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CUMMINS
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C1200 N5C
Owner's Manual
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CUMMINS C1750 N5C, C1400 N5C, C1200 N5C, C1160 N5C, C1000 N6C Owner's Manual

...
OwnersOwners ManualManual
Generator Set
QSK60G and QSV91 Engines with PowerCommand
3.3 Control
®
C1250 N6C C1400 N6C C1540 N6C C1750 N6C C2000 N6C C1000 N6 C1250 N6 C1350 N6 C1700 N6
English Original Instructions
3-2016 0908-0209 (Issue 6)

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............................................................................................... 4
1.3.1 Moving Parts Can Cause Severe Personal Injury or Death................................... 4
1.3.2 Positioning of Generator Set - Open Sets .............................................................. 4
1.3.3 Moving the Generator Set ...................................................................................... 4
1.3.4 Alternator Operating Areas..................................................................................... 6
1.4 Electrical Shocks and Arc Flashes Can Cause Severe Personal Injury or Death ............ 6
1.4.1 AC Supply and Isolation ......................................................................................... 7
1.4.2 Medium Voltage Equipment (601 V to 15 kV - North America).............................. 7
1.5 Fuel and Fumes Are Flammable ....................................................................................... 7
1.5.1 Natural Gas ............................................................................................................ 7
1.5.2 Spillage.................................................................................................................. 8
1.5.3 Fluid Containment ................................................................................................. 8
1.5.4 Do Not Operate in Flammable and Explosive Environments ................................. 8
1.6 Exhaust Gases Are Deadly ............................................................................................... 8
1.6.1 Exhaust Precautions.............................................................................................. 9
1.7 Decommissioning and Disassembly.................................................................................. 9
2. INTRODUCTION .................................................................................................................... 11
2.1 About This Manual .......................................................................................................... 11
2.2 Schedule of Abbreviations............................................................................................... 11
2.3 Related Literature ............................................................................................................ 13
2.3.1 Further Information - Literature............................................................................. 13
2.4 After Sales Services ........................................................................................................ 14
2.4.1 Maintenance........................................................................................................ 14
2.4.2 Warranty ............................................................................................................... 14
2.4.3 How to Obtain Service ......................................................................................... 14
2.5 Project Details ................................................................................................................. 15
3. SYSTEM OVERVIEW............................................................................................................. 17
3.1 Generator Set Identification............................................................................................. 17
3.1.1 Generator Set Rating............................................................................................ 17
3.1.2 Nameplate - Open Generator Set ........................................................................ 17
3.2 Generator Set Components ............................................................................................ 17
3.3 Air Cleaner....................................................................................................................... 19
3.3.1 Air Cleaner System............................................................................................... 19
3.4 Coolant Specification....................................................................................................... 20
3.5 Gas Train......................................................................................................................... 21
3.6 Heaters ............................................................................................................................ 21
3.6.1 Heater Supply and Isolation ................................................................................. 21
3.7 Mains (Utility) Powered Battery Charger ......................................................................... 22
3.8 Oil Specification............................................................................................................... 22
3.8.1 Low BTU Gas Engines ......................................................................................... 23
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Copyright © 2016 Cummins Inc.
Table of Contents 3-2016
3.9 Sensors ........................................................................................................................... 24
3.10 System Options ............................................................................................................. 24
3.10.1 PowerCommand Universal Annunciator............................................................. 24
3.10.2 Mains (Utility) Powered Battery Charger ............................................................ 25
3.10.3 Coolant Heater ................................................................................................... 26
4. CONTROL SYSTEM - POWERCOMMAND 3.3 .................................................................... 27
4.1 Control System Description............................................................................................. 27
4.1.1 Control System Panel........................................................................................... 27
4.1.2 Operating Modes .................................................................................................. 28
4.1.3 Power On and Sleep Modes ................................................................................ 30
4.2 Operator Panel ................................................................................................................ 30
4.2.1 Selection Buttons.................................................................................................. 31
4.2.2 Default Settings .................................................................................................... 32
4.2.3 Lamp Indicators .................................................................................................... 32
4.2.4 Lamp (LED) Test Button ...................................................................................... 32
4.2.5 Reset Button ........................................................................................................ 32
4.2.6 CB Open Button .................................................................................................. 32
4.2.7 CB Closed Button ................................................................................................ 33
4.2.8 Graphical Display and Buttons ............................................................................. 33
4.3 Operator Panel - Initial Operator Menu ........................................................................... 35
4.3.1 Initial Menu Data................................................................................................... 35
4.4 Operator Panel - Generator Set Data Operator Menu .................................................... 37
4.4.1 Generator Set Data .............................................................................................. 37
4.5 Operator Panel - Engine Data Operator Menu................................................................ 39
4.5.1 Engine Data.......................................................................................................... 39
4.5.2 History/About Menu .............................................................................................. 41
4.6 Operator Panel - Alternator Data Operator Menu ........................................................... 43
4.6.1 Alternator Data ..................................................................................................... 44
4.7 Operator Panel - Faults and Warnings Menus................................................................ 46
4.7.1 Fault Menu............................................................................................................ 46
4.7.2 Fault Messages .................................................................................................... 48
4.7.3 Fault Acknowledgement ....................................................................................... 48
4.7.4 Warning Fault Menu ............................................................................................. 48
4.7.5 Faults History Data Operator Menu...................................................................... 50
4.8 Operator Panel - Adjust Menu......................................................................................... 52
4.9 Operator Panel - Genset Setup Data Operator Menu..................................................... 53
4.10 Operator Panel - Paralleling Status Menu..................................................................... 54
4.11 Operator Panel - Paralleling/Basic Setup Menu............................................................ 61
4.12 Selecting Operating Modes ........................................................................................... 64
4.12.1 Passwords and Mode Change Access............................................................... 64
4.12.2 Selecting Manual Run Mode .............................................................................. 65
4.12.3 Selecting Auto Mode .......................................................................................... 66
4.12.4 Selecting Off Mode............................................................................................. 67
5. OPERATION - POWERCOMMAND 3.3................................................................................. 69
5.1 Safety .............................................................................................................................. 69
5.2 Introduction ...................................................................................................................... 69
5.3 Maintenance .................................................................................................................... 69
5.4 Operating Recommendations.......................................................................................... 70
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5.4.1 Running-in ............................................................................................................ 70
