CUMMINS DFAC, DFCC, DFAB, DFGE, DFLB Service Manual
...
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Service Manual
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PowerCommand Control
2100 Series
Generator Sets
Printed in U.S.A.
Models
DFAB, DFAC, DFBF, DFCB, DFCC, DFCE
DFGB, DFGE, DFLB, DFLC, DFLE
960-0519C 02-2004
Table of Contents
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by any means, is strictly prohibited.
SECTION TITLE PAGE
IMPORTANT SAFETY INSTRUCTIONS iii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 INTRODUCTION
About this Manual 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Overview 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Equipment 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How To Obtain Service 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 CONTROL OPERATION
General 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Panel Power On/Off Modes 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Panel 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Menu Display and Buttons 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Menus 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controller Configuration Menu 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Menu 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Menu 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjust Menu 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Faults Menu 2-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Menu 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
History Menu 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About Menu 2-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Transfer Menu 2-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 CIRCUIT BOARDS AND MODULES
General 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Base Board 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 TROUBLESHOOTING
General 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
InPower Service Tool 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Network Application and Customer Inputs 4-1. . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Considerations 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Procedure 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 POWER TRANSFER CONTROL (PTC) TROUBLESHOOTING
General 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PTC Module 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sequence of Events 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting using Fault Codes 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PTC Fault Code Troubleshooting Procedure 5-3. . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting with Symptoms 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Source 1 Power Fails, But Genset Does Not Start 5-9. . . . . . . . . . . . . . . . . . .
i
SECTION TITLE PAGE
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5 POWER TRANSFER CONTROL (PTC) TROUBLESHOOTING (CONT.)
Genset Starts, But Does Not Assume Load 5-11. . . . . . . . . . . . . . . . . . . . . . . .
PTC Module Does Not Retransfer When Source 1 Utility Power
Is Restored After A Power Failure Or On Initial Installation 5-13. . . . . . . .
Genset Continues To Run After Retransfer Of Load To S1 Utility 5-15. . . . . .
Genset Starts During Normal Power Service 5-15. . . . . . . . . . . . . . . . . . . . . . .
Generator Test Runs But Genset Does Not Assume Load 5-15. . . . . . . . . . . .
6 CONTROL ADJUSTMENT AND SERVICE
General 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Board Removal/Replacement 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Modifying Setup Submenus 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Password Submenu 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crank/Idle Setup Menu 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor/Regulator Setup Menu 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Transfer Setup Menu 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PCC Control Panel Box Components (Standard/Optional) 6-12. . . . . . . . . . .
Engine Sensors 6-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Magnetic Speed Pickup Unit (MPU) 6-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Current Transformer (CT) Installation 6-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 SERVICING THE GENERATOR
Testing the Generator 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator/Base Board Isolation Procedure 7-2. . . . . . . . . . . . . . . . . . . . . . . . .
Testing the PMG 7-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Disassembly 7-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Reassembly 7-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 FUEL TRANSFER PUMP AND CONTROL
General 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Connections 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Transfer Pump Motor Connections 8-6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing the Float Switch Assembly 8-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 OPTIONAL ENCLOSURE FUEL TANK SYSTEM
General 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Connections 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Transfer Pump 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External Fuel Fill Box 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External Alarm Panel 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rupture Basin Leak Detect Switch Test 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 WIRING DIAGRAMS
General 10-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii
IMPORTANT SAFETY INSTRUCTIONS
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by any means, is strictly prohibited.
SAVE THESE INSTRUCTIONS − This manual contains
important instructions that should be followed during
installation and maintenance of the generator and batteries.
Before operating the generator set (genset), read the
Operator’s Manual and become familiar with it and the
equipment. Safe and efficient operation can be
achieved only if the equipment is properly operated
and maintained. Many accidents are caused by failure
to follow fundamental rules and precautions.
The following symbols, found throughout this manual,
alert you to potentially dangerous conditions to the operator, service personnel, or the equipment.
This symbol warns of immediate
hazards which will result in severe personal injury or death.
WARNING
This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death.
CAUTION
This symbol refers to a hazard or unsafe practice which can result in personal injury
or product or property damage.
FUEL AND FUMES ARE FLAMMABLE
Fire, explosion, and personal injury or death can result
from improper practices.
• DO NOT fill fuel tanks while engine is running, un-
less 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 zinc
coated or copper fuel lines with diesel fuel.
• Be sure all fuel supplies have a positive shutoff
valve.
• Be sure 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.
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 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.
• Be sure the unit is well ventilated.
• Engine exhaust and some of its constituents are
known to the state of California to cause cancer,
birth defects, and other reproductive harm.
MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
•
Keep your hands, clothing, and jewelry away from
moving parts.
• Before starting work on the generator set, discon-
nect battery charger from its AC source, then disconnect starting batteries, 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 adjustment must be made while the unit is run-
ning, use extreme caution around hot manifolds,
moving parts, etc.
