CUMMINS GGHG, GGHH Installation Manual

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InstallationInstallation ManualManual

Generator Set

Ford V-10 6.8L Engine with PowerCommand®2100 Control

GGHG (Spec L-N) GGHH (Spec L-N)

English Original Instructions 7-2016 A034G612 (Issue 8)

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1. IMPORTANT SAFETY INSTRUCTIONS ....................................................................................... 1

1.1 Warning, Caution, and Note Styles Used in This Manual ..................................................... 1

1.2 General Information ................................................................................................................ 1

1.2.1 General Safety Precautions ......................................................................................... 2

1.3 Generator Set Safety Code .................................................................................................... 4

1.3.1 Moving Parts Can Cause Severe Personal Injury or Death ........................................ 4

1.3.2 Positioning of Generator Set....................................................................................... 5

1.3.3 Positioning of Generator Set - Open Sets ................................................................... 5

1.4 Electrical Shocks and Arc Flashes Can Cause Severe Personal Injury or Death.................. 5

1.4.1 AC Supply and Isolation............................................................................................... 6

1.4.2 Medium Voltage Equipment (601 V to 15 kV - North America) ................................... 6

1.5 Fuel and Fumes Are Flammable ............................................................................................ 7

1.5.1 Gaseous Fuels............................................................................................................. 7

1.5.2 Spillage ....................................................................................................................... 7

1.5.3 Fluid Containment....................................................................................................... 7

1.5.4 Do Not Operate in Flammable and Explosive Environments ...................................... 7

1.6 Exhaust Gases Are Deadly..................................................................................................... 8

1.6.1 Exhaust Precautions ................................................................................................... 8

1.7 Earth Ground Connection ....................................................................................................... 9

1.8 Decommissioning and Disassembly ....................................................................................... 9

2. INTRODUCTION.......................................................................................................................... 11

2.1 About This Manual................................................................................................................ 11

2.1.1 Additional Installation Manual Information ................................................................. 11

2.2 Schedule of Abbreviations .................................................................................................... 12

2.3 Related Literature ................................................................................................................. 13

2.3.1 Further Information - Literature .................................................................................. 14

2.4 After Sales Services.............................................................................................................. 14

2.4.1 Maintenance.............................................................................................................. 14

2.4.2 Warranty..................................................................................................................... 14

3. SYSTEM OVERVIEW .................................................................................................................. 15

3.1 Generator Set Identification .................................................................................................. 15

3.1.1 Nameplate.................................................................................................................. 15

3.2 Generator Set Components.................................................................................................. 15

3.3 Generator Set Rating ............................................................................................................ 16

3.4 Engine ................................................................................................................................... 17

3.5 Sensors ................................................................................................................................. 17

3.6 System Options..................................................................................................................... 18

3.6.1 Annunciators .............................................................................................................. 18

3.6.2 Battery Charger.......................................................................................................... 18

3.6.3 Heaters....................................................................................................................... 18

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Table of Contents 7-2016

3.6.4 Seismic Installation Requirements............................................................................. 21

4. INSTALLATION OVERVIEW ....................................................................................................... 23

4.1 Application and Installation ................................................................................................... 23

4.2 Safety Considerations........................................................................................................... 23

4.3 Standby Heating Devices...................................................................................................... 23

4.4 Product Modifications............................................................................................................ 24

4.5 Seismic Installations ............................................................................................................. 24

4.5.1 Seismic Installation Notes.......................................................................................... 24

5. SPECIFICATIONS ....................................................................................................................... 27

5.1 Generator Set Specifications ................................................................................................ 27

5.2 Engine Fuel Consumption..................................................................................................... 27

6. INSTALLING THE GENERATOR SET ........................................................................................ 29

6.1 Location ................................................................................................................................ 29

6.2 Mounting ............................................................................................................................... 30

6.3 Access to Set........................................................................................................................ 31

6.4 Vibration Isolator Installation and Adjustment Procedure ..................................................... 31

6.5 Rigging Instructions .............................................................................................................. 33

6.6 Moving the Generator Set..................................................................................................... 34

6.6.1 Positioning a Generator Set Using a Forklift Truck ................................................... 35

6.7 Transportation ....................................................................................................................... 36

7. MECHANICAL CONNECTIONS .................................................................................................. 37

7.1 Fuel System .......................................................................................................................... 37

7.1.1 Gaseous Fuel Supply................................................................................................. 37

7.1.2 Gaseous Fuel Quality ................................................................................................ 37

7.1.3 Site Fuel System Design............................................................................................ 41

7.1.4 Gaseous Fuel System Calculations ........................................................................... 43

7.2 Exhaust System .................................................................................................................... 55

7.3 Ventilation and Cooling......................................................................................................... 58

7.4 Vents and Ducts.................................................................................................................... 59

7.5 Dampers ............................................................................................................................... 59

7.6 Air Inlet and Outlet Openings................................................................................................ 60

8. DC CONTROL WIRING ............................................................................................................... 63

8.1 Guidelines for Customer Connections to the Control System .............................................. 63

8.2 Digital Connections ............................................................................................................... 64

8.3 Relay Connections................................................................................................................ 64

8.4 PCC 2100 TB1 Customer Connections ................................................................................ 64

8.4.1 Remote Start.............................................................................................................. 65

8.4.2 Remote Emergency Stop........................................................................................... 65

8.4.3 Remote Fault Reset ................................................................................................... 65

8.4.4 Configurable Inputs.................................................................................................... 65

8.4.5 Configurable Outputs ................................................................................................. 66

8.4.6 Contact Ratings for Configurable Outputs ................................................................. 66

8.4.7 Switched B+ ............................................................................................................... 66

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Table of Contents7-2016

8.5 Customer Relays .................................................................................................................. 67

8.5.1 Location of Customer Relays..................................................................................... 67

9. AC ELECTRICAL CONNECTIONS ............................................................................................. 69

9.1 Transfer Switch ..................................................................................................................... 70

9.2 Alternator Voltage Connections ............................................................................................ 71

9.3 Load Connections ................................................................................................................. 72

9.4 Load Balancing ..................................................................................................................... 72

9.5 Current Transformers............................................................................................................ 72

9.5.1 CT Installation Requirements..................................................................................... 72

9.6 Coolant Heater...................................................................................................................... 72

9.6.1 Coolant Heater Connection........................................................................................ 72

9.6.2 Coolant Heater Specifications.................................................................................... 73

9.7 Alternator Heaters................................................................................................................. 73

9.7.1 Alternator Heater Installation ..................................................................................... 73

9.7.2 Alternator Heater Specifications ................................................................................ 74

9.8 Battery Charger..................................................................................................................... 74

9.8.1 PowerCommand Battery Charger - 15 Amp @ 12 Volt and 12 Amp @ 24 Volt ....... 74

9.9 Control Box Heater ............................................................................................................... 75

9.9.1 Control Cabinet Heaters ............................................................................................ 75

9.10 Oil Heaters .......................................................................................................................... 76

9.10.1 Oil Pan Heaters........................................................................................................ 76

9.11 Annunciators....................................................................................................................... 78

9.11.1 PowerCommand Universal Annunciator .................................................................. 78

9.12 Grounding ........................................................................................................................... 79

10. PRE-START PREPARATION..................................................................................................... 83

10.1 Electrical System ................................................................................................................ 83

10.2 Site-specific Configuration .................................................................................................. 83

10.3 Starting................................................................................................................................ 83

11. INSTALLATION CHECKLIST ..................................................................................................... 85

11.1 Installation Checklist ........................................................................................................... 85

12. MANUFACTURING FACILITIES ................................................................................................ 89

12.1 How to Obtain Service ....................................................................................................... 89

12.1.1 Locating a Distributor ............................................................................................... 89

APPENDIX A. WIRING DIAGRAMS ................................................................................................. 91

A.1 GGHG/H Wiring Diagram with PowerCommand 2100 Control ............................................ 93

APPENDIX B. CUSTOMER CONNECTIONS .................................................................................. 97

B.1 GGHG/H Customer Connections with PowerCommand 2100 Control ................................ 99

APPENDIX C. OUTLINE DRAWINGS ............................................................................................ 101

C.1 GGHG/GGHH Outline Drawing with PowerCommand 2100 Control ................................. 103

APPENDIX D. ALTERNATOR RECONNECT DRAWING.............................................................. 107

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Table of Contents 7-2016

D.1 GGHG/GGHH Alternator Reconnect Drawing ................................................................... 109

APPENDIX E. SEISMIC REQUIREMENTS.................................................................................... 111

E.1 Seismic Installation Instructions ......................................................................................... 113

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1 Important Safety Instructions

Save these instructions. This manual contains important instructions that should be followed during installation and maintenance of the generator set.

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.

1.1 Warning, Caution, and Note Styles Used in This Manual

The following safety styles and symbols found throughout this manual indicate potentially hazardous conditions to the operator, service personnel, or equipment.

DANGER

Indicates a hazardous situation that, if not avoided, will result in death or serious injury.

WARNING

Indicates a hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION

Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

Indicates information considered important, but not hazard-related (e.g., messages relating to property damage).

1.2 General Information

This manual should form part of the documentation package supplied by Cummins Power Generation with specific generator sets. In the event that this manual has been supplied in isolation please contact your authorized distributor.

It is in the operator’s interest to read and understand all warnings and cautions contained within the documentation relevant to the generator set, its operation and daily maintenance.

NOTICE

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1. Important Safety Instructions 7-2016

1.2.1 General Safety Precautions

WARNING

Hot Pressurized Liquid Contact with hot liquid can cause severe burns. Do not open the pressure cap while the engine is running. Let the engine cool down before

removing the cap. Turn the cap slowly and do not open it fully until the pressure has been relieved.

WARNING

Moving Parts Moving parts can cause severe personal injury. Use extreme caution around moving parts. All guards must be properly fastened to prevent

unintended contact.

WARNING

Toxic Hazard Used engine oils have been identified by some state and federal agencies to cause cancer or

reproductive toxicity. Do not ingest, breathe the fumes, or contact used oil when checking or changing engine oil.

Wear protective gloves and face guard.

WARNING

Electrical Generating Equipment Incorrect operation can cause severe personal injury or death. Do not operate equipment when fatigued, or after consuming any alcohol or drug.

WARNING

Toxic Gases Substances in exhaust gases have been identified by some state and federal agencies to cause

cancer or reproductive toxicity. Do not breathe in or come into contact with exhaust gases.

WARNING

Combustible Liquid Ignition of combustible liquids is a fire or explosion hazard which can cause severe burns or

death. Do not store fuel, cleaners, oil, etc., near the generator set.

WARNING

High Noise Level Generator sets in operation emit noise, which can cause hearing damage. Wear appropriate ear protection at all times.

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1. Important Safety Instructions7-2016

WARNING

Hot Surfaces Contact with hot surfaces can cause severe burns. Wear appropriate PPE when working on hot equipment and avoid contact with hot surfaces.

WARNING

Electrical Generating Equipment Incorrect operation and maintenance can result in severe personal injury or death Make sure that only suitably trained and experienced service personnel perform electrical and/or

mechanical service.

WARNING

Toxic Hazard Ethylene glycol, used as an engine coolant, is toxic to humans and animals. Wear appropriate PPE. Clean up coolant spills and dispose of used coolant in accordance with

local environmental regulations.

WARNING

Combustible Liquid Ignition of combustible liquids is a fire or explosion hazard which can cause severe burns or

death. Do not use combustible liquids like ether.

WARNING

Automated Machinery Accidental or remote starting of the generator set can cause severe personal injury or death. Isolate all auxiliary supplies and use an insulated wrench to disconnect the starting battery

cables (negative [–] first).

WARNING

Fire Hazard Materials drawn into the generator set are a fire hazard. Fire can cause severe burns or death. Make sure the generator set is mounted in a manner to prevent combustible materials from

accumulating under the unit.

WARNING

Fire Hazard Accumulated grease and oil are a fire hazard. Fire can cause severe burns or death. Keep the generator set and the surrounding area clean and free from obstructions. Repair oil

leaks promptly.

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1. Important Safety Instructions 7-2016

WARNING

Fire Hazard Materials drawn into the generator set are a fire hazard. Fire can cause severe burns or death. Keep the generator set and the surrounding area clean and free from obstructions.

NOTICE

Keep multi-class ABC fire extinguishers handy. Class A fires involve ordinary combustible materials such as wood and cloth. Class B fires involve combustible and flammable liquid fuels and gaseous fuels. Class C fires involve live electrical equipment. (Refer to NFPA No. 10 in applicable region.)

NOTICE

Before performing maintenance and service procedures on enclosed generator sets, make sure the service access doors are secured open.

NOTICE

Stepping on the generator set can cause parts to bend or break, leading to electrical shorts, or to fuel, coolant, or exhaust leaks. Do not step on the generator set when entering or leaving the generator set room.

1.3 Generator Set Safety Code

Before operating the generator set, read the manuals and become familiar with them 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.

WARNING

Electrical Generating Equipment Incorrect operation and maintenance can result in severe personal injury or death. Read and follow all Safety Precautions, Warnings, and Cautions throughout this manual and the

documentation supplied with the generator set.

1.3.1 Moving Parts Can Cause Severe Personal Injury or Death

• Keep hands, clothing, and jewelry away from moving parts.

• Before starting work on the generator set, disconnect the battery charger from its AC source, then

disconnect the starting batteries using an insulated wrench, negative (–) cable first. This will prevent accidental starting.

• Make sure that fasteners on the generator set are secure. Tighten supports and clamps; keep guards in position over fans, drive belts, etc.

• Do not wear loose clothing or jewelry in the vicinity of moving parts or while working on electrical equipment. Loose clothing and jewelry can become caught in moving parts.

• If any adjustments must be made while the unit is running, use extreme caution around hot manifolds, moving parts, etc.

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1.3.2 Positioning of Generator Set

The generator set should be placed on level ground with adequate open space around it. The immediate area around the generator set should be free of any flammable material.

NOTICE

Access or service doors must be closed and locked before repositioning, and they must remain locked during transportation and siting.

NOTICE

The generator set is capable of operating at inclines of up to +/– 10 degrees, however, for optimal performance and reliability, any incline should be +/– 5 degrees.

1.3.3 Positioning of Generator Set - Open Sets

The area for positioning the set should be adequate and level, and the area immediately around the set must be free of any flammable material.

