Beruflich Dokumente
Kultur Dokumente
Generator Set
with PowerCommand 3100 Controller
DGBB (Spec A−M), DGBC (Spec C−K), DGCA (Spec M−U),
DGCB (Spec B), DGCC (Spec B), DGDA (Spec L−R),
DGDB (Spec L−S), DGDK (Spec A), DGEA (Spec K−N),
DGFA (Spec K−S), DGFC (Spec A−N)
i
5 CONTROL SERVICE AND CALIBRATION
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Circuit Board Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Initial Start Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Setup and Calibration Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Accessory Box Control Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Engine Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Magnetic Speed Pickup Unit (MPU) Installation . . . . . . . . . . . . . . . . . . . . . 5-26
Current Transformer (CT) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
6 SERVICING THE GENERATOR
Testing the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Generator Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Generator Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Servicing the PMG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
7 FUEL TRANSFER PUMP AND CONTROL
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Fuel Transfer Pump Motor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Testing the Float Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
8 WIRING DIAGRAMS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
ii
IMPORTANT SAFETY INSTRUCTIONS
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
Operator’s 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,
alert you to potentially dangerous conditions to the oper-
Engine exhaust and some of its constituents are
ator, service personnel, or the equipment. known to the state of California to cause cancer ,
birth defects, and other reproductive harm.
This symbol warns of immediate
MOVING PARTS CAN CAUSE SEVERE
hazards which will result in severe personal in-
jury or death. PERSONAL INJURY OR DEATH
Keep your hands, clothing, and jewelry away from
WARNING This symbol refers to a hazard or un-
moving parts.
safe practice which can result in severe person-
al injury or death. Before starting work on the generator set, discon-
nect battery charger from its AC source, then dis-
CAUTION This symbol refers to a hazard or un- connect starting batteries, negative ( −) cable first.
safe practice which can result in personal injury This will prevent accidental starting.
or product or property damage. 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 shutof f 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 dif ferently 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.
iv
1. Introduction
ABOUT THIS MANUAL TEST EQUIPMENT
This manual covers models produced under the To perform the test procedures in this manual, the
Cummins/Onan and Cummins Power Genera- following test equipment must be available
tion brand names. True RMS meter for accurate measurement of
small AC and DC voltages. Fluke models 87 or
This manual provides troubleshooting and repair 8060A are good choices.
information regarding the PowerCommand
Grounding wrist strap to prevent circuit board
Control 3100 (PCC) and generators for the gensets
damage due to electrostatic discharge (ESD).
listed on the front cover. Engine service instructions
Battery Hydrometer
are in the applicable engine service manual.
Operating and maintenance instructions are in the Jumper Leads
applicable Operator’s Manual. Tachometer or Frequency Meter
This manual does not have instructions for Wheatstone Bridge or Digital Ohmmeter
servicing printed circuit board assemblies. After Variac
determining that a printed circuit board assembly is Load Test Panel
faulty, replace it. Do not repair it. Attempts to repair a Megger or Insulation Resistance Meter
printed circuit board can lead to costly damage to PCC Service Tool Kit (Harness Tool and Sen-
the equipment. sor Tool)
This manual contains basic (generic) wiring HOW TO OBTAIN SERVICE
diagrams and schematics that are included to help
Always give the complete Model, Specification and
in troubleshooting. Service personnel must use the
Serial number of the generator set as shown on the
actual wiring diagram and schematic shipped with
nameplate when seeking additional service
each unit. The wiring diagrams and schematics that
information or replacement parts. The nameplate is
are maintained with the unit should be updated
located on the side of the generator output box.
when modifications are made to the unit.
WARNING Incorrect service or replacement of
Read Safety Precautions and carefully observe all
instructions and precautions in this manual. parts can result in severe personal injury or
death, and/or equipment damage. Service per-
sonnel must be trained and experienced to per-
form electrical and mechanical service. Read
and follow Safety Precautions, on pages iii and
iv.
