CUMMINS C20 N6, C25 N6, C36 N6, C40 N6H, C30 N6H Operator's Manual

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OperatorOperator ManualManual

Generator Set

QSJ2.4 Engine with PowerCommand® 1.1 Control

C20 N6 (Spec A), C22 N6 (Spec A) C25 N6 (Spec A), C30 N6 (Spec A) C36 N6 (Spec A), C40 N6 (Spec A) C30 N6H (Spec A), C36 N6H (Spec A) C40 N6H (Spec A), C45 N6H (Spec A) C50 N6H (Spec A), C60 N6H (Spec A)

English Original Instructions

7-2018 A045R242 (Issue 12)

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

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

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

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

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

1.5 Electrical Shocks and Arc Flashes Can Cause Severe Personal Injury or Death.................. 5

1.6 Fuel and Fumes Are Flammable ............................................................................................ 5

1.7 Batteries Can Explode ............................................................................................................ 6

1.8 Exhaust Gases Are Deadly..................................................................................................... 7

1.9 The Hazards of Carbon Monoxide.......................................................................................... 9

1.10 Earth Ground Connection ..................................................................................................... 9

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

2.1 Safety .................................................................................................................................... 11

2.2 About This Manual................................................................................................................ 11

2.3 Schedule of Abbreviations .................................................................................................... 12

2.4 Related Literature ................................................................................................................. 14

2.5 Model Specifications ............................................................................................................. 15

2.6 After Sales Services.............................................................................................................. 20

3. CONTROL SYSTEM .................................................................................................................... 25

3.1 Control System Description .................................................................................................. 25

3.2 Display Text or Symbolic Version ......................................................................................... 29

3.3 Exercise Settings ................................................................................................................. 30

3.4 Time Setup (1-Phase ATS)................................................................................................... 34

3.5 Brightness and Contrast ....................................................................................................... 38

3.6 History and About Menu ....................................................................................................... 40

3.7 Fault Log ............................................................................................................................... 42

3.8 Operating Modes .................................................................................................................. 44

3.9 Selecting Operating Modes................................................................................................... 44

4. OPERATION ................................................................................................................................ 51

4.1 Safety Considerations........................................................................................................... 51

4.2 Introduction ........................................................................................................................... 52

4.3 Maintenance ......................................................................................................................... 52

4.4 Operating Recommendations ............................................................................................... 52

4.5 Generator Set Operation....................................................................................................... 54

5. MAINTENANCE ........................................................................................................................... 65

5.1 Maintenance Safety .............................................................................................................. 65

5.2 Periodic Maintenance ........................................................................................................... 68

5.3 Engine Oil ............................................................................................................................. 76

5.4 Air Intake System.................................................................................................................. 81

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Table of Contents 7-2018

5.5 Generator Set Output - AC Electric System Checks ............................................................ 84

5.6 DC Electrical System ............................................................................................................ 85

5.7 Batteries ................................................................................................................................ 86

5.8 Spark Plugs .......................................................................................................................... 89

5.9 Cleaning the Generator Set Housing.................................................................................... 90

5.10 Complete System Test ...................................................................................................... 90

6. TROUBLESHOOTING ................................................................................................................. 91

6.1 Avoiding Generator Set Shutdowns ..................................................................................... 91

6.2 Control System ..................................................................................................................... 91

6.3 Fault Finding ......................................................................................................................... 91

6.4 Fault/Status Codes - PowerCommand 1.1 ........................................................................... 92

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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 and batteries.

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.

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

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 Inc. with specific generator sets. If this manual has been supplied in isolation, please contact your authorized dealer.

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

CAUTION

NOTICE

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1. IMPORTANT SAFETY INSTRUCTIONS 7-2018

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.

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 and maintenance can result in severe personal injury or

death. Do not operate equipment when fatigued, or after consuming any alcohol or

drug. Make sure that only suitably trained and experienced service personnel

perform electrical and/or mechanical service.

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

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

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1. IMPORTANT SAFETY INSTRUCTIONS7-2018

WARNING

Hot Surfaces Contact with hot surfaces can cause severe burns. The unit is to be installed so that the risk of hot surface contact by people is

minimized. Wear appropriate PPE when working on hot equipment and avoid contact with hot surfaces.

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

combustible liquids like ether.

WARNING

Combustible Gases Generator sets in operation have combustible gases under pressure, which

if ignited can cause eye and ear damage. Wear appropriate eye and ear protection at all times.

WARNING

Combustible Gases Generator sets in operation have combustible gases under pressure, which

if ignited can cause severe injury. Do not operate the generator set with any doors open.

WARNING

Fire Hazard Materials drawn into the generator set, as well as 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. Make sure the generator set is mounted in a manner to prevent combustible materials from accumulating under the unit.

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1. IMPORTANT SAFETY INSTRUCTIONS 7-2018

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).

NOTICE

Keep multi-type ABC fire extinguishers close by. 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 the applicable region.)

NOTICE

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

NOTICE

Stepping on the generator set can cause parts to bend or break, leading to electrical shorts, or to fuel leaks, coolant leaks, 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.

1.4 Moving Parts Can Cause Severe Personal Injury or Death

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

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1. IMPORTANT SAFETY INSTRUCTIONS7-2018

• 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.

1.5 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.

1.6 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.

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1. IMPORTANT SAFETY INSTRUCTIONS 7-2018

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 distributor for more information.

Spillage

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

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.

1.7 Batteries Can Explode

Batteries can explode, causing severe skin and eye burns and can release toxic electrolytes.

Combustible Gases Batteries can explode, causing severe skin and eye burns, and can release

toxic electrolytes. Do not dispose of the battery in a fire, because it is capable of exploding. Do

not open or mutilate the battery. Do not charge frozen batteries.

WARNING

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1. IMPORTANT SAFETY INSTRUCTIONS7-2018

WARNING

Electric Shock Hazard Batteries present the risk of high short circuit current. When servicing the generator set:

• Remove watches, rings, or other metal objects.

• Use tools with insulated handles.

NOTICE

Servicing of batteries must be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries.

• Wear safety glasses.

• Do not smoke.

• Do not charge frozen batteries.

• To prevent arcing when disconnecting the battery:

1. Press the Off switch from the display and then press the E-Stop button.

2. Disconnect AC power from any battery chargers.

3. Remove the negative (-) battery cables to prevent starting.

• To prevent arcing when reconnecting the battery:

1. Reconnect the positive (+) cables.

2. Reconnect the negative (-) cables.

3. Reconnect the battery charger to AC power supply.

• When replacing the generator set battery, always replace it with a battery as specified in this manual.

1.8 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. IMPORTANT SAFETY INSTRUCTIONS 7-2018

Exhaust Precautions

WARNING

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

WARNING

Hot Surfaces Contact with hot surfaces can cause severe burns. The unit is to be installed so that the risk of hot surface contact by people is

minimized. Wear appropriate PPE when working on hot equipment and avoid contact with hot surfaces.

WARNING

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.

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.

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1. IMPORTANT SAFETY INSTRUCTIONS7-2018

1.9 The Hazards of Carbon Monoxide

Carbon monoxide (CO) is an odorless, colorless, tasteless and non-irritating gas. You cannot see it or smell it. Red blood cells, however, have a greater affinity for CO than for oxygen. Therefore, exposure even to low levels of CO for a prolonged period can lead to asphyxiation (lack of oxygen) resulting in death. Mild effects of CO poisoning include eye irritation, dizziness, headaches, fatigue and the inability to think clearly. More extreme symptoms include vomiting, seizures and collapse.

Engine-driven generator sets produce harmful levels of carbon monoxide that can injure or kill you.

Special Risks of CO near the Home

WARNING

Toxic Gases Carbon monoxide (CO) gas can cause nausea, fainting, or death. Residents

can be exposed to lethal levels of CO when the generator set is running. Depending on air temperature and wind, CO can accumulate in or near the home.

To protect yourself and others from the dangers of CO poisoning, it is recommended that reliable, approved, and operable CO detector alarms are installed in proper locations in the home as specified by their manufacturer.

Protecting Yourself from CO Poisoning

• Locate the generator set in an area where there are no windows, doors, or other access points into the home.

• Make sure all CO detectors are installed and working properly.

• Pay attention for signs of CO poisoning.

• Check the exhaust system for corrosion, obstruction, and leaks every time you start the generator set and every eight hours when you run it continuously.

1.10 Earth Ground Connection

The neutral of the generator set may be required to be bonded to earth ground at the generator set location, or at a remote location, depending on system design requirements. Consult the engineering drawings for the facility or a qualified electrical design engineer for proper installation.

NOTICE

The end user is responsible to make sure that the ground connection point surface area is clean and free of rust before making a connection.

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1. IMPORTANT SAFETY INSTRUCTIONS 7-2018

NOTICE

The end user is responsible for making sure that an earthing arrangement that is compliant with local conditions is established and tested before the equipment is used.

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2 Introduction

2.1 Safety

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.

WARNING

2.2 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 Inc. cannot accept any liability whatsoever for problems arising as a result of following recommendations in this manual.

The information contained within the manual is based on information available at the time of going to print. In line with Cummins Inc. policy of continuous development and improvement, information may change at any time without notice. The users should therefore make sure that they have the latest information available before starting any work. 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 people to carry out any installation work. Consult your authorized dealer for further installation information. It is essential that the utmost care is taken with the application, installation, and operation of any generator set due to their potentially hazardous nature. Careful reference should also be made to other Cummins Inc. literature. You must operate and maintain your generator set properly if you are to expect safe and reliable operation.

For further assistance, contact your authorized Cummins Inc. dealer.

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2. Introduction 7-2018

NOTICE

This device complies with part 15 of the FCC rules. Operation is subject to the following two conditions:

• This device may not cause harmful interferences.

• This device must accept any interference received, including interference that may cause undesired operation.

2.3 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.

