator set output box while the generator set is running. Read and

observe all warnings and cautions in the generator set manuals.

CAUTION

Hazardous Voltage Contact with high voltages can cause severe electrical shock, burns, or death. Make sure that only suitably trained and experienced service personnel perform electrical

and/or mechanical service. Even with the power removed, improper handling of components can cause electrostatic discharge.

Only trained and experienced personnel should carry out generator set operations. Before operating the system, the operator should become familiar with all health and safety procedures, warnings, cautions, precautions, and the other documentation supplied with the generator set. (See Chapter 1

on page 1). Observe all of the warnings and cautions at all times.

Before operating the generator set 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 generator set is operated correctly.

5.2 Introduction

This section describes the operation of the generator set. The text should be read in conjunction with the System Overview and the Control System Sections of this manual.

All indicators, control switches/buttons, and graphical display are located on the face of the Operator Panel as illustrated in Figure 11 on page 31.

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 are carried out, as detailed in Chapter 6 on page 97.

NOTICE

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5.4 Operating Recommendations

5.4.1 Running-in

Refer to the Maintenance section of this manual: Chapter 6 on page 97. 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.

The engine should be run at varying loads during the first few hours of operation to allow the components to 'bed in.' Avoid long periods of light load or full load running particularly during the early life of the engine.

5.4.2 No Load Operation

Periods of no load operation should be held to no longer than 15 minutes. Long periods of no load operation can result in engine and (if fitted) diesel particulate filter damage.

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 a 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 that 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 will help provide reliable starting under adverse weather conditions. Make sure the voltage of the separate power source is correct for the heater element rating.

5.4.5 High Operating Temperatures

In high ambient temperatures, when operating at full load, it is normal for the high temperature warning to be given. This indicates that the engine is operating near to its maximum capacity and is normal. If operation in high temperature environments is anticipated, increase the frequency of checks for coolant level, obstructions of cooling air inlets and outlets, and debris at the radiator.

Refer to the generator set nameplate for the maximum operating temperature, if applicable.

5.4.6 Operating Conditions

All generator sets supplied by Cummins Power Generation must be run under the following operating conditions, and in accordance with the operating information contained within the literature package supplied with each generator set.

NOTICE

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5.4.6.1 Continuous Power Rating (COP) for Constant Load Applications

The Continuous Power Rating (COP) 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 Cummins Power Generation manuals. No 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 (PRP)

The Prime Power Rating (PRP) 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 Cummins Power Generation 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 1 hour within a 12-hour period of operation, in accordance with ISO 8528-1 2005. Total operating time at the 10% overload power shall not exceed 25 hours per year.

• Limited running time prime power (for constant load applications) (LTP)

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. Generator sets 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 set 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 Emergency Standby Power Rating (ESP) for Variable Load Applications

The Emergency Standby Power Rating (ESP) 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 Cummins Power Generation 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 utilized as applicable.

This rating is applicable to installations served by a reliable normal utility source. Generator sets 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 Applicable to all Ratings

The following information applies to all ratings, unless otherwise agreed by the Regional Sales Manager of Cummins Power Generation 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 are taken as 30% and time at no load shall not be counted.

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• Variable load is calculated in accordance with methods and formulas 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:

1. Ambient temperature — 27 °C (81 °F).

2. Altitude above sea level — 150 meters (490 feet).

3. Relative humidity — 60%.

4. 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

Engine power and resulting electrical output decrease as ambient temperature or altitude increases. For de-rating factors applicable at specific sites, contact your authorized distributor.

5.5 Generator Set Operation

WARNING

Combustible Vapors Engine over speeding can cause component failure, fire, or an explosion; which can cause

severe personal injury or death. Do not operate an engine where there are or can be combustible vapors.

Correct care of the engine will result in longer life, better performance, and more economical operation.

Numerous safety devices may be 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 the engine will be used. The equipment owner and operator, therefore, is responsible for safe operation in a hostile environment. Consult your authorized distributor for further information.

NOTICE

Cummins Power Generation recommends the installation of an air intake shutoff device or a similar safety device to minimize the risk of overspeeding where an engine will be operated in a combustible environment.

NOTICE

Long periods of idling (more than ten minutes) can damage an engine. Do not idle the engine for excessively long periods.

