CUMMINS C125 N6, C150 N6 Installation Manual

InstallationInstallation ManualManual

Generator Set

QSJ8.9G Engine with PowerCommand® 2.3 Control

C125 N6 (Spec A) C150 N6 (Spec A)

English Original Instructions

6-2017 A056K396 (Issue 2)

1. IMPORTANT SAFETY INSTRUCTIONS....................................................................................... 1

1.1 Warning, Caution, and Note Styles Used in This Manual ..................................................... 1

1.2 Save These Instructions ........................................................................................................ 1

1.3 General Information ................................................................................................................ 2

1.4 General Precautions .............................................................................................................. 2

1.5 Generator Set Voltage Is Deadly ........................................................................................... 6

1.6 Fuel and Fumes Are Flammable ............................................................................................ 6

1.7 Starting Batteries .................................................................................................................... 7

1.8 Batteries Can Explode............................................................................................................ 7

1.9 Vented Batteries ..................................................................................................................... 8

1.10 Moving Parts Can Cause Severe Personal Injury or Death ................................................ 9

1.11 Exhaust Gases Are Deadly................................................................................................... 9

1.12 The Hazards of Carbon Monoxide...................................................................................... 10

2. INTRODUCTION.......................................................................................................................... 11

2.1 About This Manual................................................................................................................ 11

2.2 Schedule of Abbreviations.................................................................................................... 11

2.3 Related Literature ................................................................................................................. 13

2.4 Model Specifications............................................................................................................. 14

2.5 Before Installation ................................................................................................................. 19

3. PRE-INSTALLATION CONSIDERATIONS.................................................................................. 21

3.2 Installation Codes and Standards for Safety ........................................................................ 22

3.3 Required Items for Installation.............................................................................................. 24

4. INSTALLATION............................................................................................................................ 27

4.1 Site Assessment and Preparation ........................................................................................ 27

4.2 Fuel System Connection....................................................................................................... 31

4.3 Engine Exhaust..................................................................................................................... 35

4.4 Electrical Connections .......................................................................................................... 36

5. STARTUP AND CONFIGURATION............................................................................................. 45

5.1 Operator Panel...................................................................................................................... 45

5.2 Checklist ............................................................................................................................... 57

5.3 Before Starting...................................................................................................................... 59

5.4 Startup ................................................................................................................................. 65

APPENDIX A. FUEL LINE SELECTION........................................................................................... 67

A.0 Fuel System Pipe Sizing Introduction................................................................................... 68

A.1 Gas Pipe Sizing.................................................................................................................... 69

APPENDIX B. OUTLINE AND SYSTEM DRAWINGS...................................................................... 75

APPENDIX C. WIRING DIAGRAMS................................................................................................. 85

Table of Contents 6-2017

C.0 Wiring Diagrams................................................................................................................... 86

APPENDIX D. SEISMIC REQUIREMENTS.................................................................................... 101

D.1 Seismic Installation Instructions......................................................................................... 103

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 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 Save These Instructions

This manual contains important instructions for the generator set that should be followed during installation, operation and maintenance of the generator set and batteries.

Thoroughly read the operator manual before operating the generator set. Safe operation and top performance can only be obtained when equipment is properly operated and maintained.

The following symbols in this manual alert you to potential hazards to the operator, service person and equipment.

1. IMPORTANT SAFETY INSTRUCTIONS 6-2017

DANGER

Alerts you to an immediate hazard that will result in severe personal injury or death.

WARNING

Alerts you to a hazard or unsafe practice that can result in severe personal injury or death.

CAUTION

Alerts you to a hazard or unsafe practice that can result in personal injury or equipment damage.

1.3 General Information

This manual should form part of the documentation package supplied by Cummins Inc. with specific generator sets. If this manual has been supplied in isolation, please contact your authorized dealer.

It is in the operator's interest to read and understand all warnings and cautions contained in the documentation relevant to the generator set operation and daily maintenance.

