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Page 2
Installation Manual
Redistribution or publication of this document,
by any means, is strictly prohibited.
PowerCommand Control
2100 Series
Generator Sets
Printed in U.S.A.
Models
DFAB, DFAC, DFBF, DFCB, DFCC, DFCE
960-0634C 02-2004
Page 3
Table of Contents
Redistribution or publication of this document,
by any means, is strictly prohibited.
SECTION TITLE PAGE
IMPORTANT SAFETY INSTRUCTIONS iii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 INTRODUCTION
About this Manual 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Overview 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 SPECIFICATIONS 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 MOUNTING THE GENERATOR SET
General 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Access to Set 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vibration Isolators 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aligning Generator with Engine (750 kW Gensets and Larger) 3-5. . . . . . . . .
4 MECHANICAL CONNECTIONS
General 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust System 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ventilation and Cooling 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 DC CONTROL WIRING
Control Wiring 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TB1 Remote Monitor/Control Connections 5-2. . . . . . . . . . . . . . . . . . . . . . . . . .
TB2 Power Transfer Control (PTC) Connections (Optional) 5-2. . . . . . . . . . . .
Control Relays (K11, K12, K13) 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
California
Proposition 65 Warning
i
Page 4
SECTION TITLE PAGE
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by any means, is strictly prohibited.
6 AC ELECTRICAL CONNECTIONS
General 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Switch 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Wiring 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Heater (Optional) 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant Heater (Optional) 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Heater (Optional) 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Transfer Pump (Optional) 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground Fault Alarm Relay (Optional) 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 ENCLOSURE ELECTRICAL CONNECTIONS
General 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional AC Distribution Panel 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Motorized Inlet/Outlet Louvers 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Transfer Fuel Pump 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 PRESTART PREPARATION
General 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PCC Options Prestart Checks 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting 8-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 INSTALLATION CHECKLIST
General 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Set Support 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling Air Flow 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diesel Fuel System 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust System 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC and DC Wiring 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Set Prestart 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 WIRING DIAGRAMS
General 10-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii
Page 5
IMPORTANT SAFETY INSTRUCTIONS
Redistribution or publication of this document,
by any means, is strictly prohibited.
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-14L
iii
Page 6
ELECTRICAL SHOCK CAN CAUSE
Redistribution or publication of this document,
by any means, is strictly prohibited.
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.
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
Page 7
1. Introduction
Redistribution or publication of this document,
by any means, is strictly prohibited.
ABOUT THIS MANUAL
This manual provides installation instructions for
the generator set models listed on the front cover.
This includes the following information:
Mounting Recommendations - for fastening
generator set to base and space requirements
for normal operation and service.
Mechanical and Electrical Connections covers most aspects of the generator set installation.
Prestart − checklist of items or procedures
needed to prepare generator set for operation.
Initial Startup − test complete system to ensure proper installation, satisfactory perfor-
mance, and safe operation. Refer to Operators
Manual for troubleshooting information.
Installation Checklist − reference checks
upon completion of installation.
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.), additional information is required. Review
standard installation practices. For engineering
data specific to the generator set, refer to the
fication
tion, refer to Application Manual T-030, “Liquid
Cooled Generator Sets”.
and
Data Sheets
. For application informa-
Speci-
1-1
Page 8
INSTALLATION OVERVIEW
Redistribution or publication of this document,
by any means, is strictly prohibited.
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
your nearest Cummins Power Generation distributor for assistance.
Application and Installation
installed, maintained, 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.
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 or
other trained specialists 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,
sheetmetal 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
Standby Heating Devices
In accordance with NFPA 110, Cummins Power
Generation recommends installing diesel standby
generator sets (life safety systems) equipped with
engine jacket water coolant heaters in locations
where the minimum ambient temperature is above
40
°F (4°C). NFPA also requires that the engine
jacket water coolant be maintained at a minimum of
°F (32°C) and, for most applications, accept the
90
emergency load in 10 seconds or less. Although
most Cummins Power Generation generator sets
will start in temperatures down to −25
when equipped with engine jacket water coolant
heaters, it might take more than 10 seconds to
warm the engine up before a load can be applied
when ambient temperatures are below 40
The Engine Cold (Code 1435) message, in con-
junction with illumination of the Warning LED, is provided to meet the requirements of NFPA 110. The
engine cold sensing logic initiates a warning when
the engine jacket water coolant temperature falls
below 70
ent temperature falls below 40
°F (21°C). In applications where the ambi-
°F (4°C), a cold en-
gine may be indicated even though the coolant
heaters are connected. Under these conditions, although the generator set may start, it may not be
able to accept load within 10 seconds. When this
condition occurs, check the coolant heaters for
proper operation. If the coolant heaters are operating properly, other precautions may be necessary to
warm the engine before applying a load.
°F (−32°C)
°F (4°C).
Copyright2003 Cummins Power Generation. All rights reserved.
Cummins and PowerCommand are registered trademarks of Cummins Inc.
1-2
Page 9
2. Specifications
Redistribution or publication of this document,
by any means, is strictly prohibited.
MODEL DFAB/DFAC DFBF DFCB/DFCC DFCE
Cummins Diesel Series LTA10 NT855 NTA855 NTA855
Generator kW Rating See Genset Nameplate for rating information.
Cooling System
Capacity with Standard Radiator 13 Gal (49 L) 13.5 Gal (51 L) 13.5 Gal (51 L) 15 Gal (57 L)
Oil Capacity* 9.5 Gal (36 L) 10.5 Gal (40 L) 10.5 Gal (40 L) 10 Gal (38 L)
Engine Fuel Connection
Inlet/Oultet Thread Size
Fuel Flow
Max. Fuel Inlet Restriction
Max. Fuel Return Restriction
Exhaust
Outlet Size
Max. Allowable Back Pressure
H20
kPa
Electrical System
Starting Voltage
Battery
Group number
CCA (minimum)
Cold Soak @ 0° F (-18° C)
* Refer to Cummins engine
Operation and Maintenance Manual
4 in. Hg. (13.5 kPa)
6.5 in. Hg. (22 kPa)
4 in. NPT
41
10.2
for lubricating oil recommendations/specifications.
Refer to Generator Outline Drawing
4 in. Hg. (13.5 kPa)
6 in. Hg. (20.3 kPa)
5 in. NPT
41
10.2
24 Volts DC
Two, 12 Volt
8D
1400
6 in. NPT
41
10.2
6 in. NPT
41
10.2
FUEL CONSUMPTION (STANDBY/FULL LOAD/60HZ)
MODEL DFAB DFAC DFBF DFCB DFCC DFCE
US gph (L/hr) 15.6 (59) 16.8 (63.7) 20.4 (77.3) 22.5 (85.3) 24.4 (92.5) 29.1 (110.3)
2-1
Page 10
THIS PAGE LEFT INTENTIONALLY BLANK
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2-2
Page 11
3. Mounting the Generator Set
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by any means, is strictly prohibited.
GENERAL
• Discharge of exhaust gases
• Electrical connections
Generator set installations must be engineered so
the generator set will function properly under the expected load 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:
• Level mounting surface
• Adequate cooling air
• Adequate fresh induction air
• Discharge of generator set air
• Non-combustible mounting surface.
• Accessibility for operation and servicing
• Noise levels
• Vibration isolation
LOCATION
Generator set location is decided mainly by related
systems such as ventilation, wiring, fuel, and exhaust. The set should be located as near as possible to the main power service entrance. Exhaust
must not be able to enter or accumulate around inhabited areas.
Provide a location away from extreme ambient temperatures and protect the generator set from adverse weather conditions. An optional housing is
available for outside operation.
WARNING
INCORRECT INSTALLATION, SERVICE OR PARTS REPLACEMENT CAN RESULT IN SEVERE
PERSONAL INJURY, DEATH, AND/OR EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST
BE TRAINED AND EXPERIENCED TO PERFORM ELECTRICAL AND MECHANICAL COMPONENT INSTALLATION.
DEPENDING ON Y O U R L O C ATION AND INTENDED USE, FEDERAL, STATE OR LOCAL LA WS
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.
IMPORTANT
3-1
Page 12
MOUNTING
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by any means, is strictly prohibited.
Generator sets are mounted on a steel skid or fuel
tank that provides proper support. The engine-generator assembly is isolated from the skid frame by
rubber mounts that provide adequate vibration
isolation for normal installations. Where required by
building codes or special isolation needs, generator
sets may be mounted on rubber pads or mechanical
spring isolators. The use of unapproved isolators
may result in harmful resonances and may void the
genset warranty.
