Service Manual

Generator Set
with PowerCommand  3201 Controller

DQFAA (Spec A−F)

DQFAB (Spec A−F)
DQFAC (Spec A−F)
DQFAD (Spec A−F)
DQGAA (Spec A−C)
DQGAB (Spec A−C)
DQKAA (Spec A−D)
DQKAB (Spec A−D)

English
Original Instructions 2-2020 0961−0508 (Issue 15)
Table of Contents

SECTION PAGE

SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
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
HISTORY/ABOUT SUBMENUS (CONT.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
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
3. CONTROL CALIBRATION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
SOFTWARE CALIBRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
MODIFYING SETUP/ADJUST SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
SETUP MENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

i Copyright  2020 Cummins Inc.

 GOVERNING/VOLT REG SUBMENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
CUSTOMER FAULTS SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
CALIBRATION SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
ISOLATED BUS SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
UTILITY SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
POWER TRANSFER CONTROL MAIN MENUS . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
UTILITY SENSORS SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
GENSET SENSORS SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
TIMERS SUBMENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
TEST/EXERCISE SUBMENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
ADJUST SUBMENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
CALIBRATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
CONTROL BOX WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
RUN RELAYS (K11, K12, K13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
ALARM RELAY (K16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
MAGNETIC SPEED PICKUP UNIT (MPU) INSTALLATION . . . . . . . . . . . . . . . . . 3-28
4. SERVICING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
TESTING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
GENERATOR/PCC CONTROL ISOLATION PROCEDURE . . . . . . . . . . . . . . . . . 4-2
INSULATION RESISTANCE (MEGGER) & POLARIZATION INDEX (PI) TESTING
4-3
DRYING THE WINDINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
EXCITER STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
EXCITER RECTIFIER BRIDGE (ROTATING RECTIFIER ASSEMBLY) . . . . . . 4-9
EXCITER ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
MAIN ROTOR (GENERATOR FIELD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
MAIN STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
TABLE 4-2. WINDING RESISTANCE VALUES* . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
TESTING THE PMG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
HC6/P7 BEARING INSPECTION/REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
HC6/P7 GENERATOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
P80 BEARING INSPECTION/REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Bearing Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
P80 GENERATOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
ALIGNING GENERATOR WITH ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
5. ENCLOSURE FUEL TANK SYSTEM(DQFAA−AD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Copyright  2020 Cummins Inc. ii

 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
WIRING CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
FUEL TRANSFER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
EXTERNAL/INTERNAL ALARM PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
RUPTURE BASIN LEAK DETECT SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . 5-4
6. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
STATUS INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
READING FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
LINE CIRCUIT BREAKER (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
CONTROL AND DIAGNOSTICS VIA NETWORK OR PERSONAL COMPUTER (LAP-
TOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
TABLE 4-2. WARNING AND SHUTDOWN CODES . . . . . . . . . . . . . . . . . . . . . . . 6-8
7. WIRING DIAGRAMS (GENERATOR SET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

iii Copyright  2020 Cummins Inc.

 Intentionally Blank

Copyright  2020 Cummins Inc. iv

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 set and  Provide an adequate exhaust system to properly
batteries. expel discharged gases away from enclosed or
sheltered areas and areas where individuals are
Before operating the generator set (genset), read likely to congregate. Visually and audibly inspect
the Operator’s Manual and become familiar with it and the exhaust daily for leaks per the maintenance
the equipment. Safe and efficient operation can be schedule. Make sure that exhaust manifolds are
achieved only if the equipment is properly operated secured and not warped. Do not use exhaust
and maintained. Many accidents are caused by failure gases to 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 op-
 Engine exhaust and some of its constituents are
erator, 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
moving parts.
unsafe practice which can result in severe per-
sonal 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 connect starting batteries, negative (−) cable first.
unsafe practice which can result in personal This will prevent accidental starting.
injury or product or property damage.  Make sure that fasteners on the generator set are
secure. Tighten supports and clamps, keep
FUEL AND FUMES ARE FLAMMABLE guards 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
from improper practices. of moving parts, or while working on electrical
equipment. Loose clothing and jewelry can be-
 DO NOT fill fuel tanks while engine is running, un- come caught in moving parts.
less tanks are outside the engine compartment.
Fuel contact with hot engine or exhaust is a poten-  If adjustment must be made while the unit is run-
tial 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
made with an approved flexible line. Do not use and become difficult to stop, resulting in possible fire,
zinc coated or copper fuel lines with diesel fuel. explosion, severe personal injury and death. Do not op-
erate a genset where a flammable vapor environment
 Be sure all fuel supplies have a positive shutoff can be created by fuel spill, leak, etc., unless the genset
valve. is equipped with an automatic safety device to block the
 Be sure battery area has been well-ventilated prior air intake and stop the engine. The owners and opera-
to servicing near it. Lead-acid batteries emit a tors of the genset are solely responsible for operating
highly explosive hydrogen gas that can be ignited the genset safely. Contact your authorized Cummins
by arcing, sparking, smoking, etc. distributor for more information.

v Copyright  2020 Cummins Inc.

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

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

Copyright  2020 Cummins Inc. vi

1. Introduction
ABOUT THIS MANUAL nameplate when seeking additional service infor-
mation or replacement parts. The nameplate is lo-
This manual provides PowerCommand Control cated on the side of the generator output box.
3201 (PCC) calibration and adjustment procedures,
control operation, alternator test and repair proce- WARNING Incorrect service or replacement of
dures and initial startup and test of paralleled gener- parts can result in severe personal injury or
ator sets. death, and/or equipment damage. Service per-
sonnel must be trained and experienced to per-
Operating and maintenance instructions are in the
form electrical and mechanical service. Read
applicable Operator’s Manual. Generator set trou-
and follow Safety Precautions, on pages iii and
bleshooting and repair (control and engine) infor-
iv.
mation is provided in the following manual.
 Troubleshooting and Repair Manual Power- Breakerless Conductor Connections
Command Control QSX15 QSK45, QSK60
Generator Sets, Bulletin No. 402-1419. (Not
shown on front cover, but includes QST30 and Overload and Short Circuit Protection of
QSK50 troubleshooting information.) Generator

Read Safety Precautions and carefully observe all NFPA 70: National Electrical Code compliant gen-
instructions and precautions in this manual. erator sets are required to be protected from an
overload. Cummins generator sets with UL Listed
TEST EQUIPMENT
AmpSentry Protective Relay as a standard feature
To perform the test procedures in this manual, the do not require a circuit breaker or other protective
following test equipment must be available device for NEC compliance or UL 2200 Listing.

 True RMS meter for accurate measurement of CEC: Each conductor between the generator termi-
small AC and DC voltages. Fluke models 87 or nal and the point where load receives supply of gen-
8060A are good choices. erator current must be protected by an overcurrent
 Battery Hydrometer device in accordance with the requirement of CEC
 Power Factor Indicator 14−100: Overcurrent Protection of Conductor.
 Jumper Leads UL label indicate to the Authority Having Jurisdiction
 Tachometer or Frequency Meter (AHJ) that the generator set incorporates a UL
 Wheatstone Bridge or Digital Ohmmeter Listed Protective Relay that provides overload and
 Variac short circuit protection for the generator and its
conductors. The generator set does not require
 Load Test Panel
use of a circuit breaker or other protective device
 Megger or Insulation Resistance Meter for NFPA 70: National Electrical Code compliance
 InPower Service Tool (PC based genset ser- or UL 2200 Listing.
vice tool)
HOW TO OBTAIN SERVICE AmpSentry Labels

Always give the complete Model, Specification and These are typical labels for compliant generator
Serial number of the generator set as shown on the sets produced after January 2012.

1-1 Copyright  2020 Cummins Inc.

 FIGURE 1−1. POWER COMMAND 2.2 LABEL

FIGURE 1−2. TYPICAL INFORMATION LABEL

Copyright  2020 Cummins Inc. 1-2

 FIGURE 1−3. POWER COMMAND 2.2, 2.3, AND 3.3 SPECIFIC CHECK LABEL

AmpSentry Protective Relay Time−Over plied, so adjustments to the operation points for this
Current Characteristic Curve curve are not allowed.

The protection provided is shown in the figure Note: The values shown on the current scale are
below, which shows the time−current characteris- shown based on the value of 1.0 being equal to the
tic of the supplied protection. This protection curve nameplate rated current of the generator set for the
is specifically designed to protect the generator sup- specific operating voltage.

1-3 Copyright  2020 Cummins Inc.

 FIGURE 1−4. AMPSENTRY PROTECTIVE RELAY TIME OVER−CURRENT CHARACTERISTIC
CURVE
Coordination of Protective Devices the generator set when choosing a generator set.
Visit www.cumminspower.com for a copy of docu-
Conduct a selective coordination (discrimination) ment R−1053, or it can be found using SKM Power
study on the distribution system that incorporates Tools for Windows library or from your distributor.

Copyright  2020 Cummins Inc. 1-4

2. Control Operation
GENERAL On reaching rated speed and voltage, the control
checks the system bus voltage. If no bus voltage is
The following describes the function and operation present, it will wait for a pulse from a remote Master
of the PowerCommand Control 3201 (PCC). All in- First Start Sensor. On receiving that pulse, the con-
dicators, control switches/buttons and graphical trol will signal the paralleling breaker to close.
display are located on the face of the control panel
as illustrated in Figure 2-1. If bus voltage is present, the control will check for
proper phase rotation, adjust the generator set to
Normally, generator set configuration options are the bus voltage and frequency level, and then syn-
set at the factory. When a new control is installed on chronize the generator set to the system bus. When
a generator set or when parts are replaced, the con- a synchronous condition is achieved, the control will
trol must be configured for that generator set. Setup send a signal to close the paralleling breaker.
and calibration procedures are described in Sec-
When the paralleling breaker is closed, the genera-
tion 3.
tor set will assume it’s 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 MODES
mode, it will cause the generator set to start on re-
ceiving a signal from a remote device. The control The power on/off modes of the control panel and op-
will initiate a starter cranking signal and verify that erating software are Power On, Screen Saver and
the engine is rotating. The control will provide suffi- Sleep/Awake.
cient fuel to the engine to accelerate to start discon-
nect speed. On reaching that speed, the control will Power On Mode: In this mode, power is continu-
ramp the generator set to rated speed and voltage. ously supplied to the control panel. The control’s op-
(In MANUAL mode, the control will ramp the gener- erating software and control panel LEDs/graphical
ator set to idle mode, if needed for warm-up, then display will remain active until the Screen Saver
ramp to rated speed and voltage.) mode is activated.

2-1 Copyright  2020 Cummins Inc.

Screen Saver Mode: Power to the graphical dis-  Set switch S1 on the Genset/Paralleling Card to
play will be removed after 10 minutes (generator set Sleep/Off. This switch is located next to con-
not running or running). The 10 minute timer resets nector J8 and relay K9.
and begins after each control panel action (any but-
ton or switch selection) or signal received by the op- If these conditions are not met, Sleep mode is dis-
erating software. The bottom LEDs of the Analog abled in Auto mode.
AC Metering Panel (bar graphs) may remain on dur- Note: The graphical display can enter Screen Saver
ing Screen Saver mode, indicating that the operat- mode even if Sleep mode is disabled.
ing software is active (Awake mode).
If Sleep mode is enabled in Auto mode, Sleep mode
is activated when there are no unacknowledged
When a “Warning” signal is sensed by the PCC (for
faults and Screen Saver mode is active.
example, low coolant temp), the control will display
the warning message. The control will remain active The operating software is initialized and the control
until the Fault Acknowledge button is pressed to panel LEDs and graphical display are turned on in
clear the warning message and start the 10 minute response to one of the following:
timer.
 Moving/pressing any control panel switch/but-
ton. (If Sleep mode is enabled in Auto mode,
Sleep/Awake Mode: In the Sleep mode, the con- the control will remain asleep if Sleep mode
trol’s operating software is inactive and the LEDs was previously active in Off mode.)
and the graphical display on the control panel are all
off. Sleep mode is a feature that is used to reduce  Receiving a remote start input signal (genera-
battery power consumption when the control is not tor set in Auto mode)
being used.  Receiving an active DCD signal on the RS-232
port.
In Off mode, Sleep mode is activated when there  Modem RI latch becoming active.
are no unacknowledged faults and Screen Saver  Digital display waking up.
mode is active.  Lonworks (backplane) wakeup becoming ac-
tive.
In Auto mode, Sleep mode can be enabled or dis-  Customer fault 2 or 3 only (shutdown or warn-
abled. When shipped from the factory, it is disabled. ing indicator is on).
You can enable Sleep mode by making these
changes:
 Dial Out process becoming active.
To activate the control and view the menu display
 Use InPower service tool to set Auto Sleep En- without starting the generator set, press any button
able to Sleep in Auto. on the control panel.

Copyright  2020 Cummins Inc. 2-2

 OPERATOR SWITCH PANEL
PANEL

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

DISPLAY MENU EXERCISE MANUAL

SELECTION BUTTON & RUN/STOP
BUTTONS (1 OF 6) INDICATOR BUTTON &
INDICATOR
GRAPHICAL 0/MANUAL/AUTO
DISPLAY SWITCH

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

2-3 Copyright  2020 Cummins Inc.

 CONTROL PANEL ASSEMBLY etc. (see Figure 2-5), and paralleling opera-
tions, such as Standby, Dead BUS Close, Syn-
The control panel assembly (Figure 2-1) consist of chronize, Load Share and Load Govern.
two panels, the Operator Panel and the Switch Pan-
 Action Line − system actions, such as Warning,
el.
Derate, Shutdown Cool-down and Shutdown,
Dependent on site requirements, the Operator Pan- and fault codes.
el is either mounted on the control panel assembly  Description Line − Fault code messages.
(full-featured) as shown in Figure 2-1 or contained in
a separate enclosure and mounted remotely of the Display Menu Selection Buttons: Six momentary
control panel assembly. buttons—three on each side of the graphical display
window—are used to navigate through the system
Note: The function of several buttons on the control control menus and to adjust generator set parame-
panel will vary dependent on the location of the con- ters. The button is active when the message adja-
trol panel (remote or local of the control panel assem- cent to the button is highlighted (displayed in in-
bly). If the function differs, it is noted as either “re- verse video).
mote” or “local operator panel” in the button descrip-
tion. The display menu selection buttons are connected
through J3 to the control. The figure below shows
Operator Panel wiring breakdown of the buttons. To test, measure
The operator panel contains the following compo- voltage using a voltmeter, while pressing button. If
nents: the voltage is unequal in all buttons, membrane is
faulty.
Analog AC Metering Panel: This panel simulta-
neously displays 3-phase line to line AC volts and
current, kW, power factor and frequency.

The meter panel is composed of a series of LEDs,

that are configured in bar graphs for each function.
The LEDs are color coded, with green indicating
normal range values, amber for warning levels and
red for shutdown conditions.

Scales for each function are in % of nominal values.

Resolution is 1% for values close to nominal, and in-
creases at values further from nominal.

Graphical Display: The graphical display is capa- 8 GND

ble of displaying up to 9-lines of data with approxi- 7 NOT USED
mately 27 characters per line. The display is used to
6
view the menus of the menu-driven operating sys-
5
tem.
4
The top three lines of the graphical display contain 3
the following control information in the order de- 2
scribed: 1
J3
 State Line − modes of operation, such as
Stopped, Time Delay To Start, Warm Up At Idle, FIGURE 2−2. DISPLAY MENU CORRECTION

Copyright  2020 Cummins Inc. 2-4

Switch Panel To acknowledge a Warning message, the 0/Manual/
Auto switch can be in any position. (It is not neces-
The switch panel contains the following compo- sary to stop the generator set to acknowledge an in-
nents: active Warning condition.) To acknowledge a shut-
down message with this button, the 0/Manual/Auto
Emergency Stop Button: Push the button in for switch must be in the 0 (Off) position.
emergency shutdown of the engine. If the engine is
not running, pushing the button in will prevent the This button is also used to blink a fault code if the
starting of the engine, regardless of the start signal Shutdown or Warning Status Indicator is lit. (This
source (local or remote). function is used when the control does not contain a
graphical display.) Refer to Reading Fault Codes in
To reset: this section, which describes how to use this button
1. Pull the button out. for interpreting fault codes.
2. Move the 0/Manual/Auto switch to 0.
3. Press the front panel Fault Acknowledge Panel Lamp/Lamp Test Button: Press this button
button, and hold until the fault is cleared. to turn on or off the panel lamp. Press and hold down
4. Select Manual or Auto, as required. this button for three seconds or more to turn all con-
trol panel LEDs on to make sure all lamps illuminate.
Remote Start Indicator: This green lamp is lit The illumination will shut off after releasing the but-
whenever the control is receiving a remote run sig- ton.
nal. When flashing, it indicates a load demand stop
mode. Exercise Button: Press this button to initiate a pre-
programmed exercise sequence. To start the exer-
Not in Auto Indicator: This red lamp flashes con- cise sequence, press and hold down the Exercise
tinuously when the 0/Manual/Auto switch is not in button and move the O/Manual/Auto switch from
the Auto position. (If in Auto position and lamp is Auto to Manual and back to Auto or from Manual to
flashing, service is required.) Auto.

Shutdown Status Indicator: This red lamp is lit Manual Run/Stop Button: This button starts and
whenever the control detects a shutdown condition. stops the set locally and will bypass Time Delay to
The generator set can not be started when this lamp Start and Stop sequences. The 0/Manual/Auto
is on. After the condition is corrected, shutdown indi- switch must be in the Manual position to enable this
cators can be reset by turning the 0/Manual/Auto button.
switch to the 0 position, and pressing the Fault Ac- 0/Manual/Auto Switch: Manual position enables
knowledge button. the use of the switch panel Manual Run/Stop button.
Dependent upon the specific fault that occurs, the Auto position enables start/stop control of the en-
engine may or may not shut down immediately. A gine from a remote location. (Disables the use of the
fault that could cause engine damage, causes an switch panel Manual Run/Stop button.)
immediate engine shutdown (bypasses engine
0 (Off) position prevents the starting of the set (local
cool-down sequence). All other faults would allow
or remote). If moved to 0 during set operation, will
the engine to run during the cool-down sequence
cause an immediate engine shutdown (bypasses
before engine shutdown. In this case, the Shutdown
cool-down timers). This hot shutdown should be
Status Indicator blinks during the cooldown period.
avoided, if possible, to help prolong the life of the en-
Warning Status Indicator: This yellow lamp is lit gine. Hot shutdowns are logged by the system soft-
whenever the control detects a warning condition. ware.
After the condition is corrected, warning indicators The connections of Switch Panel components is de-
can be reset by pressing the Fault Acknowledge picted in the tables and image below. Refer to these
button. (It is not necessary to stop the generator set connections for testing the panel buttons.
if the fault becomes inactive during genset opera-
TABLE 2−1. E−STOP AND O/MANUAL/AUTO
tion.)
SWITCH CONNECTION
Fault Acknowledge: Press this button to acknowl- SIGNAL CONNECTION
edge warning and shutdown messages after the
fault has been corrected. Emergency stop button J2−1, J2−2

2-5 Copyright  2020 Cummins Inc.

