Operator Manual Home Standby Power Generator Set GSBB (Spec A-B) GSBC (Spec B) English Original Instructions 1-2014 A029V089 (Issue 9)
Table of Contents 1. IMPORTANT SAFETY INSTRUCTIONS ...................................................................................... 1.1 Save These Instructions ........................................................................................................ 1.2 General Precautions .............................................................................................................. 1.3 Generator Voltage is Deadly ..........................................................................
Table of Contents 1-2014 3.9.2 Software Info .............................................................................................................. 3.10 Event Log............................................................................................................................ 3.10.1 To Check Log of Last 20 Events.............................................................................. 3.10.2 List of Recordable Events ..................................................................
1-2014 Table of Contents 5.4.20 Invalid Set Configuration - Fault Code 37 ............................................................... 5.4.21 Processor Fault - Fault Code 43 ............................................................................. 5.4.22 Speed Sense Fault - Fault Code 45 ....................................................................... 5.4.23 Generator Set Overload - Fault Code 46 ................................................................ 5.4.
Table of Contents 1-2014 This page is intentionally blank.
1 IMPORTANT SAFETY INSTRUCTIONS 1.1 Save These Instructions This manual contains important instructions for the generator set that should be followed during the operation and maintenance of the generator and batteries. Thoroughly read this manual before operating the generator set. Safe operation and top performance can only be obtained when equipment is properly operated and maintained. The following symbols in this manual alert you to potential hazards to the operator, service person and equipment.
1. IMPORTANT SAFETY INSTRUCTIONS 1.3 1-2014 Generator Voltage is Deadly • Generator output connections must be made by a trained and experienced electrician in accordance with all applicable codes. • This standby generator set and the public utility may only be connected to the house circuits by means of the automatic transfer switch. • Improper connections can lead to electrocution of utility workers and damage to equipment. • Use caution when working on live electrical equipment.
1-2014 1. IMPORTANT SAFETY INSTRUCTIONS • Do not open or mutilate the battery. • Released electrolytes have been known to be harmful to the skin and eyes and to be toxic. • Batteries present the risk to high short circuit current: • Remove watches, rings or other metal objects and use tools with insulated handles.
1. IMPORTANT SAFETY INSTRUCTIONS 1.8.3 1-2014 Only You Can Protect Yourself From CO Poisoning! • Locate the generator in an area where there are no windows, doors or other access points into the home. • Make sure all CO detectors are working properly. • Pay attention to the signs of CO poisoning. • Check the exhaust system for corrosion, obstruction and leaks each time you start the generator set and every eight hours if you run it continuously.
2 Introduction This generator set application is intended for stationary emergency use. Important note for Brazil applications: The manufacturer warns that the installation, operation and maintenance of equipment by the user must fully comply with the Manual's guidelines and current Brazilian laws, including those of the Brazilian Agency of Petroleum, Natural Gas and Fuels (ANP) and the Brazilian Energy Agency (ANEEL). 2.1 About this Manual This is the Operator Manual for the Model GSBB generator set.
2. Introduction 1-2014 A more in-depth illustration of the operation of the generator set and transfer switch can be found in the Timing Charts, located in the Typical Operation chapter of this manual. 2.2.1 Generator Set Nameplate WARNING Improper service or replacement of parts can lead to severe personal injury or death and to damage to equipment and property. Service personnel must be qualified to perform electrical and mechanical service.
1-2014 2.2.2 2. Introduction Model Specifications TABLE 1. GSBB AND GSBC MODEL VARIATIONS Product Description 20GSBB-6713A\B 60 Hz Warm 20GSBB-6714A\B 60 Hz Cold * 14GSBB-6716A\B 50 Hz (AU/NZ) 20GSBB-6717A\20GSBC-6927B 60 Hz CSA Cold * * Includes an engine oil heater. NOTICE See the Cold Weather Specifications Table for recommendations. TABLE 2.