DO NOT OPERATE IN FLAMMABLE AND
EXPLOSIVE ENVIRONMENTS
Flammable vapor can cause an engine to overspeed and
become difficult to stop, resulting in possible fire, explosion, severe personal injury and death. Do not operate a
genset where a flammable vapor environment can be
created by fuel spill, leak, etc., unless the genset is
equipped with an automatic safety device to block the air
intake and stop the engine. The owners and operators of
the genset are solely responsible for operating the genset safely. Contact your authorized Cummins Power
Generation distributor for more information.
LS-14L
iii
ELECTRICAL SHOCK CAN CAUSE
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by any means, is strictly prohibited.
SEVERE PERSONAL INJURY OR DEATH
Remove electric power before removing protective
•
shields or touching electrical equipment. Use rubber insulative mats placed on dry wood platforms
over floors that are metal or concrete when around
electrical equipment. Do not wear damp clothing
(particularly wet shoes) or allow skin surface to be
damp when handling electrical equipment. Do not
wear jewelry. Jewelry can short out electrical contacts and cause shock or burning.
• Use extreme caution when working on electrical
components. High voltages can cause injury or
death. DO NOT tamper with interlocks.
• Follow all applicable state and local electrical
codes. Have all electrical installations performed by
a qualified licensed electrician. Tag and lock open
switches to avoid accidental closure.
• DO NOT CONNECT GENERATOR SET DIRECT-
LY TO ANY BUILDING ELECTRICAL SYSTEM.
Hazardous voltages can flow from the generator set
into the utility line. This creates a potential for electrocution or property damage. Connect only
through an approved isolation switch or an approved paralleling device.
GENERAL SAFETY PRECAUTIONS
Coolants under pressure have a higher boiling point
•
than water. DO NOT open a radiator or heat exchanger pressure cap while the engine is running.
Allow the generator set to cool and bleed the system
pressure first.
• Used engine oils have been identified by some state
or federal agencies as causing cancer or reproductive toxicity . When checking or changing engine oil,
take care not to ingest, breathe the fumes, or contact used oil.
• Keep multi-class ABC fire extinguishers handy.
Class A fires involve ordinary combustible materials
such as wood and cloth; Class B fires, combustible
and flammable liquid fuels and gaseous fuels; Class
C fires, live electrical equipment. (ref. NFP A No. 10).
• Make sure that rags are not left on or near the en-
gine.
• Make sure generator set is mounted in a manner to
prevent combustible materials from accumulating
under the unit.
• Remove all unnecessary grease and oil from the
unit. Accumulated grease and oil can cause overheating and engine damage which present a potential fire hazard.
• Keep the generator set and the surrounding area
clean and free from obstructions. Remove any debris from the set and keep the floor clean and dry.
• Do not work on this equipment when mentally or
physically fatigued, or after consuming any alcohol
or drug that makes the operation of equipment unsafe.
• Substances in exhaust gases have been identified
by some state or federal agencies as causing cancer or reproductive toxicity. Take care not to breath
or ingest or come into contact with exhaust gases.
• Do not store any flammable liquids, such as fuel,
cleaners, oil, etc., near the generator set. A fire or
explosion could result.
• Wear hearing protection when going near an oper-
ating generator set.
• To prevent serious burns, avoid contact with hot
metal parts such as radiator, turbo charger and exhaust system.
KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE
iv
1. Introduction
Redistribution or publication of this document,
by any means, is strictly prohibited.
ABOUT THIS MANUAL
This manual provides troubleshooting and repair
information regarding the PowerCommand
Control (PCC) and generators for the gensets listed
on the front cover. Engine service instructions are in
the applicable engine service manual. Operating
and maintenance instructions are in the applicable
Operator’s Manual.
This manual does not have instructions for
servicing printed circuit board assemblies. After
determining that a printed circuit board assembly is
faulty, replace it. Do not repair it. Attempts to repair a
printed circuit board can lead to costly damage to
the equipment.
This manual contains basic (generic) wiring
diagrams and schematics that are included to help
in troubleshooting. Service personnel must use the
actual wiring diagram and schematic shipped with
each unit. The wiring diagrams and schematics that
are maintained with the unit should be updated
when modifications are made to the unit.
Read
Safety Precautions
and carefully observe all
instructions and precautions in this manual.
2100
TEST EQUIPMENT
To perform the test procedures in this manual, the
following test equipment must be available
• True RMS meter for accurate measurement of
small AC and DC voltages. Fluke models 87 or
8060A are good choices.
• Grounding wrist strap to prevent circuit board
damage due to electrostatic discharge (ESD).
• Battery Hydrometer
• Jumper Leads
• Tachometer or Frequency Meter
• Wheatstone Bridge or Digital Ohmmeter
• Variac
• Load Test Panel
• Megger or Insulation Resistance Meter
• PCC Service Tool Kit (Harness Tool and Sen-
sor Tool)
• InPower Service Tool (PC based genset ser-
vice tool)
SYSTEM OVERVIEW
The PCC is a microprocessor-based control for
Cummins Power Generation generator sets. All
generator set control functions are contained on
one circuit board (Base board). The Base board
provides engine speed governing, main alternator
voltage output regulation, and complete generator
set control and monitoring.