1. Important Safety Instructions7-2016

1.4 Electrical Shocks and Arc Flashes Can Cause Severe Personal Injury or Death

WARNING

Electric Shock Hazard Voltages and currents present an electrical shock hazard that can cause severe burns or death. Contact with exposed energized circuits with potentials of 50 Volts AC or 75 Volts DC or higher

can cause electrical shock and electrical arc flash. Refer to standard NFPA 70E or equivalent safety standards in corresponding regions for details of the dangers involved and for the safety requirements.

Guidelines to follow when working on de-energized electrical systems:

• Use proper PPE. Do not wear jewelry and make sure that any conductive items are removed from pockets as these items can fall into equipment and the resulting short circuit can cause shock or burning. Refer to standard NFPA 70E for PPE standards.

• De-energize and lockout/tagout electrical systems prior to working on them. Lockout/Tagout is intended to prevent injury due to unexpected start-up of equipment or the release of stored energy. Please refer to the lockout/tagout section for more information.

• De-energize and lockout/tagout all circuits and devices before removing any protective shields or making any measurements on electrical equipment.

• Follow all applicable regional electrical and safety codes.

Guidelines to follow when working on energized electrical systems:

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1. Important Safety Instructions 7-2016

NOTICE

It is the policy of Cummins Inc. to perform all electrical work in a de-energized state. However, employees or suppliers may be permitted to occasionally perform work on energized electrical equipment only when qualified and authorized to do so and when troubleshooting, or if deenergizing the equipment would create a greater risk or make the task impossible and all other alternatives have been exhausted.

NOTICE

Exposed energized electrical work is only allowed as per the relevant procedures and must be undertaken by a Cummins authorized person with any appropriate energized work permit for the work to be performed while using proper PPE, tools and equipment.

In summary:

• Do not tamper with or bypass interlocks unless you are authorized to do so.

• Understand and assess the risks - use proper PPE. Do not wear jewelry and make sure that any conductive items are removed from pockets as these items can fall into equipment and the resulting short circuit can cause shock or burning. Refer to standard NFPA 70E for PPE standards.

• Make sure that an accompanying person who can undertake a rescue is nearby.

1.4.1 AC Supply and Isolation

NOTICE

Local electrical codes and regulations (for example, BS EN 12601:2010 Reciprocating internal combustion engine driven generating sets) may require the installation of a disconnect means

for the generator set, either on the generator set or where the generator set conductors enter a facility.

NOTICE

The AC supply must have the correct over current and earth fault protection according to local electrical codes and regulations. This equipment must be earthed (grounded).

It is the sole responsibility of the customer to provide AC power conductors for connection to load devices and the means to isolate the AC input to the terminal box; these must comply with local electrical codes and regulations. Refer to the wiring diagram supplied with the generator set.

The disconnecting device is not provided as part of the generator set, and Cummins Power Generation accepts no responsibility for providing the means of isolation.

1.4.2 Medium Voltage Equipment (601 V to 15 kV - North America)

• 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 experienced to work on such devices. Improper use or procedures will result in severe personal injury or death.

• Do not work on energized equipment. Unauthorized personnel must not be permitted near energized equipment. Due to the nature of medium voltage electrical equipment, induced voltage remains even after the equipment is disconnected from the power source. Plan the time for maintenance with authorized personnel so that the equipment can be de-energized and safely grounded.

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1.5 Fuel and Fumes Are Flammable

Fire, explosion, and personal injury or death can result from improper practices.

• Do not fill fuel tanks while the engine is running unless the 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 copper piping on flexible lines as copper will become brittle if continuously vibrated or repeatedly bent.

• Make sure all fuel supplies have a positive shutoff valve.

• Make sure the 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.

1.5.1 Gaseous Fuels

Natural gas is lighter than air, and will tend to gather under covered areas. Propane is heavier than air, and will tend to gather in sumps or low areas. NFPA code requires all persons handling propane to be trained and qualified.

1. Important Safety Instructions7-2016

1.5.2 Spillage

Any spillage that occurs during fueling or during oil top-off or oil change must be cleaned up before starting the generator set.

1.5.3 Fluid Containment

NOTICE

Where spillage containment is not part of a Cummins supply, it is the responsibility of the installer to provide the necessary containment to prevent contamination of the environment, especially water courses and sources.

If fluid containment is incorporated into the bedframe, it must be inspected at regular intervals. Any liquid present should be drained out and disposed of in line with local health and safety regulations. Failure to perform this action may result in spillage of liquids which could contaminate the surrounding area.

Any other fluid containment area must also be checked and emptied, as described above.

1.5.4 Do Not Operate in Flammable and Explosive Environments

Flammable vapor can cause an engine to over speed and become difficult to stop, resulting in possible fire, explosion, severe personal injury, and death. Do not operate a generator set where a flammable vapor environment can be created, unless the generator set is equipped with an automatic safety device to block the air intake and stop the engine. The owners and operators of the generator set are solely responsible for operating the generator set safely. Contact your authorized Cummins Power Generation distributor for more information.

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1. Important Safety Instructions 7-2016

1.6 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 system 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.

• Make sure the unit is well ventilated.

1.6.1 Exhaust Precautions

WARNING

Hot Exhaust Gases Contact with hot exhaust gases can cause severe burns. Wear personal protective equipment when working on equipment.

WARNING

Hot Surfaces Contact with hot surfaces can cause severe burns. Wear appropriate PPE when working on hot equipment and avoid contact with hot surfaces.

WARNING

Toxic Gases Inhalation of exhaust gases can cause asphyxiation and death. Pipe exhaust gas outside and away from windows, doors, or other inlets to buildings. Do not

allow exhaust gas to accumulate in habitable areas.

WARNING

Fire Hazard Contaminated insulation is a fire hazard. Fire can cause severe burns or death. Remove any contaminated insulation and dispose of it in accordance with local regulations.

The exhaust outlet may be sited at the top or bottom of the generator set. Make sure that the exhaust outlet is not obstructed. Personnel using this equipment must be made aware of the exhaust position. Position the exhaust away from flammable materials - in the case of exhaust outlets at the bottom, make sure that vegetation is removed from the vicinity of the exhaust.

The exhaust pipes may have some insulating covers fitted. If these covers become contaminated they must be replaced before the generator set is run.

To minimize the risk of fire, make sure the following steps are observed:

• Make sure that the engine is allowed to cool thoroughly before performing maintenance or operation tasks.

• Clean the exhaust pipe thoroughly.

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1.7 Earth Ground Connection

The neutral of the generator set may be required to be bonded to earth ground at the generator set location, or at a remote location, depending on system design requirements. Consult the engineering drawings for the facility or a qualified electrical design engineer for proper installation.

NOTICE

The end user is responsible to make sure that the ground connection point surface area is clean and free of rust before making a connection.

NOTICE

The end user is responsible for making sure that an earthing arrangement that is compliant with local conditions is established and tested before the equipment is used.

1.8 Decommissioning and Disassembly

NOTICE

1. Important Safety Instructions7-2016

Decommissioning and disassembly of the generator set at the end of its working life must comply with local guidelines and legislation for disposal/recycling of components and contaminated fluids. This procedure must only be carried out by suitably trained and experienced service personnel. For more information contact your authorized distributor.

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1. Important Safety Instructions 7-2016

This page is intentionally blank.

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2 Introduction

Hazardous Voltage Contact with high voltages can cause severe electrical shock, burns, or death. Make sure that only a trained and experienced electrician makes generator set electrical output

connections, in accordance with the installation instructions and all applicable codes.

Electrical Generating Equipment Faulty electrical generating equipment can cause severe personal injury or death. Generator sets must be installed, certified, and operated by trained and experienced person in

accordance with the installation instructions and all applicable codes.

2.1 About This Manual

The purpose of this manual is to provide the users with sound, general information. It is for guidance and assistance with recommendations for correct and safe procedures. Cummins Power Generation (CPG) cannot accept any liability whatsoever for problems arising as a result of following recommendations in this manual.

WARNING

The information contained within the manual is based on information available at the time of going to print. In line with Cummins Power Generation policy of continuous development and improvement, information may change at any time without notice. The users should therefore make sure that before commencing any work, they have the latest information available. The latest version of this manual is available on QuickServe Online (https://quickserve.cummins.com).

Users are respectfully advised that, in the interests of good practice and safety, it is their responsibility to employ competent persons to carry out any installation work. Consult your authorized distributor for further installation information. It is essential that the utmost care is taken with the application, installation, and operation of any engine due to their potentially hazardous nature. Careful reference should also be made to other Cummins Power Generation literature. A generator set must be operated and maintained properly for safe and reliable operation.

For further assistance, contact your authorized distributor.

2.1.1 Additional Installation Manual Information

The purpose of this manual is to provide the Installation Engineer with sound, general information for the installation of the generator set. Refer to the Generator Set Operator Manual for additional information which must also be read before operating the set.

This manual provides installation instructions for the generator set models listed on the front cover. This includes the following information:

• Mounting Recommendations - for fastening the generator set to a base and space requirements for normal operation and service.

• Mechanical and Electrical Connections - covers most aspects of the generator set installation.

• Prestart - checklist of items or procedures needed to prepare the generator set for operation.

• Installation Checklist - reference checks upon completion of the installation.

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2. Introduction 7-2016

This manual DOES NOT provide application information for selecting a generator set or designing the complete installation. If it is necessary to design the various integrated systems (fuel, exhaust, cooling, etc.), additional information is required. Review standard installation practices. For engineering data specific to the generator set, refer to the Specification and Data Sheets. For application information, refer to Application Manual T-030, "Liquid Cooled Generator Sets." To find this manual online:

1. Go to www.powersuite.cummins.com

2. Click on "Application & Technical Manuals" on the Home page.

3. Click on "Liquid Cooled Genset Application Manual"

2.2 Schedule of Abbreviations

This list is not exhaustive. For example, it does not identify units of measure or acronyms that appear only in parameters, event/fault names, or part/accessory names.

AmpSentry, INSITE, and InPower are trademarks of Cummins Inc. PowerCommand is a registered trademark of Cummins Inc.

ABBR. DESCRIPTION ABBR. DESCRIPTION

AC Alternating Current LED Light-emitting Diode

AMP AMP, Inc., part of Tyco Electronics LTS Long Term Storage

ANSI American National Standards

Institute

ASOV Automatic Shut Off Valve MFM Multifunction Monitor

ASTM American Society for Testing and

Materials (ASTM International)

ATS Automatic Transfer Switch MLD Masterless Load Demand

AVR Automatic Voltage Regulator NC Normally Closed

AWG American Wire Gauge NC Not Connected

CAN Controlled Area Network NFPA National Fire Protection Agency

CB Circuit Breaker NO Normally Open

CE Conformité Européenne NWF Network Failure

CFM Cubic Feet per Minute OEM Original Equipment Manufacturer

CGT Cummins Generator Technologies OOR Out of Range

CMM Cubic Meters per Minute OORH / ORH Out of Range High

CT Current Transformer OORL / ORL Out of Range Low

D-AVR Digital Automatic Voltage

Regulator

LVRT Low Voltage Ride Through

Mil Std Military Standard

PB Push Button

DC Direct Current PCC PowerCommand®Control

DEF Diesel Exhaust Fluid PGI Power Generation Interface

DPF Diesel Particulate Filter PGN Parameter Group Number

ECM Engine Control Module PI Proportional/Integral

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2. Introduction7-2016

ABBR. DESCRIPTION ABBR. DESCRIPTION

ECS Engine Control System PID Proportional/Integral/Derivative

EMI Electromagnetic interference PLC Programmable Logic Controller

EN European Standard PMG Permanent Magnet Generator

EPS Engine Protection System PPE Personal Protective Equipment

E-Stop Emergency Stop PT Potential Transformer

FAE Full Authority Electronic PTC Power Transfer Control

FMI Failure Mode Identifier PWM Pulse-width Modulation

FRT Fault Ride Through RFI Radio Frequency Interference

FSO Fuel Shutoff RH Relative Humidity

Genset Generator Set RMS Root Mean Square

GCP Generator Control Panel RTU Remote Terminal Unit

GND Ground SAE Society of Automotive Engineers

LCT Low Coolant Temperature SCR Selective Catalytic Reduction

HMI Human-machine Interface SPN Suspect Parameter Number

IC Integrated Circuit SWL Safe Working Load

ISO International Organization for

Standardization

LBNG Lean-burn Natural Gas UL Underwriters Laboratories

LCD Liquid Crystal Display UPS Uninterruptible Power Supply

2.3 Related Literature

Before any attempt is made to operate the generator set, the operator should take time to read all of the manuals supplied with the generator set, and to familiarize themselves with the warnings and operating procedures.

A generator set must be operated and maintained properly if you are to expect safe and reliable operation. The Operator manual includes a maintenance schedule and a troubleshooting guide

The relevant manuals appropriate to your generator set are also available:

• Operator Manual for GGHG/GGHH (A034G614)

SW_B+ Switched B+

CAUTION

• Installation Manual for GGHG/GGHH (A034G612)

• Specification and Data Sheet (For engineering data specific to the generator set)

• Application Manual T-030, Liquid Cooled Generator Sets (For application information)

• Parts Manual for GGHG/GGHH (0928-0245)

• Recommended Spares List (RSL) for GGHG/GGHH (RSL_458)

• Warranty Manual (F1117-0002)

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2. Introduction 7-2016

• Global Commercial Warranty Statement (A028U870)

• Ford V10 Wiring Diagram (WH-0000-15)

2.3.1 Further Information - Literature

Contact your authorized distributor for more information regarding related literature for this product.

2.4 After Sales Services

Cummins Power Generation offers a full range of maintenance and warranty services.

2.4.1 Maintenance

WARNING

mechanical service.

For expert generator set service at regular intervals, contact your local distributor. Each local distributor offers a complete maintenance contract package covering all items subject to routine maintenance, including a detailed report on the condition of the generator set. In addition, this can be linked to a 24-hour call-out arrangement, providing year-round assistance if necessary. Specialist engineers are available to maintain optimum performance levels from generator sets. Maintenance tasks should only be undertaken by trained and experienced technicians provided by your authorized distributor.

2.4.2 Warranty

For details of the warranty coverage for your generator set, refer to the Global Warranty Statement listed in the Related Literature section.

In the event of a breakdown, prompt assistance can normally be given by factory trained service technicians with facilities to undertake all minor and many major repairs to equipment on site.

Extended warranty coverage is also available.

For further warranty details, contact your authorized service provider.

Damage caused by failure to follow the manufacturer's recommendations will not be covered by the warranty. Please contact your authorized service provider.

2.4.2.1 Warranty Limitations

NOTICE

For details of the warranty limitations for your generator set, refer to the warranty statement applicable to the generator set.

