CUMMINS PowerCommand 3100 Series, DQAD, DQAF, DQAE Installation Manual

Power
Generation

Installation Manual

PowerCommand® Control

3100

Series

Generator

Sets

Printed in U.S.A.

DQAD.

Models

DQAE. DQAF

960-0624 5-2001

Table of Contents

SECTION

2
3

TITLE

IMPORTANT SAFETY INSTRUCTIONS iii

INTRODUCTION

SPECIFICATIONS
MOUNTING

MECHANICAL

DC

PAGE

About this Manual 1-1
Installation Overview 1-2

2-1

THE

GENERATOR

General 3-1
Location 3-1

Mounting 3-2
Access to Set 3-2
Vibration Isolators 3-4

CONNECTIONS

General 4-1
Fuel System 4-1
Exhaust System 4-4
Ventilation and Cooling 4-6

CONTROL

Control Wiring .* 5-1

TB1 Remote Monitor/Control Connections 5-1

Run Relays (K11,K12, Kl

Alarm Relay (K14) 5-4

WIRING

SET

3)

5-3

California

Proposition 65

Diesel engine exhaust
to the State of California to cause cancer, birth defects, and
other reproductive harm.

and

some of its constituents are known

Warning

6 AC

7

PRESTART

8

INSTALLATION

ELECTRICAL

General 6-1
Transfer Switch 6-2
AC Wiring 6-3
Control Heater (Optional) 6-5
Coolant Heater 6-6
Generator Heater 6-7
Fuel Transfer Pump 6-8

Ground Fault Alarm Relay (Optional) 6-9

PREPARATION

General 7-1
PCC Power On/Standby Mode 7-1
Electrical System 7-2
PCC Options Prestart Checks 7-3

Starting 7-5

General ..8-1
Generator Set Support 8-1
Cooling Air Flow 8-1

Diesel Fuel System 8-1

Exhaust System 8-2
AC and DC Wiring 8-2
Genset Prestart 8-2

CONNECTIONS

CHECKLIST

9

WIRING

General .• 9-1

DIAGRAMS

IMPORTANT

SAFETY

INSTRUCTIONS

SAVE THESE INSTRUCTIONS ­important instructions that should be followed during
installation and maintenance of the generator
ies.

Before operating the generator set (genset), read the
Operator's Manual and become familiar with it and the

equipment. Safe and efficient operation can be
achieved only if the equipment is properly operated
and maintained. Many accidents are caused by failure
to follow fundamental rules and precautions.

The following symbols, found throughout this manual,
alert you to potentially dangerous conditions to the op­erator, service personnel, or the equipment.

ri^ij'isMazd This symbol warns of immediate
hazards which will result in severe personal in-

jury or death.

IAWARNINGI This symbol refers to a hazard or un-

safe practice which can result in severe per­sonal injury or death.

IACAUTIONI This symbol refers to a hazard or un-

safe practice which can result in personal injury
or product or property damage.

This

manual contains

and

batter-

FUEL AND FUMES ARE FLAMMABLE

Fire,

explosion, and personal injury or death can result

from improper practices.

• DO NOT fill fuel tanks while engine is running, un­less tanks are outside the engine compartment.
Fuel contact

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.
made with an approved flexible
coated or copper fuel lines with diesel

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

• Be sure battery area has been well-ventilated prior

to sen/icing near
explosive hydrogen gas that can be ignited by arc­ing,

sparking, smoking, etc.

with

hot engine or exhaust is a potential

Fuel connection at the engine should be

line.

Do not

it.

Lead-acid batteries emit a highly

fuel.

use

zinc

EXHAUST

• Provide an adequate exhaust system to properly
expel discharged gases away from enclosed or
sheltered areas and areas where individuals are
likely to congregate. Visually and audibly inspect
the exhaust daily for leaks per the maintenance
schedule. Make sure that exhaust manifolds are se­cured and not
heat a compartment.

• Be sure the unit is well ventilated.

• Engine exhaust and some of its constituents are
known to the state of California to cause cancer,
birth defects, and other reproductive harm.

GASES

warped.

ARE

DEADLY

Do not use exhaust gases to

MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH

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

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

connect starting batteries, negative (-) cable first.
This will prevent accidental starting.

• Make sure that fasteners on the generator set are

secure. Tighten supports and clamps, keep guards
in position over

• Do not wear loose clothing or jewelry
moving parts, or while working on electrical equip­ment. Loose clothing and jewelry can become

caught in moving parts.

• If adjustment must be made while the unit is

ning,

use extreme caution around hot manifolds,

moving parts, etc.

fans,

drive belts, etc.

in

the vidnity of

run-

DO NOT OPERATE IN FLAMMABLE AND
EXPLOSIVE ENVIRONMENTS

Flammable vapor
become difficult to stop, resulting in possible fire, explo­sion,

severe personal injury and
genset where a flammable vapor environment can be
created by fuel
equipped with an automatic safety device to block the air
intake and stop the

the genset are solely responsible for operating the
set safely. Contact your authorized Onan/Cummins
er or distributor for more information.

can

cause an engine to overspeed and

death.

spill,

leak, etc., unless the genset is

engine.

The owners and operators of

Do not operate a

gen-

deal-

in

LS-13L

ELECTRICAL
SEVERE

• Remove electric power before removing protective
shields or touching electrical equipment. Use rub­ber insulative mats placed on dry wood platforms
over floors that are metal or concrete when around
electrical equipment. Do not wear damp clothing
(particularly wet shoes) or allow skin surface to be

damp when handling electrical equipment. Do not
wear jewelry. Jewelry can short out electrical
tacts and cause shock or burning.

• Use extreme caution when working on electrical

components. High voltages can cause injury or
death.

• Follow all applicable state and local electrical
codes. Have all electrical installations performed by
a qualified licensed electrician. Tag and lock open
switches to avoid accidental closure.

• DO NOT CONNECT GENERATOR SET DI­RECTLY TO ANY BUILDING ELECTRICAL SYS-

TEM.

Hazardous voltages can flow from the
erator set into the utility
for electrocution or property
through an approved isolation switch or an ap­proved paralleling device.

GENERAL

• Coolants under pressure have a higher boiling point
than

water.
changer pressure cap while the engine is running.
Allow the generator
pressure first.

• Used engine oils have been identified by some state
or federal agencies as causing cancer or reproduc-

tive toxicity. When checking or changing engine oil,
take care not to ingest, breathe the fumes, or
tact used oil.

SHOCK

PERSONAL

DO NOT tamper with interlocks.

SAFETY

DO NOT open a radiator or heat ex-

CAN

INJURY

line.

CAUSE

OR

DEATH

This creates a potential

damage.

Connect only

PRECAUTIONS

set

to cool and bleed the system

con-

gen-

con-

Keep multi-class ABC fire extinguishers handy.
Class A fires involve ordinary combustible materials

such as wood and
and flammable liquid fuels and gaseous
C

fires,

live electrical equipment, (ref. NFPA

Make sure that rags are not left on or near the en­gine.

Make sure generator set is mounted in a manner to
prevent combustible materials from accumulating
under the unit.

Remove all unnecessary grease and oil from the

* unit. Accumulated grease and oil can cause

heating and engine damage which present a poten-

tial fire hazard.
Keep the generator set and the surrounding area

clean and free from obstructions. Remove any de­bris from the set and keep the floor clean and dry.

Do not work on this equipment when mentally or

physically
or drug that makes the operation of equipment un­safe.

Substances in exhaust gases have been identified
by some state or federal agencies as causing
cer or reproductive toxicity. Take care not to breath
or ingest or come into contact with exhaust gases

Do not store any flammable liquids, such as
cleaners, oil, etc., near the generator set. A fire or
explosion could result.

Wear hearing protection when going near an
ating generator set.

To prevent serious burns, avoid contact with hot
metal parts such as radiator, turbo charger and ex­haust system.

fatigued,

cloth;

Class B

or after consuming any alcohol

fires,

combustibli

fuels;

Clas

No.

10).

over-

can-

fuel,

oper-

KEEP

THIS

MANUAL

NEAR

THE

IV

GENSET

FOR

EASY

REFERENCE

1.

Introduction

ABOUT

This manual covers models produced under the

Cummins®/Onan® and Cummins Power Genera-

tion brand names.
This manual provides installation instructions for

the generator set models listed on the front cover.
This includes the following information:

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

Mechanical Connections and Electrical
connections - covers most aspects of
erator set installation.

THIS

MANUAL

the

gen-

Prestart - Checklist of items or procedures
needed to prepare generator set for operation.

Initial Startup - Test complete system to en­sure proper installation, satisfactory perform­ance,

and safe operation. Refer to Operators

Manual for troubleshooting information.

