Page 1
Installation Manual
Generator Set
with PowerCommandR 1.1 Controller
DSKAA
DSKAB
DSKBA
DSKCA
English 04-2008 961-0620 (Issue 2)
Page 2
Page 3
Table of Contents
SECTION TITLE PAGE
IMPORTANT SAFETY INSTRUCTIONS iii. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. INTRODUCTION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About this Manual 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Overview 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. SPECIFICATIONS 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. MOUNTING THE GENERATOR SET 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Access to Set 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vibration Isolators 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. MECHANICAL CONNECTIONS 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust System 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ventilation and Cooling 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. DC CONTROL WIRING 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Wiring 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TB1 Remote Monitor/Control Connections 5-2. . . . . . . . . . . . . . . . . . . . . . . .
Switched B+ 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I/O Module 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Run Relays (K10, K11) 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
i
Page 4
SECTION TITLE PAGE
6. AC ELECTRICAL CONNECTIONS 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Switch 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Wiring 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Heater (Optional) 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant Heater (Optional) 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Heater (Optional) 6-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. PRESTART PREPARATION 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
InPower Service Tool General Information 7-1. . . . . . . . . . . . . . . . . . . . . . . .
Electrical System 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PCC Options Prestart Checks 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screen Adjust Menu 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8. INSTALLATION CHECKLIST 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Set Support 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling Air Flow 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diesel Fuel System 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust System 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC and DC Wiring 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Set Prestart 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9. WIRING DIAGRAMS 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii
Page 5
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS − This manual contains
important instructions that should be followed during
installation and maintenance of the generator and batteries.
Before operating the generator set (genset), read the
Operator’s Manual and become familiar with it and the
equipment. Safe and efficient operation can be
achieved only if the equipment is properly operated
and maintained. Many accidents are caused by failure
to follow fundamental rules and precautions.
The following symbols, found throughout this manual,
alert you to potentially dangerous conditions to the op-
erator, service personnel, or the equipment.
This symbol warns of immediate
hazards which will result in severe personal in-
jury or death.
WARNING
This symbol refers to a hazard or un-
safe practice which can result in severe per-
sonal injury or death.
CAUTION
This symbol refers to a hazard or un-
safe 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 se-
cured 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 dis-
connect 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 equip-
ment. 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, explo-
sion, 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-16L
iii
Page 6
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 con-
tacts 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 DI-
RECTLY TO ANY BUILDING ELECTRICAL SYS-
TEM. Hazardous voltages can flow from the gen-
erator set into the utility line. This creates a potential
for electrocution or property damage. Connect only
through an approved isolation switch or an ap-
proved paralleling device.
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
before 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 con-
tact 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 or combustible material are not
left on or near the generator set.
• 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 over-
heating and engine damage which present a poten-
tial fire hazard.
• Keep the generator set and the surrounding area
clean and free from obstructions. Remove any de-
bris 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 un-
safe.
• Substances in exhaust gases have been identified
by some state or federal agencies as causing can-
cer 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 near an operating
generator set.
• To prevent serious burns, avoid contact with hot
metal parts such as radiator system, turbo charger
system and exhaust system.
KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE
iv
Page 7
1. Introduction
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 instal-
lation.
Prestart − checklist of items or procedures
needed to prepare generator set for operation.
Initial Startup − test complete system to en-
sure 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 infor-
mation 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 Speci-
fication Sheet and Data Sheet. For application infor-
mation, refer to Application Manual T-030, “Liquid
Cooled Generator Sets”. To find this manual online:
1. Go to http://www.cumminspower.com
2. Click on “Application Engineering” under head-
ing Technical Information
3. Click on “Liquid Cooled Genset Application
Manual.
INSTALLATION OVERVIEW
These installation recommendations apply to typical installations with standard model generator
sets. Whenever possible, these recommendations
also cover factory designed options or modifica-
tions. 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 distribu-
tor for assistance.
Application and Installation
A power system must be carefully planned and cor-
rectly installed for proper operation. This involves
two essential elements: application and installa-
tion.
Application (as it applies to generator set installa-
tions) refers to the design of the complete power
system that usually includes power distribution
equipment, transfer switches, ventilation equip-
ment, mounting pads, and cooling, exhaust, and
fuel systems. Each component must be correctly
designed so the complete system will function as in-
tended. 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 de-
sign of the complete power system and for selecting
the materials and products required.
Installation refers to the actual set-up and assem-
bly 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 system normally requires the special skills of
qualified electricians, plumbers, sheetmetal work-
ers, etc. to complete the various segments of the
installation. This is necessary so all components
are assembled using standard methods and prac-
tices.
1-1
Page 8
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 speci-
fied in this manual. All systems external to the gen-
erator (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 certi-
fying the installation is complete and ready for ser-
vice.
