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DQKB, DQKC, DQKD, DQKH

with PowerCommand Control


PCC3201

Printed in U.S.A. 9610500B 11-2004


SECTION TITLE PAGE
IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Language/Units Selection Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Engine Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Alternator Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Control Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
History/About Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Parallel Data Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Power Transfer Main/Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Utility (PWR TRAN) Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Status (PWR TRAN) Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Transfer Control (PWR TRAN) Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Genset (PWR TRAN) Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

i
SECTION TITLE PAGE
3 CONTROL CALIBRATION AND ADJUSTMENT
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Modifying Setup/Adjust Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Setup Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Governing/Volt Reg Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Customer Faults Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Calibration Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Isolated Bus/Utility Submenus (Paralleling Application) . . . . . . . . . . . . . . . 3-7
Isolated Bus Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Utility Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Power Transfer Control Main Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Utility Sensors Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Genset Sensors Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Timers Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Test/Exercise Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Adjust Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Control Box Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Run Relays (K11, K12, K13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Alarm Relay (K16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Magnetic Speed Pickup Unit (MPU) Installation . . . . . . . . . . . . . . . . . . . . . 3-26
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
Testing the PMG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
P7 Bearing Inspection/Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
P7 Generator Disassembly/Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
P80 Bearing Inspection/Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
P80 Generator Disassembly/Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Aligning Generator with Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
5 WIRING DIAGRAMS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

ii
SAVE THESE INSTRUCTIONS This manual contains EXHAUST GASES ARE DEADLY
important instructions that should be followed during
installation and maintenance of the generator and batter- Provide an adequate exhaust system to properly
ies. expel discharged gases away from enclosed or
sheltered areas and areas where individuals are
Before operating the generator set (genset), read the likely to congregate. Visually and audibly inspect
Operators Manual and become familiar with it and the the exhaust daily for leaks per the maintenance
equipment. Safe and efficient operation can be schedule. Make sure that exhaust manifolds are se-
achieved only if the equipment is properly operated cured and not warped. Do not use exhaust gases to
and maintained. Many accidents are caused by failure heat a compartment.
to follow fundamental rules and precautions.
Be sure the unit is well ventilated.
The following symbols, found throughout this manual,
Engine exhaust and some of its constituents are
alert you to potentially dangerous conditions to the oper-
ator, service personnel, or the equipment. 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
FUEL AND FUMES ARE FLAMMABLE in position over fans, drive belts, etc.
Fire, explosion, and personal injury or death can result Do not wear loose clothing or jewelry in the vicinity of
from improper practices. moving parts, or while working on electrical equip-
ment. Loose clothing and jewelry can become
DO NOT fill fuel tanks while engine is running, un-
caught in moving parts.
less tanks are outside the engine compartment.
Fuel contact with hot engine or exhaust is a potential If adjustment must be made while the unit is run-
fire hazard. ning, use extreme caution around hot manifolds,
moving parts, etc.
DO NOT permit any flame, cigarette, pilot light,
spark, arcing equipment, or other ignition source DO NOT OPERATE IN FLAMMABLE AND
near the generator set or fuel tank.
EXPLOSIVE ENVIRONMENTS
Fuel lines must be adequately secured and free of
leaks. Fuel connection at the engine should be Flammable vapor can cause an engine to overspeed and
made with an approved flexible line. Do not use zinc become difficult to stop, resulting in possible fire, explo-
coated or copper fuel lines with diesel fuel. sion, severe personal injury and death. Do not operate a
genset where a flammable vapor environment can be
Be sure all fuel supplies have a positive shutoff
created by fuel spill, leak, etc., unless the genset is
valve. equipped with an automatic safety device to block the air
Be sure battery area has been well-ventilated prior intake and stop the engine. The owners and operators of
to servicing near it. Lead-acid batteries emit a highly the genset are solely responsible for operating the gen-
explosive hydrogen gas that can be ignited by arc- set safely. Contact your authorized Cummins Power
ing, sparking, smoking, etc. Generation distributor for more information.

LS-14M
iii
ELECTRICAL SHOCK CAN CAUSE GENERAL SAFETY PRECAUTIONS
SEVERE PERSONAL INJURY OR DEATH Coolants under pressure have a higher boiling point
than water. DO NOT open a radiator or heat ex-
Remove electric power before removing protective changer pressure cap while the engine is running.
shields or touching electrical equipment. Use rub- Allow the generator set to cool and bleed the system
ber insulative mats placed on dry wood platforms pressure first.
over floors that are metal or concrete when around
electrical equipment. Do not wear damp clothing Used engine oils have been identified by some state
(particularly wet shoes) or allow skin surface to be or federal agencies as causing cancer or reproduc-
damp when handling electrical equipment. Do not tive toxicity. When checking or changing engine oil,
wear jewelry. Jewelry can short out electrical con- take care not to ingest, breathe the fumes, or con-
tacts and cause shock or burning. tact used oil.
Keep multi-class ABC fire extinguishers handy.
Use extreme caution when working on electrical
Class A fires involve ordinary combustible materials
components. High voltages can cause injury or
such as wood and cloth; Class B fires, combustible
death. DO NOT tamper with interlocks.
and flammable liquid fuels and gaseous fuels; Class
Follow all applicable state and local electrical C fires, live electrical equipment. (ref. NFPA No. 10).
codes. Have all electrical installations performed by Make sure that rags are not left on or near the en-
a qualified licensed electrician. Tag and lock open gine.
switches to avoid accidental closure.
Make sure generator set is mounted in a manner to
DO NOT CONNECT GENERATOR SET DIRECT- prevent combustible materials from accumulating
LY TO ANY BUILDING ELECTRICAL SYSTEM. under the unit.
Hazardous voltages can flow from the generator set Remove all unnecessary grease and oil from the
into the utility line. This creates a potential for elec- unit. Accumulated grease and oil can cause over-
trocution or property damage. Connect only heating and engine damage which present a poten-
through an approved isolation switch or an ap- tial fire hazard.
proved paralleling device.
Keep the generator set and the surrounding area
clean and free from obstructions. Remove any de-
MEDIUM VOLTAGE GENERATOR SETS bris from the set and keep the floor clean and dry.
(601V to 15kV) Do not work on this equipment when mentally or
physically fatigued, or after consuming any alcohol
Medium voltage acts differently than low voltage. or drug that makes the operation of equipment un-
Special equipment and training is required to work safe.
on or around medium voltage equipment. Operation Substances in exhaust gases have been identified
and maintenance must be done only by persons by some state or federal agencies as causing can-
trained and qualified to work on such devices. Im- cer or reproductive toxicity. Take care not to breath
proper use or procedures will result in severe per- or ingest or come into contact with exhaust gases.
sonal injury or death.
Do not store any flammable liquids, such as fuel,
Do not work on energized equipment. Unauthorized cleaners, oil, etc., near the generator set. A fire or
personnel must not be permitted near energized explosion could result.
equipment. Due to the nature of medium voltage
Wear hearing protection when going near an oper-
electrical equipment, induced voltage remains even
after the equipment is disconnected from the power ating generator set.
source. Plan the time for maintenance with autho- To prevent serious burns, avoid contact with hot
rized personnel so that the equipment can be de-en- metal parts such as radiator, turbo charger and ex-
ergized and safely grounded. haust system.

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

iv
ABOUT THIS MANUAL Battery Hydrometer

This manual provides PowerCommand Control Power Factor Indicator


3201 (PCC) calibration and adjustment Jumper Leads
procedures, control operation, alternator test and
repair procedures and initial startup and test of Tachometer or Frequency Meter
paralleled generator sets. Wheatstone Bridge or Digital Ohmmeter
Operating and maintenance instructions are in the
Variac
applicable Operators Manual. Generator set
troubleshooting and repair (control and engine) Load Test Panel
information is provided in the following manuals.
Megger or Insulation Resistance Meter
Troubleshooting and Repair Manual Power-
Command Control QSK45, QSK60, QSX15
Generator Sets, Bulletin No. 3666394 HOW TO OBTAIN SERVICE
Operation and Maintenance Manual QSK 45
Always give the complete Model, Specification and
and QSK60 Series Engines (engine repair and
Serial number of the generator set as shown on the
service) Bulletin No. 3666260
nameplate when seeking additional service
Read and carefully observe all information or replacement parts. The nameplate is
instructions and precautions in this manual. located on the side of the generator output box.

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.

Copyright 2004 Cummins Power Generation. All rights reserved.


Cummins and PowerCommand are registered trademarks of Cummins Inc.

1-1
THIS PAGE LEFT INTENTIONALLY BLANK

1-2
GENERAL present, it will wait for a pulse from a remote Master
First Start Sensor. On receiving that pulse, the con-
The following describes the function and operation trol will signal the paralleling breaker to close.
of the PowerCommand Control 3201 (PCC). All in-
dicators, control switches/buttons and graphical If bus voltage is present, the control will check for
display are located on the face of the control panel proper phase rotation, adjust the generator set to
as illustrated in Figure 2-1. the bus voltage and frequency level, and then syn-
chronize the generator set to the system bus. When
Normally, generator set configuration options are
set at the factory. When a new control is installed on a synchronous condition is achieved, the control will
a generator set or when parts are replaced, the con- send a signal to close the paralleling breaker.
trol must be configured for that generator set. Setup
and calibration procedures are described in When the paralleling breaker is closed, the genera-
. tor set will assume its proportional share of the total
load on the system bus.
SEQUENCE OF OPERATION
CONTROL PANEL POWER ON/OFF
When the PowerCommand control is in the AUTO
mode, it will cause the generator set to start on re-
MODES
ceiving a signal from a remote device. The control
will initiate a starter cranking signal and verify that The power on/off modes of the control panel and op-
the engine is rotating. The control will provide suffi- erating software are Power On, Screen Saver and
cient fuel to the engine to accelerate to start discon- Sleep/Awake.
nect speed. On reaching that speed, the control will
ramp the generator set to idle (warm-up) or rated Power On Mode: In this mode, power is continu-
speed and voltage. ously supplied to the control panel. The controls
operating software and control panel LEDs/graphi-
On reaching rated speed and voltage, the control cal display will remain active until the Screen Saver
checks the system bus voltage. If no bus voltage is mode is activated.

2-1
Screen Saver Mode: Power to the graphical dis- Manual/Auto switch is in the Auto position) the
play will be removed after 10 minutes (generator set Sleep mode will be activated.
not running or running). The 10 minute timer resets
and begins after each control panel action (any but- The operating software is initialized and the control
ton or switch selection) or signal received by the op- panel LEDs and graphical display is turned on in re-
erating software. The bottom LEDs of the Analog sponse to one of the following:
AC Metering Panel (bar graphs) may remain on dur- moving/pressing any control panel switch/but-
ing Screen Saver mode, indicating that the operat- ton.
ing software is active (Awake mode).
a remote start input signal (generator set in
When a Warning signal is sensed by the PCC (for Auto mode), or
example, low coolant temp), the control will display customer fault 2 or 3 only (shutdown or warning
the warning message. The control will remain active indicator is on).
until the Fault Acknowledge button is pressed to
clear the warning message and start the 10 minute To activate the control and view the menu display
timer. without starting the generator set, press any button
on the control panel.
Sleep/Awake Mode: In the Sleep mode, the con-
trols operating software is inactive and the LEDs The InPower service tool is required to enable or
and the graphical display on the control panel are all disable the Sleep mode. When shipped from the
off. Sleep mode is a feature that is used to reduce factory, the Sleep mode is disabled. When disabled,
battery power consumption when the control is in the operating software will always remain active
the Auto mode and is not being used. (Awake mode) when the control is in Auto mode.

When all conditions are met (i.e., no unacknowl- InPower service tool is required to selected desired
edged faults, Screen Saver Mode is active, and O/ mode.

2-2
OPERATOR PANEL SWITCH PANEL

REMOTE START,
NOT IN AUTO,
SHUTDOWN,
WARNING
STATUS INDICATORS
ANALOG AC PANEL LAMP/ FAULT EMERGENCY
METERING LAMP TEST ACKNOWLEDGE STOP PUSH
PANEL BUTTON BUTTON BUTTON

DISPLAY MENU EXERCISE MANUAL RUN/


SELECTION BUTTONS BUTTON & STOP BUTTON
(1 of 6) INDICATOR & INDICATOR

GRAPHICAL 0/MANUAL/AUTO
DISPLAY SWITCH

FIGURE 2-1. CONTROL PANEL ASSEMBLY (FULL-FEATURED)

2-3
CONTROL PANEL ASSEMBLY Scales for each function are in % of nominal values.
Resolution is 1% for values close to nominal, and in-
The control panel assembly (Figure 2-1) consist of creases at values further from nominal.
two panels, the and the
. The graphical display is capa-
ble of displaying up to 9-lines of data with approxi-
Dependent on site requirements, the mately 27 characters per line. The display is used to
is either mounted on the control panel assembly view the menus of the menu-driven operating sys-
(full-featured) as shown in Figure 2-1 or contained tem.
in a separate enclosure and mounted remotely of
the control panel assembly. The top three lines of the graphical display contain
the following control information in the order de-
The function of several buttons on the control panel scribed:
will vary dependent on the location of the control
panel (remote or local of the control panel assem- modes of operation, such as
bly). If the function differs, it is noted as either re- Stopped, Time Delay To Start, Warm Up At
mote or local operator panel in the button de- Idle, etc. (see Figure 2-2), and paralleling op-
scription. erations, such as Standby, Dead BUS Close,
Synchronize, Load Share and Load Govern.
Operator Panel
system actions, such as Warning,
The operator panel contains the following compo- Derate, Shutdown Cool-down and Shutdown,
nents: and fault codes.
This panel simulta- Fault code messages.
neously displays 3-phase line to line AC volts and
current, kW, power factor and frequency. Six momentary
buttonsthree on each side of the graphical dis-
The meter panel is composed of a series of LEDs, play windoware used to navigate through the sys-
that are configured in bar graphs for each function. tem control menus and to adjust generator set pa-
The LEDs are color coded, with green indicating rameters. The button is active when the message
normal range values, amber for warning levels and adjacent to the button is highlighted (displayed in in-
red for shutdown conditions. verse video).