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 MPU Magnetic Pickup

ASTM American Society for

Testing and Materials (ASTM International)

ATS Automatic Transfer

Switch

AVR Automatic Voltage

Regulator

AWG American Wire Gauge NO Normally Open

CAN Controlled Area Network NWF Network Failure

CB Circuit Breaker OEM Original Equipment

CE Conformité Européenne OOR Out Of Range

MFM Multifunction Monitor

Mil Std Military Standard

NC Normally Closed

NC Not Connected

NFPA National Fire Protection

Agency

Manufacturer

CCA Cold Cranking Ampere OORH/

ORH

CFM Cubic Feet per Minute OORL/ORL Out Of Range Low

CGT Cummins Generator

Technologies

CMM Cubic Meters per Minute PCC PowerCommand®Control

PB Push Button

Out Of Range High

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2. Introduction7-2018

Abbr. Description Abbr. Description

CT Current Transformer PGI Power Generation

Interface

DC Direct Current PGN Parameter Group

Number

DEF Diesel Exhaust Fluid PI Proportional/Integral

DPF Diesel Particulate Filter PID Proportional/Integral/

Derivative

EBS Excitation Boost System PLC Programmable Logic

Controller

ECM Engine Control Module PMG Permanent Magnet

Generator

ECS Engine Control System PPE Personal Protective

Equipment

EMI Electromagnetic

PT Potential Transformer

Interference

EN European Standard PTC Power Transfer Control

EPS Engine Protection

PWM Pulse-Width Modulation

System

E-Stop Emergency Stop RFI Radio Frequency

Interference

FAE Full Authority Electronic RH Relative Humidity

FMI Failure Mode Identifier RMS Remote Monitoring

System

FSO Fuel Shutoff RMS Root Mean Square

Genset Generator Set RTU Remote Terminal Unit

GCP Generator Control Panel SAE Society of Automotive

Engineers

GND Ground scfh Standard Cubic Feet of

gas per Hour

HMI Human-Machine

Interface

SCR Selective Catalytic

Reduction

IC Integrated Circuit SPN Suspect Parameter

Number

ISO International Organization

SW_B+ Switched B+

for Standardization

LBNG Lean-Burn Natural Gas UL Underwriters

Laboratories

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2. Introduction 7-2018

Abbr. Description Abbr. Description

LCD Liquid Crystal Display UPS Uninterruptible Power

Supply

LCT Low Coolant

Temperature

2.4 Related Literature

The literature provided with the generator set is as follows:

• Installation Manual (A045R241)

• Operator Manual (A045R242)

CAUTION

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)

• Warranty Statement (A040H442)

• Emissions Component Defect Warranty Statement (A028X278)

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

• Service Manual (A045R243)

• Parts Manual (A046Z094)

• EControls, Inc. Service Manual (A035C596)

• Global Control Platform (GCP) Engine Display Interface Software (EDIS) Training Manual (A035C608)

• RA Series Transfer Switch Owner Manual (A046S594) (if applicable)

• PowerCommand® 1302 Controller Owner's Manual (900-0661)

• Standard Repair Times (SRT) Manual (A046Z674)

• Application Manual T-030 - for application information (A040S369)

• Service Tool Manual (A043D529)

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2. Introduction7-2018

2.5 Model Specifications

TABLE 1. 2.4L MODEL VARIATIONS

Models Description

C20 N6, C22 N6, C25 N6, C30 N6, C36 N6, C40 N6 60 Hz, 1800 RPM

C30 N6H, C36 N6H, C40 N6H, C45 N6H, C50 N6H, C60 N6H 60 Hz, 3600 RPM

TABLE 2. COLD WEATHER SPECIFICATIONS (ALL MODELS)

Temperature Description Battery Type Group

Above 4 °C (40 °F) No starting aids required. Standard 26

Additional coolant heater and

-17 to 4 °C (0 to 40 °F)

Below -17 °C (0 °F)

battery charger recommended for starting. Factory options available.

All starting aides (battery heater, coolant heater, battery charger) recommended. Factory options available.

Standard 26

Larger 34

NOTICE

For NFPA 110 applications, a coolant heater is required. A factory option is available.

TABLE 3. FUEL SPECIFICATIONS 60 HZ, 1800 RPM

C20 N6 C22 N6 C25 N6 C30 N6 C36 N6 C40 N6

Full Load (Propane)

Full Load (Natural Gas)

Fuel Pressure 6-13 inches of water column (1.5 - 3.2 kPa) under any condition

105.1 scfh 265,000

BTU/hr

259.6 scfh 270,000

BTU/hr

112.7 scfh 285,000

BTU/hr

278.8 scfh 290,000

BTU/hr

125.4 scfh 315,000

BTU/hr

309.5 scfh 320,000

BTU/hr

164.1 scfh 410,000

BTU/hr

380.9 scfh 395,000

BTU/hr

182.7 scfh 460,000

BTU/hr

472.3 scfh 490,000

BTU/hr

193.6 scfh 490,000

BTU/hr

519 scfh

540,000

BTU/hr

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2. Introduction 7-2018

TABLE 4. FUEL SPECIFICATIONS 60 HZ, 3600 RPM

C30 N6H C36 N6H C40 N6H C45 N6H C50 N6H C60 N6H

Full Load (Propane)

Full load (Natural Gas)

195.5 scfh 490,000

BTU/hr

476.1 scfh 495,000

BTU/hr

219.6 scfh 550,000

BTU/hr

533.3 scfh 555,000

BTU/hr

236.2 scfh 595,000

BTU/hr

573.2 scfh 595,000

BTU/hr

256.9 scfh 645,000

BTU/hr

623.0 scfh 645,000

BTU/hr

289.5 scfh 725,000

BTU/hr

704.7 scfh 730,000

BTU/hr

324.6 scfh 820,000

BTU/hr

814.2 scfh 840,000

BTU/hr

Fuel Pressure 6-13 inches of water column (1.5 - 3.2 kPa) under any condition

TABLE 5. ENGINE SPECIFICATIONS (ALL MODELS)

Specification Value

Engine 4 cylinder-in-line, SOHC, liquid-cooled, 4-stroke, spark ignited

Displacement 2351 cc (144 in3)

Spark Plug Gap

1.0 mm (0.040 in) (NA)

0.76 mm (0.030 in) (T/TAA)

Spark Plug Torque 20 Nm (15 ft-lb)

Coolant 50/50 coolant solution (50% pure water and 50% ethylene glycol)

High Crankcase Pressure No higher than 1.5 kPa

Compression

135 psi (dry test) or higher with less than 15 psi range between cylinders

Oil Capacity 4.3 L (4.54 quarts)

Oil Recommendation 5W30 API SM or newer

TABLE 6. GENERATOR SET SIZE SPECIFICATIONS WITH SOUND LEVEL 1

ENCLOSURE (L X W X H)

kW RPM mm in

20-25 1800

1830 x 864 x 1152 72 x 34 x 45.2

30 3600

30-40 1800

2384 x 864 x 1152 94 x 34 x 45.2

36-60 3600

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2. Introduction7-2018

TABLE 7. GENERATOR SET WEIGHT 60 HZ, 1800 RPM

Sound Level 1 (Wet) C20 N6 C22 N6 C25 N6 C30 N6 C36 N6 C40 N6

kg 503 503 520 580 615 646

lb 1109 1109 1147 1279 1356 1424

TABLE 8. GENERATOR SET WEIGHT 60 HZ, 3600 RPM

Sound Level 1 (Wet) C30 N6H C36 N6H C40 N6H C45 N6H C50 N6H C60 N6H

kg 514 567 635 635 635 648

lb 1134 1249 1399 1399 1399 1429

TABLE 9. ALTERNATOR SPECIFICATIONS 60 HZ, 1800 RPM

C20 N6 C22 N6 C25 N6 C30 N6 C36 N6 C40 N6

Alternator Brushless, 4-pole rotating field, single bearing

Power (kVa):

1-Phase 20 22 25 30 36 40

3-Phase 25 27.5 31.3 37.5 45 50

Rated Voltages (V):

1-Phase 120/240

120/240

3-Phase

120/208 277/480 347/600

TABLE 10. ALTERNATOR SPECIFICATIONS 60 HZ, 3600 RPM

C30 N6H C36 N6H C40 N6H C45 N6H C50 N6H C60 N6H

Alternator Brushless, 2-pole rotating field, single bearing

Power (kVa):

1-Phase 30 36 40 45 50 60

3-Phase 37.5 45 50 56.3 62.5 75

Rated Voltages (V):

1-Phase 120/240

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2. Introduction 7-2018

C30 N6H C36 N6H C40 N6H C45 N6H C50 N6H C60 N6H

120/240

3-Phase

120/208 277/480

NOTICE

Maximum I2= 8%.

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TABLE 11. GENERATOR SET DERATING GUIDELINES

Engine Power Available Up To... Derate At…

2. Introduction7-2018

Model Fuel Elevation

Ambient

Temperature

C20 N6 NG, LP 1005 m (3300 ft) 40 °C (104 °F)

C22 N6 NG 670.5 m (2200 ft) 40 °C (104 ° F)

C22 N6 LP 1005 m (3300 ft) 40 °C (104 °F)

C25 N6 NG 0 m (0 ft) 25 °C (77 °F)

C25 N6 LP 114 m (375 ft) 25 °C (77 °F)

C30 N6 NG 762 m (2500 ft) 40 °C (104 ° F)

C30 N6 LP 1005 m (3300 ft) 40 °C (104 °F)

C36 N6 NG, LP 1005 m (3300 ft) 40 °C (104 °F)

C40 N6 NG, LP 114 m (375 ft) 40 °C (104 °F)

C30 N6H NG, LP 945 m (3100 ft) 40 °C (104 °F)

C36 N6H NG, LP 1005 m (3300 ft) 40 °C (104 °F)

Elevation Temperature

2% per 10 °C

(18 °F)

above 40 °C

(104 °F)

2% per 10 °C

(18 °F)

above 25 °C

(77 °F)

4% per

305 m

(1000 ft)

2% per 10 °C

(18 °F)

above 40 °C

(104 °F)

C40 N6H NG, LP 1005 m (3300 ft) 40 °C (104 °F)

C45 N6H LP 1005 m (3300 ft) 40 °C (104 °F)

C45 N6H NG, LP 914 m (3000 ft) 40 °C (104 °F)

C50 N6H NG, LP 114 m (375 ft) 25 °C (77 °F)

C60 N6H NG, LP 114 m (375 ft) 40 °C (104 °F)

TABLE 12. CONTROL SPECIFICATION (ALL MODELS)

Specification

Integrated microprocessor based engine, generator, transfer switch control

2% per 10 °C

(18 °F)

above 25 °C

(77 °F)

2% per 10 °C

(18 °F)

above 40 °C

(104 °F)

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2. Introduction 7-2018

TABLE 13. DC SYSTEM SPECIFICATIONS (ALL MODELS)

Specification Value

Nominal Battery Voltage 12 VDC

Battery Group

Battery Type Maintenance free

Minimum Cold Crank Amps

26 standard, 34 high capacity (a high capacity battery requires an accessory battery tray)

545 standard, 850 high capacity (a high capacity battery requires an accessory battery tray)

2.6 After Sales Services

Cummins offers a full range of maintenance and warranty services.

Maintenance

Electrical Generating Equipment Incorrect service or parts replacement can result in severe personal injury,

death, and/or equipment damage. Make sure service personnel are qualified to perform electrical and

mechanical service.

WARNING

For expert generator set service at regular intervals, contact your Cummins Inc. service provider. See power.cummins.com/sales-service-locator for service locations that service this application. Maintenance tasks should only be undertaken by trained and experienced technicians provided by your Cummins Inc. service provider.