For fuel tank mounted generator sets, it is required
that the tank be mounted such that an air space is
provided between the bottom of the tank and the
floor underneath to reduce corrosion and permit
visual inspections for leaks.
Mount the generator set on a substantial and level
base such as a concrete pad. A non-combustible
material must be used for the pad.
Use 5/8 inch or 16 mm anchored mounting bolts to
secure the vibration isolators to the base. Secure
the vibration isolators using flat or bevel washer and
hexagonal nut for each bolt (see Figure 3-1). The
1-1/2 x 6 inch pipe inserted over the mounting bolts
allows minor adjustment of the bolts to align them to
the holes in the subbase or vibration isolator.
Locate the isolators as shown on the generator set
Outline Drawing
referenced in the
Data Sheet
.
MOUNTING
BASE
MOUNTING
BOLT
SUBBASE OR
VIBRATION
ISOLATOR
FLANGE
HEX NUT
FLAT OR BEVEL
WASHER
1-1/2 x 6 INCH
PIPE
12 IN.
(305 mm)
CONCRETE
FIGURE 3-1. BOLT DIAGRAM
ACCESS TO SET
Generally, at least 1 meter (3 feet) of clearance
should be provided on all sides of the generator set
for maintenance and service access. (Increase
clearance by width of door if optional housing is
used.) A raised foundation or slab of 150 mm (6
inches) or more above floor level will make servicing easier.
Lighting should be adequate for operation, maintenance and service operations and should be connected on the load side of the transfer switch so that
it is available at all times.
3-2
Page 13
MUFFLER
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by any means, is strictly prohibited.
THIMBLE
FLEXIBLE SECTION
DC CONTROL
WIRING
CONDENSATION
DRAIN TRAP
SWEEPING
ELBOW
AC POWER
WIRING
AIR
IN
AIR OUTLET
DUCT
SHIPPING SCREW
(DFCE ONLY) EACH SIDE
VIBRATION
ISOLATORS
COOLING AIR INLET MUST BE AT LEAST 1-1/2
TIMES LARGER THAN RADIATOR DUCT OUTLET
AREA ON RADIATOR COOLED MODELS
FLOW OR COOLING AIR AND HEATED AIR CAN
BE CONTROLLED BY AUTOMATICALLY
FIGURE 3-2. TYPICAL INSTALLATION
3-3
CONCRETE
BASE
IMPORTANT!
OPERATED LOUVRES
Page 14
VIBRATION ISOLATORS
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by any means, is strictly prohibited.
Installation and Adjustment Procedure
1. Place the vibration 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 that the
isolator bases rest on must also be flat and level.
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. (Clearance
on all isolators should be roughly equal). Once
all isolators have been set, 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.
7. Model DFCE only: With the genset in position
and secured to the isolators, remove the two
controller cabinet shipping screws (see Figure
3-2).
CAUTION
Remove shipping screws (two)
prior to genset operation. Genset operation
with shipping screws in place will damage
control components.
GENSET SKID
LEVELING BOLT
LOCK NUT
CLEARANCE
SNUBBER
BASE
FIGURE 3-3. VIBRATION ISOLATORS
3-4
Page 15
ALIGNING GENERATOR WITH ENGINE
Redistribution or publication of this document,
by any means, is strictly prohibited.
(750 kW GENSETS AND LARGER)
Proper alignment of the generator and engine assemblies is necessary to avoid premature wear and
improper operation of the genset. Review the following alignment conditions and procedures for
aligning the generator assembly to engine flywheel
housing.
Angular Misalignment
Angular misalignment is the result of the generator
bearing center axis not aligning with axis of the engine crankshaft. This condition creates an angle
between the generator shaft axis and the crankshaft axis . The cause of this type of misalignment is
usually shimming error.
Axial Misalignment
Axial misalignment is the result of the generator
shaft axis not aligning with engine crankshaft axis.
The tolerances in the bolted flywheel and drive disc
connection may add up to displace the generator
axially relative to the crankshaft axis.
Misalignment Symptoms
If the assembly is allowed to run under these conditions, the discs must flex in alternate directions
twice for each engine revolution. It is important to
minimize the amount of disc flexing since, if it is excessive, the drive disc will crack. Although perfect
bearing alignment is desirable, it is more important
to keep disc deflection to the very minimum possible. This procedure assumes that the pilot bore of
the drive discs are in the exact center and the flywheel counterbore (pilot) has no practical runout.
Under these conditions, perfect Angular alignment
will be attained when no deflection of the discs is
measured.
Excessive Axial alignment will cause more generator vibration than Angular misalignment.
Axial misalignment needs to be checked only when
an objectionable vibration is present.
Either type off misalignment may be present in a
generator set assembly , with angular misalignment
being the most common problem. Angular alignment may also be effected by set installation conditions and/or mishandling during shipping of the genset.
GENERATOR
AND ENGINE
CRANKSHAFT
CENTERLINE
SHIMS
SEE DETAIL A
CLAMP
MOUNTING BOLT
TO DISC
MEASUREMENT
FIGURE 3-4. ANGULAR ALIGNMENT MEASUREMENT
AXIAL
ALIGNMENT
DIAL INDICATOR
FLEX
DISCS
DETAIL A
3-5
Page 16
Angular Alignment Procedure
Redistribution or publication of this document,
by any means, is strictly prohibited.
WARNING
set during this procedure presents the hazard
of severe personal injury or death. Make sure to
disconnect the negative (-) battery cable(s) before beginning.
Accidental starting of the generator
-.015”.) The indicator is closer to the top and further
away at the bottom. This example indicates that the
generator bearing is high. Since the side readings
are equal, the generator is centered side to side. T o
lower the generator, remove equal shims from under both generator mounting feet. To approximate
the amount of shims to remove or add:
Fasten a dial indicator to either the generator shaft
or the cooling fan with the sensing point resting on
the capscrew head or the flat surface of the drive
disc at the bolt circle diameter, see Figure 3-4. Bar
the engine over in a clockwise rotation as viewed
from engine flywheel. Do not allow it to roll back on
compression at the end of the travel of each reading. It is unnecessary to zero the indicator since the
total indicator reading (T.I.R.) of the deflection measurement to the bolt heads is what is required. T.I.R.
will be the sum of the maximum positive and negative dial indicator readings as the engine completes
one revolution.
CAUTION
Do not bar engine over by prying on
fan blade. This may damage the blade and result
in premature, sudden blade failure.
Sample Generator Runout Readings: When taking
the deflection readings described, make a diagram
similar to the example shown in Figure 3-5, with a
total indicator reading of .025”. (The highest positive value of +.010” and the largest negative value of
1. Measure the distance between the center of
the generator shaft to the point the indicator is
measuring at. (For example; a SAE 18 Disc
coupling distance is 10.7”).
2. Measure the distance from the generator side
of the flex discs to the center of the generator
mounting bolt, refer to Figure 3-4. (For example; a HC6 Frame’s distance is 28.4”.)
3. Compare the distance measured in steps 1 and
2. (28.4” vs 10.7” or a 2.65 to 1 ratio.) Multiply
this ratio times one half the T.I.R. (In our example, .025” divided by 2 is .0125”. This, times
2.65 equals .033”. Therefore, remove .033” of
shims from under both mounting feet.)
In general, the T.I.R. should not be more than .001”
for each inch of radius (center of shaft to indicator
axis). If w e use our example of 10.7 inches, then the
maximum T.I.R. would be .011”. This would only require a correction of .014” from the T.I.R. of .025”. (A
reading of +.002 at the top and −.009 at the bottom
would fall within the satisfactory range.)
FIGURE 3-5. ANGULAR ALIGNMENT MEASUREMENT READINGS (EXAMPLE)
−.004
−.010
+.010
MEASURED AT
BOLT CIRCLE
DIAMETER
−.015
−.015
3-6
+.010
−.002
10.7 IN.
−.010
Page 17
Axial Alignment Procedure
Redistribution or publication of this document,
by any means, is strictly prohibited.
Axial misalignment needs to be checked only when
an objectionable vibration is present.
If excessive vibration remains after the angular
alignment, check for concentric alignment of the
generator shaft/engine crankshaft axis.
to the varying surface quality of the generator
shaft’s drive disc mounting hub.
The goal of the Axial alignment is to reduce the
vibration level of the genset while it is operating. A
small improvement in the T.I.R. runout may have
dramatic effects in the mechanically measured or
physically observed vibration levels.