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 operator panel to indicate the operating run mode of the generator set. The PowerCommand®control initiates a starter cranking signal and performs 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.

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The choice of Auto or Manual Run mode is decided by authorized personnel during the generator set initial setup. An access code is required to switch between the Auto, Manual Run, or Off modes, and this facility may be permitted or denied by the authorized personnel during the initial setup of the generator set.

5.6 Starting

One operator should be in complete charge, or working under the direction of someone who is in charge. Remember that, upon starting the engine, cables and switchgear will become energized, possibly for the first time. Furthermore, equipment that does not form part of the generator set installation may become electrically charged. Only authorized and competent personnel should carry out this work.

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.

5. Operation - PowerCommand 3.33-2016

NOTICE

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 should read through this entire manual and the specific literature 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 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®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 30 seconds of rest.

NOTICE

The number of starting cycles, and the crank and rest times are set from within the Setup menu. Trained and experienced service personnel are required to change the default setting. Contact your authorized distributor.

5.6.1 Operator’s Pre-start Checks

WARNING

Arc Flash and Shock Hazard Electric arc flash can cause electrical shock, severe burns, or death. Make sure the alternator is dry before the generator set is operated.

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WARNING

Hot Pressurized Liquid Contact with hot liquid can cause severe burns. Do not open the pressure cap while the engine is running. Let the engine cool down before

removing the cap. Turn the cap slowly and do not open it fully until the pressure has been relieved.

NOTICE

Some radiators have two fill necks, both of which must be filled when the cooling system has been drained.

• Fuel Supply – Make sure the fuel tank is filled to the normal level with clean water-free fuel and that the fuel system is primed and all the valves required for operation are open. Make sure there are no leaks and that all fittings are tight.

• Lubrication – With the engine stationary, check the engine lubrication oil level and ensure that the correct level is always maintained.

• Coolant – Check the engine coolant level and make sure 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.

• Cooling Air Inlet/Outlets – Make sure that the cooling air inlets/outlets are unobstructed.

• Exhaust Outlet – Make sure 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. Make sure that there are no leaks and that all fittings are tight.

• Batteries – Make sure that the batteries are charged and that all connections are correct and tight.

• Auxiliary AC Supplies – Make sure that all auxiliary equipment is receiving power from the customer’s supply.

• Emergency Stop – Make sure that the emergency stop button is fully operational.

5.6.2 Starting at Operator Panel (Manual Run Mode)

NOTICE

Make sure that all Pre-start Checks are carried out before starting the generator set. Do not attempt to start the generator set until it is safe to do so. Warn all others in the vicinity of the generator set and the connected load equipment that the generator set is about to start.

1. Make sure the main circuit breaker is in the open position.

2. To start the generator set in the Manual Run mode, press the Manual button on the

Operator 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 on page 65).

If the mode change access code feature has been enabled, enter the access code when prompted.(See Section 4.12.1 on page 64).

NOTICE

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The PowerCommand®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 Chapter 7 on

page 123.

To disable Manual mode, change to Auto or Off 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.

3.Allow the engine to warm up and reach the rated speed and voltage.

4.Close the main circuit breaker and apply load as required.

5.6.3 Starting from Remote Location (Auto Mode)

NOTICE

To start the generator set in the Auto Run mode, select the Auto button from the Operator Panel. (Refer also to Section 4.12.3 on page 66).

Only on receipt of a remote start signal, and after a Time Delay to Start, will the PowerCommand control initiate the starting sequence as above.

The Remote Start LED will be lit.

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, except for the following:

• In Auto position, the control will complete the Time Delay to Start (0 to 300 seconds) for a nonemergency start signal only.

NOTICE

If the mode change access code feature has been enabled, enter the access code when prompted. (See Section 4.12.1 on page 64)

To disable Auto mode, change to Manual or Stop mode. Refer to Section 5.7 on page 76.

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5.6.4 Cold Starting with Loads

NOTICE

Make sure that all pre-start checks are carried out before starting the generator set. Do not attempt to start the generator set until it is safe to do so. Warn all others in the vicinity that the generator set is about to start.

Use a coolant heater if a separate source of power is available. The optional heater available from Cummins Power Generation 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 recommends equipping standby generator sets (life safety systems) with engine water jacket coolant heaters to maintain the coolant at a minimum of 32 °C (90 °F) and, for most applications, accept the emergency load in ten seconds or less. Although most Cummins Power Generation generator sets will start in temperatures down to -32 °C (-25 °F) 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 4 °C (40 °F).

