Installation Manual

Generator Set

DFHA (Spec A−J)DFHB (Spec A−J)DFHC (Spec A−J)DFHD (Spec A−J)

with PowerCommand Control PCC3100

English − Original Instructions 10−2011 960−0617 (Issue 9)

i

Table of Contents

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 SETGeneral 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Location 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Access to Set 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vibration Isolators 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aligning Generator with Engine (750 kW Generator Sets and Larger) 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 MECHANICAL CONNECTIONS

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

5 DC CONTROL WIRING

Control Wiring 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB1 Remote Monitor/Control Connections 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . Run Relays (K11, K12, K13) 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alarm Relay (K14) 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RTD Relay (Optional) 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermistor Relay (Optional) 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

California

Proposition 65 WarningDiesel engine exhaust and some of its constituents are knownto the State of California to cause cancer, birth defects, andother reproductive harm.

ii

SECTION TITLE PAGE

6 AC ELECTRICAL CONNECTIONS

General 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Insulation Resistance (Megger) & Polarization Index (PI) Testing 6-2. . . . . . . Transfer Switch 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Wiring 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Heater (Optional) 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant Heater 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Heater 6-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Transfer Pump 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ground Fault Alarm Relay (Optional) 6-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 ENCLOSURE ELECTRICAL CONNECTIONS 7-1 . . . . . . . . . . . . . . . . . . . . . . .

General 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optional AC Distribution Panel 7-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optional Motorized Inlet/Outlet Louvers 7-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optional Fuel Transfer Pump 7-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 PRESTART PREPARATION 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PCC Power On / Standby Mode 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical System 8-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PCC Options Prestart Checks 8-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting 8-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 INSTALLATION CHECKLIST 9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General 9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LS-14Miii

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS − This manual containsimportant instructions that should be followed duringinstallation and maintenance of the generator and batter-ies.

Before operating the generator set (genset), read theOperator’s Manual and become familiar with it and theequipment. Safe and efficient operation can beachieved only if the equipment is properly operatedand maintained. Many accidents are caused by failureto follow fundamental rules and precautions.

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

This symbol warns of immediatehazards which will result in severe personal in-jury or death.

WARNING This symbol refers to a hazard or un-safe practice which can result in severe per-sonal injury or death.

CAUTION This symbol refers to a hazard or un-safe practice which can result in personal injuryor product or property damage.

FUEL AND FUMES ARE FLAMMABLE

Fire, explosion, and personal injury or death can resultfrom 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 potentialfire hazard.

DO NOT permit any flame, cigarette, pilot light,spark, arcing equipment, or other ignition sourcenear the generator set or fuel tank.

Fuel lines must be adequately secured and free ofleaks. Fuel connection at the engine should bemade with an approved flexible line. Do not use zinccoated or copper fuel lines with diesel fuel.

Be sure all fuel supplies have a positive shutoffvalve.

Be sure battery area has been well-ventilated priorto servicing near it. Lead-acid batteries emit a highlyexplosive hydrogen gas that can be ignited by arc-ing, sparking, smoking, etc.

EXHAUST GASES ARE DEADLY

Provide an adequate exhaust system to properlyexpel discharged gases away from enclosed orsheltered areas and areas where individuals arelikely to congregate. Visually and audibly inspectthe exhaust daily for leaks per the maintenanceschedule. Make sure that exhaust manifolds are se-cured and not warped. Do not use exhaust gases toheat a compartment.

Be sure the unit is well ventilated.

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

MOVING PARTS CAN CAUSE SEVEREPERSONAL INJURY OR DEATH

Keep your hands, clothing, and jewelry away frommoving parts.

Before starting work on the generator set, discon-nect battery charger from its AC source, then dis-connect starting batteries, negative (−) cable first.This will prevent accidental starting.

Make sure that fasteners on the generator set aresecure. Tighten supports and clamps, keep guardsin position over fans, drive belts, etc.

Do not wear loose clothing or jewelry in the vicinity ofmoving parts, or while working on electrical equip-ment. Loose clothing and jewelry can becomecaught 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 ANDEXPLOSIVE ENVIRONMENTS

Flammable vapor can cause an engine to overspeed andbecome difficult to stop, resulting in possible fire, explo-sion, severe personal injury and death. Do not operate agenset where a flammable vapor environment can becreated by fuel spill, leak, etc., unless the genset isequipped with an automatic safety device to block the airintake and stop the engine. The owners and operators ofthe genset are solely responsible for operating the gen-set safely. Contact your authorized Cummins PowerGeneration distributor for more information.

iv

ELECTRICAL SHOCK CAN CAUSESEVERE PERSONAL INJURY OR DEATH

Remove electric power before removing protectiveshields or touching electrical equipment. Use rub-ber insulative mats placed on dry wood platformsover floors that are metal or concrete when aroundelectrical equipment. Do not wear damp clothing(particularly wet shoes) or allow skin surface to bedamp when handling electrical equipment. Do notwear jewelry. Jewelry can short out electrical con-tacts and cause shock or burning.

Use extreme caution when working on electricalcomponents. High voltages can cause injury ordeath. DO NOT tamper with interlocks.

Follow all applicable state and local electricalcodes. Have all electrical installations performed bya qualified licensed electrician. Tag and lock openswitches to avoid accidental closure.

DO NOT CONNECT GENERATOR SET DI-RECTLY TO ANY BUILDING ELECTRICAL SYS-TEM. Hazardous voltages can flow from the gen-erator set into the utility line. This creates a potentialfor electrocution or property damage. Connect onlythrough an approved isolation switch or an ap-proved paralleling device.

MEDIUM VOLTAGE GENERATOR SETS

(601V to 15kV)

Medium voltage acts differently than low voltage.Special equipment and training is required to workon or around medium voltage equipment. Operationand maintenance must be done only by personstrained and qualified to work on such devices. Im-proper use or procedures will result in severe per-sonal injury or death.

Do not work on energized equipment. Unauthorizedpersonnel must not be permitted near energizedequipment. Due to the nature of medium voltageelectrical equipment, induced voltage remains evenafter the equipment is disconnected from the powersource. Plan the time for maintenance with author-ized personnel so that the equipment can be de-en-ergized and safely grounded.

GENERAL SAFETY PRECAUTIONS

Coolants under pressure have a higher boiling pointthan water. DO NOT open a radiator or heat ex-changer pressure cap while the engine is running.Allow the generator set to cool and bleed the systempressure first.

Used engine oils have been identified by some stateor federal agencies as causing cancer or reproduc-tive toxicity. When checking or changing engine oil,take care not to ingest, breathe the fumes, or con-tact used oil.

Keep multi-class ABC fire extinguishers handy.Class A fires involve ordinary combustible materialssuch as wood and cloth; Class B fires, combustibleand flammable liquid fuels and gaseous fuels; ClassC 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 toprevent combustible materials from accumulatingunder the unit.

Remove all unnecessary grease and oil from theunit. Accumulated grease and oil can cause over-heating and engine damage which present a poten-tial fire hazard.

Keep the generator set and the surrounding areaclean and free from obstructions. Remove any de-bris from the set and keep the floor clean and dry.

Do not work on this equipment when mentally orphysically fatigued, or after consuming any alcoholor drug that makes the operation of equipment un-safe.

Substances in exhaust gases have been identifiedby some state or federal agencies as causing can-cer or reproductive toxicity. Take care not to breathor 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 orexplosion could result.

Wear hearing protection when going near an oper-ating generator set.

To prevent serious burns, avoid contact with hotmetal parts such as radiator, turbo charger and ex-haust system.

LS-14Mv

CONTAINERIZED RENTAL UNITSPOTENTIAL TIPPING PROBLEM

On all containerized rental equipment, there is a potentialproblem of having the container tip forward over the land-ing legs, pulling the axles off the ground when the con-

tainer is fully fueled without a semi-tractor under the kingpin. Jack stands for the front of the container are requiredto mitigate this potential problem.

Note: The figure below shows the jack stands andtheir placement at the nose of the container.

Jack Stands at Nose of Container

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

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1-1

1. Introduction

ABOUT THIS MANUAL

This manual covers models produced under theCummins/Onan and Cummins Power Genera-tion brand names.

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

Mounting Recommendations - for fasteninggenerator set to base and space requirementsfor normal operation and service.Mechanical Connections Electrical Con-nections - covers most aspects of the genera-tor set installation.Prestart − checklist of items or proceduresneeded to prepare generator set for operation.

Initial Startup − test complete system to en-sure proper installation, satisfactory perfor-mance, and safe operation. Refer to OperatorsManual for troubleshooting information.

Installation Checklist − reference checksupon completion of installation.

This manual DOES NOT provide application infor-mation for selecting a generator set or designing thecomplete installation. If it is necessary to design thevarious integrated systems (fuel, exhaust, cooling,etc.), additional information is required. Reviewstandard installation practices. For engineeringdata specific to the generator set, refer to the Speci-fication and Data Sheets. For application informa-tion, refer to Application Manual T-030, ”LiquidCooled Generator Sets”.

1-2

INSTALLATION OVERVIEW

These installation recommendations apply to typi-cal installations with standard model generatorsets. Whenever possible, these recommendationsalso cover factory designed options or modifica-tions. However, because of the many variables inany installation, it is not possible to provide specificrecommendations for every situation. If there areany questions not answered by this manual, contactyour nearest Cummins Power Generation distribu-tor for assistance.

Application and Installation

A standby power system must be carefully plannedand correctly installed for proper operation. This in-volves two essential elements: application andinstallation.

Application (as it applies to generator set installa-tions) refers to the design of the complete standbypower system that usually includes power distribu-tion equipment, transfer switches, ventilation equip-ment, mounting pads, and cooling, exhaust, andfuel systems. Each component must be correctlydesigned so the complete system will function as in-tended. Application and design is an engineeringfunction generally done by specifying engineers orother trained specialists. Specifying engineers areresponsible for the design of the complete standby

system and for selecting the materials and productsrequired.

Installation refers to the actual set−up and assem-bly of the standby power system. The installers setup and connect the various components of the sys-tem as specified in the system design plan. Thecomplexity of the standby system normally requiresthe special skills of qualified electricians, plumbers,sheetmetal workers, etc. to complete the varioussegments of the installation. This is necessary soall components are assembled using standardmethods and practices.