2-4
Switch Panel Press this button to acknowl-
edge warning and shutdown messages after the
The switch panel contains the following compo- fault has been corrected.
nents:
To acknowledge a Warning message, the 0/Manu-
Push the button in for al/Auto switch can be in any position. (It is not nec-
emergency shutdown of the engine. If the engine is essary to stop the generator set to acknowledge an
not running, pushing the button in will prevent the inactive Warning condition.) To acknowledge a
starting of the engine, regardless of the start signal shutdown message with this button, the 0/Manual/
source (local or remote). Auto switch must be in the 0 (Off) position.
To reset: This button is also used to blink a fault code if the
1. Pull the button out. Shutdown or Warning Status Indicator is lit. (This
2. Move the 0/Manual/Auto switch to 0. function is used when the control does not contain a
3. Press the front panel Fault Acknowledge graphical display.) Refer to in
button. this section, which describes how to use this button
4. Select Manual or Auto, as required. for interpreting fault codes.
This green lamp is lit Press this button
whenever the control is receiving a remote run sig- to turn on or off the panel lamp. Press and hold
nal. When flashing, it indicates a load demand stop down this button for three seconds or more to turn
mode. all control panel LEDs on to make sure all lamps illu-
minate. The illumination will shut off after releasing
This red lamp flashes con- the button.
tinuously when the 0/Manual/Auto switch is not in
the Auto position. (If in Auto position and lamp is Press this button to initiate a pre-
flashing, service is required.) programmed exercise sequence. To start the exer-
cise sequence, press and hold down the Exercise
This red lamp is lit button and move the O/Manual/Auto switch from
whenever the control detects a shutdown condition. Auto to Manual and back to Auto or from Manual to
The generator set can not be started when this lamp Auto.
is on. After the condition is corrected, shutdown in-
dicators can be reset by turning the 0/Manual/Auto This button starts and
switch to the 0 position, and pressing the Fault Ac- stops the set locally and will bypass Time Delay to
knowledge button. Start and Stop sequences. The 0/Manual/Auto
switch must be in the Manual position to enable this
Dependent upon the specific fault that occurs, the button.
engine may or may not shut down immediately. A
fault that could cause engine damage, causes an Manual position enables
immediate engine shutdown (bypasses engine the use of the switch panel Manual Run/Stop but-
cool-down sequence). All other faults would allow ton.
the engine to run during the cool-down sequence Auto position enables start/stop control of the en-
before engine shutdown. In this case, the Shutdown gine from a remote location. (Disables the use of the
Status Indicator blinks during the cooldown period. switch panel Manual Run/Stop button.)
This yellow lamp is lit 0 (Off) position prevents the starting of the set (local
whenever the control detects a warning condition. or remote). If moved to 0 during set operation, will
After the condition is corrected, warning indicators cause an immediate engine shutdown (bypasses
can be reset by pressing the Fault Acknowledge cool-down timers). This hot shutdown should be
button. (It is not necessary to stop the generator set avoided, if possible, to help prolong the life of the
if the fault becomes inactive during genset opera- engine. Hot shutdowns are logged by the system
tion.) software.

2-5
READING FAULT CODES A three digit fault code is indicated by three sets of
blinks separated by a two second pause. The first
If the genset contains the optional graphical display set corresponds to the hundreds position, the sec-
and a fault occurs, the fault code/message will be ond to the tens position and the third to the ones dig-
displayed in the display Description Line (Figure it. Example for Code No. 213:
2-2). If the control does not contain the graphical
display, the fault code is read from the Warning and Shutdown LED:
Shutdown status indicators.
Warning LED:
If the Warning or Shutdown status indi- (2 seconds)
cator is lit, press and hold the Fault Acknowledge The light will display the fault codes (active or inac-
button and release after one second or more. After tive) in succession, starting with the most recent. Up
one second, the Shutdown lamp will begin to blink to 32 (unacknowledged) fault codes can be stored
the active fault code(s) as follows. in control panel memory.
The Warning lamp is used to indicate the start of a To return the control to the most recent fault code,
new code. The Warning lamp will remain on for 2 press and release the Fault Acknowledge button
seconds, followed by the Shutdown lamp blinking (less than one second) and repeat procedure.
the fault code. This sequence occurs three times for
each code. The fourth flash of the Warning lamp in- When the fault code is acknowledged and cor-
dicates the beginning of the second fault code. rected, the recorded fault will be deleted from the
LED fault log, but will remain in a data log that main-
There are distinct pauses between repetitions of the tains a fault code history. (The InPower service tool
code blink transmissions of the Shutdown lamp. is required to view this data log.)

2-6
MENU DISPLAY AND SWITCHES Six momentary buttonsthree on
each side of the graphical display windoware
Figure 2-2 shows the graphical display and the used to navigate through the system control menus
menu selection buttons. and to adjust generator set parameters. The button
The graphical display is capa- is active when the message or symbol adjacent to
ble of displaying up to 9-lines of data with approxi- the switch is highlighted (displayed in inverse vid-
mately 27 characters per line. The display is used to eo). The displayed message or symbol indicates
view the menus of the menu-driven operating sys- the function of the button.
tem. Refer to the menu trees later in this section.
The display is also used to show the following sys- In the graphical display, the symbol indicates
tem information: that selecting the adjacent button causes the operat-
ing program to go to the next menu displayas
modes of operation, such as shown in the menu diagrams.
Stopped, Time Delay To Start, Warm Up At
Idle, etc., and paralleling operations, such as
Standby, Dead BUS Close, Synchronize, etc. In the graphical display, the symbol indicates
that selecting the adjacent button causes the operat-
system actions, such as Warning, ing program to go back to the previous menu display.
Derate, Shutdown Cool-down and Shutdown,
and fault codes.
In the graphical display, the symbol indicates
Fault code/status mes- that selecting the adjacent button causes the operat-
sages. ing program to go back to Main Menu A (Figure 2-4).

STATE LINE
ACTION LINE
DESCRIPTION LINE

MENU DISPLAY
AREA

GRAPHICAL
DISPLAY

MENU MENU
BUTTONS BUTTONS

FIGURE 2-2. GRAPHICAL DISPLAY AND MENU SELECTION BUTTONS

2-7
LANGUAGE/UNITS SELECTION MENU
During any control panel operation, you can select
one of three languages and change how units are
displayed by pressing the two lower menu buttons LANGUAGE ENGLISH
+ LOCATION LOCAL
(one on each side of display). When pressing these TEMP F
two buttons simultaneously, the language/units PRESS FLD PSI ENTER
menu will appear (Figure 2-3). After making desired PRESS GAS INHG
selections, press the ENTER button in this menu to FLOW AIR CFM
change and save the selections.
Use the + buttons to select the desired option for
each field. Use the arrow ( ) button to move to the
FIGURE 2-3. LANGUAGE/UNITS MENU
next field. Selected field is highlighted.
Language: Used to select desired language (de-
fault = English).
Location: This selection must be set to Local when
the graphical display is mounted on the generator
set front control panel or Remote when mounted re-
motely from the generator set.
The Local/Remote selection determines which but-
tons in the Control submenu (page 2-13) are active
(displayed).
Temp: Used to select F or C for temperature read-
ings.
Pressure Fluid: Used to select PSI, KPA, BAR or
IN for pressure readings.
Pressure Gas: Used to select INHG or MMHG for
pressure readings.
Flow Air: Used to select CFM or CMM for air flow
readings.

2-8
MAIN MENU _\_ Button (Paralleling Applications Only)
Figure 2-4 shows the main menus (Menu A and When displayed, indicates that the feature for gen-
Menu B) of the system control. The two main menus erator set paralleling applications is installed. This
are used to divide the system submenus into major button is used to open and close the generator set
categories, such as, Engine Data, Alternator Data, circuit breaker (CB). The symbol indicates if the CB
Control, etc. is opened or closed. Opened _\_, push to close.
To view system data, simply press the appropriate Closed __, push to open.
menu button to select the category. After pressing
the desired menu button, refer to the page number With the control panel 0/Manual/Auto switch in the
shown in Figure 2-4 for detailed information related Auto position, the opening and closing of the CB is
to the selected category. controlled by the control system software. The CB
symbol will indicate an open or closed CB, but the
In the following figures, the boxed/highlighted field button will be inactive when the control is in Auto.
indicates that the adjacent menu button is active.
Also, the submenus are shown in the order in which In the Manual position, the CB can only be closed
they are displayed when scrolling up or down . by using this button. When manually closed and the
CB opens, it must be closed again by using this but-
Adjust Button ton. To close the CB, press and hold the button until
The Adjust submenu is intended for qualified site the symbol indicates a closed CB. (CB close will oc-
personnel only. Note that a password may be as- cur only when setup conditions allow dead bus or
signed to allow only authorized operators to modify generator synchronized with bus.)
this data. (Password is not required if not assigned.)
Power Trans Button (Power Transfer
Setup Button Control Applications Only)
The Setup submenu is described in When displayed, indicates that the Power Transfer
The Adjust and Setup submenus can be viewed, Control (PTC) feature is installed. Refer to page
but not modified without entering the correct pass- 2-17 for PTC Data submenu description. The PTC
words. setup submenu is described in

2-9
MENU A
MENU MENU
BUTTONS PAGE MENU BUTTONS
2-11 B

ENGINE MORE>>
PAGE ALTERNATOR POWER TRAN or _\_ Page
2-12 CONTROL HISTORY/ABOUT 2-9

PAGE PAGE
2-13 2-14

MENU B

Section
3

ADJUST
PARALLEL DATA PAGE
SETUP BACK<< 2-16

GRAPHICAL
Section DISPLAY MENU
3 A

FIGURE 2-4. SYSTEM CONTROL MAIN MENUS A AND B

2-10
ENGINE SUBMENUS

If you press the ENGINE button in Menu A, the En-


gine submenus will appear (Figure 2-5). ENGINE
The first submenu displays general information that
applies to all gensets (coolant temp, oil pressure,
etc.) The data in the remaining submenu(s) will vary
according to the type and number of sensors pro- COOLANT TEMP 180 F
vided with the engine. OIL PRESSURE 75 PSI
ENGINE SPEED 1800 RPM
BATTERY 29.1 VDC

MANF TEMP 75 F
MANF PRESS ABS 180 INHG
RAIL PRESS ABS 180 PSI
PUMP PRESS ABS 291 PSI
FUEL INLET TEMP 172 F
COOLANT PRESSURE 59 PSI

BLOWBY FLOW 25 CFM


TIMING PRESS 50 PSI
AFTERCOOLER TEMP 76 F
AMBIENT PRESS 88 INHG

FIGURE 2-5. ENGINE SUBMENUS

2-11
ALTERNATOR SUBMENUS

If you press the ALTERNATOR button in Menu A,


the Alternator Data submenus will appear (Figure ALTERNATOR
2-6).
Voltage L-L and L-N: Indicates voltage Line-to
Line and Line-to-Neutral. Note that the Line-to-Neu-
tral column will not be displayed for a 3 phase/3 wire V L-L L-N AMPS
system. Accuracy 1%. L1 480 277 1340
L2 480 277 1290
The voltage Line-to-Line (L1, L2 and L3) are mea- L3 480 277 1260
sured between L1 to L2, L2 to L3 and L3 to L1, re- FREQUENCY 60.0 HZ
spectively. AVR DUTY CYCLE 10.3 %

Amps: All phases. Accuracy 1%.


Frequency: Generator set output frequency.
AVR DUTY CYCLE: Displays voltage regulator kW kVA PF
(drive) level in percentage of maximum. L1 350 500 .80
L2 350 500 .80
kW, kVA and PF: Displays generator set kW and L3 350 500 .80
kVA output (average and individual phase, and di- TOT 1050 1500 .80
rection of flow) and power factor with leading/lag-
ging indication. Accuracy 5%.
The PF reading will contain an asterisk if the power
factor is leading (for example, *.30). FIGURE 2-6. ALTERNATOR SUBMENUS

2-12
CONTROL SUBMENU

If you press the CONTROL button in Menu A, the


Control submenu will appear (Figure 2-7). CONTROL
(Local)
Local CONTROL Submenu Function

When the operator panel is mounted on the control


panel assembly, the Run Mode Idle/Rated button is
active (displayed). Note in Figure 2-7 that this but- + RUN MODE IDLE
ton is not displayed in remote applications.
ENABLE SYNC
The shaded area in Figure 2-7 displays the se-
lected/active mode of operation, either IDLE or
RATED.

Remote CONTROL Submenu Functions


BARGRAPH TEST
When the operator panel (Figure 2-1) is mounted
remotely of the control panel assembly, the menu
buttons in the Control submenu are used to perform
the following remote operations. (To activate these
menu buttons for remote/local use, refer to page
2-8.)
CONTROL
The 0/Manual/Auto switch must be in the Auto posi- (Remote)
tion to activate the Remote Menu Buttons of the Con-
trol submenu.

Remote START or STOP Button: This button is


used to start and stop the generator set when the
START GENSET
operator panel is mounted in a remote location.
FAULT ACKNOWLEDGE
When the generator set is operating, Stop will be ENABLE SYNC
displayed for this button and Start will be displayed
when not operating.

Fault Acknowledge Button: Used to reset inactive


Warning messages, not Shutdown messages.
BARGRAPH TEST
Local/Remote CONTROL Submenu
Function

Bargraph Test: The function of this button remains


the same and is not dependent on operator panel
location. This button sequentially lights the LEDs to FIGURE 2-7. CONTROL SUBMENU
test the bar graph display.

Enable Sync: Displayed in paralleling applications


only. Intended for service personnel to turn off the
synchronizer for troubleshooting/testing purposes.

2-13
HISTORY/ABOUT SUBMENUS

If you press the HISTORY/ABOUT button in Menu


A, the History/About submenus will appear (Figure HISTORY/ABOUT
2-8).
HISTORY: The control maintains a data log of the
number of engine starts and number of operating
hours for the engine and control, and the megawatt STARTS 533
and maximum torque hours of the generator set. ENGINE HOURS 1236
This information is stored in non-volatile memory CONTROL HOURS 7879
and will not be deleted due to loss of battery power. KWHRS 890

ABOUT: The About submenus provide the follow-


ing generator set information.
Genset model and wattage (kW/MW)
Output voltage and WYE, DELTA or SINGLE
HISTORY-HRS@ %MAX TORQUE
Frequency 50 or 60 Hz 12345@0-9 23455@50-59
Rating: Standby, Prime or Base 12345@10-19 12345@60-69
12345@20-29 12345@70-79
Version level of the controller and panel operat- 12345@30-39 12345@80-89
ing software.

MODEL 1750DQKB
VOLTAGE 416 WYE
FREQUENCY 60
RATING STANDBY

CONTROLLER VERSION
RTOP DN30008.DFA
BATS APR 23 1999
OP PANEL VERSION
RTOP 1.09 AUG 17 1999
BATS 1.02 MAY 6 1999

CONTINUED TO NEXT PAGE

FIGURE 2-8. HISTORY/ABOUT SUBMENUS

2-14
HISTORY/ABOUT SUBMENUS (CONT.)

FAULT HISTORY: The control maintains a data log


of all fault conditions as they occur, and time stamps HISTORY/ABOUT (CONT.)
them with the control and engine operating hours.
Up to 32 (unacknowledged) fault codes can be
stored in control panel memory. After the fault is ac-
knowledged and corrected, the recorded fault will
be deleted from the control panel memory, but will FAULT HISTORY: 1 OF 24
+ CNTL HOURS 459
remain in a data log that maintains a fault code his- OCCURRENCES 5
tory. (The InPower service tool is required to view ENGINE HOURS 334
this data log.) FAULT CODE 1437
( )
The display line: 1 of 24 indicates that
24 faults are recorded and that the most recent fault
(1) detected by the controller is displayed.
The display line: In this example, 5 in- FIGURE 2-8. HISTORY/ABOUT SUBMENUS (CONT.)
dicates that this is the fifth occurrence of this fault.
(The InPower service tool is required to review the
last four faults of this code.)
The Occurrences number is incremented for each
new occurrence of the same fault. The controller
must detect that the original sensed fault is cor-
rected before it will increment the occurrence num-
ber for that fault.
For example, when a Low Oil Pressure fault is de-
tected, the controller will increment the Occurrences
number by 1. This fault will remain active until the
fault is acknowledged and the controller detects that
the fault is corrected. An active fault will prevent the
controller from incrementing the Occurrences num-
ber each time the engine is started. When the con-
troller detects that the oil pressure is normal the fault
will become inactive, allowing the occurrences num-
ber to be incremented for the next detected Low Oil
Pressure fault.