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3 System Overview

This section provides an overview of the generator set.

3.1 Generator Set Identification

Each generator set is provided with a nameplate similar to that shown below. The nameplate provides information unique to the generator set.

3.1.1 Nameplate

FIGURE 1. TYPICAL GENERATOR SET NAMEPLATE

3.2 Generator Set Components

The main components of a typical Ford V-10 6.8L engine generator set are shown below, and referred to within this section.

There are various options are listed although they may not be available for all models.

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3. System Overview 7-2016

1 Radiator (Not indicated)

2 Engine Battery and Tray

3 Controller Alarm Module

4 Battery Battery Charger

5 Alternator Engine Coolant Heater

6 Bed Frame Alternator Heater

FIGURE 2. TYPICAL FORD V-10 6.8L ENGINE GENERATOR SET

3.3 Generator Set Rating

For details of the generator set rating, refer to the generator set nameplate. For operation at temperatures or altitudes above those stated on the nameplate, a derate may be necessary.

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3.4 Engine

For additional engine specific information, refer to the relevant engine manual for your generator set.

3. System Overview7-2016

1 Oil filler cap

2 Fan belt

3 Dipstick

FIGURE 3. TYPICAL ENGINE COMPONENTS (FORD V-10 6.8L)

3.5 Sensors

Various generator set parameters are measured by sensors, and the resulting signals are processed by the control board.

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3. System Overview 7-2016

Engine-mounted sensors monitor a number of different systems, such as:

• Lube Oil Pressure

• Cooling System Temperature

3.6 System Options

The system options available with this installation include:

• Annunciator - see Section 9.11.1 on page 78.

• Battery Charger - see Section 3.6.2.

• Heaters:

◦ Alternator Heater - see Section 9.7.2 on page 74.

◦ Control Cabinet Heater - see Section 3.6.3.3 on page 18.

◦ Oil Pan Heaters - see Section 9.10.

3.6.1 Annunciators

The annunciator's lamps and alarm indicate the operating status and fault conditions of an emergency power system. For more information, see Section 9.11 on page 78.

3.6.2 Battery Charger

Battery chargers can be wall, bench, or skid mounted. For more information, see Section 9.8 on page 74.

3.6.3 Heaters

3.6.3.1 Heater Supply and Isolation

An external power supply is required for the operation of the generator set heaters.

If not already provided, it is the sole responsibility of the customer to provide the power supply and the means to isolate the AC input to the terminal box. Cummins Power Generation accepts no responsibility for providing the means of isolation.

3.6.3.2 Coolant Heater

Coolant heaters heat the coolant to maintain a minimum engine temperature when the generator set is not running. For more information on coolant heater components and specifications, see Section 9.6 on page

72.

3.6.3.3 Control Cabinet Heaters

A thermostat heater is installed inside the control cabinet. Both 120V and 240V heaters are available.

NOTICE

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3. System Overview7-2016

No. Description No Description

1 Heater Assembly 3 Cable Assembly

2 Cable Assembly 4 Strain Relief

FIGURE 4. TYPICAL CONTROL CABINET HEATER

3.6.3.4 Oil Pan Heaters

Three 300W oil pan heaters are available.

• 120V single phase

• 208/240V single phase

• 480V single phase

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3. System Overview 7-2016

NOTICE

For 120V applications, the optional location is shown. The primary location is on the left hand side of the oil pan.

FIGURE 5. OIL PAN HEATER USED IN 120V AND 208/240V APPLICATIONS

FIGURE 6. OIL PAN HEATER USED IN 480V APPLICATIONS

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3.6.4 Seismic Installation Requirements

Seismically certified generator set installations have special requirements, as defined by IAA-VMC (Independent Approval Agency, the VMC Group).

For special installation requirements, refer to the tabulated and written seismic requirements listed in

Section 4.5.1 and Appendix E on page 111. The installation of the seismically certified generator set

should be overseen by the installation project structural engineer of record.

The "Seismic Certificate of Compliance" should be kept with the Warranty and other generator set documents.

The seismic requirements installation drawing and the Seismic Certificate of Compliance for generator sets are included in the literature package of each seismically certified generator set.

3. System Overview7-2016

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4 Installation Overview

These installation recommendations apply to typical installations with standard model generator sets. Whenever possible, these recommendations also cover factory designed options or modifications. However, because of the many variables in any installation, it is not possible to provide specific recommendations for every situation. If there are any questions not answered by this manual, contact your nearest authorized distributor for assistance.

4.1 Application and Installation

A power system must be carefully planned and correctly installed for proper operation. This involves two essential elements.

• 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, cooling, exhaust, and fuel systems. Each component must be correctly designed so the complete system will function as intended. Application and design is an engineering function generally done by specifying engineers or other trained specialists. Specifying engineers or other trained specialists are responsible for the design of the complete 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 system normally requires the special skills of qualified electricians, plumbers, sheet-metal workers, etc. to complete the various segments of the installation. This is necessary so that all components are assembled using standard methods and practices.

4.2 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.

4.3 Standby Heating Devices

Cummins Power Generation requires installing standby generator sets (life safety systems) with engine jacket water coolant heaters in order to ensure a 10 second start. Jacket water coolant heaters are also recommended in prime and continuous applications where time and load acceptance is to be minimized.

The jacket water coolant heater provided by Cummins Power Generation is rated to provide the above requirements in ambient temperatures as low as 4 °C (40 °F). Although most Cummins Power Generation generator sets will start in temperatures down to –32 °C (–25 °F) 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 4 °C (40 °F).

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4. Installation Overview 7-2016

On generator sets equipped with a graphic display, the Low Coolant Temperature message, in conjunction with illumination of the Warning LED, is provided to meet the current requirements. The engine cold sensing logic initiates a warning when the engine jacket water coolant temperature falls below 21 °C (70 °F). In applications where the ambient temperature falls below 4 °C (40 °F), or there exists a high amount of cold airflow, the jacket water coolant heater may not provide the necessary heating. 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.

4.4 Product Modifications

Agency certified products purchased from Cummins Power Generation comply only with those specific requirements 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 modifications must be submitted to the local authority having jurisdiction for approval.

4.5 Seismic Installations

Seismically certified generator set installations have special requirements, as defined by IAA-VMC (Independent Approval Agency, the VMC Group).

For special installation requirements, refer to the tabulated and written seismic requirements listed in

Appendix E on page 111.

The installation of the seismically certified generator set should be overseen by the installation project structural engineer of record.

The "Seismic Certificate of Compliance" should be kept with the Warranty and other generator set documents.

The seismic requirements installation drawing and the Seismic Certificate of Compliance for generator sets are included in the literature package of each seismically certified generator set.

4.5.1 Seismic Installation Notes

1. The design of post-installed anchors in concrete used for the component anchorage is pre-qualified for seismic applications in accordance with "ACI 355.2" and documented in a report by a reputable testing agency. (ex. the evaluation service report issued by the International Code Council)

2. Anchors must be installed to an embedment depth as recommended in the pre-qualification test report as defined in Note 1. For "IBC 2000" and "IBC 2003" applications, the minimum embedment must be 8X for the anchor diameter.

3. Anchors must be installed in minimum 4000 PSI compressive strength normal weight concrete. Concrete aggregate must comply with "ASTM C33". Installation in structural lightweight concrete is not permitted unless otherwise approved by the structural engineer of record.

4. Anchors must be installed to the torque specification as recommended by the anchor manufacturer to obtain maximum loading.

5. Anchors must be installed in locations specified in this section.

6. Wide washers must be installed at each anchor location between the anchor head and equipment for tension load distribution. Wide washers must be Series "W" of American National Standard Type "A" plain washers (ANSI B18.22.1-1965, R1975) with the nominal washer size selected to match the specified nominal anchor diameter.

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4. Installation Overview7-2016

7. Concrete floor slab and concrete housekeeping pads must be designed and rebar reinforced for seismic applications in accordance with "ACI 318". The design loads shall be taken as those specified in this section.

8. All housekeeping pad thicknesses must be designed in accordance with the pre-qualification test report as defined in Note 1 or a minimum of 1.5X the anchor embedment depth, whichever is largest.

9. All housekeeping pads must be dowelled or cast into the building structural floor slab and designed for seismic application per "ACI 318" and as approved by the structural engineer of record.

10. Wall mounted equipment must be installed to a rebar reinforced structural concrete wall that is seismically designed and approved by the engineer of record to resist the added seismic loads from components being anchored to the wall.

11. Floor mounted equipment (with or without a housekeeping pad) must be installed to a rebar reinforced structural concrete floor that is seismically designed and approved by the engineer of record to resist the added seismic loads from components being anchored to the floor.

12. When installing to a floor or wall, rebar interference must be considered.

13. Attaching seismic certified equipment to any floor or wall other than those constructed of structural concrete and designed to accept the seismic loads from said equipment is not permitted by this specification and beyond the scope of this certification.

14. Attaching seismic certified equipment to any floor constructed of light weight concrete over steel decking is not permitted by this specification and beyond the scope of this certification.

15. Attaching the seismic certified equipment to any concrete block walls or cinder block walls is not permitted by this specification and beyond the scope of this certification.

16. Installation upon a rooftop steel dunnage shall be coordinated with the structural engineer of record.

17. Installation upon any rooftop curb shall be coordinated with the curb manufacturer and the structural engineer of record. Any curb or concrete pad that supports the generator set unit is beyond the scope of this certification.

18. Connections to the equipment, including but not limited to conduit, wiring from cable trays, other electrical services, ducting, piping such as exhaust, steam, water, coolant, refrigerant, fuel, or other connections, are the responsibility of the installing contractor and beyond the scope of this document. Typical requirements for these connections are stated in the equipment installation manual. Special considerations for seismic applications are as follows; connections to non-isolated components or equipment may be installed as typical for that particular application. Connections to isolated components (ex. breaker box bolted directly to an isolated generator set) or isolated equipment (ex. an enclosed generator set mounted on external isolators) must be flexibly attached. The flexible attachment must provide for enough relative displacement to remain connected to the equipment and functional during and after a seismic event.

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5 Specifications

5.1 Generator Set Specifications

TABLE 1. GGHG AND GGHH SPECIFICATIONS

MODELS GGHG, GGHH

Engine Ford V-10 6.8L

Generator kW Rating See generator set nameplate for rating information.

Engine Fuel Connection

Inlet/Outlet Thread Size Refer to generator get outline drawing supplied (0500-4087)

Fuel Flow (Inlet Pressure)

Minimum Operating Pressure Maximum Operating Pressure

Exhaust

Outlet Size Max. Allowable Back Pressure Exhaust Flow at Rated Load Exhaust Temperature

1500 RPM

2 in. (50 mm) Hg

15273 cfm (7208L/s at SBY)

x °C (800 °F)

7.0 in. water column (13.07 mmHg)

13.6 in. water column (25.4 mmHg)

12 in. NB

1800 RPM

12 in. NB

2 in. (50 mm) Hg

15273 cfm (7208L/s at SBY)

x °C (800 °F)

Electrical System

Starting Voltage Battery Group Number CCA (minimum) Cold Soak @ 0 °F (-18 °C)

Cooling System

Capacity with Standard Radiator

Lubricating System

Oil Capacity with Filters 5.5 liters (1.5 US gal)

For 50 °C radiator; x l HT; x l LT; G9 HT x l HT; x l LT For 40 °C radiator; x l HT; x l LT; G9 HT x l HT; x l LT

12 Volts DC

37 A at -18 °C to 0 °C

5.2 Engine Fuel Consumption

TABLE 2. FULL LOAD FUEL CONSUMPTION (M3/HR) AT 1800 RPM (60 HZ)

Model GGHG GGHG GGHH GGHH

Engine NG LPG NG LPG

Engine Performance Data at 60Hz

1. Standby/Full Load Refer to Data Sheets for other applications. In line with the CPG policy of continuous improvement, these

figures are subject to change.

26.8 11.5 33.3 13.2

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5. Specifications 7-2016

TABLE 3. FULL LOAD FUEL CONSUMPTION (FT3/ HR)

Model GGHG GGHH

Standby

LPG (Vapor or Liquid) (scfh) 407 467

Natural Gas (scfh) 945 1090

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6 Installing the Generator Set

Generator set installations must be engineered so that the generator set will function properly under the expected load conditions. Use these instructions as a general guide only. Follow the instructions of the consulting engineer when locating or installing any components. The complete installation must comply with all local and state building codes, fire regulations, and other applicable regulations.

Requirements to be considered prior to installation are:

• 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

NOTICE

Depending on the location and intended use, ensure that international, national or local laws and regulations regarding Air Quality Emissions have been observed and complied with. Be sure to consult local pollution control or air quality authorities before completing construction plans.

6.1 Location

mechanical service.

Incorrect installation Incorrect installation of the generator set, 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.

WARNING

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6. Installing the Generator Set 7-2016

NOTICE

Depending on your location and intended use, additional laws and regulations may require for you to obtain an air quality emissions permit before beginning installation of your generator set. Be sure to consult local pollution control or air quality authorities before completing your construction plans.

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 gases 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.

Use the following information to locate the generator set for optimal operating conditions:

Surface: Concrete or compacted gravel with the generator set resting on solid, poured concrete blocks, or timber blocks spaced at reasonable intervals around the perimeter of the generator set.

Leveling: Level the generator set from side-to-side within + 3.5°, and end-to-end within +2.5°.

Placement:

• Generator sets should be a minimum of 5 m (16.4 ft) apart to allow for adequate access.

• Make sure that the air inlets are not obstructed by surrounding trees, buildings, or other obstructions.

• Make sure noise distribution (to prevent echoing) is kept to a minimum.

• Consider exhaust for immediate neighbors.

• The prevailing wind direction should be considered so that the engine combustion air inlet is upwind and the exhaust discharge is downwind.

• The immediate area around the proposed location of the mounting surface should be evaluated for proper drainage so that moisture run-off is sufficient to prevent ponding around the unit(s).

6.2 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 generator set 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 16 mm (5/8inch) or anchored mounting bolts to secure the generator set bedframe to the base. Use a flat washer and hexagonal nut for each bolt (see Figure 7). The 38 mm x 152 mm (11/2x 6 inch) pipe inserted over the mounting bolts allows minor adjustment of the bolts to align them to the holes in the bedframe.

NOTICE

The fixing centers for the mounting bolts can be found on the generator set Outline Drawing.