5.4.2 No Load Operation ............................................................................................... 70
5.4.3 Exercise Period .................................................................................................... 70
5.4.4 Low Operating Temperatures............................................................................... 70
5.4.5 High Operating Temperatures.............................................................................. 70
5.4.6 Operating Conditions............................................................................................ 70
5.4.7 De-Rating Factors ............................................................................................... 72
5.5 Generator Set Operation ................................................................................................. 72
5.5.1 Sequence of Operation......................................................................................... 72
5.6 Starting ............................................................................................................................ 73
5.6.1 Operator’s Pre-start Checks ................................................................................. 73
5.6.2 Starting at Operator Panel (Manual Run Mode)................................................... 74
5.6.3 Starting from Remote Location (Auto Mode)........................................................ 75
5.6.4 Cold Starting with Loads ...................................................................................... 76
5.7 Stopping .......................................................................................................................... 76
5.7.1 Stopping at Operator Panel (Manual Mode)......................................................... 77
5.7.2 Stopping from Operator Panel (Auto Mode) ......................................................... 77
5.7.3 Stopping from Remote Location (Auto Mode)...................................................... 77
5.7.4 Emergency Stop (Code 1433 or 1434) ............................................................... 78
5.8 Paralleling Operation ....................................................................................................... 79
5.8.1 Speed and Voltage Matching ............................................................................... 79
5.8.2 Operation When in Parallel ................................................................................. 79
5.8.3 Generator Set Application Type ........................................................................... 79
5.8.4 Standalone Application......................................................................................... 80
5.8.5 Synchronize Only ................................................................................................. 81
5.8.6 Isolated Bus Only ................................................................................................. 82
5.8.7 Power Transfer Control ........................................................................................ 83
5.8.8 Conditions for Each Paralleling State................................................................... 87
6. MAINTENANCE...................................................................................................................... 97
6.1 Locking the Generator Set Out of Service ...................................................................... 98
6.1.1 Immobilizing for Safe Working.............................................................................. 98
6.2 Periodic Maintenance ...................................................................................................... 99
6.2.1 Periodic Maintenance Schedule........................................................................... 99
6.3 Maintenance Procedures - Daily ................................................................................... 100
6.3.1 General Information............................................................................................ 101
6.3.2 Engine Operation Report................................................................................... 101
6.4 Air Intake System .......................................................................................................... 101
6.4.1 Air Cleaner Service Indicator.............................................................................. 102
6.4.2 Air Cleaner System............................................................................................. 102
6.4.3 Air Cleaner System............................................................................................. 103
6.4.4 Air Cleaner System............................................................................................. 103
6.4.5 Air Cleaner Element Replacement ..................................................................... 104
6.5 Batteries ........................................................................................................................ 105
6.5.1 Storage ............................................................................................................... 105
6.5.2 Safety Precautions ............................................................................................. 105
6.5.3 Battery Maintenance........................................................................................... 106
6.5.4 Electrolyte - Specific Gravity and Temperature.................................................. 108
6.5.5 Electrolyte Levels and Bench Charging Rates................................................... 110
6.5.6 Battery Fault Finding .......................................................................................... 112
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Table of Contents 3-2016
6.6 Cooling System ............................................................................................................. 113
6.6.1 Water Quality Check........................................................................................... 113
6.6.2 Radiator - Check................................................................................................. 113
6.6.3 Cooling Fan - Inspection .................................................................................... 114
6.7 DC Electrical System..................................................................................................... 114
6.8 Engine Oil ...................................................................................................................... 115
6.8.1 Oil Maintainer - Level Check and Fill ................................................................. 115
6.8.2 Crankcase Ventilation Re-circulator ................................................................... 116
6.9 Exhaust System............................................................................................................. 117
6.10 Fuel System................................................................................................................. 118
6.10.1 Fuel consumption ............................................................................................. 118
6.10.2 Methane Index.................................................................................................. 118
6.10.3 De-rate.............................................................................................................. 118
6.11 Gearbox Inspection ..................................................................................................... 119
6.12 Generator Set Output - AC Electric System ................................................................ 119
6.13 Hoses and Fuel Lines - Check .................................................................................... 120
6.14 Lubricating Oil Analysis ............................................................................................... 120
6.15 Storage and Lay-up of Generator Set ......................................................................... 121
7. TROUBLESHOOTING.......................................................................................................... 123
7.1 Control System .............................................................................................................. 123
7.2 Safety Considerations ................................................................................................... 123
7.3 Fault Finding.................................................................................................................. 124
7.4 Status Indicators - PowerCommand 3.3........................................................................ 125
7.4.1 Not in Auto ......................................................................................................... 125
7.4.2 Remote Start ..................................................................................................... 125
7.4.3 Warning ............................................................................................................. 125
7.4.4 Shutdown Status ............................................................................................... 125
7.4.5 Generator Set Running Lamp ........................................................................... 125
7.5 Fault/Status Codes - PowerCommand 3.3.................................................................... 125
7.5.1 Fault Messages .................................................................................................. 126
7.5.2 Fault Acknowledgement ..................................................................................... 126
7.5.3 Fault Codes - PowerCommand 3.3 .................................................................... 126
7.5.4 Troubleshooting Procedure for Fault Codes ...................................................... 161
7.6 Line Circuit Breaker....................................................................................................... 165
8. BATTERY CHARGER .......................................................................................................... 167
8.1 Mains (Utility) Powered Battery Charger - Wall-Mounted (24 VDC - 30 Amp) ............. 167
8.1.1 Boost................................................................................................................... 167
8.1.2 Specifications - 30 Amp...................................................................................... 168
8.2 Circuits........................................................................................................................... 168
9. MANUFACTURING FACILITIES .......................................................................................... 169
Copyright © 2016 Cummins Inc.
iv 0908-0209 (Issue 6)

1 Important Safety Instructions

Save these instructions. This manual contains important instructions that should be followed during installation and maintenance of the generator set.
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 Manual

The following safety styles and symbols found throughout this manual indicate potentially hazardous conditions to the operator, service personnel, or equipment.
DANGER
Indicates a hazardous situation that, if not avoided, will result in death or serious injury.
WARNING
Indicates a hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION
Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
NOTICE
Indicates information considered important, but not hazard-related (e.g., messages relating to property damage).