Fasten dial indicator holding device to skid base,
engine block, or generator shell with a magnetic
base or clamp and position so the sensor point of in dicator rests on the generator shaft hub, see Figure
3-6. Bar the engine over in a clockwise rotation as
viewed from engine flywheel, through a couple of
rotations. Record indicator readings in eight equally spaced points around the shaft diameter. This will
provide a T.I.R. for Axial shaft misalignment.
The maximum allowable T.I.R. runout is subjective,
the optimal T.I.R. for runout would be .000 inches,
however that may not be attainable. The recommendation of this procedure will be to reduce the
measured T.I.R. runout by one half. Specific out-oftolerance runout levels are difficult to establish due
ANGULAR ALIGNMENT
To correct for an out-of-tolerance T.I.R. indication,
remove the capscrews connecting drive discs and
flywheel. Mark the drive discs and flywheel with respect to each other. Rotate either the engine or generator so that drive discs holes are repositioned 180
degrees from their original location. Put the drive
discs capscrews back in and retorque. Recheck
shaft alignment as before. If shaft T.I.R. runout remains unchanged then discs should be rotated to
either 30, 60 or 90 degrees from original location to
correct the out-of-tolerance condition. If the T.I.R.
does not improve after repositioning, a closer inspection of the flywheel pilot and drive disc runouts
is required. This will help determine the cause of the
Axial misalignment.
SEE DETAIL A
GENERATOR
AND ENGINE
CRANKSHAFT
CENTERLINE
GENERATOR
SHAFT
HUB
DIAL
INDICATOR
CLAMP
FAN HOUSING
DETAIL A
FIGURE 3-6. AXIAL ALIGNMENT MEASUREMENT
3-7
Page 18
THIS PAGE LEFT INTENTIONALLY BLANK
Redistribution or publication of this document,
by any means, is strictly prohibited.
3-8
Page 19
4. Mechanical Connections
Redistribution or publication of this document,
by any means, is strictly prohibited.
GENERAL
The generator set mechanical system installation
includes connecting the fuel, exhaust, ventilation
and cooling systems. 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 normally use ASTM No. 2 diesel
fuel. They will, however , operate on alternate diesel
fuels within the specifications shown in the Cummins engine
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 into the fuel system. Clean all fuel system components before installing.
A fuel filter/strainer/water separator of 100-120 mesh
or equivalent (approximately 150 microns nominal)
must be fitted between either the main tank and day
tank or between the main tank and the engine.
Use only compatible metal fuel lines to avoid electrolysis when fuel lines must be buried. Buried fuel
lines must be protected from corrosion.
Operation and Maintenance Manual.
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 valve in the supply line is recommended for all installations and required for indoor automatic or remote starting installations.
Connect the solenoid wires to the genset “Switched
B+” circuit to open the valve during generator set
operation.
Separate fuel return lines to the day tank or supply
tank must be provided for each generator set in a
multiple-set installation to prevent the return lines of
idle sets from being pressurized. Fuel return lines
must not contain a shutoff device. Engine damage
will occur if the engine is run with the return fuel lines
blocked or restricted.
CAUTION
Never install shutoff device in fuel
return line(s). If fuel return line(s) is blocked or
exceeds fuel restriction limit, engine damage
will occur.
Fuel Return Restriction (or Pressure) Limit: Fuel
return drain restriction (consisting of friction head
and static head) between the engine injector return
line connection and the fuel tank must not exceed
the limit stated in the
Specification
section.
4-1
Page 20
Fuel Lines − Routing
Redistribution or publication of this document,
by any means, is strictly prohibited.
A flexible fuel hose(s) or section of flexible fuel
hose(s) must be used between the engine’s fuel
system and fuel supply and return line(s) to protect
the fuel system from damage caused by vibration,
expansion and contraction. Flexible lines for connecting between the engine and the stationary fuel
lines are supplied as standard equipment.
Installation of the fuel hose must be done according
to all applicable codes and standards, and installation recommendations provided by the manufacturer. The supplied flexible hose is approved by the
hose manufacture for use with the genset fuel type
and product application.
Support fuel lines to restrain movement and prevent
chaffing or contact with sharp edges, electrical wiring and hot exhaust parts.
WARNING
Sparks and hot surfaces can ignite
fuel, leading to severe personal injury or death.
Do not route fuel lines near electrical wiring or
hot exhaust parts.
Fuel lines must be routed and secured to maintain a
1/2 inch (12.7 mm) minimum clearance from electrical wiring and a 2 inch (51 mm) minimum clearance
from hot exhaust parts.
Engine Fuel Connections
Identification tags are attached to the fuel supply
line and fuel return line connections.
Supply Tank
Locate the f uel tank as close as possible to the generator set and within the restriction limitations of the
fuel pump.
Install a fuel tank that has sufficient capacity to supply the genset operating continuously at full rated
load for the planned period of operation or power
outage. Refer to
Data Sheet
for fuel consumption
data.
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 and return to
avoid line failure and leaks due to vibration. The
fuel system must meet applicable codes.
If the fuel inlet restriction exceeds the defined limit
due to the distance/customer-supplied plumbing
between the genset and the main fuel tank, 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.
For critical start applications, where generator sets
are paralleled or must satisfy emergency start-time
requirements, it is recommended that a fuel tank or
reservoir be located such that the lowest possible
fuel level is not less than 6 inches (150 mm) above
the fuel pump inlet. This will prevent air from accumulating in the fuel line while the set is in standby,
eliminating the period during startup when it has to
be purged.
Fuel Inlet Pressure/Restriction Limit:: Engine
performance and fuel system durability will be compromised if the fuel inlet pressure or restriction limits
are not adhered to. Fuel inlet pressure or restriction
must not exceed the limits stated in the
tion
section.
Specifica-
4-2
Page 21
Day Tank (If Used)
Redistribution or publication of this document,
by any means, is strictly prohibited.
Fuel day tanks are used when fuel inlet restriction
limits can not be met, or the supply tank is overhead
and presents problems of high fuel head pressure
for the fuel inlet and return lines.
Supply T ank Lower Than Engine:
lation, the day tank is installed near the generator
set, below the fuel injection system and within the
fuel inlet restriction limit. Install an auxiliary fuel
pump, 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.
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. Plumb the re-
With this instal-
turn line to the bottom of day tank as shown in Figure 4-1. Provide a day tank overflow line to the supply tank in case the float switch fails to shut off the
fuel transfer pump. Also, the overflow line should be
one pipe diameter larger than the supply line.
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:
Install the day
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.
WARNING
Spilled fuel can create environmental hazards. Check local requirements for containment
and prevention of draining to sewer and ground water.
ENGINE
FUEL
PUMP
DAY TANK
FUEL TRANSFER
PUMP ELECTRIC
MOTOR DRIVEN
VENTED
FILL CAP
SHUTOFF
VALVE
1 INCH
BAFFLE
FLOAT
SWITCH
INJECTOR FUEL
RETURN LINE
CONNECT TO
AC OUTPUT
SUPPLY
LINE
All models require a fuel return
line from injectors to tank.
VENT LINE
FILL PIPE
120 MESH FUEL
STRAINER
LARGER OVER-
FLOW LINE
FIGURE 4-1. TYPICAL FUEL SUPPLY INSTALLATION
FUEL TANK
4-3
Page 22
EXHAUST SYSTEM
Redistribution or publication of this document,
by any means, is strictly prohibited.
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
sult in severe personal injury or death. Use extreme care during installation to provide a tight
exhaust system. Terminate exhaust pipe away
from enclosed or sheltered areas, windows,
doors and vents.
For indoor installation, the exhaust system must
use sealed joint type fittings, (for example NPT fittings) to provide a tighter exhaust system. Use of
slip type fittings (secured with a muffler clamp) may
allow leakage of exhaust gases into the building.
WARNING
sult in severe personal injury or death. Use extreme care during installation to provide a tight
exhaust system. Use NPT or equivalent type fittings for all indoor installations.
Use an approved thimble (Figure 4-2) where exhaust pipes pass through wall or partitions. Insulated wall/roof thimbles are used where exhaust
pipes pass through a combustible roof or wall. This
includes structures, such as wood framing or insulated steel decking, etc. Uninsulated wall/roof
thimbles are used where exhaust pipes pass
through a non-combustible wall or roof, such as
concrete. Refer to NFPA 37, Section 6-3. “Stationary Combustion Engines and Gas Turbines” for ac-
Inhalation of exhaust gases can re-
Inhalation of exhaust gases can re-
cepted design practices. Build according to the
code requirements in effect at the installation site.
