CUMMINS Detector DFBF Series, Detector DFCB Series, Detector DFCC Series, Detector 275 DFBF, Detector 350 DFCC Installation Manual

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Installation Manual
Detector Control Generator Sets
Printed in U.S.A.
Models
DFBF, DFCB, DFCC
960-0606 1-2003
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SECTION TITLE PAGE
1 INTRODUCTION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About this Manual 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Overview 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 SPECIFICATIONS 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 MOUNTING THE GENERATOR SET 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Access to Set 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vibration Isolators 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 MECHANICAL CONNECTIONS 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust System 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ventilation and Cooling 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 ELECTRICAL CONNECTIONS 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Switch 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Wiring 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Wiring 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 PRESTART PREPARATION 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ventilation 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust System 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Checks 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 INITIAL START AND CHECKS 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Gauges 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Meters 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Monitor Indicator Lamps 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust System 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Electrical System 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling System 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Adjustments 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 WIRING DIAGRAMS 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be followed during installation and maintenance of the generator and batter­ies.
Before operating the generator set (genset), read the Operator’s Manual and become familiar with it and the equipment. Safe and efficient operation can be
achieved only if the equipment is properly operated and maintained. Many accidents are caused by failure
to follow fundamental rules and precautions. The following symbols, found throughout this manual,
alert you to potentially dangerous conditions to the oper­ator, service personnel, or the equipment.
This symbol warns of immediate hazards which will result in severe personal in­jury or death.
WARNING
This symbol refers to a hazard or un­safe practice which can result in severe person­al injury or death.
CAUTION
This symbol refers to a hazard or un­safe practice which can result in personal injury or product or property damage.
FUEL AND FUMES ARE FLAMMABLE
Fire, explosion, and personal injury or death can result from improper practices.
DO NOT fill fuel tanks while engine is running, un-
less tanks are outside the engine compartment. Fuel contact with hot engine or exhaust is a potential fire hazard.
DO NOT permit any flame, cigarette, pilot light,
spark, arcing equipment, or other ignition source near the generator set or fuel tank.
Fuel lines must be adequately secured and free of
leaks. Fuel connection at the engine should be made with an approved flexible line. Do not use zinc coated or copper fuel lines with diesel fuel.
Be sure all fuel supplies have a positive shutoff
valve.
Be sure 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.
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 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.
Be sure the unit is well ventilated.
Engine exhaust and some of its constituents are
known to the state of California to cause cancer, birth defects, and other reproductive harm.
MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH
Keep your hands, clothing, and jewelry away from moving parts.
Before starting work on the generator set, discon-
nect battery charger from its AC source, then dis­connect starting batteries, negative (–) cable first. This will prevent accidental starting.
Make sure that fasteners on the generator set are
secure. Tighten supports and clamps, keep guards in position over fans, drive belts, etc.
Do not wear loose clothing or jewelry in the vicinity of
moving parts, or while working on electrical equip­ment. Loose clothing and jewelry can become caught in moving parts.
If adjustment must be made while the unit is run-
ning, use extreme caution around hot manifolds, moving parts, etc.
DO NOT OPERATE IN FLAMMABLE AND EXPLOSIVE ENVIRONMENTS
Flammable vapor can cause an engine to overspeed and become difficult to stop, resulting in possible fire, explo­sion, severe personal injury and death. Do not operate a genset where a flammable vapor environment can be created by fuel spill, leak, etc., unless the genset is equipped with an automatic safety device to block the air intake and stop the engine. The owners and operators of the genset are solely responsible for operating the gen­set safely. Contact your authorized Cummins Power Generation distributor for more information.
LS-14M
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ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH
Remove electric power before removing protective
shields or touching electrical equipment. Use rub­ber insulative mats placed on dry wood platforms over floors that are metal or concrete when around electrical equipment. Do not wear damp clothing (particularly wet shoes) or allow skin surface to be damp when handling electrical equipment. Do not wear jewelry. Jewelry can short out electrical con­tacts and cause shock or burning.
Use extreme caution when working on electrical
components. High voltages can cause injury or death. DO NOT tamper with interlocks.
Follow all applicable state and local electrical
codes. Have all electrical installations performed by a qualified licensed electrician. Tag and lock open switches to avoid accidental closure.
DO NOT CONNECT GENERATOR SET DIRECT-
LY TO ANY BUILDING ELECTRICAL SYSTEM. Hazardous voltages can flow from the generator set into the utility line. This creates a potential for elec­trocution or property damage. Connect only through an approved isolation switch or an ap­proved paralleling device.
MEDIUM VOLTAGE GENERATOR SETS (601V to 15kV)
Medium voltage acts differently than low voltage.
Special equipment and training is required to work on or around medium voltage equipment. Operation and maintenance must be done only by persons trained and qualified to work on such devices. Im­proper use or procedures will result in severe per­sonal injury or death.
Do not work on energized equipment. Unauthorized
personnel must not be permitted near energized equipment. Due to the nature of medium voltage electrical equipment, induced voltage remains even after the equipment is disconnected from the power source. Plan the time for maintenance with autho­rized personnel so that the equipment can be de-en­ergized and safely grounded.
GENERAL SAFETY PRECAUTIONS
Coolants under pressure have a higher boiling point
than water. DO NOT open a radiator or heat ex­changer pressure cap while the engine is running. Allow the generator set to cool and bleed the system pressure first.
Used engine oils have been identified by some state
or federal agencies as causing cancer or reproduc­tive toxicity . When checking or changing engine oil, take care not to ingest, breathe the fumes, or con­tact used oil.
Keep multi-class ABC fire extinguishers handy.
Class A fires involve ordinary combustible materials such as wood and cloth; Class B fires, combustible and flammable liquid fuels and gaseous fuels; Class C fires, live electrical equipment. (ref. NFP A No. 10).
Make sure that rags are not left on or near the en-
gine.
Make sure generator set is mounted in a manner to
prevent combustible materials from accumulating under the unit.
