2 - Cummins Onan
Contents
1. Time Duration seconds 1 i i i j Utility Failure 1 Delay Engine Starti 249 Engine Start upTime 5 3min 3min 5min Load Control 2Delay i jLoad Control 1Delay Transfer Delay Transfer Utility kenn Delay 5min jEngine Cool Down Generator Off FIGURE 4 TYPICAL POWER OUTAGE CYCLE TIMING DIAGRAM A029V089 Issue 2 13 3 Operation Utility Present Off Utility Connected Dispay S i LED Generator Runni Flashing unning Generator Red Standby Off UA is Available BILE Not Aabi UR Rau On c i EC M 1 Transfer Utility Switch Load Control 1 Load Control 2 on Time Duration seconds 4 2010 Exercise 2 19 20 min 5 min Engine Start Generator Engine Cool Generator 1 upTime Exercise Down Off FIGURE 5 EXERCISE TIMING DIAGRAM 14 A029V089 Issue 2 4 2010 3 Operation Manual Start Stop Utility Present eae Utility Connected Off Display LED Generator Running Generator Red Standby Of si ae m Available VU PONT lee available ees ee Generator en Ss RET Transfer Switch Time Duration seconds Start Stop l l Generator Start Stop Button Engine Starts Transfer Load Control Load Control Stopped Button Standby Pressed upTime2. Software Info GEN SW P N 3261234 SW VERSION 12 34 Dis SW P N 3261234 SW VERSION 10 23 FIGURE 17 DISPLAY SETUP AND SOFTWARE INFO SCREENS 3 9 2 Software Info To check on the generator set and display software 24 1 Press the MENU button on the home screen 2 Press the up or down arrow button on the menu screen to select Display Setup 3 4 Press the INFO button on the Display Setup screen and note the values displayed on the Press the ENTER button on the menu screen Software Info screen A029V089 Issue 2 4 2010 3 Operation 5 Press the BACK button to return to the home screen 3 10 Event Log 3 10 1 To Check Log of Last 20 Events 1 Press the MENU button on the home screen 2 Press the up or down arrow button on the menu screen to select Event Log 3 Press the ENTER button on the menu screen 4 Scroll through the event log with the up and down double arrow buttons Each screen provides a brief description of the event along with the time and date of the event 5 Press the BACK button to return to the home screen Sun 10 35 AM Battery 12 5 Genset Load LIW 128 EXCER CLOCK LOAD MENU Genset Status Display Setup Fault Log Ethernet Setup Event Log Standby Enabled 05 04 2007 1 18PM FIGURE 18 EVENT LOG SCREEN 3 10 2 List of Recordable Events e Genset started manually Standby Ready Disabled e Genset stoppe
3. 4 1 Periodic Maintenance Selgedulcsee 4 2 Cleaning the Housing TOP deiesetet deci eee ia aunt d Sostieni unes 4 3 Exercising the Generato 4 4 Engine Oil Maintenance A029V089 Issue 2 ce Maen CAEP b doen v fe ie D RES EID E LR A CA CQ OO MN NNa gt a aa A 11 11 12 13 18 18 19 21 21 23 25 26 27 28 31 31 32 32 32 Table of Contents 4 2010 4 5 Replacing the Air Filter Element uae tip eoi th oie based celina ath tadashi 34 4 0 Battery Maintenatice defe in oe e elc e end deo ed cosctetur da 35 4 7 Spark Plugs iere ee D enu Ltd M taba ie p AME 36 4 5 M inteliance Record sac occa hee aaa C eL LE IL LL D DC DE M 36 5 TROUBLESHOOTINGS EE eseeeennm Mee EDO 39 5 1 Troubleshooting With the In Home Operator Panel seeeeenemm 39 5 2 FauluttodsiBlnlandgec E SA coo SEM m 39 5 adsestonng aut eodelBlinange m Nu ee eu 39 5 4 Troubleshooting with the Flashing Indicator Light sessseeeeenene 40 B15 Ce MUU eS Mela IPO BIG Soo e Mik RD ILE DS 45 6 OPTIONAL INTERNET EMAIL INTERFACE DESCRIPTIONS eee 51 S agers eroien o cue c ESSA MERE E RD T TU a et Ca emerat ras 51 o 2 55creenibescrpuons eee OO TEES 52 6 Sseihermew Gonnectionsy ptional yp aec e m see seasons 56 ii A029V089 Issue 2 1 IMPORTANT SAFETY INSTRUCTIONS 1 1 Save These Instructions This manual contains important instru
4. Operator Manual Cummins Onan Performance you rely on Home Standby Generator Set GSBB Spec A English Original Instructions 4 2010 A029V089 Issue 2 Table of Contents 1 IMPORTANT SAFETY INSTRUC DOM Serene if PNE 1 1 Save These Instructions 1 2 General Precautions 1 3 Ceon OV OUaAg etsy ecu c Ee es 1 4 Engine Exhaust is Dead y EU eer eine ee E T d 5srueltisitlammablerandiExplosiVemeee m eee Ree RS 1 6 Batteries Can Explode 1 7 Moving Parts Can Cause Severe Personal Injury or Death seeessssessss 1 8 The Hazards of Carbon 2 INTRODUCTION 2 1 About this Manual Monoxide A m ENTRE RENE 2 29 Atoutsthie Generator oo E r rhet nre dn nnne nune naga ki nra ER an 2 3 How to Obtain Service 3 OPERATION 3 9209 3 1 3 Position Switch 3 2 In Home Operator Pane 3 3 Typical Operation RET Uo nelelsseteele S e ODDS uec eee 3 90 Manually Start Stop Generator elm ceci ccsp te nce L caca tula une pM CE T DPA DD IpE LIEU IPSE 3 6 Fault Maintenance and 3 7 Genset Status 3 8 Load Management NewiEverntiocreensssee E e pue EXTUS HR 3 9 Display Setup and Software Info sssssessesseeeeeeee eene nne ener nnne nnns 3 10 Event Login Sd sp AIO Carrer tee aes 3 12 Exercise Settings 3 13 Time Setup 4 MAINTENANCE
5. Delay 1Delay 2 Delay ATSx fer l ressa Enabled FIGURE 6 MANUAL START STOP TIMING DIAGRAM A029V089 Issue 2 15 3 Operation 4 2010 Utility Present Teen G Q Utility Connected Generator Running Generator Standby Off ES Available UH Power ot AVallsbS On Generator OF Transfer Utility Switch Generator On I Load Control 1 Of On Load Control 2 Off i Time Duration 5 3mi 3min i 3min 3min i i i 10 ipecon Ee j Wi j d d d Transfer iLoad Control Load Control iLoad Control Load ControfLoad Control i ln tility ma Control Delay f 1 Delay T 2 Delay f i 182 de 1 Delay i 2 Delay i i i 182 Load lt 70 lt 70 lt 95 gt 95 lt 50 lt 50 lt 95 gt 95 FIGURE 7 LOAD MANAGEMENT TIMING DIAGRAM 3 3 1 Normal Operation Utility Power Available and Connected As long as utility power is available and connected both of the green UTILITY lamps PRESENT and CONNECTED will stay on and the LCD screen will indicate Genset Stopped If the red GENERATOR STANDBY OFF light is on the generator set will not start up automatically if utility power is interrupted See the To Enable Disable Standby section of this manual to enable STANDBY so that the generator set will automatically supply power if utility power is interrupted 16 A029V089 Issue 2 4 20
6. 59 in 993 cc Spark Plug Gap 020 inch 51 mm Spark Plug Torque 15 ft Ib 20 N m Intake and Exhaust Cold Valve 0 004 0 006 inch 0 10 0 15 mm Lash Measure at 0 25 6 35mm past top dead center Oil Capacity Approximately 80 oz 2 3 Liters Oil Recommendation OW 40 Synthetic Engine Oil See Operator Manual TABLE 7 GENERATOR SPECIFICATIONS TABLE sonz S0Hz Propane Vapor NaturalGas Propane Vapor NaturalGas Brush Type 2 Pole Rotating Field Single Bearing Power kVA o de o hese M38 Single Phase Phase Type Single Phase Circuit Breaker Amps Hoo ho Jeo Jo De rating Guidelines Maximum wattage or maximum current are subject to and limited by such factors as fuel Btu content ambient temperature altitude engine power and condition etc Full rated power is available at 60 F 15 5 C at sea level De rate 3 5 for each 1000 ft 304 8 m above sea level and 3 for each 10 F 5 5 C increase in ambient temperature above 60 F 15 5 C This generator is rated in accordance with UL 2200 Stationary Engine Generator Assemblies or CSA C22 2 No 100 04 Motors and Generators The maximum continuous current values that are listed on the generator set nameplate and specification tables occur at the lower limit of acceptable voltage Maximum current occurs at 108 and 216 volts 10 below nominal voltage 120 240 The voltage set point of this generator set can be
7. CABLE Static IP 192 168 000 150 a NOTE IPS menonsa inteso instructions are samples only GENERATOR SET CONTROL BOARD PERSONAL COMPUTER FIGURE 41 NETWORK CONNECTIONS 4 2010 A029V089 Issue 2 Cummins Power Generation 1400 73rd Ave NE Minneapolis MN 55432 USA Phone 1 763 574 5000 Toll free 1 800 888 6626 Fax 1 763 574 5298 Copyright 2010 Cummins Power Generation Inc All rights reserved Cummins Onan the C logo and Performance you rely on are trademarks of Cummins Inc
8. Onan dealer Generator Set Overload Fault Code 46 Possible causes Loads wire connections windings Corrective Actions 1 Reduce the number of connected loads especially loads that require higher starting current such as air conditioners 2 Check and service air filter as necessary 3 Have unit serviced by an authorized Cummins Onan dealer Alternator Over Temp Fault Code 76 Possible Causes Wire connections faulty temperature sensor faulty DC fan blocked intake or exhaust openings Corrective Actions 1 Verify the generator set enclosure for clear intake and exhaust openings 2 Have unit serviced by an authorized Cummins Onan dealer A029V089 Issue 2 4 2010 5 Troubleshooting 5 4 25 Low Fuel Pressure Fault Code 78 Possible Causes Wire connections fuel system fuel pressure switch Corrective Actions 1 Open any closed fuel valves 2 Have unit serviced by an authorized Cummins Onan dealer 5 4 26 Failure To Transfer To Generator Set Fault Code 79 Possible Causes Wire connections faulty positional switch faulty transfer switch component s Diagnosis amp Solution 1 Verify that the main AC circuit breaker on the generator set is to On 2 Have unit serviced by an authorized Cummins Onan dealer 5 5 Communication Troubleshooting 5 5 1 In Home Network Access to Generator Set Troubleshooting A WARNING Some Generator Set service procedures present hazards that can result in severe
