Service Manual Home Standby Generator Set GSBB (Spec A-B) GSBC (Spec B) English Original Instructions 9-2013 A030A239 (Issue 10)
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 9-2013 4.5.1 Fuel Pressure............................................................................................................. 4.5.2 Gas-Air Mixer ............................................................................................................ 4.5.3 Governor Actuator...................................................................................................... 4.5.4 Governor Linkage Adjustment (50 Hz LP Only)....................................................
9-2013 Table of Contents 5.12 Time Setup ......................................................................................................................... 5.13 Load Management .............................................................................................................. 5.13.1 Automatic Load Management .................................................................................. 5.13.2 Manual Load Management .....................................................................
Table of Contents 9-2013 9.2 Troubleshooting with the Flashing Indicator Light ............................................................... 9.3 Fault Code Blinking .............................................................................................................. 9.4 Restoring Fault Code Blinking ............................................................................................. 9.5 Generator Set Starts or Stops Without Command - No Fault Code ....................................
1 IMPORTANT SAFETY INSTRUCTIONS 1.1 Save These Instructions This manual contains important instructions for the generator set that should be followed during installation, operation and maintenance of the generator and batteries. Thoroughly read the Operator Manual before operating the generator set. Safe operation and top performance can only be obtained when equipment is properly operated and maintained.
1. IMPORTANT SAFETY INSTRUCTIONS 1.3 9-2013 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.
-2013 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 9-2013 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 Service Manual for the Model GSBB generator set.
2. Introduction 2.2.1 9-2013 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.
9-2013 2. Introduction TABLE 4.
2. Introduction 9-2013 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.
9-2013 2. Introduction CAUTION Unauthorized modifications or replacement of fuel, exhaust, air intake or speed control system components that affect engine emissions are prohibited by law in the State of California. Model, Spec and Serial Numbers: Be ready to provide the model, spec and serial numbers on the generator set nameplate when contacting Cummins Onan for information, parts and service. Record these numbers so that they are easy to find when needed.
2. Introduction 9-2013 This page is intentionally blank.
3 Maintenance 3.1 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.
3. Maintenance 3.2 9-2013 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. 3.3 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.
9-2013 3. Maintenance 3.5 Engine Oil Maintenance 3.5.1 Recommended Engine Oil Check the oil level prior to starting the generator set to verify that the oil level is between the FULL and ADD marks. • The generator set is shipped with engine oil • 5W-30 synthetic engine oil is recommended 3.5.2 Checking Engine Oil Level WARNING State and federal agencies have determined that contact with used engine oil can cause cancer or reproductive toxicity. Avoid skin contact and breathing of vapors.
3. Maintenance 9-2013 3. Open the oil drain valve to release oil from the engine into the appropriate container. 4. Re-check the engine oil level (Checking Engine Oil Level) Based on the results, add or drain oil. 5. When a sufficient amount of oil has been drained from the system: a. Close the oil drain valve b. Remove the drain hose c. Wipe the oil drain valve clean d. Dispose of the used oil in accordance with local/state regulations. 3.5.3.
9-2013 3.6 3. Maintenance Replacing the Air Filter Element WARNING Before working on the generator set, move the Switch (S2) to the Stop Position, disconnect the remote harness (P7) to disable the ATS mounted charger, and remove the negative (-) battery cable from the battery to prevent starting. Refer to the Periodic Maintenance Table for scheduled air filter replacements. Replace it more often in dusty environments. To change the filter element: 1.
3. Maintenance 3.7 9-2013 Battery Maintenance WARNING Arcing at battery terminals or in light switches or other equipment, and flames or sparks, can ignite battery gas causing severe personal injury—Ventilate battery area before working on or near battery—Wear safety glasses—Do not smoke—Switch work light ON or OFF away from battery—Stop the generator set—Disconnect the negative (-) battery cable first and reconnect it last.
9-2013 3.9 3. Maintenance Accessory Heater Kits WARNING Electrical connections must be made by a trained and experienced electrician. Improper installation can lead to electrocution and damage to property. Automatic startup of the generator set during installation can cause severe personal injury or death. Push the control switch Off and disconnect the negative (–) cable from the battery to keep the generator set from starting.
3. Maintenance DATE HOUR METER READING 9-2013 MAINTENANCE OR SERVICE PERFORMED Record the name, address, and phone number of your authorized Cummins Onan service center.