This manual DOES NOT provide application infor-

mation for selecting a generator set or designing the
complete installation. If it is necessary to design the
various integrated systems (fuel, exhaust, cooling,
etc.),

additional information is required. Review
standard installation practices. For engineering
data specific to the generator
ator set Specifications
cation information, refer to Application Manual

T-030, "Liquid Cooled Generator Sets".

and

set,

refer

to

the gener-

Data sheets. For appli-

1-1

INSTALLATION

These installation recommendations apply to

OVERVIEW

typi­cal installations with standard model generator
sets.

Whenever possible, these recommendations

also cover factory designed options or modifica-

tions.

However, because of the many variables in
any installation, it is not possible to provide specific
recommendations for every situation. If there are

any questions not answered by this manual, contact
your nearest Cummins Power Generation distribu­tor for assistance.

Application and Installation

A standby power system must be carefully planned
and correctly installed for proper

operation.

This in­volves two essential elements: application and in­stallation.

Application (as it applies to generator set installa­tions) refers to the design of the complete standby
power system that usually includes power distribu-

tion equipment, transfer

switches,

ventilation equip-

ment, mounting pads, and cooling, exhaust, and

fuel systems. Each component must be correctly
designed so the complete system will function as in­tended.

Application and design is an engineering
function generally done by specifying engineers or
other trained specialists. Specifying engineers are
responsible for the design of the complete standby

system and for selecting the materials and products
required.

Installation refers to the actual set-up and assem­bly of the standby power

system.

The installers set

up and connect the various components of the sys­tem as specified in the system design plan. The
complexity of

the

standby system normally requires
the special skills of qualified electricians, plumbers,
sheetmetal workers, etc. to complete the various
segments of the installation. This is necessary so
all components are assembled using standard
methods and practices.

Safety

Considerations

The generator set has been carefully designed to
provide safe and efficient service when properly 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
code requirements have been satisfied before

and

tests have been completed and all

certi­fying the installation is complete and ready for serv­ice.

Copyright®
Cummins, Onan and PowerCommand are registered trademarks of Cummins Inc.

2001

Cummins Power

Generation.

All rights reserved.

1-2

2.

Specifications

MODEL

Cummins
Generator kW Rating See Genset Nameplate for rating information.
Cooling

Capacity with Standard Radiator

Oil

Capacity*

Engine

Inlet/Outlet Thread Size

Fuel

Max. Fuel Inlet Pressure
Max. Fuel Inlet Restriction
Max. Fuel Return Restriction

Exhaust

Outlet Size
Maximum Allowable Back Pres.

Electrical

Starting Voltage
Battery

* Referto Cummins engine Operation and Maintenance Manual for lubricating oil recommendations/specifications.

Diesel

System

Fuel

Flow

System

Group Number
Cold Cranking Amps (minimum)

Cold Soak@0oF(-18o C)

Series

Connection

Refer to Generator Outline Drawing

DQAD/DQAE/DQAF

QSM11

10.5 Gal (40 L)

9.7 Gal (36.7 L)

10PSI(69kPa)

4 in. Hg. (13.5 kPa)

2.5 in. Hg. (8.5 kPa)

5 in. NPT

41 in. H20(10.2kPa)

24 Volts DC
Two,

12 Volt
8D

900

MODEL

US gph (L/hr)

FUEL

CONSUMPTION

DQAD

17.3 (65.5)

(STANDBY/FULL

DQAE

19.4 (73.4)

LOAD/60Hz)

DQAF

21.4(81.0)

2-1

3.

Mounting

the Generator Set

GENERAL

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

these requirements before installation:

Requirements to be considered prior to installation:

• Level mounting surface

• Adequate cooling air

• Adequate fresh induction air

• Discharge of generator set air

• Non-combustible mounting surface.

INCORRECT
PERSONAL
BE

TRAINED AND

PONENT

conditions.

INSTALLATION,

INJURY,

INSTALLATION.

Use these instructions as a

DEATH,

EXPERIENCED

SERVICE
AND/OR EQUIPMENT DAMAGE.

the

ex-

IAWARNING
OR

PARTS

TO

PERFORM

• Discharge of exhaust gases

• Electrical connections

• Accessibility for operation and servicing

• Noise levels

• Vibration isolation

LOCATION

Generator set location is decided mainly by related
systems such as ventilation, wiring, fuel, and ex­haust. The set should be located as near as possi­ble to the main power service entrance. Exhaust
must not be able to enter or accumulate around in­habited areas.

Provide a location away from extreme ambient tem­peratures and protect the generator set from ad-

verse weather conditions.

REPLACEMENT

ELECTRICAL

CAN

SERVICE

AND MECHANICAL COM-

RESULT

PERSONNEL

IN

SEVERE

MUST

DEPENDING
AND

REGULATIONS
BEFORE
POLLUTION
STRUCTION

BEGINNING INSTALLATION OF YOUR

ON YOUR

MAY

CONTROL
PLANS.

LOCATION

REQUIRE

OR AIR QUALITY

AND INTENDED

YOU TO OBTAIN AN AIR QUALITY EMISSIONS PERMIT

IMPORTANT

USE,

GENSET.

AUTHORITIES

3-1

FEDERAL,

BE

SURE

BEFORE

COMPLETING

STATE

TO

OR

LOCAL

CONSULT

YOUR

LAWS

LOCAL

CON-

MOUNTING

Generator sets are mounted on a steel

skid

that pro­vides proper support. The engine-generator as­sembly is isolated from the skid frame by rubber
mounts that provide adequate vibration isolation for
normal installations. Where required by building

codes or special isolation needs, generator sets
may be mounted on rubber pads or mechanical
spring isolators. The use of unapproved isolators
may result in harmful resonances and may void the

genset warranty.
Mount the generator set on a substantial and level

base such as a concrete pad. A non-combustible
material must be used for the pad.

Use 5/8 inch or 16 mm anchored mounting bolts to

secure the vibration isolators to the base. Secure
the vibration isolators to the skid using flat or bevel
washer and hexagonal nut for each bolt (see Figure
3-1). The 1-1/2 x 6 inch pipe inserted over the

mounting bolts allows minor adjustment of the bolts

to align them to the holes

in

the subbase or vibration

isolator.

Locate
Outline Drawing

the

isolators

as

shown

referenced

on the

generator set

in the Data Sheet

MOUNTING

BASE

MOUNTING

BOLT

SUBBASE OR

VIBRATION

ISOLATOR

FLANGE

CONCRETE

HEX NUT

FLAT OR BEVEL

WASHER

1-1/2x6

INCH

PIPE

12 IN.

(305 mm)

ACCESS

TO SET

Generally, at least 1 meter (3 feet) of clearance
should be provided on all sides of the generator set
for maintenance and service access. A raised
foundation or slab of 150 mm (6 inches) or more
above floor level will make servicing easier.

Lighting should be adequate for
nance and service operations and should be
nected on the load side of

the

operation,

mainte-

con-

transfer switch so that

it is available at all times.

FIGURE

3-1.

BOLT DIAGRAM

3-2

MUFFLER

THIMBLE

FLEXIBLE

SECTION

CONDENSATION

DRAIN TRAP

DC CONTROL

WIRING

AC POWER

WIRING

AIR OUTLET

DUCT (FLEXIBLE

BELLOWS)

LEVEL

CONCRETE

BASE

FIGURE

3-2.

TYPICAL

3-3

IMPORTANT!

COOLING AIR INLET MUST BE AT LEAST 1-1/2

TIMES LARGER THAN RADIATOR DUCT OUTLET

AREA ON RADIATOR COOLED MODELS

FLOW OF COOLING AIR AND HEATED AIR CAN

BE CONTROLLED BY AUTOMATICALLY

OPERATED LOUVRES

INSTALLATION

VIBRATION

ISOLATORS

Installation and Adjustment Procedure

1.

Place the vibration isolators (Figure 3-3) on the

genset support structure. The isolators should
be shimmed or grouted to ensure that all of the
isolator bases are within 0.25 inch (6 mm) ele-

vation of each

other.

The surface that the isola-

tor bases rest on must also be flat and level.

2.

Loosen the side snubber lock nuts so that the

top plate ofthe isolator is free to move vertically

and horizontally. Be sure that the top plate is

correctly aligned with the base and springs.

3. Place the genset onto the isolators while align­ing the skid's mounting with the threaded isola-

tor

hole.

The top plates will move down and ap­proach the base of the isolator as load is ap­plied.

4.

Once the genset is in position, the isolators

may require adjusting so that the set is level.

The isolators are adjusted by inserting the lev­eling bolt through the skid and into the isolator
(the leveling bolt's locking nut should be
threaded up towards the bolt head).

The leveling bolt will adjust the clearance be-

tween the top plate and the isolator base. A

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

5. The genset may not be level

yet;

therefore, ad­just the leveling bolts until the set is level and
sufficient clearance still remains. (Clearance
on all isolators should be roughly
all isolators have been set, lock

equal).

the

leveling bolt

in place with the lock nut. -

6. The snubber nuts may remain loose

and
fore provide better isolation between the
set and support structure.