AUTO J2−3 Exercise J1−6

MANUAL J2−4 Exercise GND J1−5

Manual Run/Stop J1−8
OFF J2−5
Manual Run/Stop GND J1−7
OFF/MANUAL/AUTO GND J2−6
Reset J1−2
Reset GND J1−1
J2
1
E−STO J2 MEMBRANE
2 J1
P PANEL 4
PANEL J1
5 AUT J2 3
3 LAMP/LAMP
O J2 TEST GN
4 3 MANU
4 4 D
AL J2
1 OFF 5 J1
6
J2 EXERCIS J1
OFF/MANUAL/AUTO SWITCH 6 5
E
GND MAN J1 GN
RUN/STOP 8 D
FIGURE 2−3. E−STOP AND O/MANUAL/AUTO J1
7
SWITCH CONNECTION GN
D
TABLE 2−2. MEMBRANE PANEL CONNECTION
J1
2
RESE J1
SIGNAL CONNECTION 1
T
GN
Panel Lamp/Lamp test J1−4
D
Panel Lamp/Lamp test GND J1−3 FIGURE 2−4. MEMBRANE PANEL CONNECTION

Copyright  2020 Cummins Inc. 2-6

 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:
2-5). If the control does not contain the graphical
display, the fault code is read from the Warning and Shutdown LED:
Shutdown status indicators. blink-blink-pause-blink-pause-blink-blink-blink

Warning LED:
Reading Fault codes Using Warning/Shutdown
blink (2 seconds)
Indicators: If the Warning or Shutdown status indi-
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 in
the active fault code(s) as follows. 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.)

2-7 Copyright  2020 Cummins Inc.

 MENU DISPLAY AND SWITCHES Menu Buttons: Six momentary buttons—three on
each side of the graphical display window—are
Figure 2-5 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
is active when the message or symbol adjacent to
Graphical Display: The graphical display is capa- the switch is highlighted (displayed in inverse vid-
ble of displaying up to 9-lines of data with approxi- eo). The displayed message or symbol indicates the
mately 27 characters per line. The display is used to function of the button.
view the menus of the menu-driven operating sys-
tem. Refer to the menu trees later in this section. Note: In the graphical display, the “B” symbol indi-
The display is also used to show the following sys- cates that selecting the adjacent button causes the
tem information: operating program to go to the next menu display—
as shown in the menu diagrams.
 State Line − modes of operation, such as
Stopped, Time Delay To Start, Warm Up At Idle, Note: In the graphical display, the “Y” symbol indi-
etc., and paralleling operations, such as Stand- cates that selecting the adjacent button causes the
by, Dead BUS Close, Synchronize, etc. operating program to go back to the previous menu
 Action Line − system actions, such as Warning, display.
Derate, Shutdown Cool-down and Shutdown,
and fault codes. Note: In the graphical display, the “ ” symbol indi-
cates that selecting the adjacent button causes the
 Description Line − Fault code/status mes- operating program to go back to Main Menu A (Figure
sages. 2-7).

STATE LINE
ACTION LINE
DESCRIPTION LINE

MENU DISPLAY
AREA

GRAPHICAL
DISPLAY

MENU MENU
BUTTONS BUTTONS

FIGURE 2-5. GRAPHICAL DISPLAY AND MENU SELECTION BUTTONS

Copyright  2020 Cummins Inc. 2-8

 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 2-6). After making desired  PRESS GAS INHG
selections, press the ENTER button in this menu to FLOW AIR CFM
change and save the selections.
Note: Use the + buttons to select the desired option
for each field. Use the arrow () button to move to the FIGURE 2-6. 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.

2-9 Copyright  2020 Cummins Inc.

 MAIN MENU _\_ Button (Paralleling Applications Only)
Figure 2-7 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 2-7 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
Note: In the following figures, the boxed/highlighted button will be inactive when the control is in Auto.
field indicates that the adjacent menu button is ac-
tive. Also, the submenus are shown in the order in
which they are displayed when scrolling up Y or In the Manual position, the CB can only be closed
down B. 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 symbol indicates a closed CB. (CB close will oc-
The Adjust submenu is intended for qualified site cur only when setup conditions allow − dead bus or
personnel only. Note that a password may be as- generator synchronized with bus.)
signed to allow only authorized operators to modify
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 Section 3.
When displayed, indicates that the Power Transfer
Note: The “Adjust” and “Setup” submenus can be Control (PTC) feature is installed. Refer to page
viewed, but not modified without entering the correct 2-17 for PTC Data submenu description. The PTC
passwords. setup submenu is described in Section 3.

Copyright  2020 Cummins Inc. 2-10

 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

SECTIO
N3

ADJUST
PARALLEL DATA PAGE
SETUP BACK<< 2-16

GRAPHICAL
SECTIO DISPLAY MENU
N3 A

FIGURE 2-7. SYSTEM CONTROL MAIN MENUS A AND B

2-11 Copyright  2020 Cummins Inc.

 ENGINE SUBMENUS

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

gine submenus will appear (Figure 2-8). 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 Y
ENGINE SPEED 1800 RPM
BATTERY 29.1 VDC B

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

BLOWBY FLOW 25 CFM

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

FIGURE 2-8. ENGINE SUBMENUS

Copyright  2020 Cummins Inc. 2-12

 ALTERNATOR SUBMENUS

If you press the “ALTERNATOR” button in Menu A,

the Alternator Data submenus will appear (Figure ALTERNATOR
2-9).

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

and Line-to-Neutral. Note that the Line-to-Neutral
column will not be displayed for a 3 phase/3 wire V L-L L-N AMPS
system. Accuracy 1%. L1 480 277 1340 Y
L2 480 277 1290
L3 480 277 1260 B
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- AVR DUTY CYCLE 10.3 %
spectively.

Amps: All phases. Accuracy 1%.

Frequency: Generator set output frequency.

KW KVA PF
AVR DUTY CYCLE: Displays voltage regulator L1 350 500 .80 Y
(drive) level in percentage of maximum. L2 350 500 .80
L3 350 500 .80
TOT 1050 1500 .80
kW, kVA and PF: Displays generator set kW and
kVA output (average and individual phase, and di-
rection of flow) and power factor with leading/lag-
ging indication. Accuracy 5%.
Note: The PF reading will contain an asterisk if the
power factor is leading (for example, *.30). FIGURE 2-9. ALTERNATOR SUBMENUS

2-13 Copyright  2020 Cummins Inc.

 CONTROL SUBMENU

If you press the “CONTROL” button in Menu A, the location. This button sequentially lights the LEDs to
Control submenu will appear (Figure 2-10). test the bar graph display.

Local CONTROL Submenu Function Enable Sync: Displayed in paralleling applications

only. Intended for service personnel to turn off the
When the operator panel is mounted on the control synchronizer for troubleshooting/testing purposes.
panel assembly, the Run Mode Idle/Rated button is
active (displayed). Note in Figure 2-10 that this but-
ton is not displayed in remote applications. CONTROL
(LOCAL)
The shaded area in Figure 2-10 displays the se-
lected/active mode of operation, either IDLE or
RATED.

Remote CONTROL Submenu Functions

+ RUN MODE IDLE Y
When the operator panel (Figure 2-1) is mounted re- B
motely of the control panel assembly, the menu but- ENABLE SYNC
tons 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.)

Note: The 0/Manual/Auto switch must be in the Auto

position to activate the Remote Menu Buttons of the BARGRAPH TEST Y
Control submenu.

Remote START or STOP Button: This button is

used to start and stop the generator set when the
operator panel is mounted in a remote location.
CONTROL
When the generator set is operating, Stop will be (REMOTE)
displayed for this button and Start will be displayed
when not operating.

When the generator set is operating in the Remote

Start mode, removing the Remote Start command
START GENSET Y
does not shut off the engine if the load is more than
FAULT ACKNOWLEDGE B
10 per cent, the cooldown timer is set to zero, and
the control is configured for a single unit (not in par- ENABLE SYNC
allel). The generator set continues to operate until it
runs out of fuel, the E−stop button is used, or the
load is removed.

Fault Acknowledge Button: Used to reset inactive

Warning messages, not Shutdown messages.
BARGRAPH TEST Y

Local/Remote CONTROL Submenu

Function

Bargraph Test: The function of this button remains

the same and is not dependent on operator panel FIGURE 2-10. CONTROL SUBMENU

Copyright  2020 Cummins Inc. 2-14

 HISTORY/ABOUT SUBMENUS

If you press the “HISTORY/ABOUT” button in Menu

A, the History/About submenus will appear (Figure HISTORY/ABOUT
2-11).

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 Y
This information is stored in non-volatile memory CONTROL HOURS 7879
KWHRS 890 B
and will not be deleted due to loss of battery power.

ABOUT: The About submenus provide the following

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 Y
12345@10-19 12345@60-69
 Rating: Standby, Prime or Base 12345@20-29 12345@70-79 B
12345@30-39 12345@80-89
 Version level of the controller and panel operat-
ing software.

MODEL 1750DQKB Y
VOLTAGE 416 WYE
FREQUENCY 60 B
RATING STANDBY

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

CONTINUED TO NEXT PAGE

FIGURE 2-11. HISTORY/ABOUT SUBMENUS

2-15 Copyright  2020 Cummins Inc.

 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
FAULT HISTORY: 1 OF 24
be deleted from the control panel memory, but will CNTL HOURS 459
+ Y
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
(FAULT DESCRIPTION)
The Fault History 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 Occurrences display line: In this example, 5 in- FIGURE 2-12. HISTORY/ABOUT SUBMENUS
dicates that this is the fifth occurrence of this fault. (CONT.)
(The InPower service tool is required to review the
last four faults of this code.)
Note: The Occurrences number is incremented for
each new occurrence of the same fault. The control-
ler must detect that the original sensed fault is cor-
rected before it will increment the occurrence num-
ber for that fault.
Note: For example, when a Low Oil Pressure fault is
detected, the controller will increment the Occur-
rences 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
number each time the engine is started. When the
controller detects that the oil pressure is normal the
fault will become inactive, allowing the occurrences
number to be incremented for the next detected Low
Oil Pressure fault.

Copyright  2020 Cummins Inc. 2-16

 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
2-12). 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

the graphical display is used to indicate the follow- With the control panel 0/Manual/Auto switch in the
ing PARALLEL DATA status: Auto position, the opening and closing of the CB is
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
− SYNCHRONIZE: Genset is synchronizing to this button. When manually closed and the CB
bus. opens, it must be closed again by using this button.
− LOAD SHARE: Genset has closed to bus and is To close the CB, press and hold the button until the
sharing load with other gensets in system. symbol indicates a closed CB. (CB close will occur
only when setup conditions allow − dead bus or gen-
− LOAD GOVERN: Genset closed to bus in par-
erator 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 Y
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 2-13. BUS DATA SUBMENU

2-17 Copyright  2020 Cummins Inc.

 POWER TRANSFER MAIN/SUBMENUS

If you press the “POWER TRANS” button in Menu The symbol displayed in the middle of the Power
A, the Power Transfer main menu will appear (Fig- Transfer main menu indicates which breaker (utility
ure 2-13). The Power Transfer Control (PTC) fea- or genset) is closed/opened to the load. The symbol
ture must be installed to display this menu. 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. 2-13 for the Power Transfer submenu descriptions.

Copyright  2020 Cummins Inc. 2-18

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 Section 3).
− 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
disabled (TB8-3 terminal closed). Test mode is
− MANUAL: Control panel switch is in Manual
non-emergency, which means that a retransfer
position. All PTC actions or genset start/stop
to utility will occur if any problems occur with the
actions are manually controlled.
genset while testing with load. This test can be
− NORMAL UTIL: Load is connected to the util- performed with or without load (refer to TEST/
ity. EXERCISE submenu in Section 3).
− RETRAN: Retransfer of load to utility. − EXERCISE: Exercise sequence initiated
− RETRAN OVRD: Immediate retransfer of load through control panel. This test can be per-
to utility due to genset fault (e.g., warning, der- formed with or without load (refer to TEST/EX-
ate, or shutdown w/cooldown fault). The retran- ERCISE submenu in Section 3). A retransfer to
sfer timer is ignored as is the retransfer inhibit. 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

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

PAGE MENU
2-21 A

FIGURE 2-14. POWER TRANSFER MAIN MENU

2-19 Copyright  2020 Cummins Inc.

 UTILITY (PWR TRAN) SUBMENUS

If you press the “Utility” button in the Power Transfer

Main menu, the Utility submenus will appear (Figure UTILITY
2-14).

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 Y
wire system. Accuracy 1%. L1 480 277
B
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:
KW KVA PF Y
Frequency: Utility frequency. L1
L2 125 175 .96
kW, kVA and PF: Displays (L2 only) utility kW and L3
TOT
kVA output (average and direction of flow) and pow-
er factor with leading/lagging indication. Accuracy
5%.
FIGURE 2-15. UTILITY SUBMENUS
Note: The PF reading will contain an asterisk if the
power factor is leading (for example, *.30).

Copyright  2020 Cummins Inc. 2-20

 STATUS (PWR TRAN) SUBMENUS

If you press the “Status” button in the Power Trans-

fer Main menu, the Status submenus will appear STATUS
(Figure 2-15).
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 Y
quency. Both can be available simultaneously. AVAILABLE YES NO
B
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 load TRAN INH OFF
RETRAN INH ON Y
transfer to the genset. When activated, load 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 contact
disables it. When enabled, the event is displayed on
the graphical display. FIGURE 2-16. 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 In-
hibit 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.

2-21 Copyright  2020 Cummins Inc.

 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 2-16).

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
CB ENABLE CB ENABLE
utility breaker is closed and supplying power to the
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 2-16) ENABLE UTIL CB

In the example in Figure 2-16, the CB ENABLE but-

CANCEL
ton for “Utility” was pressed. (If the CB ENABLE
button for the “Genset” was pressed, ENABLE GEN
CB would be displayed in the second submenu, al-
lowing you to open or close the genset circuit break-
er.)

After pressing the “utility” CB ENABLE button, the UTILITY GENSET

second submenu will be displayed allowing you to
either CANCEL or ENABLE the entered selection. OPEN UTIL CB ENABLE
<< BACK
Pressing the CANCEL button will return the display
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 GENSET
utility circuit breaker (press <<BACK) or you can
press the OPEN UTIL button. CLOSE UTIL CB ENABLE

Pressing the OPEN UTIL button will display the << BACK
fourth submenu, indicating that the utility circuit
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 2-17. TRANSFER CONTROL SUBMENUS

Copyright  2020 Cummins Inc. 2-22

 GENSET (PWR TRAN) SUBMENUS

If you press the “Genset” button in the Power Trans-

fer Main menu, the Genset submenus will appear GENSET
(Figure 2-17).

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

and Line-to-Neutral. Note that the Line-to-Neutral
column will not be displayed for a 3 phase/3 wire GENSET:
system. Accuracy 1%. V L-L L-N AMPS Y
L1 480 277 1320
L2 480 277 1320 B
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 Y
L1 100 150 .97
kW, kVA and PF: Displays generator set kW and 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%.

Note: The PF reading will contain an asterisk if the

power factor is leading (for example, *.30). FIGURE 2-18. GENSET SUBMENUS

2-23 Copyright  2020 Cummins Inc.

 INTENTIONALLY BLANK

Copyright  2020 Cummins Inc. 2-24

3. Control Calibration and Adjustment
GENERAL CAUTION If the base card has software as-
sembly A026 F566 v1.0 on the U33 flash memory
This section contains calibration and adjustment chip, you must use the latest software calibra-
procedures for the generator set control. tion for the control, or the board will lock up per-
manently.
SOFTWARE CALIBRATIONS
If the base card has software assembly A026 F566 MODIFYING SETUP/ADJUST SUBMENUS
v1.0 on the U33 flash memory chip, you must use
the latest software calibration for the control. If you The Setup and Adjust submenus allow you to cali-
load an earlier software calibration onto a base card brate the graphical display meters and to adjust sys-
with software assembly A026 F566 v1.0, the soft- tem parameters, customer defined faults, generator
ware calibration will fail, and the board will lock up set voltage/frequency and paralleling applications.
permanently.
CAUTION Improper calibration or adjustment
of the control can cause equipment malfunction
or damage. Calibration and adjustment must be
performed by technically qualified personnel
only.

The Setup submenus are intended for qualified ser-

vice personnel only. The Adjust submenu is in-
tended for qualified service and site personnel only.
For this reason, a password must be entered before
this data can be modified. The Setup and Adjust
submenus can be viewed, but not modified without
entering the correct password.

Saving Menu Changes

Changes are automatically saved when the menu is

FIGURE 3-1. U33 FLASH MEMORY CHIP exited.

3-1 Copyright  2020 Cummins Inc.

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 time−out.
words are assigned within the system software. An
Application password is used for the Setup subme- Entering Password
nus and a User password is used for the Adjust sub-
menu.
To enter the password:
The two passwords are assigned during the initial
installation of the generator set (via InPower) and 1. Display submenu to modify.
will vary between sites. The installer must make 2. Press either the + or − button within the dis-
sure that the passwords are available to the ap- played submenu. The Password menu ap-
propriate personnel. pears.