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.
NOTICE
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
Hot Pressurized Liquid Contact with hot liquid can cause severe burns. Do not open the pressure cap while the engine is running. Let the engine cool down before
removing the cap. Turn the cap slowly and do not open it fully until the pressure has been relieved.
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Copyright © 2016 Cummins Inc.
1. Important Safety Instructions 3-2016
WARNING
Moving Parts Moving parts can cause severe personal injury. Use extreme caution around moving parts. All guards must be properly fastened to prevent
unintended contact.
WARNING
Toxic Hazard Used engine oils have been identified by some state and federal agencies to cause cancer or
reproductive toxicity. Do not ingest, breathe the fumes, or contact used oil when checking or changing engine oil.
Wear protective gloves and face guard.
WARNING
Electrical Generating Equipment Incorrect operation can cause severe personal injury or death. Do not operate equipment when fatigued, or after consuming any alcohol or drug.
WARNING
Toxic Gases Substances in exhaust gases have been identified by some state and federal agencies to
cause cancer or reproductive toxicity. Do not breathe in or come into contact with exhaust gases.
WARNING
Combustible Liquid Ignition of combustible liquids is a fire or explosion hazard which can cause severe burns or
death. Do not store fuel, cleaners, oil, etc., near the generator set.
WARNING
High Noise Level Generator sets in operation emit noise, which can cause hearing damage. Wear appropriate ear protection at all times.
WARNING
Hot Surfaces Contact with hot surfaces can cause severe burns. Wear appropriate PPE when working on hot equipment and avoid contact with hot surfaces.
Electrical Generating Equipment Incorrect operation and maintenance can result in severe personal injury or death Make sure that only suitably trained and experienced service personnel perform electrical
and/or mechanical service.
Copyright © 2016 Cummins Inc.
WARNING
2 0908-0209 (Issue 6)
1. Important Safety Instructions3-2016
WARNING
Toxic Hazard Ethylene glycol, used as an engine coolant, is toxic to humans and animals. Wear appropriate PPE. Clean up coolant spills and dispose of used coolant in accordance
with local environmental regulations.
WARNING
Combustible Liquid Ignition of combustible liquids is a fire or explosion hazard which can cause severe burns or
death. Do not use combustible liquids like ether.
WARNING
Automated Machinery Accidental or remote starting of the generator set can cause severe personal injury or death. Isolate all auxiliary supplies and use an insulated wrench to disconnect the starting battery
cables (negative [–] first).
WARNING
Fire Hazard Materials drawn into the generator set are a fire hazard. Fire can cause severe burns or death. Make sure the generator set is mounted in a manner to prevent combustible materials from
accumulating under the unit.
WARNING
Fire Hazard Accumulated grease and oil are a fire hazard. Fire can cause severe burns or death. Keep the generator set and the surrounding area clean and free from obstructions. Repair oil
leaks promptly.
WARNING
Fire Hazard Materials drawn into the generator set are a fire hazard. Fire can cause severe burns or death. Keep the generator set and the surrounding area clean and free from obstructions.
NOTICE
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. (Refer to NFPA No. 10 in applicable region.)
NOTICE
Before performing maintenance and service procedures on enclosed generator sets, make sure the service access doors are secured open.
30908-0209 (Issue 6)
Copyright © 2016 Cummins Inc.
1. Important Safety Instructions 3-2016
NOTICE
Stepping on the generator set can cause parts to bend or break, leading to electrical shorts, or to fuel, coolant, or exhaust leaks. Do not step on the generator set when entering or leaving the generator set room.

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
Electrical Generating Equipment Incorrect operation and maintenance can result in severe personal injury or death. Read and follow all Safety Precautions, Warnings, and Cautions throughout this manual and
the documentation supplied with the generator set.

1.3.1 Moving Parts Can Cause Severe Personal Injury or Death

• Keep 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 using an insulated wrench, 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 - 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.

1.3.3 Moving the Generator Set

WARNING
Heavy Load Incorrect lifting or repositioning can cause severe personal injury or death. Make sure that only suitably trained and experienced personnel transport and handle
generator sets and associated components.
Heavy Load Incorrect lifting or repositioning can cause severe personal injury or death. Do not lift the generator set by attaching to the engine or alternator lifting points. Do not
stand under or near the generator set when lifting.
Copyright © 2016 Cummins Inc.
WARNING
4 0908-0209 (Issue 6)
1. Important Safety Instructions3-2016
WARNING
Mechanical Hazard Failed components may be ejected or operate incorrectly which can cause severe personal
injury or death. Do not climb the generator set; this may damage critical parts.
NOTICE
Access or service doors must be closed and locked before repositioning, and they must remain locked during transportation and siting.
It is essential that there are sufficient trained and experienced personnel in attendance to make sure the lifting and transportation of the generator set is undertaken in a safe and appropriate manner, and in accordance to local guidelines and legislation.
Before lifting the generator set, lifting points, angle of slings, mass, access to intended site, and the distance of movement should all be taken into account when organizing a suitable crane/hoist. Consult the generator set information supplied with the generator set for details of dimensions and mass.
• Make sure that the crane operating area is able to support the mass of the crane and the generator set.
• Make sure the equipment used for lifting is adequate to support the weight of the generator set.
• Attach the lifting device to the lifting points only using suitable shackles, chains, and spreader bars.
• Slowly tighten the slings. Inspect the lifting attachments before commencing a full lift to make sure they are attached correctly.
• Hoist the generator set slowly using the indicated lifting points only.
• Guide the generator set with ropes at a safe distance to prevent uncontrolled rotation when positioning the generator set.
• Move the generator set to the desired location and place in position, bringing the set down slowly.
• Loosen the slings; unhook and remove the shackles.
1.3.3.1 Positioning a Generator Set Using a Forklift Truck
WARNING
Heavy Load Incorrect lifting or repositioning can cause severe personal injury or death. Make sure that only suitably trained and experienced personnel transport and handle
generator sets and associated components.
WARNING
Heavy Load Incorrect lifting or repositioning can cause severe personal injury or death. Do not attempt to lift a generator set with an undersized forklift truck.
NOTICE
Access or service doors must be closed and locked before repositioning, and they must remain locked during transportation and siting.
When using a forklift truck to transport/position the generator set, the dimensions, mass, and route must be taken into account when selecting an appropriate lifting truck.
50908-0209 (Issue 6)
Copyright © 2016 Cummins Inc.
1. Important Safety Instructions 3-2016
It is essential that there are sufficient trained and experienced personnel in attendance to make sure the lifting and transportation of the generator set is undertaken in a safe and appropriate manner.
1. Insert the arms of the forklift into the forklift pockets. Make sure the generator set completely rests on the forklift arms.
2. Lift and handle the equipment slowly.
3. Lower the generator set in position.