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6. Installing the Generator Set7-2016

No. Description No. Description

1 Generator Bedframe Flange 5 38 mm x 152 mm Pipe (1½ inch x 6 inch)

2 Hexagonal Nut 6 Mounting Bolt Set in Concrete

3 Flat or Bevel Washer 7 305 mm (12 inch)

4 Mounting Base on Concrete

FIGURE 7. BOLT DIAGRAM

6.3 Access to Set

Generally, at least 1 meter (3.3 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 152 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.

6.4 Vibration Isolator Installation and Adjustment Procedure

1. Place the vibration isolators (see Figure 8) on the generator set support structure. The isolators

should be shimmed or grouted to make sure 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.

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6. Installing the Generator Set 7-2016

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 generator set 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 generator set is in position, the isolators may require adjusting so that the set is level. The isolators are adjusted by inserting the leveling bolt through the skid and into the isolator (the leveling bolt's locking nut should be threaded up towards the bolt head).

The leveling bolt will adjust the clearance between the top plate and the isolator base. A nominal clearance of 0.25 inch (6 mm) or greater is desired. This will provide sufficient clearance for the rocking that occurs during startup and shutdown. If the 0.25 inch (6 mm) clearance is not present, turn the leveling bolt until the desired clearance is achieved.

5. If the radiator and engine are mounted on separate skids, make sure the radiator skid and engine/alternator skid are level with each other after adjusting the isolators. If not level, proper fan belt alignment cannot be achieved.

6. If the generator set is not yet level, adjust the leveling bolts until the set is level and sufficient clearance still remains. (Clearance on all isolators should be roughly equal).

7. Once all isolators have been set, lock the leveling bolt in place with the lock nut.

8. The snubber nuts must remain loose to provide better isolation between the generator set and the support structure.

No. Description No. Description

1 Skid 4 Lock Nut

2 Snubber 5 Clearance

3 Leveling Bolt 6 Base

FIGURE 8. VIBRATION ISOLATOR INSTALLATION

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6.5 Rigging Instructions

Heavy Load Incorrect lifting or repositioning can cause severe personal injury or death. Do not lift the generator set by attaching to the engine or alternator lifting points. Do not stand

under or near the generator set when lifting.

Heavy Load Incorrect lifting or repositioning can cause severe personal injury or death. Make sure that only suitably trained and experienced personnel transport and handle generator

sets and associated components.

1. Consult the generator set outline drawing for weight and center-of-gravity information.

2. Attach cables from the lifting lugs to a spreader bar. Never make the spreader bar cable attachment points wider than the attachment points on the skid or the bars. Make sure cables do not touch any other part of the generator set other than the skid.

6. Installing the Generator Set7-2016

WARNING

NOTICE

Spreader bar cable attach points width "Y" must never be wider than skid cable attach points "X." Distance "X" is the narrowest width.

NOTICE

Angle B must be slightly greater than angle A. Angle B should be as close to 90 degrees as possible to provide a stable lift.

3. With pedestal box (not shown), the spreader bars (front and back) should be used to clear the pedestal box and the attachment cables must be as vertical as possible.

NOTICE

The lifting angle (angle C) must not exceed 20° from vertical.

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6. Installing the Generator Set 7-2016

Item Description Item Description

A Angle A 1 Spreader Bar

B Angle B 2 Lifting Point

C Angle C (20° Maximum) 3 Lifting Cables

X The Narrowest Width (On the Skid) 4 Center of Gravity

Y This Distance Must be Less than Distance "X"

FIGURE 9. RIGGING

6.6 Moving the Generator Set

WARNING

Heavy Load Incorrect lifting or repositioning can cause severe personal injury or death. Make sure that only suitably trained and experienced personnel transport and handle generator

sets and associated components.

WARNING

Heavy Load Incorrect lifting or repositioning can cause severe personal injury or death. Do not lift the generator set by attaching to the engine or alternator lifting points. Do not stand

under or near the generator set when lifting.

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6. Installing the Generator Set7-2016

WARNING

Mechanical Hazard Failed components may be ejected or operate incorrectly which can cause severe personal injury

or death. Do not climb the generator set; this may damage critical parts.

NOTICE

Make sure that any shipping brackets supplied with the generator set are fitted, before moving the generator set. Failure to install the shipping brackets before moving may result in damage to the generator set.

NOTICE

Access or service doors must be closed and locked before repositioning, and they must remain locked during transportation and siting.

It is essential that there are sufficient trained and experienced personnel in attendance to make sure the lifting and transportation of the generator set is undertaken in a safe and appropriate manner, and in accordance to local guidelines and legislation.

Before lifting the generator set, lifting points, angle of slings, mass, access to intended site, and the distance of movement should all be taken into account when organizing a suitable crane/hoist. Consult the generator set information supplied with the generator set for details of dimensions and mass.

• Make sure that the crane operating area is able to support the mass of the crane and the generator set.

• Make sure the equipment used for lifting is adequate to support the weight of the generator set.

• Attach the lifting device to the lifting points only using suitable shackles, chains, and spreader bars.

• Slowly tighten the slings. Inspect the lifting attachments before commencing a full lift to make sure they are attached correctly.

• Hoist the generator set slowly using the indicated lifting points only.

• Guide the generator set with ropes at a safe distance to prevent uncontrolled rotation when positioning the generator set.

• Move the generator set to the desired location and place in position, bringing the set down slowly.

• Loosen the slings; unhook and remove the shackles.

6.6.1 Positioning a Generator Set Using a Forklift Truck

WARNING

Heavy Load Incorrect lifting or repositioning can cause severe personal injury or death. Make sure that only suitably trained and experienced personnel transport and handle generator

sets and associated components.

WARNING

Heavy Load Incorrect lifting or repositioning can cause severe personal injury or death. Do not attempt to lift a generator set with an undersized forklift truck.

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6. Installing the Generator Set 7-2016

NOTICE

Access or service doors must be closed and locked before repositioning, and they must remain locked during transportation and siting.

When using a forklift truck to transport/position the generator set, the dimensions, mass, and route must be taken into account when selecting an appropriate lifting truck.

1. Insert the arms of the forklift into the forklift pockets. Make sure the generator set completely rests on the forklift arms.

2. Lift and handle the equipment slowly.

3. Lower the generator set in position.

6.7 Transportation

WARNING

Heavy Load Incorrect lifting or repositioning can cause severe personal injury or death. Make sure that only suitably trained and experienced personnel transport and handle generator

sets and associated components.

WARNING

Heavy Load Incorrect lifting or repositioning can cause severe personal injury or death. Do not lift the generator set by attaching to the engine or alternator lifting points. Do not stand

under or near the generator set when lifting.

NOTICE

Any panels or doors must be locked before re-positioning and must remain locked during transportation and siting.

• Ensure the generator set is prepared for transport. If necessary drain fluids and ensure that acid or fumes do not leak from the battery (where applicable).

• If the generator set is transported over long distances, protect it against environmental influences by sealing it in a plastic cover or similar.

• Ensure the generator set is secured to the vehicle with suitable securing straps. Wooden chocks and pallets alongside the securing straps can prevent movement during transportation.

• If required, attached impact indicators to the generator set. Upon delivery, check these impact indicators and contact the transport company immediately if an impact has been detected. Impacts can cause serious damage to the generator set and its components.

• Ensure that the generator set cannot turn over during transportation.

• Do not overload the transport vehicle. Under no circumstances should the generator set be started while inside a truck.

• Lifting eyes, where fitted, are to be checked at regular intervals to ensure they are damage free and tight.

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7 Mechanical Connections

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.

7.1 Fuel System

In all fuel system installations, cleanliness is of the utmost 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. Use only compatible metal fuel lines to avoid electrolysis when fuel lines must be buried. Buried fuel lines must be protected from corrosion.

7.1.1 Gaseous Fuel Supply

Gaseous fueled generator sets (also called "spark-ignited generator sets") may utilize natural gas or Liquid Petroleum gas (Propane), or both. Dual fuel systems with natural gas as primary fuel and propane as a backup can be used in seismic risk areas and where there is concern that a natural event could disrupt a public utility gas system.

Regardless of the fuel used, the primary factors in successful installation and operations of a gas fuel system are:

• The gas supplied to the generator set must be of acceptable quality. Refer to the Application Manual T-030, Liquid Cooled Generator Sets for more detailed information about Cummins approved fuel types and quality.

• The gas supply must have sufficient pressure (defined for each generator set on the respective datasheets). Care must be taken to be sure that the gas supply at the generator set, not just at the source, is of proper pressure for operation. The specified pressure must be available while the generator set is running at full load.

• The gas must be supplied to the generator set in sufficient volume to support operation of the generator set. This is normally a matter of selecting fuel line size to be large enough to transport the volume of fuel needed. For LP vapor-withdrawal fuel systems the size and temperature of the fuel tank also affects this requirement.

Failure to meet the minimum requirements of the generator set in these areas will result in the inability of the generator set to operate, or inability to carry rated load, or poor transient performance. Insufficient flow can also result in engine damage or catastrophic failure.

7.1.2 Gaseous Fuel Quality

Gaseous fuels are actually a mixture of several different hydrocarbon gases such as methane, ethane, propane and butane; other gaseous elements such as oxygen and nitrogen; vaporized water; and various contaminants, some of which are potentially damaging to an engine over time. The quality of the fuel is based on the amount of energy per unit volume in the fuel and the amount of contaminants in the fuel.

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7. Mechanical Connections 7-2016

7.1.2.1 Energy Content

One of the most important characteristics of the gaseous fuel used in a generator set is the heat value of the fuel. The heat value of a fuel describes how much energy is stored in specific volume of the fuel. Gaseous fuel has a low heat value (LHV) and a high heat value (HHV). The low heat value is the heat available to do work in an engine after the water in the fuel is vaporized. If the low heat value of a fuel is too low, even if a sufficient volume of fuel reaches the engine, the engine will not be able to maintain full output power, because sufficient energy is not available in the engine to convert to mechanical energy. If the LHV is below 905 BTU/ft3the engine may not produce rated power at standard ambient temperature conditions.

If the local fuel has a higher energy content than 1000 BTU/ft3, the actual flow requirements in ft3/min will be lower and the pressure requirements drop slightly. Conversely, if the local fuel has a lower energy content than 1000 BTU/ft3, the actual flow requirements in ft3/min will be higher and a higher minimum supply pressure will be needed to meet published performance for any given generator set.

Each engine may have slightly different performance characteristics based on the type of fuel provided, due to differences in engine compression ratio, and whether the engine is naturally aspirated or turbocharged.

7.1.2.2 Pipeline Natural Gas

The most common fuel for generator sets is called Pipeline Natural Gas. In the US, Dry Pipeline Natural Gas has specific qualities, based on federal requirements. In other countries, Pipeline Gas may vary in content, so fuel characteristics should be verified prior to use with a generator set. US Pipeline Gas in a mixture composed of approximately 98% Methane and Ethane with the other 2% being hydrocarbons such as Propane and Butane, Nitrogen, Carbon Dioxide and water vapor. "Dry" means that it is free of liquid hydrocarbons, such as gasoline, but NOT that it is free of water vapor. Dry Pipeline Gas typically has a LHV of 936 BTU/ft3, and a HHV of 1,038 BTU/ft3.

7.1.2.3 Field Gas

The composition of Field Natural Gas varies considerably by region and by continent. Careful analysis is necessary prior to using Field Natural Gas in an engine. Field Natural Gas can contain heavier hydrocarbon gases such as Pentane, Hexane and Heptane, which may require derating of the output of the engine. Other contaminants, such as Sulfur, may also be present in the fuel. A typical Field Gas might have an LHV of 1203 BTU/ft3, and an HHV of 1,325 BTU/ft3.

7.1.2.4 Propane/Liquid Petroleum Gas (LPG)

Propane is available in two grades, either commercial or special duty. Commercial Propane is used where high volatility is required. Not all spark-ignition engines will operate acceptably with this fuel due to its volatility. Special duty Propane (also called HD5) is a mixture of 95% Propane and other gases, such as Butane, that allow better engine performance due to the reduction pre-ignition due to reduced volatility. Special duty Propane fuel gas that meets the ASTM D 1835 specification for special-duty Propane (equivalent to HD-5 Propane of Gas Producers Association Standard 2140) is suitable for most engines. Propane has an LHV of approximately 2,353 BTU/ft3, and an HHV of 2,557 BTU/ft3. The higher heating value of the fuel necessitates mixing of different volumes of air in the fuel system for Propane vs. Natural Gas applications, so dual fuel engines essentially have two fuel arrangements for this purpose.

NOTICE

Clarification of abbreviations often seen:

LP - Liquid Petroleum or Propane LPV - Propane Vapor (gaseous fuel) LPL - Propane Liquid (liquid fuel) LPG - Liquid Petroleum Gas **LPG and LP are the same and are often used interchangeably.**

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7.1.2.5 Contaminants

The most harmful contaminants in gaseous fuels are water vapor and Sulfur.

Water vapor is damaging to an engine because it may cause uncontrolled burning, pre-ignition, or other effects that can damage an engine. Liquid vapor or droplets must be removed from the fuel prior to entry into the engine by use of a dry filter that is mounted in the fuel system prior to the primary fuel pressure regulator. The dew point of fuel gas should be at least 20 °F (11 °C) below the minimum ambient temperature at the installation site.

Sulfur and Hydrogen sulfides will cause corrosion and serious damage to an engine over a relative short period of time. Different engines have different levels of tolerance to sulfur contamination, and some engines simply should not be operated with fuel that contains significant Sulfur content. Contact the engine manufacturer for approval of specific engines with specific fuels. The effects of Sulfur in the fuel can be counteracted in part by use of high-ash Natural Gas lubricating oils. In general, engines should not be operated with fuels in excess of 10 parts per million (ppm).

Certain fuels, such as those derived from land fill applicants, can have useful chemical energy content, but very high sulfur levels (>24 ppm). These fuels are often termed "sour gas". If this fuel is scrubbed of the Sulfur content, it can be used as fuel for many engines, provided that it has sufficient BTU content.

7.1.2.6 Fuel Analysis

The gaseous fuel supplier can provide a fuel analysis that describes the chemical makeup of the fuel to be provided. This fuel analysis can be used to make certain that the fuel is suitable for use in the specific engine proposed for a specific application, and also to verify that the BTU content of the fuel is sufficient to provide necessary kW output of the machine. Gas suppliers may change the Pipeline Natural Gas composition without notice, so there is no long-term guarantee of performance, but the process of evaluation of the fuel can be briefly described as:

7. Mechanical Connections7-2016

1. List the percent of each gas constituent in the fuel.

2. Calculate the percent of the total fuel that is combustible. The combustible portion of the fuel is 100% less the inert component percentages. Inert components include Oxygen, Carbon Dioxide and water vapor.

