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Cummins onan dgdk generator set with power command 3100 controller service repair manual

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This document is a service manual that provides information on servicing generator sets with PowerCommand 3100 controllers. It contains sections on control operation, circuit boards and modules, troubleshooting, control service and calibration, servicing the generator, fuel transfer pumps, and wiring diagrams. The manual provides safety instructions and describes the generator set components and how to test, maintain, and repair the system.

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Service Manual Generator Set with PowerCommand 3100 Controller DGBB (Spec A−M), DGBC (Spec C−K), DGCA (Spec M−U), DGCB (Spec B), DGCC (Spec B), DGDA (Spec L−R), DGDB (Spec L−S), DGDK (Spec A), DGEA (Spec K−N), DGFA (Spec K−S), DGFC (Spec A−N) English − Original Instructions 7−2010 960−0511 (Issue 3)
i Table of Contents SECTION TITLE PAGE IMPORTANT SAFETY INSTRUCTIONS iii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 INTRODUCTION About this Manual 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Equipment 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How To Obtain Service 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Overview 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Set Control Function 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CONTROL OPERATION General 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Considerations 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PCC Power On/Standby Mode 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Panel 2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Menu Display and Switches 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Menu 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Menu 2-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gen Menu 2-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 CIRCUIT BOARDS AND MODULES General 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital Board (A32) 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Interface Board (A31) 3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog Board (A33) 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital Display Board (A35) 3-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Customer Interface Board (A34) 3-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PT/CT Board (A36) 3-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage Regulator Output Module (A37) 3-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . Governor Output Module (A38) 3-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 TROUBLESHOOTING General 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Considerations 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Status Indicators 4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resetting the Control 4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warning and Shutdown Codes 4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pressure Warning and Shutdown Limits 4-9 . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Procedure 4-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii 5 CONTROL SERVICE AND CALIBRATION General 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Board Removal/Replacement 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Initial Start Setup Menu 5-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust Menu 5-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup and Calibration Menus 5-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibration Procedure 5-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accessory Box Control Components 5-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Sensors 5-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Magnetic Speed Pickup Unit (MPU) Installation 5-26 . . . . . . . . . . . . . . . . . . . . . Current Transformer (CT) Installation 5-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SERVICING THE GENERATOR Testing the Generator 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Disassembly 6-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Reassembly 6-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing the PMG 6-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 FUEL TRANSFER PUMP AND CONTROL General 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation 7-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Connections 7-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Transfer Pump Motor Connections 7-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing the Float Switch Assembly 7-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 WIRING DIAGRAMS General 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LS-14M 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 shutof f 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. MEDIUM VOLTAGE GENERATOR SETS (601V to 15kV)  Medium voltage acts dif ferently than low voltage. Special equipment and training is required to work on or around medium voltage equipment. Operation and maintenance must be done only by persons trained and qualified to work on such devices. Im- proper use or procedures will result in severe per- sonal injury or death.  Do not work on energized equipment. Unauthorized personnel must not be permitted near energized equipment. Due to the nature of medium voltage electrical equipment, induced voltage remains even after the equipment is disconnected from the power source. Plan the time for maintenance with autho- rized personnel so that the equipment can be de-en- ergized and safely grounded. 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 covers models produced under the Cummins/Onan and Cummins Power Genera- tion brand names. This manual provides troubleshooting and repair information regarding the PowerCommand  Control 3100 (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. 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) 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 trained and experienced to per- form electrical and mechanical service. Read and follow Safety Precautions, on pages iii and iv.