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 21 °C (70 °F). In applications where the ambient temperature falls below 4 °C (40 °F), 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.

5.6.4.1 Checking Coolant Heater Operation

WARNING

Hot Surfaces Contact with the hot surfaces can cause severe burns. Avoid contact with hot parts. Allow hot parts to completely cool.

Do not touch the cooling system outlet hose. The coolant heater is operating if radiant heat can be felt with your hand held close to the outlet hose and the engine is not running.

5.7 Stopping

NOTICE

The access code may be required before initiating the Off button sequence. Refer to Section

4.12.1 on page 64.

NOTICE

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.

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5.7.1 Stopping at Operator Panel (Manual Mode)

NOTICE

If possible, hot shutdown under load should be avoided to help prolong the reliability of the set. A hot shutdown results in a Hot Shutdown Warning.

NOTICE

Hot shutdown under load should be avoided whenever possible to prolong the reliability of the set. A hot shutdown may result in a Hot Shutdown Warning.

NOTICE

Pressing the stop button twice stops the generator set immediately without a cool down run after which the set enters the off mode.

To shutdown a generator set that was started in manual mode.

1. Remove the load.

2. Open the main circuit breaker.

3. Press the stop button on the HMI Operator panel. This initiates the generator set cool down run. The HMI displays the cool down count down timer at this time. Once the cool down timer has expired, the generator set shuts off and enters off mode.

5.7.2 Stopping from Operator 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 generator 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.

NOTICE

If possible, hot shutdown under load should be avoided to help prolong the reliability of the set. A hot shutdown will result in a Hot Shutdown Warning.

NOTICE

When MLD is enabled, stopping a generator set may cause one or more stopped generator sets to start.

5.7.3 Stopping from Remote Location (Auto Mode)

If the control receives a remote stop signal, the generator set completes its normal shutdown sequence incorporating a Cooldown run (Refer to Section 4.12.3). (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.

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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.

NOTICE

The InPower service tool or access to the Setup menus is required to enable and change the time delay start/stop settings. Contact your authorized distributor for assistance.

5.7.4 Emergency Stop (Code 1433 or 1434)

The local Emergency Stop button is situated on the front of the operator panel. This is a mechanically latched switch that will unconditionally stop the engine when pressed, bypassing any time delay to stop. Push this button for emergency shutdown of the engine.

NOTICE

If the engine is not running, pushing the button will prevent the starting of the engine, regardless of the start signal source (Manual or Auto - Remote).

When the 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 LOCAL EMERGENCY STOP

A remote Emergency Stop button may be incorporated within the installation. If this remote Emergency 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 Operator Panel to acknowledge this action.

3. Press the Reset button.

4. Press the Auto or Manual Run button, as previously determined. (See Section 4.12 on page

64).

NOTICE

Do not use an 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 away heat from the engine combustion chamber and bearings in a safe manner.

NOTICE

Make sure that the cause of the Emergency Stop is fully investigated and remedied before a fault Reset and generator Start are attempted.

An Emergency Stop button is situated in close proximity to the Operator Panel viewing window.

NOTICE

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5.8 Paralleling Operation

5.8.1 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 PowerCommand®3.3 control unit monitors both the incoming supply and the busbar voltage and frequency. It adjusts the incoming supply to match the busbar supply over a wide span of busbar parameters. Synchronization is achieved under full control and at the correct phase coincidence.

In Automatic mode, the PowerCommand®3.3 control receives a breaker close signal when synchronization 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.

NOTICE

The PowerCommand®3.3 control performs a synchronization check in both Manual and Auto modes before allowing the generator set circuit breaker to close.

5.8.2 Operation When in Parallel

5. Operation - PowerCommand 3.33-2016

When in parallel with the busbar supply, the generator set voltage and frequency are dependent upon the busbar parameters and the control is changed to kW and kVAR load management.

Each generator set is individually controlled by a separate PowerCommand®3.3 control.

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 affecting the others.

When the control system detects that the generator set is up to speed and voltage, the load ramps from the mains to the generator set. The engine governor control system keeps the electrical output within the correct parameters.