Remove all unnecessary grease and oil from the
unit. Accumulated grease and oil can cause over­heating and engine damage which present a poten­tial fire hazard.
Keep the generator set and the surrounding area
clean and free from obstructions. Remove any de­bris from the set and keep the floor clean and dry.
Do not work on this equipment when mentally or
physically fatigued, or after consuming any alcohol or drug that makes the operation of equipment un­safe.
Substances in exhaust gases have been identified
by some state or federal agencies as causing can­cer or reproductive toxicity. Take care not to breath or ingest or come into contact with exhaust gases.
Do not store any flammable liquids, such as fuel,
cleaners, oil, etc., near the generator set. A fire or explosion could result.
Wear hearing protection when going near an oper-
ating generator set.
To prevent serious burns, avoid contact with hot
metal parts such as radiator, turbo charger and ex­haust system.
KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE
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1. Introduction
ABOUT THIS MANUAL
This manual provides installation instructions for the DF Series generator sets. This includes the fol­lowing information:
Mounting Recommendations - for fastening generator set to base and space requirements for normal operation and service.
Mechanical Connections - Location of con­nection points for fuel, exhaust, ventilation, and cooling.
Electrical Connections – Location of electri­cal connection points for the control, generator, and starting system.
Prestart – Checklist of items or procedures needed to prepare generator set for operation.
Initial Startup – Test complete system to en­sure proper installation, satisfactory perfor­mance, and safe operation. Refer to Operators Manual for troubleshooting information.
This manual DOES NOT provide application infor­mation for selecting a generator set or designing the complete installation. If it is necessary to design the various integrated systems (fuel, exhaust, cooling, etc.), review standard installation practices, or specify system materials, additional information is required. For engineering data specific to the gen­erator set, refer to the specification and product data sheets. For application information, refer to Application Manual T-030, ”Liquid Cooled Genera­tor Sets”, available from Onan.
INSTALLATION OVERVIEW
These installation recommendations apply to typi­cal installations with standard model generator sets. Whenever possible, these recommendations also cover factory designed options or modifica­tions. However, because of the many variables in any installation, it is not possible to provide specific recommendations for every situation. If there are any questions not answered by this manual, contact an Onan distributor for assistance.
Application and Installation
A standby power system must be carefully planned and correctly installed for proper operation. This in­volves two essential elements: application and installation.
Application (as it applies to generator set installa­tions) refers to the design of the complete standby power system that usually includes power distribu­tion equipment, transfer switches, ventilation equipment, mounting pads, and cooling, exhaust, and fuel systems. Each component must be cor­rectly designed so the complete system will function as intended. Application and design is an engineer­ing function generally done by specifying engineers or other trained specialists. Specifying engineers are responsible for the design of the complete standby system and for selecting the materials and products required.
Installation refers to the actual set-up and assem­bly of the standby power system. The installers set up and connect the various components of the sys­tem as specified in the system design plan. The complexity of the standby system normally requires the special skills of qualified electricians, plumbers, sheet metal workers, etc. to complete the various segments of the installation. This is necessary so all components are assembled using standard methods and practices.
Safety Considerations
The generator set has been carefully designed to provide safe and efficient service when properly installed and operated. However, the overall safety and reliability of the complete system is dependent on many factors outside the control of the generator set manufacturer. To avoid possible safety haz­ards, make all mechanical and electrical connec­tions to the generator set exactly as specified in this manual. All systems external to the generator (fuel, exhaust, electrical, etc.) must comply with all appli­cable codes. Make certain all required inspections and tests have been completed and all code re­quirements have been satisfied before certifying the installation is complete and ready for service.
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1-2
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2. Specifications
Systems 275 DFBF 300 DFCB 350 DFCC
Cummins Model Engine NT855-G6 NTA855-G2 NTA855-G3 Coolant Capacity 66 Qt. 68 Qt. 68 QT.
Engine and Radiator (62.5L) (64.4L) (64.4L)
Oil Capacity 42 QT. 42 Qt. 42 Qt.
(40L) (40L) (40L)
Fuel Pump
Inlet Thread Size 7/8-14 UNF 7/8-14 UNF 7/8-UNF Outlet Thread Size 3/4-16 UNF 3/4-16 UNF 3/4-16 UNF Maximum Lift 5 ft (1.5m) 5 ft (1.5m) 5 ft (1.5m)
Exhaust
Outlet Size 5 in NPT 6 in NPT 6 in NPT Maximum Allowable 40.8 in H Exhaust Back Pressure (10.2 kPa) (10.2 kPa) (10.2 kPa)
0 40.8 in H20 40.8 in H20
2
Starting System
Voltage DC 24 24 24
Battery Requirements
Battery Two, 12V Two, 12V Two, 12V
Group 8D Group 8D Group 8D
Cold Cranking Amps 975 975 975
IMPORTANT
DEPENDING ON Y O U R L O C ATION AND INTENDED USE, FEDERAL, STATE OR LOCAL LAWS AND REGULATIONS MAY REQUIRE YOU TO OBTAIN AN AIR QUALITY EMISSIONS PERMIT BEFORE BEGINNING INSTALLATION OF YOUR GENSET. BE SURE TO CONSULT LOCAL POLLUTION CONTROL OR AIR QUALITY AUTHORITIES BEFORE COMPLETING YOUR CONSTRUCTION PLANS.
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3. Mounting the Generator Set
GENERAL
Most generator set installations must be designed so the generator set will function properly under all anticipated operating conditions. Use these instruc­tions as a general guide only. Follow the instruc­tions of the consulting engineer when locating or installing any components. The complete installa­tion must comply with all local and state building codes, fire ordinances, and other applicable regula­tions.
Requirements to be considered prior to installation (refer to Figure 3-2):
Level mounting surface
Adequate cooling air supply
Adequate fresh induction air
Discharge of cooling air
Discharge of exhaust gases
Fuel system installation
Electrical connections
Accessibility for operation and servicing
Noise levels
Vibration isolation
LOCATION
Optimum generator set location is determined by related systems such as ventilation, wiring, fuel, and exhaust. The set should be located as near as possible to the main power fuse box.