Note: When the generator set is first installed, the Ap-

3. Press the + and − button to select the first char-
plication and User password are both set to GENSET acter of the password (A−Z or 0−9). (Enter Ap-
to allow initial modification of the Setup and Adjust plication password for Setup submenus; Enter
submenus. Assign new passwords when site instal- User password for Adjust submenu.)
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 −
button will display the User Password menu. 5. Repeat steps 3 and 4 to enter remaining pass-
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 ENTER USER PASSWORD

PASSWORD
+ ENTER + ENTER
− −
 XXXXXXXX  XXXXXXXX

SETUP SUBMENU PASSWORD MENU ADJUST SUBMENU PASSWORD MENU

FIGURE 3-2. PASSWORD MENUS

Copyright  2020 Cummins Inc. 3-2

 SETUP MENUS fields. Refer to PASSWORD Menu in this section to
enter password and to save menu changes.
Figure 3-3 shows the main menus (Menu A and
Menu B) of the system control and the two Setup To display the two Setup menus, press the
menus. MORE>> button in Menu A and then the SETUP
button in Menu B.
Paralleling − Non−Paralleling
To view system data or to adjust system parame-
If the generator set was purchased for a paralleling ters, press the appropriate Setup menu button to
application but will be used for a non−paralleling ap- display the desired Setup submenu(s). Refer to the
plication, entering the checksum data into the Data- page number shown in Figure 3-3 for detailed infor-
plate Checksum dialog in InPowert is not re- mation related to the selected submenu(s).
quired. However, the Adjustments Paralleling − Par-
alleling Level must be set to Basic. CAUTION Improper calibration or adjustment
of the control can cause equipment malfunction
The Setup procedure is intended for qualified ser- or damage. Calibration and adjustment must be
vice personnel only. The APPLICATION password performed by technically qualified personnel
must be entered to modify the Setup submenu only.

3-3 Copyright  2020 Cummins Inc.

 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 Y
PAGE CUSTOMER FAULTS B NEXT
3-5 MENU
CALIBRATION

PAGE MENU
3-6 A

SETUP MENU 2
PAGE ABOVE
3-12 MENU

POWER TRANSFER SETUP Y

PAGE ISOLATED BUS
3-7 UTILITY

PAGE MENU
3-11 A

FIGURE 3-3. SETUP SUBMENUS

Copyright  2020 Cummins Inc. 3-4

 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 3-4).

Note: Use the + and − buttons to increase or decrease

the values in the following fields. Use the arrow ()
button to move the cursor within a field or to the next
field. Exit menu to safe changes. + GOV GAIN 80% Y
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 3-4. 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.

3-5 Copyright  2020 Cummins Inc.

 CUSTOMER FAULTS SUBMENUS

If you press the “CUSTOMER FAULTS” button in Note: If these messages are changed, you should
the Setup menu, the Customer Faults submenus note these changes in the Troubleshooting section
will appear (Figure 3-5). of the Operator’s manual for this generator set.

There are a total of four customer fault inputs.

(Faults 3 and 4 paralleling only.) The message dis-
played at the bottom of the menu can be modified for
each of these faults in addition to selecting the fol-
lowing operating parameters for each fault.
 Enable − On or Off
 Active − Closed or Open
 Response − Shutdown, Cooldown, Derate or
Warning
Shutdown: Genset will immediately shut
down. Normally used for engine faults.
Cooldown: Cooldown sequence will be initi-
ated before shutdown. Should not be used for
certain engine faults.
Derate: Used to lower kW output of genset for
warnings such as pre-high coolant tempera-
ture, etc. Paralleling application − controller will
reduce percentage of kW load sharing on the
set. Non-paralleling application − controller will
lower percentage of kW load by operating load
shed relay contacts.
Warning: Display message, genset continues
to operate.
Note: The Enable and the Active fields apply to the
Fault 1 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 B or Y 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 position
within the fault message line.
With the desired character position selected, use +
or − buttons to select the appropriate character.

Copyright  2020 Cummins Inc. 3-6

 CUSTOMER FAULTS

CUSTOMER FAULT1:
+ ENABLE ON Y
− ACTIVE CLOSED B
RESPONSE WARNING

***CUSTOMER FAULT1
******************

CUSTOMER FAULT2:
+ Y
− RESPONSE WARNING B

***CUSTOMER FAULT2
******************

CONTINUES THROUGH TWO

ADDITIONAL MENUS FOR A
TOTAL OF FOUR POSSIBLE
CUSTOMER FAULT
MESSAGES

FIGURE 3-5. CUSTOMER FAULTS SUBMENUS

3-7 Copyright  2020 Cummins Inc.

 CALIBRATION SUBMENUS

If you press the “CALIBRATION” button in the Setup

menu, the Calibration submenus will appear (Figure CALIBRATION
3-6).
Note: Use the + and − buttons to increase or decrease
the values in the following fields. Use the arrow ()
button to move the cursor within a field or to the next VOLTAGE CALIBRATION
field. Exit menu to safe changes. L1 480 -X.X%
+ Y
L2 480 -X.X%
The Calibration submenus allow you to calibrate the − L3 480 -X.X% B
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 replacing CURRENT CALIBRATION

certain circuit cards. Refer to the Calibration Proce- + L1 234 -X.X% Y
dure in this section which contains a list of the cards L2 123 -X.X%
− L3 562 -X.X% B
that require control calibration. 

Note: 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% Y
L2 480 -X.X%
− L3 480 -X.X%


FIGURE 3-6. CALIBRATION SUBMENUS

Copyright  2020 Cummins Inc. 3-8

ISOLATED BUS / UTILITY Submenus can force the generator set to match bus voltage
(Paralleling Application) and frequency in a range of minus 40% to plus 10%
of normal bus conditions. When the paralleling
The Isolated BUS submenus (Figure 3-7) and the breaker has closed, the control will bring the gener-
Utility submenus (Figure 3-8) adjust the control pa- ator set back to normal voltage and frequency.
rameters for generator set protection, synchroniz-
ing and load sharing for both isolated bus and utility When the generator set is paralleled to another gen-
(mains) paralleling applications. Utility (mains) par- erator set, the control provides automatic load shar-
allel applications may require adjustment of both the ing functions for both real (kW) and reactive (kVAR)
Isolated BUS and Utility submenus. loads. Load sharing is proportional between gener-
ator sets based on their standby ratings. If two gen-
Note: Always perform ISO BUS calibration before erator sets of different sizes are paralleled, they will
Utility BUS calibration. assume the same percentage of the system load
automatically. This can easily be verified on the kW
The sync check (permissive) function is operational Load LED bar graph on the front of the control panel.
in both automatic and manual (RUN) modes. The
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 0−5 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
and greater, the control will operate the generator
The synchronizing function of the control is enabled set at 110% of the generator set base load setting.
when the control has brought the generator set to When the load govern signal is between 1 VDC and
90% of rated speed and voltage, and has sensed 4.5 VDC the control will operate the generator set at
that bus voltage is available. The control automati- a load level which is determined by a linear relation-
cally adjusts the generator set speed and voltage to ship between the kW reference and the load govern
match the bus frequency and voltage. The control signal.

3-9 Copyright  2020 Cummins Inc.

 ISOLATED BUS SUBMENUS

If you press the “ISOLATED BUS” button in the Set-

up menu, the Isolated BUS submenus will appear ISOLATED BUS
(Figure 3-7).
Note: Use the + and − buttons to increase or decrease
the values in the following fields. Use the arrow ()
button to move the cursor within a field or to the next
field. Exit menu to safe changes. ISOLATED BUS:
+ SYNC TIME LIMIT 120 SEC Y
SYNC TIME LIMIT: This parameter adjusts the time REV PWR LMT 10 %
− B
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 3-7. ISO BUS SUBMENUS
Note: Lower reverse power set points can result in
nuisance 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 sec-
onds for isolated bus applications.

Copyright  2020 Cummins Inc. 3-10

Note: Adjusting the control for a smaller sync-check
window or longer time delay will cause synchroniz-
ISOLATED BUS (CONT.)
ing 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 Y
KW BALANCE 0.3
− KVAR BALANCE 1.2 B
Note: KW Balance and KVAR Balance changes
should be 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
CONTINUED TO NEXT PAGE
be performed. If the total load on the system is not
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 3-8. 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 changing,
reduce the gain adjustment on the generator set.
This also allows modification of the rate of load as-
sumption 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.

3-11 Copyright  2020 Cummins Inc.

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
ISOLATED BUS:
present load level on the set to the ramp unload lev- 1ST FAIL TIME 12 SEC
+ Y
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 3-9. 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 cir-
cuit breaker closes.
LOSS FIELD TIME: Adjusts the loss of field function
time delay. A typical delay which is suitable for Pow-
erCommand generator sets is 2 seconds.

Copyright  2020 Cummins Inc. 3-12

 UTILITY SUBMENUS

If you press the “UTILITY” button in the Setup menu,

the Utility submenus will appear (Figure 3-8). UTILITY
Note: Use the + and − buttons to increase or decrease
the values in the following fields. Use the arrow ()
button to move the cursor within a field or to the next
field. Exit menu to safe changes.
UTILITY:
BASE LOAD (%): This controls the maximum kW BASE LOAD 80%
+ Y
load level that the generator set will operate at when PF LEVEL 1.00
− B
paralleled with the utility (mains). The value shown RAMP LOAD 3
indicates the steady state load on the generator as a  RAMP UNLD 20
MODE MULTIPLE
percent of the generator set standby rating.
Check generator set ratings for maximum load level
at which the generator set should operate when par-
alleled with the utility (mains). Extended operation
at load levels in excess of the generator set rating UTILITY:
can cause abnormal engine wear or premature en- + KW GOVERN GAIN 1.00 Y
gine 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
FIGURE 3-10. UTILITY SUBMENUS
analog input. This is active when the control first en-
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.

3-13 Copyright  2020 Cummins Inc.

 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 3-9 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 3-3, the two main
menus of the optional Power Transfer Control
(PTC) feature will appear (Figure 3-9).

PTC MAIN MENU 1

PAGE
3-13

UTILITY SENSORS Y
PAGE GENSET SENSORS B NEXT
3-15 MENU
TIMERS

PAGE
3-17
PTC MAIN MENU 2

PAGE
TEST/EXERCISE Y
3-18

FIGURE 3-11. PTC SETUP MAIN MENUS

Copyright  2020 Cummins Inc. 3-14

 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: 1−18000 (1A).
will appear (Figure 3-10).
CAUTION This CT must be rated for 1 Amp out-
The following field descriptions show the valid field
put (e.g. NOT 5 Amp). Be sure CT secondary cir-
entries and default value (shown in parenthesis) for
cuit has burden resistor or a shorting jumper in
each field.
place before putting power through the CT. Ex-
Note: Use the + and − buttons to increase or decrease ample: CT Ratio = 2650:1. Thus enter 2650.
the values in the following fields. Use the arrow ()
button to move the cursor within a field or to the next U SENSOR TYPE: Enter the line-to-line (L-N) for 3
field. Exit menu to save changes. phase line-neutral voltage sensing or line-to-line
(L-L) for 3 phase line-line voltage sensing. This ap-
U PT VOLT LL: Enter the value of the utility line-to-
plies to both the utility undervoltage and overvoltage
line voltage which yields 100% voltage at the termi-
sensors. Range: L−L, L−N (L−N).
nals of the utility (bus) PT module.

Range: 1−15000V, 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- U UNLOADED KW: Enter the kW on utility Line 2 at
ity (bus) PT modules are as follows, based on mod- which the utility is considered as unloaded. This is
ule dash number: the L2 kW level at which a closed transition soft
−01 = 208 volts LL transfer will disconnect from the utility.
−02 = 416 volts LL
−03 = 600 volts LL UTILITY UNDERVOLTAGE: Non-adjustable field,
−04 = 120 volts LL always enabled.
Example 1: 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.
UV PICKUP: Enter a number between 85 and 100%
Example 2: Nominal Utility voltage is 4160V. A pri- of the nominal voltage (90%).
mary stage transformer with a ratio of 4200/240 is
used. This means that utility (bus) PT module num- UV DROP OUT: Enter a number between 75 and
ber −01 should be used. The voltage which will yield 98% of the under-voltage pick-up percentage
the 100% volts (208V from above table) is calcu- (90%).
lated as follows:
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:
1−15000 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.

3-15 Copyright  2020 Cummins Inc.

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%).
U PT VOLT LL 416
OV DELAY: Enter a range between 0 and 120 sec- + U NOM VOLT LL 480 Y
onds (3 seconds). U CT RATIO: 1 1000
− U SENSOR TYPE L−L B
OV MAX PHASE: Displays the highest line voltage 
U UNLOADED KW 50 KW
of the three utility phases.

CENTER (FREQ): Enter a frequency between 45

and 65 Hz (60 Hz).

PICK UP (FREQ): Enter a percentage between 5 UTILITY UV: ENABLED

+ % VLL Y
and 20% of the nominal frequency (10%). PICK UP 95 475
− DROP OUT 85 465 B
DROP OUT (FREQ): Enter a percentage between 1  DELAY 0.5 S
and 5% of the nominal frequency (1%). 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

UTILITY OV: DISABLED
line frequency. + % VLL Y
PICK UP 95 487
− DROP OUT 110 490 B
 DELAY 3.0 S
MAX PHASE 485

UTILITY FREQ: DISABLED

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

FIGURE 3-12. UTILITY SENSORS SUBMENUS

Copyright  2020 Cummins Inc. 3-16

 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 transition
will appear (Figure 3-11). soft load retransfer. Ramp rate is −100%kW divided
by this time setting. Range: 0−900 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-
Note: Use the + and − buttons to increase or decrease loaded. This is the %kW level at which a closed tran-
the values in the following fields. Use the arrow () sition soft retransfer will disconnect from the genset.
button to move the cursor within a field or to the next Range: 0−100% (5%).
field. Exit menu to save changes.
GEN UNDERVOLTAGE: Non-adjustable field, al-
G NOM VOLT LL: Non-adjustable field, displays
ways enabled.
current setting of genset nominal voltage. (See Ad-
just submenu to adjust the output voltage 5%.) GEN OVERVOLTAGE, FREQUENCY: Used to en-
able or disable menu function. Choose Enabled or
G SENSOR TYPE: Enter the line-to-line (L-N) for 3
Disabled (Enabled).
phase line-neutral voltage sensing or line-to-line
(L-L) for 3 phase line-line voltage sensing. This ap- UV PICKUP: Enter a number between 85 and 100%
plies to both the genset undervoltage and overvol- of the nominal voltage (90%).
tage sensors. Range: L−L, L−N (L−N).
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%).
0−100% (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 time UV MIN PHASE: Displays the lowest line voltage of
setting. Range: 0−900 seconds (20 sec). the three genset phases.

3-17 Copyright  2020 Cummins Inc.

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%).
G NOM VOLT LL 480
OV DELAY: Enter a range between 0 and 120 sec- + G SENSOR TYPE L−L Y
onds (3 seconds). G BASE LOAD 80.0%
− G RAMP LOAD 20 S B
OV MAX PHASE: Displays the highest line voltage  G RAMP UNLOAD 20 S
G UNLOADED KW 5 %
of the three genset phases.

CENTER (FREQ): Enter a frequency between 45

and 65 Hz (60 Hz).

PICK UP (FREQ): Enter a percentage between 5 GEN UV: ENABLED

+ % VLL Y
and 20% of the nominal frequency (10%). PICK UP 95 475
− DROP OUT 85 465 B
DROP OUT (FREQ): Enter a percentage between 1  DELAY 1.0 S
and 5% of the nominal frequency (1%). 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-

GEN OV: DISABLED
quency. + % VLL Y
PICK UP 95 487
− DROP OUT 110 490 B
 DELAY 8.0 S
MAX PHASE 485

GEN FREQ: DISABLED

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

FIGURE 3-13. GENSET SENSORS SUBMENUS

Copyright  2020 Cummins Inc. 3-18

 TIMERS SUBMENU

If you press the “TIMERS” button in the PTC Main

Menu 1, the Timers submenu will appear (Figure TIMERS
3-12).
The following field descriptions show the valid field
entries and default value (shown in parenthesis) for
each field.
START DELAY 60 S
Note: Use the + and − buttons to increase or decrease + STOP DELAY 60 S Y
the values in the following fields. Use the arrow () −
TRANSFER 10 S
button 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 3-14. 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 seconds
(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).

3-19 Copyright  2020 Cummins Inc.

 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 3-13).
The following field descriptions show the valid field
entries and default value (shown in parenthesis) for
each field.
Note: Use the + and − buttons to increase or decrease + MODE CT-SOFT Y
the values in the following fields. Use the arrow () −
button to move the cursor within a field or to the next TEST WITH LOAD OFF
field. Exit menu to save changes.  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 3-15. 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

Copyright  2020 Cummins Inc. 3-20

 ADJUST SUBMENU disabled to prevent inadvertent misadjustment of
the paralleling load sharing functions.
Figure 3-14 shows the main menus (Menu A and
Menu B) of the system control and the Adjust sub- Note: Use the + and − buttons to increase or decrease
menu. the values in the following fields. Use the arrow ()
button 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.
PASSWORD Menu in this section to enter pass-
word. VOLTAGE: Used to adjust the output voltage 5%.

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

MENU A

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

MENU B

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

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

FIGURE 3-16. ADJUST SUBMENU

3-21 Copyright  2020 Cummins Inc.

 CALIBRATION PROCEDURE is not possible to calibrate the genset output voltage
display of the genset that is running when the bus is
There are several circuit cards/modules that, when energized. If it is necessary to adjust the output volt-
removed and replaced, require you to recalibrate age display of the genset that is running, the InPower
the control panel display for genset voltage and cur- service tool must be used to switch off the synchro-
nizer function of the control.
rent and bus voltage.
1. Display the Voltage Calibration 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 L1 so that the
 Bus PT (C) reading on the display agrees with the cali-
 CT’s (B) brated voltmeter.
5. Shut the generator set OFF.
6. Repeat steps 2 through 5 for L2 and L3. (In step
WARNING Contacting high voltage compo- 2 attach meter to the AC output from L2 to L3 to
nents can cause electrocution, resulting in se- calibrate L2 and L3 to L1 to calibrate L3.)
vere personal injury or death. Calibration and 7. Exit menu to safe changes.
adjustment must be performed by technically
qualified personnel only. Read and observe all (B) Genset Ammeter Display Calibration
WARNINGS and CAUTIONS in your generator 1. Display the Current Calibration submenu
set manuals. (Page 3-6).
CAUTION Improper calibration or adjustment 2. With the genset OFF, attach a calibrated am-
of the PowerCommand control can cause meter to L1.
equipment malfunction or damage. Calibration 3. Start the genset and allow it to reach normal
and adjustment must be performed by techni- operating speed.
cally qualified personnel only.
4. Load the genset to maximum rated kVA at rated
Use a calibrated RMS multimeter for accurate mea- voltage.
surements. Fluke models 87 or 8060A are good 5. Calibrate the reading for L1 current so that the
choices. reading on the display agrees with calibrated
ammeter.
(A) Genset Voltage Display Calibration 6. Repeat steps 2 through 5 for L2 and L3. (In step
Note: The PowerCommand control automatically
2, attach meter to L2 to calibrate L2 current and
synchronizes to the system bus when bus voltage is L3 to calibrate L3 current.)
available and the genset is running. Consequently, it 7. Exit menu to safe changes.