WARNING
Hot exhaust pipes can start a fire
and cause severe injury or death if improperly
routed through walls. Use an approved thimble
where exhaust pipes pass through walls or
partitions.
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.
Use a section of flexible exhaust pipe between the
engine and remainder of exhaust system. Support
exhaust system to prevent weight from being 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.
The exhaust system design should meet local code
requirements.
Liability for injury, death, damage, and warranty expense due to use of unapproved mufflers or modifications becomes the responsibility of the person
installing the unapproved muffler or performing the
modification. Contact a Cummins Power Generation
distributor for approved exhaust system parts.
4-4
Page 23
Avoid sharp bends by using sweeping, long radius
Redistribution or publication of this document,
by any means, is strictly prohibited.
elbows and provide adequate support for muffler
and tailpipe. Pitch a horizontal run of exhaust pipe
DOWNWARD (away from engine) 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. Before installing insulation on exhaust system components, check the exhaust system for leaks while operating the genset under full
load and correct all leaks.
RAIN CAP
9 INCH
(230 mm)
VERTICAL
DRIP CAP
HOLES IN
END OF INNER
SLEEVE
ROOF
9 INCH
(230 mm)
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.
HORIZONTAL
WALL OR PARTITION
FIGURE 4-2. MOUNTING EXHAUST THIMBLE
IF EXHAUST LINE MUST BE
PITCHED UPWARD, CONSTRUCT
A TRAP AT POINT OF RISE
AVOID
SHARP
BENDS
DRAIN CONDENSATION
TRAP PERIODICALLY
FIGURE 4-3. CONDENSATION TRAP
4-5
Page 24
VENTILATION AND COOLING
Redistribution or publication of this document,
by any means, is strictly prohibited.
Generator sets dissipate heat and fumes that must
be removed by proper cooling and ventilation.
Generator sets in factory-mounted housings for
outdoor installation are designed for proper cooling
and ventilation.
Indoor installations require careful design with respect to cooling and ventilation. In an indoor installation, all radiator cooling air must be discharged to
the out-of-doors. Duct adapter kits are available.
See Figure 4-5 for a typical indoor installation.
PREVAILING WINDS PREVAILING WINDS
WARNING
Engine or radiator cooling air may
carry deadly carbon monoxide gas which can
cause asphyxiation and death. All engine or radiator cooling air must be discharged to the outof-doors. Do not use it for heating a room or
compartment.
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 genset
flow requirements and allowed airflow restriction.
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.
Data Sheet
for the air-
FIGURE 4-4. WIND BARRIER
4-6
Page 25
Dampers
Redistribution or publication of this document,
by any means, is strictly prohibited.
Dampers or louvres 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 control
end 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 to 2
times larger than the radiator area.
Louvers and screens over air inlet and outlet openings restrict air flow and vary widely in performance.
A louver assembly with narrow vanes, for example,
tends to be more restrictive than one with wide
vanes. The effective open area specified by the louver or screen manufacturer should be used.
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.
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.]
INLET AIR
DAMPER
COOL AIR
* Louvers should close when room
ambient is above 60
° F (16° C)
FIGURE 4-5. TYPICAL RADIATOR SET INSTALLATION
THERMOSTATIC AIR RE-
CIRCULATING DAMPER
*
RADIATOR FLEXIBLE DUCT
CONNECTOR
WIND/NOISE
BARRIER
HOT AIR
D
DISTANCE SHOULD NOT
BE LESS THAN HEIGHT
OF RADIATOR
4-7
Page 26
Remote Radiator Cooling (Optional) substitutes
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by any means, is strictly prohibited.
a remote mounted radiator and an electrically driven fan in place of mounted components. Removal
of the radiator and the fan from the set reduces
noise levels without forcing dependence on a continuous cooling water supply (necessary with heat
exchanger cooling). 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 or remote mounted radiator.
Engine Coolant Heater (Optional)
An optional coolant heater is available to keep the
engine warm for improved starting and code compliance. Connect the heater to a power source that
will be energized 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 system may 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
The engine coolant side of the system can be protected from freezing; the raw water side cannot be
protected.
° F and 195° F (74° C and
COOL AIR
WATER
SOLENOID
VALVE
VENTILATING
FAN
WARM
AIR
FLEXIBLE WA-
TER
CONNECTIONS
MOUNTED HEAT
EXCHANGER
RAW WATER
SUPPLY
RAW WATER
DISCHARGE
FIGURE 4-6. TYPICAL HEAT EXCHANGER INSTALLATION
4-8
Page 27
5. DC Control Wiring
Redistribution or publication of this document,
by any means, is strictly prohibited.
CONTROL WIRING
The generator set control panel box contains connection points for remote control and monitor options.
CAUTION
for all customer connections to the control panel. Solid copper wire may break due to genset
vibration.
Use flexible conduit for all wiring connections to the
generator set. All conduit used for control wiring is
attached to the control housing.
Stranded copper wire must be used
NETWORK COMMUNICATION
MODULE
Route the control wiring through the control housing
and into the access holes on the bottom of the control panel box. Figure 5-1 also shows the access
holes that should be used according to where the
wires are terminated inside the control box.
A compression type strain-relief connector should
be used to prevent dust, insects, etc. from entering
control box.
Use cable ties to keep control wiring away from
sharp edg e s a n d A C power cables within the control
housing.
CONTROL RELAYS
(K10, K1 1, K12) &
CONTROL BOX
HEATER
FIGURE 5-1. SUGGESTED CUSTOMER WIRE ROUTING
TB2
5-1
TB1
STRAIN-RELIEF
CONNECTOR
Page 28
TB1 REMOTE MONITOR/CONTROL
Redistribution or publication of this document,
by any means, is strictly prohibited.
CONNECTIONS
Customer monitor/control connections are attached to terminal block TB1 (Figure 5-2). Optional
equipment such as a remote annunciator panel,
sensing devices used to monitor genset operation,
remote start/stop switches, battery charger, etc. ar e
attached to TB1. Refer to Customer Connections
diagram in Section 9.
TB1 Wiring
CAUTION
a separate metal conduit from AC power cables
to avoid inducing currents that could cause
problems within the control.
Always run control circuit wiring in
Relay Connections: Due to the wide variety of de-
vices that can be attached to the relay outputs of
TB1, the electrical contractor must determine the
gauge of the stranded copper wire that is used at
this installation site. Refer to PCC Customer Connections diagram in Section 9 for the relay specifications.
Network Connections: Refer to 900-0366
Power-
Command Network Installation and Operation
manual for the type/gauge wire to use for these connections.
Switched B+: (Fused at 5 amps.) Same as Relay
Connection description.
B+: (Fused at 10 amps.) Same as Relay Connection description.
Digital Connections: Connection points, other
than relayed outputs, network, switched B+ and B+
are considered digital connections to terminal strip
TB1. The type/gauge wire to use for these connections are:
• Less than 1000 feet (305m), use 20 gauge
stranded copper wire.
• 1000 to 2000 feet (305 to 610m), use 18 gauge
stranded copper wire.
TB2 POWER TRANSFER CONTROL (PTC)
CONNECTIONS (OPTIONAL)
TB2 is used to connect the optional PTC module to
the control. With this option installed, the control will
monitor the utility voltage (mains) and frequency for
failure. If power fails, the PTC control will start the
generator, open the mains circuit breakers and
close the generator circuit breakers. Refer to Customer Connections diagram in Section 9 and installation instructions sent with the PTC Module Kit.
5-2
Page 29
BASE
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by any means, is strictly prohibited.
BOARD
VOLTAGE
SUPPRESSOR
TB2
TERMINAL
END BRACKET
CONTROL
RELAYS
TB1
MACHINE
FIGURE 5-2. CONTROL PANEL BOX
SCREW
TERMINAL
DIN RAIL
TERMINAL
END BRACKET
5-3
Page 30
CONTROL RELAYS (K11, K12, K13)
Redistribution or publication of this document,
by any means, is strictly prohibited.
4-pole relay with 2 poles normally open and two
poles normally closed.
CAUTION
Damage to the Base board can occur if the voltage suppressors (Figures 5-2 and
5-3) are not installed accross relay coils (A1/A2)
of control relays K11, K12 and K13 before connecting genset battery cables.
