CUMMINS DFBF, DFAC, DFCC, DFCB, DFCE Installation Manual
...
Installation Manual
Generator Set
with PowerCommandR 3100 Controller or Detectort Control
DFAA (Spec A−H), DFAB (Spec A−M), DFAC (Spec A−M),
DFBC (Spec A−F), DFBD (Spec A−F), DFBE (Spec A−F),
DFBF (Spec A−Z), DFCB (Spec A−Z), DFCC (Spec A−Z),
DFCE (Spec A−J), DFEB (Spec E−T), DFEC (Spec A−L),
DFED (Spec A−H), DFFA (Spec E−F), DFFB (Spec E−L),
DFGA (Spec A−H), DFGB (Spec A−K), DFGC (Spec A),
DFJA (Spec E−M), DFJB (Spec E−M), DFJC (Spec E−S),
DFJD (Spec A−J), DFLA (Spec E−H), DFLB (Spec E−T),
DFLC (Spec E−W), DFLD (Spec E−N), DFLE (Spec A−F),
DFMB (Spec E−T), DQAA (Spec A−F), DQAB (Spec A−F),
DQBA (Spec A−G), DQBB (Spec A−G)
English 1-2013 960−0619 (Issue 7)
Table of Contents
SECTION TITLE PAGE
SAFETY PRECAUTIONS iii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 INTRODUCTION
About this Manual 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Overview 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. SPECIFICATIONS 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. MOUNTING THE GENERATOR SET 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. MECHANICAL CONNECTIONS 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. DC CONTROL WIRING (PCC) 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. DC CONTROL WIRING (Detector Control) 6-1. . . . . . . . . . . . . . . . . . . . . . . . .
7. AC ELECTRICAL CONNECTIONS 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8. ENCLOSURE ELECTRICAL CONNECTIONS 8-1. . . . . . . . . . . . . . . . . . . . . . .
General 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional AC Distribution Panel 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Motorized Inlet/Outlet Louvers 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Fuel Transfer Pump 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9. PRESTART PREPARATION (PCC3100) 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PCC Power On / Standby Mode 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PCC Optiopns Prestart Checks 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting 9-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10. PRESTART PREPARATION (DECTECTOR) 10-1. . . . . . . . . . . . . . . . . . . . . . . .
General 10-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System 10-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting 10-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11. INSTALLATION CHECKLIST 11-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General 11-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Set Support 11-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling Air Flow 11-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diesel Fuel System 11-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaut System 11-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC and DC Wiring 11-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Set Prestart 11-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12. FAN BELT ALIGNMENT (DFLE ONLY) 12-1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General 12-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 12-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13. WIRING DIAGRAMS 13-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General 13-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
i
-
California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
ii
Safety Precautions
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 op-
erator, service personnel, or the equipment.
This symbol warns of immediate hazards which will result in severe personal injury or
death.
WARNING
jury or death.
CAUTION
product or property damage.
FUEL AND FUMES ARE FLAMMABLE
Fire, explosion, and personal injury or death can result from improper practices.
This symbol refers to a hazard or unsafe practice which can result in severe personal in-
This symbol refers to a hazard or unsafe practice which can result in personal injury or
DO NOT fill fuel tanks while engine is running, unless 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 shel-
tered 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, disconnect 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.
iii
Do not wear loose clothing or jewelry in the vicinity of moving parts, or while working on electrical equip-
ment. Loose clothing and jewelry can become caught in moving parts.
If adjustment must be made while the unit is running, 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.
ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH
Remove electric power before removing protective shields or touching electrical equipment. Use rubber
insulative mats placed on dry wood platforms over floors that are metal or concrete when around electrical
equipment. Do not wear damp clothing (particularly wet shoes) or allow skin surface to be damp when
handling electrical equipment. Do not wear jewelry. Jewelry can short out electrical contacts and cause
shock or burning.
