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Installation Manual
Redistribution or publication of this document,
by any means, is strictly prohibited.
PowerCommand Control
3200 Series
Generator Sets
Printed in U.S.A.
Models
DFEG, DFEH, DFEJ, DFEK
960-0633B 02-2004
Table of Contents
Redistribution or publication of this document,
by any means, is strictly prohibited.
SECTION TITLE PAGE
IMPORTANT SAFETY INSTRUCTIONS iii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 INTRODUCTION
About this Manual 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Overview 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 SPECIFICATIONS 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 MOUNTING THE GENERATOR SET
General 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Moving 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Access to Set 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vibration Isolators 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 MECHANICAL CONNECTIONS
General 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust System 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ventilation and Cooling 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 DC CONTROL WIRING
Control Wiring 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Monitor/Control Connections 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Run Relays (K11, K12, K13) 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alarm Relay (K16) 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Transfer Control (Optional) 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
California
i
SECTION TITLE PAGE
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by any means, is strictly prohibited.
6 AC ELECTRICAL CONNECTIONS
General 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Switch 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Wiring 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Heater (Optional) 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant Heater (Optional) 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Heater (Optional) 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 ENCLOSURE ELECTRICAL CONNECTIONS
General 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional AC Distribution Panel 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Motorized Inlet/Outlet Louvers 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Fuel Transfer Pump 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 PRESTART PREPARATION
General 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
InPower Service Tool General Information 8-1. . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Prestart Checks 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUST Submenu 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Transfer Control Main Menus 8-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UTILITY SENSORS Submenus 8-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENSET SENSORS Submenus 8-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIMERS Submenu 8-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TEST/EXERCISE Submenu 8-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PTC Detailed Field Descriptions 8-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting 8-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 INSTALLATION CHECKLIST
General 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Set Support 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling Air Flow 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diesel Fuel System 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust System 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC and DC Wiring 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Set Prestart 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 WIRING DIAGRAMS
Customer Connections 10-1/10-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Enclosure Options Wiring 10-5/10-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii
IMPORTANT SAFETY INSTRUCTIONS
Redistribution or publication of this document,
by any means, is strictly prohibited.
SAVE THESE INSTRUCTIONS − This manual contains
important instructions that should be followed during
installation and maintenance of the generator and batteries.
Before operating the generator set (genset), read the
Operator’s Manual and become familiar with it and the
equipment. Safe and efficient operation can be
achieved only if the equipment is properly operated
and maintained. Many accidents are caused by failure
to follow fundamental rules and precautions.
The following symbols, found throughout this manual,
alert you to potentially dangerous conditions to the operator, service personnel, or the equipment.
This symbol warns of immediate
hazards which will result in severe personal injury or death.
WARNING
This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death.
CAUTION
This symbol refers to a hazard or unsafe practice which can result in personal injury
or product or property damage.
FUEL AND FUMES ARE FLAMMABLE
Fire, explosion, and personal injury or death can result
from improper practices.
• DO NOT fill fuel tanks while engine is running, un-
less tanks are outside the engine compartment.
Fuel contact with hot engine or exhaust is a potential
fire hazard.
• DO NOT permit any flame, cigarette, pilot light,
spark, arcing equipment, or other ignition source
near the generator set or fuel tank.
• Fuel lines must be adequately secured and free of
leaks. Fuel connection at the engine should be
made with an approved flexible line. Do not use zinc
coated or copper fuel lines with diesel fuel.
• Be sure all fuel supplies have a positive shutoff
valve.
• Be sure battery area has been well-ventilated prior
to servicing near it. Lead-acid batteries emit a highly
explosive hydrogen gas that can be ignited by arcing, sparking, smoking, etc.
EXHAUST GASES ARE DEADLY
Provide an adequate exhaust system to properly
•
expel discharged gases away from enclosed or
sheltered areas and areas where individuals are
likely to congregate. Visually and audibly inspect
the exhaust daily for leaks per the maintenance
schedule. Make sure that exhaust manifolds are secured and not warped. Do not use exhaust gases to
heat a compartment.
• Be sure the unit is well ventilated.
• Engine exhaust and some of its constituents are
known to the state of California to cause cancer,
birth defects, and other reproductive harm.
MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
•
Keep your hands, clothing, and jewelry away from
moving parts.
• Before starting work on the generator set, discon-
nect battery charger from its AC source, then disconnect starting batteries, negative (−) cable first.
This will prevent accidental starting.
• Make sure that fasteners on the generator set are
secure. Tighten supports and clamps, keep guards
in position over fans, drive belts, etc.
• Do not wear loose clothing or jewelry in the vicinity of
moving parts, or while working on electrical equipment. Loose clothing and jewelry can become
caught in moving parts.
• If adjustment must be made while the unit is run-
ning, use extreme caution around hot manifolds,
moving parts, etc.
DO NOT OPERATE IN FLAMMABLE AND
EXPLOSIVE ENVIRONMENTS
Flammable vapor can cause an engine to overspeed and
become difficult to stop, resulting in possible fire, explosion, severe personal injury and death. Do not operate a
genset where a flammable vapor environment can be
created by fuel spill, leak, etc., unless the genset is
equipped with an automatic safety device to block the air
intake and stop the engine. The owners and operators of
the genset are solely responsible for operating the genset safely. Contact your authorized Cummins Power
Generation distributor for more information.
LS-14L
iii
ELECTRICAL SHOCK CAN CAUSE
Redistribution or publication of this document,
by any means, is strictly prohibited.
SEVERE PERSONAL INJURY OR DEATH
Remove electric power before removing protective
•
shields or touching electrical equipment. Use rubber insulative mats placed on dry wood platforms
over floors that are metal or concrete when around
electrical equipment. Do not wear damp clothing
(particularly wet shoes) or allow skin surface to be
damp when handling electrical equipment. Do not
wear jewelry. Jewelry can short out electrical contacts and cause shock or burning.
• Use extreme caution when working on electrical
components. High voltages can cause injury or
death. DO NOT tamper with interlocks.
• Follow all applicable state and local electrical
codes. Have all electrical installations performed by
a qualified licensed electrician. Tag and lock open
switches to avoid accidental closure.
• DO NOT CONNECT GENERATOR SET DIRECT-
LY TO ANY BUILDING ELECTRICAL SYSTEM.
Hazardous voltages can flow from the generator set
into the utility line. This creates a potential for electrocution or property damage. Connect only
through an approved isolation switch or an approved paralleling device.
GENERAL SAFETY PRECAUTIONS
Coolants under pressure have a higher boiling point
•
than water. DO NOT open a radiator or heat exchanger pressure cap while the engine is running.
Allow the generator set to cool and bleed the system
pressure first.
• Used engine oils have been identified by some state
or federal agencies as causing cancer or reproductive toxicity . When checking or changing engine oil,
take care not to ingest, breathe the fumes, or contact used oil.
• Keep multi-class ABC fire extinguishers handy.
Class A fires involve ordinary combustible materials
such as wood and cloth; Class B fires, combustible
and flammable liquid fuels and gaseous fuels; Class
C fires, live electrical equipment. (ref. NFP A No. 10).
• Make sure that rags are not left on or near the en-
gine.
• Make sure generator set is mounted in a manner to
prevent combustible materials from accumulating
under the unit.
• Remove all unnecessary grease and oil from the
unit. Accumulated grease and oil can cause overheating and engine damage which present a potential fire hazard.
• Keep the generator set and the surrounding area
clean and free from obstructions. Remove any debris from the set and keep the floor clean and dry.
• Do not work on this equipment when mentally or
physically fatigued, or after consuming any alcohol
or drug that makes the operation of equipment unsafe.
• Substances in exhaust gases have been identified
by some state or federal agencies as causing cancer or reproductive toxicity. Take care not to breath
or ingest or come into contact with exhaust gases.
• Do not store any flammable liquids, such as fuel,
cleaners, oil, etc., near the generator set. A fire or
explosion could result.
• Wear hearing protection when going near an oper-
ating generator set.
• To prevent serious burns, avoid contact with hot
metal parts such as radiator, turbo charger and exhaust system.
KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE
iv
1. Introduction
Redistribution or publication of this document,
by any means, is strictly prohibited.
ABOUT THIS MANUAL
This manual provides installation instructions for
the generator set models listed on the front cover.
This manual includes the following information:
Mounting Recommendations - for fastening
generator set to base and space requirements
for normal operation and service.
Mechanical and Electrical Connections covers most aspects of the generator set installation.
Optional Enclosure Electrical Connections - covers installation of enclosure optional
features.
Prestart − checklist of items or procedures
needed to prepare generator set for operation.
Initial Startup − test complete system to ensure proper installation, satisfactory performance, and safe operation. Refer to Operators
Manual for troubleshooting information.
Installation Checklist − reference checks
upon completion of installation.
This manual DOES NOT provide application information for selecting a generator set or designing the
complete installation. If it is necessary to design the
various integrated systems (fuel, exhaust, cooling,
etc.), additional information is required. Review
standard installation practices. For engineering
data specific to the generator set, refer to the
fication
tion, refer to Application Manual T-030, “Liquid
Cooled Generator Sets”.
and
Data Sheets
. For application informa-
Speci-
1-1
INSTALLATION OVERVIEW
Redistribution or publication of this document,
by any means, is strictly prohibited.
These installation recommendations apply to typical installations with standard model generator
sets. Whenever possible, these recommendations
also cover factory designed options or modifications. However, because of the many variables in
any installation, it is not possible to provide specific
recommendations for every situation. If there are
any questions not answered by this manual, contact
your nearest Cummins Power Generation distributor for assistance.
Application and Installation
installed, maintained, and operated. However, the
overall safety and reliability of the complete system
is dependent on many factors outside the control of
the generator set manufacturer. To avoid possible
safety hazards, make all mechanical and electrical
connections to the generator set exactly as specified in this manual. All systems external to the generator (fuel, exhaust, electrical, etc.) must comply
with all applicable codes. Make certain all required
inspections and tests have been completed and all
code requirements have been satisfied before certifying the installation is complete and ready for service.
A standby power system must be carefully planned
and correctly installed for proper operation. This involves two essential elements: application and
installation.
Application (as it applies to generator set installations) refers to the design of the complete standby
power system that usually includes power distribution equipment, transfer switches, ventilation equipment, mounting pads, and cooling, exhaust, and
fuel systems. Each component must be correctly
designed so the complete system will function as intended. Application and design is an engineering
function generally done by specifying engineers or
other trained specialists. Specifying engineers or
other trained specialists are responsible for the design of the complete standby system and for selecting the materials and products required.
Installation refers to the actual set-up and assembly of the standby power system. The installers set
up and connect the various components of the system as specified in the system design plan. The
complexity of the standby system normally requires
the special skills of qualified electricians, plumbers,
sheetmetal workers, etc. to complete the various
segments of the installation. This is necessary so all
components are assembled using standard methods and practices.
Safety Considerations
The generator set has been carefully designed to
provide safe and efficient service when properly
Standby Heating Devices
In accordance with NFPA 110, Cummins Power
Generation recommends installing diesel standby
generator sets (life safety systems) equipped with
engine jacket water coolant heaters in locations
where the minimum ambient temperature is above
40
°F (4°C). NFPA also requires that the engine
jacket water coolant be maintained at a minimum of
°F (32°C) and, for most applications, accept the
90
emergency load in 10 seconds or less. Although
most Cummins Power Generation generator sets
will start in temperatures down to −25
when equipped with engine jacket water coolant
heaters, it might take more than 10 seconds to
warm the engine up before a load can be applied
when ambient temperatures are below 40
The Engine Cold (Code 1435) message, in con-
junction with illumination of the Warning LED, is provided to meet the requirements of NFPA 110. The
engine cold sensing logic initiates a warning when
the engine jacket water coolant temperature falls
below 70
ent temperature falls below 40
°F (21°C). In applications where the ambi-
°F (4°C), a cold en-
gine may be indicated even though the coolant
heaters are connected. Under these conditions, although the generator set may start, it may not be
able to accept load within 10 seconds. When this
condition occurs, check the coolant heaters for
proper operation. If the coolant heaters are operating properly, other precautions may be necessary to
warm the engine before applying a load.