Copyright  2020 Cummins Inc. 3-22

(C) Bus Voltage Calibration 2. With all gensets OFF, attach a calibrated volt-
meter to TB1-A (L1) and TB1-B (L2) of the bus
PT module (Figure 3-15).
Note: The PowerCommand control automatically 3. Start another genset and allow it to reach nor-
synchronizes to the system bus when bus voltage is mal operating speed and voltage. Connect op-
available and the genset is running. Consequently, it erating genset to the bus.
is not possible to calibrate the genset bus voltage
4. Calibrate the voltage reading for Bus Volts L1
display of the genset that is running when the bus is
energized. If it is necessary to adjust the bus voltage
so that the reading on the display matches the
display of the genset that is running, the InPower ser- reading on the calibrated meter.
vice tool must be used to switch off the synchronizer 5. Shut the generator set OFF.
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 from
1. Display the Bus Voltage Calibration submenu L2 to L3 to calibrate L2; L3 to L1 to calibrate L3.)
(Page 3-6). 7. Exit menu to safe changes.

CONTROL
BOX DOOR

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

TB1-B (L2)

FIGURE 3-17. BUS PT MODULE

3-23 Copyright  2020 Cummins Inc.

 CONTROL BOX WIRING Optional equipment such as a remote annunciator
panel, sensing devices used to monitor genset op-
The generator set control box assembly, which can eration, remote start/stop switches, control box
be located on either side of the genset, contains heater, and etc. are also attached to these terminal
connection points for remote control and monitor
blocks. Driver signals for customer supplied relays
options.
are also provided for several alarm and shut down
Customer monitor/control connections are attached conditions. Refer to Customer Connections dia-
to terminal blocks TB3 and TB8 (see Figure 3-16). gram in Section 5.

Copyright  2020 Cummins Inc. 3-24

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

TB8

CARD
CAGE

*QSK30 DOES NOT USE THE FUEL PCB

FIGURE 3-18. CONTROL BOX ASSEMBLY INTERIOR

3-25 Copyright  2020 Cummins Inc.

 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 3-16). 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
3-17) 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 3-19. OPTIONAL RUN RELAYS (K11, K12, K13)

Copyright  2020 Cummins Inc. 3-26

 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 3-20. OPTIONAL ALARM RELAY (K16)

3-27 Copyright  2020 Cummins Inc.

 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
SENSOR
the mounting hole. Thread the sensor in gently by
hand until it just touches the gear tooth. Back it out
one quarter turn and set the locknut.
CAUTION Do not use fan blade to bar over en-
gine. That can damage blades and cause prop-
erty damage and personal injury.

ENGINE
FLYWHEEL
RING GEAR

FIGURE 3-21. MPU SENSOR

Copyright  2020 Cummins Inc. 3-28

4. Servicing the Generator
TESTING THE GENERATOR WARNING Incorrect service or replacement of
This section describes how to isolate a voltage fault parts can result in severe personal injury or
to the PCC control circuitry or generator, and the death, and/or equipment damage. Service per-
procedures to test, disassemble and reassemble sonnel must be trained and experienced to per-
the generator (Figure 4-1). form electrical and mechanical service.

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 Copyright  2020 Cummins Inc.

 GENERATOR/PCC CONTROL ISOLATION Connect the jumper from the positive (+) post of
PROCEDURE the battery to the X pin of plug P10-6. Be pre-
pared to connect the jumper from the negative
DANGER Medium-voltage, 601 to 15,000 volts, (−) post of the battery to the XX pin of plug
present special hazards of severe personal inju- P10-3. If one of the 12 volt cranking batteries is
ry or death. Even after genset shutdown, an used, bring the jumpers from the battery con-
electrical shock hazard may still exist, caused nected on the grounded side of the system to
by induced voltage within the generator or avoid inadvertently imposing 24 volts on the
cables. Service personnel must be well-trained/ system.
qualified to work with distribution voltages. 5. Check polarity again. Polarity must be correct
or this test will be inconclusive because the in-
The following procedure is used to determine if the duced and residual magnetic polarities in the
generator or the PCC control circuitry is causing a exciter stator will be opposed.
high AC voltage shutdown fault. DANGER HIGH VOLTAGE. Touching unin-
1. Throw the line circuit breaker OFF and shut sulated parts inside the control housing
down the set. and power output boxes can result in se-
vere personal injury or death. Measure-
CAUTION This test involves unregulated ments and adjustments must be done with
excitation of the generator. To prevent dam- care to avoid touching high voltage parts.
age to the generator due to overcurrent,
make sure that all loads have been discon- Stand on a dry wooden platform or rubber
nected and that all faults have been cleared insulating mat, make sure your clothing and
from the power output terminals of the gen- shoes are dry, remove jewelry and wear el-
erator. bow length insulating gloves.
6. Start the set and connect the jumper from the
2. Open the control box door and remove plug
battery negative (−) terminal to the XX lead.
P10 from the AVR module.
7. The generator circuitry is probably okay if rated
DANGER Do not perform these proce- output voltage or higher is obtained and the
dures unless fully trained in medium volt- voltages for all phases are balanced when the
age testing procedures and have necessary exciter is powered by a 12 volt battery. Refer to
safety equipment. Severe injury or death Troubleshooting and Repair PCC Manual to
due to high voltage electrical shock may re- troubleshoot the PCC control circuitry. (Normal
sult. excitation voltage ranges from approximately
10 VDC at no-load to approximately 40 VDC at
3. Prepare to measure output voltage across the full−load.)
generator terminals while the set is running.
8. If the voltages are unbalanced, troubleshoot
4. Bring two jumpers from a 12 volt battery for con- the main stator first. If the voltages are uniform-
nection to the X (Field +) and XX (Field −) pins ly low, troubleshoot the exciter and field circuits
of plug P10. first. (Note that in medium-voltage generator
X = Plug P10-6 sets, a defective stepdown transformer could
XX = Plug P10-3 also cause unbalanced output voltages.)

Copyright  2020 Cummins Inc. 4-2

 INSULATION RESISTANCE (MEGGER) & Before these tests can be performed on medium
POLARIZATION INDEX (PI) TESTING voltage generator sets, you must first perform the
generator grounding procedure.
WARNING The windings of medium-voltage
(601 through 15,000 volts) generator sets must Generator Set Grounding Procedure
be dry before the generator is operated. Failure
to make sure windings are dry before start-up Prior to performing service or inspection procedures
may result in catastrophic equipment failure, that may expose personnel to conductors normally
severe personal injury or death. energized with voltages greater than 600 volts, the
following generator set grounding procedure must
The initial condition of the windings should be as- be followed.
sessed both visually and by measurement of insula-
tion resistance to earth using a 500v megger. DANGER Do not perform these procedures

Megger and PI testing must be performed on all unless fully trained in medium voltage ground-
medium voltage (601 through 15,000 volts) genera- ing procedures and have necessary safety
tor sets before initial start-up. Failure to do so, may equipment. Severe injury or death due to high
void generator set warranty. PI testing for low volt- voltage electrical shock may result.
age (less than 600 volts) generator sets is also rec- 1. Open, lock-out and tag-out all sources of power
ommended by Cummins. to the immediate work area.
These tests are used to verify that the windings are 2. Disable the starting system of the generator
dry before the generator set is operated and devel- set:
ops a reference point for future test comparison. a. Move the O/Manual/Auto switch on the
Care should be taken when dealing with windings control panel to the O (OFF) position.
which are suspected of being excessively damp or b. Turn off or remove AC power from the bat-
dirty. The initial measurement of insulation resist- tery charger.
ance should be established using a low voltage c. Press the Emergency Stop button and wait
(500V) megger type instrument and if manually at least 30 seconds before completing
powered the handle should initially be turned slowly. Step d.
Full voltage megger tests or any other form of high d. Remove the negative battery cable (−)
voltage test should not be applied until the windings from the battery.
have been dried out and if necessary cleaned. e. Install a lockout device on the battery cable
CAUTION The AVR plus any voltage trans- end. (For engines equipped with an air-
formers should be disconnected, and any tem- powered starting system, close air valve
perature detector leads (RTDs/thermistors) and install valve locking device.)
should be grounded during the test. Refer to the 3. Put on high voltage gloves with leather protec-
generator wiring diagram for details. tors.

4-3 Copyright  2020 Cummins Inc.

4. Using two pre-tested voltage detection devices 7. With the Grounding Cluster in place, you are
(of the proper rating), verify de-energized con- protected from static and/or induced charges
dition in the work area. (Retest voltage detec- that may have been present in the generator
tion devices immediately after verification of stator.
de-energized condition.) Leave grounds connected for at least one min-
ute so static charge can dissipate. Remove
5, Remove the metal cover from the generator
ground cluster and perform PI and/or any other
output box to gain access to generator load ter-
tests required on the stator winding. Reconnect
minals.
grounds if additional generator service is nec-
6. Securely install the Grounding Cluster ground essary.
clamp to a verified “grounded” conductor. 8. When work on the generator set is complete,
remove the Grounding Cluster in the reverse
WARNING Hazardous voltage. Can cause order of installation.
severe personal injury or death. After DC 9. After getting clearance from all personnel in-
voltage from the test equipment has been volved in the lock-out/tag-out procedure, re-
applied to the windings and ground, there move all lock-out devices in reverse order of
will be a definite static charge on the wind- installation.
ings. Reconnect Grounding Cluster to re-
move static charge from the winding after
each generator test.

Copyright  2020 Cummins Inc. 4-4

Megger and PI Test Definition PI Test: The PI test consists of applying a voltage
between the winding and ground for ten minutes
DANGER Medium-voltage, 601 to 15,000 volts,
and recording resistance values at one minute and
present special hazards of severe personal inju- at ten minutes. The PI is the ratio of a ten minute
ry or death. Even after genset shutdown, an
reading in megohms divided by a one minute read-
electrical shock hazard may still exist, caused
ing in megohms.
by induced voltage within the generator or
cables. Service personnel must be well-trained/
qualified to work with distribution voltages. The polarization index should be in the order of 2 or
(See Generator Set Grounding Procedure in this greater at 20C. (PI = IR10 min / IR1 min )
section.)
IMPORTANT ! The windings have been H.V. If low readings are obtained, the cause should be in-
tested during manufacture and further H.V. test- vestigated and corrected before the generator set is
ing may degrade the insulation with consequent returned to service. If moisture is determined to be
reduction in operating life. Should it be neces- the cause of low test readings, a winding drying pro-
sary to demonstrate H.V. testing, for customer
cess will be required (refer to Drying The Windings
acceptance, the tests must be carried out at re-
procedure in this section).
duced voltage levels (i.e. Test Voltage = 0.8 [2 X
Rated voltage + 1000]).
Megger Test: The megger test consists of applying Insulation Test Procedure
voltage for up to one minute. The highest resistance
values shown in Table 6-1 should be obtained for a 1. Perform the Generator Set Grounding Proce-
new generator with dry windings. For a set that has dure in this section.
been in service, the resistance reading should not
be less than the lower value shown. 2. Open the control box door and remove connec-
tor 10 from the AVR module.
The insulation resistance values quoted are for
windings at an ambient temperature of 20C. It 3. Remove connector 33 from the PT/CT module
should be noted that as winding temperature in- (AC voltage sense leads and CT leads).
creases, values of insulation resistance will signifi-
cantly reduce. Therefore, the reference values for 4. If the RTD (resistance temperature detector)
insulation resistance can only be properly estab- option is installed, ground all six RTD tempera-
lished with windings at a temperature of approxi- ture leads. Each RTD has three leads, one red
mately 20C. and two white leads. Total of 18 leads must be
An approximate guide to allow comparison with val- grounded.
ues taken at other temperatures is to assume that 5. Perform the Insulation Resistance Test and PI
the IR reduces by 50% for every 10C increase in
Test procedures for the desired windings as
temperature. Thus the reduction factors are:
noted in this section.
20C x 1.0
30C x 0.5 If low readings are obtained, the cause should be in-
40C x 0.25 vestigated and corrected before the generator set is
“ “ returned to service.
80C x 0.015 etc.
Should the values be less than the quoted limits, If moisture is determined to be the cause of low test
drying out the generator windings is essential. readings, a winding drying process will be required.

4-5 Copyright  2020 Cummins Inc.

 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 5.0 − 1.0 5.0 − 1.0 5.0 − 1.0
HC6 500 5.0 − 1.0
less
LV7 600 VAC or
500 10 − 1 10 − 1 10 − 1 10 − 1
(P7) less
MV7 600 thru 2500 100 − 50
(P7) 50000 VAC 500 10 − 1
1000 10 − 5
LV80 600 VAC or
(P80) less 500 200 − 100
5−3 10 − 5
(*Combined rotors)
2500 100 − 50
MV80 601 thru 5000
(P80) VAC 500 200 − 100
5−3 10 − 5
(*Combined rotors)
5000 300 − 150
HV80 5001 thru
(P80) 15000 VAC 500 200 − 100
5−3 10 − 5
(*Combined rotors)

* Exciter rotor with diode carrier and main rotor.

Copyright  2020 Cummins Inc. 4-6

 DRYING THE WINDINGS 3. Bolt the generator three phase output terminals
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 CAUTION Voltage must begin at zero volts
generator terminals to heat the windings. This pro- and be gradually increased or equipment
cedure must be done as described or equipment damage will result. The current will increase
damage can result. To do this: rapidly and it must be monitored to prevent
exceeding the generator rating.
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 Test/Manual Operation 12 VDC source for zero voltage, start the set
group, set the parameter Excitation Disable and very slowly increase the excitation voltage.
Override to Excitation Off. (Note that this pa- Obtain the highest current possible without ex-
rameter will return to Excitation On 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.

4-7 Copyright  2020 Cummins Inc.

 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
Note: Before performing the following insulation re- ground and conduct the test. Refer to Table 4-1 for
sistance test, refer to the Insulation Resistance and megger voltage selection and required resistance
Polarization Index Test 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

Copyright  2020 Cummins Inc. 4-8

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 an scale) in both directions. Torque the terminals to 24
ohmmeter, measure electrical resistance between in-lbs (2.6 Nm) when reassembling.
each diode pigtail and the plate on which the diode
is mounted. Reverse the meter test probes and re-
peat the tests. The electrical resistance across CAUTION Layers of dust can cause diodes to
each diode should be high in one direction and low overheat and fail. Brush dust off regularly.
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 (ONE OF SIX)
PIGTAIL FROM THE TERMINAL
AND MEASURE ELECTRICAL
RESISTANCE BETWEEN THE
DIODE PLATES
PIGTAIL AND THE METAL
(TWO)
PLATE UNDER THE DIODE

SURGE SUPPRESSER
REMOVE TO TEST

FIGURE 4-3. TESTING THE ROTATING RECTIFIER ASSEMBLY

4-9 Copyright  2020 Cummins Inc.

 EXCITER ROTOR Note: Before performing the following insulation re-
sistance test, refer to the Insulation Resistance and
Testing Winding Resistance: Disconnect the six Polarization Index Test procedure at the beginning of
this section.
rotor winding leads from the terminal posts on the
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 CR6) CR1 through CR6 and isolate them from ground.
and U (CR1 or CR4). See the winding schematic.
Replace the whole rotor shaft assembly if the resist- Connect the megger between one of the leads and
ance of any winding is not as specified in Tables ground and conduct the test. Refer to Table 4-1 for
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

Copyright  2020 Cummins Inc. 4-10

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

MEASURE WINDING INSULATION

RESISTANCE 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

4-11 Copyright  2020 Cummins Inc.

 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
Note: Before performing the following insulation re- values.
sistance test, refer to the Insulation Resistance and
Polarization Index Test 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

Copyright  2020 Cummins Inc. 4-12

 TABLE 4-2. WINDING RESISTANCE VALUES*

MAIN STATOR
FRAME EXCITER EXCITER MAIN
WINDING WINDING WINDING WINDING
SIZE STATOR ROTOR ROTOR
11 12 17 07
6G 17 0.158 1.44 0.0037 0.0148 N/A 0.011
6H 17 0.158 1.54 0.0027 0.0108 N/A 0.0072
6J 17 0.158 1.73 0.0024 0.0096 N/A 0.006
6K 17 0.158 1.95 0.0019 0.0076 N/A 0.0052
P7B 17.5 0.048 1.67 N/A 0.0016 N/A 0.0026
P7C 17.5 0.048 1.85 N/A 0.00126 N/A 0.0020
P7D 17.5 0.048 1.98 N/A 0.00114 N/A 0.0018
P7E 17.5 0.048 2.17 N/A 0.00093 N/A 0.0015
P7F 17.5 0.048 2.31 N/A 0.00076 N/A 0.0011
P7G 17.5 0.048 2.42 N/A 0.00080 N/A 0.00212

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

4-13 Copyright  2020 Cummins Inc.

 TABLE 4-3. WINDING RESISTANCE VALUES*
VOLTS MAIN EXCITER EXCITER
FRAME SIZE HZ MAIN ROTOR
L-L STATOR STATOR ROTOR
3.3K 50
MV7F 0 1780
0.1780 2 350
2.350 17 0 10
0.10
4.16K 60
3.3K 50
MV7G 0 1360
0.1360 2 760
2.760 17 0 10
0.10
4.16K 60
3.3K 50
MV7H 0 1120
0.1120 1 70
1.70 17 0 10
0.10
4.16K 60
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 approximate, at 68 F (20 C) + 10%.

Copyright  2020 Cummins Inc. 4-14

 TABLE 4-3. WINDING RESISTANCE VALUES (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%.

4-15 Copyright  2020 Cummins Inc.