Use extreme caution when working on electrical components. High voltages can cause injury or death.
DO NOT tamper with interlocks.
Follow all applicable state and local electrical codes. Have all electrical installations performed by a quali-
fied licensed electrician. Tag and lock open switches to avoid accidental closure.
DO NOT CONNECT GENERATOR SET DIRECTLY TO ANY BUILDING ELECTRICAL SYSTEM. Haz-
ardous voltages can flow from the generator set into the utility line. This creates a potential for electrocu-
tion or property damage. Connect only through an approved isolation switch or an approved paralleling
device.
MEDIUM VOLTAGE GENERATOR SETS
(601V to 15kV)
Medium voltage acts differently than low voltage. Special equipment and training is required to work on or
around medium voltage equipment. Operation and maintenance must be done only by persons trained
and qualified to work on such devices. Improper use or procedures will result in severe personal injury or
death.
Do not work on energized equipment. Unauthorized personnel must not be permitted near energized
equipment. Due to the nature of medium voltage electrical equipment, induced voltage remains even af-
ter the equipment is disconnected from the power source. Plan the time for maintenance with authorized
personnel so that the equipment can be de-energized and safely grounded.
GENERAL SAFETY PRECAUTIONS
Coolants under pressure have a higher boiling point than water. DO NOT open a radiator or heat ex-
changer pressure cap while the engine is running. To prevent severe scalding, let engine cool down be-
fore removing coolant pressure cap. Turn cap slowly, and do not open it fully until the pressure has been
relieved.
Used engine oils have been identified by some state or federal agencies as causing cancer or reproduc-
tive 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. NFPA No. 10).
Make sure that rags are not left on or near the generator set.
iv
Make sure generator set is mounted in a manner to prevent combustible materials from accumulating
under or near 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 explo-
sion could result.
Wear hearing protection when going near an operating generator set.
To prevent serious burns, avoid contact with hot metal parts such as radiator system, turbo charger sys-
tem and exhaust system.
CONTAINERIZED RENTAL UNITS POTENTIAL TIPPING PROBLEM
On all containerized rental equipment, there is a potential problem of having the container tip forward over the
landing legs, pulling the axles off the ground when the container is fully fueled without a semi-tractor under the
king pin. Jack stands for the front of the container are required to mitigate this potential problem.
Note: The figure below shows the jack stands and their placement at the nose of the container.
v
Jack Stands at Nose of Container
KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE
vi
1. Introduction
ABOUT THIS MANUAL
This manual provides installation instructions for the generator set models listed on the front cover. This manual 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.
Optional Enclosure Electrical Connections - covers installation of enclosure optional features.
Prestart − checklist of items or procedures needed to prepare generator set for operation.
Initial Startup − test complete system to ensure proper installation, satisfactory performance, and safe operation.
Refer to Operators Manual for troubleshooting information.
Installation Checklist − reference checks upon completion of installation.
This manual DOES NOT provide application information for selecting a generator set or designing the com-
plete installation. If it is necessary to design the various integrated systems (fuel, exhaust, cooling, etc.), addi-
tional information is required. Review standard installation practices. For engineering data specific to the gen-
erator set, refer to the Specification and Data Sheets. For application information, refer to Application Manual
T-030, “Liquid Cooled Generator Sets”.
INSTALLATION OVERVIEW
These installation recommendations apply to typical installations with standard model generator
sets. Whenever possible, these recommendations also cover factory designed options or modifications. How-
ever, 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
A power system must be carefully planned and correctly installed for proper operation. This involves two es-
sential elements: application and installation.
Application (as it applies to generator set installations) refers to the design of the complete 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 engi-
neers or other trained specialists. Specifying engineers or other trained specialists are responsible for the de-
sign of the complete power system and for selecting the materials and products required.
Installation refers to the actual set-up and assembly of the 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 power
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.
1-1
Safety Considerations
The generator set has been carefully designed to provide safe and efficient service when properly 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.
