CUMMINS C13N6H (Spec A), C17N6H (Spec A), C20N6HC (Spec A), C20N6H (Spec A) Installation Manual

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InstallationInstallation ManualManual

Home Standby Generator Set

C13N6H (Spec A) C17N6H (Spec A) C20N6H (Spec A) C20N6HC (Spec A)

English Original Instructions

12-2016 A053X172 (Issue 6)

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

1.1 Save These Instructions ........................................................................................................ 1

1.2 General Information ................................................................................................................ 1

1.3 General Precautions .............................................................................................................. 1

1.4 Generator Set Voltage Is Deadly ........................................................................................... 5

1.5 Engine Exhaust Is Deadly ...................................................................................................... 5

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

1.7 Batteries Can Explode............................................................................................................ 6

1.8 Starting Batteries .................................................................................................................... 7

1.9 Moving Parts Can Cause Severe Personal Injury or Death .................................................. 7

1.10 The Hazards of Carbon Monoxide........................................................................................ 8

2. INTRODUCTION............................................................................................................................ 9

2.1 About This Manual.................................................................................................................. 9

2.2 Schedule of Abbreviations...................................................................................................... 9

2.3 Related Literature ................................................................................................................. 11

2.4 Before Installation ................................................................................................................. 12

2.5 Model Specifications............................................................................................................. 13

3. PRE-INSTALLATION CONSIDERATIONS.................................................................................. 17

3.1 Pre-Installation Considerations Introduction......................................................................... 17

3.2 Installation Codes and Standards for Safety ........................................................................ 18

3.3 Required Items for Installation.............................................................................................. 20

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

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

4.2 Fuel Selection and Fuel System Connection........................................................................ 31

4.3 Engine Exhaust..................................................................................................................... 43

4.4 Electrical Connections .......................................................................................................... 44

5. STARTUP AND CONFIGURATION............................................................................................. 55

5.1 "Establishing Communications" Message ............................................................................ 55

5.2 "Clock Setup" Screen............................................................................................................ 55

5.3 "Exercise" Screen ................................................................................................................ 61

5.4 "Brightness and Contrast" Screen ........................................................................................ 64

5.5 "About" Screen...................................................................................................................... 66

5.6 "Event Log" Screen............................................................................................................... 68

5.7 "Fault Log" Screen................................................................................................................ 69

5.8 "System Status" Screen........................................................................................................ 70

5.9 "Mode" Screen...................................................................................................................... 71

5.10 Automatic Load Management............................................................................................. 74

5.11 Manual Start Sequence (Local).......................................................................................... 75

5.12 Checklist ............................................................................................................................. 75

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Table of Contents 12-2016

5.13 Startup ............................................................................................................................... 78

6. OPTIONAL REMOTE MONITORING SYSTEM (RMS) DESCRIPTION ..................................... 79

6.1 Introduction .......................................................................................................................... 79

6.2 Optional Remote Monitoring System (RMS) Account Setup and Generator Set Control

Connection ............................................................................................................................ 80

APPENDIX A. FUEL LINE SELECTION........................................................................................... 81

A.0 Fuel System Pipe Sizing Introduction................................................................................... 82

A.1 Gas Pipe Sizing.................................................................................................................... 83

APPENDIX B. OUTLINE AND SYSTEM DRAWINGS...................................................................... 95

APPENDIX C. WIRING DIAGRAMS............................................................................................... 101

C.0 Wiring Diagrams................................................................................................................. 102

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1 Important Safety Instructions

1.1 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.

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.

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

1.3 General Precautions

• Keep ABC fire extinguishers accessible.

CAUTION

NOTICE

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

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1. Important Safety Instructions 12-2016

• 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.

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

• 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

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.

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1. Important Safety Instructions12-2016

WARNING

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.

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 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.

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1. Important Safety Instructions 12-2016

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.

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.

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.

• 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. The generator set must be off and locked out of service whenever the air

inlet, air outlet, or any interior panels are removed.

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).

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1. Important Safety Instructions12-2016

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.

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.

1.4 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.

1.5 Engine Exhaust Is Deadly

• See The Hazards of Carbon Monoxide to learn the symptoms of Carbon Monoxide poisoning.

• Locate the generator set away from doors, windows, other openings into the house, and where exhaust gases will disperse away from the house.

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1. Important Safety Instructions 12-2016

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 Batteries Can Explode

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

WARNING

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.

WARNING

Electric Shock Hazard Batteries present the risk of high short circuit current. Remove watches, rings, or other metal objects. Use tools with insulated

handles.

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.

• 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.

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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.

1.8 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 Instructions12-2016

WARNING

1.9 Moving Parts Can Cause Severe Personal Injury or Death

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

• Keep hands away from moving parts.

• Keep guards in place over fans.

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1. Important Safety Instructions 12-2016

1.10 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.

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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; this product must never be installed indoors.

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.

Abbr. Description Abbr. Description

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

Electronics)

MFM Multifunction Monitor

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2. Introduction 12-2016

Abbr. Description Abbr. Description

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 ECS Engine Control System PPE Personal Protective

Equipment EMI Electromagnetic

Interference

PT Potential Transformer

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2. Introduction12-2016

Abbr. Description Abbr. Description

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

IC Integrated Circuit SPN Suspect Parameter

PWM Pulse-Width Modulation

Interference

System

Engineers

gas per Hour

SCR Selective Catalytic

Reduction

Number 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.

SW_B+ Switched B+

Laboratories

Supply

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2. Introduction 12-2016

NOTICE

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, as well as the Warranty Statements.

The literature provided with the generator set is as follows:

• Installation Manual (A053X172)

• Operator Manual (A053X174)

• Quick Start Installation Guide (A053X181)

• Quick Start Operator Guide (A053X183)

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

• Global Warranty Statement (A056F206)

• Emission Warranty Statement (Federal Emissions EPA Title 40 CFR Part 90 Component Warranty) (A028X278)

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

• Generator Set Service Manual (A053X177)

• RA Series RA112L1 Automatic Transfer Switch Owner Manual (A052S254) - if applicable

• RA Series 100A/200A/400A Automatic Transfer Switch Owner Manual (A046S594) - if applicable

• Parts Manual (A053X179)

• Standard Repair Times - HO Family (A053X186)

• Service Tool Manual (A043D529)

• Warranty Failure Code Manual (F1115C)

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

2.4 Before Installation

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

• Model

• Specifications

• Options

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• Fuel Supply

◦ The gas supplied to the generator set must be of acceptable quality. ◦ 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. For liquid propane vapor-withdrawal fuel systems the size and temperature of the fuel tank also affects this requirement.

2.5 Model Specifications

TABLE 1. MODEL VARIATIONS

2. Introduction12-2016

Model

C13N6H Both 13 54.2 C17N6H Both 17 70.8

C20N6H,

C20N6HC

Maximum load imbalance allowed is 50% of generator set rating.