The operating software provides control of the generator set and its performance characteristics, and
displays performance information on a digital display panel. It accepts menu-driven control and setup input from the push button switches on the front
panel.
Copyright2003 Cummins Power Generation. All rights reserved.
Cummins and PowerCommand are registered trademarks of Cummins Inc.
HOW TO OBTAIN SERVICE
Always give the complete Model, Specification and
Serial number of the generator set as shown on the
nameplate when seeking additional service
information or replacement parts. The nameplate is
located on the side of the generator output box.
WARNING
parts can result in severe personal injury or
death, and/or equipment damage. Service personnel must be qualified to perform electrical
and mechanical service. Read and follow Safety
Precautions, on pages iii and iv.
Incorrect service or replacement of
1-1
THIS PAGE LEFT INTENTIONALLY BLANK
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1-2
2. Control Operation
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GENERAL
The following describes the function and operation
of the PowerCommand 2100 Control (PCC). All
indicators, control switches/buttons and digital display are located on the face of the control panel as
illustrated in Figure 2-1.
CONTROL PANEL POWER ON/OFF
MODES
The power on/off modes of the control panel and operating software are Power On, Screen Saver and
Sleep/Awake.
Power On Mode: In this mode, power is continuously supplied to the control panel. The control’s
operating software and control panel LEDs/digital
display will remain active until the Screen Saver
mode is activated.
Screen Saver Mode: Power to the digital display is
removed after 30 minutes (generator set not running or running). The 30 minute timer resets and begins after each control panel action (any button or
switch selection) or signal received by the operating
software. All LEDs on the control panel operate normally during Screen Saver mode, indicating that the
operating software is active (Awake mode).
When a “Warning” signal is sensed by the PCC (for
example, low coolant temp), the control displays the
warning message.
Sleep/Awake Mode: In the Sleep mode, the control’s operating software is inactive and the LEDs
and the digital display on the control panel are all off.
Sleep mode is a feature used to reduce battery
power consumption when the control is not being
used and the O/Manual/Auto switch is in the O position.
When all conditions are met (i.e., no unacknowledged faults and O/Manual/Auto switch is in the O
position) the Sleep mode is activated.
The operating software is initialized and the digital
display and control panel LEDs are turned on in response to moving/pressing the following control
panel switch/buttons:
• OManual/Auto switch
• Emergency Stop button
• Fault Acknowledge/Reset button
• Panel Lamp/Lamp Test button
To activate the control and view the menu display
without starting the generator set, press Fault Acknowledge or Panel Lamp button or move mode
switch from O to Manual.
The InPower service tool is required to enable or
disable the Sleep mode. When shipped from the
factory, the Sleep mode is disabled. When disabled,
the operating software will always remain active
(Awake mode). (If network and/or power transfer
control feature is installed, the sleep mode is not
available and should not be enabled − will cause error condition.)
2-1
HOME
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BUTTON
MENU
SELECTION
BUTTON
(1 of 4)
PANEL
LAMP
(1 of 3)
PREVIOUS
MAIN MENU
BUTTON
DIGITAL
DISPLAY
SHUTDOWN
AND WARNING
STATUS
INDICATORS
EMERGENCY
STOP PUSH
BUTTON
(Pull to reset)
RUNNING/REMOTE
START/NOT IN AUTO
INDICATORS
CONFIGURABLE
INDICATORS
ANALOG AC
METERING
PANEL
(OPTIONAL)
FAULT
ACKNOWLEDGEMENT/
RESET BUTTON
PANEL LAMP
AND LAMP
TEST
BUTTON
FIGURE 2-1. FRONT PANEL
2-2
OFF/MANUAL/
AUTO SWITCH
MANUAL
RUN/STOP
BUTTON
FRONT PANEL
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by any means, is strictly prohibited.
Figure 2-1 shows the features of the front panel.
Remote Start Indicator:
This green lamp is lit
whenever the control is receiving a remote start signal.
Digital Display:
This two-line, 20-characters per
line alphanumeric display is used to view menus of
the menu-driven operating system. Refer to the
menu trees later in this section. The display is also
used to show warning and shutdown messages.
Display Menu Selection Buttons:
Four momentary buttons—two on each side of the digital display
window—are used to step through the various
menu options and to adjust generator set parame-
ters. A green triangle (
or ), arrow ( , , , or ),
>>, or plus/minus sign (+ or −) in the digital display
adjacent to the button is shown when the button can
be used (button is “active”). Refer to
And Buttons
Home Button:
later in this section.
Press this button ( ) to view the
Menu Display
Home Menu. Refer to the menu trees later in this
section.
Previous Main Menu Button:
Press this button ( )
to view the previous Main Menu. All main menus include both types of green triangles (
and ). Refer
to the menu trees later in this section.
NOTE: The up and down arrows (
and ) are used
to navigate between submenus.