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
maintain the water jacket temperature determined by the manufacturer for cold start and load acceptance for
the type of system. Although most Cummins Power Generation generator sets will start in temperatures down
to −25
F (−32C) when equipped with engine jacket water coolant heaters, it might take more than 10 seconds
to warm the engine before a load can be applied when ambient temperatures are below 40
On generator sets equipped with a graphic display, the Low Coolant Temperature (Code 210) message, in
conjunction with illumination of the Warning LED, is provided to meet the requirements of NFPA 110. The en-
gine cold sensing logic initiates a warning when the engine jacket water coolant temperature falls below 70
C). In applications where the ambient temperature falls below 40F (4C), a cold engine may be indicated
(21
even though the coolant heaters are connected and operating correctly. 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 (4C). NFPA also requires that the engine be heated as necessary to
F (4C).
F
Product Modifications
Agency certified products purchased from Cummins Power Generation comply only with those specific re-
quirements and as noted on company product specification sheets. Subsequent modifications must meet
commonly accepted engineering practices and/or local and national codes and standards. Product modifica-
tions must be submitted to the local authority having jurisdiction for approval.
1-2
2. Specifications
MODEL DFAA/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
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
H
0
2
kPa
Electrical System
Starting Voltage
Battery
Group number
CCA (minimum)
Cold Soak @ 0F (-18 C)
* Refer to Cummins engine Operation and Maintenance Manual for lubricating oil recommendations/specifications.
13 Gal (49 L) 13.5 Gal (51 L) 13.5 Gal (51 L) 15 Gal (57 L)
Refer to Generator Outline Drawing
4 in. Hg. (13.5 kPa)
6.5 in. Hg. (22 kPa)
4 in. NPT
41
10.2
5 in. NPT
41
10.2
24 Volts DC
Two, 12 Volt
4 in. Hg. (13.5 kPa)
6 in. Hg. (20.3 kPa)
6 in. NPT
41
10.2
8D
1400
6 in. NPT
10.2
41
FUEL CONSUMPTION (STANDBY/FULL LOAD/60HZ)
MODEL
US gph (L/hr) 13.9 (52.7) 15.6 (59) 16.8 (63.7) 20.4 (77) 22.5 (85) 24.4 (92.5) 29.1 (110)
DFAA DFAB DFAC DFBF DFCB DFCC DFCE
2-1
MODEL DFEB DFEC DFED
Cummins Diesel Series KTA19 KTA19 KTA19-G4
Generator kW Rating See Genset Nameplate for rating information.
Cooling System
Capacity with Standard Radiator
Oil Capacity* 12 Gal (45 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
H
0
2
kPa
Electrical System
Starting Voltage
Battery
Group number
CCA (minimum)
Cold Soak @ 0F (-18 C)
* Refer to Cummins engine Operation and Maintenance Manual for lubricating oil recommendations/specifications.
5 in. NPT
40.8
10.2
Refer to Generator Outline Drawing
24 Gal (91 L)
4 in. Hg. (13.5 kPa)
6.5 in. Hg. (22 kPa)
6 in. NPT
40.8
10.2
24 Volts DC
Two, 12 Volt
8D
1400
6 in. NPT
40.8
10.2
FUEL CONSUMPTION (STANDBY/FULL LOAD/60HZ)
MODEL
US gph (L/hr) 28.9 (109.5) 31 (117.5) 34 (128.9)
DFEB DFEC DFED
2-2
MODEL DFGA/DFGB DFGE
Cummins Diesel Series VTA28-G5 VTA28-G7
Generator kW Rating See Genset Nameplate for rating information.
Cooling System
Capacity with Standard Radiator
Oil Capacity* 22.25 Gal (84 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
H
0
2
kPa
Electrical System
Starting Voltage
Battery
Group number
CCA (minimum)
Cold Soak @ 0F (-18 C)
* Refer to Cummins engine Operation and Maintenance Manual for lubricating oil recommendations/specifications.