The three optional control relays are rail mounted
inside the control panel housing. Each relay is a
VOLTAGE
SUPPRESSOR
These relays (Figure 5-3) are used to control auxiliary equipment, such as fans, pumps and motorized
air dampers. Energizing of the relays is user definable.
The contacts are rated at 10 amps at 600 VAC.
Refer to Customer Connections diagram in Sec-
tion 9.
20 AWG Wire, UL Rated for 600 VAC
FIGURE 5-3. OPTIONAL CONTROL RELAYS (K10, K11, K12)
5-4
Page 31
6. AC Electrical Connections
Redistribution or publication of this document,
by any means, is strictly prohibited.
GENERAL
This section provides the procedure that is used to
connect the AC electrical system of the genset.
Before making any AC electrical connections, make
certain the generator set cannot be accidentally
started. Place the control panel run switch in the
OFF position. Turn off or remove AC power from the
battery charger and then remove the negative (−)
battery cable from the set starting battery.
WARNING
can cause severe personal injury or death. Arcing at battery terminals, light switch or other
equipment, flame, pilot lights and sparks can ignite battery gas. Do not smoke, or switch
trouble light ON or OFF near battery. Discharge
static electricity from body before touching batteries by first touching a grounded metal surface.
Ventilate battery area before working on or near
battery—Wear goggles—Stop genset and disconnect charger before disconnecting battery
cables—Disconnect negative (−) cable first and
reconnect last.
CAUTION
source before disconnecting battery cables.
Otherwise, disconnecting cables can result in
voltage spikes damaging to DC control circuits
of the set.
WARNING
set can cause severe personal injury or death.
Prevent accidental starting by disconnecting
the negative (−) cable from the battery terminal.
Ignition of explosive battery gases
Disconnect battery charger from AC
Accidental starting of the generator
Connecting the genset AC electrical system involves:
• Generator insulation check
• Installation of transfer switch
• Generator output voltage selection
• Load cable connection
• Standard and optional AC equipment connec-
tions (e.g., control box heater, coolant heater,
etc.
• Optional enclosure electrical connections (re-
fer to
Section 7
Local regulations often require that wiring connections be made by a licensed electrician, and that the
installation be inspected and approved before operation. All connections, wire sizes, materials used,
etc. must conform to the requirements of 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.
Before starting the genset, check to make sure that
all electrical connections are secure, and that all
wiring is complete. Replace and secure any access
panels that have been removed during installation.
Check that the load cables from the genset are
properly connected.
).
WARNING
Each of the operations described in
this section should be done only by persons
trained and experienced in electrical maintenance. Improper procedures may result in property damage, bodily injury or death.
WARNING
Backfeed to utility system can
cause electrocution or property damage. Do
not connect to any building electrical system
except through an approved device and after
building main switch is opened.
6-1
Page 32
TRANSFER SWITCH
Redistribution or publication of this document,
by any means, is strictly prohibited.
If the installation is for standby service, a transfer
switch must be used for switching the load from the
normal power source to the genset (see Figure 6-1).
Follow the installation instructions provided with the
transfer switch when connecting the load and control wiring.
LOAD
NORMAL
SOURCE
FIGURE 6-1. TYPICAL LOAD TRANSFER
FUNCTION
GENSET
6-2
Page 33
AC WIRING
Redistribution or publication of this document,
by any means, is strictly prohibited.
Generator Voltage Connections
The available generator output voltages and maximum current ratings 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.
All loads are connected to the generator by bolting
stranded load wires to the appropriate terminals on
the generator reconnection terminal block or circuit
breaker lugs. 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).
Load Balancing
These generators can be configured to the nameplate voltages as shown on the Reconnection Diagram located on the side access cover of the control
housing. Many of the voltages listed will require reconfiguration of the generator output leads on the
connection terminal block. This reconfiguration
must only be done by service personnel that are
trained and experienced to perform electrical installation. The generator set was adjusted to produce a
specified voltage during production verification testing prior to shipment. The installer must always
check the stator lead terminal block connections
and perform any necessary reconnect to obtain the
voltage required.
Some generator sets are capable of producing a
wide range of voltages and connection configurations, others have specific limited capabilities. Refer to wiring diagram and generator voltages (from
the nameplate) when reviewing the voltage connection information and use the wiring diagram supplied with your generator set when actually performing load connections.
CAUTION
Reconfiguring generator sets to
higher voltages can exceed the voltage capability of the specific generator windings and damage the generator and also decrease line current, rendering line circuit breakers too large.
Consult with your distributor before performing
reconnection for a different voltage.
CAUTION
Reconfiguring generator sets to
lower voltages can reduce generator set ratings, and also increase line current, rendering
line circuit breakers too small. Consult with
your distributor before performing reconnection for a different voltage.
Load Connections
Flexible conduit and stranded conductors must be
used for connections to take up movement of the
generator set.
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.
Current Transformers
Current transformers (CT’s) are required on gensets that contain AC meters. The CT’s must be
installed as noted in the following CT Installation
Requirements.
Refer to the Reconnection Diagram to identify the
output leads/phase that must be routed through
each CT, and also appropriate transformer post
selection for meter sensing leads. The transformers
are labeled CT1, CT2 and CT3 on the reconnection
wiring diagram. (The Reconnection Diagram is located on the upper side cover of the control housing.)
CT Installation Requirements:
A. The CT has a dot on one side. This dot must be
facing toward the generator (conventional current flowing into the dot). A dot is also used to
indicate pin 1 of the CT.
B. CT1 − U load leads (A phase),
CT2 − V load leads (B phase)
CT3 − W load leads (C phase)
C. Route the appropriate load wires through each
CT.
D. The CT’s have dual secondaries (3 pins). The
CT secondary wire marked 1 is connected to
pin 1 of the CT. CT secondary wire marked 2/3
is connected to pin 2 for high voltage gensets or
to pin 3 for low voltage gensets. (Refer to Reconnection Diagram.)
6-3
Page 34
Grounding
Redistribution or publication of this document,
by any means, is strictly prohibited.
The following is a brief description of system and
equipment grounding of permanently installed AC
generators within a facility wiring system. It is important to follow the requirements of the local electrical
code.
Figure 6-2 illustrates typical system grounding for a
3-pole and a 4-pole automatic transfer switch
(ATS). In the 3-pole ATS, note that the generator
neutral is connected to the ATS and is NOT bonded
to ground at the generator. In the 4-pole ATS system, a grounding electrode conductor and a bonding jumper are used to connect the generator neutral to ground.
Make sure the genset is grounded to earth in one
location only. On generators without a circuit breaker, ground to the point indicated on the top of the
generator. O n gensets with circuit breakers, use the
ground lug provided in the circuit breaker box.
WARNING
Electric current can cause severe
personal injury or death. Bonding and grounding must be done properly. 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.
SERVICE ENTRANCE
THREE-PHASE, FOUR-WIRE UTILITY, THREE-POLE ATS
SERVICE ENTRANCE
GENERATOR SET
3-POLE ATS
LOAD
GENERATOR SET
4-POLE ATS
FIGURE 6-2. TYPICAL SYSTEM GROUNDING ONE-LINE DIAGRAMS
LOAD
THREE-PHASE, FOUR-WIRE UTILITY, FOUR-POLE ATS
6-4
Page 35
CONTROL HEATER (OPTIONAL)
Redistribution or publication of this document,
by any means, is strictly prohibited.
A control heater (Figure 6-3) provides a means of
humidity/temperature control of the control box inte-
rior. I t protects the components when the generator
set is subjected to varying ambient air conditions
during extended periods of non-use.
THERMOSTAT
HEATER
240V PLUG
FIGURE 6-3. OPTIONAL CONTROL HEATER
120V PLUG
6-5
Page 36
COOLANT HEATER
Redistribution or publication of this document,
by any means, is strictly prohibited.
The coolant heater keeps 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.
CAUTION
erated while the cooling system is empty or
damage to the heater will occur.
Figure 6-4 shows a typical coolant heater. Connect
the heater to a source of power that will be on during
The coolant heater must not be op-
the time the engine is not running. Be sure the supply voltage and circuit amperage is correct for the
heater element rating.
A battery charger is required to prevent battery discharge. The heater control relay draws 83 mA of current when the heater(s) is off. The heater is off when
the engine has reached the proper temperature or
the engine is running.
CAUTION
Do not connect AC power to the
heater before connecting battery cables. Heater
will run continuously without DC power and
can overheat and damage heater.