1.4 General Precautions

• Keep multi-type ABC fire extinguishers accessible.

• Make sure that all fasteners are secure and torqued properly.

• Keep the generator set and its compartment clean. Do not store any items in the generator set compartment.

• Before working on the generator set, make sure the generator set is shut down and disabled.

1. Press the generator set's "O" (Off) button or the red STOP button on the local display (whichever is applicable) to stop the generator set. Allow the generator set to thoroughly cool to the touch.

2. If applicable, turn off and disconnect the battery charger from the AC source before disconnecting the battery cables.

NOTICE

3. Disconnect the negative (–) cable from the battery and secure it from contacting the battery terminals to prevent accidental starting.

1. IMPORTANT SAFETY INSTRUCTIONS6-2017

• Use caution when making adjustments when the generator set is running, hot, or when parts are electrically live, as all situations may cause personal injury or death.

• Used engine oil has been identified by some state and federal agencies as causing cancer or reproductive toxicity. Do not ingest, inhale, or come into contact with used oil or its vapors.

• Do not work on the generator set when mentally or physically fatigued or after consuming alcohol or drugs.

NOTICE

Only trained and authorized personnel shall maintain or service the generator set.

NOTICE

The installation of the generator set shall provide enough ventilation to ensure that gases generated by vented batteries during charging, or caused by equipment malfunction, are removed.

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.

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.

1. IMPORTANT SAFETY INSTRUCTIONS 6-2017

WARNING

Electrical Generating Equipment Incorrect operation and maintenance can result in severe personal injury or

death. Do not operate equipment when fatigued, or after consuming any alcohol or

drug. Make sure that only suitably trained and experienced service personnel

perform electrical and/or mechanical service.

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

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. The unit is to be installed so that the risk of hot surface contact by people is

minimized. Wear appropriate PPE when working on hot equipment and avoid contact with hot surfaces.

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 store fuel, cleaners, oil, etc., near the generator set. Do not use

combustible liquids like ether.

1. IMPORTANT SAFETY INSTRUCTIONS6-2017

WARNING

Combustible Gases Generator sets in operation have combustible gases under pressure, which

if ignited can cause eye and ear damage. Wear appropriate eye and ear protection at all times.

WARNING

Combustible Gases Generator sets in operation have combustible gases under pressure, which

if ignited can cause severe injury. Do not operate the generator set with any doors open.

WARNING

Fire Hazard Materials drawn into the generator set, as well as 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. Make sure the generator set is mounted in a manner to prevent combustible materials from accumulating under the unit.

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).

NOTICE

Keep multi-type ABC fire extinguishers close by. 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 the applicable region.)

NOTICE

Before performing maintenance and service procedures on enclosed generator sets, make sure the service access doors are secured open.

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. IMPORTANT SAFETY INSTRUCTIONS 6-2017

1.5 Generator Set Voltage Is Deadly

• Generator set output connections must be made by a trained and experienced electrician in accordance with all applicable codes.

• This generator set and the public utility may only be connected to house circuits by means of the automatic transfer switch.

CAUTION

Improper connections can lead to electrocution of utility workers and damage to equipment. Make sure that the connections are installed properly by a trained technician.

• Use caution when working on live electrical equipment. Remove jewelry, and make sure clothing and shoes are dry. Stand on a dry wooden platform.

1.6 Fuel and Fumes Are Flammable

Fire, explosion, and personal injury or death can result from improper practices.

• DO NOT permit any flame, cigarette, pilot light, spark, arcing equipment, or other ignition source near the generator set or fuel system.

• 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 because copper will become brittle if continuously vibrated or repeatedly bent.

• Be sure all fuel supplies have a positive shutoff valve.

• Be 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.