9. adjusted from the operator panel if desired Refer to the Operator manual procedure To Adjust the Output Voltage 8 A029V089 Issue 2 4 2010 2 Introduction TABLE 8 CONTROL SPECIFICATIONS TABLE Propane Vapor NaturalGas Propane Vapor NaturalGas Controller Integrated Microprocessor Based Engine Generator Transfer Switch Controller TABLE 9 DC SYSTEM SPECIFICATIONS TABLE Propane Vapor NaturalGas PropaneVapor NaturalGas DC System 2 3 How to Obtain Service For parts service and product information such as the Service Manual contact the nearest authorized Cummins Onan distributor You may go to Web site www cumminsonan com for information on contacting our distributors worldwide In North America Call 1 800 888 6626 to contact the nearest Cummins Onan distributor in the United States or Canada If you are unable to contact a distributor using the automated service consult the Yellow Pages Typically our distributors are listed under GENERATORS ELECTRIC ENGINES GASOLINE OR DIESEL If you have difficulty arranging service or resolving a problem please contact the Service Manager at the nearest Cummins Onan distributor for assistance Outside North America If you are outside North America call Cummins Onan at 1 763 574 5000 from 7 30 AM to 4 00 PM Central Standard Time Monday through Friday or fax 1 763 528 7229 Information to Have Ready Before calling for service have the
10. been corrected WARNING Some Generator Set service procedures present hazards that can result in severe personal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform Generator Set service Troubleshooting with the Flashing Indicator Light The status indicator light on the Control Switch inside the generator set flashes the diagnostic fault code when a fault shutdown occurs For a single digit fault code 2 or 4 the light will flash 2 or 4 times and after a short pause will repeat For a two digit fault code the light will flash the tens digit pause and flash the units digit and repeat after a longer pause Fault 36 would be flashed as follows flash flash flash pause flash flash flash flash flash flash ong pause repeat NOTE For fault history go to the in home Operator Panel No Response Status Indicator Light Dead Possible Cause Low No battery voltage poor battery connection faulty battery open harness connection faulty start stop switch faulty LED Corrective Actions 1 Try generator set Start Switch if the remote display Start Switch does not respond and vice versa 2 Clean and tighten positive and negative battery cable connections at the battery 3 Recharge or replace battery Refer to the battery manufacturer s recommendations Starting Battery Runs Down Possible Cause Marginal battery connections batt
11. field to change 3 Press the up or down arrow button to increase or decrease or change the date or time 4 Press the BACK button to save the settings and return to the home screen 28 A029V089 Issue 2 4 2010 A029V089 Issue 2 3 Operation Sun 10 35 AM Battery 12 9 Genset Load LIW I2NMN EXCERICLOCK LOAD MENU 4 Time Setup Date NEW Time FIGURE 21 TIME SETUP SCREEN 29 3 Operation 4 2010 This page is intentionally blank 30 A029V089 Issue 2 4 Maintenance 4 1 Periodic Maintenance Schedule Periodic maintenance is essential for top generator set performance Use the Maintenance Frequency table as a guide for normal periodic maintenance e n hot and dusty environments some maintenance procedures should be performed more frequently as indicated by the footnotes in the table e Maintenance replacement or repair of emission control devices and systems may be performed by any engine repair establishment or individual e Warranty work MUST be completed by an authorized Cummins Onan dealer A WARNING Accidental or remote starting of the generator set can cause severe personal injury or death Before working on the generator set move the switch S2 to the Stop position disconnect the remote harness P7 to disable the ATS mounted charger and remove the negative battery cable from the battery to prevent starting TABLE 12 MAINTENANCE FREQUENCY Maintenance Task Main
12. personal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform Generator Set service Possible Causes Bad connections or bad communications Corrective Actions 1 Check connections a Verify that the Ethernet cable is plugged into the generator set control and the router b Verify that the computer is connected to the same router as the generator set via an Ethernet cable c Verify that the wireless card on the computer is turned off d Check to see if both ends of the Ethernet cable are assembled and crimped as described in the installation instructions If not reassemble and crimp as described in the installation instructions e Verify that the Ethernet cable connections between the generator set and the router are solid and correct f Proceed to Check communications 2 Check communications a Check to see if you can access a standard web page with the computer connected to the same router as the generator set If not contact your router manufacturer for troubleshooting information A029V089 Issue 2 45 5 Troubleshooting 4 2010 b Check to see if the green and orange lights are illuminated at the Ethernet connection port on the generator set control board If not disconnect the Ethernet cable from the generator control board and connect it to the computer Check to see if you can access a standard web page with the computer conne
13. sun 10 35 AN GENERATOR Battery RUNNING Genset Stopped STA OFF ACTION REQUIRED EXCER CLOCK LOAD MENU No Description E Back Button When navigating through the LCD menus press this button to return to the main operating Screen 2 Standby On Off Button See the To Enable Disable Standby section of this manual Start Stop Button See the To Manually Start Stop Generator Set section of this manual Navigation Buttons The function of these buttons change as different screens appear FIGURE 3 IN HOME OPERATOR PANEL 3 2 1 BACK Button When navigating through the LCD menus press the BACK button to return to the main operating screen 3 2 2 START STOP Button See To Manually Start Stop Generator Set 3 2 3 Standby ON OFF Button See To Enable Disable Standby 12 A029V089 Issue 2 4 2010 3 3 Typical Operation 3 Operation The following diagrams are based on an APPROXIMATE time duration Your genset may vary slightly from the timing diagrams in this manual CE NOTE a Green Utility P t ility Presen Of Utility Green Connected Off Display LED Green Generator Running Flashing Off Generator Red Standby Off Off E Available Utility Power Not Available On Generator Of Transfer Utility Switch Generator Load Control 1 On Off Load Control 2 Typical Power Outage Cycle
14. the Periodic Maintenance Table for scheduled battery maintenance and follow the battery manufacturer s instructions Have the battery charger in the transfer switch replaced if the battery keeps running down 029V089 Issue 2 35 4 Maintenance 4 2010 Always 1 Keep the battery case and terminals clean and dry and the terminals tight 2 Remove battery cables with a battery terminal puller Torque threaded stud battery terminals as recommended by the battery manufacturer 3 Make sure which terminal is positive and which is negative before making battery connections always removing the negative cable first and reconnecting it last to reduce arcing CS NOTE If the battery needs to be replaced be sure that the replacement battery 4 7 A 36 specs match those found in the Specifications Table in this manual Spark Plugs WARNING Before working on the generator set move the Switch S2 to the Stop Position disconnect the remote harness P7 to disable the ATS mounted charger and remove the negative battery cable from the battery to prevent starting Set the genset control to the Off position before checking the spark plugs Refer to the Periodic Maintenance Table for scheduled spark plug replacement The genset has two spark plugs one on each side of the engine The spark plugs must be in good condition for proper engine starting and performance A spark plug that fouls frequently or has heav
15. the generator set and transfer switch perform the following functions together 1 Senses an interruption of utility power 2 Starts the generator set 3 Transfers the load to the generator set when operation has stabilized 4 Senses the return of utility power 5 Retransfers the load to the utility A029V089 Issue 2 5 2 Introduction 4 2010 6 Stops the generator set A more in depth illustration of the operation of the generator set and transfer switch can be found in the Timing Charts located in the Typical Operation chapter of this manual 2 2 1 Generator Set Nameplate A WARNING Improper service or replacement of parts can lead to severe personal injury or death and to damage to equipment and property Service personnel must be qualified to perform electrical and mechanical service CAUTION Unauthorized modifications or replacement of fuel exhaust air intake or speed control system components that affect engine emissions are prohibited by law in the State of California Model Spec and Serial Numbers Be ready to provide the model spec and serial numbers on the generator set nameplate when contacting Cummins Onan for information parts and service Record these numbers so that they are easy to find when needed Each character in these numbers is significant for obtaining the right parts listed in the Parts Catalog Genuine Cummins Onan replacement parts are recommended for best results My Generator Set Info