Once

there-

gen-

GENSET SKID.

SNUBBER

FIGURE

3-3. VIBRATION

CLEARANCE

ISOLATORS

3-4

4. Mechanical

Connections

GENERAL

The generator set mechanical system installation
includes connecting the
and cooling systems. Before starting any type of
fuel installation, all pertinent state and local codes
must be complied with and the installation must be
inspected before the unit is put in service.

FUEL

Cummins engines normally use ASTM No. 2 diesel
fuel. They will, however, operate on alternate diesel
fuels within
mins engine Operation and Maintenance Manual.

In all fuel system installations, cleanliness is ofthe

upmost importance. Make every effort to prevent
entrance of moisture, dirt or contaminants of any
kind into the fuel
ponents before installing.

A

fuel filter/strainer/water separator of 100-120 mesh
or equivalent (approximately 150 microns nominal)
must

be

tank or between the main tank
Use only compatible metal fuel lines to avoid elec-

trolysis when fuel lines must be buried. Buried fuel
lines must be protected from corrosion.

IACAUTIONI

lines, fittings
tank and
fuel to produce sulfuric acid. The molecular
structure
tanks reacts with the
fuel.

An electric solenoid valve in the supply line is rec­ommended for all installations and required for in­door automatic or remote starting installations.
Connect the solenoid wires to the genset "Switched
B+"

circuit to open the valve during generator set

operation.

the

specifications shown

system.

fitted between either the main tank and day

Never use galvanized

or

fuel tanks. Condensation

lines combines with the

of the copper or

fuel,

exhaust, ventilation

SYSTEM

in the Cum-

Clean all fuel system com-

and

the engine.

or

copper fuel

sulfur in

galvanized

acid

and contaminates

lines or

in the

diesel

the

must not contain a shutoff
will occur if
blocked or restricted.

IA

retum
exceeds fuel
will

Fuel Retum Restriction (or Pressure) Limit: Fuel
return drain restriction (consisting of friction head

and static head) between the engine injector return

line connection and the fuel tank must not exceed

the limit stated in the Specification section.

Fuel

A flexible fuel hose(s) or section of flexible fuel

hose(s) must be used between the engine's fuel
system and fuel supply and return line(s) to protect
the fuel system from damage caused by vibration,
expansion and contraction. Flexible lines for
necting between the engine and the stationary fuel
lines are supplied as standard equipment.

Installation of

to all applicable codes and standards, and installa­tion recommendations provided by the manufactur­er. The supplied flexible hose is approved by the
hose manufacture for use with the genset fuel type
and product application.

Support fuel lines to restrain movement
chaffing or contact with sharp edges, electrical
ing and hot exhaust parts.

IAWARNINGI

fuel,
Do not
hot exhaust parts.

Fuel lines must be routed and secured to maintain a

1/2 inch (12.7 mm) minimum clearance from electri­cal wiring and a 2 inch
from hot exhaust parts.

CAUTION I

line(s).

occur.

Lines

leading

route

device.

the

engine is

Never

If

fuel return

restriction

- Routing

the

fuel hose must be done according

Sparks

to

severe personal injury

fuel

install

and hot

lines

(51

run

with the return fuel lines

shutoff

limit, engine damage

near

mm) minimum clearance

Engine damage

device

linefs) is

surfaces can

electrical wiring

blocked

and

prevent

or

in fuel

or

con-

wir-

ignite

death.

or

Separate fuel return lines to the day tank or supply

ank must be provided for each generator set in a
multiple-set installation to prevent the return lines of
idle sets from being pressurized. Fuel return lines

Engine

Identification tags are attached to the fuel supply

line and fuel return line connections.

Fuel

Connections

4-1

ENGINE

FUEL

PUMP

DAY TANK

FUEL TRANSFER•

PUMP ELECTRIC '

MOTOR DRIVEN

VENTED

FILL CAP

120 MESH FUEL

STRAINER

LARGER OVER-

FLOW LINE

INJECTOR FUEL

RETURN LINE

CONNECT TO

AC OUTPUT

FUELTANK

All models require a fuel return
line from injectors to tank.

VENT LINE

. FILL PIPE

FIGURE 4-1 TYPICAL FUEL SUPPLY INSTALLATION

Supply

Tank

fer tank (referred to as a day tank) and auxiliary

pump will also be required. If an overhead main fuel

Locate the fuel tank as close as possible to the
erator set and within the restriction limitations of the
fuel pump. /

Install a fuel tank that has sufficient capacity to sup­ply the genset operating continuously at full rated
load for the planned period of operation or power
outage. Refer to product Specification Sheet for
fuel consumption data.

gen-

tank is installed, a transfer tank and float valve will
be required to prevent fuel head pressures from be-

ing placed on the fuel system components.

For critical start applications, where generator sets
are paralleled or must satisfy emergency start-time
requirements, it is recommended that a fuel tank or
reservoir be located such that the lowest possible

fuel level is not less than 6 inches (150 mm) above
the fuel pump inlet This will prevent air from accu-

IAWARNINGI Fuel leaks create fire and explosion

hazards which can result in severe personal in-

jury or death. Always use flexible tubing be-

tween engine and fuel supply to avoid line fail­ure and leaks due to vibration. The fuel system
must meet applicable codes.

If the fuel inlet restriction exceeds the defined limit
due to the distance/customer-supplied plumbing
between the genset and the main fuel tank, a trans-

mulating in the fuel line while the set is in standby,

eliminating the period during startup when it has to

be purged.
Fuel Inlet Pressure/Restriction Limit:: Engine

performance and fuel system durability will be com­promised ifthe fuel inlet pressure or restriction limits

are not adhered to. Fuel inlet pressure or restriction

must not exceed the limits stated in the Specifica­tion section.

4-2

Day Tank (If

Used)

Fuel day tanks are used when fuel inlet restriction

limits can not be

met,

or

the

supply tank is overhead
and presents problems of high fuel head pressure
for the fuel inlet and return lines.

Supply Tank Lower Than
lation,

the day tank is installed near the generator

Engine:

With

this instal-

set, below the fuel injection system and within the

fuel inlet restriction limit. Install an auxiliary fuel

pump,

to pump fuel from the supply tank to the day
tank. A float switch in the day tank controls opera­tion of the auxiliary fuel pump.

The supply tank top must
to prevent siphoning from

be

below the

the

fuel

day

tank top

supply to the day

tank.
Provide a return line from the engine injection sys-

tem return connection to the day

tank.

Plumb the re-

turn line to the bottom of day tank as shown in

ure

4-1.

Provide a day tank overflow line to the sup-

Fig-

ply tank in case the float switch fails to shut off the
fuel transfer pump.

IAWARNINGI Spilled fuel presents the hazard of

fire or

sonal injury or

to the supply tank

explosion which can

death.

Provide an overflow line

from

the day tank.

result

in severe per-

Supply Tank Higher Than Engine: Install the day

tank near the generator

set,

but below the fuel injec-

tion system. Use fuel line at least as large as the fuel

pump inlet. The engine fuel return line must enter

the day tank.

Include a shutoff valve in the fuel line between the
fuel supply tank and the day tank to stop fuel flow
when the generator set is off.

IAWARNINGI

and

prevention

Spilled fuel can create environmental hazards. Check local requirements

of

draining

to

sewer and

ground

water.

for

containment

4-3

EXHAUST

SYSTEM

Pipe exhaust gases to the outside of any enclosure.
Locate the exhaust outlets away from any air inlets

to avoid gases re-entering the enclosure. Exhaust

installations are subject to various detrimental

con­ditions such as extreme heat, infrequent operation
and light loads. Regularly inspect the exhaust sys­tem both visually and audibly to see that the entire
system remains fume tight and safe for operation.

IAWARNINGI

sult

in
treme
exhaust system.

Inhalation

severe

care

personal

during installation

Terminate

of exhaust

injury or

death.

to

exhaust pipe away

gases

Use ex-

provide

can re-

a tight

from enclosed or sheltered areas, windows,
doors

and

vents.

For indoor installation, the exhaust system must

use sealed joint type fittings, (for example NPT fit­tings) to provide a tighter exhaust system. Use of
slip type fittings (secured with a muffler clamp) may
allow leakage of exhaust gases into the building.

IAWARNINGI

sult in severe

treme
exhaust
tings for all indoor

Inhalation

personal

care during

system.

of exhaust

injury or

installation

Use

NPT or

installations.

gases

death.

to

provide

can re-

Use ex-

a tight

equivalent type

fit-

Use an approved thimble (Figure 4-2) where ex­haust pipes pass through wall or partitions.

Insu-

lated wall/roof thimbles are used where exhaust

pipes pass through a combustible roof or
includes structures, such as wood framing or

wall.

This

insu-

lated steel decking, etc. Uninsulated wall/roof
thimbles are used where exhaust pipes pass
through a non-combustible wall or

roof,

such as
concrete. Refer to NFPA 37, Section 6-3. "Station­ary Combustion Engines and Gas Turbines" for ac-

cepted design practices. Build according to the
code requirements in effect at the installation site.