4 Service 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. WARNING Accidental or remote starting of the generator set can cause severe personal injury or death. Disconnect the negative (–) battery cable and place the control switch in its OFF position before starting work. Hazardous Voltage.
4. Service 4.3 9-2013 Engine This generator set is powered by a Briggs & Stratton Vanguard M61 Engine. Engine Part Number Spec A and Canadian GSBB Spec B A026L548 US GSBB Spec B and Canadian GSBC Spec B A040R203 For engine-specific service, refer to the Engine Service Manual. 4.4 Engine - Generator Assembly 4.4.1 Engine - Alternator Removal 1. Shut down the generator set and disconnect all power from the house to the generator set. WARNING Hazardous Voltage.
9-2013 4.4.2 4. Service Engine-Alternator Installation Reference the image below for installation of the engine-alternator assembly. See the Testing The Fuel System for Leaks section of this manual for appropriate fuel testing methods.
4. Service No. Description 1 Fan housing 2 Fan guard 3 Wound armature 4 Generator stator 5 Alternator brush block 6 Generator end bell 7 Alternator adapter 8 Alternator fan 9-2013 FIGURE 3.
9-2013 4.5 4. Service Fuel System Components Testing WARNING Fuel systems must be installed by qualified service technicians. Improper installation presents hazards of fire and improper operation, resulting in severe personal injury or property damage. WARNING Gaseous fuels are flammable and explosive and can cause severe personal injury or death. Do not smoke if you smell gas or are near fuel tanks or fuel-burning equipment or are in an area sharing ventilation with such equipment.
4. Service 9-2013 No. Description 1 Fuel Regulator 2 Solenoid FIGURE 5. 4.5.1 No. 3 Description Nipple Fitting FUEL SYSTEM COMPONENTS (US GSBB SPEC B AND CANADIAN GSBC SPEC B) Fuel Pressure WARNING High gas supply pressure can cause gas leaks which can lead to fire and severe personal injury or death. Gas supply pressure must be adjusted to specifications by trained and experienced personnel.
9-2013 4.5.3 4. Service Governor Actuator Governor Actuator Testing: Disconnect the two actuator leads and apply 12 VDC. Replace the actuator if the actuator arm does not move smoothly and without binding to the wide open throttle position (rotation of approximately 35 degrees). Governor Actuator Replacement: NOTICE It is beneficial to remove the air cleaner including the base for this procedure and to place a clean rag in the "V" between the cylinders to catch any small fasteners that may drop. 1.
4. Service No. 9-2013 Description 1 Rotate arm counter-clockwise to fully open slide until the lever just touches the rod. Tighten the fasteners. 2 3/32" rod 3 Lever just touches the rod FIGURE 6.
9-2013 No. 4. Service Description 1 Fully closed actuator 2 Lever touches set screw FIGURE 7. 4.5.4 GOVERNOR ACTUATOR - CLOSED Governor Linkage Adjustment (50 Hz LP Only) NOTICE It is beneficial to remove the air cleaner including the base for this procedure and to place a clean rag in the "V" between the cylinders to catch any small fasteners that may drop.
4. Service No. 1 9-2013 Description Fasteners FIGURE 8. 4.5.5 GOVERNOR ACTUATOR - FASTENERS Gas Demand Regulator Conduct a lock-off pressure test as follows before replacing a demand regulator. Replace the demand regulator only if lock-off pressure is not within the range of 0.20–0.35 inches (5.1–8.9 mm) WC (Spec A and Canadian GSBB Spec B) or 0.075 ± 0.025 inches (19 ± 6.35 mm) WC (US GSBB Spec B and Canadian GSBC Spec B).
9-2013 4. Service NOTICE Make sure the diaphragm is in a vertical plane (as in the genset) when performing a bench test, otherwise the weight of the diaphragm will cause erroneous readings of lock-off pressure. Vent Hose: Make sure to reconnect the regulator vent hose to the vent insect screen as required. 4.5.
4. Service 9-2013 NOTICE Testing for gas leaks with a flame can cause a fire or explosion that can lead to severe personal injury or death. Use approved methods only. After assembly, and before initial operation, all fuel system connections, hose valves, regulators and fittings must be tested and proven free of leaks using a soap-and-water (or equivalent) solution while the system is under gas or air pressure of at least 1.5 times the supply pressure or 3 psi (20.7 kPa) minimum.
