Installation Manual - Norwall PowerSystems · Natural gas is lighter than air, and will tend to gather under hoods. Propane is heavier than air, and will tend to gather in sumps or

Installation Manual

Generator Set

GGHE (Spec E−K)GGHF (Spec E−K)

with PowerCommand� 2100 Controller

English − Original Instructions 9−2010 928-0617 (Issue 5)

i

Table of Contents

SECTION TITLE PAGE

IMPORTANT SAFETY PRECAUTIONS iii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 INTRODUCTIONAbout 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 and Lighting 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 MECHANICAL CONNECTIONSGeneral 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust System 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ventilation and Cooling 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 DC CONTROL WIRINGControl Wiring 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB1 Remote Monitor/Control Connections 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . TB2 Power Transfer Control (PTC) Connections (Optional) 5-3. . . . . . . . . . . . Control Relays (K11, K12, K13) 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The engine exhaust from this productcontains chemicals known to the State

of California to cause cancer, birth defects or other reproductive harm.

! !

ii

SECTION TITLE PAGE

6 AC ELECTRICAL CONNECTIONSGeneral 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Switch 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Wiring 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Heater (Optional) 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant Heater (Optional) 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Heater (Optional) 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 PRESTART PREPARATIONGeneral 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . InPower Service Tool General Information 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . Electrical System 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PCC Options Prestart Checks 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 INSTALLATION CHECKLISTGeneral 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Set Support 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling Air Flow 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust System 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC and DC Wiring 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Set Prestart 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 WIRING DIAGRAMSGeneral 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MS-5iii

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 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 usecopper piping on flexible lines as copper will be-come brittle if continuously vibrated or repeatedlybent.

Natural gas is lighter than air, and will tend to gatherunder hoods. Propane is heavier than air, and willtend to gather in sumps or low areas. NFPA code re-

quires all persons handling propane to be trainedand qualified.

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. Jewelry can short out elec-trical contacts and cause shock or burning.

If adjustment must be made while the unit is run-ning, use extreme caution around hot manifolds,moving parts, etc.

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.

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.

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.

Benzene and lead, found in some gasoline, havebeen identified by some state and federal agenciesas causing cancer or reproductive toxicity. Whenchecking, draining or adding gasoline, take care notto ingest, breathe the fumes, or contact gasoline.

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.

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

1-1

1. Introduction

Beginning with spec J, read the warranty statementprovided with the genset for US EnvironmentalProtection Agency (EPA) restrictions on servicingspecific components.

ABOUT THIS MANUALThis 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 and Electrical Connections -covers most aspects of the generator set instal-lation.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 Sheet and Data Sheet. For application infor-mation, refer to Application Manual T-030, “LiquidCooled Generator Sets”. To find this manual online:

1. Go to http://www.cumminspower.com

2. Click on “Application Engineering” under head-ing Technical Information

3. Click on “Liquid Cooled Genset ApplicationManual.

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 so allcomponents are assembled using standard meth-ods 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 GGHE/GGHF

EngineOnan Modified Ford V-10 WSG-1068

Generator kW Rating See Genset Nameplate for rating information.

Engine Fuel ConnectionInlet/Outlet Size Refer to Generator Outline Drawing

Fuel or a combination of two fuels Propane (Liquid or Vapor)Natural Gas

Fuel Flow (Inlet Pressure)Minimum:

NG/LPG

Maximum:NG/LPG Vapor withdrawalLPG Liquid withdrawal

7.0 inch H2O (1.7 kPa)

13.6 inch H2O (3.4 kPa)312 psi (2,153 kPa)

ExhaustConnectionBackpressure (Max. Allowed)

3 inch NPT20 inch H2O (5.0 kPa)

Electrical SystemStarting VoltageBattery Charging Alternator (Max. Rating)

12 Volts DC37 A

Cooling SystemCapacity with Standard Radiator 8.5 Gal (32.2 L)

Lubricating SystemOil Capacity with Filters

Standby Power (Normal Oil Filter)Prime Power (Heavy Duty Oil Filter)

6.5 Qts (6.2 L)11 (10.4 L)

Tune-up SpecificationsSpark Plug Gap 0.044

(1.1 mm)

BatteryGroundRequired Battery VoltageGroup NumberCCA (minimum)

Cold Soak @ 0 F (-18 C)

Negative12 Volts DC

31

660

FUEL CONSUMPTION (STANDBY/PRIME/60HZ)

MODEL GGHE GGHF

Standby cfh (m3/hr)

LPG (Vapor or Liquid)Natural Gas

313 (8.86)798 (22.34)

366 (10.36)898 (25.43)

Full Loadcfh (m3/hr)

LPG (Vapor or Liquid)Natural Gas

277 (7.84)705 (19.95)

320 (9.06)807 (22.84)

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THIS PAGE LEFT INTENTIONALLY BLANK

3-1

3. Mounting the Generator Set

GENERALGenerator 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. Considerthese requirements before installation: Level mounting surface Adequate cooling air Adequate fresh induction air Discharge of generator set air Non-combustible mounting surface Discharge of exhaust gases

Electrical connections

Accessibility for operation and servicing

Noise levels

Vibration isolation

LOCATIONGenerator 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. An optional housing isavailable for outside operation.

