Operator Manual Home Standby Generator Set GSBB (Spec A) English Original Instructions 9-2010 A029V089 (Issue 3)
Table of Contents 1. IMPORTANT SAFETY INSTRUCTIONS ...................................................................................... 1 1.1 Save These Instructions ........................................................................................................ 1 1.2 General Precautions .............................................................................................................. 1 1.3 Generator Voltage is Deadly ..............................................................
Table of Contents 9-2010 4.5 Replacing the Air Filter Element .......................................................................................... 34 4.6 Battery Maintenance ............................................................................................................ 35 4.7 Spark Plugs ......................................................................................................................... 36 4.8 Maintenance Record ................................................
1 IMPORTANT SAFETY INSTRUCTIONS 1.1 Save These Instructions This manual contains important instructions 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.
1. IMPORTANT SAFETY INSTRUCTIONS 9-2010 · This standby generator set and the public utility may only be connected to the house circuits by means of the automatic transfer switch. · Improper connections can lead to electrocution of utility workers and damage to equipment. · Use caution when working on live electrical equipment. Remove jewelry, make sure clothing and shoes are dry and stand on a dry wooden platform. 1.
9-2010 1. IMPORTANT SAFETY INSTRUCTIONS · To prevent arcing when disconnecting the battery: · 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. · To prevent arcing when reconnecting the battery: · First, reconnect the positive (+) cable, then the negative (-) cable, and finally reconnect the battery charger.
1. IMPORTANT SAFETY INSTRUCTIONS 1.8.3 9-2010 Only You Can Protect Yourself From CO Poisoning! · Locate the generator in an area where there are no windows, doors or other access points into the home. · Make sure all CO detectors are working properly. · Pay attention to the signs of CO poisoning. · Check the exhaust system for corrosion, obstruction and leaks each time you start the generator set and every eight hours if you run it continuously.
2 Introduction 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.
2. Introduction 2.2.1 9-2010 Generator Set Nameplate 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.
9-2010 2. Introduction TABLE 1. GSBB MODEL VARIATIONS Product Description 20GSBB-6713A 60 Hz Warm 20GSBB-6714A 60 Hz Cold * 14GSBB-6716A 50 Hz (AU/NZ) 20GSBB-6717A 60 Hz CSA Cold * * Includes an alternator dryer and engine heater. NOTE: See the Cold Weather Specifications Table for recommendations. TABLE 2.
2. Introduction 9-2010 Full Load 275,000 Btu/Hr 110 ft3/Hr 240,000 Btu/Hr 240 ft3/Hr 229,000 Btu/Hr 90 ft3/Hr 213,000 Btu/Hr 205 ft3/Hr Fuel Pressure 7-11 inches WC 5-11 inches WC 7-11 inches WC 5-11 inches WC Tank Size Contact your local gas company to verify the tank size required for your application. TABLE 5.
9-2010 2. Introduction TABLE 8. DC SYSTEM SPECIFICATIONS TABLE 60 Hz Propane Vapor 50 Hz Natural Gas Propane Vapor Natural Gas DC System Nominal Battery Voltage 12 Volts DC Battery Group 26 R Battery Type Maintenance Free Minimum Cold Crank Amps 545 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.
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3 Operation 3.1 3 Position Switch A three-position Start/Stop switch is located at the genset control panel. Switch positions available: · 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. · Stop (middle position): This switch disables the set.
3. Operation 3.2 9-2010 In-Home Operator Panel The operator panel must be hard-wired to the generator set in order for the generator system to operate. 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. No.
9-2010 3.3 3. Operation Typical Operation NOTE: The following diagrams are based on an APPROXIMATE time duration. Your genset may vary slightly from the timing diagrams in this manual. FIGURE 4.
3. Operation 9-2010 FIGURE 5.
9-2010 3. Operation FIGURE 6.
