Operator Manual Norwall PowerSystems

Operator Manual Norwall Powersystems-Free PDF

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Table of Contents,1 IMPORTANT SAFETY INSTRUCTIONS 1. 1 1 Warning Caution and Note Styles Used In This Manual 1. 1 2 General Information 1,1 2 1 General Safety Precautions 1. 1 3 Generator Set Safety Code 2, 1 3 1 Moving Parts Can Cause Severe Personal Injury Or Death 3. 1 3 2 Positioning of Generator Set 3,1 3 3 Positioning of Generator Set Open Sets 3. 1 4 Electrical Shocks and Arc Flashes Can Cause Severe Personal Injury or Death 3. 1 4 1 AC Supply and Isolation 4,1 5 Fuel And Fumes Are Flammable 4.
1 5 1 Gaseous Fuels 5,1 5 2 Spillage 5,1 5 3 Fluid Containment 5. 1 5 4 Do Not Operate in Flammable and Explosive Environments 5. 1 6 Exhaust Gases Are Deadly 5,1 6 1 Exhaust Precautions 6. 2 INTRODUCTION 7,2 1 About This Manual 7,2 2 Schedule of Abbreviations 7. 2 3 Related Literature 8,2 3 1 Further Information Literature 9. 2 4 After Sales Services 9,2 4 1 Maintenance 9,2 4 2 Warranty 9.
2 4 3 How to Obtain Service 9,3 SYSTEM OVERVIEW 11. 3 1 Generator Set Identification 11,3 1 1 Nameplate 11. 3 2 Generator Set Components 11,3 3 Generator Set Rating 12. 3 4 Engine 13,3 4 1 Engine Data 14,3 5 Sensors 14,3 6 Heaters 15. 3 6 1 Heater Supply and Isolation 15,3 7 Mains Utility Powered Battery Charger 15.
3 8 Alarm Module 15,3 9 Coolant Heater 16,3 10 System Options 16. A034G614 Issue 3 i,Table of Contents 9 2011,3 10 1 Normal Duty Air Cleaner 16. 3 10 2 PowerCommand Universal Annunciator 17,4 CONTROL SYSTEM PCC 2100 19. 4 1 Control System Description 19,4 2 Control Panel Power On Off Modes 20. 4 2 1 Power On Mode 20,4 2 2 Screen Saver Mode 21,4 2 3 Sleep Awake Mode 21.
4 3 Battle Short Mode 21,4 4 Front Panel 22,4 4 1 Digital Display 23. 4 4 2 Display Menu Selection Button 23,4 4 3 Home Button 24. 4 4 4 Previous Main Menu Button 24,4 4 5 Emergency Stop Button 24. 4 4 6 Running Indicator 25,4 4 7 Remote Start Indicator 25. 4 4 8 Not in Auto 25,4 4 9 Analog AC Metering Panel 25.
4 4 10 Shutdown Status 25,4 4 11 Warning Status Indicator 25. 4 4 12 Fault Acknowledgement Reset Button 26,4 4 13 Panel Lamp and Lamp LED Test Button 26. 4 4 14 Manual Run Stop Button 26,4 4 15 O Manual Auto Switch 26. 4 4 16 Configurable Indicators 26,4 5 Control Menus 27. 4 5 1 Main Menus 27,4 5 2 Adjusting Default Settings 29.
4 5 3 System Messages 30,4 5 4 Controller Configuration Menu 30. 4 5 5 Engine Menu 31,4 5 6 Alternator Menu 34,4 5 7 Adjust Menu 35. 4 5 8 Faults Menu 38,4 5 9 System Menu 39,4 5 10 History Menu 40. 4 5 11 About Menu 42,5 OPERATION PCC 2100 45,5 1 Safety 45. 5 2 Introduction 45,5 3 Maintenance 46,5 4 Starting 46.
5 4 1 Starting Safety Consideration 46,5 4 2 Operator s Pre start Checks 46. ii A034G614 Issue 3,9 2011 Table of Contents, 5 4 3 Starting at the Control Panel Manual Mode 47. 5 4 4 Starting From a Remote Location PTC or Remote Start Signal Auto Mode 48. 5 4 5 Cold Starting With Loads 52,5 5 Stopping 52,5 5 1 Emergency Stop 52. 5 5 2 Stopping at Control Panel Manual Mode 52, 5 5 3 Stopping from Remote Location Remote Stop Signal Auto Mode 53. 5 6 Operating Recommendations 53,5 6 1 Running in 53.
5 6 2 No Load Operation 53,5 6 3 Exercise Period 53. 5 6 4 Low Operating Temperature 54,5 6 5 High Operating Temperature 54. 6 MAINTENANCE 55,6 1 Locking the Generator Set Out of Service 56. 6 1 1 Immobilizing for Safe Working 56,6 1 2 Periodic Maintenance 57. 6 2 Daily or Refueling Maintenance Procedures 60,6 2 1 General Information 60.
