Form# AME Service Engineering Rev.2 SR No.

03669545 Page 1 of 8

Cummins
Failure / Incident Report

Engine Family AutoXpert Technical Report Report Distribution

KTA50GS8

Genset Family *List all Stakeholders. Must be updated

03669545
per site, per issue.
C1675D5A
ESN
33233773

GSN Title: C1675D5A SURGING ISSUE (1) Technical Library

G23D010529 (2) Author
SR Customer: SGUHMC (3) TTM
03669545
(4) ABO Service Engineering
New/Rebuilt Author: Nader Abou Elias (5) Policy/Warranty
New
(6) Distributor
Engine/Genset Hours Date: January 26, 2024
(7) Marketing
2273
(8) General Manager
Equipment Application Dept. \ Dist Autoxpert Service Engineering
Genset

SUMMARY
Purpose
The purpose of this report is to troubleshoot synchronization, vibration, and Belts Rupture issues of a new C1675D5A
Genset serial number G23D010529
Conclusions
Following Cummins guidelines and based on required data logging and diagnosis on site, we are eliminating the
probabilities to achieve the root causes of mentioned issues.
Next Steps
Up on DFSE Support instructions.

This document (and the information shown thereon) is PROPRIETARY to Cummins Incorporated and shall not be disclosed to others in
hard copy or electronic form, reproduced by any means, or used for any purpose without consent of Cummins Engine Company, Inc.
(CTC-OPS-7-11-01)
Form# AME Service Engineering Rev.2 SR No. 03669545 Page 2 of 8

Table of Contents
INTRODUCTION................................................................................................................................................................... 2

DESCRIPTION OF FAILURE & TROUBLESHOOTING STEPS........................................................................................................ 4

OBSERVATIONS.................................................................................................................................................................. 4

REBUILD / SERVICE AND REPAIR HISTORY............................................................................................................................ 5

OIL / FUEL ANALYSIS........................................................................................................................................................... 5
INPOWER CAPTURE FILE / ECM IMAGES.............................................................................................................................. 5
MONITOR LOG ANALYSIS...................................................................................................................................................... 5
ANY OTHER TOPIC AS APPLICABLE....................................................................................................................................... 5

DISCUSSION........................................................................................................................................................................ 5

CONCLUSIONS.................................................................................................................................................................... 5

RECOMMENDATIONS......................................................................................................................................................... 5

SIGNATURE......................................................................................................................................................................... 5

This is the initial PID settings for G2 generators, where all gensets was settled near those values.
Form# AME Service Engineering Rev.2 SR No. 03669545 Page 3 of 8

Introduction
This project consists of 6 parallel C1675D5A Cummins gensets controlled by third party controller which is DSE 8610
that is responsible of load share between gensets. The PCC3.3 receives an analog signal from the DSE 8610 to adjust
the speed and voltage then allow gensets to synchronize to the bus and share load between each other’s.

The issue is that the gensets exposed to a brutal vibration suddenly while loaded. We had faced this case before,
and we did an adjustment for PCC3.3 Governor PID settings for some gensets. But then we had received a complaint
from the hospital team that this case still happening. Also, we have faced a problem with the gensets fan and
alternator belts what indicate that maybe the redundant vibration can be the cause of belt rupture.

Product Information Failure Information

ESN 33233773 SR# 03669545

GSN G23D010529 Customer POTEL

Model C1675D5A Customer Site SGUHMC

New/Rebuild New OEM

Unit # Application Prime

(Re)Build Date September 27-2023 Date in Service May-2023

Rated Power Failure Date 27/11/2024
(HP/kW/kVA (1915/1200/1500)
Engine Hours 2273
Rated Speed 1500
Unit Hours 2273
Engine Config # D283022DX02 Fault Code(s)
CPL 2354 Failure Code
Installed Functional Volume Related TSRs 02610323
Oil Reserve Part Numbers

Centinel Engine arrival Date

Prelube Tear Down Date

Report Release Date 29/8/2024

This is the initial PID settings for G2 generators, where all gensets was settled near those values.
Form# AME Service Engineering Rev.2 SR No. 03669545 Page 4 of 8

Description of Failure & Troubleshooting Steps

On 28/11/2024 we received a video that show G6 vibrating same as previous case that we had faced when Lesego was in
Lebanon.