5.8.3 Generator Set Application Type

Generator set application type is the primary setting for configuring the paralleling features of the PowerCommand®3.3 control. Table 12 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 12. OVERVIEW OF GENERATOR SET APPLICATION TYPES; PARALLELING STATES AND

PROCESSES

Standalone Synchronizer

Only

Isolated Bus

Only

Utility Single Utility

Multiple

Power

Transfer

Control

Parallel with Utility

Parallel with other generator sets

Paralleling States:

Standby Yes Yes Yes Yes Yes Yes

Yes Yes

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Standalone Synchronizer

Only

Dead Bus/First Start

Synchronize Yes Yes Yes Yes Yes

Load Share Yes Yes

Load Govern Yes Yes Yes

Masterless Load Demand (MLD)

Generator Set CB trip

Generator Set CB Control

Utility CB Control

In general, generator set application types are distinguished by what may be run in parallel with the generator set. Synchronizer Only and Power Transfer Control are further distinguished by other characteristics as follows:

Yes Yes

Isolated Bus

Only

Yes Yes Yes

Yes

Yes Yes Yes Yes

Utility Single Utility

Multiple

Power

Transfer

Control

Yes

• Synchronizer Only: The generator set is not running in parallel with other generator sets or with the utility, but the PowerCommand®3.3 control can synchronize 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 synchronizer.

• In Power Transfer Control: The PowerCommand®3.3 controls the generator set’s circuit breaker and utility circuit breaker to ensure the load has power. The PowerCommand®3.3 control does not control the utility circuit breaker in any other generator set application type.

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.

5.8.4 Standalone Application

In the generator set application shown in Figure 29, 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.

NOTICE

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No. Description

1 PowerCommand®3.3 Controller

5. Operation - PowerCommand 3.33-2016

2 Generator Set

3 Generator Set Circuit Breaker

FIGURE 29. STANDALONE

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.

5.8.5 Synchronize Only

In the generator set application shown in Figure 30, the generator set is not running in parallel with other sets or with the utility, but the PowerCommand®3.3 control can synchronize 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 synchronizer.

FIGURE 30. SYNCHRONIZED ONLY

The PowerCommand®3.3 control is in the Standby paralleling state until event 1465 (Ready to Load) is active. Then the PowerCommand®3.3 control synchronizes if all of the following conditions are met:

• The sync enable signal is active.

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• The synchronizer conditions are met.

If any of these conditions are not met the PowerCommand®3.3 control remains in the Standby paralleling state.

The Sync Enable Signal may come from the PowerCommand®3.3 control’s 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 PowerCommand®3.3 control synchronizes with the live bus.

5.8.6 Isolated Bus Only

In the generator set application shown in Figure 31, the generator set is running in parallel with other generator sets.

FIGURE 31. ISOLATED BUS ONLY – STANDBY PARALLELING STATE

The generator set is in the Standby paralleling state until event 1465 (Ready to Load) is active. The PowerCommand®3.3 control then considers the current position of the generator set circuit breaker.

Before the PowerCommand®3.3 control 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:

1. There are no generator set circuit breaker Open requests.

2. There is a generator set circuit breaker Close request.

If the PowerCommand®3.3 control is in Manual mode, the CB Close button must be pressed.

NOTICE

The PowerCommand®3.3 control inhibits closure of the paralleling breaker outside the synccheck window. Therefore the breaker close button can be operated even before synchronization, although the breaker will not close until a signal is sent from the PowerCommand®3.3 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 32 the PowerCommand®3.3 control 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.

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FIGURE 32. ISOLATED BUS ONLY - LOAD SHARE PARALLELING STATE

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.

5.8.7 Power Transfer Control

In the generator set application shown in Figure 33 (utility circuit breaker closed and taking the load), a single generator set runs in parallel with the utility; no other generators are connected. This is the only application whereby the PowerCommand®3.3 control controls the utility circuit breaker as well as the generator set to make sure the load has continuous power.

FIGURE 33. POWER TRANSFER CONTROL

The PowerCommand®3.3 controls the generator set, the generator set circuit breaker, and the utility circuit breaker to make sure the load has power. For example, the PowerCommand®3.3 control monitors the utility; if the utility fails, the PowerCommand®3.3 control starts the generator and transfers the load to the generator set. When the utility is available again, the PowerCommand®3.3 control 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.