1-2 SYSTEM OVERVIEW The PCC is a microprocessor-based control for Cummins Power Generation generator sets. It pro- vides fuel control and engine speed governing, main alternator voltage output regulation, and com- plete 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. GENERATOR SET CONTROL FUNCTION Figure 1-1 shows some of the control functions. A more complete block diagram is provided in Section 3. A system schematic is provided in Section 8. The PCC monitors frequency from both the mag- netic pick-up (MPU) and the main stator inputs. The control sends a low power pulse-width modulated (PWM) signal to the governor output module, which then sends an amplified signal to the engine fuel control. The external PT/CT module reduces generator volt- age to approximately 18 VAC, and produces a rep- resentative AC voltage from CT output current. The voltage regulation function sends a low power PWM signal to the voltage regulator output module, which then sends an amplified signal to the exciter stator. Oil, coolant, and exhaust temperatures are sensed by variable resistance element sensors. Oil pres- sure is sensed by a capacitive element active sen- sor. Sensors Governor Output Output MPU N S PMG Battery BT1 Fuel Control Regulator FIGURE 1-1. GENERATOR SET CONTROL FUNCTIONS
2-1 2. Control Operation GENERAL The following describes the function and operation of the PowerCommand generator set control. All in- dicators, displays, meters and control switches are located on the face of the control panel as illustrated in Figure 2-1. Normally, generator set configuration options are set at the factory. When a new control is installed on a generator set or when parts are replaced, the con- trol must be configured for that generator set with the use of the “Initial Start Setup” portion of the inter- nal software. Setup and calibration procedures are described in Section 5. The automatic voltage regulator (AVR) and gover- nor operation characteristic adjustments are also described in Section 5. SAFETY CONSIDERATIONS AC power is present when the set is running. Do not open the generator output box while the set is run- ning. WARNING Contacting high voltage compo- nents can cause electrocution, resulting in se- vere personal injury or death. Do not open the generator output box while the set is running. Read and observe all WARNINGS and CAU- TIONS in your generator set manuals. The PCC control cabinet must be opened only by technically qualified personnel. CAUTION The PCC control cabinet must be opened only by technically qualified personnel. Lower level voltages (18 VAC to 15 VDC) are present in PCC control cabinet. These voltages can cause electrical shock, resulting in person- al injury. Even with power removed, improper handling of components can cause electrostatic dis- charge and damage to circuit components. PCC POWER ON / STANDBY MODE Standby Mode In the Standby (sleep) mode (selector switch S5 on the Digital Board is set to the right and the generator set is not running), the control’s operating software is inactive and the LEDs and displays on front panel are all off. The operating software is initialized and the front panel is turned on in response to a run signal or any one of eight “wake up” inputs from remote sensing switches. The wake up signals are:  Emergency Stop  Low Coolant Level  Low Coolant Temperature  Low Fuel  Customer Fault Inputs 2 and 3  Run Selected on Run/Off/Auto Switch  Remote Start Signal in Auto Mode  Self Test switch To activate and view the menu displays, press and release the Self Test switch. The PCC will initialize the operating software and permit operation of the menu display panel. If no menu selections are made, the power to the control panel will shut down after 30 seconds. Power On Mode In the Power On (awake) mode (selector switch S5 on the Digital Board is set to the left), the PCC will initialize the operating software and permit opera- tion of the menu display panel. (See Figure 3-1 for S5 location.) Power will stay on until switch (S5) is set to the Standby mode. It is recommended that switch S5 be left in the Power On mode in all ap- plication, except those where auxiliary battery charging is not available. CAUTION Electrostatic discharge will damage circuit boards. Always wear a grounding wrist strap when touching or handling circuit boards or socket-mounted ICs and when disconnect- ing or connecting harness connectors.