2-15
PARALLEL DATA SUBMENU
If you press the PARALLEL DATA button in Menu _\_ Button: Used to open and close the generator
B, the Parallel Data submenu will appear (Figure set circuit breaker (CB). The symbol indicates if the
2-9). This menu is displayed in paralleling applica- CB is opened or closed. Opened _\_, push to close.
tions only. Closed __, push to open.
PARALLEL DATA STATUS LINE: The top line of With the control panel 0/Manual/Auto switch in the
the graphical display is used to indicate the follow- Auto position, the opening and closing of the CB is
ing PARALLEL DATA status: controlled by the control system software. The CB
STANDBY: Indicates no paralleling activity is symbol will indicate an open or closed CB, but the
occurring at present. button will be inactive when the control is in Auto.
DEAD BUS CLOSE: Indicates first genset in
system to close to bus. In the Manual position, the CB must be closed by
this button. When manually closed and the CB
SYNCHRONIZE: Genset is synchronizing to
opens, it must be closed again by using this button.
bus.
To close the CB, press and hold the button until the
LOAD SHARE: Genset has closed to bus and symbol indicates a closed CB. (CB close will occur
is sharing load with other gensets in system. only when setup conditions allow dead bus or
LOAD GOVERN: Genset closed to bus in par- generator synchronized with bus.)
allel with utility (mains).
BUS Voltage L-L: The BUS voltage Line-to-Line
(L1, L2 and L3) are measured between L1 to L2, L2
to L3 and L3 to L1, respectively. PARALLEL DATA

BUS/GEN HZ: BUS/GEN hertz.


BUS/GEN SYNC STATUS: The bottom line of the LOAD GOVERN
graphical display is used to indicate the following V BUS GEN
BUS/GEN Sync status: L1 480 480
L2 480 480
NOT SYNCHRONIZING: Genset is in service L3 480 480 _\_
mode that does not allow auto sync feature. HZ 60.1 60.1
(Selected via InPower service tool deactivate DEG 122 NOT SYNCHRONIZING
to allow synchronization.)
SYNCHRONIZING: Genset is synchronizing to
bus.
READY TO CLOSE: In manual mode, push cir-
cuit breaker close button to close breaker. FIGURE 2-9. BUS DATA SUBMENU

2-16
POWER TRANSFER MAIN/SUBMENUS

If you press the POWER TRANS button in Menu The symbol displayed in the middle of the Pow-
A, the Power Transfer main menu will appear (Fig- er Transfer main menu indicates which breaker
ure 2-10). The Power Transfer Control (PTC) fea- (utility or genset) is closed/opened to the load. The
ture must be installed to display this menu. symbol presently shown indicates that the utility
breaker is closed and supplying power to the load.
The PTC feature enables the PCC to monitor the
utility voltage (mains) and frequency for failure and
The Power Transfer main menu also indicates if the
control the opening and closing of the contacts (cir-
utility and the generator set are available to accept
cuit breakers) for the utility (S1) and the genset
(S2). load. When the control detects that either source is
ready to accept load, UTILITY and/or GENSET will
If utility fails, the control will initiate the genset start- be displayed in inverse video.
ing sequence, open S1 and close S2 to the load.
When utility returns, the load is retransferred to the The Power Transfer main menu has four submenu
utility (S1 closes/S2 opens) and the control initiates groups. Refer to the page numbers shown in Figure
the genset shutdown sequence. 2-10 for the Power Transfer submenu descriptions.

2-17
PTC Status Line the genset will continue to run even if a genset
warning or derate fault occurs. This test can be
The top line of the graphical display is used to indi- performed with or without load (refer to TEST/
cate the following PTC status: EXERCISE submenu in ).
NOT ENABLED: PTC is not enabled. Control TEST: Test sequence initiated through Remote
panel switch in O (Off) position. Start switch with emergency start sequence
MANUAL: Control panel switch is in Manual disabled (TB8-3 terminal closed). Test mode is
position. All PTC actions or genset start/stop non-emergency, which means that a retransfer
actions are manually controlled. to utility will occur if any problems occur with
NORMAL UTIL: Load is connected to the util- the genset while testing with load. This test can
ity. be performed with or without load (refer to
RETRAN: Retransfer of load to utility. TEST/EXERCISE submenu in ).
RETRAN OVRD: Immediate retransfer of load EXERCISE: Exercise sequence initiated
to utility due to genset fault (e.g., warning, der- through control panel. This test can be per-
ate, or shutdown w/cooldown fault). The re- formed with or without load (refer to TEST/EX-
transfer timer is ignored as is the retransfer in- ERCISE submenu in ). A retransfer to
hibit. utility will occur if any problems occur with the
EMERG TEST: Emergency Test sequence ini- genset during the exercise sequence.
tiated through Remote Start switch with emer- UTILITY FAIL: Utility has failed. (Initiates
gency start sequence enabled (TB8-3 terminal transfer of load to genset if O/MANUAL/AUTO
opened). Emergency test mode means that switch is in AUTO.)

MENU MENU
BUTTONS PAGE PTC STATUS LINE PAGE BUTTONS
2-19 2-22

UTILITY GENSET
PAGE STATUS
2-20 TRANSFER CONTROL
DEG 123 SYNCHRONIZING

PAGE MENU
2-21 A

FIGURE 2-10. POWER TRANSFER MAIN MENU

2-18
UTILITY (PWR TRAN) SUBMENUS

If you press the Utility button in the Power Transfer


Main menu, the Utility submenus will appear (Fig- UTILITY
ure 2-11).

Voltage L-L and L-N: Indicates utility voltage Line-


to Line and Line-to-Neutral. Note that the Line-to-
Neutral column will not be displayed for a 3 phase/3 UTILITY:
V L-L L-N AMPS
wire system. Accuracy 1%. L1 480 277
L2 480 277 1320
L3 480 277
The voltage Line-to-Line (L1, L2 and L3) are mea- FREQUENCY 60.0 HZ
sured between L1 to L2, L2 to L3 and L3 to L1, re-
spectively.

Amps: L2 only. Accuracy 1%.


UTILITY:
Frequency: Utility frequency. kW kVA PF
L1
L2 125 175 .96
kW, kVA and PF: Displays (L2 only) utility kW and L3
kVA output (average and direction of flow) and pow- TOT
er factor with leading/lagging indication. Accuracy
5%.
FIGURE 2-11. UTILITY SUBMENUS
The PF reading will contain an asterisk if the power
factor is leading (for example, *.30).

2-19
STATUS (PWR TRAN) SUBMENUS

If you press the Status button in the Power Trans-


fer Main menu, the Status submenus will appear STATUS
(Figure 2-12).
Connected: Indicates which source(s) is con-
nected to the load.
Available: Indicates when the corresponding UTIL GEN
sources have acceptable output voltage and fre- CONNECTED YES NO
quency. Both can be available simultaneously. AVAILABLE YES NO
VOLT L12 480 0
Volt L12: Indicates utility and generator set Line 1 to HZ 60.0 0.0
Line 2 voltage. KW L2 456 0
HZ: Utility and generator set output frequency.
KW L2: Utility and generator set Phase B (L2) kW
output.
Transfer Inhibit: This feature is used to control TRAN INH OFF
load transfer to the genset. When activated, load RETRAN INH ON
transfer to the genset will not take place if the utility
fails.
Transfer inhibit is controlled by connecting a remote
contact between TB3-57 and TB3-58. Closing the
contact enables the feature and opening the con-
tact disables it. When enabled, the event is dis-
played on the graphical display. FIGURE 2-12. STATUS SUBMENUS
Retransfer Inhibit: This feature is used to prevent
the PTC from automatically transferring the load
back to the utility. When activated, load transfer will
not take place unless the genset fails (Retransfer
Inhibit is ignored if the genset fails).
Retransfer inhibit is controlled by connecting a re-
mote contact between TB3-64 and TB3-65. Closing
the contact enables the feature and opening the
contact disables it. When enabled, the event is dis-
played on the graphical display.

2-20
TRANSFER CONTROL (PWR TRAN) SUBMENU

If you press the TRANSFER CONTROL button in


the Power Transfer Main menu, the Transfer Con- TRANSFER CONTROL
trol submenu will appear (Figure 2-13).
The symbol displayed in the middle of the
TRANSFER CONTROL submenu indicates which
breaker (utility or genset) is closed/opened to the UTILITY GENSET
load. The symbol presently shown indicates that the
utility breaker is closed and supplying power to the CB ENABLE CB ENABLE
load. << BACK

During genset operation in the manual mode, you


can manually transfer/retransfer load between the
utility and the genset. To transfer load, press the ap-
propriate CB ENABLE button (Utility or Genset).

Example (Figure 2-13)


ENABLE UTIL CB
In the example in Figure 2-13, the CB ENABLE but-
ton for Utility was pressed. (If the CB ENABLE CANCEL
button for the Genset was pressed, ENABLE
GEN CB would be displayed in the second subme-
nu, allowing you to open or close the genset circuit
breaker.)
After pressing the utility CB ENABLE button, the
second submenu will be displayed allowing you to UTILITY GENSET
either CANCEL or ENABLE the entered selection.
OPEN UTIL CB ENABLE
Pressing the CANCEL button will return the display << BACK
to the previous menu.
Pressing the ENABLE button will display the third
submenu. With this submenu displayed you can re-
turn to the second submenu without opening the
utility circuit breaker (press <<BACK) or you can
press the OPEN UTIL button. UTILITY GENSET

Pressing the OPEN UTIL button will display the CLOSE UTIL CB ENABLE
fourth submenu, indicating that the utility circuit << BACK
breaker is now opened.
Note that the fourth submenu displays CLOSE
UTIL. Pressing this button will close the utility circuit
breaker and redisplay the third submenu. FIGURE 2-13. TRANSFER CONTROL SUBMENUS

2-21
GENSET (PWR TRAN) SUBMENUS

If you press the Genset button in the Power Trans-


fer Main menu, the Genset submenus will appear GENSET
(Figure 2-14).

Voltage L-L and L-N: Indicates voltage Line-to


Line and Line-to-Neutral. Note that the Line-to-Neu-
tral column will not be displayed for a 3 phase/3 wire GENSET:
system. Accuracy 1%. V L-L L-N AMPS
L1 480 277 1320
L2 480 277 1320
The voltage Line-to-Line (L1, L2 and L3) are mea- L3 480 277 1320
sured between L1 to L2, L2 to L3 and L3 to L1, re- FREQUENCY 60.0 HZ
spectively.

Amps: All phases. Accuracy 1%.

Frequency: Generator set output frequency. GENSET:


kW kVA PF
kW, kVA and PF: Displays generator set kW and L1 100 150 .97
L2 125 175 .96
kVA output (average and individual phase, and di- L3 150 200 .95
rection of flow) and power factor with leading/lag- TOT 375 525 .96
ging indication. Accuracy 5%.

The PF reading will contain an asterisk if the power


factor is leading (for example, *.30). FIGURE 2-14. GENSET SUBMENUS

2-22
GENERAL The Setup submenus are intended for qualified ser-
This section contains calibration and adjustment vice personnel only. The Adjust submenu is in-
procedures for the generator set control. tended for qualified service and site personnel only.
For this reason, a password must be entered before
MODIFYING SETUP/ADJUST SUBMENUS this data can be modified. The Setup and Adjust
The Setup and Adjust submenus allow you to cali- submenus can be viewed, but not modified without
brate the graphical display meters and to adjust entering the correct password.
system parameters, customer defined faults, gen-
erator set voltage/frequency and paralleling ap- Saving Menu Changes
plications. Changes are automatically saved when the menu is
exited.

3-1
PASSWORD Menu unauthorized adjustment, the entered password is
valid for 10 minutes after the last button is pressed
To allow the site personnel to modify only the Adjust (i.e., the password will need to be reentered after
submenu and not the Setup submenus, two pass- the ten minute timeout.
words are assigned within the system software. An
Application password is used for the Setup sub- Entering Password
menus and a User password is used for the Adjust
submenu. To enter the password:
The two passwords are assigned during the initial 1. Display submenu to modify.
installation of the generator set (via InPower) and
2. Press either the + or button within the dis-
will vary between sites. The installer must make
played submenu. The Password menu ap-
sure that the passwords are available to the ap-
pears.
propriate personnel.
3. Press the + and button to select the first char-
When the generator set is first installed, the acter of the password (AZ or 09). (Enter Ap-
and password are both set to GENSET to plication password for Setup submenus; En-
allow initial modification of the Setup and Adjust ter User password for Adjust submenu.)
submenus. Assign new passwords when site instal-
lation is complete. 4. Press the button to select the next character
field. Selected character field is highlighted.
When viewing the Adjust menu, pressing the + or
5. Repeat steps 3 and 4 to enter remaining pass-
button will display the User Password menu.
word characters.
When viewing a Setup menu, pressing the + or 6. Press the Enter button after entering the pass-
button will always display the Application Password word. The submenu selected in step 1 will re-
menu. appear.
After entering the correct password, the system will 7. After making desired changes to submenu, exit
allow you to modify the submenus. To help prevent submenu to save changes.

+ OR BUTTON + OR BUTTON

ENTER APPLICATION PASSWORD ENTER USER PASSWORD


+ ENTER + ENTER

XXXXXXXX XXXXXXXX

SETUP SUBMENU PASSWORD MENU ADJUST SUBMENU PASSWORD MENU

FIGURE 3-1. PASSWORD MENUS

3-2
SETUP MENUS MORE>> button in Menu A and then the SETUP
button in Menu B.
Figure 3-2 shows the main menus (Menu A and
To view system data or to adjust system parame-
Menu B) of the system control and the two Setup
ters, press the appropriate Setup menu button to
menus.
display the desired Setup submenu(s). Refer to the
page number shown in Figure 3-2 for detailed infor-
The Setup procedure is intended for qualified ser- mation related to the selected submenu(s).
vice personnel only. The APPLICATION password
must be entered to modify the Setup submenu
fields. Refer to in this section to
enter password and to save menu changes.

To display the two Setup menus, press the

MENU A MENU B

MENU
ENGINE MORE>> B ADJUST
ALTERNATOR POWER TRAN or _\_ PARALLEL DATA
MENU
CONTROL HISTORY/ABOUT SETUP BACK<<
A

SETUP MENU 1
PAGE MENU
3-4 B

GOVERNING/VOLT REG
PAGE CUSTOMER FAULTS NEXT
3-5 MENU
CALIBRATION

PAGE MENU
3-6 A

SETUP MENU 2
PAGE ABOVE
3-12 MENU

POWER TRANSFER SETUP


PAGE ISOLATED BUS
3-7 UTILITY

PAGE MENU
3-11 A

FIGURE 3-2. SETUP SUBMENUS

3-3
GOVERNING/VOLT REG SUBMENU

If you press the GOVERNING/VOLT REG button


in the Setup menu, the Governing/Volt Regulator GOVERNING/VOLT REG
submenu will appear (Figure 3-3).

Use the + and buttons to increase or decrease the


values in the following fields. Use the arrow ( ) but-
ton to move the cursor within a field or to the next
field. Exit menu to safe changes. + GOV GAIN 80%
AVR GAIN 100%
GOV GAIN: If the gain adjustment is set too high,
engine speed will hunt or oscillate. If gain is set too
low, the engine will respond too slowly to changes in
load and overspeed may result. (Gain should be re-
duced to 80% for paralleling installations.)
FIGURE 3-3. GOVERNING/VOLT REG SUBMENU
AVR GAIN: If the gain adjustment is set too high,
output voltage will be unstable. If gain is set too low,
the output voltage will respond sluggishly to
changes in load and overshoot may result.