Heating Devices for Standby Applications
In accordance with NFPA 110, Cummins Power
Generation recommends installing standby gener-
ator sets (life safety systems) equipped with engine
jacket water coolant heaters in locations where the
minimum ambient temperature is above 40
(4
°C). NFPA also requires that the engine be
heated as necessary to maintain the water jacket
temperature determined by the manufacturer for
cold start and load acceptance for the type of sys-
tem.
Although Cummins Power Generation generator
sets may start in temperatures below 40
when equipped with engine jacket water coolant
°F (4°C)
°F
heaters, it might take more than 10 seconds to
warm the engine before a load can be applied and
may also require other supplemental starting aids.
Refer to engine manual for specific engine requirements.
On generator sets equipped with a graphic display,
the Low Coolant Temperature (Code 1435) mes-
sage, in conjunction with illumination of the Warning
LED, is provided to meet the requirements of NFPA
110. The engine cold sensing logic initiates a warn-
ing when the engine jacket water coolant tempera-
ture falls below 70
the ambient temperature falls below 40
cold engine may be indicated even though the cool-
ant 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 apply-
ing a load.
°F (21°C). In applications where
°F (4°C), a
Product Modifications
Agency certified products purchased from Cum-
mins Power Generation comply only with those
specific requirements and as noted on company
product specification sheets. Subsequent modifica-
tions must meet commonly accepted engineering
practices and/or local and national codes and stan-
dards. Product modifications must be submitted to
the local authority having jurisdiction for approval.
Copyright© 2008 Cummins Power Generation. All rights reserved.
Cummins and PowerCommand are registered trademarks of Cummins Inc.
1-2
Page 9
2. Specifications
MODEL DSKAA DSKAB DSKBA DSKCA
Engine
Kubota Diesel Series D1703-M-E3 BG
3 Cylinder
Generator kW Rating See Genset Nameplate for rating information
Electrical System
Battery Charging
Starting Voltage
Battery
Group Number
CCA (minimum)
Cold Soak @ 32° F (0° C)
Cooling System
Capacity with Standard Radiator 2.0 Gal (7.7 L)* 2.0 Gal (7.7 L)* 2.5 Gal (9.4 L)* 2.5 Gal (9.5 L)*
Lubricating System
Oil Capacity with Filters 7.4 Qts (7.0 L) 7.4 Qts (7.0 L) 10.0 Qts (9.5 L) 13.9 Qts (13.2 L)
Oil Type
Above 75° F (25° C)
32° F (0° C) to 75° F (25° C)
Below 32° F (0° C)
Oil Grade
D1703-M-E3 BG
3 Cylinder
40A Alternator
12 Volts DC
One, 12 Volt
G24
350 Amps
SAE 30 or SAE 10W30
SAE 20 or SAE 10W30
SAE 10W or SAE 10W30
API CF or better
V2203-M-E3 BG
4 Cylinder
V3300-E3 BG
4 Cylinder
40A Alternator
12 Volts DC
One, 12 Volt
G31
450 Amps
Exhaust
Outlet Size
@ Standby:
Maximum Allowable Back Pres-
sure
Exhaust Flow at Rated Load
Exhaust Temperature
Fuel Pump
Fuel Supply
Fuel Return
Maximum Fuel Lift
**Fuel Consumption
Standby/Full Load/60Hz GPH
(L/HR)
* Use 50/50 antifreeze (ethylene glycol and water) mixture.
** Refer to generator set Specifications Sheet for other applications.
Normal Oil Pressure
Warning Limit
Shutdown Limit
2 inch NPT
40 in H2O (10
kPa)
99 cfm (2.8
m3/min)
630° F (332° C)
0.95 (3.6) 1.37 (5.2) 1.93 (7.3) 2.43 (9.2)
OIL PRESSURE WARNING AND
SHUTDOWN LIMITS
2 inch NPT
40 in H2O (10
kPa)
126 cfm (3.6
m3/min)
919° F (493° C)
3/8 inch Hose Barb
3/16 inch Hose Barb
31.5 inches (800 mm)
40-70 psi (276-483 kPa)
20 psi (138 kPa)
15 psi (103 kPa)
40 in H2O (10
174 cfm (4.9
970° F (521° C)
2 inch NPT
kPa)
m3/min)
2 inch NPT
40 in H2O (10
kPa)
219 cfm (6.2
m3/min)
735° F (391° C)
2-1
Page 10
THIS PAGE LEFT INTENTIONALLY BLANK
2-2
Page 11
3. Mounting the Generator Set
GENERAL
Generator set installations must be engineered so
the generator set will function properly under the ex-
pected 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 com-
ply with all local and state building codes, fire ordi-
nances, and other applicable regulations. A typical
generator set installation is shown in Figure 3-1.