3. Calculate the percent of each combustible component of the fuel.

4. Verify acceptability of the fuel by checking the percent of each combustible element vs. the recommendations of the engine manufacturer.

For example, for a gas analysis of:

90% Methane

6% Ethane

2% Hydrogen

1% Normal Pentane

1% Nitrogen

• Total percent inert elements: 1%

• Total combustible: 100% - 1% = 99%

• % Methane: 90% ÷ 99% = 91%

• % Ethane: 6% ÷ 99% = 6.1%

• % Hydrogen: 2% ÷ 99% = 2%

• % Normal Pentane: 1% ÷ 99% = 1%

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See the following tables for a typical listing of Maximum Permissible Combustibles in Cummins Gas generator sets. Note that in this example, the analysis shows the fuel will be acceptable for a lower compression ratio engine (typically around 8.5:1) but not for a higher compression engine. A higher compression engine will have more stringent fuel composition requirements but may operate satisfactorily with a derating of its output - consult the engine manufacturer.

5. Verify the rating of the generator set based on the use of the proposed fuel.

The total BTU content of the fuel will determine the rating of the generator set when using fuel of a specific composition. If any component of the fuel has more than the specific value allowed derating will be required. Consult the engine manufacturer for fuel requirements and derating instructions.

Note that the fuel derating and the altitude/temperature derating 21 are not additive. Only the maximum value of the fuel derate or the altitude/temperature derate need be applied.

Turbocharged engines have unique fuel composition requirements due to higher cylinder pressures. To avoid problems with pre-ignition or denotation, power output derating is required if propane and/or ISOButane content exceed the percentages listed in the following tables.

TABLE 4. MAXIMUM ALLOWABLE PERCENTAGES FOR ENGINE FUEL COMBUSTIBLES

8.5:1 Compression Ratio 10.5:1 Compression Ratio

Methane (C1) 100 100

Ethane (C2) 100 100

Propane (C3) 10 2

ISO-Butane (IC4) 7 0.2

Hydrogen (H2) 7 trace

Normal Butane (NC4) 3 0.2

ISO-Pentane (IC5) 3 0.2

Normal Pentane (NC5) 1 0.1

Hexane (C6) 1 0.1

Heptane (C7) 1 0.1

TABLE 5. MAXIMUM ALLOWABLE PERCENTAGES OF CONSTITUENT GASES BEFORE DERATING

TURBOCHARGED ENGINES

8.5:1 Compression Ratio 10.5:1 Compression Ratio

Methane N/A N/A

Ethane N/A N/A

Propane 5% *

ISO-Butane 2% *

*High compression ratio turbocharged engines cannot consume any Propane or ISO-Butane.

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7.1.3 Site Fuel System Design

The following should be considered when installing a natural gas and/or LPG fuel system:

• Gaseous-fuel supply system design, materials, components, fabrication, assembly, installation, testing, inspection, operation, and maintenance must comply with all applicable codes (In North America, NFPA Standards No.30, No.37, No.54 and No. 58 are typical).

• The layout and sizing of gas piping must be adequate for handling the volume of gas required by the generator set and all other equipment, such as building heating boilers, supplied by the same source. Full-load gas flow (see the recommended generator set Data Sheet) must be available at not less than the minimum required supply pressure, typically from 7 to 13.6 inches WC (water column), depending on model. Final determination of pipe sizes must, however, be based upon the method approved by the authority having jurisdiction (see NFPA No.54).

• Most installations will require a service gas pressure regulator. Gas supply pressure should not exceed 14 inches WC, depending on model, at the inlet to the generator set. Refer to the generator set data sheet for model specific details. Depending on distribution gas pressure, more than one stage of pressure regulation may be required. High-pressure gas piping is not permitted inside buildings (5 PSIG for natural gas and 20 PSIG for LPG, unless higher pressures are approved by the authority having jurisdiction). Gas pressure regulators must be vented to the outdoors according to code.

• The pressure regulator installed on the supply line at the gas source for generator applications should never be a "pilot" regulator. A "pilot" style regulator is the type where the regulator requires a pressure line from the regulator housing to the downstream gas pipe to "sense" when downstream pressure has dropped. Pilot regulators do not work because the response time is unacceptable compared to the large instantaneous changes in demand from the generator set.

7. Mechanical Connections7-2016

• Approved fuel hose must be used for connections at the engine to take up generator set movement and vibration.

• Most codes require both manual and electric (battery-powered) shutoff valves ahead of the flexible fuel hose(s). The manual valve should be of the indicating type.

• A dryer fuel filter should be installed in each line to protect the sensitive pressure regulating components and orifices downstream from harmful foreign substances carried along in the gas stream (rust, scale, etc.)

• An LPG fuel supply system must be dedicated for the emergency power system if it is the required alternative fuel.

• An LPG vaporizer heated by engine coolant is factory installed on Cummins Power Generation generator sets equipped for a liquid-withdrawal of LPG. Because high pressure (20 PSIG or greater) gas piping is not permitted inside buildings, generator sets equipped for liquid withdrawal of LPG must not be installed inside the building. (Weather-protective housings for outdoor installation are available for most LPG models.)

• The rate of vaporization in an LPG tank depends upon the outdoor air temperature, unless the tank is equipped with a heater, and the quality of fuel in the tank. Even on cold days outdoor air heats and vaporizes LPG (mostly through the wetted tank surface) when air temperature is higher than LPG temperature. Withdrawing vapor causes tank temperature and pressure to drop. (At -38 °C (-37 °F) LPG has zero vapor pressure.) Unless there is enough fuel and enough heat available from ambient air, the vaporization rate will drop off, as the generator set runs, to less than that required to continue running properly.

Refer to Application Manual T-030 Liquid Cooled Generator Sets or Cummins Sales Application Engineering for more information on Site Fuel System Design.

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No. Description No. Description

1 Heat shield 7 Wire leads

2 Fuel line (Natural Gas) 8 Coolant hose

3 Vapor outlet 9 Fuel hose (Propane vapor)

4 Pipe cap 10 Coolant hose

5 Converter 11 Fuel shutoff solenoid (Propane vapor)

6 Solenoid valve 12 Fuel shutoff solenoid (Natural Gas)

FIGURE 10. GASEOUS FUEL SYSTEM.

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No. Description No. Description

1 Solenoid Valve 4 Governor Actuator

2 Pressure Regulator 5 Fuel Mixer

3 Fuel Control

FIGURE 11. TYPICAL GASEOUS FUEL SYSTEM

7.1.4 Gaseous Fuel System Calculations

Tank Size

Use the "Minimum LPG Tank Size (50% Full) Required to Maintain 5 PSIG at Specific Withdrawal Rate and Minimum Expected Winter Temperature" figure as a quick reference for sizing an LPG tank on the basis of the lowest ambient temperature expected. For example, on a 40 °F day, withdrawal at 1000 ft3/hr requires a 2000 gallon tank at least half full. Note: In many instances the amount of total fuel required for proper vaporization is far greater than that required for the number of hours of operation stipulated by code.

For instance, in an NFPA 110 Class 6 application, there must be enough fuel for the generator set to run for 6 hours before refilling the tank. LPG yields approximately 36.5 ft3of gas per gallon of liquid. If the generator set withdrawal rate is 1000 ft3/h:

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FIGURE 12. TANK SIZE EQUATION.

In this instance the tank must be sized for at least 2000 gallons based on the lowest expected temperature rather than on the fuel consumed in 6 hours (164 gallons).

Gas Pipe Sizing

Sizing of gas piping for proper fuel delivery, both flow and pressure, can become quite complex. However, a simplified method, as with other piping for exhaust and coolant, is to convert all fittings, valves, etc. to equivalent lengths of pipe in the diameter(s) being considered. The total equivalent length can then be related to flow capacity.

Notes about the following tables:

• Equivalent Lengths of Pipe Fittings and Valves applies to gas as well as liquid piping.

• Show maximum gas capacity for equivalent length for various pipe sizes.

• Reproduced from NFPA 54-2002, National Fuel Gas Code, and are selected considering the general fuel system operating requirements for generator sets.

• Included for natural gas, propane liquid withdrawal and propane vapor withdrawal under specified conditions.

• Consult NFPA 54 or other applicable codes for other operating conditions or other fuel system installation requirements.

A calculation of minimum pipe size is fairly straightforward:

• Make a list of all the fittings and valves in a proposed system and sum their equivalent lengths using the table.

• Add to this total, all lengths of straight pipe to arrive at a total equivalent length.

• Choose the applicable table based on the fuel system.

• Obtain the maximum fuel requirements for the specific generator set(s) from the manufacturer's specification sheets. Convert to ft3/hr as needed (Be cognizant of BTU content as discussed earlier in this section.)

• Locate the equivalent length of pipe (or next larger equivalent length) in the left hand column. Move across to the columns to where the number is as large or larger than the total equivalent length calculated above. At the top of that column is the minimum nominal pipe size or tubing size required for the system as designed.

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FIGURE 13. MINIMUM LPG TANK SIZE (50% FULL) REQUIRED TO MAINTAIN 5 PSIG AT SPECIFIC

WITHDRAWAL RATE AND MINIMUM EXPECTED WINTER TEMPERATURE

TABLE 6. NATURAL GAS SCHEDULE 40 IRON PIPE SIZING (1/4-3/4 IN.)

Gas: Natural Inlet Pressure: 0.5 PSI or less Pressure Drop: 0.5 in. w.c. Specific Gravity: 0.60

Pipe Size (in.)

Nominal 1/4 3/8 1/2 3/4

Actual ID (0.364) (0.493) (0.622) (0.824)

Length (ft.) Maximum Capacity in Cubic Feet of Gas per Hour

10 43 95 175 360

20 29 65 120 250

30 24 52 97 200

40 20 45 82 170

50 18 40 73 151

60 16 36 66 138

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70 15 33 61 125

80 14 31 57 118

90 13 29 53 110

100 12 27 50 103

125 11 24 44 93

150 10 22 40 84

175 9 20 37 77

200 8 19 35 72

TABLE 7. NATURAL GAS SCHEDULE 40 IRON PIPE SIZING (1-2 IN.)

Gas: Natural Inlet Pressure: 0.5 PSI or less Pressure Drop: 0.5 in. w.c. Specific Gravity: 0.60

Pipe Size (in.)

Nominal 1 1 1/4 1 1/2 2

Actual ID (1.049) (1.380) (1.610) (2.067)

Length (ft.) Maximum Capacity in Cubic Feet of Gas per Hour

10 680 1400 2100 3950

20 465 950 1460 2750

30 375 770 1180 2200

40 320 660 990 1900

50 285 580 900 1680

60 260 530 810 1520

70 240 490 750 1400

80 220 460 690 1300

90 205 430 650 1220

100 195 400 620 1150

125 175 360 550 1020

150 160 325 500 950

175 145 300 460 850

200 135 280 430 800

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TABLE 8. NATURAL GAS SCHEDULE 40 IRON PIPE SIZING (2 1/2-4 IN.)

Gas: Natural Inlet Pressure: 0.5 PSI or less Pressure Drop: 0.5 in. w.c. Specific Gravity

Pipe Size (in.)

Nominal 2 1/2 3 4

Actual ID (2.469) (3.068) (4.026)

Length (ft.) Maximum Capacity in Cubic Feet of Gas per Hour

10 6300 11000 23000

20 4350 7700 15800

30 3520 6250 12800

40 3000 5300 10900

50 2650 4750 9700

60 2400 4300 8800

70 2250 3900 8100

80 2050 3700 7500

90 1950 3450 7200

100 1850 3250 6700

125 1650 2950 6000

150 1500 2650 5500

175 1370 2450 5000

200 1280 2280 4600

TABLE 9. NATURAL GAS SEMI-RIGID COPPER TUBING SIZING (1/4-3/4IN.)

*TABLE CAPACITIES ARE BASED ON TYPE K COPPER TUBING INSIDE DIAMETER (SHOWN), WHICH HAS

THE SMALLEST INSIDE DIAMETER OF THE COPPER TUBING PRODUCTS.

Gas: Natural Inlet Pressure: 0.5 PSI or less Pressure Drop: 0.5 in. w.c. Specific Gravity: 0.6

Tube Size (in.)

Nominal K&L 1/4 3/8 1/2 5/8 3/4

ACR 3/8 1/2 5/8 3/4 7/8

Outside 0.375 0.500 0.625 0.750 0.875

Inside* 0.305 0.402 0.527 0.652 0.745

Length (ft.) Maximum Capacity in Cubic Feet of Gas per Hour

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10 27 55 111 195 276

20 18 38 77 134 190

30 15 30 61 107 152

40 13 26 53 92 131

50 11 23 47 82 116

60 10 21 42 74 105

70 9.3 19 39 68 96

80 8.6 18 36 63 90

90 8.1 17 34 59 84

100 7.6 16 32 56 79

125 6.8 14 28 50 70

150 6.1 13 26 45 64

175 5.6 12 24 41 59

200 5.2 11 22 39 55

250 4.7 10 20 34 48

300 4.2 8.7 18 31 44

TABLE 10. NATURAL GAS SEMI-RIGID COPPER TUBING SIZING (1-2 1/2IN.)

*TABLE CAPACITIES ARE BASED ON TYPE K COPPER TUBING INSIDE DIAMETER (SHOWN), WHICH HAS

THE SMALLEST INSIDE DIAMETER OF THE COPPER TUBING PRODUCTS.

Gas: Natural Inlet Pressure: 0.5 PSI or less Pressure Drop: 0.5 in. w.c. Specific Gravity: 0.6

Tube Size (in.)

Nominal K&L 1 1 1/4 1 1/2 2 2 1/2

ACR 1 1/8 1 3/8 1 5/8 2 1/8 2 5/8

Outside 1.125 1.375 1.625 2.125 2.625

Inside* 0.995 1.245 1.481 1.959 2.435

Length (ft.) Maximum Capacity in Cubic Feet of Gas per Hour

10 590 1062 1675 3489 6173

20 406 730 1151 2398 4242

30 326 586 925 1926 3407

40 279 502 791 1648 2916

50 247 445 701 1461 2584

60 224 403 635 1323 2341

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70 206 371 585 1218 2154

80 192 345 544 1133 2004

90 180 324 510 1063 1880

100 170 306 482 1004 1776

125 151 271 427 890 1574

150 136 245 387 806 1426

175 125 226 356 742 1312

200 117 210 331 690 1221

250 103 186 294 612 1082

300 94 169 266 554 980

TABLE 11. PROPANE VAPOR SCHEDULE 40 IRON PIPE SIZING (1/2-1 1/2IN.)