2-2 ACTIVE SWITCH INDICATOR (1 of 6) UPPER AND LOWER SCALE INDICATOR FREQUENCY METER KILOWATT METER (PERCENT LOAD) PHASE SELECTOR SWITCH AND INDICATORS RUN/OFF/AUTO SWITCH RESET SWITCH NON-AUTOMATIC WARNING SHUTDOWN STATUS INDICATORS EMERGENCY STOP PUSH BUTTON PANEL LAMP SWITCH SELF TEST SWITCH MENU SWITCH AC VOLTMETER AC AMMETER ALPHANUMERIC DISPLAY MENU SELECTION SWITCH (1 of 4) PCC 3100 LABEL FIGURE 2-1. FRONT PANEL (PCC 3100)
2-3 FRONT PANEL Figure 2-1 shows the features of the front panel. AC Voltmeter: Dual scale instrument indicates AC voltage. Measurement scale in use is shown on scale indicator lamp. AC Ammeter: Indicates current output in percent of maximum rated current. (Percent current is based on .8 PF three-phase and 1.0 PF single phase.) Kilowatt Meter: Indicates AC power output as per- cent of rated load. Frequency Meter: Indicates generator output fre- quency in hertz. Upper and Lower Scale Indicator Lamps: Indi- cate AC voltmeter scale. Digital Display: This two-line, 16-character per line alphanumeric display is used in the menu-driven operating system, in conjunction with the display menu selection switches and the Menu switch. Re- fer to the menu trees later in this section. The dis- play is also used to show warning and shutdown messages. Display Menu Selection Switches: Four momen- tary switches—two on each side of the digital dis- play window—are used to step through the various menu options and to adjust generator set parame- ters. The green arrow adjacent to the switch is lit when the switch can be used (switch is “active”). Menu Switch: Press this switch to return the digital display to the MAIN MENU. Refer to the menu trees later in this section. Reset Switch: Press this switch to reset warning and shutdown messages after the condition has been corrected. To reset a shutdown message with the Reset switch, the Run/Off/Auto switch must be in the Off position. In the Auto mode, shutdown faults can be reset by removing the remote start input and then cycling the remote reset input. Self Test Switch: Press and hold this switch to light all front panel LEDs and cycle through all shutdown and warning messages. Panel Lights Switch: Press this switch to turn con- trol panel illumination on and off. The illumination will shut off after about eight minutes. Phase Selector Switch and Indicators: Press this momentary switch to select phases of generator output to be measured by the AC voltmeter and am- meter. LEDs indicate the selected phase. Run/Off/Auto Switch: This switch starts and stops the genset locally, or enables start/stop control of the engine from a remote location. (Ground to start.) Note: When the generator set is operating in the Re- mote Start mode, removing the Remote Start com- mand does not shut off the engine if the load is more than 10 per cent, the cooldown timer is set to zero, and the control is configured for a single unit (not in parallel). The generator set continues to operate un- til it runs out of fuel, the E−stop button is used, or the load is removed. Emergency Stop Button: Push the switch in for emergency shutdown of the engine. Remote Reset switch will not reset emergency stop. Can only be reset at the PCC front panel. To reset: 1. Pull the button out or turn the switch clockwise (button with arrow) and allow it to pop out. 2. Move the Run/Off/Auto switch to Off. 3. Press the front panel Reset switch. 4. Select Run or Auto, as required. Non-Automatic Status Indicator: This red lamp flashes continuously when the Run/Off/Auto switch is not in the Auto position. 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 Reset switch. (It is not necessary to stop the generator set.) In the Auto mode, warnings can also be reset by cycling the remote reset input after the condition is corrected. Shutdown Status Indicator: This red lamp is lit whenever the control detects a shutdown condition. After the condition is corrected, shutdown indica- tors can be reset by turning the Run/Off/Auto switch to the Off position, and pressing the Reset switch. In Auto mode, shutdowns can be reset by removing the remote start input and then cycling the remote reset input. Emergency Stop shutdown status (Code 102) can be reset only at the PCC front panel.
2-4 FIGURE 2-2. DIGITAL DISPLAY AND MENU SELECTION SWITCHES MENU DISPLAY AND SWITCHES Figure 2-2 shows the digital display and the menu selection switches. Refer to heading “Front Panel” which describes the menu display and switches. In the Standby Mode, to activate and view the menu displays without starting the generator set, press and release the Self Test switch. This will initialize the PCC operating software and permit operation of the menu display panel. If no menu selections are made, a software timer will shut down the power af- ter 30 seconds. In the Power On Mode, power is continuously supplied to the control panel. Display will always remain on. In the digital display, the “>>” symbol indicates that selecting the adjacent button causes the operating program to branch to the next menu display—as shown in the menu diagrams. In the digital display, the “<<” symbol indicates that selecting the adjacent button causes the operating program to go back to the previous menu display. MAIN MENU The facing page shows the main menu and a block representation of the available submenus. As shown in the diagram, the main menu can branch into one of four directions. To display engine parameters, such as oil pressure and temperature, water temperature, engine speed (RPM), and exhaust temperature, press the button next to the word “ENGINE” in the display. Refer to ENGINE MENU in this section. To display generator parameters, such as volts, amps, power (kW), and frequency, press the button next to the word “GEN” in the display. Turn to the GEN MENU in this section. To adjust output voltage and frequency, or start and stop delays, press the button next to the word “AD- JUST” in the display. Refer to ADJUST MENU in Section 5. To display the selected generator set model and the resident version software, press the button next to the “>>” in the display. Refer to VERSION & DIS- PLAYS MENUS in Section 5.