THERMOSTAT
COOLANT
FLOW
AC ELECTRICAL CONNECTION
BOX (ELECTRICAL DIAGRAM
INSIDE COVER)
DC SUPPLY
LINE
COOLANT
FLOW
DC CONTROL
LINE
DRAIN
AC POWER
LINE
FIGURE 6-4. TYPICAL COOLANT HEATER
6-6
Page 37
GENERATOR HEATER
Redistribution or publication of this document,
by any means, is strictly prohibited.
A generator heater(s) is used to help keep the generator free of condensation when the generator set
is not running. During cool and humid conditions,
condensation can form within a generator, creating
flashing and a shock hazard.
WARNING
tor increases the possibility of flashing and
electrical shock, which can cause equipment
damage and severe personal injury or death. Do
not use a generator which is not dry inside and
out.
Water or moisture inside a genera-
HEATER LEADS
Figure 6-5 illustrates the installation of two heater
elements. Connect the heater(s) terminals to a
source of power that will be on during the time the
engine is not running. Be sure the supply voltage
and circuit amperage is correct for the heater element rating.
HEATER
HEATER LEADS
HEATERS
TERMINAL BOX
HEATER
VOLT/WATTS
LABEL
TERMINAL
BLOCK
FIGURE 6-5. TYPICAL GENERATOR HEATER INSTALLATION
6-7
Page 38
FUEL TRANSFER PUMP
Redistribution or publication of this document,
by any means, is strictly prohibited.
A fuel transfer pump and control are available when
a sub-base or in-skid day tank are provided. The automatic control operates the fuel pump to maintain a
reservoir of fuel in the day tank.
WARNING
Diesel fuel is highly combustible.
Improper installation of this kit can lead to spillage of large quantities of fuel and loss of life and
property if the fuel is accidentally ignited. Installation and service must be performed by trained
and experienced persons in accordance with
the applicable codes.
Do not smoke near fuel and keep flames,
sparks, pilot lights, arcing switches and equipment, and other sources of ignition well away.
CONTROL
FLEXIBLE FUEL
RETURN LINE
FLEXIBLE FUEL
SUPPLY LINE
FUEL PUMP
AND MOTOR
FLOAT SWITCH
ASSEMBLY
DAY
TANK
FUEL
GAUGE
FIGURE 6-6. TYPICAL IN-SKID DAY TANK INSTALLATION
6-8
FUEL FILL
CAP
Page 39
Fuel Pump Control AC Connections
Redistribution or publication of this document,
by any means, is strictly prohibited.
The control can be powered by 120 VAC or 240
VAC. The control is set up at the factory for connection to 240 VAC.
1. To convert the day tank controller from 240
VAC to 120 VAC, perform the following steps.
A. Remove the two jumpers between termi-
nals TB1-6 and TB1-7 in the control box
and connect one between terminals
TB1-5 and TB1-6 and the other between
terminals TB1-7 and TB1-8.
2. To convert the day tank controller from 120
VAC to 240 VAC, perform the following steps.
A. Remove the jumpers between terminals
TB1-5 and TB1-6, and TB1-7 and TB1-8
in the control box and connect the two
jumpers between terminals TB1-6 and
TB1-7.
B. Move selector switch S103 on the control
PCB to the down position for 240 VAC.
C. If the control is equipped with a transform-
er, remove the jumpers between terminals
H1 and H3, and H2 and H4 and connect
the two jumpers between H2 and H3.
B. Move selector switch S103 on the control
PCB to the up position for 120V.
C. If the control is equipped with a transform-
er, remove the two jumpers between terminals H2 and H3 and connect one be-
tween H1 and H3 and the other between
H2 and H4.
3 Attach a tag to the control box indicating the
supply voltage.
4 Terminals TB1-8 and TB1-5 are available for
connection of a 120 or 240 VAC electric fuel
shutoff valve rated not more than 0.5 amps.
The voltage rating of the valve must correspond with the voltage utilized for the pump.
See Item 2 above.
FIGURE 6-7. FUEL PUMP CONTROL TERMINAL BOARD
6-9
Page 40
GROUND FAULT ALARM RELAY
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by any means, is strictly prohibited.
(OPTIONAL)
The optional Ground Fault Relay (GFR) (Figure
6-8) is typically located behind the lower control
housing grille. The ground fault relay continuously
monitors the neutral to ground connection and activates a fault alarm when the connection is broken.
During genset operation, the relay continuously
monitors the line to neutral and activates a fault
alarm when a ground fault is sensed.
After the installation of the genset is complete, perform the following procedure to test the operation of
the ground fault relay.
A. Verify that the N-G Fault Indicator on the
GFR is not lit. If lit, it indicates that the
bonding jumper circuit (neutral to ground)
is open. If genset does not require bonding
jumper, a bonding jumper must be
installed at the facility service entrance.
The relay alarm contacts are typically connected to
the genset control to provide a “Ground Fault
Alarm” indication.
A control reset will clear the fault at the control panel
and will also reset the ground fault relay.
The relay has a time delay setting of zero to one
second and a current setting of 5 to 1200 amperes.
Adjust the Current and the Time Delay controls on
the ground fault relay to the customers specifications.
B. Move the control switch to the Run posi-
tion.
C. Press the TEST switch on the ground fault
relay.
D. Verify that the control panel warning mes-
sage is displayed and the Fault Indicator
(>I) on the GFR is lit.
E. Reset the control panel fault (this will also
reset the ground fault relay).
6-10
Page 41
CONTROL
Redistribution or publication of this document,
by any means, is strictly prohibited.
HOUSING
GROUND FAULT
RELAY
ASSEMBLY
GRILLE
TEST BUTTON
FAULT INDICATORS
> I
(OVER CURRENT)
N−G
(OPEN CIRCUIT)
FIGURE 6-8. GROUND FAULT ALARM RELAY
ON INDICATOR
RESET BUTTON
(N.U., FACTORY SET
TO AUTO RESET)
TIME DELAY CONTROL
CURRENT CONTROL
6-11
Page 42
THIS PAGE LEFT INTENTIONALLY BLANK
Redistribution or publication of this document,
by any means, is strictly prohibited.
6-12
Page 43
7. Enclosure Electrical Connections
Redistribution or publication of this document,
by any means, is strictly prohibited.
GENERAL
Generator sets configured with an enclosure can
contain one or more optional features. The optional
features that require electrical connections when
installing the generator set are described in this
section. For wiring diagrams of enclosure options,
refer to Section 10,
FUEL ALARM
PANEL
Enclosure/Options Wiring
OVERFILL
ALARM
FUEL
FILL
.
CAUTION
Flexible conduit and stranded conductors must be used for connections to take
up movement of the genset. Solid copper wire
may break due to genset vibration.
Figure 7-1 shows the location of the optional features within the enclosure.
FUEL SYSTEM
CONTROL
EMERGENCY
STOP SWITCH
EXTERNAL
FUEL FILL BOX
MOTORIZED
INLET LOUVER
FIGURE 7-1. OPTIONAL ENCLOSURE FEATURES (WEATHER ENCLOSURE SHOWN)
120 VAC
EXTERNAL
RECEPTACLE
AC DISTRIBUTION
PANEL
7-1
Page 44
OPTIONAL AC DISTRIBUTION PANEL
Redistribution or publication of this document,
by any means, is strictly prohibited.
The AC distribution panel (Figure 7-2) provides a
centralized power source (120/220VAC) for all optional enclosure features.
CAUTION
the OFF position before applying power to the
AC distribution panel. Other options may require additional installation before connecting
to power.
CAUTION
the fuel transfer pump option, power to the AC
distribution panel must be fed from a transfer
switch and step-down transformer to maintain
120V power to the pump when utility power is interrupted. If the transfer pump option is not
installed, power to the AC distribution panel can
be fed from a non-emergency source. (Other optional features connected to the AC distribution
Make sure all circuit breakers are in
When the generator set contains
panel are not needed for generator set operation.)
All connections to the AC distribution panel are to be
done in compliance with the National Electric Code
and all applicable local codes and standards using
60 or 75 degree conductors.
The AC distribution panel is designed to be fed with
a 100AMP, 120/240VAC, single phase feeder. The
two line conductors connect into the 100AMP main
breaker that is listed for #4 to 2/0 conductors, AL or
CU when torqued to 50 in-lbs.
The neutral conductor connects into the neutral bus
which is listed for #5 to 300KCMIL conductors, AL or
CU when torqued to 21 ft-lbs.
The grounding conductor, if used, connects into the
ground bar which is listed for #1 to 2/0 conductors,
AL or CU when torqued to 17 ft-lbs.