9-2013 4.6 No. 4. Service Control Description 1 Circuit breaker 2 Rocker switch 3 Insulation boot 4 Sensor bracket 5 Temperature switch 6 Battery lead 7 Electrical strap 8 Control card 9 Engine harness 10 Single pole dual relay FIGURE 9.
4. Service 4.6.1 9-2013 Generator Control General: The generator control is an integrated microcontroller-based engine, generator and transfer switch control. It provides all the control, monitoring and diagnostic functions required to operate a standby generator set. Transfer Switch Control: When a transfer switch without a built-in controller is used, all transfer and retransfer signals come from the generator control. Transfer times are pre-set and not adjustable.
9-2013 4.6.5 4. Service Alternator Temperature Switch The alternator temperature switch contacts are normally closed. The switch contacts open at 170 °F ± 5°. 4.7 Generator 4.7.1 Operation This is a single-bearing, two-pole, revolving field generator with brushes and slip rings. Output voltage is regulated by the generator set control. Stator: The stator consists of steel laminations with two sets of windings in the lamination slots.
4. Service No. Description 1 Fan housing 2 Fan guard 3 Wound armature 4 Generator stator 5 Alternator brush block 6 Generator end bell 7 Alternator adapter 8 Alternator fan 9-2013 FIGURE 10.
9-2013 4.8 4. Service Alternator Temperature Switch The alternator temperature switch contacts are normally closed. The switch contacts open at 170 °F ± 5°. 4.9 Brush Block/Slip Ring Service Disconnect the field leads from the brush block (F1, F2), remove the two mounting screw and withdraw the brush block from the generator end bell. Replace the brush block assembly if either brush is shorter than 7/16 inch (11 mm), binds in the brush block or is damaged in any way.
4. Service 9-2013 2. Remove the stator and stator through studs. 3. Remove the nut and flat washer on the rotor through stud and remove the through stud. (Use two nuts locked together at the end of the rotor through stud to loosen and remove the stud from the crankshaft.) 4. Thread in a rotor removal rod (shortened rotor through stud or 7/16-14 UNC-2A threaded rod) and turn it with a screwdriver until it bottoms in the crankshaft.
9-2013 4. Service Tests Measurement Values L2 to N 0.094 ohms ± 10% L1 to L2 (Equal to sum of L1 to N and L2 to N) ± 1% Q1 to Q2 1.
4. Service 9-2013 Expected output will be 73.2 amp - 11.7 amp = 61.5 amp To verify generator set performance: 1. Follow de-rate guidelines above and determine % reduction in generator set output due to temperature and elevation. See example calculation. 2. While the generator set is running, determine the output voltage at the customer connection block TB2. 3. Use the table below to find the expected current value for the measured voltage and apply the de-rate calculated in step 1. 4.
5 Operation 5.1 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.
5. Operation 5.1.3 9-2013 START STOP Button See To Manually Start/Stop Generator Set. 5.2 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 12.
9-2013 5. Operation FIGURE 13.
5. Operation 9-2013 FIGURE 14.
9-2013 5. Operation FIGURE 15. 5.2.1 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.
5. Operation 9-2013 FIGURE 16. 5.2.2 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).
9-2013 5.3 5. Operation To Enable/Disable Standby Normally, you should not have to disable generator set STANDBY. • STANDBY should always be enabled (ON) except during maintenance/service. • STANDBY will have to be re-enabled (STANDBY OFF light on) if the generator set is started or stopped manually (normally a maintenance/service function) or a fault shutdown has occurred. CAUTION When STANDBY is disabled the generator set will NOT automatically start to supply power if utility power is interrupted.
5. Operation 9-2013 To manually start or stop the generator set: 1. Press the START STOP button on the operator panel, which takes you to the Genset START/STOP screen. • The screen will display “Genset Stopped" or “Genset Running," as appropriate. 2. Press START to manually start the generator set and connect it to supply power to the house. The STANDBY OFF lamp will come on and the display will state: “Genset started manually (Standby Ready Disabled)." 3.
9-2013 5. Operation FIGURE 20. 5.5.2 TYPICAL FAULT SCREEN Maintenance Due Screen A Maintenance Due screen appears when a scheduled maintenance operation is due. • The warning does not time out. • Perform the maintenance. Press the BACK button to return to the home screen. FIGURE 21. 5.5.3 TYPICAL MAINTENANCE DUE SCREEN New Event Screen A New Event screen appears whenever system status changes, such as when there is an interruption of utility power.