Emergency Stop Button:
Push this button in for
emergency shutdown of the generator set. This will
stop the generator set immediately and prevent
starting of the set from any location (local and remote).
To reset:
1. Pull the button and allow it to pop out.
2. Turn the O/Manual/Auto switch to O (Off).
3. Press the front panel Fault Acknowledge/Reset button.
4. Select Manual or Auto, as required.
Emergency Stop shutdown can be reset only at the
PCC front panel.
Running Indicator:
This green lamp is lit whenever
the generator (local or remote) is running.
Not in Auto Indicator:
This red lamp flashes continuously when the O/Manual/Auto switch is not in
the Auto position.
Analog AC Metering Panel (Optional):
This panel
simultaneously displays (in percent of genset rated
output):
• 3-phase line-to-line AC current (A~)
• Kilowatts (kW)
• Generator output frequency in hertz (Hz)
• 3-phase line-to-line AC volts (V~)
• Power Factor (PF) (shown in 0.2 increments)
Shutdown Status Indicator:
This red lamp is lit
whenever the control detects a shutdown condition.
The generator set cannot be started when this lamp
is on. After the condition is corrected, shutdown indicators can be reset by turning the O/Manual/Auto
switch to the O position and pressing the Fault Acknowledge/Reset button.
Warning Status Indicator:
This yellow lamp is lit
whenever the control detects a warning condition.
After the condition is corrected, warning indicators
can be reset by pressing the Fault Acknowledge/
Reset button. (It is not necessary to stop the generator set.) In auto mode, warning indicators can also
be reset by cycling the remote reset input after the
condition is corrected.
Some warnings remain active after the condition is
corrected and the control reset button is pressed.
This will require the genset to be shutdown to reset
the warning indicator.
Fault Acknowledge/Reset Button:
Press this button to acknowledge warning and shutdown messages after the fault has been corrected. Pressing
this button clears the fault from the current fault list.
To acknowledge a Warning message, the O/Manual/Auto switch can be in any position. (It is not necessary to stop the generator set to acknowledge an
inactive Warning condition.) To acknowledge a
shutdown message with this button, the O/Manual/
Auto switch must be in the O position.
2-3
Panel Lamp and Lamp Test Button:
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by any means, is strictly prohibited.
Press this
button to turn the control panel lamps on or off. The
lights will shut of f after about ten minutes. Press and
hold this button to test all front panel LEDs and meters. The meters will light one bar at a time.
Manual Run/Stop Button:
This button starts and
stops the set locally and will bypass Time Delay to
Start and Stop sequences. The O/Manual/Auto
switch must be in the Manual position to enable this
button.
O/Manual/Auto Switch:
The Manual position en-
ables the use of the Manual Run/Stop button.
The Auto position enables start/stop control of the
engine from a remote location. (It disables the use
of the Manual Run/Stop button.)
The O (Off) position prevents the starting of the set
(local or remote). If the switch is set to O during set
operation, the engine will immediately shut down
(cool-down timers are bypassed). This hot shutdown should be avoided, if possible, to help prolong
the life of the engine.
Configurable Indicators
The following configurable indicators (default values shown) can be changed with the InPower service tool. The configurable items are: change generator event and LED color (green, yellow or red),
and enable/disable indicator.
Low Oil Pressure Warning Indicator:
lamp indicates the oil pressure is lower than the normal range of operation.
High Engine Temperature Warning Indicator:
This yellow lamp indicates the engine temperature
is higher than the normal range of operation.
Low Oil Pressure Shutdown Indicator:
lamp indicates the engine has shut down because
of low oil pressure.
Overspeed Shutdown Indicator:
dicates
speed.
Fail to Start Indicator:
the engine has shut down because of excessive
This red lamp indicates the
engine failed to start.
This yellow
This red
This red lamp in-
2-4
MENU DISPLAY AND BUTTONS
Redistribution or publication of this document,
by any means, is strictly prohibited.
Figure 2-2 shows the digital display and the menu
selection buttons.
Digital Display:
line, digital display is used to view the menus of the
menu-driven operating system. Refer to the menu
trees later in this section. The display is also used to
show fault messages.
Display Menu Selection Buttons:
tary buttons—two on each side of the digital display
window—are used to step through the various
menu options and to adjust generator set parameters. The button is active when a symbol adjacent to
the button is displayed. The displayed symbol indicates the function of the button.
• In the digital display for main menus (Figure
2-3), the
the adjacent button causes the operating pro-
gram to go to the selected submenu (e.g., Engine Menu in Figure 2-5).
The two-line, 20 characters per
Four momen-
and symbols indicate that pressing
• In the digital display, the plus or minus symbols
(+ or −) indicate that pressing the adjacent button can be used to change a parameter or value shown on the display.
When there is a choice of two parameters, one
parameter is associated with the + symbol and
the other is associated with the − symbol.
When changing values, pressing the button a d jacent to the + symbol increase the value and
pressing the button adjacent to the − symbol
decreases the value. Only one numeric character of a field can be changed at a time.