Warranty

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

Extended warranty coverage is also available. 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.

For further warranty details, contact your authorized dealer.

NOTICE

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

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2. Introduction7-2018

Warranty Limitations

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

How to Obtain Service

For parts, service, and product information, contact the nearest authorized Cummins Inc. dealer. To easily locate the nearest certified distributor/dealer for Cummins generator sets in your area, or for more information, contact us at 1-800CUMMINSTM(1-800-286-6467) or visit www.cummins.com/support.

Generator Set Nameplate

WARNING

Electrical Generating Equipment Improper service or replacement of parts can lead to severe personal

injury or death and to damage to equipment and property. Make sure service personnel are qualified to perform electrical and

mechanical service.

Model

Spec

Serial Number

NOTICE

Unauthorized modifications or replacement of fuel, exhaust, air intake or speed control system components that affect engine emissions are prohibited by law in the State of California.

Model, Spec, and Serial Numbers: Be ready to provide the model, spec, and

serial numbers on the generator set nameplate when contacting Cummins Inc. for information, parts, and service. The nameplate is located on the inside of the customer access door on enclosed generator sets.

Record these numbers so that they are easy to find when needed. Each character in these numbers is significant for obtaining the right parts listed in the Parts Catalog. Genuine Cummins Inc. replacement parts are recommended for best results.

My Generator Set Information

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2. Introduction 7-2018

Manufacturing Facilities

Facility Address Phone Numbers

U.S. and CANADA

Cummins Inc. 1400 73rd Ave. NE Minneapolis, MN 55432 USA

Toll Free 1-800-CUMMINS (1-800-286-6467) Phone +1 763-574-5000 Fax +1 763-574-5298

EMEA, CIS Cummins Inc.

Columbus Avenue Manston Park Manston, Ramsgate Kent CT12 5BF United Kingdom

----------Cummins Inc. Royal Oak Way South Daventry Northamptonshire NN11 8NU United Kingdom

ASIA PACIFIC

Cummins Inc. 10 Toh Guan Road #07-01 TT International Tradepark Singapore 608838

BRAZIL Rua Jati, 310, Cumbica

Guarulhos, SP 07180-900 Brazil

Phone +44 1843 255000 Fax +44 1843 255902

Phone +65 6417 2388 Fax +65 6417 2399

Phone +55 11 2186 4195 Fax +55 11 2186 4729

CHINA Cummins Inc.

2 Rongchang East Street, Beijing Economic – Technological Development Area Beijing 100176, P.R. China

INDIA Cummins Inc.

Plot No B-2, SEZ Industrial Area, Village-Nandal & Surwadi, Taluka- Phaltan Dist- Satara, Maharashtra 415523 India

LATIN AMERICA

3350 Southwest 148th Ave. Suite 205 Miramar, FL 33027 USA

Phone 86 10 59023001 Fax +86 10 5902 3199

Phone +91 021 66305514

Phone +1 954 431 551 Fax +1 954 433 5797

Page 27

Facility Address Phone Numbers

MEXICO Eje 122 No. 200 Zona Industrial

San Luis Potosi, S.L.P. 78395

Phone +52 444 870 6700 Fax +52 444 824 0082

Mexico

2. Introduction7-2018

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This page is intentionally blank.

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3 Control System

3.1 Control System Description

The control system is used to start and stop the generator set, and provides full generator set monitoring capability and protection in a stand-alone situation (nonparalleling) from the display screen. It monitors the engine for temperature, as well as oil pressure and speed. It also provides voltage and current metering. In the event of a fault, the unit indicates the fault type and, on critical faults, automatically shuts down the generator set.

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

There are three fault level signals generated by the control system:

• Event: Signals that a temporary condition exists.

• 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 VDC (or 24 VDC if applicable) battery power. History data is stored in non-volatile memory and is not deleted if battery power is lost.

Standard Operator Panel

The operator panel includes indicator lights (LEDs), display buttons used to navigate through the menus, control mode buttons, and an LCD display. The display enables the operator to check the status, adjust the settings, and start and stop the generator set. The standard operator panel (show below) is located on every generator set. An optional remote display operator panel accessory is also available.

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FIGURE 1. STANDARD OPERATOR PANEL (HMI211)

Standard Key Functions (HMI211)

The user interface includes two fixed action buttons and four soft key buttons. The action of the soft key buttons changes to meet the requirements of each screen.

TABLE 14. KEY FUNCTIONS

Key/Symbol Action

Switches to Off mode (fixed action button).

Switches to Auto mode.

Switches to Manual Run mode.

Navigates to the previous menu level (fixed action button).

(Up Arrow) Navigates to the previous screen/menu in a list.

(Down Arrow) Navigates to the next screen/menu in a list.

and Hold the up and down arrows simultaneously for two seconds from any

Info Menu to navigate to the Menu screen.

Save Saves changes and navigates to the associated screen.

Adjust Navigates to the Adjust Menu of a specific menu.

(Right Arrow) Advances the highlighted field to the next editable field.

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Key/Symbol Action

- Decreases value of the highlighted editable field.

+ Increases value of highlighted editable field.

Standard LED Indicators (HMI211)

The operator panel has six LED indicators. Colors, flashing frequency, and conditions to turn them on/off/blink are included in the table below.

TABLE 15. LED INDICATORS

LED Color Action

Not in Auto Red Indicates the generator set is in Manual or Off Mode.

Shutdown Red Indicates a Shutdown Fault has occurred.

Warning Yellow Indicates a Warning Fault has occurred.

3. Control System7-2018

Remote Start

Auto Green Indicates that the generator set is in Auto Mode. The generator starts

Manual Run Green Indicates that the generator set has received a Manual Run

Green Indicates that the generator set has received a Remote Start

Command.

when it receives a Remote Start Command.

Command.

In-Home Operator Panel (Accessory)

The in-home operator panel is an optional display that may be purchased. This panel is intended to serve as a convenience option to the standard operator panel mounted on the generator set.

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FIGURE 2. IN-HOME OPERATOR PANEL

Key Functions (In-Home Operator Panel)

The user interface includes two fixed action buttons and four soft key buttons. The action of the soft key buttons changes to meet the requirements of each screen.

TABLE 16. KEY FUNCTIONS

Key/Symbol Action

Stop Switches to Off mode. This key works from any screen (fixed action

button).

(Up Arrow) Navigates to the previous screen/menu in a list.

(Down Arrow) Navigates to the next screen/menu in a list.

and Hold the up and down arrows simultaneously for two seconds from any Info

Menu to navigate to the Service Menu.

Back Navigates to the previous screen/menu in a list (fixed action button). In

Adjust screens, settings are not saved.

Save Saves changes and navigates to the associated screen.

Adjust Navigates to the Adjust Menu of a specific menu.

(Right Arrow) Advances the highlighted field to the next editable field.

- Decreases value of the highlighted editable field.

+ Increases value of highlighted editable field.

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LED Indicators (In-Home Operator Panel)

The operator panel has five LED indicators. Colors, flashing frequency, and conditions to turn them on/off/blink are included in the table below.

TABLE 17. LED INDICATORS

LED Color Action

Shutdown Red Indicates a Shutdown Fault has occurred.

Warning Yellow Indicates a Warning Fault has occurred.

Auto Start Green Indicates that the generator set has received a Remote Start

Command.

Auto Green Indicates that the generator set is in Auto Mode. The

generator starts when it receives a Remote Start Command.

Manual Run Green Indicates that the generator set has received a Manual Run

Command.

3.2 Display Text or Symbolic Version

The operator panel graphical display can be set to show text (English only) or symbols for fault messages, operator menus, and the Mode Change Menu. Descriptions of commonly used symbols are included in the following table. Combinations of symbols are used to display some fault conditions.

When shipped from the factory, the display is set to display symbols. Qualified service personnel are required to change the default setting.

TABLE 18. SYMBOLS

Symbol Text

Generator Warning Fault

Generator Shutdown Fault

Coolant Temperature

Oil Pressure

Voltage Alternating Current (VAC)

Voltage Direct Current (VDC)

AC Current

Hz Frequency

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3. Control System 7-2018

Symbol Text

Battery

Out of Range

High or Pre-High

Low or Pre-Low

Annunciator

Over Speed

Crank Fail

Emergency Stop

3.3 Exercise Settings

When battery power is lost, these settings must be reset.

Not applicable without a single phase RA series transfer switch.

To access the Clock/Exerciser Menu:

1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears.

2. Navigate through the screens to find and select Clock/Excr in the Service Menu.

The following screens represent the standard operator panel (that is, HMI211). If using an in-home operator panel, which may be additionally purchased as an option, the screens may look slightly different. This procedure applies to both operator panels.

NOTICE

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FIGURE 3. CLOCK/EXERCISER MENU NAVIGATION

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Updating Exercise Frequency (1-Phase ATS)

NOTICE

Not applicable without a single phase RA series transfer switch.

To update the exercise frequency and dates on the Clock/Exerciser Menu:

1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears.

2. Access the Time Setup screen by selecting Clock Exerciser on the Genset Service Menu.

3. Press the down key on the Time Setup screen to access the Daylight Saving Adjust screen.

4. Select Adjust.

5. Press the down key on the Daylight Saving Adjust Start screen.

6. Select Adjust.

7. Press Exercise Schdr on the Daylight Saving Adjust End screen.

8. Press Adjust.

When updating these settings, the functions of the keys are as follows:

• The horizontal right arrow key is used to select successive blocks for editing settings on the screen.

• Use the + or - keys to edit the following settings:

◦ Schdr Enable: Enable or Disable

◦ Exercise Schedule: Semi-Annual (every six months), Quarterly, Monthly,

Bi-Monthly (the first and third week of every month based on the time set when the Bi-Monthly option is selected), or Weekly

◦ Exercise Schedule: Day, Hours, Minutes, AM/PM

• Press Save to save any changes. After saving, the Save button changes to the Adjust button.

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FIGURE 4. EXERCISE FREQUENCY NAVIGATION

3. Control System7-2018

Updating Exercise Duration (1-Phase ATS)

NOTICE

Not applicable without a single phase RA series transfer switch.

To update the exercise duration on the Clock/Exerciser Menu:

1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears.

2. Access the Time Setup screen by selecting Clock Exerciser on the Genset Service Menu.

3. Press the down key on the Time Setup screen to access the Daylight Saving Adjust screen.

4. Select Adjust.

5. Press the down key on the Daylight Saving Adjust Start screen.

6. Select Adjust.

7. Press Exercise Schdr on the Daylight Saving Adjust End screen.

8. Press the down key on the Exercise Schdr Menu.

9. Press Adjust.

When updating these settings, the functions of the keys are as follows:

• The horizontal right arrow key is used to select the duration block for editing exercise duration.