3. Operation 9-2010 FIGURE 7. 3.3.1 LOAD MANAGEMENT TIMING DIAGRAM Normal Operation: Utility Power Available and Connected As long as utility power is available and connected, both of the green UTILITY lamps (PRESENT and CONNECTED) will stay on and the LCD screen will indicate “Genset Stopped". If the red GENERATOR STANDBY OFF light is on, the generator set will not start up automatically if utility power is interrupted.
9-2010 3. Operation FIGURE 8. 3.3.2 UTILITY PRESENT AND CONNECTED—STANDBY OFF LAMP ON Emergency Operation: Utility Power Interrupted If utility power is interrupted, 1. The green UTILITY PRESENT lamp will go out 2. The generator set will start automatically and the green GENERATOR RUNNING lamp will turn on. 3. The UTILITY CONNECTED light will go out when the generator set is connected to supply power. The LCD screen will provide a visual indication of “Genset Load" (bar graphs).
3. Operation 3.3.3 9-2010 To Adjust the Output Voltage Use the following procedure: 1. Connect an accurate AC volt meter across L1 and L2 while the generator set is running. 2. With Output Volts selected on the Adjustments Menu screen, press the up or down arrow button to adjust the voltage to the desired setting 3. The control allows an adjustment of 240 VAC ± 7% (17 VAC). 4. Press the BACK button to save the settings and return to the home screen. 3.
9-2010 3. Operation 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.
3. Operation 9-2010 FIGURE 12. 3.6.2 TYPICAL FAULT SCREEN Maintenance Due Screen A Maintenance Due screen appears when a scheduled maintenance operation is due. · The warning does not time out. · Perform the maintenance. Press the BACK button to return to the home screen. FIGURE 13. 3.6.3 TYPICAL MAINTENANCE DUE SCREEN New Event Screen A New Event screen appears whenever system status changes, such as when there is an interruption of utility power.
9-2010 3.7 3. Operation Genset Status To check generator set output voltage and frequency and the total numbers of hours run: 1. Press the MENU button on the home screen. 2. Press the up or down arrow button on the menu screen to select Genset Status. 3. Press the ENTER button on the menu screen and note the values displayed on the Genset Status screen. 4. Press the BACK button to return to the home screen. FIGURE 15. 3.
3. Operation 3.8.1 9-2010 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 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.
9-2010 3. Operation FIGURE 16. LOAD MANAGEMENT SCREEN 3.9 Display Setup and Software Info 3.9.1 Brightness and Contrast To change the Brightness and Contrast of the display screen: 1. Press the MENU button on the home screen. 2. Press the up or down arrow button on the menu screen to select Display Setup. 3. Press the ENTER button on the menu screen. 4. Press the NEXT button to select Brightness or Contrast. 5. Press the increase or decrease arrow button to increase or decrease brightness. 6.
3. Operation 9-2010 FIGURE 17. 3.9.2 DISPLAY SETUP AND SOFTWARE INFO SCREENS Software Info To check on the generator set and display software: 1. Press the MENU button on the home screen. 2. Press the up or down arrow button on the menu screen to select Display Setup. 3. Press the ENTER button on the menu screen. 4. Press the INFO button on the Display Setup screen and note the values displayed on the Software Info screen.
9-2010 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.
3.
9-2010 3. Operation FIGURE 19. 3.12 FAULT LOG SCREEN Exercise Settings To set the generator set exercise schedule: 1. Press the EXCER button on the home screen. 2. Press the NEXT button on the Exerciser Clock screen to select the field to change. 3. Press the up or down arrow button to increase or decrease the frequency of exercise and the day of the week and time of day for exercise.
3. Operation 9-2010 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. NOTE: Scheduled or prompted exercise does not transfer the house loads to the generator set. FIGURE 20. 3.13 EXERCISE CLOCK SCREEN Time Setup To set up the generator set clock for the current date and time: 1. Press the CLOCK button on the home screen. 2.
9-2010 3. Operation FIGURE 21.