3-4
CUSTOMER FAULTS SUBMENUS

If you press the CUSTOMER FAULTS button in


the Setup menu, the Customer Faults submenus CUSTOMER FAULTS
will appear (Figure 3-4).
There are a total of four customer fault inputs.
( .) The message dis-
played at the bottom of the menu can be modified
for each of these faults in addition to selecting the CUSTOMER FAULT1:
+ ENABLE ON
following operating parameters for each fault.
ACTIVE CLOSED
Enable On or Off RESPONSE WARNING
Active Closed or Open ***CUSTOMER FAULT1 ******************
Response Shutdown, Cooldown, Derate or
Warning
Shutdown: Genset will immediately shut
down. Normally used for engine faults.
Cooldown: Cooldown sequence will be initi- CUSTOMER FAULT2:
+
ated before shutdown. Should not be used for
engine faults.
RESPONSE WARNING
Derate: Used to lower kW output of genset for
warnings such as pre-high coolant tempera- ***CUSTOMER FAULT2 ******************
ture, etc. Paralleling application controller will
reduce precentage of kW load sharing on the
set. Non-paralleling application controller will CONTINUES THROUGH TWO
ADDITIONAL MENUS FOR A
lower percentage of kW load by operating load TOTAL OF FOUR POSSIBLE
shed relay contacts. CUSTOMER FAULT MESSAGES
Warning: Display message, genset continues
to operate.
The Enable and the Active fields apply to the Fault 1 FIGURE 3-4. CUSTOMER FAULTS SUBMENUS
and 4 submenus only.
With the Active field selected, pressing the + or
buttons will toggle the selection between CLOSED
and OPEN. Use same operation for remaining field
selections.
To enter the desired customer fault message, press
the or button to display the submenu that con-
tains the customer fault message (1 through 4) to be
changed. Use the button to scroll down through
the menu selections to the editable fault message
(bottom menu line).
Use the button to move to each character posi-
tion within the fault message line.
With the desired character position selected, use +
or buttons to select the appropriate character.
If these messages are changed, you should note
these changes in the section of the
Operators manual for this generator set.

3-5
CALIBRATION SUBMENUS

If you press the CALIBRATION button in the Setup


menu, the Calibration submenus will appear (Fig- CALIBRATION
ure 3-5).
Use the + and buttons to increase or decrease the
values in the following fields. Use the arrow ( ) but-
ton to move the cursor within a field or to the next
VOLTAGE CALIBRATION
field. Exit menu to safe changes.
+ L1 480 -X.X%
L2 480 -X.X%
The Calibration submenus allow you to calibrate the L3 480 -X.X%
control with the reading from a calibrated meter.
Calibration is accomplished by using this section of
the menu software to adjust the display so that it
matches the reading taken on an accurate, recently
calibrated meter.
Calibration is normally only required when replac-
CURRENT CALIBRATION
ing certain circuit cards. Refer to the L1 234 -X.X%
+
in this section which contains a list of the L2 123 -X.X%

cards that require control calibration. L3 562 -X.X%

When performing Bus Voltage Calibration from the


graphical display, the genset must be off and the Bus
live. If the genset is running, it will synchronize to the
Bus.

BUS VOLTAGE CALIBRATION


+ L1 480 -X.X%
L2 480 -X.X%
L3 480 -X.X%

FIGURE 3-5. CALIBRATION SUBMENUS

3-6
ISOLATED BUS / UTILITY Submenus and frequency in a range of minus 40% to plus 10%
(Paralleling Application) of normal bus conditions. When the paralleling
breaker has closed, the control will bring the gener-
The Isolated BUS submenus (Figure 3-6) and the ator set back to normal voltage and frequency.
Utility submenus (Figure 3-7) adjust the control pa-
rameters for generator set protection, synchroniz- When the generator set is paralleled to another
ing and load sharing for both isolated bus and utility generator set, the control provides automatic load
(mains) paralleling applications. Utility (mains) par- sharing functions for both real (kW) and reactive
allel applications may require adjustment of both (kVAR) loads. Load sharing is proportional between
the Isolated BUS and Utility submenus. generator sets based on their standby ratings. If two
generator sets of different sizes are paralleled, they
Always perform ISO BUS calibration before Utility will assume the same percentage of the system
BUS calibration.
load automatically. This can easily be verified on the
The sync check (permissive) function is operational kW Load LED bar graph on the front of the control
in both automatic and manual (RUN) modes. The panel.
control will make sure that the generator set is at
When the utility paralleling mode is enabled and the
proper voltage, within the defined sync check win-
generator set paralleling breaker is closed, the gen-
dow for the defined period of time and that phase
erator set will assume load based on external ana-
rotation is correct. When all criteria are met, the par-
log input signal. The input signal must be calibrated
alleling breaker is closed automatically by the con-
from 05 VDC. When the signal is at 0.5 to 1 VDC,
trol (auto mode), or by operation of the breaker
the control will operate the generator at no load in
close switch by the operator (manual mode).
parallel with the utility (mains) source. At 4.5 VDC
The synchronizing function of the control is enabled and greater, the control will operate the generator
when the control has brought the generator set to set at 110% of the generator set base load setting.
90% of rated speed and voltage, and has sensed When the load govern signal is between 1 VDC and
that bus voltage is available. The control automati- 4.5 VDC the control will operate the generator set at
cally adjusts the generator set speed and voltage to a load level which is determined by a linear relation-
match the bus frequency and voltage. The control ship between the kW reference and the load govern
can force the generator set to match bus voltage signal.

3-7
ISOLATED BUS SUBMENUS

If you press the ISOLATED BUS button in the Set-


up menu, the Isolated BUS submenus will appear ISOLATED BUS
(Figure 3-6).
Use the + and buttons to increase or decrease the
values in the following fields. Use the arrow ( ) but-
ton to move the cursor within a field or to the next
field. Exit menu to safe changes. ISOLATED BUS:
+ SYNC TIME LIMIT 120 SEC
SYNC TIME LIMIT: This parameter adjusts the time REV PWR LMT 10 %
delay in seconds before the Fail To Synchronize REV PWR TIME 3 SEC
alarm will operate. PERM WIN-PH 20 DEG
PERM WIN-TIME .5 SEC
REVERSE PWR LMT: Adjusts the reverse power
set point. For PowerCommand generator sets, a
typical set point is 10-15%.
CONTINUED TO NEXT PAGE
REVERSE PWR TIME: Adjusts the reverse power
function time delay. A typical time delay which is
suitable for PowerCommand generator sets is 3
seconds.
FIGURE 3-6. ISO BUS SUBMENUS
Lower reverse power set points can result in nui-
sance reverse power shutdown faults.
PERM WIN-PHASE: Adjusts the width of the per-
missive (sync-check) acceptance window. The ad-
justment range is from five to twenty electrical de-
grees. Recommended set point is 20 degrees for
isolated bus applications, and 15 degrees for utility
(mains) paralleling applications.
PERM WIN-TIME: Adjusts the time period (in sec-
onds) for which the generator set must be synchro-
nized with the system bus, before a breaker close
signal is issued by the PowerCommand control.
Available range is 0.5 to 5 seconds. Recommended
value for PowerCommand generator sets is 0.5
seconds for isolated bus applications.

3-8
Adjusting the control for a smaller sync-check win-
dow or longer time delay will cause synchronizing
ISOLATED BUS (CONT.)
time to be extended.
SYNC GAIN: The sync gain adjustment controls
how quickly the governor will respond to try to mini-
mize the bus/generator phase difference. Increas-
ing the gain speeds up the response. If the gain is ISOLATED BUS:
too high instability can result. + SYNC GAIN 1.0
KW BALANCE 0.3
KW Balance and KVAR Balance changes should be KVAR BALANCE 1.2
equally shared among all generator sets. KW GAIN 1.0
KVAR GAIN 1.0
KW BALANCE: This function adjusts the kW load
sharing function of the generator set. Before adjust-
ing this value, all generator set calibrations should
be performed. If the total load on the system is not CONTINUED TO NEXT PAGE
shared proportionately, the kW Balance can be
used to adjust the generator set for more precise
load sharing. Increasing the kW Balance value will
cause the generator set to reduce the percentage of FIGURE 3-6. ISO BUS SUBMENUS (CONT.)
the total kW load on that set.
KVAR BALANCE: This function adjusts the kVAR
load sharing function of the generator set. Before
adjusting this value, all generator set calibrations
should be performed. If the total load on the system
is not shared proportionately, the kVAR balance can
be used to adjust the generator set for more precise
load sharing. Increasing the kVAR balance value
will cause the generator set to reduce the percent-
age of the total kVAR load on that set.
KW GAIN: Adjusts the rate of change of kW load on
the generator set. With a constant load on the sys-
tem, if the generator set load is constantly chang-
ing, reduce the gain adjustment on the generator
set. This also allows modification of the rate of load
assumption on transient load change.
KVAR GAIN: Adjusts the rate of change of kVAR
load on the generator set. With a constant load on
the system, if the generator set load is constantly
changing, reduce the gain adjustment on the gener-
ator set. This also allows modification of the rate of
load assumption on transient load change.

3-9
1ST FAIL TIME: Time delay in seconds after a sig-
nal from the first start master is not sensed by the ISOLATED BUS (CONT.)
PCC that a FIRST START FAIL warning is dis-
played.
RAMP UNLOAD TIME: When a load demand stop
input is sensed the load is ramped down from the
present load level on the set to the ramp unload lev- ISOLATED BUS:
+ 1ST FAIL TIME 12 SEC
el in the time specified in seconds. RAMP UNLD 20 SEC
RAMP UNLD LEVEL 10 %
RAMP UNLOAD LEVEL: The load demand ramp
RAMP LOAD TIME 3 SEC
unload function will ramp the load down from the LOSS FIELD 20 SEC
present level on the set to this level before opening
the set circuit breaker. Value shown is in % of genset
standby rating.
FIGURE 3-6. ISO BUS SUBMENUS (CONT.)
RAMP LOAD TIME: When the load demand stop
signal is removed the load is ramped from 0kW to
the load share level in the specified time after the
circuit breaker closes.
LOSS FIELD TIME: Adjusts the loss of field func-
tion time delay. A typical delay which is suitable for
PowerCommand generator sets is 2 seconds.

3-10
UTILITY SUBMENUS

If you press the UTILITY button in the Setup


menu, the Utility submenus will appear (Figure 3-7). UTILITY
Use the + and buttons to increase or decrease the
values in the following fields. Use the arrow ( ) but-
ton to move the cursor within a field or to the next
field. Exit menu to safe changes.
BASE LOAD (%): This controls the maximum kW UTILITY:
+ BASE LOAD 80%
load level that the generator set will operate at when PF LEVEL 1.00
paralleled with the utility (mains). The value shown RAMP LOAD 3
indicates the steady state load on the generator as RAMP UNLD 20
MODE MULTIPLE
a percent of the generator set standby rating.
Check generator set ratings for maximum load level
at which the generator set should operate when
paralleled with the utility (mains). Extended opera-
tion at load levels in excess of the generator set rat-
UTILITY:
ing can cause abnormal engine wear or premature + KW GOVERN GAIN 1.00
engine failure. KVAR GOVERN GAIN 1.00

PF LEVEL: Adjusts the power factor that the gener-
ator set will run at when paralleled to the utility
(mains). Recommended setting is 1.0.
RAMP LOAD TIME: This is the ramp time from
present set load to level determined by the load set
analog input. This is active when the control first en- FIGURE 3-7. UTILITY SUBMENUS
ters the load govern mode.
RAMP UNLOAD TIME: This is the ramp time from
present set load to 0 kW. This ramp is active when
the load set analog input is less than 0.5 volts.
MODE MULTIPLE/SINGLE: This controls wheth-
er the set is to operate as part of a multiple set or
single set (PLTE or PLTF) system. (Refer to LOAD
DEMAND SHUTDOWN and SINGLE MODE EN-
ABLE function descriptions in wiring diagram,
page 5-8.)
KW GOVERN GAIN: This controls the rate that the
generator set kW load is increased after the genera-
tor set has closed to the system bus when utility
(mains) paralleled. Decreasing this value will result
in slower loading of the generator set.
KVAR GOVERN GAIN: This controls the rate that
the generator set kVAR load is increased after the
generator set has closed to the system bus when
utility (mains) paralleled. Decreasing this value will
result in slower loading of the generator set.

3-11
POWER TRANSFER CONTROL MAIN To adjust PTC system parameters, press the ap-
MENUS propriate PTC main menu button and refer to the
page number shown in Figure 3-8 for detailed infor-
If you press the POWER TRANSFER SETUP but-
mation related to the submenu selected.
ton in the Setup menu 2 in Figure 3-2, the two main
menus of the optional Power Transfer Control
(PTC) feature will appear (Figure 3-8).

PAGE PTC MAIN


3-13 MENU 1

UTILITY SENSORS
PAGE GENSET SENSORS NEXT
3-15 MENU
TIMERS

PAGE
3-17
PTC MAIN
MENU 2
PAGE
TEST/EXERCISE
3-18

FIGURE 3-8. PTC SETUP MAIN MENUS

3-12
UTILITY SENSORS SUBMENUS

If you press the UTILITY SENSORS button in the U CT RATIO: Enter the CT Ratio of the Utility L2 CT.
PTC Main Menu 1, the Utility Sensors submenus This is the Ratio to 1 Amp. Range: 118000 (1A).
will appear (Figure 3-9).
The following field descriptions show the valid field
entries and default value (shown in parenthesis) for
each field.
Use the + and buttons to increase or decrease the
values in the following fields. Use the arrow ( ) but-
ton to move the cursor within a field or to the next
field. Exit menu to save changes.
U SENSOR TYPE: Enter the line-to-line (L-N) for 3
phase line-neutral voltage sensing or line-to-line
U PT VOLT LL: Enter the value of the utility line-to- (L-L) for 3 phase line-line voltage sensing. This ap-
line voltage which yields 100% voltage at the termi- plies to both the utility undervoltage and overvol-
nals of the utility (bus) PT module. tage sensors. Range: LL, LN (LN).
Range: 115000V, adjustable by standard nominal U <wye> <delta>: Enter utility connection type.
voltage values, 100V, 10V and 1V increments (1V). Range: Delta, Wye (Wye).
The 100% voltages for each of the four possible util-
ity (bus) PT modules are as follows, based on mod- U UNLOADED KW: Enter the kW on utility Line 2 at
ule dash number: which the utility is considered as unloaded. This is
01 = 208 volts LL the L2 kW level at which a closed transition soft
02 = 416 volts LL transfer will disconnect from the utility.
03 = 600 volts LL
04 = 120 volts LL UTILITY UNDERVOLTAGE: Non-adjustable field,
always enabled.
Nominal Utility voltage is 480V. This
means that utility (bus) PT module number 02 UTILITY OVERVOLTAGE, FREQUENCY: Used to
should be used. The voltage which will yield 100% enable or disable menu function. Choose Enabled
volts at this PT module is 416 per the above table. or Disabled (Enabled).
Thus enter 416V.
Nominal Utility voltage is 4160V. A pri- UV PICKUP: Enter a number between 85 and
mary stage transformer with a ratio of 4200/240 is 100% of the nominal voltage (90%).
used. This means that utility (bus) PT module num-
ber 01 should be used. The voltage which will yield UV DROP OUT: Enter a number between 75 and
the 100% volts (208V from above table) is calcu- 98% of the under-voltage pick-up percentage
lated as follows: (90%).
208 x (4200/240) = 3640. Thus enter 3640V.
UV DELAY: Enter a time between 0.1 and 5.0 sec-
U NOM VOLT LL: Enter the nominal utility line-to- onds (0.5 seconds).
line voltage. For example, 480, 4160, etc.. Range:
115000 V, adjustable by standard nominal voltage UV MIN PHASE: Displays the lowest line voltage of
values, 100V, 10V and 1V increments (1V). the three utility phases.