1.3.4 Alternator Operating Areas

WARNING
Ejected Debris Debris ejected during catastrophic failure can cause serious injury or death by impact,
severing or stabbing. To prevent injury:
• Keep away from the air inlet and air outlet when the alternator is running.
• Do not put operator controls near the air inlet and air outlet.
• Do not cause overheating by running the alternator outside rating plate parameters.
• Do not overload the alternator.
• Do not run an alternator with excessive vibration.
• Do not synchronize parallel alternators outside the specified parameters.
Always wear suitable PPE when working in the hatched areas shown in the diagram or directly in-line with any air inlet/outlet.
Make sure this consideration is captured in your risk assessment.

1.4 Electrical Shocks and Arc Flashes Can Cause Severe Personal Injury or Death

• Only qualified service personnel certified and authorized to work on power circuits should work on exposed energized power circuits.
• All relevant service material must be available for any electrical work performed by certified service personnel.
• Exposure to energized power circuits with potentials of 50 VAC or 75 VDC or higher poses a significant risk of electrical shock and electrical arc flash.
• Refer to standard NFPA 70E, or equivalent safety standards in corresponding regions, for details of the dangers involved and for safety requirements.
Copyright © 2016 Cummins Inc.
6 0908-0209 (Issue 6)
1. Important Safety Instructions3-2016

1.4.1 AC Supply and Isolation

NOTICE
Local electrical codes and regulations (for example, BS EN 12601:2010 Reciprocating internal combustion engine driven generating sets) may require the installation of a disconnect
means for the generator set, either on the generator set or where the generator set conductors enter a facility.
NOTICE
The AC supply must have the correct over current and earth fault protection according to local electrical codes and regulations. This equipment must be earthed (grounded).
It is the sole responsibility of the customer to provide AC power conductors for connection to load devices and the means to isolate the AC input to the terminal box; these must comply with local electrical codes and regulations. Refer to the wiring diagram supplied with the generator set.
The disconnecting device is not provided as part of the generator set, and Cummins Power Generation accepts no responsibility for providing the means of isolation.

1.4.2 Medium Voltage Equipment (601 V to 15 kV - North America)

• Medium voltage acts differently than low voltage. Special equipment and training is required to work on or around medium voltage equipment. Operation and maintenance must be done only by persons trained and experienced to work on such devices. Improper use or procedures will result in severe personal injury or death.
• Do not work on energized equipment. Unauthorized personnel must not be permitted near energized equipment. Due to the nature of medium voltage electrical equipment, induced voltage remains even after the equipment is disconnected from the power source. Plan the time for maintenance with authorized personnel so that the equipment can be de-energized and safely grounded.

1.5 Fuel and Fumes Are Flammable

Fire, explosion, and personal injury or death can result from improper practices.
• Do not fill fuel tanks while the engine is running unless the tanks are outside the engine compartment. Fuel contact with hot engine or exhaust is a potential fire hazard.
• Do not permit any flame, cigarette, pilot light, spark, arcing equipment, or other ignition source near the generator set or fuel tank.
• Fuel lines must be adequately secured and free of leaks. Fuel connection at the engine should be made with an approved flexible line. Do not use copper piping on flexible lines as copper will become brittle if continuously vibrated or repeatedly bent.
• Make sure all fuel supplies have a positive shutoff valve.
• Make sure the battery area has been well-ventilated prior to servicing near it. Lead-acid batteries emit a highly explosive hydrogen gas that can be ignited by arcing, sparking, smoking, etc.

1.5.1 Natural Gas

Pipeline Natural Gas is lighter than air. If leakage occurs the gas will first accumulate at high levels, including ceiling voids. Gas detection equipment should be installed at high level to be effective. If leakage occurs isolate the gas supply, do not operate any equipment (electrical or otherwise) that may cause a spark or may be a source of ignition, evacuate the building and completely ventilate the area. Only suitable qualified personnel who are adequately trained to manage natural gas emergencies are to be allowed near the plant room or generator set(s) in such emergencies.
70908-0209 (Issue 6)
Copyright © 2016 Cummins Inc.
1. Important Safety Instructions 3-2016
Non-Pipeline Gas Generator Sets are designated by Cummins, Inc. as Low Btu Generator Sets. Non­Pipeline Gas classification includes Landfill Gas, Digester Gas, Well Head Gas and Coal Bed Methane. Non-pipeline gas, depending on its properties, can be lighter than air, neutral, or heavier than air. If leakage occurs the gas can accumulate either at high level, mid-level or low level. Gas detection equipment siting is dependant upon the properties of the gas.
Non-pipeline gases may also contain other substances which may be harmful and can cause personal injury or death. Analysis of the non-pipeline gas available at site should be performed to identify the gases properties and consistencies.
Shut down the generator set by following the shut down procedure as described in this manual. Fully shut the gas train shut-off valve(s). Fully shut all external gas supply valves to the generator set. Alert the emergency services and local gas supplier.