Refer to Generator Outline Drawing
44 Gal (167 L)
4 in. Hg. (13.5 kPa)
6.5 in. Hg. (22 kPa)
5 in. NPT
41
10.2
24 Volts DC
Two, 12 Volt
8D
1400
FUEL CONSUMPTION (STANDBY/FULL LOAD/60HZ)
MODEL
US gph (L/hr) 37.4 (141.7) 44.2 (167.5) 58.5 (221)
DFGA DFGB DFGE
2-3
MODEL DFJA DFJB/DFJC DFJD
Cummins Diesel Series KTA38 KTA38 KTA38
Generator kW Rating See Genset Nameplate for rating information.
Cooling System
Capacity with Standard Radiator
Oil Capacity*
Standby
Prime
Engine Fuel Connection
Inlet/Oultet Thread Size
Fuel Flow
Max. Fuel Inlet Restriction
Max. Fuel Return Restriction
Exhaust
Outlet Size
Max. Allowable Back Pressure
H
0
2
kPa
Electrical System
Starting Voltage
Battery
Group number
CCA (minimum)
Cold Soak @ 0F (-18 C)
* Refer to Cummins engine Operation and Maintenance Manual for lubricating oil recommendations/specifications.
81.5 Gal (308 L) 85.3 Gal (323 L) 68.9 Gal (337 L)
34 Gal (129 L)
41 Gal (155 L)
Refer to Generator Outline Drawing
4 in. Hg. (13.5 kPa)
6.5 in. Hg. (22 kPa)
6 in. NPT
41
10.2
24 Volts DC
Four, 12 Volt
8D
1400
FUEL CONSUMPTION (STANDBY/FULL LOAD/60HZ)
MODEL
US gph (L/hr) 54.9 (208) 57.8 (219) 61.1 (231.6) 70.1 (265.7)
DFJA DFJB DFJC DFJD
2-4
MODEL DFLB DFLC/DFLD DFLE DFMB
Cummins Diesel
Series
Generator kW Rating See Genset Nameplate for rating information.
Cooling System
Capacity w/Standard Ra-
diator − Gal (L)
Oil Capacity*
Standby − Gal (L)
Prime − Gal (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
H
0
2
kPa
Electrical System
Starting Voltage
Battery
Group number
CCA (minimum)
Cold Soak @ 0F (-18 C)
* Refer to Cummins engine Operation and Maintenance Manual for lubricating oil recommendations/specifications.
KTA50 KTA50 KTTA50
92 (348) 102 (386) 102 (386)
44.7 (169 )
58.7 (222 )
Refer to Generator Outline Drawing
4 in. Hg. (13.5 kPa)
6.5 in. Hg. (22 kPa)
6 in. NPT
41
10.2
24 Volts DC
Four, 12 Volt
8D
1400
6 in. NPT
27
6.7
6 in. NPT
41
10.2
FUEL CONSUMPTION (STANDBY/FULL LOAD/60HZ)
MODEL
US gph (L/hr) 77.2 (292.6) 87.3 (330.9) 77.4 (293) 103.6 (392.6) 103.3 (391.5)
DFLB DFLC DFLD DFLE DFMB
2-5
MODEL DQAA/DQAB DQBA/DQBB
Cummins Diesel Series M11 N14
Generator kW Rating See Genset Nameplate for rating information.
Cooling System
Capacity with Standard Radiator
Oil Capacity* 9.5 Gal (36 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
H
0
2
kPa
Electrical System
Starting Voltage
Battery
Group number
CCA (minimum)
Cold Soak @ 0F (-18 C)
* Refer to Cummins engine Operation and Maintenance Manual for lubricating oil recommendations/specifications.