°F (−32°C)
°F (4°C).
Copyright2003 Cummins Power Generation. All rights reserved.
Cummins and PowerCommand are registered trademarks of Cummins Inc.
1-2
2. Specifications
Redistribution or publication of this document,
by any means, is strictly prohibited.
MODEL DFEG, DFEH, DFEJ, DFEK
Cummins Diesel Series QSX15 (50/60 Hz)
Generator Kw Rating See Genset Nameplate for rating information.
Cooling System
(Capacity Std. Raidiator) − Gal (L) 15.3 (58)
Lubricating System
Oil Cap. w/Filters
Oil Type
Engine Fuel Connection
Inlet/Outlet Thread Size Refer to Generator Outline Drawing
Fuel Flow
Max. Fuel Inlet Pressure
Max. Fuel Inlet Restriction
Max. Fuel Return Restriction
Exhaust
Outlet Size
Maximum Allowable Back Pres.
*
H20
kPa
Hg
26 Gallons (58 L)
10 PSI (69 kPa)
5 in. Hg. (16.9 kPa)
3.05 in. Hg. (10.3 kPa)
6” NPT Male STD. (A299)/ASA Flange (A355) or
Slip-on (A298) Optional
27 in (686 mm)
6.8
2.0 in (51 mm)
Electrical System
Starting Voltage
Battery
Group number
CCA (minimum)
Cold Soak @ 0° F (-18° C)
24 Volts DC
Two, 12 Volt
8D
1400
* Refer to Cummins QSX15 Series Engine Operation and Maintenance Manual for lubricating oil
recommendations/specifications.
FUEL CONSUMPTION (STANDBY/FULL LOAD/60HZ)
MODEL DFEG DFEH DFEJ DFEK
US gph (L/hr) 24.6 (93.2) 27.1 (102.7) 30 (113.7) 34.8 (131.9)
2-1
THIS PAGE LEFT INTENTIONALLY BLANK
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by any means, is strictly prohibited.
2-2
3. Mounting the Generator Set
Redistribution or publication of this document,
by any means, is strictly prohibited.
GENERAL
Generator set installations must be engineered so
the generator set will function properly under the expected load conditions. Use these instructions as a
general guide only. Follow the instructions of the
consulting engineer when locating or installing any
components. The complete installation must comply with all local and state building codes, fire ordinances, and other applicable regulations.
Requirements to be considered prior to installation:
• Level mounting surface
• Adequate cooling air
• Adequate fresh induction air
• Discharge of generator set air
• Discharge of exhaust gases
• Non-combustible mounting surface.
• 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 breaker box. Exhaust must
not be able to enter or accumulate around inhabited
areas.
Provide a location away from extreme ambient temperatures and protect the generator set from adverse weather conditions.
WARNING
INCORRECT INSTALLATION, SERVICE OR PARTS REPLACEMENT CAN RESULT IN SEVERE
PERSONAL INJURY, DEATH, AND/OR EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST
BE TRAINED AND EXPERIENCED TO PERFORM ELECTRICAL AND MECHANICAL COMPONENT INSTALLATION.
IMPORTANT
DEPENDING ON Y O U R L O C ATION AND INTENDED USE, FEDERAL, STATE OR LOCAL LAWS
AND REGULATIONS MAY REQUIRE YOU TO OBTAIN AN AIR QUALITY EMISSIONS PERMIT
BEFORE BEGINNING INSTALLATION OF YOUR GENSET. BE SURE TO CONSULT LOCAL
POLLUTION CONTROL OR AIR QUALITY AUTHORITIES BEFORE COMPLETING YOUR
CONSTRUCTION PLANS.
3-1
MOVING
Redistribution or publication of this document,
by any means, is strictly prohibited.
WARNING
vere personal injury or death. Use extreme caution when lifting, hoisting, or moving the generator set. Make certain to use a hoist or other lifting device whose capacity is rated well above
the weight of the generator set. The generator
sets models listed on the front cover of this
manual can weigh 9800 pounds (4445 kgs) (refer to Specification Sheet for Model weight).
Make certain that the maximum lifting capacity
of the hoist exceeds the weight of the generator
set by a large margin. Follow the manufacturer’s instructions carefully regarding the weight
capacity of the hoist and the recommended
hoisting procedure.
Generator set weight can cause se-
When lifting, hoisting, or moving the generator set,
use only the lifting eyes (optional) or skid lifting
holes as shown in Figure 3-1. Do not attach lifting
device to brackets on engine or generator.
These brackets are only used and designed for the
removal of the engine or the generator from the
generator set.
WARNING
Improper genset lifting can cause
severe personal injury or death. Do not use engine or generator lift brackets to move or hoist
the generator set. Brackets are designed for
weight of engine or generator only. When moving or lifting genset, use skid eye brackets/
holes.
USED FOR
GENSET LIFTING
ENGINE LIFT
BRACKETS
OPTIONAL
GENSET LIFT
EYE BRACKETS
GENSET PASS THRU
HOLES FOR LIFTING BARS
NOT USED FOR
GENSET LIFTING
GENERATOR
LIFT BRACKETS
FIGURE 3-1. GENERATOR SET LIFTING/HOISTING/MOVING LOCATIONS
3-2
MOUNTING
Redistribution or publication of this document,
by any means, is strictly prohibited.
Generator sets are mounted on a steel skid or fuel
tank that provide proper support. The engine-generator assembly is isolated from the skid frame by
rubber mounts that provide adequate vibration
isolation for normal installations. Where required by
building codes or special isolation needs, generator
sets may be mounted on rubber pads or mechanical
spring isolators. The use of unapproved isolators
may result in harmful resonances and may void the
genset warranty.
For fuel tank mounted generator sets, it is required
that the tank be mounted such that an air space is
provided between the bottom of the tank and the
floor underneath to reduce corrosion and permit
visual inspections for leaks.
Mount the generator set on a substantial and level
base such as a concrete pad. A non-combustible
material must be used for the pad.
Use 5/8 inch or 16 mm anchored mounting bolts to
secure the vibration isolators to the base. Secure
the vibration isolators using flat or bevel washer and
hexagonal nut for each bolt (see Figure 3-1). The
1-1/2 x 6 inch pipe inserted over the mounting bolts
allows minor adjustment of the bolts to align them to
the holes in the subbase or vibration isolator.
MOUNTING
BASE
MOUNTING
BOLT
FIGURE 3-2. BOLT DIAGRAM
SKID
HEX NUT
FLAT OR BEVEL
WASHER
12 IN.
(305 mm)
CONCRETE
Locate the isolators as shown on the generator set
Outline Drawing
referenced in the
Data Sheet
.
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 operation, maintenance and service operations and should be connected on the load side of the transfer switch so that
it is available at all times.
3-3
CONDENSATION
Redistribution or publication of this document,
by any means, is strictly prohibited.
DRAIN TRAP
MUFFLER
SWEEPING
ELBOW
DC CONTROL
WIRING
AC POWER
WIRING
THIMBLE
FLEXIBLE
SECTION
AIR OUTLET
DUCT (FLEXIBLE
BELLOWS)
FLEXIBLE
SECTION
AIR
IN
LEVEL
CONCRETE
BASE
FIGURE 3-3. TYPICAL INSTALLATION
IMPORTANT!
COOLING AIR INLET MUST BE AT LEAST 1-1/2
TIMES LARGER THAN RADIATOR DUCT OUTLET
AREA ON RADIATOR COOLED MODELS
FLOW OR COOLING AIR AND HEATED AIR CAN
BE CONTROLLED BY AUTOMATICALLY
OPERATED LOUVRES
3-4
VIBRATION ISOLATORS
Redistribution or publication of this document,
by any means, is strictly prohibited.
Installation and Adjustment Procedure
1. Place the vibration isolators (Figure 3-4) on the
genset support structure. The isolators should
be shimmed or grouted to ensure that all of the
isolator bases are within 0.25 inch (6 mm)
elevation of each other. The surface that the
isolator bases rest on must also be flat and level.
2. Loosen the side snubber lock nuts so that the
top plate of the isolator is free to move vertically
and horizontally. Be sure that the top plate is
correctly aligned with the base and springs.
3. Place the genset onto the isolators while aligning the skid’s mounting with the threaded isolator hole. The top plates will move down and approach the base of the isolator as load is applied.
4. Once the genset is in position, the isolators
may require adjusting so that the set is level.
The isolators are adjusted by inserting the leveling bolt through the skid and into the isolator
(the leveling bolt’s locking nut should be
threaded up towards the bolt head).
The leveling bolt will adjust the clearance between the top plate and the isolator base. A
nominal clearance of 0.25 inch (6 mm) or greater is desired. This will provide sufficient clearance for the rocking that occurs during startup
and shutdown. If the 0.25 inch (6 mm) clearance is not present, turn the leveling bolt until
the desired clearance is achieved.
5. The genset may not be level yet; therefore, adjust the leveling bolts until the set is level and
sufficient clearance still remains. (Clearance
on all isolators should be roughly equal). Once
all isolators have been set, lock the leveling bolt
in place with the lock nut.
6. The snubber nuts must remain loose and
therefore provide better isolation between the
genset and support structure.
GENSET SKID
SNUBBER
LEVELING BOLT
LOCK NUT
CLEARANCE
BASE
FIGURE 3-4. VIBRATION ISOLATORS
3-5
THIS PAGE LEFT INTENTIONALLY BLANK
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3-6
4. Mechanical Connections
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by any means, is strictly prohibited.
GENERAL
The generator set mechanical system installation
includes connecting the fuel, exhaust, ventilation
and cooling systems. Before starting any type of
fuel installation, all pertinent state and local codes
must be complied with and the installation must be
inspected before the unit is put in service.
FUEL SYSTEM
Cummins engines normally use ASTM No. 2 diesel
fuel. They will, however , operate on alternate diesel
fuels within the specifications shown in the Cummins engine
In all fuel system installations, cleanliness is of the
upmost importance. Make every effort to prevent
entrance of moisture, dirt or contaminants of any
kind into the fuel system. Clean all fuel system components before installing.
A fuel filter/strainer/water separator of 100-120 mesh
or equivalent (approximately 150 microns nominal)
must be fitted between either the main tank and day
tank or between the main tank and the engine.
Use only compatible metal fuel lines to avoid electrolysis when fuel lines must be buried. Buried fuel
lines must be protected from corrosion.
CAUTION
lines, fittings or fuel tanks. Condensation in the
tank and lines combines with the sulfur in diesel
fuel to produce sulfuric acid. The molecular
structure of the copper or galvanized lines or
tanks reacts with the acid and contaminates the
fuel.
Operation and Maintenance Manual.
Never use galvanized or copper 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 TB3-5 and TB3-6
(see Customer Connections, Section 9) which provide switched B+ that opens the valve during genset
operation and closes the valve 10 seconds after a
stop signal is received. This 10 second delay keeps
the fuel line open during genset shutdown (normal
or warning) sequence. If the valve is allowed to
close before the engine stops, hard starts and possible damage to the engine can occur.