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
LOCATION
Generator set location is decided mainly by related
systems such as ventilation, wiring, fuel, and ex-
haust. The set should be located as near as pos-
sible to the main power service entrance. Exhaust
must not be able to enter or accumulate around in-
habited areas.
Provide a location away from extreme ambient tem-
peratures and protect the generator set from ad-
verse weather conditions. An optional housing is
available for outdoor 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 COM-
PONENT INSTALLATION.
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.
3-1
Page 12
SWEEPING
ELBOW
MUFFLER
THIMBLE
AC POWER WIRING
DC
CONTROL
WIRING
FLEXIBLE SECTION
AIR OUT
AIR
IN
FLEXIBLE
BELLOWS
COOLING
AIR
IN
CONCRETE
IMPORTANT!
COOLING AIR INLET MUST BE AT LEAST 1-1/2 TIMES LARGER
THAN RADIATOR DUCT OUTLET AREA ON RADIATOR-COOLED
MODELS.
FLOW OF COOLING AIR AND HEATED AIR MAY BE
CONTROLLED BY AUTOMATICALLY OPERATED LOUVRES.
FIGURE 3-1. TYPICAL GENERATOR SET (WITH RADIATOR) INSTALLATION
3-2
BASE
Page 13
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 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.
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 to the skid using a flat washer
and hexagonal nut for each bolt (see Figure 3-2).
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 isola-
tor.
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 WASHER
1-1/2 x 6 INCH
PIPE
12 IN.
(305 mm)
CONCRETE
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 servic-
ing easier.
Lighting should be adequate for operation, mainte-
nance and service operations and should be con-
nected on the load side of the transfer switch so that
it is available at all times.
FIGURE 3-2. BOLT DIAGRAM
3-3
Page 14
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 lev-
el.
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 align-
ing the skid’s mounting with the threaded isola-
tor hole. The top plates will move down and ap-
proach the base of the isolator as load is ap-
plied.
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 clear-
ance for the rocking that occurs during startup
and shutdown. If the 0.25 inch (6 mm) clear-
ance is not present, turn the leveling bolt until
the desired clearance is achieved.
5. The genset may not be level yet; therefore, ad-
just 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 there-
fore provide better isolation between the gen-
set and support structure.
GENSET SKID
LEVELING BOLT
LOCK NUT
CLEARANCE
SNUBBER
BASE
FIGURE 3-3. VIBRATION ISOLATORS
3-4
Page 15
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
Engines used on these generator sets normally use
ASTM No. 2 Diesel fuel. They will, however, operate
on alternate diesel fuels within the specifications
shown in the engine manual.
In all fuel system installations, cleanliness is of the
upmost importance. Make every effort to prevent
entrance of moisture, dirt or contaminants of any
kind into the fuel system. Clean all fuel system com-
ponents 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 elec-
trolysis when fuel lines must be buried. Buried fuel
lines must be protected from corrosion.
CAUTION
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 rec-
ommended for all installations and required for in-
door 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
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 model-specific genset Specifi-
cation Sheet.
Never use galvanized or copper fuel
Never install shutoff device in fuel
4-1
Page 16
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 contraction. Flexible lines for connecting between the engine and the stationary fuel
lines are supplied as standard equipment.
WARNING
hazards which can result in severe personal in-
jury or death. Always use flexible tubing be-
tween engine and fuel supply to avoid line fail-
ure and leaks due to vibration. The fuel system
must meet all applicable codes.
Installation of the fuel hose must be done according
to all applicable codes and standards, and installa-
Fuel leaks create fire and explosion
tion 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 electri-
cal 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 fuel tank as close as possible to the gen-
erator set and within the restriction limitations of the
fuel pump.
Install a fuel tank that has sufficient capacity to sup-
ply the genset operating continuously at full rated
load for the planned period of operation or power
outage. Refer to Specification Sheet for fuel con-
sumption 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 trans-
fer tank (sometimes 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 pres-
sures from being placed on the fuel system compo-
nents.
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 accu-
mulating in the fuel line while the set is in not run-
ning, eliminating the period during startup when it
has to be purged.
Fuel Inlet Pressure/Restriction Limit: Engine
performance and fuel system durability will be com-
promised 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-spe-
cific genset Specification Sheet.
4-2
Page 17
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, below the fuel injection system and within the
fuel inlet restriction limit. Install a fuel transfer pump,
to pump fuel from the supply tank to the day tank. A
float switch in the day tank controls operation of the
fuel transfer pump.
When using a fuel transfer 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 sys-
tem return connection to the day tank. Plumb the re-
turn line to the bottom of day tank as shown in Fig-
ure 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: With this
installation, the day tank is installed near the gener-
ator set, below the fuel injection system and within
the fuel inlet restriction limit. Include an automatic
fuel 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.