TABLE 2. COLD WEATHER SPECIFICATIONS (ALL MODELS)

Temperature Description

Above 40 °F (4 °C) No starting aids required 0 to 40 °F (-17 to 4 °C) Alternator heater (supplied with the generator set)

Natural Gas or

Propane Vapor

Natural Gas Only 18 75

Propane Vapor

Only

kW Amps Frequency Voltage

20 83.3

NOTICE

60 Hz

120/240 VAC Single Phase

Below 0 °F (-17 °C)

• Alternator, battery, oil and regulator heaters

• 0W30 oil (see Lubricating Oil System Specifications)

• Accessory kit available

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2. Introduction 12-2016

TABLE 3. FUEL SPECIFICATIONS (AT FULL LOAD) (ALL MODELS)

C13N6H C17N6H C20N6H, C20N6HC

Type

scfh BTU/hr scfh BTU/hr scfh BTU/hr

Natural Gas 253 260,000 289 297,000 300 309,000 Propane 85 212,000 101 252,000 116 290,000

Natural Gas: 3.5 - 12 inch water column (0.9 - 3.0 kPa)

Fuel Pressure

Propane Vapor: 6 - 12 inch water column (1.5 - 3.0 kPa) Maximum pressure for either fuel under any condition: 13 inch water

column (3.2 kPa)

TABLE 4. ENGINE SPECIFICATIONS (ALL MODELS)

Type Value

Engine

2 cylinder v-twin, OHV, air-cooled, 4-stroke, spark

ignited Displacement 999 cc (60.9 in3) Spark Plug Gap 0.7 - 0.8 mm (0.027 - 0.031 in) Spark Plug Torque (Cold Engine) 25 - 30 Nm (18 - 22 ft-lb) RPM 3600 Lubricating Oil Pressure at Rated

Speed (Minimum)

45 psi (310 kPa)

Full synthetic gasoline engine oil which meets or

exceeds API service SN/SN-RC and ILSAC GF-5: Oil Recommendation

• 5W30: Temperatures above 0 °F (-18 °C)

• 0W30: All temperatures, required below 0 °F (-18 °C)

Lubricating Oil Capacity:

Lubricating Oil Pressure at Rated Speed (Minimum)

310 kPa (45 psi)

--Full at High Mark on Dipstick 2.3 L (2.4 qt)

--Low Mark on Dipstick 1.3 L (1.4 qt)

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Model

2. Introduction12-2016

TABLE 5. GENERATOR SET SIZE (ALL MODELS)

Dimension Value

Length 877 mm (34.5 in) Width 915 mm (36 in) Height 694 mm (27.3 in)

TABLE 6. GENERATOR SET WET WEIGHT (INCLUDING BATTERY)

Model Value

C13N6H 218 kg (479 lb) C17N6H, C20N6H, C20N6HC 241 kg (531 lb)

TABLE 7. GENERATOR SET DERATING GUIDELINES

Engine Power Available Up To... Derate At…

Elevation Ambient Temperature Elevation Temperature

C13N6H 2100 m (6900 ft) 25 °C (77 °F) C17N6H 300 m (1000 ft) 25 °C (77 °F)

C20N6H,

C20N6HC

0 m (0 ft) 15 °C (60 °F)

NOTICE

Derating guidelines: This product's output power is limited by factors such

as BTU content of fuel, ambient temperature, altitude, humidity, engine condition, etc. The derating guidelines are based on properly maintained product, using the appropriate fuel. Derate values are based on expected engine power changes from elevation and temperatures listed.

TABLE 8. ALTERNATOR SPECIFICATIONS (ALL MODELS)

Type Specification

Design Rotating field

Poles 2

3.5% per 300 m

(1000 ft)

1% per

5.5 °C (10 °F)

RPM 3600

Voltage 240

Hz 60

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2. Introduction 12-2016

TABLE 9. CONTROL SPECIFICATIONS (ALL MODELS)

Control

Integrated Microprocessor-Based Engine, Alternator, Transfer Switch Controller

TABLE 10. DC SYSTEM SPECIFICATIONS (ALL MODELS)

Type Value

Nominal Battery Voltage 12 VDC Battery Group 51 R Battery Type Lead Acid Minimum Cold Crank Amps (CCA) 450

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3 Pre-Installation Considerations

3.1 Pre-Installation Considerations Introduction

WARNING

The installer is responsible for complying with all applicable installation codes and safety requirements. See the Installation Codes and Standards for Safety section of this manual for more information.

The following sections create a step-by-step overview of a typical generator set installation. Review these sections to become familiar with specific procedures and important safety before beginning the installation.

NOTICE

For information on tools and materials, see the Required Items for Installation section. For information on locating the generator set, see the Installation section. For codes and standards, see the Installation Codes and Standards for Safety section. For specifications, see the Model Specification section.

Areas of consideration:

• 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 or propane - 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

• Minimum distance from the propane tank fill:

◦ Verify the legal minimum distance with local code officials. ◦ Verify the minimum distance from the service pressure regulator to the

generator set.

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3. Pre-Installation Considerations 12-2016

◦ Verify any minimum clearance requirements to the generator set that the

gas supplier or equipment supplier may have.

• Accessories required (if any) for the customer's application (utility power is required at the generator set for the battery charger and may be required for the heaters; make plans accordingly)

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.

TABLE 11. INSTALLATION CODES AND STANDARDS FOR SAFETY

RECOMMENDATIONS

Code or Standard Organization

NFPA 37 - Installation and Use of Stationary Combustion Engines and Gas Turbines

NFPA 54 - National Fuel Gas Code NFPA 58 - Storage and Handling of Liquefied

Petroleum Gases NFPA 70 - National Electrical Code

CSA Electrical Bulletin CSA 22.1 Canadian Electrical Code CSA B149 CSA C22.2 No. 100 CSA C22.2 No. 14

National Fire Protection Association 470 Atlantic Avenue Boston, MA 02210

Canadian Standards Association Housing and Construction Materials

Section 178 Rexdale Blvd. Rexdale, Ontario, Canada M9Q 1R3

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3. Pre-Installation Considerations12-2016

Code or Standard Organization

California Administrative Code - Title 25 Chapter 3 State of California

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

Operating the Generator Set Cover Safely

To configure the local display or access the generator set, you will need to lift the cover (lid). The cover of the generator set is designed to latch securely into the "up" position to prevent accidental closure.

• To open: Lift the cover until the hinge pin drops into the hinge pin slot. Test that the cover is secure by gently pressing down on the cover.

• To close: Lift up on the cover while pressing upward on the hinge pin and slide the pin upwards out of the hinge pin slot. Carefully push the cover downward and let go of the hinge pin allowing it to ride along the hinge until the cover is closed.

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3. Pre-Installation Considerations 12-2016

FIGURE 1. HINGE LOCATION

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.