1.5.2 Spillage

Any spillage that occurs during fueling or during oil top-off or oil change must be cleaned up before starting the generator set.

1.5.3 Fluid Containment

NOTICE
Where spillage containment is not part of a Cummins supply, it is the responsibility of the installer to provide the necessary containment to prevent contamination of the environment, especially water courses and sources.
If fluid containment is incorporated into the bedframe, it must be inspected at regular intervals. Any liquid present should be drained out and disposed of in line with local health and safety regulations. Failure to perform this action may result in spillage of liquids which could contaminate the surrounding area.
Any other fluid containment area must also be checked and emptied, as described above.

1.5.4 Do Not Operate in Flammable and Explosive Environments

Flammable vapor can cause an engine to over speed and become difficult to stop, resulting in possible fire, explosion, severe personal injury, and death. Do not operate a generator set where a flammable vapor environment can be created, unless the generator set is equipped with an automatic safety device to block the air intake and stop the engine. The owners and operators of the generator set are solely responsible for operating the generator set safely. Contact your authorized Cummins Power Generation distributor for more information.

1.6 Exhaust Gases Are Deadly

• Provide an adequate exhaust system to properly expel discharged gases away from enclosed or sheltered areas, and areas where individuals are likely to congregate. Visually and audibly inspect the exhaust system daily for leaks per the maintenance schedule. Make sure that exhaust manifolds are secured and not warped. Do not use exhaust gases to heat a compartment.
• Make sure the unit is well ventilated.
Copyright © 2016 Cummins Inc.
8 0908-0209 (Issue 6)

1.6.1 Exhaust Precautions

Hot Exhaust Gases Contact with hot exhaust gases can cause severe burns. Wear personal protective equipment when working on equipment.
Hot Surfaces Contact with hot surfaces can cause severe burns. Wear appropriate PPE when working on hot equipment and avoid contact with hot surfaces.
Toxic Gases Inhalation of exhaust gases can cause asphyxiation and death. Pipe exhaust gas outside and away from windows, doors, or other inlets to buildings. Do not
allow exhaust gas to accumulate in habitable areas.
1. Important Safety Instructions3-2016
WARNING
WARNING
WARNING
WARNING
Fire Hazard Contaminated insulation is a fire hazard. Fire can cause severe burns or death. Remove any contaminated insulation and dispose of it in accordance with local regulations.
The exhaust outlet may be sited at the top or bottom of the generator set. Make sure that the exhaust outlet is not obstructed. Personnel using this equipment must be made aware of the exhaust position. Position the exhaust away from flammable materials - in the case of exhaust outlets at the bottom, make sure that vegetation is removed from the vicinity of the exhaust.
The exhaust pipes may have some insulating covers fitted. If these covers become contaminated they must be replaced before the generator set is run.
To minimize the risk of fire, make sure the following steps are observed:
• Make sure that the engine is allowed to cool thoroughly before performing maintenance or operation tasks.
• Clean the exhaust pipe thoroughly.

1.7 Decommissioning and Disassembly

NOTICE
Decommissioning and disassembly of the generator set at the end of its working life must comply with local guidelines and legislation for disposal/recycling of components and contaminated fluids. This procedure must only be carried out by suitably trained and experienced service personnel. For more information contact your authorized distributor.
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Copyright © 2016 Cummins Inc.
1. Important Safety Instructions 3-2016
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Copyright © 2016 Cummins Inc.
10 0908-0209 (Issue 6)

2 Introduction

Hazardous Voltage Contact with high voltages can cause severe electrical shock, burns, or death. Make sure that only a trained and experienced electrician makes generator set electrical
output connections, in accordance with the installation instructions and all applicable codes.
Electrical Generating Equipment Faulty electrical generating equipment can cause severe personal injury or death. Generator sets must be installed, certified, and operated by trained and experienced person
in accordance with the installation instructions and all applicable codes.

2.1 About This Manual

The purpose of this manual is to provide the users with sound, general information. It is for guidance and assistance with recommendations for correct and safe procedures. Cummins Power Generation (CPG) cannot accept any liability whatsoever for problems arising as a result of following recommendations in this manual.
WARNING
WARNING
The information contained within the manual is based on information available at the time of going to print. In line with Cummins Power Generation policy of continuous development and improvement, information may change at any time without notice. The users should therefore make sure that before commencing any work, they have the latest information available. The latest version of this manual is available on QuickServe Online (https://quickserve.cummins.com).
Users are respectfully advised that, in the interests of good practice and safety, it is their responsibility to employ competent persons to carry out any installation work. Consult your authorized distributor for further installation information. It is essential that the utmost care is taken with the application, installation, and operation of any engine due to their potentially hazardous nature. Careful reference should also be made to other Cummins Power Generation literature. A generator set must be operated and maintained properly for safe and reliable operation.
For further assistance, contact your authorized distributor.