Wood floors should be covered with sheet metal ex­tending 12 inches (305 mm) beyond the extremities of the set.
Provide a location away from extreme ambient tem­peratures. Protect the generator set from adverse weather conditions, and unauthorized personnel.
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MOUNTING
Generator sets are mounted on a steel subbase that provides proper support. For critical installa­tions, install vibration isolators between the sub­base and the foundation.
Mount the generator set on a substantial and level base such as a concrete pad. For typical installa­tions, use 3/4 inch anchored mounting bolts to se­cure the generator set subbase to the floor to pre­vent movement. Secure the subbase/vibration iso­lators using flat or bevel washer and hexagonal nut for each bolt (see Figure 3-1). For proper spacing of mounting bolts and set mounting dimensions, see your generator set outline drawing.
ACCESS TO SET
Plan for access to the generator set for servicing and provide adequate lighting around the set. For convenience in general servicing such as the radia­tor, fan belt, and changing the crankcase oil, the surface of the mounting base should be at least 6 inches (152 mm) above the floor.
FLAT
WASHER
BEVEL
WASHER
MOUNTING
BOLT
HEX NUT
SKID
12 INCH
(305 mm)
M-1627
FIGURE 3-1. TYPICAL ANCHOR BOLT DIAGRAM
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CONDENSATION
DRAIN TAP
DC
CONTROL
WIRING
MUFFLER
THIMBLE
FLEXIBLE SEC-
TION
AIR
OUTLET
DUCT
SWEEPING
ELBOW
AC POWER WIRING
AIR
IN
M-1808
VIBRATION
ISOLATORS
CONCRETE
BASE
IMPORTANT!
COOLING AIR INLET MUST BE AT LEAST 1-1/2 TIMES LARGER THAN RADIATOR DUCT OUTLET AREA ON RADIATOR COOLED MODELS
FLOW OF COOLING AIR AND HEATED AIR CAN BE CONTROLLED BY AUTOMATICALLY OPERATED LOUVRES
FIGURE 3-2. TYPICAL INSTALLATION
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VIBRATION ISOLATORS
Installation and Adjustment Procedure
1. Place the isolators (Figure 3-3) on the genset support structure. The isolators should be shimmed or grouted to ensure that all of the iso­lator bases are within 0.25 inch (6 mm) eleva­tion of each other. The surface on which the isolator bases rest on must also be flat.
2. Loosen the side snubber lock nuts so that the top plate of the isolator is free to move vertically and horizontally. Be sure that the top plate is correctly aligned with the base and springs.
3. Place the genset onto the isolators while align­ing the skid’s mounting with the threaded isola­tor hole. The top plates will move down and ap­proach the base of the isolator as load is ap­plied.
4. Once the genset is in position, the isolators may require adjusting so that the set is level.
The isolators are adjusted by inserting the lev­eling bolt through the skid and into the isolator (the leveling bolt’s locking nut should be threaded up towards the bolt head).
The leveling bolt will adjust the clearance be­tween the top plate and the isolator base. A nominal clearance of 0.25 inch (6 mm) or great­er is desired. This will provide sufficient clear­ance for the rocking that occurs during startup and shutdown. If the 0.25 inch (6 mm) clear­ance is not present, turn the leveling bolt until the desired clearance is achieved.
5. The genset may not be level yet, therefore ad­just the leveling bolts until the set is level and sufficient clearance still remains. Once all iso­lators have been set, then lock the leveling bolt in place with the lock nut.
6. The snubber nuts may remain loose and there­fore provide better isolation between the gen­set and support structure.
GENSET SKID
SNUBBER
LEVELING BOLT
LOCK NUT
CLEARANCE
BASE
M1828–1s
FIGURE 3-3. VIBRATION ISOLATORS
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4. Mechanical Connections
GENERAL
The generator set mechanical system installation includes connecting the fuel, exhaust, ventilation and cooling systems (Figure 3-2). Before starting any type of fuel installation, all pertinent state and local codes must be complied with and the installa­tion must be inspected before the unit is put in ser­vice.
FUEL SYSTEM
Cummins engines used on DF series generator sets normally use ASTM No. 2 Diesel fuel. They will, however, operate on alternate diesel fuels within the specifications shown in engine manual.
In all fuel system installations, cleanliness is of the upmost importance. Make every effort to prevent entrance of moisture, dirt or contaminants of any kind. Clean all fuel system components before installing.
Use only compatible metal fuel lines to avoid elec­trolysis when fuel lines must be buried. Use a flex­ible section of tubing between the engine and fuel
supply line to provide vibration isolation. Refer to your generator set outline drawing for sizes and locations.
CAUTION
Never use galvanized or copper fuel lines, fittings or fuel tanks. Condensation in the tank and lines combines with the sulfur in diesel fuel to produce sulfuric acid. The molecular structure of the copper or galvanized lines or tanks reacts with the acid and contaminates the fuel.
An electric solenoid shutoff valve in the supply line is recommended for all installations and required for indoor automatic or remote starting installations. Connect the so l enoid wires to the battery run circuit to open the valve during genset operation.
Supply Tank
Locate the f uel t ank as close as possible to the gen­set and within the 5 foot (1.5 m) lift capacity of the fuel pump. Install a fuel tank that has sufficient ca­pacity to keep the genset operating continuously at full load for at least 36 hours. Refer to product Spec­ification sheet for fuel consumption data.
FUEL PUMP
WATER/SEDIMENT SEPARATOR
INJECTOR FUEL
RETURN LINE
VENTED
FILL CAP
DAY TANK
FUEL TRANSFER PUMP - ELECTRIC MOTOR DRIVEN
FIGURE 4-1. TYPICAL FUEL SUPPLY INSTALLATION
FLOAT
SWITCH
LARGER
OVERFLOW
LINE
CONNECT TO
AC OUTPUT
SUPPLY
LINE
FUEL TANK
All models require a fuel return line from injectors to tank.