1/3
5/7
CIRCUIT BREAKERS
1/3: 100A MAIN
2: 20A J1/J2 RECEPTACLES
4: 20A J3/J4 RECEPTACLES
5/7: 40A COOLANT HEATERS
6: 20A INLET/OUTLET LOUVERS
8: 20A INTERNAL/EXTERNAL
SERVICE RECEPTACLES
2
4
6
8
FOR OPTIONAL FEATURES
J1: ENGINE OIL HEATER
J2: BATTERY HEATER
J3: ALTERNATOR /CONTROL
J4: BA TTERY CHARGER/TRANS-
GFCI SERVICE
RECEPTACLE
COOLANT HEATER
CONTROL AC SUPPLY
J1 J2 J3 J4
120VAC RECEPTACLES
24 V AC
TRANSFORMERS
(LOUVER MOTORS)
CABINET HEATERS
FER PUMP CONTROLLER
FIGURE 7-2. AC DISTRIBUTION PANEL FEATURES
7-2
Page 45
OPTIONAL MOTORIZED INLET/OUTLET
Redistribution or publication of this document,
by any means, is strictly prohibited.
LOUVERS
Louvers (inlet and/or outlet) are powered by either
24VDC supplied by genset control switched B+ or
24VAC transformer connected to shore power.
With switched B+ or gensets having the AC distribution panel, the motorized louvers are prewired and
require no further installation (Figure 7-3).
Without the AC distribution panel, the 24VAC louvers are not prewired. Louvers operating on 24VAC
require 30VAC, 24 volt class 2 transformer(s).
(Transformers are not supplied with genset that
does not contain an AC distribution panel.) Mount
and connect the transformer(s) to the 18 gauge
wires terminated at the AC distribution panel location. Connect the transformer(s) to a source of power that will be on during the time the engine is not
running.
MOTORIZED
INLET LOUVER
30VAC
TRANSFORMER(S)
MOTORIZED
OUTLET LOUVER
AC DISTRIBUTION
PANEL
FIGURE 7-3. MOTORIZED LOUVER
7-3
Page 46
OPTIONAL FUEL TRANSFER PUMP
Redistribution or publication of this document,
by any means, is strictly prohibited.
A fuel transfer pump and control are available when
a sub-base fuel tank is provided. The automatic
control operates the fuel pump to maintain a reservoir of fuel in the sub-base tank.
CAUTION
must be fed from a transfer switch and stepdown transformer to maintain 120V power to the
pump when utility power is interrupted. Power
must be supplied to the transfer pump during
the time the genset is running or not running.
The fuel transfer pump/controller is prewired and
ready to connect to a 120VAC source.
NOTE: When power is applied to the control or is restored after a power interruption, the control will au-
Power to the fuel transfer pump
tomatically go to the power on mode (functions the
same as pressing the ON switch). The pump will start
if the control detects low fuel in sub-base tank.
CAUTION
Do not connect AC power to the fuel
transfer pump control without having fuel in the
supply tank. Damage to the pump can occur if
pump operates with no fuel in supply tank.
Supply Tank
Refer to
installation/plumping of the supply tank to the subbase fuel tank.
The fuel transfer pump has a maximum inlet restriction capability of 16 inch Hg (which is approximately
equivalent to 20 feet of diesel).
FUEL SYSTEM
CONTROL
Section 4
for information regarding the
FUEL
FILL
OVERFILL
ALARM
TO 120 VAC
EMERGENCY SUPPLY
FIGURE 7-4. FUEL TRANSFER PUMP/CONTROL LOCATION
7-4
Page 47
8. Prestart Preparation
Redistribution or publication of this document,
by any means, is strictly prohibited.
GENERAL
Before attempting the initial start of the generator
set, be sure to complete the
Section 9
.
Installation Checklist
in
INPOWER SERVICE TOOL
GENERAL INFORMATION
InPower is a PC based service tool for the PowerCommand
• Make adjustments to the controls trims and set-
• Perform diagnostics and monitoring.
• Create a capture file of the controls trims and
• Update control calibrations (InPower PRO ver-
Refer to INPOWER User’s Guide for specifics.
tings.
settings.
sion).
2100 Control (PCC). Use InPower to:
InPower Adjust Mode
when troubleshooting the genset (determine if parameters/settings have been modified after installation) and when replacement of the Base board is
necessary. The capture file can be used as a template to write the previous settings to the new Base
board software.
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.
Battery Connections
WARNING
set can cause severe personal injury or death.
Make sure that the Run/Off/Auto switch on the
control panel is set to the Off position before
connecting the battery cables.
Starting the unit requires a 12 volt battery . Connect
positive battery cable before connecting negative
battery cable to prevent arcing.
Accidental starting of the generator
The adjustment feature allows you to make adjustments to genset parameters, calibrations and settings. There are several groups of adjustment parameters; note that not all gensets will have the
same adjustments available.
InPower Capture File Description
InPower provides a method of extracting (capturing) a device’s parameter values. Capturing saves
device information in a file that is identified with a
.CAP extension.
Capture files are used to store a copy of the genset’s parameter values. During genset installation,
it is suggested that a capture file be made before
and after changes are made to the genset operating
parameters. This information can be a very useful
Service the batteries as necessary. If an automatic
transfer switch is installed without a built-in charge
circuit, connect a separate battery charger. A battery charger is required when the PowerCommand
control is set to the Awake mode.
WARNING
Ignition of explosive battery gases
can cause severe personal injury or death. Always connect negative (−) battery cable last to
prevent arcing.
WARNING
Ventilate battery area before working on or near battery. Arcing at battery terminals, light switch or other equipment, flame, pilot lights and sparks can ignite battery gas. Do
not smoke, or switch trouble light ON or OFF
near battery. Discharge static electricity from
body before touching batteries by first touching
a grounded metal surface.
8-1
Page 48
PCC OPTIONS PRESTART CHECKS
Redistribution or publication of this document,
by any means, is strictly prohibited.
All generator set configuration options are set at the
factory except for site related options, (e.g., Language, Start/Stop Time Delays, Idle Start, Cycle
Crank, Customer Fault 1 and 2, etc..
Adjustment of these options are divided into two
categories within the menu driven system. These
two categories are
tion/Adjust.
Setup
and
Controller Configura-
Controller Configuration
Figure 8-1 shows a block representation of the Controller Configuration menus.
To view the first Controller Configuration menu,
make sure Main Menu 1 is displayed and simultaneously press the Home Menu and Previous Main
Menu buttons.
As shown in the diagram, the Controller Configuration menu has three submenus.
Press the buttons next to the
digital display to navigate between the menus.
and symbols in the
The
Setup
submenus are intended for qualified service personnel only and require a password to
modify these submenus. The
tion
and
Adjust
submenus are intended for service
Controller Configura-
personnel and site personnel.
Controller Configuration,
The
submenus are used
to change the default language, temperature units,
and pressure units to be displayed in menus.
The
Adjust
submenus allow site personnel to calibrate the generator set voltage/frequency, idle
speed and start/stop time delays. For the prestart
checks, adjustment of only the start/stop delays is
required.
Press the button next to the
symbol in the display
until the + and − symbols are displayed.
Press the button next to the + or − symbol to select
the desired option.
After selecting option, pressing the
symbol results
in the changes being saved. If the Home button or
Previous Main Menu button is pressed before
pressing the
Language Selected submenu:
symbol, the changes are not saved.
Used to select de-
sired language (default = English).
Temperature Units submenu:
Used to select
Fahrenheit or Centigrade for temperature readings.
Fluid Pressure Units submenu:
Used to select
PSI or kPA for pressure readings.
8-2
Page 49
CONTROLLER CONFIGURATION MENU
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by any means, is strictly prohibited.
Main Menu 1
Engine
Alternator
Language Selected
English
Temperature Units
Deg F
Adjust
More>>
+Language Selected
− English
Back
+Temperature Units
− Deg C
Back
Fluid Pressure Units
PSI
+Fluid Pressure Units
− kPa
FIGURE 8-1. CONTROLLER CONFIGURATION MENU
8-3
Back
Page 50
Adjust Menu
Redistribution or publication of this document,
by any means, is strictly prohibited.
Figure 8-2 shows a block representation of the Adjust menu. If you press the button next to the word
“Adjust” in the display, the first Adjust submenu is
displayed.
As shown in the diagram, the Adjust menu has five
submenus. Each submenu includes a parameter or
value that can be changed.