1.7 Starting Batteries

Toxic Hazard The electrolyte in starting batteries is a dilute sulfuric acid that is harmful to

the skin and eyes. It is also electrically conductive and corrosive. Always:

1. Wear full eye protection and protective clothing;

2. If the electrolyte contacts the skin, wash it off immediately with water;

3. If the electrolyte contacts the eyes, flush them thoroughly and

immediately with water and seek medical attention; and

4. Wash spilled electrolyte down with an acid neutralizing agent. A

common practice is to use a solution of one pound (500 grams) bicarbonate of soda (also known as baking soda or sodium bicarbonate) to one gallon (4 liters) of water.

5. Continue to add the bicarbonate of soda solution until the evidence of

reaction (that is, foaming) has stopped.

6. Flush the resulting liquid with water and dry the area.

1. IMPORTANT SAFETY INSTRUCTIONS6-2017

WARNING

1.8 Batteries Can Explode

Batteries can explode, causing severe skin and eye burns and can release toxic electrolytes.

Combustible Gases Batteries can explode, causing severe skin and eye burns, and can release

toxic electrolytes. Do not dispose of the battery in a fire, because it is capable of exploding. Do

not open or mutilate the battery. Do not charge frozen batteries.

Electric Shock Hazard Batteries present the risk of high short circuit current. When servicing the generator set:

• Remove watches, rings, or other metal objects.

• Use tools with insulated handles.

WARNING

1. IMPORTANT SAFETY INSTRUCTIONS 6-2017

NOTICE

Servicing of batteries must be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries.

• Wear safety glasses.

• Do not smoke.

• Do not charge frozen batteries.

• To prevent arcing when disconnecting the battery:

1. Press the Off switch from the display and then press the E-Stop button.

2. Disconnect AC power from any battery chargers.

3. Remove the negative (-) battery cable to prevent starting.

• To prevent arcing when reconnecting the battery:

1. Reconnect the positive (+) cable.

2. Reconnect the negative (-) cable.

3. Reconnect the battery charger to AC power supply.

• When replacing the generator set battery, always replace it with a battery as specified in this manual.

1.9 Vented Batteries

Toxic Hazard The electrolyte in vented batteries is a dilute sulfuric acid that is harmful to

the skin and eyes. It is also electrically conductive and corrosive. Always:

1. Wear full eye protection and protective clothing;

2. If the electrolyte contacts the skin, wash it off immediately with water;

3. If the electrolyte contacts the eyes, flush them thoroughly and

immediately with water and seek medical attention; and

4. Wash spilled electrolyte down with an acid neutralizing agent. A

common practice is to use a solution of one pound (500 grams) bicarbonate of soda (also known as baking soda or sodium bicarbonate) to one gallon (4 liters) of water.

5. Continue to add the bicarbonate of soda solution until the evidence of

reaction (that is, foaming) has stopped.

6. Flush the resulting liquid with water and dry the area.

WARNING

1. IMPORTANT SAFETY INSTRUCTIONS6-2017

1.10 Moving Parts Can Cause Severe Personal Injury or Death

• Do not wear loose clothing or jewelry near moving parts, such as cooling fans.

• Keep hands away from moving parts.

• Keep guards in place over fans.

1.11 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.

Exhaust Precautions

WARNING

Hot Exhaust Gases Contact with hot exhaust gases can cause severe burns. Wear personal protective equipment when working on equipment.

WARNING

Hot Surfaces Contact with hot surfaces can cause severe burns. The unit is to be installed so that the risk of hot surface contact by people is

minimized. Wear appropriate PPE when working on hot equipment and avoid contact with hot surfaces.

WARNING

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.

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.

1. IMPORTANT SAFETY INSTRUCTIONS 6-2017

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.

1.12 The Hazards of Carbon Monoxide

Carbon monoxide (CO) is an odorless, colorless, tasteless and non-irritating gas. You cannot see it or smell it. Red blood cells, however, have a greater affinity for CO than for oxygen. Therefore, exposure even to low levels of CO for a prolonged period can lead to asphyxiation (lack of oxygen) resulting in death. Mild effects of CO poisoning include eye irritation, dizziness, headaches, fatigue and the inability to think clearly. More extreme symptoms include vomiting, seizures and collapse.