2-5 DISPLAYS << METERS >>  VOLTAGE  _______ >> < > < > ENGINE GEN ADJUST >> < ACTIVE BUTTON < ACTIVE BUTTON SELECTED INACTIVE BUTTON RESET MENU > RETURN TO MAIN MENU CLEAR WARNING AND SHUTDOWN MESSAGES PAGES 2-6 & 2-7 MAIN MENU VERSION SETUP / CAL (ACCESS CODE) PAGES 2-8 & 2-9 OIL << COOLANT >> BATTERY << HOURS >> RPM << EXHAUST  FREQUENCY  _______ >>  START DELAY  _______ SEC >>  STOP DELAY  _______SEC >> VOLTS << AMPS >> POWER << KW HRS >> %GOV / REG << FREQUENCY GOV / REG << SETUP SECTION 5 SECTION 5 SECTION 5 SECTION 5  IDLE SPEED  _______RPM >>
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2-6 ENGINE MENU The facing page 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 will appear. As shown in the diagram, the ENGINE menu has three submenus. OIL/COOLANT submenu: This is the first subme- nu. Select OIL for a display of oil pressure and oil temperature. Select COOLANT for a display of coolant temperature. When oil or coolant parame- ters are displayed, pressing the button next to the “<<” will return the display (“BACK”) to the OIL/ COOLANT submenu. BATTERY/HOURS submenu: From the OIL/ COOLANT submenu, press the button next to the “>>” in the display to move to the BA TTERY/ HOURS submenu. Select BATTERY for a display of battery voltage. Select HOURS for a display of the number of starts and the running hours. When battery or hours parameters are displayed, press- ing the button next to the “<<” will return the display (“BACK”) to the BATTERY/HOURS submenu. RPM/EXHAUST submenu: From the BA TTERY/ HOURS submenu, press the button next to the “>>” in the display to move to the RPM/EXHAUST sub- menu. Select RPM for a display of engine RPM. Select EXHAUST for a display of the (optional) ex- haust temperature. When RPM or exhaust param- eters are displayed, pressing the button next to the “<<” will return the display (“BACK”) to the RPM/EX- HAUST submenu.
2-7 BATTERY << ___VDC < > < > < > < > > L___F / C << R___F / C (or n/a) > > > < > < > < > < > BATTERY << HOURS >> > < > < > < > ENGINE GEN ADJUST >> < > < > OIL << COOLANT >> < > ___PSI / KPA << ___F / C ENGINE GEN ADJUST >> < > < > < > OIL << COOLANT >> < > < > OIL << COOLANT >> OIL << COOLANT >> < > > < > BATTERY << HOURS >> STARTS ___ << HOURS ___ < > < > BATTERY << HOURS >> < > BATTERY << HOURS >> L___F/C (or n/a) << R___F/C (or n/a) < RPM << EXHAUST < > < RPM << EXHAUST < > < RPM << EXHAUST RPM << ___ BATTERY << HOURS >> < > BACK BACK BACK BACK BACK BACK ENGINE MENU OIL << COOLANT >> Indicates OR Condition
2-8 GEN MENU The facing page shows a block representation of the GEN menu. If you press the button next to the word “GEN” in the display, the first GEN submenu will appear. As shown in the diagram, the GEN menu has three submenus. Within these submenus, bold boxes in- dicate the possible selections made in the “Initial Start Setup” submenus (e.g., DELTA or WYE) and how the submenus will vary dependent on these selections. VOLTS/AMPS submenu: This is the first subme- nu. Select VOLTS for a display of a line-line or line- neutral selection. Select line-line or line-neutral for the desired voltage display. Select AMPS for a dis- play of L1, L2, and L3 current in amps. When volt- age or current parameters are displayed, pressing the button next to the “” will return the display (“BACK”) to the L-L/L-N submenu.