3-13
OV PICKUP: This adjusts the over-voltage pickup
as a percentage of the over-voltage drop-out. Enter UTILITY SENSORS
a number between 95 and 99% (95%).
OV DROP OUT: Enter a percentage between 105
and 135% of the nominal voltage (110%).
OV DELAY: Enter a range between 0 and 120 sec- U PT VOLT LL 416
+ U NOM VOLT LL 480
onds (3 seconds). U CT RATIO: 1 1000
U SENSOR TYPE LL
OV MAX PHASE: Displays the highest line voltage
of the three utility phases. U UNLOADED KW 50 KW
CENTER (FREQ): Enter a frequency between 45
and 65 Hz (60 Hz).
PICK UP (FREQ): Enter a percentage between 5
and 20% of the nominal frequency (10%). UTILITY UV: ENABLED
+ % VLL
DROP OUT (FREQ): Enter a percentage between PICK UP 95 475
DROP OUT 85 465
1 and 5% of the nominal frequency (1%). DELAY 0.5 S
MIN PHASE 470
DELAY (FREQ): Enter a time between 0.1 and 15.0
seconds (5.0 seconds).
FREQUENCY: This field displays the sensed utility
line frequency.
UTILITY OV: DISABLED
+ % VLL
PICK UP 95 487
DROP OUT 110 490
DELAY 3.0 S
MAX PHASE 485

UTILITY FREQ: DISABLED


+ CENTER 60 HZ
PICK UP 10 %
DROP OUT 1 %
DELAY 1.0 S
FREQUENCY 60.5 HZ

FIGURE 3-9. UTILITY SENSORS SUBMENUS

3-14
GENSET SENSORS SUBMENUS

If you press the GENSET SENSORS button in the G RAMP UNLOAD: Enter the ramp time for the
PTC Main Menu 1, the Genset Sensors submenus genset ramp unload rate during a closed transtion
will appear (Figure 3-10). soft load retransfer. Ramp rate is 100%kW divided
by this time setting. Range: 0900 seconds (20
The following field descriptions show the valid field sec).
entries and default value (shown in parenthesis) for
each field. G UNLOADED KW: Enter the %kW (based on
standby rating) that the genset is considered un-
Use the + and buttons to increase or decrease the
loaded. This is the %kW level at which a closed tran-
values in the following fields. Use the arrow ( ) but-
ton to move the cursor within a field or to the next sition soft retransfer will disconnect from the gen-
field. Exit menu to save changes. set. Range: 0100% (5%).

G NOM VOLT LL: Non-adjustable field, displays GEN UNDERVOLTAGE: Non-adjustable field, al-
current setting of genset nominal voltage. (See Ad- ways enabled.
just submenu to adjust the output voltage 5%.) GEN OVERVOLTAGE, FREQUENCY: Used to en-
G SENSOR TYPE: Enter the line-to-line (L-N) for 3 able or disable menu function. Choose Enabled or
phase line-neutral voltage sensing or line-to-line Disabled (Enabled).
(L-L) for 3 phase line-line voltage sensing. This ap- UV PICKUP: Enter a number between 85 and
plies to both the genset undervoltage and overvol- 100% of the nominal voltage (90%).
tage sensors. Range: LL, LN (LN).
UV DROP OUT: Enter a number between 75 and
G BASE LOAD: Enter the maximum load the gen- 98% of the under-voltage pick-up percentage
set will carry during a closed transition. Range: (90%).
0100% (80%).
UV DELAY: Enter a time between 0.1 and 5.0 sec-
G RAMP LOAD: Enter the ramp time for the genset onds (4 seconds).
ramp load rate during a closed transition soft load
transfer. Ramp rate is +100%kW divided by this UV MIN PHASE: Displays the lowest line voltage of
time setting. Range: 0900 seconds (20 sec). the three genset phases.

3-15
OV PICKUP: This adjusts the over-voltage pickup
as a percentage of the over-voltage drop-out. Enter GENSET SENSORS
a number between 95 and 99% (95%).
OV DROP OUT: Enter a percentage between 105
and 135% of the nominal voltage (110%).
OV DELAY: Enter a range between 0 and 120 sec- G NOM VOLT LL 480
+ G SENSOR TYPE LL
onds (3 seconds). G BASE LOAD 80.0%
G RAMP LOAD 20 S
OV MAX PHASE: Displays the highest line voltage G RAMP UNLOAD 20 S
of the three genset phases. G UNLOADED KW 5 %
CENTER (FREQ): Enter a frequency between 45
and 65 Hz (60 Hz).
PICK UP (FREQ): Enter a percentage between 5
and 20% of the nominal frequency (10%). GEN UV: ENABLED
+ % VLL
DROP OUT (FREQ): Enter a percentage between PICK UP 95 475
DROP OUT 85 465
1 and 5% of the nominal frequency (1%). DELAY 1.0 S
MIN PHASE 470
DELAY (FREQ): Enter a time between 0.1 and 15.0
seconds (5.0 seconds).
FREQUENCY: Displays the sensed genset line fre-
quency.
GEN OV: DISABLED
+ % VLL
PICK UP 95 487
DROP OUT 110 490
DELAY 8.0 S
MAX PHASE 485

GEN FREQ: DISABLED


+ CENTER 59 HZ
PICK UP 12 %
DROP OUT 2 %
DELAY 5.0 S
FREQUENCY 60.0 HZ

FIGURE 3-10. GENSET SENSORS SUBMENUS

3-16
TIMERS SUBMENU

If you press the TIMERS button in the PTC Main


Menu 1, the Timers submenu will appear (Figure TIMERS
3-11).
The following field descriptions show the valid field
entries and default value (shown in parenthesis) for
each field.
START DELAY 60 S
Use the + and buttons to increase or decrease the + STOP DELAY 60 S
values in the following fields. Use the arrow ( ) but- TRANSFER 10 S

ton to move the cursor within a field or to the next RETRANSFER 900 S
field. Exit menu to save changes. PGM TRANSIT 5 S
MAX PARALLEL 30 S
START DELAY: Sets time delay for genset engine
start. Prevents nuisance genset starting during brief
power interruptions.
Enter a range from 0 to 300 seconds (0 seconds).
FIGURE 3-11. TIMERS SUBMENU
STOP DELAY: Sets the time delay for engine cool-
down following a re-transfer. This stop delay works
in conjunction with and is activated at the same time
as the normal cooldown timer. (Will extend normal
cooldown timer if entered time is greater.)
Enter a time from 0 to 600 seconds (0 seconds).
TRANSFER: In a Normal to Emergency transfer
this function allows the genset to stabilize before
the load is applied. Enter a time from 0 to 120 sec-
onds (10 seconds).
RETRANSFER: In a Emergency to Normal transfer
this function allows the utility to stabilize before the
load is applied.
Enter a time from 0 to 1800 seconds (600 seconds).
PGM TRANSIT: Sets the time delay for Pro-
grammed Transition. A setting of 0.0 disables the
program.
Enter a time from 0 to 60 seconds (0 seconds).
MAX PARALLEL: Sets the maximum time during
closed transition that utility and genset can be paral-
leled.
Enter a time from 0 to 1800 seconds (20 seconds).

3-17
TEST/EXERCISE SUBMENU

If you press the TEST/EXERCISE button in the


PTC Main Menu 2, the Test/Exercise submenu will TEST/EXERCISE
appear (Figure 3-12).
The following field descriptions show the valid field
entries and default value (shown in parenthesis) for
each field.
Use the + and buttons to increase or decrease the +
values in the following fields. Use the arrow ( ) but- MODE CT-SOFT

ton to move the cursor within a field or to the next
field. Exit menu to save changes. TEST WITH LOAD OFF
EXER WITH LOAD OFF
MODE: Indicates the generator set application type
for PTC option.
OT-PGM TRAN Open transition load transfer.
CT-MOMENT Closed transition load transfer
FIGURE 3-12. TIMERS SUBMENU
with momentary (<100ms) overlap.
CT-SOFT Closed transition load transfer with
load ramping.
TEST WITH LOAD: Feature allows genset Test se-
quence, which is initiated through the Remote Start
(TEST) switch, to operate with or without load. De-
fault: OFF
EXER WITH LOAD: Feature allows genset Exer-
cise sequence, which is initiated through control
panel Exercise button to operate with or without
load. Default: OFF

3-18
ADJUST SUBMENU are disabled to prevent inadvertent misadjustment
of the paralleling load sharing functions.
Figure 3-13 shows the main menus (Menu A and
Menu B) of the system control and the Adjust sub- Use the + and buttons to increase or decrease the
menu. values in the following fields. Use the arrow ( ) but-
ton to move the cursor within a field or to the next
To display the Adjust submenu, press the MORE>> field. Exit menu to safe changes.
button in Menu A and then the ADJUST button in
Menu B. START DELAY: This delay applies only to remote
starting in the Auto mode. The Start Delay adjust-
The Adjust submenus are intended for qualified ment range is 0 to 300 seconds.
service personnel and site personnel only and may
require a USER password. If a password is re- STOP DELAY: This delay applies only to remote
quired, the USER password menu will appear when stopping in the Auto mode. The Stop Delay adjust-
you try to modify the Adjust submenus. (Refer to ment range is 0 to 600 seconds.
in this section to enter pass-
word. VOLTAGE: Used to adjust the output voltage 5%.

Changes are automatically saved when you exit FREQUENCY: Used to adjust the frequency 3 Hz.
this menu.
VOLTAGE/SPEED DROOP: These two submenus
If the generator set is operating in parallel with a apply to a genset that has the paralleling option and
system bus, the voltage and frequency adjustments is configured to operate in droop mode.

MENU A

ADJUST:
MENU START DELAY 5 SEC
ENGINE MORE>> +
B STOP DELAY 11 SEC
ALTERNATOR _\_ VOLTAGE 208 1.2 %
CONTROL HISTORY/ABOUT FREQ 60.0 HZ -0.0 HZ

MENU B

ADJUST:
+ STANDBY
VOLTAGE DROOP OFF
ADJUST BUS L1 480 V
BUS DATA POWER FACTOR 0.80
MENU VOLT 4.99 %
SETUP BACK<<
A

ADJUST:
+ STANDBY
SPEED DROOP OFF
BUS FREQ 60.0 HZ
TOTAL KW 300 KW
FREQ 60.0 0.40 HZ

FIGURE 3-13. ADJUST SUBMENU

3-19
CALIBRATION PROCEDURE display of the genset that is running when the bus is
energized. If it is necessary to adjust the output volt-
There are several circuit cards/modules that, when age display of the genset that is running, the InPower
removed and replaced, require you to recalibrate service tool must be used to switch off the synchro-
the control panel display for genset voltage and cur- nizer function of the control.
rent and bus voltage.
1. Display the submenu
Note that the type of calibration to perform varies for (Page 3-6).
each card. The letters A, B and C are used to desig- 2. With the genset OFF, attach a calibrated volt-
nate which of the following three calibration proce- meter to the AC output from L1 to L2. (L1 to
dures are required for each card/module. Neutral for single phase alternators.)
Genset/Parallel board (A, B & C) 3. Start the genset and allow it to reach normal
operating speed.
PT/CT board (A & B)
4. Calibrate voltage reading for so that the
Bus PT (C) reading on the display agrees with the cali-
CTs (B) brated voltmeter.
5. Shut the generator set OFF.
6. Repeat steps 2 through 5 for L2 and L3. (In step
2 attach meter to the AC output from L2 to L3 to
calibrate and L3 to L1 to calibrate .)
7. Exit menu to safe changes.
(B) Genset Ammeter Display Calibration
1. Display the Current Calibration submenu
(Page 3-6).
2. With the genset OFF, attach a calibrated am-
meter to L1.
3. Start the genset and allow it to reach normal
operating speed.
4. Load the genset to maximum rated kVA at
Use a calibrated RMS multimeter for accurate mea- rated voltage.
surements. Fluke models 87 or 8060A are good
choices. 5. Calibrate the reading for current so that the
reading on the display agrees with calibrated
(A) Genset Voltage Display Calibration ammeter.
6. Repeat steps 2 through 5 for and . (In step
The PowerCommand control automatically synchro-
2, attach meter to L2 to calibrate current and
nizes to the system bus when bus voltage is avail-
able and the genset is running. Consequently, it is L3 to calibrate current.)
not possible to calibrate the genset output voltage 7. Exit menu to safe changes.

3-20
(C) Bus Voltage Calibration meter to TB1-A (L1) and TB1-B (L2) of the bus
PT module (Figure 3-14).
The PowerCommand control automatically synchro- 3. Start another genset and allow it to reach nor-
nizes to the system bus when bus voltage is avail- mal operating speed and voltage. Connect op-
able and the genset is running. Consequently, it is erating genset to the bus.
not possible to calibrate the genset bus voltage dis- 4. Calibrate the voltage reading for Bus Volts
play of the genset that is running when the bus is en-
so that the reading on the display matches the
ergized. If it is necessary to adjust the bus voltage
display of the genset that is running, the InPower reading on the calibrated meter.
service tool must be used to switch off the synchro- 5. Shut the generator set OFF.
nizer function of the control. 6. Repeat steps 2 through 5 for Bus Volts L2 and
L3. (In step 2 attach meter to the AC output
1. Display the Bus Voltage Calibration submenu from L2 to L3 to calibrate L3 to L1 to cali-
(Page 3-6). brate .)
2. With all gensets OFF, attach a calibrated volt- 7. Exit menu to safe changes.

CONTROL
BOX DOOR

TB1-A (L1) TB1-C (L3)


TB1-B (L2)

FIGURE 3-14. BUS PT MODULE

3-21
CONTROL BOX WIRING 3-15). Optional equipment such as a remote annun-
ciator panel, sensing devices used to monitor gen-
The generator set control box assembly, which can set operation, remote start/stop switches, control
be located on either side of the genset, contains box heater, and etc. are also attached to these ter-
connection points for remote control and monitor
minal blocks. Driver signals for customer supplied
options.
relays are also provided for several alarm and shut
Customer monitor/control connections are at- down conditions. Refer to Customer Connections
tached to terminal blocks TB3 and TB8 (see Figure diagram in Section 5.

