CUMMINS Detector DFBF Series, Detector DFCB Series, Detector DFCC Series, Detector 275 DFBF, Detector 350 DFCC Installation Manual
...
Installation Manual
Detector Control
Generator Sets
Printed in U.S.A.
Models
DFBF, DFCB, DFCC
960-0606 1-2003
Table of Contents
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
i
ii
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
iii
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
iv
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.
1-1
1-2
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.
2-1
2-2
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.
3-1
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
3-2
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