2.2 Schedule of Abbreviations

This list is not exhaustive. For example, it does not identify units of measure or acronyms that appear only in parameters, event/fault names, or part/accessory names.
AmpSentry, INSITE, and InPower are trademarks of Cummins Inc. PowerCommand is a registered trademark of Cummins Inc.
ABBR. DESCRIPTION ABBR. DESCRIPTION
AC Alternating Current LED Light-emitting Diode
AMP AMP, Inc., part of Tyco
Electronics
ANSI American National Standards
Institute
ASOV Automatic Shut Off Valve MFM Multifunction Monitor
110908-0209 (Issue 6)
LTS Long Term Storage
LVRT Low Voltage Ride Through
Copyright © 2016 Cummins Inc.
2. Introduction 3-2016
ABBR. DESCRIPTION ABBR. DESCRIPTION
ASTM American Society for Testing
and Materials (ASTM International)
ATS Automatic Transfer Switch MLD Masterless Load Demand
AVR Automatic Voltage Regulator NC Normally Closed
AWG American Wire Gauge NC Not Connected
CAN Controlled Area Network NFPA National Fire Protection Agency
CB Circuit Breaker NO Normally Open
CE Conformité Européenne NWF Network Failure
CFM Cubic Feet per Minute OEM Original Equipment
CGT Cummins Generator
Technologies
CMM Cubic Meters per Minute OORH / ORH Out of Range High
CT Current Transformer OORL / ORL Out of Range Low
D-AVR Digital Automatic Voltage
Regulator
DC Direct Current PCC PowerCommand®Control
Mil Std Military Standard
Manufacturer
OOR Out of Range
PB Push Button
DEF Diesel Exhaust Fluid PGI Power Generation Interface
DPF Diesel Particulate Filter PGN Parameter Group Number
ECM Engine Control Module PI Proportional/Integral
ECS Engine Control System PID Proportional/Integral/Derivative
EMI Electromagnetic interference PLC Programmable Logic Controller
EN European Standard PMG Permanent Magnet Generator
EPS Engine Protection System PPE Personal Protective Equipment
E-Stop Emergency Stop PT Potential Transformer
FAE Full Authority Electronic PTC Power Transfer Control
FMI Failure Mode Identifier PWM Pulse-width Modulation
FRT Fault Ride Through RFI Radio Frequency Interference
FSO Fuel Shutoff RH Relative Humidity
Genset Generator Set RMS Root Mean Square
GCP Generator Control Panel RTU Remote Terminal Unit
GND Ground SAE Society of Automotive Engineers
LCT Low Coolant Temperature SCR Selective Catalytic Reduction
HMI Human-machine Interface SPN Suspect Parameter Number
IC Integrated Circuit SWL Safe Working Load
ISO International Organization for
Standardization
LBNG Lean-burn Natural Gas UL Underwriters Laboratories
Copyright © 2016 Cummins Inc.
SW_B+ Switched B+
12 0908-0209 (Issue 6)
ABBR. DESCRIPTION ABBR. DESCRIPTION
LCD Liquid Crystal Display UPS Uninterruptible Power Supply

2.3 Related Literature

Before any attempt is made to operate the generator set, the operator should take time to read all of the manuals supplied with the generator set, and to familiarize themselves with the warnings and operating procedures.
A generator set must be operated and maintained properly if you are to expect safe and reliable operation. The Operator manual includes a maintenance schedule and a troubleshooting guide.
The Health and Safety manual must be read in conjunction with this manual for the safe operation of the generator set:
• Health and Safety Manual (0908-0110)
The relevant manuals appropriate to your generator set are also available, the documents below are in English:
2. Introduction3-2016
NOTICE
• Operator Manual for QSV91 & QSK60G Generator Sets with PowerCommand 3.3 control (0908-
0209)
• Installation Manual for QSV91 & QSK60G Generator Sets with PowerCommand 3.3 control (A029R140)
• Recommended Spares List (RSL) for QSK60G (A046W059)
• Recommended Spares List (RSL) for QSK60G (A046W060)
• Recommended Spares List (RSL) for QSV91 (<2MW) (A046W061)
• Recommended Spares List (RSL) for QSV91 (>2MW) (A046W064)
• Service Manual for PowerCommand 3.3 Control (0900-0670_
• Parts Manual for QSK60G (A029C810)
• Parts Manual for QSV91 (A029B383)
• Service Tool Manual (A043D529)
• Failure Code Manual (F1115C)
• Application Manual T-030, Liquid Cooled Generator Sets - for application information (A040S369)
• Engine Operation & Maintenance Manual for QSV81/91 (4021313)
• Engine Operation & Maintenance Manual for QSK60G (4021395)
• Engine Owners Manual for QSV81/91 (4915546)
• Engine Owners Manual for QSK60G (4915558)
• Warranty Manual (A040W374)
• ESB Warranty Statement - Lean-Burn Gaseous Fuel Generating Set (A050L829)

2.3.1 Further Information - Literature

Contact your authorized distributor for more information regarding related literature for this product.
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Copyright © 2016 Cummins Inc.
2. Introduction 3-2016

2.4 After Sales Services

Cummins Power Generation offers a full range of maintenance and warranty services.

2.4.1 Maintenance

WARNING
Electrical Generating Equipment Incorrect operation and maintenance can result in severe personal injury or death Make sure that only suitably trained and experienced service personnel perform electrical
and/or mechanical service.
For expert generator set service at regular intervals, contact your local distributor. Each local distributor offers a complete maintenance contract package covering all items subject to routine maintenance, including a detailed report on the condition of the generator set. In addition, this can be linked to a 24-hour call-out arrangement, providing year-round assistance if necessary. Specialist engineers are available to maintain optimum performance levels from generator sets. Maintenance tasks should only be undertaken by trained and experienced technicians provided by your authorized distributor.

2.4.2 Warranty

For details of the warranty coverage for your generator set, refer to the Global Commercial Warranty Statement listed in the Related Literature section.
In the event of a breakdown, prompt assistance can normally be given by factory trained service technicians with facilities to undertake all minor and many major repairs to equipment on site.
Extended warranty coverage is also available.
For further warranty details, contact your authorized distributor.
Damage caused by failure to follow the manufacturer's recommendations will not be covered by the warranty. Please contact your authorized distributor.
2.4.2.1 Warranty Limitations
For details of the warranty limitations for your generator set, refer to the warranty statement applicable to the generator set.

2.4.3 How to Obtain Service

When a product requires servicing, contact the nearest Cummins Power Generation distributor. To locate the distributor, refer to power.cummins.com and select Distributor Locator. When contacting the distributor, always supply the complete model, specification, and serial number as shown on the nameplate.
NOTICE
2.4.3.1 Locating a Distributor
In North America
To easily locate the nearest certified distributor/dealer for Cummins generator sets in your area, or for more information, contact us at 1-800-344-0039 or visit power.cummins.com.
If unable to contact a distributor using the automated service, consult the Internet.
If unable to arrange a service or resolve an issue, contact the Service Manager at the nearest Cummins Power Generation distributor for assistance.
Copyright © 2016 Cummins Inc.
14 0908-0209 (Issue 6)
When contacting the distributor, always supply the complete Model, Specification, and Serial Number as shown on the product nameplate.
Outside North America
Refer to power.cummins.com and select Distributor Locator, or send an email to ask.powergen@cummins.com.

