SlideShare a Scribd company logo

Cummins onan dgdk generator set with power command 2100 controller service repair manual

J
jfksekfmsme

This service manual provides information for troubleshooting and servicing generator sets with PowerCommand 2100 controllers. It covers general operation of the controller and menus, circuit boards and modules, troubleshooting procedures, power transfer control troubleshooting, control adjustment and service procedures, servicing the generator, fuel transfer pump operation and wiring diagrams. The manual is intended to be used as a reference for technicians working on these generator sets.

Automotive
1 of 15
Download to read offline
1
2
Most read
3
4
5
6
7
Most read
8
Most read
9
10
11
12
13
14
15
Service Manual Generator Sets DGBB (Spec A−M) DGBC (Spec A−L) DGCA (Spec A−V) DGCB (Spec A−V) DGCG (Spec A−C) DGDA (Spec A−R) DGDB (Spec A−S) DGDK (Spec A−D) DGFA (Spec A−S) DGFB (Spec A−S) DGFC (Spec A−N) DGFS (Spec A−C) with PowerCommand 2100 Controller English − Original Instructions 11−2010 960−0518 (Issue 2)
i Table of Contents 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii SECTION TITLE PAGE 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 . . . . . . . . . . . . . . . . . . . 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) 6-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Current Transformer (CT) Installation 6-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SERVICING THE GENERATOR Testing the Generator 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator/Base Board Isolation Procedure 7-2 . . . . . . . . . . . . . . . . . . . . . . . . . Generator Disassembly 7-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Reassembly 7-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing the PMG 7-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 WIRING DIAGRAMS General 9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LS-14L iii IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS − This manual contains important instructions that should be followed during installation and maintenance of the generator and batter- ies. 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 oper- ator, service personnel, or the equipment. This symbol warns of immediate hazards which will result in severe personal in- jury or death. WARNING This symbol refers to a hazard or un- safe practice which can result in severe person- al injury or death. CAUTION This symbol refers to a hazard or un- safe 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 arc- ing, 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 se- cured 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 dis- connect 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 equip- ment. 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, explo- sion, 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 gen- set safely. Contact your authorized Cummins Power Generation distributor for more information.
iv ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH  Remove electric power before removing protective shields or touching electrical equipment. Use rub- ber 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 con- tacts 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 elec- trocution or property damage. Connect only through an approved isolation switch or an ap- proved paralleling device. GENERAL SAFETY PRECAUTIONS  Coolants under pressure have a higher boiling point than water. DO NOT open a radiator or heat ex- changer 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 reproduc- tive toxicity. When checking or changing engine oil, take care not to ingest, breathe the fumes, or con- tact 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. NFPA 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 over- heating and engine damage which present a poten- tial fire hazard.  Keep the generator set and the surrounding area clean and free from obstructions. Remove any de- bris 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 un- safe.  Substances in exhaust gases have been identified by some state or federal agencies as causing can- cer 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 ex- haust system. KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE
1-1 1. Introduction ABOUT THIS MANUAL This manual provides troubleshooting and repair information regarding the PowerCommand 2100 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. 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 gen- erator set and its performance characteristics, and displays performance information on a digital dis- play panel. It accepts menu-driven control and set- up input from the push button switches on the front panel. 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) 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 Incorrect service or replacement of parts can result in severe personal injury or death, and/or equipment damage. Service per- sonnel must be qualified to perform electrical and mechanical service. Read and follow Safety Precautions, on pages iii and iv.
2-1 2. Control Operation GENERAL The following describes the function and operation of the PowerCommandR 2100 Control (PCC). All indicators, control switches/buttons and digital dis- play 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 op- erating software are Power On, Screen Saver and Sleep/Awake. Power On Mode: In this mode, power is continu- ously 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 run- ning or running). The 30 minute timer resets and be- gins after each control panel action (any button or switch selection) or signal received by the operating software. All LEDs on the control panel operate nor- mally 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 con- trol’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 posi- tion. When all conditions are met (i.e., no unacknowl- edged 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 re- sponse to moving/pressing the following control panel switch/buttons:  Off/Manual/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 Ac- knowledge 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 er- ror condition.)