16. the results add or drain oil 3 Clean up and dispose of any oil in accordance with local state regulations Changing Engine Oil and Oil Filter Refer to the Periodic Maintenance Schedule for scheduled engine oil changes and to the control panel for the oil filter part number Change oil more often in hot and dusty environments 1 Run the generator set until warm shut down and place pan under the end of the oil drain hose attached to the drain valve 2 Make sure the oil drain hose is connected to the oil drain valve and open the drain valve Reclose the valve when oil stops draining 3 Spin off the oil filter canister and clean the filter mounting surface on the engine block Remove the old gasket if it remains 4 Make sure the gasket is in place on the new filter and apply a thin film of clean oil to the gasket Spin the new filter on until the gasket just touches the block Turn it an additional 1 2 to 3 4 turn Do not over tighten A029V089 Issue 2 33 4 Maintenance 4 2010 4 5 5 Refill with 67 oz 2 liters of oil CAUTION Too much oil can cause high oil consumption Too little oil can cause severe engine damage Keep the oil level between the Full and Add marks 6 Start and run for 30 seconds 7 Shut the engine off and wait 30 seconds 8 Add more oil slowly to bring the oil level to the FULL mark on the dipstick 9 Dispose of the used oil and oil filter according to local environmental regulations Re
17. v Outgoing Server SMTP Server Name max 42 chars User Name max 48 chars Password max 16 chars Network Setup Destination Email Addresses max 48 chars each Address 1 Address 2 Address 3 FIGURE 37 EMAIL ADDRESSES 6 2 8 Saving Changes After the email addresses are added and Done is selected this screen will appear verifying that all changes have been saved A029V089 Issue 2 55 6 Optional Internet Email Interface Descriptions 4 2010 FIGURE 38 SAVE SCREEN 6 3 Ethernet Connections Optional Wiring connections to the Ethernet RJ 45 plug are shown in the Ethernet RJ 45 Connector Wiring illustration Utilize an appropriate Ethernet stripping and crimping tool for these connections FIGURE 39 ETHERNET CONNECTOR 56 A029V089 Issue 2 4 2010 6 Optional Internet Email Interface Descriptions PIN 1 P gGoBbObBR gGoBboOLbhr BR g Green and White G Green o Orange and White O Orange b Blue and White B Blue br Brown and White BR Brown FIGURE 40 ETHERNET RJ 45 CONNECTOR WIRING A029V089 Issue 2 57 6 Optional Internet Email Interface Descriptions 58 UPS RECOMMENDED INTERNET WORLD WIDE WEB Public IP 176 196 052 094 Forward Port 80 to 192 168 000 001 Device IP 192 168 000 001 orward Port 80 to 192 168 000 150 CAT 5
18. 10 3 3 2 3 Operation Cummins Onan UTILITY PRESENT Sun 10 35 AM RUNNING STANDBY OFF ACTION REQUI FIGURE 8 UTILITY PRESENT AND CONNECTED STANDBY OFF LAMP ON Emergency Operation Utility Power Interrupted If utility power is interrupted 1 The green UTILITY PRESENT lamp will go out 2 The generator set will start automatically and the green GENERATOR RUNNING lamp will turn on 3 The UTILITY CONNECTED light will go out when the generator set is connected to supply power The LCD screen will provide a visual indication of Genset Load bar graphs The bar graphs indicate how much of the available power is being used in each supply line L1 and L2 If the red ACTION REQUIRED light comes on either the generator shut down or periodic maintenance has come due The LCD screen will indicate what maintenance is due or which fault occurred Cummins Onan UTILITY PRESENT CONNECTED Sun 10 35 AM GENERATOR Battery 12 5 RUNNING Genset Load STANDBY Q SEMEN cn ACTION EXCER CLOCK LOAD MENU FIGURE 9 GENERATOR SET RUNNING ACTION REQUIRED LAMP ON A029V089 Issue 2 17 3 Operation 4 2010 3 3 3 To Adjust the Output Voltage Use the following procedure 1 Connect an accurate AC volt meter across L1 and L2 while the generator set is running 2 With Output Volts selected on the Adjustments Menu screen press the up or down arrow button to adjust the voltage to the desired setting 3 The control a
19. 8 Utility Utility Present Utility Connected Running Standby Off Action Required FIGURE 25 GENERATOR SET HOME PAGE Network Setup Email Setup Alert Level All Events Outgoing Server SMTP Server Name max 42 chars yourservername User Name max 48 chars yourusername domainname Password max 16 chars yourpassword FIGURE 26 NETWORK SETUP PAGE 2 A029V089 Issue 2 49 5 Troubleshooting 4 2010 Network Setup Destination Email Addresses max 48 chars each Address 1 youremail youremail com Address 2 yourCumminsOnanDealer theiremail com Address 3 yourCumminsOnanServiceTech theiremail com FIGURE 27 NETWORK SETUP PAGE 3 50 A029V089 Issue 2 6 Optional Internet Email Interface Descriptions 6 1 Introduction This feature allows for in home or remote access to your generator set through a web page On this web page you can start or stop the generator set adjust the exerciser day and time determine if utility power is available and view the last 20 events faults on the generator set This feature is useful for homeowners who travel or have a second home and want to be able to remotely interface with their generator set This feature can also help to reduce troubleshooting time and service calls when the service technician has access to the same web page Use of the Ethernet is not required if you do not use web acc
20. A WARNING Carbon Monoxide CO gas can cause nausea fainting or death A029V089 Issue 2 3 1 IMPORTANT SAFETY INSTRUCTIONS 4 2010 1 8 3 Only You Can Protect Yourself From CO Poisoning e Locate the generator in an area where there are no windows doors or other access points into the home e Make sure all CO detectors are working properly e Pay attention to the signs of CO poisoning e Check the exhaust system for corrosion obstruction and leaks each time you start the generator set and every eight hours if you run it continuously 4 A029V089 Issue 2 2 Introduction Important note for Brazil applications The manufacturer warns that the installation operation and maintenance of equipment by the user must fully comply with the Manual s guidelines and current Brazilian laws including those of the Brazilian Agency of Petroleum Natural Gas and Fuels ANP and the Brazilian Energy Agency ANEEL 2 1 About this Manual This is the Operator Manual for the Model GSBB generator set Each operator of this generator set should become thoroughly familiar with the information in this manual and observe all of it s instructions and precautions Refer to the Operation chapter of this manual for instructions and guidelines for operating and monitoring the genset Refer to the Maintenance chapter of this manual for instructions and guidelines for performing periodic maintenance The operator is responsible for generator set maintenanc
21. Ready Disabled Seprember 14 2007 2 22 PM Standby ready enabled by user September 14 2007 2 08 PM Genset stopped manually Standby Ready Disabled September 14 2007 2 02 PM Gensel starte manually Standby Ready Disabled Septeniber 14 200 1308 PM Standby ranky elisssdilised ly war E Suplumiun 14 2027 4 58 PM Standhy rearly enabled by user Snprember 14 2077 1 37 PM Censet stopped manually Standby Ready Disabled September 14 2007 1 37 PM Genset started manually Standby Ready Disabled January 4 2006 4 20 AM Standby ready enabled by user January 2 2006 7 11 FM Gensel stopped manually Slandby Ready Disabled January 2 2006 14 EM Morini ers amie Chotruge ail and chick vaka kesh dsauanny 2 2006 42 25 PIA Genser started manually Sranriby Ready Disabled January 1 2006 4 74 PM Genset stopped manually Standby Ready Disabled Jenuery 1 2006 4 22 PM Genset stopped with return of utility zm January 1 2006 4 21 PM E Standby ready enabled by user January 1 2006 4 21 EM Genset slarled manually Slanuby Ready Disabled January 12006 4 20 PM 1 Switeh on qensor maved ro remote pasitian Wanuary 1 2906 42 00 ALA FIGURE 32 EVENT LOG 6 2 5 Fault Log Select the Fault Log Tab on the Home Screen to review the last 5 faults Genset Exercise Time Date Schedule Fault Log Fault Description Engine Hours FIGURE 33 FAULT LOG 6 2 6 Network Setup Screen Descriptions An owner custom passwo
22. art Network Setup Exercise Schedule Frequency Neus v Sunday 12 v 6 v AM v Apply Lxercise Now FIGURE 30 SET EXERCISE SCHEDULE 6 2 3 Load Control Management Select the Load Control Tab on the Home Screen to enable Automatic or Manual Load Control In Automatic mode the user can only view which loads are connected In Manual mode the user can view loads and also connect or disconnect them See Load Management for details Home Genset Exercise Loac Fault Time i Date Schedule Cantal lon Genset Load Management ace 4 Connessi Load 2 Connected Nowe Taare arn always dlecannentod for n warm ip period when the nenerarr stris oven when In Mani Mads Luuus are enubled ore ai u fiume wilh a delay betwee eucit Mudu Automate Apply FIGURE 31 GENSET LOAD MANAGEMENT 6 2 4 Event Log Select the Event Log Tab on the Home Screen to review the last 20 events See the Event Log screen capture below for a list of all of the recordable events A029V089 Issue 2 53 6 Optional Internet Email Interface Descriptions 4 2010 Home Genset Excicise vU Network lime Date Schedule Log Setup Event Log Cvent Description Time Date Genset started manually Standby Ready Disabled September 13 200 amp cot PM Standby ready enabled by user September 14 2007 3 21 PM Genser stopped manually Standby Ready Dl shind Srpremher 14 2007 3 24 PM Censer started manually Standby