VENT LINE
FILL PIPE
ES-1214-2
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WARNING
Fuel leaks create fire and explosion hazards which can result in severe personal in­jury or death. Always use flexible tubing be­tween engine and fuel supply to avoid line fail­ure and leaks due to vibration. The fuel system must meet applicable codes.
If the main fuel tank is installed below the lift capabil­ities of the standard fuel transfer pump, a transfer tank (referred to as a day tank) and auxiliary pump will also be required. If an overhead main fuel tank is installed, a transfer tank and float valve will be re­quired to prevent fuel head pressures from being placed on the fuel system components. See Day Tank and Figure 4-1.
Day Tank (If Used)
Fuel day tanks are used when the standard engine fuel pump does not have the capacity to draw the fuel from the supply tank; or the supply tank is over­head and presents problems of high fuel head pres­sure for the fuel return.
Supply T ank Lower Than Engine:
lation, the day tank is installed near the generator set and within the engine fuel pump lift capability, but below the fuel injection system. Install an auxil­iary fuel pump as close as possible to the supply tank to pump fuel from the supply tank to the day tank. A float switch in the day tank controls opera­tion of the auxiliary fuel pump.
With this instal-
The supply tank top must be below the day tank top to prevent siphoning from the fuel supply to the day tank.
Provide a return line from the engine injection sys­tem return connection to the day tank (near the top). Provide a day tank overflow line to the supply tank in case the float switch fails to shut off the fuel transfer pump.
WARNING
Spilled fuel presents the hazard of fire or explosion which can result in severe per­sonal injury or death. Provide an overflow line to the supply tank from the day tank.
Supply Tank Higher Than Engine:
tank near the generator set, but below the fuel injec­tion system. Use fuel line at least as large as the fuel pump inlet. The engine fuel return line must enter the day tank.
Include a shutoff valve in the fuel line between the fuel supply tank and the day tank to stop fuel flow when the generator set is off.
Install the day
Engine Fuel Connections
Identification tags are attached to the fuel supply line and fuel return line connections by the factory. Flexible lines for connecting between the engine and the stationary fuel line are supplied as standard equipment.
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EXHAUST SYSTEM
Pipe exhaust gases to the outside of any enclosure. Locate the exhaust outlets away from any air inlets to avoid gases re-entering the enclosure. Exhaust installations are subject to various detrimental con­ditions such as extreme heat, infrequent operation and light loads. Regularly inspect the exhaust sys­tem both visually and audibly to see that the entire system remains fume tight and safe for operation.
WARNING
Inhalation of exhaust gases can re­sult in severe personal injury or death. Use ex­treme care during installation to provide a tight exhaust system. Terminate exhaust pipe away from enclosed areas, windows, doors and vents.
Use an approved thimble (Figure 4-2) where ex­haust pipes pass through wall or partitions. Refer to NFPA 37, Section 6-3. “Stationary Combustion En­gines and Gas Turbines” for accepted design prac­tices. Build according to the code requirements in effect at the installation site.
WARNING
Inhalation of exhaust gases can re­sult in severe personal injury or death. Do not use exhaust heat to warm a room, compartment or storage area.
Rain caps are available for the discharge end of ver­tical exhaust pipes. The rain cap clamps onto the end of the pipe and opens due to exhaust discharge force from the generator set. When the generator set is stopped, the rain cap automatically closes, protecting the exhaust system from rain, snow, etc.
RAIN CAP
9 INCH MIN
(230 mm)
VERTICAL
HORIZONTAL
WALL OR PARTITION
FIGURE 4-2. MOUNTING EXHAUST THIMBLE
DRIP CAP
HOLES IN
END OF
INNER SLEEVE
ROOF
9 INCH MIN
(230 mm)
EXS-1036
Use a section of flexible exhaust pipe between the engine and remainder of exhaust system. Support exhaust system to minimize weight applied to en­gine exhaust outlet elbow/turbocharger connec­tion.
CAUTION
Weight applied to the engine man­ifold can result in turbocharger damage. Sup­port the muffler and exhaust piping so no weight or stress is applied to engine exhaust el ­bow.
4-3
Page 17
Avoid sharp bends by using sweeping, long radius elbows and provide adequate support for muffler and tailpipe. Pitch a horizontal run of exhaust pipe DOWNWARD to allow any moisture condensation to drain away from the engine. If an exhaust pipe must be turned upward, install a condensation trap at the point where the rise begins (Figure 4-3).
Shield or insulate exhaust lines if there is danger of personal contact. Allow at least 12 inches (305 mm) of clearance if the pipes pass close to a combustible wall or partition.
IF EXHAUST LINE MUST BE
PITCHED UPWARD, CONSTRUCT
A TRAP AT POINT OF RISE
AVOID SHARP BENDS
WARNING
Exhaust pipes are very hot and they can cause severe personal injury or death from direct contact or from fire hazard. Shield or in­sulate exhaust pipes if there is danger of per­sonal contact or when routed through walls or near other combustible materials.
VENTILATION AND COOLING
Generator sets create considerable heat that must be removed by proper ventilation. Outdoor installa­tions rely on natural air circulation but indoor instal­lations need properly sized and positioned vents for required airflow.
Vents and Ducts
For indoor installations, locate vents so incoming air passes through the immediate area of the installa­tion before exhausting. Install the air outlet higher than the air inlet to allow for convection air move­ment.
Size the vents and ducts so they are large enough to allow the required flow rate of air . The “free area” of ducts must be as large as the exposed area of the radiator. Refer to the DF series Product Data Sheets for the airflow requirements.
DRAIN CONDENSATION
TRAP PERIODICALLY
EXS-1046s
FIGURE 4-3. CONDENSATION TRAP
Wind will restrict free airflow if it blows directly into the air outlet vent. Locate the outlet vent so the ef­fects of wind are eliminated. See Figure 4-4.
