6/30/2020

C150D2Re, C200D2Re, C275D2Re Circuit Breaker Testing Procedure

Technical Service Bulletin
Technical Service Bulletin: TSB200142
Released Date: 19-Jun-2020
C150D2Re, C200D2Re, C275D2Re Circuit Breaker Testing Procedure

C150D2Re, C200D2Re, C275D2Re Circuit Breaker
Testing Procedure
Warranty Statement
The information in this document has no effect on present warranty coverage or repair practices,
nor does it authorize TRP or Campaign actions.

Contents
Product Affected
C150D2Re
C200D2Re
C275D2Re
Issue
Issue: Field replacement of circuit breakers, that are found to be working when sent to factory, with
below symptoms because of lack of troubleshooting procedure.
Symptom:
Generator sets C150D2Re, C200D2Re, and C275D2Re while in operation appear to have
malfunctioning circuit breakers. These circuit breakers appear to fail to open (Fault code 1453)
and/or fail to close (Fault code 1452).
Root Cause:
Failure of subcomponents associated with the circuit breaker and/or excessive dust ingress.
Verification/Confirmation
Affected population includes Mobile Rental Unit models C150D2Re, C200D2Re, and C275D2Re. If
the circuit breaker (CB) on any of these models appear to fail to open or close, follow the service
instructions below before returning the breaker to Cummins.
Table 1, Circuit Breaker Model and Part number

https://quickserve.cummins.com/qs3/pubsys2/xml/en/tsb/2020/tsb200142.html

1/11

6/30/2020

C150D2Re, C200D2Re, C275D2Re Circuit Breaker Testing Procedure

Table 1, Circuit Type
Breaker
of Model and Part number
Generator
Cummins
circuit
Amperage
Set Model
Part Number
breaker

Generator
Set Model

Type of
circuit
breaker

C150D2Re

PowerPact P
frame, 3PAuto

C200D2Re

PowerPact P
frame, 3PAuto

C275D2Re

PowerPact P
frame, 3PAuto

Amperage

600A

800A

1200A

Manufacture
r

Manufacture
r Part
Number

Cummins
Part Number

Manufacture
r

Manufacture
r Part
Number

A051C957

Schneider
Electric

PGL36060U3
3AABUKMO
YB

A051C959

Schneider
Electric

PGL36080U3
3AABUKMO
YB

A051C966

Schneider
Electric

PGL36120U3
3AABUKMO
YB

Resolution
Follow the troubleshooting steps for circuit breaker in Service Instructions section of this TSB. After
performing the tests, check for the CB operation, if it still fails to open/close then replace with a
new one.
Service Instructions

Note : Only qualified and authorized technicians may perform this troubleshooting
procedure as needed.
Ensure proper safety measures are taken with the right Personal Protective Equipment (PPEgloves, safety goggle, etc.) and do not put hand/finger(s) inside CB during test. Also, while working
on live power make sure to follow all electrical safety procedure according to NFPA 70E.
Generator Set Circuit Breaker Troubleshooting Procedure
Clean the Circuit breaker:
Ensure the generator set is in STOP condition and is de-energized electrically and mechanically.
Before performing any test, clean the CB to ensure no dust will affect the mechanical parts from
closing.
Remove any buildup of dust, dirt, grease or moisture from circuit breaker surfaces and do the
same with the top-cover of the CB removed. The CB can be cleaned with a lint-free dry cloth or
vacuum cleaner. Do not use compressed air. Use caution when using detergent-based cleaners or
solvents as these may deteriorate faceplate, labels, and insulation materials. If required, clean
contact surfaces of circuit breaker terminals and terminal pads or bus bars with a nonabrasive
cleaner. Abrasive cleaners will remove plating, resulting in joint deterioration.
https://quickserve.cummins.com/qs3/pubsys2/xml/en/tsb/2020/tsb200142.html