Engine-driven generator sets produce harmful levels of carbon monoxide that can injure or kill you.

Special Risks of CO near the Home

WARNING

Toxic Gases Carbon monoxide (CO) gas can cause nausea, fainting, or death. Residents

can be exposed to lethal levels of CO when the generator set is running. Depending on air temperature and wind, CO can accumulate in or near the home.

To protect yourself and others from the dangers of CO poisoning, it is recommended that reliable, approved, and operable CO detector alarms are installed in proper locations in the home as specified by their manufacturer.

Protecting Yourself from CO Poisoning

• Locate the generator set in an area where there are no windows, doors, or other access points into the home.

• Make sure all CO detectors are installed and working properly.

• Pay attention for signs of CO poisoning.

• Check the exhaust system for corrosion, obstruction, and leaks every time you start the generator set and every eight hours when you run it continuously.

2 Introduction

2.1 About This Manual

Improper installation can result in severe personal injury, death and damage to equipment. The installation must comply with all applicable building codes (including project permits and inspections). The installer should be properly trained and licensed to perform electrical and mechanical equipment installations (including gaseous fuel installation).

Manuals are updated from time to time to reflect changes in the equipment and its specifications. The most up-to-date version of this manual is found on the QuickServe website (https://quickserve.cummins.com/info/index.html).

This manual is a guide for the installation of the generator set models listed on the front cover. Proper installation is essential for top performance, reliable operation, and safety. Read through this manual before starting the installation. This manual covers outdoor applications only; for other installations, refer to the T-030: Liquid- Cooled Generator Set Application manual available from your Cummins distributor.

WARNING

NOTICE

The installation must comply with all applicable building codes.

See the generator set's specific operator manual for operation and maintenance and specific service manual for service.

Refer to the Model Specifications section for specific information about the system and its components.

Refer to the Outline and System Drawings appendix and the Wiring Diagrams appendix for specific information about installation and wiring connections.

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.

2. Introduction 6-2017

Abbr. Description Abbr. Description

AC Alternating Current LED Light-Emitting Diode AMP AMP, Inc. (part of Tyco

MFM Multifunction Monitor

Electronics)

ANSI American National

Mil Std Military Standard

Standards Institute ASOV Automatic Shut Off Valve MPU Magnetic Pickup ASTM American Society for

NC Normally Closed Testing and Materials (ASTM International)

ATS Automatic Transfer

NC Not Connected Switch

AVR Automatic Voltage

Regulator

NFPA National Fire Protection

Agency AWG American Wire Gauge NO Normally Open CAN Controlled Area Network NWF Network Failure CB Circuit Breaker OEM Original Equipment

Manufacturer CE Conformité Européenne OOR Out Of Range CCA Cold Cranking Ampere OORH/

Out Of Range High

ORH CFM Cubic Feet per Minute OORL/ORL Out Of Range Low CGT Cummins Generator

PB Push Button

Technologies CMM Cubic Meters per Minute PCC PowerCommand®Control CT Current Transformer PGI Power Generation

Interface

DC Direct Current PGN Parameter Group

Number DEF Diesel Exhaust Fluid PI Proportional/Integral DPF Diesel Particulate Filter PID Proportional/Integral/

Derivative EBS Excitation Boost System PLC Programmable Logic

Controller ECM Engine Control Module PMG Permanent Magnet

Generator

2. Introduction6-2017

Abbr. Description Abbr. Description

ECS Engine Control System PPE Personal Protective

Equipment EMI Electromagnetic

Interference EN European Standard PTC Power Transfer Control EPS Engine Protection

System E-Stop Emergency Stop RFI Radio Frequency

FAE Full Authority Electronic RH Relative Humidity FMI Failure Mode Identifier RMS Remote Monitoring

FSO Fuel Shutoff RMS Root Mean Square Genset Generator Set RTU Remote Terminal Unit GCP Generator Control Panel SAE Society of Automotive

GND Ground scfh Standard Cubic Feet of

HMI Human-Machine

Interface

PT Potential Transformer

PWM Pulse-Width Modulation

Interference

System

Engineers

gas per Hour

SCR Selective Catalytic

Reduction

IC Integrated Circuit SPN Suspect Parameter

ISO International Organization

for Standardization LBNG Lean-Burn Natural Gas UL Underwriters

LCD Liquid Crystal Display UPS Uninterruptible Power

LCT Low Coolant

Temperature

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 familiarize themselves with the warnings and operating procedures.