2. Introduction 1-2014 TABLE 4.
1-2014 2. Introduction TABLE 7. GENERATOR SPECIFICATIONS TABLE 60 Hz Propane Vapor 50 Hz Natural Gas Propane Vapor Natural Gas Generator Brush-Type, 2-Pole Rotating Field, Single Bearing Power (kVA) --- --- 13.5 13.5 Rated Voltage (V) 120/240 120/240 115/230 115/230 Rated Current (Amps) 162/81.25 144/72 117.4/58.7 117.4/58.
2. Introduction 1-2014 GENERATORS - ELECTRIC ENGINES - GASOLINE OR DIESEL If you have difficulty arranging service or resolving a problem, please contact the Service Manager at the nearest Cummins Power Generation distributor for assistance. Outside North America If you are outside North America, call Cummins Power Generation at 1-763-574-5000 from 7:30 AM to 4:00 PM, Central Standard Time, Monday through Friday, or fax 1-763-528-7229.
3 Operation 3.1 3 Position Switch A three-position Start/Stop switch is located at the genset control panel. Switch positions available: • Manual Start: Normally only the maintenance/service technician has occasion to manually start and stop the generator set. Push the switch down at the thick end to start the set immediately. • Stop (middle position): This switch disables the set.
3. Operation 3.2 1-2014 In-Home Operator Panel The operator panel must be hard-wired to the generator set in order for the generator system to operate. NOTICE The in-home operator panel and Internet/Email interface can be used simultaneously The operator panel consists of two UTILITY status lamps, three GENERATOR status lamps, three action buttons and an LCD display screen with four navigation buttons. No.
1-2014 3.3 3. Operation Typical Operation NOTICE The following diagrams are based on an APPROXIMATE time duration. Your genset may vary slightly from the timing diagrams in this manual. FIGURE 4.
3. Operation 1-2014 FIGURE 5.
1-2014 3. Operation FIGURE 6.
3. Operation 1-2014 FIGURE 7. 3.3.1 LOAD MANAGEMENT TIMING DIAGRAM Normal Operation: Utility Power Available and Connected As long as utility power is available and connected, both of the green UTILITY lamps (PRESENT and CONNECTED) will stay on and the LCD screen will indicate “Genset Stopped". If the red GENERATOR STANDBY OFF light is on, the generator set will not start up automatically if utility power is interrupted.
1-2014 3. Operation FIGURE 8. 3.3.2 UTILITY PRESENT AND CONNECTED—STANDBY OFF LAMP ON Emergency Operation: Utility Power Interrupted If utility power is interrupted, 1. The green UTILITY PRESENT lamp will go out 2. The generator set will start automatically and the green GENERATOR RUNNING lamp will turn on. 3. The UTILITY CONNECTED light will go out when the generator set is connected to supply power. The LCD screen will provide a visual indication of “Genset Load" (bar graphs).
3. Operation 3.3.3 1-2014 To Adjust the Output Voltage Use the following procedure: 1. Connect an accurate AC volt meter across L1 and L2 while the generator set is running. 2. With Output Volts selected on the Adjustments Menu screen, press the up or down arrow button to adjust the voltage to the desired setting 3. The control allows an adjustment of 240 VAC ± 7% (17 VAC). 4. Press the BACK button to save the settings and return to the home screen. 3.
1-2014 3.5 3. Operation To Manually Start/Stop Generator Set Normally, only the maintenance/service technician has to manually start and stop the generator set. • Starting the generator set will result in the generator powering the house loads. CAUTION Manually starting or stopping the generator set disables generator set STANDBY. The generator set will not automatically start to supply power if utility power is interrupted.
3. Operation 3.6.1 1-2014 Fault Screen If a generator set shutdown fault occurs, a FAULT warning appears with the following information: • Brief description of the warning or fault • The two-digit Fault Code Number • The time of occurrence of the fault Press the BACK button to reset the fault and return to the home screen. See the Fault Log section of this manual to review the log of the last 5 faults. FIGURE 12. 3.6.
1-2014 3. Operation • Press the BACK button to return to the home screen. FIGURE 14. 3.7 TYPICAL NEW EVENT SCREEN Genset Status To check generator set output voltage and frequency and the total numbers of hours run: 1. Press the MENU button on the home screen. 2. Press the up or down arrow button on the menu screen to select Genset Status. 3. Press the ENTER button on the menu screen and note the values displayed on the Genset Status screen. 4. Press the BACK button to return to the home screen.