6 2 2 Engine Operation Report 60,6 3 Cooling System 61. 6 3 1 Coolant Level Check 61,6 3 2 Cooling Fan Inspect 62. 6 3 3 Drive Belt Inspection 63,6 3 4 Radiator Check 64. 6 4 Engine Oil Level Check 64,6 5 Fluid Containment 65. 6 6 Hoses and Fuel Lines Check 65,6 7 Normal Duty Air Cleaner 66.
6 7 1 Air Cleaner Element Removal 66,6 7 2 Air Cleaner Element Installation 67. 6 8 Exhaust System 68,6 9 Generator Set Output AC Electric System 68. 6 10 DC Electrical System 69,6 11 Lead Acid Batteries 69. 6 11 1 Storage 69,6 11 2 Safety Precautions 70,6 11 3 Battery Commissioning 70. 6 11 4 Battery Maintenance 72, 6 11 5 Electrolyte Specific Gravity and Temperature 74.
6 11 6 Battery Replacement 76, 6 11 7 Electrolyte Levels and Bench Charging Rates 76. 6 11 8 Battery Fault Finding 77,7 TROUBLESHOOTING 79. 7 1 Control System 79,A034G614 Issue 3 iii,Table of Contents 9 2011. 7 2 Safety Considerations 79,7 3 Fault Finding 80,7 4 Status Indicators PCC 2100 80. 7 4 1 Running Indicator 80,7 4 2 Remote Start Indicator 81.
7 4 3 Not in Auto 81,7 4 4 Configurable Indicators 81. 7 4 5 Shutdown Status 81,7 4 6 Warning Status Indicator 81. 7 5 Fault Status Codes PCC 2100 81,7 5 1 Fault Status Codes 81. 7 5 2 Fault Messages 82,7 5 3 Fault Acknowledgement 82. 7 5 4 Category A Fault Codes 83,7 5 5 Category B Fault Codes 83.
7 5 6 Category C Fault Codes 83,7 5 7 Category D Fault Codes 83. 7 5 8 Category E Fault Codes 83,7 5 9 PCC 2100 Fault Codes Table 83. 7 5 10 Warning and Shutdown Codes 85,7 6 Line Circuit Breaker 88. 8 BATTERY CHARGER 89, 8 1 Battery Charger 15 Amp 12 Volt and 12 Amp 24 Volt 89. 8 1 1 Control Panel 90,8 1 2 Battery Charger Configuration 91.
8 1 3 Battery Temperature Sensor 91,8 2 Circuits 92. 9 MANUFACTURING FACILITIES 93,9 1 How to Obtain Service 93. 9 1 1 Locating Your Distributor 93,iv A034G614 Issue 3. 1 Important Safety Instructions, SAVE THESE INSTRUCTIONS This manual contains important instructions that should be. followed during installation and maintenance of the generator set and batteries. Safe and efficient operation can be achieved only if the equipment is properly operated. and maintained Many accidents are caused by failure to follow fundamental rules and. precautions,1 1 Warning Caution and Note Styles Used In This.
The following safety styles and symbols found throughout this manual indicate potentially. hazardous conditions to the operator service personnel or the equipment. DANGER Warns of a hazard that will result in severe personal injury or death. WARNING Warns of a hazard that may result in severe personal injury or death. CAUTION Warns of a hazard or an unsafe practice that can result in product or property. NOTE A short piece of text giving information that augments the current text. 1 2 General Information, This manual should form part of the documentation package supplied by Cummins Power. Generation with specific generator sets In the event that this manual has been supplied in. isolation please contact your authorized distributor. NOTE It is in the Operator s interest to read and understand all Warnings and. Cautions contained within the documentation relevant to the generator set. its operation and daily maintenance,1 2 1 General Safety Precautions. WARNING Coolants under pressure have a higher boiling point than water DO NOT. open a radiator or heat exchanger pressure cap while the engine is. running Allow the generator set to cool and bleed the system pressure first. To prevent severe scalding let the engine cool down before removing the. coolant pressure cap Turn the cap slowly and do not open it fully until the. pressure has been relieved, WARNING Used engine oils have been identified by some state or federal agencies as. causing cancer or reproductive toxicity When checking or changing engine. oil take care not to ingest breathe the fumes or contact used oil. NOTE Keep multi class ABC fire extinguishers handy Class A fires involve ordinary. combustible materials such as wood and cloth Class B fires involve. combustible and flammable liquid fuels and gaseous fuels Class C fires. involve live electrical equipment ref NFPA No 10 in applicable region. CAUTION Make sure that rags are not left on or near the engine. A034G614 Issue 3 1,1 Important Safety Instructions 9 2011. CAUTION Make sure the generator set is mounted in a manner to prevent combustible. materials from accumulating under the unit, CAUTION Remove all unnecessary grease and oil from the unit Accumulated grease and oil.