• In the digital display, the
or symbol indicates
that pressing the adjacent button causes the
operating program to move the cursor to the
next numeric character. The selected numeric
character can then be changed by pressing the
buttons adjacent to the + and − symbols. Only
symbol is displayed when the cursor is on
the
the first character of a field that can be
changed. Only the
is displayed when the cursor is on the last character. Both symbols are
displayed when the cursor is on any other character.
• In the digital display, the More>> symbol indicates that pressing the adjacent button causes
the operating program to go to the next main
menu, as shown in Figure 2-3.
• In the digital display, the
or symbols indicate that pressing the adjacent button causes
the operating program to go to the next or previous submenu, as shown in the menu diagrams. Only the
first submenu. Only the
symbol is displayed in the
is displayed in the
last submenu. Both symbols are displayed in
the rest of the submenus.
• After adjusting values/parameters, pressing
the
symbol results in the changes being
saved. If the Home button or Previous Main
Menu button is pressed before pressing the
symbol, the changes are not saved.
Home Button:
Pressing this button causes the operating system to show Main Menu 1 (Figure 2-3) in
the digital display.
Previous Main Menu Button:
Pressing this button
causes the operating system to show the previous
Main Menu in the digital display . All main menus in-
clude both types of green triangles (
and ).
2-5
2 LINE, 20 CHARACTERS PER LINE
Redistribution or publication of this document,
by any means, is strictly prohibited.
MENU DISPLAY
DIGITAL DISPLAY
HOME
BUTTON
FIGURE 2-2. DIGITAL DISPLAY AND MENU SELECTION BUTTONS
PREVIOUS MAIN
MENU BUTTON
2-6
MAIN MENUS
Redistribution or publication of this document,
by any means, is strictly prohibited.
Figure 2-3 shows the three major main menus available to t h e user . Figure 2-3 also includes references
to pages in this section where you can find additional information on submenus. When viewing a submenu, you can press the previous main menu button at any time to view its main menu.
Main Menu 1
As shown in the illustration, each main menu can
branch into one of four directions. Press the button
next to “More>>” in the display to view the next Main
menu. Main Menu 1 is redisplayed when you press
the button next to “More>>” in the Main Menu 3 display.
PAGE
2-11
PAGE
2-13
Engine
Alternator
PAGE
2-17
PAGE
2-19
Adjust
More>>
Main Menu 2
Faults
System
PAGE
NO TAG
History
More>>
PAGE
2-21
Main Menu 3
PAGE
2-23
PAGE
2-25
FIGURE 2-3. MAIN MENUS
About
Pwr Tran
2-7
Setup
More>>
PAGE
5-5
CONTROLLER CONFIGURATION MENU
Redistribution or publication of this document,
by any means, is strictly prohibited.
Figure 2-4 shows a block representation of the Controller Configuration menus. These menus are used
to change the default language, temperature units,
and pressure units to be displayed in menus.
To view the first Controller Configuration menu,
make sure Main Menu 1 is displayed and simultaneously press the Home Menu and Previous Main
Menu buttons.
As shown in the diagram, the Controller Configuration menu has three submenus.
Press the button next to the symbol in the display
until the + and − symbols are displayed.
Press the button next to the + or − symbol to select
the desired option.
After selecting option, pressing the
symbol results
in the changes being saved. If the Home button or
Previous Main Menu button is pressed before
pressing the
Language Selected submenu:
symbol, the changes are not saved.
Used to select de-
sired language (default = English).
Temperature Units submenu:
Used to select
Fahrenheit or Centigrade for temperature readings.
Press the buttons next to the
and symbols in the
digital display to navigate between the menus.
Fluid Pressure Units submenu:
PSI or kPA for pressure readings.
Used to select
2-8
CONTROLLER CONFIGURATION MENU
Redistribution or publication of this document,
by any means, is strictly prohibited.
Main Menu 1
Engine
Alternator
Language Selected
English
Temperature Units
Deg F
Adjust
More>>
+Language Selected
− English
Back
+Temperature Units
− Deg C
Back
Fluid Pressure Units
PSI
+Fluid Pressure Units
− kPa
FIGURE 2-4. CONTROLLER CONFIGURATION MENU
2-9
Back
ENGINE MENU
Redistribution or publication of this document,
by any means, is strictly prohibited.
Figure 2-5 shows a block representation of the Engine menu. If you press the button next to the word
“Engine” in the display, the first Engine submenu is
displayed.
As shown in the diagram, the Engine menu has
seven submenus. The data in the submenus will
vary according to the type and number of sensors
provided with the engine.
Press the buttons next to the
digital display to navigate between the menus.
Press the Home button or the Previous Main Menu
button to return to Main Menu 1.
and symbols in the
Coolant Temperature submenu:
This submenu
displays the engine coolant temperature which can
be viewed in degrees Fahrenheit or Centigrade
(see
Controller Configuration Menu
Oil Pressure submenu:
This submenu displays
in this section).
the engine oil pressure which can be viewed in PSI
or kPA (see
Controller Configuration Menu Menu
in
this section).