1-1
SYSTEM OVERVIEW The PCC monitors frequency from both the mag-
The PCC is a microprocessor-based control for netic pick-up (MPU) and the main stator inputs. The
Cummins Power Generation generator sets. It pro- control sends a low power pulse-width modulated
vides fuel control and engine speed governing, (PWM) signal to the governor output module, which
main alternator voltage output regulation, and com- then sends an amplified signal to the engine fuel
plete generator set control and monitoring. control.
The operating software provides control of the gen- The external PT/CT module reduces generator volt-
erator set and its performance characteristics, and age to approximately 18 VAC, and produces a rep-
displays performance information on a digital dis- resentative AC voltage from CT output current. The
play panel. It accepts menu-driven control and set- voltage regulation function sends a low power PWM
up input from the push button switches on the front signal to the voltage regulator output module, which
panel. then sends an amplified signal to the exciter stator.
GENERATOR SET CONTROL FUNCTION Oil, coolant, and exhaust temperatures are sensed
Figure 1-1 shows some of the control functions. A by variable resistance element sensors. Oil pres-
more complete block diagram is provided in Section sure is sensed by a capacitive element active sen-
3. A system schematic is provided in Section 8. sor.
Fuel
Governor Control MPU
Output
Regulator
Output
PMG Sensors
S N
Battery
BT1
1-2
2. Control Operation
GENERAL PCC POWER ON / STANDBY MODE
Standby Mode
The following describes the function and operation
In the Standby (sleep) mode (selector switch S5 on
of the PowerCommand generator set control. All in-
the Digital Board is set to the right and the generator
dicators, displays, meters and control switches are set is not running), the control’s operating software
located on the face of the control panel as illustrated is inactive and the LEDs and displays on front panel
in Figure 2-1. are all off.
Normally, generator set configuration options are The operating software is initialized and the front
set at the factory. When a new control is installed on panel is turned on in response to a run signal or any
a generator set or when parts are replaced, the con- one of eight “wake up” inputs from remote sensing
switches.
trol must be configured for that generator set with
The wake up signals are:
the use of the “Initial Start Setup” portion of the inter-
nal software. Setup and calibration procedures are Emergency Stop
described in Section 5. Low Coolant Level
The automatic voltage regulator (AVR) and gover- Low Coolant Temperature
nor operation characteristic adjustments are also Low Fuel
described in Section 5. Customer Fault Inputs 2 and 3
Run Selected on Run/Off/Auto Switch
SAFETY CONSIDERATIONS
Remote Start Signal in Auto Mode
AC power is present when the set is running. Do not Self Test switch
open the generator output box while the set is run- To activate and view the menu displays, press and
ning. release the Self Test switch. The PCC will initialize
the operating software and permit operation of the
WARNING Contacting high voltage compo-
menu display panel. If no menu selections are
nents can cause electrocution, resulting in se-
made, the power to the control panel will shut down
vere personal injury or death. Do not open the after 30 seconds.
generator output box while the set is running.
Read and observe all WARNINGS and CAU- Power On Mode
TIONS in your generator set manuals. In the Power On (awake) mode (selector switch S5
on the Digital Board is set to the left), the PCC will
The PCC control cabinet must be opened only by initialize the operating software and permit opera-
technically qualified personnel. tion of the menu display panel. (See Figure 3-1 for
CAUTION The PCC control cabinet must be S5 location.) Power will stay on until switch (S5) is
opened only by technically qualified personnel. set to the Standby mode. It is recommended that
switch S5 be left in the Power On mode in all ap-
Lower level voltages (18 VAC to 15 VDC) are
plication, except those where auxiliary battery
present in PCC control cabinet. These voltages
charging is not available.
can cause electrical shock, resulting in person-
CAUTION Electrostatic discharge will damage
al injury.
circuit boards. Always wear a grounding wrist
Even with power removed, improper handling strap when touching or handling circuit boards
of components can cause electrostatic dis- or socket-mounted ICs and when disconnect-
charge and damage to circuit components. ing or connecting harness connectors.