23. cted to the generator side of the Ethernet cable a If you can access a standard web page cal Cummins Support at 1 800 888 6626 and select option 1 b If you cannot access a standard web page go to Check connections above c Check to see if the correct generator IP Address has been entered as described in the Network Setup Guide If not enter the correct IP Address d Check to see if you can access the generator set via the in home network If not call Cummins Support at 1 800 888 6626 and select option 1 FIGURE 23 NETWORK CONNECTIONS CONTROL BOARD AND ETHERNET CONNECTION 5 5 2 Remote Internet Access to Generator Set Troubleshooting A WARNING Some Generator Set service procedures present hazards that can result in severe personal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform Generator Set service Possible Causes An improper setup no high speed internet connection the public IP address is not active or properly set up an incorrect IP address is entered the computer is connect to the same router or network and the generator set or the internet connection is bad Corrective Actions 1 Check to see if you are able to access the generator set with your in home computer If not refer to the In Home Network Access Troubleshooting procedures 2 Verify that you followed the network setup procedures Refer to the Network Se
24. ctions for the generator set that should be followed during the operation and maintenance of the generator and batteries Thoroughly read this manual before operating the generator set Safe operation and top performance can only be obtained when equipment is properly operated and maintained The following symbols in this manual alert you to potential hazards to the operator service person and equipment DANGER Alerts you to an immediate hazard that will result in severe personal injury or death WARNING Alerts you to a hazard or unsafe practice that can result in severe personal injury or death gt p e CAUTION Alerts you to a hazard or unsafe practice that can result in personal injury or equipment damage 1 2 General Precautions e Keep ABC fire extinguishers handy e Make sure all fasteners are secure and torqued properly e Keep the generator set and its compartment clean Do not store any items in the genset compartment e Excess oil oily rags etc can catch fire e Dirt and gear stowed in the compartment will restrict cooling air flow e Before working on the generator set move the Stop Switch S2 to the Stop position disconnect the remote harness P7 to disable the ATS mounted charger and then remove the negative battery cable to prevent starting e Use caution when making adjustments while the generator set is running hot moving or when parts are electrically live as all situations may cause personal i
25. d manually Standby Ready Disabled e Genset exercise started A029V089 Issue 2 25 3 Operation 3 11 26 s 4 2010 Genset exercise completed Genset started due to loss of utility Genset stopped with return of utility Switch on genset moved to remote position Switch on genset moved to run position Switch on genset moved to off position Standby ready disabled by user Standby ready enabled by user Utility lost not in Standby Ready Utility returned not in Standby Ready Maintenance reminder Change oil and check valve lash Maintenance reminder Change oil amp filter air filter adjust valve lash clean and check battery amp engine cooling fins Genset fault Fault description appended Genset warning Transfer Switch Signal Failure Genset warning Transfer Switch Failed to Transfer to Utility Genset warning Low Battery or Battery Charger Failure Fault Log To check the log of the last 5 faults ij 5 Press the MENU button on the home screen 2 Press the up or down arrow button on the menu screen to select Fault Log 3 4 Scroll through the fault log with the up and down double arrow buttons Each screen Press the ENTER button on the menu screen provides a brief description of the fault the fault code number and the time and date of the fault Press the BACK button to return to the home screen NOTE If there are no faults recorded the No Sto
26. e in accordance with the Periodic Maintenance Schedule Refer to the Troubleshooting chapter for steps to be taken to diagnose and correct situations that cause a generator set to shutdown A WARNING This generator set is not for life support It can stop without warning Children persons with physical or mental limitations and pets could suffer personal injury or death A personal attendant redundant power or an alarm system must be used if power system operation is critical 2 2 About the Generator Set The model GSBB generator set is an engine powered generator set fueled by Natural Gas or Propane It is for installation as a standby generator set only in conjunction with the model RSS Automatic Transfer Switch produced under the Cummins Power Generation brand name See the Specifications section of this manual for specific information about the generator set N CAUTION It is recommended that the model GSBB generator set be installed with the model RSS Automatic Transfer Switch by a trained and experienced electrician or authorized Cummins Onan service representative The generator set is intended as a back up to utility power Whenever utility power is interrupted the house electrical loads are automatically switched by the transfer switch from the utility normal power source to the generator set emergency power source When utility power is restored the loads are automatically switched back to the utility To do this
27. enerator set and letting it run for 20 minutes once every 28 days or more often if desired Refer to the Exercise Settings section of this manual for more information on setting up the exerciser Engine Oil Maintenance Recommended Engine Oil Check the oil level prior to starting the generator set to verify that the oil level is between the FULL and ADD marks e The generator set is shipped with engine oil e Any 40W synthetic oil can be used for normal operating temperatures e For cold weather operation below 10 F Mobil1 0W 40 synthetic engine oil is recommended Checking Engine Oil Level WARNING State and federal agencies have determined that contact with used engine oil can cause cancer or reproductive toxicity Avoid skin contact and breathing of vapors Use rubber gloves and wash exposed skin Accidental or remote starting of the generator set can cause severe personal injury or death Disconnect the negative battery cable and place the control switch in its OFF position before starting work 1 Pull out the dip stick and wipe it clean 2 Reinsert the dip stick 3 Remove the dipstick one final time and check the oil level NOTE The engine oil level indicated on the dipstick should be between the FULL and ADD marks 4 Reinsert the dipstick If the engine oil level check shows excessive or insufficient levels of oil oil level line above the FULL mark or below the ADD mark oil must be drained or added Re
28. ery charging system excessive cranking Corrective Actions 1 Clean and tighten positive and negative battery cable connections at the battery 2 Recharge or replace battery Refer to the battery manufacturer s recommendations 3 Have battery charger serviced by an authorized Cummins Onan dealer Starter Engages Disengages Possible Cause Cranking voltage dips below 8 VDC Battery connections battery charging system start stop switches Corrective Actions 1 Clean and tighten positive and negative battery cable connections at the battery 2 Recharge or replace battery Refer to the battery manufacturer s recommendations 3 Have the battery charger serviced by an authorized Cummins Onan dealer A029V089 Issue 2 4 2010 5 4 4 5 4 5 5 4 6 5 4 7 5 4 8 5 Troubleshooting No AC Power generator set Running Status LED On Steady or Flashing Rapidly Possible Cause Circuit breakers tripped due to short circuit or overloading Corrective Actions 1 Reduce number of loads 2 Reset or turn on generator set circuit breaker 3 Reset or turn on circuit breaker in the distribution panel 4 Have the circuits from the generator set and distribution panel verified by an authorized electrician Generator Set Cranks But Does Not Start No Fault Code Possible Cause Faulty or incorrect spark plugs Corrective Actions 1 Check and record last fault code 2 Crank generator set and troubleshoot fa
29. esent and areas sharing ventilation e Fuel lines must be secured free of leaks and separated or shielded from electrical wiring e Leaks can lead to explosive accumulations of gas Prevent leaks and the accumulation of gas e A rotten egg smell indicates a possible Natural Gas or Propane leak e Natural Gas rises when released and can accumulate under hoods and inside housings and buildings e Propane sinks when released and can accumulate inside housings and basements and other below grade spaces 1 6 Batteries Can Explode Batteries can explode causing severe skin and eye burns and can release toxic electrolytes e Wear safety glasses e Do not smoke e Do not dispose of the battery in a fire e The battery is capable of exploding e Do not open or mutilate the battery e Released electrolytes have been known to be harmful to the skin and eyes and to be toxic e Batteries present the risk to high short circuit current e Remove watches rings or other metal objects and use tools with insulated handles 2 A029V089 Issue 2 4 2010 1 7 1 8 1 8 1 1 8 2 1 IMPORTANT SAFETY INSTRUCTIONS e To prevent arcing when disconnecting the battery e Move the Stop Switch S2 to the Stop position disconnect the remote harness P7 to disable the ATS mounted charger and then remove the negative battery cable to prevent starting e To prevent arcing when reconnecting the battery e First reconnect the positi