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3. Pre-Installation Considerations12-2016

NOTICE

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

NOTICE

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

TABLE 12. MATERIALS REQUIRED

Requirement Specification

Electrical Materials

Code compliant AC power wires Four (L1, L2, N and Gnd) For accessories (alternator heater, oil heater, battery heater,

and/or regulator heater) (if equipped)

Code compliant 20 A, 120 VAC, GFCI protected circuit, copper wire only

RA switches only: Control wires from the generator set to the

Four DC wires

transfer switch Ethernet cable for Internet installation (as required) Cat 5, Cat 5e or Cat 6 All AC and DC wire and cable ratings Must be 75 °C minimum with

600 V minimum insulation, stranded copper, rated for wet

Wire sizes (for all DC customer connections): Under 1000 ft

locations. 18-14 AWG

wire length Conduit Code compliant for all wires

Mounting Materials

Bolts or anchor assemblies Two base tie-down

Fuel System Materials

Fuel line Flexible Pipe thread sealant UL listed Fuel service pressure regulator (as required) -Manual fuel shut-off at generator set ahead of automatic

valves on generator set fuel system

Remote Display Materials (if Applicable)

Remote display --

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3. Pre-Installation Considerations 12-2016

Requirement Specification

Hardware, Cummins provided:

Pigtail harnesses Two (one for local display and

one for remote display); 5wire (RS485-A2, RS485-B2, B+, WAKEUP and B-), 1 ft long each

Hardware, customer provided: Intermediate wires of required

Five wires, 600V insulation length to connect to the pigtail harnesses using splices provided in the remote display kit

Wire sizes (RS485-A2,

Under 1000 ft wire length 20-14 AWG

RS485-B2, B+, WAKEUP): Wire sizes (B+ and B-): Under 100 ft wire length 18 AWG

Under 200 ft wire length 16 AWG Under 300 ft wire length 14 AWG

Hardware, Miscellaneous If wires can be concealed in a

wall cavity: If wires cannot be concealed

in a wall cavity:

3 wall anchors and screws

(number 6 or number 8)

3 wall anchors and screws

(number 6 or number 8),

standoffs, and conduit or wire

raceway

300V insulation is acceptable for Ethernet and DC cables if routed in a separate conduit

from AC wiring.

Use twisted pair wires for RS485-A and RS485-B wires.

1, 2

Tools Required

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

Transfer Switch Requirements

A transfer switch must be a part of every generator set installation. Transfer switches transfer loads to the generator set during power outages.

NOTICE

Cummins offers a variety of transfer switches, including residential and light commercial options.

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3. Pre-Installation Considerations12-2016

FIGURE 2. CUMMINS AUTOMATIC TRANSFER SWITCH (ATS)

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

• Specifications (voltage, amperage, frequency, poles, and phases)

• Enclosure (indoor vs. outdoor)

• Model

Cummins recommends that any RA series transfer switch be used with these generator sets. Refer to the appropriate RA series ATS owner manual for more detailed information.

Choosing a Transfer Switch

This section includes block diagrams showing partial or full load coverage for the following Cummins UL 1008 listed transfer switches:

TABLE 13. CUMMINS TRANSFER SWITCH MODELS

Model Non-Service Entrance Service Entrance

RA 100A ■ ■ RA 200A ■ ■ RA 400A ■ ■

RA112L1 ■

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3. Pre-Installation Considerations 12-2016

NOTICE

These generator sets can be used with either service entrance transfer switches or non-service entrance transfer switches.

NOTICE

If the load exceeds the generator set rating, it may be necessary to use Cummins’ load management kit (A051C329).

FIGURE 3. TRANSFER SWITCH CONNECTIONS FOR PARTIAL COVERAGE LOAD

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3. Pre-Installation Considerations12-2016

FIGURE 4. TRANSFER SWITCH CONNECTIONS FOR FULL COVERAGE LOAD

Loose Parts Shipped with the Generator Set

The following loose parts are shipped with the generator set:

• Two enclosure keys

• Generator set mounting spacers

• Circuit breaker cover and screw

• Chassis plugs

• Transfer switch TB4 jumper

NOTICE

This jumper must be installed in the RA series transfer switch according to the interconnect diagram in the RA series transfer switch owner manual.

• Literature (Operator Manual, Quick Start Operator Guide, Installation Manual, Quick Start Installation Guide, Health and Safety Manual, and Warranty Statements)

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4 Installation

4.1 Site Assessment and Preparation

Proper component location and site preparation have a very important impact on completing a successful installation. The major components and sources of power needed for installation include the following items:

• Generator set

• Transfer switch

• Electrical utility

• Fuel source

• Accessories (may be required under certain conditions)

Generator Set Installation Suggestions and Guidelines

• Locate the generator set on stable ground, not subject to flooding. Generator set should not be installed where significant water runoff from a roof or downspouts is present. Sump pump discharge should be routed away from the generator set.

• Locate and orient the generator set such that prevailing winds will carry exhaust gases and fuel leaks away from the house or occupied areas.

• This unit is to be installed so that the risk of contact by people is minimized.

Picking a Location

WARNING

Exhaust gas is deadly. Install the generator set outdoors only. Locate the generator set away from doors, windows, and other openings to the house and where exhaust gases will disperse away from the house or occupied areas.

NOTICE

All parts of the generator set enclosure must be at least 60 inches (1524 mm) from any openings in walls of structures that may be occupied.

Generator set location is critical for safety and performance. Follow the guidelines below:

• The installation must comply with all applicable codes and standards (NFPA, NEC, IBC, etc.).

• This manual only covers outdoor installations with Cummins factory installed enclosures. This product must never be installed indoors.

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4. Installation 12-2016

• Consider access to utilities (electric meters, transfer switch, fuel supply line and fuel tank, etc.).

• Call the local utilities to mark the locations of buried utility services (gas, electric, telephone, etc.) before digging.

• Verify the locations of any other buried components (gas, electric telephone, etc.) with the homeowner before digging.

• Consideration should be given to the location of sprinkler heads for irrigation systems. The generator set should not be located where it is subjected to substantial wetting (especially on the inlet air side) when the irrigation system is in operation.

• Always install this generator set service regulator above the snow line.

Follow the clearance requirements below (refer to the Outline and System Drawings appendix):

• All parts of the generator set enclosure must be at least 60 inches (1524 mm) from any openings in walls of structures that may be occupied. Examples of wall openings include but are not limited to: operable windows, doors, dryer vents, fresh air intake for heaters, etc.

• The engine side and alternator side of the generator set must be located as follows:

◦ One side (either engine or alternator) must be located not less than 18

inches (458 mm) from any structures having combustible walls. This space must be free of any obstructions for service access.

◦ The opposite side must be located not less than 60 inches (1524 mm) from

any structures having combustible walls. A minimum of 18 inches (458 mm) of unobstructed space is required for service access.

• The intake (cooling air inlet) side of the generator set must be located not less than 30 inches (762 mm) from any structures having combustible walls. This space must be free of obstructions to air flow and service access.

• The generator set must be located such that exhaust gases are not able to accumulate in an occupied area. The air discharge side must always be unobstructed and spaced a minimum of 60 inches (1524 mm) from any structures having combustible walls. A minimum of 36 inches (915 mm) must be free of any combustible items, and unobstructed for service access.

• The generator set must have enough room for installation, service, and maintenance.

• The generator set must be located to ensure ventilation openings are not blocked.

• Position the generator set so that cooling air is free to enter and leave the area.

• Locate and position the generator set so that prevailing winds carry exhaust gases and potential fuel leaks away from the house or occupied area.