Oil Temperature submenu:
This submenu displays the engine oil temperature which can be
viewed in degrees Fahrenheit or Centigrade (see
Controller Configuration Menu
Engine Speed submenu:
in this section).
This submenu displays
the engine RPM.
Battery Voltage submenu:
This submenu dis-
plays the engine battery voltage.
Governor Duty Cycle submenu:
This submenu
displays the governor duty cycle (drive) levels in
percentage of maximum.
Active Time Delay submenu:
This submenu displays the time delay that is currently active: warm−
up, cool down, start or stop delays.
2-10
ENGINE MENU
Redistribution or publication of this document,
by any means, is strictly prohibited.
Main Menu 1
Coolant Temperature
nnn Deg F
Oil Pressure
nnn PSI
Oil Temperature
nn Deg F
Engine Speed
nnnn RPM
Engine
Alternator
Adjust
More>>
Battery Voltage
nn.n VDC
Governor Duty Cycle
nnn %
Active Time Delay
None nnnn Sec
FIGURE 2-5. ENGINE MENU
2-11
ALTERNATOR MENU
Redistribution or publication of this document,
by any means, is strictly prohibited.
Figure 2-6 shows a block representation of the Alternator menu. If you press the button next to the
word “Alternator” in the display, the first Alternator
submenu is displayed.
As shown in the diagram, the Alternator menu has
eleven submenus.
Press the buttons next to the
digital display to navigate between the menus.
Press the Home button or the Previous Main Menu
button to return to Main Menu 1.
and symbols in the
Line-to-Line V oltage submenu:
The voltage Lineto-Line (L1, L2 and L3) are measured between L1 to
L2, L2 to L3 and L3 to L1, respectively. (Single
phase − L1 to L2 only.)
Line-to-Neutral Voltage submenu:
Note that the
Line-to -Neutral column will not be displayed for a 3
phase/3 wire system. Single phase − L1 to N and L2
to N.
Amps submenu:
All phases. (Single phase − L1
and L2 only.)
Frequency submenu:
Generator set output fre-
quency.
Total Real Power submenu:
This submenu displays the total amount of real power output, in kilowatts (kW).
Real Power submenu:
This submenu displays the
amount of real power output for L1, L2, and L3, in
kilowatts (kW). (Single phase − L1 and L2 only.)
Total Apparent Power submenu:
This submenu
displays the total amount of apparent power output,
in kilovolt amps (kVA).
Apparent Power submenu:
This submenu displays the amount of apparent power output for L1,
L2, and L3, in kilovolt amps (kVA). (Single phase −
L1 and L2 only.)
Total Power Factor submenu:
This submenu displays the power factor with leading/lagging indication.
The PF reading will contain an asterisk if the power
factor is leading (for example, Total PF 0.9 * ).
Power Factor submenu:
This submenu displays a
power factor value for L1, L2, and L3. (Single
phase − L1 and L2 only.)
The PF reading will contain an asterisk if the power
factor is leading (for example, PF L1 0.9*).
AVR Duty Cycle submenu:
This submenu displays the voltage regulator (drive) level in percentage of maximum. (Where maximum is 100% Duty
Cycle, software clamps Duty Cycle maximum to
60% for PMG and 90% for shunt.)
2-12
ALTERNATOR MENU
Redistribution or publication of this document,
by any means, is strictly prohibited.
Main Menu 1
Volts L12 L23 L31
V nnn nnn nnn
Volts L1N L2N
V nnn nnn
Amps L1 L2 L3
nnn nnn nnn
Engine
Alternator
Total Power
nn.n kVA
Power L1 L2 L3
kVA nn.n nn.n nn.n
Adjust
More>>
Frequency
nn.n Hz
Total Power
nnn kW
Power L1 L2 L3
kW nn.n nn.n nn.n
Total PF
n.nn*
PF L1 L2 L3
*n.nn *n.nn *n.nn
AVR Duty Cycle
nnn %
FIGURE 2-6. ALTERNATOR MENU
2-13
ADJUST MENU
Redistribution or publication of this document,
by any means, is strictly prohibited.
Figure 2-7 shows a block representation of the Adjust menu. If you press the button next to the word
“Adjust” in the display, the first Adjust submenu is
displayed.
As shown in the diagram, the Adjust menu has five
submenus. Each submenu includes a parameter or
value that can be changed.
Press the buttons next to the
digital display to navigate between the menus.
Press the Home button or the Previous Main Menu
button to return to Main Menu 1.
Adjusting Values/Parameters:
and symbols in the
Voltage Adjust submenu:
Voltage can be adjusted to 5 percent of the nominal voltage. For ex-
ample, if genset output voltage is 208 volts, the voltage can be adjusted from 198 to 218 volts.
If the displayed value is greater or less than the allowed (5%) range, the control will not except the
entry and will return to the previous setting. Retry by
entering a smaller change in one volt increments.
Frequency Adjust submenu:
Frequency can be
adjusted to 5 percent of the nominal frequency.
For example, if the genset frequency is 60.0 Hz, the
frequency can be adjusted from 57.0 to 63.0 Hz.