Press the buttons next to the
digital display to navigate between the menus.
Press the Home button or the Previous Main Menu
button to return to Main Menu 1.
Adjusting Values/Parameters:
1.. Press the button next to the symbol in the display until the + and − symbols are displayed.
2.. If necessary, press the button next to the or
symbols to move to the numeric character you
wish to change.
3.. Press the button next to the + symbol to increase the value or select parameter; press the
button next to the − symbol to decrease the value or select parameter.
4.. After adjusting values/selecting parameters,
pressing the
symbol results in the changes
being saved. (When adjusting values, make
sure the cursor is on the last numeric character
before pressing the
If the Home button or Previous Main Menu button is pressed before pressing the
the changes are not saved.
and symbols in the
symbol).
symbol,
Voltage Adjust submenu:
Voltage can be adjusted to 5 percent of the nominal voltage. For ex-
ample, if genset output voltage is 208 volts, the voltage can be adjusted from 197 to 218 volts.
If the revised value is greater or less than the allowed
(5%) range, the control will round off the displayed
value (up or down). For example, if changing the value by −5% (maximum) equals 197.6, the display will
show 197, but will display and change the output to
198 when saved.
Frequency Adjust submenu:
Frequency can be
adjusted to 5 percent of the nominal frequency.
For example, if the genset frequency is 60.0 Hz, the
frequency can be adjusted from 57.0 to 63.0 Hz.
Start Delay submenu:
Start Delay can be set from
0 to 300 seconds (default = 0). This function is bypassed during a manual start/stop sequence.
Stop Delay submenu:
Stop Delay can be set from
0 to 600 seconds (default = 0). This function is bypassed during a manual start/stop sequence and
engine shutdown faults.
Rated To Idle (Beginning Version 2.303):
Rated
To Idle delay can be set from 0 to 10 seconds (default = 0). (Enter 1 or more to enable.) Entering a
non-zero delay will cause the genset to delay the
transition to Cooldown At Idle.
Idle Start submenu (Only available on some
models):
Idle Start can be enabled or disabled (default = Disable). This function is only enabled when
the genset is started in manual mode. Idle Start can
also be enabled while the set is running in manual
mode.
Enabling Idle Start will cause the genset to run in
idle mode until Idle Start is disabled. A warning is
displayed if genset is left in idle more than 10 minutes. Long periods of engine idling can eventually
affect engine performance and may void engine
warranty.
8-4
Page 51
ADJUST MENU
Redistribution or publication of this document,
by any means, is strictly prohibited.
Main Menu 1
Voltage Adjust
nnn V
Frequency Adjust
nn.n Hz
Start Delay
nnn Sec
Engine
Alternator
Adjust
More>>
+Voltage Adjust
− nnn V
Back
+Frequency Adjust
− nn.n Hz
Back
+Start Delay
− nnn Sec
Back
Stop Delay
nnn Sec
Rated To Idle Delay
nn Sec
Idle Start
Disable
+Stop Delay
− nnn Sec
Back
+Rated To Idle Delay
− nn Sec
Back
+Idle Start
− Enable
Back
FIGURE 8-2. ADJUST MENU
8-5
Page 52
STARTING
Redistribution or publication of this document,
by any means, is strictly prohibited.
Refer to the generator set
Operator’s
manual for important safety precautions and recommended procedures for starting the genset and verifying proper
operation. Start the generator set and verify all engine and generator menus are displaying the correct values.
8-6
Page 53
9. Installation Checklist
Redistribution or publication of this document,
by any means, is strictly prohibited.
GENERAL
Generator set wattage capacity is sufficient to handle maximum anticipated load.
At least 3 feet of clearance (or greater for housing door) is provided around entire generator set for servic-
ing and ventilation.
Generator set is located in an area not subject to flooding.
All operating personnel have read and are familiar with Operator’s Manual.
All operators have been thoroughly briefed on preventive maintenance procedures.
All operators have read and understand all Important Safety Instructions in Operator’s Manual.
GENERATOR SET SUPPORT
Floor, roof or earth on which the generator set rests is strong enough and will not allow shifting or movement. Observe local codes on soil bearing capacity due to freezing and thawing.
Generator set is properly supported and retained to approved base.
Supporting base is large enough and is of non-combustible material − extends 6-inches all around set.
COOLING AIR FLOW
Generator set air inlet is faced into direction of strongest, prevailing winds.
Air inlet openings are unrestricted and at least 1−1/2 times larger than air outlet area.
Cooling air outlet is on downwind side of building (if not, wind barrier is constructed).
Proper ducting material (sheet metal, canvas) is used between radiator and air outlet.
DIESEL FUEL SYSTEM
Fuel tanks meet or exceed all Local, State or National codes.
Fuel lines are properly installed, supported and protected against damage.
Approved flexible fuel line is installed between main fuel supply line and generator set’s fuel system, near
the generator set, to protect the fuel system from damage caused by vibration, expansion and contraction.
Strainer or fuel screen (100 to 120 mesh) is installed in the fuel supply line to protect the fuel lift pump, day
tank transfer pump or float valve seat from fuel supply tank debris.
Fuel supply line shutoff valves are installed to prevent fuel flow in case of leaks.
No shutoff valves are installed on engine fuel return line.
External fuel pumps are connected and operational at all times (generator set started or shut down).
Fuel system is properly primed.
No fuel leaks are found in supply line or engine fuel system.
9-1
Page 54
EXHAUST SYSTEM
Redistribution or publication of this document,
by any means, is strictly prohibited.
Operators are thoroughly briefed on the dangers of carbon monoxide gas.
Areas around set are well ventilated. No possibility of exhaust fumes entering building doors, windows, or
intake fans.
Exhaust gases are piped safely outside and away from building.
The correct length of approved rigid pipe is connected to the generator set flexible pipe using approved
securing methods with no weight resting on engine exhaust components. There are no bends in flex section.
Condensation drain is provided in lowest section of exhaust piping.
Exhaust piping is insulated to guard against burns to personnel.
Exhaust piping passing through walls or ceilings have approved fire-proof materials and are in com-
pliance with all codes.
Exhaust piping is large enough in diameter to prevent excessive back pressure on engine.
AC AND DC WIRING
Wire sizes, insulation, conduits and connection methods all meet applicable codes.
AC and DC wires are separated in their own conduit to prevent electrical induction.
All load, line and generator connections are proper and correct.
Flexible conduit between generator set and building or surrounding structure.
GENERATOR SET PRESTART
Generator set engine is properly serviced with oil and coolant.
Batteries are properly installed, serviced and charged.
Battery charger and engine coolant heater are connected and operational.
All generator set covers and safety shields are installed properly.
All fuel and coolant shutoff valves are operational.
Created capture file of the genset’s parameter values before and after modifications.
9-2
Page 55
10. Wiring Diagrams
Redistribution or publication of this document,
by any means, is strictly prohibited.
GENERAL
This section consists of the schematic and connection wiring diagrams referenced in the text. The following drawings are included.
• Page 10-2 − Customer Connections Diagram
• Page 10-3 and 4 − Enclosure/Options Wiring
10-1
Page 56
THIS IS A REPRESENTATIVE (GENERIC)
Redistribution or publication of this document,
by any means, is strictly prohibited.
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.
TB1-CUSTOMER FAULTS:
TB1-CUSTOMER RELAYS:
DEFAULT SETTING
1 CUSTOMER FAULT 1
2 GROUND FAULT
3 LOW FUEL
4 RUPTURE BASIN FAULT
1 COMMON WARNING
2 COMMON SHUTDOWN
3 NOT IN AUTO
4 READY TO LOAD
No. 620-0247 sh 1 of 1
Rev. A
Modified 4-18-02
CUSTOMER CONNECTIONS DIAGRAM
10-2
Page 57
THIS IS A REPRESENTATIVE (GENERIC)
Redistribution or publication of this document,
by any means, is strictly prohibited.
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.
No. 630-2672 sh 2 of 4
Rev. B
Modified 10-03
ENCLOSURE/OPTIONS WIRING (SHEET 1 OF 2)
10-3
Page 58
THIS IS A REPRESENTATIVE (GENERIC)
Redistribution or publication of this document,
by any means, is strictly prohibited.
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.
No. 630-2672 sh 4 of 4
Rev. B
Modified 10-03
ENCLOSURE/OPTIONS WIRING (SHEET 2 OF 2)
10-4
Page 59
Cummins Power Generation
Redistribution or publication of this document,
by any means, is strictly prohibited.
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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