Gas: Undiluted Propane Inlet Pressure: 11.0 in. w.c. Pressure Drop: 0.5 in. w.c. Specific Gravity: 1.50 Special Use: Pipe sizing between single or second stage (low pressure regulator) and appliance.

Pipe Size (in.)

Nominal Inside

Actual: 0.622 0.824 1.049 1.38 1.61

Length (ft.) Maximum Capacity in Thousands of BTU per Hour

10 291 608 1145 2352 3523

20 200 418 787 1616 2422

30 160 336 632 1298 1945

40 137 287 541 1111 1664

50 122 255 480 984 1475

60 110 231 434 892 1337

80 94 197 372 763 1144

100 84 175 330 677 1014

125 74 155 292 600 899

150 67 140 265 543 814

200 58 120 227 465 697

250 51 107 201 412 618

1/2 3/4 1 1 1/4 1 1/2

300 46 97 182 373 560

350 42 89 167 344 515

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400 40 83 156 320 479

TABLE 12. PROPANE VAPOR SCHEDULE 40 IRON PIPE SIZING (2-4IN.)

Gas: Undiluted Propane Inlet Pressure: 11.0 in. w.c. Pressure Drop: 0.5 in. w.c. Specific Gravity: 1.50 Special Use: Pipe Sizing between single or second stage (low pressure regulator) and appliance.

Pipe Size (in.)

Nominal Inside

Actual: 2.067 3.068 3.548 4.026

Length (ft.) Maximum Capacity in Thousands of BTU per Hour

10 6786 19119 27993 38997

20 4664 13141 19240 26802

30 3745 10552 15450 21523

40 3205 9031 13223 18421

50 2841 8004 11720 16326

60 2574 7253 10619 14793

80 2203 6207 9088 12661

100 1952 5501 8055 11221

125 1730 4876 7139 9945

150 1568 4418 6468 9011

200 1342 3781 5536 7712

250 1189 3351 4906 6835

300 1078 3036 4446 6193

2 3 3 1/2 4

350 991 2793 4090 5698

400 922 2599 3805 5301

TABLE 13. PROPANE VAPOR SEMI-RIGID COPPER TUBING SIZING (1/4-3/4IN.)

*TABLE CAPACITIES ARE BASED ON TYPE K COPPER TUBING INSIDE DIAMETER (SHOWN), WHICH HAS

THE SMALLEST INSIDE DIAMETER OF THE COPPER TUBING PRODUCTS.

Gas: Undilute Propane Inlet Pressure: 11.0 in. w.c. Pressure Drop: 0.5 in. w.c. Specific Gravity: 1.50 Special Use: Sizing between single or second stage (low pressure regulator) and appliance

Tube Size (in.)

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Nominal K&L 1/4 3/8 1/2 5/8 3/4

ACR 3/8 1/2 5/8 3/4 7/8

Outside 0.375 0.500 0.625 0.750 0.875

Inside* 0.305 0.402 0.527 0.652 0.745

Length (ft.) Maximum Capacity in Thousands of BTU per Hour

10 45 93 188 329 467

20 31 64 129 226 321

30 25 51 104 182 258

40 21 44 89 155 220

50 19 39 79 138 195

60 17 35 71 125 177

70 16 32 66 115 163

80 15 30 61 107 152

90 14 28 57 100 142

100 13 27 54 95 134

125 11 24 48 84 119

150 10 21 44 76 108

175 10 20 40 70 99

200 8.9 18 37 65 92

225 8.3 17 35 61 87

250 7.9 16 33 58 82

275 7.5 15 31 55 78

300 7.1 15 30 52 74

TABLE 14. PROPANE VAPOR SEMI-RIGID COPPER TUBING SIZING (1-2 1/2IN.)

*TABLE CAPACITIES ARE BASED ON TYPE K COPPER TUBING INSIDE DIAMETER (SHOWN), WHICH HAS

THE SMALLEST INSIDE DIAMETER OF THE COPPER TUBING PRODUCTS.

Gas: Undilute Propane Inlet Pressure: 11.0 in. w.c. Pressure Drop: 0.5 in. w.c. Specific Gravity: 1.50 Special Use: Sizing between single or second stage (low pressure regulator) and appliance

Tube Size (in.)

Nominal K&L 1 1 1/4 1 1/2 2 2 1/2

ACR 1 1/8 1 3/8 1 5/8 2 1/8 2 5/8

Outside 1.125 1.375 1.625 2.125 2.625

Inside* 0.995 1.245 1.481 1.959 2.435

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Length (ft.) Maximum Capacity in Thousands of BTU per Hour

10 997 1795 2830 5895 10429

20 685 1234 1945 4051 7168

30 550 991 1562 3253 5756

40 471 848 1337 2784 4926

50 417 752 1185 2468 4366

60 378 681 1074 2236 3956

70 348 626 988 2057 3639

80 324 583 919 1914 3386

90 304 547 862 1796 3177

100 287 517 814 1696 3001

125 254 458 722 1503 2660

150 230 415 654 1362 2410

175 212 382 602 1253 2217

200 197 355 560 1166 2062

225 185 333 525 1094 1935

250 175 315 496 1033 1828

275 166 299 471 981 1736

300 158 285 449 936 1656

TABLE 15. PROPANE SCHEDULE 40 IRON PIPE SIZING, LIQUID WITHDRAWAL - MAXIMUM CAPACITY OF

PIPE IN CUBIC FEET OF GAS PER HOUR. PIPE SIZE RECOMMENDATIONS ARE BASED ON SCHEDULE 40

BLACK IRON PIPE. (1/2 -1 1/2IN.)

Equivalent Length of Pipe, ft.

30 733 1532 2885 5924 8876

40 627 1311 2469 5070 7597

50 556 1162 2189 4494 6733

60 504 1053 1983 4072 6100

70 463 969 1824 3746 5612

1/2

(0.622)

Schedule 40 Iron Pipe Size, in.: Nominal (Inside Diameter)

3/4

(0.824)

(1.049)

1 1/4

(1.38)

1 1/2

(1.61)

80 431 901 1697 3484 5221

90 404 845 1593 3269 4899

100 382 798 1504 3088 4627

150 307 641 1208 2480 3716

200 262 549 1034 2122 3180

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250 233 486 916 1881 2819

300 211 441 830 1705 2554

350 194 405 764 1568 2349

400 180 377 711 1459 2186

450 169 354 667 1369 2051

500 160 334 630 1293 1937

600 145 303 571 1172 1755

700 133 279 525 1078 1615

800 124 259 488 1003 1502

900 116 243 458 941 1409

1000 110 230 433 889 1331

1500 88 184 348 713 1069

2000 76 158 297 611 915

TABLE 16. PROPANE SCHEDULE 40 IRON PIPE SIZING. LIQUID WITHDRAWAL - MAXIMUM CAPACITY OF

PIPE IN CUBIC FEET OF GAS PER HOUR. PIPE SIZE RECOMMENDATIONS ARE BASED ON SCHEDULE 40

BLACK IRON PIPE. (2-4IN.)

Equivalent Length of Pipe, ft.

30 17094 48164 70519 98238

40 14630 41222 60355 84079

50 12966 36534 53492 74518

60 11748 33103 48467 67519

70 10808 30454 44589 62116

80 10055 28331 41482 57787

90 9434 26583 38921 54220

100 8912 25110 36764 51216

150 7156 20164 29523 41128

200 6125 17258 25268 35200

250 5428 15295 22395 31198

(2.067)

Schedule 40 Iron Pipe Size, in.: Nominal (Inside Diameter)

(3.068)

3 1/2

(3.548)

(4.026)

300 4919 13859 20291 28267

350 4525 12750 18667 26006

400 4209 11861 17366 24193

450 3950 11129 16295 22700

500 3731 10512 15391 21442

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600 3380 9525 13946 19428

700 3110 8763 12830 17873

800 2893 8152 11936 16628

900 2715 7649 11199 15601

1000 2564 7225 10579 14737

1500 2059 5802 8495 11834

2000 1762 4966 7271 10128

TABLE 17. EQUIVALENT LENGTHS OF PIPE FITTINGS IN FEET (METERS) (2-6IN.)

Type of Fitting Nominal Inch (Millimeter) Pipe Size

(50)

90° Standard Elbow

90° Medium Radius Elbow

90° Long Radius

Elbow

45° Elbow 2.4

TEE, Side Inlet or

Outlet

18 Inch Flexible

Tube

24 Inch Flexible

Tube

5.2

(1.6)

4.6

(1.4)

3.5

(1.1)

(0.7)

(3.0)

(0.9)

(1.2)

2 1/2

(65)

6.2

(1.9)

5.4

(1.6)

4.2

(1.3)

2.9

(0.9)

(3.7)

(0.9)

(1.2)

(80)

7.7

(2.3)

6.8

(2.1)

5.2

(1.6)

3.6

(1.1)

(4.9)

(0.9)

(1.2)

3 1/2

(90)

9.6

(2.9)

(2.4)

(1.8)

4.2

(1.3)

(5.5)

(0.9)

(1.2)

(100)

(3.0)

(2.7)

6.8

(2.1)

4.7

(1.4)

(6.1)

(0.9)

(1.2)

(125)

(4.0)

(3.4)

8.5

(2.6)

5.9

(1.8)

(7.6)

(0.9)

(1.2)

(150)

(4.6)

(4.0)

(3.0)

7.1

(2.2)

(9.4)

(0.9)

(1.2)

TABLE 18. EQUIVALENT LENGTHS OF PIPE FITTINGS IN FEET (METERS) (8-18IN.)

Type of Fitting Nominal Inch (Millimeter) Pipe Size

90° Standard Elbow

90° Medium Radius Elbow

(200)

(6.4)

(5.5)

(250)

(7.9)

(6.7)

(300)

(9.8)

(7.9)

(350)

(11.3)

(9.8)

(400)

(12.8)

(10.7)

(450)

(14.3)

(12.2)

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90° Long Radius

Elbow

45° Elbow 6

TEE, Side Inlet or

Outlet

18 Inch Flexible

Tube

24 Inch Flexible

Tube

(4.3)

(1.8)

(13)

(0.9)

(1.2)

(5.2)

(2.4)

(17)

(0.9)

(1.2)

7.2 Exhaust System

Toxic Gases Inhalation of exhaust gases can cause asphyxiation and death. Use extreme care during installation to provide a tight exhaust system. Terminate exhaust pipes

away from enclosed or sheltered areas, windows, doors, and vents. Do not use exhaust heat to warm a room, compartment, or storage area.

(6.1)

(2.7)

(20)

(0.9)

(1.2)

WARNING

(7.3)

(5.2)

(23.8)

(0.9)

(1.2)

(7.9)

(5.8)

(27.1)

(0.9)

(1.2)

(9.4)

(6.7)

110

(33.5)

(0.9)

(1.2)

WARNING

Hot Surface Hot surfaces can start a fire which can cause severe burns or death. Use an approved thimble where exhaust pipes pass through wall or partitions.

NOTICE

Weight applied to the engine manifold can result in turbocharger damage. Support the silencer and exhaust piping so no weight or stress is applied to the engine exhaust elbow.

NOTICE

Gaseous fuels are susceptible to high condensation levels in the exhaust. It is important to have properly routed/sized exhaust systems to prevent harm to turbochargers and Oxygen sensors (HEGO).

NOTICE

Liability for injury, death, damage, and warranty expense due to use of unapproved silencers or modifications to the exhaust system becomes the responsibility of the person installing the unapproved silencer or performing the modification. Contact your authorized distributor for approved exhaust system parts.

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7. Mechanical Connections 7-2016

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.

NOTICE

Enclosed generator sets are not generally designed to be used in a building. If the generator set is to be used in a building, additional requirements must be applied.

Where an enclosed generator set is used in a building, the exhaust system should be extended to vent the exhaust gases. Use sealed joint type fittings where possible to provide a tight exhaust system. Use of slip type fittings (secured with a clamp) may allow leakage of exhaust gases into the building if not fitted correctly. Check to make sure there are no exhaust leaks.

When a unit is provided with a partially installed or incomplete exhaust system, exhaust piping and chimneys shall be designed, constructed, and installed in accordance with the Standard for the Installation and Use of Stationary Combustion Engines and Gas Turbines, NFPA 37, or applicable local standards. Build according to the code requirements in effect at the installation site.

For indoor installation, the exhaust system should use sealed joint type fittings where possible to provide a tight exhaust system. Use of slip type fittings (secured with a clamp) may allow leakage of exhaust gases into the building if not fitted correctly fitted. Check to make sure there are no exhaust leaks.

Use an approved thimble (see Figure 14 on page 57) where exhaust pipes pass through a wall or partition. 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. When a unit is provided with a partially installed or incomplete exhaust system, exhaust piping and chimneys shall be designed, constructed, and installed in accordance with the Standard for the Installation and Use of Stationary Combustion Engines and Gas Turbines, NFPA 37, or applicable local standards. Build according to the code requirements in effect at the installation site.

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 the exhaust system to prevent weight from being applied to engine exhaust outlet elbow/turbocharger connection.

The exhaust system design should meet local code requirements.

Avoid sharp bends by using sweeping, long radius elbows and provide adequate support for the silencer 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 (see Figure 15 on page 57).

Shield or insulate exhaust lines if there is danger of personal contact. Allow at least 305 mm (12 inches) of clearance if the pipes pass close to a combustible wall or partition. Before installing insulation on exhaust system components, check the exhaust system for leaks while operating the generator set under full load and correct all leaks.

Refer to Application Manual T-030, Liquid Cooled Generator Sets for more detailed information about sizes of exhaust system pipes and fittings.

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7. Mechanical Connections7-2016

No. Description No. Description

1 Rain Cap 6 Exhaust Pipe Diameter Plus 304 mm (12 Inches)

2 Drip Cap 7 Flashing

3 Holes in End of Inner Sleeve 8 230 mm (9 Inches) Minimum

4 Roof 9 Outside or Dividing Wall

5 230 mm (9 inches) Minimum

FIGURE 14. EXHAUST THIMBLE

FIGURE 15. CONDENSATION TRAP

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7. Mechanical Connections 7-2016

No. Description No. Description

1 Exhaust Thimble 4 Water Trap with Drain

2 Support Brackets 5 Muffler

3 Flexible Bellows 6 Exhaust Pipe

FIGURE 16. TYPICAL SUSPENDED EXHAUST SYSTEM

7.3 Ventilation and Cooling

WARNING

Toxic Gases Engine and radiator cooling air may carry carbon monoxide gas, which can cause asphyxiation

and death. Pipe exhaust gas outside and away from windows, doors, or other inlets to buildings. Do not

allow exhaust gas to accumulate in habitable areas.