2.5 Project Details

It is important when contacting your authorised distributor to have project information at hand. Complete this form in order to assist you and the distributor when referencing the installation. (Make duplicate copies of this page as required.)
2. Introduction3-2016
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Copyright © 2016 Cummins Inc.
2. Introduction 3-2016
Balance of Plant Details
Project Title
Company Name
Address
Contact Name
Phone Numbers Tel: Mobile:
Email
Site Details
Customer Order Number
Site Name
Address
Contact Name
Phone Numbers Tel: Mobile:
Email
Equipment Details
Generator Model(s)
Number of Sets
Generator Set Serial Number(s)
Engine Serial Number(s)
Alternator Serial Number(s)
Date of Commissioning
Additional Information
Copyright © 2016 Cummins Inc.
16 0908-0209 (Issue 6)

3 System Overview

This section provides an overview of the generator set.

3.1 Generator Set Identification

Each generator set is provided with a nameplate similar to that shown below. The nameplate provides information unique to the generator set.

3.1.1 Generator Set Rating

Refer to the generator set nameplate for generator set rating. Refer to Section 5.4 on page 70 for operation at temperatures or altitudes above those stated on the nameplate.

3.1.2 Nameplate - Open Generator Set

FIGURE 1. TYPICAL OPEN GENERATOR SET NAMEPLATE

3.2 Generator Set Components

The main components of a typical QSV91G engine generator set are shown below, and referred to within this section.
There are various options listed although they may not be available for all models.
170908-0209 (Issue 6)
Copyright © 2016 Cummins Inc.
3. System Overview 3-2016
No Description No Description No Description
1 Gas Mass Flow Valve 14 Lube-oil Make-up Valve 27 CENSE Module
2 Air Filter 15 DSSOV Solenoid Shut Off
Valve
3 Turbocharger 16 Gas Pipe 29 Low Temp Water Coolant pipe
4 Fuel/Air Mixer 17 Vent Valve 30 Steel Bedframe
5 Gas Mass Flow Valve 18 Centrifugal Oil Filter 31 Electric Starter Motor
6 Crankcase Breather Filter 19 AVR/Controls Box 32 AC Auxiliaries Box
7 Alternator 20 Lube Oil Filters 33 Exhaust Bellows
8 Generator Set Terminal Box 21 Coolant Water Pump 34 Gearbox
9 Generator Set Dataplate 22 Spark Plugs & Ignition Coils 35 Lifting Point
10 Dirty Oil Leak-off Tank 23 Multihousing Cover 36 Jacking Point
11 Engine Dataplate 24 Lube Oil Cooler Coolant Return
Pipe
12 Aftercooler 25 Flotech Gas Valve
13 Lube-oil Dipstick 26 Governor Driver Modules
FIGURE 2. TYPICAL QSV91G ENGINE GENERATOR SET
28 Governor Actuator Module
37 High Temp Water Coolant pipe
Copyright © 2016 Cummins Inc.
18 0908-0209 (Issue 6)

3.3 Air Cleaner

An air cleaner includes an element that must be replaced periodically. Some air cleaners include a service indicator that indicates when an air cleaner element is dirty and must be replaced.

3.3.1 Air Cleaner System

An air cleaner is used to filter particles from the air supply to the engine. Regular maintenace is critical in achieving optimum performance of the generator set.
Depending on the requirements, one of the following air cleaner systems will be fitted on the generator set.
3. System Overview3-2016
FIGURE 3. AIR CLEANER ASSEMBLY
FIGURE 4. AIR CLEANER ASSEMBLY
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Copyright © 2016 Cummins Inc.
3. System Overview 3-2016
FIGURE 5. AIR CLEANER ASSEMBLY
FIGURE 6. AIR CLEANER ASSEMBLY

3.4 Coolant Specification

Incorrect coolant concentration or level may allow an engine to overheat without protection of shutdown device, and cause severe damage to the engine. Maintain coolant level for proper operation of high engine temperature shutdown system.
It is important that the quality of coolant used in Cummins engines meets the Cummins recommended specifications (Consult your authorised distributor). A premixed fully formulated coolant or a 50/50 mixture of high quality water and fully formulated concentrated anti-freeze must meet Cummins Engineering Standard 14603.
Cummins recommend the use of Fleetguard®Antifreeze Coolant ES Compleat containing DCA4 Plus.
Copyright © 2016 Cummins Inc.
NOTICE
20 0908-0209 (Issue 6)
For filling and maintenance of Cooling Systems refer to the Operation and Maintenance Manual, or consult your authorised distributor.

3.5 Gas Train

Installation, maintenance and testing of gas pipe work system must be carried out by suitably trained and experienced personnel.
Natural Gas is supplied to the engines’ fuel management system through a flexible pipe attached to a gas train. The gas train includes a main shut-off valve and other gas control components. Control equipment for the fuel/air ratio and engine speed, are provided on the generator set.
A typical gas train, starting at the gas main supply point, includes the components shown below.
3. System Overview3-2016
NOTICE
No Description No Description
1 Gas Shut-off Valve (GSOV) 5 Pressure Relief Valve (PRV)
2 Filter 6 Flexible Pipe
3 Flowmeter (optional) 7 Double Block & Double Solenoid Shut Off Valve
(DSSOV) (Mounted off-genset - Option)
4 Pressure Regulator
FIGURE 7. TYPICAL GAS TRAIN

3.6 Heaters

3.6.1 Heater Supply and Isolation

A power supply is required for the operation of the engine, coolant, and alternator heaters (if fitted).
NOTICE
It is the sole responsibility of the customer to provide the power supply and the means to isolate the AC input to the terminal box. Cummins Power Generation accepts no responsibility for providing the means of isolation. Contact your distributor for more information.
NOTICE
This disconnecting device is not provided as part of the generator set.
210908-0209 (Issue 6)
Copyright © 2016 Cummins Inc.
3. System Overview 3-2016

3.7 Mains (Utility) Powered Battery Charger

CAUTION
Hazardous Voltage Contact with high voltages can cause severe electrical shock, burns, or death. Disconnect the battery charger before isolating the battery.
This unit maintains the battery in a fully charged condition without over-charging. The unit also provides rapid charging, when necessary, at a current up to the rated output.
The charger’s electronic control circuit allows the charger to be left in circuit during engine cranking and to operate in parallel with the charge alternator.
The charger will supply current to the battery system until the battery terminal voltage becomes equal to the set float voltage, at which point only a trickle charge current is present. When the battery becomes discharged due to a load being present and the terminal voltage falls, the charger will again supply current to restore the voltage of the battery to the float voltage.