CAUTION
Hard starts or engine damage will
occur if fuel supply solenoid is not connected to
the Delayed Switched B+ circuit. Fuel supply
line must remain open until engine has completely stopped.
Separate fuel return lines to the day tank or supply
tank must be provided for each generator set in a
multiple-set installation to prevent the return lines of
idle sets from being pressurized. Fuel return lines
must not contain a shutoff device. Engine damage
will occur if the engine is run with the return fuel lines
blocked or restricted.
CAUTION
Never install shutoff device in fuel
return line(s). If fuel return line(s) is blocked or
exceeds fuel restriction limit, engine damage
will occur.
Fuel Return Restriction (or Pressure) Limit: Fuel
return drain restriction (consisting of friction head
and static head) between the engine injector return
line connection and the fuel tank must not exceed
the limit stated in the
Specification
section.
4-1
Fuel Lines − Routing
Redistribution or publication of this document,
by any means, is strictly prohibited.
A flexible fuel hose(s) or section of flexible fuel
hose(s) must be used between the engine’s fuel
system and fuel supply and return line(s) to protect
the fuel system from damage caused by vibration,
expansion and contraction. Flexible lines for connecting between the engine and the stationary fuel
lines are supplied as standard equipment.
Installation of the fuel hose must be done according
to all applicable codes and standards, and installation recommendations provided by the manufacturer. The supplied flexible hose is approved by the
hose manufacture for use with the genset fuel type
and product application.
Support fuel lines to restrain movement and prevent
chaffing or contact with sharp edges, electrical wiring and hot exhaust parts.
WARNING
Sparks and hot surfaces can ignite
fuel, leading to severe personal injury or death.
Do not route fuel lines near electrical wiring or
hot exhaust parts.
Fuel lines must be routed and secured to maintain a
1/2 inch (12.7 mm) minimum clearance from electrical wiring and a 2 inch (51 mm) minimum clearance
from hot exhaust parts.
Engine Fuel Connections
Identification tags are attached to the fuel supply
line and fuel return line connections.
Supply Tank
Locate the f uel tank as close as possible to the generator set and within the restriction limitations of the
fuel pump.
Install a fuel tank that has sufficient capacity to supply the genset operating continuously at full rated
load for the planned period of operation or power
outage. Refer to the
Specification
section for fuel
consumption data.
WARNING
Fuel leaks create fire and explosion
hazards which can result in severe personal injury or death. Always use flexible tubing between engine and fuel supply to avoid line failure and leaks due to vibration. The fuel system
must meet applicable codes.
If the fuel inlet restriction exceeds the defined limit
due to the distance/customer-supplied plumbing
between the genset and the main fuel tank, a transfer tank (referred to as a day tank) and auxiliary
pump will also be required. If an overhead main fuel
tank is installed, a transfer tank and float valve will
be required to prevent fuel head pressures from being placed on the fuel system components.
For critical start applications, where generator sets
are paralleled or must satisfy emergency start-time
requirements, it is recommended that a fuel tank or
reservoir be located such that the lowest possible
fuel level is not less than 6 inches (150 mm) above
the fuel pump inlet. This will prevent air from accumulating in the fuel line while the set is in standby,
eliminating the period during startup when it has to
be purged.
Fuel Inlet Pressure/Restriction Limit: Engine
performance and fuel system durability will be compromised if the fuel inlet pressure or restriction limits
are not adhered to. Fuel inlet pressure or restriction
must not exceed the limits stated in the
tion
section.
Specifica-
4-2
Day Tank (If Used)
Redistribution or publication of this document,
by any means, is strictly prohibited.
Fuel day tanks are used when fuel inlet restriction
limits can not be met, or the supply tank is overhead
and presents problems of high fuel head pressure
for the fuel inlet and return lines.
Supply T ank Lower Than Engine:
lation, the day tank is installed near the generator
set, below the fuel injection system and within the
fuel inlet restriction limit. Install an auxiliary fuel
pump, to pump fuel from the supply tank to the day
tank. A float switch in the day tank controls operation of the auxiliary fuel pump.
The supply tank top must be below the day tank top
to prevent siphoning from the fuel supply to the day
tank.
Provide a return line from the engine injection system return connection to the day tank. Plumb the re-
With this instal-
turn line to the bottom of day tank as shown in Figure 4-1. Provide a day tank overflow line to the supply tank in case the float switch fails to shut off the
fuel transfer pump. Also, the overflow line should be
one pipe diameter larger than the supply line.
WARNING
Spilled fuel presents the hazard of
fire or explosion which can result in severe personal injury or death. Provide an overflow line
to the supply tank from the day tank.
Supply Tank Higher Than Engine:
Install the day
tank near the generator set, but below the fuel injection system. Use fuel line at least as large as the fuel
pump inlet. The engine fuel return line must enter
the day tank.
Include a shutoff valve in the fuel line between the
fuel supply tank and the day tank to stop fuel flow
when the generator set is off.
WARNING
Spilled fuel can create environmental hazards. Check local requirements for containment
and prevention of draining to sewer and ground water.
ENGINE
FUEL
PUMP
DAY TANK
FUEL TRANSFER
PUMP ELECTRIC
MOTOR DRIVEN
VENTED
FILL CAP
SHUTOFF
VALVE
1 INCH
BAFFLE
FLOAT
SWITCH
INJECTOR FUEL
RETURN LINE
CONNECT TO
AC OUTPUT
SUPPLY
LINE
All models require a fuel return
line from injectors to tank.
VENT LINE
FILL PIPE
120 MESH FUEL
STRAINER
LARGER OVER-
FLOW LINE
FIGURE 4-1. TYPICAL FUEL SUPPLY INSTALLATION
FUEL TANK
4-3
EXHAUST SYSTEM
Redistribution or publication of this document,
by any means, is strictly prohibited.
Pipe exhaust gases to the outside of any enclosure.
Locate the exhaust outlets away from any air inlets
to avoid gases re-entering the enclosure. Exhaust
installations are subject to various detrimental conditions such as extreme heat, infrequent operation
and light loads. Regularly inspect the exhaust system both visually and audibly to see that the entire
system remains fume tight and safe for operation.
WARNING
sult in severe personal injury or death. Use extreme care during installation to provide a tight
exhaust system. Terminate exhaust pipe away
from enclosed or sheltered areas, windows,
doors and vents.
For indoor installation, the exhaust system must
use sealed joint type fittings, (for example NPT fittings) to provide a tighter exhaust system. Use of
slip type fittings (secured with a muffler clamp) may
allow leakage of exhaust gases into the building.
WARNING
sult in severe personal injury or death. Use extreme care during installation to provide a tight
exhaust system. Use NPT or equivalent type fittings for all indoor installations.
Use an approved thimble (Figure 4-2) where exhaust pipes pass through wall or partitions. Insulated wall/roof thimbles are used where exhaust
pipes pass through a combustible roof or wall. This
includes structures, such as wood framing or insulated steel decking, etc. Uninsulated wall/roof
thimbles are used where exhaust pipes pass
through a non-combustible wall or roof, such as
concrete. Refer to NFPA 37, Section 6-3. “Stationary Combustion Engines and Gas Turbines” for ac-
Inhalation of exhaust gases can re-
Inhalation of exhaust gases can re-
cepted design practices. Build according to the
code requirements in effect at the installation site.
WARNING
Hot exhaust pipes can start a fire
and cause severe injury or death if improperly
routed through walls. Use an approved thimble
where exhaust pipes pass through walls or
partitions.
WARNING
Inhalation of exhaust gases can result in severe personal injury or death. Do not
use exhaust heat to warm a room, compartment
or storage area.
Rain caps are available for the discharge end of vertical exhaust pipes. The rain cap clamps onto the
end of the pipe and opens due to exhaust discharge
force from the generator set. When the generator
set is stopped, the rain cap automatically closes,
protecting the exhaust system from rain, snow, etc.
Use a section of flexible exhaust pipe between the
engine and remainder of exhaust system. Support
exhaust system to prevent weight from being applied to engine exhaust outlet elbow/turbocharger
connection.
CAUTION
Weight applied to the engine manifold can result in turbocharger damage. Support the muffler and exhaust piping so no
weight or stress is applied to engine exhaust el bow.
The exhaust system design should meet local code
requirements.
Liability for injury, death, damage, and warranty expense due to use of unapproved mufflers or modifications becomes the responsibility of the person
installing the unapproved muffler or performing the
modification. Contact a Cummins Power Generation
distributor for approved exhaust system parts.
4-4
Avoid sharp bends by using sweeping, long radius
Redistribution or publication of this document,
by any means, is strictly prohibited.
elbows and provide adequate support for muffler
and tailpipe. Pitch a horizontal run of exhaust pipe
DOWNWARD (away from engine) to allow any
moisture condensation to drain away from the engine. If an exhaust pipe must be turned upward,
install a condensation trap at the point where the
rise begins (Figure 4-3).
Shield or insulate exhaust lines if there is danger of
personal contact. Allow at least 12 inches (305 mm)
of clearance if the pipes pass close to a combustible
wall or partition. Before installing insulation on exhaust system components, check the exhaust system for leaks while operating the genset under full
load and correct all leaks.
RAIN CAP
9 INCH MIN
(230 mm)
VERTICAL
DRIP CAP
HOLES IN END
OF INNER
SLEEVE
ROOF
9 INCH MIN
(230 mm)
WARNING
Exhaust pipes are very hot and they
can cause severe personal injury or death from
direct contact or from fire hazard. Shield or insulate exhaust pipes if there is danger of personal contact or when routed through walls or
near other combustible materials.
HORIZONTAL
WALL OR PARTITION
FIGURE 4-2. MOUNTING EXHAUST THIMBLE
IF EXHAUST LINE MUST BE
PITCHED UPWARD, CONSTRUCT
A TRAP AT POINT OF RISE
AVOID
SHARP
BENDS
DRAIN CONDENSATION
TRAP PERIODICALLY
FIGURE 4-3. CONDENSATION TRAP
4-5
VENTILATION AND COOLING
Redistribution or publication of this document,
by any means, is strictly prohibited.
Generator sets create considerable heat that must
be removed by proper ventilation. Outdoor installations normally rely on natural air circulation but indoor installations need properly sized and positioned vents for required airflow.
Vents and Ducts
For indoor installations, locate vents so incoming air
passes through the immediate area of the installation before exhausting. Install the air outlet higher
than the air inlet to allow for convection air movement.
Size the vents and ducts so they are large enough to
allow the required flow rate of air . The ”free area” of
ducts must be as large as the exposed area of the
radiator. Refer to the genset
flow requirements and allowed airflow restriction.
Data Sheet
for the air-
PREVAILING WINDS PREVAILING WINDS
Wind will restrict free airflow if it blows directly into
the air outlet vent. Locate the outlet vent so the effects of wind are eliminated. See Figure 4-4.
Dampers
Dampers or louvres protect the genset and equipment room from the outside environment. Their operation of opening and closing should be controlled
by operation of the genset.
In cooler climates movable or discharge dampers
are used. These dampers allow the air to be recirculated back to the equipment room. This enables the
equipment room to be heated while the genset engine is still cold, increasing the engine efficiency.
FIGURE 4-4. WIND BARRIER
4-6
Radiator Set Requirements
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by any means, is strictly prohibited.
Radiator set cooling air is drawn past the control
end of the set by a pusher fan that blows air through
the radiator (Figure 4-5). Locate the air inlet to the to
the rear of the set. Make the inlet vent opening 1-1/2
to 2 times larger than the radiator area.
Louvers and screens over air inlet and outlet openings restrict air flow and vary widely in performance.
A louver assembly with narrow vanes, for example,
tends to be more restrictive than one with wide
vanes. The effective open area specified by the louver or screen manufacturer should be used.