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Cummins onan dgdk generator set with power command 3100 controller service repair manual

  • 1. Service Manual Generator Set with PowerCommand 3100 Controller DGBB (Spec A−M), DGBC (Spec C−K), DGCA (Spec M−U), DGCB (Spec B), DGCC (Spec B), DGDA (Spec L−R), DGDB (Spec L−S), DGDK (Spec A), DGEA (Spec K−N), DGFA (Spec K−S), DGFC (Spec A−N) English − Original Instructions 7−2010 960−0511 (Issue 3)
  • 2. i Table of Contents SECTION TITLE PAGE IMPORTANT SAFETY INSTRUCTIONS iii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 INTRODUCTION About this Manual 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Equipment 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How To Obtain Service 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Overview 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Set Control Function 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CONTROL OPERATION General 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Considerations 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PCC Power On/Standby Mode 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Panel 2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Menu Display and Switches 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Menu 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Menu 2-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gen Menu 2-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 CIRCUIT BOARDS AND MODULES General 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital Board (A32) 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Interface Board (A31) 3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog Board (A33) 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital Display Board (A35) 3-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Customer Interface Board (A34) 3-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PT/CT Board (A36) 3-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage Regulator Output Module (A37) 3-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . Governor Output Module (A38) 3-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 TROUBLESHOOTING General 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Considerations 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Status Indicators 4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resetting the Control 4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warning and Shutdown Codes 4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pressure Warning and Shutdown Limits 4-9 . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Procedure 4-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  • 3. ii 5 CONTROL SERVICE AND CALIBRATION General 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Board Removal/Replacement 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Initial Start Setup Menu 5-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust Menu 5-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup and Calibration Menus 5-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibration Procedure 5-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accessory Box Control Components 5-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Sensors 5-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Magnetic Speed Pickup Unit (MPU) Installation 5-26 . . . . . . . . . . . . . . . . . . . . . Current Transformer (CT) Installation 5-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SERVICING THE GENERATOR Testing the Generator 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Disassembly 6-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Reassembly 6-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing the PMG 6-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 FUEL TRANSFER PUMP AND CONTROL General 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation 7-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Connections 7-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Transfer Pump Motor Connections 7-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing the Float Switch Assembly 7-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 WIRING DIAGRAMS General 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  • 4. LS-14M 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 shutof f 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. MEDIUM VOLTAGE GENERATOR SETS (601V to 15kV)  Medium voltage acts dif ferently than low voltage. Special equipment and training is required to work on or around medium voltage equipment. Operation and maintenance must be done only by persons trained and qualified to work on such devices. Im- proper use or procedures will result in severe per- sonal injury or death.  Do not work on energized equipment. Unauthorized personnel must not be permitted near energized equipment. Due to the nature of medium voltage electrical equipment, induced voltage remains even after the equipment is disconnected from the power source. Plan the time for maintenance with autho- rized personnel so that the equipment can be de-en- ergized and safely grounded. 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 covers models produced under the Cummins/Onan and Cummins Power Genera- tion brand names. This manual provides troubleshooting and repair information regarding the PowerCommand  Control 3100 (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. 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) 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 trained and experienced to per- form electrical and mechanical service. Read and follow Safety Precautions, on pages iii and iv.