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Preparing the Generator Set Mounting Surface

Cummins recommends the generator set be installed on a non-combustible mounting pad (available as an accessory) or a poured concrete slab. The surface beneath the mounting surface must be properly prepared to minimize the risk of the generator set settling and causing undue stress on the fuel system or electrical connections. The surface preparation is the same when preparing the site for installing on the accessory mounting pad or poured slab.

Cummins recommends the generator set be installed above grade for easier maintenance, and lower risk of submersion in water.

1. Clear obstructions and make sure that there is adequate clearance for access to the site.

2. Ensure that the ground is stable and is not subject to flooding.

3. Level the ground, and make sure that the subgrade is compacted and settled. Local soil condition may dictate the need for addition of sub-base and base material layers above the subgrade. Consult with your local building officials for requirements and recommendations for your area.

4. Either pour a concrete slab or set an accessory mounting pad on the prepared surface. The poured concrete slab should be:

• Constructed of concrete with a 28-day compressive strength of at least 2500 psi (17,200 kPa); typical bagged concrete mix meets this requirement

• A minimum of 3 inches (76.2 mm) thick

• At least 2 inches (50.8 mm) larger in length and width than the generator set base

5. Place the generator set on the pad and secure it to the mounting surface using the mounting spacers (provided) and appropriate fasteners. See the Securing the Generator Set to the Mounting Pad section for more information.

Lifting and Moving the Generator Set

WARNING

Heavy Load The generator set is heavy. Handle with care. Dropping the generator set can cause severe personal injury or death. Use

appropriate lifting techniques to move the generator set. Keep feet and hands clear when lifting the generator set.

CAUTION

The generator set is shipped with oil in the engine crankcase. Keep the generator set upright.

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4. Installation 12-2016

Securing the Generator Set to the Mounting Pad

The generator set should be securely attached to either a poured concrete slab or prefabricated mounting pad (accessory pad) made of non-combustible material.

NOTICE

An accessory mounting pad is available that includes ½ -13 UNC x 1.25 inch mounting holes located in the proper location for these generator sets. Two hex head cap screws (½-13 x 3 inch long) and flat washers are needed with this accessory pad.

1. Position the two spacers (which were shipped with the generator set) appropriately on the generator set base.

No. Description No. Description

1 Spacer Length (2.18 in [55.4 mm]) 2 Spacer Through-Hole Diameter (0.59

in)

FIGURE 5. MOUNTING SPACER

2. Prefabricated pad only: Install the bolts into the prefabricated pad and tighten. Torque value: 37 ft-lb (50 Nm).

3. Poured slab only:

a. Mark the location for the anchor bolts with the generator set in place. b. Install the anchor bolts per the manufacturer's recommendation for both

embedment and tightening torque.

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4. Installation12-2016

NOTICE

There are several styles of anchor bolts available. Follow the anchor bolt manufacturer's requirements for hole size and depth. The length of the anchor bolt must accommodate:

• The embedment length of the bolt into the pad

• The length of the spacer

• The thickness of the washer and

• The thickness of the nut (if used)

4. Install the chassis plugs in the generator set's lifting holes after the unit is in its final position.

4.2 Fuel Selection and Fuel System Connection

This generator set has a convertible fuel system. The generator may run on natural gas or propane, depending on the preferences of the owner. All generator sets come preconfigured from the factory for natural gas fuel. For more information on converting the fuel system type, see the Service Manual.

NOTICE

Fuel systems must be installed by qualified service technicians. Improper installation presents hazards of fire and improper operation, resulting in severe personal injury or property damage.

NOTICE

In some jurisdictions fuel system installations to the generator set must be performed by licensed or registered personnel. Check with the authority having jurisdiction for requirements.

WARNING

Gaseous fuels are flammable, explosive, and can cause severe personal injury or death. Do not smoke if you smell gas, are near fuel tanks for fuelburning equipment, or are in an area sharing ventilation with such equipment. Keep flames, sparks, pilot lights, electrical arcs, arc-producing equipment and all other sources of ignition well away. Keep a type ABC fire extinguisher handy.

In all fuel system installations, cleanliness is extremely important.

• Make every effort to prevent fuel contamination from:

◦ Moisture ◦ Dirt

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4. Installation 12-2016

◦ Excess thread sealant ◦ Contaminants of any kind

• Clean all fuel system components before installing.

Gaseous-fuel supply system design, materials, components, fabrication, assembly, installation, testing, inspection, operation, and maintenance must comply with the applicable codes. See NFPA Standards No. 37, 54, and 58. If this is a seismic installation, refer to IBC codes and standards. Where seismic installation is required, there may be specific anchorage requirements for the generator set and other installed components.

Most codes require a manual shutoff valve ahead of a flexible fuel hose. The generator set includes electric (battery-powered) shutoff valves.

NOTICE

It is recommended that a shutoff valve be located near the generator set for emergency shut off or servicing the generator set. Follow applicable codes.

Until the generator set is connected, cap the fuel line stub-up at the generator set to prevent dirt from entering and gas from discharging if the gas supply shutoff valve is opened accidentally.

To determine the required capacity, refer to the Fuel Line Selection section.

Fuel Line Connections

WARNING

Fuel presents the hazard of fire or explosion that can result in severe personal injury or death. Do not smoke or allow any flame, spark, pilot light or other ignition sources near fuel or in the installation area. Read the important safety precautions in this manual.

1. Refer to the Outline and System Drawings appendix for the location of the fuel supply connection through the side of the generator set.

2. Install a flexible fuel hose, which must be used between the engine's fuel system and fuel supply line to protect the fuel system from damage caused by vibration, expansion and contraction. The fuel hose must be installed according to all applicable codes and standards.

Natural Gas Fuel System

WARNING

Fuel leaks can lead to explosive accumulations of gas. Prevent gas leaks and the accumulation of gaseous fuel in the event of a leak.

Requirements for a natural gas generator set are as follows:

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TABLE 14. NATURAL GAS GENERATOR SET REQUIREMENTS

Component Description

Gas Pipeline quality Fuel Supply Adequate fuel supply to operate correctly and run at full load Shutoff Valve Manual Fuel Pipe Size The length of the fuel supply pipe from the gas service entrance to the

generator set must be known to determine the correct fuel pipe size. Refer to the charts in the Fuel Line Selection appendix.

Iron pipe must be a minimum of schedule 40 subject to the authority having jurisdiction.

Flexible Fuel Line Protects the fuel system from vibration, expansion, and contraction. Must

meet code requirements for application and be installed per manufacturer instructions.

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No. Description No. Description

1 Distance as Required by Code and/or

Component Suppliers

7 Secondary Service Pressure Regulator

(If Required) 2 Primary Service Pressure Regulator 8 Flexible Fuel Line 3 Natural Gas Supply 9 Sediment Trap 4 Gas Meter 10 Fuel Line Connection at Generator Set 5 Note: A branch in the fuel line to the

11 Generator Set generator set may allow selection of a smaller diameter line size to the generator set and remainder of gas appliances.

6 Full Flow Manual Shutoff Valve

FIGURE 6. TYPICAL NATURAL GAS INSTALLATION

Natural Gas Supply Line Size

See the Model Specifications section for fuel specifications (such as BTU/hr). The natural gas supply meter may need to be exchanged for a higher capacity

meter to supply the additional gas consumed by the generator set.