Provide a return line from the engine injection sys-
tem return connection to the day tank. Plumb the re-
turn line to the bottom of day tank as shown in Fig-
ure 4-1.
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
120 MESH FUEL
STRAINER
INJECTOR FUEL
RETURN LINE
CONNECT TO
AC OUTPUT
SUPPLY
LINE
FUEL TANK
All models require a fuel return
line from injectors to tank.
VENT LINE
FILL PIPE
LARGER OVER-
FLOW LINE
FIGURE 4-1. TYPICAL FUEL SUPPLY INSTALLATION
4-3
Page 18
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
sult in severe personal injury or death. Use ex-
treme 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 fit-
tings) to provide a tight exhaust system. Use of slip
type fittings (secured with a muffler clamp) may al-
low leakage of exhaust gases into the building.
WARNING
sult in severe personal injury or death. Use ex-
treme care during installation to provide a tight
exhaust system. Use NPT or equivalent type fit-
tings for all indoor installations.
Use an approved thimble (Figure 4-2) where ex-
haust pipes pass through wall or partitions. Insu-
lated wall/roof thimbles are used where exhaust
pipes pass through a combustible roof or wall. This
includes structures, such as wood framing or insu-
lated 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. “Station-
ary 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 re-
sult 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 ver-
tical 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 ap-
plied to engine exhaust outlet.
CAUTION
Weight applied to the engine man-
ifold can result in damage. Support the muffler
and exhaust piping so no weight or stress is ap-
plied to engine exhaust elbow.
The exhaust system design should meet local code
requirements.
Liability for injury, death, damage, and warranty ex-
pense due to use of unapproved mufflers or modifi-
cations to the exhaust system becomes the respon-
sibility of the person installing the unapproved muf-
fler or performing the modification. Contact a Cum-
mins Power Generation distributor for approved ex-
haust system parts.
4-4
Page 19
Avoid sharp bends by using sweeping, long radius
elbows and provide adequate support for muffler
and tailpipe. Pitch a horizontal run of exhaust pipe
DOWNWARD (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 ex-
haust system components, check the exhaust sys-
tem 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 in-
sulate exhaust pipes if there is danger of per-
sonal 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
4-5
AVOID
SHARP
BENDS
DRAIN CONDENSATION
TRAP PERIODICALLY
FIGURE 4-3. CONDENSATION TRAP
Page 20
VENTILATION AND COOLING
Generator sets create considerable heat that must
be removed by proper ventilation. Outdoor installations normally rely on natural air circulation but indoor installations need properly sized and positioned vents for required airflow.
Vents and Ducts
For indoor installations, locate vents so incoming air
passes through the immediate area of the installa-
tion before exhausting. Install the air outlet higher
than the air inlet to allow for convection air move-
ment.
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 Specification Sheet for
the airflow requirements and allowed airflow restric-
tion.
Wind will restrict free airflow if it blows directly into
the air outlet vent. Locate the outlet vent so the ef-
fects of wind are eliminated, or if outlet vent cannot
be located as mentioned, install wind barrier. See
Figure 4-4.
PREVAILING WINDS PREVAILING WINDS
WIND
BARRIER
FIGURE 4-4. WIND BARRIER
4-6
Page 21
Dampers
Dampers or louvres protect the generator set and
equipment room from the outside environment.
Their operation of opening and closing should be
controlled by operation of the generator set.
In cold climates, the radiator exhaust air can be recirculated to modulate the ambient air temperature
in the generator set room. This will help the genera-
tor set warm up faster, and help to keep fuel temper-
atures higher than the cloud point of the fuel. If recir-
culation dampers are used, they should be de-
signed to “fail closed”, with the main exhaust damp-
ers open, so that the generator set can continue to
operate when required. Designers should be aware
that the generator set room operating temperature
will be very close to the outdoor temperature, and
either not route water piping through the generator
set room, or protect it from freezing.
Radiator Set Requirements
Louvers and screens over air inlet and outlet open-
ings 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.
Radiator set cooling air is drawn past the control
end of the set by a pusher fan that blows air through
the radiator. Locate the air inlet to the rear of the set.
Make the inlet vent opening 1-1/2 times larger than
the radiator area.
Locate the cooling air outlet directly in front of the ra-
diator 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 air outlet
opening using screws and nuts so duct can be re-
moved for maintenance purposes. The duct pre-
vents recirculation of heated air. Before installing
the duct, remove the radiator core guard.
ENGINE-DRIVEN
FAN
DAMPER
COOL
AIR
INLET
AIR
RADIATOR
THERMOSTATICALLY
CONTROLLED
RECIRCULATING DAMPER
FLEXIBLE
DUCT
CONNECTOR
OUTLET AIR
DAMPER
WIND/
NOISE
BARRIER
HOT
AIR
D
DISTANCE SHOULD
NOT BE LESS THAN
HEIGHT OF RADIATOR
FIGURE 4-5. TYPICAL RADIATOR SET INSTALLATION
4-7
Page 22
THIS PAGE LEFT INTENTIONALLY BLANK
4-8
Page 23
5. DC Control Wiring
CONTROL WIRING
The generator set control box contains connection
points for remote control and monitor options.