Number

SW_B+ Switched B+

Laboratories

Supply

2. Introduction 6-2017

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 the Operator manual for the safe operation of the generator set.

The following documents are shipped with the generator set:

• Installation Manual for QSJ8.9G Engine with PowerCommand 2.3 Control (A056K396)

• Operator Manual for QSJ8.9G Engine with PowerCommand 2.3 Control (A056K398)

• Health and Safety Manual (0908-0110-00)

• Global Commercial Warranty Statement (A040H442)

• Emission Warranty Statement (Federal Emissions EPA Title 40 CFR Part 90 Component Warranty) (A028X279)

The relevant manuals appropriate to your generator set are also available; the documents below are in English:

• Generator Set Service Manual for QSJ8.9G Engine with PowerCommand 2.3 Control (A056K400)

• Controller Service Manual for PowerCommand 2.3 Controller (A030F082 [09000666])

• Recommended Spares List (RSL) for each model:

◦ C125 N6 (A057P648) ◦ C150 N6 (A057P650)

• Parts Manual for QSJ8.9G Engine with PowerCommand 2.3 Control (A056K402)

• Universal Annunciator Owner Manual (0900-0301)

• Standard Repair Times - IB Family (A057P652)

• Service Tool Manual (A043D529)

• Failure Code Manual (F1115C)

• Engineering Application Manual T-030: Liquid Cooled Generator Sets (A040S369)

2.4 Model Specifications

Damage caused by failure to follow the manufacturer's recommendation will not be covered by the warranty. Please contact your authorized distributor.

NOTICE

TABLE 1. 8.9L MODEL VARIATIONS

Models Description

C125 N6, C150 N6 60 Hz, 1800 RPM

TABLE 2. COLD WEATHER SPECIFICATIONS (ALL MODELS)

2. Introduction6-2017

Temperature Description of Components

Battery

Quantity

Group

Above 4 °C (40 °F) Battery charger 1 34 –17 - 4 °C (0 to 40 °F)

Below –17 °C (0 °F)

Battery charger, coolant heater (1500 W), CCV heater*

Battery charger, coolant heater (2000 W), oil heater, battery heater, CCV heater*

1 34

2 34

*CCV heaters are provided as part of the cold and extreme cold coolant heater packages.

NOTICE

For NFPA 110 applications, a coolant heater is required. A factory option is available.

TABLE 3. FUEL SPECIFICATIONS 60 HZ, 1800 RPM

Type Unit C125 N6 C150 N6

Natural Gas Full Load

scfh 1655 1893.3

BTU/hr 1,580,079 1,807,610

Fuel Pressure 1.5 - 3.2 kPa (6 to 13 inches of water column) under any condition

TABLE 4. ENGINE SPECIFICATIONS (ALL MODELS)

Type Specification

Engine

6 cylinder in-line, single-cam, liquid-cooled, 4-stroke, spark

ignited Bore 114 mm (4.49 in) Stroke 145 mm (5.69 in) Displacement 8.9 L (543.1 in3) Compression Ratio (Natural

Gas)

9.7:1

Firing Order 1-5-3-6-2-4

2. Introduction 6-2017

Type Specification

Spark Plug Gap 0.40 mm (.016 in) Spark Plug Torque 38 Nm (28 ft-lb) Crankshaft Rotation (Viewed

from the Front of the Engine) Engine Weight (Dry, Long Block

Only)

Clockwise

693 kg (1527.8 lb) Valve Clearance (Intake) 0.355 mm (0.014 in)