Safety Considerations

The generator set has been carefully designed toprovide safe and efficient service when properlyinstalled, maintained, and operated. However, theoverall safety and reliability of the complete systemis dependent on many factors outside the control ofthe generator set manufacturer. To avoid possiblesafety hazards, make all mechanical and electricalconnections to the generator set exactly as speci-fied in this manual. All systems external to the gen-erator (fuel, exhaust, electrical, etc.) must complywith all applicable codes. Make certain all requiredinspections and tests have been completed and allcode requirements have been satisfied before certi-fying the installation is complete and ready for ser-vice.

2-1

2. Specifications

MODEL DFHA, DFHB DFHC DFHD

Cummins Diesel Series QST30

Generator kW Rating See Genset Nameplate for rating information.

Coolant CapacityEngine and Radiator

104 F (40 C)122 F (50 C)

53 Gal (201 L)57 Gal (216 L)

Lubrication SystemOil Capacity with FiltersOil Type*

35 Gal (132 L)

Engine Fuel ConnectionInlet/Oultet Thread Size Refer to Generator Outline Drawing

Fuel FlowMax. Fuel Inlet PressureMax. Fuel Inlet RestrictionMax. Fuel Return Restriction

10 PSI (69 kPa)4 in. Hg. (13.5 kPa)10 in. Hg. (33.8 kPa)

10 PSI (69 kPa)4 in. Hg. (13.5 kPa)20 in. Hg. (67.6 kPa)

ExhaustOutlet SizeMax. Allowable Back Pressure

6 in. (152 mm) flange41 in. H2O (10.2 kPa)

6 in. (152 mm) flange27 in. H2O (6.7 kPa)

Electrical SystemStarting VoltageBattery

Group numberCCA (minimum)

Cold Soak @ 0 F (-18 C)

24 Volts DCTwo, 12 Volt

8D

1400

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

FUEL CONSUMPTION (STANDBY/FULL LOAD/60HZ)

MODEL DFHA DFHB DFHC DFHD

US gph (L/hr) 54.7 (207.3) 57.8 (219.1) 60.2 (228.2) 69.3 (262.6)

2-2

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3-1

3. Mounting the Generator Set

GENERAL

Generator set installations must be engineered sothe generator set will function properly under the ex-pected load conditions. Use these instructions as ageneral guide only. Follow the instructions of theconsulting engineer when locating or installing anycomponents. The complete installation must com-ply with all local and state building codes, fire ordi-nances, 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

Non-combustible mounting surface.

Discharge of exhaust gases

Electrical connections

Accessibility for operation and servicing

Noise levels

Vibration isolation

LOCATION

Generator set location is decided mainly by relatedsystems such as ventilation, wiring, fuel, and ex-haust. The set should be located as near as pos-sible to the main power service entrance. Exhaustmust not be able to enter or accumulate around in-habited areas.

Provide a location away from extreme ambient tem-peratures and protect the generator set from ad-verse weather conditions.

WARNING

INCORRECT INSTALLATION, SERVICE OR PARTS REPLACEMENT CAN RESULT IN SEVEREPERSONAL INJURY, DEATH, AND/OR EQUIPMENT DAMAGE. SERVICE PERSONNEL MUSTBE TRAINED AND EXPERIENCED TO PERFORM ELECTRICAL AND MECHANICAL COM-PONENT INSTALLATION.

IMPORTANT

DEPENDING ON YOUR LOCATION AND INTENDED USE, FEDERAL, STATE OR LOCAL LAWSAND REGULATIONS MAY REQUIRE YOU TO OBTAIN AN AIR QUALITY EMISSIONS PERMITBEFORE BEGINNING INSTALLATION OF YOUR GENSET. BE SURE TO CONSULT LOCALPOLLUTION CONTROL OR AIR QUALITY AUTHORITIES BEFORE COMPLETING YOURCONSTRUCTION PLANS.

3-2

MOUNTINGGenerator sets are mounted on a steel skid that pro-vides proper support. The engine-generator as-sembly is isolated from the skid frame by rubbermounts that provide adequate vibration isolation fornormal installations. Where required by buildingcodes or special isolation needs, generator setsmay be mounted on rubber pads or mechanicalspring isolators. The use of unapproved isolatorsmay result in harmful resonances and may void thegenset warranty.

Mount the generator set on a substantial and levelbase such as a concrete pad. A non-combustiblematerial must be used for the pad.

Use 5/8 inch or 16 mm anchored mounting bolts tosecure the vibration isolators to the base. Securethe vibration isolators to the skid using flat or bevelwasher and hexagonal nut for each bolt (see Figure3-1). The 1-1/2 x 6 inch pipe inserted over themounting bolts allows minor adjustment of the boltsto align them to the holes in the subbase or vibrationisolator.

Locate the isolators as shown on the generator setOutline Drawing referenced in the Data Sheet.

ACCESS TO SETGenerally, at least 1 meter (3 feet) of clearanceshould be provided on all sides of the generator setfor maintenance and service access. A raisedfoundation or slab of 150 mm (6 inches) or moreabove floor level will make servicing easier.

Lighting should be adequate for operation, mainte-nance and service operations and should be con-nected on the load side of the transfer switch so thatit is available at all times.

FLAT OR BEVELWASHER

MOUNTINGBOLT

12 IN.(305 mm)

MOUNTINGBASE

1-1/2 x 6 INCHPIPE

SUBBASE ORVIBRATIONISOLATORFLANGE

HEX NUT

CONCRETE

ÇÇÇÇ

ÇÇÇ

FIGURE 3-1. BOLT DIAGRAM

3-3

THIMBLE

MUFFLER

CONDENSATIONDRAIN TRAP

SWEEPINGELBOW

FLEXIBLESECTION

AC POWERWIRING

DC CONTROLWIRING

CONCRETE BASE

IMPORTANT!

COOLING AIR INLET MUST BE ATLEAST 1-1/2 TIMES LARGER THANRADIATOR DUCT OUTLET AREAON RADIATOR COOLED MODELS

FLOW OF COOLING AIR ANDHEATED AIR CAN BE CONTROLLEDBY AUTOMATICALLY OPERATEDLOUVRES

VIBRATIONISOLATORS

(5 EACH SIDE)

AIR OUTLETDUCT

AIR IN

FIGURE 3-2. TYPICAL INSTALLATION

3-4

VIBRATION ISOLATORS

Installation and Adjustment Procedure

1. Place the vibration isolators (Figure 3-3) on thegenset support structure. The isolators shouldbe shimmed or grouted to ensure that all of theisolator bases are within 0.25 inch (6 mm)elevation of each other. The surface that theisolator bases rest on must also be flat and lev-el.

2. Loosen the side snubber lock nuts so that thetop plate of the isolator is free to move verticallyand horizontally. Be sure that the top plate iscorrectly aligned with the base and springs.

3. Place the genset onto the isolators while align-ing the skid’s mounting with the threaded isola-tor hole. The top plates will move down and ap-proach the base of the isolator as load is ap-plied.

4. Once the genset is in position, the isolatorsmay require adjusting so that the set is level.

The isolators are adjusted by inserting the lev-eling bolt through the skid and into the isolator(the leveling bolt’s locking nut should bethreaded up towards the bolt head).

The leveling bolt will adjust the clearance be-tween the top plate and the isolator base. Anominal clearance of 0.25 inch (6 mm) or great-er is desired. This will provide sufficient clear-ance for the rocking that occurs during startupand shutdown. If the 0.25 inch (6 mm) clear-ance is not present, turn the leveling bolt untilthe desired clearance is achieved.

5. The genset may not be level yet; therefore, ad-just the leveling bolts until the set is level andsufficient clearance still remains. (Clearanceon all isolators should be roughly equal). Onceall isolators have been set, lock the leveling boltin place with the lock nut.

6. The snubber nuts may remain loose and there-fore provide better isolation between the gen-set and support structure.

GENSET SKID

SNUBBER

LEVELING BOLT

LOCK NUT

CLEARANCE

BASE

FIGURE 3-3. VIBRATION ISOLATORS

3-5

ALIGNING GENERATOR WITH ENGINE(750 kW GENSETS AND LARGER)

Proper alignment of the generator and engine as-semblies is necessary to avoid premature wear andimproper operation of the genset. Review the fol-lowing alignment conditions and procedures foraligning the generator assembly to engine flywheelhousing.

Angular Misalignment

Angular misalignment is the result of the generatorbearing center axis not aligning with axis of the en-gine crankshaft. This condition creates an anglebetween the generator shaft axis and the crank-shaft axis. The cause of this type of misalignment isusually shimming error.

Axial Misalignment

Axial misalignment is the result of the generatorshaft axis not aligning with engine crankshaft axis.The tolerances in the bolted flywheel and drive discconnection may add up to displace the generatoraxially relative to the crankshaft axis.

Misalignment Symptoms

If the assembly is allowed to run under these condi-tions, the discs must flex in alternate directionstwice for each engine revolution. It is important tominimize the amount of disc flexing since, if it is ex-cessive, the drive disc will crack. Although perfectbearing alignment is desirable, it is more importantto keep disc deflection to the very minimum pos-sible. This procedure assumes that the pilot bore ofthe drive discs are in the exact center and the fly-wheel counterbore (pilot) has no practical runout.Under these conditions, perfect Angular alignmentwill be attained when no deflection of the discs ismeasured.

Excessive Axial alignment will cause more genera-tor vibration than Angular misalignment.

Axial misalignment needs to be checked only whenan objectionable vibration is present.

Either type off misalignment may be present in agenerator set assembly, with angular misalignmentbeing the most common problem. Angular align-ment may also be effected by set installation condi-tions and/or mishandling during shipping of the gen-set.

FIGURE 3-3. ANGULAR ALIGNMENT MEASUREMENT

CLAMP

FLEXDISCS

DIAL INDICATOR

DETAIL A

SEE DETAIL A

AXIALALIGNMENT

MOUNTING BOLTTO DISC

MEASUREMENT

GENERATORAND ENGINECRANKSHAFTCENTERLINE

SHIMS

FIGURE 3-4. ANGULAR ALIGNMENT MEASUREMENT

3-6

Angular Alignment Procedure

WARNING Accidental starting of the generatorset during this procedure presents the hazardof severe personal injury or death. Make sure todisconnect the negative (-) battery cable(s) be-fore beginning.

Fasten a dial indicator to either the generator shaftor the cooling fan with the sensing point resting onthe capscrew head or the flat surface of the drivedisc at the bolt circle diameter, see Figure 3-4. Barthe engine over in a clockwise rotation as viewedfrom engine flywheel. Do not allow it to roll back oncompression at the end of the travel of each read-ing. It is unnecessary to zero the indicator since thetotal indicator reading (T.I.R.) of the deflection mea-surement to the bolt heads is what is required. T.I.R.will be the sum of the maximum positive and nega-tive dial indicator readings as the engine completesone revolution.