These connection points are located inside of the
control box (Figure 5-1).
Use flexible conduit for all wiring connections to the
generator set.
CAUTION
for all customer connections to the control pan-
el. Solid copper wire may break due to genset
vibration.
Stranded copper wire must be used
K11
K10
TB10
WARNING
HAZARDOUS VOLTAGE Touching
uninsulated high voltage parts inside the control box can result in severe personal injury or
death. Control wire installation must be done
with care to avoid touching uninsulated live
parts.
Stand on a clean dry wooden platform or clean
rubber insulating mat, make sure your clothing
and shoes are dry, remove jewelry and use tools
with insulated handles.
BASE
BOARD
CUSTOMER WIRING
FIGURE 5-1. CONTROL BOX
TB1
ACCESS HOLE
5-1
Page 24
TB1 REMOTE MONITOR/CONTROL
CONNECTIONS
Customer monitor/control connections are attached to terminal block TB1 (Figure 5-1). Optional
equipment, such as sensing devices used to monitor genset operation, remote start/stop switches,
etc. are 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.
Digital Connections: Connection points, other
than relayed outputs and network are considered
digital connections to terminal strip TB1. The type/
gauge wire to use for these connections are:
Always run control circuit wiring in
• Less than 1000 feet (305m), use 20 gauge
stranded copper wire.
• 1000 to 2000 feet (305 to 610m), use 18 gauge
stranded copper wire.
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.
TB1 Customer Inputs
Refer to Page 9-1 for typical connections to TB1.
Remote Start: When the control is in Auto/Remote
mode, grounding this input initiates the engine
cranking and start sequence. This circuit must be
opened to permit resetting a shutdown condition
with the Reset input. (The remote stop is actually
the removal of the remote start signal to the control.)
Remote Emergency Stop: Opening this input
causes an immediate shutdown. Emergency stop
must be reset at the front panel.
Customer Fault Inputs 1 and 2: Grounding any
one of these inputs activates the corresponding
warning or shutdown sequence.
External sensing equipment must be connected to
the designated digital input.
The nature of the fault is an optional customer
selection. Example inputs: Low Coolant Level, Low
Fuel Level, Ground Fault, etc.
Each of the two fault functions can be programmed
as follows:
• Status, Warning or Shutdown. Default = Warning.
• Enter a brief description of the event (up to 32
characters).
The InPower service tool or access to the Setup Sub-
menus is required to modify the customer fault in-
puts. Contact an authorized service center for assis-
tance.
TB1 Customer Outputs
Refer to Page 9-1 for typical connections to TB1.
Customer Outputs 1 and 2: One set of normally
open (NO) contacts, rated for 2 amps at 30 VDC for
each of the two output signals. The relays can be
used to control small devices and indicator lamps.
The nature of the customer output signal (contacts
closed) is an optional customer selection. Example
outputs: Genset running (event), common warning,
common shutdown, etc. (Refer to Operator’s manu-
al for warning and shutdown code listing and the
Service manual for event code listing.)
Each relay can be independently programmed to
energize by entering a code number (0 through 255,
default = 0) for the desired event.
The InPower service tool or access to the Setup Sub-
menus is required to modify the customer outputs.
Contact an authorized service center for assistance.
Ready To Load: Operates when the generator set
has reached 90% of rated speed and voltage and
latches until generator set is switched to off mode
(B+ signal output).
SWITCHED B+
Switched B+ is fused at 15 amps. Wiring is the
same as Relay Connection description.
Switched B+ quick connect terminal is located on
the right side of the engine (facing the control) near
the flywheel housing. Wire color is Red/Orange
stripe.
5-2
Page 25
I/O MODULE
The optional I/O module(s) provides additional customer inputs and outputs for control and monitoring
of the power system. Up to sixteen relay outputs
and twelve discrete analog inputs are available
when the control contains both the Base I/O Module
(AUX101) and the Expansion I/O Module
(AUX102).
RUN RELAYS (K10, K11)
The optional run relays (Figure 5-1 and Figure 5-2)
are mounted inside the control box. The singlepole, double-throw run relays are used to control
auxiliary equipment such as fans, pumps and motorized air dampers. The run relays are energized
when the generator set control receives a start signal.
The contacts are rated:
Refer to Instruction Sheet C693 for I/O module con-
figuration/wiring information.