5. Operation 9-2013 FIGURE 22. 5.6 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.
9-2013 5. Operation FIGURE 23. GENERATOR SET STATUS SCREEN 5.7 Display Setup and Software Info 5.7.1 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.
5. Operation 9-2013 FIGURE 24. 5.7.2 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.
9-2013 5. Operation 5.8 Event Log 5.8.1 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 25. 5.8.
5.
9-2013 5. Operation FIGURE 26. 5.10 FAULT LOG SCREEN Ethernet Settings This feature allows for in-home or remote access to your generator set through a web page.
5. Operation 9-2013 • determine if utility power is available • view the last 20 events/faults on the generator set This feature is useful for homeowners who travel or have a second home and want to be able to remotely interface with their generator set. This feature can also help to reduce troubleshooting time and service calls when the service technician has access to the same web page. Use of the Ethernet is not required if you do not use web access.
9-2013 5. Operation FIGURE 27. 5.11 NETWORK SETUP 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. Frequency selections are: Weekly Bimonthly Monthly Never 4.
5. Operation 9-2013 NOTICE Scheduled or prompted exercise does not transfer the house loads to the generator set. FIGURE 28. 5.12 EXERCISE CLOCK SCREEN Time Setup To set up the generator set clock for the current date and time: 1. Press the CLOCK button on the home screen. 2. Press the NEXT button on the Time Setup screen to select the field to change. 3. Press the up or down arrow button to increase or decrease or change the date or time. 4.
9-2013 5. Operation FIGURE 29. 5.13 TIME SETUP 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.
5. Operation 9-2013 5.13.2 Manual Load Management CAUTION To reduce unnecessary loss of service, it is highly recommended that manual load management be undertaken only by an authorized Cummins Onan dealer. When set to manual mode, the user is able to view, connect, and disconnect loads. If the connection of loads L1 and L2 exceeds generator capacity, the AC circuit breaker trips. To select manual load management when the generator is running: 1. Press the LOAD button on the home screen. 2.
6 Startup and Configuration 6.1 Pre-startup Inspection Before starting the genset inspect the installation and check off each of the following questions if it can be answered “YES". If a question cannot be checked off, review the appropriate section in the manual.
6. Startup and Configuration 9-2013 NOTICE Before leaving the site, if the genset is ready to be placed in service, set the control switch to the REMOTE position to provide automatic standby power. 6.3 Generator Set Configuration The operator panel has a menu with four generator set/transfer switch parameters that must be configured for the installation. To configure the generator set: 1. Press the MENU button on the home screen. 2.
9-2013 6. Startup and Configuration FIGURE 31.
6. Startup and Configuration 9-2013 6.4 Generator Adjustments 6.4.1 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. 6.4.
9-2013 6. Startup and Configuration 6. Press the BACK button to save the setting and return to the home screen. FIGURE 33. 6.6 TRANSFER SWITCH CONFIGURATION Transfer Switch Parameter Adjustments Model RSS100-6634 and RSS200-6635 Transfer Switches: Refer to Transfer Switch Installation Manual 962-0620 to set the parameters inside the transfer switch. Model RSS100-6868 and RSS200-6869 Transfer Switches: To make transfer switch parameter adjustments: 1. Press the MENU button on the home screen. 2.
6. Startup and Configuration 9-2013 4. Press Enter on the Config Menu to go to the Transfer Switch screen. 5. Press the NEXT button on the Generator Config Menu screen to select the Pickup, Dropout or Nominal field. 6. To set Nominal - Press the up or down double-arrow button to increase or decrease the nominal utility voltage parameter to match actual (Present) utility voltage. The Pickup and Dropout parameters are percentages of the nominal voltage parameter. 7.
7 Optional Internet/Email Interface Descriptions 7.1 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.
7. Optional Internet/Email Interface Descriptions 7.2 Screen Descriptions FIGURE 35. 7.2.1 9-2013 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.
9-2013 7. Optional Internet/Email Interface Descriptions FIGURE 36. 7.2.2 SET GENSET TIME AND DATE Set Exercise Schedule Select the Exercise Schedule Tab on the Home Screen to set the generator set exercise schedule. 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.
7. Optional Internet/Email Interface Descriptions FIGURE 38. 7.2.4 9-2013 GENSET LOAD MANAGEMENT Event Log Select the Event Log Tab on the Home Screen to review the last 20 events. See the Event Log screen capture below for a list of all of the recordable events. FIGURE 39. 7.2.5 EVENT LOG Fault Log Select the Fault Log Tab on the Home Screen to review the last 5 faults.