On 4/12/2024 I sent an email for Lesego to follow this case and I asked her for technical support about this critical issue.

On 5/12/2024 we had received an email from Lesego containing a list of trouble shooting steps.

On 10/12/2024 we went to the site and completed all the steps that you requested on your email that was received
on 5/12/2024. on 11/12/2024 we did a visit to install USBs for the six DSE controllers. On 17/12/2024 we received a
complain about vibration issue on G2 and G5. After diagnosing data, we find that the power factor was fluctuating
between 0.6 and 1, the KVAR was surging and the AVR outputs wasn’t stable, so we had adjusted the AVR PID
settings to stabilize the AVR output. As shown in the attached video to the SR, the AVR output signal is treated well.

Also, I reduced the governor PID settings for some gensets and took capture to the DSE configuration file but I didn’t
recognized than that the Scada parameters cannot be stored.

On 16/12/2024 G2 and G4 was loaded when G3 started at 17:22:13 to switch the load with G2 that opened its
breaker at 17:23:02 But G3 breaker tripped at 17:23:47 and an out of synch alarm activated on G3 so G4 took all the
load then overloaded at 17:24:15 and a power cut off occurred until G5 and G6 started and loaded.

Between 17:36:46 and 17:42:00 G3 repeated this issue 3 times what cause overload alarm on G5 at 17:40:03 and
overload warning on G6 at 17:41:29.

From this reading I conclude that the generator breakers inside the totalizing panel must be cheeked for proper
function.

On 22/12/2024 we have aligned the parameters, since the AVR is a solid-state device and there is no need to set
every controller for a specific value. Also, we have reduced the Governor gain because the data logs sometimes
show some KW load share oscillation, but we still face this KW issue specially when G5 is running on load with other
gensets. I am not assuring that G5 is the cause, but I observed that he always existing when the KW fluctuation
occurs.

Until now we didn’t face the kVAR surging again and the customer is satisfied but I am trying to reach the better load
share stability level to avoid fluctuation when the load is changed in the summer and an increase in load demand will
occur.

This is the initial PID settings for G2 generators, where all gensets was settled near those values.
Form# AME Service Engineering Rev.2 SR No. 03669545 Page 5 of 8

Observations

This is the initial PID settings for G2 generators, where all gensets was settled near those values.
Form# AME Service Engineering Rev.2 SR No. 03669545 Page 6 of 8

G2 PID settings Final tuning where all gensets are aligned to this values

This is the initial PID settings for G2 generators, where all gensets was settled near those values.
Form# AME Service Engineering Rev.2 SR No. 03669545 Page 7 of 8

This is the initial PID settings for G6, as indicated all gensets PID values was close to those in the picture

This indicate that G6 is aligned with G2, same as remains controllers.

Rebuild / Service and Repair History

The engine is in very good condition and use to be serviced every 200 running hours as part of periodic maintenance.

This is the initial PID settings for G2 generators, where all gensets was settled near those values.
Form# AME Service Engineering Rev.2 SR No. 03669545 Page 8 of 8

Oil / Fuel Analysis

Very good quality of fuel, oil & Fleet guard filters are used on this KTA50-GS8 engine.

InPower Capture File / ECM Images

PCC3300 capture file is attached to the SR 03073558

Monitor Log Analysis

PCC3300 Data monitor log is attached to the SR 03669545

Any Other Topic as Applicable

Discussion
After KVAR load share PID settings tuning the vibration issue is disappeared, so this is so important to have an
adequate tunning for KW and KVAR load share PID. We are looking for the best possible tunning that prevent us
facing such case.

Conclusions
. What affect the power plant is miss alignment and a lack of adequate tunning for the load share PID settings.

Recommendations
As the soft tuning is a sensitive calibration that can affect the system stability, indicating that a limited trials
are possible due to the hospital administrative pressures we are obliged to find effective way that help us
achieve an adequate method to improve the stability in less

Signature
Nader AE
Nader Abou Elias, Technical Support Engineer, AutoXpert SAL

This is the initial PID settings for G2 generators, where all gensets was settled near those values.