Valve Clearance (Exhaust) 0.6604 mm (0.026 in)

• 50/50 coolant solution (50% pure water and 50% anti-

Coolant

freeze)

• 11 L (2.9 gal) capacity

Oil Capacity 22 L (5.81 gal)

• Must adhere to Cummins®Engineering Standard (CES) 20085

• Use of improper oils can result in engine damage. Use only the required oils:

◦ 5W-40 (all ambient temperatures) ◦ 15W-40 (above 4 °C [40 °F] ambient temperature)

Oil Standards

(use of GEO 15W-40 oil in ambient temperatures below 4 °C (40 °F] could result in engine turbocharger damage)

• A sulfated ash limit of 0.6% mass has been placed on all engine lubricating oils recommended for use in Cummins® B, natural gas engines. Higher ash oils can cause valve and/or piston damage, cause spark plug fouling, and lead to excessive oil consumption and degradation of the catalyst.

TABLE 5. LUBRICATING OIL SYSTEM SPECIFICATIONS

Type Specification

Lubricating Oil Pressure at Idle (Minimum) 69 kPa (10 psi) Lubricating Oil Pressure at Rated Speed (Minimum) 138 kPa (20 psi) Filter Bypass Valve-Opening Pressure 345 kPa (50 psi) Pressure Regulator Valve-Opening Pressure 417 kPa (60 psi) Lubricating Oil Capacity (Standard Sump):

--High 19 L (20 qt)

2. Introduction6-2017

Type Specification

--Low 15 L (16 qt)

--Total System 20.8 L (22 qt)

TABLE 6. GENERATOR SET SIZE SPECIFICATIONS

Enclosure

Type

Open/Weather

2867 x 1016 x 1666 mm (113 x 40 x 65.6 in); does not include exhaust

Size (L x W x H)

discharge elbow Sound Level 1 3621 x 1016 x 1666 mm (143 x 40 x 65.6 in) Sound Level 2 4061 x 1016 x 1666 mm (160 x 40 x 65.6 in)

TABLE 7. GENERATOR SET WET WEIGHT (ALL MODELS) (60 HZ, 1800 RPM)

Configuration lbs kg

Open 3475 1576 Weather 3801 1724 Sound Level 1 3907 1772 Sound Level 2 3940 1787

NOTICE

Weights are approximate and can be affected by selected options. Refer to outline drawings for specific weight information.

TABLE 8. ALTERNATOR SPECIFICATIONS 60 HZ, 1800 RPM

Type C125 N6 C150 N6

Generator Brushless, 4-pole rotating field, single bearing Power (kVA) 1 Phase 125 150 Power (kVA) 3 Phase 156.25 187.5

2. Introduction 6-2017

Type C125 N6 C150 N6

120/240, 1 Ph (Reconnectable)

227/480, 3 Ph WYE 347/600, 3 Ph WYE

Rated Voltages (V)

120/240, 3 Ph DELTA

120/208, 3 Ph WYE 127/220, 3 Ph WYE

NOTICE

Maximum I2= 8%. Generator set load unbalance must not exceed 25% between any phases.

TABLE 9. GENERATOR SET DERATING GUIDELINES

Engine Power Available Up To... Derate At…

Model Phase

Elevation

Ambient

Temperature

C125 N6 1 & 3 2010 m (6600 ft)

40 °C (104 °F)

C150 N6 1 & 3 885 m (2900 ft)

TABLE 10. CONTROL SPECIFICATIONS (ALL MODELS)

Control Purpose

PowerCommand 2.3 Generator Set Enovation 4G LDI Engine (125, 150 kW Generator Sets)

TABLE 11. DC SYSTEM SPECIFICATIONS (ALL MODELS)

Type Specification

Nominal Battery Voltage 12 VDC Battery Group 34 (1 standard; 2 optional)

Elevation Temperature

4.5% per

300 m (985 ft)

1.5% per

10 °C (18 °F)