  • 7. 1-2 SYSTEM OVERVIEW The PCC is a microprocessor-based control for Cummins Power Generation generator sets. It pro- vides fuel control and engine speed governing, main alternator voltage output regulation, and com- plete 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. GENERATOR SET CONTROL FUNCTION Figure 1-1 shows some of the control functions. A more complete block diagram is provided in Section 3. A system schematic is provided in Section 8. The PCC monitors frequency from both the mag- netic pick-up (MPU) and the main stator inputs. The control sends a low power pulse-width modulated (PWM) signal to the governor output module, which then sends an amplified signal to the engine fuel control. The external PT/CT module reduces generator volt- age to approximately 18 VAC, and produces a rep- resentative AC voltage from CT output current. The voltage regulation function sends a low power PWM signal to the voltage regulator output module, which then sends an amplified signal to the exciter stator. Oil, coolant, and exhaust temperatures are sensed by variable resistance element sensors. Oil pres- sure is sensed by a capacitive element active sen- sor. Sensors Governor Output Output MPU N S PMG Battery BT1 Fuel Control Regulator FIGURE 1-1. GENERATOR SET CONTROL FUNCTIONS
  • 8. 2-1 2. Control Operation GENERAL The following describes the function and operation of the PowerCommand generator set control. All in- dicators, displays, meters and control switches are located on the face of the control panel as illustrated in Figure 2-1. Normally, generator set configuration options are set at the factory. When a new control is installed on a generator set or when parts are replaced, the con- trol must be configured for that generator set with the use of the “Initial Start Setup” portion of the inter- nal software. Setup and calibration procedures are described in Section 5. The automatic voltage regulator (AVR) and gover- nor operation characteristic adjustments are also described in Section 5. SAFETY CONSIDERATIONS AC power is present when the set is running. Do not open the generator output box while the set is run- ning. WARNING Contacting high voltage compo- nents can cause electrocution, resulting in se- vere personal injury or death. Do not open the generator output box while the set is running. Read and observe all WARNINGS and CAU- TIONS in your generator set manuals. The PCC control cabinet must be opened only by technically qualified personnel. CAUTION The PCC control cabinet must be opened only by technically qualified personnel. Lower level voltages (18 VAC to 15 VDC) are present in PCC control cabinet. These voltages can cause electrical shock, resulting in person- al injury. Even with power removed, improper handling of components can cause electrostatic dis- charge and damage to circuit components. PCC POWER ON / STANDBY MODE Standby Mode In the Standby (sleep) mode (selector switch S5 on the Digital Board is set to the right and the generator set is not running), the control’s operating software is inactive and the LEDs and displays on front panel are all off. The operating software is initialized and the front panel is turned on in response to a run signal or any one of eight “wake up” inputs from remote sensing switches. The wake up signals are:  Emergency Stop  Low Coolant Level  Low Coolant Temperature  Low Fuel  Customer Fault Inputs 2 and 3  Run Selected on Run/Off/Auto Switch  Remote Start Signal in Auto Mode  Self Test switch To activate and view the menu displays, press and release the Self Test switch. The PCC will initialize the operating software and permit operation of the menu display panel. If no menu selections are made, the power to the control panel will shut down after 30 seconds. Power On Mode In the Power On (awake) mode (selector switch S5 on the Digital Board is set to the left), the PCC will initialize the operating software and permit opera- tion of the menu display panel. (See Figure 3-1 for S5 location.) Power will stay on until switch (S5) is set to the Standby mode. It is recommended that switch S5 be left in the Power On mode in all ap- plication, except those where auxiliary battery charging is not available. CAUTION Electrostatic discharge will damage circuit boards. Always wear a grounding wrist strap when touching or handling circuit boards or socket-mounted ICs and when disconnect- ing or connecting harness connectors.