K10
TB1
K11
BASE
BOARD
• 20 amps resistive @ 30VDC
• 15 amps inductive @ 30VDC
TB10
CUSTOMER
CONNECTIONS
FIGURE 5-2. OPTIONAL RUN RELAYS (K10, K11)
5-3
Page 26
THIS PAGE LEFT INTENTIONALLY BLANK
5-4
Page 27
6. AC Electrical Connections
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. Arc-
ing at battery terminals, light switch or other
equipment, flame, pilot lights and sparks can ig-
nite battery gas. Do not smoke, or switch
trouble light ON or OFF near battery. Discharge
static electricity from body before touching bat-
teries by first touching a grounded metal sur-
face.
Ventilate battery area before working on or near
battery—Wear goggles—Stop genset and dis-
connect 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
WARNING
this section should be done only by persons
trained and experienced in electrical maintenance. Improper procedures may result in prop-
erty damage, bodily injury or death.
Connecting the genset AC electrical system in-
volves:
Each of the operations described in
• 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.).
Local regulations often require that wiring connec-
tions be made by a licensed electrician, and that the
installation be inspected and approved before op-
eration. All connections, wire sizes, materials used,
etc. must conform to the requirements of electrical
codes in effect at the installation site.
WARNING
electrical hazard, 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
cause electrocution or property damage. Do not
connect to any building electrical system ex-
cept through an approved device and after
building main switch is opened.
Improper wiring can cause a fire or
Backfeed to utility system can
6-1
Page 28
TRANSFER SWITCH
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 29
AC WIRING
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.
CAUTION
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.
Reconfiguring generator sets to
Load Connections
These generators can be configured to the name-
plate voltages as shown on the Reconnection Dia-
gram located on the side access cover of the power
output box. 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 instal-
lation. The generator set was adjusted to produce a
specified voltage during production verification test-
ing 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 configura-
tions, others have specific limited capabilities. Re-
fer to wiring diagram and generator voltages (from
the nameplate) when reviewing the voltage connec-
tion information and use the wiring diagram sup-
plied with your generator set when actually perform-
ing load connections.
CAUTION
higher voltages can exceed the voltage capabil-
ity of the specific generator windings and dam-
age the generator and also decrease line cur-
rent, rendering line circuit breakers too large.
Consult with your distributor before performing
reconnection for a different voltage.
Reconfiguring generator sets to
Load wires are brought into the stub-up space in the
lower left corner of the power output box (Figure
6-2).
Flexible conduit and stranded conductors must be
used for connections to take up movement of the
generator set.
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.
Load Balancing
When connecting loads to the generator set, bal-
ance the loads so the current flow from each line ter-
minal (L1, L2 and L3) is about the same. This is es-
pecially 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, with-
in 10 percent of median value and no line current ex-
ceeds the nameplate rating of the generator. After
all load wires are connected, check the current flow
from each line, by observing the control panel am-
meter. If the control panel does not contain a graphi-
cal display, use of a multimeter will be required to
check current flow.
6-3
Page 30
Current Transformers
The current transformers (CT’s) are used to display/
monitor genset load in kVA and alternator amperage. The CT’s must be installed as noted in the following CT Installation Requirements.
Refer to the Reconnection Diagram to identify the
generator output leads/phase that must be routed
through each CT, and also appropriate transformer
post selection for control sensing leads. The trans-
formers are labeled CT1, CT2 and CT3 on the re-
connection wiring diagram. (The Reconnection Dia-
gram is located on the power output box cover.)
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 generator output lead
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 above 300 VAC gen-
sets or to pin 3 for below 300 VAC gensets. (Re-
fer to Reconnection Diagram.)
6-4
Page 31
GENERATOR
LEAD ENTRANCE
CURRENT TRANSFORMERS CT1,
CT2 AND CT3 (WHEN PROVIDED)
THE POLARITY DOTS MUST BE
TOWARDS ALTERNATOR.
LINE CIRCUIT
BREAKERS (WHEN
PROVIDED)
TERMINALS FOR CONNECTING
GENERATOR LEADS ON
OPTIONAL CIRCUIT BREAKER
120-240 VAC TERMINALS
FOR GENERATOR HEATER
(CONNECTED TO NORMAL
SOURCE)
THESE TERMINALS ARE
LIVE WHEN THE SET IS NOT
RUNNING—DISCONNECT
POWER BEFORE REMOVING
AC OUTPUT BOX COVER.
LOAD WIRING
STUB-UP SPACE
GENSET
GROUNDING
LUG
FIGURE 6-2. POWER OUTPUT BOX
AC CONTROL
WIRING HARNESS
TERMINAL BLOCKS
6-5
LOAD TERMINALS
ON OPTIONAL
CIRCUIT BREAKER
Page 32
Grounding
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 6-3 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 sys-
tem, a grounding electrode conductor and a bond-
ing jumper are used to connect the generator neu-
tral to ground.