Generator sets create considerable heat that must be removed by proper ventilation.

Generator sets in factory-mounted housings for outdoor installation are designed for proper cooling and ventilation.

Indoor installations require careful design with respect to cooling and ventilation. In an indoor installation, all radiator cooling air must be discharged to the out-of-doors. Duct adapter kits are available.

Outdoor installations normally rely on natural air circulation but indoor installations need properly sized and positioned vents for required airflow.

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7.4 Vents and Ducts

For indoor installations, locate vents so incoming air passes through the immediate area of the installation before exhausting. Install the air outlet higher than the air inlet to allow for convection air movement.

Size the vents and ducts so they are large enough to allow the required flow rate of air.

The "free area" of ducts must be as large as the exposed area of the radiator. Refer to the generator set Specification Sheet for the airflow requirements and allowed airflow restriction.

Wind will restrict free airflow if it blows directly into the air outlet vent. Locate the outlet vent so the effects of wind are eliminated, or if outlet vent cannot be located as mentioned, install a wind barrier, see Figure

17.

7. Mechanical Connections7-2016

NOTICE

No. Description No. Description

1 Prevailing Wind Away from Air Outlet Vent 2 Prevailing Wind Towards Air Outlet Vent, Wind

Barrier Installed

FIGURE 17. WIND BARRIER

7.5 Dampers

Dampers or louvers 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.

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7. Mechanical Connections 7-2016

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 generator set warm up faster, and help to keep fuel temperatures higher than the cloud point of the fuel. If recirculation dampers are used, they should be designed to 'fail closed', with the main exhaust dampers 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.

7.6 Air Inlet and Outlet Openings

Louvers and screens over air inlet and outlet openings restrict air flow and vary widely in performance.

A louver assembly with narrow vanes, for example, tends to be more restrictive than one with wide vanes. The effective open area specified by the louver or screen manufacturer should be used.

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 1.5 times larger than the radiator area.

Locate the cooling air outlet directly in front of the radiator and as close as possible. The outlet opening must be at least as large as the radiator area. Length and shape of the air outlet duct should offer minimum restriction to airflow.

A flexible duct connector must be provided at the radiator to prevent exhaust air recirculation around the radiator, to take up generator set movement and vibration, and to prevent transmission of noise. Attach the flexible duct using screws and nuts so that the duct can be removed for maintenance purposes. Before installing the duct, remove the radiator core guard.

Enclosed generator sets are primarily designed to work in an open environment. When considering installing an enclosed generator set in an enclosed environment specific application factors must be considered (air flow, exhaust gas extraction, fuel supply and storage, etc.). For advice, contact the Application Engineering Group at Cummins Power Generation.

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7. Mechanical Connections7-2016

No. Description No. Description

1 Cool Air Inlet Damper 5 Flexible Duct Connector

2 Engine Driven Fan 6 Hot Air Outlet Damper

3 Radiator 7 Distance Should Not be Less Than Height of

Radiator

4 Thermostat Controlled Re-Circulating Damper 8 Wind/Noise Barrier

FIGURE 18. TYPICAL OPEN GENERATOR SET INSTALLATION

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8 DC Control Wiring

Electric Shock Hazard Voltages and currents present an electrical shock hazard that can cause severe burns or death. Avoid contact with the voltage sense and bus sense leads; voltages of up to 600 VAC may still

be present. These voltages could be live even when the generator set is switched off.

Electric Shock Hazard Voltages and currents present an electrical shock hazard that can cause severe burns or death. Make sure all power is off before performing control wire installation.

Electric Shock Hazard Voltages and currents present an electrical shock hazard that can cause severe burns or death. To prevent accidental electrocution, stand on a clean dry wooden platform or clean rubber

insulating mat, make sure your clothing and shoes are dry, remove all jewelry, and use tools with insulated handles.

WARNING

The generator set control box contains connection points for remote control and monitor options.

NOTICE

Always run control circuit wiring in a separate metal conduit from the AC power cables to avoid inducing currents that could cause problems within the control.

Use cable ties to keep control wiring away from sharp edges and AC power cables within the control housing.

NOTICE

Stranded copper wire must be used for all customer connections to the control panel. Solid copper wire may break due to the generator set vibration.

Use flexible conduit for all wiring connections to the generator set.

8.1 Guidelines for Customer Connections to the Control System

• Torque terminals to 0.5 Nm (4.4 in-lb)

• Wire type: Use 60 C rated minimum copper wire

• Terminal screws are slotted 0.6 mm

• Use flat bladed screwdriver with 2.5 mm blade

• Strip wire length to 6.0 mm (0.236 in)

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8. DC Control Wiring 7-2016

8.2 Digital Connections

Connection points, other than relayed outputs and network are considered digital connections. The type/gauge wire to use for these connections are:

• Less than 305 m (1000 ft), use 0.5 mm2(20 gauge) stranded copper wire.

• 305 m to 610 m (1000 ft to 2000 ft), use 0.75 mm2(18 gauge) stranded copper wire.

8.3 Relay Connections

Due to the wide variety of devices that can be attached to the relay outputs, the electrical contractor must determine the gauge of the stranded copper wire that is used.

8.4 PCC 2100 TB1 Customer Connections

No. Description No. Description

1 Remote start 12 Configurable output 3

2 Remote emergency stop 13 Configurable output 3 (common)

3 Remote fault reset 14 Configurable output 4

4 Configurable input 1 15 Configurable output 4 (common)

5 Configurable input 2 16 Not used

6 Configurable input 3 17 B+

7 Configurable input 4 18 B+

8 Configurable output 1 19 Switched B+

9 Configurable output 1 (common) 20 Ground

10 Configurable output 2 21 Ground

11 Configurable output 2 (common) 22 Ground

FIGURE 19. PCC 2100 TB1 CUSTOMER CONNECTIONS

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8.4.1 Remote Start

Automated Machinery Accidental or remote starting of the generator set can cause severe personal injury or death. Make sure that the generator set can not be started accidentally or remotely before starting work

on the generator.

Remote start terminals should only be used for a remote application. Remote start terminals are not to be shorted if the remote start function is not intended to be used.

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.)

8.4.2 Remote Emergency Stop

Opening this input causes an immediate shutdown. Emergency stop must be reset at the remote panel, then at the front panel.

8. DC Control Wiring7-2016

WARNING

NOTICE

8.4.3 Remote Fault Reset

Ground this input to acknowledge faults after they have been corrected. The control must be in Auto mode.

Faults are re-announced if they are detected again after being acknowledged.

Using the InPower service tool or accessing the Setup submenus is required to modify the customer outputs. Contact an authorized distributor for assistance.

8.4.4 Configurable Inputs

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.

The InPower service tool or access to the Setup submenus is required to modify the customer fault inputs. Contact your authorized distributor for assistance.

NOTICE

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8. DC Control Wiring 7-2016

8.4.5 Configurable Outputs

Each output has normally-open contacts. The contacts can be used to control small devices, indicator lamps, or relays.

The contacts are programmed to energize by entering a code number for the desired event.

NOTICE

Using the InPower service tool or accessing the Setup submenus is required to modify the customer outputs. Contact an authorized distributor for assistance.

8.4.6 Contact Ratings for Configurable Outputs

TABLE 19. CONTACT RATINGS FOR CONFIGURABLE OUTPUTS

Description Value

Maximum voltage 30 VDC

Maximum current 2 Amps

8.4.7 Switched B+

This output is active when the control receives a run command, for example, a remote start signal in Auto mode or the Start button in Manual mode.

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8.5 Customer Relays

8.5.1 Location of Customer Relays

8. DC Control Wiring7-2016

No. Description No. Description

K10 Configurable Output 1 K12 Configurable Output 3

K11 Configurable Output 2

FIGURE 20. LOCATION OF CUSTOMER RELAYS

8.5.1.1 Configurable Outputs

This relay is connected to the corresponding configurable output on the control. If the configurable output is active, the relay is active. If the configurable output is inactive, the relay is inactive.

This relay allows the configurable output to control larger devices, and it isolates the control from these devices.

8.5.1.2 Contact Specifications

The contacts are rated at 10 A at 600 VAC.

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8. DC Control Wiring 7-2016

8.5.1.3 Schematic

FIGURE 21. SCHEMATIC

Page 75

9 AC Electrical Connections

WARNING

Arc Flash and Shock Hazard Voltages and currents present an electrical shock hazard that can cause severe burns or death. Make sure that only service personnel who are trained and experienced perform electrical and

mechanical component installations. The AC sensing harness and other cabling will become energized when the generator set is in operation.

WARNING

Hazardous Voltage Contact with high voltages can cause severe electrical shock, burns, or death. Make sure that only personnel who are trained and qualified to work on this equipment are

allowed to operate the generator set and perform maintenance on it.

WARNING

cables (negative [–] first).

WARNING

Combustible Gases Ignition of battery gases is a fire and explosion hazard which can cause severe personal injury or

death. Do not smoke, or switch the trouble light ON or OFF near a battery. Touch a grounded metal

surface first before touching batteries to discharge static electricity. Stop the generator set and disconnect the battery charger before disconnecting battery cables. Using an insulated wrench, disconnect the negative (–) cable first and reconnect it last.

WARNING

be present. These voltages could be live even when the generator set is switched off.

This section provides the procedure that is used to connect the AC electrical system of the generator set.

Before making any AC electrical connections, make certain the generator set cannot be accidentally started. Make sure the Operator Panel is in OFF mode. Turn off or remove AC power from the battery charger and then remove the negative (–) battery cable from the set starting battery using an insulated wrench.

If the generator set is being installed in an application where it may parallel with other generators or utility sources, the generator set control system may be energized from an external source. Lock out tag out any external source that can provide AC power to the generator set.

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9. AC Electrical Connections 7-2016

NOTICE

Ventilate the battery area before working on or near battery. Wear goggles. Stop the generator set and disconnect the battery charger before disconnecting battery cables. Disconnect negative (–) cable first and reconnect last using an insulated wrench.

Connecting the generator set AC electrical system involves:

• Installation of transfer switch

• Installation or verification of paralleling switchboard

• Generator output voltage selection

• Load cable connection

• Standard and optional AC equipment connections (e.g., control box heater, coolant heater, etc.).

For all output connections, including when field connection is made at the alternator terminations, installation should be completed with conductors of appropriate size, type, and rating specified in local codes (or UL). For UL compliant installations, use conductor size, X AWG, 75 °C or 90 °C copper wire, 600V. Where X AWG is the conductor size specified by the local electrical code for 75 °C at the rated output current for the generator set. For non-UL compliant installations, use cable sizes, composition, and rating per local codes. Strain relief, bending space, raceway, and other installation features should be completed in compliance with local code.

Local regulations often require that wiring connections be made by a licensed electrician, and that the installation be inspected and approved before operation. All connections, wire sizes, materials used, etc. must conform to the requirements of electrical codes in effect at the installation site.

Before starting the generator set, 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 generator set are properly connected.

Backfeed to a utility system can cause electrocution or property damage. Do not connect to any building electrical system except through an approved device and after the building main switch is opened.

9.1 Transfer Switch

A transfer switch must be used for switching the load from the normal power source to the generator set (see Figure 22). Follow the installation instructions provided with the transfer switch when connecting the load and control wiring.

NOTICE

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9. AC Electrical Connections7-2016

No. Description No. Description

1 Normal Power Source 3 Load

2 Overcurrent Protective Device 4 Emergency Power Source

FIGURE 22. TYPICAL LOAD TRANSFER FUNCTION

9.2 Alternator Voltage Connections

These alternators can be configured to the nameplate voltages as shown on the Reconnection Diagram decal, attached to the backside of the control box cover. Many of the voltages listed will require reconfiguration of the alternator output leads on the connection terminal block. This reconfiguration must only be done by service personnel that are trained and experienced to perform electrical installation. The generator set was adjusted to produce a specified voltage during production verification testing prior to shipment. The installer must always check the stator lead terminal block connections and perform any necessary reconnect to obtain the voltage required.

Some generator sets are capable of producing a wide range of voltages and connection configurations; others have specific limited capabilities. Refer to wiring diagram and generator voltages (from the nameplate) when reviewing the voltage connection information and use the wiring diagram supplied with your generator set when actually performing load connections.

NOTICE

Reconfiguring generator sets to higher voltages can exceed the voltage capability of the specific generator windings and damage the generator and also decrease line current, rendering line circuit breakers too large. Consult with your authorized distributor before performing reconnection for a different voltage.

NOTICE

Reconfiguring generator sets to lower voltages can reduce generator set ratings, and also increase line current, rendering line circuit breakers too small. Consult with your authorized distributor before performing reconnection for a different voltage.

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9. AC Electrical Connections 7-2016

9.3 Load Connections

NOTICE

Flexible conduit and stranded conductors must be used for connections to take up movement of the generator set.

All loads are connected to the alternator by bolting stranded load wires to the appropriate terminals on the alternator reconnection terminal block or circuit breaker lugs. The terminals are marked U, V, W, and N to indicate the line and neutral connections. (Reference: U, V, and W correspond with L1, L2 and L3; and N with L0 respectively). See Appendix C on page 101 for details about the following:

• Load connections

• Conduit

• Cable Size

9.4 Load Balancing

When connecting loads to the generator set, balance the loads so that the current flow from each line terminal (L1, L2, and L3) is about the same. This is especially important if both single phase and three phase loads are connected. Any combination of single phase and three phase loading can be used as long as each line current is about the same, within 10 percent of median value and no line current exceeds the name plate rating of the generator. Check the current flow from each line after connections by observing the Operator Panel ammeter.

9.5 Current Transformers

Current transformers (CTs) reduce high voltage currents (AC) to enable safe monitoring.

9.5.1 CT Installation Requirements

The CT has a dot on one side. This dot must be facing toward the alternator reconnection terminal block (conventional current flowing into the dot). A dot is also used to indicate pin 1 of the CT.

Route the load lead through the appropriate CT (refer to the Reconnection Diagram in Appendix D on

page 107.

The CTs 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 3 for low voltage generator sets.

9.6 Coolant Heater

The coolant heaters are designed to allow the generator set to start and pick up load within 10 seconds in a 4.4 °C (40 °F) environment. In colder ambient temperature environments the starting time may be longer.