For operation outside a building, a shelter housing with electrically operated louvers is available as an option. T ransformers connected across the genera­tor output supply current to the motors.
CS-1366
FIGURE 4-4. WIND BARRIER
4-4
Page 18
Dampers
Dampers or louvers protect the genset and equip­ment room from the outside environment. Their op­eration of opening and closing should be controlled by operation of the genset.
In cooler climates movable or discharge dampers are used. These dampers allow the air to be recircu­lated back to the equipment room. This enables the equipment room to be heated while the genset en­gine is still cold, increasing the engine efficiency.
Radiator Set Requirements
Radiator set cooling air is drawn past the rear of the set by a pusher fan that blows air through the radia­tor (Figure 4-5). Locate the air inlet to the rear of the set. Make the inlet vent opening 1-1/2 times larger than the radiator area.
Locate the cooling air outlet directly in front of the ra­diator and as close as possible. The outlet opening must be at least as large as the radiator area. Length and shape of the air outlet duct should offer minimum restriction to airflow.
The radiator has an air discharge duct adapter flange. Attach a canvas or sheet metal duct to the flange and the air outlet opening using screws and
nuts so duct can be removed for maintenance pur­poses. The duct prevents circulation of heated air. Before installing the duct, remove the radiator core guard.
Standard Radiator Cooling uses a set mounted radiator and engine pusher fan to cool engine water jacket. Air travels from the generator end of the set, across the engine and out through the radiator. An integral discharge duct adapter flange surrounds the radiator grille.
Remote Radiator Cooling (Optional) substitutes a remote mounted radiator and an electrically driv­en fan for the set mounted components. Removal of the radiator and the fan from the set reduces noise levels without forcing dependence on a continuous cooling water supply. The remote radiator installa­tion must be completely protected against freezing.
Remote radiator plumbing will vary with installation. Follow recommendations given in Application Manual T-030. See product data sheet for friction head and static head limits.
Before filling cooling system, check all hardware for security. This includes hose clamps, capscrews, fit­tings and connections. Use flexible coolant lines with heat exchanger, standpipe or remote mounted radiator.
INLET
AIR
DAMPER
COOL
AIR
* Louvers should close when room ambient is above 60
° C)
(16
° F
FIGURE 4-5. TYPICAL RADIATOR SET INSTALLATION
THERMOSTATIC AIR
RECIRCULATING
DAMPER *
RADIATOR
FLEXIBLE DUCT
CONNECTOR
WIND/
NOISE
BARRIER
HOT
AIR
D
DISTANCE SHOULD NOT
BE LESS THAN HEIGHT
OF RADIATOR
CS-1382c
4-5
Page 19
Water Jacket Heater (Optional)
An optional water jacket heater can be installed to keep the engine warm for starting under adverse weather conditions. Connect the heater to a power source that will be on when the engine is NOT run­ning.
Heat Exchanger (Optional)
The optional heat exchanger (Figure 4-6) uses a shell and tube type heat exchanger instead of the standard radiator and fan. Engine jacket coolant cir­culates through the shell side of the heat exchanger while the cooling water is pumped through the
tubes. Engine coolant and raw water do not mix. This type of cooling separation is necessary when the raw water contains scale forming lime or other impurities.
This system can reduce set enclosure airflow re­quirements and noise levels. Proper operation de­pends on a constant supply of raw water for heat re­moval. Adjust the flow to maintain engine coolant temperature between165
° C) while viewing the water temperature gauge.
91
° F and 195° F (74° C and
The engine coolant side of the system can be pro­tected from freezing; the raw water side cannot be protected.
VENTILATING
FAN
COOL AIR
WATER
SOLENOID
VALVE
FIGURE 4-6. TYPICAL HEAT EXCHANGER INSTALLATION
WARM
AIR
FLEXIBLE WA-
TER
CONNECTIONS
MOUNTED HEAT
EXCHANGER
RAW WATER
SUPPLY
RAW WATER
DISCHARGE
4-6
Page 20
Coolant Filter
One spin-on type corrosion filter (Figure 4-7) is standard equipment. This precharge filter is com­patible with plain water and all ethylene glycol base permanent antifreeze coolants. Refer to engine manufacturer’s manual for instructions if a methoxy propanal base antifreeze is desired. Replace filter periodically as recommended in the
Maintenance
section of the Operator’s manual.
Coolant Heater
A coolant heater is used to keep the engine coolant warm when the engine is shut down. It heats and cir­culates the coolant within the engine. This reduces startup time and lessens engine wear caused by cold starts. It is electrically operated and thermo­statically controlled.
COOLANT
FILTER
SHUTOFF
VALVES
FILTER
WARNING
The coolant heater must not be op­erated while the cooling system is empty or when the engine is running or damage to the heater will occur.
Figure 4-8 shows the heater line connections. Con­nect the heater to a source of power that will be on during the time the engine is not running. Be sure the voltage rating is correct for the heater element rating.
NOTE: OPEN COOLANT FILTER SHUTOFF VALVES BEFORE OPERATING GENERATOR SET.
CS-1198
FIGURE 4-7. TYPICAL COOLANT FILTER
THERMOSTAT
1/2 NPT
OUTLET
(FOR 1” ID HOSE)
DRAIN
4-7
INLET
(FOR 1” ID HOSE)
CS-1367
FIGURE 4-8. TYPICAL COOLANT HEATER
Page 21
4-8
Page 22
5. Electrical Connections
GENERAL
The genset electrical system includes connecting the load, installing the control wiring and connecting the batteries. Connect the batteries last to avoid ac­cidental starting of the unit during installation.
WARNING
Accidental starting of the generator set while working on it can cause severe per­sonal injury or death. Prevent accidental start­ing by disconnecting the starting battery cables (negative [–] first).
Arcing can ignite the explosive hydrogen gas given off by batteries, causing severe personal injury. Arcing can occur if the negative (–) bat­tery cable is connected and a tool being used to connect or disconnect the positive (+) battery cable accidentally touches the frame or other grounded metal part of the set. To prevent arc­ing, always remove the negative (–) cable first, and reconnect it last.