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To correctly size the fuel pipe, you must also take other loads operated from the fuel supply line into consideration, such as space heating and water heating equipment.

Use the total fuel requirement of the generator set and other connected appliances to determine the size of the fuel supply pipe. Use the tables and charts in the Fuel Line Selection appendix to determine the correct pipe size.

The installation site might require upgrading and repair of the gas supply system. Schedule an upgrade or repair to minimize power and gas supply interruptions.

Make sure the full load fuel supply pressure at the inlet to the generator set fuel shutoff valves is set between 3.5 - 12 inch water column (0.9 - 3.0 kPa) for all operating loads (no load to full load). Refer to the Model Specifications section.

See the Natural Gas Fuel System section for an example of a typical natural gas installation.

Propane Fuel System

4. Installation12-2016

WARNING

Fuel leaks can lead to explosive accumulations of gas. Propane sinks in air and can accumulate inside housings, basements, and other below-grade spaces. Prevent gas leaks and the accumulation of gaseous fuel in the event of a leak.

NOTICE

NFPA Standard No. 58 requires all persons handling and operating propane to be trained in proper handling and operating procedures.

TABLE 15. REQUIRED COMPONENTS IN A PROPANE VAPOR FUEL SYSTEM

Component Description

Propane Tank Make sure to identify and use the correct tank size based on fuel flow

requirements and the lowest average temperature for your region. If the tank is sized incorrectly, the generator set could run out of fuel. Refer to the Minimum LPG Tank Size figure in the Fuel Line Selection appendix.

Shutoff Valve Useful during installation or in the event of a leak (may be required to

meet local codes).

Primary Pressure Regulator

Located at the tank outlet, the primary regulator reduces the tank pressure to the working pressure in the fuel supply line. Primary and secondary regulators must be properly matched for a safe and functional system. Consult with your propane supplier to ensure that the regulators are properly sized.

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Component Description

Secondary Pressure Regulator

Located near the generator set, the secondary regulator reduces the higher line pressure to a working pressure of 6 - 12 inch water column (1.5 - 3.0 kPa). Higher pressure before the secondary regulator is necessary to ensure that there is enough fuel available at the secondary regulator for a fully loaded generator set. Always install this generator set’s service regulator above the expected snow line.

Fuel Line Connects to the fuel supply. It must be sized properly using the propane

fuel line sizing charts (see the Fuel Line Selection appendix). Installation must comply with all national, state, and local codes.

Flexible Fuel Line Protects the fuel system from vibration, expansion, and contraction. Must

meet code requirements for application and be installed per manufacturer instructions.

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No. Description No. Description

4. Installation12-2016

1 Distance as Required by Code and/or

6 Full Flow Manual Shutoff Valve

Component Suppliers

2 Secondary Service Pressure Regulator 7 Flexible Fuel Line 3 Primary Service Pressure Regulator 8 Sediment Trap 4 Liquid Propane Fuel Tank 9 Fuel Line Connection at Generator Set 5 Note: A branch in the fuel line to the

10 Generator Set generator set may allow selection of a smaller diameter line size to the generator set and the remainder of gas appliances.

FIGURE 7. TYPICAL PROPANE INSTALLATION

Propane Fuel Requirements

WARNING

Propane presents the hazard of fire or explosion that can cause severe personal injury or death. Do not permit any flame, spark, arc-producing equipment, switch, pilot light, cigarette, or other ignition source near the fuel system. Keep an ABC type fire extinguisher nearby.

WARNING

Fuel leaks can lead to explosive accumulations of gas. Propane sinks in air and can accumulate inside housings, basements and other below-grade spaces. Prevent gas leaks and the accumulation of gaseous fuel in the event of a leak.

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Use clean, fresh HD-5 grade propane or equivalent product consisting of at least 90% propane.

NOTICE

NFPA Standard No. 58 requires all persons handling and operating propane to be trained in proper handling and operating procedures.

NOTICE

Commercial propane may contain more than 2.5% butane, which can result in poor fuel vaporization and low tank pressure, resulting in poor engine starting and operation in below 32 °F (O °C) temperatures.

Propane Tank Size

When propane is used, size the tank correctly to ensure successful generator set operation.

Considerations when figuring the proper propane tank size:

• Temperature is a critical factor that affects the size of the tank. ◦ Ambient temperatures can affect how quickly liquid is converted to

gas.

◦ Generator set fuel consumption is the same regardless of the

surrounding temperatures.

◦ Colder weather climates require larger fuel tanks. Larger tanks have

greater surface area, allowing more liquid propane to vaporize and maintain the required fuel rate.

◦ Propane is stored as liquid. Keep the fuel tank at least 50% full to

operate properly. Fuel tanks that are less than 50% full may not have the capacity to vaporize enough propane to operate the generator set and other LP appliances.

• Propane tanks are sized by their internal volume in gallons, not the

amount of fuel they can hold (which is less).

• Propane tanks are generally filled to only 80% of their capacity.

Therefore, a 500-gallon (1892 L) tank results in 400-gallon (1514 L) tank capacity.

• Low ambient temperatures affect the amount of fuel available from the

propane tank.

• Approximately 60% of the fuel (in gallons) filled in the tank can be

effectively used. Therefore, a 500-gallon (1892 L) tank results in 240gallon (908 L) usable capacity.

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To assist in the proper installation of the propane tank, follow the guidelines below.

• Consult your tank and propane supplier for assistance in all aspects of

determining tank size, selection of components and installation requirements.

• Fit the propane tanks with a pressure reducing regulator before

connection to the generator set to prevent fuel system damage.

• Locate the propane tanks and all other fuel system components at least

10 feet (3 meters) from any source of combustion (including the generator set). The fuel supplier or local code may require a larger distance between the tank and source of combustion.

• Install the propane tanks according to all national and local codes and

standards, and as required by the fuel tank and fuel supplier.

Refer to the Fuel Line Selection appendix for propane figures and tables.

Propane Vapor Fuel Supply Line Size and Pressure

Fuel line size depends on the amount of fuel needed to run the generator set at full load at the distance the fuel must be moved.

To correctly size the fuel pipe, you must also take other loads operated from the fuel supply line into consideration, such as space heating and water heating equipment.

See the Model Specifications section for fuel system specifications, including fuel consumption and required fuel system pressure at the generator set.

See the Propane Fuel System section for a typical propane vapor installation. See the Fuel Line Selection appendix for fuel capacity at given distances and

pipe size.

NOTICE

Make sure the fuel supply pressure at the inlet of the generator set fuel regulator (at service port) matches the requirements in the Model Specifications section.

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Converting the Fuel System Type

The generator set leaves the factory set up for natural gas. For operation on liquid propane vapor, the generator set must be converted by configuring the generator set control for propane and manually changing the fuel valve position from natural gas to propane.

1. To change the generator set control's fuel type from natural gas to liquid propane vapor:

a. From the Main screen, select Menu. b. Press and hold the Next key on the Menu screen for at least 5

seconds to view the Config Menu.

c. Use the arrow keys to highlight "Config" and click the Enter key. The

Generator Config screen appears.

d. Use the Next key to navigate to the Fuel Type field. Use the arrow

keys to select the fuel type: NG (natural gas; default) or LP (liquid propane).