30. ess To set up your generator set for web access complete installation instructions are included in the Network Setup Guide instruction sheet included with your generator set literature package The Internet Email Interface can make the same fault maintenance and event notices available to you and to your generator set service contract agency with appropriate Internet Service and email account CS NOTE Technical support for setup and troubleshooting of the hardware used for in home network access to the generator set is available through the selling Cummins Onan dealer distributor The owner may be required to contact their ISP and or email provider for technical support of the email notification feature setup and troubleshooting Due to the variations in network equipment network configurations and ISPs the owner is responsible for acquiring the needed support service from a qualified network specialist to properly and securely set up the owner s network for remote monitoring of the generator set Cummins Onan does not provide technical support for setup and troubleshooting of the owner s network and email service A029V089 Issue 2 51 6 Optional Internet Email Interface Descriptions 6 2 Screen Descriptions d Standby Power by Cummins Microsoft Internet Explorer File Edit View Favorites Tools Help O O x la GD s 3X pe carentes a E E lad a address httpit92 168 000 002 v G Search am
31. fer to the battery manufacturer s recommendations 3 Verify engine oil viscosity is correct for the ambient temperature If not refill and replace engine oil with correct viscosity 4 Have unit serviced by an authorized Cummins Onan dealer 5 4 18 Control Card Failure Fault Code 35 Possible Causes Faulty program Corrective Actions 1 Have unit serviced by an authorized Cummins Onan dealer 5 4 19 Generator Set Stopped Without Fault Condition Fault Code 36 Possible Causes Fuel supply air fuel mixture exhaust system choke demand regulator carburetor generator windings ignition wire connections A029V089 Issue 2 43 5 Troubleshooting 4 2010 5 4 20 5 4 21 5 4 22 5 4 23 5 4 24 44 Diagnosis amp Repair 1 Check the fuel source Open any closed fuel valves Secure spark plug leads to spark plugs Check and service air filter as necessary Replace spark plugs Quo fF oO N Check for mechanical damage Invalid Set Configuration Fault Code 37 Possible Causes Generator set configuration control Diagnosis amp Repair 1 Have unit serviced by an authorized Cummins Onan dealer Processor Fault Fault Code 43 Possible Causes Faulty program Corrective Actions 1 Have unit serviced by an authorized Cummins Onan dealer Speed Sense Fault Fault Code 45 Possible Causes Loads generator windings wire connections Corrective Actions 1 Have unit serviced by an authorized Cummins
32. fer to the following sections Drain Oil or Add Oil as needed for instructions and guidelines for draining and adding oil A029V089 Issue 2 4 4 3 2 4 4 4 4 Maintenance Add or Drain Oil CAUTION Too much oil can cause high oil consumption Too little oil can cause severe engine damage Keep the oil level between the FULL and ADD marks on the dipstick Drain Oil If the oil level is found to be excessive see Checking Engine Oil Level oil must be drained from the engine 1 Attach one end of the drain hose shipped loose with the genset to the oil drain valve 2 Place the other end of the drain hose into an appropriate container Refer to local state regulations to determine the appropriate container for used oil 3 Open the oil drain valve to release oil from the engine into the appropriate container 4 Re check the engine oil level Checking Engine Oil Level Based on the results add or drain oil 5 When a sufficient amount of oil has been drained from the system a Close the oil drain valve b Remove the drain hose c Wipe the oil drain valve clean d Dispose of the used oil in accordance with local state regulations Add Oil If the oil level is found to be insufficient see Checking Engine Oil Level oil must be added 1 Add the appropriate amount of oil based on the engine oil level check performed beforehand 2 Re check the engine oil level see Checking Engine Oil Level Based on
33. following information available 1 Complete model number and serial number 2 Date of purchase 3 Nature of problem A029V089 Issue 2 9 2 Introduction 4 2010 This page is intentionally blank 10 A029V089 Issue 2 3 Operation 3 1 3 Position Switch A three position Start Stop switch is located at the genset control panel Switch positions available e Manual Start Normally only the maintenance service technician has occasion to manually start and stop the generator set Push the switch down at the thick end to start the set immediately e Stop middle position This switch disables the set e Remote For automatic operation the Start Stop switch must be in the Remote position and Standby On must be activated on the In Home Display Push the switch down at the thin end to put into the Remote position No Description No Description E Manual Start Position m Remote Position 3 Stop Position ee MN FIGURE 2 3 POSITION SWITCH STOP SWITCH A029V089 Issue 2 11 3 Operation 4 2010 3 2 In Home Operator Panel The operator panel must be hard wired to the generator set in order for the generator system to operate CS NOTE The in home operator panel and Internet Email interface can be used simultaneously The operator panel consists of two UTILITY status lamps three GENERATOR status lamps three action buttons and an LCD display screen with four navigation buttons UTILITY PRESENT CONNECTED
34. g heater recommended humidity Below 20 F 7 C Additional oil heater recommended for starting Factory installed model available Below 0 F 18 C Additional accessory breather heater required to avoid possible engine damage See warranty statement Below 10 F 23 C Additional accessory battery blanket recommended for starting Below 20 F 29 C Not warranted See warranty statement TABLE 4 GENERATOR SET SPECIFICATIONS TABLE NENNEN Propane Vapor NaturalGas Propane Vapor NaturalGas Weight With Oil 540 Ibs 245 kg Size Lx W x H 48 x 43 x 34 6 in 1219 x 864 x 880 mm 62 dB A at 23 ft 7 m at normal load Normal load is equal to the typical household consumption of 3 KW TABLE 5 FUEL SPECIFICATIONS TABLE SS Propane Vapor NaturalGas Propane Vapor A029V089 Issue 2 2 Introduction 4 2010 1 2 Load 132 500 Btu Hr 135 000 Btu Hr 122 000 Btu Hr 114 000 Btu Hr 35 ft Hr 135 ft Hr 48 ft Hr 110 ft Hr Full Load 275 000 Btu Hr 240 000 Btu Hr 229 000 Btu Hr 213 000 Btu Hr ua eee aml ft Hr 240 ft Hr 90 ft Hr 205 ft Hr Fuel Pressure si Pressure 7 11 inches WC 5 11 inches WC 7 11 inches WC 5 11 inches WC Contact your local gas company to verify the tank size required for your application TABLE 6 ENGINE SPECIFICATIONS TABLE yr o Propane Vapor NaturalGas Propane Vapor __ Natural Gas 2 Cylinder V Twin OHV Air Cooled 4 Stroke Spark Ignited 3600 RPM 60
35. he house loads 18 A029V089 Issue 2 4 2010 3 Operation A CAUTION Manually starting or stopping the generator set disables generator set STANDBY The generator set will not automatically start to supply power if utility power is interrupted Manually start and stop the generator set once every 3 months to test that these functions are working properly To manually start or stop the generator set 1 Press the START STOP button on the operator panel which takes you to the Genset START STOP screen e The screen will display Genset Stopped or Genset Running as appropriate 2 Press START to manually start the generator set and connect it to supply power to the house The STANDBY OFF lamp will come on and the display will state Genset started manually Standby Ready Disabled 3 Press STOP to manually stop the generator set and disconnect it The STANDBY OFF lamp will come on and the display will state Genset stopped manually Standby Ready Disabled NOTE To start the generator set without connecting loads pick Exercise Now on the Exerciser Clock screen Manual Operation Disables Standby Genset Stopped FIGURE 11 GENSET START STOP SCREEN 3 6 Fault Maintenance and New Event Screens Various warning and event screens may appear on the operator panel during Normal or Emergency Operation 3 6 1 Fault Screen If a generator set shutdown fault occurs a FAULT warning appears with the following info