Start Delay submenu:
Start Delay can be set from
0 to 300 seconds (default = 0). This function is bypassed during a manual start/stop sequence.
Stop Delay submenu:
Stop Delay can be set from
0 to 600 seconds (default = 0). This function is bypassed during a manual start/stop sequence and
engine shutdown faults.
1.. Press the button next to the symbol in the display until the + and − symbols are displayed.
2.. If necessary , press the button next to the
or
symbols to move to the numeric character you
wish to change.
3.. Press the button next to the + symbol to increase the value or select parameter; press the
button next to the − symbol to decrease the value or select parameter.
4.. After adjusting values/selecting parameters,
pressing the
symbol results in the changes
being saved. (When adjusting values, make
sure the cursor is on the last numeric character
before pressing the
symbol).
If the Home button or Previous Main Menu button is pressed before pressing the
symbol,
the changes are not saved.
Rated To Idle (Beginning Version 2.303):
Rated
To Idle delay can be set from 0 to 10 seconds (default = 0). (Enter 1 or more to enable.) Entering a
non-zero delay will cause the genset to delay the
transition to Cooldown At Idle.
Idle Start submenu (Not available on all mod-
Idle Start can be enabled or disabled (default =
els):
Disable). This function is only enabled when the
genset is started in manual mode. Idle Start can
also be enabled while the set is running in manual
mode.
Enabling Idle Start will cause the genset to run in
idle mode until Idle Start is disabled. A warning is
displayed if genset is left in idle more than 10 minutes. Long periods of engine idling can eventually
affect engine performance and may void engine
warranty.
The idle speed can be adjusted from 700 to 1100
RPM (default of 800 RPM). Refer to
up Menu
in Section 5. A countdown timer is used to
Crank/Idle Set-
limit engine idle time. With InPower , idle time can be
adjusted from 0 to 60 minutes in 1 minute increments.
2-14
ADJUST MENU
Redistribution or publication of this document,
by any means, is strictly prohibited.
Main Menu 1
Voltage Adjust
nnn V
Frequency Adjust
nn.n Hz
Start Delay
nnn Sec
Engine
Alternator
Adjust
More>>
+Voltage Adjust
− nnn V
Back
+Frequency Adjust
− nn.n Hz
Back
+Start Delay
− nnn Sec
Back
Stop Delay
nnn Sec
Rated To Idle Delay
nn Sec
Idle Start
Disable
+Stop Delay
− nnn Sec
Back
+Rated To Idle Delay
− nn Sec
Back
+Idle Start
− Enable
Back
FIGURE 2-7. ADJUST MENU
2-15
FAULTS MENU
Redistribution or publication of this document,
by any means, is strictly prohibited.
Figure 2-9 shows a block representation of the
Faults menu. Up to 20 of the most recent faults can
be viewed. An example of how a fault code is displayed is shown in Figure 2-8.
The available menus are dependent on the number
of faults that have occurred.
• If there are
word “Faults” is not displayed and no Fault
menus are available.
• If
more than one fault
the button next to the word “Fault” in the
screen display to view the Faults Main Menu.
As shown in the diagram, the Faults Main
Menu has two submenus. Press the Previous
Main Menu button to return to the Faults
Main Menu. Press the Previous Main Menu
button a second time to return to Main
Menu 2.
Press the Home button at any time to return to Main
Menu 1.
no faults
, the symbol next to the
has occurred, press
History submenu:
From the Faults Main Menu,
press the button next to the word “History” in the display to view up to twenty of the most recent ac-
knowledged faults. Press the buttons next to the
and symbols in the digital display to navigate be-
tween the menus. Press the Previous Main Menu
button to return to the Faults Main Menu.
Current Fault submenu:
From the Faults Main
Menu, press the button next to the word “Current” in
the display to view up to twenty of the most recent
unacknowledged faults. Press the Previous Main
Menu button to return to the Faults Main Menu.
ASTERISK =
ACTIVE FAULT
W = WARNING
S = SHUTDOWN
FIGURE 2-8. HISTORY/CURRENT FAULT SUBMENU
FAULT
CODE
HOUR FAULT
OCCURRED
FAULT
DESCRIPTION
2-16
FAULTS MENU
Redistribution or publication of this document,
by any means, is strictly prohibited.
Main Menu 2
Faults Main Menu
nnnnn @Hr nnnnn.n
W xxxxxxxxxxxxxxxxxxxx
Fault 1
History
Current
Faults
System
nnnnn @Hr nnnnn.n
S xxxxxxxxxxxxxxxxxxxx
Fault 1
History
More>>
nnnnn @Hr nnnnn.n
S xxxxxxxxxxxxxxxxxxxx
Fault 2
nnnnn @Hr nnnnn.n
W xxxxxxxxxxxxxxxxxxxx
Fault 20
nnnnn @Hr nnnnn.n
W xxxxxxxxxxxxxxxxxxxx
Fault 2
nnnnn @Hr nnnnn.n
W xxxxxxxxxxxxxxxxxxxx
Fault 20
FIGURE 2-9. FAULTS MENU
2-17
SYSTEM MENU
Redistribution or publication of this document,
by any means, is strictly prohibited.