• Use the + or - keys to edit the exercise duration minutes.

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• Press Save to save any changes. After saving, the Save button changes to the Adjust button.

FIGURE 5. EXERCISE DURATION NAVIGATION

3.4 Time Setup (1-Phase ATS)

NOTICE

When battery power is lost, these settings must be reset.

NOTICE

Not applicable without a single phase RA series transfer switch.

To set up the generator set clock for the current date and time:

1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears.

2. Access the Time Setup screen by selecting Clock Exerciser on the Genset Service Menu.

3. Select Adjust.

When updating these settings, the functions of the keys are as follows:

• The horizontal right arrow key is used to select successive blocks for editing settings on the screen.

• Select the left arrow to return to the previous screen.

• Adjust values by using the + or - keys on the Adjust Menu of the Time Setup screen.

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• Press Save to save any changes. After saving, the Save button changes to the Adjust button.

FIGURE 6. TIME SETUP SCREEN

Updating Daylight Saving Adjust Screens

Update Values on the Daylight Saving Adjust Screen

1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears.

2. Navigate to the Genset Service Menu.

3. Select Clock Exerciser to access the Time Setup screen.

4. Press the down key on the Time Setup screen to access the Daylight Saving Adjust screen.

5. Select Adjust. When updating these settings, the functions of the keys are as follows:

TABLE 19. KEY FUNCTIONS ON THE DAYLIGHT SAVING ADJUST SCREEN

Key/Button Function

Horizontal right arrow key Select successive blocks for editing settings on the screen

Left arrow key Return to the previous screen

+ or - keys Adjust values on the Adjust screen of the Daylight Saving Adjust

screen

Save button Save any changes; after saving, the Save button changes to the

Adjust button

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3. Control System 7-2018

FIGURE 7. "DAYLIGHT SAVING ADJUST SAVING TIME" SCREEN NAVIGATION

Access and Update the Daylight Saving Adjust Start Screen

1. Press the down arrow key on the Daylight Saving Adjust screen.

2. Press Adjust. When updating these settings, the functions of the keys are as follows:

TABLE 20. KEY FUNCTIONS ON THE DAYLIGHT SAVING ADJUST START SCREEN

Key/Button Function

Horizontal right arrow key Select successive blocks for editing settings on the screen

+ or - keys Adjust Month, Week, Day or Hour

Save button Save any changes; after saving, the Save button changes to the

Adjust button

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FIGURE 8. DAYLIGHT SAVING ADJUST START SCREEN

3. Control System7-2018

Update the Daylight Saving Adjust End Screen

1. Press the down key on the Daylight Saving Adjust Start screen.

2. Press Adjust. When updating these settings, the functions of the keys are as follows:

TABLE 21. KEY FUNCTIONS ON THE DAYLIGHT SAVING ADJUST END SCREEN

Key/Button Function

Horizontal right arrow key Select successive blocks for editing settings on the screen

+ or - keys Adjust Month, Week, Day or Hour

Save button Save any changes; after saving, the Save button changes to the

Adjust button

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3. Control System 7-2018

FIGURE 9. DAYLIGHT SAVING ADJUST END SCREEN

3.5 Brightness and Contrast

The Screen Adjust screen allows the contrast, brightness, and units to be set. To access the Screen Adjust screen:

1. From any Information screen, hold down the up and down arrows simultaneously for two seconds to gain access to the Service Menu screen.

2. Select Screen Adjust.

To adjust the contrast, brightness, or units from the Screen Adjust screen:

1. From the Screen Adjust screen, select Adjust to access the screen variables.

2. Press the right arrow to move between the variables.

3. Adjust settings, and press Save to save any changes.

When updating these settings, the functions of the keys are as follows:

• The horizontal right arrow key is used to select successive blocks for editing settings on the screen.

• Select the left arrow to return to the previous screen.

• Adjust values by using the + or - keys on the Adjust screen of the Display Setup screen.

• Press Save to save any changes. After saving, the Save button changes to the Adjust button.

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3. Control System7-2018

NOTICE

The following screens represent the standard operator panel (HMI211). If using an in-home operator panel, which may be additionally purchased as an option, the screens may look slightly different. This procedure applies to both operator panels.

FIGURE 10. BRIGHTNESS AND CONTRAST SCREEN NAVIGATION

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3. Control System 7-2018

NOTICE

Adjusting the brightness on the operator panel adjusts the brightness of both the LCD backlight and the LEDs on the display. The contrast should never be 0 or 100% on any of the screens. The default value for Brightness is 50%.

3.6 History and About Menu

To access the History/About screen:

1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears.

2. Select History/About.

3. Advance through the screens to view information about the generator set, control, and display.

NOTICE

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3. Control System7-2018

FIGURE 11. HISTORY/ABOUT MENU

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3. Control System 7-2018

3.7 Fault Log

To check the fault log:

1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears.

2. Select Fault History.

NOTICE

The active faults are displayed first. If there are no active faults, this screen is skipped. Following the Active Faults screen are the Fault History screens. These screens display the faults in chronological order from newest to oldest.

NOTICE

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3. Control System7-2018

FIGURE 12. FAULT LOG SCREEN

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3. Control System 7-2018

3.8 Operating Modes

The generator set's PowerCommand®control has Manual Run, Off, and Auto operating modes that are available from the operator panel.

Off Mode

When in the Off mode, the control does not allow the generator set to start.

If the generator set is running in either Manual Run or Auto mode and the Off button is pressed, the control immediately stops the generator set, and the control transitions to the Off mode.

Pressing the Off mode button resets all active faults.

Manual Run Mode

When in Manual Run mode, the generator set starts and continues to run until the control is put into the Off mode. While in Manual Run mode, the remote start signal is ignored.

Auto Mode

When in Auto mode, the control allows the generator set to be started at any time with a remote signal only. When a remote start signal is received, the generator set starts after a time delay start is completed (default delay is zero seconds).

When all remote start signals are removed, the control performs a normal shutdown sequence which includes a time delay stop (default delay is five minutes).

If the generator set is running in Auto mode and the Off button is pressed, the control immediately stops the generator set and the control transitions to the Off mode.

3.9 Selecting Operating Modes

Selecting Manual Run Mode

WARNING

Electrical Generating Equipment When changing modes, the generator set can start or stop without warning

(for example, Auto Mode may have been selected with no mains (utility) power available).

Make sure there is no danger to personnel or equipment, if the generator set starts or stops when changing modes.

1. Before proceeding to change the mode, make sure that it is safe to do so.

2. Press the Manual Run button on any of the Operator menus or the "Establishing/Re-establishing communication with control" menus.

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3. Control System7-2018

3. If the Mode Change Access Code menu is enabled, the Mode Change Access Code is displayed. Enter the Mode Change Access Code.

4. A menu with alternating arrows is displayed above a second symbol.

5. Press the second Manual Run button, and the generator set will now begin the Manual start sequence. The Operator menu that was displayed before

Manual Run mode was selected is re-displayed, but with the symbol blacked out.

NOTICE

To disable Manual Run mode, press the Off button.

NOTICE

Auto mode can also be selected while in Manual Run mode. Switching to Auto mode may result in the generator set shutting down.

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3. Control System 7-2018

No. Description No. Description

1 Menu Displayed Only When the Mode

3 Manual Run Mode Selected Change Access Code Feature Is Enabled

2 Alternating Arrows Displayed

FIGURE 13. SELECTING MANUAL RUN MODE

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3. Control System7-2018

Selecting Auto Mode

WARNING

Electrical Generating Equipment When changing modes, the generator set can start or stop without warning

(for example, Auto Mode may have been selected with no mains (utility) power available).

Make sure there is no danger to personnel or equipment, if the generator set starts or stops when changing modes.

To switch to Auto mode (see Figure 14 on page 48),

1. Ensure that it is safe to do so before proceeding to change the mode.

2. Press the Auto button on any of the Operator menus, or the ‘Establishing/Re-establishing communication with control’ menus.

3. If the mode change access code feature is enabled, the Mode Change Access Code menu is displayed. Enter the Mode Change Access Code.

4. A menu with alternating arrows will then be displayed above a second Auto symbol.

5. Press this second Auto button. The Operator menu that was displayed before Auto mode was selected is re-displayed, but with the Auto symbols

blacked out and Manual Run symbols visible.

To disable Auto mode, press the Off button.

The generator set is now ready to receive a remote start signal that will initiate the Auto run mode.

WARNING

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.

NOTICE

Manual Run mode can also be selected FROM Auto mode. Switching to Manual Run mode results in the generator set starting up.

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3. Control System 7-2018

No. Description No. Description

1 This Menu Is Displayed Only if the

3 Auto Mode Selected Mode Change Access Code Feature Is Enabled

2 Alternating Arrows Are Displayed

FIGURE 14. SELECTING AUTO MODE

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3. Control System7-2018

Selecting Off Mode

WARNING

Electrical Generating Equipment When changing modes, the generator set can start or stop without warning

(for example, Auto Mode may have been selected with no mains (utility) power available).

Make sure there is no danger to personnel or equipment, if the generator set starts or stops when changing modes.

To switch to Off mode (see the figure below),

1. Make sure that it is safe to do so before proceeding to stop the set.

2. Press the Off button on any of the Operator menus or the "Establishing/Reestablishing communication with control" menus.

3. If the Mode Change Access Code is enabled, the Mode Change Access Code will be displayed. Enter the Mode Change Access Code.

4. On entering the last correct digit, the basic screen will re-appear, and the set will stop without a Time Delay to Stop.

NOTICE

Make sure that there is no danger to personnel or equipment if the generator set is stopped.

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3. Control System 7-2018

No. Description No. Description

1 Off Button 2 This Mode Is Displayed Only if the

Mode Change Access Code Feature Is Enabled

FIGURE 15. SELECTING OFF MODE

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4 Operation

4.1 Safety Considerations

Hazardous Voltage Contact with high voltages can cause severe electrical shock, burns, or

death. Make sure that only personnel who are trained and qualified to work on this

equipment are allowed to operate the generator set and perform maintenance on it.

Automated Machinery Accidental or remote starting of the generator set can cause severe personal

injury or death. Make sure that the generator set cannot be started accidentally or remotely

before starting work on the generator.

WARNING

Combustible Gases Ignition of battery gases is a fire and explosion hazard which can cause

severe personal injury or death. Do not smoke, or switch the trouble light ON or OFF near a battery. Touch a

grounded metal surface first before touching batteries to discharge static electricity. Stop the generator set and disconnect the battery charger before disconnecting battery cables. Using an insulated wrench, disconnect the negative (–) cable first and reconnect it last.