Make sure the genset is grounded to earth in one
location only. Use the ground lug provided in the
power output 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
LOAD
THREE-PHASE, FOUR-WIRE UTILITY, FOUR-POLE ATS
FIGURE 6-3. TYPICAL SYSTEM GROUNDING ONE-LINE DIAGRAMS
6-6
Page 33
CONTROL HEATER (OPTIONAL)
A control heater (Figure 6-4) provides a means of
humidity / temperature control of the control box interior. It protects the components when the genera-
120V OR
240V PLUG
tor set is subjected to varying ambient air conditions
during extended periods of non-use.
The heater is equipped with a power cord that terminates with a 120V or 240V NEMA plug.
HEATER
BOTTOM VIEW OF
CONTROL BOX
FIGURE 6-4. OPTIONAL CONTROL HEATER
6-7
Page 34
COOLANT HEATER (OPTIONAL)
A 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.
OUTLET
TUBE
CAUTION
The coolant heater must not be operated while the cooling system is empty or
damage to the heater will occur.
Figure 6-5 shows a typical coolant heater installation. Connect the heater 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.
COOLANT
HEATER
INLET
TUBE
POWER
PLUG
FIGURE 6-5. TYPICAL COOLANT HEATER
6-8
Page 35
GENERATOR HEATER (OPTIONAL)
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 shock hazards.
The generator heater is connected as shown in Figure 6-6. Terminal strip is located inside of power output box (Figure 6-2). Connect 120 or 240 volt AC
power to this terminal strip from an outside source
so heater is on when genset is not running.
WARNING
Water or moisture inside a generator 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.
GENERATOR HEATER
(VIEW AA)
LEADS FROM
GENERATOR HEATER
CONNECTION FOR 120V CONNECTION FOR 240V
CUSTOMER SUPPLIED
POWER LEADS
FIGURE 6-6. TYPICAL GENERATOR HEATER INSTALLATION
6-9
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6-10
Page 37
7. Prestart Preparation
GENERAL
Before attempting the initial start of the generator
set, be sure to complete the Installation Checklist in
Section 8.
INPOWER SERVICE TOOL GENERAL
INFORMATION
InPower is a PC based service tool for the Power-
Command
• 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).
1.1 controller (PCC). Use InPower to:
InPower Adjust Mode
The adjustment feature allows you to make adjust-
ments to genset parameters, calibrations and set-
tings. There are several groups of adjustment pa-
rameters; note that not all gensets will have the
same adjustments available.
InPower Capture File Description
InPower provides a method of extracting (captur-
ing) 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 gen-
set’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
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 tem-
plate 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 se-
cure any access panels that may have been re-
moved during installation.
Battery Connections
WARNING
set can cause severe personal injury or death.
Make sure that the PCC is in the OFF mode be-
fore connecting the battery cables.
Starting the unit requires a 12 volt battery. Connect
positive battery cable before connecting negative
battery cable to prevent arcing.
Service the batteries as necessary. If an automatic
transfer switch is installed without a built-in charge
circuit, connect a separate battery charger. Proper
selection and maintenance of batteries and battery
chargers is essential for system reliability.
WARNING
can cause severe personal injury or death. Al-
ways connect negative (−) battery cable last to
prevent arcing.
WARNING
ing on or near battery. Arcing at battery termi-
nals, light switch or other equipment, flame, pi-
lot 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.
Accidental starting of the generator
Ignition of explosive battery gases
Ventilate battery area before work-
7-1
Page 38
PCC OPTIONS PRESTART CHECKS
All generator set configuration options are set at the
factory except for site related options, (e.g., Start/
Stop Time Delays, 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 Setup and Screen Adjust.
The Setup menus are intended for qualified service
personnel only and require a password to modify
these submenus (refer to Service manual). The
Screen Adjust menu is intended for service person-
nel and site personnel.
SCREEN ADJUST MENU
Figure 7-1 shows a block representation of the
Screen Adjust menu. The Screen Adjust menu is
displayed when the (3) button is pressed in the first
Service Menu.
From any of the Operator menus, simultaneously
press the and selection buttons for two sec-
onds to display the first Service menu.
Adjusting Values/Parameters
1. Press the ADJUST selection button to select
the first parameter or value to be changed.
2. Press the + or − selection buttons to adjust val-
ues or select parameters.
3. Press the arrow selection button
gate to the next or previous adjustable value or
parameter.
4. After adjusting values/selecting parameters,
press the SAVE button to save your settings.
NOTE: If the Previous Menu button
pressed before pressing the SAVE but-
ton, the changes are not saved.
5. Press the
Menu.
button to return to the Service
to navi-
is
Screen Adjust Menu
This menu allows for adjusting the screen’s contrast
and brightness and for selecting the units of mea-
surement (SAE or SI) to be displayed.