36. ing is not present proceed to step 6 6 Check to see if you are using an email account capable of using port 25 with plain authentication SMTP server setup If necessary obtain an email account capable of using port 25 with plain authentication SMTP and enter detail into the network setup screen 7 Verify that the domain name is included in the user name field of the Network Setup screen i e username domainname 8 Verify with your ISP that the Static DNS Domain Name Server 1 and 2 are correct 9 If the previous steps do not correct the problem contact a computer network specialist to diagnose No authentication is possible by leaving the username and password fields blank IMPORTANT NOTE Changes are not saved unless you navigate through all three Network Setup screens and click on Done The message Settings Saved Successfully is then displayed Network Setup DHCP Off On IP Number 192 Subnet Mask 255 255 Gateway 192 168 Static DNS 1 192 1168 Static DNS 82 134 171 FIGURE 24 NETWORK SETUP PAGE 1 48 A029V089 Issue 2 4 2010 Event Control Log Exercise Load Schedule Genset Time Date Genset Status Stopped Battery Voltage 13 8 VDC Genset Load 95 Line 11 Line 21 Output Voltage Frequency 0 VAC 0 Hz Engine Hours 389 Hours 5 Troubleshooting Fault Network Log Setup Genset Clock 6 11 PM March 10 200
37. isted below in numerical order along with step by step corrective actions 5 2 Fault Code Blinking At fault shutdown the status indicator light will repeatedly blink sets of 1 2 3 or 4 blinks e One blink indicates shutdown due to high engine temperature e Two blinks indicate shutdown due to a loss of engine oil pressure e Three blinks indicate a service fault Press Stop once to cause the two digit second level shutdown code to blink Pressing Stop again will stop the blinking The two digit code consists of 1 2 3 4 or 5 blinks a brief pause and then 1 to 9 blinks The first set of blinks represents the tens digit and the second set of blinks the units digit of the shutdown code number e Four blinks indicate that cranking time exceeded 35 seconds e Fault Code Nos 1 2 3 and 4 are first level faults Pay close attention to the pause sequence to avoid interpreting first level faults as second level Fault Codes Nos 11 22 33 or 44 e To avoid the possibility of anyone misinterpreting Code Nos 3 and 4 as Code Nos 33 and 44 the latter have not been assigned faults 5 3 Restoring Fault Code Blinking The fault code stops blinking after five minutes Press Stop three times within three seconds to restore fault code blinking A029V089 Issue 2 39 5 Troubleshooting 4 2010 e A 5 4 5 4 1 5 4 2 5 4 3 40 NOTE The last fault logged will blink even though the condition that caused the shutdown may have
38. llows an adjustment of 240 VAC x 796 17 VAC 4 Press the BACK button to save the settings and return to the home screen 3 4 To Enable Disable Standby Normally you should not have to disable generator set STANDBY e STANDBY should always be enabled ON except during maintenance service e STANDBY will have to be re enabled STANDBY OFF light on if the generator set is started or stopped manually normally a maintenance service function or a fault shutdown has occurred A CAUTION When STANDBY is disabled the generator set will NOT automatically start to supply power if utility power is interrupted To enable or disable generator set standby 1 Press the STANDBY ON OFF button on the operator panel which takes you to the Standby ON OFF screen 2 Press the up or down arrow button to select ON or OFF 3 To enable STANDBY select ON and press the BACK button The STANDBY OFF lamp will go out and the display will state Standby ready enabled by user 4 To disable STANDBY select OFF and press the BACK button The STANDBY OFF lamp will come on and the display will state Standby ready disabled by user Standby required for automatic start stop Standby OW OFF FIGURE 10 ENABLE DISABLE STANDBY SCREEN 3 5 To Manually Start Stop Generator Set Normally only the maintenance service technician has to manually start and stop the generator set e Starting the generator set will result in the generator powering t
39. n 2 Press the up or down arrow button on the menu screen to select Genset Status 3 Press the ENTER button on the menu screen and note the values displayed on the Genset Status screen 4 Press the BACK button to return to the home screen Battery 12 5 Genset Load Li I28N EXCER CLOCK LOAD MENU i Genset Status Display Setup Event Log Fault Log Ethernet Setup Genset Status Voltage 240V Frequency 60Hz Hr Meter 1234 6 FIGURE 15 GENERATOR SET STATUS SCREEN 3 8 Load Management The generator set may have been set up at installation to connect and disconnect certain large loads such as air conditioners to manage the total load so as not to overload the generator set This requires the installation of relays to the load management signals which allow for the disconnection of loads Load management can be set to operate in automatic or manual mode Whether in automatic or manual mode there is a delayed start Load 1 is enabled three minutes after the generator set is connected to the house loads and Load 2 is enabled six minutes after the generator set is connected to the house loads 029V089 Issue 2 21 3 Operation 4 2010 3 8 1 3 8 2 22 Automatic Load Management When set to automatic mode the user takes no action and can only view which loads are connected Three minutes after the generator starts the load that is connected to genset load L1 is connected After a delay
40. njury or death e Used engine oil has been identified by some state and federal agencies as causing cancer or reproductive toxicity Do not ingest inhale or come into contact with used oil or it s vapors e Do not work on the generator set when mentally or physically fatigued or after consuming alcohol or drugs 1 3 Generator Voltage is Deadly e Generator output connections must be made by a trained and experienced electrician in accordance with all applicable codes A029V089 Issue 2 1 1 IMPORTANT SAFETY INSTRUCTIONS 4 2010 e This standby generator set and the public utility may only be connected to the house circuits by means of the automatic transfer switch e Improper connections can lead to electrocution of utility workers and damage to equipment e Use caution when working on live electrical equipment Remove jewelry make sure clothing and shoes are dry and stand on a dry wooden platform 1 4 Engine Exhaust is Deadly e See What Is Carbon Monoxide Poisoning to learn the symptoms of Carbon Monoxide poisoning e This generator set is for outdoor installation only e t must be located well away from doors windows other openings into the house and where the exhaust gases will disperse away from the house 1 5 Fuel is Flammable and Explosive e Keep flames cigarettes sparks pilot lights electrical arc producing equipment switches and all other sources of ignition well away from areas where fuel fumes are pr
41. o go the load connect disconnect screen 5 Connect or disconnect Load 1 or Load 2 as necessary by pressing either button under Load 1 or Load 2 6 Press the BACK button to save the setting and return to the home screen A029V089 Issue 2 4 2010 3 9 3 9 1 12 5 Battery Genset Load LIW L28MN3 EXCER CLOCK LOAD MENU 4 Load Management Mode BNUESNSENSI 1 Disconnected 2 Connnected AUTOMATIC MODE 3 Operation Load Management Mode Meman 1 2 Disconnected Connnected When running Disconnected Connected Connect Disconnect Load 1 Load 2 MANUAL MODE FIGURE 16 LOAD MANAGEMENT SCREEN Display Setup and Software Info Brightness and Contrast To change the Brightness and Contrast of the display screen 1 Press the MENU button on the home screen S GP Quoi E D A029V089 Issue 2 Press the up or down arrow button on the menu screen to select Display Setup Press the ENTER button on the menu screen Press the NEXT button to select Brightness or Contrast Press the increase or decrease arrow button to increase or decrease brightness Change Contrast the same way as Brightness Press the BACK button to save the settings and return to the home screen 23 3 Operation 4 2010 Sun 10 35 AM Battery 12 5 Genset Load LIW 1288 EXCER CLOCK LOAD MENU Genset Status Event Log Fault Log Ethernet Setup
42. of three more minutes the load that is connected to genset load L2 is connected If the connection of loads L1 and L2 exceeds 95 of the generator s load capacity they are disconnected by the generator Following another three minute delay the control reconnects both loads following the same connection sequence used in the first attempt three minutes apart If generator load capacity is exceeded again both loads are disconnected and no further reconnection is tried To select automatic load management and view whether the selected loads are connected while the generator set is running 1 Press the LOAD button on the home screen 2 Press the up or down arrow button to select Automatic 3 Note which loads are connected or disconnected 4 Press the BACK button to return to the home screen Adjust percent load to match the de rate Manual Load Management CAUTION To reduce unnecessary loss of service it is highly recommended that manual load management be undertaken only by an authorized Cummins Onan dealer When set to manual mode the user is able to view connect and disconnect loads If the connection of loads L1 and L2 exceeds generator capacity the AC circuit breaker trips To select manual load management when the generator is running 1 Press the LOAD button on the home screen 2 Press the up or down arrow button to select Manual 3 Note which loads are connected or disconnected 4 Press the double down arrow button t
