CUMMINS PCC2100 Wiring Diagram OPERATOR Manual

PowerCommand  Control 2100 Series Generator Sets Printed in U.S.A. 960-0176C 02-2004 Operator’s Manual Models DFBF, DFCB, DFCC, DFCE Redistribution or publication of this document by any means, is strictly prohibited.

i Table of Contents SECTION TITLE PAGE IMPORTANT SAFETY INSTRUCTIONS iii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 INTRODUCTION General 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How to Obtain Service 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIFICATIONS 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 CONTROL OPERATION General 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prestart Checks 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel Power On/Off Modes 3-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Panel 3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stopping 3-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Menu Display and Buttons 3-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Menus 3-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting Default Settings 3-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Messages 3-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controller Configuration Menu 3-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Menu 3-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Menu 3-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust Menu 3-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Faults Menu 3-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Menu 3-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . History Menu 3-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . About Menu 3-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Transfer Menu 3-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Redistribution or publication of this document by any means, is strictly prohibited.

ii SECTION TITLE PAGE 4 TROUBLESHOOTING General 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Considerations 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Status Indicators 4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Line Circuit Breaker (Optional) 4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control and Diagnostics VIA Network or PC (Laptop) 4-2 . . . . . . . . . . . . . . . . . Fault Codes 4-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault Code Table 4-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Table 4-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 MAINTENANCE General 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Schedule 5-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Set Inspection 5-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Set Maintenance (Battery Disconnected) 5-4 . . . . . . . . . . . . . . . . . . Lubrication System 5-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankcase Breather 5-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling System 5-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Change Air Piping 5-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System 5-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cleaner 5-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Batteries 5-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 OPERATING RECOMMENDATIONS No-Load Operation 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exercise Period 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Operating Temperature 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Operating Temperature 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 OPTIONAL ENCLOSURE FEATURES General 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Receptacle 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overfill Alarm 7-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Emergency Stop Switch 7-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Distribution Panel 7-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Transfer Pump 7-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Alarm Panel 7-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Fuel Fill Box 7-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Redistribution or publication of this document by any means, is strictly prohibited.

1-1 1. Introduction GENERAL Each operator should read this manual before operating the set for the first time. A generator set (genset) must be operated and maintained properly if you are to expect safe and reliable operation. The manual includes a troubleshooting guide and a maintenance schedule. The engine manual is included with the set. Where there is conflicting information, this manual takes precedence over the engine manual. WARNING Improper operation and maintenance can lead to severe personal injury or loss of life and property by fire, electrocution, mechanical breakdown or exhaust gas asphyxi- ation. Read and follow the safety precautions on page iii and carefully observe all instructions and precautions in this manual. HOW TO OBTAIN SERVICE When the generator set requires servicing, contact your nearest Cummins Power Generation distributor. Factory-trained Parts and Service representa- tives are ready to handle all your service needs. To contact your local Cummins Power Generation distributor in the United States or Canada, call 1-800-888-6626 (this automated service utilizes touch-tone phones only). By selecting Option 1 (press 1), you will be automatically connected to the distributor nearest you. If you are unable to contact a distributor using the automated service, consult the Yellow Pages. Typi- cally, our distributors are listed under: GENERATORS-ELECTRIC or ELECTRICAL PRODUCTS For outside North America, call Cummins Power Generation, 1-763-574-5000, 7:30 AM to 4:00 PM, Central Standard Time, Monday through Friday. Or, send a fax to Cummins Power Generation using the fax number 1-763-528-7229. When contacting your distributor, always supply the complete Model, Specification, and Serial Number as shown on the generator set nameplate. WARNING INCORRECT SERVICE OR PARTS REPLACEMENT CAN RESULT IN SEVERE PERSONAL IN- JURY, DEATH, AND/OR EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST BE TRAINED AND EXPERIENCED TO PERFORM ELECTRICAL AND/OR MECHANICAL SERVICE. Copyright 2003 Cummins Power Generation. All rights reserved. Cummins and PowerCommand are registered trademarks of Cummins Inc. Redistribution or publication of this document by any means, is strictly prohibited.

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2-1 2. Specifications MODEL DFBF DFCB DFCC DFCE Engine Cummins Diesel Series NT855 NTA855 NTA855 NTA855 Generator kW Rating See Genset Nameplate for rating information. Electrical System Starting Voltage Battery Group Number CCA (minimum) Cold Soak @ 0° F (-18° C) 24 Volts DC Two, 12 Volt 8D 1400 Cooling System Capacity with Standard Radiator 13.5 Gal (51 L) 15 Gal (57 L) Lubricating System Oil Capacity with Filters Oil Type* 10.5 Gal (40 L) 10 Gal (38 L) * Refer to Cummins engine Operation and Maintenance Manual for lubricating oil recommendations/specifications. FUEL CONSUMPTION (STANDBY/FULL LOAD/60HZ) MODEL DFBF DFCB DFCC DFCE US gph (L/hr) 20.4 (77.3) 22.5 (85.3) 24.4 (92.5) 29.1 (110.3) OIL PRESSURE WARNING AND SHUTDOWN LIMITS Normal Oil Pressure Warning Limit Shutdown Limit 35-50 psi (242-345 kPa) 30 psi (207 kPa) 25 psi (172 kPa) Idle Oil Pressure Warning Limit Shutdown Limit 15 psi (104 kPa) 12 psi (83 kPa) 8 psi (55 kPa) Redistribution or publication of this document by any means, is strictly prohibited.

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3-1 3. Control Operation GENERAL The following describes the function and operation of the PowerCommand  2100 Control (PCC). All indicators, control switches/buttons and digital display are located on the face of the control panel as illustrated in Figure 3-1. This section covers prestart checks, starting and stopping and operating the generator set. Each operator should read through this entire section before attempting to start the set. It is essential that the operator be completely familiar with the set and the PCC control. Refer to Section 6 for operating recommendations. Before starting, be sure the following checks have been made and the unit is ready for operation. PRESTART CHECKS Lubrication Check the engine oil level. Keep the oil level near as possible to the dipstick high mark without overfilling. Coolant Check the engine coolant level. Refer to “Cooling Systems” in the Maintenance section of this manu- als for proper procedure. Fuel Make sure the fuel tanks have sufficient fuel and that fuel system is primed. Check to make sure there are no leaks and that all fittings are tight. Ventilation Make sure the generator set cooling inlet/outlet and exhaust ventilation openings are clear (not blocked) and operational. Remove all loose debris from surrounding area of generator set. Air flow from the radiator fan can blow loose items around and into ventilation openings. Exhaust Check to make sure entire exhaust system is tight, that no combustible materials are near system, and gases are discharged away from building openings. Redistribution or publication of this document by any means, is strictly prohibited.

3-2 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, Sleep mode is disabled. When disabled, the operating software will always remain active (Awake mode). If network and/or power transfer control (PTC) feature is installed, the sleep mode is not available. The InPower service tool is required to select the de- sired mode. Contact an authorized service center for assistance. Redistribution or publication of this document by any means, is strictly prohibited.

3-3 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 3-1. FRONT PANEL Redistribution or publication of this document by any means, is strictly prohibited.

CUMMINS PCC2100 Wiring Diagram OPERATOR Manual

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