Locate the cooling air outlet directly in front of the radiator and as close as possible. The outlet opening
THERMOSTATIC AIR RE-
CIRCULATING DAMPER
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.
Coolant Heater (Optional)
An optional coolant heater can be installed to keep
the engine warm for starting under adverse weather
conditions. Connect the heater to a power source
that will be on when the engine is NOT running.
*
INLET AIR
DAMPER
COOL AIR
* Louvers should close when room
ambient is above 60
° F (16° C)
FIGURE 4-5. TYPICAL RADIATOR SET INSTALLATION
RADIATOR FLEXIBLE DUCT
CONNECTOR
WIND/NOISE
BARRIER
HOT AIR
D
DISTANCE SHOULD NOT
BE LESS THAN HEIGHT
OF RADIATOR
4-7
LUBRICATION
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by any means, is strictly prohibited.
Before starting, check the engine oil level. Gensets
are shipped with oil. Fill if needed using the recommended oil. Refer to the Cummins
Engines Operation and Maintenance Manual
the recommended oil.
OIL FILL
CAP
QSX15 Series
for
FUEL
Fill the fuel tanks with the recommended fuel. Open
all manual shutoff valves. Engine fuel may not be
primed at the fuel filters after shipment. To check
and reprime the fuel system, refer to the Cummins
QSX15 Series Engines Operation and Maintenance Manual
for the recommended procedure.
OIL LEVEL
DIPSTICK
OIL DRAIN
HOSE
FUEL
FILTER
OIL DRAIN
VALVE
FLEX FUEL
LINE
FIGURE 4-6. LUBRICATION AND FUEL COMPONENTS
4-8
COOLANT
Redistribution or publication of this document,
by any means, is strictly prohibited.
Before starting, check the engine coolant level.
Gensets are shipped with coolant. Fill the cooling
system wit h t h e recommended coolant. Refer to the
Cummins
Maintenance Manual
QSX15 Series Engines Operation and
for the recommended cool-
ant.
Coolant Filters
A spin-on type corrosion filter (Figure 4-7) is stan-
dard equipment. An on/off valve is provided to prevent coolant leakage while changing the coolant filter. With the valve in the ON position, the coolant
flows through the filter. I n the OFF position, the coolant does not flow through the filter.
Make sure coolant shut off valve is in the ON position before operating the generator set.
OIL
FILTER
ON
COOLANT FILTER
SHUTOFF VALVE
FIGURE 4-7. COOLANT AND LUBRICATION COMPONENTS
COOLANT
FILTER
OFF
4-9
THIS PAGE LEFT INTENTIONALLY BLANK
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4-10
5. DC Control Wiring
Redistribution or publication of this document,
by any means, is strictly prohibited.
CONTROL WIRING
The generator set control box assembly (Figure
5-1), which is located on the rear or optionally on either side of the control housing, contains connection points for remote control and monitor options.
CAUTION
box assembly for any reason. All conduit must
be attached to the control housing. Attaching
conduit to the control box assembly will compress the control box vibration isolators, causing the box to vibrate and damage the electronic
circuitry.
Use flexible conduit for all wiring connections to the
generator set. All conduit used for control wiring
Do not attach conduit to the control
CONTROL BOX
ASSEMBLY
(REAR MOUNT)
must be attached to the control housing, not to the
control box assembly. Route the control wiring
through the control housing and into the access
hole on the back panel of the control box assembly
(Figure 5-2). Use cable ties to keep control wiring
away from sharp edges and AC power cables within
control housing.
After completing all customer connections (wires
routed and secured), heat shrink the boot that is located on backside of access hole, until sealed.
CAUTION
Stranded copper wire must be used
for all customer connections to the electronics
box. Solid copper wire may break due to genset
vibration.
CONTROL
HOUSING
ASSEMBLY
DO NOT ATTACH
CONDUIT TO CONTROL
BOX ASSEMBLY FOR
ANY REASON
VIBRATION
ISOLATORS
(QTY 4)
FIGURE 5-1. CONTROL BOX − REAR MOUNT
5-1
REMOTE MONITOR/CONTROL
Redistribution or publication of this document,
by any means, is strictly prohibited.
CONNECTIONS
blocks. The type/gauge wire to use for these connections are:
Customer monitor/control connections are attached to terminal blocks TB3 and TB8 (see Figure
5-2). Optional equipment such as a remote annunciator panel, sensing devices used to monitor genset operation, remote start/stop switches, control
box heater, and etc. are also attached to these terminal blocks. Driver signals for customer supplied
relays are also provided for several alarm and shut
down conditions. Refer to Customer Connections
diagram in Section 10.
CAUTION
When removing terminal block connector TB8 from Base card, note orientation of
connector. This terminal block connector is not
keyed and can be installed incorrectly, which
will cause control failures.
Terminal Block Wiring
CAUTION
a separate metal conduit from AC power cables
to avoid inducing currents that could cause
problems within the control.
Digital Connections: Connection points, other
then relayed outputs, network, switched B+ and B+
are considered digital connections to the terminal
Always run control circuit wiring in
• Less than 1000 feet (305m), use 20 gauge
stranded copper wire.
• 1000 to 2000 feet (305 to 610m), use 18 gauge
stranded copper wire.
Relay Connections: Due to the wide variety of devices that can be attached to the relay outputs of terminal blocks, 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 10 for the relay
specifications.
Switched B+: (Fused at 10 amps.) Same as Relay
Connection description.
Delayed Switched B+: (Fused at 10 amps. with a
10 second dropout) Use for external fuel shut-off
solenoid. Same as Relay Connection description.
B+: (Fused at 10 amps.) Same as Relay Connection description.
Network Connections: Refer to Onan 900-0366
PowerCommand Network Installation and Opera-
manual for the type/gauge wire to use for these
tion
connections.
5-2
OPTIONAL
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by any means, is strictly prohibited.
RUN RELAYS
K11, K12 & K13
OPTIONAL
SHUTDOWN
ALARM RELAY K16
CONTROL WIRING
ACCESS
TB8
CARD
CAGE
FIGURE 5-2. CONTROL BOX ASSEMBLY INTERIOR
5-3
RUN RELAYS (K11, K12, K13)
Redistribution or publication of this document,
by any means, is strictly prohibited.
The optional run relays are rail mounted inside the
control box (Figure 5-2). The rail mount allows you
to easily remove and replace the snap-on relays.
The generator set can be equipped with one, two or
three run relays.
The three-pole, double-throw run relays (Figure
5-3) are used to control auxiliary equipment such as
K11, K12, K13
fans, pumps and motorized air dampers. The run
relays are energized when the generator set reaches operating speed.
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
TB3-5
(SWITCHED B+)
K11, K12, K13
K11, K12, K13
K11
RUN RELAY
NO
NC
COIL
COM
TB3-7
(GND)
CUSTOMER
CONNECTIONS
K12
RUN RELAY
NO
NC
K13
RUN RELAY
NO
NC
FIGURE 5-3. OPTIONAL RUN RELAYS (K11, K12, K13)
5-4
ALARM RELAY (K16)
Redistribution or publication of this document,
by any means, is strictly prohibited.
The optional alarm relay is rail mounted inside the
control box (Figure 5-2). The rail mount allows you
to easily remove and replace the snap-on relay.
The three-pole, double-throw alarm relay (Figure
5-4) is often used to energize warning devices such
K16
as audible alarms. Any generator set 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
TB3-17
(COM ALARM)
K16
K16
SHUTDOWN ALARM
K16
CUSTOMER
CONNECTIONS
NO
NC
COIL
COM
TB3-18
(GND)
FIGURE 5-4. OPTIONAL ALARM RELAY (K16)
5-5
POWER TRANSFER CONTROL
Redistribution or publication of this document,
by any means, is strictly prohibited.
(OPTIONAL)
The optional Power Transfer Control (PTC) feature
requires connecting the control relays of the PTC
circuit to the generator set and utility circuit breakers. These relays are used to control the opening
and closing of these circuit breakers via the PCC,
for transfer and retransfer of the load to the generator set or the utility. A typical PTC installation is
shown in Figure 5-5.
GENERATOR SET
Relay Connections: Due to a wide verity of circuit
breakers that can be attached to the relay outputs of
PCC terminal block TB3, the system designer must
determine if the electrical requirements of the installation does not exceed the limits of the PTC control
relays. Relays that can handle larger switching current/voltage will need to be connected to the PTC
control relays if the electrical limits of the PTC relays
are exceeded.
The four PTC control relays are each rated at 16
amps at 250 VAC or 24 VDC.
PCC 3200
ALTERNATOR
PT/CT
MODULE
L2 L3 LN L1 L2 L3 LN
L1
CB POSITION
GENSET
CIRCUIT
BREAKER
CLOSE COMMAND
OPEN COMMAND
PTC CONTROL
RELAYS (4)
BUS PT
MODULE
CB POSITION
CLOSE COMMAND
OPEN COMMAND
REMOTE (TEST) START
TRANSFER INHIBIT
RETRANSFER INHIBIT
MANUAL MODE
TO SERVICE
F
F
F
UTILITY
CIRCUIT
BREAKER
FIGURE 5-5. TYPICAL POWER TRANSFER CONTROL INSTALLATION
LOAD
5-6
6. AC Electrical Connections
Redistribution or publication of this document,
by any means, is strictly prohibited.
GENERAL
This section provides the procedure that is used to
connect the AC electrical system of the genset.
Before making any AC electrical connections, make
certain the generator set cannot be accidentally
started. Move the O/Manual/Auto switch on the
control panel to the O (off) position. Turn off or remove AC power from the battery charger and then
remove the negative (−) battery cable from the set
starting battery.
WARNING
can cause severe personal injury or death. Arcing at battery terminals, light switch or other
equipment, flame, pilot lights and sparks can ignite battery gas. Do not smoke, or switch
trouble light ON or OFF near battery. Discharge
static electricity from body before touching batteries by first touching a grounded metal surface.
Ignition of explosive battery gases
WARNING
Each of the operations described in
this section should be done only by persons
trained and experienced in electrical maintenance. Improper procedures may result in property damage, bodily injury or death.
Connecting the genset AC electrical system involves:
• Installation of transfer switch
• Generator output voltage selection
• Load cable connection
• Standard and optional AC equipment connec-
tions (e.g., control box heater, coolant heater,
etc.
• Optional enclosure electrical connections (re-
fer to
Section 7
Local regulations often require that wiring connections be made by a licensed electrician, and that the
installation be inspected and approved before operation. All connections, wire sizes, materials used,
etc. must conform to the requirements of electrical
codes in effect at the installation site.
).
Ventilate battery area before working on or near
battery—Wear goggles—Stop genset and disconnect charger before disconnecting battery
cables—Disconnect negative (−) cable first and
reconnect last.
CAUTION
Disconnect battery charger from AC
source before disconnecting battery cables.
Otherwise, disconnecting cables can result in
voltage spikes damaging to DC control circuits
of the set.
WARNING
Accidental starting of the generator
set can cause severe personal injury or death.
Prevent accidental starting by disconnecting
the negative (−) cable from the battery terminal.
WARNING
Improper wiring can cause a fire or
electrocution, resulting in severe personal injury or death and/or property and equipment damage.
Before starting the genset, check to make sure that
all electrical connections are secure, and that all
wiring is complete. Replace and secure any access
panels that have been removed during installation.
Check that the load cables from the genset are
properly connected.
WARNING
Backfeed to utility system can
cause electrocution or property damage. Do
not connect to any building electrical system
except through an approved device and after
building main switch is opened.
6-1
TRANSFER SWITCH
Redistribution or publication of this document,
by any means, is strictly prohibited.
If the installation is for standby service, a transfer
switch must be used for switching the load from the
normal power source to the genset (see Figure 6-1).
Either a manual or automatic transfer switch may be
used. Follow the installation instructions provided
with the transfer switch when connecting the load
and control wiring.
LOAD
NORMAL
SOURCE
FIGURE 6-1. TYPICAL LOAD TRANSFER
FUNCTION
GENSET
6-2
AC WIRING
Redistribution or publication of this document,
by any means, is strictly prohibited.
Generator Voltage Connections
The available generator output voltages and maximum current ratings are specified on the generator
set nameplate. Line-to-neutral voltage is always the
lower voltage shown and line-to-line voltage is the
higher rating.
All loads are connected to the generator by bolting
stranded load wires to the appropriate terminals on
the generator reconnection terminal block or circuit
breaker lugs. The terminals are stamped U, V, W
and N to indicate the line and neutral connections.
(Reference: U, V, and W correspond with L1, L2 and
L3; and N with L0 respectively).
Load Balancing
These generators can be configured to the nameplate voltages as shown on the Reconnection Diagram located on the side access cover of the control
housing. Many of the voltages listed will require reconfiguration of the generator output leads on the
connection terminal block. This reconfiguration
must only be done by service personnel that are
trained and experienced to perform electrical installation. The generator set was adjusted to produce a
specified voltage during production verification testing prior to shipment. The installer must always
check the stator lead terminal block connections
and perform any necessary reconnect to obtain the
voltage required.
Some generator sets are capable of producing a
wide range of voltages and connection configurations, others have specific limited capabilities. Refer to wiring diagram and generator voltages (from
the nameplate) when reviewing the voltage connection information and use the wiring diagram supplied with your generator set when actually performing load connections.
CAUTION
Reconfiguring generator sets to
higher voltages can exceed the voltage capability of the specific generator windings and damage the generator and also decrease line current, rendering line circuit breakers too large.
Consult with your distributor before performing
reconnection for a different voltage.
CAUTION
Reconfiguring generator sets to
lower voltages can reduce generator set ratings, and also increase line current, rendering
line circuit breakers too small. Consult with
your distributor before performing reconnection for a different voltage.
Load Connections
Flexible conduit and stranded conductors must be
used for connections to take up movement of the
generator set.
When connecting loads to the generator set, balance the loads so the current flow from each line terminal (L1, L2 and L3) is about the same. This is especially important if both single phase and three
phase loads are connected. Any combination of
single phase and three phase loading can be used
as long as each line current is about the same, within 10 percent of median value and no line current exceeds the nameplate rating of the generator . Check
the current flow from each line after connections by
observing the control panel ammeter.
Current Transformers
Current transformers (CT’s) are required on gensets that contain AC meters. The CT’s must be
installed as noted in the following CT Installation
Requirements.
Refer to the Reconnection Diagram to identify the
output leads/phase that must be routed through
each CT, and also appropriate transformer post
selection for meter sensing leads. The transformers
are labeled CT21, CT22 and CT23 on the reconnection wiring diagram. (The Reconnection Diagram is located on the upper side cover of the control housing.)
CT Installation Requirements:
A. The CT has a dot on one side. This dot must be
facing toward the generator (conventional current flowing into the dot). A dot is also used to
indicate pin 1 of the CT.
B. 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 CT. CT secondary wire marked 2/3
is connected to pin 2 for high voltage gensets or
to pin 3 for low voltage gensets. (Refer to Reconnection Diagram.)
6-3
Grounding
Redistribution or publication of this document,
by any means, is strictly prohibited.
The following is a brief description of system and
equipment grounding of permanently installed AC
generators within a facility wiring system. It is important to follow the requirements of the local electrical
code.
Figure 6-2 illustrates typical system grounding for a
3-pole and a 4-pole automatic transfer switch
(ATS). In the 3-pole ATS, note that the generator
neutral is connected to the ATS and is NOT bonded
to ground at the generator. In the 4-pole ATS system, a grounding electrode conductor and a bonding jumper are used to connect the generator neutral to ground.
Make sure the genset is grounded to earth in one
location only. On generators without a circuit breaker, ground to the point indicated on the top of the
generator. O n gensets with circuit breakers, use the
ground lug provided in the circuit breaker box.
WARNING
Electric current can cause severe
personal injury or death. Bonding and grounding must be done properly. All metallic parts
that could become energized under abnormal
conditions must be properly grounded.
Typical requirements for bonding and grounding
are given in the National Electrical Code, Article
250. All connections, wire sizes, etc. must conform
to the requirements of the electrical codes in effect
at the installation site.
SERVICE ENTRANCE
THREE-PHASE, FOUR-WIRE UTILITY, THREE-POLE ATS
SERVICE ENTRANCE
GENERATOR SET
3-POLE ATS
LOAD
GENERATOR SET
4-POLE ATS
FIGURE 6-2. TYPICAL SYSTEM GROUNDING ONE-LINE DIAGRAMS
LOAD
THREE-PHASE, FOUR-WIRE UTILITY, FOUR-POLE ATS
6-4
CONTROL HEATER (OPTIONAL)
Redistribution or publication of this document,
by any means, is strictly prohibited.
A control heater (Figure 6-3) provides a means of
humidity /temperature control of the control box interior. I t protects the components when the generator set is subjected to varying ambient air conditions
during extended periods of non-use. Thermostat
INPUT POWER
TB10 (240/120 V AC)
75° F (24° C)
THERMOSTAT
control de−energizes the heater when the control
box interior reaches 75
° F (24° C).
Connect the heater to a source of power that will be
on during the time the engine is not running. Be sure
the supply voltage and circuit amperage is correct
for the heater rating.
TO 120 VAC
SUPPLY
150W STRIP
HEATER
FIGURE 6-3. OPTIONAL CONTROL HEATER
6-5
COOLANT HEATER (OPTIONAL)
Redistribution or publication of this document,
by any means, is strictly prohibited.
Coolant heaters keep the engine coolant warm
when the engine is shut down. It heats and circulates the coolant within the engine. This reduces
startup time and lessens engine wear caused by
cold starts. It is electrically operated and thermostatically controlled.
CAUTION
erated while the cooling system is empty, when
ball valves are closed or when the engine is running or damage to the heater will occur.
Figure 6-4 shows a typical coolant heater. Connect
the heater to a source of power that will be on during
The coolant heater must not be op-
THERMOSTAT
the time the engine is not running. Be sure the supply voltage and circuit amperage is correct for the
heater element rating.
A battery charger is required to prevent battery discharge. The heater control relay draws 83 mA of current when the heater(s) is off. The heater is off when
the engine has reached the proper temperature or
the engine is running.
CAUTION
Do not connect AC power to the
heater before connecting battery cables. Heater
will run continuously without DC power and can
overheat and damage heater.
COOLANT
FLOW
BALL VALVE (OPEN
POSITION SHOWN)
CHECK VALVE
COOLANT
FLOW
COOLANT HEATER
AC POWER LINE
DC CONTROL
LINE
DRAIN
AC ELECTRICAL CONNECTION
BOX (ELECTRICAL DIAGRAM
INSIDE COVER)
FIGURE 6-4. TYPICAL COOLANT HEATER
6-6
GENERATOR HEATER (OPTIONAL)
Redistribution or publication of this document,
by any means, is strictly prohibited.
A generator heater(s) is used to help keep the generator free of condensation when the generator set
is not running. During cool and humid conditions,
condensation can form within a generator, creating
flashing and a shock hazard.
WARNING
tor increases the possibility of flashing and
electrical shock, which can cause equipment
damage and severe personal injury or death. Do
not use a generator which is not dry inside and
out.
Water or moisture inside a genera-
HEATER LEADS
Figure 6-5 illustrates the installation of two heater
elements. Connect the heater(s) to a source of power that will be on during the time the engine is not
running. Be sure the supply voltage and circuit amperage is correct for the heater element rating.
HEATER
HEATER LEADS
HEATERS
TERMINAL BOX
HEATER
VOLT/WATTS
LABEL
TERMINAL
BLOCK
TO 120 VAC
SUPPLY
FIGURE 6-5. TYPICAL GENERATOR HEATER INSTALLATION
6-7
THIS PAGE LEFT INTENTIONALLY BLANK
Redistribution or publication of this document,
by any means, is strictly prohibited.
6-8
7. Enclosure Electrical Connections
Redistribution or publication of this document,
by any means, is strictly prohibited.
GENERAL
Generator sets configured with an enclosure can
contain one or more optional features. The optional
features that require electrical connections when
installing the generator set are described in this
section. For wiring diagrams of enclosure options,
refer to Section 10,
FUEL ALARM
PANEL
Enclosure/Options Wiring
OVERFILL
ALARM
FUEL
FILL
.
CAUTION
Flexible conduit and stranded conductors must be used for connections to take
up movement of the genset. Solid copper wire
may break due to genset vibration.
Figure 7-1 shows the location of the optional features within the enclosure.
FUEL SYSTEM
CONTROL
EMERGENCY
STOP SWITCH
EXTERNAL
FUEL FILL BOX
MOTORIZED
INLET LOUVER
FIGURE 7-1. OPTIONAL ENCLOSURE FEATURES (WEATHER ENCLOSURE SHOWN)
120 VAC
EXTERNAL
RECEPTACLE
AC DISTRIBUTION
PANEL
7-1
OPTIONAL AC DISTRIBUTION PANEL
Redistribution or publication of this document,
by any means, is strictly prohibited.
The AC distribution panel (Figure 7-2) provides a
centralized power source (120/220VAC) for all optional enclosure features.
CAUTION
the OFF position before applying power to the
AC distribution panel. Other options may require additional installation before connecting
to power.
CAUTION
the fuel transfer pump option, power to the AC
distribution panel must be fed from a transfer
switch and step-down transformer to maintain
120V power to the pump when utility power is interrupted. If the transfer pump option is not
installed, power to the AC distribution panel can
be fed from a non-emergency source. (Other optional features connected to the AC distribution
Make sure all circuit breakers are in
When the generator set contains
panel are not needed for generator set operation.)
All connections to the AC distribution panel are to be
done in compliance with the National Electric Code
and all applicable local codes and standards using
60 or 75 degree conductors.
The AC distribution panel is designed to be fed with
a 100AMP, 120/240VAC, single phase feeder. The
two line conductors connect into the 100AMP main
breaker that is listed for #4 to 2/0 conductors, AL or
CU when torqued to 50 in-lbs.
The neutral conductor connects into the neutral bus
which is listed for #5 to 300KCMIL conductors, AL or
CU when torqued to 21 ft-lbs.
The grounding conductor, if used, connects into the
ground bar which is listed for #1 to 2/0 conductors,
AL or CU when torqued to 17 ft-lbs.
1/3
5/7
CIRCUIT BREAKERS
1/3: 100A MAIN
2: 20A J1/J2 RECEPTACLES
4: 20A J3/J4 RECEPTACLES
5/7: 40A COOLANT HEATERS
6: 20A INLET/OUTLET LOUVERS
8: 20A INTERNAL/EXTERNAL
SERVICE RECEPTACLES
2
4
6
8
FOR OPTIONAL FEATURES
J1: ENGINE OIL HEATER
J2: BATTERY HEATER
J3: ALTERNATOR /CONTROL
J4: BA TTERY CHARGER/TRANS-
GFCI SERVICE
RECEPTACLE
COOLANT HEATER
CONTROL AC SUPPLY
J1 J2 J3 J4
120VAC RECEPTACLES
24 V AC
TRANSFORMERS
(LOUVER MOTORS)
CABINET HEATERS
FER PUMP CONTROLLER
FIGURE 7-2. AC DISTRIBUTION PANEL FEATURES
7-2
OPTIONAL MOTORIZED INLET/OUTLET
Redistribution or publication of this document,
by any means, is strictly prohibited.
LOUVERS
Louvers (inlet and/or outlet) are powered by either
24VDC supplied by genset control switched B+ or
24VAC transformer connected to shore power.
With switched B+ or gensets having the AC distribution panel, the motorized louvers are prewired and
require no further installation (Figure 7-3).
Without the AC distribution panel, the 24VAC louvers are not prewired. Louvers operating on 24VAC
require 30VAC, 24 volt class 2 transformer(s).
(Transformers are not supplied with genset that
does not contain an AC distribution panel.) Mount
and connect the transformer(s) to the 18 gauge
wires terminated at the AC distribution panel location. Connect the transformer(s) to a source of power that will be on during the time the engine is not
running.
MOTORIZED
INLET LOUVER
30VAC
TRANSFORMER(S)
MOTORIZED
OUTLET LOUVER
AC DISTRIBUTION
PANEL
FIGURE 7-3. MOTORIZED LOUVER
7-3
OPTIONAL FUEL TRANSFER PUMP
Redistribution or publication of this document,
by any means, is strictly prohibited.
A fuel transfer pump and control are available when
a sub-base fuel tank is provided. The automatic
control operates the fuel pump to maintain a reservoir of fuel in the sub-base tank.
CAUTION
must be fed from a transfer switch and stepdown transformer to maintain 120V power to the
pump when utility power is interrupted. Power
must be supplied to the transfer pump during
the time the genset is running or not running.
The fuel transfer pump/controller is prewired and
ready to connect to a 120VAC source.
NOTE: When power is applied to the control or is restored after a power interruption, the control will au-
Power to the fuel transfer pump
tomatically go to the power on mode (functions the
same as pressing the ON switch). The pump will start
if the control detects low fuel in sub-base tank.
CAUTION
Do not connect AC power to the fuel
transfer pump control without having fuel in the
supply tank. Damage to the pump can occur if
pump operates with no fuel in supply tank.
Supply Tank
Refer to
installation/plumping of the supply tank to the subbase fuel tank.
The fuel transfer pump has a maximum inlet restriction capability of 16 inch Hg (which is approximately
equivalent to 20 feet of diesel).
FUEL SYSTEM
CONTROL
Section 4
for information regarding the
FUEL
FILL
OVERFILL
ALARM
TO 120 VAC
EMERGENCY SUPPLY
FIGURE 7-4. FUEL TRANSFER PUMP/CONTROL LOCATION
7-4
8. Prestart Preparation
Redistribution or publication of this document,
by any means, is strictly prohibited.
GENERAL
Before attempting the initial start of the generator
set, be sure to complete the
Section 9
.
Installation Checklist
in
INPOWER SERVICE TOOL
GENERAL INFORMATION
InPower is a PC based service tool for the PowerCommand
• Make adjustments to the controls trims and set-
• Perform diagnostics and monitoring.
• Review event history.
• Create a capture file of the controls trims and
• Update control calibrations (InPower PRO ver-
Refer to INPOWER User’s Guide for specifics.
tings.
settings.
sion).
3200 Control (PCC). Use InPower to:
InPower Adjust Mode
The adjustment feature allows you to make adjustments to genset parameters, calibrations and settings. There are several groups of adjustment parameters; note that not all gensets will have the
same adjustments available.
InPower Capture File Description
InPower provides a method of extracting (capturing) a device’s parameter values. Capturing saves
device information in a file that is identified with a
.CAP extension.
Capture files are used to store a copy of the genset’s parameter values. During genset installation,
it is suggested that a capture file be made before
and after changes are made to the genset operating
parameters. This information can be a very useful
when troubleshooting the genset (determine if parameters/settings have been modified after installation) and when replacement of the Base board is
necessary. The capture file can be used as a template to write the previous settings to the new Base
board software.
8-1
ELECTRICAL SYSTEM
Redistribution or publication of this document,
by any means, is strictly prohibited.
Make sure all electrical connections are secure and
all wiring is complete and inspected. Replace and
secure any access panels that may have been removed during installation.
Battery Connections
gency standby service), may allow battery to selfdischarge to the point where it cannot start the unit.
If installing an automatic transfer switch that has no
built-in charge circuit, connect a separate trickle
charger. Onan automatic transfer switches include
such a battery charging circuit.
WARNING
Accidental starting of the generator
set can cause severe personal injury or death.
Make sure that the O/Manual/Auto switch on the
control panel is set to the O (Off) position before
connecting the battery cables.
Starting the unit requires 24 volt battery current, using 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 8-1.
Necessary battery cables are on the unit. Service
batteries as necessary . Infrequent use (as in emer-
WARNING
Ignition of explosive battery gases
can cause severe personal injury or death. Always connect negative (−) battery cable last to
prevent arcing.
WARNING
Ventilate battery area before working on or near battery. Arcing at battery terminals, light switch or other equipment, flame, pilot lights and sparks can ignite battery gas. Do
not smoke, or switch trouble light ON or OFF
near battery. Discharge static electricity from
body before touching batteries by first touching
a grounded metal surface.
BATTERY POSITIVE
(+) CONNECTION
BATTERY
NEGATIVE (−)
CONNECTION
USE TWO, 12
VOLT BATTERIES
FOR THE
STARTER
FIGURE 8-1. GENSET BATTERY CONNECTIONS
8-2
CONTROL PRESTART CHECKS
Redistribution or publication of this document,
by any means, is strictly prohibited.
All generator set configuration options are set at the
factory except for site related options, (e.g., Start/
Stop Delays, Cycle Crank, Customer Fault names,
etc.) and the optional Power T ransfer Control (PTC)
feature.
Adjustments of these options are divided into two
categories within the menu driven system. These
two categories are Setup and Adjust.
The following procedures describe how to modify
the Adjust submenu options and if installed, the
PTC Setup submenus, which are required to complete the genset installation.
The Adjust submenu allows you to calibrate the
generator set voltage/frequency and start/stop time
delays. For the prestart checks, adjustment of only
the start/stop delays is required.
The Setup submenus are intended for qualified service personnel only. The Adjust submenu is intended for qualified service and site personnel only.
For this reason, a separate password is required to
modify the Setup submenus. The Adjust submenu
may or may not require a password (site dependent).
CAUTION
Improper calibration or adjustment
of the control can cause equipment malfunction
or damage. Calibration and adjustment must be
performed by technically qualified personnel
only.
The PTC Setup submenus contain parameters with
adjustable default values that should be checked
and modified if necessary for this site. The descriptions in this section include ranges for the parameters and default values for this feature.
Saving Menu Changes
Changes are automatically saved when the menu is
exited.
8-3
Password Menu
Redistribution or publication of this document,
by any means, is strictly prohibited.
To allow the site personnel to modify only the Adjust
submenu and not the Setup submenus, two passwords are assigned within the system software. An
Application password is used for the Setup submenus and a User password is used for the Adjust
submenu.
unauthorized adjustment, the entered password is
valid for 10 minutes after the last button is pressed
(i.e., the password will need to be reentered after
the ten minute time−out.
Entering Password
To enter the password:
The two passwords are assigned during the initial
installation of the generator set (via InPower) and
will vary between sites. The installer must make
sure that the passwords are available to the appropriate personnel.
When the generator set is first installed, the
and
User
tion
allow initial modification of the Setup and Adjust
submenus. Assign new passwords when site installation is complete.
password are both set to GENSET to
Applica-
When viewing the Adjust menu, pressing the + or −
button will display the User Password menu.
When viewing a Setup menu, pressing the + or −
button will always display the Application Password
menu.
After entering the correct password, the system will
allow you to modify the submenus. To help prevent
+ OR − BUTTON
1. Display submenu to modify.
2. Press either the + or − button within the displayed submenu. The Password menu appears.
3. Press the + and − button to select the first char-
acter of the password (A−Z or 0−9). (Enter Ap-
plication password for Setup submenus; Enter User password for Adjust submenu.)
4. Press the
→ button to select the next character
field. Selected character field is highlighted.
5. Repeat steps 3 and 4 to enter remaining password characters.
6. Press the Enter button after entering the password. The submenu selected in step 1 will reappear.
7. After making desired changes to submenu, exit
submenu to save changes.
+ OR − BUTTON
ENTER APPLICATION PASSWORD
+
−
→
SETUP SUBMENU PASSWORD MENU
XXXXXXXX
ENTER
FIGURE 8-2. PASSWORD MENUS
+
−
→
ADJUST SUBMENU PASSWORD MENU
8-4
ENTER USER PASSWORD
ENTER
XXXXXXXX
ADJUST SUBMENU
Redistribution or publication of this document,
by any means, is strictly prohibited.
Figure 8-2 shows the main menus (Menu A and
Menu B) of the system control and the Adjust submenu.
To display the Adjust submenu, press the MORE>>
button in Menu A and then the ADJUST button in
Menu B.
The Adjust procedure is intended for qualified service personnel and site personnel only and may require a USER password. If a password is required,
the USER password menu will appear when you try
to modify the Adjust submenu. (Refer to
WORD Menu
in this section to enter password.
Changes are automatically saved when you exit
this menu.
Use the + and − buttons to increase or decrease the
values in the following fields. Use the arrow (
ton to move the cursor within a field or to the next
field.
PASS-
→) but-
START DELAY: This delay applies only to remote
starting in the Auto mode. The Start Delay adjustment range is 0 to 300 seconds.
STOP DELAY: This delay applies only to remote
stopping in the Auto mode. The Stop Delay adjustment range is 0 to 600 seconds.
VOLTAGE: Used to adjust the output voltage ±5%.
FREQUENCY: Used to adjust the frequency ±3 Hz.
VOLTAGE/SPEED DROOP: These two submenus
apply to a genset that has the paralleling option and
is configured to operate in droop mode. These adjustments must be performed by technically qualified personnel only.
ENGINE
ALTERNATOR
CONTROL
SETUP
MENU A
HISTORY/ABOUT
MENU B
MORE>>
_\_
ADJUST
BUS DATA
BACK<<
MENU
B
ADJUST
ADJUST
ADJUST:
START DELAY 5 SEC
+
STOP DELAY 11 SEC
−
VOLTAGE 208 1.2 %
FREQ 60.0 HZ -0.0 HZ
→
ADJUST:
STANDBY
+
VOLTAGE DROOP OFF
−
BUS L1 480 V
POWER FACTOR 0.80
→
VOLT 4.99 %
ADJUST:
STANDBY
+
SPEED DROOP OFF
−
BUS FREQ 60.0 HZ
TOTAL KW 300 KW
→
FREQ 60.0 0.40 HZ
FIGURE 8-3. ADJUST SUBMENU
8-5
POWER TRANSFER CONTROL MAIN
Redistribution or publication of this document,
by any means, is strictly prohibited.
MENUS
Figure 8-4 shows the main menus (Menu A and
Menu B) o f the system control, the two setup menus
and the two main menus of the optional Power
Transfer Control (PTC) feature.
MENU A MENU B
To adjust PTC system parameters, press the appropriate PTC main menu button and refer to the
page number shown in Figure 8-4 for detailed information related to the submenu selected.
ENGINE
ALTERNATOR
CONTROL
MORE>>
_\_
HISTORY/ABOUT SETUP
GOVERNING/VOLT REG
CUSTOMER FAULTS
CALIBRATION
NEXT
MENU
POWER TRANSFER SETUP
ISOLATED BUS
UTILITY
PAGE
8-7
MENU
B
ADJUST
BUS DATA
BACK<<
NEXT
MENU
PTC MAIN
MENU 1
PAGE
8-9
PAGE
8-11
PAGE
8-12
UTILITY SENSORS
GENSET SENSORS
TIMERS
TEST/EXERCISE
FIGURE 8-4. PTC SETUP MAIN MENUS
8-6
NEXT
MENU
PTC MAIN
MENU 2
UTILITY SENSORS SUBMENUS
Redistribution or publication of this document,
by any means, is strictly prohibited.
If you press the “UTILITY SENSORS” button in the
PTC Main Menu 1, the Utility Sensors submenus
will appear (Figure 8-5).
The following field descriptions show the valid field
entries and default value (shown in parenthesis) for
each field. For a complete explanation of these
fields, refer to heading “
“ in this section.
tions
Use the + and − buttons to increase or decrease the
values in the following fields. Use the arrow (→) button to move the cursor within a field or to the next
field. Exit menu to save changes.
PTC Detailed Field Descrip-
U PT VOLT LL: Enter the value of the utility line-toline voltage which yields 100% voltage at the terminals of the utility (bus) PT module.
Range: 1−15000V, adjustable by standard nominal
voltage values, 100V, 10V and 1V increments (1V).
The 100% voltages for each of the four possible utility (bus) PT modules are as follows, based on module dash number:
−01 = 208 volts LL
−02 = 416 volts LL
−03 = 600 volts LL
−04 = 120 volts LL
U CT R ATIO: Enter the CT Ratio of the Utility L2 CT.
This is the Ratio to 1 Amp. Range: 1−18000 (1A).
CAUTION
This CT must be rated for 1 Amp
output (e.g. NOT 5 Amp). Be sure CT secondary
circuit has burden resistor or a shorting jumper
in place before putting power through the CT.
Example: CT Ratio = 2650:1. Thus enter 2650.
U SENSOR TYPE: Enter the line-to-line (L-N) for 3
phase line-neutral voltage sensing or line-to-line
(L-L) for 3 phase line-line voltage sensing. This applies to both the utility undervoltage and overvoltage sensors. Range: L−L, L−N (L−N).
U <wye> <delta>: Enter utility connection type.
Range: Delta, Wye (Wye).
U UNLOADED KW: Enter the kW on utility Line 2 at
which the utility is considered as unloaded. This is
the L2 kW level at which a closed transition soft
transfer will disconnect from the utility.
UTILITY UNDERVOLTAGE: Non-adjustable field,
always enabled.
Example 1:
Nominal Utility voltage is 480V. This
means that utility (bus) PT module number −02
should be used. The voltage which will yield 100%
volts at this PT module is 416 per the above table.
Thus enter 416V.
Example 2:
Nominal Utility voltage is 4160V. A primary stage transformer with a ratio of 4200/240 is
used. This means that utility (bus) PT module number −01 should be used. The voltage which will yield
the 100% volts (208V from above table) is calculated as follows:
208 x (4200/240) = 3640. Thus enter 3640V.
U NOM VOLT LL: Enter the nominal utility line-toline voltage. For example, 480, 4160, etc.. Range:
1−15000 V, adjustable by standard nominal voltage
values, 100V, 10V and 1V increments (1V).
UTILITY OVERVOLTAGE, FREQUENCY: Used to
enable or disable menu function. Choose Enabled
or Disabled (Enabled).
UV PICKUP: Enter a number between 85 and
100% of the nominal voltage (90%).
UV DROP OUT: Enter a number between 75 and
98% of the under-voltage pick-up percentage
(90%).
UV DELAY: Enter a time between 0.1 and 5.0 seconds (0.5 seconds).
UV MIN PHASE: Displays the lowest line voltage of
the three utility phases.
8-7
OV PICKUP: This adjusts the over-voltage pickup
Redistribution or publication of this document,
by any means, is strictly prohibited.
as a percentage of the over-voltage drop-out. Enter
a number between 95 and 99% (95%).
OV DROP OUT: Enter a percentage between 105
and 135% of the nominal voltage (110%).
UTILITY SENSORS
OV DELAY: Enter a range between 0 and 120 sec-
onds (3 seconds).
OV MAX PHASE: Displays the highest line voltage
of the three utility phases.
CENTER (FREQ): Enter a frequency between 45
and 65 Hz (60 Hz).
PICK UP (FREQ): Enter a percentage between 5
and 20% of the nominal frequency (10%).
DROP OUT (FREQ): Enter a percentage between
1 and 5% of the nominal frequency (1%).
DELAY (FREQ): Enter a time between 0.1 and 15.0
seconds (5.0 seconds).
FREQUENCY: This field displays the sensed utility
line frequency.
U PT VOLT LL 416
U NOM VOLT LL 480
+
U CT RATIO: 1 1000
−
U SENSOR TYPE L−L
→
U UNLOADED KW 50 KW
UTILITY UV: ENABLED
+
PICK UP 95 475
−
DROP OUT 85 465
DELAY 0.5 S
→
MIN PHASE 470
UTILITY OV: DISABLED
+
PICK UP 95 487
−
DROP OUT 110 490
DELAY 3.0 S
→
MAX PHASE 485
% VLL
% VLL
8-8
UTILITY FREQ:DISABLED
CENTER 60 HZ
+
PICK UP 10 %
−
DROP OUT 1 %
DELAY 1.0 S
→
FREQUENCY 60.5 HZ
FIGURE 8-5. UTILITY SENSORS SUBMENUS
GENSET SENSORS SUBMENUS
Redistribution or publication of this document,
by any means, is strictly prohibited.
If you press the “GENSET SENSORS” button in the
PTC Main Menu 1, the Genset Sensors submenus
will appear (Figure 8-6).
The following field descriptions show the valid field
entries and default value (shown in parenthesis) for
each field. For additional information regarding
these fields, refer to heading “
Descriptions
Use the + and − buttons to increase or decrease the
values in the following fields. Use the arrow (→) button to move the cursor within a field or to the next
field. Exit menu to save changes.
“ in this section.
PTC Detailed Field
G NOM VOLT LL: Non-adjustable field, displays
current setting of genset nominal voltage. (See Adjust submenu to adjust the output voltage
±5%.)
G SENSOR TYPE: Enter the line-to-line (L-N) for 3
phase line-neutral voltage sensing or line-to-line
(L-L) for 3 phase line-line voltage sensing. This applies to both the genset undervoltage and overvoltage sensors. Range: L−L, L−N (L−N).
G BASE LOAD: Enter the maximum load the genset will carry during a closed transition. Range:
0−100% (80%).
G RAMP LOAD: Enter the ramp time for the genset
ramp load rate during a closed transition soft load
transfer. Ramp rate is +100%kW divided by this
time setting. Range: 0−900 seconds (20 sec).
G RAMP UNLOAD: Enter the ramp time for the
genset ramp unload rate during a closed transtion
soft load retransfer. Ramp rate is −100%kW divided
by this time setting. Range: 0−900 seconds (20
sec).
G UNLOADED KW: Enter the %kW (based on
standby rating) that the genset is considered unloaded. Thi s i s t h e %kW level at which a closed transition soft retransfer will disconnect from the genset. Range: 0−100% (5%).
GEN UNDERVOLTAGE: Non-adjustable field, always enabled.
GEN OVERVOLTAGE, FREQUENCY: Used to enable or disable menu function. Choose Enabled or
Disabled (Enabled).
UV PICKUP: Enter a number between 85 and
100% of the nominal voltage (90%).
UV DROP OUT: Enter a number between 75 and
98% of the under-voltage pick-up percentage
(90%).
UV DELAY: Enter a time between 0.1 and 5.0 seconds (4 seconds).
UV MIN PHASE: Displays the lowest line voltage of
the three genset phases.
8-9
OV PICKUP: This adjusts the over-voltage pickup
Redistribution or publication of this document,
by any means, is strictly prohibited.
as a percentage of the over-voltage drop-out. Enter
a number between 95 and 99% (95%).
OV DROP OUT: Enter a percentage between 105
and 135% of the nominal voltage (110%).
GENSET SENSORS
OV DELAY: Enter a range between 0 and 120 sec-
onds (3 seconds).
OV MAX PHASE: Displays the highest line voltage
of the three genset phases.
CENTER (FREQ): Enter a frequency between 45
and 65 Hz (60 Hz).
PICK UP (FREQ): Enter a percentage between 5
and 20% of the nominal frequency (10%).
DROP OUT (FREQ): Enter a percentage between
1 and 5% of the nominal frequency (1%).
DELAY (FREQ): Enter a time between 0.1 and 15.0
seconds (5.0 seconds).
FREQUENCY: Displays the sensed genset line fre-
quency.
G NOM VOLT LL 480
G SENSOR TYPE L−L
+
G BASE LOAD 80.0%
−
G RAMP LOAD 20 S
G RAMP UNLOAD 20 S
→
G UNLOADED KW 5 %
GEN UV: ENABLED
+
PICK UP 95 475
−
DROP OUT 85 465
DELAY 1.0 S
→
MIN PHASE 470
GEN OV: DISABLED
+
PICK UP 95 487
−
DROP OUT 110 490
DELAY 8.0 S
→
MAX PHASE 485
% VLL
% VLL
8-10
GEN FREQ: DISABLED
CENTER 59 HZ
+
PICK UP 12 %
−
DROP OUT 2 %
DELAY 5.0 S
→
FREQUENCY 60.0 HZ
FIGURE 8-6. GENSET SENSORS SUBMENUS
TIMERS SUBMENU
Redistribution or publication of this document,
by any means, is strictly prohibited.
If you press the “TIMERS” button in the PTC Main
Menu 1, the Timers submenu will appear (Figure
8-7).
The following field descriptions show the valid field
entries and default value (shown in parenthesis) for
each field. For a complete explanation of these
fields, refer to heading “
tions
“ in this section.
Use the + and − buttons to increase or decrease the
values in the following fields. Use the arrow (→) button to move the cursor within a field or to the next
field. Exit menu to save changes.
START DELAY: Sets time delay for genset engine
start. Prevents nuisance genset starting during brief
power interruptions.
Enter a range from 0 to 300 seconds (0 seconds).
STOP DELAY : Sets the time delay for engine cool-
down following a re-transfer. This stop delay works
in conjunction with and is activated at the same time
as the normal cooldown timer. (Will extend normal
cooldown timer if entered time is greater.)
Enter a time from 0 to 600 seconds (0 seconds).
TRANSFER: In a Normal to Emergency transfer
this function allows the genset to stabilize before
the load is applied. Enter a time from 0 to 120 seconds (10 seconds).
RETRANSFER: In a Emergency to Normal transfer
this function allows the utility to stabilize before the
load is applied.
Enter a time from 0 to 1800 seconds (600 seconds).
PGM TRANSIT: Sets the time delay for Pro-
grammed Transition. A setting of 0.0 disables the
program.
Enter a time from 0 to 60 seconds (0 seconds).
MAX PARALLEL: Sets the maximum time during
closed transition that utility and genset can be paralleled.
Enter a time from 0 to 1800 seconds (20 seconds).
PTC Detailed Field Descrip-
TIMERS
START DELAY 60 S
STOP DELAY 60 S
+
TRANSFER 10 S
−
RETRANSFER 900 S
PGM TRANSIT 5 S
→
MAX PARALLEL 30 S
FIGURE 8-7. TIMERS SUBMENU
8-11
TEST/EXERCISE SUBMENU
Redistribution or publication of this document,
by any means, is strictly prohibited.
If you press the “TEST/EXERCISE” button in the
PTC Main Menu 2, the Test/Exercise submenu will
appear (Figure 8-8).
The following field descriptions show the valid field
entries and default value (shown in parenthesis) for
each field.
Use the + and − buttons to increase or decrease the
values in the following fields. Use the arrow (→) button to move the cursor within a field or to the next
field. Exit menu to save changes.
MODE: Indicates the generator set application type
for PTC option.
OT-PGM TRAN − Open transition load transfer.
CT-MOMENT − Closed transition load transfer
with momentary (<100ms) overlap.
CT-SOFT − Closed transition load transfer with
load ramping.
TEST WITH LOAD: Feature allows genset Test sequence, which is initiated through the Remote Start
(TEST) switch, to operate with or without load. Default: OFF
EXER WITH LOAD: Feature allows genset Exercise sequence, which is initiated through control
panel Exercise button to operate with or without
load. Default: OFF
TEST/EXERCISE
+
MODE CT-SOFT
−
TEST WITH LOAD OFF
→
EXER WITH LOAD OFF
FIGURE 8-8. TIMERS SUBMENU
8-12
PTC DETAILED FIELD DESCRIPTIONS
Redistribution or publication of this document,
by any means, is strictly prohibited.
WARNING
of electronic control modules can cause death,
severe personal injury, and equipment or property damage. Calibration and adjustment of
these components must be performed by technically qualified personnel only.
Start Delay:
0 to 300 seconds. This brief time delay prevents the
generator set from starting during short power interruptions. Timing starts at the utility power interruption. If the duration of interruption exceeds the delay
time, the control system starts the generator.
Stop Delay:
0 to 600 seconds. The Stop Delay begins timing
when the load is retransferred to the utility.
Improper calibration or adjustment
This start time delay is adjustable from
This stop time delay is adjustable from
At the end of the delay, the stop signal is sent to the
generator set. This stop delay works in conjunction
with and is activated at the same time as the normal
cooldown timer. (Will extend normal cooldown timer
if entered time for Stop Delay is greater.)
Transfer:
This transfer time delay begins when
genset voltage and frequency reach the settings of
the control. After the delay, the PTC transfers the
load to the utility. This brief time delay allows the
generator set to stabilize before the load is applied.
It has an adjustable range of 0 to 120 seconds. The
default value is 10 seconds.
Retransfer:
This retransfer time delay begins the
moment utility line voltage and frequency return to
specified values. After the delay, the PTC can retransfer the load to the utility. The delay allows the
utility to stabilize before retransfer. It has an adjustable range of 0 to 1800 seconds. The default value
is 600 seconds.
8-13
Under-Voltage Sensing
Redistribution or publication of this document,
by any means, is strictly prohibited.
Over-Voltage Sensing
The PTC feature includes under-voltage sensors
for the utility and the genset. When a sensor detects
a low voltage condition over a specified time period,
it initiates a transfer. When the source voltage returns to an acceptable value again, the sensor initiates a retransfer.
These parameters are adjustable. The under-voltage sensing range for a falling voltage (drop-out) is
75 to 98% of the pick-up voltage setting. The default
value is 90%. The pick-up range for a rising voltage
is 85 to 100% of the nominal voltage setpoint. The
default value is 90%. The adjustable range for the
time delay period is 0.1 to 5.0 seconds. The default
delay time is 4 seconds. See Figure 8-9 for an example using the default values.
Example using Default Settings
for Nominal Voltage of 240 VAC
Drop-out
Setting
(194V)
Pick-up
Setting
(216V)
Nominal
Setpoint
(240V)
The PTC feature includes over-voltage sensors for
the utility and the genset that can be disabled and
not used. When a sensor detects a high voltage
condition over a specified time period (delay), it initiates a transfer. When the source voltage falls to an
acceptable value again, the sensor initiates a retransfer.
These parameters are adjustable. The over-voltage
sensing range (drop-out) for a rising voltage is 105
to 135% of the nominal voltage setpoint. The default
value is 110%. The pick-up range for a falling voltage is 95 to 99% of the drop-out setting. The default
value is 95%. The adjustable range for the delay
time period is 0.0 to 120.0 seconds. The default
delay time is 3.0 seconds. See Figure 8-10 for an
example using the default values.
Example using Default Settings
for Nominal Voltage of 240 VAC
Nominal
Setpoint
(240V)
Pick-up
Setting
(251V)
Drop-out
Setting
(264V)
VOLTS
90% of
Pick-up
FIGURE 8-9. UNDER-VOLTAGE SENSING
90% of
Nominal
VOLTS
95% of
Drop-out
FIGURE 8-10. OVER-VOLTAGE SENSING
110% of
Nominal
8-14
Frequency Sensing
Redistribution or publication of this document,
by any means, is strictly prohibited.
The PTC feature includes frequency sensors for the
utility and the genset that can be disabled and not
used. When a sensor detects a high or low frequency condition over a specified delay time period, it initiates a transfer. When the frequency returns to an
acceptable value again, the sensor initiates a retransfer.
Example using Default Settings
for Nominal Frequency of 60 Hz
60 Hz
Pick-up Frequencies
54 Hz
Drop-out Frequencies
53.5 Hz
FIGURE 8-11. FREQUENCY SETTING
These parameters are adjustable. The nominal frequency can be set between 45.0 and 65.0 Hz. The
default frequency is 60 Hz. The acceptable frequency bandwidth (pick-up) is ±5 to ±20% of the nominal
frequency setpoint. The default value is 10%. The
drop-out frequency is 1 to 5% beyond the pick-up.
The default value is 1%. The range for the delay
66 Hz
66.7 Hz
time period is 0.1 to 15 seconds. The default delay
time is 5 seconds. The frequency sensing feature is
enabled by default. This feature can also be disabled.
Programmed Transition
Programmed T ransition introduces a delay (TDPT)
during an “open transition” transfer or retransfer.
Programmed transition causes a pause in the neutral position for an adjustable interval of time. In this
position, the load is not connected to either the utility or the genset. This delay allows residual current
from inductive loads to decay to an acceptable level
before transfer is completed.
The length of time that the utility or genset breaker/
contactors are both in the neutral (open) position
can be adjusted from 0 to 60 seconds. The default
value is 0 seconds. The proper adjustment is a function of the load. This feature is enabled by default.
This featu r e i s not used in closed transition paralleling applications.
STARTING
Refer to the generator set
portant safety precautions and recommended procedures for starting the genset and verifying proper
operation. Start the generator set and verify all engine and generator gauges are displaying the correct values.
Operator’s
manual for im-
8-15
THIS PAGE LEFT INTENTIONALLY BLANK
Redistribution or publication of this document,
by any means, is strictly prohibited.
8-16
9. Installation Checklist
Redistribution or publication of this document,
by any means, is strictly prohibited.
GENERAL
Generator set wattage capacity is sufficient to handle maximum anticipated load.
At least 3 feet of clearance (or greater for housing door) is provided around entire generator set for servic-
ing and ventilation.
Generator set is located in an area not subject to flooding.
All operating personnel have read and are familiar with Operator’s Manual.
All operators have been thoroughly briefed on preventive maintenance procedures.
All operators have read and understand all Important Safety Instructions in Operator’s Manual.
GENERATOR SET SUPPORT
Floor, roof or earth on which the generator set rests is strong enough and will not allow shifting or movement. Observe local codes on soil bearing capacity due to freezing and thawing.
Generator set is properly supported and retained to approved base.
Supporting base is large enough and is of non-combustible material − extends 6-inches all around set.
COOLING AIR FLOW
Generator set air inlet is faced into direction of strongest, prevailing winds.
Air inlet openings are unrestricted and at least 1−1/2 times larger than air outlet area.
Cooling air outlet is on downwind side of building (if not, wind barrier is constructed).
Proper ducting material (sheet metal, canvas) is used between radiator and air outlet.
DIESEL FUEL SYSTEM
Fuel tanks meet or exceed all Local, State or National codes.
Fuel lines are properly installed, supported and protected against damage.
Approved flexible fuel line is installed between main fuel supply line and generator set’s fuel system, near
the generator set, to protect the fuel system from damage caused by vibration, expansion and contraction.
Strainer or fuel screen (100 to 120 mesh) is installed in the fuel supply line to protect the fuel lift pump, day
tank transfer pump or float valve seat from fuel supply tank debris.
Fuel supply line shutoff valves are installed to prevent fuel flow in case of leaks.
No shutoff valves are installed on engine fuel return line.
External fuel pumps are connected and operational at all times (generator set started or shut down).
Fuel system is properly primed.
No fuel leaks are found in supply line or engine fuel system.
9-1
EXHAUST SYSTEM
Redistribution or publication of this document,
by any means, is strictly prohibited.
Operators are thoroughly briefed on the dangers of carbon monoxide gas.
Areas around set are well ventilated. No possibility of exhaust fumes entering building doors, windows, or
intake fans.
Exhaust gases are piped safely outside and away from building.
The correct length of approved rigid pipe is connected to the generator set flexible pipe using approved
securing methods with no weight resting on engine exhaust components. There are no bends in flex section.
Condensation drain is provided in lowest section of exhaust piping.
Exhaust piping is insulated to guard against burns to personnel.
Exhaust piping passing through walls or ceilings have approved fire-proof materials and are in com-
pliance with all codes.
Exhaust piping is large enough in diameter to prevent excessive back pressure on engine.
AC AND DC WIRING
Wire sizes, insulation, conduits and connection methods all meet applicable codes.
AC and DC wires are separated in their own conduit to prevent electrical induction.
All load, line and generator connections are proper and correct.
Flexible conduit between generator set and building or surrounding structure.
GENERATOR SET PRESTART
Generator set engine is properly serviced with oil and coolant.
Batteries are properly installed, serviced and charged.
Battery charger and engine coolant heater are connected and operational.
All generator set covers and safety shields are installed properly.
All fuel and coolant shutoff valves are operational.
9-2
DOOR INTERIOR
Redistribution or publication of this document,
by any means, is strictly prohibited.
(SEE PAGE 10-2 FOR
TERMINAL DESCRIPTIONS)
CUSTOMER CONNECTIONS (PAGE 1 OF 4)
10-1
TERMINAL BLOCK TB3
Redistribution or publication of this document,
by any means, is strictly prohibited.
(SEE PAGE 10-1 FOR TB3 LOCATION)
CUSTOMER CONNECTIONS (PAGE 2 OF 4)
10-2
DOOR INTERIOR LEFT SIDE INTERIOR
Redistribution or publication of this document,
by any means, is strictly prohibited.
CUSTOMER CONNECTIONS (PAGE 3 OF 4)
10-3
LONWORKS PCB (OPTIONAL)
Redistribution or publication of this document,
by any means, is strictly prohibited.
STANDARD PCB
CUSTOMER CONNECTION INFORMATION
MISCELLANEOUS
CUSTOMER CONNECTIONS (PAGE 4 OF 4)
10-4
THIS IS A REPRESENTATIVE (GENERIC)
Redistribution or publication of this document,
by any means, is strictly prohibited.
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.
No. 630-2592 sh 9 of 1 1
Rev. E
Modified 12-03
ENCLOSURE/OPTIONS WIRING (SHEET 1 OF 2)
10-5
THIS IS A REPRESENTATIVE (GENERIC)
Redistribution or publication of this document,
by any means, is strictly prohibited.
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.
No. 630-2592sh 11 of 11
Rev. E
Modified 12-03
ENCLOSURE/OPTIONS WIRING (SHEET 2 OF 2)
10-6
Cummins Power Generation
Redistribution or publication of this document,
by any means, is strictly prohibited.
1400 73rd Avenue N.E.
Minneapolis, MN 55432
1-800-888-6626
763-574-5000 International Use
Fax: 763-528-7229
Cummins is a registered trademark of Cummins Inc.
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