43. p 3 Eu opuens amp Cummins Onan Genset Exercise Load Time Date Event Schedule Control Log Genset Status Running Battery Voltage 11 7 VDC Genset Load Line 1 Mm Line 2 ME M 0 25 50 75 100 Output Voltage Frequency 240VAC 60Hz Engine Hours 105 4 Hours Start Genset Stop Genset Network Setup Genset Clock 8 12 AM September 16 2007 Utility Utility Present Utility Connected enerator Running Standby Off Action Required Enable Standby Disable Standby FIGURE 28 HOME PAGE 6 2 1 Setting Time and Date 4 2010 Select the Genset Time Date Tab on the Home Screen to set the time and date for the generator set control Genset Time Date Datu September x 15 v 2007 Time 0 20 vl An Apply FIGURE 29 52 Nelwurk Setup SET GENSET TIME AND DATE A029V089 Issue 2 4 2010 6 Optional Internet Email Interface Descriptions 6 2 2 Set Exercise Schedule Select the Exercise Schedule Tab on the Home Screen to set the generator set exercise schedule CS NOTE The generator set will exercise on the first scheduled day for which it is programmed After that it exercises on that day at the scheduled interval For example if the generator set is scheduled on a Wednesday for Saturdays with a monthly interval the generator set starts on the next available Saturday After that it exercises on Saturdays one month ap
44. placing the Air Filter Element A WARNING Before working on the generator set move the Switch S2 to the Stop 34 Position disconnect the remote harness P7 to disable the ATS mounted charger and remove the negative battery cable from the battery to prevent starting Refer to the Periodic Maintenance Table for scheduled air filter replacements Replace it more often in dusty environments To change the filter element 1 Remove the outer and inner cover and reassemble with a new air filter element 2 Make sure the outer cover is seated before tightening its wing nut A029V089 Issue 2 4 2010 4 Maintenance No Description No Description 5 Batey Circuit Breaker S 7 jCowoSwih EP FIGURE 22 MAINTENANCE POINTS 4 6 Battery Maintenance A WARNING Arcing at battery terminals or in light switches or other equipment and flames or sparks can ignite battery gas causing severe personal injury Ventilate battery area before working on or near battery Wear safety glasses Do not smoke Switch work light ON or OFF away from battery Stop the generator set Disconnect the negative battery cable first and reconnect it last WARNING Before working on the generator set move the Switch S2 to the Stop Position disconnect the remote harness P7 to disable the ATS mounted charger and remove the negative battery cable from the battery to prevent starting Refer to
45. rd can be defined in the Network Setup screen shown below The user will be prompted to enter the User Name and Password to access this screen The Network Setup Parameters screen allows dynamic addresses to be changed to static addresses This screen allows the user to configure the static address for the in home network See the Network Setup Parameters screen shown below Genset Exercise Load Network Time Date Schedule Control Setup Network Setup Click here to start Network Setup Enter new webpage password max 8 chars cummins Save Password MAC address 00 1C E8 23 00 01 Software Part Number 3267344 Software Version 0 56 FIGURE 34 NETWORK SETUP SCREEN 54 A029V089 Issue 2 4 2010 6 Optional Internet Email Interface Descriptions Network Setup DHCP Off On IP Number Subnet Mask Gateway Static DNS 1 205 i Static DNS 2205 FIGURE 35 NETWORK SETUP PARAMETERS 6 2 7 Email Setup Screen Descriptions The user must determine what events will trigger an email notification of the event e Never e All Events e Maintenance and Attention Required or Attention Required Only This screen is also used to set up e mail configuration The user may enter up to three email addresses for receiving notifications of the home standby generator set status See the Email Addresses figure below Network Setup Email Setup Alert Level Maintenance and Attention Required
46. red Faults screen will appear A029V089 Issue 2 4 2010 3 Operation Battery 12 5 Genset Load LIW 1288 EXCER CLOCK LOAD MENU Genset Status Display Setup Event Lo Ethernet Setup Fault Log 1 of 5 Speed Sense Lost Fault No 27 Hour 10000 1 Fault History No Stored Fault FIGURE 19 FAULT LOG SCREEN 3 12 Exercise Settings To set the generator set exercise schedule 1 Press the EXCER button on the home screen 2 Press the NEXT button on the Exerciser Clock screen to select the field to change 3 Press the up or down arrow button to increase or decrease the frequency of exercise and the day of the week and time of day for exercise Frequency selections are 029V089 Issue 2 27 3 Operation 4 2010 Weekly Bimonthly Monthly Never 4 Press the BACK button to save the settings and return to the home screen 5 If you want to exercise the generator set now select Exercise Now and press either the up or down arrow CS NOTE Scheduled or prompted exercise does not transfer the house loads to the generator set Sun 10 35 AM Battery 1245 Genset Load LIW 128 EXCER CLOCK LOAD MENU 4 Exerciser Clock Exercise Weekly Bite FIGURE 20 EXERCISE CLOCK SCREEN 3 13 Time Setup To set up the generator set clock for the current date and time 1 Press the CLOCK button on the home screen 2 Press the NEXT button on the Time Setup screen to select the
47. rmation See 5 IMPORTANT ENGINE INFORMATION um CUMMINS POWER GENERATION puo er P e 400 73rd Ave NE EIL aer SUPR h P ___ Minneapais MM 55432 ca cm J 1 M 7 em z Model LUE Sac Wada in USA Rast a lemme D c3 N BM li ME KVA Pf er PH RPM Pis B l SIBI d 80 Hz j As Manufactured Freg AC Volts Ampe 5 1 Options EE 7 7 Fuek jBet Software Cfg Wiro Diegren Ineuletion NEMA Claes Ambient 40C MARINE ENGINE EMISSION CONTROL NFO ENGINE MARINZED WITHOUT AFFECTING EMISSION CONTROL 98 2495410 FIGURE 1 NAMEPLATE 6 A029V089 Issue 2 4 2010 2 Introduction 2 2 2 Model Specifications Model GSBB consists of four different variations These variations are defined in the GSBB Model Variations table below TABLE 2 GSBB MODEL VARIATIONS Product Description 60 Hz Warm 60 Hz Cold 50 Hz AUINZ 20GSBB 6717A 60 Hz CSA Cold Includes an alternator dryer and engine heater CS NOTE See the Cold Weather Specifications Table for recommendations TABLE 3 COLD WEATHER SPECIFICATIONS TABLE ill Propane Vapor Natural Gas Propane Vapor jNatualGas Operating Temperature Range Above 32 F 0 C and low No dryers or starting aids required humidity Below 32 F 0 C or high Alternator dryin
48. rmation e Brief description of the warning or fault e The two digit Fault Code Number e The time of occurrence of the fault Press the BACK button to reset the fault and return to the home screen See the Fault Log section of this manual to review the log of the last 5 faults A029V089 Issue 2 19 3 Operation 4 2010 Starting Fault Fault Number 32 Hour 10000 1 FIGURE 12 TYPICAL FAULT SCREEN 3 6 2 Maintenance Due Screen A Maintenance Due screen appears when a scheduled maintenance operation is due e The warning does not time out e Perform the maintenance Press the BACK button to return to the home screen Maintenance Due Air Filter FIGURE 13 TYPICAL MAINTENANCE DUE SCREEN 3 6 3 New Event Screen A New Event screen appears whenever system status changes such as when there is an interruption of utility power The screen provides a brief description of the event along with the time and date of the event e The message does not time out unless superseded by a new event e Press the BACK button to return to the home screen See the Event Log section of this manual to review the log of the last 20 events New Event Auto Start Loss of Utility 07 10 2007 4 08PM FIGURE 14 TYPICAL NEW EVENT SCREEN 20 A029V089 Issue 2 4 2010 3 Operation 3 7 Genset Status To check generator set output voltage and frequency and the total numbers of hours run 1 Press the MENU button on the home scree
49. rvice personnel with knowledge of fuels electricity and machinery hazards should perform Generator Set service Overvoltage Fault Code 12 Possible Causes Generator set loads wire connections windings Corrective Actions 1 Have unit serviced by an authorized Cummins Onan dealer Undervoltage Fault Code 13 Possible Causes Generator set loads wire connections windings Corrective Actions 1 Have unit serviced by an authorized Cummins Onan dealer Overfrequency Fault Code 14 Possible Causes Generator set loads engine governor function fuel supply air fuel mixture exhaust system choke demand regulator carburetor generator windings wire connections Corrective Actions 1 Have unit serviced by an authorized Cummins Onan dealer Underfrequency Fault Code 15 Possible causes Generator set loads engine governor function fuel supply air fuel mixture exhaust system choke demand regulator carburetor generator windings ignition wire connections Corrective Actions 1 Reduce the number of connected loads especially loads that require higher starting current such as air conditioners 2 Have unit serviced by an authorized Cummins Onan dealer Governor Actuator shutdown Fault Code 19 Possible causes Wire connections governor actuator Corrective Actions 1 Have unit serviced by an authorized Cummins Onan dealer Governor Actuator Overload Fault Code 22 Possible causes Generator set load