2/11

6/30/2020

C150D2Re, C200D2Re, C275D2Re Circuit Breaker Testing Procedure

Figure 1, Circuit breaker with top-cover(gray) removed
Equipment needed: Multimeter
Resources:
C150D2Re/C200D2Re service manual literature number: A047Z290
C275D2Re service manual literature number: A048A404
Appendix B.4 Wiring Diagram A060K411
Sheet 3 of 17: Genset connections (refer for Idle/Run switch wiring)
Sheet 5 of 17: Genset connections (refer for door switch and R6 wiring)
Sheet 6 of 17: Circuit breaker connections

Note : Before beginning this procedure, ensure that Circuit Breaker connections, PCC
TB5, PCC TB10 connections are wired as per wiring diagram A060K411 in Appendix
B.4 (sheet 6 of 17) of service manual. Trace each wire for confirmation.
Brief explanation about the CB Open and CB Close signals:
Circuit Breaker Open Signal is received when the CB open coil A4 receives switch B+ signal and
this happens if:
1.
2.
3.
4.

The Customer Load AC Distribution door is open OR
The generator set Idle/Run switch is in IDLE position OR
The CB Open button is pressed on the HMI operator panel OR
One or more of the associated relays and wiring connection is faulty thus providing switch B+
at A4

https://quickserve.cummins.com/qs3/pubsys2/xml/en/tsb/2020/tsb200142.html

3/11

6/30/2020

C150D2Re, C200D2Re, C275D2Re Circuit Breaker Testing Procedure

Circuit Breaker Close Signal is received when the CB close coil A2 receives switch B+ and this
happens if:
1. The CB Close button is pressed on the HMI operator panel OR
2. One or more of the associated relays and wiring connection is faulty thus providing switch B+
at A2
If there is an active CB Open signal, then it will override CB Close signal.

Figure 2, A section of the wiring diagram A060K411, sheet 6 of 17, circuit breaker connections
For the purpose of troubleshooting, it is recommended to run the generator set in manual
mode.
Troubleshooting steps:
1. Ensure both control and power paralleling cables are disconnected from the generator set.
2. Ensure the Customer Load AC Distribution door is closed.
3. Before attempting to close CB, make sure the generator set is in RUN mode and not in IDLE
mode. Start generator set and try to close and open the CB. If CB opens and closes as
desired, then there is no issue.
4. If CB fails to close on FC1452, the CB might be getting an open signal at A4 or is not getting
the close signal at A2. Perform the following checks:
a. Test Distribution door switch at J43. Switch should be closed when door is closed.
Replace switch if found bad and retry for CB closing operation.
b. Test the R6 door switch relay. R6-30 is at 0VDC when door switch is closed. R6-30 is at
switch B+ voltage when door switch is open. Replace R6 relay if found bad and retry for
CB closing operation.
https://quickserve.cummins.com/qs3/pubsys2/xml/en/tsb/2020/tsb200142.html

4/11

6/30/2020

C150D2Re, C200D2Re, C275D2Re Circuit Breaker Testing Procedure

c. Test relay K23. Check for voltage at K23-A1 black connector located behind the panel.
K23-A1 and K23-14 is at switch B+ and the indicator light on the relay is ON when door
switch is open. Check the operation of K23 relay and it’s NO contact. Replace K23 if
found bad and retry for CB closing operation. Check wiring from K23-14 to J71/P71 5-6
and to K17-14.
d. Test Idle/Run switch. When in Idle position, P64 (on the rear side of the Idle/Run switch)
is at switch B+ voltage. When in Run position, P64 is at 0VDC. Replace switch if found
bad and retry for CB closing operation.
e. Test K16 relay. To close the CB a positive 24 V (switch B+) signal should be applied at
the breaker A2 interconnection point. This signal arrives from K16-14 when K16 is
commanded by PCC (TB5-1 to K16-A2, signal is a B+ return). The closing command
from PCC is pulse type. You will need to set your multimeter on MIN/MAX value to
record the signal at the breaker A2 point when commanded from CB Close button on
operator panel. Replace K16 if found bad and retry for CB closing operation.
5. If CB fails to open on FC1453, the CB might not be getting the open signal at A4. Perform the
following checks:
a. Test K17 relay. To Open the CB, a positive 24 V (switch B+) signal should be applied at
the breaker A4 interconnection point. This signal arrives from K17-14 when K17 is
commanded by PCC (TB5-5 to K17-A2, signal is a B+ return). The opening command
from PCC is pulse type. You will need to set your multimeter on MIN/MAX value to
record the signal at the breaker A4 point when commanded from CB Open button on
operator panel. Replace K17 if found bad and retry for CB opening operation.
6. Remove top cover from circuit breaker and locate contacts OF3-1, OF3-2, OF2-1, OF2-4,
SDE-1, and SDE-4.
7. Check auxiliary contact between SDE 1 and SDE 4, they should be open (when CB is in open
state). Replace contacts if found bad.
8. Check auxiliary contact OF2 between OF2-1 and OF2-4, they should be open (when CB is in
open state). Replace contacts if found bad.
9. Check auxiliary contact OF3 between OF3-1 and OF3-2, they should be closed (when CB is in
open state). Replace contacts if found bad.
10. Check auxiliary contact OF2 between OF2-1 and OF2-4, they should be closed (when CB is in
closed state). Replace contacts if found bad.
11. Check auxiliary contact OF3 between OF3-1 and OF3-2, they should be open (when CB is in
closed state). Replace contacts if found bad.
12. Check for CB operation, if the CB still fails to open/close, turn off battery power, disconnect all
connections to the CB and replace with a new CB.
13. If CB was replaced with a new one, please check the CB close/open operation after
installation.