  • 9. 2-2 ACTIVE SWITCH INDICATOR (1 of 6) UPPER AND LOWER SCALE INDICATOR FREQUENCY METER KILOWATT METER (PERCENT LOAD) PHASE SELECTOR SWITCH AND INDICATORS RUN/OFF/AUTO SWITCH RESET SWITCH NON-AUTOMATIC WARNING SHUTDOWN STATUS INDICATORS EMERGENCY STOP PUSH BUTTON PANEL LAMP SWITCH SELF TEST SWITCH MENU SWITCH AC VOLTMETER AC AMMETER ALPHANUMERIC DISPLAY MENU SELECTION SWITCH (1 of 4) PCC 3100 LABEL FIGURE 2-1. FRONT PANEL (PCC 3100)
  • 10. 2-3 FRONT PANEL Figure 2-1 shows the features of the front panel. AC Voltmeter: Dual scale instrument indicates AC voltage. Measurement scale in use is shown on scale indicator lamp. AC Ammeter: Indicates current output in percent of maximum rated current. (Percent current is based on .8 PF three-phase and 1.0 PF single phase.) Kilowatt Meter: Indicates AC power output as per- cent of rated load. Frequency Meter: Indicates generator output fre- quency in hertz. Upper and Lower Scale Indicator Lamps: Indi- cate AC voltmeter scale. Digital Display: This two-line, 16-character per line alphanumeric display is used in the menu-driven operating system, in conjunction with the display menu selection switches and the Menu switch. Re- fer to the menu trees later in this section. The dis- play is also used to show warning and shutdown messages. Display Menu Selection Switches: Four momen- tary switches—two on each side of the digital dis- play window—are used to step through the various menu options and to adjust generator set parame- ters. The green arrow adjacent to the switch is lit when the switch can be used (switch is “active”). Menu Switch: Press this switch to return the digital display to the MAIN MENU. Refer to the menu trees later in this section. Reset Switch: Press this switch to reset warning and shutdown messages after the condition has been corrected. To reset a shutdown message with the Reset switch, the Run/Off/Auto switch must be in the Off position. In the Auto mode, shutdown faults can be reset by removing the remote start input and then cycling the remote reset input. Self Test Switch: Press and hold this switch to light all front panel LEDs and cycle through all shutdown and warning messages. Panel Lights Switch: Press this switch to turn con- trol panel illumination on and off. The illumination will shut off after about eight minutes. Phase Selector Switch and Indicators: Press this momentary switch to select phases of generator output to be measured by the AC voltmeter and am- meter. LEDs indicate the selected phase. Run/Off/Auto Switch: This switch starts and stops the genset locally, or enables start/stop control of the engine from a remote location. (Ground to start.) Note: When the generator set is operating in the Re- mote Start mode, removing the Remote Start com- mand does not shut off the engine if the load is more than 10 per cent, the cooldown timer is set to zero, and the control is configured for a single unit (not in parallel). The generator set continues to operate un- til it runs out of fuel, the E−stop button is used, or the load is removed. Emergency Stop Button: Push the switch in for emergency shutdown of the engine. Remote Reset switch will not reset emergency stop. Can only be reset at the PCC front panel. To reset: 1. Pull the button out or turn the switch clockwise (button with arrow) and allow it to pop out. 2. Move the Run/Off/Auto switch to Off. 3. Press the front panel Reset switch. 4. Select Run or Auto, as required. Non-Automatic Status Indicator: This red lamp flashes continuously when the Run/Off/Auto switch is not in the Auto position. 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 Reset switch. (It is not necessary to stop the generator set.) In the Auto mode, warnings can also be reset by cycling the remote reset input after the condition is corrected. Shutdown Status Indicator: This red lamp is lit whenever the control detects a shutdown condition. After the condition is corrected, shutdown indica- tors can be reset by turning the Run/Off/Auto switch to the Off position, and pressing the Reset switch. In Auto mode, shutdowns can be reset by removing the remote start input and then cycling the remote reset input. Emergency Stop shutdown status (Code 102) can be reset only at the PCC front panel.
  • 11. 2-4 FIGURE 2-2. DIGITAL DISPLAY AND MENU SELECTION SWITCHES MENU DISPLAY AND SWITCHES Figure 2-2 shows the digital display and the menu selection switches. Refer to heading “Front Panel” which describes the menu display and switches. In the Standby Mode, to activate and view the menu displays without starting the generator set, press and release the Self Test switch. This will initialize the PCC operating software and permit operation of the menu display panel. If no menu selections are made, a software timer will shut down the power af- ter 30 seconds. In the Power On Mode, power is continuously supplied to the control panel. Display will always remain on. In the digital display, the “>>” symbol indicates that selecting the adjacent button causes the operating program to branch to the next menu display—as shown in the menu diagrams. In the digital display, the “<<” symbol indicates that selecting the adjacent button causes the operating program to go back to the previous menu display. MAIN MENU The facing page shows the main menu and a block representation of the available submenus. As shown in the diagram, the main menu can branch into one of four directions. To display engine parameters, such as oil pressure and temperature, water temperature, engine speed (RPM), and exhaust temperature, press the button next to the word “ENGINE” in the display. Refer to ENGINE MENU in this section. To display generator parameters, such as volts, amps, power (kW), and frequency, press the button next to the word “GEN” in the display. Turn to the GEN MENU in this section. To adjust output voltage and frequency, or start and stop delays, press the button next to the word “AD- JUST” in the display. Refer to ADJUST MENU in Section 5. To display the selected generator set model and the resident version software, press the button next to the “>>” in the display. Refer to VERSION & DIS- PLAYS MENUS in Section 5.