CAUTION Do not bar engine over by prying onfan blade. This may damage the blade and resultin premature, sudden blade failure.

Sample Generator Runout Readings: When takingthe deflection readings described, make a diagramsimilar to the example shown in Figure 3-5, with atotal indicator reading of .025”. (The highest posi-tive value of +.010” and the largest negative value of

-.015”.) The indicator is closer to the top and furtheraway at the bottom. This example indicates that thegenerator bearing is high. Since the side readingsare equal, the generator is centered side to side. Tolower the generator, remove equal shims from un-der both generator mounting feet. To approximatethe amount of shims to remove or add:

1. Measure the distance between the center ofthe generator shaft to the point the indicator ismeasuring at. (For example; a SAE 18 Disccoupling distance is 10.7”).

2. Measure the distance from the generator sideof the flex discs to the center of the generatormounting bolt, refer to Figure 3-4. (For exam-ple; a HC6 Frame’s distance is 28.4”.)

3. Compare the distance measured in steps 1 and2. (28.4” vs 10.7” or a 2.65 to 1 ratio.) Multiplythis ratio times one half the T.I.R. (In our exam-ple, .025” divided by 2 is .0125”. This, times2.65 equals .033”. Therefore, remove .033” ofshims from under both mounting feet.)

In general, the T.I.R. should not be more than .001”for each inch of radius (center of shaft to indicatoraxis). If we use our example of 10.7 inches, then themaximum T.I.R. would be .011”. This would only re-quire a correction of .014” from the T.I.R. of .025”. (Areading of +.002 at the top and −.009 at the bottomwould fall within the satisfactory range.)

MEASURED ATBOLT CIRCLE

DIAMETER

+.010 +.010

−.010

−.004

−.015 −.015

−.010

−.002

10.7 IN.

FIGURE 3-5. ANGULAR ALIGNMENT MEASUREMENT READINGS (EXAMPLE)

3-7

Axial Alignment Procedure

Axial misalignment needs to be checked only whenan objectionable vibration is present.

If excessive vibration remains after the angularalignment, check for concentric alignment of thegenerator shaft/engine crankshaft axis.

Fasten dial indicator holding device to skid base,engine block, or generator shell with a magneticbase or clamp and position so the sensor point of in-dicator rests on the generator shaft hub, see Figure3-6. Bar the engine over in a clockwise rotation asviewed from engine flywheel, through a couple ofrotations. Record indicator readings in eight equal-ly spaced points around the shaft diameter. This willprovide a T.I.R. for Axial shaft misalignment.

The maximum allowable T.I.R. runout is subjective,the optimal T.I.R. for runout would be .000 inches,however that may not be attainable. The recom-mendation of this procedure will be to reduce themeasured T.I.R. runout by one half. Specific out-of-tolerance runout levels are difficult to establish due

to the varying surface quality of the generatorshaft’s drive disc mounting hub.

The goal of the Axial alignment is to reduce thevibration level of the genset while it is operating. Asmall improvement in the T.I.R. runout may havedramatic effects in the mechanically measured orphysically observed vibration levels.

To correct for an out-of-tolerance T.I.R. indication,remove the capscrews connecting drive discs andflywheel. Mark the drive discs and flywheel with re-spect to each other. Rotate either the engine or gen-erator so that drive discs holes are repositioned 180degrees from their original location. Put the drivediscs capscrews back in and retorque. Recheckshaft alignment as before. If shaft T.I.R. runout re-mains unchanged then discs should be rotated toeither 30, 60 or 90 degrees from original location tocorrect the out-of-tolerance condition. If the T.I.R.does not improve after repositioning, a closer in-spection of the flywheel pilot and drive disc runoutsis required. This will help determine the cause of theAxial misalignment.

GENERATORSHAFT

HUB

DIALINDICATOR

CLAMP

FAN HOUSING

DETAIL A

SEE DETAIL A

ANGULAR ALIGNMENT

GENERATORAND ENGINECRANKSHAFTCENTERLINE

FIGURE 3-6. AXIAL ALIGNMENT MEASUREMENT

3-8

THIS PAGE LEFT INTENTIONALLY BLANK

4-1

4. Mechanical Connections

GENERAL

The generator set mechanical system installationincludes connecting the fuel, exhaust, ventilationand cooling systems. Before starting any type offuel installation, all pertinent state and local codesmust be complied with and the installation must beinspected before the unit is put in service.

FUEL SYSTEM

Cummins engines normally use ASTM No. 2 dieselfuel. They will, however, operate on alternate dieselfuels within the specifications shown in the Cum-mins engine Operation and Maintenance Manual.

In all fuel system installations, cleanliness is of theupmost importance. Make every effort to prevententrance of moisture, dirt or contaminants of anykind into the fuel system. Clean all fuel system com-ponents before installing.

A fuel filter/strainer/water separator of 100-120 meshor equivalent (approximately 150 microns nominal)must be fitted between either the main tank and daytank or between the main tank and the engine.

Use only compatible metal fuel lines to avoid elec-trolysis when fuel lines must be buried. Buried fuellines must be protected from corrosion.

CAUTION Never use galvanized or copper fuellines, fittings or fuel tanks. Condensation in thetank and lines combines with the sulfur in dieselfuel to produce sulfuric acid. The molecularstructure of the copper or galvanized lines ortanks reacts with the acid and contaminates thefuel.

An electric solenoid valve in the supply line is rec-ommended for all installations and required for in-door automatic or remote starting installations.Connect the solenoid wires to the genset “SwitchedB+” circuit to open the valve during generator setoperation.

Separate fuel return lines to the day tank or supplytank must be provided for each generator set in amultiple-set installation to prevent the return lines ofidle sets from being pressurized. Fuel return lines

must not contain a shutoff device. Engine damagewill occur if the engine is run with the return fuel linesblocked or restricted.

CAUTION Never install shutoff device in fuelreturn line(s). If fuel return line(s) is blocked orexceeds fuel restriction limit, engine damagewill occur.

Fuel Return Restriction (or Pressure) Limit: Fuelreturn drain restriction (consisting of friction headand static head) between the engine injector returnline connection and the fuel tank must not exceedthe limit stated in the Specification section.

Fuel Lines − Routing

A flexible fuel hose(s) or section of flexible fuelhose(s) must be used between the engine’s fuelsystem and fuel supply and return line(s) to protectthe fuel system from damage caused by vibration,expansion and contraction. Flexible lines for con-necting between the engine and the stationary fuellines are supplied as standard equipment.

Installation of the fuel hose must be done accordingto all applicable codes and standards, and installa-tion recommendations provided by the manufactur-er. The supplied flexible hose is approved by thehose manufacture for use with the genset fuel typeand product application.

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

WARNING Sparks and hot surfaces can ignitefuel, leading to severe personal injury or death.Do not route fuel lines near electrical wiring orhot exhaust parts.

Fuel lines must be routed and secured to maintain a1/2 inch (12.7 mm) minimum clearance from electri-cal wiring and a 2 inch (51 mm) minimum clearancefrom hot exhaust parts.

Engine Fuel Connections

Identification tags are attached to the fuel supplyline and fuel return line connections.

4-2

VENT LINE

FILL PIPE

FUEL TANK

INJECTOR FUELRETURN LINE

ENGINEFUELPUMP

DAY TANK

CONNECT TOAC OUTPUT

VENTEDFILL CAP

SUPPLYLINE

All models require a fuel returnline from injectors to tank.

SHUTOFFVALVE

1 INCH

FUEL TRANSFERPUMP ELECTRICMOTOR DRIVEN

LARGER OVER-FLOW LINE

120 MESH FUELSTRAINER

FLOATSWITCH

BAFFLE

FIGURE 4-1. TYPICAL FUEL SUPPLY INSTALLATION

Supply Tank

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

Install a fuel tank that has sufficient capacity to sup-ply the genset operating continuously at full ratedload for the planned period of operation or poweroutage. Refer to Data Sheet for fuel consumptiondata.

WARNING Fuel leaks create fire and explosionhazards which can result in severe personal in-jury or death. Always use flexible tubing be-tween engine and fuel supply to avoid line fail-ure and leaks due to vibration. The fuel systemmust meet applicable codes.

If the fuel inlet restriction exceeds the defined limitdue to the distance/customer-supplied plumbingbetween the genset and the main fuel tank, a trans-

fer tank (referred to as a day tank) and auxiliarypump will also be required. If an overhead main fueltank is installed, a transfer tank and float valve willbe required to prevent fuel head pressures from be-ing placed on the fuel system components.

For critical start applications, where generator setsare paralleled or must satisfy emergency start-timerequirements, it is recommended that a fuel tank orreservoir be located such that the lowest possiblefuel level is not less than 6 inches (150 mm) abovethe fuel pump inlet. This will prevent air from accu-mulating in the fuel line while the set is in standby,eliminating the period during startup when it has tobe purged.

Fuel Inlet Pressure/Restriction Limit:: Engineperformance and fuel system durability will be com-promised if the fuel inlet pressure or restriction limitsare not adhered to. Fuel inlet pressure or restrictionmust not exceed the limits stated in the Specifica-tion section.

4-3

Day Tank (If Used)

Fuel day tanks are used when fuel inlet restrictionlimits can not be met, or the supply tank is overheadand presents problems of high fuel head pressurefor the fuel inlet and return lines.

Supply Tank Lower Than Engine: With this instal-lation, the day tank is installed near the generatorset, below the fuel injection system and within thefuel inlet restriction limit. Install an auxiliary fuelpump, to pump fuel from the supply tank to the daytank. A float switch in the day tank controls opera-tion of the auxiliary fuel pump.

The supply tank top must be below the day tank topto prevent siphoning from the fuel supply to the daytank.

Provide a return line from the engine injection sys-tem return connection to the day tank. Plumb the re-

turn line to the bottom of day tank as shown in Fig-ure 4-1. Provide a day tank overflow line to the sup-ply tank in case the float switch fails to shut off thefuel transfer pump.

WARNING Spilled fuel presents the hazard offire or explosion which can result in severe per-sonal injury or death. Provide an overflow lineto the supply tank from the day tank.

Supply Tank Higher Than Engine: Install the daytank near the generator set, but below the fuel injec-tion system. Use fuel line at least as large as the fuelpump inlet. The engine fuel return line must enterthe day tank.