3-22
CONTROL WIRING
OPTIONAL OPTIONAL ACCESS
RUN RELAYS SHUTDOWN
K11, K12 & K13 ALARM RELAY K16

TB8

CARD
CAGE

FIGURE 3-15. CONTROL BOX ASSEMBLY INTERIOR

3-23
RUN RELAYS (K11, K12, K13) as fans, pumps and motorized air dampers. The run
relays are energized when the generator set reach-
The optional run relays are rail mounted inside the es operating speed.
control box (Figure 3-15). The rail mount allows you
to easily remove and replace the snap-on relays. The contacts are rated:
The generator set can be equipped with one, two or
three run relays. 10 amps at 28 VDC or 120 VAC, 80%PF

The three-pole, double-throw run relays (Figure 6 amps at 240 VAC, 80%PF
3-16) are used to control auxiliary equipment such 3 amps at 480/600 VAC, 80%PF

K11, K12, K13

CUSTOMER
K11, K12, K13
CONNECTIONS

K11, K12, K13

K11 K12 K13


RUN RELAY RUN RELAY RUN RELAY

NO NO NO
NC NC NC

COIL TB3-9
TB3-5
(SWITCHED B+) COM (GND)

FIGURE 3-16. OPTIONAL RUN RELAYS (K11, K12, K13)

3-24
ALARM RELAY (K16) as audible alarms. Any generator set shutdown will
energize the alarm relay.
The optional alarm relay is rail mounted inside the
control box (Figure 5-2). The rail mount allows you The contacts are rated:
to easily remove and replace the snap-on relay. 10 amps at 28 VDC or 120 VAC, 80%PF
The three-pole, double-throw alarm relay (Figure 6 amps at 240 VAC, 80%PF
5-4) is often used to energize warning devices such 3 amps at 480/600 VAC, 80%PF

K16

CUSTOMER
K16
CONNECTIONS

K16

K16
SHUTDOWN ALARM

NO
NC

COIL TB3-24
TB3-20
(SWITCHED B+) COM (COM ALARM - GND)

FIGURE 3-17. OPTIONAL ALARM RELAY (K16)

3-25
MAGNETIC SPEED PICKUP UNIT (MPU)
INSTALLATION
To install the MPU sensor, bar the engine until a MAGNETIC
gear tooth on the flywheel lines up in the center of PICKUP
the mounting hole. Thread the sensor in gently by SENSOR
hand until it just touches the gear tooth. Back it out
one quarter turn and set the locknut.

ENGINE
FLYWHEEL
RING GEAR

FIGURE 3-18. MPU SENSOR

3-26
TESTING THE GENERATOR
These tests can be performed without removing the
generator. Before starting tests, disconnect the
starting battery cables (negative [] first) to make
sure the engine will not start while performing these
tests.

EXCITER
RECONNECTION
STATOR
TERMINALS
END BRACKET

PMG
STATOR

END
STATOR BEARING

BLOWER PMG
ROTOR

COUPLING

EXCITER
ROTOR

ROTATING
RECTIFIER
ASSEMBLY

DRIVE ROTOR
DISCS
FRAME

END BRACKET/ENGINE
ADAPTOR
AIR DISCHARGE
PRESSURE COVERS
ROTOR
PLATE
SHAFT

FIGURE 4-1. TYPICAL GENERATOR

4-1
INSULATION RESISTANCE (MEGGER) & air-powered starting system, close air
POLARIZATION INDEX (PI) TESTING valve and install valve locking device.)
3. Put on high voltage gloves with leather protec-
Megger and PI testing must be performed on all tors.
medium voltage (601 through 15,000 volts) genera-
4. Using two pre-tested voltage detection devices
tor sets before initial start-up. PI testing for low volt-
(of the proper rating), verify de-energized con-
age (less than 600 volts) generator sets is recom-
dition in the work area. (Retest voltage detec-
mended by Cummins Power Generation.
tion devices immediately after verification of
These tests are used to verify that the windings are de-energized condition.)
dry before the generator set is operated and devel- 5, Remove the metal cover from the generator
ops a base line for future test comparison. output box to gain access to generator load ter-
minals.
Before these tests can be performed on medium 6. Securely install the Grounding Cluster ground
voltage generator sets, you must first perform the clamp to a verified grounded conductor.
generator grounding procedure.

Generator Set Grounding Procedure


Prior to performing service or inspection proce-
dures that may expose personnel to conductors
normally energized with voltages greater than 600
volts, the following generator set grounding proce-
dure must be followed.
7. With the Grounding Cluster in place, you are
protected from static and/or induced charges
that may have been present in the generator
stator.
Leave grounds connected for at least one min-
ute so static charge can dissipate. Remove
1. Open, lock-out and tag-out all sources of power ground cluster and perform PI and/or any other
to the immediate work area. tests required on the stator winding. Reconnect
2. Disable the starting system of the generator grounds if additional generator service is nec-
set: essary.
a. Move the 0/Manual/Auto switch to the 0 8. When work on the generator set is complete,
(Off) position and wait for the controller to remove the Grounding Cluster in the reverse
power down (approximately 10 minutes). order of installation.
b. Disconnect the battery charger from its AC 9. After getting clearance from all personnel in-
source. volved in the lock-out/tag-out procedure, re-
move all lock-out devices in reverse order of
c. Remove the negative battery cable from installation.
the battery.
d. Install a lockout device on the battery
cable end. (For engines equipped with an

4-2
Megger and PI Test reading in megohms divided by a one minute read-
ing in megohms. A ratio of two or greater is consid-
ered good for new and in service sets.
1. Perform the
in this section.
2. Open the control box door and remove connec-
tor 10 from the AVR module.
3. Disconnect the AC voltage sense leads from
the generator output terminals. The AC voltage
sense leads are marked 5, 6, 7 and 8.
4. If the RTD (resistance temperature detector)
option is installed, ground all six RTD tempera-
ture leads. Each RTD has three leads, one red
and two white leads. Total of 18 leads must be
grounded.
5. Perform the proce-
Megger Test: The megger test consists of applying dure for the desired windings as noted in this
voltage for up to one minute (Figure 4-2, 4-4, 4-5 section.
and 4-6). The highest resistance values shown in 6. Perform the and
Table 4-1 should be obtained for a new generator procedures for the desired windings as
with dry windings. For a set that has been in service, noted in this section.
the resistance reading should not be less than the
lower value shown. If low readings are obtained, the cause should be in-
vestigated and corrected before the generator set is
PI Test: The PI test consists of applying a voltage returned to service.
between the winding and ground for ten mInutes
and recording resistance values at one minute and If moisture is determined to be the cause of low test
at ten minutes. The PI is the ratio of a ten minute readings, a winding drying process will be required.

TABLE 4-1. GENERATOR INSULATION RESISTANCE


MEGGER MINIMUM RESISTANCE (MEG)
FRAME GENERATOR
SIZE VOLTAGE VDC MAIN EXCITER
SETTING MAIN ROTOR PMG
STATOR STATOR
600 VAC or 500 10 1 10 1 10 1 10 1
P7
less
1000 10 5
600 VAC or
P80 500 200 100 53 10 5
less
(Combined rotors)
2500 100 50
601 thru 5000
P80 500 200 100 53 10 5
VAC
(Combined rotors)
5000 300 150
5001 thru
P80 500 200 100 53 10 5
15000 VAC
(Combined rotors)

4-3
DRYING THE WINDINGS 3. Bolt the generator three phase output termi-
nals together.
If low readings are obtained and moisture is deter-
mined to be the problem, the windings should be 4. Connect the positive and negative leads of a
dried out and the test repeated. The windings can variable 12 VDC source to plug P10 as follows:
be dried by blowing warm air through the generator Positive lead Plug 10-6 (X)
with a fan for 24 hours and then retesting.
Negative lead Plug 10-3 (XX)
A more effective way is to run the genset without ex-
citation and using a bolted 3-phase short across the
generator terminals to heat the windings. This pro-
cedure must be done as described or equipment
damage can result. To do this:
1. Open the control box door and remove plug
P10 from the AVR module. 5. Attach a clamp-on ammeter to the generator
2. Disable generator excitation using the InPower leads to measure generator current, adjust the
service tool. In the 12 VDC source for zero voltage, start the set
group, set the parameter and very slowly increase the excitation voltage.
to . (Note that this pa- Obtain the highest current possible without ex-
rameter will return to whenever ceeding generator rating.
the controller powers down.) 6. Run the genset for approximately one hour,
Without disabling excitation, the controller will then repeat the insulation resistance tests. If
shutdown the genset and display Low AC Volt- further drying time is indicated, continue the
age. drying process.

4-4
GENERATOR/PCC CONTROL ISOLATION avoid inadvertently imposing 24 volts on the
PROCEDURE system.
5. Check polarity again. Polarity must be correct
The following procedure is used to determine if the or this test will be inconclusive because the in-
generator or the PCC control circuitry is causing a duced and residual magnetic polarities in the
high AC voltage shutdown fault. exciter stator will be opposed.
1. Throw the line circuit breaker OFF and shut
down the set.

2. Open the control box door and remove plug


P10 from the AVR module.
6. Start the set and connect the jumper from the
3. Prepare to measure output voltage across the
battery negative () terminal to the XX lead.
generator terminals while the set is running.
7. The generator circuitry is probably okay if rated
4. Bring two jumpers from a 12 volt battery for output voltage or higher is obtained and the
connection to the X (Field +) and XX (Field ) voltages for all phases are balanced when the
pins of plug P10. exciter is powered by a 12 volt battery. Refer to
X = Plug P10-6 to
XX = Plug P10-3 troubleshoot the PCC control circuitry. (Normal
Connect the jumper from the positive (+) post excitation voltage ranges from approximately
of the battery to the X pin of plug P10-6. Be pre- 10 VDC at no-load to approximately 40 VDC at
pared to connect the jumper from the negative fullload.)
() post of the battery to the XX pin of plug 8. If the voltages are unbalanced, troubleshoot
P10-3. If one of the 12 volt cranking batteries is the main stator first. If the voltages are uniform-
used, bring the jumpers from the battery con- ly low, troubleshoot the exciter and field circuits
nected on the grounded side of the system to first.

4-5
EXCITER STATOR Testing Winding Insulation Resistance: Discon-
nect exciter stator leads F1 and F2 from their con-
Testing Winding Resistance: Measure winding nectors in the AC generator wiring harness and iso-
resistance with a Wheatstone bridge or digital ohm- late them from ground.
meter. Replace the stator if winding resistance is
not as specified in Tables 4-2/4-3.
Connect the megger between one of the leads and
Before performing the following insulation resist- ground and conduct the test. Refer to Table 4-1 for
ance test, refer to the megger voltage selection and required resistance
procedure at the beginning of values.
this section.

MEASURE WINDING INSULATION


RESISTANCE BETWEEN EITHER
LEAD AND THE STATOR
LAMINATIONS

MEASURE WINDING RESISTANCE


BETWEEN THE TWO STATOR
LEADS, F1 (X) AND F2 (XX)

FIGURE 4-2. TESTING THE EXCITER STATOR

4-6
EXCITER RECTIFIER BRIDGE (ROTATING Replacing Diodes: Make sure the replacement
RECTIFIER ASSEMBLY) diode is of the correct polarity. Disconnect the pigtail
from the terminal post and unscrew the old diode.
The exciter rectifier bridge is mounted on the exciter Apply heat-sink compound under the head of the
rotor, inboard, facing the main rotor. It consists of a diode. Make sure the compound does not get on the
positive plate and a negative plate, split diametrical- threads. Torque the diodes to 36 to 42 in-lbs (4 to 4.8
ly. Each carries three diodes, three terminal posts N m) and the pigtail terminals to 24 in-lbs (2.7 N m)
for connecting exciter rotor leads to the diode pig- when reassembling.
tails and a terminal for the main rotor (generator
field) lead. A surge suppresser is connected across
the two plates to prevent transient voltages that Surge Suppresser Testing and Replacement:
could damage the diodes. Remove the suppresser. Replace the suppresser if
it appears to have overheated or if ohmmeter read-
Testing Diodes: Disconnect the diode pigtails from ings indicate less than infinite resistance (end of
the terminal posts. Using the diode test setting on scale) in both directions. Torque the terminals to 24
an ohmmeter, measure electrical resistance be- in-lbs (2.6 N m) when reassembling.
tween each diode pigtail and the plate on which the
diode is mounted. Reverse the meter test probes
and repeat the tests. The electrical resistance
across each diode should be high in one direction
and low in the other. If the resistance is high or low in
both directions, replace the diode. (If one diode has
failed, replace all six for best reliability.)

DIODE (ONE OF SIX) TERMINAL


DISCONNECT THE DIODE PIG- (ONE OF SIX)
TAIL FROM THE TERMINAL
AND MEASURE ELECTRICAL
RESISTANCE BETWEEN THE
PIGTAIL AND THE METAL DIODE PLATES
PLATE UNDER THE DIODE (TWO)

SURGE SUPPRESSER
REMOVE TO TEST

FIGURE 4-3. TESTING THE ROTATING RECTIFIER ASSEMBLY

4-7
EXCITER ROTOR Before performing the following insulation resist-
ance test, refer to the
Testing Winding Resistance: Disconnect the six procedure at the beginning of
rotor winding leads from the terminal posts on the this section.
rectifier assembly. With a Wheatstone bridge, mea-
sure electrical resistance across each pair of rotor Testing Winding Insulation Resistance: Discon-
windings: U (CR1 or CR4) and V (CR2 or CR5), V nect all six exciter rotor leads from diode terminals
(CR2 or CR5) and W (CR3 or CR6), W (CR3 or CR1 through CR6 and isolate them from ground.
CR6) and U (CR1 or CR4). See the winding sche-
matic. Replace the whole rotor shaft assembly if the Connect the megger between one of the leads and
resistance of any winding is not as specified in ground and conduct the test. Refer to Table 4-1 for
Tables 4-2/4-3. megger voltage selection and required resistance
values.

MEASURE WINDING INSULATION


RESISTANCE BETWEEN ANY LEAD
OR THE TERMINAL TO WHICH IT IS
CONNECTED AND THE ROTOR
LAMINATIONS
MAIN ROTOR
LEADS

WINDING SCHEMATIC

DISCONNECT THE SIX ROTOR WINDING


LEADS FROM THEIR TERMINALS AND
MEASURE ELECTRICAL RESISTANCE
ACROSS EACH PAIR OF WINDINGS: U-V,
V-W, W-U

FIGURE 4-4. TESTING THE EXCITER ROTOR

4-8
MAIN ROTOR (GENERATOR FIELD) procedure at the beginning of
this section.
Testing Winding Resistance: Disconnect the two
leads of the main rotor from the terminals on the ro- Insulation Resistance and PI Test: Disconnect
tating rectifier assembly. See Figure 4-5. Measure the main rotor and voltage suppressor leads from
electrical resistance between the two leads with a terminals F1+ and F2 on the rotating rectifier as-
Wheatstone bridge or digital ohmmeter. Replace semblies and isolate them from ground. Tag and
the rotor if the resistance is not as specified in mark each lead with its terminal number (F1+ or
Tables 4-2/4-3. Connect the rotor leads and torque F2).
the terminals to 24 in-lbs (2.6 N m) when reassem-
bling. Connect the megger between one of the rotor leads
and ground and conduct the test. Refer to Table 4-1
Before performing the following insulation resist- for megger voltage selection and required resist-
ance test, refer to the ance values.