 TESTING THE PMG 3. Measure voltage across lead pairs P10-1 &
P10-4, P10-4 & P10-5, and P10-5 & P10-1.
DANGER HIGH VOLTAGE. Touching unin-
Voltage should be at least 150 VAC for 50 Hz
sets and at least 180 VAC for 60 Hz sets, and
sulated high voltage parts inside the con-
should be approximately the same for each set
trol and power output boxes will result in
of leads. If the voltages are low or uneven,
severe personal injury or death. Measure-
check all the leads and connections between
ments and adjustments must be done with
the voltage regulator output stage module and
care to avoid touching high voltage parts.
the PMG and repair as necessary before disas-
sembling the PMG.
For your protection, stand on a dry wooden
platform or rubber insulating mat, make 4. Stop the set and measure electrical resistance
sure your clothing and shoes are dry, re- across lead pairs P10-1 & P10-4, P10-4 &
move jewelry and wear elbow length insu- P10-5, and P10-5 & P10-1 with a Wheatstone
lating gloves intended for hazardous volt- bridge or digital ohmmeter.
ages.
TABLE 4-3. PMG STATOR RESISTANCE
1. Open the control box door and remove plug
FRAME SIZE PMG STATOR RESISTANCE
P10 from the AVR module.
HC6/P7 2.6 +10%
2. Start the engine at the set and let the speed sta-
bilize. P80 2.7 +10%

Copyright  2020 Cummins Inc. 4-16

HC6/P7 BEARING INSPECTION/REMOVAL P7 generator component parts cannot be ordered
from Cummins. Refer to the Newage nameplate
The end bearing is enclosed in a pre-packed ma- and supply all available information. Contact your
chined cartridge. 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- 1. Lift slightly on end of rotor shaft and install
ing with it installed, check the color of the grease. wooden shims to hold rotor on center with sta-
The color of the grease is the only indication that can tor.
be used to determine if the bearing is defective.
2. Install bearing onto rotor shaft. Refer to bearing
New grease is a whitish-beige color but some mild kit instruction sheet.
discoloration will occur with use. If the grease shows 3. Install two threaded studs into end bearing car-
signs of gross discoloration, the bearing should be tridge to aid subsequent procedures. Position
replaced. the end bearing cartridge assembly close to
Bearing Removal: The bearing is press fitted onto proper position for hole alignment with end-
the shaft and can be removed with standard work- bracket.
shop tools (i.e., two or three legged manual or hy- 4. Install endbracket to the stator frame using the
draulic bearing pullers). The bearing should only be proper screws and lock washers, but do not
removed for replacement (bearing is destroyed dur- tighten securely as yet.
ing removal and must be replaced).
The end bearing is enclosed in a pre-packed car- 5. Insert and start the threads of the bearing car-
tridge housing and must only be dismantled as nec- tridge fasteners, and remove threaded align-
essary for relubrication, replacement, or when a ment studs, through the endbracket into the
major overhaul is carried out on the generator set. cartridge housing.

P7 Bearing Removal 6. Lift slightly on endbracket and remove wooden

shims holding rotor on center with stator.
1. Remove the endbracket (complete steps 1
through 29 of the Main Stator and Rotor Re- 7. Securely tighten the endbracket fasteners.
moval (P7) procedure. 8. Tighten the bearing cartridge fasteners to 4.5 ft-
2. Remove the four screws holding bearing cap. lbs. (6 Nm) torque.
3. Remove cap. 9. Install the PMG assembly. Refer to Permanent
4. Remove circlip. Magnet (PMG) Installation procedure.

5. Remove bearing cartridge housing complete P7 Bearing Lubrication

with bearing.
A grease fitting is provided to allow re-greasing of
P7 Bearing Replacement
the bearing with a grease gun (see Operator’s
The instruction sheet provided with the bearing kit is manual for grease quantities/type, maintenance in-
required to complete the following procedure. tervals, and procedure).

4-17 Copyright  2020 Cummins Inc.

HC6 Bearing Removal apply pressing force to the inner face of the bearing
only.
1. Remove the endbracket (complete steps 1
through 29 of the Main Stator and Rotor Re- HC6 Bearing Lubrication
moval (P7) procedure.
Bearing Lubrication: When re-lubricating or re-
2. Remove the four screws holding bearing cap placing the bearing, review the following.
3. Remove cap.  Recommended Lubricant: Lithium based
4. Remove circlip. grease, Mobilux No. 2 or Shell Alvania R3.
 Temperature Range: -22F to +248F (-30C to
5. Remove bearing cartridge housing complete
with bearing. +120C).
 Quantity: 2.74 oz. (81 ml). The grease should
HC6 Bearing Replacement be equally divided between the bearing, the
bearing cap cavity, and the bearing cartridge
When replacing bearing onto rotor shaft, be sure to cavity.

Copyright  2020 Cummins Inc. 4-18

 HC6/P7 GENERATOR DISASSEMBLY 2. Remove the three M5X12mm capscrews and
lockwashers from the PMG cover, and remove
The following procedures provide information for re-
cover.
moval and reassembly of the generator PMG excit-
er, the control housing and stator/rotor assemblies. 3. Disconnect the PMG wiring harness connector.
Be sure to read through this section first, before per-
4. Remove the four bolts and clamps retaining the
forming procedures listed, to determine the steps
exciter stator housing to the endbracket.
most appropriate for the service attention required.
DANGER Medium-voltage, 601 to 15,000 volts, 5. Tap the stator housing out of its spigot, and
present special hazards of severe personal inju- carefully remove from generator endbracket.
ry or death. Even after genset shutdown, an
The highly magnetic rotor will attract the stator
electrical shock hazard may still exist, caused
core; care must be taken to avoid any contact
by induced voltage within the generator. Ser- which may damage the windings.
vice personnel must be well-trained/qualified to
work with distribution voltages. 6. Remove the hex head through-bolt from the ro-
tor shaft and firmly pull the complete rotor as-
Permanent Magnet (PMG) Removal sembly from its location. Keep the rotor clean
(HC6/P7) by avoiding contact with metal dust or particles.
1. Disconnect the negative (-) battery cable to Place in a plastic bag as soon as is practicable.
prevent accidental starting of the generator set
while servicing. CAUTION The rotor assembly must not be
dismantled, or the magnetic properties will
WARNING Arcing at battery terminals, arc- be destroyed.
ing in light switch or other equipment,
flame, pilot lights and sparks can ignite bat- Permanent Magnet (PMG) Installation
tery gas causing severe personal injury. (HC6/P7)
Ventilate battery area before working on or 1. Install the complete rotor assembly to the end
near battery—Wear safety glasses—Do not of the main rotor shaft using the hex head
smoke—Switch trouble light ON or OFF through-bolt. Keep the rotor clean by avoiding
away from battery—Stop genset and dis- contact with metal dust or particles.
connect charger before disconnecting bat-
2. Carefully locate the stator housing to position
tery cables—Disconnect negative (−) cable
on the generator endbracket. (The leads must
first and reconnect last.
be located at the top and facing out, Figure 4-2.)
CAUTION Disconnect battery charger Fasten in place using the 4 bolts and clamps,
from AC source before disconnecting bat- and tighten securely.
tery cables. Otherwise, disconnecting
cables can result in voltage spikes damag- The highly magnetic rotor will attract the stator
ing to DC control circuits of the set. core, care must be taken to avoid any contact
which may damage the windings.
WARNING Accidental starting of the gener-
3. Connect the PMG wiring harness connector.
ator set while working on it can cause se-
vere personal injury or death. Prevent acci- 4. Install the PMG assembly cover using the three
dental starting by disconnecting the nega- M5x12mm capscrews and lockwashers, and
tive (−) cable from the battery terminal. tighten securely.

4-19 Copyright  2020 Cummins Inc.

Main Stator and Rotor Removal (HC6/P7) WARNING To prevent personal injury, use
1. Remove the PMG, refer to Permanent Magnet adequate lifting devices to support heavy
Exciter Removal, earlier this section. components. Keep hands and feet clear
while lifting.
2. Remove all access covers from the control
housing. 6. Use a hoist or similar lifting device to support
3. Remove the generator air discharge covers the control housing assembly.
(see Figure 4-1).
7. Loosen the fasteners that secure the control
4. Disconnect all load wires from the reconnection housing side panels to generator. Make sure
terminal block assembly. If equipped with the that hoisting device is controlling weight of con-
circuit breaker option, disconnect load wires trol housing assembly.
from circuit breaker. Check that all leads are la-
beled to ease reassembly. 8. Remove control housing fasteners, and re-
5. Disconnect the remote control wiring between move the control housing assembly from the
generator and control box. For reconnections generator. Replace panel fasteners to their re-
later, make sure each wire is clearly marked to spectable positions for safe keeping, and tight-
indicate the correct terminal. en finger-tight.

CONTROL HOUSING CONTROL HOUSING

ACCESS COVERS
(BOTH SIDES)

PMG
ASSEMBLY
GENERATOR AIR INLET GENERATOR
COVER (ROTATING AIR DISCHARGE
RECTIFIER ACCESS) COVERS

FIGURE 4-7. GENERATOR AND CONTROL HOUSING ASSEMBLY

Copyright  2020 Cummins Inc. 4-20

 CAUTION Do not use fan blade to bar over
engine. That can damage blades and cause GENERATOR
property damage and personal injury. LIFTING
POSITIONS
9. Crank or bar the engine/generator to position
the rotor such that a full pole face is at the bot-
tom of the main stator core. Proper positioning
can be viewed through the generator access
openings. Refer to engine service manual for
proper cranking or barring procedure.

To remove the stator and rotor at the same time,

refer to step 2. To remove the stator and rotor in-
dividually, continue with step 19.

10. Remove the four bolts retaining the bearing

cartridge housing in the endbracket (outer four
bolts). MOUNTING FEET
BRACKETS
11. Remove the eight bolts holding the endbracket
to the generator housing.

12. Insert two bolts (M10) in the two holes provided FIGURE 4-8. HC6 GENERATOR LIFTING POSITIONS
for “jacking” purposes, on the endbracket cen-
ter line. Screw bolts in until endbracket pilot is
GENERATOR
clear of locating recess. LIFTING EYE
LOCATION
13. Carefully tap the whole assembly off the bear-
ing cartridge housing, ensuring the endbracket
is supported to prevent the exciter stator from
damaging the windings on the exciter rotor.

14. The exciter stator is now accessible for inspec-

tion and removal from endbracket/engine
adaptor.

15. The end bearing can now be removed if re-

quired. Refer to Bearing Removal (P7).

WARNING To prevent personal injury, use

adequate lifting devices to support heavy
components. Keep hands and feet clear MOUNTING FEET
while lifting. BRACKET
16. Attach cables of lifting device to generator lift-
ing points as shown on the label attached to the FIGURE 4-9. P7 LIFTING POSITION
generator lifting eye.

4-21 Copyright  2020 Cummins Inc.

17. Remove the fasteners from the four generator 19. Disconnect the grounding strap from the fly-
mounting feet brackets. wheel housing.
20. Using a forklift, position a lifting bar of the forklift
18. Using an adequate lifting device, lift the genera- (inside and inline with the generator) under the
tor (at lifting eyes, and main stator housing) un- rotor shaft. Lift the rotor shaft slightly so that ro-
til the mounting feet brackets are clear of the tor is not resting on inside of stator assembly.
frame member (see Figure 4-7). See Figure 4-8.

STATOR ROTOR
ASSEMBLY ASSEMBLY
LIFT LIFT

USE FORKLIFT OR
OTHER ADEQUATE
LIFTING DEVICE TO
SLIGHTLY LIFT ROTOR
SHAFT UNTIL ROTOR
CAN BE SUPPORTED
BY HOIST/SLING.

STATOR
ROTOR
ASSEMBLY
ASSEMBLY

FIGURE 4-10. REMOVING HC6 STATOR ASSEMBLY

Copyright  2020 Cummins Inc. 4-22

 USE FORKLIFT OR STATOR ROTOR
OTHER ADEQUATE ASSEMBLY ASSEMBLY
LIFTING DEVICE TO LIFT LIFT
SLIGHTLY LIFT ROTOR
SHAFT UNTIL ROTOR
CAN BE SUPPORTED
BY HOIST/SLING.

STATOR ROTOR
ASSEMBLY ASSEMBLY

FIGURE 4-11. REMOVING P7 STATOR ASSEMBLY

4-23 Copyright  2020 Cummins Inc.

21. Verify that the stator is adequately supported CAUTION Drive disc damage can be
and then carefully remove the capscrews from caused by allowing the rotor assembly to
the stator attachment ring. hang on flywheel. Use adequate hoist and
sling to support the rotor assembly.
23. Reposition or add hoist and sling support for the
WARNING To prevent personal injury, use
main rotor, and remove the forklift. See Figure
adequate lifting devices to support heavy 4-12, Rotor Lift detail.
components. Keep hands and feet clear
while lifting. WARNING To prevent personal injury, use
adequate lifting devices to support heavy
components. Keep hands and feet clear
CAUTION Improper stator assembly rig- while lifting.
ging and handling can result in damage to
24. Remove the stator assembly, being careful not
stator and rotor assemblies. Lifting eyes to drag the windings on the rotor. Place stator
may not be at center-of-gravity position of assembly away from the chassis in the horizon-
stator assembly. Therefore, lifting and mov- tal position.
ing the stator assembly alone, by hoisting
25. Using the hoist and sling to support the rotor,
at lifting eyes only, presents the hazard of
carefully remove the capscrews and flat wash-
load imbalance; allowing one end to drop ers that secure the drive discs to the engine fly-
and other end to rise. Make sure the stator is wheel.
adequately hooked/strapped to maintain
level control of stator assembly while lifting WARNING To prevent personal injury, use
and moving. adequate lifting devices to support heavy
components. Keep hands and feet clear
22. Being careful not to drag the windings on the ro- while lifting.
tor, move the stator assembly sufficiently away 26. Remove the rotor assembly and place it on
from engine to sling and support the rotor as- wood blocks in the horizontal position. To avoid
sembly. Do not allow rotor assembly to hang on possible distortion, do not allow the drive discs
engine flywheel. and fan to rest on anything.

STATOR LIFT
(EXAMPLE)

ROTOR LIFT
(EXAMPLE)

FIGURE 4-12. STATOR/ROTOR LIFT EXAMPLE

Copyright  2020 Cummins Inc. 4-24

Generator Assembly Removal (HC6/P7) tor drive discs with the holes of the engine fly-
wheel. Install the capscrews and flat washers
27. Remove the fasteners from the four generator
that secure the drive discs to the engine fly-
mounting feet brackets.
wheel, hand tighten.
28. Using an adequate lifting device, lift the genera-
tor (refer to Step 31). WARNING To prevent personal injury, use
adequate lifting devices to support heavy
29. Disconnect the grounding strap from the fly-
components. Keep hands and feet clear
wheel housing.
while lifting.
30. Carefully remove the capscrews and flat wash-
ers that secure the drive discs to the engine fly- CAUTION Improper generator assembly
wheel. rigging and handling can result in damage
to stator and rotor assemblies. Lifting eyes
31. Verify that the generator assembly is adequate- may not be at center-of-gravity position of
ly supported. Carefully remove the capscrews stator assembly. Therefore, lifting and mov-
securing the engine adaptor endbracket to the ing the generator by hoisting at lifting eyes
engine flywheel housing. only, presents the hazard of load imbal-
WARNING To prevent personal injury, use ance; allowing one end to drop and other
adequate lifting devices to support heavy end to rise. Make sure the generator is ade-
components. Keep hands and feet clear quately hooked/strapped to maintain level
while lifting. control of assembly while lifting and mov-
ing.
CAUTION Improper generator assembly 2. Align the holes of the engine adaptor endbrack-
rigging and handling can result in damage et with the holes in the flywheel housing and
to stator and rotor assemblies. Lifting eyes install the capscrews and lock washers. Tight-
may not be at center-of-gravity position of en fasteners to 95-100 ft-lbs. (129-136 Nm).
stator assembly. Therefore, lifting and mov-
ing the generator by hoisting at lifting eyes 3. Secure the rotor assembly to the flywheel.
only, presents the hazard of load imbal- Tighten fasteners to 150-180 ft-lbs. (204-245
ance; allowing one end to drop and other Nm).
end to rise. Make sure the generator is ade- 4. Connect the grounding strap to the flywheel
quately hooked/strapped to maintain level housing using a capscrew and EIT locking
control of assembly while lifting and mov- washer; and tighten securely.
ing.
5. Install the mounting feet bracket fasteners; and
32. Remove the generator assembly away from tighten securely.
engine. Place generator assembly on floor with
a piece of wood beneath the stator housing (to- If endbracket has been removed, continue with
ward PMG end) to allow for endbracket remov- step 6, otherwise skip to step 14.
al, if desired. 6. Lift slightly on end of rotor shaft and install
wooden shims to hold rotor on center with sta-
Generator Reassembly (HC6/P7) tor.
Generator reassembly is the reverse of disassem- 7. If removed, install end bearing. Refer to Bear-
bly procedure. ing Inspection/Removal/Replacement proce-
Note: To assemble the stator and rotor at the same dure in this section.
time, continue with step 1. To assemble the stator 8. Install two threaded studs into end bearing car-
and rotor individually, skip to step 15. tridge to aid subsequent procedures. Position
1. Using an adequate lifting device, locate the the end bearing cartridge assembly close to
generator assembly into position near the en- proper position for hole alignment with end-
gine flywheel housing. Align the holes of the ro- bracket

4-25 Copyright  2020 Cummins Inc.

 9. Assemble exciter stator, if removed, to inside of WARNING To prevent personal injury, use
endbracket. Tighten fasteners to 4.5 ft-lbs. (6 adequate lifting devices to support heavy
Nm) torque. components. Keep hands and feet clear
10. Install endbracket to the stator frame using the while lifting.
proper capscrews and lock washers, but do not 19. 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.
11. 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. CAUTION Drive disc damage can be
12. Lift slightly on endbracket and remove wooden caused by allowing the rotor assembly to
shims holding rotor on center with stator. hang on flywheel. Use adequate hoist and
sling to support the rotor assembly.
13. Securely tighten the endbracket fasteners.
20. Reassemble engine adaptor endbracket to sta-
14. Tighten the bearing cartridge fasteners to 4.5 ft- tor frame if removed. Using an adequate lifting
lbs. (6 Nm) torque. device, carefully move the stator into position
15. Install the PMG assembly, if removed. Refer to over the rotor assembly, being careful not to
Permanent Magnet Exciter Installation. drag the windings on the rotor.
WARNING To prevent personal injury, use
Perform the ‘Aligning Generator with Engine’
procedures, later in this section, then return to adequate lifting devices to support heavy
the following steps. components. Keep hands and feet clear
while lifting.
If the stator and rotor are not separated, skip to
step 36. CAUTION Improper stator assembly rig-
ging and handling can result in damage to
To assemble the stator and rotor individually be- stator and rotor assemblies. Lifting eyes
gin here. may not be at center-of-gravity position of
16. If removed, replace exciter rotor and rotating stator assembly. Therefore, lifting and mov-
rectifier assembly to main rotor shaft. Recon- ing the stator assembly alone, by hoisting
nect main rotor wire leads to positive and nega- at lifting eyes only, presents the hazard of
tive terminals of rectifier assembly. load imbalance; allowing one end to drop
and other end to rise. Make sure the stator is
17. If removed, install the drive disk spacer, drive adequately hooked/strapped to maintain
disc and pressure plate on the rotor shaft. level control of stator assembly while lifting
Install the cap screws and flat washers and and moving.
tighten to 607 ft-lbs. (822 Nm).
21. Using a forklift, position a lifting bar of the forklift
18. 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.