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NOTICE

In this generator set application type, Utility Single Mode verify/configurable input #29 function pointer must be set to Default if the PowerCommand®3.3 control is allowed to close the generator circuit breaker onto a dead bus.

The PTC operating mode determines the conditions under which the PowerCommand®3.3 control opens and closes the generator set circuit breaker and the utility circuit breaker, as well as conditions under which the PowerCommand®3.3 control starts and stops the generator set.

The PTC operating mode is related to the mode of operation. Table 13 provides a summary of the relationships between the mode of operation and the PTC operating mode.

TABLE 13. SUMMARY OF RELATIONSHIPS BETWEEN MODES OF OPERATION AND PTC OPERATING

MODES.

Mode of Operation Condition PTC Operating Mode

Off Default Mode Off

Auto Default Mode Normal

PTC Mode Switch Signal Manual

Exercise Signal Exercise

Remote Start Signal Test

Extended Parallel Signal Extended Parallel

Generator Set is Unavailable Normal Override

Utility is Unavailable Utility Fail

Manual Default Mode Manual

5.8.7.1 Exercise Mode

In this PTC operating mode the PowerCommand®3.3 control 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 (the Remote Start signal must be inactive).

• If the Exercise Scheduler is active, Scheduler Program Run mode replaces Test With Load Enable.

5.8.7.2 Extended Parallel Mode

In this PTC operating mode, the PowerCommand®3.3 control responds to the Extended Parallel signal. The PowerCommand®3.3 control 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 PowerCommand®3.3 control 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.

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5.8.7.3 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 PowerCommand®3.3 control is in Manual mode.

When the PowerCommand®3.3 control enters this PTC operating mode, it considers the current position of both the generator’s and the utility’s circuit breaker. However, the generator set must be started manually and the generator set’s circuit breaker will not close to accept the load until the generator set is up to speed and voltage.

In the following sequences the PowerCommand®3.3 control must be in the Standby Paralleling State unless otherwise stated and assumes that the PowerCommand®3.3 control menus have been set for the correct paralleling parameters.

Figure 34 on page 85, Figure 35 on page 86, Figure 36 on page 87 and Figure 37 on page 87

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.

5. Operation - PowerCommand 3.33-2016

NOTICE

In Figure 34 on page 85, the Utility has become unavailable while the generator set is in the Standby paralleling state.

1 Generator Set

2 PowerCommand®3.3 Controller

3 Utility

4 Utility Circuit Breaker (shown Open)

5 Load

6 Generator Set Circuit Breaker (shown Open)

FIGURE 34. MANUAL MODE – CIRCUIT BREAKER CONTROL SEQUENCE 1

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Start the generator set in Manual mode. 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.

NOTICE

The PowerCommand®3.3 control inhibits closure of the paralleling breaker outside the synccheck window. Therefore, the breaker close button can be operated even before synchronization, although the breaker will not close until a signal is sent from the PowerCommand®3.3 control to allow it.

In Figure 35 on page 86, the generator set’s circuit breaker is open while the utility circuit breaker is closed and is therefore accepting the load.

FIGURE 35. MANUAL MODE – CIRCUIT BREAKER CONTROL SEQUENCE 2

The generator’s 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 synchronized.

NOTICE

Synchronization requires the Sync Enable signal to be present; otherwise, the PowerCommand®3.3 control does not automatically synchronize 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 36 on page 87, the generator set’s circuit breaker is closed and the utility circuit breaker is open. The load in this instance is receiving power from the generator set only.

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FIGURE 36. MANUAL MODE – CIRCUIT BREAKER CONTROL SEQUENCE 3

When the utility is again providing power, the utility circuit breaker can be closed.

In Figure 37 on page 87, both generator set and utility are providing power for the load.

FIGURE 37. MANUAL MODE – CIRCUIT BREAKER CONTROL SEQUENCE 4

In this condition, the PowerCommand®3.3 control 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, the 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 synchronized.

5.8.8 Conditions for Each Paralleling State

5.8.8.1 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.

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FIGURE 38. 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 38 on page 88.

Figure 39 on page 89, Figure 40 on page 90, Figure 41 on page 90 and Figure 42 on page 91

illustrate the various conditions for each paralleling state.

NOTICE

In the following sequences, the PowerCommand®3.3 control must be in the Standby Paralleling state unless otherwise stated and assumes that the PowerCommand®3.3 control menus have been set with the correct paralleling parameters.