MEASURE WINDING INSULATION RE-


SISTANCE BETWEEN EITHER ROTOR LEAD
AND THE ROTOR LAMINATIONS

DISCONNECT THE MAIN ROTOR LEADS


FROM THE ROTATING RECTIFIER ASSEMBLY
AND MEASURE THE WINDING RESISTANCE
BETWEEN THEM

FIGURE 4-5. TESTING THE MAIN ROTOR

4-9
MAIN STATOR Insulation Resistance and PI Test: Remove and
separate all leads of the generator from the genera-
Testing Main Stator Winding Resistance: Dis- tor load terminal block. Number of neutral leads
connect all stator leads from the terminals to which (three or six) to remove will vary between low and
they are connected. Using a Wheatstone bridge medium voltage generators.
having at least 0.001 ohm precision, measure elec-
trical resistance across each pair of stator leads:
U1-U2, V1-V2, W1-W2, U5-U6, V5-V6 and W5-W6. Connect the megger between one phase of the sta-
Replace the stator if the resistance of any winding is tor and ground while grounding the other two
not as specified in Tables 4-2/4-3. phases and conduct the test. Refer to Table 4-1 for
megger voltage selection and required resistance
Before performing the following insulation resist- values.
ance test, refer to the
procedure at the beginning of
this section. Repeat this step in turn for the other two phases.

WHEATSTONE
BRIDGE

FIGURE 4-6. TESTING THE GENERATOR STATOR

4-10
TABLE 4-2. WINDING RESISTANCE VALUES (P7)*
MAIN STATOR MAIN EXCITER EXCITER
FRAME SIZE
WINDING 12 WINDING 07 ROTOR STATOR ROTOR

P7G 0.00074 0.0011 2.369 17 0.12

* Resistance figures are approximates, at 68 F (20 C) + 10%.

TABLE 4-3. WINDING RESISTANCE VALUES (P80)*


VOLTS MAIN EXCITER EXCITER
FRAME SIZE HZ MAIN ROTOR
L-L STATOR STATOR ROTOR
400 50 0.00069
690 50 0.00158
LV804R 1 32
1.32 15 0 10
0.10
480 60 0.00069
600 60 0.00097
400 50 0.00054
690 50 0.00145
LV804S 1 40
1.40 15 0 10
0.10
480 60 0.00054
600 60 0.00078
400 50 0.00044
690 50 0.00115
LV804T 1 50
1.50 15 0 10
0.10
480 60 0.00044
600 60 0.00075
3.3K 50
MV804R 0 0338
0.0338 1 32
1.32 15 0 10
0.10
4.16K 60
3.3K 50
MV804S 0 0334
0.0334 1 40
1.40 15 0 10
0.10
4.16K 60
3.3K 50
MV804T 0 0281
0.0281 1 50
1.50 15 0 10
0.10
4.16K 60

* Resistance figures are approximates, at 68 F (20 C) + 10%.

4-11
TABLE 4-3. WINDING RESISTANCE VALUES (P80)* (CONT.)
VOLTS MAIN EXCITER EXCITER
FRAME SIZE HZ MAIN ROTOR
L-L STATOR STATOR ROTOR
6.0K 50 0.1489
6.61K 50 0.1636
10K 50 0.4716
HV804R 1 32
1.32 15 0 10
0.10
11K 50 0.6007
7.2K 60 0.1489
13.8K 60 0.6736
6.0K 50 0.1243
6.61K 50 0.1549
10K 50 0.3833
HV804S 1 40
1.40 15 0 10
0.10
11K 50 0.4903
7.2K 60 0.1243
13.8K 60 0.5554
6.0K 50 0.1068
6.61K 50 0.1305
10K 50 0.2981
HV804T 1 50
1.50 15 0 10
0.10
11K 50 0.4022
7.2K 60 0.1068
13.8K 60 0.4484

* Resistance figures are approximates, at 68 F (20 C) + 10%.

4-12
TESTING THE PMG Voltage should be at least 150 VAC for 50 Hz
sets and at least 180 VAC for 60 Hz sets, and
should be approximately the same for each set
of leads. If the voltages are low or uneven,
check all the leads and connections between
the voltage regulator output stage module and
the PMG and repair as necessary before disas-
sembling the PMG.
4. Stop the set and measure electrical resistance
across lead pairs P10-1 & P10-4, P10-4 &
P10-5, and P10-5 & P10-1 with a Wheatstone
bridge or digital ohmmeter. Refer to
in this section for frame size.
TABLE 4-3 PMG STATOR RESISTANCE

1. Open the control box door and remove plug


P10 from the AVR module. FRAME SIZE PMG STATOR RESISTANCE
2. Start the engine at the set and let the speed sta- P7 2.6 10
bilize.
3. Measure voltage across lead pairs P10-1 & P80 2.7 10
P10-4, P10-4 & P10-5, and P10-5 & P10-1.

4-13
P7 BEARING INSPECTION/REMOVAL Bearing Replacement: The instruction sheet pro-
vided with the bearing kit is required to complete the
The end bearing is enclosed in a pre-packed ma-
following procedure.
chined cartridge. A grease fitting is provided to al-
low re-greasing of the bearing with a grease gun P7 generator component parts cannot be ordered
(see manual for grease quantities, from Cummins. Refer to the Newage nameplate
maintenance intervals, and procedure). and supply all available information. Contact your
nearest Newage distributor for assistance in order-
Bearing Inspection: If a situation occurs which al- ing component parts.
lows an opportunity to visually inspect the end bear-
ing with it installed, check the color of the grease. 1. Lift slightly on end of rotor shaft and install
The color of the grease is the only indication that wooden shims to hold rotor on center with sta-
can be used to determine if the bearing is defective. tor.

New grease is a whitish-beige color but some mild 2. Install bearing onto rotor shaft. Refer to bearing
discoloration will occur with use. If the grease kit instruction sheet.
shows signs of gross discoloration, the bearing
should be replaced. 3. Install two threaded studs into end bearing car-
tridge to aid subsequent procedures. Position
Bearing Removal: The bearing is press fitted onto
the end bearing cartridge assembly close to
the shaft and can be removed with standard work-
proper position for hole alignment with end-
shop tools (i.e., two or three legged manual or hy-
bracket.
draulic bearing pullers). The bearing should only be
removed for replacement (bearing is destroyed dur- 4. Install endbracket to the stator frame using the
ing removal and must be replaced). proper screws and lock washers, but do not
The end bearing is enclosed in a pre-packed car- tighten securely as yet.
tridge housing and must only be dismantled as nec-
essary for relubrication, replacement, or when a 5. Insert and start the threads of the bearing car-
major overhaul is carried out on the generator set. tridge fasteners, and remove threaded align-
Removal of the bearing can only be accomplished ment studs, through the endbracket into the
after removal of the endbracket, as follows: cartridge housing.
1. Remove the endbracket (complete steps 1 6. Lift slightly on endbracket and remove wooden
through 21 of the shims holding rotor on center with stator.
procedure.
7. Securely tighten the endbracket fasteners.
2. Remove the four screws holding bearing cap.

3. Remove cap. 8. Tighten the bearing cartridge fasteners to 4.5


ft-lbs. (6 N m) torque.
4. Remove circlip.
9. Install the PMG assembly. Refer to
5. Remove bearing cartridge housing complete proce-
with bearing. dure.

4-14
P7 GENERATOR DISASSEMBLY 2. Remove the three M5X12mm capscrews and
The following procedures provide information for lockwashers from the PMG cover, and remove
removal and reassembly of the generator PMG ex- cover.
citer, the control housing and stator/rotor assem-
blies. Be sure to read through this section first, be- 3. Disconnect the PMG wiring harness connector.
fore performing procedures listed, to determine the
4. Remove the four bolts and clamps retaining the
steps most appropriate for the service attention re-
quired. exciter stator housing to the endbracket.

5. Tap the stator housing out of its spigot, and


carefully remove from generator endbracket.

The highly magnetic rotor will attract the stator


core; care must be taken to avoid any contact
which may damage the windings.

6. Remove the hex head through-bolt from the ro-


Permanent Magnet (PMG) Removal tor shaft and firmly pull the complete rotor as-
(P7) sembly from its location. Keep the rotor clean
by avoiding contact with metal dust or particles.
1. Disconnect the negative (-) battery cable to
prevent accidental starting of the generator set Place in a plastic bag as soon as is practicable.
while servicing.

Permanent Magnet (PMG) Installation (P7)


1. Install the complete rotor assembly to the end
of the main rotor shaft using the hex head
through-bolt. Keep the rotor clean by avoiding
contact with metal dust or particles.

2. Carefully locate the stator housing to position


on the generator endbracket. (The leads must
be located at the top and facing out, Figure
4-2.) Fasten in place using the 4 bolts and
clamps, and tighten securely.

The highly magnetic rotor will attract the stator


core, care must be taken to avoid any contact
which may damage the windings.

3. Connect the PMG wiring harness connector.

4. Install the PMG assembly cover using the three


M5x12mm capscrews and lockwashers, and
tighten securely.

4-15
Main Stator and Rotor Removal (P7) 9. Insert two bolts (M10) in the two holes provided
for jacking purposes, on the endbracket cen-
1. Remove the PMG, refer to ter line. Screw bolts in until endbracket pilot is
earlier this section. clear of locating recess.
2. Remove all access covers and terminal box lid. 10. Carefully tap the whole assembly off the bear-
ing cartridge housing, ensuring the endbracket
3. Remove the generator air discharge covers is supported to prevent the exciter stator from
(see Figure 4-1). damaging the windings on the exciter rotor.

4. Crank or bar the engine/generator to position


the rotor such that a full pole face is at the bot- 11. Attach cables of lifting device to generator lift-
tom of the main stator core. Proper positioning ing points as shown on the label attached to the
can be viewed through the generator access generator lifting eye.
openings. Refer to engine service manual for
proper cranking or barring procedure.

5. Disconnect all load wires from the reconnec-


tion terminal block assembly. If equipped with
the circuit breaker option, disconnect load
wires from circuit breaker. Check that all leads
are labeled to ease reassembly.

6. Disconnect the remote control wiring between


generator and control box. For reconnections
later, make sure each wire is clearly marked to
indicate the correct terminal.

To remove the stator and rotor at the same time,


refer to , later this
section. To remove the stator and rotor individu-
ally, continue with step 7.

7. Remove the four bolts retaining the bearing


cartridge housing in the endbracket (outer four
bolts).

8. Remove the eight bolts holding the endbracket FIGURE 4-7. P7 LIFTING POSITION
to the generator housing.

4-16
12. The exciter stator is now accessible for inspec- until the mounting feet brackets are clear of the
tion and removal from endbracket/engine frame member (see Figure 4-7).
adaptor.
16. Disconnect the grounding strap from the fly-
13. The end bearing can now be removed if re- wheel housing.
quired. Refer to Bearing Removal (P7).

14. Remove the fasteners from the four generator 17. Using a forklift, position a lifting bar of the forklift
mounting feet brackets. (inside and inline with the generator) under the
rotor shaft. Lift the rotor shaft slightly so that ro-
15. Using an adequate lifting device, lift the gener- tor is not resting on inside of stator assembly.
ator (at lifting eyes, and main stator housing) See Figure 4-8.

FIGURE 4-8. REMOVING STATOR ASSEMBLY (P7)

4-17
18. Verify that the stator is adequately supported 20. Reposition or add hoist and sling support for
and then carefully remove the capscrews from the main rotor, and remove the forklift. See Fig-
the stator attachment ring. ure 4-9, Rotor Lift detail.

21. Remove the stator assembly, being careful not


to drag the windings on the rotor. Place stator
assembly away from the chassis in the horizon-
tal position.

22. Using the hoist and sling to support the rotor,


carefully remove the capscrews and flat wash-
ers that secure the drive discs to the engine fly-
wheel.

19. Being careful not to drag the windings on the


rotor, move the stator assembly sufficiently
away from engine to sling and support the rotor
assembly. Do not allow rotor assembly to hang
on engine flywheel.

23. Remove the rotor assembly and place it on


wood blocks in the horizontal position. To avoid
possible distortion, do not allow the drive discs
and fan to rest on anything.

FIGURE 4-9. STATOR/ROTOR LIFT EXAMPLE

4-18
Generator Assembly Removal (P7) gine flywheel housing. Align the holes of the ro-
tor drive discs with the holes of the engine fly-
24. Remove the fasteners from the four generator wheel. Install the capscrews and flat washers
mounting feet brackets. that secure the drive discs to the engine fly-
wheel, hand tighten.
25. Using an adequate lifting device, lift the gener-
ator (refer to Step 11).

26. Disconnect the grounding strap from the fly-


wheel housing.

27. Carefully remove the capscrews and flat wash-


ers that secure the drive discs to the engine fly-
wheel.

28. Verify that the generator assembly is ade-


quately supported. Carefully remove the caps-
crews securing the engine adaptor endbracket
to the engine flywheel housing.

2. Align the holes of the engine adaptor endbrack-


et with the holes in the flywheel housing and
install the capscrews and lock washers. Tight-
en fasteners to 85-100 ft-lbs. (116-136 N m).

3. Secure the rotor assembly to the flywheel.


Tighten fasteners to 150-180 ft-lbs. (204-245
N m).

4. Connect the grounding strap to the flywheel


housing using a capscrew and EIT locking
washer; and tighten securely.
29. Remove the generator assembly away from
5. Install the mounting feet bracket fasteners; and
engine. Place generator assembly on floor with
tighten securely.
a piece of wood beneath the stator housing (to-
ward PMG end) to allow for endbracket remov- If endbracket has been removed, continue with
al, if desired. step 6, otherwise skip to step 14.
Generator Reassembly (P7) 6. Lift slightly on end of rotor shaft and install
Generator reassembly is the reverse of disassem- wooden shims to hold rotor on center with sta-
bly procedure. tor.
To assemble the stator and rotor at the same time,
continue with step 1. To assemble the stator and ro- 7. Install two threaded studs into end bearing car-
tor individually, skip to step 15. tridge to aid subsequent procedures. Position
the end bearing cartridge assembly close to
1. Using an adequate lifting device, locate the proper position for hole alignment with end-
generator assembly into position near the en- bracket

4-19
8. Assemble exciter stator, if removed, to inside of
endbracket. Tighten fasteners to 4.5 ft-lbs. (6
N m) torque.

9. Install endbracket to the stator frame using the


proper capscrews and lock washers, but do not 18. Secure the rotor assembly drive disc to the fly-
tighten securely as yet. wheel using appropriate capscrews and flat
washers. Tighten fasteners to 150-180 ft-lbs.
10. Insert and start the threads of the bearing car- (204-245 N m). Do not allow rotor assembly to
tridge fasteners, and remove threaded align-
hang on engine flywheel.
ment studs, through the endbracket into the
cartridge housing.

11. Lift slightly on endbracket and remove wooden


shims holding rotor on center with stator.

12. Securely tighten the endbracket fasteners.


19. Reassemble engine adaptor endbracket to
13. Tighten the bearing cartridge fasteners to 4.5 stator frame if removed. Using an adequate lift-
ft-lbs. (6 N m) torque. ing device, carefully move the stator into posi-
tion over the rotor assembly, being careful not
14. Install the PMG assembly, if removed. Refer to to drag the windings on the rotor.
Permanent Magnet Exciter Installation.
Perform the Aligning Generator with Engine
procedures, later in this section, then return to
the following steps.

If the stator and rotor are not separated, skip to


step 32.

To assemble the stator and rotor individually be-


gin here.

15. If removed, replace exciter rotor and rotating


rectifier assembly to main rotor shaft. Recon-
nect main rotor wire leads to positive and nega-
tive terminals of rectifier assembly.