3.8 Oil Specification

NOTICE
High quality engine oil, approved by Cummins should be used only. The use of unapproved oil may cause severe damage to the engine.
Selecting and using the correct grade of engine oil is critical for achieving engine service life, engine reliability and performance.
It is important to understand that the generator set must be operated and maintained in accordance to Cummins published recommendations. Failure to follow applicable service intervals and recommendations in the Operation and Maintenance Manual applicable to the engine can result in severe engine damage. Consult your authorised distributor for more information.
Use high-quality SAE40 (mono-grade) NG engine oils, such as Valvoline® Premium Blue GEO LA or its equivalent. The use of the ‘Premium Grade – Long Change Interval’ oils are strongly recommended. The SAE40 oils approved for use in Cummins HHP natural gas fuelled engines are as follows:
TABLE 1. QSV91G 2MWE ENGINE (18.2BAR BMEP MODELS): C2000 N5C, C2000 N6C
Manufacturer Oil Names Grade TBN Sulphated Ash %
Manufacturer Oil Names Grade TBN Sulphated Ash %
Mobil Pegasus 805* SAE40 6.2 0.54
Valvoline Premium Blue GEO
LA*
SAE40 5.5 0.44
Valvoline Premium Blue GEO
MA*
Shell Mysella XL* SAE40 4.5 0.48
*Premium grade oil
Copyright © 2016 Cummins Inc.
SAE40 7.2 0.7
22 0908-0209 (Issue 6)
3. System Overview3-2016
TABLE 2. QSV81/91G ENGINE (14 & 16BAR BMEP MODELS): C1540 N5C, C1750 N5C, C1250 N6C, C1540
N6C, C1750 N6C, C1700 N6
Manufacturer Oil Names Grade TBN Sulphated Ash %
Mobil Pegasus 805* SAE40 6.2 0.54
Mobil Pegasus 705 SAE40 5.6 0.52
Elf Nateria MH40 SAE40 5.2 0.45
Shell Mysella LA SAE40 5.0 0.45
Shell Mysella XL* SAE40 4.5 0.48
Caltex Geostar LA SAE40 5.2 0.49
Valvoline Premium Blue GEO
SAE40 5.5 0.44
LA*
*Premium grade oil
TABLE 3. QSK60G ENGINE (MULTI AND SINGLE-TURBOCHARGER MODELS): C995 N5C, C1160 N5C,
C1200 N5C, C1400 N5C, C1000 N6C, C1100 N6C, C1400 N6C, C1000 N6, C1250 N6, C1350 N6
Manufacturer Oil Names Grade TBN Sulphated Ash %
Mobil Pegasus 805* SAE40 6.2 0.54
Valvoline Premium Blue GEO
SAE40 5.5 0.44
LA*
Shell Mysella XL* SAE40 4.5 0.48
*Premium grade oil
Regularly sample the oil and perform oil analysis. If regular oil analysis is not performed, then the oil change interval is reduced and oil analysis must be carried out immediately prior to the oil change to determine that the oil contamination was within acceptable limits at the time of the oil change. Refer to the engine specific Operation and Maintenance manual for guidance on intervals and procedures.

3.8.1 Low BTU Gas Engines

Cummins Inc., recommends the use of a high quality SAE40 lubricating oil specifically formulated for use in Low BTU and aggressive gaseous fueled engines.
Various lubricating oil brands are available worldwide and careful selection is required to match the product with the type of fuel in use. Cummins Inc. has Low BTU engines operating experience with ChevronTexaco and ExxonMobil who offer a wide range of products for the various categories of fuel.
The more acidic fuel sources require oil with a higher Total Base Number (TBN) to protect the engine.
Supplier Product Fuel
Chevron Texaco (Caltex) Geotex LA
Geotex HD
Geotex LF
®
®
®
Geotex HDAX LA
Geotex HDAX LFG
ExxonMobil Pegasus 805
Pegasus 605
Pipeline Natural Gas
Non-Pipeline Natural Gas
Non-Pipeline Natural Gas
®
®
®
®
230908-0209 (Issue 6)
Natural Gas
Non-Pipeline Natural Gas
Natural Gas
Non-Pipeline Natural Gas
Copyright © 2016 Cummins Inc.
3. System Overview 3-2016
Supplier Product Fuel
Pegasus 610
®
Non-Pipeline Natural Gas

3.9 Sensors

Various generator set parameters are measured by sensors, and the resulting signals are processed by the control board.
Engine-mounted sensors monitor a number of different systems, such as:
• Lube Oil Pressure
• Cooling System Temperature

3.10 System Options

3.10.1 PowerCommand Universal Annunciator

A universal annunciator provides lamps and a horn to annunciate the operating status and fault conditions of an emergency power system. It is designed for connection to either a 12 VDC or a 24 VDC control system. It can be configured to be either a positive or negative signal device.
Two versions of the PowerCommand universal annunciator are available.
• Panel Mounted
• Panel with Enclosure
The universal annunciator can communicate using either a PCCNet or a Modbus network.
Refer to the annunciator owner's manual for more information.
Copyright © 2016 Cummins Inc.
24 0908-0209 (Issue 6)
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