In Figure 39 on page 89, 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.

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FIGURE 39. UTILITY SINGLE – SEQUENCE 1

Before the PowerCommand®3.3 control closes the generator set circuit breaker, all of the following conditions must be met:

• 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 PowerCommand®3.3 control is in Manual mode, the circuit breaker Close button must be pressed.

The generator set will then provide power for the load.

NOTICE

In Figure 40 on page 90, the generator set is running with the circuit breaker open and the utility circuit breaker closed, providing power for the load.

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FIGURE 40. UTILITY SINGLE – SEQUENCE 2

The PowerCommand®3.3 control will automatically initiate the Synchronize procedure, since it is synchronizing to the utility.

Before the PowerCommand®3.3 control closes the generator set circuit breaker, both of the following conditions must be met:

• There are no generator set circuit breaker Open requests.

• There is a generator set circuit breaker Close request.

If the PowerCommand®3.3 control is in Manual mode, the circuit breaker Close button must be pressed. The generator set will then load share with the utility.

In Figure 41 on page 90, the utility circuit breaker is Open and the generator set is running with the circuit breaker closed, providing power for the load.

FIGURE 41. UTILITY SINGLE – SEQUENCE 3

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When the utility is available, its circuit breaker may be closed and therefore available to supply power to 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 synchronizer, thereby allowing a re-transfer of load back to the utility.

NOTICE

Utility CB sync check and utility breaker controls are not part of the PowerCommand®3.3 control system.

NOTICE

In Manual mode, it will be necessary to press the CB Open button on the operator panel.

In this condition (see Figure 42 on page 91), the PowerCommand®3.3 control is now in the Load Govern paralleling state. Both the generator and utility circuit breakers are closed; therefore, the load is now receiving power from both sources.

FIGURE 42. UTILITY SINGLE – SEQUENCE 4

Open the generator set circuit breaker if there are any generator set circuit breaker Open requests.

5.8.8.2 Utility Multiple

For paralleing with a PC 3.3 Controllar and Motorised Circuit Breaker, to avoid false tripping of the circuit breaker it is recommened to switch off the earth fault protection. The earth fault protection switch is located on the control panel .

In the generator set application shown in Figure 43 on page 92, the generator set is running in parallel with other generator sets which in turn are running in parallel with the utility .

NOTICE

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FIGURE 43. UTILITY MULTIPLE

The PowerCommand®3.3 control is in the Standby paralleling state until Event 1465 (Ready to Load) is active. The PowerCommand®3.3 control then considers the current position of the generator set circuit breaker and the utility circuit breaker, as illustrated in Figure 43 on page 92. 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 synchronizing to it.

Figure 44 on page 93, Figure 45 on page 94, Figure 46 on page 94 and Figure 47 on page 95

illustrate the various conditions for each paralleling state.

NOTICE

In the following sequences, the PowerCommand®3.3 control must be in the Standby Paralleling State unless otherwise stated and assumes that the PowerCommand®3.3 control menus have been set with the correct paralleling parameters.

In Figure 44 on page 93, 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.

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FIGURE 44. UTILITY MULTIPLE – SEQUENCE 1

Before the PowerCommand®3.3 control closes the generator set circuit breaker, all of the following conditions must be met:

• The generator set circuit breaker is then closed if the following conditions are met:

1. There are no generator set circuit breaker Open requests.

2. There is a generator set circuit breaker Close request.

If the PowerCommand®3.3 control is in Manual mode, the circuit breaker Close button must be pressed.

NOTICE

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 45 on page 94, the generator set is running with the circuit breaker open and the utility circuit breaker closed, providing power for the load.

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FIGURE 45. UTILITY MULTIPLE – SEQUENCE 2

The PowerCommand®3.3 control will automatically initiate the Synchronize procedure since it is synchronizing to the utility.

Before the PowerCommand®3.3 control closes the generator set circuit breaker, all of the following conditions must be met:

• There are no generator set circuit breaker Open requests.

• There is a generator set circuit breaker Close request.

If the PowerCommand®3.3 control is in Manual mode, the circuit breaker Close button must be pressed. The generator set will then load share with the utility.

In Figure 46 on page 94, 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 46. UTILITY MULTIPLE - SEQUENCE 3

94 0908-0209 (Issue 6)