CAUTION

Hazardous Voltage Contact with high voltages can cause severe electrical shock, burns, or

death. Isolate all external electrical supplies prior to access of the control panel.

Internal components have live exposed terminations even when the generator set is not running.

NOTICE

Isolator switch only: Do not open the output box while the generator set is

running as the isolator switch will cause the generator set to shut down. Keep the output box covers in place during troubleshooting.

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4. Operation 7-2018

NOTICE

Always disconnect a battery charger from its AC source before disconnecting the battery cables. Failure to do so can result in voltage spikes high enough to damage the DC control circuits of the generator set.

NOTICE

Ventilate the battery area before working on or near the battery. Wear goggles. Stop the generator set and disconnect the battery charger before disconnecting the battery cables using an insulated wrench. Disconnect the negative (–) cable first and reconnect it last.

All maintenance tasks must be assessed for health and safety risks; the preventive measures identified must be performed. An additional person is required for any task where doing so significantly adds to the safety of the task.

The installation of a generator set can be designed for remote starting. When troubleshooting a generator set that is shut down, make sure that the generator set cannot be accidentally re-started. Refer to the Locking the Generator Set Out of Service section.

4.2 Introduction

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

All indicators, control switches/buttons, and graphical display are located on the face of the Operator Panel.

4.3 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 the Maintenance chapter.

4.4 Operating Recommendations

Running-In

Refer to the Maintenance section of this manual. 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.

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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.

Low Operating Temperatures

NOTICE

Operating engines at idle (650 to 1000 rpm) in cold ambient temperatures wastes fuel, accelerates wear, and can result in serious engine damage. Under low temperature conditions, incomplete combustion will occur, allowing deposits of unburned tars and carbon to buildup on the valve guide and valves, and eventually cause valve sticking.

In cold climates it is critical that the following items be appropriately maintained and selected based on ambient operating temperatures. Check to be sure:

• The battery is properly sized.

• An appropriate mixture of antifreeze is used in the cooling system.

• The proper grade of fuel is being used.

• The correct weight of engine oil is being used.

Use a coolant heater if a separate source of power is available. The optional heater available from Cummins will help provide reliable starting under adverse weather conditions. Make sure the voltage of the separate power source is correct for the heater element rating.

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.

General Operating Conditions

The area surrounding the generator set is critical for safety and its performance. Follow the guidelines below.

• Do not stack anything on top of the generator set.

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4. Operation 7-2018

• Do not store anything inside of the generator set.

• Keep areas clear in front of the cool air in and hot air out (free of obstructions, debris, plants, etc.).

NOTICE

All maintenance procedures must be performed or supervised by authorized and trained service personnel only.

4.5 Generator Set Operation

WARNING

Combustible Vapors Do not operate an engine where there are or can be combustible vapors. These vapors can be sucked through the air intake system and cause engine

acceleration and overspeeding, which can result in a fire, an explosion, personal injury and extensive property damage.

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

Cummins Inc. does not know how you will use your generator set. The equipment owner and operator, therefore, is responsible for safe operation in the installation site environment. Consult your authorized Cummins dealer for further information.

NOTICE

Diesel engines only: Cummins Inc. 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.

Sequence of Operation

NOTICE

The following sequences are based on an approximate time duration. Your generator set may vary slightly from the timing diagrams in this manual. All referenced times are based on default control settings. The following sequences are applicable to generator sets connected to an RA series transfer switch.

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Power Outage Sequence

The sequence of operation after a power outage (when the generator set is in Auto Mode) is as follows:

1. In normal operation, the utility power is running to the transfer switch and then to the building load, and the generator set is off.

2. The utility power turns off (power outage).

3. One second after the power outage, the transfer switch sends the command to the generator set to start.

4. The generator set starts and provides voltage to the transfer switch, but the transfer switch does not switch (allowing the voltage to go to the building) until after a delay.

FIGURE 16. TIME REMAINING UNTIL TRANSFER SCREEN

5. Five seconds after starting, the generator set provides a signal to the transfer switch to transfer the building load to the generator set.

FIGURE 17. BUILDING LOAD TRANSFER IN PROCESS

6. The transfer switch switches the generator set power to the building load. The building is now running on generator power.

FIGURE 18. GENERATOR SET POWERING BUILDING LOAD

7. When the utility power is back and providing voltage to the transfer switch, the transfer switch waits for utility power stability.

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4. Operation 7-2018

FIGURE 19. TIME REMAINING UNTIL RE-TRANSFER

8. When the utility power is stable for 5 minutes, the transfer switch switches back to utility power.

FIGURE 20. BUILDING LOAD TRANSFER IN PROCESS

FIGURE 21. UTILITY POWERING BUILDING LOAD

9. The generator set runs for a 5-minute cooldown and shuts off.

FIGURE 22. TIME REMAINING UNTIL STOP

10. Normal operation resumes.

Exercise Sequence

The exercise sequence when the programmed exercise time is realized (the generator set is in Auto Mode) is as follows:

1. The generator set starts and runs.

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2. The Exerciser Scheduler On screen displays every 3 seconds and toggles between the existing Information screen that is displayed for 1 second.

FIGURE 23. EXERCISER SCHEDULER SCREEN AND INFORMATION SCREEN

TOGGLE - EXAMPLE

3. The transfer switch is not commanded to switch the building load to the generator set.

NOTICE

The user may navigate to other screens from the Information screens during this duration. No functional keys are active on the Exerciser Scheduler On screen.

4. The generator set stops after programmed exercise run time.

Manually Starting the Generator Set Sequence

If the generator set is manually started with the standard operator panel, HMI211 (the generator set is in Man Mode), the sequence is as follows:

NOTICE

Open the generator set main line circuit breaker to prevent the transfer switch from transferring building load to the generator set.

1. In normal operation, the utility power is running to the transfer switch and then to the building load, and the generator set is off.

2. Manually start the generator set via the standard control (HMI211) mounted on the generator set.

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4. Operation 7-2018

FIGURE 24. MANUAL START SCREEN, STANDARD OPERATOR PANEL

3. The generator set starts and provides voltage to the transfer switch.

4. The generator set provides a signal to the transfer switch to transfer the building load to the generator set.

FIGURE 25. BUILDING LOAD TRANSFER IN PROCESS

5. The transfer switch switches the generator set power to the building load. The building is now running on generator power.

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FIGURE 26. GENERATOR SET POWERING BUILDING LOAD

6. Press the Off button to switch the load back to the utility power.

FIGURE 27. BUILDING LOAD TRANSFER IN PROCESS

4. Operation7-2018

FIGURE 28. UTILITY POWERING BUILDING LOAD

7. Normal operation resumes.

Remote Starting the Generator Set Sequence

If the generator set is remote started with the in-home operator panel accessory, if equipped (the generator set is in Auto Mode), the sequence is as follows:

1. In a normal operation, the utility power is running to the transfer switch and then to the building load, and the generator set is off.

2. The generator set-mounted control (HMI211) is set in Auto Mode.

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FIGURE 29. HMI211 SET IN AUTO MODE

3. Manually start the generator set via the in-home operator panel.

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4. Operation7-2018

FIGURE 30. MANUAL START SCREEN, IN-HOME OPERATOR PANEL

4. The generator set starts and provides voltage to the transfer switch, but the transfer switch does not switch (allowing the voltage to go to the building) until after a delay.

FIGURE 31. TIME REMAINING UNTIL TRANSFER SCREEN

5. Five seconds after starting, the generator set provides a signal to the transfer switch to transfer the building load to the generator set.

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4. Operation 7-2018

FIGURE 32. BUILDING LOAD TRANSFER IN PROCESS

6. The transfer switch switches the generator set power to the building load. The building is now running on generator power.

FIGURE 33. GENERATOR SET POWERING BUILDING LOAD

7. When the remote display Stop button is pressed, the transfer switch switches back to utility power after a 5 minute retransfer delay.

FIGURE 34. BUILDING LOAD TRANSFER IN PROCESS

FIGURE 35. UTILITY POWERING BUILDING LOAD

8. The generator set runs for a 5-minute cooldown and shuts off.

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FIGURE 36. TIME REMAINING UNTIL STOP

9. Normal operation resumes.

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5 Maintenance

5.1 Maintenance Safety

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).

Hydrogen Gas Arcing can ignite explosive hydrogen gas given off by batteries, causing

severe personal injury or death. Arcing can occur when cables are removed or replaced, or when the negative (–) battery cable is connected and a tool used to connect or disconnect the positive (+) battery cable touches the frame or other grounded metal part of the generator set.

Insulated tools must be used when working in the vicinity of the batteries. Always remove the negative (–) cable first and reconnect last.

WARNING

Explosive Fumes Arcing can ignite explosive fumes causing severe personal injury or death. Make sure hydrogen from the battery, engine fuel and other explosive fumes

are fully dissipated before working on the generator set.

WARNING

Working at Heights Using the incorrect equipment when working at heights can result in severe

personal injury or death. Suitable equipment for performing these tasks must be used in accordance

with the local guidelines and legislation. Failure to follow these instructions can result in severe personal injury or death.

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5. Maintenance 7-2018

WARNING

Access Using the generator set or part of as a means of access when attaching

lifting shackles, chains, or other lifting aids, may damage the generator set, causing severe personal injury or death.

Do not use the generator set as a means of access. Failure to follow these instructions can result in severe personal injury or death.

WARNING

Exposed Terminations Some panel internal components may have live exposed terminations even if

the generator set is not running. Voltages are present which can cause electrical shock, resulting in personal injury or damage to equipment.

Isolate all external electrical supplies prior to access of the control panel

NOTICE

Only authorized and qualified maintenance technicians who are familiar with the equipment and its operation should carry out maintenance.

NOTICE

Dependent upon the control system fitted, this unit may operate automatically and could start without warning.

NOTICE

All maintenance tasks must be performed, but be sure to assess them for health and safety risks before starting. For example, perform a task with someone present if doing so will add significantly to the safety of the task.

Read, understand, and comply with all Caution, Warning, and Danger notes in this section, the Important Safety Instructions section, and the documentation supplied with the generator set.

Make sure that adequate lighting is available.

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Locking the Generator Set Out of Service

NOTICE

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 (–) cable first.

Before any work is carried out for maintenance, etc., the generator set must be immobilized. Even if the generator set is put out of service by pressing the Off switch on the Operator Panel (or the STOP button if applicable), the generator set cannot be considered safe to work on until the engine is properly immobilized, as detailed in the following procedure.

NOTICE

Refer also to the engine-specific Operator Manual, if applicable. This manual contains specific equipment instructions that may differ from the standard generator set.

To immobilize the generator set:

1. Press the Off switch from the display and then press the E-Stop button to shut down the engine. This will prevent the starting of the generator set regardless of the Start signal source and will therefore provide an additional safety step for immobilizing the generator set. Alternatively, make sure the generator set is in manual mode (which allows it to be started by manually pushing the buttons).