16. If removed, install the drive disk spacer, drive


disc and pressure plate on the rotor shaft.
Install the cap screws and flat washers and
tighten to 607 ft-lbs. (822 N m).
20. Using a forklift, position a lifting bar of the forklift
17. Using a hoist and sling to support the rotor, (inside and inline with the generator) under the
align the holes in the drive disc with the corre- rotor shaft. Lift the rotor shaft slightly so that ro-
sponding holes in the flywheel. tor is not resting on inside of stator assembly.

4-20
21. Remove the hoist/sling support of the rotor as- 28. Insert and start the threads of the bearing car-
sembly. Align the holes of the engine adaptor tridge fasteners, and remove threaded align-
endbracket with the holes in the flywheel hous- ment studs, through the endbracket into the
ing and install the capscrews and lock wash- cartridge housing.
ers. Tighten fasteners to 95-105 ft-lbs.
(129-142 N m). 29. Lift slightly on endbracket and remove wooden
shims holding rotor on center with stator.
Perform the Aligning Generator with Engine
procedures, later in this section, then return to 30. Securely tighten the endbracket fasteners.
step 22.
31. Tighten the bearing cartridge fasteners to 4.5
22. Reassemble the covers over the generator air ft-lbs. (6 N m) torque.
discharge openings and fasten securely.
32. Connect all control wires and generator leads
23. Connect the grounding strap to the flywheel using the proper generator set AC and DC wir-
housing using a capscrew and EIT locking ing diagram/schematic.
washer; and tighten securely.
33. Install access covers and terminal box lid.
24. Install the mounting feet bracket fasteners; and
34. Reassemble any engine air intake compo-
tighten securely.
nents removed during generator disassembly.
25. Install two threaded studs into end bearing car- 35. Refer to Permanent Magnet Installation.
tridge to aid subsequent procedures. Position
the end bearing cartridge assembly close to 36. If equipped with the circuit breaker option, re-
proper position for hole alignment with end- connect load wires to circuit breaker. Recon-
bracket. nect all lead wires to the terminal block assem-
bly.
26. Assemble exciter stator, if removed, to inside of
endbracket. Tighten fasteners to 4.5 ft-lbs. (6 37. Verify that all connections are proper and se-
N m) torque. cure and then install the air inlet panel and ac-
cess covers to control housing.
27. Install endbracket to the stator frame using the
proper capscrews and lock washers, but do not 38. Connect the negative () battery cable and test
tighten securely as yet. the generator set for operation.

4-21
P80 BEARING INSPECTION/REMOVAL 6. Crank or bar the engine/generator to position
the rotor such that a full pole face is at the bot-
The end bearing is enclosed in a pre-packed ma- tom of the main stator core. Refer to engine
chined cartridge. A grease fitting is provided to al- service manual for proper cranking or barring
low re-greasing of the bearing with a grease gun procedure.
(see manual for grease quantities,
maintenance intervals, and procedure). 7. Remove the four bolts retaining the bearing
Bearing Inspection: If a situation occurs which al- cartridge housing in the endbracket (outer four
lows an opportunity to visually inspect the end bear- bolts).
ing with it installed, check the color of the grease. 8. Remove the eight bolts holding the endbracket
The color of the grease is the only indication that to the generator housing.
can be used to determine if the bearing is defective.
9. To support the end bracket and rotor during end
New grease is a whitish-beige color but some mild bracket to frame removal, attach a suitable
discoloration will occur with use. If the grease sling with a pair of hooks located into two of the
shows signs of gross discoloration, the bearing end bracket inspection holes. The lifting capac-
should be replaced. ity will vary according to the generators core
Bearing Removal: The bearing is press fitted onto length, but could be as much as 11,685 pounds
the shaft and can be removed with standard work- (5300 kg).
shop tools (i.e., two or three legged manual or hy- 10. Insert two bolts (M10) in the two holes provided
draulic bearing pullers). The bearing should only be for jacking purposes, on the endbracket cen-
removed for replacement (bearing is destroyed dur- ter line. Screw bolts in until endbracket spigot
ing removal and must be replaced). is clear of locating recess.
1. Remove the PMG (see
11. Carefully tap the whole assembly off the bear-
procedure).
ing cartridge housing, ensuring the endbracket
2. Disconnect PMG stator leads P2, P3, and P4. is supported to prevent the exciter rotor from
dropping onto the exciter field bore.
3. Remove external bearing lubricating pipe.
Note component locations before removal to
aid in re-assembly.

4. Remove the four bolts retaining the outer bear-


ing cap and remove the outer bearing cap and 12. Remove bearing cartridge housing complete
PMG stator as an assembly, taking care not to with bearing.
damage the PMG stator windings.
13. The cartridge housing contains an O-ring
5. Remove wave washer and circlip on the outer which should be examined and replaced if
side of the bearing inner race. worn.

4-22
Bearing Replacement: The instruction sheet pro- 4. Install endbracket to the stator frame using the
vided with the bearing kit is required to complete the proper screws and lock washers, but do not
following procedure. tighten securely as yet.
P80 generator component parts cannot be ordered
from Cummins. Refer to the Newage nameplate 5. Insert and start the threads of the bearing car-
and supply all available information. Contact your tridge fasteners, and remove threaded align-
nearest Newage distributor for assistance in order- ment studs, through the endbracket into the
ing component parts. cartridge housing.
1. Lift slightly on end of rotor shaft and install
wooden shims to hold rotor on center with sta- 6. Lift slightly on endbracket and remove wooden
tor. shims holding rotor on center with stator.

2. Install bearing onto rotor shaft. Refer to bearing 7. Securely tighten the endbracket fasteners.
kit instruction sheet.

3. Install two threaded studs into end bearing car- 8. Tighten the bearing cartridge fasteners to 4.5
tridge to aid subsequent procedures. Position ft-lbs. (6 N m) torque.
the end bearing cartridge assembly close to
proper position for hole alignment with end- 9. Install the PMG assembly. Refer to
bracket. .

4-23
P80 GENERATOR DISASSEMBLY
The following procedures provide information for
removal and reassembly of the generator PMG ex-
citer and generator assembly from the engine and
removal of end bearing. Be sure to read through this
section first, before performing procedures listed, to 3. Place shims (non-compressible material such
determine the steps most appropriate for the ser-
as plastic) between all four poles. Minimum air
vice attention required.
gap must be maintained in all radial directions
from the center of the bore to prevent damage
to the exciter and PMG assembly. Minimum air
gap is 0.2 inch (5 mm). Normal air gap is
approximately 0.3 inch (7.5 mm).

4. Disconnect all load wires from the reconnec-


tion terminal block assembly. If equipped with
the circuit breaker option, disconnect load
Generator Assembly Removal wires from circuit breaker. Check that all leads
are labeled to ease reassembly.
1. Remove the generator air discharge covers.
5. Disconnect remote control wiring between
generator and control box. For reconnections
later, make sure each wire/plug is clearly
marked to indicate the correct terminal.

6. Remove as necessary, air intake components


2. Crank or bar the engine/generator to position to engine that may interfere with removal of the
the rotor such that a full pole face is at the bot- generator assembly.
tom of the main stator core. Proper positioning
can be viewed through the generator access 7. Attach cables of lifting device to generator lift-
openings. Refer to engine service manual for ing points as shown on the label attached to the
proper cranking or barring procedure. generator lifting eye.

4-24
8. Remove the fasteners from the four generator
mounting feet brackets.
9. Disconnect the grounding strap from the fly-
wheel housing.
10. Remove the capscrews and flat washers that
secure the drive discs to the engine flywheel.
11. Remove the capscrews securing the engine
adaptor endbracket to the engine flywheel 12. Remove the generator assembly away from
housing. engine. Place generator assembly on the floor
using wood blocks under the four mounting feet
brackets so that the stator does not rest on the
floor (Figure 4-10) and also to prevent the gen-
erator from rolling.

FIGURE 4-10. TYPICAL GENERATOR SUPPORTED BY BLOCKS

4-25
Generator Reassembly (P80) install the capscrews and lock washers. Tight-
en fasteners to 85-100 ft-lbs. (116-136
Generator reassembly is the reverse of disassem-
bly procedure. 3. Secure the rotor assembly to the flywheel.
Tighten fasteners to 150-180 ft-lbs. (204-245
1. Using an adequate lifting device, locate the
generator assembly into position near the en-
gine flywheel housing. Align the holes of the ro- Perform the Aligning Generator with Engine
tor drive discs with the holes of the engine fly- procedures, later in this section, then return to
wheel. Install the capscrews and flat washers the following steps.
that secure the drive discs to the engine fly-
wheel, hand tighten.

4. Reassemble any engine air intake compo-


nents removed during generator disassembly.

5. Connect all control wires and generator leads.

6. If equipped with the circuit breaker option, re-


connect load wires to circuit breaker. Recon-
nect all lead wires to the terminal block assem-
bly.

2. Align the holes of the engine adaptor endbrack- 7. Connect the negative (-) battery cable and test
et with the holes in the flywheel housing and the generator set for operation.

4-26
Permanent Magnet (PMG) Removal 5. Tap the stator housing out of its spigot, and
(P80) carefully remove from generator endbracket.

1. Disconnect the negative (-) battery cable to The highly magnetic rotor will attract the stator
prevent accidental starting of the generator set core; care must be taken to avoid any contact
while servicing. which may damage the windings.

6. Remove the hex head through-bolt from the ro-


tor shaft and firmly pull the complete rotor as-
sembly from its location. Keep the rotor clean
by avoiding contact with metal dust or particles.
Place in a plastic bag as soon as is practicable.

Permanent Magnet (PMG) Installation


(P80)
1. Install the complete rotor assembly to the end
of the main rotor shaft using the hex head
through-bolt. Keep the rotor clean by avoiding
contact with metal dust or particles.

2. Carefully locate the stator housing to position


on the generator endbracket. Fasten in place
using the 4 bolts and clamps, and tighten se-
curely.

The highly magnetic rotor will attract the stator


2. Remove the four screws and lockwashers from core, care must be taken to avoid any contact
the PMG cover, and remove cover. which may damage the windings.

3. Disconnect the PMG wiring harness connector. 3. Connect the PMG wiring harness connector.

4. Remove the four bolts and clamps retaining the 4. Install the PMG assembly cover using the four
exciter stator housing to the endbracket. screws and lockwashers, and tighten securely.

4-27
ALIGNING GENERATOR WITH ENGINE flex in alternate directions twice for each engine rev-
olution. It is important to minimize the amount of
Proper alignment of the generator and engine as- disc flexing since, if it is excessive, the drive disc will
semblies is necessary to avoid premature wear and crack. Although perfect bearing alignment is desir-
improper operation of the genset. Review the fol- able, it is more important to keep disc deflection to
lowing alignment conditions and procedures for the minimum possible. This procedure assumes
aligning the generator assembly to engine flywheel that the pilot bore of the drive discs are in the exact
housing. center and the flywheel counterbore (pilot) has no
Is the result of the genera- practical runout. Under these conditions, perfect
tor bearing center axis not aligning with axis of the Angular alignment will be attained when no deflec-
engine crankshaft. This condition creates an angle tion of the disks is measured.
between the generator shaft axis and the crank- Excessive Axial misalignment will cause more gen-
shaft axis. The cause of this type of misalignment is erator vibration than Angular misalignment.
usually shimming error.
Axial misalignment should be checked only when an
Is the result of the generator objectionable vibration is present.
shaft axis not aligning with engine crankshaft axis. Either type of misalignment may be present in a
The tolerances in the bolted flywheel and drive disc generator set assembly, with angular misalignment
connection may add up to displace the generator being the most common problem. Angular align-
axially relative to the crankshaft axis. ment may also be effected by set installation condi-
If the assembly is al- tions and/or mishandling during shipping of the gen-
lowed to run under these conditions, the discs must set.

4-28
Angular Alignment Procedure disc at the bolt circle diameter, see Figure 4-11. Bar
the engine over in a clockwise rotation as viewed
from engine flywheel. Do not allow it to roll back on
compression at the end of the travel of each read-
ing. It is unnecessary to zero the indicator since the
total indicator reading (T.I.R.) of the deflection mea-
surement to the bolt heads is what is required. T.I.R.
Fasten a dial indicator to either the generator shaft will be the sum of the maximum positive and nega-
or the cooling fan with the sensing point resting on tive dial indicator readings as the engine completes
the capscrew head or the flat surface of the drive one revolution.

FIGURE 4-11. ANGULAR ALIGNMENT MEASUREMENT

4-29
Sample Generator Runout Readings 2. Measure the distance from the generator side
of the flex discs to the center of the generator
When taking the deflection readings described, mounting bolt, refer to Figure 4-11. (For exam-
make a diagram similar to the example shown in ple; a HC6 Frames distance is 28.4.)
Figure 4-12, where the total indicator reading is 3. Compare the distance measured in steps 1 and
.025. (The highest positive value of +.010 and the 2. (28.4 vs 10.7 or a 2.65 to 1 ratio.) Multiply
largest negative value of -.015.) The indicator is this ratio times one half the T.I.R. (In our exam-
closer at the top and further away at the bottom. ple, .025 divided by 2 is .0125. This, times
This example indicates that the generator bearing is 2.65 equals .033. Therefore, remove .033 of
high. Since the side readings are equal, the genera- shims from under the four mounting feet of the
tor is centered side to side. To lower the generator, generator.)
remove equal shims from under the four generator
In general, the T.I.R. should not be more than .001
mounting feet. To approximate the amount of shims
for each inch of radius (center of shaft to indicator
to remove or add:
axis). If we use our example of 10.7, then the maxi-
1. Measure the distance between the center of mum T.I.R. would be .011. This would only require
the generator shaft to the point the indicator is a correction of .014 from the T.I.R. of .025. (A read-
measuring at. (For example; a SAE 18 Disc ing of +.002 at the top and -.009 at the bottom would
coupling distance is 10.7). fall within the satisfactory range.)

FIGURE 4-12. ANGULAR ALIGNMENT MEASUREMENT READINGS (Example)

4-30
Axial Alignment Procedure To correct for possible axial misalignment, remove
the capscrews connecting drive discs and flywheel.
Axial misalignment needs to be checked only when Mark the drive discs and flywheel with respect to
an objectionable vibration is present. each other. Rotate either the engine or generator so
If excessive vibration remains after the angular that drive discs holes are repositioned two bolt
alignment, concentric alignment of the generator holes from their original location. Put the drive discs
shaft/engine crankshaft axes may be at fault. capscrews back in and retorque. Recheck/record
The goal of the axial realignment is to reduce the vibration levels as before. Repeat this test until the
vibration level of the genset while it is operating. A drive discs holes are repositioned 180 degrees from
small improvement in the axial alignment may have their original location.
dramatic effects in the measured or physically ob- Review vibration data and position drive disc in low-
served vibration levels. est recorded level location.

4-31
THIS PAGE LEFT INTENTIONALLY BLANK

4-32
GENERAL
This section consists of the schematic and connec-
tion wiring diagrams referenced in the text. The fol-
lowing drawings are included.
Page 5-2 through 5-8, Genset Wiring Diagram

5-1
Cummins Power Generation
1400 73rd Avenue N.E.
Minneapolis, MN 55432
1-800-888-6626
763-574-5000 International Use
Fax: 763-528-7229
Cummins is a registered trademark of Cummins Inc.