• Contrast and Brightness: Press the + or −
selection buttons to adjust the screen’s con-
trast and brightness. Changing the bright-
ness setting also affects the brightness of the
LEDs on the control panel.
• Units: Press the + or − selection buttons to
select SAE (_F, PSI) or SI (C, kPa) units of
measurement to be displayed.
SCREEN ADJUST MENU
FIGURE 7-1. SCREEN ADJUST MENU
7-2
Page 39
STARTING
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.
7-3
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7-4
Page 41
8. Installation Checklist
GENERAL
j Generator set wattage capacity is sufficient to
handle maximum anticipated load.
j At least 3 feet of clearance (or greater for hous-
ing door) is provided around entire generator
set for servicing and ventilation.
j Generator set is located in an area not subject
to flooding.
j All operating personnel have read and are fa-
miliar with Operator’s manual.
j All operators have been thoroughly briefed on
preventive maintenance procedures.
j All operators have read and understand all Im-
portant Safety Instructions in Operator’s manu-
al.
GENERATOR SET SUPPORT
j 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.
j Generator set is properly supported and re-
tained to approved base.
j Supporting base is large enough and is of non-
combustible material − extends 6-inches all
around set.
COOLING AIR FLOW
j Generator set air inlet is faced into direction of
strongest, prevailing winds.
j Air inlet openings are unrestricted and at least
1−1/2 times larger than air outlet area.
j Cooling air outlet is on downwind side of build-
ing (if not, wind barrier is constructed).
j Proper ducting material (sheet metal, canvas)
is used between radiator and air outlet.
DIESEL FUEL SYSTEM
j Fuel tanks meet or exceed all Local, State or
National codes.
j Fuel lines are properly installed, supported and
protected against damage.
j 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.
j 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.
j Automatic fuel supply line shutoff valves are
installed to prevent fuel flow in case of leaks.
j No shutoff valves are installed on engine fuel
return line.
j External fuel pumps are connected and opera-
tional at all times (generator set started or shut
down).
j Fuel system is properly primed.
j No fuel leaks are found in supply line or engine
fuel system.
8-1
Page 42
EXHAUST SYSTEM
AC AND DC WIRING
j Operators are thoroughly briefed on the dan-
gers of carbon monoxide gas.
j Areas around set are well ventilated. No possi-
bility of exhaust fumes entering building doors,
windows, or intake fans.
j Exhaust gases are piped safely out-of-doors
and away from building.
j The correct length of approved rigid pipe is
connected to the generator set flexible pipe us-
ing approved securing methods with no weight
resting on engine exhaust components. There
are no bends in flex section.
j Condensation drain is provided in lowest sec-
tion of exhaust piping.
j Exhaust piping is insulated to guard against
burns to personnel.
j Exhaust piping passing through walls or ceil-
ings have approved fire-proof materials and
are in compliance with all codes.
j Exhaust piping is large enough in diameter to
prevent excessive back pressure on engine.
j Wire sizes, insulation, conduits and connection
methods all meet applicable codes.
j AC and DC wires are separated in their own
conduit to prevent electrical induction.
j All load, line and generator connections are
proper and correct.
j Flexible conduit between generator set and
building or surrounding structure.
GENERATOR SET PRESTART
j Generator set engine is properly serviced with
oil and coolant.
j Batteries are properly installed, serviced and
charged.
j Battery charger and engine coolant heater are
connected and operational.
j All generator set covers and safety shields are
installed properly.
j All fuel and coolant shutoff valves are opera-
tional.
j Created control capture file of the genset’s pa-
rameter values before and after modifications.
8-2
Page 43
9. Wiring Diagrams
NOTES:
1. TORQUE TERMINALS TO 4.4 IN/LBS (0.5 Nm).
2. WIRE SIZE, 30−12 AWG (0.14−2.5MM) (TB1).
3. WIRE TYPE, USE 60°C RATED MINIMUM. COPPER WIRE (TB1).
4. TERMINAL SCREWS ARE SLOTTED (0.6MM).
5. USE FLAT−BLADED SCREWDRIVER WITH 2.5MM BLADE.
6. STRIP WIRE LENGTH TO 6.0MM.
7. FAULT IN #2 USED FOR OPTIONAL RUPTURE BASIN INPUT.
CUSTOMER CONNECTION DIAGRAM
9-1
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9-2
Page 45
Cummins Power Generation
1400 73rd Ave. NE
Minneapolis, MN 55432 USA
Phone 1 763 574 5000
Toll-free 1 800 888 6626
Fax 1 763 574 5298
Email ask.powergen@cummins.com
www.cumminspower.com
CumminsR, the “C” logo, and “Our energy working for you.”
are trademarks of Cummins Inc.
E2008 Cummins Power Generation, Inc. All rights reserved.
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