50. s wire connections fuel supply air fuel mixture exhaust system governor actuator ignition system A029V089 Issue 2 4 2010 5 Troubleshooting Corrective Actions 1 Reduce the number of connected loads especially loads that require higher starting current such as air conditioners 2 Check and service air filter as necessary 3 Have unit serviced by an authorized Cummins Onan dealer 5 4 15 Voltage Sense Lost Fault Code 27 Possible Causes Generator set loads generator windings ignition wire connections Corrective Actions 1 Have unit serviced by an authorized Cummins Onan dealer A WARNING Some Generator Set service procedures present hazards that can result in severe personal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform Generator Set service 5 4 16 High Battery Voltage Fault Code 29 Possible Causes Incorrect battery configuration wire damage faulty charger control Corrective Actions 1 Have battery charger serviced by an authorized Cummins Onan dealer 5 4 17 Low Cranking Speed Sense Fault Code 32 Possible Causes Starter engine components air intake system exhaust system generator windings wire connections battery battery connections oil viscosity Corrective Actions 1 Clean and tighten positive and negative battery cable connections at the battery 2 Recharge or replace battery Re
51. tenance Frequency First Startup Daily or Every Yearly or Every 250 Every 400 24 Hours Every 100 Hours Hours EE 3 Check ICheckEngine Oil Level Oil Level Change Engine Oil and Oil Filter c first 8 hours Adjust Engine Valve Clearance After first 50 mE IReplace Engine Air Filter Engine Air Filter Clean and Check Starting Battery Replace Spark Plugs and Wires Clean Engine Cooling Fins a Complete System Test es ee ee ee Perform more often when operating in dusty conditions Perform more often when operating in high temperature conditions Perform sooner if engine performance deteriorates Must be performed by a qualified mechanic authorized Cummins Onan dealer Check daily during power outages or monthly without power outages See automatic transfer switch manual for testing of load transfer 029V089 Issue 2 31 4 Maintenance 4 2010 4 2 4 3 4 4 4 4 1 4 4 2 32 Cleaning the Housing Top The top surface of the generator set housing can be damaged by pressure washing or solvents and other cleaning agents Only use soap and water or an all citrus degreaser to clean the top Exercising the Generator Set Exercising the generator set drives off moisture re lubricates the engine and removes oxides from electrical contacts The result is better starting more reliable operation and longer engine life The generator set exerciser is capable of automatically starting the g
52. tup Guide 3 Verify that you are using a high speed internet connection 46 A029V089 Issue 2 4 2010 5 5 3 5 Troubleshooting 4 Verify that the public IP Address is active and set up properly with the ISP Internet Service Provider If necessary contact the ISP to verify your setup 5 Verify that the correct public IP Address is entered into the web browser of the computer i e XXX XXX XXX XXX 6 Verify that the computer is not connected to the same router or network as the generator set e The computer used for internet access must be connect to a different internet connection than the generator set 7 Check to see if you can access a standard web page from a computer e If not contact the ISP to troubleshoot the internet connection 8 Verify all settings as described in the Network Setup Guide 9 If the previous steps do not correct the problem contact a computer network specialist to diagnose To verify your IP Address access whatismyipaddress com from the browser of a computer connected to the internet and on the same network as the generator set This web page displays your current IP Address which should match the IP Address assigned to you by your ISP Email Alert Troubleshooting WARNING Some Generator Set service procedures present hazards that can result in severe personal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery ha
53. ult code and reference last fault code recorded above if necessary WARNING Some Generator Set service procedures present hazards that can result in severe personal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform Generator Set service Genset Warning Transfer Switch Failed to Transfer to Utility No Fault Code Possible Cause Transfer switch is faulty or wire is disconnected or broken Corrective Actions 1 Have the utility switch position wire wire connections and transfer switch checked by an authorized electrician Low Oil Pressure Fault Fault Code 2 Possible Cause Oil Level too low high faulty switch faulty oil pressure relief valve faulty oil pump Corrective Actions 1 Check oil level add or drain oil as necessary Overcrank Fault Code 4 Possible Cause Faulty switch faulty external start command fuel supply air fuel mixture exhaust system wire connections starter ignition system Corrective Actions 1 Open any closed fuel valves 2 Secure spark plug leads to spark plugs A029V089 Issue 2 41 5 Troubleshooting 4 2010 A 5 4 9 5 4 10 5 4 11 5 4 12 5 4 13 5 4 14 42 3 Check and service air filter as necessary 4 Replace spark plugs WARNING Some Generator Set service procedures present hazards that can result in severe personal injury or death Only trained and experienced se
54. ve cable then the negative cable and finally reconnect the battery charger e When replacing the generator set battery always replace it with a battery as specified in the Model Specifications section of this manual Moving Parts Can Cause Severe Personal Injury or Death e Do not wear loose clothing or jewelry near moving parts such as fans e Keep hands away from moving parts e Keep guards in place over fans The Hazards of Carbon Monoxide Engine driven generators can produce harmful levels of carbon monoxide that can injure or kill you What Is Carbon Monoxide Poisoning Carbon Monoxide CO is an odorless colorless tasteless and non irritating gas You cannot see it or smell it Red blood cells however have a greater affinity for CO than for Oxygen Therefore exposure even to low levels of CO for a prolonged period can lead to asphyxiation lack of Oxygen resulting in death Mild effects of CO poisoning include eye irritation dizziness headaches fatigue and the inability to think clearly More extreme symptoms include vomiting seizures and collapse What Are the Special Risks of CO Near the Home Residents can be exposed to lethal levels of CO when the genset is running Depending on air temperature and wind CO can accumulate in or near the home To protect yourself and others from the dangers of CO poisoning it is recommended that reliable and approved CO detector alarms be installed in the home
55. y soot deposits indicates the need for engine service To prevent cross threading a spark plug always thread it in by hand until it seats Torque the spark plug to 15 Ib ft 20 N m Return the genset control to Auto when finished performing maintenance Maintenance Record Record all periodic and unscheduled maintenance and service See the Periodic Maintenance Schedule for a list of scheduled maintenance frequency HOUR METER MAINTENANCE OR SERVICE PERFORMED READING A029V089 Issue 2 4 2010 4 Maintenance Record the name address and phone number of your authorized Cummins Onan service center A029V089 Issue 2 37 4 Maintenance 4 2010 This page is intentionally blank 38 A029V089 Issue 2 5 Troubleshooting By regularly performing the following periodic maintenance and guidelines you greatly reduce the chances of a genset shutdown e Maintain an appropriate oil level e Checking Engine Oil Level e Add or Drain Oil e Keep battery connections clean and tight e Battery Maintenance e Do not overload the generator set e Keep the air inlet and outlet openings clear 5 1 Troubleshooting With the In Home Operator Panel If a fault shutdown occurs the ACTION REQUIRED lamp on the in home Operator Panel will come on and the LCD screen will display the a description of the Fault the Fault Number and the hour in total generator set running time when the Fault occurred The shutdown codes are l
56. zards should perform Generator Set service Possible Causes An improper setup the alert level is not set to all events emails cannot be received the outgoing email address is not included in your contact list the email account is not capable of using port 25 with plain SMTP for the outgoing SMTP server setup the domain name is not included in the user name filed of the Network Setup screen or the DNS 1 and 2 values are incorrect on the Network Setup screen Corrective Actions 1 Check to see if you are able to access the generator set with your in home computer If not refer to In Home Computer Access Troubleshooting 2 Verify that you followed the network setup instructions Refer to the Network Setup Guide 3 Verify that the alert level is set to All Events a To verify that your generator set can send emails select Disable Standby and wait several minutes to verify that you did receive an email b Select Enable Standby and wait a few more minutes to verify that you did receive a second email 4 Send an email to the destination email address and check to see if you received this email If not contact your email service provider or your ISP Internet service provider to diagnose 5 Check to see if the destination email accounts have spam filtering a If spam filtering is present add the outgoing email address to your contact list A029V089 Issue 2 47 5 Troubleshooting 4 2010 b If spam filter
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