CAUTION
To prevent arcing, always discon­nect a battery charger from its AC source before disconnecting the battery cables. Otherwise, disconnecting the cables can result in voltage spikes high enough to damage the DC control circuits of the set.
LOAD
NORMAL SOURCE
NOTE: SHOWN WITH LINE
CONNECTED TO LOAD
FIGURE 5-1. TYPICAL LOAD TRANSFER SWITCH
GENSET
SC-1101-1
Most local regulations require that wiring connec­tions be made by a licensed electrician and the installation be inspected and approved before op­eration. All connections, wire sizes, etc. must con­form to the requirements of all electrical codes in ef­fect at the installation site.
WARNING
Improper wiring can cause a fire or electrocution, resulting in severe personal inju­ry or death and/or property and equipment dam­age.
TRANSFER SWITCH
If the installation is for standby service, a transfer switch is required for switching the load from the normal power source to the generator set (Figure 5-1). Either a manual or automatic switch can be used. Follow the installation instructions provided with the transfer switch when connecting the load and control wiring.
5-1
Page 23
AC WIRING
Generator Voltage Connections
The generator output voltage and maximum current rating are specified on the generator set nameplate. Line-to-neutral voltage is always the lower voltage shown and line-to-line voltage is the higher rating.
These generators can be configured for the volt­ages shown in these voltages must be reconnected by the installer to give the voltage required by the installation. Be­fore shipping, the factory tests the generator set output by connecting the generator to produce a particular test voltage. The generator may be con­nected at the factory to produce a specified voltage per customer order. The installer must always check the stator lead terminal block connections and perform any necessary reconnect to obtain the voltage desired.
Wiring Diagram
section. Most of
ers are labeled CT21, CT22 and CT23 on the wiring diagram. Refer to fy the output leads that must be routed through each current transformer, and also appropriate trans­former post selection for meter lead harness con­nection. Use cable ties to secure the loose trans­formers to the generator output leads.
Wiring Diagram
section to identi-
Load Balancing
When connecting loads to the generator set, bal­ance the loads so the current flow from each line ter­minal (L1, L2 and L3) is about the same. This is es­pecially important if both single phase and three phase loads are connected. Any combination of single phase and three phase loading can be used as long as each line current is about the same, with­in 10 percent of median value and no line current exceeds the nameplate rating of the generator. Check the current flow from each line after connec­tions by observing the control panel ammeter.
Refer to the voltage connection information; and use the electrical schematic supplied with your generator set when actually performing load connections.
CAUTION
Wiring Diagram
section when reviewing
Reconnecting factory connected generator sets to lower voltages can reduce se t ratings, and also render line circuit breakers too small. Consult with your distributor before per­forming reconnection for a different voltage.
Load Connections
Connecting the Load:
the generator by bolting the load wires to the ap­propriate terminals on the generator terminal block. The terminals are stamped U, V, W and N to indicate the line and neutral connections. (Reference: U, V, and W correspond with L1, L2 and L3; and N with L0 respectively).
When installing sets with AC meters, the generator output leads must be routed through current trans­formers for proper meter operation. The transform-
All loads are connected to
Grounding
Grounding involves making a conducting connec­tion between the metal parts of the generator set or one of its electrical circuits and the earth. The de­sign and installation of a grounding system is af­fected by many factors such as the use of multiple transformers, ground fault protection requirements and physical location of the generator. Follow the recommendations of the consulting engineer when installing the grounding system.
WARNING
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.
Typical requirements for bonding and grounding are given in the National Electrical Code, Article
250. All connections, wire sizes, etc. must conform to the requirements of the electrical codes in effect at the installation site.
Contact with electrical equipment
5-2
Page 24
DC WIRING
Remote Control Connections
inducing currents that could cause problems within the control.
Provisions are made inside the control box for add­ing optional remote starting stations and alarms. Connections are made on the terminal block (TB1) located on the engine monitor circuit board (A11). Connect one or more remote switches across re­mote terminal and B+ terminal. Refer to Figure 5-2.
If the distance between the generator set and re­mote stations is less than 1000 feet (305 m), use 18 gauge stranded copper wire. If the distance is 1000 to 2000 feet (305 to 610 m), use 16 gauge stranded copper wire. Always run control circuit wiring in a separate conduit from the AC power cables to avoid
TB1
7
B+ (DC POWER)
6
RMT (REMOTE START)
5
GND (GROUND)
4
ALM (COMMON ALARM)
CONTROL
PANEL BOX
TB1
Remote Monitor Connections
Provisions are made inside the control box for add­ing optional remote monitoring on these gensets employing optional Detector 12 (12 lamp panel). Connections are made on the terminal block (TB2) located on the engine monitor circuit board A11. Re­fer to Figure 5-2.
CAUTION
the same conduit as the AC power. AC voltage induced currents can create operational prob­lems with electronic solid-state devices.
ENGINE
CONTROL
MONITOR
A11
Do not install DC control wiring in
TB2
10 11 12
13 14 15
16
1 2 3
4
5 6
7
8
9
FAULT 2 - INPUT FAULT 2 - OUTPUT
FAULT 1 - INPUT FAULT 1 - OUTPUT
LAMP TEST/RESET OVERCRANK OVERSPEED HIGH ENGINE TEMPERATURE LOW OIL PRESSURE PRE-HIGH ENGINE TEMPERATURE PRE-LOW OIL PRESSURE SWITCH OFF LOW ENGINE TEMPERATURE LOW FUEL - INPUT LOW FUEL - OUTPUT SHUTDOWN
NON-TIMED SHUTDOWN
TIMED SHUTDOWN
GROUND STUD
(USE GROUND
STUD OR A11-TB1-5
FOR CONTROL
GROUND WIRES)
FIGURE 5-2. REMOTE CONTROL AND REMOTE MONITOR CONNECTION POINTS
A13 A14
INTERFACE
RELAY MODULES
5-3
TB2
ES-1561
Page 25
Battery Connections
Starting the unit requires 24 volt battery current. Use two, 12 volt (Type 8D) batteries for a normal installation (Figure 5-3). Connect the batteries in series (negative post of first battery to the positive post of the second battery) as shown in Figure 5-3.