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

WARNING Spilled fuel can create environmental hazards. Check local requirements for containmentand prevention of draining to sewer and ground water.

4-4

EXHAUST SYSTEM

Pipe exhaust gases to the outside of any enclosure.Locate the exhaust outlets away from any air inletsto avoid gases re-entering the enclosure. Exhaustinstallations are subject to various detrimental con-ditions such as extreme heat, infrequent operationand light loads. Regularly inspect the exhaust sys-tem both visually and audibly to see that the entiresystem remains fume tight and safe for operation.

WARNING Inhalation of exhaust gases can re-sult in severe personal injury or death. Use ex-treme care during installation to provide a tightexhaust system. Terminate exhaust pipe awayfrom enclosed or sheltered areas, windows,doors and vents.

For indoor installation, the exhaust system mustuse sealed joint type fittings, (for example NPT fit-tings) to provide a tighter exhaust system. Use ofslip type fittings (secured with a muffler clamp) mayallow leakage of exhaust gases into the building.

WARNING Inhalation of exhaust gases can re-sult in severe personal injury or death. Use ex-treme care during installation to provide a tightexhaust system. Use NPT or equivalent type fit-tings for all indoor installations.

Use an approved thimble (Figure 4-2) where ex-haust pipes pass through wall or partitions. Insu-lated wall/roof thimbles are used where exhaustpipes pass through a combustible roof or wall. Thisincludes structures, such as wood framing or insu-lated steel decking, etc. Uninsulated wall/roofthimbles are used where exhaust pipes passthrough a non-combustible wall or roof, such asconcrete. Refer to NFPA 37, Section 6-3. “Station-ary Combustion Engines and Gas Turbines” for ac-

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

WARNING Hot exhaust pipes can start a fireand cause severe injury or death if improperlyrouted through walls. Use an approved thimblewhere exhaust pipes pass through walls orpartitions.

WARNING Inhalation of exhaust gases can re-sult in severe personal injury or death. Do notuse exhaust heat to warm a room, compartmentor storage area.

Rain caps are available for the discharge end of ver-tical exhaust pipes. The rain cap clamps onto theend of the pipe and opens due to exhaust dischargeforce from the generator set. When the generatorset is stopped, the rain cap automatically closes,protecting the exhaust system from rain, snow, etc.

Use a section of flexible exhaust pipe between theengine and remainder of exhaust system. Supportexhaust system to prevent weight from being ap-plied to engine exhaust outlet elbow/turbochargerconnection.

CAUTION Weight applied to the engine man-ifold can result in turbocharger damage. Sup-port the muffler and exhaust piping so noweight or stress is applied to engine exhaust el-bow.

The exhaust system design should meet local coderequirements.

Liability for injury, death, damage, and warranty ex-pense due to use of unapproved mufflers or modifi-cations becomes the responsibility of the personinstalling the unapproved muffler or performing themodification. Contact a Cummins Power Generationdistributor for approved exhaust system parts.

4-5

Avoid sharp bends by using sweeping, long radiuselbows and provide adequate support for mufflerand tailpipe. Pitch a horizontal run of exhaust pipeDOWNWARD (away from engine) to allow anymoisture condensation to drain away from the en-gine. If an exhaust pipe must be turned upward,install a condensation trap at the point where therise begins (Figure 4-3).

Shield or insulate exhaust lines if there is danger ofpersonal contact. Allow at least 12 inches (305 mm)of clearance if the pipes pass close to a combustiblewall or partition. Before installing insulation on ex-haust system components, check the exhaust sys-tem for leaks while operating the genset under fullload and correct all leaks.

WARNING Exhaust pipes are very hot and theycan cause severe personal injury or death fromdirect contact or from fire hazard. Shield or in-sulate exhaust pipes if there is danger of per-sonal contact or when routed through walls ornear other combustible materials.

DRIP CAPRAIN CAP

ROOF

9 INCH MIN(230 mm)

9 INCH MIN(230 mm)

WALL OR PARTITION

HORIZONTAL

VERTICAL

HOLES IN ENDOF INNERSLEEVE

FIGURE 4-2. MOUNTING EXHAUST THIMBLE

AVOIDSHARPBENDS

IF EXHAUST LINE MUST BEPITCHED UPWARD, CONSTRUCT

A TRAP AT POINT OF RISE

DRAIN CONDENSATIONTRAP PERIODICALLY

FIGURE 4-3. CONDENSATION TRAP

4-6

VENTILATION AND COOLING

Generator sets create considerable heat that mustbe removed by proper ventilation. Outdoor installa-tions normally rely on natural air circulation but in-door installations need properly sized and posi-tioned vents for required airflow.

Vents and Ducts

For indoor installations, locate vents so incoming airpasses through the immediate area of the installa-tion before exhausting. Install the air outlet higherthan the air inlet to allow for convection air move-ment.

Size the vents and ducts so they are large enough toallow the required flow rate of air. The ”free area” ofducts must be as large as the exposed area of theradiator. Refer to the genset Data Sheet for the air-flow requirements and allowed airflow restriction.

Wind will restrict free airflow if it blows directly intothe air outlet vent. Locate the outlet vent so the ef-fects of wind are eliminated. See Figure 4-4.

PREVAILING WINDS PREVAILING WINDS

FIGURE 4-4. WIND BARRIER

4-7

Dampers

Dampers or louvres protect the genset and equip-ment room from the outside environment. Their op-eration of opening and closing should be controlledby operation of the genset.

In cooler climates movable or discharge dampersare used. These dampers allow the air to be recircu-lated back to the equipment room. This enables theequipment room to be heated while the genset en-gine is still cold, increasing the engine efficiency.

Radiator Set Requirements

Radiator set cooling air is drawn past the controlend of the set by a pusher fan that blows air throughthe radiator (Figure 4-5). Locate the air inlet to the tothe rear of the set. Make the inlet vent opening 1-1/2to 2 times larger than the radiator area.

Louvers and screens over air inlet and outlet open-ings restrict air flow and vary widely in performance.

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

Locate the cooling air outlet directly in front of the ra-diator and as close as possible. The outlet openingmust be at least as large as the radiator area.Length and shape of the air outlet duct should offerminimum restriction to airflow.

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

Standard Radiator Cooling uses a set mountedradiator and engine pusher fan to cool engine waterjacket. Air travels from the generator end of the set,across the engine and out through the radiator. Anintegral discharge duct adapter flange surroundsthe radiator grille.]

COOL AIR

INLET AIRDAMPER

RADIATOR FLEXIBLE DUCTCONNECTOR

THERMOSTATIC AIR RE-CIRCULATING DAMPER

*

HOT AIR

WIND/NOISEBARRIER

D

* Louvers should close when room ambient is above 60 F (16 C)

DISTANCE SHOULD NOTBE LESS THAN HEIGHT

OF RADIATOR

FIGURE 4-5. TYPICAL RADIATOR SET INSTALLATION

4-8

Remote Radiator Cooling (Optional) substitutesa remote mounted radiator and an electrically driv-en fan in place of mounted components. Removalof the radiator and the fan from the set reducesnoise levels without forcing dependence on a con-tinuous cooling water supply (necessary with heatexchanger cooling). The remote radiator installa-tion must be completely protected against freezing.

Remote radiator plumbing will vary with installation.Follow recommendations given in ApplicationManual T-030. See product Data Sheet for frictionhead and static head limits.

Before filling cooling system, check all hardware forsecurity. This includes hose clamps, capscrews, fit-tings and connections. Use flexible coolant lineswith heat exchanger or remote mounted radiator.

Engine Coolant Heater (Optional)

An optional coolant heater is available to keep the

engine warm for improved starting and code com-pliance. Connect the heater to a power source thatwill be energized when the engine is NOT running.

Heat Exchanger (Optional)

The optional heat exchanger (Figure 4-6) uses ashell and tube type heat exchanger instead of thestandard radiator and fan. Engine jacket coolant cir-culates through the shell side of the heat exchangerwhile the cooling water is pumped through thetubes. Engine coolant and raw water do not mix.

This system may reduce set enclosure airflow re-quirements and noise levels. Proper operation de-pends on a constant supply of raw water for heat re-moval. Adjust the flow to maintain engine coolanttemperature between165 F and 195 F (74 C and91 C) while viewing the water temperature gauge.The engine coolant side of the system can be pro-tected from freezing; the raw water side cannot beprotected.

WARMAIR

COOL AIR

WATERSOLENOID

VALVE

VENTILATINGFAN

FLEXIBLE WA-TER

CONNECTIONS

MOUNTED HEATEXCHANGER

RAW WATERSUPPLY

RAW WATERDISCHARGE

FIGURE 4-6. TYPICAL HEAT EXCHANGER INSTALLATION

5-1

5. DC Control Wiring

CONTROL WIRING

The generator set accessory box (Figure 5-1),which is located on the backside of the control hous-ing, contains connection points for remote controland monitor options.

CAUTION Stranded copper wire must be usedfor all customer connections to the AccessoryBox. Solid copper wire may break due to gensetvibration.

TB1 REMOTE MONITOR/CONTROLCONNECTIONS

Customer monitor/control connections are at-tached to terminal block TB1 (Figure 5-1). Optionalequipment such as a remote annunciator panel,sensing devices used to monitor genset operation,remote start/stop switches, control box heater, bat-tery charger and etc. are attached to TB1. Refer toPCC Customer Connections diagram in Section 10.

TB1 Wiring

CAUTION Always run control circuit wiring ina separate metal conduit from AC power cablesto avoid inducing currents that could causeproblems within the control.

Digital Connections: Connection points, otherthen relayed outputs, network, switched B+ and B+are considered digital connections to terminal stripTB1. The type/gauge wire to use for these connec-tions are:

Less than 1000 feet (305m), use 20 gaugestranded copper wire.

1000 to 2000 feet (305 to 610m), use 18 gaugestranded copper wire.

Relay Connections: Due to the wide variety of de-vices that can be attached to the relay outputs ofTB1, the electrical contractor must determine thegauge of the stranded copper wire that is used atthis installation site. Refer to PCC Customer Con-nections diagram in Section 10 for the relay specifi-cations.

Network Connections: Refer to the PowerCom-mand Network Installation and Operation manual(900-0366 for TP-78 networks or 900−0529 forFT-10 networks) for the type/gauge wire to use forthese connections.

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

B+: (Fused at 20 amps.) Same as Relay Connec-tion description.