NOTICE

Do not change the number in the Config field.

NOTICE

The Rating field is not configurable by the user. Instead, it will be automatically populated based on the Config and Fuel Type field selections.

e. Keep selecting the Back button to save the settings and return to the

Main screen.

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FIGURE 8. GENERATOR CONFIG SCREEN

2. Adjust the manual fuel selector to the LP setting:

a. Use a 6 mm external hex wrench to rotate the center section of the

fuel valve. b. Turn the center section clockwise until the detent is reached. c. When you reach the detent, the required force to turn the valve will

increase significantly - do not rotate center section of valve beyond

this point.

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FIGURE 9. LOCATION OF FUEL SELECTOR VALVE

No. Description No. Description

1 Natural Gas Fuel Position 2 Liquid Propane Vapor Fuel Position

FIGURE 10. MANUAL FUEL SELECTOR

Testing the Fuel System for Leaks

After assembly and before initial operation, all of the fuel system components must be tested and proven free of any leaks.

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WARNING

Fuel presents the hazard of explosion or fire which can result in severe personal injury or death. Do not use an open flame to check for leaks. Do not smoke or allow any flame, spark, pilot light, arc-producing equipment, switch or other ignition sources around fuel or fuel components. Keep multi-class ABC fire extinguishers handy.

NOTICE

Follow any local codes and standards, as they may require a different method or documentation of a leak test.

Perform the following fuel piping system leak check:

1. After assembly and before initial operation of generator set, test all fuel system components as required per the National Fuel Gas Code (NFPA 54).

2. The National Fuel Gas Code requires that the generator set be isolated from the piping system by disconnecting it and capping the outlet prior to test. The test pressure required is the greater of 1.5 times the supply pressure or 3 psi (20.7 kPa) minimum.

3. After successfully completing the previous step, connect the generator set to the fuel piping system.

4. To verify that all connections from the fuel piping system to the generator set are free of leaks, conduct a bubble test using an approved leak detection solution (or equivalent method) with the system pressure of 0.8 to 1.0 psi (5.5 to

7.0 kPa).

5. Spray the bubble solution on all of the joints.

6. Inspect all of the joints and monitor the line pressure. If bubbles appear, there is a leak.

7. If any leaks are found, repair the joint or replace components as needed.

8. Verify the leak has been fixed.

The leak detection solution (that is, bubble solution) must be non-corrosive and be free of ammonia and chlorine.

4.3 Engine Exhaust

NOTICE

The exhaust system for this generator set is complete and was designed specifically for this generator set. Do not modify or add to the exhaust system of this generator set.

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WARNING

Exhaust gas is deadly. Make sure that the exhaust system terminates away from building vents, windows, doors, and sheltered spaces that may not have ample fresh air ventilation.

WARNING

Engine discharge air and exhaust carry carbon monoxide gas (odorless and invisible) which can cause asphyxiation and death. Never use engine discharge air or exhaust for heating a room or enclosed space.

4.4 Electrical Connections

WARNING

Improper installation can lead to electrocution and damage to property. Electrical connections must be made by a licensed electrician.

NOTICE

Refer to regional codes and the National Electrical Code (NFPA 70) for all electrical installation requirements.

NOTICE

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

Electrical Preparations

1. Run all wires through a single conduit (unless prohibited by the authority having jurisdiction).

NOTICE

Be sure to account for any needed accessories, such as a remote display, etc.

2. Connect the conduit to the generator set. Refer to the specific outline drawing in the Outline and System Drawings section for the size and location of the hole provided for electrical conduit connection. The existing hole may be increased in size to match conduit used.

3. Route and secure customer wiring along the generator set harness above the engine intake manifold, using wire ties.

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AC Connections

WARNING

Automatic startup of the generator set during installation can cause severe personal injury or death.

Make sure the generator set is shut down and disabled:

1. Press the generator set's red STOP button on the local display to stop the generator set. Allow the generator set to thoroughly cool to the touch.

2. Turn off and disconnect the battery charger from the AC source before disconnecting the battery cables.

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

For grounding and neutral connections, look for the following symbols on the generator set. The neutral connection is at the rear of the breaker box; the ground connection is inside the enclosure on the panel to the left of the breaker box.

Equipment Grounding Conductor Symbol Equipment Neutral Connection Symbol

FIGURE 11. SYMBOLS ON CIRCUIT BREAKER BOX

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4. Installation 12-2016

No. Description No. Description

1 L1 2 L2

FIGURE 12. CIRCUIT BREAKER AC LOAD CONNECTIONS LOCATION

Make the AC load connections to the generator set in the circuit breaker box as follows:

1. Open the circuit breaker box door.

2. Place the circuit breaker handle in the OFF position.

3. Lift the top cover. Undo the two screws on top of the intake panel and remove the panel.

4. Route the load conductors through the access holes found at the bottom of the circuit breaker box.

5. Connect the conductors to the circuit breaker load side terminals. Torque the circuit breaker terminals to 45 in-lb (5 Nm).

6. Unless there is no utility source connected to ATS or house loads, remove the bonding jumper from the neutral lug on the back of the circuit breaker box to the equipment grounding lug as shown in Figure 12. Refer to NFPA 70E or CEC.

7. Install the neutral line to the neutral lug found on the back of the circuit breaker box. Torque the neutral lug to 120 in-lb (13.6 Nm).

8. Install the ground line to the equipment grounding lug. Torque the equipment grounding lug to 120 in-lb (13.6 Nm).

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9. Install the circuit breaker cover with the screw provided. Torque the pan-head screw to 12 in-lb (1.36 Nm).

10. Reinstall the intake panel.

11. Reinstall the two screws. Torque to 44 - 58 in-lb (5 - 6.6 Nm).

12. Close the lid and lock it if the installation is complete.

13. Close the circuit breaker box door.

Automatic Transfer Switch AC Connections

WARNING

Failure to use an approved transfer switch can lead to the electrocution of personnel working on the utility lines, damage to equipment, fire, or personal injury. An approved switching device must be used to prevent interconnection to the public utility.

Install the transfer switch in accordance with the appropriate RA series transfer switch owner manual.

Customer AC Connections

The customer supplied AC circuit is used to power the following components:

• Alternator heater (if applicable)

• Battery charger (standard)

• Battery heater (if applicable)

• Engine oil heater (if applicable)

The AC circuit must be 120 VAC, 20 Amp protected. The wires from this customer supplied circuit are terminated within the enclosure at the five place connectors labeled "Ground", "Line" and "Neutral". Follow regional regulations and applicable electrical codes for installation.

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FIGURE 13. CUSTOMER AC CONNECTIONS

DC Connections

NOTICE

See the Wiring Diagrams appendix for DC customer connections.

Automatic Transfer Switch (ATS) DC Connections

WARNING

Install the transfer switch in accordance with the appropriate RA Series Transfer Switch Owner Manual.

The following image shows the location of the connectors in the generator set where the ATS DC control wires terminate. This is also the location of the connectors where load management control wires terminate.