I AWARNING I Hot

and cause severe
routed

through walls.

where exhaust

exhaust

injury

pipes can start a fire

or

Use

death

an

if

improperly

approved thimble

pipes pass through walls

or par-

titions.

IAWARNINGI

sult in severe
use

exhaust heat to warm a room, compartment

Inhalation

personal

of

exhaust gases

injury or

death.

can

re-

Do not

or storage area.

Rain caps are available for

the

discharge

end

of

ver­tical exhaust pipes. The rain cap clamps onto the
end of the pipe and opens due to exhaust discharge
force from the generator set. When the generator
set is stopped, the rain cap automatically closes,
protecting the exhaust system from

rain,

snow, etc.

Use a section of flexible exhaust pipe between the
engine and remainder of exhaust system. Support
exhaust system to prevent weight from being ap­plied to engine exhaust outlet elbow/turbocharger

connection.

IACAUTIONI

fold can result in

Weight applied

turbocharger damage.

to

the

engine mani-

Sup-

port the muffler and exhaust piping so no

weight or

stress

is

applied

to

engine exhaust el-

bow.

The exhaust system design should meet local code
requirements.

Liability for injury,
pense

cations

due

to the

to

sibility of the
fler

or

performing
mins
haust

Power

system

Generation

death,

use

of unapproved

exhaust

person

system

installing

the modification.

distributor for

parts.

damage,

mufflers

becomes

the

and

warranty

or

modifi-

the

respon-

unapproved

Contact

a Cum-

approved

ex-

muf-

ex-

4-4

Avoid sharp bends by using sweeping, long radius
elbows and provide adequate support for muffler

and tailpipe. Pitch a horizontal run of exhaust pipe

DOWNWARD (away from engine) to allow any
moisture condensation to drain away from the en­gine.

If an exhaust pipe must be turned upward, in­stall a condensation trap at the point where the rise
begins (Figure 4-3).

Shield or insulate exhaust lines if there is danger of
personal contact. Allow at least 12 inches (305 mm)

of clearance if

the

pipes pass close to a combustible

wall or partition. Before installing insulation on ex-

haust system components, check the exhaust sys-

tem for leaks while operating the genset under full
load and correct all leaks.

RAIN

CAP

9 INCH MIN

(230 mm)

DRIP CAP

HOLES IN END

OF INNER

SLEEVE

ROOF

9 INCH MIN

(230 mm)

IAWARNINGI Exhaust

can

cause severe personal injury

direct contact

sulate

exhaust
sonal contact
near other

or

or

combustible materials.

pipes

from

pipes if

when

fire

there

routed

are very hot and

or

death

hazard. Shield

is danger of per-

through

walls or

they

from

or in-

WALL OR PARTITION

FIGURE 4-2.

MOUNTING

\ PITCHED UPWARD, CONSTRUCT

EXHAUST

IF EXHAUST LINE MUST BE
A TRAP AT POINT OF RISE

THIMBLE

4-5

AVOID ^LM
SHARP M
BENDS

^fl DRAIN CONDENSATION
jl TRAP PERIODICALLY

FIGURE

4-3.

CONDENSATION

TRAP

VENTILATION

AND

COOLING

Generator sets create considerable heat that must
be removed by proper

ventilation.

Outdoor installa­tions normally rely on natural air circulation but in­door installations need properly sized and

posi-

tioned vents for required airflow.

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 move-

ment.
Size the vents and ducts so they are large enough to

allow the required flow rate of

air.

The "free

area"

of
ducts must be as large as the exposed area of the
radiator. Refer to the model-specific Specification
Sheet for the airflow requirements and allowed

air-

flow restriction.
Wind will restrict free airflow if it blows directly into

the air outlet vent. Locate the outlet vent so the ef-

fects of wind are eliminated. See Figure 4-4.

PREVAILING WINDS PREVAILING WINDS

FIGURE

4-4.

WIND

BARRIER

4-6

Dampers

Dampers or louvres protect the genset and equip­ment room from the outside environment. Their
operation of opening and closing should be

trolled by operation of the genset.

In cooler climates movable or discharge dampers

are

used.

These dampers allow

lated back

equipment room to be heated while the genset en­gine is still

Radiator Set Requirements

Radiator set cooling air is drawn past the control

end of
the radiator (Figure
the rear of
to 2 times larger than the radiator area.

to

the equipment

cold,

increasing the engine efficiency.

the

set by a pusher
the

set.

4-5).

Locate the air inlet to the to

Make the inlet vent opening 1-1/2

the

air

to

room.

fan

This enables the

that blows air through

con-

be recircu-

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

Attach a canvas or sheet metal duct to the flange
and the air outlet opening using screws and nuts so
duct can be removed for maintenance purposes.
The duct prevents circulation of heated air. Before
installing the duct, remove the radiator core guard.

Standard Radiator Cooling uses a set mounted

radiator and engine pusher fan to cool the engine.
Air travels from the generator end of the set, across
the engine and out through the radiator. An integral
discharge duct adapter flange surrounds the radia­tor grille.

Engine

Coolant

Heater

(Optional)

the

ra-

Louvers and screens over air inlet and outlet open­ings restrict air flow
A louver assembly with narrow
tends to be more restrictive than one with wide
vanes.
ver or screen manufacturer should be used.

The effective open

and

INLET AIR

DAMPER

COOL AIR

vary widely in performance.

vanes,

area

specified by the

for example,

lou-

THERMOSTATIC AIR

An optional engine coolant heater is available to
keep the engine warm for starting under adverse
weather conditions. Connect the heater to a power
source that will be energized when the engine is
NOT running.

RECIRCULATING

DAMPER *

WIND/NOISE

BARRIER

I

HOT AIR

)

Louvers should close when room

ambient is above 60° F (16° C)

FIGURE 4-5. TYPICAL RADIATOR SET INSTALLATION

RADIATOR

4-7

FLEXIBLE DUCT

CONNECTOR

DISTANCE SHOULD NOT
BE LESS THAN HEIGHT

OF RADIATOR

5. DC Control

Wiring

CONTROL

The generator set accessory box (Figure 5-1),

which is located on the backside of

ing,

contains connection points for remote control

and monitor options.

IACAUTIONI

for all

Box.

Solid

vibration.

TB1

Customer monitor/control connections are at­tached to terminal block
equipment such as sensing devices used to monitor
genset operation, remote start/stop switches,
trol box heater, battery charger and etc. are at­tached to

tions diagram in Section 9.

TBI

Wiring

a

separate metal conduit from

to avoid inducing currents that could cause

problems within

Stranded copper wire must

customer connections

copper wire

REMOTE

CONNECTIONS

TB1.

Refer to PCC Customer Connec-

Always

the

WIRING

the

control hous-

be

to

the

Accessory

may

break

MONITOR/CONTROL

TB1

(Figure 5-1). Optional

run

control circuit wiring

control.

due to

AC

power cables

genset

con-

used

in

Digital Connections: Connection points, other

then relayed outputs, network, switched B+ and B+

are considered digital connections to terminal strip

TB1.

The type/gauge wire to use for these connec-

tions are:

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

• 1000 to 2000 feet (305 to

stranded copper wire.

Relay Connections:
vices that can be attached to the relay outputs of
TB1,

the electrical contractor must determine the

gauge of the stranded copper wire that is used at

this installation site. Refer to Customer Connec­tions diagram in Section 9 for the relay
specifications.

Network Connections: Refer to 900-0366 Power-

Command Network Installation and Operation

manual for the type/gauge wire to use for
nections.

Switched B+: (Fused at 10 amps.) Same as Relay
Connection description.

B+:

(Fused at 20 amps.) Same as Relay Connec-

tion description.

Due

610m),

to the wide variety of de-

use 18 gauge

these

con-

5-1

OPTIONAL

COMMON ALARM

RELAY K14

TBI-1

OPTIONAL RUN

RELAYS

K11,

K13

K12 &

TBI-62

FIGURE

5-1. ACCESSORY BOX

5-2

RUN

RELAYS

The optional run relays are rail mounted inside the

accessory box (Figure 5-1). The rail mount allows

you to easily remove and replace the snap-on re-

lays.

The generator set can be equipped with one,

two or three run relays.
The three-pole, double-throw run relays (Figure

5-2) are

used

to control auxiliary equipment such as

(Kl

1,

K12, 13)

K11,K12, K13

K11,K12, K13

fans,

pumps and motorized air dampers. The run
relays are energized when the generator set control
receives a start signal.

The contacts are rated:

• 10 amps at 28 VDC or 120 VAC, 80%PF

• 6 amps at 240

• 3 amps at 480/600 VAC, 80%PF

I
7
4

2
8
5

CUSTOMER

CONNECTIONS

VAC,

80%PF

A40-TB1-8 _

(SWITCHED B+)

RUN RELAY

®

5

ffl

©

I®

K11,

K12, K13

K11

©
©

© © ©

3
9
6

NO

NC

CO

"- A40-TB1-12

COM (B-)

RUN RELAY

©
©

5

©
©

3-

K12

©

©

©

© ©

NO
NC

K13

RUN RELAY

©

©

©

©

r-®

© ©

©

©

©

NO
NC

FIGURE

5-2. OPTIONAL

RUN RELAYS

5-3

(Kll,

K12,

K13)

ALARM

RELAY

(K14)

The optional alarm relay is rail mounted inside the
accessory box (Figure 5-1). The rail mount allows
you to easily remove and replace the snap-on relay.

The three-pole, double-throw alarm relay (Figure
5-3) is often used to energize warning devices such

as audible alarms. Any generator set warning or
shutdown will energize the alarm relay.

The contacts are rated:

• 10 amps at 28 VDC or 120 VAC, 80%PF

• 6 amps at 240 VAC, 80%PF

• 3 amps at 480/600 VAC, 80%PF

A40-TB1-11

(GND)

A40-TB1-31 —

(COMMON ALARM)

K14

K14

K14

JUMPER WIRE

REQUIRED FOR K14

RELAY OPTION

I

A40-TB1-1

(B+)

7

4
2

8
5

3
9
6

COMMON ALARM

CUSTOMER,

CONNECTIONS

K14

©
©

3

"51

9. lei

2

©

©

©

NO

©

NC

©

C011

©

- A40-TB1-30

COM (COMMON ALARM)

©

FIGURE

5-3.

OPTIONAL

ALARM

5-4

RELAY

(K14)

6. AC

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

IACAUTIONI Before disconnecting battery

cablefs),

wait at least 30
may be affected (e.g., engine dying or hard
starting) if battery
the 30 second
nel may be

Electrical

GENERAL

press

the Emergency Stop button
seconds. Engine performance

cablefs)

waiting period. Service

required

to

correct fault.

is

removed

Connections

and

during

person-

2.

Press the Emergency Stop button and wait at

least 30 seconds before completing Step 3.

3. Turn off or remove AC power from the battery
charger.

4.

Remove the negative (-) battery cable from the

generator set starting battery.

Connecting the genset AC electrical system in-

volves:

IAWARNINGI

can

cause
ing at battery
equipment, name,
nite battery gas. Do not smoke, or switch
trouble light ON

static

teries by first
face.

Ventilate

battery—Wear goggles—Stop
connect charger before
cables—Disconnect negative
reconnect

IACAUTIONI Disconnect battery

source before

Otherwise, disconnecting cables
voltage spikes damaging to DC control circuits

of

the

IAWARNINGI

set

can
Prevent accidental starting by
the negative

Before making any AC electrical connections, make

certain the generator set cannot be accidentally

started as follows:

1.

Move the Run/Off/Auto switch on the control

panel to the OFF

Ignition

severe

terminals,

electricity from

touching a grounded

battery

last.

set

Accidental starting

cause

severe personal injury

(-)

of

personal injury

pilot

or OFF near

area before working on

disconnecting

cable from the battery terminal.

position.

explosive battery gases

or

light

lights

body

disconnecting

switch

and

battery. Discharge

before touching bat-

genset and dis-

(-)

cable

charger from

battery cables.

of

disconnecting

death.

sparks can ig-

metal sur-

can result in

the generator

or

Arc-

or other

or near

battery

first

and

AC

death.

• Installation of transfer switch

• Generator output voltage selection

• Load cable connection

• Standard and optional AC equipment connec­tions

(e.g.,

control box heater, coolant heater,

etc.

Local regulations often require that wiring connec­tions be made by a licensed electrician, and that the
installation be inspected and approved before op­eration.
etc. must conform to the requirements of electrical

codes in effect at the installation

IAWARNINGI Improper

electrocution, resulting
ry or

age.

Before starting the genset, check to make sure that
all electrical connections are secure, and that all
wiring
panels that have been removed during installation.
Check that the load cables from the genset are
properly

IAWARNINGI Backfeed to utility system can

cause electrocution or property damage. Do
not connect to any building electrical system
except through an approved device and after
building main

All connections, wire

death

is

and/or property and

complete.

connected.

Replace and secure any access

switch is opened.

sizes,

wiring

in

materials

site.

can

cause

severe personal inju-

equipment dam-

used,

a fire or

6-1

TRANSFER

SWITCH

If the installation is for standby service, a transfer
switch must be used for switching the load from the
normal power source to the genset (see Figure 6-1).

Follow the installation instructions provided with the
transfer switch when connecting the load and
trol wiring.

con-

NORMAL
SOURCE

FIGURE

6-1.

LOAD

TYPICAL

FUNCTION

LOAD

GENSET

TRANSFER

•

1

i

i .... J

6-2

AC

WIRING

Generator

Voltage

Connections

The available generator output voltages and maxi-

mum current ratings are specified on the generator
set nameplate. Line-to-neutral voltage is always the
lower voltage shown and line-to-line voltage is the
higher rating.

All loads are connected to the generator by bolting
stranded load wires to the appropriate terminals on

the generator reconnection terminal block or circuit

breaker lugs. The terminals are stamped U, V, W
and N to indicate the line and neutral connections.
(Reference:
L3;

and N with

Load

Balancing

U,

V,

and

W correspond

LO

respectively).

with

Ll, L2 and

These generators can be configured to the name­plate voltages as shown on the Reconnection Dia­gram located on the side access cover of

housing.

Many of the voltages listed will require re-

the

control

configuration of the generator output leads on the
connection terminal block. This reconfiguration
must only be done by service personnel that are

trained and experienced to perform electrical instal-

lation.

The generator set was adjusted to produce a
specified voltage during production verification 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.

Reconfiguring generator sets to
higher
ity of
age the
rent,
Consult with your

voltages can exceed the voltage capabil-

the specific generator windings

generator

rendering

and also decrease line cur-

line circuit breakers too large.

and

dam-

distributor before performing

reconnection for a different voltage.

IACAUTIONI Reconfiguring generator sets to

lower voltages can reduce generator set rat­ings,

and

also increase

line

current,

rendering
line circuit breakers too small. Consult with
your distributor before performing reconnec-

tion

fora

different voltage.

Load

Connections

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

When connecting loads to the generator set,
ance the loads so the current flow
minal (Ll, L2 and L3) is about the

from

same.

each line

This is es-

bal-

ter-

pecially important if both single phase and three
phase loads are

connected.

Any combination of

sin­gle phase and three phase loading can be used as
long as each line current is about the same, within

10 percent of median value and no line current ex-

ceeds the nameplate rating of the generator. Check

the current flow from each line after connections by

observing the control panel ammeter.

Current

Current transformers (CT's) are required on

Transformers

gen­sets that contain AC meters. The CT's must be
installed as noted in the following CT Installation
Requirements.

Refer to the Reconnection Diagram to identify the

output leads/phase that must be routed through
each CT, and also appropriate transformer post
selection for meter sensing
are labeled

CT21,

CT22 and CT23 on the recon-

leads.

The transformers

nection wiring diagram. (The Reconnection Dia­gram is located on the upper side cover of the

con-

trol housing.)

CT

Installation Requirements:

A. The CT has a dot

facing toward the generator (conventional
rent flowing into the

on

one

side.

This dot must be

dot).

A dot is also used to

cur-

indicate pin 1 of the CT.

B. CT21 - U load leads (A phase),

CT22 - V load leads (B phase)
CT23 - W load leads (C phase)

C. Route the appropriate load wires through each

CT.

D. The CT's have dual secondaries (3 pins). The

CT secondary wire marked 1 is connected to
pin 1 of the
is connected to

CT.

CT secondary wire marked 2/3

pin

2 for high voltage gensets or
to pin 3 for low voltage gensets. (Refer to Re­connection Diagram.)

6-3

Grounding

The following is a brief description of system and
equipment grounding of permanently installed AC
generators within a facility wiring system. It is
important to follow the requirements of the local
electrical code.

Figure 6-2 illustrates typical system grounding for a

3-pole and a 4-pole automatic transfer switch

(ATS).

neutral is connected to the ATS and is NOT bonded
to ground at the generator. In the 4-pole ATS sys­tem,

ing jumper are used to connect the generator
tral to ground. In some installations, a CT may be

required for ground fault monitoring (refer to Figure
6-2 for CT location).

In the 3-pole ATS, note that the generator

a grounding electrode conductor and a bond-

neu-

Make sure the genset is grounded to earth in one
location only. On generators without a circuit break-

er, ground to the point indicated on the top of the
generator. On gensets
ground lug provided in the circuit breaker box.

IAWARNINGI Electric current can cause severe

personal
ing must be done

that could become energized under
conditions

Typical requirements for bonding and grounding
are given in the National Electrical Code, Article

250.
to the requirements of the electrical codes in effect
at the installation site.

injury

must be

All connections, wire sizes, etc. must conform

with

circuit breakers, use the

or

death. Bonding

properly.

properly grounded.

All metallic parts

and

ground-

abnormal

TO UTILITY

SERVICE

30
N

TO UTILITY

SERVICE

SERVICE

r

30

N

L --X —L..

SERVICE ENTRANCE

r

-O O-

r-ob-

L

___r—1_.

1

ENTRANCE

4-POLE AUTOMATIC
TRANSFER SWITCH

3-POLE
TRANSFER SWITCH

AUTOMATIC

45

IS

4 WIRES & GROUND

TO LOAD

GENERATOR

4 WIRES & GROUND

TO LOAD

GENERATOR SET

SET

BONDING

.JUMPER

CT LOCATION IF
REQUIRED FOR

GFI MONITORING

GROUNDING

ELECTRODE

CONDUCTOR

FIGURE

6-2.

TYPICAL

SYSTEM

GROUNDING ONE-LINE DIAGRAMS

6-4

CONTROL

HEATER

(OPTIONAL)

A control heater (Figure 6-3) provides a means of
humidity /temperature control of the control box in-

TO ACCESSORY BOX

A40-TB1-36 & 37

(PCC CONTROL)

terior.

It protects the components when the genera-

tor set is subjected to varying ambient air conditions

during extended periods of non-use.

nn

k

-ELJ

lur =.j

HEATER

RGURE

BOTTOM VIEW OF

CONTROL BOX

6-3. OPTIONAL

CONTROL

HEATER

6-5

COOLANT

HEATER

The coolant heater keeps engine coolant warm
when the engine is shut down. It heats and circu­lates the coolant within the engine. This reduces

startup time and lessens engine wear caused by
cold starts. It is electrically operated and thermos­tatically controlled.

IACAUTIONI

TTie coolant

heater

must

not be op­erated while the cooling system is empty or
damage

to

the

heater will

occur.

Figure 6-4 shows a typical coolant heater. Connect

the heater to a source of power that

will

be

on

during

the time the engine is not running. Be sure the sup-

ply voltage and circuit amperage is correct for the
heater element rating.

Refer to the electrical diagram located inside

the

AC
electrical connection box cover (Figure 6-4) for
coolant heater power connections/voltage selec-

tions.

A

battery

charge.

rent

The

when

charger

heater

the

heater(s)

is

required to prevent

control

relay

draws

is

off. The heater

battery

83

mA

is

off

dis-

of

cur-

when
the engine has reached the proper temperature or
the engine

IACAUTIONI DO not connect AC power to the

heater

will

run continuously without

overheat and

is

running.

before connecting

damage

heater.

battery

DC power

cables. Heater

and can

THERMOSTAT

COOLANT

FLOW

AC ELECTRICAL CONNECTION

BOX (ELECTRICAL DIAGRAM

INSIDE COVER)

DC CONTROL

LINE

DRAIN

AC POWER

LINE

FIGURE

6-4.

TYPICAL

6-6

COOLANT

HEATER

GENERATOR

A generator heater(s) is

HEATER

used

to help keep the

gen-

erator free of condensation when the generator set

is not running. During cool and humid conditions,
condensation can form within a generator, creating
flashing and a shock hazard.

Figure 6-5 illustrates the installation of two heater
elements. Connect the heater(s) terminals to a
source of power that will be on during the time the
engine is not running. Be sure the supply voltage

and circuit amperage is correct for the heater ele-

ment rating.

IAWARNINGI

tor increases the
electrical
damage
not

use a generator which

Water

possibiUty

shock,

which can cause equipment

and severe

out.

or

moisture inside

of flashing and

personal injury

is not dry

a genera-

or

death.

inside

and

HEATER

Do

LEADS

\

n

1 3

HEATER

FIGURE

TERMINAL

6-5.

TYPICAL

BOX

HEATER

TERMINAL.

BLOCK

GENERATOR

HEATER

6-7

LEADS

TOTAUHATT8

HEATER

HEATERS

VOLT/WATTS

-

LABEL

INSTALLATION

3

FUEL

TRANSFER

PUMP

A fuel transfer pump and control are available when
a sub-base or in-skid day tank are
automatic control operates the fuel pump to

provided.

main-

The

tain a reservoir of fuel in the day tank.

IAWARNINGI Diesel fuel is highly

Improper installation
age of

property if

lation and

large quantities

the

fuel

service must
and experienced
the

applicable codes.

of

this

of fuel and

is

accidentally

be

persons

performed

in accordance with

combustible.

kit

can

lead

loss

ignited. Instal-

by

to

spill-

of

life

trained

anc

Do not smoke near fuel and keep flames,
sparks,
ment, and other

pilot

lights, arcing switches

sources

of

and

equip-

ignition well away.

CONTROL

FLEXIBLE FUEL

RETURN LINE

FLEXIBLE FUEL

SUPPLY LINE

FUEL PUMP

AND MOTOR

FLOAT SWITCH

ASSEMBLY

FIGURE

6-6.

TYPICAL

DAY

TANK

IN-SKID DAY TANK INSTALLATION

FUEL

GAUGE

6-8

FUEL FILL

CAP

Fuel Pump Control

The control

VAC.

The control is set up at the factory for connec-

can be

AC

Connections

powered

by

120 VAC

tion to 240 VAC.

1.

To

convert

the day

tank controller from

VAC to 120 VAC, perform the following steps.

A.

Remove the two jumpers between termi-

nals

TB1-6 and TB1-7 in the control box

and connect

TBI-5

and TB1-6 and the other between

terminals TBI-7 and

one

between terminals

TBI-8.

,

or 240

240

2.

To

convert

the day

tank controller from

VAC to 240 VAC, perform the following steps.

A.

Remove

TBI-5
in

the

jumpers

the

jumpers between terminals

and

TBI-6,

control

and TB1-7 and TB1-8

box and

connect

between terminals TBI-6

the two

TBI-7.

B. Move selector switch SI

03

on the control

PCB to the down position for 240 VAC.

C.

If

the control is equipped with a transform­er, remove the jumpers between terminals
H1 and H3, and H2 and H4 and connect
the two jumpers between H2 and H3.

120

and

B. Move selector switch S103 on the control

PCB to the up position

C.

If the

control

is

equipped with a trans-

for

120V.

former, remove the two jumpers between
terminals H2 and H3 and connect one be­tween

HI

and H3 and the other between

H2 and H4.

AC

(240V)
EARTH
NEUTRAL
AC

GND

(I20V)-

(I20/240V)

-

I

2 3 4 5 6 7 8

3 Attach a tag

supply voltage.

4 Terminals TBI-8 and TBI-5 are available

connection

shutoff valve rated
The voltage rating
spond with
See Item 2 above.

PI03-GND
PI

03-4
PI03-WHITE
PI

03-3
PI

03-I

9I0II I2I3I4I5I6I7I8I9

00

T

0

to

the control

of a

120

not

of the

the

voltage utilized

20 2I

00

box

indicating

or

240 VAC electric fuel
more than

0.5

amps.

valve must corre-

for

the pump.

-SI

+

USED

-GND

W/O

TRANSFORMER

the

for

J5

oooooooooo

J6

(ooooooooooooo

J3

o

r°°)

FIGURE

6-7.

FUEL

PUMP

PCB

ASSY-DAYTANK 300-3464

CONTROL

6-9

o

CD

TERMINAL

o

to

J4

BOARD

GROUND

The optional Ground Fault Relay (GFR) (Figure

6-8) is typically located behind the lower control

housing grille. The ground fault relay continuously
monitors the neutral to ground connection and
vates a fault alarm when the connection is broken.
During genset operation, the relay continuously
monitors the line to neutral and activates a fault

alarm when a ground fault is sensed.

FAULT

(OPTIONAL)

ALARM

RELAY

acti-

After the installation of the genset is complete, per­form the following procedure to test the operation of
the ground fault relay.

A. Verify that the N-G Fault Indicator on the

GFR is not lit. If lit, it indicates that the
bonding jumper circuit (neutral to ground)
is

open.

jumper, a bonding jumper must be

installed at the facility service entrance.

If genset does not require bonding

The relay alarm contacts are typically connected to
the genset control to provide a "Ground Fault
Alarm"

A control reset will clear

and will also reset the ground fault relay.

The relay has a time delay setting of zero to one se­cond and a current setting of 5 to 1200 amperes.

Adjust the Current and the Time Delay controls on
the ground fault relay to the customers specifica­tions.

indication.

the

fault at the control panel

A. Move the control switch to the Run

tion.

B. Press the TEST switch on the ground fault

relay.

C. Verify that the control panel warning mes-

* sage is displayed and the Fault Indicator

(>l)

on the GFR is lit.

D. Reset the control panel fault (this will also

reset the ground fault relay).

posi-

6-10

CONTROL

HOUSING

GROUND FAULT

RELAY

ASSEMBLY

GRILLE

TEST BUTTON

FAULT

INDICATORS

>l

(OVER CURRENT)

N-G

(OPEN CIRCUIT)

FIGURE6-8.

ON INDICATOR

0-S 4-50 8-&00
1

• 10 5 • IOO 9 - 1200
2 • 20 6 ­3

• 23 7 =

GROUND

200

300

FAULT

RESET BUTTON

(N.U.,

TO AUTO RESET)

TIME DELAY CONTROL

CURRENT CONTROL

ALARM

RELAY

FACTORY SET

6-11

7.

Prestart

Preparation

GENERAL

Before attempting
set, be sure to complete the Installation Checklist in
Section

IACAUTIONI Before disconnecting battery

cablefs),

wait at least 30
may be affected (e.g., engine dying or hard
starting) if battery
the 30 second
nel may be

IAWARNINGI Ignition of

can
tery
flame,

gas.

OFF near
from body before touching batteries by first
touching a grounded metal surface.

Ventilate

battery—Wear goggles—Stop
connect charger
cables—Disconnect negative
reconnect last.

8.

PCC

POWER

press

required

cause severe personal injury. Arcing

terminals, light switch

pilot

lights

Do

not

smoke,

battery.

battery

the

initial start

ON /

STANDBY

the

Emergency Stop button

seconds.

cablefs)

waiting period.

and

or

Discharge static electricity

area before working

before disconnecting

Engine performance

is removed during

to

correct fault.

explosive

or other

sparks

switch trouble light

of

MODE

Service person-

battery

equipment,

can

ignite battery

genset and dis-

f-)

cable first and

the

generator

and

gases

at bat-

ON

on

or near

battery

IACAUTIONI

source before disconnecting battery cables.

Otherwise, disconnecting
voltage spikes damaging

of

IAWARNINGI

set
Prevent accidental starting by disconnecting
the

Before opening the PCC control cabinet to make

the following Power On/Standby Mode

remove the negative (-) battery cable(s) from the
generator set starting battery as follows:

or

Disconnect battery charger from

cables can result in

to DC

the

set.

Accidental starting

can

cause

negative

1.

Move the Run/Off/Auto switch on the control

panel to the OFF

2.

Press the Emergency Stop button and wait at

least 30 seconds before completing Step 3.

3. Turn off or remove AC power from the battery
charger.

4.

Remove the negative (-) battery cable from the

generator set starting battery.

severe

(-)

cable

personal injury or death.

from

position.

control circuits

of

the generator

the battery terminal.

selection,

AC

7-1

Selecting

IACAUTIONI

circuit
wear a grounding

Power On or Standby

Mode

Electrostatic discharge will damage

boards. To prevent this damage,

always

wrist strap when working

in-

side control box.

Set the Power On / Standby Mode switch (S5 in

Fig-

ure 7-1) to the desired position.
Power On Mode: Slide the switch to the left to se-

lect the Power On (awake) mode. It is recom­mended that switch

S5

be left

in

the Power

On

mode

in all applications, except those where battery

charging is not available.
The PCC will initialize the operating software and

permit operation of the menu display panel. Power
will stay on until the switch is reset to the Standby
Mode.

Standby Mode: Slide the switch to the right to se­lect the Standby (sleep) Mode. In this mode, the

PCC operating software will be initiated by:

• moving the Run/Off/Auto switch to the Run
position,

• pressing the Self Test button,

• a remote start input signal (genset in Auto
mode),

or

• any one of several "wake-up" signals from ex­ternal switches.

With the switch set to Standby mode, pressing the
Self Test button will allow you to activate and view

the menu displays without starting the generator

set. If no menu selections are made, a software

tim-

er will shut down the power after 30 seconds.

When left in the Standby Mode, and a "Warning"
signal is sensed by the PCC (for example, low
engine temp), the control will wake up and display
the warning message. The control will remain active

until the warning condition is corrected and the Re-

set button is pressed to clear the warning message.

DISPLAY

(A35)

BOARD

PCC

g,

POWER

MODE

SWITCH

\

LA

ON /

STANDBY

ENGINE

(S5)

DIGITAL

ANALOG

INTERFACE

(A31) (A34)

BOARD

(A32)

BOARD

(A33)

CUSTOMER

INTERFACE

FIGURE

7-1.

CABINET

INTERIOR (PCC 3100)

7-2

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 re-

moved during installation.

Battery

IAWARNINGI

set
Make sure that the
control panel is set to the Off
connecting

Starting,
ing

Connections

can

Accidental starting

cause

severe

personal

Run/Off/Auto switch

the

battery

cables.

of

the generator

injury

or

death.
on the

position

before

the unit requires 24 volt battery current, us-

two 12 volt batteries (see Specification section).

Connect the batteries in series (negative post of first

battery to the positive post of

the

second battery) as

shown in Figure 7-2.

Service the batteries as necessary. If an automatic
transfer switch is installed without a built-in charge
circuit, connect a separate battery charger. A bat­tery charger is required when the PowerCommand
control is set to the Power On (awake) mode.

IAWARNINGI Ignition of

can cause

severe personal injury.

explosive

battery gases

Always con­nect negative (-) battery cable last to prevent
arcing.

IAWARNINGI

ing on or near

nals,

light switch

lot

lights

not

smoke,

near

battery.

body

before touching batteries

a

grounded

Ventilate

battery.

and

sparks

battery area before work-

Arcing at battery termi-

or

other equipment, flame,

can

ignite battery gas. Do

or switch trouble light ON or OFF

Discharge static electricity from

by

first

touching

metal

surface.

pi-

POSITIVE

FIGURE 7-2. GENSET BATTERY

NEGATIVE

TWO, 12

BATTERIES

VOLT

CONNECTIONS

7-3

PCC

OPTIONS

All generator set configuration options are set at the
factory except for site related options,
Stop Time Delays, Cycle Crank, Customer Fault 1
and 2, etc..

Adjustment of these options are divided into two
categories within the menu driven system. These
two categories are Adjust and Setup/Calibrate.

The Setup/Calibrate submenus are intended for
qualified service personnel only and require a pass­word to modify these submenus. The Adjust sub­menus are intended for service personnel and site
personnel.

The Adjust submenus allow site personnel to
brate the generator set voltage/frequency, and
start/stop time delays. For the prestart checks, ad-

justment of only the start/stop delays is required.

Adjust

To adjust the start and stop delays, press the button
next to the word "ADJUST' in the Main Menu.
ure 7-3 shows a block representation of the AD­JUST menu. After you press the button next to the
word "ADJUST' in the display, the VOLTAGE sub­menu will appear.

As shown in the diagram, the ADJUST menu has
four submenus, including a save/exit procedure. To

move through the VOLTAGE and FREQUENCY
submenus, press the button next to
play the STOP DELAY submenu.

Menu

PRESTART

CHECKS

(e.g.,

Start/

cali-

Fig-

the"»'

to dis-

START DELAY

to remote starting in the Auto mode. Use the buttons

next to the "ff" and'T symbols to set the start delay.

The start delay adjustment range is 0 to 300 sec-

onds.

STOP DELAY submenu: This delay applies only

to remote stopping in the Auto mode. From the

START DELAY submenu, press the button next to
the"»"
submenu.
symbols to set the stop delay. The stop delay adjust­ment range is 0 to 600 seconds.

SAVE/EXIT submenu: From the STOP DELAY

'submenu,

display to move to the SAVE/EXIT submenu. Select
SAVE to save your changes. At the CHANGES
SAVED submenu, select EXIT to return to the Main
menu.

If you select

after shutdown, and will be in effect when the set is

restarted.
adjustments will remain in effect until the genset is
shut down and return to the previous settings when
the set is restarted.

in the display to move to the STOP DELAY

Use the buttons next to the "tt" and

press the button next to the "»"' in the

If you select EXIT without saving first, the

submenu:

SAVE,

This delay applies only

the adjustments will be retained

7-4

I

ADJUST

MENU

•<

ENGINE
ADJUST

•<

•<

ft

VOLTAGE

•<

11

»

•<

tt

•<

•<

•<

•<

•<

FREQUENCY

tt

START

Ji

SEC >>

tt

STOP

U

SEC >>

SAVE
EXIT

DELAY

DELAY

GEN

>>

>>

>•

>•

•

•

•

CHANGES

EXIT

SAVED

>>

•

>U

• <

u<

ENGINE
ADJUST

GEN >•

>> >•

•<

•<

•<

SAVE
EXIT

SAVE
EXIT

•

j

>>

>>

•

>IJ

•

:

•

•<

u<

•<

u<

CHANGES
EXIT

>>

ENGINE

ADJUST

tt

VOLTAGE

ii-

FIGURE

7-3.

SAVED

ADJUST

GEN

>•

>> >•

>> >•

MENU

tt

•

•

•<

u<

VOLTAGE

>> >•

Indicates "OR" ConditiorTI

•

7-5

•<

•<

•<

>•

>•

STARTING

Refer to the generator
portant
cedures
operation. Start the generator set and verify all en­gine and generator gauges are displaying the cor­rect values.

safety precautions and recommended pro-

for starting the genset and verifying proper

set

Operator's manual for im-

7-6

8. Installation

Checklist

GENERAL

• Generator set wattage capacity is sufficient to handle maximum anticipated

• At least 3 feet of clearance (or greater for housing door) is provided around entire generator set for servic­ing and ventilation.

• Generator set is located in an area not subject to flooding.

• All operating personnel have read and are familiar with Operator's Manual.

• All operators have been thoroughly briefed on preventive maintenance procedures.

• All operators have read and understand all Important Safety Instructions in Operator's Manual.

GENERATOR

• Floor, roof or earth on which the generator set rests is strong enough and will not allow shifting or move­ment. Observe local codes on soil bearing capacity due to freezing and thawing.

• Generator set is properly supported and retained to approved base.

• Supporting base is large enough and is of non-combustible material - extends 6-inches all around set.

COOLING

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

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

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

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

SET

SUPPORT

AIR

FLOW

load.

DIESEL

• Fuel tanks meet or exceed all Local, State or National codes.

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

• Approved flexible fuel line is installed between main fuel supply line and generator set's fuel system, near
the generator
tion.

• Strainer or

tank transfer pump or float valve seat from fuel supply tank debris.

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

• No shutoff valves are installed on engine fuel return line.

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

• Fuel system is properly primed.

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

set,

to protect the fuel system from damage caused by vibration, expansion and contrac-

fuel

screen (100 to 120 mesh) is installed in the

FUEL

SYSTEM

fuel

supply line to protect the fuel lift

pump,

day

8-1

EXHAUST

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

• Areas around set are well
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.

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

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

ventilated.

No possibility of exhaust fumes entering building doors, windows, or

AC

AND DC

SYSTEM

WIRING

• All

• Flexible conduit between generator set and building or surrounding structure.

• Generator set engine is properly serviced with oil and coolant.

• Batteries are properly installed, serviced and charged.

• Battery charger and engine coolant heater are connected and operational.

• All generator set covers and safety shields are installed properly.

• All fuel and coolant shutoff valves are operational.

load,

line and generator connections are proper and correct.

GENERATOR

SET

PRESTART

8-2

TBI-PIA

(TOP)

TBI-PIB (SIDE)

•B+ (20A

•SWITCHED B+

-CHASSIS

NET

POWER
NET
NET DATA I
NET DATA
RUPTURE

CMSTO

CMS70

CMSTO
CMSTO
CMSTO

CUSTOMER
CUSTOMER

FAULT
ENGINE
LOW
REMOTE
REMOTE
(N/O)

COMM

(N/C)

+

POWER

-

2

BASIN
IDLE/RATED
EMERG
FAULT

ACKN
WARNING
SHUTDOWN

FAULT
FAULT

RESET

IDLE

FUEL

START
EMERG

STOP

I
2

STOP

FUSED)

(IOA

GROUND

COMMON

ALARM

>

FUSED)

A

-w-

-Ih

-yf-

H*—I

_P2l4

PZ-12
CONT

CONT

2-U
P2-I3
P2-I2

2-8

P2-7
P2-5
PZli.

P3-9

at

P

-3

-4

-23

-8

P

-

PF~5
P2-23

HEATER
HEATER

I
2

(N/O)
(N/O)

CUSTOMER
HEATER
HEATER 2

COMM

SPARE
UTILITY
UTILITY
N/C
N/C
MASTER
LOAD
CB
CB
KVAR
KVAR ­KW
KW
SHIELD
EXTERNAL
EXTERNAL
SPARE
SPARE

RTN

I

(N/O)

READY

(N/O)

LOAD

(N/O)
(N/O)
(N/C)
(N/C)

CB
CB

START/SYNC

DEMAND/UTILITY

OPEN/CLOSE

POSITION

*

•

­ LOAD

LOAD

TO

LOAD

DUMP

AUX
AUX

INHIBIT

SET
SET

TERMINAL BLOCK POSITIONS
TBI-41 THROUGH TBI-60

ARE

FOR PARALLELING ONLY

ENAB1

SINGLE

•

-

NOTE:

A

A
A
A
A

&

A
A
A

OCCURS.

A

APPLY
UTILITY

A

SA 0
TO

A

PULSED

A
A

APPLY A GROUND
CIRCUIT

A

APPLY A GROUND

A

PARALLEL

A

ANALOG
MODE.

A

APPLY
'WAKE

2A 0 30VDC
SA • 30VDC

DROPS
REFER

CMSTO

2A 0 30VDC
AC VOLTAGE AND

2A 0 30VDC
FROUENCY

TERMINAL
20A, 600V
22
TOROUE

SA 0 30

IN
IN

IN

(LESS

18

GROUND

UP'

OUT TO

TO

ENGINE

OR

TO

12

TERMINAL

Bt

BREAKER

30VDC

OPEN

INPUT

THAN

STRANDED.

0-5VDC

CONTROL.

GA FOR
RELAY
RELAY

ONAN

ISOLATED

240VAC 0 SO

ISOLATED

RELAY

CONDITION
BLOCK
GA WIRE

VDC RELAY

AND A GROUND

RELAY

THE

GENERATOR

TO

MODE.

BREAKER

50mA).

LOAD

1000 FT. 18

INTERCONNECTION
IA « 30VDC

I20VAC

SINGLE/UTILITY
MULTIPLE UNIT

SINGLE

GA

TO

ACTIVE INPUT.

USE

RUNS
CONTACTS.
CONTACTS.

THE

OPEN

900-0366

INSTRUCTIONS

RELAY

CONTROL

SHARE

INPUTS

MODULE

WATTS

RELAY

FREQUENCY

CONTACTS.

OCCURS.

RATING

SCREWS

CONTACTS.

TO CIRCUIT

CLOSURE

CONTACTS.

CIRCUIT

ENABLE

GENSET

PARALLEL

OPERATION
GROUND

TO

REMOTELY

WHEN

PCC

TO

INDICATE

LINES

MAXIMUM RUN SOO FT.

TO

CUSTOMER

COPPER

FROM

IOOO

THIS

THIS

THE

BREAKER.

POWER

COMMAND

(OPTIONAL

CONTACTS.

FAULTS

(OPTIONAL).

CONTACTS.

EXCEED

THIS

TO

T IN-LBS
THIS

(LESS

THAN

THIS

BREAKER.

AS

MODE.
MODE

TERMINAL

OPEN

IS

IN

GENERATOR

(0 - ImA).

CONTROL

STRANDED

APPLY

AUTO

GENERATOR

FAULT

WIRE.

TO

2000

RELAY

PICKS

RELAY

PICKS

NETWORK

PCC

THESE RELAYS

ALLOWING FOR

THIS

901

OF

NORMAL.

RELAY

PICKS

(0.8

NM)

RELAY

PICKS

BRAKER

AUXILARY

50 mA).

RELAY

PICKS

FIRST ON

APPLY

24V0C

GROUND

TO

ENABLE

OR

INHIBIT

MODE
CIRCUIT

USE 4 CONDUCTOR

2 AND

20

FT.

(LESS

UP

SHUT

UP

CLOSE

AND

NETWORK

RELAY

PICKS UP

UP

IF

UP

WHEN A WARNING

TO

UP TO

LINE

FOR

TO

ENABLE

TO

BREAKER

CLOSURE

(LESS

BREAKER

LOAD

IN

CUSTOMER

GA FOR

OPERATION

INTERFACE
PICK UP

MONITORING

AN

INDICATE

CLOSE

MULTIPLE UNITS.

CAUSE

THAN

UTILITY

FAULT

RUNS

THAN

50mA

DOWNS

ONLY.

THE

BREAKER

MANUAL

MODULE).

ON

ASSIGNED

OF

WHEN

OVERLOAD

A

AND

SYNCHRONIZER.

LOAD

THE

GENERATOR

SOmA).

IS

CLOSED

SHIELDED

PARALLELING

DEMAND

CLOSURE.
OF

3

LESS

THAN

CURRENT)

AND

FOR

CMSTO

FAULTS.

GENERATOR

OR

UNDER-

CONDITION

DROPS

OUT

STOP.

CABLE.

No. 612-6759
Rev.
Modified

CUSTOMER CONNECTIONS DIAGRAM (PCC)

9-2

B

3-01

sh

4 of

4

9-

Wiring

This section contains the Customer Connections

Diagram referenced in text.

Diagrams

GENERAL

9-1

Cummins Power Generation
1400 73rd Avenue N.E.
Minneapolis, MN 55432
1-800-888-6266
763-574-5000 International Use

Fax: [phone]

Cummins is a registered trademark of Cummins Inc.

Power
Generation