9-2013 7. Optional Internet/Email Interface Descriptions FIGURE 40. 7.2.6 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. This screen allows the user to configure the static address for the in-home network.
7. Optional Internet/Email Interface Descriptions 9-2013 • Maintenance and Attention Required or Attention Required Only This screen is also used to set up e-mail configuration. The user may enter up to three email addresses for receiving notifications of the home-standby generator set status. See the Email Addresses figure below. FIGURE 43. EMAIL SETUP PARAMETERS FIGURE 44. 7.2.
8 Optional Internet/Email Interface Setup 8.1 Network Connectivity Options Network connectivity includes in-home Network access to the generator set, e-mail notification, and remote access to the generator set. 8.2 Material/Cable Routing Route the category 5 Ethernet cable from the generator in the same conduit as the control lines and display cable (for in-home mounted displays) to the transfer switch and into the house. Ensure the cable is long enough to reach the network router.
8. Optional Internet/Email Interface Setup 9-2013 NOTICE Some email accounts will not accept unauthenticated emails and will not work with the system. Ensure the email account and SMTP port accept non-SSL and TLS connections. Email Server Static IP Address:_________________________________________ Email Server Name (SMTP):____________________________________________ (Example: smtp.hughes.net) Email Account User Name: _____________________________________________ (Example: include@emailprovider.
9-2013 8. Optional Internet/Email Interface Setup FIGURE 46. NETWORK SETUP SCREEN ON THE IN-HOME OPERATOR PANEL NOTICE Leave the DHCP (Dynamic Host Configuration Protocol) on, as it assigns a dynamic IP adress to your internet connection. 3. Type the IP address in the address bar of the web browser of a computer established on the same in-home network as the generator set. The computer’s web browser will display the generator set’s web page. 4. Enter the User Name and Password.
8. Optional Internet/Email Interface Setup FIGURE 47. FIGURE 48.
9-2013 8. Optional Internet/Email Interface Setup FIGURE 49. 8.5 NETWORK SETUP (PAGE 1) Setting Up Internet Access and E-mail Alerts 1. Set up the in-home computer access to the generator set. See Section 8.4. NOTICE For the following steps, refer to the figures below. A030A239 (Issue 10) FIGURE 50. NETWORK SETUP SCREEN FIGURE 51.
8. Optional Internet/Email Interface Setup 9-2013 FIGURE 52. NETWORK SETUP PAGE 2 FIGURE 53. NETWORK SETUP PAGE 3 2. Click Network Setup on the home page. 3. Click Click here to start Network Setup. 4. Click Off to turn off the generator set DHCP. NOTICE Skip step 5 is a unique IP address was already provided by the router. 5.
9-2013 8. Optional Internet/Email Interface Setup 12. Click Next to enter the destination e-mail addresses. 13. Enter up to three different e-mail addresses which will receive generator set e-mail alerts. E-mail Address 1:___________________________________________ E-mail Address 2:___________________________________________ E-mail Address 3:___________________________________________ 14. Press Done to complete the e-mail confirmation.
8. Optional Internet/Email Interface Setup 9-2013 NOTICE Acquiring a static IP may incur additional service charges from your ISP. 2. Use the provided static IP address to access the generator set webpage from any location with Internet access. 8.8 Dynamic IP Monitoring NOTICE If a static IP address has been authorized from your ISP, the following steps are not required. Some services may require software to be installed on a home computer. 1.
9-2013 8.9.2 8. Optional Internet/Email Interface Setup Email Addresses You may enter up to three Email addresses to whom to send generator set status and event messages. FIGURE 55. FIGURE 56. NETWORK SETUP PARAMETERS FIGURE 57.
8. Optional Internet/Email Interface Setup 9-2013 FIGURE 58. FIGURE 59. 8.10 EMAIL ADDRESSES RETURN TO HOME PAGE Remote Internet Access to the Generator Set See the network connection information, provided in Appendix A of this manual. Be sure to read through the procedure and collect all needed information before attempting this procedure. WARNING Opening ports in your firewall can pose network security risks. The following instructions require forwarding port 80.
9-2013 8. Optional Internet/Email Interface Setup 2. To access the generator set's web page on any computer or wireless device not connected to the same modem/router as the generator set, type in the owner's public IP address and enter the user name and password. 3. To access the generator set's web page on any computer or wireless device connected to the same modem/router as the generator set, type in the unique in-home network address of the generator set and enter the username and password. 8.