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NOTICE

Class 1 wiring methods should be used for connecting the generator set and transfer switch signal wiring.

FIGURE 14. LOCATION OF CONNECTION POINTS FOR ATS DC CONTROL WIRES

AND LOAD MANAGEMENT CONTROL WIRES

Refer to the Wiring Diagrams appendix for generator set to RA transfer switch DC customer connections.

Grounding

Use the Typical System Grounding One-Line Diagrams in this section to be sure that the generator set, transfer switch, power supply wiring and all connected electrical equipment are bonded to a common grounding point in accordance with the applicable codes and standards. Refer to local codes and standards for grounding procedures.

NOTICE

The generator set grounding terminal must be connected to the grounding terminal in the transfer switch. Do not provide a separate grounding rod for the generator set.

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NOTICE

Generator set neutral is not typically grounded at the generator set, but at the common system grounding point.

WARNING

Contact with electrical equipment can result in severe personal injury or death. It is extremely important that bonding and equipment grounding be properly done. All metallic parts that could become energized under abnormal conditions must be properly grounded.

No. Description No. Description

1 Service Entrance 4 Loads 2 2-Pole Transfer Switch 5 To Utility Service 3 Generator Set

FIGURE 15. TYPICAL SYSTEM GROUNDING ONE-LINE DIAGRAM (SEPARATE

SERVICE ENTRANCE AND 2-POLE TRANSFER SWITCH)

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No. Description No. Description

4. Installation12-2016

1 Combined Service Entrance and 2-

Pole Transfer Switch

2 Generator Set 4 To Utility Service

FIGURE 16. TYPICAL SYSTEM GROUNDING ONE-LINE DIAGRAM (COMBINED

SERVICE ENTRANCE AND 2-POLE TRANSFER SWITCH)

3 Loads

Display Communication Wires

NOTICE

There are two unmarked connectors on the back of the display, either one may be used for connecting the display to the generator set.

Class 1 wiring methods should be used for the remote display and transfer switch communication conductors between the generator set and transfer switch.

See the Operator Manual for information regarding using the display to operate and monitor the generator set.

Load Management Wiring

See the Automatic Transfer Switch (ATS) DC Connections section for the location of the connectors (TB-1, TB-2, TB-3, and TB-4) in the generator set, which are used for load management control wire termination. Class 1 wiring methods should be used for installing load management devices.

Cummins offers a kit for load management wiring (A051C329).

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Battery

The generator set requires a 12V battery for engine cranking and powering the electronic control system. When the generator set is running, the battery is charged from the engine-driven battery charger. When the generator set is not running, an AC powered battery charger is provided to keep the battery charged.

WARNING

To avoid injury, wear proper safety protection when working around batteries. Keep open flames and sparks away from the equipment.

WARNING

Automatic startup of the generator set during installation can cause severe personal injury or death. Make sure the generator set is shut down and disabled:

1. Press the generator set's red STOP button on the local display to stop the generator set. Allow the generator set to thoroughly cool to the touch.

2. Turn off and disconnect the battery charger from the AC source before disconnecting the battery cables.

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

To connect the battery:

1. Connect the battery cables to the battery with the positive (+) cable first. Immediately cover the battery post and terminal with the red terminal cover provided on the battery cable.

2. Connect the negative (-) cable to the battery's minus terminal.

Refer to the Model Specifications section for battery specifications. An optional thermostatically controlled battery heater is available for more reliable

starting.

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FIGURE 17. BATTERY LOCATION

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5 Startup and Configuration

5.1 "Establishing Communications" Message

NOTICE

Once the battery is connected to the generator set and any display button is pressed, the local display shows an "establishing communications" message for approximately 5 seconds. (This may take longer if the signal integrity is poor between the control and display due to a bad wire or Electro-Magnetic Interference [EMI].) Once communication is established, the display shows the HOME screen.

The “establishing communications” message will also be displayed whenever the control is brought out of “sleep” mode by pressing any button on the display. Sleep mode is entered after 30 minutes without utility or generator set power to preserve battery energy since the battery charger will not have AC power. The 30-minute timer is reset with any button press on the display.

5.2 "Clock Setup" Screen

The Clock needs to be reset whenever the battery power is lost or disconnected, or the control has entered “sleep” mode. Sleep mode is entered after 30 minutes without utility or generator set power to preserve battery energy since the battery charger will not have AC power. The 30minute timer is reset with any button press on the display.

The optional Remote Monitoring System (RMS) uses the generator set's clock. The clock must be set accurately for the RMS to function properly.

To set up the generator set clock for the current date and time:

1. From the Main screen, select Menu.

2. Use the arrow keys to highlight Clock. Select the Enter key.

3. Use the arrow keys to set the time and date.

NOTICE

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FIGURE 18. CLOCK SETUP SCREEN

4. Select the Next key to go to the Daylight Savings screen.

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5. Use the arrow keys to enable/disable Daylight Savings. If enabling, select the

Next key to highlight the Offset field.

FIGURE 19. DAYLIGHT SAVINGS TIME (ENABLED)

6. Use the arrow keys and Next key to set the offset value for Daylight Savings time.

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FIGURE 20. OFFSET VALUE

7. Select the Next key to go the screen that is used to set up when Daylight Savings should start. Use the arrow keys and Next key to set Month (1 – 12), Week (0 – 5), Day (Sun – Sat) and Hour (12AM – 12PM).

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FIGURE 21. DAYLIGHT SAVINGS TIME (START TIME SETUP)

8. Select the Next key to go the screen that is used to set up when Daylight Savings should end. Use the arrow keys and Next key to set Month (1 – 12), Week (0 – 5), Day (Sun – Sat) and Hour (12AM – 12PM).

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FIGURE 22. DAYLIGHT SAVINGS TIME (END TIME SETUP)

9. Keep selecting the Back button to save the settings and return to the main screen.

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5.3 "Exercise" Screen

When installing an RA series transfer switch, follow these steps to configure the Exercise mode in the generator set's local display or remote display.

Exercise settings need to be reset whenever battery power is lost or disconnected, or the control has entered “sleep” mode.

Sleep mode is entered after 30 minutes without utility or generator set power to preserve battery energy since the battery charger will not have AC power. The 30-minute timer is reset with any button press on the display.

To set up the exercise function:

1. From the Main screen, select Menu.

2. Use the arrow keys to highlight Exercise. Select the Enter key.

5. Startup and Configuration12-2016

NOTICE

If the time and date have not been set, a pop-up will appear that says, "Set Valid Date and Time".

3. Use the arrow keys to enable or disable the Crank Exercise feature. Select the Next key to go to the Exercise Time field. See the Exercise Sequences section in the operator manual for more information.

NOTICE

When the Crank Exercise feature is enabled, an exercise command will cause the engine starter to engage and rotate the engine, but will not allow the engine to start. This feature allows the control system to monitor critical generator set systems without running the engine. When Crank Exercise is enabled, the generator set's exercising will alternate between the Crank Exercise sequence and the normal exercise sequence (that is, engine running) at scheduled times.