can cause overheating and engine damage which present a potential fire hazard. CAUTION Keep the generator set and the surrounding area clean and free from obstructions. Remove any debris from the set and keep the floor clean and dry. WARNING Do not work on this equipment when mentally or physically fatigued or after. consuming any alcohol or drug that makes the operation of equipment. WARNING Substances in exhaust gases have been identified by some state or federal. agencies as causing cancer or reproductive toxicity Take care not to breath. ingest or come into contact with exhaust gases, WARNING Do not store any flammable liquids such as fuel cleaners oil etc near the. generator set A fire or explosion could result, WARNING Wear hearing protection when going near an operating generator set. WARNING To prevent serious burns avoid contact with hot metal parts such as the. radiator the turbo charger and the exhaust system, WARNING Use personal protective equipment when maintaining or installing the. generator set Examples of personal protective equipment include but are not. limited to safety glasses protective gloves hard hats steel toed boots and. protective clothing, WARNING Do not use starting fluids that evaporate They are highly explosive. CAUTION Do not step on the generator set when entering or leaving the generator room. Parts can bend or break leading to electrical shorts or to fuel coolant or exhaust. CAUTION To prevent accidental or remote starting while working on the generator set. disconnect the negative battery cable at the battery. WARNING Ethylene glycol used as engine coolant is toxic to humans and animals. Clean up spills and dispose of used engine coolant in accordance with local. environmental regulations, WARNING Moving parts can cause severe personal injury or death Hot exhaust parts.
can cause severe burns Make sure all protective guards are properly in. place before starting the generator set,1 3 Generator Set Safety Code. Before operating the generator set read the manuals and become familiar with them and the. equipment Safe and efficient operation can be achieved only if the equipment is properly. operated and maintained Many accidents are caused by failure to follow fundamental rules. and precautions, WARNING Improper operation and maintenance can lead to severe personal injury or. loss of life and property by fire electrocution mechanical breakdown or. exhaust gas asphyxiation Read and follow all Safety Precautions Warnings. and Cautions throughout this manual and the documentation supplied with. your generator set,2 A034G614 Issue 3,9 2011 1 Important Safety Instructions. WARNING Lifting and repositioning of the generator set must only be carried out using. suitable lifting equipment shackles and spreader bars in accordance with. local guidelines and legislation by suitably trained and experienced. personnel Incorrect lifting can result in severe personal injury death and or. equipment damage For more information contact your authorized. distributor, 1 3 1 Moving Parts Can Cause Severe Personal Injury Or Death. Keep your hands clothing and jewelry away from moving parts. Before starting work on the generator set disconnect the battery charger from its AC. source then disconnect the starting batteries negative cable first This will prevent. accidental starting, Make sure that fasteners on the generator set are secure Tighten supports and clamps.
keep guards in position over fans drive belts etc, Do not wear loose clothing or jewelry in the vicinity of moving parts or while working on. electrical equipment Loose clothing and jewelry can become caught in moving parts. If any adjustments must be made while the unit is running use extreme caution around hot. manifolds moving parts etc,1 3 2 Positioning of Generator Set. The area for positioning the set should be adequate and level and the area immediately around. the set must be free of any flammable material, WARNING On an enclosed generator set the canopy doors must be locked before re. positioning and they must remain locked during transportation and sitting. 1 3 3 Positioning of Generator Set Open Sets, The area for positioning the set should be adequate and level and the area immediately around. the set must be free of any flammable material,1 4 Electrical Shocks and Arc Flashes Can Cause.
Severe Personal Injury or Death, WARNING Any work with exposed energized circuits with potentials of 50 Volts AC or. 75 Volts DC or higher poses a significant risk of electrical shock and. electrical arc flash These silent hazards can cause severe injuries or death. Refer to standard NFPA 70E or equivalent safety standards in corresponding. regions for details of the dangers involved and for the safety requirements. Guidelines to follow when working on de energized electrical systems. Use proper PPE Do not wear jewelry and ensure that any conductive items are removed. from pockets as these items can fall into equipment and the resulting short circuit can. cause shock or burning Refer to standard NFPA 70E for PPE standards. De energize and lockout tagout electrical systems prior to working on them. Lockout Tagout is intended to prevent injury due to unexpected start up of equipment or. Operator Manual Generator Set Ford V 10 6 8L Engine with PowerCommand This manual should form part of the documentation package supplied by Cummins Power Generation with specific generator sets In the event that this manual has been supplied in isolation please contact your authorized distributor NOTE It is in the Operator s interest to read and understand all Warnings and Cautions

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