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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. · In hot and dusty environments some maintenance procedures should be performed more frequently, as indicated by the footnotes in the table. · Maintenance, replacement or repair of emission control devices and systems may be performed by any engine repair establishment or individual.
4. Maintenance 4.2 9-2010 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. 4.3 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.
9-2010 4.4.3 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. 4.4.3.1 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.
4. Maintenance 9-2010 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. 4.
9-2010 No. 4. Maintenance Description No. Description 1 Dipstick 2 Air Filter 3 Oil Filter 4 Oil Drain 5 Battery 6 Circuit Breaker 7 Control Switch FIGURE 22. 4.
4. Maintenance 9-2010 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. NOTE: 4.
9-2010 4. Maintenance Record the name, address, and phone number of your authorized Cummins Onan service center.
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5 Troubleshooting By regularly performing the following periodic maintenance and guidelines, you greatly reduce the chances of a genset shutdown. · Maintain an appropriate oil level · Keep battery connections clean and tight · Do not overload the generator set · Keep the air inlet and outlet openings clear 5.
5. Troubleshooting 9-2010 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 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.
9-2010 5.4.4 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. 5.4.
5. Troubleshooting 9-2010 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 service personnel with knowledge of fuels, electricity, and machinery hazards should perform Generator Set service. 5.4.9 Overvoltage - Fault Code 12 Possible Causes: Generator set loads, wire connections, windings Corrective Actions: 1.
9-2010 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.
5. Troubleshooting 9-2010 Diagnosis & Repair: 1. Check the fuel source. 2. Open any closed fuel valves. 3. Secure spark plug leads to spark plugs. 4. Check and service air filter as necessary. 5. Replace spark plugs. 6. Check for mechanical damage. 5.4.20 Invalid Set Configuration - Fault Code 37 Possible Causes: Generator set configuration, control Diagnosis & Repair: 1. Have unit serviced by an authorized Cummins Onan dealer. 5.4.
9-2010 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 & Solution: 1. Verify that the main AC circuit breaker on the generator set is to “On". 2.
5. Troubleshooting 9-2010 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 connected to the generator side of the Ethernet cable. a. If you can access a standard web page, call Cummins Support at 1-800-8886626 and select option 1. b.
9-2010 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.
5. Troubleshooting 9-2010 b. If spam filtering 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.
9-2010 5. Troubleshooting FIGURE 25. FIGURE 26.
5. Troubleshooting 9-2010 FIGURE 27.
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.
6. Optional Internet/Email Interface Descriptions 6.2 Screen Descriptions FIGURE 28. 6.2.1 9-2010 HOME PAGE Setting Time and Date Select the Genset Time/Date Tab on the Home Screen to set the time and date for the generator set control. FIGURE 29.
9-2010 6.2.2 6. Optional Internet/Email Interface Descriptions Set Exercise Schedule Select the Exercise Schedule Tab on the Home Screen to set the generator set exercise schedule. 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.
6. Optional Internet/Email Interface Descriptions 9-2010 FIGURE 32. 6.2.5 EVENT LOG Fault Log Select the Fault Log Tab on the Home Screen to review the last 5 faults. FIGURE 33. 6.2.6 FAULT LOG Network Setup Screen Descriptions An owner-custom password can be defined in the Network Setup screen shown below. The user will be prompted to enter the User Name and Password to access this screen. The Network Setup Parameters screen allows dynamic addresses to be changed to static addresses.
9-2010 6. Optional Internet/Email Interface Descriptions FIGURE 35. 6.2.7 NETWORK SETUP PARAMETERS Email Setup Screen Descriptions The user must determine what events will trigger an email notification of the event: · Never · All Events · 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.
6. Optional Internet/Email Interface Descriptions 9-2010 FIGURE 38. 6.3 SAVE SCREEN 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.
9-2010 6. Optional Internet/Email Interface Descriptions FIGURE 40.
6. Optional Internet/Email Interface Descriptions FIGURE 41.
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.