Copyright  2020 Cummins Inc. 4-26

22. Remove the hoist/sling support of the rotor as- 32. Securely tighten the endbracket fasteners.
sembly. Align the holes of the engine adaptor 33. Tighten the bearing cartridge fasteners to 4.5 ft-
endbracket with the holes in the flywheel hous- lbs. (6 Nm) torque.
ing and install the capscrews and lock washers.
Tighten fasteners to 95-105 ft-lbs. (129-142 34. Install the PMG assembly, if removed. Refer to
Nm). Permanent Magnet Exciter Installation.
23. Connect the grounding strap to the flywheel Perform the ‘Aligning Generator with Engine’
housing using a capscrew and EIT locking procedures, later in this section, then return to
washer; and tighten securely. step 36.
24. Install the mounting feet bracket fasteners; and WARNING To prevent personal injury, use
tighten securely. adequate lifting devices to support heavy
25. Lift slightly on end of rotor shaft and install components. Keep hands and feet clear
wooden shims to hold rotor on center with sta- while lifting.
tor. 35. Use an adequate lifting device to lift the control
housing in position for mounting to the stator
26. If removed, install end bearing. Refer to Bear-
frame. Replace the capscrews and lock wash-
ing Inspection/Removal/Replacement proce-
ers and tighten to 20 ft-lbs. (27 Nm) torque.
dure in this section.
36. Connect all control wires and generator leads
27. Install two threaded studs into end bearing car-
using the proper generator set AC and DC wir-
tridge to aid subsequent procedures. Position
ing diagram/schematic.
the end bearing cartridge assembly close to
proper position for hole alignment with end- 37. Reassemble the covers over the generator air
bracket. discharge openings and fasten securely.
28. Assemble exciter stator, if removed, to inside of 38. Reassemble any engine air intake components
endbracket. Tighten fasteners to 4.5 ft-lbs. (6 removed during generator disassembly.
Nm) torque. 39. Refer to Permanent Magnet Installation.
29. Install endbracket to the stator frame using the 40. If equipped with the circuit breaker option, re-
proper capscrews and lock washers, but do not connect load wires to circuit breaker. Recon-
tighten securely as yet. nect all lead wires to the terminal block assem-
30. Insert and start the threads of the bearing car- bly.
tridge fasteners, and remove threaded align- 41. Verify that all connections are proper and se-
ment studs, through the endbracket into the cure and then install access covers to control
cartridge housing. housing.
31. Lift slightly on endbracket and remove wooden 42. Connect the negative (−) battery cable and test
shims holding rotor on center with stator. the generator set for operation.

4-27 Copyright  2020 Cummins Inc.

 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 ser-
chined cartridge. A grease fitting is provided to allow vice manual for proper cranking or barring pro-
re-greasing of the bearing with a grease gun (see cedure.
Operator’s manual for grease quantities, mainte-
nance intervals, and procedure). 7. Remove the four bolts retaining the bearing
cartridge housing in the endbracket (outer four
Bearing Inspection: If a situation occurs which al- bolts).
lows an opportunity to visually inspect the end bear- 8. Remove the eight bolts holding the endbracket
ing with it installed, check the color of the grease. to the generator housing.
The color of the grease is the only indication that can
be used to determine if the bearing is defective. 9. To support the end bracket and rotor during end
bracket to frame removal, attach a suitable
New grease is a whitish-beige color but some mild sling with a pair of hooks located into two of the
discoloration will occur with use. If the grease shows end bracket inspection holes. The lifting capac-
signs of gross discoloration, the bearing should be ity will vary according to the generators core
replaced. length, but could be as much as 11,685 pounds
(5300 kg).
Bearing Removal: The bearing is press fitted onto
10. Insert two bolts (M10) in the two holes provided
the shaft and can be removed with standard work-
for “jacking” purposes, on the endbracket cen-
shop tools (i.e., two or three legged manual or hy-
ter line. Screw bolts in until endbracket spigot
draulic bearing pullers). The bearing should only be
is clear of locating recess.
removed for replacement (bearing is destroyed dur-
ing removal and must be replaced). 11. Carefully tap the whole assembly off the bear-
1. Remove the PMG (see Permanent Magnet Re- ing cartridge housing, ensuring the endbracket
moval procedure). is supported to prevent the exciter rotor from
dropping onto the exciter field bore.
2. Disconnect PMG stator leads P2, P3, and P4.
WARNING To prevent personal injury, use
3. Remove external bearing lubricating pipe. Note
adequate lifting devices to support heavy
component locations before removal to aid in
components. Keep hands and feet clear
re-assembly.
while lifting.
4. Remove the four bolts retaining the outer bear- 12. Remove bearing cartridge housing complete
ing cap and remove the outer bearing cap and with bearing.
PMG stator as an assembly, taking care not to
damage the PMG stator windings. 13. The cartridge housing contains an O-ring which
should be examined and replaced if worn.
5. Remove wave washer and circlip on the outer
side of the bearing inner race.

Copyright  2020 Cummins Inc. 4-28

 Bearing Replacement: THE INSTRUCTION proper position for hole alignment with end-
SHEET PROVIDED WITH THE BEARING KIT IS bracket.
REQUIRED TO COMPLETE THE FOLLOWING 4. Install endbracket to the stator frame using the
PROCEDURE. proper screws and lock washers, but do not
P80 generator component parts cannot be ordered tighten securely as yet.
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 6. Lift slightly on endbracket and remove wooden
wooden shims to hold rotor on center with sta- shims holding rotor on center with stator.
tor.
7. Securely tighten the endbracket fasteners.
2. Install bearing onto rotor shaft. Refer to bearing
kit instruction sheet. 8. Tighten the bearing cartridge fasteners to 4.5 ft-
lbs. (6 Nm) torque.
3. Install two threaded studs into end bearing car-
tridge to aid subsequent procedures. Position 9. Install the PMG assembly. Refer to Permanent
the end bearing cartridge assembly close to Magnet (PMG) P80.

4-29 Copyright  2020 Cummins Inc.

 P80 GENERATOR DISASSEMBLY CAUTION Use shims between all poles to
maintain air gap between rotor and stator
The following procedures provide information for re-
during generator removal or permanent
moval and reassembly of the generator PMG excit-
damage to exciter and PMG assembly will
er and generator assembly from the engine and re-
occur.
moval 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
DANGER Medium-voltage, 601 to 15,000 volts,
to the exciter and PMG assembly. Minimum air
present special hazards of severe personal inju-
gap is 0.2 inch (5 mm). Normal air gap is
ry or death. Even after genset shutdown, an
approximately 0.3 inch (7.5 mm).
electrical shock hazard may still exist, caused
by induced voltage within the generator. Ser- 4. Disconnect all load wires from the reconnection
vice personnel must be well-trained/qualified to terminal block assembly. If equipped with the
work with distribution voltages. circuit breaker option, disconnect load wires
from circuit breaker. Check that all leads are la-
Generator Assembly Removal beled to ease reassembly.
1. Remove the generator air discharge covers. 5. Disconnect remote control wiring between gen-
erator and control box. For reconnections later,
CAUTION Do not use fan blade to bar over
make sure each wire/plug is clearly marked to
engine. That can damage blades and cause
indicate the correct terminal.
property damage and personal injury
2. Crank or bar the engine/generator to position 6. Remove as necessary, air intake components
the rotor such that a full pole face is at the bot- to engine that may interfere with removal of the
tom of the main stator core. Proper positioning generator assembly.
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.

Copyright  2020 Cummins Inc. 4-30

 8. Remove the fasteners from the four generator CAUTION Improper generator assembly
mounting feet brackets. rigging and handling can result in damage
9. Disconnect the grounding strap from the fly- to stator and rotor assemblies. Make sure
wheel housing. the generator is adequately hooked/
10. Remove the capscrews and flat washers that strapped to maintain level control of assem-
secure the drive discs to the engine flywheel. bly while lifting and moving.
11. Remove the capscrews securing the engine 12. Remove the generator assembly away from
adaptor endbracket to the engine flywheel engine. Place generator assembly on the floor
housing. using wood blocks under the four mounting feet
brackets so that the stator does not rest on the
WARNING To prevent personal injury, use floor (Figure 4-13) and also to prevent the gen-
adequate lifting devices to support heavy erator from rolling.
components. Keep hands and feet clear
while lifting.

WOOD
BLOCKS

FIGURE 4-13. TYPICAL GENERATOR SUPPORTED BY BLOCKS

4-31 Copyright  2020 Cummins Inc.

Generator Reassembly (P80) install the capscrews and lock washers. Tight-
en fasteners to 85-100 ft-lbs. (116-136 Nm).
Generator reassembly is the reverse of disassem-
bly procedure. 3. Secure the rotor assembly to the flywheel.
1. Using an adequate lifting device, locate the Tighten fasteners to 150-180 ft-lbs. (204-245
generator assembly into position near the en- Nm).
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. WARNING To prevent personal injury, use
adequate lifting devices to support heavy
WARNING To prevent personal injury, use
components. Keep hands and feet clear
adequate lifting devices to support heavy while lifting.
components. Keep hands and feet clear
while lifting. 4. Reassemble any engine air intake components
removed during generator disassembly.
CAUTION Improper generator assembly
5. Connect all control wires and generator leads.
rigging and handling can result in damage
to stator and rotor assemblies. Make sure 6. If equipped with the circuit breaker option, re-
the generator is adequately hooked/ connect load wires to circuit breaker. Recon-
strapped to maintain level control of assem- nect all lead wires to the terminal block assem-
bly while lifting and moving. 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.

Copyright  2020 Cummins Inc. 4-32

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.
WARNING Arcing at battery terminals, arc- 6. Remove the hex head through-bolt from the ro-
ing in light switch or other equipment, tor shaft and firmly pull the complete rotor as-
flame, pilot lights and sparks can ignite bat- sembly from its location. Keep the rotor clean
tery gas causing severe personal injury. by avoiding contact with metal dust or particles.
Ventilate battery area before working on or Place in a plastic bag as soon as is practicable.
near battery—Wear safety glasses—Do not
CAUTION The rotor assembly must not be
smoke—Switch trouble light ON or OFF
away from battery—Stop genset and dis- dismantled, or the magnetic properties will
connect charger before disconnecting bat- be destroyed.
tery cables—Disconnect negative (−) cable
Permanent Magnet (PMG) Installation
first and reconnect last.
(P80)
CAUTION Disconnect battery charger
1. Install the complete rotor assembly to the end
from AC source before disconnecting bat- of the main rotor shaft using the hex head
tery cables. Otherwise, disconnecting through-bolt. Keep the rotor clean by avoiding
cables can result in voltage spikes damag- contact with metal dust or particles.
ing to DC control circuits of the set.
2. Carefully locate the stator housing to position
WARNING Accidental starting of the gener- on the generator endbracket. Fasten in place
ator set while working on it can cause se- using the 4 bolts and clamps, and tighten se-
vere personal injury or death. Prevent acci- curely.
dental starting by disconnecting the nega-
tive (−) cable from the battery terminal. 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.

4-33 Copyright  2020 Cummins Inc.

 ALIGNING GENERATOR WITH ENGINE flex in alternate directions twice for each engine rev-
olution. It is important to minimize the amount of disc
Proper alignment of the generator and engine as- 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
Angular Misalignment: 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 crankshaft Excessive Axial misalignment will cause more gen-
axis. The cause of this type of misalignment is usu- erator vibration than Angular misalignment.
ally shimming error. Note: Axial misalignment should be checked only
Axial Misalignment: Is the result of the generator when an 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-
Misalignment Symptoms: If the assembly is al- tions and/or mishandling during shipping of the gen-
lowed to run under these conditions, the discs must set.

Copyright  2020 Cummins Inc. 4-34

Angular Alignment Procedure disc at the bolt circle diameter, see Figure 4-14. Bar
the engine over in a clockwise rotation as viewed
WARNING Accidental starting of the generator from engine flywheel. Do not allow it to roll back on
set during this procedure presents the hazard of compression at the end of the travel of each read-
severe personal injury or death. Make sure to ing. It is unnecessary to zero the indicator since the
disconnect the negative (−) battery cable(s) be- total indicator reading (T.I.R.) of the deflection mea-
fore beginning. 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.

DIAL
CLAMP INDICATOR

GENERATOR AND MOUNTING BOLT

ENGINE TO DISC HC6 AXIAL
CRANKSHAFT MEASUREMENT ALIGNMENT, SEE
CENTERLINE FIGURE 4-15
SHIMS FLEX
DISCS

FIGURE 4-14. ANGULAR ALIGNMENT MEASUREMENT

4-35 Copyright  2020 Cummins Inc.

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 4-14. (For exam-
make a diagram similar to the example shown in ple; a HC6 Frame’s distance is 28.4”.)
Figure 4-15, 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. This ple, .025” divided by 2 is .0125”. This, times
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 a
the generator shaft to the point the indicator is 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.)

+.010
+.010
MEASURED AT
BOLT CIRCLE
DIAMETER

-.002
-.004

10.7 IN.

-.010
-.010

-.015
-.015

FIGURE 4-15. ANGULAR ALIGNMENT MEASUREMENT READINGS (Example)

Copyright  2020 Cummins Inc. 4-36

HC6 Axial Alignment Procedure varying surface quality of the generator shaft’s drive
disc mountain hub.
Note: Axial misalignment needs to be checked only
when an objectionable vibration is present. The goal of the Axial realignment is to reduce the
vibration level of the genset while it is operating. A
If excessive vibration remains after the angular small improvement in the T.I.R. runout may have
alignment, check for concentric alignment of the dramatic effects in the mechanically measured or
generator shaft/engine crankshaft axes. physically observed vibration levels.
Fasten dial indicator holding device to skid base, To correct for an out of tolerance T.I.R. indication, re-
engine block, or generator shell with a magnetic move the capscrews connecting drive discs and fly-
base or clamp and position so the sensor point of in- wheel. Mark the drive discs and flywheel with re-
dicator rests on the generator shaft hub, see Figure spect to each other. Rotate either the engine or gen-
6-15. Bar the engine over in a clockwise rotation as erator so that drive discs holes are repositioned 180
viewed from engine flywheel, through a couple of degrees from their original location. Put the drive
rotations. Record indicator readings in eight equally discs capscrews back in and retorque. Recheck
spaced points around the shaft diameter. This will shaft alignment as before. If shaft T.I.R. runout re-
provide a T.I.R. for Axial shaft misalignment. mains unchanged then the discs should be rotated
The maximum allowable T.I.R. runout is subjective, to either 30, 60, or 90 degrees from original location
the optimal T.I.R. for runout would be .000”, howev- to correct the out of tolerance condition. If the T.I.R.
er, that may not be attainable. The recommendation does not improve after repositioning, a closer in-
of this procedure will be to reduce the measured spection of the flywheel pilot and drive disc runouts
T.I.R. runout by one half. Specific out-of-tolerance is required. This will help determine the cause of the
runout levels are difficult to establish due to the Axial misalignment.

ANGULAR ALIGNMENT,
SEE FIGURE 6-15

GENERATOR
SHAFT HUB

DIAL
INDICATOR

GENERATOR
CLAMP
AND ENGINE
CRANKSHAFT SEE DETAIL A FAN HOUSING
CENTERLINE
DETAIL A

FIGURE 4-16. HC6 AXIAL ALIGNMENT MEASUREMENT

4-37 Copyright  2020 Cummins Inc.

P7/P80 Axial Alignment Procedure To correct for possible axial misalignment, remove
the capscrews connecting drive discs and flywheel.
Note: Axial misalignment needs to be checked only Mark the drive discs and flywheel with respect to
when 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 holes
alignment, concentric alignment of the generator from their original location. Put the drive discs caps-
shaft/engine crankshaft axes may be at fault. crews back in and retorque. Recheck/record vibra-
tion levels as before. Repeat this test until the drive
The goal of the axial realignment is to reduce the
discs holes are repositioned 180 degrees from their
vibration level of the genset while it is operating. A
original location.
small improvement in the axial alignment may have
dramatic effects in the measured or physically ob- Review vibration data and position drive disc in low-
served vibration levels. est recorded level location.

Copyright  2020 Cummins Inc. 4-38

5. Enclosure Fuel Tank System(DQFAA−AD)

GENERAL PCC Customer Inputs

This section describes the operation and testing of
the components of the optional fuel tank system PCC Customer Fault Inputs 3 (Low Fuel) and 4
shown in Figure 5-1.
(Rupture Basin) are prewired to the sub-base fuel
When a sub-base fuel tank is provided, a fuel trans- tank when shipped from the factory.
fer pump with control and external or internal fuel
alarm panel are available as options.
The “Low Fuel” warning message, when displayed
WIRING CONNECTIONS by the PCC, indicates that the fuel level has dropped
below the low fuel level (approximately 62%).
Fuel Transfer Control Customer Outputs
See Enclosure/Options Wiring (DQFAA−DQFAD)
diagram in Section 6 for customer connections to re- The “Rupture Basin” warning message is used to in-
mote annunciators. dicate that fuel is detected in the fuel tank basin.

FUEL TRANSFER EXTERNAL

PUMP AND CONTROL FUEL ALARM
PANEL

INTERNAL FUEL
ALARM PANEL

FIGURE 5-1. FUEL TANK SYSTEM OPTIONAL COMPONENTS

5-1 Copyright  2020 Cummins Inc.

 FUEL TRANSFER PUMP  SYSTEM TEST: This switch will test all front
panel lamps and activate pump/motor for as
The fuel transfer pump and control are available as long as the switch is in the System Test posi-
an option when a sub-base fuel tank is provided. tion. All alarm relays will not activate but will
The automatic control operates the fuel pump to maintain their original state.
maintain a reservoir of fuel in the sub-base tank.
 RESET: This switch will reset the control sys-
This section explains functions of the control panel tem after a latched alarm event.
lamps, components and operation/testing of the day
tank fuel control system.
Operation
Control Panel Switches and Indicators
The following paragraphs describe the operation of The following steps describe how to operate the day
the control switches and indicators. tank controller.