Necessary battery cables and rack are on the unit. Service batteries as necessary. Infrequent use (as in emergency standby service), may allow battery to self-discharge to the point where it cannot start the unit. If installing an automatic transfer switch that has no built-in charge circuit, connect a sepa­rate trickle charger. Onan automatic transfer switches include such a battery charging circuit.
WARNING
Ignition of explosive battery gases can cause severe personal injury. Always con­nect battery negative last to prevent arcing.
WARNING
Do not smoke while servicing the batteries. Explosive gases are emitted from bat­teries in operation. Ignition of these gases can cause severe personal injury.
Control Heater (Optional)
A control heater provides a means of humidity/tem­perature control of the control box interior. It pro­tects the components and ensures their effective­ness when the generator set is subjected to varying ambient air conditions during extended periods of non-use. The element is controlled by an adjustable thermostat (Figure 5-4).
POSITIVE
NEGATIVE
TWO, 12 VOLT
BATTERIES
ES-1865–1s
FIGURE 5-3. BATTERY CONNECTIONS
THERMOSTAT
TO 120 VAC
SUPPLY
5-4
HEATER
ELEMENT
ES-1563s–3
FIGURE 5-4. OPTIONAL CONTROL HEATER
Page 26
6. Prestart Preparation
GENERAL
Before attempting the initial starting of the genera­tor set, be sure it is serviced and ready for operation (Figure 6-1). Perform the following:
Check ventilation and exhaust systems
Check all mechanical connections
Fill the coolant, lubrication and fuel systems
Prime the lubrication and fuel systems
Check the fuel system for leaks
Check the lubrication system for leaks
VENTILATION
Verify all air vents and ducts are open and free from any obstructions. Verify dampers, if used, operate properly.
EXHAUST SYSTEM
Check the exhaust system for proper installation. Verify there is at least 12 inches (305 mm) clear­ance between exhaust pipes and combustible ma­terials, and all connections are tight.
MECHANICAL CHECKS
Check the generator set for loose or damaged com­ponents and repair or replace as required.
ELECTRICAL SYSTEM
Verify all electrical connections are secure and all wiring is complete and inspected. Replace and se­cure any access panels that may have been re­moved during installation.
Load Connections
Check that load cables from generator set are prop­erly connected to either a transfer switch or circuit breaker panel.
EXHAUST
SYSTEM
AIR OUTLET
FILL COOLANT SYSTEM
FILL AND PRIME LUBRICATION SYSTEM
FILL AND PRIME FUEL SYSTEM
FIGURE 6-1. TYPICAL INSTALLATION
AIR INLET
CHECK THAT ALL ASPECTS
OF INSTALLATION ARE
READY FOR OPERATION
M-1808
6-1
Page 27
Battery Connections
4
Use two 12 volt batteries for a normal installation. Connect the negative (-) battery cable last to reduce the risk of arcing.
Service the batteries as necessary. If an automatic transfer switch is not used or installed without a built-in charge circuit, connect a separate float char­ger to the battery.
OIL SUPPLY INLET
LINE. DISCONNECT AT
THIS POINT TO PRIME
COOLANT
Engine coolant is drained prior to shipment. Before starting, fill the cooling system with the recom­mended coolant. See Operator’s manual
nance
section for more information.
Mainte-
LUBRICATION
Engine oil is drained prior to shipment. Before start­ing, fill and prime the lubrication system as follows:
1. Remove oil inlet line from turbocharger hous­ing (Figure 6-2), fill bearing housing with clean engine lubricating oil; replace line and secure.
2. Fill crankcase to “L” (low) mark on dipstick (Fig­ure 6-3) and refer to Operator’s manual for oil recommendations.
3. Remove plug from head of oil filter housing. Connect a hand or motor driven priming pump, equipped with pressure gauge, from a source of clean lubricating oil to the plug boss in the fil­ter housing.
4. Prime until a 30 psi (207 kPa) pressure is ob­tained.
5. Disconnect wire from fuel solenoid valve (Fig­ure 6-4).
6. On the engine control panel, depress the RUN switch to crank the engine, while maintaining an oil priming pressure of 15 psi (103 kPa) for 15 seconds, at filter head priming port.
7. Stop engine cranking, remove external priming equipment, reinstall plug in filter housing and torque to 15 to 20 ft lb (20 to 27 N
8. Reconnect wire to fuel solenoid valve.
9. Complete oil fill to “H” (high) mark on dipstick.
Maintenance
section in
m).
TURBOCHARGER
HOUSING
PRIMING
PLUG
OIL
FILTER
B-342-3s
FIGURE 6-2. PRIMING TURBOCHARGER
OIL
DIPSTICK
STARTER
B342–7s
FIGURE 6-3. OIL DIPSTICK LOCATION
B3
6-2
Page 28
FUEL
Fill the fuel tanks with the recommended fuel. En­gine fuel may not be primed at the fuel filters after shipment. To verify and reprime the fuel system per­form the following procedure:
1. Remove each fuel filter and fill with clean fuel (Figure 6-5).
CAUTION
Due to the precise tolerances of diesel injection systems, it is extremely im­portant the fuel be kept clean and free of water. Dirt or water in the system can cause severe damage to both the injection pump and the injection nozzles.
2. Put a light coat of fuel on the sealing gasket.
3. Install and tighten by hand until the gasket just touches the filter head.
4. Tighten the filter an additional one-half to three­fourths turn.
FUEL SOLENOID
FS1692s
FIGURE 6-4. FUEL SOLENOID VALVE LOCATION
FUEL SUPPLY
INLET
FIGURE 6-5. FUEL FILTERS
SUPPLY LINE,
FILTER TO
INJECTION
PUMP
FUEL FILTERS
FS1803s
6-3
Page 29
6-4
Page 30
7. Initial Start and Checks
Before putting the generator set under load condi­tions, verify the set will perform correctly by check­ing the following areas.
