S | Technical Service Bulletin

Technical Service Bulletin: TSB220023 Released Date: 16-Jan-2024
HDKAG Configuration Options for Isolated Neutral

HDKAG Configuration Options for Isolated Neutral

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
¢ HDKAG (Spec kK)

Issue
Symptom:

¢ NoAC voltage is generated at rated RPM when configured to star (wye) terminal connection
using an isolated neutral configuration on an HDKAG unit

Root Cause:

¢ The field flash function of the generator set control does not function as intended on start-up,
causing the generator set to not produce any output AC voltage at rated RPM.

Verification/Confirmation

Measure field flash voltage while terminal connections are configured to Star (Wye) as per
HDKAG Service Manual (LN: 0981-0516 Issue 8):

1. In isolated neutral:

o F1-F2 voltage: OVDC

eo K15-87-ground voltage: ~11VDC
2. In grounded neutral:

o F1-F2 voltage: 11VDC

eo K15-87-ground voltage: ~11VDC

Resolution
Two solutions are currently available to have an HDKAG unit operate with an isolated neutral.

1. Configure terminal connections to Series Delta and isolate neutral wire, given that the output
voltage available from this configuration is acceptable.

2. If a Star (Wye) configuration is absolutely required, a work around solution has been deployed
for field use. See service instructions below for further detail.

Consult with regional branch and/or regional DFSE before implementing any changes.

Customer Communication

Manuals (Service) do not indicate any intended use of star (wye) configuration with an isolated
neutral on HDKAG units. Requirement and necessity to change terminal configurations should be
thoroughly evaluated, if any changes are to be made.

Consult with regional branch and/or regional DFSE before implementing any changes. Policy
coverage and modification approval to be reviewed by regional DFSE teams.

Service Instructions
Solution 1: Configure terminal connections to Series Delta and isolate neutral wire

e Review if output voltage from Delta connection is acceptable for customer requirement.
e Authorized Cummins service provider may reconfigure terminal connections to series delta as
per HDKAG Service Manual (LN: 0981-0516, Issue 8

3e

50 HZ
CODE M,P,Z
110/220V
1157230V
120/240V

110/220V
1157230V

17101394

Figure 1, Delta configuration for terminal connections

Solution 2: Configure terminal connections to Series Star (wye) and isolate neutral wire

e Review if output voltage from Star (Wye) connection is acceptable for customer requirement.
e Authorized Cummins service provider may reconfigure terminal connections to series star as
per HDKAG Service Manual (LN: 0981-0516, Issue 8)

3e

60 HZ
CODE L,G
240/416V
254/440V
277/480V

3e

50 HZ
CODE _Z,T
220/380V
230/400V
240/416V
254/440V

17101395

Figure 2, Star (Wye) configuration for terminal connections

e Further implementation of a relay solution, as below, will be required.

$11-1-START

F1

A

F2

Relay 1

wal

re

+12 VDC

30] O

5186
\erl)|4 Relay 2
87| 9 85

AVR pint (VR1-1) |

Figure 3, Relay Diagram

AVR pin2 (VR1-2)

17101396

« Relays and wires are to be sourced locally and must meet the below operational
requirements:
o Relay Required: 5 pin 12 V 40 Amp or greater automotive relay
o Wire Gauge: 18 Ga (1.024 mm) or greater
© Diode Rating: 40 Amp 200 VDC or greater

40A 12V-C

300287"
ny oe

17101397

Figure 4, 5 pin 12V 40A Relay

¢ Arrangement and mounting of components to be left to installer and customer discretion.

Policy coverage and modification approval to be reviewed by regional DFSE teams.

Document History

Date Details
2022-2-4 Module Created
2024-1-5 Non-Product Problem Solving (PPS)

Last Modified: 16-Jan-2024