Indicators: 1. Activate the control ON switch for automatic op-

 POWER: indicates that AC power is available eration. The PUMP light will come on and the
to the control. pump will fill the tank. The level of fuel in the
tank will be automatically kept between a set of
 PUMP: indicates that the fuel pump is running.
pump-on and pump-off float gauge switches.
It will go on and off as fuel is pumped to maintain
the fuel tank level. 2. The PUMP light indicates when the pump is
 CRITICAL HIGH: indicates that the fuel has running. It will go on and off as fuel is pumped to
reached an abnormally high level. It indicates a maintain the proper level in the tank.
possible failure of the ”pump-off” float gauge in
the sub-base tank. The lamp will turn off when
the fuel level drops to normal.
 LOW FUEL SUPPLY TANK: indicates that the
fuel level in the main fuel tank has dropped be-
low the customer set low fuel level. This signal
is used by the fuel system control to stop the op-
eration of the fuel transfer pump to prevent
pump damage. The control will enable the fuel
transfer pump operation after tank fuel level is
restored.
 RUPTURE BASIN: indicates that the fuel has
flooded the safety basin surrounding the fuel
tank. The basin float switch turns off the fuel
pump. The pump cannot function again until
the basin is drained of fuel. Possible cause,
leak in fuel tank.
Switches:
 ON: This switch activates the control.
 OFF: This switch disables the control for rou-
tine maintenance to the tank system without
disrupting the control.
 TEST: This switch will activate the pump for as
long as the switch is in the Test position. All
alarm functions will operate accordingly. Pump-
on and pump-off float switches will remain de- FIGURE 5-2. TRANSFER PUMP CONTROL FRONT
energized. PANEL

Copyright  2020 Cummins Inc. 5-2

 EXTERNAL/INTERNAL ALARM PANELS The horn can be turned off by pressing the mute but-
ton. The indicator will turn off when the fuel level
drops to normal.
The following paragraphs describe the operation of
the external/internal alarm panel components. Fuel Gauge

Overfill Indicator/Horn/Silence Button Indicates the amount of fuel that is contained in the
sub-base tank.
The overfill alarm Indicates that the fuel has Test Button
reached an abnormally high level (95%). Immedi-
ately stop adding fuel. It also indicates a possible Press the TEST switch to test the indicator light and
failure of the “pump-off” float gauge for fuel systems the horn. The test will remain active for as long as
that contain the fuel transfer pump. the button is pressed.

OVERFILL
INDICATOR/ FUEL
TEST BUTTON GAUGE

HORN

HORN
SILENCE
BUTTON
HORN SILENCE/
TEST BUTTON

INTERNAL ALARM PANEL

HORN

EXTERNAL ALARM PANEL

FIGURE 5-3. EXTERNAL AND INTERNAL ALARM PANELS

5-3 Copyright  2020 Cummins Inc.

RUPTURE BASIN LEAK DETECT SWITCH 1. Move the O/Manual/Auto switch to the MANU-
TEST AL position.

The rupture basin leak detect switch (Figure 5-4) is 2. Activate leak detect switch (move float up-
provided with sub-base fuel tanks used with the op- ward).
tional enclosure. This switch should be checked
once a year to make sure switch is properly operat- 3. Check control display for Rupture Basin fault
ing. In some areas, weekly inspections may be re- message. If no indication of fault, repair defec-
quired by safety code regulations. tive circuit. Refer to Enclosure/Options Wiring
(DQCA−DQCC) diagram in Section 6.
To test the leak detect switch:
1. Remove the pipe fitting/switch assembly from 4. Apply thread sealant to pipe fitting and install
the rupture basin tank. switch assembly.

ENCLOSURE
SUB-BASE
LEAK DETECT FUEL TANK
SWITCH ASSEMBLY

FIGURE 5-4. RUPTURE BASIN LEAK DETECT SWITCH

Copyright  2020 Cummins Inc. 5-4

6. Troubleshooting

GENERAL Ventilate battery area before working on or near

battery—Wear goggles—Stop genset and dis-
connect charger before disconnecting battery
The generator set control continuously monitors the cables—Disconnect negative (−) cable first and
engine for abnormal conditions when genset is op- reconnect last.
erating, such as low oil pressure and high coolant
temperature. If any of these conditions occur, the CAUTION Disconnect battery charger from AC
control will light a yellow Warning lamp or a red source before disconnecting battery cables.
Shutdown lamp and display a message on the Otherwise, disconnecting cables can result in
graphical display. voltage spikes damaging to DC control circuits
of the set.
In the event of an engine shutdown fault (red Shut- WARNING Accidental starting of the generator
down lamp), the control will stop the engine immedi- set can cause severe personal injury or death.
ately; an alternator shutdown fault, the engine will Prevent accidental starting by disconnecting
stop after the cool-down timer has timed out. If the the negative (−) cable from the battery terminal.
generator set is stopped for this reason, the opera-
tor can restart the set after making adjustments or When troubleshooting a set that is shut down, make
corrections. This section lists the warning and shut- certain the generator set cannot be accidentally re-
down codes/messages (Table 4-1), and suggests started as follows:
troubleshooting procedures (Table 4-2).
1. Move the O/Manual/Auto switch on the control
panel to the O (off) position.
Note: Displayed error codes that are not listed in
Table 4-2 will require an authorized service represen- 2. Turn off or remove AC power from the battery
tative to correct the fault. Contact an authorized ser- charger.
vice center for assistance.
3. Remove the negative (−) battery cable from the
generator set starting battery.
SAFETY CONSIDERATIONS
STATUS INDICATORS
WARNING Contacting high voltage compo- Not In Auto Indicator: This red lamp flashes con-
nents can cause electrocution, resulting in se- tinuously when the 0/Manual/Auto switch is not in
vere personal injury or death. Keep the output the Auto position (Figure 4-1).
box covers in place during troubleshooting.
Shutdown Status Indicator: This red lamp is lit
whenever the control detects a shutdown condition.
High voltages are present when the generator set is
After the condition is corrected, the shutdown indi-
running. Do not open the generator control box or
cator can be reset by turning the 0/Manual/Auto
the circuit breaker box while the generator set is run-
switch to the 0 position, and pressing the Fault Ac-
ning.
knowledge button. The generator set can not be
started when this lamp is on.
WARNING Ignition of explosive battery gases
can cause severe personal injury or death. Arc- Warning Status Indicator: This yellow lamp is lit
ing at battery terminals, light switch or other whenever the control detects a warning condition.
equipment, flame, pilot lights and sparks can ig- After the condition is corrected, the warning indica-
nite battery gas. Do not smoke, or switch trouble tor can be reset by pressing the Fault Acknowledge
light ON or OFF near battery. Discharge static button. (It is not necessary to stop the generator set
electricity from body before touching batteries if the fault becomes inactive during genset opera-
by first touching a grounded metal surface. tion.)

6-1 Copyright  2020 Cummins Inc.

 READING FAULT CODES power output box. If the load exceeds the circuit
breaker current rating, the line circuit breaker will
Refer to History/About Submenus in Section 3, open. If the circuit breaker trips, locate the source of
which describes how to view fault codes using the the overload and correct as necessary. Manually re-
graphical display. set the breaker to reconnect the load to the genera-
tor.
After the fault is acknowledged and corrected, the
recorded fault will be deleted from the control panel CONTROL AND DIAGNOSTICS VIA
memory, but will remain in a data log to maintain a NETWORK OR PERSONAL COMPUTER
fault code history. The InPower service tool is re- (LAPTOP)
quired to view this data log.
See your authorized Cummins dealer regarding
LINE CIRCUIT BREAKER (OPTIONAL) software, hardware and network requirements for
control and diagnostics via network or personal
The optional line circuit breaker is mounted on the computer.

Copyright  2020 Cummins Inc. 6-2

 SHUTDOWN,
WARNING
STATUS
INDICATORS

FAULT
ACKNOWLEDGE
BUTTON

STATE LINE
ACTION LINE
DESCRIPTION LINE
MENU DISPLAY
AREA

OPERATOR SWITCH
GRAPHICAL
PANEL PANEL
DISPLAY

FIGURE 4-1. FRONT CONTROL PANEL (FULL-FEATURED)

6-3 Copyright  2020 Cummins Inc.

 FAULT CODES critical loads and cannot be shut down. Requires re-
pair by trained and experienced service personnel.
The fault codes have been divided into five catego- Category C Fault Codes: Consist of faults that do
ries to help you determine what corrective action to not affect generator set performance but require
take for safe operation of the generator set. Use qualified service personnel to repair. These codes
Table 4-1 to find the category (CTG) and fault de- indicate a defective harness or wiring problem.
scription for all codes. Gaps in the code numbers
are for codes that do not apply to this genset These codes can also indicate a defective engine
model. Also, some of the codes listed are fea- sensor, leaving no engine protection. (Engine dam-
ture dependent, and will not be displayed by this age can occur without detection.) Continued op-
genset control. eration may void generator set warranty if dam-
age occurs that relates to fault condition.
Category A Fault Codes: Pertain to engine or al-
ternator shutdown faults that require immediate re- Category D Fault Codes: Consist of faults that are
pair by trained and experienced service personnel repairable by site personnel. Service will be re-
(generator set non-operational). Control prevents quired by trained and experienced service person-
the generator set from being restarted if shutdown nel if site personnel cannot resolve the problem af-
fault is not corrected. ter taking the corrective actions suggested in Table
4-2.

Category B Fault Codes: Consist of faults that can Category E Fault Codes: Indicates non-critical op-
affect generator set performance or can cause en- erational status of generator set, external faults, or
gine, alternator, or connected equipment dam- customer fault inputs. May require repair by trained
age. Operate generator set only when it is powering and experienced service personnel.

Copyright  2020 Cummins Inc. 6-4

 TABLE 4-1. FAULT CODES
CTG CODE LAMP DISPLAYED MESSAGE CTG CODE LAMP DISPLAYED MESSAGE
A 111 Shtdn Internal ECM error A 254 Shtdn Fuel shutoff valve
A 112 Shtdn Actuator not responding C 259 Wrng Fuel shutoff valve
B 113 Wrng Actuator sensor fault C 261 Wrng Fuel temperature sensor
A 115 Shtdn No speed signal C 263 Wrng Fuel temperature sensor
A 116 Shtdn Time press sensor high C 265 Wrng Fuel temperature sensor
A 117 Shtdn Time press sensor low A 266 Shtdn Fuel temperature
B 118 Wrng Pump press sensor high B 316 Wrng Fuel supply pump
B 119 Wrng Pump press sensor low B 318 Wrng Fuel supply pump
C 121 Wrng No engine speed signal D 326 Wrng Oil level warning
B 122 Wrng Manifold air press sensor B 343 Wrng Internal ECM error
B 123 Wrng Manifold air press sensor D 359 Wrng Engine failed to start
C 135 Wrng Oil pressure sensor A 378 Wrng Fueling actuator #1
C 141 Wrng Oil pressure sensor A 379 Wrng Fueling actuator #1
B 143 Wrng Low oil pressure A 394 Wrng Fueling actuator #1
C 144 Wrng Coolant temperature sensor A 395 Wrng Fueling actuator #1
C 145 Wrng Coolant temperature sensor A 396 Wrng Fueling actuator #2
D 146 Wrng High coolant temp warning A 397 Wrng Fueling actuator #2
D 151 Shtdn High coolant temp alarm A 398 Wrng Fueling actuator #2
D 152 Wrng Low coolant temp A 399 Wrng Fueling actuator #2
C 153 Wrng Manifold air temp sensor A 415 Shtdn Low oil pressure alarm
C 154 Wrng Manifold air temp sensor B 421 Wrng High oil temperature
A 155 Shtdn Manifold air temp alarm B 423 Wrng Fuel timing
D 197 Wrng Coolant level warning D 441 Wrng Low battery voltage
C 212 Wrng Oil temperature sensor D 442 Wrng High battery voltage
C 213 Wrng Oil temperature sensor B 449 Wrng High fuel supply pressure
A 214 Shtdn High oil temperature B 451 Wrng Fuel rail pressure sensor
C 221 Wrng Air pressure sensor B 452 Wrng Fuel rail pressure sensor
C 222 Wrng Air pressure sensor A 455 Shtdn Fuel control valve sensor
A 228 Shtdn Low coolant pressure B 467 Wrng Timing rail act sensor
C 231 Wrng Coolant pressure sensor B 468 Wrng Fuel rail actuator sensor
C 232 Wrng Coolant pressure sensor D 471 Wrng Low oil level
B 233 Wrng Coolant pressure warning B 482 Wrng High fuel supply pressure
A 234 Shtdn Overspeed B 488 Wrng High intake manifold temp
D 235 Shtdn Coolant level alarm C 498 Wrng Oil level sensor
A 236 Shtdn Position sensor C 499 Wrng Oil level sensor
D 253 Shtdn Oil level alarm A 514 Shtdn Fuel control valve

6-5 Copyright  2020 Cummins Inc.

 TABLE 4-1. FAULT CODES (CONT.)
CTG CODE LAMP DISPLAYED MESSAGE CTG CODE LAMP DISPLAYED MESSAGE
B 546 Wrng Fuel pressure sensor E 1318 Shtdn/ Customer input #4
B 547 Wrng Fuel pressure sensor Wrng

B 554 Wrng Fuel rail pressure sensor B 1319 Wrng High alternator temp
B 555 Wrng Blowby pressure C 1321 Wrng Common warning driver
A 556 Shtdn Blowby pressure A 1322 Shtdn Load gov kW setpoint oor hi
A 586 Shtdn Run/Stop switch A 1323 Shtdn Load gov kW setpoint oor lo
A 587 Shtdn Run/Stop switch B 1324 Wrng Load gov kVAR oor hi
D 611 Wrng Engine hot B 1325 Wrng Load gov kVAR oor lo
D 688 Shtdn High oil level alarm B 1326 Wrng Backup starter disconnect
B 689 Wrng Crank shaft sensor A 1327 Shtdn Load gov kW analog oor
B 719 Wrng Blowby pressure sensor D 1328 Wrng Genset CB tripped
B 729 Wrng Blowby pressure sensor B 1329 Wrng AVR DC power failure
B 731 Wrng Cam/Crank misalignment A 1331 Shtdn AVR driver shorted
B 778 Wrng Camshaft sensor A 1332 Shtdn Manual switch oor lo
C 1118 Wrng Prelube relay driver A 1333 Shtdn Manual switch oor hi
A 1121 Shtdn Failed to Disconnect A 1334 Shtdn Critical scaler oor
C 1219 Wrng Utility CB tripped
B 1335 Wrng Non critical scaler oor
C 1222 Wrng Power transfer not in auto
E 1336 None Cooldown complete
C 1223 Wrng Utility frequency sensor
E 1337 None Network wink
C 1224 Wrng Gen over voltage sensor
E 1341 Shtdn Load demand stop
C 1225 Wrng Gen under voltage sensor
A 1342 Shtdn Slot 0 card
C 1226 Wrng genset frequency sensor
A 1343 Shtdn Slot 1 card
E 1311 Shtdn/ Customer input #1
Wrng A 1345 Shtdn Slot 3 card
E 1312 Shtdn/ Customer input #2 A 1346 Shtdn Slot 4 incorrect
Wrng C 1351 Wrng Slot 4 / network enabled
E 1313 Shtdn/ Network Fault 1 C 1414 Wrng Run relay contact
Wrng
C 1415 Wrng Run relay driver
E 1314 Shtdn/ Network Fault 2
Wrng D 1417 Wrng Power down error
E 1315 Shtdn/ Network Fault 3 B 1419 Wrng Fuel rail driver
Wrng
B 1421 Wrng Timing rail driver #1
E 1316 Shtdn/ Network Fault 4
B 1422 Wrng Timing rail driver #2
Wrng
C 1424 Wrng High side driver
E 1317 Shtdn/ Customer input #3
Wrng C 1427 Wrng Overspeed relay driver

Copyright  2020 Cummins Inc. 6-6

 TABLE 4-1. FAULT CODES (CONT.)
CTG CODE LAMP DISPLAYED MESSAGE CTG CODE LAMP DISPLAYED MESSAGE
C 1428 Wrng LOP shutdown relay driver C 1469 Wrng Speed freq conflict
D 1433 Shtdn Emergency stop − local B 1471 Wrng High current
D 1434 Shtdn Emergency stop − remote A 1472 Shtdn Overcurrent
D 1435 Wrng Engine cold A 1473 Shtdn Watchdog failure
B 1436 Wrng PT fuel system drivers A 1474 Shtdn Software version mismatch
A 1437 Shtdn E-stop path fuse blown C 1475 Wrng First start backup
D 1438 Wrng Fail to crank C 1476 Wrng LonWorks card
D 1439 Wrng Fuel level low in day C 1477 Wrng Crank relay contact
D 1441 Wrng Fuel level low in main C 1478 Wrng Crank relay driver
D 1442 Wrng Battery is weak A 1481 Shtdn AVR driver open
D 1443 Wrng Battery is dead E 1483 None Common alarm status
B 1444 Wrng kW overload A 1485 Shtdn EFC driver shorted
A 1445 Shtdn Alternator short circuit A 1486 Shtdn EFC driver open
A 1446 Shtdn AC output voltage is high C 1487 Wrng Auto acknowledge driver
A 1447 Shtdn AC output voltage is low C 1488 Wrng Warning LED driver
A 1448 Shtdn AC output frequency low C 1489 Wrng Shutdown LED driver
A 1449 Wrng AC output frequency high C 1491 Wrng Ready to load relay driver
B 1451 Wrng Gen/Bus voltage differ C 1492 Wrng Load dump relay driver
A 1452 Shtdn Gen CB failed to close C 1493 Wrng Display control driver
A 1453 Shtdn Gen CB failed to open C 1494 Wrng Modem power relay driver
C 1454 Wrng Gen CB position contact C 1495 Wrng Common shutdown2 driver
A 1455 Wrng Util CB contact C 1496 Wrng Auto mode relay driver
E 1456 Wrng Bus out of range C 1497 Wrng Manual run LED driver
E 1457 Wrng Fail to synchronize C 1498 Wrng Exercise run LED driver
E 1458 Wrng Phase rotation C 1499 Wrng Remote start LED driver
A 1459 Shtdn Reverse kW C 2111 Wrng Aftercooler temp sensor
A 1461 Shtdn Loss of field C 2112 Wrng Aftercooler temp sensor
B 1462 Wrng High ground current B 2113 Wrng High aftercooler temp
E 1463 None Not in Auto A 2114 Shtdn High aftercooler temp
E 1464 None Load dump C 2331 Wrng Utility under volt sensor
E 1465 None Ready to load C 2358 Wrng Utility over volt sensor
C 1466 Wrng Modem failure C 2396 Wrng Utility CB failed to close
C 1467 Wrng Unable to connect modem C 2397 Wrng Utility CB failed to open
C 1468 Wrng Network error C 3611 Wrng Custom Overcurrent Fault

6-7 Copyright  2020 Cummins Inc.