8. Optional Internet/Email Interface Setup 9-2013 Question: What is the difference between Static and Dynamic IP Addresses? Answer: Dynamic IP Address - On your in-home network, the router (with DHCP enabled) will assign a dynamic IP Address to all devices (computer, home generator set, etc.) connected to the router. As devices are added and removed from the router, the devices are automatically updated with new IP Addresses.
9-2013 8. Optional Internet/Email Interface Setup 2. Establish an Ethernet connection between the computer and generator set via a common modem. 3. On the computer, Click Start>Run. 4. On the run menu that appears type “cmd " and click OK. 5. Type “ipconfig " on the DOS window that appears.
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9 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 9.
9. Troubleshooting 9-2013 • Fault Code Nos. 1, 2, 3, and 4 are first level faults. Pay close attention to the pause sequence to avoid interpreting first level faults as second-level Fault Codes Nos. 11, 22, 33 or 44. • To avoid the possibility of anyone misinterpreting Code Nos. 3 and 4 as Code Nos. 33 and 44, the latter have not been assigned faults. 9.4 Restoring Fault Code Blinking The fault code stops blinking after five minutes.
9-2013 9. Troubleshooting 6. Reconnect J1 connector and test run generator set for symptom: repair or replace pins in connector as necessary. 7. Measure battery voltage at generator set while attempting to start from local or remote switch: recharge or replace battery if voltage drops below 8 VDC, test and service generator set battery charger. 8. Measure battery voltage and check for voltage increase while generator set is running. 9.
9. Troubleshooting 9-2013 • Use any suitable device that will not damage the inside contact wipers of the pin socket 7. Reconnect the J1 connector and test run the generator set for start operation. 9.7 Starting Battery Runs Down Logic: Low/No battery voltage Possible Causes: Marginal battery connections, battery, charging system, excessive cranking Diagnosis and Repair: 1. Measure battery voltage at the battery and the generator set. 2.
9-2013 9. Troubleshooting 2. Inspect the battery connections and cables for cleanliness, tightness, and damage: clean, tighten, and repair connections and cables as necessary. 3. Check electrolyte level and hydrometer reading in maintenance type batteries: replace electrolyte and recharge or replace the battery as necessary. 4. Disconnect the generator set control J1 connector. Verify that the J1 pins are fully inserted and inspect pin condition, using one of the processes listed below.
9. Troubleshooting 9-2013 3. Inspect the battery connections and cables for cleanliness, tightness, and damage: clean, tighten, and repair connections and cables as necessary. 4. Check electrolyte level and hedrometer reading in maintenance type batteries: replace electrolyte and recharge or replace the battery as necessary. 5. Check the fuel supply pressure coming into the generator regulator and ensure it is within specification. 6.
9-2013 9. Troubleshooting 5. Measure continuity change across the start/stop switch between rest and under simulated pressure: replace the switch as necessary. 6. Measure continuity between ground and J1-6: repair or replace the harness as necessary. 7. Measure oil pressure with a mechanical gauge: repair or replace the relief valve and oil pump as necessary. 9.
9. Troubleshooting 9-2013 8. Check for blocked or damaged exhaust system: repair or replace exhaust components as necessary. 9. Propane Models a. When ambient temperatures are less than 40°F vapor – withdrawal Propane tanks should be at least half full to provide proper vaporization rate. b. Propane having more than 2.5 percent Butane will not vaporize in ambients at less than 32°F; use HD-5 grade Propane. c. Run the generator set on shop fuel supply; verify tank level and fuel line condition. 10.
9-2013 9. Troubleshooting 3. Measure and verify AC frequency while changing engine rpm to determine if frequency response matches engine rpm response. 4. Cycle loads to determine if a particular load causes fault: diagnose faulty load as necessary. 5. Verify balanced loads in 120/240 VAC applications: balance loads within 10 percent line-toline as required. 6.
9. Troubleshooting 9-2013 b. If misalignment is toward the bearing, the cause is not from this tolerance issue and is likely the result of the end bell not being seated properly during assembly. Inspect for cause and repair as necessary. 9.17 Overfrequency - Fault Code 14 Logic: Instantaneous Fault - Frequency greater than 72Hz Delayed Fault - Frequency greater than 66Hz, but less than 72Hz, for 6 continuous seconds NOTICE This fault code is for both the 50 Hz and 60 Hz models.
