Cummins Onan PowerCommand (2100 Series) Control Generator Sets OEM Service & Repair Manual

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PowerCommand  Control 2100 Series Generator Sets Printed in U.S.A. 960-0518D 02-2004 Service Manual Models DGBB, DGBC, DGCA, DGCB, DGCG, DGDA, DGDB, DGDK, DGFA, DGFB, DGFC

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 batteries. Before operating the generator set (genset), read the Operator’s Manual and become familiar with it and the equipment. Safe and efficient operation can be achieved only if the equipment is properly operated and maintained. Many accidents are caused by failure to follow fundamental rules and precautions. The following symbols, found throughout this manual, alert you to potentially dangerous conditions to the operator, service personnel, or the equipment. This symbol warns of immediate hazards which will result in severe personal injury or death. WARNING This symbol refers to a hazard or un- safe practice which can result in severe personal 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, unless tanks are outside the engine compartment. Fuel contact with hot engine or exhaust is a potential fire hazard. • DO NOT permit any flame, cigarette, pilot light, spark, arcing equipment, or other ignition source near the generator set or fuel tank. • Fuel lines must be adequately secured and free of leaks. Fuel connection at the engine should be made with an approved flexible line. Do not use zinc coated or copper fuel lines with diesel fuel. • Be sure all fuel supplies have a positive shutoff valve. • Be sure battery area has been well-ventilated prior to servicing near it. Lead-acid batteries emit a highly explosive hydrogen gas that can be ignited by arcing, sparking, smoking, etc. EXHAUST GASES ARE DEADLY • Provide an adequate exhaust system to properly expel discharged gases away from enclosed or sheltered areas and areas where individuals are likely to congregate. Visually and audibly inspect the exhaust daily for leaks per the maintenance schedule. Make sure that exhaust manifolds are secured and not warped. Do not use exhaust gases to heat a compartment. • Be sure the unit is well ventilated. • Engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm. MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH • Keep your hands, clothing, and jewelry away from moving parts. • Before starting work on the generator set, discon- nect battery charger from its AC source, then 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 equipment. Loose clothing and jewelry can become caught in moving parts. • If adjustment must be made while the unit is running, use extreme caution around hot manifolds, moving parts, etc. DO NOT OPERATE IN FLAMMABLE AND EXPLOSIVE ENVIRONMENTS Flammable vapor can cause an engine to overspeed and become difficult to stop, resulting in possible fire, explosion, severe personal injury and death. Do not operate a genset where a flammable vapor environment can be created by fuel spill, leak, etc., unless the genset is equipped with an automatic safety device to block the air intake and stop the engine. The owners and operators of the genset are solely responsible for operating the genset safely. Contact your authorized Cummins Power Generation distributor for more information.

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 approved 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 reproductive toxicity. When checking or changing engine oil, take care not to ingest, breathe the fumes, or contact used oil. • Keep multi-class ABC fire extinguishers handy. Class A fires involve ordinary combustible materials such as wood and cloth; Class B fires, combustible and flammable liquid fuels and gaseous fuels; Class C fires, live electrical equipment. (ref. NFPA No. 10). • Make sure that rags are not left on or near the engine. • 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 potential 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 cancer or reproductive toxicity. Take care not to breath or ingest or come into contact with exhaust gases. • Do not store any flammable liquids, such as fuel, cleaners, oil, etc., near the generator set. A fire or explosion could result. • Wear hearing protection when going near an operating generator set. • To prevent serious burns, avoid contact with hot metal parts such as radiator, turbo charger and exhaust system. KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

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 generator set and its performance characteristics, and displays performance information on a digital display panel. It accepts menu-driven control and setup input from the push button switches on the front panel. 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 service 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 personnel must be qualified to perform electrical and mechanical service. Read and follow Safety Precautions, on pages iii and iv. Copyright 2003 Cummins Power Generation. All rights reserved. Cummins and PowerCommand are registered trademarks of Cummins Inc.

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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 display are located on the face of the control panel as illustrated in Figure 2-1. CONTROL PANEL POWER ON/OFF MODES The power on/off modes of the control panel and operating software are Power On, Screen Saver and Sleep/Awake. Power On Mode: In this mode, power is 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 running 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 control’s operating software is inactive and the LEDs and the digital display on the control panel are all off. Sleep mode is a feature used to reduce battery power consumption when the control is not being used and the O/Manual/Auto switch is in the O position. When all conditions are met (i.e., no 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

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Cummins Onan PowerCommand (2100 Series) Control Generator Sets OEM Service & Repair Manual

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