2-1
KILOWATT FREQUENCY AC AC AMMETER
METER METER VOLTMETER
(PERCENT LOAD)
2-2
FRONT PANEL output to be measured by the AC voltmeter and am-
meter. LEDs indicate the selected phase.
Figure 2-1 shows the features of the front panel.
Run/Off/Auto Switch: This switch starts and stops
AC Voltmeter: Dual scale instrument indicates AC the genset locally, or enables start/stop control of
voltage. Measurement scale in use is shown on the engine from a remote location. (Ground to
scale indicator lamp. start.)
AC Ammeter: Indicates current output in percent of Note: When the generator set is operating in the Re-
maximum rated current. (Percent current is based mote Start mode, removing the Remote Start com-
on .8 PF three-phase and 1.0 PF single phase.) mand does not shut off the engine if the load is more
than 10 per cent, the cooldown timer is set to zero,
Kilowatt Meter: Indicates AC power output as per- and the control is configured for a single unit (not in
cent of rated load. parallel). The generator set continues to operate un-
Frequency Meter: Indicates generator output fre- til it runs out of fuel, the E−stop button is used, or the
quency in hertz. load is removed.
2-3
FIGURE 2-2. DIGITAL DISPLAY AND MENU SELECTION SWITCHES
2-4
MAIN MENU
VOLTAGE
_______ >> VERSION
SECTION 5 SETUP / CAL
FREQUENCY
_______ >>
(ACCESS CODE)
START DELAY
_______ SEC >>
STOP DELAY
_______SEC >>
DISPLAYS <<
SECTION 5 METERS >>
IDLE SPEED
_______RPM >>
SECTION 5
GOV / REG <<
SECTION 5 SETUP
INACTIVE BUTTON
2-5
ENGINE MENU
The facing page shows a block representation of OIL/COOLANT submenu: This is the first subme-
the ENGINE menu. If you press the button next to nu. Select OIL for a display of oil pressure and oil
the word “ENGINE” in the display, the first ENGINE temperature. Select COOLANT for a display of
submenu will appear. coolant temperature. When oil or coolant parame-
ters are displayed, pressing the button next to the
As shown in the diagram, the ENGINE menu has
three submenus. “<<” will return the display (“BACK”) to the OIL/
COOLANT submenu.
2-6
ENGINE MENU
BACK
< ENGINE GEN > < OIL << > ___PSI / KPA << >
< ADJUST >> > < COOLANT >> > ___F / C
BACK
< OIL << > L___F / C << >
< COOLANT >> > R___F / C (or n/a)
BACK
< BATTERY << > BATTERY << >
< HOURS >> > ___VDC
BACK
< BATTERY << > STARTS ___ << >
< HOURS >> > HOURS ___
BACK
< RPM << > RPM << >
< EXHAUST ___
BACK
< RPM << > L___F/C (or n/a) << >
< EXHAUST R___F/C (or n/a)
2-7
GEN MENU
The facing page shows a block representation of VOLTS/AMPS submenu: This is the first subme-
the GEN menu. If you press the button next to the nu. Select VOLTS for a display of a line-line or line-
word “GEN” in the display, the first GEN submenu neutral selection. Select line-line or line-neutral for
will appear. the desired voltage display. Select AMPS for a dis-
As shown in the diagram, the GEN menu has three play of L1, L2, and L3 current in amps. When volt-
submenus. Within these submenus, bold boxes in- age or current parameters are displayed, pressing
dicate the possible selections made in the “Initial the button next to the “<<” will return the display
Start Setup” submenus (e.g., DELTA or WYE) and (“BACK”) to the L-L/L-N submenu.
how the submenus will vary dependent on these
selections.
2-8
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