NOTICE

When the E-Stop button is pressed, the Operator Panel indicates the

Shutdown condition by illuminating the red Shutdown status LED and displaying a message on the graphical LCD display.

2. Thoroughly ventilate the generator set before disconnecting any leads.

3. Turn off and disconnect the heater (where fitted) from the AC source before disconnecting the battery cables.

4. Turn off and disconnect the battery charger (where fitted) from the AC source before disconnecting the battery cables.

5. Turn off the fuel supply to the engine.

6. Disconnect the battery. Disconnect the negative (–) cable first, using an insulated wrench.

7. Place warning notices at each of the above locations that state, "Maintenance in Progress – Immobilized for Safe Working."

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5.2 Periodic Maintenance

WARNING

Electrical Generating Equipment Accidental or remote starting of the generator set can cause severe personal

injury or death. Before working on the generator set, make sure that the generator set is in

Off mode, disable the battery charger, and remove the negative (– ) battery cable from the battery to prevent starting.

The table(s) that follow show the recommended service intervals for a generator set on standby service. If the generator set will be subjected to extreme operating conditions, the service intervals should be reduced accordingly.

At each scheduled maintenance interval, perform all previous maintenance checks that are due for scheduled maintenance.

Some of the factors that can affect the maintenance schedule are:

• Extremes in ambient temperature

• Exposure to elements

• Exposure to salt water

• Exposure to windblown dust or sand

Consult with your authorized Cummins Inc. service provider if the generator set will be subjected to any extreme operating conditions, and determine if extra protection or a reduction in service intervals is needed. Use the engine hours shown on the system status screen to keep to keep an accurate log of all service performed for warranty support. Perform all service at the time period indicated, or after the number of operating hours indicated, whichever comes first.

Repair or replace worn, damaged, or improperly functioning components identified during periodic maintenance procedures.

Periodic Maintenance Guidelines

Regularly performing the following periodic maintenance tasks greatly reduces the chances of a generator set shutdown:

• Maintain an appropriate oil level.

• Keep battery connections clean and tight.

• Do not overload the generator set.

• Keep the air inlet and outlet openings clear.

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Periodic Maintenance Schedule

NOTICE

Perform maintenance tasks as specified using the period of operation that occurs first.

TABLE 22. PERIODIC MAINTENANCE SCHEDULE

Maintenance Item

Check air cleaner restriction indicator (where fitted): If the service indicator shows red, replace air cleaner elements and reset the air cleaner service indicator.

Check air intake system for leaks: Visually inspect the air intake system for signs of wear or damage. Check audibly when the generator set is running. Replace worn or damaged components.

Daily

or After

24 Hours

■

Weekly

or After

50 Hours

100

Hours

1 Year

or After

200 Hours

Years

4000

Hours

Check operation of operator panel: Check display (the system will perform a control panel test on initial activation). Replace component if not functioning properly.

■

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5. Maintenance 7-2018

Maintenance Item

Check coolant level of radiator(s) (water jacket & LTA): If low, top up to coolant system specifications level, with Cummins recommended coolant mix.

Check cooling fan blades: Visually inspect the fan blades through the guarding for signs of wear or damage.

Check drive belt, condition and tension: Visually check belt for evidence of wear or slippage.

Daily

or After

24 Hours

■

Weekly

or After

50 Hours

100

Hours

1 Year

or After

200 Hours

Years

4000

Hours

Check coolant lines and radiator hoses for leaks, wear, and cracks: Visually check for leaks, worn or damaged hoses.

Check radiator air flow: Visually inspect the radiator through the guarding for blockage, build-up of debris, signs of wear or damage.

■ ■

■

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5. Maintenance7-2018

Maintenance Item

Verify that the coolant heater has power and is running (where fitted). Check for evidence of leaks. Remove any corrosion from fittings.

Check engine oil level: If low, top up to engine specifications level, with recommended oil.

Check fuel lines and hoses: Visually check for leaks, worn or damaged hoses.

Daily

or After

24 Hours

■

Weekly

or After

50 Hours

100

Hours

1 Year

or After

200 Hours

Years

4000

Hours

Check charge alternator: Check visually and audibly when the generator set is running.

Check all exhaust components, and hardware (fittings, clamps, fasteners, etc.): Visually inspect the exhaust system for signs of wear or damage. Check audibly when the generator set is running.

■

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5. Maintenance 7-2018

Maintenance Item

Check generator set enclosure: Visually check enclosure, walk around inspection of generator set. Make sure no inlets/outlets are covered/restricted, service access doors are operational and safety systems are in place and operational.

Check operation of Emergency Stop Button (where fitted): With the generator set running, press the

Emergency Stop

button. Check all systems, before resetting the fault.

Replace engine oil and filters. Refer to the procedure in the Engine Oil section.

Daily

or After

24 Hours

■

Weekly

or After

50 Hours

■

100

Hours

1 Year

or After

200 Hours

■

Years

4000

Hours

Check battery: Check connections to verify that they are secure.

Replace air cleaner.

Clean radiator core.

Check charge air cooler for damage and debris (where fitted).

■ ■

■

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Maintenance Item

Check water pump for leaks. Check weep holes for evidence of leaks. Replace if leaking.

Check engine ground. Clean as necessary.

Check engine mounts general condition and for signs of excessive wear.

Check starting motor for general condition, wiring connections.

Daily

or After

24 Hours

Weekly

or After

50 Hours

100

Hours

1 Year

or After

200 Hours

■

Years

4000

Hours

Check turbocharger (where fitted) for signs of leakage. Listen for excessive noise when test running the generator set.

Check timing belt condition. Visually inspect.

Inspect spark plugs. Replace if showing signs of excessive wear, carbon deposits, oil accumulation or damaged.

Check battery condition.

■

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5. Maintenance 7-2018

Maintenance Item

Check electrical connections (battery, starter motor, alternator connections). Check for tight connections, general condition and remove any corrosion.

Check alternator heater (where fitted). Check general condition and wiring connections.

Check battery heater (where fitted). Check general condition and wiring connections.

Daily

or After

24 Hours

Weekly

or After

50 Hours

100

Hours

1 Year

or After

200 Hours

■

Years

4000

Hours

Replace cooling

■

system coolant.

Inspect all sealed bearings every 4000 to 4500 hours

To be performed by a qualified Service Technician.

After the initial 50 hour interval and every 200 hours thereafter.

Cleaning schedule may be reduced depending on operating conditions/environment.

Replace all bearings every 30000 hours or 5 years (or if necessary after 10000 hours or 2

years).

Maintenance Record

Record all periodic and unscheduled maintenance and service. See the Periodic Maintenance Schedule for a list of scheduled maintenance frequency.

■

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Date

Engine

Hours

Meter

Reading

5. Maintenance7-2018

Maintenance or Service Performed

Record the name, address, and phone number of your authorized Cummins Inc. service center:

Name Address Phone

Exercising the Generator Set

NOTICE

Audible engine RPM variation may be heard when there is no load applied. This is normal and does not affect the generator set performance.

Exercising the generator set drives off moisture, relubricates the engine, and removes oxides from electrical contacts. The result is better starting, more reliable operation and longer engine life.

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5. Maintenance 7-2018

The generator set exerciser mode defaults are as follows.

• Day: Tuesday

• Time: 2:00 pm

• Period: Monthly

• Run Time: 5 minutes

Refer to the Exercise Settings section of this manual for more information on setting up the exerciser.

5.3 Engine Oil

Recommended Engine Oil

Check the oil level prior to starting the generator set to verify that the oil level is between the High and Low marks. The generator set is shipped with engine oil (5W30 API SM or newer engine oil is recommended).

Checking Engine Oil Level

NOTICE

Check the engine oil level when the engine is not running and is out of Auto mode.

WARNING

Crankcase pressure can blow out hot oil and cause severe burns. Do NOT check oil while the engine is operating.

CAUTION

Overfilling can cause foaming or aeration of the oil while operation below the low mark may cause loss of oil pressure. Do not operate the engine with the oil level below the low mark or above the high mark.

WARNING

State and federal agencies have determined that contact with used engine oil can cause cancer or reproductive toxicity. Avoid skin contact and breathing of vapors. Use rubber gloves and wash exposed skin. Accidental or remote starting of the generator set can cause severe personal injury or death. Disconnect the negative (-) battery cable and place the control switch in its OFF position (or press the STOP button if applicable) before starting work.

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No. Description No. Description

5. Maintenance7-2018

1 Fill Cap 3 Oil Filter

2 Dipstick 4 Oil Drain Hose

FIGURE 37. ENGINE OIL COMPONENTS

To check the engine oil level:

1. Make sure that the engine has not been running for approximately five minutes.

2. Clean off the area surrounding the dipstick port to prevent entry of debris into the oil pan.

3. Pull out the dipstick and wipe it clean.

4. Reinsert and fully seat the dipstick.

5. Remove the dipstick and check the oil level.

NOTICE

The engine oil level indicated on the dipstick should be between the High (4.3 L or 4.5 qt) and Low (3.8 L or 4.0 qt) marks.

6. Reinsert and fully seat the dipstick.

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5. Maintenance 7-2018

No. Description No. Description

1 High Oil Level (4.3 L or 4.5 qt) 2 Low Oil Level (3.8 L or 4.0 qt)

FIGURE 38. ENGINE OIL DIPSTICK

Adding or Draining Oil

WARNING

Hot Surfaces Contact with hot surfaces can cause severe burns. Wear appropriate PPE

when working on hot equipment and avoid physical contact with hot surfaces.

WARNING

Hot Engines Contact with hot engines can cause severe burns. Ensure that the generator

set engine has cooled down before adding or draining the oil.

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5. Maintenance7-2018

NOTICE

Too much oil can cause high oil consumption. Too little oil can cause severe engine damage. Keep the oil level between the High and Low marks on the dipstick.

Adding Oil

If the oil level is found to be insufficient, oil must be added.

1. Ensure that the oil fill cap area is clean, and prevent debris from entering the engine.

2. Add the appropriate amount of oil, based on the engine oil level check. Refer to the Checking Engine Oil Level section and the Model Specifications section.

3. Recheck the engine oil level. Based on the results, add or drain oil.

4. Clean up and dispose of any oil in accordance with local/state regulations.

Draining Oil

If the oil level is found to be excessive, oil must be drained from the engine.

1. Detach the oil drain hose from the side of the engine.

2. Place the end of the drain hose into an appropriate container.

Refer to local regulations to determine the appropriate container for used oil.

• Open the oil drain valve to release oil from the engine into the appropriate container.

• Recheck the engine oil level. Based on the results, add or drain oil.