9.6.1 Coolant Heater Connection

NOTICE

The coolant heater must not be operated while the cooling system is empty or damage to the heater will occur.

Page 79

A coolant heater keeps the engine coolant warm when the engine is shut down. It heats and circulates the coolant within the engine. This reduces start-up time and lessens engine wear caused by cold starts. It is electrically operated and thermostatically controlled.

Refer to Appendix A for electrical connections.

9.6.2 Coolant Heater Specifications

An installation may include one of two types of coolant heaters.

• 4990 watt at nominal voltage - This coolant heater is used in an environment where the minimum temperature is 4.4 °C (40 °F).

• 6420 watt at nominal voltage - This coolant heater is used in an environment where the temperature is less than 4.4 °C (40 °F).

A coolant heater can be set up for 480 VAC or 240-208 VAC configurations.

9.7 Alternator Heaters

9. AC Electrical Connections7-2016

9.7.1 Alternator Heater Installation

An alternator heater(s) is used to help keep the alternator free of condensation when the generator set is not running. During cool and humid conditions, condensation can form within a alternator, creating flashing and shock hazards.

WARNING

Water or moisture inside an alternator increases the possibility of flashing and electrical shock, which can cause equipment damage and severe personal injury or death. Do not use an alternator which is not dry inside and out.

Figure 23 on page 74 shows the installation of a heater element. Connect the heater(s) terminals to a

source of power that will be on during the time the engine is not running. Be sure the supply voltage and circuit amperage is correct for the heater element rating.

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9. AC Electrical Connections 7-2016

No. Description No. Description

1 Heater Cartridge 3 Terminal Box Cover

2 Terminal Block 4 Terminal Box (Mounted on the Alternator Housing)

FIGURE 23. TYPICAL ALTERNATOR HEATER

9.7.2 Alternator Heater Specifications

The 120V alternator heater is used with UCD22 alternators.

The 240V alternator heater is used with UCD27 alternators.

9.8 Battery Charger

9.8.1 PowerCommand Battery Charger - 15 Amp @ 12 Volt and 12 Amp @ 24 Volt

The two available types of 15/12-amp PowerCommand battery chargers are shown below. For more information, refer to the battery charger owner's manual.

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9. AC Electrical Connections7-2016

No. Description No. Description

120, 208, and 240 VAC Battery Charger

277, 380, 416, 480, and 600 VAC Battery

Charger

1 Status LED 6 Fault Alarm Output Connector

2 Control Panel 7 10 Amp AC Fuse Holders

Reset Button

FIGURE 24. 15/12-AMP POWERCOMMAND BATTERY CHARGERS

20 Amp DC Circuit Breaker Switch (Shown in the

"On" position)

10 Amp AC Circuit Breaker Switches (Shown in

the "On" position)

Connector for Optional Battery Temperature

Sensor

9.9 Control Box Heater

9.9.1 Control Cabinet Heaters

A thermostat heater is installed inside the control cabinet. Both 120V and 240V heaters are available.

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9. AC Electrical Connections 7-2016

No. Description No Description

1 Terminal Block (Ground) 4 Terminal Block

2 Terminal Endplate 5 Terminal DIN Rail

3 Thermostat 6 Flexible Heater Pad

FIGURE 25. TYPICAL CONTROL CABINET HEATER

9.10 Oil Heaters

9.10.1 Oil Pan Heaters

Three 300W oil pan heaters are available.

• 120V single phase

• 208/240V single phase

• 480V single phase

NOTICE

For 120V applications, the optional location is shown. The primary location is on the left hand side of the oil pan.

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9. AC Electrical Connections7-2016

FIGURE 26. OIL PAN HEATER USED IN 120V AND 208/240V APPLICATIONS

FIGURE 27. OIL PAN HEATER USED IN 480V APPLICATIONS

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9. AC Electrical Connections 7-2016

9.11 Annunciators

9.11.1 PowerCommand Universal Annunciator

A universal annunciator provides lamps and a horn to annunciate the operating status and fault conditions of an emergency power system. It is designed for connection to either a 12 VDC or a 24 VDC control system. It can be configured to be either a positive or negative signal device.

Two versions of the PowerCommand universal annunciator are available.

• Panel Mounted

• Panel with Enclosure

The universal annunciator can communicate using either a PCCNet or a Modbus network.

Refer to the annunciator owner's manual for more information.

No. Description No. Description

1 System Status Lamps 4 Silence/Lamp Test Button

2 Insert Card 5 Network Status Lamp

3 Horn

FIGURE 28. ANNUNCIATOR COMPONENTS

Page 85

9.12 Grounding

Electric Shock Hazard Voltages and currents present an electrical shock hazard that can cause severe burns or death. Make sure that only service personnel who are trained and experienced perform electrical and

mechanical component installations. Bonding and grounding must be done properly. All metallic parts that could become energized under abnormal conditions must be properly grounded.

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 29, Figure 30 and Figure 31 illustrate typical system grounding for a 2-pole, 3-pole, and 4-pole

Automatic Transfer Switch (ATS). In the 2-pole and 3-pole ATS, note that the generator neutral is connected to the ATS and is NOT bonded to ground at the generator. In the 4-pole ATS system, a grounding electrode conductor and a bonding jumper are used to connect the generator neutral to ground.

9. AC Electrical Connections7-2016

WARNING

NOTICE

Make sure the generator set is grounded to earth in one location only. On generator sets without a circuit breaker, ground to the point indicated on the top of the generator. On generator sets with circuit breakers, use the ground lug provided in the circuit breaker box.

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9. AC Electrical Connections 7-2016

No. Description

1 Service Entrance

2 2-Pole ATS

3 Generator Set

4 Load

FIGURE 29. TYPICAL SYSTEM - ONE-PHASE, THREE WIRE UTILITY, TWO-POLE ATS

Page 87

No. Description

9. AC Electrical Connections7-2016

1 Service Entrance

2 3-Pole ATS

3 Generator Set

4 Load

FIGURE 30. TYPICAL SYSTEM - THREE-PHASE, FOUR WIRE UTILITY, THREE-POLE ATS

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9. AC Electrical Connections 7-2016

No. Description

1 Service Entrance

2 4-Pole ATS

3 Generator Set

4 Load

FIGURE 31. TYPICAL SYSTEM - THREE-PHASE, FOUR WIRE UTILITY, FOUR-POLE ATS

Page 89

10 Pre-Start Preparation

WARNING

mechanical service.

Before an initial start of the generator set, complete the Installation Checklist, see Chapter 11 on page

85.

10.1 Electrical System

Verify all electrical connections are secure and all wiring is complete and inspected. Replace and secure any access panels that may have been removed during installation.

10.2 Site-specific Configuration

NOTICE

Site-specific configuration is to be undertaken by suitably trained and qualified service personnel only.

The generator set is configured at the factory. Before starting the generator set, any site-specific configuration should be completed by qualified service personnel.

10.3 Starting

Refer to the generator set Operator manual for important safety precautions and recommended procedures for starting the generator set and verifying proper operation. Start the generator set and verify all engine and generator set menus are displaying the correct values.

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11 Installation Checklist

11.1 Installation Checklist

Tick General Items

Generator set wattage capacity is sufficient to handle maximum anticipated load.

At least 3 feet (914.4 mm) of clearance (or greater for housing door) is provided around the entire generator set for service and ventilation.

The generator set is located in an area not subject to flooding.

All operating personnel have read and are familiar with the generator set Operator manual, all health and safety procedures, warnings, cautions, precautions, and the other documentation supplied with the generator set.

All operators have been thoroughly briefed on preventative maintenance procedures.

All operators have read and understand all important safety instructions.

Generator Set Support

The 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.

The generator set is properly supported and retained to an approved base

The supporting base is large enough and is of non-combustible material, extending 6 inches (152.4 mm) all around the generator set.

Cooling Air Flow

Generator set air inlet is faced into direction of strongest, prevailing winds.

Air inlet openings are unrestricted and are at least 1 to 11/2times larger than air outlet area.

Cooling air outlet is on downwind side of building (if not, wind barrier is constructed).

Proper ducting material (sheet metal, canvas) is used between radiator and air outlet.

Diesel Fuel System (if applicable)

Fuel tanks meet or exceed all Local, State, or National codes (if applicable).

Fuel lines are properly installed, supported, and protected against damage.

The fuel filters have been installed.

Approved flexible fuel line is installed between the main fuel supply and the generator set’s fuel system near the generator set, to protect it against damage caused by vibration, expansion, and contraction.

Strainer or fuel screen (100 to 200 mesh) is installed in the fuel supply line to protect the fuel lift pump, day tank transfer pump, or float valve seat from fuel tank debris (if applicable).

The fuel filter assembly shipped with the generator set is installed and operational (if applicable).

Fuel supply shutoff valves are installed to prevent fuel flow in case of leaks.

No shutoff valves are installed on engine fuel return line (if applicable).

External fuel pumps are connected and operational at all times - generator set started or shut down (if applicable).

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11. Installation Checklist 7-2016

Fuel tanks are filled with the correct grade / type of fuel (if applicable).

Fuel system is properly primed.

No fuel leaks are found in supply line or engine fuel system.

Gaseous Fuel System (if applicable)

Check fuel line and use equations to verify it has proper volume capability.

Check if fuel pressure is between 7-13 inches water column.

Check for any gas leaks.

If necessary, perform initial demand regulator adjustment procedure.

Make sure furl pressure does not drop below 7 inches water column under full load.

Exhaust System

The breather tube routing is set up to blow the fumes away from the generator set (if applicable)

Operators are thoroughly briefed on the dangers of carbon monoxide gas.

If the installation includes a heavy duty air cleaner, it has been installed.

Areas around generator set are well ventilated. No possibility of exhaust fumes entering building doors, windows, or intake fans.

Exhaust gases are piped safely outside and away from building.

The correct length of approved rigid pipe is connected to the generator set flexible pipe using approved securing methods with no weight resting on engine exhaust components. There are no bends in flex section.

Condensation drain is provided in lowest section of exhaust piping.

Exhaust piping is insulated to guard against burns to personnel.

Exhaust piping passing through walls or ceilings have approved fire-proof materials and are in compliance with all codes.

Exhaust piping is large enough in diameter to prevent excessive back pressure on engine.

AC and DC Wiring

For bottom entry circuit breaker installations, the cable chute has been installed (if applicable).

Wire sizes, insulation, conduits and connection methods all meet applicable codes.

AC and DC wires are separated in their own conduit to prevent electrical induction.

All load, line and generator connections are well made and correct.

Flexible conduit is used between the generator and the building or surrounding structure.

Check phase rotation.

Generator Set Pre-Start

Generator set engine is properly serviced with oil and coolant.

Battery charger is installed using the appropriate cable size and is operational.

Battery charger is configured for the proper DC battery voltage, battery type, and float voltage.

Batteries are properly installed, serviced and charged.

Battery temperature sensor is connected and operational (if applicable).

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Engine coolant heater is connected and operational.

All generator set covers and safety shields are installed correctly.

All fuel and coolant shutoff valves are operational.

Radiator fan and other external moving parts including drive belts are unrestricted.

11. Installation Checklist7-2016

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11. Installation Checklist 7-2016

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12 Manufacturing Facilities

NORTH AMERICA EMEA, CIS ASIA PACIFIC

Cummins Power Generation Limited 1400 73rd Ave. NE Minneapolis, MN 55432 USA

Phone +1 763 574 5000 Toll Free +1 800 888 6626 Fax +1 763 574 5298

BRAZIL CHINA INDIA

Rua Jati, 310, Cumbica Guarulhos, SP 07180-900 Brazil

Phone +55 11 2186 4195 Fax +55 11 2186 4729

Cummins Power Generation Limited Columbus Avenue Manston Park Manston, Ramsgate Kent CT12 5BF United Kingdom

Phone +44 1843 255000 Fax +44 1843 255902

Cummins Power Generation 2 Rongchang East Street, Beijing Economic – Technological Development Area Beijing 100176, P.R.China

Phone 86 10 59023001 Fax +86 10 5902 3199

Cummins Power Generation Limited 10 Toh Guan Road #07-01 TT International Tradepark Singapore 608838

Phone +65 6417 2388 Fax +65 6417 2399

Cummins India Ltd, Power Generation Business Unit, Plot No B-2, SEZ Industrial Area, Village-Nandal & Surwadi, Taluka-

Phaltan Dist- Satara, Maharashtra 415523 India

Phone +91 021 66305514

LATIN AMERICA MEXICO

3350 Southwest 148th Ave. Suite 205 Miramar, FL 33027 USA

Phone +1 954 431 551 Fax +1 954 433 5797

Eje 122 No. 200 Zona Industrial San Luis Potosi, S.L.P. 78395 Mexico

Phone +52 444 870 6700 Fax +52 444 824 0082

12.1 How to Obtain Service

When a product requires servicing, contact the nearest Cummins Power Generation distributor. To locate the distributor, refer to power.cummins.com and select Distributor Locator. When contacting the distributor, always supply the complete model, specification, and serial number as shown on the nameplate.

12.1.1 Locating a Distributor

In North America

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12. Manufacturing Facilities 7-2016

To easily locate the nearest certified distributor/dealer for Cummins generator sets in your area, or for more information, contact us at 1-800-344-0039 or visit power.cummins.com.

If unable to contact a distributor using the automated service, consult the Internet.

If unable to arrange a service or resolve an issue, contact the Service Manager at the nearest Cummins Power Generation distributor for assistance.

When contacting the distributor, always supply the complete Model, Specification, and Serial Number as shown on the product nameplate.

Outside North America

Refer to power.cummins.com and select Distributor Locator, or send an email to ask.powergen@cummins.com.

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Appendix A. Wiring Diagrams

Table of Contents

Figure 32. A032Y198 Sheet 1 ...................................................................................................................... 93

Figure 33. A032Y198 Sheet 2 ...................................................................................................................... 94

Figure 34. A032Y198 Sheet 3 ...................................................................................................................... 95

Figure 35. A032Y198 Sheet 4 ...................................................................................................................... 96

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Appendix A. Wiring Diagrams 7-2016

The drawings included in this section are representative. For current complete information, refer to the drawing package that was shipped with the unit.

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A.1 GGHG/H Wiring Diagram with PowerCommand 2100 Control

Appendix A. Wiring Diagrams7-2016

FIGURE 32. A032Y198 SHEET 1

93A034G612 (Issue 8)

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Appendix A. Wiring Diagrams 7-2016

FIGURE 33. A032Y198 SHEET 2

94 A034G612 (Issue 8)