5-2

OPTIONAL RTDRELAY

OPTIONAL RUN RELAYSK11, K12 & K13

OPTIONALCOMMON ALARM

RELAY K14

OPTIONALTHERMISTOR

RELAY 160/140 C

TB1-1

TB1-40

GOVERNOROUTPUT MODULE

A38

PT/CT BOARD A36

VOLTAGEREGULATOR

OUTPUT MODULEA37

FIGURE 5-1. ACCESSORY BOX COMPONENTS

5-3

RUN RELAYS (K11, K12, K13)

The optional run relays are rail mounted inside theaccessory box (Figure 5-1). The rail mount allowsyou to easily remove and replace the snap-on re-lays. The generator set can be equipped with one,two or three run relays.

The three-pole, double-throw run relays (Figure5-2) are used to control auxiliary equipment such asfans, pumps and motorized air dampers. The run

relays are energized when the generator set controlreceives a start signal.

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

Note: Heater Relay Kit (541−1416) is available forfailed units DFHA, DFHB, DFHC and DFHD. Opera-tional units will not need Heater Relay Kit.

CUSTOMERCONNECTIONS

A40-TB1-4(B-)

A40-TB1-2(SWITCHED B+)

NO

COIL

COM

NC

K11, K12, K13

K11RUN RELAY

K11, K12, K13

K11, K12, K13

K12RUN RELAY

K13RUN RELAY

NO

NC

NO

NC

FIGURE 5-2. OPTIONAL RUN RELAYS (K11, K12, K13)

5-4

ALARM RELAY (K14)

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

The three-pole, double-throw alarm relay (Figure5-3) is often used to energize warning devices such

as audible alarms. Any generator set warning orshutdown 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

CUSTOMERCONNECTIONS

A40-TB1-7(COMMON ALARM)

A40-TB1-1(B+)

NO

COIL

COM

NC

K14

K14

K14

K14COMMON ALARM

A40-TB1-4

A40-TB1-8

JUMPER WIREREQUIRED FOR K14

RELAY OPTION

(GND)

(COMMON ALARM)

FIGURE 5-3. OPTIONAL ALARM RELAY (K14)

5-5

RTD RELAY (OPTIONAL)

The optional RTD relay is rail mounted inside theaccessory box (Figure 5-1). This relay is used tomonitor six separate temperature zones in the gen-erator windings using resistive temperature detec-tors (RTDs). The relay determines the sensed tem-perature and acts to isolate, alarm, or initiate cor-rective action.

The RTD relay (Figure 5-4) compares the six inputsto the predetermined setpoint (temperature set-point is factory adjusted). If one or more of the inputsexceed the setpoint, the output relay is energized.

LED’s indicate the state of the output relay (greenfor normal, red for tripped). Additional red LED’s areused to indicate which inputs exceed the setpoint.

The relay terminals 11, 12 and 14 are for customerconnection. These terminals can be attached to anyone of the four Customer Fault inputs on TB1 to pro-vide a warning/shutdown condition or to other cus-tomer warning devices.

The contacts are rated:

240 VAC, 5 amps non-inductive

24 VDC, 25 amps resistive

OUTPUT RELAY(CUSTOMER USE)

TO RTD TERMINALBLOCK

TEMPERATURE RELAY CONNECTIONS

TO RTD TERMINALBLOCK

24 VDC

(−)(+)

A40TB1-2(SWITCHED B+)

A40TB1-4(GROUND)

FIGURE 5-4. RTD RELAY (OPTIONAL)

5-6

THERMISTOR RELAY (OPTIONAL)

The optional thermistor relays are rail mounted in-side the accessory box (Figure 5-1). Each relaymonitors three thermistors (one per phase) that areconnected in series inside the generator. One se-ries or chain of thermistors are rated at 140 C andthe other at 160 C. The 140 C relay is commonlyused in a pre-alarm circuit. The relay will energize

(trip) when the thermistor chain resistance reaches3000 500 ohms.

The relay terminals 1, 2 and 3 are for customer con-nection and are normally connected to a breakershunt trip or a load shed circuit (Figure 5-5).

The contacts are rated:

3 amps at 250 VAC

1 amp at 480 VAC

A40-TB1-4(GROUND)

WHITE/REDTHERMISTORSA B C

A40-TB1-2(SWITCHED B+)

BLUE

FAULT CHANNELS(CUSTOMER

CONNECTIONS)

RELAY CONTACTS

FIGURE 5-5. THERMISTOR RELAY (OPTIONAL)

6-1

6. AC Electrical Connections

GENERAL

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

Before making any AC electrical connections, makecertain the generator set cannot be accidentallystarted. Move the Run/Off/Auto switch on the con-trol panel to the OFF position. Turn off or remove ACpower from the battery charger and then removethe negative (−) battery cable from the set startingbattery.

WARNING Ignition of explosive battery gasescan cause severe personal injury or death. Arc-ing at battery terminals, light switch or otherequipment, flame, pilot lights and sparks can ig-nite battery gas. Do not smoke, or switchtrouble light ON or OFF near battery. Dischargestatic electricity from body before touching bat-teries by first touching a grounded metal sur-face.

Ventilate battery area before working on or nearbattery—Wear goggles—Stop genset and dis-connect charger before disconnecting batterycables—Disconnect negative (−) cable first andreconnect last.

CAUTION Disconnect battery charger from ACsource before disconnecting battery cables.Otherwise, disconnecting cables can result involtage spikes damaging to DC control circuitsof the set.

WARNING Accidental starting of the generatorset can cause severe personal injury or death.Prevent accidental starting by disconnectingthe negative (−) cable from the battery terminal.

WARNING Each of the operations described inthis section should be done only by personstrained and experienced in electrical mainte-nance. Improper procedures may result in prop-erty damage, bodily injury or death.

Connecting the genset AC electrical system in-volves:

Generator insulation check

Installation of transfer switch

Generator output voltage selection

Load cable connection

Standard and optional AC equipment connec-tions (e.g., control box heater, coolant heater,etc.

Local regulations often require that wiring connec-tions be made by a licensed electrician, and that theinstallation be inspected and approved before op-eration. All connections, wire sizes, materials used,etc. must conform to the requirements of electricalcodes in effect at the installation site.

WARNING Improper wiring can cause a fire orelectrocution, resulting in severe personal inju-ry or death and/or property and equipment dam-age.

Before starting the genset, check to make sure thatall electrical connections are secure, and that allwiring is complete. Replace and secure any accesspanels that have been removed during installation.Check that the load cables from the genset areproperly connected.

WARNING Backfeed to utility system cancause electrocution or property damage. Donot connect to any building electrical systemexcept through an approved device and afterbuilding main switch is opened.

6-2

INSULATION RESISTANCE (MEGGER) &POLARIZATION INDEX (PI) TESTING

Megger and PI testing must be performed on allmedium voltage (601 through 15,000 volts) genera-tor sets before initial start-up. PI testing for low volt-age (less than 600 volts) generator sets is recom-mended by Cummins Power Generation.

These tests are used to verify that the windings aredry before the generator set is operated and devel-ops a base line for future test comparison.

Before these tests can be performed on mediumvoltage generator sets, you must first perform thegenerator grounding procedure.

Generator Set Grounding Procedure

Prior to performing service or inspection proce-dures that may expose personnel to conductorsnormally energized with voltages greater than 600volts, the following generator set grounding proce-dure must be followed.

WARNING No person should attempt to per-form these procedures unless they are fullytrained in medium voltage grounding proce-dures and have the necessary safety tools andequipment. Persons who attempt these proce-dures without these qualification are at risk ofsevere injury or death due to high voltage elec-trical shock.

1. Open, lock-out and tag-out all sources of powerto the immediate work area.

2. Disable the starting system of the generatorset:

a. Disconnect the battery charger from its ACsource.

b. Remove the negative battery cable fromthe battery.

c. Install a lockout device on the batterycable end. (For engines equipped with anair-powered starting system, close airvalve and install valve locking device.)

3. Put on high voltage gloves with leather protec-tors.

4. Using two pre-tested voltage detection devices(of the proper rating), verify de-energized con-dition in the work area. (Retest voltage detec-tion devices immediately after verification ofde-energized condition.)

5, Remove the metal cover from the generatoroutput box to gain access to generator load ter-minals.

6. Securely install the Grounding Cluster groundclamp to a verified “grounded” conductor.

WARNING Hazardous voltage. Can causesevere personal injury or death. After DCvoltage from the test equipment has beenapplied to the windings and ground, therewill be a definite static charge on the wind-ings. Reconnect Grounding Cluster to re-move static charge from the winding aftereach generator test.

7. With the Grounding Cluster in place, you areprotected from all static and/or inducedcharges that may have been present in thegenerator stator.

Leave grounds connected for one minute to in-sure static charge dissipation. Remove groundcluster and perform PI and/or any other testsrequired on the stator winding. Reconnectgrounds if additional generator service is nec-essary.

8. When work on the generator set is complete,remove the Grounding Cluster in the reverseorder of installation.

9. After getting clearance from all personnel in-volved in the lock-out/tag-out procedure, re-move all lock-out devices in reverse order ofinstallation.

6-3

Megger and PI Test

WARNING Medium-voltage, 601 to 15,000volts, present special hazards of severe person-al injury or death. Even after genset shutdown,an electrical shock hazard may exist. Servicepersonnel must be well trained and qualified towork with distribution voltages.

WARNING Windings of medium voltage (601through 15,000 volts) generator sets must bedry before the generator is operated. Failure toensure dry windings before start-up may resultin catastrophic failure, severe personal injuryand death.

Megger Test: The megger test consists of applyingvoltage for up to one minute. The highest resistancevalues shown in Table 6-1 should be obtained for anew generator with dry windings. For a set that hasbeen in service, the resistance reading should notbe less than the lower value shown.

PI Test: The PI test consists of applying a voltagebetween the winding and ground for ten minutesand recording resistance values at one minute andat ten minutes. The PI is the ratio of a ten minutereading in megohms divided by a one minute read-ing in megohms. A ratio of two or greater is consid-ered good for new and in-service sets.

If low readings are obtained, investigate the causeand correct before the generator set is returned toservice.

1. Perform the Generator Set Grounding Proce-dure.

2. Disconnect plug J10 from the voltage regulatoroutput stage module and the AC control inputleads from the generator output terminals. TheAC control leads are marked 4, 5, 6, 7 and 8.Refer to the reconnection diagram, which is lo-cated on the upper side cover of the controlhousing.

3. If the RTD (resistive thermal device) option isinstalled, ground all six resistive thermal devicetemperature leads. Each RTD has three leads,one red and two white leads. Total of 18 leadsmust be grounded.