13 Gal (49 L) 13.5 Gal (51 L)
Refer to Generator Outline Drawing
4 in. Hg. (13.5 kPa)
6.5 in. Hg. (22 kPa)
4 in. NPT
41
10.2
24 Volts DC
Two, 12 Volt
8D
1400
4 in. Hg. (13.5 kPa)
6 in. Hg. (20.3 kPa)
FUEL CONSUMPTION (STANDBY/FULL LOAD/60HZ)
MODEL
US gph (L/hr) 13.9 (52.7) 17.1 (64.8) 20.8 (78.8) 23.7 (89.8)
DQAA DQAB DQBA DQBB
2-6
3. Mounting the Generator Set
GENERAL
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 engi-
neer 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.
Discharge of exhaust gases
Electrical connections
Accessibility for operation and servicing
Noise levels
Vibration isolation
CAUTION
drive must be checked after the genset is mounted. Failure to check fan drive alignment can result in
severe fan/radiator damage. Refer to Section 11 for alignment procedure.
Model DFLE 50C radiator-cooled genset only: The alignment of the cooling system fan
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.
3-1
IMPORTANT
DEPENDING ON YOUR LOCATION AND INTENDED USE, FEDERAL, STATE OR LOCAL LAWS
AND REGULATIONS MAY REQUIRE YOU TO OBTAIN AN AIR QUALITY EMISSIONS PERMIT
BEFORE BEGINNING INSTALLATION OF YOUR GENSET. BE SURE TO CONSULT LOCAL
POLLUTION CONTROL OR AIR QUALITY AUTHORITIES BEFORE COMPLETING YOUR
CONSTRUCTION PLANS.
MOUNTING
Generator sets are mounted on a steel skid that provides proper support. The engine-generator assembly is
isolated from the skid frame by rubber mounts that provide adequate vibration isolation for normal installa-
tions. 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.
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 vibra-
tion isolators to the skid 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.
3-2
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.
SUBBASE OR
VIBRATION
ISOLATOR
FLANGE
HEX NUT
FLAT OR BEVEL
WASHER
1-1/2 x 6 INCH
PIPE
MOUNTING
BASE
MOUNTING
BOLT
12 IN.
(305 mm)
CONCRETE
FIGURE 3-1. BOLT DIAGRAM
3-3
MUFFLER
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
FIGURE 3-2. TYPICAL INSTALLATION
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
3-4
CONCRETE
BASE
IMPORTANT!
OPERATED LOUVRES
VIBRATION ISOLATORS
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 clear-
ance 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.
Model DFLE 50C radiator-cooled genset only: Make sure radiator skid and engine/alternator skid are level with each other after adjust-
ing isolators. If not level, proper fan belt alignment cannot be achieved (Section 11).
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 sup-
port structure.
7. Model DFCE only: With the genset in position and secured to the isolators, remove the two controller cabi-
net shipping screws (see Figure 3-2).
CAUTION
screws in place will damage control components.
Remove shipping screws (two) prior to genset operation. Genset operation with shipping
8. Model DFLE 50C radiator-cooled genset only: With the genset in position and secured to the isolators,
check the alignment of the cooling system fan drive (refer to Section 11).
GENSET SKID
LEVELING BOLT
LOCK NUT
CLEARANCE
SNUBBER
BASE
FIGURE 3-3. VIBRATION ISOLATORS
3-5
ALIGNING GENERATOR WITH ENGINE (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 toler-
ances 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.
Note: 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 mishan-
dling during shipping of the genset.
SEE DETAIL A
CLAMP
DIAL INDICATOR
FLEX
DISCS
GENERATOR
AND ENGINE
CRANKSHAFT
CENTERLINE
SHIMS
MOUNTING BOLT
TO DISC
MEASUREMENT
FIGURE 3-4. ANGULAR ALIGNMENT MEASUREMENT
AXIAL
ALIGNMENT
3-6
DETAIL A
Angular Alignment Procedure
WARNING
Accidental starting of the generator set during this procedure presents the hazard of severe personal injury or death. Make sure to disconnect the negative (-) battery cable(s) before beginning.