Battery Type Lead acid, maintenance-free Minimum Cold Crank Amps 850 standard, 1080 high capacity

TABLE 12. FUSE SPECIFICATIONS

Fuse Amps Volts Comment

F1 20 F2 10

2. Introduction6-2017

F3 20

F4 5 F5 20 F6 10 F7 10

600 Class G size-rejecting, current limiting

F8 10

2.5 Before Installation

Before beginning the installation of the generator set, verify that the unit was correctly selected. Check the following features:

• Model

• Specifications

• Options

• Fuel Supply ◦ The gas supplied to the generator set must be of acceptable quality.

¼” x 1¼” cylindrical glass cartridge,

fast acting

◦ The gas supply must have sufficient pressure. Care must be taken to be

sure that the gas supply at the generator set, not just at the source, is of proper pressure for operation. The specified pressure must be available while the generator set is starting and running at full load.

◦ The gas must be supplied to the generator set in sufficient volume to

support operation of the generator set. This is normally a matter of selecting fuel line size to be large enough to transport the volume of fuel needed.

2. Introduction 6-2017

This page is intentionally blank.

3 Pre-Installation Considerations

Areas of consideration:

No. Description No. Description

1 Generator Set 3 Electrical Meter 2 Transfer Switch 4 Natural Gas Meter

FIGURE 1. SITE PREPARATION EXAMPLE

• Location of the generator set - this is one of the first decisions to be made, as it

affects all other aspects of the installation, such as:

◦ Length of electric wiring ◦ Length of gas lines (natural gas line must be inspected by the gas utility

inspectors and building inspectors)

◦ Site preparation:

▪ Access to the site ▪ Trenches ▪ Site preparation materials needed

• Fuel supply pressure

• Automatic transfer switch location and connections

• Tools and materials required

• Accessories required (if any) for the customer's application (utility power may

be required at the generator set; make plans accordingly)

3. Pre-Installation Considerations 6-2017

NOTICE

Depending on the locality and use of the generator set, it may be necessary to obtain an air quality emissions permit before installation begins. Check with local pollution control or air quality authority to determine permit requirements.

3.2 Installation Codes and Standards for Safety

NOTICE

The generator set installer bears sole responsibility for following all applicable local codes and regulations.

The following list of codes and standards may apply to the installation and operation of the generator set. This list is for reference only and not intended to be inclusive of all applicable codes and standards. The address of each agency is listed so that copies of the codes may be obtained for reference. Installation codes and recommendations are subject to change, and may vary by location or over time.

3. Pre-Installation Considerations6-2017

TABLE 13. INSTALLATION CODES AND STANDARDS FOR SAFETY

RECOMMENDATIONS

Type

Code or

Standard

Code

NFPA 70 - National Electrical Code

Title Organization

NFPA 37 - Installation and Use

Code

of Stationary Combustion Engines and Gas Turbines

Code

NFPA 54 - National Fuel Gas Code

NFPA 58 - Storage and

Code

Handling of Liquefied Petroleum Gases

NFPA 110 - Standard for

Code

Emergency and Standby Power Systems

Code CSA Electrical Bulletin Code

CSA 22.1 Canadian Electrical Code

National Fire Protection Association

470 Atlantic Avenue Boston, MA 02210

Code

Canada

Standard

Code

California Code

CSA B149 Installation Code for Gas Burning Appliances and Equipment

CSA C22.2 No. 100 Motors and Generators

CSA C22.2 No. 14 Industrial Control Equipment

CSA C282 Emergency Electrical Power Supply for Buildings

CSA Z32 Electrical Safety in Health Care Facilities

California Administrative Code Title 25 Chapter 3

Canadian Standards Association

Housing and Construction Materials Section

178 Rexdale Blvd. Rexdale, Ontario, Canada M9Q

1R3

State of California Documents Section P.O. Box 1015 North Highlands, CA 95660

3. Pre-Installation Considerations 6-2017

3.3 Required Items for Installation

Tools and materials are used for the installation of this generator set. These items are identified in the following sections. Please refer to local codes and standards, because they may affect the materials required.