Main Stator:

4. Remove and separate the neutral leads of thegenerator from the generator load terminalmarked “N”.

5. Connect the megger between one phase of thestator and ground while grounding the othertwo phases and conduct the test. Refer to Table6-1 for megger voltage selection and requiredresistance values.Repeat this step in turn for the other twophases.

Main Rotor:

6. Disconnect the main rotor and voltage sup-pressor leads from terminals F1+ and F2− onthe rotating rectifier assemblies and isloatethem from ground. Tag and mark each leadwith its terminal number (F1+ or F2−).

7. Connect the megger between one of the rotorleads and ground and conduct the test. Refer toTable 6-1 for megger voltage selection and re-quired resistance values.

GENERATOR VOLTAGE MEGGER VDCSETTING

MINIMUM RESISTANCE (MEG)

MAIN STATOR MAIN ROTOR

600 VAC or less

TABLE 6-1. GENERATOR INSULATION RESISTANCE

500 5.0 − 1.0 5.0 − 1.0

601 thru 5000 VAC 2500 400 − 50

5.0 − 1.0

5001 thru 15000 VAC 5000 1000 − 200

1000

1000 5.0 − 1.0

6-4

TRANSFER SWITCH

If the installation is for standby service, a transferswitch must be used for switching the load from thenormal power source to the genset (see Figure 6-1).Follow the installation instructions provided with thetransfer switch when connecting the load and con-trol wiring.

LOAD

GENSETNORMALSOURCE

FIGURE 6-1. TYPICAL LOAD TRANSFERFUNCTION

6-5

AC WIRING

Generator Voltage Connections

The available generator output voltages and maxi-mum current ratings are specified on the generatorset nameplate. Line-to-neutral voltage is always thelower voltage shown and line-to-line voltage is thehigher rating.

These generators can be configured to the name-plate voltages as shown on the Reconnection Dia-gram located on the side access cover of the controlhousing. Many of the voltages listed will require re-configuration of the generator output leads on theconnection terminal block. This reconfigurationmust only be done by service personnel that aretrained and experienced to perform electrical instal-lation. The generator set was adjusted to produce aspecified voltage during production verification test-ing prior to shipment. The installer must alwayscheck the stator lead terminal block connectionsand perform any necessary reconnect to obtain thevoltage required.

Some generator sets are capable of producing awide range of voltages and connection configura-tions, others have specific limited capabilities. Re-fer to wiring diagram and generator voltages (fromthe nameplate) when reviewing the voltage connec-tion information and use the wiring diagram sup-plied with your generator set when actually perform-ing load connections.

CAUTION Reconfiguring generator sets tohigher voltages can exceed the voltage capabil-ity of the specific generator windings and dam-age the generator and also decrease line cur-rent, rendering line circuit breakers too large.Consult with your distributor before performingreconnection for a different voltage.

CAUTION Reconfiguring generator sets tolower voltages can reduce generator set rat-ings, and also increase line current, renderingline circuit breakers too small. Consult withyour distributor before performing reconnec-tion for a different voltage.

Load Connections

Flexible conduit and stranded conductors must beused for connections to take up movement of thegenerator set.

All loads are connected to the generator by boltingstranded load wires to the appropriate terminals onthe generator reconnection terminal block or circuitbreaker lugs. The terminals are stamped U, V, Wand N to indicate the line and neutral connections.(Reference: U, V, and W correspond with L1, L2 andL3; and N with L0 respectively).

Load Balancing

When connecting loads to the generator set, bal-ance the loads so the current flow from each line ter-minal (L1, L2 and L3) is about the same. This is es-pecially important if both single phase and threephase loads are connected. Any combination ofsingle phase and three phase loading can be usedas long as each line current is about the same, with-in 10 percent of median value and no line current ex-ceeds the nameplate rating of the generator. Checkthe current flow from each line after connections byobserving the control panel ammeter.

Current Transformers

Current transformers (CT’s) are required on gen-sets that contain AC meters. The CT’s must beinstalled as noted in the following CT InstallationRequirements.

Refer to the Reconnection Diagram to identify theoutput leads/phase that must be routed througheach CT, and also appropriate transformer postselection for meter sensing leads. The transformersare labeled CT21, CT22 and CT23 on the recon-nection wiring diagram. (The Reconnection Dia-gram is located on the upper side cover of the con-trol housing.)

CT Installation Requirements:

A. The CT has a dot on one side. This dot must befacing toward the generator (conventional cur-rent flowing into the dot). A dot is also used toindicate 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 eachCT.

D. The CT’s have dual secondaries (3 pins). TheCT secondary wire marked 1 is connected topin 1 of the CT. CT secondary wire marked 2/3is connected to pin 2 for high voltage gensets orto pin 3 for low voltage gensets. (Refer to Re-connection Diagram.)

6-6

Grounding

The following is a brief description of system andequipment grounding of permanently installed ACgenerators within a facility wiring system. It is impor-tant to follow the requirements of the local electricalcode.

Figure 6-2 illustrates typical system grounding for a3-pole and a 4-pole automatic transfer switch(ATS). In the 3-pole ATS, note that the generatorneutral is connected to the ATS and is NOT bondedto ground at the generator. In the 4-pole ATS sys-tem, a grounding electrode conductor and a bond-ing jumper are used to connect the generator neu-tral to ground. In some installations, a CT may be re-quired for ground fault monitoring (refer to Figure6-2 for CT location).

Make sure the genset is grounded to earth in onelocation only. On generators without a circuit break-er, ground to the point indicated on the top of thegenerator. On gensets with circuit breakers, use theground lug provided in the circuit breaker box.

WARNING Electric current can cause severepersonal injury or death. Bonding and ground-ing must be done properly. All metallic partsthat could become energized under abnormalconditions must be properly grounded.

Typical requirements for bonding and groundingare given in the National Electrical Code, Article250. All connections, wire sizes, etc. must conformto the requirements of the electrical codes in effectat the installation site.

3-POLE AUTOMATICTRANSFER SWITCH

4-POLE AUTOMATICTRANSFER SWITCH

GENERATOR SET

GENERATOR SETSERVICE ENTRANCE

4 WIRES & GROUNDTO LOAD

4 WIRES & GROUNDTO LOAD

GROUNDINGELECTRODECONDUCTOR

BONDINGJUMPER

CT LOCATION IFREQUIRED FOR

GFI MONITORING

3

NTO UTILITYSERVICE

SERVICE ENTRANCE

3

N

TO UTILITYSERVICE

FIGURE 6-2. TYPICAL SYSTEM GROUNDING ONE-LINE DIAGRAMS

6-7

CONTROL HEATER (OPTIONAL)A control heater (Figure 6-3) provides a means ofhumidity /temperature control of the control box in-

terior. It protects the components when the genera-tor set is subjected to varying ambient air conditionsduring extended periods of non-use.

HEATER

BOTTOM VIEW OFCONTROL BOX

TO ACCESSORY BOXA40−TB1-36 & 37

FIGURE 6-3. OPTIONAL CONTROL HEATER

6-8

COOLANT HEATER

The coolant heater keeps engine coolant warmwhen the engine is shut down. It heats and circu-lates the coolant within the engine. This reducesstartup time and lessens engine wear caused bycold starts. It is electrically operated and thermo-statically controlled.

CAUTION The coolant heater must not be op-erated while the cooling system is empty ordamage to the heater will occur.

Figure 6-4 shows a typical coolant heater. Connectthe heater to a source of power that will be on duringthe time the engine is not running. Be sure the sup-

ply voltage and circuit amperage is correct for theheater element rating.

Refer to the Single/Dual Coolant Heater Diagram inSection 10 for coolant heater power connections/voltage selections.

A battery charger is required to prevent battery dis-charge. The heater control relay draws 83 mA of cur-rent when the heater(s) is off. The heater is off whenthe engine has reached the proper temperature orthe engine is running.

CAUTION Do not connect AC power to theheater before connecting battery cables. Heaterwill run continuously without DC power andcan overheat and damage heater.

COOLANTFLOW

COOLANTFLOW

DRAIN

AC ELECTRICAL CONNECTIONBOX (ELECTRICAL DIAGRAM

INSIDE COVER)

THERMOSTAT

AC POWERLINEDC CONTROL

LINE

DC SUPPLYLINE

FIGURE 6-4. TYPICAL COOLANT HEATER

6-9

GENERATOR HEATERA generator heater(s) is used to help keep the gen-erator free of condensation when the generator setis not running. During cool and humid conditions,condensation can form within a generator, creatingflashing and a shock hazard.

WARNING Water or moisture inside a genera-tor increases the possibility of flashing andelectrical shock, which can cause equipmentdamage and severe personal injury or death. Donot use a generator which is not dry inside andout.

Figure 6-5 illustrates the installation of two heaterelements. Connect the heater(s) terminals to asource of power that will be on during the time theengine is not running. Be sure the supply voltageand circuit amperage is correct for the heater ele-ment rating.

HEATER LEADS

HEATER

TERMINALBLOCK

HEATERS

VOLT/WATTSLABEL

HEATER LEADS

TERMINAL BOXHEATER

FIGURE 6-5. TYPICAL GENERATOR HEATER INSTALLATION

6-10

FUEL TRANSFER PUMP

A fuel transfer pump and control are available whena sub-base or in-skid day tank are provided. The au-tomatic control operates the fuel pump to maintain areservoir of fuel in the day tank.

WARNING Diesel fuel is highly combustible.Improper installation of this kit can lead to spill-age of large quantities of fuel and loss of life andproperty if the fuel is accidentally ignited. Instal-lation and service must be performed by trainedand experienced persons in accordance withthe applicable codes.

Do not smoke near fuel and keep flames,sparks, pilot lights, arcing switches and equip-ment, and other sources of ignition well away.

CONTROL

FUELGAUGE

FLEXIBLE FUELSUPPLY LINE

FLEXIBLE FUELRETURN LINE

DAYTANK

FLOAT SWITCHASSEMBLY

FUEL FILLCAP

FUEL PUMPAND MOTOR

FIGURE 6-6. TYPICAL IN-SKID DAY TANK INSTALLATION

6-11

Fuel Pump Control AC Connections

The control can be powered by 120 VAC or 240VAC. The control is set up at the factory for connec-tion to 240 VAC.

1. To convert the day tank controller from 240VAC to 120 VAC, perform the following steps.

A. Remove the two jumpers between termi-nals TB1-6 and TB1-7 in the control boxand connect one between terminalsTB1-5 and TB1-6 and the other betweenterminals TB1-7 and TB1-8.