• When a sufficient amount of oil has been drained from the system:

1. Close the oil drain valve.

2. Wipe the oil drain valve clean.

3. Re-attach the drain hose to the side of the engine.

4. Dispose of the used oil in accordance with local/state regulations.

Changing Engine Oil and Oil Filter

WARNING

Toxic Hazard State and federal agencies have determined that contact with used engine oil

can cause cancer or reproductive toxicity. Avoid skin contact and breathing of vapors. Use rubber gloves and wash

exposed skin. Accidental or remote starting of the generator set can cause severe personal injury or death. Disconnect the negative (-) battery cable and place the control switch in its OFF position (or press the STOP button if applicable) before starting work.

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5. Maintenance 7-2018

NOTICE

If the oil and/or oil filter are not reused, dispose of them in accordance with local environmental regulations.

NOTICE

Change the engine oil and filter when the engine is not running and is out of Auto mode.

NOTICE

Change the oil more often in hot and dusty environments.

NOTICE

Cummins highly recommends that any service or maintenance work be performed by qualified technicians.

1. Before changing the oil, the generator set should be operated until the water temperature is approximately 140 °F (60 °C).

2. Turn off the generator set.

3. Drain the oil.

4. Remove the oil filter, and clean the filter mounting surface on the engine block. Remove the old gasket if it remains.

5. Make sure the gasket is in place on the new filter and apply a thin film of clean oil to the gasket. Install the new filter until the gasket just touches the block. Turn it an additional 1/2 to 3/4 turn. Do not over-tighten.

6. Close the oil drain valve.

7. Refill with oil until full.

NOTICE

Too much oil can cause high oil consumption. Too little oil can cause severe engine damage. Keep the oil level between the High and Low marks.

8. Operate generator set with no load to inspect for leaks at the lubricating oil filter and the drain plug.

9. Confirm that the correct oil level is in the pan:

a. Shut the generator set off and wait 5 minutes.

b. Check the engine oil level.

10. Check and repair any leaks identified.

11. Dispose of the used oil and oil filter according to local environmental regulations.

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5.4 Air Intake System

The direct flow air cleaner consists of a primary filter and a secondary filter within the air cleaner housing. The air cleaner has been designed for a maximum restriction, at which point the filter elements should be changed. Refer to the Model Specifications section.

Normal Duty Air Cleaner

Normal Duty Air Cleaner Element Replacement

Holes, loose-end seals, dented sealing surfaces, corrosion of pipes, and other forms of damage render the air cleaner inoperative and require immediate element replacement or engine damage can occur.

Cummins Inc. does not recommend cleaning paper-type air cleaner elements.

5. Maintenance7-2018

NOTICE

1. Remove the existing air cleaner:

a. Loosen the strap clamp (2).

b. Wipe away any debris accumulated around the air cleaner

connection to the engine. Ensure that no debris is allowed to enter the body of the air cleaner or the connection on the engine.

c. Remove the dirty air cleaner (1).

d. Dispose of the dirty element in accordance with local environmental

agency requirements.

2. Install the replacement air cleaner (1) as follows:

a. Install the air cleaner (1).

b. Tighten strap clamp (2). Torque to 2.5 - 3.3 ft-lb (4.3 - 4.65 Nm).

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5. Maintenance 7-2018

No. Description No. Description

1 Air Cleaner 2 Strap Clamp

FIGURE 39. EXAMPLE OF NORMAL DUTY AIR CLEANER

Heavy Duty Air Cleaner

Heavy Duty Air Cleaner Maintenance

Fall Hazard Falls can result in severe personal injury or death. Make sure that suitable equipment for performing tasks at height are

used in accordance with local guidelines and legislation.

There is a dust ejector valve (DEV) on the bottom of each filter pre-cleaner that should be checked periodically to make sure it is free of dust and dirt.

When there is a filter pre-cleaner, it includes a primary and secondary element that is checked periodically to make sure they are clean. Refer to the Periodic Maintenance Schedule table for additional information.

Heavy Duty Air Cleaner Element Replacement

Holes, loose-end seals, dented sealing surfaces, corrosion of pipes, and other forms of damage render the air cleaner inoperative and require immediate element replacement or engine damage can occur.

WARNING

CAUTION

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5. Maintenance7-2018

NOTICE

Cummins Inc. does not recommend cleaning paper-type air cleaner elements.

1. To remove the existing air cleaner element:

a. Before disassembly, wipe dirt from the cover and the upper portion of

the air cleaner.

b. Lift the latch (3) and turn the end cover (4) counterclockwise.

c. Pull the end cover (4) away from the housing (1).

d. Remove the air filter element (2) from the housing (1).

e. Dispose of the dirty element in accordance with local environmental

agency requirements.

2. To install the replacement air cleaner element:

a. Ensure that no debris enters the filter element or connection point on

the air cleaner housing.

b. Insert the air filter element (2) into the housing (1).

c. Install the end cover (4) onto the housing (1).

d. Turn the end cover (4) clockwise until the latch (3) snaps into place.

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5. Maintenance 7-2018

No. Description No. Description

1 Housing 3 Latch

2 Air Filter Element 4 End Cover

FIGURE 40. EXAMPLE OF HEAVY DUTY AIR CLEANER

5.5 Generator Set Output - AC Electric System Checks

1. Check the following while the generator set is operating.

TABLE 23. AC ELECTRIC SYSTEM CHECKS

Check Description

Frequency The generator set frequency should be stable and the reading should be

the same as the generator set nameplate rating. See the Model Specifications section.

AC Voltage At no load, the line-to-line voltage, or voltages, should be the same as

the generator set nameplate rating.

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Check Description

AC Ammeter At no load, the current readings should be zero. With a load applied,

each line current should be similar.

Panel Lamps When the operating panel is first connected to the DC supply, the

system runs a check by illuminating each of the indicator lamps in turn.

2. If all of the LEDs do not illuminate, replace the operator panel.

5.6 DC Electrical System

WARNING

Combustible Gases Ignition of battery gases is a fire and explosion hazard which can cause

severe personal injury or death. Do not smoke, or switch the trouble light ON or OFF near a battery. Touch a

5. Maintenance7-2018

1. Check the harness connections. If any harness connections are damaged, contact your service representative.

FIGURE 41. CHECK HARNESS CONNECTIONS

2. Check the terminals on the batteries for clean and tight connections. Loose or corroded connections create resistance, which can hinder starting. Clean and reconnect the battery cables if loose, using an insulated wrench. Always disconnect both ends of the negative battery cable. Reconnect one end of the cable to the negative battery terminal and the other end to ground. This will make sure that any arcing will be away from the battery and least likely to ignite explosive battery gases.

3. Check connections at the battery charging alternator.

4. Visually inspect the alternator belt to make sure it is not loose or cracked.

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5. Maintenance 7-2018

5.7 Batteries

Batteries are an essential part of any standby generator set system. A significant amount of generator set failures are due to battery issues.

It is therefore vital that batteries are stored, commissioned, and maintained as detailed here. Reference should also be made to the battery manufacturer’s instructions.

Maintenance free batteries (if supplied with the generator set) need no maintenance for commissioning.

Storage

Batteries must be stored in a cool, dry, well-ventilated place, in the upright position, and with the vent caps securely in place.

Batteries must never be stacked on top of each other and must be protected from the floor by a wooden pallet or suitably thick cardboard sheet.

Safety Precautions

Servicing of batteries are to be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries.

General Precautions for Maintenance-Free Batteries

Handling and proper use of batteries is not hazardous if the correct precautions are observed and personnel are trained in their use.

WARNING

Arcing Hazard Laying tools or metal objects across the battery can cause arcing that

may ignite battery gases causing explosions resulting in personal injury.

Never lay tools or metal objects across the top of the battery.

WARNING

Electric Shock Hazard Voltages and currents present an electrical shock hazard that can

cause severe burns or death. Use tools with insulated handles to prevent the risk of electric shock.

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5. Maintenance7-2018

CAUTION

Toxic Hazard Electrolyte is a dilute sulphuric acid that is harmful to the skin and

eyes. It is electrically conductive and corrosive. Wear full eye protection and protective clothing. If electrolyte contacts

the skins, wash it off immediately with water. If electrolyte contacts the eyes, flush thoroughly and immediately with water and seek medical attention. Wash spilled electrolyte with an acid neutralizing agent.

NOTICE

Keep batteries upright to prevent spillage.

Fire Hazard

WARNING

Combustible Gases Lead acid batteries present a risk of fire because they generate

hydrogen gas. Do not smoke near the batteries. Do not cause flame or spark in the

battery area. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface.

WARNING

Before disconnecting a battery, always remove power from the AC powered battery charger.

WARNING

When putting a battery into service on a generator set, connect the negative lead LAST; when removing the battery, disconnect the negative lead FIRST.

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5. Maintenance 7-2018

Vented Batteries

WARNING

Toxic Hazard The electrolyte in vented batteries is a dilute sulfuric acid that is

harmful to the skin and eyes. It is also electrically conductive and corrosive.

Always:

1. Wear full eye protection and protective clothing;

2. If the electrolyte contacts the skin, wash it off immediately with water;

3. If the electrolyte contacts the eyes, flush them thoroughly and immediately with water and seek medical attention; and

4. Wash spilled electrolyte down with an acid neutralizing agent. A common practice is to use a solution of one pound (500 grams) bicarbonate of soda (also known as baking soda or sodium bicarbonate) to one gallon (4 liters) of water.

5. Continue to add the bicarbonate of soda solution until the evidence of reaction (that is, foaming) has stopped.

6. Flush the resulting liquid with water and dry the area.

Battery Maintenance

WARNING

Automated Machinery Accidental or remote starting of the generator set can cause severe personal

injury or death. Arcing at battery terminals or in light switches or other equipment, and flames or sparks can ignite battery gas causing severe personal injury.

Always follow these procedures to avoid injury and/or damage:

• Ventilate the battery area before working on or near the battery.

• Wear safety glasses.

• Do not smoke.

• Switch a work light on or off away from the battery.

Make sure the generator set is shut down and disabled:

1. Press the generator set's red STOP button on the local display to stop the generator set. Allow the generator set to thoroughly cool to the touch.

2. Turn off and disconnect the battery charger from the AC source before disconnecting the battery cables.

3. Disconnect the negative (–) cable from the battery and secure it from contacting the battery terminals to prevent accidental starting.

4. Once work is complete, reconnect the negative (-) battery cable last.

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5. Maintenance7-2018

See Battery Charger Maintenance for troubleshooting the charger.

Always:

• Keep the battery case and terminals clean and dry and the terminals tight.

• Remove battery cables with an insulated wrench or battery terminal puller.

• Make sure which terminal is positive (+) and which is negative (-) before

making battery connections, always removing the negative (-) cable first and reconnecting it last to reduce arcing.