  • 12. 2-5 DISPLAYS << METERS >>  VOLTAGE  _______ >> < > < > ENGINE GEN ADJUST >> < ACTIVE BUTTON < ACTIVE BUTTON SELECTED INACTIVE BUTTON RESET MENU > RETURN TO MAIN MENU CLEAR WARNING AND SHUTDOWN MESSAGES PAGES 2-6 & 2-7 MAIN MENU VERSION SETUP / CAL (ACCESS CODE) PAGES 2-8 & 2-9 OIL << COOLANT >> BATTERY << HOURS >> RPM << EXHAUST  FREQUENCY  _______ >>  START DELAY  _______ SEC >>  STOP DELAY  _______SEC >> VOLTS << AMPS >> POWER << KW HRS >> %GOV / REG << FREQUENCY GOV / REG << SETUP SECTION 5 SECTION 5 SECTION 5 SECTION 5  IDLE SPEED  _______RPM >>
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  • 14. 2-6 ENGINE MENU The facing page 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 will appear. As shown in the diagram, the ENGINE menu has three submenus. OIL/COOLANT submenu: This is the first subme- nu. Select OIL for a display of oil pressure and oil temperature. Select COOLANT for a display of coolant temperature. When oil or coolant parame- ters are displayed, pressing the button next to the “<<” will return the display (“BACK”) to the OIL/ COOLANT submenu. BATTERY/HOURS submenu: From the OIL/ COOLANT submenu, press the button next to the “>>” in the display to move to the BA TTERY/ HOURS submenu. Select BATTERY for a display of battery voltage. Select HOURS for a display of the number of starts and the running hours. When battery or hours parameters are displayed, press- ing the button next to the “<<” will return the display (“BACK”) to the BATTERY/HOURS submenu. RPM/EXHAUST submenu: From the BA TTERY/ HOURS submenu, press the button next to the “>>” in the display to move to the RPM/EXHAUST sub- menu. Select RPM for a display of engine RPM. Select EXHAUST for a display of the (optional) ex- haust temperature. When RPM or exhaust param- eters are displayed, pressing the button next to the “<<” will return the display (“BACK”) to the RPM/EX- HAUST submenu.
  • 15. 2-7 BATTERY << ___VDC < > < > < > < > > L___F / C << R___F / C (or n/a) > > > < > < > < > < > BATTERY << HOURS >> > < > < > < > ENGINE GEN ADJUST >> < > < > OIL << COOLANT >> < > ___PSI / KPA << ___F / C ENGINE GEN ADJUST >> < > < > < > OIL << COOLANT >> < > < > OIL << COOLANT >> OIL << COOLANT >> < > > < > BATTERY << HOURS >> STARTS ___ << HOURS ___ < > < > BATTERY << HOURS >> < > BATTERY << HOURS >> L___F/C (or n/a) << R___F/C (or n/a) < RPM << EXHAUST < > < RPM << EXHAUST < > < RPM << EXHAUST RPM << ___ BATTERY << HOURS >> < > BACK BACK BACK BACK BACK BACK ENGINE MENU OIL << COOLANT >> Indicates OR Condition
  • 16. 2-8 GEN MENU The facing page shows a block representation of the GEN menu. If you press the button next to the word “GEN” in the display, the first GEN submenu will appear. As shown in the diagram, the GEN menu has three submenus. Within these submenus, bold boxes in- dicate the possible selections made in the “Initial Start Setup” submenus (e.g., DELTA or WYE) and how the submenus will vary dependent on these selections. VOLTS/AMPS submenu: This is the first subme- nu. Select VOLTS for a display of a line-line or line- neutral selection. Select line-line or line-neutral for the desired voltage display. Select AMPS for a dis- play of L1, L2, and L3 current in amps. When volt- age or current parameters are displayed, pressing the button next to the “” will return the display (“BACK”) to the L-L/L-N submenu.