2-2 PANEL LAMP (1 of 3) CONFIGURABLE INDICATORS MANUAL RUN/STOP BUTTON OFF/MANUAL/ AUTO SWITCH SHUTDOWN AND WARNING STATUS INDICATORS EMERGENCY STOP PUSH BUTTON (Pull to reset) HOME BUTTON ANALOG AC METERING PANEL (OPTIONAL) DIGITAL DISPLAY MENU SELECTION BUTTON (1 of 4) PREVIOUS MAIN MENU BUTTON FAULT ACKNOWLEDGEMENT/ RESET BUTTON RUNNING/REMOTE START/NOT IN AUTO INDICATORS PANEL LAMP AND LAMP TEST BUTTON FIGURE 2-1. FRONT PANEL
2-3 FRONT PANEL Figure 2-1 shows the features of the front panel. 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 momen- 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 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 Menu Display And Buttons later in this section. Home Button: Press this button ( ) to view the 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 in- clude 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 re- mote). 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/Re- set 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. Remote Start Indicator: This green lamp is lit whenever the control is receiving a remote start sig- nal. Not in Auto Indicator: This red lamp flashes con- tinuously 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 in- dicators can be reset by turning the O/Manual/Auto switch to the O position and pressing the Fault Ac- knowledge/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 gener- ator 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 but- ton to acknowledge warning and shutdown mes- sages after the fault has been corrected. Pressing this button clears the fault from the current fault list. To acknowledge a Warning message, the O/Manu- al/Auto switch can be in any position. (It is not nec- essary 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.
2-4 Panel Lamp and Lamp Test Button: Press this button to turn the control panel lamps on or off. The lights will shut off after about ten minutes. Press and hold this button to test all front panel LEDs and me- ters. 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 shut- down should be avoided, if possible, to help prolong the life of the engine. Configurable Indicators The following configurable indicators (default val- ues shown) can be changed with the InPower ser- vice tool. The configurable items are: change gen- erator event and LED color (green, yellow or red), and enable/disable indicator. Low Oil Pressure Warning Indicator: This yellow lamp indicates the oil pressure is lower than the nor- mal 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: This red lamp indicates the engine has shut down because of low oil pressure. Overspeed Shutdown Indicator: This red lamp in- dicates the engine has shut down because of ex- cessive speed. Fail to Start Indicator: This red lamp indicates the engine failed to start.
2-5 MENU DISPLAY AND BUTTONS Figure 2-2 shows the digital display and the menu selection buttons. Digital Display: The two-line, 20 characters per 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: Four momen- 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 parame- ters. The button is active when a symbol adjacent to the button is displayed. The displayed symbol indi- cates the function of the button.  In the digital display for main menus (Figure 2-3), the and symbols indicate that pressing the adjacent button causes the operating pro- gram to go to the selected submenu (e.g., En- gine Menu in Figure 2-5).  In the digital display, the More>> symbol indi- cates 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 indi- cate that pressing the adjacent button causes the operating program to go to the next or pre- vious submenu, as shown in the menu dia- grams. Only the symbol is displayed in the first submenu. Only the is displayed in the last submenu. Both symbols are displayed in the rest of the submenus.  In the digital display, the plus or minus symbols (+ or −) indicate that pressing the adjacent but- ton can be used to change a parameter or val- ue 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 ad- jacent to the + symbol increase the value and pressing the button adjacent to the − symbol decreases the value. Only one numeric char- acter 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 the symbol is displayed when the cursor is on the first character of a field that can be changed. Only the is displayed when the cur- sor is on the last character. Both symbols are displayed when the cursor is on any other char- acter.  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 op- erating 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 ).
2-6 HOME BUTTON PREVIOUS MAIN MENU BUTTON 2 LINE, 20 CHARACTERS PER LINE MENU DISPLAY DIGITAL DISPLAY FIGURE 2-2. DIGITAL DISPLAY AND MENU SELECTION BUTTONS
Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
2-7 MAIN MENUS Figure 2-3 shows the three major main menus avail- able to the user. Figure 2-3 also includes references to pages in this section where you can find addition- al information on submenus. When viewing a sub- menu, you can press the previous main menu but- ton at any time to view its main menu. 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 dis- play. About Pwr Tran Setup More>> Faults System History More>> Engine Alternator Adjust More>> Main Menu 1 Main Menu 2 Main Menu 3 PAGE 2-11 PAGE 2-13 PAGE 2-15 PAGE 2-17 PAGE 2-19 PAGE 2-21 PAGE 6-5 PAGE 2-23 PAGE 2-25 FIGURE 2-3. MAIN MENUS
2-8 CONTROLLER CONFIGURATION MENU Figure 2-4 shows a block representation of the Con- troller 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 simulta- neously press the Home Menu and Previous Main Menu buttons. As shown in the diagram, the Controller Configura- tion menu has three submenus. Press the buttons next to the and symbols in the digital display to navigate between the menus. 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 symbol, the changes are not saved. Language Selected submenu: Used to select de- sired language (default = English). Temperature Units submenu: Used to select Fahrenheit or Centigrade for temperature readings. Fluid Pressure Units submenu: Used to select PSI or kPA for pressure readings.