3. Operation 1-2014 FIGURE 15. 3.8 GENERATOR SET STATUS SCREEN Load Management The generator set may have been set up at installation to connect and disconnect certain large loads, such as air conditioners, to manage the total load so as not to overload the generator set. This requires the installation of relays to the load management signals which allow for the disconnection of loads. Load management can be set to operate in automatic or manual mode.
1-2014 3.8.1 3. Operation Automatic Load Management When set to automatic mode, the user takes no action and can only view which loads are connected. Three minutes after the generator starts, the load that is connected to genset load L1 is connected. After a delay of three more minutes, the load that is connected to genset load L2 is connected. If the connection of loads L1 and L2 exceeds 95% of the generator's load capacity, they are disconnected by the generator.
3. Operation 1-2014 FIGURE 16. LOAD MANAGEMENT SCREEN 3.9 Display Setup and Software Info 3.9.1 Brightness and Contrast To change the Brightness and Contrast of the display screen: 1. Press the MENU button on the home screen. 2. Press the up or down arrow button on the menu screen to select Display Setup. 3. Press the ENTER button on the menu screen. 4. Press the NEXT button to select Brightness or Contrast. 5. Press the increase or decrease arrow button to increase or decrease brightness. 6.
1-2014 3. Operation FIGURE 17. 3.9.2 DISPLAY SETUP AND SOFTWARE INFO SCREENS Software Info To check on the generator set and display software: 1. Press the MENU button on the home screen. 2. Press the up or down arrow button on the menu screen to select Display Setup. 3. Press the ENTER button on the menu screen. 4. Press the INFO button on the Display Setup screen and note the values displayed on the Software Info screen. 5. Press the BACK button to return to the home screen.
3. Operation 3.10 1-2014 Event Log 3.10.1 To Check Log of Last 20 Events 1. Press the MENU button on the home screen. 2. Press the up or down arrow button on the menu screen to select Event Log. 3. Press the ENTER button on the menu screen. 4. Scroll through the event log with the up and down double-arrow buttons. Each screen provides a brief description of the event along with the time and date of the event. 5. Press the BACK button to return to the home screen. FIGURE 18. EVENT LOG SCREEN 3.10.
3. Operation 1-2014 FIGURE 19. 3.12 FAULT LOG SCREEN Exercise Settings To set the generator set exercise schedule: 1. Press the EXCER button on the home screen. 2. Press the NEXT button on the Exerciser Clock screen to select the field to change. 3. Press the up or down arrow button to increase or decrease the frequency of exercise and the day of the week and time of day for exercise.
1-2014 3. Operation Frequency selections are: Weekly Bimonthly Monthly Never 4. Press the BACK button to save the settings and return to the home screen. 5. If you want to exercise the generator set now, select Exercise Now, and press either the up or down arrow. NOTICE Scheduled or prompted exercise does not transfer the house loads to the generator set. FIGURE 20. 3.13 EXERCISE CLOCK SCREEN Time Setup To set up the generator set clock for the current date and time: 1.
3. Operation 1-2014 FIGURE 21.
4 Maintenance 4.1 Periodic Maintenance Schedule Periodic maintenance is essential for top generator set performance. Use the Maintenance Frequency table as a guide for normal periodic maintenance. • In hot and dusty environments some maintenance procedures should be performed more frequently, as indicated by the footnotes in the table. • Maintenance, replacement or repair of emission control devices and systems may be performed by any engine repair establishment or individual.
4. Maintenance 4.2 1-2014 Cleaning the Housing Top The top surface of the generator set housing can be damaged by pressure washing or solvents and other cleaning agents. Only use soap and water or an “all citrus degreaser" to clean the top. 4.3 Exercising the Generator Set NOTICE Audible engine RPM variation may be heard while there is no load applied. This is normal and does not affect genset performance.