 TABLE 4-2. WARNING AND SHUTDOWN CODES

WARNING Many troubleshooting procedures present hazards which can result in severe per-
sonal injury or death. Only qualified service personnel with knowledge of fuels, electricity, and
mechanical hazards should perform service procedures. Review safety precautions.

SYMPTOM CORRECTIVE ACTION

CODE: 146 Indicates engine is operating near cooling system capacity. Increase in
LAMP: Warning load or higher ambient temperature may cause High Coolant Temp
MESSAGE: (151) shutdown. Review code 151 correction list for other possible
HIGH COOLANT TEMP WARNING causes.

CODE: 151 Indicates engine has overheated (engine coolant temperature has ris-
LAMP: Shutdown en above the shutdown trip point. Allow engine to cool down complete-
MESSAGE: ly before proceeding with the following checks:
HIGH COOLANT TEMP ALARM
a. Check coolant level and replenish if low. Look for coolant leaks
and repair if necessary.
b. Check for obstructions to cooling airflow and correct as neces-
sary.
c. Check fan belt and repair if necessary.
d. Check blower fan and circulation pumps on remote radiator
installations.
e. Reset control and restart after locating and correcting problem.

CODE: 152 Indicates engine coolant heater is not operating or is not circulating
LAMP: Warning coolant. Set is in standby mode but is not operating. Warning occurs
MESSAGE: when engine jacket water coolant temperature is 70 F (21 C) or lower.
LOW COOLANT TEMP
NOTE: In applications where the ambient temperature falls below
40 F (4 C), Low Coolant Temp may be indicated even though the
coolant heaters are operating.

Check for the following conditions:

a. Check that ball valves in coolant heater system are both open.
b. Coolant heater not connected to power supply. Check for blown
fuse or disconnected heater cord and correct as required.
c. Check for low jacket water coolant level and replenish if required.
Look for possible coolant leaks and repair as required.

CODE: 197 Indicates engine coolant level has fallen to an unacceptable level. If
LAMP: Warning generator is powering critical loads and cannot be shut down, wait until
MESSAGE: next shutdown period, then follow 235 Coolant Level Alarm proce-
COOLANT LEVEL WARNING dure. If engine can be stopped, follow code 235 procedure.

CODE: 235 Indicates engine coolant level has fallen below the alarm trip point. Al-
LAMP: Shutdown low engine to cool down completely before proceeding.
MESSAGE:
a. Check jacket water coolant level and replenish if low. Look for
COOLANT LEVEL ALARM
possible coolant leakage points and repair if necessary.
b. Reset control and restart after locating and correcting problem.

Copyright  2020 Cummins Inc. 6-8

 TABLE 4-2. WARNING AND SHUTDOWN CODES (CONT.)

WARNING Many troubleshooting procedures present hazards which can result in severe per-
sonal injury or death. Only qualified service personnel with knowledge of fuels, electricity, and
mechanical hazards should perform service procedures. Review safety precautions.

SYMPTOM CORRECTIVE ACTION

CODE: 359 Indicates possible fuel system or air induction problem. (Engine cranks
LAMP: Warning but fails to start)
MESSAGE:
a. Check for empty fuel tank, fuel leaks, or plugged fuel lines and
ENGINE FAILED TO START
correct as required.
b. Check for dirty fuel filter and replace if necessary.
c. Check for dirty or plugged air filter and replace if necessary.
d. Reset the control and restart after correcting the problem.

CODE: 441 Indicates battery voltage is below 24 VDC.

LAMP: Warning
a. Discharged or defective battery. Check the battery charger fuse.
MESSAGE:
Recharge or replace the battery.
LOW BATTERY VOLTAGE
b. Poor battery cable connections. Clean the battery cable terminals
and tighten all connections.
c. Check engine DC alternator. Replace engine DC alternator if nor-
mal battery charging voltage (24 to 26 VDC) is not obtained.
d. Check battery charge voltage float level if applicable (raise float
level).

CODE: 442 Indicates battery voltage exceeds 32 VDC.

LAMP: Warning
MESSAGE: Check float level on battery charger if applicable (lower float level).
HIGH BATTERY VOLTAGE
Check engine DC alternator. Replace engine DC alternator if normal
battery charging voltage (24 to 26 VDC) is not obtained.

CODE: 611 Indicates that an engine hot shut down has occurred (cool-down timers
LAMP: Warning were bypassed). This condition will occur when the operator presses
MESSAGE: the Emergency Switch or moves the 0/Manual/Auto switch to the 0
ENGINE HOT (Off) position before the genset completes the cooldown operation.
(Genset should run at 10% or less load for 3 minutes before engine
shutdown.) This type of shutdown should be avoided. Can cause pos-
sible loss of performance and engine damage.

CODE: 1311 through 1318 When any one of these customer defined inputs is detected by the con-
LAMP: Shutdown/Warning trol, the corresponding fault message is displayed. The nature of the
MESSAGE: fault is an optional customer selection. These fault functions can be
Customer Defined Fault programmed to initiate a shutdown or warning as indicated by the
Warning or Shutdown lamp.

Note: Customer fault messages are editable. The message displayed

for the code shown (1311 through 1318) is determined by the custom-
er.

6-9 Copyright  2020 Cummins Inc.

 TABLE 4-2. WARNING AND SHUTDOWN CODES (CONT.)

WARNING Many troubleshooting procedures present hazards which can result in severe per-
sonal injury or death. Only qualified service personnel with knowledge of fuels, electricity, and
mechanical hazards should perform service procedures. Review safety precautions.

SYMPTOM CORRECTIVE ACTION

CODE: 1417 Indicates that the control can not power down due to some unknown
LAMP: Warning condition. Possible drain on battery. Contact an authorized service
MESSAGE: center for service.
POWER DOWN ERROR

CODE: 1433 / 1434 Indicates local or remote Emergency Stop. Emergency Stop shutdown
LAMP: Shutdown status can be reset only at the local control panel.
MESSAGE: To reset the local/remote Emergency Stop button:
EMERGENCY STOP − LOCAL / Pull the button out.
EMERGENCY STOP − REMOTE Move the O/Manual/Auto switch to O (Off).
Press the front panel Fault Acknowledge button.
Select Manual or Auto, as required.

CODE: 1438 Indicates possible fault with control, speed sensing or starting system.
LAMP: Warning See code 441 for corrective action.
MESSAGE:
FAIL TO CRANK

CODE: 1439 Indicates fuel supply is running low. Check fuel supply and replenish as
LAMP: Warning required.
MESSAGE:
FUEL LEVEL LOW IN DAY

CODE: 1441 Indicates fuel supply is running low. Check fuel supply and replenish as
LAMP: Warning required.
MESSAGE:
FUEL LEVEL LOW IN MAIN

CODE: 1442 Indicates battery voltage drops below 14.4 volts for two seconds dur-
LAMP: Warning ing starting.
MESSAGE: Discharged or defective battery. See code 441 for corrective action.
BATTERY IS WEAK

CODE: 1443 Indicates battery has dropped below genset operating range (3.5 volts
LAMP: Warning when cranking) to power the starter and the control circuitry. See code
MESSAGE: 441 for corrective action.
BATTERY IS DEAD

Copyright  2020 Cummins Inc. 6-10

 TABLE 4-2. WARNING AND SHUTDOWN CODES (CONT.)

WARNING Many troubleshooting procedures present hazards which can result in severe per-
sonal injury or death. Only qualified service personnel with knowledge of fuels, electricity, and
mechanical hazards should perform service procedures. Review safety precautions.

SYMPTOM CORRECTIVE ACTION

CODE: 1472 If the AmpSentry High Current shutdown threshold has been exceed-
LAMP: Warning ed, fault code 1472 (shutdown) becomes active.
MESSAGE:
OVERCURRENT
This fault remains active and cannot be reset until the Alternator
Overheat Integral time has expired (which takes up to five min-
utes). The Alternator Overheat Integral time allows the alternator
to cool down before allowing a restart.

Possible Causes:
1. Short or Overload
2. Incorrect CT ratio, CTs, or CT connections
3. Incorrect generator set rating set up
Diagnosis and Repair:
1. Short or Overload
a. Inspect the load cables and AC harness connections. Check for a
short circuit to engine block ground. Refer to fault code 1444 for over-
load condition troubleshooting.
2. Incorrect CT ratio, CTs, or CT connections
a. Check that correct CT’s have been installed. Verify that the CTs are
installed in the correct order and location. With the use of InPower ad-
just the CT ratio appropriately in the generator setup menu.

6-11 Copyright  2020 Cummins Inc.

 TABLE 4-2. WARNING AND SHUTDOWN CODES (CONT.)

CODE: 3611 If the ”Custom Overcurrent Protection Enable” is enabled and current
LAMP: Warning flow exceeds the ”Custom Overcurrent Threshold” for a period of time
MESSAGE: as determined by the ”Custom Overcurrent Time Characteristic” pa-
CUSTOM OVERCURRENT FAULT rameter the genset will limit the current flow amount with the warning
fault code 3611.

This fault remains active and cannot be reset until the Alternator
Overheat Integral time has expired. The Alternator Overheat Inte-
gral time allows the alternator to cool down before accepting the
load again.

Possible Causes:
1. The ”Custom Overcurrent Threshold” parameter is configured incor-
rectly (low).
2. The ”Custom Overcurrent Characteristic” parameter is configured
incorrectly.
3. There is excessive current flow.
Diagnosis and Repair:
1. The ”Custom Overcurrent Threshold” parameter is configured incor-
rectly (low).
a. Make sure that the ”Custom Overcurrent Threshold” percent value is
set appropriately for the application. Verify the corresponding setting
with the use of InPower software. Go to Setup > Advanced Setup >
OEM Setup > OEM Alternator Setup and set the parameter appropri-
ately for the application.

2. The ”Custom Overcurrent Characteristic” parameter is configured

incorrectly.
a. Make sure that the appropriate overcurrent time characteristic set-
ting is used for calculating the custom overcurrent trip time and reset
times to avoid a nuisance fault tripping. (Trip Time = A / (M2−1) when M
> 1; Reset Time = A / (1−M2) when M < 1, where M = ratio of the actual
current / trip threshold; A = seconds to trip when M = 1.414, and sec-
onds to reset when M = 0). Trip and reset times will be decreased
significantly if time characteristic value is lowered. Verify the corre-
sponding setting with the use of InPower software. Go to Setup > Ad-
vanced Setup > OEM Setup > OEM Alternator Setup and set the pa-
rameter appropriately for the application.

3. There is excessive current flow.

a. Custom overcurrent protection provides the ability for the user to de-
fine a custom overcurrent trip curve in addition to the normal AmpSen-
try overcurrent protection fault which would, still, operate normally. De-
pending on the curve settings this curve would normally be configured
to trip faster than the AmpSentry curve. If the overcurrent threshold
has been exceeded the overcurrent protection function will limit the
current flow for the period of time that is based on the calculated time
characteristic value. Reset time period is allowed after the occurrence
of the fault for the necessary alternator cool down time. In order to ad-
dress the issue of the overcurrent, refer to the event/fault code 1472 on
page 144.

Copyright  2020 Cummins Inc. 6-12

7. Wiring Diagrams (Generator Set)
The following pages provide typical wiring diagrams
for the generator sets.

7-1 Copyright  2020 Cummins Inc.

 THIS PAGE LEFT INTENTIONALLY BLANK

Copyright  2020 Cummins Inc. 7-2

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO. 625-3100 SH 1 OF 2
REV. H
MODIFIED 2/2011

AC RECONNECT WIRING DIAGRAM (SHEET 1)

7-3 Copyright  2020 Cummins Inc.

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO. 625-3100 SH 2 OF 2
REV. H
MODIFIED 2/2011

AC RECONNECT WIRING DIAGRAM (SHEET 2)

7-4
Copyright  2020 Cummins Inc. 7-4
 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO. 630-2645 SH 1 OF 1
REV. A
MODIFIED 4-03

GENSET RECONNECTION WIRING DIAGRAM (P7 ONLY)

7-5 Copyright  2020 Cummins Inc.

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO. 630-3210 SH 1 OF 7
REV. D
MODIFIED 6/2012

30L GENSET WIRING DIAGRAM

7-6
Copyright  2020 Cummins Inc. 7-6
 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO. 630-3210 SH 2 OF 7
REV. D
MODIFIED 6/2012

30L GENSET WIRING DIAGRAM

7-7 Copyright  2020 Cummins Inc.

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO. 630-3210 SH 3 OF 7
REV. DE
MODIFIED 6/2012

30L GENSET WIRING DIAGRAM

7-8
Copyright  2020 Cummins Inc. 7-8
 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO. 630-3210 SH 4 OF 7
REV. D
MODIFIED 6/2012

30L GENSET WIRING DIAGRAM

7-9 Copyright  2020 Cummins Inc.

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO. 630-3210 SH 5 OF 7
REV. D
MODIFIED 6/2012

30L GENSET WIRING DIAGRAM

7-10
Copyright  2020 Cummins Inc. 7-10
 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO. 630-3210 SH 6 OF 7
REV. D
MODIFIED 6/2012

30L GENSET WIRING DIAGRAM

7-11 Copyright  2020 Cummins Inc.

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO. 630-3210 SH 7 OF 7
REV. D
MODIFIED 6/2012

30L GENSET WIRING DIAGRAM

7-12
Copyright  2020 Cummins Inc. 7-12
 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO. 630-3178 SH 1 OF 7
REV. F
MODIFIED 10/2012

50L, 60L GENSET WIRING DIAGRAM (SHEET 1)

7-13 Copyright  2020 Cummins Inc.

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO. 630-3178 SH 2 OF 7
REV. F
MODIFIED 10/2012

50L, 60L GENSET WIRING DIAGRAM (SHEET 2)

7-14
Copyright  2020 Cummins Inc. 7-14
 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO. 630-3178 SH 3 OF 7
REV. F
MODIFIED 10/2012

50L, 60L GENSET WIRING DIAGRAM (SHEET 3)

7-15 Copyright  2020 Cummins Inc.

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO. 630-3178 SH 4 OF 7
REV. F
MODIFIED 10/2012

50L, 60L GENSET WIRING DIAGRAM (SHEET 4)

7-16
Copyright  2020 Cummins Inc. 7-16
 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO. 630-3178 SH 5 OF 7
REV. F
MODIFIED 10/2012

50L, 60L GENSET WIRING DIAGRAM (SHEET 5)

7-17 Copyright  2020 Cummins Inc.

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO. 630-3178 SH 6 OF 7
REV. F
MODIFIED 10/2012

50L, 60L GENSET WIRING DIAGRAM (SHEET 6)

7-18
Copyright  2020 Cummins Inc. 7-18
 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO. 630-3178 SH 7 OF 7
REV. F
MODIFIED 10/2012

50L, 60L GENSET WIRING DIAGRAM (SHEET 7)

7-19 Copyright  2020 Cummins Inc.

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO. 620-0281 SH 1 OF 2
REV. A
MODIFIED 11-04

ENCLOSURE/OPTIONS WIRING (DQFAA-AD) (SHEET 1)

7-20
Copyright  2020 Cummins Inc. 7-20
 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO. 620-0281 SH 2 OF 2
REV. A
MODIFIED 11-04

ENCLOSURE/OPTIONS WIRING (DQFAA-DQFAD) (SHEET 2)

7-21 Copyright  2020 Cummins Inc.

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO. 500-4196 SH 1 OF 1
REV. C
MODIFIED 12/2010

7-22
Copyright  2020 Cummins Inc. 7-22
 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO. A040V834 SH 1 OF 2
REV. B
MODIFIED 9−2011

ENTRANCE BOX OUTLINE (SHEET 1 OF 2)

7-23 Copyright  2020 Cummins Inc.

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO. A040V834 SH 2 OF 2
REV. B
MODIFIED 9−2011

ENTRANCE BOX OUTLINE (SHEET 2 OF 2)

7-24
Copyright  2020 Cummins Inc. 7-24
 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO. A047M944 SH 1 OF 3
REV A
MODIFIED 10−2013

GENERATOR SET OUTLINE (SHEET 1 OF 3)

7-25 Copyright  2020 Cummins Inc.

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO A047M944 SH 2 OF 3
REV A
MODIFIED 10−2013

GENERATOR SET OUTLINE (SHEET 2 OF 3)

7-26
Copyright  2020 Cummins Inc. 7-26
 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO. A047M944 SH 3 OF 3
REV A
MODIFIED 10−2013

GENERATOR SET OUTLINE (SHEET 3 OF 3)

7-27 Copyright  2020 Cummins Inc.

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO.A034P810 SH1 OF 13
REV F
MODIFIED 4−2015

7-28
Copyright  2020 Cummins Inc. 7-28
 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO.A034P810 SH2 OF 13
REV F
MODIFIED 4−2015

7-29 Copyright  2020 Cummins Inc.

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO.A034P810 SH3 OF 13
REV F
MODIFIED 4−2015

7-30
Copyright  2020 Cummins Inc. 7-30
 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO.A034P810 SH4 OF 13
REV F
MODIFIED 4−2015

7-31 Copyright  2020 Cummins Inc.

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO.A034P810 SH5 OF 13
REV F
MODIFIED 4−2015

7-32
Copyright  2020 Cummins Inc. 7-32
 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO.A034P810 SH6 OF 13
REV F
MODIFIED 4−2015

7-33 Copyright  2020 Cummins Inc.

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO.A034P810 SH7 OF 13
REV F
MODIFIED 4−2015

7-34
Copyright  2020 Cummins Inc. 7-34
 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO.A034P810 SH8 OF 13
REV F
MODIFIED 4−2015

7-35 Copyright  2020 Cummins Inc.

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO.A034P810 SH9 OF 13
REV F
MODIFIED 4−2015

7-36
Copyright  2020 Cummins Inc. 7-36
 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO.A034P810 SH10 OF 13
REV F
MODIFIED 4−2015

7-37 Copyright  2020 Cummins Inc.

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO.A034P810 SH11 OF 13
REV F
MODIFIED 4−2015

7-38
Copyright  2020 Cummins Inc. 7-38
 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO.A034P810 SH12 OF 13
REV F
MODIFIED 4−2015

7-39 Copyright  2020 Cummins Inc.

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NO.A034P810 SH13 OF 13
REV F
MODIFIED 4−2015

7-40
Copyright  2020 Cummins Inc. 7-40
power.cummins.com
Copyright E 2020 Cummins Inc. All rights reserved.
Cummins, the “C” logo, PowerCommand, AmpSentry, and InPower are trademarks of Cummins Inc.
Other company, product, or service names may be trademarks or service marks of others.
Specifications are subject to change without notice.