More Related Content

PPTX
Everything you wanted to know, but were afraid to ask about Oozie
Chicago Hadoop Users Group
 
PDF
2016年6月23日 デジタルガジェット祭り！「これで安心！おやじ臭計れます」
aitc_jp
 
PDF
Jvm分享20101228
lunfu zhong
 
PDF
MANUAL BÁSICO LAPTOP XO SECUNDARIA
AIP I.E."J. M. Arguedas"
 
PDF
개인화 추천은 어디로 가고 있는가?
choi kyumin
 
PDF
코로나19로 인해 변화된 우리 시대의 데이터 트랜드
Yongho Ha
 
PDF
OpenvSwitchの落とし穴
Takashi Naito
 
PDF
[CB19] FileInsight-plugins: Decoding toolbox for malware analysis by 萬谷 暢崇
CODE BLUE
 
Everything you wanted to know, but were afraid to ask about Oozie
Chicago Hadoop Users Group
 
2016年6月23日 デジタルガジェット祭り！「これで安心！おやじ臭計れます」
aitc_jp
 
Jvm分享20101228
lunfu zhong
 
MANUAL BÁSICO LAPTOP XO SECUNDARIA
AIP I.E."J. M. Arguedas"
 
개인화 추천은 어디로 가고 있는가?
choi kyumin
 
코로나19로 인해 변화된 우리 시대의 데이터 트랜드
Yongho Ha
 
OpenvSwitchの落とし穴
Takashi Naito
 
[CB19] FileInsight-plugins: Decoding toolbox for malware analysis by 萬谷 暢崇
CODE BLUE
 

What's hot (6)

PDF
나도 할 수 있다 오픈소스
효준 강
 
PDF
Alphorm.com Formation KVM
Alphorm
 
PDF
제 15회 보아즈(BOAZ) 빅데이터 컨퍼런스 - [Hands-on 팀] : 수어 번역을 통한 위험 상황 속 의사소통 시스템 구축
BOAZ Bigdata
 
PDF
메타버스 서비스에 Android 개발자가 할 일이 있나요?
Myungwook Ahn
 
PPTX
Introduce of open swoole
Thanh Tai
 
PDF
데이터는 차트가 아니라 돈이 되어야 한다.
Yongho Ha
 
나도 할 수 있다 오픈소스
효준 강
 
Alphorm.com Formation KVM
Alphorm
 
제 15회 보아즈(BOAZ) 빅데이터 컨퍼런스 - [Hands-on 팀] : 수어 번역을 통한 위험 상황 속 의사소통 시스템 구축
BOAZ Bigdata
 
메타버스 서비스에 Android 개발자가 할 일이 있나요?
Myungwook Ahn
 
Introduce of open swoole
Thanh Tai
 
데이터는 차트가 아니라 돈이 되어야 한다.
Yongho Ha
 
Ad

More from jfksekfmsme (20)

PDF
Cummins onan hqdsb hybrid quiet diesel power system service repair manual
jfksekfmsme
 
PDF
Cummins onan power unit hqdpb hybrid quiet diesel power system service repair...
jfksekfmsme
 
PDF
Cummins onan dskaa generator set with power command 1.1 controller service re...
jfksekfmsme
 
PDF
Cummins onan dqaf generator set with power command controller pcc2100 service...
jfksekfmsme
 
PDF
Cummins onan dqad generator set with power command 3100 controller service re...
jfksekfmsme
 
PDF
Cummins onan egmbg p3500 (spec a) generator service repair manual
jfksekfmsme
 
PDF
Cummins onan dghe generator set with power command 1301 controller service re...
jfksekfmsme
 
PDF
Cummins onan egmbe p5450ec 60 hz portable generator set service repair manual
jfksekfmsme
 
PDF
Cummins onan egmbd, p5500 (spec a) generator service repair manual
jfksekfmsme
 
PDF
Cummins onan dgdb generator set with power command 2100 controller service re...
jfksekfmsme
 
PDF
Cummins onan dgda generator set with power command 3100 controller service re...
jfksekfmsme
 
PDF
Cummins onan dggd generator set with power command 2100 controller service re...
jfksekfmsme
 
PDF
Cummins onan dgda generator set with power command 2100 controller service re...
jfksekfmsme
 
PDF
Cummins onan dgdb generator set with power command 3100 controller service re...
jfksekfmsme
 
PDF
Cummins onan dgcg generator set with power command 2100 controller service re...
jfksekfmsme
 
PDF
Cummins onan dgcc generator set with power command 3100 controller service re...
jfksekfmsme
 
PDF
Cummins onan dfmb detector control generator set service repair manual
jfksekfmsme
 
PDF
Cummins onan dfga detector control generator set service repair manual
jfksekfmsme
 
PDF
Cummins onan dffb detector control generator set service repair manual
jfksekfmsme
 
PDF
Cummins onan dffa detector control generator set service repair manual
jfksekfmsme
 
Cummins onan hqdsb hybrid quiet diesel power system service repair manual
jfksekfmsme
 
Cummins onan power unit hqdpb hybrid quiet diesel power system service repair...
jfksekfmsme
 
Cummins onan dskaa generator set with power command 1.1 controller service re...
jfksekfmsme
 
Cummins onan dqaf generator set with power command controller pcc2100 service...
jfksekfmsme
 
Cummins onan dqad generator set with power command 3100 controller service re...
jfksekfmsme
 
Cummins onan egmbg p3500 (spec a) generator service repair manual
jfksekfmsme
 
Cummins onan dghe generator set with power command 1301 controller service re...
jfksekfmsme
 
Cummins onan egmbe p5450ec 60 hz portable generator set service repair manual
jfksekfmsme
 
Cummins onan egmbd, p5500 (spec a) generator service repair manual
jfksekfmsme
 
Cummins onan dgdb generator set with power command 2100 controller service re...
jfksekfmsme
 
Cummins onan dgda generator set with power command 3100 controller service re...
jfksekfmsme
 
Cummins onan dggd generator set with power command 2100 controller service re...
jfksekfmsme
 
Cummins onan dgda generator set with power command 2100 controller service re...
jfksekfmsme
 
Cummins onan dgdb generator set with power command 3100 controller service re...
jfksekfmsme
 
Cummins onan dgcg generator set with power command 2100 controller service re...
jfksekfmsme
 
Cummins onan dgcc generator set with power command 3100 controller service re...
jfksekfmsme
 
Cummins onan dfmb detector control generator set service repair manual
jfksekfmsme
 
Cummins onan dfga detector control generator set service repair manual
jfksekfmsme
 
Cummins onan dffb detector control generator set service repair manual
jfksekfmsme
 
Cummins onan dffa detector control generator set service repair manual
jfksekfmsme
 
Ad

Recently uploaded (20)

PPTX
Advance Module FI 160.pptx para pulsaar 160 y su sistema de encencido
CarlosAlbertoRodrgue54
 
PDF
Life Cycle Analysis of Electric and Internal Combustion Engine Vehicles
SAMAA
 
PPTX
Lecture 3b C Library xnxjxjxjxkx_ ESP32.pptx
indalrenu
 
PDF
EC290C NL EC290CNL - Volvo Service Repair Manual.pdf
Service Repair Manual
 
PDF
LB85 New Holland Service Repair Manual.pdf
Service Repair Manual
 
PDF
book-slidefsdljflsk fdslkfjslf sflgs.pdf
amitJi4
 
PPTX
Applications of SAP S4HANA in Mechanical by Sidhant Vohra (SET23A24040166).pptx
majulanaswaram49
 
PDF
Marketing project 2024 for marketing students
hatimfahad17
 
PPTX
building_blocks.pptxdcsDVabdbzfbtydtyyjtj67
Muthupriyadharshini1
 
PPTX
deforestation.ppt[1]bestpptondeforestation.pptx
Shivam463160
 
PDF
LB95 New Holland Service Repair Manual.pdf
Service Repair Manual
 
PDF
6. Chapter Twenty_Managing Mass Communications Advertising Sales Promotions E...
zxq62883
 
PPTX
UNIT-2(B) Organisavtional Appraisal.pptx
chahalharry627
 
PDF
Volvo EC290C NL EC290CNL Hydraulic Excavator Specs Manual.pdf
Service Repair Manual
 
PPTX
Dipak Presentation final 18 05 2018.pptx
syedsameermech
 
PDF
Journal Meraj.pdfuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuu
emonmian100
 
PPTX
Independence_Day_Patriotic theme (1).pptx
deepupathakji
 
PPTX
Understanding Machine Learning with artificial intelligence.pptx
324MOHAMMADFARAZ
 
PPTX
368455847-Relibility RJS-Relibility-PPT-1.pptx
smriti67469
 
PPTX
internal combustion engine renewable new
majulanaswaram49
 
Advance Module FI 160.pptx para pulsaar 160 y su sistema de encencido
CarlosAlbertoRodrgue54
 
Life Cycle Analysis of Electric and Internal Combustion Engine Vehicles
SAMAA
 
Lecture 3b C Library xnxjxjxjxkx_ ESP32.pptx
indalrenu
 
EC290C NL EC290CNL - Volvo Service Repair Manual.pdf
Service Repair Manual
 
LB85 New Holland Service Repair Manual.pdf
Service Repair Manual
 
book-slidefsdljflsk fdslkfjslf sflgs.pdf
amitJi4
 
Applications of SAP S4HANA in Mechanical by Sidhant Vohra (SET23A24040166).pptx
majulanaswaram49
 
Marketing project 2024 for marketing students
hatimfahad17
 
building_blocks.pptxdcsDVabdbzfbtydtyyjtj67
Muthupriyadharshini1
 
deforestation.ppt[1]bestpptondeforestation.pptx
Shivam463160
 
LB95 New Holland Service Repair Manual.pdf
Service Repair Manual
 
6. Chapter Twenty_Managing Mass Communications Advertising Sales Promotions E...
zxq62883
 
UNIT-2(B) Organisavtional Appraisal.pptx
chahalharry627
 
Volvo EC290C NL EC290CNL Hydraulic Excavator Specs Manual.pdf
Service Repair Manual
 
Dipak Presentation final 18 05 2018.pptx
syedsameermech
 
Journal Meraj.pdfuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuu
emonmian100
 
Independence_Day_Patriotic theme (1).pptx
deepupathakji
 
Understanding Machine Learning with artificial intelligence.pptx
324MOHAMMADFARAZ
 
368455847-Relibility RJS-Relibility-PPT-1.pptx
smriti67469
 
internal combustion engine renewable new
majulanaswaram49
 

Cummins onan dgdk generator set with power command 2100 controller service repair manual

  • 1. Service Manual Generator Sets DGBB (Spec A−M) DGBC (Spec A−L) DGCA (Spec A−V) DGCB (Spec A−V) DGCG (Spec A−C) DGDA (Spec A−R) DGDB (Spec A−S) DGDK (Spec A−D) DGFA (Spec A−S) DGFB (Spec A−S) DGFC (Spec A−N) DGFS (Spec A−C) with PowerCommand 2100 Controller English − Original Instructions 11−2010 960−0518 (Issue 2)
  • 2. i Table of Contents 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  • 3. ii SECTION TITLE PAGE 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 . . . . . . . . . . . . . . . . . . . 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) 6-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Current Transformer (CT) Installation 6-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SERVICING THE GENERATOR Testing the Generator 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator/Base Board Isolation Procedure 7-2 . . . . . . . . . . . . . . . . . . . . . . . . . Generator Disassembly 7-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Reassembly 7-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing the PMG 7-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 WIRING DIAGRAMS General 9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  • 4. LS-14L iii IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS − This manual contains important instructions that should be followed during installation and maintenance of the generator and batter- ies. 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 oper- ator, service personnel, or the equipment. This symbol warns of immediate hazards which will result in severe personal in- jury or death. WARNING This symbol refers to a hazard or un- safe practice which can result in severe person- al injury or death. CAUTION This symbol refers to a hazard or un- safe 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 arc- ing, 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 se- cured 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 dis- connect 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 equip- ment. 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, explo- sion, 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 gen- set safely. Contact your authorized Cummins Power Generation distributor for more information.
  • 5. iv ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH  Remove electric power before removing protective shields or touching electrical equipment. Use rub- ber 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 con- tacts 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 elec- trocution or property damage. Connect only through an approved isolation switch or an ap- proved paralleling device. GENERAL SAFETY PRECAUTIONS  Coolants under pressure have a higher boiling point than water. DO NOT open a radiator or heat ex- changer 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 reproduc- tive toxicity. When checking or changing engine oil, take care not to ingest, breathe the fumes, or con- tact 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. NFPA 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 over- heating and engine damage which present a poten- tial fire hazard.  Keep the generator set and the surrounding area clean and free from obstructions. Remove any de- bris 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 un- safe.  Substances in exhaust gases have been identified by some state or federal agencies as causing can- cer 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 ex- haust system. KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE
  • 6. 1-1 1. Introduction ABOUT THIS MANUAL This manual provides troubleshooting and repair information regarding the PowerCommand 2100 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. 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 gen- erator set and its performance characteristics, and displays performance information on a digital dis- play panel. It accepts menu-driven control and set- up input from the push button switches on the front panel. 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) 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 Incorrect service or replacement of parts can result in severe personal injury or death, and/or equipment damage. Service per- sonnel must be qualified to perform electrical and mechanical service. Read and follow Safety Precautions, on pages iii and iv.
  • 7. 2-1 2. Control Operation GENERAL The following describes the function and operation of the PowerCommandR 2100 Control (PCC). All indicators, control switches/buttons and digital dis- play 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 op- erating software are Power On, Screen Saver and Sleep/Awake. Power On Mode: In this mode, power is continu- ously 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 run- ning or running). The 30 minute timer resets and be- gins after each control panel action (any button or switch selection) or signal received by the operating software. All LEDs on the control panel operate nor- mally 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 con- trol’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 posi- tion. When all conditions are met (i.e., no unacknowl- edged 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 re- sponse to moving/pressing the following control panel switch/buttons:  Off/Manual/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 Ac- knowledge 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 er- ror condition.)
  • 8. 2-2 PANEL LAMP (1 of 3) CONFIGURABLE INDICATORS MANUAL RUN/STOP BUTTON OFF/MANUAL/ AUTO SWITCH SHUTDOWN AND WARNING STATUS INDICATORS EMERGENCY STOP PUSH BUTTON (Pull to reset) HOME BUTTON ANALOG AC METERING PANEL (OPTIONAL) DIGITAL DISPLAY MENU SELECTION BUTTON (1 of 4) PREVIOUS MAIN MENU BUTTON FAULT ACKNOWLEDGEMENT/ RESET BUTTON RUNNING/REMOTE START/NOT IN AUTO INDICATORS PANEL LAMP AND LAMP TEST BUTTON FIGURE 2-1. FRONT PANEL