NOTICE

If the battery needs to be replaced, make sure that the replacement battery specifications match those found in the Model Specifications in this manual.

Charging

Where a consistent source of AC power is available, Cummins recommends the use of a battery charger to maintain battery condition and charge. Cummins offers several battery chargers.

Where generator sets are used infrequently and a consistent source of AC power is not available, battery recharging must be put on a recharge schedule to ensure that a fully charged condition is maintained.

NEVER allow a battery to become completely flat (fully discharged), or to stand in a discharged condition, or damage will result.

Follow the battery charger operating instructions for proper use.

5.8 Spark Plugs

Make sure service personnel are qualified to perform electrical and mechanical service.

The generator set has four spark plugs, all accessible from the top of the engine. The spark plugs must be in good condition for proper engine starting and performance. A spark plug that fouls frequently or has heavy soot deposits indicates the need for engine service.

NOTICE

1. Set the generator set control to the Off position before checking the spark plugs.

2. To prevent cross-threading a spark plug, always thread it in by hand until it seats. Torque the spark plug to 20 Nm (15 lb-ft).

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5. Maintenance 7-2018

3. Return the generator set control to the desired setting when finished performing maintenance.

5.9 Cleaning the Generator Set Housing

The housing of the generator set housing can be damaged by pressure washing or solvents and other cleaning agents. Only use soap and water or an “all citrus degreaser" to clean the housing.

5.10 Complete System Test

NOTICE

Only authorized and qualified maintenance technicians who are familiar with the equipment and its operation should carry out this test.

A complete system test is recommended to verify that the electrical system is working properly. Testing the system once every 200 hours or every 2 years is required to make sure the transfer switch will transfer the load to the generator set if there is a utility power failure. For more information, see the transfer switch owner manual.

To initiate a complete system test:

1. Before starting:

• Check the oil level.

• Make sure there is enough fuel.

• See the Checklist section in the installation manual.

2. Place the generator set in Standby mode.

3. Switch the main utility disconnect from the ON to the OFF position.

4. Make sure the following occurs:

a. The generator set starts.

b. After the generator set starts and stabilizes, the load is transferred from the

utility to the generator set.

5. Switch the main utility disconnect from the OFF to the ON position.

6. Make sure the following occurs:

a. After approximately 5 minutes, the load is transferred back to the utility.

b. Once the transfer switch is connected to utility power, after approximately 5

minutes, the generator set stops.

NOTICE

If the test fails, call your authorized Cummins service provider to fix the problem.

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6 Troubleshooting

6.1 Avoiding Generator Set Shutdowns

By regularly performing the following periodic maintenance and guidelines, you will greatly reduce the chances of a generator set shutdown:

• Maintain an appropriate oil level.

• Keep battery connections clean and tight.

• Do not overload the generator set.

• Keep the air inlet and outlet openings clear.

Refer to the Maintenance section for more information.

6.2 Control System

The generator set control system continuously monitors engine sensors for abnormal conditions, such as low oil pressure and high coolant temperature. If any of these conditions occur, the control will light a yellow Warning lamp or a red Shutdown lamp and will display a message on the graphical display panel. In the event of an engine shutdown fault (red Shutdown LED), the control will stop the engine immediately.

6.3 Fault Finding

Troubleshooting procedures. Troubleshooting procedures present hazards that can result in severe

personal injury or death. Only qualified service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review safety precautions listed in this manual together with the

documentation supplied with the generator set.

For any symptom not listed, contact your authorized dealer for assistance.

Before starting any fault finding, ensure that the following basic checks are carried out:

• All switches and controls are in their correct positions

• Fuel system is connected and fuel is available

• The lubricating oil level is correct

• The coolant level is correct

• The radiator cooling air flow is free from obstruction

WARNING

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6. Troubleshooting 7-2018

• The battery charge condition is satisfactory and the connections are secure

• The generator set electrics and alternator connections are secure

• The panel connections are secure

• The protection circuits have been reset

• Blown fuses have been replaced

• Tripped contactors or circuit breakers have been reset

6.4 Fault/Status Codes - PowerCommand 1.1

Fault Code Introduction

Fault code information, together with warning and shutdown information, is provided in this section to assist in locating and identifying the possible causes of faults in the generator set system.

Refer also to the engine-specific operator manual, if it exists. The engine operator manual contains additional information regarding the running and care of the generator set as well as specific equipment instructions that may differ from the standard generator set.

For any fault codes that occur but are not listed, contact your Cummins service representative.

Fault/Status Codes Warnings

WARNING

Electrical Generating Equipment Incorrect installation or servicing can result in severe personal injury or

death. Make sure that only suitably trained and experienced service personnel with

knowledge of fuels, electricity, and machinery hazards perform electrical and/or mechanical service.

WARNING

Automated Machinery Accidental or remote starting of the generator set can cause severe personal

injury or death. Prevent accidental starting by disconnecting the starting battery cables,

negative (–) cable first.

Code 143 - Engine Oil Pressure Low (Warning)

Logic: Engine oil pressure is below the low oil pressure shutdown threshold.

Possible Cause:

1. Low lubricating oil level

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2. External leak

Diagnosis and Repair:

1. Low lubricating oil level

a. Check the oil level. Add or drain oil, if necessary.

2. External leak

a. Inspect the engine and surrounding area for external oil leaks.

b. Contact your local dealer if a leak is present.

Code 151 - Engine Coolant Temperature High (Shutdown)

Logic:

Engine coolant temperature has exceeded the alarm (shutdown) threshold for high coolant temperature.

Possible Cause:

1. High ambient temperature

2. Coolant level is below specification

3. Cooling system components are damaged or obstructed

Diagnosis and Repair:

1. High ambient temperature

a. Reduce loads or recirculation of discharge air to generator in elevated

ambient.

2. Coolant level is below specification

a. Inspect the engine, cooling system, and surrounding area for external

coolant leaks.

i. Contact your local dealer if a leak is present.

b. Verify the coolant level is correct via the sight glass.

i. Add coolant as necessary.

3. Cooling system components are damaged or obstructed

a. Inspect the radiator, charge air cooler, and other cores (if used).

i. Inspect for damaged fins.

ii. Inspect for dirt, debris, or obstructions.

iii. Remove blockage.

b. Inspect the fan shroud and air recirculation baffles for damage and

clearance.

i. Contact your local dealer if repair or replacement is required.

c. Inspect the fan belt(s) for damage, wear, and proper tension. Inspect

pulleys and belt tensioner for damage or wear.

i. Contact your local dealer if repair or replacement is required.

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6. Troubleshooting 7-2018

d. Inspect the radiator cap and gasket for damage and proper pressure

operation.

i. Contact your local dealer if repair or replacement is required.

e. Inspect upper and lower radiator hoses for collapse, distortion, or fluid

leaks.

i. Contact your local dealer if repair or replacement is required.

f. Inspect cooling system components for external contaminates and clean as

required.

i. Open the radiator cap and inspect for contaminated coolant and scale.

ii. Contact your local dealer if flushing of cooling system is required.

Code 155 - Intake Manifold Temperature High (Shutdown)

Logic: The engine intake manifold temperature has exceeded 95 °C (203 °F) for greater than 10 seconds.

Diagnosis and Repair:

For the troubleshooting procedure, refer to DTC 127 in the E-Controls Manual, which applies to several applications. See the drawings provided with the generator set or the wiring diagrams appendix for the appropriate pin numbers.

Code 197 - Coolant Level Low (Warning)

Logic: Coolant level sensor signal is showing a low coolant level for greater 10

seconds.

Possible Cause:

1. Low coolant

Diagnosis and Repair:

1. Low coolant

a. Remove radiator cap and check that coolant is up to the required level.

Code 415 - Engine Oil Pressure Low (Shutdown)

Logic: Engine oil pressure is below the low oil pressure shutdown threshold.

Possible Causes:

1. Lubricating oil level is low

2. External leak

Diagnosis and Repair:

1. Lubricating oil level is low

a. Check the oil level. Add oil, if necessary.

2. External leak

a. Inspect the engine and surrounding area for external oil leaks.

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6. Troubleshooting7-2018

b. If a leak is present, contact your Cummins service representative.

Code 421 - Engine Oil Temperature High (Warning)

Logic: The control has detected the engine oil temperature has exceeded the

warning threshold.

Possible Cause:

1. High ambient temperature

2. Blocked enclosure air intake

3. Coolant level below specification

Diagnosis and Repair:

1. High ambient temperature

a. Reduce loads or recirculation of discharge air to generator in elevated

ambient.

2. Blocked enclosure air intake

a. Inspect for dirt, debris, or obstructions.

b. Remove blockage or snow/ice buildup as applicable.

3. Coolant level is below specification

a. Check coolant level.

b. Add coolant as necessary.

Code 441 - Battery Voltage Low (Warning)

Logic: Battery voltage is low.

Possible Causes:

1. Loose or damaged battery cable connections

2. Battery charger not connected (if equipped)

3. Battery not completely charged

4. Battery is old and does not maintain a charge

Diagnosis and Repair:

1. Loose or damaged battery cable connections

• Inspect the battery cable connections for corrosion and loose connections. Adjust or repair if needed.

2. Battery charger not connected (if equipped)

a. Make sure that the battery charger is connected to the AC power supply.

b. Make sure that the battery charger is connected correctly to the battery.

3. Battery not completely charged

• Using a voltmeter or multimeter, determine if the voltage is below 11 V. If so, recharge the battery.

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6. Troubleshooting 7-2018

4. Battery is old and does not maintain a charge

• Replace the battery.

Code 488 - Intake Manifold Temperature High (Warning)

Logic:

Engine intake manifold temperature has exceeded 185 °F (85 °C) for more than 90 seconds.

Possible Cause:

1. High ambient temperature

2. Enclosure air intake blocked

3. Coolant level is below specification

4. Radiator blocked

5. Enclosure air discharge blocked

6. Fan belt is broken or loose

Diagnosis and Repair:

1. High ambient temperature

a. Reduce loads or recirculation of discharge air to generator in elevated

ambient.

2. Enclosure air intake blocked

a. Inspect for dirt, debris, or obstructions.

b. Remove blockage or snow/ice buildup as applicable.

3. Coolant level is below specification

a. Check coolant level.

b. Add coolant as necessary.

4. Radiator blocked

a. Inspect for dirt, debris or obstructions.

b. Remove blockage or winterfront as applicable.

5. Enclosure air discharge blocked

a. Inspect for dirt, debris, or obstructions.

b. Remove blockage or snow/ice buildup as applicable.

6. Fan belt is broken or loose

a. Inspect belt(s) for damage, wear, and proper tension.

b. Repair or replace if damaged or worn.

Code 1438 - Fail to Crank (Shutdown)

Logic: