CUMMINS GSBB Manuel de service

ServiceService ManualManualHome Standby Generator SetGSBB (Spec A-B)GSBC (Spec B)EnglishOriginal Instructions 9-2013 A030A239 (Issue 10)

1. IMPORTANT SAFETY INSTRUCTIONS 9-20131.8.3 Only You Can Protect Yourself From CO Poisoning!• Locate the generator in an area where there are no wind

9. Troubleshooting 9-2013b. If misalignment is toward the bearing, the cause is not from this tolerance issue and islikely the result of the end bell

9-2013 9. Troubleshootingb. Propane having more than 2.5 percent Butane will not vaporize in ambients at lessthan 32°F; use HD-5 grade Propane.c. Run

9. Troubleshooting 9-20133. Measure generator set load capability with shop load bank (de-rate for altitude andtemperature as necessary).4. Measure AC

9-2013 9. Troubleshooting20. Verify that the spark plug cables are secure on the spark plugs: reconnect or replace asnecessary.21. Inspect ignition ki

9. Troubleshooting 9-20133. Measure the generator set load capability with a shop load bank (de-rate for altitude andtemperature as necessary).4. Meas

9-2013 9. Troubleshooting22. Inspect the spark plug leads, kill lead terminals at magnetos, and measure the magneto airgap: replace the terminals, set

9. Troubleshooting 9-2013Possible Causes: Incorrect battery configuration, wire damage, faulty charger, controlDiagnosis & Repair:1. Verify that t

9-2013 9. Troubleshooting8. Check air filter cleanliness; replace the air filter as necessary.9. Check for a blocked or damaged exhaust system: repair

9. Troubleshooting 9-20139.25 Generator Set Stopped Without Fault Condition -Fault Code 36Logic: RPM less than 500 and Sense Voltage S1-S2 at 0 VAC wh

9-2013 9. Troubleshooting16. Verify that the spark plug cables are secure on the spark plugs: reconnect or replace asnecessary.17. Inspect ignition ki

2 IntroductionThis generator set application is intended for stationary emergency use.Important note for Brazil applications: The manufacturer warns t

9. Troubleshooting 9-20133. Disconnect the generator set control J1 connector, verify that the J1 pins are fully inserted,and inspect pin condition us

9-2013 9. Troubleshooting8. Verify clear vent hose.9. Run the generator set on shop fuel supply; verify the tank level and fuel line condition.10. Che

9. Troubleshooting 9-20136. Verify the temperature sensor resistance. Replace as necessary.7. Measure the temperature sensor wiring (J1-33) for contin

9-2013 9. TroubleshootingPossible Causes: Wire connections, faulty positional switch, faulty transfer switchcomponent(s)Diagnosis & Solution:1. Ve

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10 Communication Troubleshooting10.1 In-Home Network Access to Generator SetTroubleshootingWARNINGSome generator set service procedures present hazard

10. Communication Troubleshooting 9-2013d. If none of the above troubleshooting techniques help, call Cummins Support at 1-800-888-6626 and select opt

9-2013 10. Communication Troubleshooting6. Verify that the computer is not connected to the same router or local area network as thegenerator set. If

10. Communication Troubleshooting 9-20136. Ensure that the SMTP server in use is capable of distributing non SSL certified emails. Ifthe SMTP server i

9-2013 10. Communication TroubleshootingFIGURE 62. GENERATOR SET HOME PAGEFIGURE 63. NETWORK SETUP - PAGE 2A030A239 (Issue 10) 113

2. Introduction 9-20132.2.1 Model SpecificationsTABLE 1. GSBB AND GSBC MODEL VARIATIONSProduct Description20GSBB-6713A\B 60 Hz Warm20GSBB-6714A\B 60 H

10. Communication Troubleshooting 9-2013FIGURE 64. NETWORK SETUP - PAGE 3114 A030A239 (Issue 10)

Appendix A. Outline and System DrawingsTable of ContentsFigure 65. Ethernet Connections (Optional) ...

Appendix A. Outline and System Drawings 9-2013Wiring connections to the Ethernet RJ-45 plug are shown in the Ethernet RJ-45 Connector Wiring illustrat

9-2013 Appendix A. Outline and System DrawingsFIGURE 67. ETHERNET RJ-45 CONNECTOR WIRINGA030A239 (Issue 10) 117

Appendix A. Outline and System Drawings 9-2013FIGURE 68. NETWORK CONNECTIONS118 A030A239 (Issue 10)

9-2013 Appendix A. Outline and System DrawingsFIGURE 69. MANUAL FUEL SELECTION VALVEA030A239 (Issue 10) 119

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9-2013 Appendix A. Outline and System DrawingsFIGURE 70. WIRING DIAGRAM (SHEET 1 OF 3)A030A239 (Issue 10) 121

Appendix A. Outline and System Drawings 9-2013FIGURE 71. WIRING DIAGRAM (SHEET 2 OF 3)122 A030A239 (Issue 10)

9-2013 Appendix A. Outline and System DrawingsFIGURE 72. WIRING DIAGRAM (SHEET 3 OF 3)A030A239 (Issue 10) 123

9-2013 2. IntroductionTABLE 4. FUEL SPECIFICATIONS TABLE (SPEC A AND CANADIAN GSBB SPEC B)60 Hz 50 HzPropane Vapor Natural Gas Propane Vapor Natural G

Appendix A. Outline and System Drawings 9-2013FIGURE 73. HARNESS LABEL124 A030A239 (Issue 10)

9-2013 Appendix A. Outline and System DrawingsFIGURE 74. WIRING HARNESS CONNECTIONS (SHEET 1 OF 4)A030A239 (Issue 10) 125

Appendix A. Outline and System Drawings 9-2013FIGURE 75. WIRING HARNESS CONNECTIONS (SHEET 2 OF 4)126 A030A239 (Issue 10)

9-2013 Appendix A. Outline and System DrawingsFIGURE 76. WIRING HARNESS CONNECTIONS (SHEET 3 OF 4)A030A239 (Issue 10) 127

Appendix A. Outline and System Drawings 9-2013FIGURE 77. WIRING HARNESS CONNECTIONS (SHEET 4 OF 4)128 A030A239 (Issue 10)

9-2013 Appendix A. Outline and System DrawingsFIGURE 78. OUTLINE DRAWINGA030A239 (Issue 10) 129

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Cummins Power Generation1400 73rd Ave. NEMinneapolis, MN 55432 USAPhone 1 763 574 5000Toll-free 1 800 888 6626Fax 1 763 574 5298Copyright © 2013 Cummi

2. Introduction 9-2013TABLE 7. GENERATOR SPECIFICATIONS TABLE60 Hz 50 HzPropane Vapor Natural Gas Propane Vapor Natural GasGenerator Brush-Type, 2-Pol

9-2013 2. IntroductionCAUTIONUnauthorized modifications or replacement of fuel, exhaust, air intake or speed control systemcomponents that affect engi

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3 Maintenance3.1 Periodic Maintenance SchedulePeriodic maintenance is essential for top generator set performance. Use the MaintenanceFrequency table

3. Maintenance 9-20133.2 Cleaning the Housing TopThe top surface of the generator set housing can be damaged by pressure washing or solventsand other

9-2013 3. Maintenance3.5 Engine Oil Maintenance3.5.1 Recommended Engine OilCheck the oil level prior to starting the generator set to verify that the

3. Maintenance 9-20133. Open the oil drain valve to release oil from the engine into the appropriate container.4. Re-check the engine oil level (Check

9-2013 3. Maintenance3.6 Replacing the Air Filter ElementWARNINGBefore working on the generator set, move the Switch (S2) to the Stop Position, discon

3. Maintenance 9-20133.7 Battery MaintenanceWARNINGArcing at battery terminals or in light switches or other equipment, and flames or sparks, canignit

9-2013 3. Maintenance3.9 Accessory Heater KitsWARNINGElectrical connections must be made by a trained and experienced electrician. Improperinstallatio

3. Maintenance 9-2013DATE HOUR MAINTENANCE OR SERVICE PERFORMEDMETERREADINGRecord the name, address, and phone number of your authorized Cummins Onan

4 ServiceWARNINGSome Generator Set service procedures present hazards that can result in severe personal injuryor death. Only trained and experienced

4. Service 9-20134.3 EngineThis generator set is powered by a Briggs & Stratton Vanguard M61 Engine.Engine Part NumberSpec A and Canadian GSBB A02

9-2013 4. Service4.4.2 Engine-Alternator InstallationReference the image below for installation of the engine-alternator assembly.See the Testing The

4. Service 9-2013No. Description1 Fan housing2 Fan guard3 Wound armature4 Generator stator5 Alternator brush block6 Generator end bell7 Alternator ada

9-2013 4. Service4.5 Fuel System Components TestingWARNINGFuel systems must be installed by qualified service technicians. Improper installationpresen

Table of Contents1. IMPORTANT SAFETY INSTRUCTIONS ... 11.1 Save The

4. Service 9-2013No. Description No. Description1 Fuel Regulator 3 Nipple Fitting2 SolenoidFIGURE 5. FUEL SYSTEM COMPONENTS (US GSBB SPEC B AND CANADI

9-2013 4. Service4.5.3 Governor ActuatorGovernor Actuator Testing: Disconnect the two actuator leads and apply 12 VDC. Replacethe actuator if the actu

4. Service 9-2013No. Description1 Rotate arm counter-clockwise to fully open slide until the lever just touches the rod. Tighten the fasteners.2 3/32&

9-2013 4. ServiceNo. Description1 Fully closed actuator2 Lever touches set screwFIGURE 7. GOVERNOR ACTUATOR - CLOSED4.5.4 Governor Linkage Adjustment

4. Service 9-2013No. Description1 FastenersFIGURE 8. GOVERNOR ACTUATOR - FASTENERS4.5.5 Gas Demand RegulatorConduct a lock-off pressure test as follow

9-2013 4. ServiceNOTICEMake sure the diaphragm is in a vertical plane (as in the genset) when performing a benchtest, otherwise the weight of the diap

4. Service 9-2013NOTICETesting for gas leaks with a flame can cause a fire or explosion that can lead to severepersonal injury or death. Use approved

9-2013 4. Service4.6 ControlNo. Description1 Circuit breaker2 Rocker switch3 Insulation boot4 Sensor bracket5 Temperature switch6 Battery lead7 Electr

4. Service 9-20134.6.1 Generator ControlGeneral: The generator control is an integrated microcontroller-based engine, generator andtransfer switch con

9-2013 4. Service4.6.5 Alternator Temperature SwitchThe alternator temperature switch contacts are normally closed. The switch contacts open at170 °F

Table of Contents 9-20134.5.1 Fuel Pressure...

4. Service 9-2013No. Description1 Fan housing2 Fan guard3 Wound armature4 Generator stator5 Alternator brush block6 Generator end bell7 Alternator ada

9-2013 4. Service4.8 Alternator Temperature SwitchThe alternator temperature switch contacts are normally closed. The switch contacts open at170 °F ±

4. Service 9-20132. Remove the stator and stator through studs.3. Remove the nut and flat washer on the rotor through stud and remove the through stud

9-2013 4. ServiceTests Measurement ValuesL2 to N 0.094 ohms ± 10%L1 to L2 (Equal to sum of L1 to N and L2 to N) ± 1%Q1 to Q2 1.11 ohms ± 10%L1 and N t

4. Service 9-2013Expected output will be 73.2 amp - 11.7 amp = 61.5 ampTo verify generator set performance:1. Follow de-rate guidelines above and dete

5 Operation5.1 In-Home Operator PanelThe operator panel must be hard-wired to the generator set in order for the generator system tooperate.NOTICEThe

5. Operation 9-20135.1.3 START STOP ButtonSee To Manually Start/Stop Generator Set.5.2 Typical OperationNOTICEThe following diagrams are based on an A

9-2013 5. OperationFIGURE 13. EXERCISE TIMING DIAGRAMA030A239 (Issue 10) 41

5. Operation 9-2013FIGURE 14. MANUAL START/STOP TIMING DIAGRAM42 A030A239 (Issue 10)

9-2013 5. OperationFIGURE 15. LOAD MANAGEMENT TIMING DIAGRAM5.2.1 Normal Operation: Utility Power Available and ConnectedAs long as utility power is a

9-2013 Table of Contents5.12 Time Setup ...

5. Operation 9-2013FIGURE 16. UTILITY PRESENT AND CONNECTED—STANDBY OFF LAMP ON5.2.2 Emergency Operation: Utility Power InterruptedIf utility power is

9-2013 5. Operation5.3 To Enable/Disable StandbyNormally, you should not have to disable generator set STANDBY.• STANDBY should always be enabled (ON)

5. Operation 9-2013To manually start or stop the generator set:1. Press the START STOP button on the operator panel, which takes you to the GensetSTAR

9-2013 5. OperationFIGURE 20. TYPICAL FAULT SCREEN5.5.2 Maintenance Due ScreenA Maintenance Due screen appears when a scheduled maintenance operation

5. Operation 9-2013FIGURE 22. TYPICAL NEW EVENT SCREEN5.6 Genset StatusTo check generator set output voltage and frequency and the total numbers of ho

9-2013 5. OperationFIGURE 23. GENERATOR SET STATUS SCREEN5.7 Display Setup and Software Info5.7.1 Brightness and ContrastTo change the Brightness and

5. Operation 9-2013FIGURE 24. DISPLAY SETUP AND SOFTWARE INFO SCREENS5.7.2 Software InfoTo check on the generator set and display software:1. Press th

9-2013 5. Operation5.8 Event Log5.8.1 To Check Log of Last 20 Events1. Press the MENU button on the home screen.2. Press the up or down arrow button o

5. Operation 9-2013• "Genset stopped with return of utility"• "Switch on genset moved to remote position"• "Switch on genset

9-2013 5. OperationFIGURE 26. FAULT LOG SCREEN5.10 Ethernet SettingsThis feature allows for in-home or remote access to your generator set through a w

Table of Contents 9-20139.2 Troubleshooting with the Flashing Indicator Light ... 859.3 Fa

5. Operation 9-2013• determine if utility power is available• view the last 20 events/faults on the generator setThis feature is useful for homeowners

9-2013 5. OperationFIGURE 27. NETWORK SETUP SCREEN5.11 Exercise SettingsTo set the generator set exercise schedule:1. Press the EXCER button on the ho

5. Operation 9-2013NOTICEScheduled or prompted exercise does not transfer the house loads to the generator set.FIGURE 28. EXERCISE CLOCK SCREEN5.12 Ti

9-2013 5. OperationFIGURE 29. TIME SETUP SCREEN5.13 Load ManagementThe generator set may have been set up at installation to connect and disconnect ce

5. Operation 9-20135.13.2 Manual Load ManagementCAUTIONTo reduce unnecessary loss of service, it is highly recommended that manual loadmanagement be u

6 Startup and Configuration6.1 Pre-startup InspectionBefore starting the genset inspect the installation and check off each of the following questions

6. Startup and Configuration 9-2013NOTICEBefore leaving the site, if the genset is ready to be placed in service, set the control switch to theREMOTE

9-2013 6. Startup and ConfigurationFIGURE 31. GENERATOR CONFIGURATIONA030A239 (Issue 10) 61

6. Startup and Configuration 9-20136.4 Generator Adjustments6.4.1 To Adjust the Output VoltageUse the following procedure:1. Connect an accurate AC vo

9-2013 6. Startup and Configuration6. Press the BACK button to save the setting and return to the home screen.FIGURE 33. TRANSFER SWITCH CONFIGURATION

1 IMPORTANT SAFETY INSTRUCTIONS1.1 Save These InstructionsThis manual contains important instructions for the generator set that should be followed du

6. Startup and Configuration 9-20134. Press Enter on the Config Menu to go to the Transfer Switch screen.5. Press the NEXT button on the Generator Con

7 Optional Internet/Email InterfaceDescriptions7.1 IntroductionThis feature allows for in-home or remote access to your generator set through a web pa

7. Optional Internet/Email Interface Descriptions 9-20137.2 Screen DescriptionsFIGURE 35. HOME PAGE7.2.1 Setting Time and DateSelect the Genset Time/D

9-2013 7. Optional Internet/Email Interface DescriptionsFIGURE 36. SET GENSET TIME AND DATE7.2.2 Set Exercise ScheduleSelect the Exercise Schedule Tab

7. Optional Internet/Email Interface Descriptions 9-2013FIGURE 38. GENSET LOAD MANAGEMENT7.2.4 Event LogSelect the Event Log Tab on the Home Screen to

9-2013 7. Optional Internet/Email Interface DescriptionsFIGURE 40. FAULT LOG7.2.6 Network Setup Screen DescriptionsAn owner-custom password can be def

7. Optional Internet/Email Interface Descriptions 9-2013• Maintenance and Attention Required or Attention Required OnlyThis screen is also used to set

8 Optional Internet/Email Interface Setup8.1 Network Connectivity OptionsNetwork connectivity includes in-home Network access to the generator set, e-

8. Optional Internet/Email Interface Setup 9-2013NOTICESome email accounts will not accept unauthenticated emails and will not work with thesystem. En

9-2013 8. Optional Internet/Email Interface SetupFIGURE 46. NETWORK SETUP SCREEN ON THE IN-HOME OPERATOR PANELNOTICELeave the DHCP (Dynamic Host Confi

1. IMPORTANT SAFETY INSTRUCTIONS 9-20131.3 Generator Voltage is Deadly• Generator output connections must be made by a trained and experienced electri

8. Optional Internet/Email Interface Setup 9-2013FIGURE 47. GENERATOR SET HOME PAGEFIGURE 48. NETWORK SETUP SCREEN74 A030A239 (Issue 10)

9-2013 8. Optional Internet/Email Interface SetupFIGURE 49. NETWORK SETUP (PAGE 1)8.5 Setting Up Internet Access and E-mail Alerts1. Set up the in-hom

8. Optional Internet/Email Interface Setup 9-2013FIGURE 52. NETWORK SETUP PAGE 2FIGURE 53. NETWORK SETUP PAGE 32. Click Network Setup on the home page

9-2013 8. Optional Internet/Email Interface Setup12. Click Next to enter the destination e-mail addresses.13. Enter up to three different e-mail addre

8. Optional Internet/Email Interface Setup 9-2013NOTICEAcquiring a static IP may incur additional service charges from your ISP.2. Use the provided st

9-2013 8. Optional Internet/Email Interface Setup8.9.2 Email AddressesYou may enter up to three Email addresses to whom to send generator set status a

8. Optional Internet/Email Interface Setup 9-2013FIGURE 58. EMAIL ADDRESSESFIGURE 59. RETURN TO HOME PAGE8.10 Remote Internet Access to the Generator

9-2013 8. Optional Internet/Email Interface Setup2. To access the generator set's web page on any computer or wireless device not connectedto the

8. Optional Internet/Email Interface Setup 9-2013Question: What is the difference between Static and Dynamic IP Addresses?Answer:Dynamic IP Address -

9-2013 8. Optional Internet/Email Interface Setup2. Establish an Ethernet connection between the computer and generator set via a commonmodem.3. On th

9-2013 1. IMPORTANT SAFETY INSTRUCTIONS• Do not open or mutilate the battery.• Released electrolytes have been known to be harmful to the skin and eye

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9 TroubleshootingBy regularly performing the following periodic maintenance and guidelines, you greatly reducethe chances of a genset shutdown.• Maint

9. Troubleshooting 9-2013• Fault Code Nos. 1, 2, 3, and 4 are first level faults. Pay close attention to the pausesequence to avoid interpreting first

9-2013 9. Troubleshooting6. Reconnect J1 connector and test run generator set for symptom: repair or replace pins inconnector as necessary.7. Measure

9. Troubleshooting 9-2013• Use any suitable device that will not damage the inside contact wipers of the pinsocket7. Reconnect the J1 connector and te

9-2013 9. Troubleshooting2. Inspect the battery connections and cables for cleanliness, tightness, and damage: clean,tighten, and repair connections a

9. Troubleshooting 9-20133. Inspect the battery connections and cables for cleanliness, tightness, and damage: clean,tighten, and repair connections a

9-2013 9. Troubleshooting5. Measure continuity change across the start/stop switch between rest and under simulatedpressure: replace the switch as nec

9. Troubleshooting 9-20138. Check for blocked or damaged exhaust system: repair or replace exhaust components asnecessary.9. Propane Modelsa. When amb

9-2013 9. Troubleshooting3. Measure and verify AC frequency while changing engine rpm to determine if frequencyresponse matches engine rpm response.4.