B. Move selector switch S103 on the controlPCB to the up position for 120V.

C. If the control is equipped with a transform-er, remove the two jumpers between ter-minals H2 and H3 and connect one be-tween H1 and H3 and the other betweenH2 and H4.

2. To convert the day tank controller from 120VAC to 240 VAC, perform the following steps.

A. Remove the jumpers between terminalsTB1-5 and TB1-6, and TB1-7 and TB1-8in the control box and connect the twojumpers between terminals TB1-6 andTB1-7.

B. Move selector switch S103 on the controlPCB to the down position for 240 VAC.

C. If the control is equipped with a transform-er, remove the jumpers between terminalsH1 and H3, and H2 and H4 and connectthe two jumpers between H2 and H3.

3 Attach a tag to the control box indicating thesupply voltage.

4 Terminals TB1-8 and TB1-5 are available forconnection of a 120 or 240 VAC electric fuelshutoff valve rated not more than 0.5 amps.The voltage rating of the valve must corre-spond with the voltage utilized for the pump.See Item 2 above.

FIGURE 6-7. FUEL PUMP CONTROL TERMINAL BOARD

6-12

GROUND FAULT ALARM RELAY(OPTIONAL)

The optional Ground Fault Relay (GFR) (Figure6-8) is typically located behind the lower controlhousing grille. The ground fault relay continuouslymonitors the neutral to ground connection and acti-vates a fault alarm when the connection is broken.During genset operation, the relay continuouslymonitors the line to neutral and activates a faultalarm when a ground fault is sensed.

The relay alarm contacts are typically connected tothe genset control to provide a “Ground FaultAlarm” indication.

A control reset will clear the fault at the control paneland will also reset the ground fault relay.

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

Adjust the Current and the Time Delay controls onthe ground fault relay to the customers specifica-tions.

After the installation of the genset is complete, per-form the following procedure to test the operation ofthe ground fault relay.

A. Verify that the N-G Fault Indicator on theGFR is not lit. If lit, it indicates that thebonding jumper circuit (neutral to ground)is open. If genset does not require bondingjumper, a bonding jumper must beinstalled at the facility service entrance.

A. Move the control switch to the Run posi-tion.

B. Press the TEST switch on the ground faultrelay.

C. Verify that the control panel warning mes-sage is displayed and the Fault Indicator(>I) on the GFR is lit.

D. Reset the control panel fault (this will alsoreset the ground fault relay).

6-13

RESET BUTTON(N.U., FACTORY SET

TO AUTO RESET)

TEST BUTTON

TIME DELAY CONTROL

CURRENT CONTROL

ON INDICATOR

FAULT INDICATORS

> I (OVER CURRENT)

N−G(OPEN CIRCUIT)

GROUND FAULTRELAY

ASSEMBLY

GRILLE

CONTROLHOUSING

FIGURE 6-8. GROUND FAULT ALARM RELAY

6-14

THIS PAGE LEFT INTENTIONALLY BLANK

7-1

7. Enclosure Electrical Connections

GENERAL

Generator sets configured with an enclosure cancontain one or more optional features. The optionalfeatures that require electrical connections wheninstalling the generator set are described in thissection. For wiring diagrams of enclosure options,refer to Section 10, Wiring Diagrams.

CAUTION Flexible conduit and stranded con-ductors must be used for connections to takeup movement of the genset. Solid copper wiremay break due to genset vibration.

Figure 7-1 shows the location of the optional fea-tures within the enclosure.

EMERGENCYSTOP SWITCH

120 VACEXTERNAL

RECEPTACLE

AC DISTRIBUTIONPANEL

MOTORIZEDOUTLET LOUVER

FUEL TRANSFERPUMP AND CONTROL

EXTERNALFUEL FILL BOX

EXTERNALFUEL ALARM

PANEL

INTERNAL FUELALARM PANEL

ENCLOSURELIGHTING

GENSET CONTROLPANEL

MOTORIZEDINLET LOUVER

FIGURE 7-1. OPTIONAL ENCLOSURE FEATURES

7-2

OPTIONAL AC DISTRIBUTION PANELThe AC distribution panel (Figure 7-2) provides acentralized power source (120/220VAC) for all op-tional enclosure features.

CAUTION Make sure all circuit breakers are inthe OFF position before applying power to theAC distribution panel. Other options may re-quire additional installation before connectingto power.

CAUTION When the generator set containsthe fuel transfer pump option, power to the ACdistribution panel must be fed from a transferswitch and step-down transformer to maintain120V power to the pump when utility power is in-terrupted. If the transfer pump option is notinstalled, power to the AC distribution panel canbe fed from a non-emergency source. (Other op-tional features connected to the AC distributionpanel are not needed for generator set opera-tion.)

All connections to the AC distribution panel are to bedone in compliance with the National Electric Codeand all applicable local codes and standards using60 or 75 degree conductors.

The AC distribution panel is designed to be fed witha 150AMP, 120/240VAC, single phase feeder. Thetwo line conductors connect into the 150AMP mainbreaker that is listed for #4 to 2/0 conductors, AL orCU when torqued to 50 in-lbs.

The neutral conductor connects into the neutral buswhich is listed for #5 to 300KCMIL conductors, AL orCU when torqued to 21 ft-lbs.

The grounding conductor, if used, connects into theground bar which is listed for #1 to 2/0 conductors,AL or CU when torqued to 17 ft-lbs.

7-3

120VAC RECEPTACLESFOR OPTIONAL FEATURES

24 VACTRANSFORMERS

(LOUVER MOTORS)

1/2

CIRCUIT BREAKERS1/2: 150A MAIN

3/5 : 40A COOLANT HEATERS

7/9: 40A COOLANT HEATERS

11/13: 40A ENCLOSURE HEATER

4: 20A ENCLOSURE LIGHTS RECEPTACLE

6: 20A INTERNAL/EXTERNALSERVICE RECEPTACLES

8: 20A INLET/OUTLET LOUVERS

10: 20A J1/J2 RECEPTACLES

12: 20A J3/J4 RECEPTACLES

14: SPARE

J1: ENGINE OIL HEATER

J2: BATTERY HEATER

J3: ALTERNATOR/CONTROLCABINET HEATERS

J4: BATTERY CHARGER/TRANS-FER PUMP CONTROLLER

J5: GFCI SERVICE RECEPTACLE

J7: ENCLOSURE LIGHTS RECEP-TACLE

J1 J2

J3 J4

4

6

10

12

14

3/5

7/9

11/13

J7

J58

FIGURE 7-2. AC DISTRIBUTION PANEL FEATURES

7-4

OPTIONAL MOTORIZED INLET/OUTLETLOUVERS

Louvers (inlet and/or outlet) are powered by either24VDC supplied by genset control switched B+ or24VAC transformer connected to shore power.

With switched B+ or gensets having the AC distribu-tion panel, the motorized louvers are prewired andrequire no further installation (Figure 7-3).

Without the AC distribution panel, the 24VAC lou-vers are not prewired. Louvers operating on 24VACrequire 30VA, 24 volt class 2 transformer(s). (Trans-formers are not supplied with genset that does notcontain an AC distribution panel.) Mount and con-nect the transformer(s) to the 18 gauge wires termi-nated at the AC distribution panel location. Connectthe transformer(s) to a source of power that will beon during the time the engine is not running.

30VACTRANSFORMER(S)

AC DISTRIBUTIONPANEL

MOTORIZEDOUTLET LOUVER

ENCLOSURELIGHTING

MOTORIZEDINLET LOUVER

FIGURE 7-3. MOTORIZED LOUVERS

7-5

OPTIONAL FUEL TRANSFER PUMP

A fuel transfer pump and control are available whena sub-base fuel tank is provided. The automaticcontrol operates the fuel pump to maintain a reser-voir of fuel in the sub-base tank.

CAUTION Power to the fuel transfer pumpmust be fed from a transfer switch and step-down transformer to maintain 120V power to thepump when utility power is interrupted. Powermust be supplied to the transfer pump duringthe time the genset is running or not running.

The fuel transfer pump/controller is prewired andready to connect to a 120VAC source.

CAUTION Do not connect AC power to the fueltransfer pump control without having fuel in thesupply tank. Damage to the pump can occur ifpump operates with no fuel in supply tank.

Supply Tank

Refer to Section 4 for information regarding theinstallation/plumping of the supply tank to the sub-base fuel tank.

The fuel transfer pump has a maximum inlet restric-tion capability of 16 inch Hg (which is approximatelyequivalent to 20 feet of diesel).

TO 120 VACEMERGENCY SUPPLY

FUEL SYSTEMCONTROL

EXTERNALFUEL FILL BOX

EXTERNALFUEL ALARM

PANEL

INTERNAL FUELALARM PANEL

FIGURE 7-4. FUEL TRANSFER PUMP/CONTROL LOCATION

7-6

Main Supply Tank Low Fuel Switch

The fuel control system provides a low fuel switchinput, which is used to disable the fuel transferpump and light the low fuel indicator. Fuel pumpdamage will occur if pump operates with no fuel insupply tank.

Connect the leads of the main supply tank low fuelswitch (if provided) to P204-3 & 4 of the fuel systemcontrol board.

Switch S3 on the fuel system control board is usedto select the desired input (N.O. or N.C.). If the fuelswitch opens during a low fuel condition, place S3 inthe N.C. position; If it closes, place S3 in the N.O.position.

If the Low Fuel input is not used, S3 must be set to theN.O. position to allow pump operation.

LOW FUELINPUT P204

S3

N.O.

N.C.

FIGURE 7-5. FUEL SYSTEM CONTROL BOARD

8-1

8. Prestart Preparation

GENERAL

Before attempting the initial start of the generatorset, be sure to complete the Installation Checklist inSection 9.

PCC POWER ON / STANDBY MODE

WARNING Ignition of explosive battery gasescan cause severe personal injury or death. Arc-ing at battery terminals, light switch or otherequipment, flame, pilot lights and sparks can ig-nite battery gas. Do not smoke, or switchtrouble light ON or OFF near battery. Dischargestatic electricity from body before touching bat-teries by first touching a grounded metal sur-face.

Ventilate battery area before working on or nearbattery—Wear goggles—Stop genset and dis-connect charger before disconnecting batterycables—Disconnect negative (−) cable first andreconnect last.

CAUTION Disconnect battery charger from ACsource before disconnecting battery cables.Otherwise, disconnecting cables can result involtage spikes damaging to DC control circuitsof the set.