  • 9. 2-3 FRONT PANEL Figure 2-1 shows the features of the front panel. 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 momen- 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 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 Menu Display And Buttons later in this section. Home Button: Press this button ( ) to view the 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 in- clude 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 re- mote). 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/Re- set 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. Remote Start Indicator: This green lamp is lit whenever the control is receiving a remote start sig- nal. Not in Auto Indicator: This red lamp flashes con- tinuously 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 in- dicators can be reset by turning the O/Manual/Auto switch to the O position and pressing the Fault Ac- knowledge/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 gener- ator 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 but- ton to acknowledge warning and shutdown mes- sages after the fault has been corrected. Pressing this button clears the fault from the current fault list. To acknowledge a Warning message, the O/Manu- al/Auto switch can be in any position. (It is not nec- essary 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.
  • 10. 2-4 Panel Lamp and Lamp Test Button: Press this button to turn the control panel lamps on or off. The lights will shut off after about ten minutes. Press and hold this button to test all front panel LEDs and me- ters. 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 shut- down should be avoided, if possible, to help prolong the life of the engine. Configurable Indicators The following configurable indicators (default val- ues shown) can be changed with the InPower ser- vice tool. The configurable items are: change gen- erator event and LED color (green, yellow or red), and enable/disable indicator. Low Oil Pressure Warning Indicator: This yellow lamp indicates the oil pressure is lower than the nor- mal 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: This red lamp indicates the engine has shut down because of low oil pressure. Overspeed Shutdown Indicator: This red lamp in- dicates the engine has shut down because of ex- cessive speed. Fail to Start Indicator: This red lamp indicates the engine failed to start.
  • 11. 2-5 MENU DISPLAY AND BUTTONS Figure 2-2 shows the digital display and the menu selection buttons. Digital Display: The two-line, 20 characters per 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: Four momen- 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 parame- ters. The button is active when a symbol adjacent to the button is displayed. The displayed symbol indi- cates the function of the button.  In the digital display for main menus (Figure 2-3), the and symbols indicate that pressing the adjacent button causes the operating pro- gram to go to the selected submenu (e.g., En- gine Menu in Figure 2-5).  In the digital display, the More>> symbol indi- cates 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 indi- cate that pressing the adjacent button causes the operating program to go to the next or pre- vious submenu, as shown in the menu dia- grams. Only the symbol is displayed in the first submenu. Only the is displayed in the last submenu. Both symbols are displayed in the rest of the submenus.  In the digital display, the plus or minus symbols (+ or −) indicate that pressing the adjacent but- ton can be used to change a parameter or val- ue 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 ad- jacent to the + symbol increase the value and pressing the button adjacent to the − symbol decreases the value. Only one numeric char- acter 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 the symbol is displayed when the cursor is on the first character of a field that can be changed. Only the is displayed when the cur- sor is on the last character. Both symbols are displayed when the cursor is on any other char- acter.  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 op- erating 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 ).
  • 12. 2-6 HOME BUTTON PREVIOUS MAIN MENU BUTTON 2 LINE, 20 CHARACTERS PER LINE MENU DISPLAY DIGITAL DISPLAY FIGURE 2-2. DIGITAL DISPLAY AND MENU SELECTION BUTTONS
  • 13. Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
  • 14. 2-7 MAIN MENUS Figure 2-3 shows the three major main menus avail- able to the user. Figure 2-3 also includes references to pages in this section where you can find addition- al information on submenus. When viewing a sub- menu, you can press the previous main menu but- ton at any time to view its main menu. 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 dis- play. About Pwr Tran Setup More>> Faults System History More>> Engine Alternator Adjust More>> Main Menu 1 Main Menu 2 Main Menu 3 PAGE 2-11 PAGE 2-13 PAGE 2-15 PAGE 2-17 PAGE 2-19 PAGE 2-21 PAGE 6-5 PAGE 2-23 PAGE 2-25 FIGURE 2-3. MAIN MENUS
  • 15. 2-8 CONTROLLER CONFIGURATION MENU Figure 2-4 shows a block representation of the Con- troller 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 simulta- neously press the Home Menu and Previous Main Menu buttons. As shown in the diagram, the Controller Configura- tion menu has three submenus. Press the buttons next to the and symbols in the digital display to navigate between the menus. 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 symbol, the changes are not saved. Language Selected submenu: Used to select de- sired language (default = English). Temperature Units submenu: Used to select Fahrenheit or Centigrade for temperature readings. Fluid Pressure Units submenu: Used to select PSI or kPA for pressure readings.