1-2014 4. Maintenance 4. Reinsert the dipstick If the engine oil level check shows excessive or insufficient levels of oil (oil level line above the FULL mark or below the ADD mark), oil must be drained or added. Refer to the following sections (Drain Oil or Add Oil - as needed) for instructions and guidelines for draining and adding oil. 4.4.3 Add or Drain Oil CAUTION Too much oil can cause high oil consumption. Too little oil can cause severe engine damage.
4. Maintenance 1-2014 2. Make sure the oil drain hose is connected to the oil drain valve and open the drain valve. Reclose the valve when oil stops draining. 3. Spin off the oil filter canister and clean the filter mounting surface on the engine block. Remove the old gasket if it remains. 4. Make sure the gasket is in place on the new filter and apply a thin film of clean oil to the gasket. Spin the new filter on until the gasket just touches the block. Turn it an additional 1/2 to 3/4 turn.
1-2014 No. 4. Maintenance Description No. Description 1 Dipstick 2 Air Filter 3 Oil Filter 4 Oil Drain 5 Battery 6 Circuit Breaker 7 Control Switch FIGURE 22. 4.
4. Maintenance 1-2014 Refer to the Periodic Maintenance Table for scheduled battery maintenance, and follow the battery manufacturer's instructions. Have the battery charger in the transfer switch replaced if the battery keeps running down. Always: 1. Keep the battery case and terminals clean and dry and the terminals tight. 2. Remove battery cables with a battery terminal puller. Torque threaded stud battery terminals as recommended by the battery manufacturer. 3.
1-2014 DATE 4. Maintenance HOUR METER READING MAINTENANCE OR SERVICE PERFORMED Record the name, address, and phone number of your authorized Cummins Power Generation service center.
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5 Troubleshooting By regularly performing the following periodic maintenance and guidelines, you greatly reduce the chances of a genset shutdown. • Maintain an appropriate oil level • Keep battery connections clean and tight • Do not overload the generator set • Keep the air inlet and outlet openings clear 5.
5. Troubleshooting 1-2014 WARNING Some Generator Set service procedures present hazards that can result in severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform Generator Set service. 5.4 Troubleshooting with the Flashing Indicator Light The status indicator light on the Control Switch inside the generator set flashes the diagnostic fault code when a fault shutdown occurs.
1-2014 5.4.4 5. Troubleshooting No AC Power - generator set Running, Status LED On Steady or Flashing Rapidly Possible Cause: Circuit breakers tripped due to short circuit or overloading. Corrective Actions: 1. Reduce number of loads. 2. Reset or turn on generator set circuit breaker. 3. Reset or turn on circuit breaker in the distribution panel. 4. Have the circuits from the generator set and distribution panel verified by an authorized electrician. 5.4.
5. Troubleshooting 1-2014 2. Secure spark plug leads to spark plugs. 3. Check and service air filter as necessary. 4. Replace spark plugs. WARNING Some Generator Set service procedures present hazards that can result in severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform Generator Set service. 5.4.
1-2014 5. Troubleshooting 5.4.14 Governor Actuator Overload - Fault Code 22 Possible causes: Generator set loads, wire connections, fuel supply, air fuel mixture, exhaust system, governor actuator, ignition system Corrective Actions: 1. Reduce the number of connected loads especially loads that require higher starting current such as air conditioners. 2. Check and service air filter as necessary. 3. Have unit serviced by an authorized Cummins Power Generation dealer. 5.4.
5. Troubleshooting 1-2014 5.4.19 Generator Set Stopped Without Fault Condition - Fault Code 36 Possible Causes: Fuel supply, air fuel mixture, exhaust system, choke demand regulator, carburetor, generator windings, ignition, wire connections Diagnosis & Repair: 1. Check the fuel source. 2. Open any closed fuel valves. 3. Secure spark plug leads to spark plugs. 4. Check and service air filter as necessary. 5. Replace spark plugs. 6. Check for mechanical damage. 5.4.
1-2014 5. Troubleshooting Corrective Actions: 1. Verify the generator set enclosure for clear intake and exhaust openings. 2. Have unit serviced by an authorized Cummins Power Generation dealer. 5.4.25 Low Fuel Pressure - Fault Code 78 Possible Causes: Wire connections, fuel system, fuel pressure switch Corrective Actions: 1. Open any closed fuel valves. 2. Have unit serviced by an authorized Cummins Power Generation dealer. 5.4.