WARNING Accidental starting of the generatorset can cause severe personal injury or death.Prevent accidental starting by disconnectingthe negative (−) cable from the battery terminal.

Before opening the PCC control cabinet to makethe following Power On/Standby Mode selection,remove the negative (−) battery cable(s) from thegenerator set starting battery as follows:

1. Move the Run/Off/Auto switch on the controlpanel to the OFF position.

2. Turn off or remove AC power from the batterycharger.

3. Remove the negative (−) battery cable from thegenerator set starting battery.

8-2

Selecting Power On or Standby Mode

CAUTION Electrostatic discharge will damagecircuit boards. To prevent this damage, alwayswear a grounding wrist strap when working in-side control box.

Set the Power On / Standby Mode switch (S5 in Fig-ure 8-1) to the desired position.

Power On Mode: Slide the switch to the left to se-lect the Power On (awake) mode. It is recom-mended that switch S5 be left in the Power On modein all applications, except those where batterycharging is not available.

The PCC will initialize the operating software andpermit operation of the menu display panel. Powerwill stay on until the switch is reset to the StandbyMode.

Standby Mode: Slide the switch to the right to se-lect the Standby (sleep) Mode. In this mode, thePCC operating software will be initiated by:

moving the Run/Off/Auto switch to the Runposition,

pressing the Self Test button,

a remote start input signal (genset in Automode), or

any one of several “wake-up” signals from ex-ternal switches.

With the switch set to Standby mode, pressing theSelf Test button will allow you to activate and viewthe menu displays without starting the generatorset. If no menu selections are made, a software tim-er will shut down the power after 30 seconds.

When left in the Standby Mode, and a “Warning”signal is sensed by the PCC (for example, low en-gine temp), the control will wake up and display thewarning message. The control will remain activeuntil the warning condition is corrected and the Re-set button is pressed to clear the warning message.

CUSTOMER INTERFACE(A34)

ENGINE INTERFACE(A31)

ANALOG BOARD(A33)

DIGITAL BOARD(A32)

DISPLAY BOARD (A35)

PCC POWER ON / STANDBYMODE SWITCH (S5)

FIGURE 8-1. CABINET INTERIOR (PCC 3100)

8-3

ELECTRICAL SYSTEMVerify all electrical connections are secure and allwiring is complete and inspected. Replace and se-cure any access panels that may have been re-moved during installation.

Battery ConnectionsWARNING Accidental starting of the generator

set can cause severe personal injury or death.Make sure that the Run/Off/Auto switch on thecontrol panel is set to the Off position beforeconnecting the battery cables.

Starting the unit requires 24 volt battery current, us-ing two 12 volt batteries (see Specification section).Connect the batteries in series (negative post of firstbattery to the positive post of the second battery) asshown in Figure 8-2.

Service the batteries as necessary. If an automatictransfer switch is installed without a built-in chargecircuit, connect a separate battery charger. A bat-tery charger is required when the PowerCommandcontrol is set to the Power On (awake) mode.

WARNING Ignition of explosive battery gasescan cause severe personal injury or death. Al-ways connect negative (−) battery cable last toprevent arcing.

WARNING Ventilate battery area before work-ing on or near battery. Arcing at battery termi-nals, light switch or other equipment, flame, pi-lot lights and sparks can ignite battery gas. Donot smoke, or switch trouble light ON or OFFnear battery. Discharge static electricity frombody before touching batteries by first touchinga grounded metal surface.

TWO, 12 VOLTBATTERIES

POSITIVE

NEGATIVE

FIGURE 8-2. GENERATOR SET BATTERYCONNECTIONS

8-4

PCC OPTIONS PRESTART CHECKS

All generator set configuration options are set at thefactory except for site related options, (e.g., Start/Stop Time Delays, Cycle Crank, Customer Fault 1and 2, etc..

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

The Setup/Calibrate submenus are intended forqualified service personnel only and require a pass-word to modify these submenus. The Adjust sub-menus are intended for service personnel and sitepersonnel.

The Adjust submenus allow site personnel to cali-brate the generator set voltage/frequency, idlespeed and start/stop time delays. For the prestartchecks, adjustment of only the start/stop delays isrequired.

Adjust Menu

To adjust the start and stop delays, press the buttonnext to the word “ADJUST” in the Main Menu. Fig-ure 8-3 shows a block representation of the AD-JUST menu. After you press the button next to theword “ADJUST” in the display, the VOLTAGE sub-menu will appear.

As shown in the diagram, the ADJUST menu hasfive submenus, including a save/exit procedure. Tomove through the VOLTAGE and FREQUENCYsubmenus, press the button next to the ’>>’ to dis-play the STOP DELAY submenu.

START DELAY submenu: This delay applies onlyto remote starting in the Auto mode. Use the buttonsnext to the “” and “” symbols to set the start delay.The start delay adjustment range is 0 to 300 sec-onds.

STOP DELAY submenu: This delay applies onlyto remote stopping in the Auto mode. From theSTART DELAY submenu, press the button next tothe “>>” in the display to move to the STOP DELAYsubmenu. Use the buttons next to the “” and “”symbols to set the stop delay. The stop delay adjust-ment range is 0 to 600 seconds.

IDLE SPEED submenu: From the STOP DELAYsubmenu, press the button next to the “>>” in thedisplay to move to the IDLE SPEED submenu. Usethe buttons next to the “” and “” symbols to set theidle speed. The idle speed adjustment range is 800RPM 100 RPM. (Default value is 800 RPM.)

The idle speed can be adjusted only when the gener-ator set is running in the idle mode. When not in idlemode, N/A is displayed in RPM field.

SAVE/EXIT submenu: From the STOP DELAYsubmenu, press the button next to the “>>” in thedisplay to move to the SAVE/EXIT submenu. SelectSAVE to save your changes. At the CHANGESSAVED submenu, select EXIT to return to the Mainmenu.

If you select SAVE, the adjustments will be retainedafter shutdown, and will be in effect when the set isrestarted. If you select EXIT without saving first, theadjustments will remain in effect until the genset isshut down and return to the previous settings whenthe set is restarted.

8-5

< >< >

< >

< >

< >

< >

<

<

< >

<

< >

ENGINE GENADJUST >>

< >

< >

VOLTAGE

_______ >>

<

FREQUENCY

_______ >>

START DELAY

_______ SEC >>

STOP DELAY

_______SEC >>

< SAVEEXIT >>

< SAVEEXIT >>

< >

< SAVEEXIT >>

< >CHANGES SAVEDEXIT >>

CHANGES SAVEDEXIT >>

< VOLTAGE

_______ >>

ENGINE GENADJUST >>

< >

< >

< >

< VOLTAGE

_______ >>

ENGINE GENADJUST >>

< >

< >

ADJUST MENU

< >

< IDLE SPEED

_______RPM >>

Indicates �OR" Condition

FIGURE 8-3. ADJUST MENU

8-6

STARTING

Refer to the generator set Operator’s manual for im-portant safety precautions and recommended pro-cedures for starting the genset and verifying properoperation. Start the generator set and verify all en-gine and generator gauges are displaying the cor-rect values.

9-1

9. Installation Checklist

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 move-ment. 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, nearthe generator set, to protect the fuel system from damage caused by vibration, expansion and contrac-tion.

� Strainer or fuel screen (100 to 120 mesh) is installed in the fuel supply line to protect the fuel lift pump, daytank 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.

9-2

EXHAUST SYSTEM

� 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, orintake 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 approvedsecuring methods with no weight resting on engine exhaust components. There are no bends in flex sec-tion.

� 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.

10-1

10. Wiring Diagrams

GENERAL

This section consists of the schematic and connec-tion wiring diagrams referenced in the text. The fol-lowing drawings are included.

Page 10-2 − Customer Connections Diagram

Page 10-3 − Accessory Interconnect Diagram

Page 10-4 − Single/Dual Coolant Heater Wir-ing Diagram

Pages 10-5 and 10-6 − Enclosure/Options Wir-ing Diagrams

10-2

THIS PAGE LEFT INTENTIONALLY BLANK

310-3

No. 612-6658 sh 3 of 3Rev. D Sys: HPModified 8/13/97

THIS IS A REPRESENTATIVE (GENERIC) SCHEMATIC/WIRING DIAGRAM. FORTROUBLESHOOTING, REFER TO THEWIRING DIAGRAM PACKAGE THAT WASINCLUDED WITH YOUR GENSET.

PCC CUSTOMER CONNECTIONS

10-4

No. 630-1345 sh 1Rev. JModified 11/96

GENERATOR SETWITH PCC CONTROL

OT AND BT 2 WIRE STARTUTILITY TO GENSET

THIS IS A REPRESENTATIVE (GENERIC) SCHEMATIC/WIRING DIAGRAM. FORTROUBLESHOOTING, REFER TO THEWIRING DIAGRAM PACKAGE THAT WASINCLUDED WITH YOUR GENSET.

PCC ACCESSORY NTERCONNECT DIAGRAM

10-5

No. 500-3104 sh 1 of 1Rev. AModified 9/23/96

SINGLE COOLANT HEATER DIAGRAM DUAL COOLANT HEATER DIAGRAM

SINGLE/DUAL COOLANT HEATER DIAGRAMS

THIS IS A REPRESENTATIVE (GENERIC) SCHEMATIC/WIRING DIAGRAM. FORTROUBLESHOOTING, REFER TO THEWIRING DIAGRAM PACKAGE THAT WASINCLUDED WITH YOUR GENSET.

SINGLE/DUAL HEATER WIRING DIAGRAM

10-6

No. 620-0281 sh 1 of 2Rev. AModified 11-2004

THIS IS A REPRESENTATIVE DRAWING.FOR SERVICE, USE DRAWING SUPPLIEDWITH GENSET, IF AVAILABLE.

ENCLOSURE/OPTIONS WIRING (SHEET 1 OF 2)

10-7

No. 620-0281 sh 2 of 2Rev. AModified 11-2004

THIS IS A REPRESENTATIVE DRAWING.FOR SERVICE, USE DRAWING SUPPLIEDWITH GENSET, IF AVAILABLE.

ENCLOSURE/OPTIONS WIRING (SHEET 2 OF 2)

10-8

THIS PAGE LEFT INTENTIONALLY BLANK

Cummins Power Generation1400 73rd Ave. NEMinneapolis, MN 55432 USA

Phone 1 763 574 5000Toll-free 1 800 888 6626Fax 1 763 574 5298Email ask.powergen@cummins.comwww.cumminspower.comCummins�, the “C” logo, and “Our energy working for you.”are trademarks of Cummins Inc.

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