9-2013 9. Troubleshooting b. Propane having more than 2.5 percent Butane will not vaporize in ambients at less than 32°F; use HD-5 grade Propane. c. Run the generator set on shop fuel supply; verify the tank level and fuel line condition. 12. Measure steady DC voltage at the fuel solenoid while the generator set is running; repair wiring as necessary. 13. Verify clear vent hose. 14. Check the generator set fuel lines for damage: replace the fuel line as required. 15.
9. Troubleshooting 9-2013 3. Measure generator set load capability with shop load bank (de-rate for altitude and temperature as necessary). 4. Measure AC frequency while running. 5. Measure AC frequency while changing engine rpm to determine if frequency response matches engine rpm response. 6.
9-2013 9. Troubleshooting 20. Verify that the spark plug cables are secure on the spark plugs: reconnect or replace as necessary. 21. Inspect ignition kill lead (J1-12) in the harness and at connector J1: repair or replace the lead, terminal, or pins as necessary. 22. Measure the spark plug gap: set the gap or replace the spark plugs as necessary. 23. Verify ignition spark condition. 24.
9. Troubleshooting 9-2013 3. Measure the generator set load capability with a shop load bank (de-rate for altitude and temperature as necessary). 4. Measure AC frequency and droop while the generator set is running. 5. Measure AC frequency while changing engine rpm to determine if frequency response matches engine rpm response. 6.
9-2013 9. Troubleshooting 22. Inspect the spark plug leads, kill lead terminals at magnetos, and measure the magneto air gap: replace the terminals, set the gap, or replace the magnetos as necessary. 9.21 Voltage Sense Lost - Fault Code 27 Logic: generator set frequency is greater than 40 Hz and voltage sensed less than 5 VAC on one or both lines. (The control senses if one line is lost or disconnected).
9. Troubleshooting 9-2013 Possible Causes: Incorrect battery configuration, wire damage, faulty charger, control Diagnosis & Repair: 1. Verify that the Last Fault is FC 29: Yes, continue diagnosis; No, troubleshoot actual last fault. 2. Measure DC voltage at the battery, at the generator set, and at connector J1: reconnect the battery or repair wiring as necessary. 3. Measure DC voltage with the battery charger on: reduce the boost charge rate or diagnose the faulty charger as necessary. 4.
9-2013 9. Troubleshooting 8. Check air filter cleanliness; replace the air filter as necessary. 9. Check for a blocked or damaged exhaust system: repair or replace exhaust components as necessary. 10. Measure AC frequency while changing engine rpm to determine if frequency response matches engine rpm response. 11. Propane Models a. When ambient temperatures are less than 40°F vapor – withdrawal Propane tanks should be at least half full to provide proper vaporization rate. b. Propane having more than 2.
9. Troubleshooting 9.25 9-2013 Generator Set Stopped Without Fault Condition Fault Code 36 Logic: RPM less than 500 and Sense Voltage S1-S2 at 0 VAC while fuel pressure switch open and no other fault condition occurred Possible Causes: Fuel supply, air fuel mixture, exhaust system, choke, demand regulator, carburetor, generator windings, ignition, wire connections Diagnosis & Repair: 1. Verify that the Last Fault is FC 36: Yes, continue diagnosis; No, troubleshoot actual last fault. 2.
9-2013 9. Troubleshooting 16. Verify that the spark plug cables are secure on the spark plugs: reconnect or replace as necessary. 17. Inspect ignition kill lead (J1-12) in harness and at connector J1: repair or replace the lead, terminal, or pins as necessary. 18. Measure the spark plug gap: set the gap or replace the spark plugs as necessary. 19. Verify ignition spark condition. 20.
9. Troubleshooting 9-2013 3. Disconnect the generator set control J1 connector, verify that the J1 pins are fully inserted, and inspect pin condition using the steps below: • Use the test points of the tester tool #420-0603 • Use a mating pin connector, a pin gauge of the same size (.045") as the mating control connector pin, or any suitable device that will not damage the inside contact wipers of the pin socket. • Insert, repair, or replace pins as necessary. 4.