STARTING
Move the Run/Stop/Remote switch on the engine control panel to the Run position. The starter should crank the engine and the engine should start within a few seconds. If after a few seconds of cranking the engine fails to start or starts, runs and then stops, refer to Troubleshooting charts in the Operator’s Manual.
ENGINE GAUGES
Check the following while the genset is operating:
Oil Pressure Gauge
The oil pressure should be in the range of 40 to 60 psi (275 to 414 kPa) when the engine is at operating temperature.
Water Temperature Gauge
Frequency Meter
The generator frequency should be stable and the reading should be the same as the nameplate rating (50 or 60 hertz).
AC Voltmeter
Turn the phase selector switch to each line-to-line phase selection shown on the volts scale (L1-L2 on single phase sets; L1-L2, L2-L3 and L3-L1 on three phase sets). Read the AC voltmeter using the upper or lower scale as indicated by the scale indicator light. At no load, the line-to-line voltage should be the same as the set nameplate rating.
AC Ammeter
Turn the phase selector switch to each phase selec­tion shown on the amperes scale (L1and L2 on single phase sets; L1, L2 and L3 on three phase sets). Read the ammeter using the upper or lower scale as indicated by the scale indicator light. At no load, the current readings should be zero. With a load applied, each line current should be approxi­mately the same and no line current should exceed the set nameplate reading.
ENGINE MONITOR INDICATOR LAMPS
The water temperature should be in the range of
° to 195°F (74° to 91°C) depending on the load
165 and ambient temperature.
DC Voltmeter
This is a voltage reference gauge, indicating condi­tion of the batteries and also of the battery charging circuit. Gauge should read approximately 24 to 28 volts while set is running. If reading is high or low, check batteries and the battery charging circuit.
AC METERS (IF EQUIPPED)
Note the AC instruments on the control panel. The frequency meter and voltmeter should indicate rated nameplate frequency and voltage. Turn the control panel Voltage Adjust control (if equipped) for nameplate voltage. Use the Phase Selector Switch to read each of the line-to-line voltages.
Move the Run/Stop/Remote switch on the engine panel to the Stop position. Hold the Reset/Lamp Test switch in the Test position. All indicator lamps should light. Verify all the lamps are on and then re­lease the switch. Contact your authorized service center if any lamps require replacement.
EXHAUST SYSTEM
With the genset operating, inspect the entire ex­haust system including the exhaust manifold, muf­fler, turbocharger and exhaust pipe. Visually and audibly check for leaks at all connections, welds, gaskets and joints. Make sure exhaust pipes are not heating surrounding areas excessively . If any leaks are detected, have them corrected immediately.
WARNING
sult in severe injury or death. Inspect exhaust system visually and audibly for leaks daily. Re­pair any leaks immediately.
Inhalation of exhaust gases can re-
7-1
Page 31
FUEL SYSTEM
With the genset operating, inspect the fuel supply lines, filters and fittings for leaks. Check any flexible sections for cuts, cracks and abrasions and make sure they are not rubbing against anything that could cause breakage.
WARNING
that can result in severe personal injury or death if ignited by a spark. If any leaks are de­tected, have them corrected immediately.
Leaking fuel will create a fire hazard
WARNING
Ignition of explosive gases can cause explosion and fire, resulting in severe personal injury or death. Do not smoke while servicing the batteries.
COOLING SYSTEM
When the engine is first started, remove the radiator pressure cap and monitor the coolant level. As trapped air is expelled from the system, the coolant level will drop and additional coolant must be add­ed. Replace the pressure cap when the coolant lev­el is stable.
MECHANICAL ADJUSTMENTS
DC ELECTRICAL SYSTEM
With the generator set off, check the terminals on the battery for clean and tight connections. Loose or corroded connections create resistance that can hinder starting. Clean and reconnect the battery cables if loose. Always connect the negative battery cable last.
EXCITATION
AC VOLTMETER
AC AMMETER
FIELD BREAKER
VOLTAGE ADJUST
UPPER AND LOWER SCALE INDICATOR LAMPS
With the generator stopped, check for loose belts and fittings, leaking gaskets and hoses, or any signs of mechanical damage. If any problems are found, have them corrected immediately.
With the set running, listen for any unusual noises that can indicate mechanical problems. Check the oil pressure frequently. Refer to Operator’s or Ser­vice Manual for required adjustments.
OIL PRES­SURE GAUGE
RUN-STOP-REMOTE SWITCH
PANEL LAMP
RESET, LAMP TEST, PANEL LAMP SWITCH
INDICATOR LAMPS
COOLANT TEMPERATURE GAUGE
PHASE SELECTOR SWITCH
FREQUENCY METER
WATTMETER
OTHER OPTIONAL METERS
FIGURE 7-1. CONTROL PANEL WITH OPTIONS
OIL TEMP GAUGE
7-2
TACHOMETER
DC VOLTMETER
FREQUENCY ADJUST
RUNNING TIME METER
EMERGENCY STOP PUSHBUTTON
Page 32
8. Wiring Diagrams
Reconnectible Voltages 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Non-reconnectible Voltages 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1
Page 33
8-2
Page 34
RECONNECIBLE VOLTAGES
8-3
No. 625-2165 Sh 1 of 2 Rev. J Sys: Revisio Modified 2/1994
Page 35
NON-RECONNECIBLE VOLTAGES
8-4
No. 625-2165 Sh 2 of 2 Rev. J Sys: Revisio Modified 2/1994
Page 36
Cummins Power Generation 1400 73rd Avenue N.E. Minneapolis, MN 55432 1-800-888-6626 763-574-5000 International Use Fax: 763-528-7229
Cummins is a registered trademark of Cummins Inc.
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