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 -.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 cen-
tered side to side. To lower the generator, remove equal shims from under both generator mounting feet. To
approximate the amount of shims to remove or add:
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.)
3-7
In general, the T.I.R. should not be more than .001” for each inch of radius (center of shaft to indicator axis). If
we 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
satisfactoryrange.)
+.010
MEASURED AT
BOLT CIRCLE
DIAMETER
−.004
−.010
−.015
FIGURE 3-5. ANGULAR ALIGNMENT MEASUREMENT READINGS (EXAMPLE)
+.010
−.002
10.7 IN.
−.010
−.015
3-8
Axial Alignment Procedure
Note: 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.
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 indicator 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-of-tolerance runout levels are difficult to establish due 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 im-
provement in the T.I.R. runout may have dramatic effects in the mechanically measured or physically ob-
served vibration levels.
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.
GENERATOR
AND ENGINE
CRANKSHAFT
CENTERLINE
ANGULAR ALIGNMENT
GENERATOR
SHAFT
HUB
DIAL
INDICATOR
SEE DETAIL A
CLAMP
FAN HOUSING
DETAIL A
FIGURE 3-6. AXIAL ALIGNMENT MEASUREMENT
3-9
THIS PAGE LEFT INTENTIONALLY BLANK
3-10
4. Mechanical Connections
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 Operation and Maintenance Manual.
In all fuel system installations, cleanliness is of the upmost importance. Make every effort to prevent entrance
of moisture, dirt or contaminants of any kind into the fuel system. Clean all fuel system components before
installing.
Note: 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.
CAUTION
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 auto-
matic 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
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 model-specific genset Data Sheet.
Never use galvanized or copper fuel lines, fittings or fuel tanks. Condensation in the tank
Never install shutoff device in fuel return line(s). If fuel return line(s) is blocked or exceeds
Fuel Lines − Routing
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 con-
traction. Flexible lines for connecting between the engine and the stationary fuel lines are supplied as standard
equipment.
WARNING
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.
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.
Fuel leaks create fire and explosion hazards which can result in severe personal injury or
4-1
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
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
Engine Fuel Connections
Identification tags are attached to the fuel supply line and fuel return line connections.
Supply Tank
Locate the fuel 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.
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.
Note: 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.
4-2
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 model-specific genset Data Sheet.
Day Tank (If Used)
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 Tank Lower Than Engine: With this installation, the day tank is installed near the generator set, be-
low 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.
Note: 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 return 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.
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.
EXHAUST SYSTEM
Pipe exhaust gases to the outside of any enclosure. Locate the exhaust outlets away from any air inlets to
avoid gases re-entering the enclosure. Exhaust installations are subject to various detrimental conditions
such as extreme heat, infrequent operation and light loads. Regularly inspect the exhaust system both visually
and audibly to see that the entire system remains fume tight and safe for operation.
WARNING
care during installation to provide a tight exhaust system. Terminate exhaust pipe away from en-
closed 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.
Inhalation of exhaust gases can result in severe personal injury or death. Use extreme
WARNING
Inhalation of exhaust gases can result 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 accepted design practices. Build according to the code requirements in effect at the installation site.
4-3
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 elbow.
The exhaust system design should meet local code requirements.
Note: Liability for injury, death, damage, and warranty expense due to use of unapproved mufflers or modifica-
tions becomes the responsibility of the person installing the unapproved muffler or performing the modifica-
tion. Contact a Cummins Power Generation distributor for approved exhaust system parts.
Avoid sharp bends by using sweeping, long radius elbows and provide adequate support for muffler and tail-
pipe. Pitch a horizontal run of exhaust pipe DOWNWARD (away from engine) to allow any moisture condensa-
tion 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 sys-
tem components, check the exhaust system for leaks while operating the genset under full load and correct all
leaks.
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.
4-4
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