9-2013 9. Troubleshooting 8. Verify clear vent hose. 9. Run the generator set on shop fuel supply; verify the tank level and fuel line condition. 10. Check the generator set fuel lines for damage: replace the fuel lines as required. 11. Measure regulator lock off pressure. 12. Check the intake manifold and gaskets for air leaks: tighten the fasteners and replace the gaskets and manifold as necessary. 13. Check for a blocked or damaged exhaust system: repair or replace exhaust components as necessary. 14.
9. Troubleshooting 9-2013 6. Verify the temperature sensor resistance. Replace as necessary. 7. Measure the temperature sensor wiring (J1-33) for continuity. Repair or replace as necessary. 8. Visually inspect the alternator fan for missing or damaged fins. Replace the fan if necessary. 9.31 Low Fuel Pressure - Fault Code 78 Logic: Controller sensed fuel pressure switch open and approaching fault declaration: 14, 15, 22 or 36.
9-2013 9. Troubleshooting Possible Causes: Wire connections, faulty positional switch, faulty transfer switch component(s) Diagnosis & Solution: 1. Verify that the main AC circuit breaker on generator set is to “On". 2. Verify that the Last Fault is FC 79: Yes, continue diagnosis; No, troubleshoot actual last fault. 3. Manually start an exercise session and verify the transfer switch position during the exercise. 4. Disable the generator by placing the generator local start switch in the “Off" position.
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10 Communication Troubleshooting 10.1 In-Home Network Access to Generator Set Troubleshooting 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. Possible Causes: Bad connections or bad communications Corrective Actions: 1. Check connections. a.
10. Communication Troubleshooting 9-2013 d. If none of the above troubleshooting techniques help, call Cummins Support at 1-800888-6626 and select option 1. FIGURE 60. 10.2 NETWORK CONNECTIONS (CONTROL BOARD AND ETHERNET CONNECTION) Remote Internet Access to Generator Set Troubleshooting WARNING Some generator set service procedures present hazards that can result in severe personal injury or death.
9-2013 10. Communication Troubleshooting 6. Verify that the computer is not connected to the same router or local area network as the generator set. If it is on the same network, you will be able to access the generator set using the local network IP address configured on the generator set. The computer used for internet access must be connected to a different internet connection than the generator set. 7. Check to see if you can access a standard web page from a computer.
10. Communication Troubleshooting 9-2013 6. Ensure that the SMTP server in use is capable of distributing non SSL certified emails. If the SMTP server is not capable of sending non SSL certified emails or the status is unknown, please contact your ISP technical support for information. 7. Verify that the domain name is included in the user name field of the Network Setup screen (i.e. username@domainname).** 8. Verify with your ISP that the Static DNS (Domain Name Server) #1 and #2 are correct. 9.
9-2013 10. Communication Troubleshooting FIGURE 62. FIGURE 63.
10. Communication Troubleshooting FIGURE 64.
Appendix A. Outline and System Drawings Table of Contents Figure 65. Ethernet Connections (Optional) ........................................................................................... 116 Figure 66. Ethernet Connector ................................................................................................................ 116 Figure 67. ethernet RJ-45 connector Wiring .......................................................................................... 117 Figure 68.
Appendix A. Outline and System Drawings 9-2013 Wiring connections to the Ethernet RJ-45 plug are shown in the Ethernet RJ-45 Connector Wiring illustration. Utilize an appropriate Ethernet stripping and crimping tool for these connections. FIGURE 65. ETHERNET CONNECTIONS (OPTIONAL) FIGURE 66.
9-2013 Appendix A. FIGURE 67.
Appendix A. Outline and System Drawings FIGURE 68.
9-2013 Appendix A. FIGURE 69.
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9-2013 Appendix A. FIGURE 70.
Appendix A. Outline and System Drawings 9-2013 FIGURE 71.
9-2013 Appendix A. FIGURE 72.
Appendix A. Outline and System Drawings 9-2013 FIGURE 73.
9-2013 Appendix A. FIGURE 74.
Appendix A. Outline and System Drawings 9-2013 FIGURE 75.
9-2013 Appendix A. FIGURE 76.
Appendix A. Outline and System Drawings 9-2013 FIGURE 77.
9-2013 Appendix A. FIGURE 78.
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Cummins Power Generation 1400 73rd Ave. NE Minneapolis, MN 55432 USA Phone 1 763 574 5000 Toll-free 1 800 888 6626 Fax 1 763 574 5298 Copyright © 2013 Cummins Power Generation, Inc. All rights reserved. Cummins, Onan, the "C" logo, and "Performance you rely on." are trademarks of Cummins Inc.