Figure 2-10 shows a block representation of the
System menu. If you press the button next to the
word “System” in the display, the System Main
Menu is displayed. This menu is displayed only if
the network communications module (NCM) feature is installed. The System Main Menu allows you
to view the status and load of other PCC equipment
connected on a common network with the PCC
2100 control.
As shown in the diagram, the System Main Menu
has three submenus.
When viewing ATS and Genset System submenus,
press the buttons next to the
digital display to navigate between the menus.
Press the Previous Main Menu button to return to
the System Main Menu. Press the Previous Main
Menu button a second time to return to Main
Menu 2. Press the Home button to return to Main
Menu 1.
and symbols in the
ATS System submenus:
From the System Main
Menu, press the button next to the word “A TS” in the
display to view the first of up to 16 ATS System submenus. An ATS system must be available in the network to display this submenu.
The ATS submenu allows viewing of the transfer
switch name (configured with InPower), kW load (if
monitored by the ATS system), status (e.g., not in
auto), and source connected and availability (ON =
source connected, OK = source available, or NA =
source not available).
Master System submenu:
From the System Main
Menu, press the button next to the word “Master” in
the display to view the Master System submenu. A
master controller must be available in the network
to display this submenu.
The master submenu allows viewing of the master
controller name (configured with InPower), kW load
and operational state.
Genset System submenus:
From the System
Main Menu, press the button next to the word “Genset” in the display to view the first of up to 16 Genset
System submenus. One genset must be available
in the network to display this submenu.
The genset submenu allows viewing of the genset
name (configured with InPower), kW load and operational state.
If a PCC 2100 control genset, in the network, contains the Power Transfer Control (PTC) feature, a
genset system submenu will be displayed for the
genset and the ATS System submenu will be displayed for the PTC feature.
2-18
SYSTEM MENU
Redistribution or publication of this document,
by any means, is strictly prohibited.
Main Menu 2
System Main Menu
ATSnameTag01>nnnnkW
Non Auto S1=On, S2=On
ATS Menu 1
ATS
Master
Genset
Faults
System
GensetName01>nnnnkW
Warning Fail2Start
History
More>>
Genset Menu 1
ATSnameTag02>nnnnkW
NonAut o S1=Ok, S2=NA
ATS Menu 2
ATSnameTag16>nnnnkW
NonAuto S1=Ok, S2=NA
ATS Menu 16
GensetName02>nnnnkW
NonAuto Alarm
Genset Menu 2
GensetName16>nnnnkW
NonAuto Alarm
Genset Menu 16
Master>nnnn kW
Shutdwn N=On,E=NA
FIGURE 2-10. SYSTEM MENU
2-19
HISTORY MENU
Redistribution or publication of this document,
by any means, is strictly prohibited.
Figure 2-11 shows a block representation of the
History menu. If you press the button next to the
word “History” in the display, the first History submenu is displayed.
Number of Starts submenu:
This submenu shows
the number of engine starts.
Engine Hours submenu:
This submenu shows
the number of operating hours for the engine.
As shown in the diagram, the History menu has five
submenus. This information is stored in non-volatile
memory and will not be deleted due to loss of battery power.
Press the buttons next to the
and symbols in the
digital display to navigate between the menus.
Press the the Previous Main Menu button to return
to Main Menu 2. Press the Home button to return to
Main Menu 1.
Control Hours submenu:
This submenu shows
the number of operating hours for the control.
Kilowatt Hours submenu:
This submenu shows
the number of kilowatt (kW) or megawatt (MW)
hours.
Genset Duty Cycle submenu:
This submenu
shows the percent of genset operating hours that
are less than 30 percent of rated load and percent of
hours that are greater than 90 percent.
2-20
HISTORY MENU
Redistribution or publication of this document,
by any means, is strictly prohibited.
Main Menu 2
Faults
System
History
More>>
Number Starts
nnnnn
Engine Hours
nnnnn Hours
Control Hours
nnnnn Hours
kW Hours
nnnnn kW Hrs
Genset Duty Cycle
Hr <30:nn% >90:nn%
FIGURE 2-11. HISTORY MENU
2-21
ABOUT MENU
Redistribution or publication of this document,
by any means, is strictly prohibited.
Figure 2-12 shows a block representation of the
About menu. If you press the button next to the word
“About” in the display, the first About submenu is
displayed.
As shown in the diagram, the About menu has three
submenus.
Model submenu:
This submenu shows the genset
model.
Rating submenu:
This submenu shows the rating
(Standby or Prime) and number of kilowatts (kW)).
Press the buttons next to the
and symbols in the
digital display to navigate between the menus.
Press the the Previous Main Menu button to return
to Main Menu 3. Press the Home button to return to
Main Menu 1.
Software Version submenu:
This submenu
shows the software version level. This information
is required to service the generator set.
2-22
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