5. Troubleshooting 1-2014 2. Check communications. a. If the router is also connected to an incoming connection from an ISP, check to see if you can access a standard web page with the computer connected to the same router as the generator set. If not, contact your router manufacturer for troubleshooting information. b. Check to see if the green and orange lights are illuminated at the Ethernet connection port on the generator set control board.
1-2014 5. Troubleshooting Possible Causes: Improper setup, no high-speed internet connection, public IP address is not active or properly set up, incorrect IP address is entered, computer is connected to the same router or network as the generator set, or the internet connection is faulty. Corrective Actions: 1. Check to see if you are able to access the generator set with your in-home computer. If not, refer to the In-Home Network Access Troubleshooting procedures. 2.
5. Troubleshooting 1-2014 3. Verify that the alert level is set to All Events. a. To verify that your generator set can send emails, select Disable Standby and wait several minutes to verify that you did receive an email. b. Select Enable Standby and wait a few more minutes to verify that you did receive a second email. 4. Send an email to the destination email address and check to see if you received this email.
1-2014 5. Troubleshooting FIGURE 25. FIGURE 26.
5. Troubleshooting 1-2014 FIGURE 27.
6 Optional Internet/Email Interface Descriptions 6.1 Introduction This feature allows for in-home or remote access to your generator set through a web page. NOTICE An Internet browser (i.e., Internet Explorer) is required for this option. On this web page, you can start or stop the generator set, adjust the exerciser day and time, determine if utility power is available and view the last 20 events/faults on the generator set.
6. Optional Internet/Email Interface Descriptions 6.2 Screen Descriptions FIGURE 28. 6.2.1 1-2014 HOME PAGE Setting Time and Date Select the Genset Time/Date Tab on the Home Screen to set the time and date for the generator set control. FIGURE 29. 6.2.2 SET GENSET TIME AND DATE Set Exercise Schedule Select the Exercise Schedule Tab on the Home Screen to set the generator set exercise schedule.
1-2014 6. Optional Internet/Email Interface Descriptions NOTICE The generator set will exercise on the first scheduled day for which it is programmed. After that it exercises on that day at the scheduled interval. For example, if the generator set is scheduled on a Wednesday for Saturdays with a monthly interval, the generator set starts on the next available Saturday. After that it exercises on Saturdays one month apart. FIGURE 30. 6.2.
6. Optional Internet/Email Interface Descriptions FIGURE 32. 6.2.5 1-2014 EVENT LOG Fault Log Select the Fault Log Tab on the Home Screen to review the last 5 faults. FIGURE 33. 6.2.6 FAULT LOG Network Setup Screen Descriptions An owner-custom password can be defined in the Network Setup screen shown below. The user will be prompted to enter the User Name and Password to access this screen. The Network Setup Parameters screen allows dynamic addresses to be changed to static addresses.
1-2014 6. Optional Internet/Email Interface Descriptions FIGURE 34. FIGURE 35. 6.2.7 NETWORK SETUP SCREEN NETWORK SETUP PARAMETERS Email Setup Screen Descriptions The user must determine what events will trigger an email notification of the event: • Never • All Events • Maintenance and Attention Required or Attention Required Only This screen is also used to set up e-mail configuration.
6. Optional Internet/Email Interface Descriptions FIGURE 36. EMAIL SETUP PARAMETERS FIGURE 37. 6.2.8 1-2014 EMAIL ADDRESSES Saving Changes After the email addresses are added and Done is selected, this screen will appear, verifying that all changes have been saved. FIGURE 38. 6.3 SAVE SCREEN Ethernet Connections (Optional) Wiring connections to the Ethernet RJ-45 plug are shown in the Ethernet RJ-45 Connector Wiring illustration.
1-2014 6. Optional Internet/Email Interface Descriptions FIGURE 39. FIGURE 40.
6. Optional Internet/Email Interface Descriptions FIGURE 41.
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