4. Use the arrow keys to set how long the generator set will exercise (from 1 to 20 minutes). Select the Next key to go to the Exercise field. The Exercise Sched screen appears.

5. Use the arrow keys to set how often the generator set will exercise. The frequency selections are:

• Weekly

• Bimonthly

• Monthly

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• Never

Select the Next key to go to the date and time fields.

6. Use the arrow keys to set the day and time the generator set will be exercised. Select the Next key to highlight the Exercise Now field.

7. Select either arrow key to start the Exercise Now function.

NOTICE

Initiating the Exercise Now function will cause the generator set to start immediately and run for the amount of time indicated by the Exercise Time field, or run the Crank Exercise sequence. The ATS does not transfer to generator power during exercise mode. Normally scheduled exercise events will occur after the completion of the immediate exercise event.

8. Keep selecting the Back button to save the settings and return to the Main screen.

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FIGURE 23. EXERCISE SETUP SCREEN

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5.4 "Brightness and Contrast" Screen

To adjust the brightness and contrast of the display:

1. From the Main screen, select Menu.

2. Use the arrow keys to highlight Display Setup. Select the Enter key.

3. Use the arrow keys to set brightness and contrast for the display.

4. Keep selecting the Back button to save the settings and return to the Main screen.

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FIGURE 24. BRIGHTNESS AND CONTRAST SCREEN

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5.5 "About" Screen

To retrieve information about the display:

1. From the Main screen, select Menu.

2. Use the arrow keys to highlight About. Select the Enter key.

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FIGURE 25. ABOUT SCREEN

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5.6 "Event Log" Screen

To retrieve information from the Event Log:

1. From the Main screen, select Menu.

2. Use the arrow keys to highlight Event Log. Select the Enter key.

3. Use the arrow keys to navigate through the Event Log.

4. Keep pressing the Back button to return to the Main screen.

FIGURE 26. EVENT LOG SCREEN

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5.7 "Fault Log" Screen

To retrieve information from the Fault Log:

1. From the Main screen, select Menu.

2. Use the arrow keys to highlight Fault Log. Select the Enter key.

3. Scroll through the fault log using the up and down double-arrows. Each screen provides a brief description of the fault, the fault code number, the engine hours and the time and date of the fault.

If there are no faults recorded, the “No Stored Faults" screen will appear.

4. Keep pressing the Back button to return to the Main screen.

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NOTICE

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FIGURE 27. FAULT LOG SCREEN

5.8 "System Status" Screen

To retrieve system status:

1. From the Main screen, select Menu.

2. Use the arrow keys to highlight System Status. Select the Enter key.

3. Keep pressing the Back button to return to the Main screen.

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FIGURE 28. SYSTEM STATUS SCREEN

5.9 "Mode" Screen

To prevent unexpected starts from remote devices, disable Remote mode and disconnect the connector on the back of the local display wired to any remote mounted displays.

When Remote is set to Enabled via the local display, the “Remote On” LED on the front of the display will illuminate indicating that the control will accept start commands from remote displays or remote monitoring systems including a web page or cell phone app.

WARNING

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NOTICE

The Remote function can only be activated (that is, enabled) from the local display.

When Standby is on or set to Enabled, the “Standby On” LED on the front of the display will illuminate indicating the control will start the generator set in response to a utility power outage. Standby can be turned on at the local display. It can also be enabled with a remote display, web page, or a cell phone app if Remote has already been enabled at the local display. The Standby function cannot be enabled remotely unless the Remote function is on. A manual Start or Stop event will disable the Standby function. (If the manual Stop event is performed at the local display, the Remote mode will also be disabled.)

1. To enable or disable the Remote and Standby modes on the LOCAL display:

a. From any screen, select the Mode key to get to the Mode screen. b. Use the arrow keys to enable or disable the Remote mode. Select the Next

key to go to the next screen.

c. Use the arrow keys to enable or disable the Standby mode.

NOTICE

Whenever Standby is enabled, the Remote mode will also automatically be enabled.

d. Keep pressing the Back button to save the settings and return to the Main

screen.

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FIGURE 29. MODE SETUP SCREEN (LOCAL DISPLAY)

2. To enable or disable the Standby mode on the REMOTE display:

NOTICE

Remote must be enabled before Standby mode can be changed from the Remote display. If Remote mode is not enabled, Standby will remain disabled and cannot be changed.

a. From any screen, select the Mode key to get to the Mode screen. b. Use the arrow keys to enable or disable the Standby mode. c. Keep pressing the Back button to save the settings and return to the Main

screen.

FIGURE 30. MODE SETUP SCREEN (REMOTE DISPLAY)

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5.10 Automatic Load Management

NOTICE

The capability to automatically add or remove specific electrical loads from the generator set requires that load management devices be wired to the generator set load management outputs.

When the generator set is started automatically in Standby mode due to a loss of utility or manually by the operator, the control will energize all four load management outputs, disconnecting the associated loads from AC power. Once the transfer switch transfers to generator set power, the generator set control will evaluate the total load on the generator set versus a set point programmed into the control (80% of rated).

If the generator set’s total load is below the set point, the generator set control will sequentially add the highest priority managed load every three minutes. Managed loads will continue to be added as long as the size of the next priority load to be added won’t increase total generator set load above the set point. The control measures and stores the size of each managed load in its memory. Load priorities are in the following order:

• Priority #1: load control 1

• Priority #2: load control 2

• Priority #3: load control 3

• Priority #4: load control 4

If the load on the generator set is reduced at any time to below the set point, the control will add the next highest priority managed load in three minutes provided it does not increase the total generator set load above the set point.

If the load on the generator set exceeds 95% of its rating, the generator set control will begin disconnecting the lowest managed priority loads in sequence every second until the load on the generator set is below 95% of its rating.

Priority #1 load is always the first added and the last disconnected; therefore, it should be wired to the managed load deemed most critical to the homeowner. Priority #2 load cannot be added before priority #1 load, nor can it be disconnected before priority #3 or #4, etc.

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5.11 Manual Start Sequence (Local)

NOTICE

If the utility power supply to the generator set's utility powered battery charger is interrupted, the battery can become discharged due to parasitic loads and the generator set may not start when needed. Whenever utility power is interrupted and the generator set is not in Standby mode for any reason (fuel preservation, etc.), start and run the generator set for 2 hours every 24 hour period when temperatures are above 50 °F (10 °C), or every 9 hour period when temperatures are below 50 °F (10 °C).

The following steps will be executed when Manual Start is used at the local display:

1. If you do not want the ATS to transfer load to the generator set, open the generator set mounted circuit breaker when doing a manual start.

2. From the Main screen, select the START key.

3. A second screen appears notifying the operator that Standby will be disabled. Select the START key again to start the generator set.

5. Startup and Configuration12-2016

4. After the generator set reaches rated voltage and frequency, the transfer switch transfers the building load to the generator set (unless the circuit breaker on the generator set is "off"). The building's electrical power is now provided by the generator set.

FIGURE 31. GENSET POWER

5.12 Checklist

Tick Area

General

Generator set output is sufficient to handle maximum anticipated load.

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Tick Area

Proper clearance is provided around the entire generator set for service and ventilation: