Cummins Power Generation GGHE, GGHF, GGHG, GGHH, PowerCommand 3100 Series Installaiton Manual
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Installation Manual
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Detectort Control
Generator Sets
Printed in U.S.A.
Models
GGHE, GGHF
928-0613C 7-2002
Table of Contents
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by any means, is strictly prohibited.
SECTION TITLE PAGE
SAFETY PRECAUTIONS iii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 INTRODUCTION
About this Manual 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Overview 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 SPECIFICATIONS
3 MOUNTING THE GENERATOR SET
General 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Access and Lighting 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 MECHANICAL CONNECTIONS
General 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust System 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ventilation and Cooling 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 DC CONTROL WIRING
Control Wiring 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Control Monitor Board (ECM-A11) 5-2. . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary Relay Board (Optional) 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Time-Delay Module (A15) (Optional) 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
!!
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects or other reproductive harm.
i
SECTION TITLE PAGE
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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 PRESTART PREPARATION
General 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 INSTALLATION CHECKLIST
General 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Genset Support 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling Air Flow 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust System 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC and DC Wiring 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Genset Prestart 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 WIRING DIAGRAMS
General 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii
IMPORTANT SAFETY INSTRUCTIONS
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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
tend to gather in sumps or low areas. NFPA code requires all persons handling propane to be trained
and qualified.
• 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
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
copper piping on flexible lines as copper will become brittle if continuously vibrated or repeatedly
bent.
• Natural gas is lighter than air, and will tend to gather
under hoods. Propane is heavier than air, and will
•
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. Jewelry can short out electrical contacts and cause shock or burning.
• If adjustment must be made while the unit is run-
ning, use extreme caution around hot manifolds,
moving parts, etc.
MS-4
iii
ELECTRICAL SHOCK CAN CAUSE
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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.
• Use extreme caution when working on electrical
components. High voltages can cause injury or
death. DO NOT tamper with interlocks.
• Follow all applicable state and local electrical
codes. Have all electrical installations performed by
a qualified licensed electrician. Tag and lock open
switches to avoid accidental closure.
• DO NOT CONNECT GENERATOR SET DI-
RECTLY TO ANY BUILDING ELECTRICAL 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.
• Benzene and lead, found in some gasoline, have
been identified by some state and federal agencies
as causing cancer or reproductive toxicity. When
checking, draining or adding gasoline, take care not
to ingest, breathe the fumes, or contact gasoline.
• 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. NFPA 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
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ABOUT THIS MANUAL
This manual covers models produced under the
Cummins
tion brand names.
This manual provides installation instructions for
the generator set models listed on the front cover.
This includes the following information:
/Onan and Cummins Power Genera-
Mounting Recommendations - for fastening
generator set to base and space requirements
for normal operation and service.
Mechanical Connections and Electrical
Connections - covers most aspects of the
generator set installation.
Prestart – checklist of items or procedures
needed to prepare generator set for operation.
Initial Startup – test complete system to en-
sure 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 Speci-
fication and Data Sheets. For application information, refer to Application Manual T-030, “Liquid
Cooled Generator Sets”.
INSTALLATION OVERVIEW
These installation recommendations apply to typical installations with standard model generator
sets. Whenever possible, these recommendations
also cover factory designed options or modifications. 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.
1-1
Application and Installation
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by any means, is strictly prohibited.
A standby power system must be carefully planned
and correctly installed for proper operation. This involves two essential elements: application and installation.
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.
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 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
Safety Considerations
The generator set has been carefully designed to
provide safe and efficient service when properly installed, maintained, and operated. However, the
overall safety and reliability of the complete system
is dependent on many factors outside the control of
the generator set manufacturer. To avoid possible
safety hazards, make all mechanical and electrical
connections to the generator set exactly as specified in this manual. All systems external to the generator (fuel, exhaust, electrical, etc.) must comply
with all applicable codes. Make certain all required
inspections and tests have been completed and all
code requirements have been satisfied before certifying the installation is complete and ready for service.
Copyright 2001 Cummins Power Generation. All rights reserved.
Cummins and Onan are registered trademarks of Cummins Inc.
Detector is a trademark of Cummins Inc.
1-2
2. Specifications
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MODEL GGHE/GGHF
Engine
Onan Modified Ford V-10
Generator kW Rating See Genset Nameplate for rating information.
Engine Fuel Connection
Inlet/Outlet Size
Fuel or a combination of two fuels Propane (Liquid or Vapor)
Fuel Flow (Inlet Pressure)
Minimum:
NG/LPG
Maximum:
NG/LPG Vapor withdrawal
LPG Liquid withdrawal
Exhaust
Connection
Backpressure (Max. Allowed)
Electrical System
Starting Voltage
Battery Charging Alternator (Max. Rating)
Cooling System
Capacity with Standard Radiator
Lubricating System
Oil Capacity with Filters
Standby Power (Normal Oil Filter)
Prime Power (Heavy Duty Oil Filter)
Tune-up Specifications
Spark Plug Gap
Battery
Ground
Required Battery Voltage
Group Number
CCA (minimum)
Cold Soak @ 0° F (-18° C)
Refer to Generator Outline Drawing
WSG-1068
Natural Gas
7.0 inch H2O (1.7 kPa)
13.6 inch H
312 psi (2,153 kPa)
20 inch H
8.5 Gal (32.2 L)
6.5 Qts (6.2 L)
O (3.4 kPa)
2
3 inch NPT
O (5.0 kPa)
2
12 Volts DC
37 A
11 (10.4 L)
0.044
(1.1 mm)
Negative
12 Volts DC
31
660
MODEL
Standby
cfh (m3/hr)
LPG (Vapor or Liquid)
Natural Gas
Full Load
cfh (m3/hr)
LPG (Vapor or Liquid)
Natural Gas
FUEL CONSUMPTION (STANDBY/PRIME/60HZ)
GGHE GGHF
313 (8.86)
798 (22.34)
277 (7.84)
705 (19.95)
2-1
366 (10.36)
898 (25.43)
320 (9.06)
807 (22.84)
THIS PAGE LEFT INTENTIONALLY BLANK
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2-2
3. Mounting the Generator Set
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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. Consider
these requirements before installation:
• Level mounting surface
• Adequate cooling air
• Adequate fresh induction air
• Discharge of generator set air
• Non-combustible mounting surface
• Discharge of exhaust gases
WARNING
• Electrical connections
• Accessibility for operation and servicing
• Noise levels
• Vibration isolation
LOCATION
Generator set location is decided mainly by related
systems such as ventilation, wiring, fuel, and exhaust. The set should be located as near as possible to the main power service entrance. Exhaust
must not be able to enter or accumulate around inhabited areas.
Provide a location away from extreme ambient temperatures and protect the generator set from adverse weather conditions. An optional housing is
available for outside operation.
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 YOUR LOCATION AND INTENDED USE, FEDERAL, STATE OR LOCAL LAWS
AND REGULATIONS MAY REQUIRE YOU TO OBTAIN AN AIR QUALITY EMISSIONS PERMIT
BEFORE BEGINNING INSTALLATION OF YOUR GENSET. BE SURE TO CONSULT LOCAL
POLLUTION CONTROL OR AIR QUALITY AUTHORITIES BEFORE COMPLETING YOUR CONSTRUCTION PLANS.
3-1
MOUNTING
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by any means, is strictly prohibited.
Generator sets are mounted on a steel skid that provides proper support. The engine-generator assembly is isolated from the skid frame by rubber
mounts that provide adequate vibration isolation for
normal installations. Where required by building
codes or special isolation needs, generator sets
may be mounted on rubber pads or mechanical
spring isolators. The use of unapproved isolators
may result in harmful resonances and may void the
genset warranty.
Mount the generator set on a substantial and level
base such as a concrete pad. A non-combustible
material must be used for the pad.
Use 5/8 inch or 16 mm anchored mounting bolts to
secure the generator set skid to the floor to prevent
movement. Secure the skid using a flat washer and
a hex nut for each bolt (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.
ACCESS TO SET
MOUNTING
BASE
MOUNTING
BOLT
SUBBASE OR
VIBRATION
ISOLATOR
FLANGE
HEX NUT
FLAT OR BEVEL
WASHER
1-1/2 x 6 INCH
PIPE
12 IN.
(305 mm)
CONCRETE
Generally, at least 1 meter (3 feet) of clearance
should be provided on all sides of the generator set
for maintenance and service access. (Increase
clearance by width of door if optional housing is
used.) A raised foundation or slab of 150 mm (6
inches) or more above floor level will make servicing easier.
Lighting should be adequate for operation, maintenance and service operations and should be connected on the load side of the transfer switch so that
it is available at all times.
FIGURE 3-1. BOLT DIAGRAM
3-2
4. Mechanical Connections
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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.
All pipe threaded fuel system fittings, including container fittings, must be assembled using a pipe joint
sealing compound designed for use with LPG/NG.
FUEL SYSTEM
Gensets can be equipped to operate on:
• LPG (vapor or liquid withdrawal)
• NG (natural gas) or
• Combination (NG/LPG)
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. Clean all fuel system components before
installing
Fuel Lines – Routing
A flexible fuel hose(s) or section of flexible fuel
hose(s) must be used between the engine’s fuel
system and fuel supply line to protect the fuel system from damage caused by vibration, expansion
and contraction.
WARNING
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.
Installation of the fuel hose must be done according
to all applicable codes and standards, and installa-
Fuel leaks create fire and explosion
tion recommendations provided by the manufacturer. The flexible hose used must be 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
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
2 inch (51 mm) minimum clearance from electrical
wiring and hot exhaust parts.
Sparks and hot surfaces can ignite
Natural Gas/LPG Vapor/LPG Liquid Fuel
System
WARNING
explosive and can cause severe personal injury
or death. Do not smoke if you smell gas or are
near fuel tanks or fuel-burning equipment or are
in an area sharing ventilation with such equipment. Keep flames, sparks, pilot lights, electrical arcs and arc-producing equipment and all
other sources of ignition well away from genset
and areas sharing ventilation. Keep a type ABC
fire extinguisher handy.
NFPA Standard No. 58 requires all persons handling and operating LPG to be trained in proper
handling and operating procedures.
Gaseous-fuel supply system design, materials,
components, fabrication, assembly, installation,
testing, inspection, operation and maintenance
must comply with the applicable codes. See NFPA
Standards No. 37, No. 54 and No. 58.
Gaseous fuels are flammable and
4-1
Most codes require both manual and electric (bat-
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tery-powered) shutoff valves ahead of the flexible
fuel hose(s). The manual valve should be of the indicating type. The electric valve should be wired so
that the valve is closed when the genset is off.
Install a dry-type fuel filter ahead of the service
pressure regulator to protect the sensitive pressure
regulating components and orifices downstream
from rust, scale and other solid substances carried
along in the gas stream.
The LP gas pressure will be approximately negative
0.5 inches WC (0.13 kPa) at no load and a negative
pressure of 1.0 inch WC (0.249 kPa) at full load.
Supply side: The minimum pressure refers to supply pressure under rated load (maximum gas flow).
For LPG (vapor withdrawal) and NG, the maximum
permissible fuel supply pressure is 13.6 inches WC
(3.4 kPa) and the recommended minimum is 7 inches WC (1.7 kPa).
See Specifications section for natural gas/LPG fuel
inlet size. The recommendations in Application
Manual T-030, should be followed in regard to fuel
supply system pipe sizes, manual shutoff valves,
fuel filters and gas pressure regulators.
Fuel Pressure
WARNING
gas leaks which can lead to fire and severe personal injury or death. Gas supply pressure must
be adjusted to Specifications by qualified personnel.
The gas pressure regulators in each line provide
constant gas pressure at the gas mixer under varying load conditions. There are pressure test ports
on both sides of the regulator for measuring supply
and regulated fuel pressures (NG or LPG systems).
When measuring supply pressure, the most accurate reading would be on the input side of the solenoid valve.
Mixer side: The NG gas pressure should be
approximately 5 inches WC (1.3 kPa) at full load.
High gas supply pressure can cause
For LPG (liquid withdrawal), the maximum permissible fuel supply pressure is 312 psi (2,153 kPa) under any operating condition.
WARNING
Gaseous fuel leaks into an inadequately ventilated space can lead to explosive
accumulations of gas. Natural gas rises when
released into the air and can accumulate under
overhanging hoods and inside housings and
buildings. LPG sinks when released into the air
and can accumulate inside housings, basements and other below-grade spaces. Precautions must be taken to prevent gas leaks and the
accumulation of gaseous fuel in the event of a
leak.
Check Gas Leaks and Correct
All fuel-system connections, including the container
with associated valves and fittings, must be tested
for leaks with a soap and water solution or equivalent, while the system is under pressure. LP gas
pressure should not be less than 90 psi (621 kPa) at
the inlet of the primary regulator for this test.
4-2
EXHAUST SYSTEM
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WARNING
sult in severe personal injury or death. Do not
use exhaust heat to warm a room, compartment
or storage area.
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 4-1) 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 insu-
Inhalation of exhaust gases can re-
Inhalation of exhaust gases can re-
Inhalation of exhaust gases can re-
lated steel decking, etc. Uninsulated wall/roof
thimbles are used where exhaust pipes pass
through a non-combustible wall or roof, such as
concrete. Refer to NFPA 37, Section 6-3. “Stationary Combustion Engines and Gas Turbines” for accepted 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.
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.
CAUTION
Weight applied to the engine manifold can result in damage. Support the muffler
and exhaust piping so no weight or stress is applied to engine exhaust.
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 to the exhaust system 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.
4-3
Avoid sharp bends by using sweeping, long radius
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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 4-2).
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
(230 mm)
VERTICAL
DRIP CAP
HOLES IN
END OF INNER
SLEEVE
ROOF
9 INCH
(230 mm)
WARNING
Exhaust pipes are very hot and they
can cause severe personal injury or death from
direct contact or from fire hazard. Shield or 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 4-1. MOUNTING EXHAUST THIMBLE
IF EXHAUST LINE MUST BE
PITCHED UPWARD, CONSTRUCT
A TRAP AT POINT OF RISE
AVOID
SHARP
BENDS
DRAIN CONDENSATION
TRAP PERIODICALLY
VALVE HANDLE SHOWN
IN OPEN POSITION
FIGURE 4-2. CONDENSATION TRAP
4-4
VENTILATION AND COOLING
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by any means, is strictly prohibited.
Generator sets dissipate heat and fumes that must
be removed by proper cooling and ventilation.
Generator sets in factory-mounted housings for
outdoor installation are designed for proper cooling
and ventilation.
Indoor installations require careful design with respect to cooling and ventilation. In an indoor installation, all radiator cooling air must be discharged to
the out-of-doors. Duct adapter kits are available.
See Figure 4-4 for a typical indoor installation.
PREVAILING WINDS PREVAILING WINDS
WARNING
Engine or radiator cooling air may
carry deadly carbon monoxide gas which can
cause asphyxiation and death. All engine or radiator cooling air must be discharged to the outof-doors. Do not use it for heating a room or
compartment.
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 Data Sheet for the airflow requirements and allowed airflow restriction.
Wind will restrict free airflow if it blows directly into
the air outlet vent. Locate the outlet vent so the effects of wind are eliminated. See Figure 4-3.
NOT LESS THAN
HEIGHT OF OPENING
FIGURE 4-3. WIND BARRIER
4-5
Dampers
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by any means, is strictly prohibited.
Dampers or louvres protect the generator set and
equipment room from the outside environment.
Their operation of opening and closing should be
controlled by operation of the generator set.
In 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 generator
set engine is still cold, increasing the engine efficiency.
Radiator Set Requirements
Radiator set cooling air is drawn past the control
end of the set by a pusher fan that blows air through
the radiator (Figure 4-4). Locate the air inlet to the
rear of the set. Make the inlet vent opening 1-1/2
times larger than the radiator area.
Attach a canvas or sheet metal duct to the air outlet
opening using screws and nuts so duct can be removed for maintenance purposes. The duct prevents recirculation of heated air. Before installing
the duct, remove the radiator core guard.
Remote Radiator Cooling (Optional) substitutes
a remote mounted radiator and an electrically
driven fan in place of mounted components. Removal of the radiator and the fan from the set reduces noise levels without forcing dependence on a
continuous cooling water supply (necessary with
heat exchanger cooling). The remote radiator installation must be completely protected against
freezing.
Remote radiator plumbing will vary with installation.
Follow recommendations given in Application Manual T-030. See product Data Sheet for friction head
and static head limits.
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
must be at least as large as the radiator area.
Length and shape of the air outlet duct should offer
minimum restriction to airflow.
Before filling cooling system, check all hardware for
security. This includes hose clamps, capscrews, fittings and connections. Use flexible coolant lines
with heat exchanger or remote mounted radiator.
Engine Coolant Heater (Optional)
An optional engine coolant heater is available to
keep the engine warm for improved starting and
code compliance. Connect the heater to a power
source that will be energized when the engine is
NOT running.
4-6
THIMBLE
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EXHAUST
LINE
CONDENSATION
AIR OUT
MUFFLER
DRAIN PLUG
SWEEPING
ELBOW
CONTROL
WIRING
FLEXIBLE
SECTIONS
POWER
WIRING
AIR
IN
FLEXIBLE
BELLOWS
VIBRATION
ISOLATORS
IMPORTANT!
COOLING AIR INLET MUST BE AT LEAST 1-1/2 TIMES LARGER
THAN RADIATOR DUCT OUTLET AREA ON RADIATOR-COOLED
MODELS.
FLOW OF COOLING AIR AND HEATED AIR MAY BE
CONTROLLED BY AUTOMATICALLY OPERATED LOUVRES.
FIGURE 4-4. TYPICAL GENERATOR SET INSTALLATION
LEVEL
CONCRETE
BASE
4-7
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4-8
5. DC Control Wiring (Detector Control)
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CONTROL WIRING
The generator set control panel box contains connection points for remote control and monitor options. These connection points are located on the
engine control monitor board (ECM), the time-delay
module and the optional auxiliary relay board
(ARB). (Note that if the optional ARB is installed, no
remote monitor connections are attached to the
ECM. The ARB provides all remote monitor connection points.)
CAUTION
for all customer connections to the control panel box. Solid copper wire may break due to genset vibration.
The type/gauge wire to use for these connections
are:
Stranded copper wire must be used
• Less than 1000 feet (305m), use 18 gauge
stranded copper wire.
• 1000 to 2000 feet (305 to 610m), use 16 gauge
stranded copper wire.
CAUTION
a separate metal conduit from AC power cables
to avoid inducing currents that could cause
problems within the control.
WARNING
uninsulated high voltage parts inside the control panel box can result in severe personal injury or death. Control wire installation must be
done with care to avoid touching uninsulated
live parts.
Stand on a dry wooden platform or rubber insulating mat, make sure your clothing and shoes
are dry, remove jewelry and use tools with insulated handles.
Always run control circuit wiring in
HAZARDOUS VOLTAGE Touching
5-1
ENGINE CONTROL MONITOR BOARD
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(ECM-A11)
The heart of the engine control system is the engine
monitor (A11). It is a printed circuit board assembly
mounted on the back wall of the control box (Figure
5-1). It starts and stops the engine in response to
the control panel switches, engine sensors and remote control signals.
Remote Monitor Connections
The Detector control provides the capability of attaching a remote monitor panel. Connections are
made on the terminal blocks TB1 and TB2 located
on the ECM board.
Terminal block TB3 provides an alternative direct
connection to the ECM for the RUN/STOP/REMOTE switch for troubleshooting or if desired, customer connection.
TB3-1 = REMOTE
TB3-2 = RUN
TB3-3 = STOP
A detailed connection diagram for the ECM board is
provided in Section 9. (If the optional ARB is
installed, remote monitor connections attach to the
ARB, not the ECM.)
Remote Start Connections
Connect remote start switch between A11-TB1-9
(B+) and A11-TB1-6 (RMT).
Function Selection Jumpers
ECM board has seven selection jumpers that can
be repositioned to provide the following timed or
non-timed warnings or timed or non-timed
shutdowns with warnings, and control of the
SWITCH OFF indicator:
W1 Jumper Position (jumper W8 must be in the B
position):
A Non-timed warning under FLT 2
conditions.
B Non-timed shutdown under FLT 2
conditions.
C Timed warning under FLT 2 conditions.
D Timed shutdown under FLT 2 conditions.
A Non-timed warning under FLT 1
conditions.
B Non-timed shutdown and under FLT 1
conditions.
C Timed warning under FLT 1 conditions.
D Timed shutdown under FLT 1 conditions.
W6 Jumper Position:
A Warning under Pre-High Engine
Temperature conditions.
B Shutdown under Pre-High Engine
Temperature conditions.
W7 Jumper Position:
A Warning under Pre-Low Oil Pressure
conditions.
B Shutdown under Pre-Low Oil Pressure
conditions.
W8 Jumper Position:
A Warning while running or during standby
under FLT 2 conditions.
B Allows selection of functions with W1
jumper.
W9 Jumper Position:
A Warning while running or during standby
under FLT 1 conditions.
B Allows selection of functions with W2
jumper.
W10 Jumper Position (SWITCH OFF Indicator):
A Flashing (standard)
B Constant ON
C OFF
5-2
TB1
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87654 3 2 1 65 4 321
TB2
FIGURE 5-1. ENGINE CONTROL MONITOR BOARD (ECM)
5-3
AUXILIARY RELAY BOARD (OPTIONAL)
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by any means, is strictly prohibited.
The following describes the design/functional criteria for the auxiliary relay board (ARB) with a Detector
control. The board is mounted directly over the
ECM using standoffs and has access holes for the
fuses located on the ECM. A detailed connection
diagram for the ARB is provided in Section 9.
Terminal Blocks:
• TB1 – ARB TB1 and engine monitor TB1 are
identically numbered and provide the same remote control connection points. Note that additional terminals are provided for terminals 5, 7,
and 10 of ARB TB1.
• TB2 through TB5 – Connection points for re-
lays K1 through K3. TB2 provides the N/O and
N/C connections (three form ‘C’ contacts for
each relay). TB3 through TB5 provide the common connection points (TB3 for K1, TB4 for K2
and TB5 for K3).
• TB6 and TB7 – Connection points for fault relays K4 through K15. Three terminals are provided for each relay, which are labeled COM,
N/C, N/O.
Plug-In Relays (K1, K2, K3): The ARB can be
equipped with one to three 3-pole, double-throw relays. These relays (K1, K2, K3) are field changeable
plug-in relays for easy field addition and replacement.
Each relay can be operated as a RUN, COMMON
ALARM, or ISOLATED COIL with the changing of a
jumper.
The relay contact ratings are:
• 10 amps at 28 VDC or 120 VAC, 80% PF
• 6 amps at 240 VAC, 80% PF
• Jumper Position A (Run) – The relay oper-
ates as a Run relay, energizing when SW B+ is
applied from the engine monitor.
• Jumper Position B (Common Alarm) – The
relay operates as a Common Alarm relay. The
relay energizes any time there is an engine
shutdown.
• Jumper Position C (Isolated) – The relay op-
erates as an Isolated relay. The relay coil is energized by a customer applied B+ signal
through the terminal block; TB3-1 for relay K1,
TB4-1 for relay K2, and TB6-1 for relay K3.
Jumpers W11, W12, and W13 perform the same
functions for their respective relays; W11 for relay
K1, W12 for relay K2, and W13 for relay K3. They
can be located in two different positions (A, B) independently of one another.
• Jumper Position A – The relay operates iso-
lated from the board. The customer provides
the circuit completion through terminal block;
TB3 for relay K1, TB4-5 for relay K2, and TB6-5
for relay K3. The customer can operate the relay with switched ground logic or use this relay
in the middle of more complex logic circuits if
needed.
• Jumper Position B – The relays operate with
the coils connected to ground through the
board connections. The coil will require a B+
signal to energize with the jumper in this position.
Fault Relays (K4 through K15): These relay modules are used to operate a remote alarm annunciator that has an independent power source. This allows the use of either AC or DC for alarm drives. The
relays are energized through the latching relays on
the engine monitor and provided N/O and N/C contacts for each external alarm connection.
• 3 amps at 480 VAC, 80% PF
Jumper Positions for Plug-In Relays: Jumpers
W1, W2 and W3 perform the same functions for
their respective relays, W1 for relay K1, W2 for relay
K2, and W3 for relay K3. They can be located in any
of 3 positions (A, B, C) independently of each other.
The 12 relays with form ‘C’ contacts are rated:
• 10 Amp, 120 VAC
• 10 Amp. 30 VDC
5-4
JUMPERS JUMPERS
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K1 K2 K3
RUN RELAY
MODULE(S)
J1, J2 WIRE
HARNESS PLUG
CONNECTIONS
FROM A11
TB6, TB7 AND
RELAYS K4
THROUGH K15
FIGURE 5-2. AUXILIARY RELAY BOARD (ARB)
5-5
TIME-DELAY MODULE (A15) (OPTIONAL)
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by any means, is strictly prohibited.
The start delay module is adjustable from 5 to 15 seconds and the stop delay from 30 seconds to 30
minutes. Turn the delay adjusting potentiometers
clockwise to increase delay and counterclockwise
to decrease delay.
Remote Control Connections
Remote control connections are made at the terminal block (TB1) that is located on the time-delay
module (Figure 5-3). Connect one or more remote
switches across the remote terminal (TB1-5) of the
time-delay module and the B+ terminal of the ECM
(A11).
PRIMARY START-DISCONNECT
A11 - TB1-2
SECONDARY START-DISCONNECT
(A11 – TB1-3
START DELAY
POTENTIOMETER
TB1
12345 6
RUN SIGNAL OUT (A11 - TB1-6
RUN SIGNAL IN (REMOTE
START/STOP CONTROL
STOP DELAY
POTENTIOMETER
B– (A11 - TB1-5
B+ (A11 - TB1-7)
FIGURE 5-3. PREHEAT/TIME-DELAY MODULE
5-6
6. AC Electrical Connections
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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. Place the control panel run switch in the
OFF position. Turn off or remove AC power from the
battery charger and then remove the negative (–)
battery cable from the set starting battery.
WARNING
can cause severe personal injury or death. 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.
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
source before disconnecting battery cables.
Otherwise, disconnecting cables can result in
voltage spikes damaging to DC control circuits
of the set.
WARNING
set can cause severe personal injury or death.
Prevent accidental starting by disconnecting
the negative (–) cable from the battery terminal.
Ignition of explosive battery gases
Disconnect battery charger from AC
Accidental starting of the generator
WARNING
this section should be done only by persons
trained and experienced in electrical maintenance. Improper procedures may result in
property damage, bodily injury or death.
Connecting the genset AC electrical system involves:
Each of the operations described in
• Installation of transfer switch
• Generator output voltage selection
• Load cable connection
• Standard and optional AC equipment connec-
tions (e.g., control box heater, coolant heater,
etc.).
Local regulations often require that wiring 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.
WARNING
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
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.
Improper wiring can cause a fire or
Backfeed to utility system can
6-1
TRANSFER SWITCH
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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).
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
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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 (Detector Control)
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
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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. In some installations, a CT may be
required for ground fault monitoring (refer to Figure
6-2 for CT location).
3-POLE AUTOMATIC
TRANSFER SWITCH
3∅
TO UTILITY
SERVICE
N
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. On 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.
GENERATOR SETSERVICE ENTRANCE
3∅
N
TO UTILITY
SERVICE
SERVICE ENTRANCE
FIGURE 6-2. TYPICAL SYSTEM GROUNDING ONE-LINE DIAGRAMS
4-POLE AUTOMATIC
TRANSFER SWITCH
4 WIRES & GROUND
TO LOAD
GENERATOR SET
4 WIRES & GROUND
TO LOAD
BONDING
JUMPER
CT LOCATION IF
REQUIRED FOR
GFI MONITORING
GROUNDING
ELECTRODE
CONDUCTOR
6-4
CONTROL HEATER (OPTIONAL)
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by any means, is strictly prohibited.
A control heater (Figure 6-3) provides a means of
humidity /temperature control for the Detector control box interior. It protects the components when
the generator set is subjected to varying ambient air
conditions during extended periods of non-use.
The heater is equipped with a power cord that terminates with a 120V or 240V NEMA plug.
TO ACCESSORY BOX
A40–TB1-36 & 37
(PCC CONTROL)
HEATER
TO 120/240 VAC SUPPLY
(DETECTOR CONTROL)
BOTTOM VIEW OF
CONTROL BOX
FIGURE 6-3. OPTIONAL CONTROL HEATER
6-5
COOLANT HEATER (OPTIONAL)
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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 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-
the time the engine is not running. Be sure the voltage rating 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.
POWER
PLUG
LOCATION
OUTLET
HOSE
INLET
HOSE
COOLANT
HEATER
FIGURE 6-4. COOLANT HEATER
6-6
GENERATOR HEATER (OPTIONAL)
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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 may form within a generator, creating
flashing and shock hazards.
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. Power connections are made to the terminal block in the heater terminal box. Be sure the voltage rating is correct for the heater element rating.
WARNING
Water or moisture inside a generator increases the possibility of flashing and
electrical shock, which can cause equipment
damage and severe personal injury or death. Do
not use a generator which is not dry inside and
out.
HEATER
LEADS
HEATER
HEATER
TERMINAL BOX
(VIEW AA)
FIGURE 6-5. TYPICAL GENERATOR HEATER INSTALLATION
6-7
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6-8
7. Prestart Preparation
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by any means, is strictly prohibited.
GENERAL
Before attempting the initial start of the generator
set, be sure to complete the Installation Checklist in
Section 8.
ELECTRICAL SYSTEM
Verify all electrical connections are secure and all
wiring is complete and inspected. Replace and secure any access panels that may have been removed during installation.
Battery Connections
WARNING
set can cause severe personal injury or death.
Make sure that the Run/Off/Auto switch on the
control panel is set to the Off position before
connecting the battery cables.
Starting the unit requires a 12 volt battery. Connect
positive battery cable before connecting negative
battery cable to prevent arcing.
Accidental starting of the generator
Service the battery as necessary. If an automatic
transfer switch is installed without a built-in charge
circuit, connect a separate battery charger.
WARNING
can cause severe personal injury or death. Always connect negative (–) battery last to prevent arcing.
WARNING
ing 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.
Ignition of explosive battery gases
Ventilate battery area before work-
STARTING
Refer to the generator set Operator’s manual for important safety precautions and recommended procedures to start the genset and to confirm proper
operation. Start the generator set and verify all engine and generator gauges are displaying the correct values.
7-1
THIS PAGE LEFT INTENTIONALLY BLANK
Redistribution or publication of this document
by any means, is strictly prohibited.
7-2
8. 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.
j
j At least 3 feet of clearance (or greater for housing door) is provided around entire generator set for servic-
ing and ventilation.
j Generator set is located in an area not subject to flooding.
j All operating personnel have read and are familiar with Operator’s Manual.
j All operators have been thoroughly briefed on preventive maintenance procedures.
j 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 move-
j
ment. Observe local codes on soil bearing capacity due to freezing and thawing.
j Generator set is properly supported and retained to approved base.
j 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.
j
j Air inlet openings are unrestricted and at least 1–1/2 times larger than air outlet area.
j Cooling air outlet is on downwind side of building (if not, wind barrier is constructed).
j Proper ducting material (sheet metal, canvas) is used between radiator and air outlet.
FUEL SYSTEM
Fuel tanks meet or exceed all Local, State or National codes.
j
j Fuel lines are properly installed, supported and protected against damage.
j Approved flexible fuel line is installed between main fuel supply line and generator set’s fuel system, near
the generator set, to protect the fuel system from damage caused by vibration, expansion and contraction.
j Fuel supply line shutoff valves are installed to prevent fuel flow in case of leaks.
j No fuel leaks are found in supply line or engine fuel system.
8-1
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.
j
j Areas around set are well ventilated. No possibility of exhaust fumes entering building doors, windows, or
intake fans.
j Exhaust gases are piped safely outside and away from building.
j 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.
j Condensation drain is provided in lowest section of exhaust piping.
j Exhaust piping is insulated to guard against burns to personnel.
j Exhaust piping passing through walls or ceilings have approved fire-proof materials and are in com-
pliance with all codes.
j 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.
j
j AC and DC wires are separated in their own conduit to prevent electrical induction.
j All load, line and generator connections are proper and correct.
j Flexible conduit between generator set and building or surrounding structure.
GENERATOR SET PRESTART
Generator set engine is properly serviced with oil and coolant.
j
j Batteries are properly installed, serviced and charged.
j Battery charger and engine coolant heater are connected and operational.
j All generator set covers and safety shields are installed properly.
j All fuel and coolant shutoff valves are operational.
8-2
9. Wiring Diagrams
Redistribution or publication of this document
by any means, is strictly prohibited.
GENERAL
This section consists of the schematic and connection wiring diagrams referenced in the text. The following drawings are included.
• Page 9-2 – Customer Connections at the En-
gine Monitor Board
• Page 9-3 – Customer Connections at the Auxil-
iary Relay Board
• Page 9-4 – Accessory Interconnect Diagram
9-1
9-2
+–
K12
K11
A15
CUSTOMER CONNECTIONS AT THE ENGINE MONITOR BOARD (DETECTOR CONTROL)
Redistribution or publication of this document
by any means, is strictly prohibited.
9-3
THE TERMINALS IN THE SHADED BOXES ARE FOR CUSTOMER CONNECTIONS
625-2712
NO. 300Ć4111
REV. B
MODIFIED
CUSTOMER CONNECTINS AT THE AUXILIARY RELAY BOARD (DETECTOR CONTROL)
Redistribution or publication of this document
by any means, is strictly prohibited.
9-4
No. 630Ć1345 sh 3
Rev. J
Modified 11/96
ACCESSORY INTECONNECT DIAGRAM (DETECTOR CONTROL)
Redistribution or publication of this document
by any means, is strictly prohibited.
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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