Materials Required

NOTICE

Refer to local codes and standards, which may affect material requirements.

NOTICE

If a 100% rated breaker is used, 90 °C (194 °F) wire must be used with the wire size determined by the 75 °C (167 °F) ampacity tables. Aluminum wire is not allowed with 100% rated breakers.

NOTICE

If required, a UL-listed grounding electrode terminal within its ratings and suitable for the application must be installed and labeled “Grounding Electrode Terminal”.

Electrical Materials:

NOTICE

Class 1 wiring methods must be used for connecting the generator set.

• Use code compliant AC wiring for phase, neutral, and ground connections.

• Wire sizes (DC control and power and AC sense only): ◦ Control wires under 305 m (1000 feet) circuit length => 18-14 AWG of the

insulation type below

◦ Control wires 305 - 610 m (1000 - 2000 feet) circuit length => 16-14 AWG

of the insulation type below

• All control wires and cables must be rated 75 °C (167 °F) minimum, stranded

copper, and rated for wet locations.

◦ For wire sizes 14 AWG and larger, use insulation types: RHW, RHW-2,

THHW, THW, THW-2, THWN, THWN-2, XHHW, XHHW-2, USE-2, ZW-2

◦ For wire sizes 16 and 18 AWG, use insulation types: FFH-2, KFF-2, PAFF,

PFF, PGFF, PTFF, RFH-2, RFHH-2, RFHH-3, SFF-2, TFF, TFFN, ZFF

• Code compliant 20 A, 120 VAC, GFCI protected circuit for alternator heaters,

battery charger, coolant heater, oil heater, and/or battery heater (if equipped)

NOTICE

The optional high wattage coolant heater operates at 240 VAC.

3. Pre-Installation Considerations6-2017

• Code-compliant conduit for all wires

• Circuit breaker wire binding screws: 3/16”, 5/16”, ½”, 6 mm, 8 mm hex bit

• Customer connections to auxiliary I/O boards and relays

• Pozidriv screwdriver #2 and #3

NOTICE

Seismic zone installations require compliance to specific mounting configurations.

Fuel Materials:

• Flexible fuel line (provided with the generator set, attached to the radiator

guard)

• UL listed pipe thread sealant

• Fuel line at generator set (natural gas fuel pressure: 1.5 - 3.2 kPa/6 - 13 inches

water column)

• Fuel pressure regulator (as required)

• Manual fuel shut-off at generator set ahead of automatic valves on generator

set fuel system

Tools Required

Use appropriate lifting techniques to position the generator set in place.

Loose Parts Shipped with the Generator Set

The following loose parts are shipped with the generator set:

• Flexible fuel hose assembly (attached to the radiator guard)

• One enclosure key (where applicable)

• Battery tie-down

• Sound level 2 baffle (where applicable)

• Weather enclosure exhaust elbow (where applicable)

• Literature (operator manual, installation manual, health and safety manual, and

warranty statements)

3. Pre-Installation Considerations 6-2017

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+ 82 hidden pages

CUMMINS C125 N6, C150 N6 Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

1 IMPORTANT SAFETY INSTRUCTIONS

1.2 Save These Instructions

1.3 General Information

1.4 General Precautions

1.5 Generator Set Voltage Is Deadly

1.6 Fuel and Fumes Are Flammable

1.7 Starting Batteries

1.8 Batteries Can Explode

1.9 Vented Batteries

1.10 Moving Parts Can Cause Severe Personal Injury or Death

1.11 Exhaust Gases Are Deadly

1.12 The Hazards of Carbon Monoxide

2 Introduction

2.1 About This Manual

2.2 Schedule of Abbreviations

2.3 Related Literature

2.4 Model Specifications

2.5 Before Installation

3 Pre-Installation Considerations

3.2 Installation Codes and Standards for Safety

3.3 Required Items for Installation