Cummins PowerCommand Control (3200 Series) Generator Sets Service & Repair Manual

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PowerCommand  Control 3200 Series Generator Sets Printed in U.S.A. 960Ć0512 7-2001 Service Manual Models DQKB, DQKC

i Table of Contents SECTION TITLE PAGE SAFETY PRECAUTIONS iii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 INTRODUCTION About this Manual 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Equipment 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How To Obtain Service 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CONTROL OPERATION 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sequence of Operation 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel Power On/Off Modes 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel Assembly 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reading Fault Codes 2-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Menu Display and Switches 2-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Menu Units Selection 2-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Menu 2-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Submenus 2-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Submenus 2-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Submenu 2-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . History/About Submenus 2-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bus Data Submenu 2-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 CONTROL CALIBRATION AND ADJUSTMENT General 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Modifying Setup/Adjust Submenus 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup Menus 3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust Submenu 3-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibration Procedure 3-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronics Box Control Wiring 3-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Magnetic Speed Pickup Unit (MPU) Installation 3-20 . . . . . . . . . . . . . . . . . . . . .

ii SECTION TITLE PAGE 4 SERVICING THE GENERATOR Testing the Generator 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Insulation Resistance (Megger) & Polarization Index (PI) Testing 4-2 . . . . . . . Drying the Windings 4-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator/PCC Control Isolation Procedure 4-5 . . . . . . . . . . . . . . . . . . . . . . . . . Exciter Stator 4-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exciter Rectifier Bridge (Rotating Rectifier Assembly) 4-7 . . . . . . . . . . . . . . . . Exciter Rotor 4-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Rotor (Generator Field) 4-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Stator 4-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test the PMG 4-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frame 7 Bearing Inspection/Removal 4-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frame 7 Generator Disassembly/Reassembly 4-14 . . . . . . . . . . . . . . . . . . . . . . Frame 8 Bearing Inspection/Removal 4-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frame 8 Generator Disassembly/Reassembly 4-25 . . . . . . . . . . . . . . . . . . . . . . Aligning Generator with Engine 4-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 WIRING DIAGRAMS General 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 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. MEDIUM VOLTAGE GENERATOR SETS (601V to 15kV) • Medium voltage acts differently 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 personal 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 authorized personnel so that the equipment can be de-energized 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 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 covers models produced under the Cummins  /Onan  and Cummins Power Genera- tion brand names. This manual provides PowerCommand  Control 3200 (PCC) calibration and adjustment procedures, control operation, alternator test and repair procedures and initial startup and test of paralleled generator sets. Operating and maintenance instructions are in the applicable Operator’s Manual. Generator set troubleshooting and repair (control and engine) information is provided in the following manuals. • Troubleshooting and Repair Manual Power- Command Control QSK45, QSK60, QSX15 Generator Sets, Bulletin No. 3666394 • Operation and Maintenance Manual QSK 45 and QSK60 Series Engines (engine repair and service) Bulletin No. 3666260 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. • Battery Hydrometer • Powr Factor Indicator • Jumper Leads • Tachometer or Frequency Meter • Wheatstone Bridge or Digital Ohmmeter • Variac • Load Test Panel • Megger or Insulation Resistance Meter 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 trained and experienced to perform electrical and mechanical service. Read and follow Safety Precautions, on pages iii and iv. Copyright  2001 Cummins Power Generation. All rights reserved. Cummins, Onan 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 PowerCommand generator set control. All in- dicators, control switches/buttons and graphical display 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 control must be configured for that generator set. Setup and calibration procedures are described in Sec- tion 3. SEQUENCE OF OPERATION When the PowerCommand control is in the AUTO mode, it will cause the generator set to start on receiving a signal from a remote device. The control will initiate a starter cranking signal and verify that the engine is rotating. The control will provide suffi- cient fuel to the engine to accelerate to start discon- nect speed. On reaching that speed, the control will ramp the generator set to idle (warm-up) or rated speed and voltage. On reaching rated speed and voltage, the control checks the system bus voltage. If no bus voltage is present, it will wait for a pulse from a remote Master First Start Sensor. On receiving that pulse, the control will signal the paralleling breaker to close. If bus voltage is present, the control will check for proper phase rotation, adjust the generator set to the bus voltage and frequency level, and then syn- chronize the generator set to the system bus. When a synchronous condition is achieved, the control will send a signal to close the paralleling breaker. When the paralleling breaker is closed, the generator set will assume it’s proportional share of the total load on the system bus. 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/graphical display will remain active until the Screen Saver mode is activated.

2-2 Screen Saver Mode: Power to the graphical display will be removed after 10 minutes (generator set not running or running). The 10 minute timer resets and begins after each control panel action (any button or switch selection) or signal received by the operating software. The bottom LEDs of the Analog AC Metering Panel (bar graphs) may remain on 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 will display the warning message. The control will remain active until the Fault Acknowledge button is pressed to clear the warning message and start the 10 minute timer. Sleep/Awake Mode: In the Sleep mode, the control’s operating software is inactive and the LEDs and the graphical display on the control panel are all off. Sleep mode is a feature that is used to reduce battery power consumption when the control is in the Auto mode and is not being used. When all conditions are met (i.e., no unacknowl- edged faults, Screen Saver Mode is active, and O/ Manual/Auto switch is in the Auto position) the Sleep mode will be activated. The operating software is initialized and the control panel LEDs and graphical display is turned on in re- sponse to one of the following: • moving/pressing any control panel switch/button. • a remote start input signal (generator set in Auto mode), or • customer fault 2 or 3 only (shutdown or warning indicator is on). To activate the control and view the menu display without starting the generator set, press any button on the control panel. 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) when the control is in Auto mode. InPower service tool is required to selected desired mode.

Cummins PowerCommand Control (3200 Series) Generator Sets Service & Repair Manual

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