https://quickserve.cummins.com/qs3/pubsys2/xml/en/tsb/2020/tsb200142.html

5/11

6/30/2020

C150D2Re, C200D2Re, C275D2Re Circuit Breaker Testing Procedure

Figure 3, To access K23, open the bottom half of the panel using a 10 mm socket

Figure 4, K23 is behind the panel next to K19. There is an indicator light on K23.

https://quickserve.cummins.com/qs3/pubsys2/xml/en/tsb/2020/tsb200142.html

6/11

6/30/2020

C150D2Re, C200D2Re, C275D2Re Circuit Breaker Testing Procedure

Figure 5, K23-A1 connector

Figure 6, Door switch and connector

https://quickserve.cummins.com/qs3/pubsys2/xml/en/tsb/2020/tsb200142.html

7/11

6/30/2020

C150D2Re, C200D2Re, C275D2Re Circuit Breaker Testing Procedure

Figure 7, Open front panel by removing the two screws

Figure 8, K23, K16, K17 Relay locations

https://quickserve.cummins.com/qs3/pubsys2/xml/en/tsb/2020/tsb200142.html

8/11

6/30/2020

C150D2Re, C200D2Re, C275D2Re Circuit Breaker Testing Procedure

Figure 9, A1, A2, A4, B4, D1, D2 locations

Figure 10, Marker location

https://quickserve.cummins.com/qs3/pubsys2/xml/en/tsb/2020/tsb200142.html

9/11

6/30/2020

C150D2Re, C200D2Re, C275D2Re Circuit Breaker Testing Procedure

Figure 11, Auxiliary Contact locations

Figure 12, Auxiliary Contact locations
Service Parts Availability
https://quickserve.cummins.com/qs3/pubsys2/xml/en/tsb/2020/tsb200142.html

10/11

6/30/2020

C150D2Re, C200D2Re, C275D2Re Circuit Breaker Testing Procedure

Service parts are available. See Table 2 for part numbers.
Table 2, Service Parts
Part Description

Existing Part Number

Door Switch

A052W981

R6 door switch relay

A055C353

Idle/Run Toggle Switch

A032Z092

K16/K17/K23 relay

0307-2874

Auxiliary contacts (OF/SDE)

0320-2196-01

Publications Affected/Associated Publications
Implemented for production. See Table 3.
Table 3, Publications Affected
Manual Type

QSOL
Document Part
Number

Procedure /
Section Title

Procedure

Section

Service Manual

A047Z290

Circuit Breaker

Circuit Breaker
Testing - Auto

6.11

Service Manual

A048A404

Circuit Breaker

Circuit Breaker
Testing - Auto

7.11

Document History
Date
2020-6-19

Details
Module Created

Last Modified: 19-Jun-2020

https://quickserve.cummins.com/qs3/pubsys2/xml/en/tsb/2020/tsb200142.html

11/11