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

MOUNTING

Generator 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 generator set skid to the floor to preventmovement. Secure the skid using a flat washer anda hex nut for each bolt (Figure 3-1). The 1-1/2 x 6inch pipe inserted over the mounting bolts allowsminor adjustment of the bolts to align them to theholes in the subbase or vibration isolator.

ACCESS TO SET

Generally, at least 1 meter (3 feet) of clearanceshould be provided on all sides of the generator setfor maintenance and service access. (Increaseclearance by width of door if optional housing isused.) A raised foundation or slab of 150 mm (6inches) or more above floor level will make servic-ing 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

ÇÇÇ

ÇÇ

FIGURE 3-1. BOLT DIAGRAM

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.

All pipe threaded fuel system fittings, including con-tainer fittings, must be assembled using a pipe jointsealing compound designed for use with LPG/NG.

FUEL SYSTEM

Gensets can be equipped to operate on:

LPG (vapor or liquid withdrawal)

NG (natural gas) or

Combination (NG/LPG)

In all fuel system installations, cleanliness is of theupmost importance. Make every effort to prevententrance of moisture, dirt or contaminants of anykind. Clean all fuel system components beforeinstalling

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 line to protect the fuel sys-tem from damage caused by vibration, expansionand contraction.

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.

Installation of the fuel hose must be done accordingto all applicable codes and standards, and installa-

tion recommendations provided by the manufactur-er. The flexible hose used must be 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 a2 inch (51 mm) minimum clearance from electricalwiring and hot exhaust parts.

Natural Gas/LPG Vapor/LPG Liquid FuelSystem

WARNING Gaseous fuels are flammable andexplosive and can cause severe personal injuryor death. Do not smoke if you smell gas or arenear fuel tanks or fuel-burning equipment or arein an area sharing ventilation with such equip-ment. Keep flames, sparks, pilot lights, electri-cal arcs and arc-producing equipment and allother sources of ignition well away from gensetand areas sharing ventilation. Keep a type ABCfire extinguisher handy.

NFPA Standard No. 58 requires all persons han-dling and operating LPG to be trained in properhandling and operating procedures.

Gaseous-fuel supply system design, materials,components, fabrication, assembly, installation,testing, inspection, operation and maintenancemust comply with the applicable codes. See NFPAStandards No. 37, No. 54 and No. 58.

4-2

Most codes require both manual and electric (bat-tery-powered) shutoff valves ahead of the flexiblefuel hose(s). The manual valve should be of the in-dicating type. The electric valve should be wired sothat the valve is closed when the genset is off.

Install a dry-type fuel filter ahead of the servicepressure regulator to protect the sensitive pressureregulating components and orifices downstreamfrom rust, scale and other solid substances carriedalong in the gas stream.

See Specifications section for natural gas/LPG fuelinlet size. The recommendations in ApplicationManual T-030, should be followed in regard to fuelsupply system pipe sizes, manual shutoff valves,fuel filters and gas pressure regulators.

Fuel Pressure

WARNING High gas supply pressure can causegas leaks which can lead to fire and severe per-sonal injury or death. Gas supply pressure mustbe adjusted to Specifications by qualified per-sonnel.

The gas pressure regulators in each line provideconstant gas pressure at the gas mixer under vary-ing load conditions. There are pressure test portson both sides of the regulator for measuring supplyand regulated fuel pressures (NG or LPG systems).When measuring supply pressure, the most accu-rate reading would be on the input side of the sole-noid valve.

Mixer side: The NG gas pressure should beapproximately 5 inches WC (1.3 kPa) at full load.

The LP gas pressure will be approximately negative0.5 inches WC (0.13 kPa) at no load and a negativepressure of 1.0 inch WC (0.249 kPa) at full load.

Supply side: The minimum pressure refers to sup-ply pressure under rated load (maximum gas flow).

For LPG (vapor withdrawal) and NG, the maximumpermissible fuel supply pressure is 13.6 inches WC(3.4 kPa) and the recommended minimum is 7 inch-es WC (1.7 kPa).

For LPG (liquid withdrawal), the maximum permis-sible fuel supply pressure is 312 psi (2,153 kPa) un-der any operating condition.

WARNING Gaseous fuel leaks into an inade-quately ventilated space can lead to explosiveaccumulations of gas. Natural gas rises whenreleased into the air and can accumulate underoverhanging hoods and inside housings andbuildings. LPG sinks when released into the airand can accumulate inside housings, base-ments and other below-grade spaces. Precau-tions must be taken to prevent gas leaks and theaccumulation of gaseous fuel in the event of aleak.

Check Gas Leaks and Correct

All fuel-system connections, including the containerwith associated valves and fittings, must be testedfor leaks with a soap and water solution or equiva-lent, while the system is under pressure. LP gaspressure should not be less than 90 psi (621 kPa) atthe inlet of the primary regulator for this test.

4-3

EXHAUST SYSTEM

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.

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.

The exhaust system must be designed to minimizebackpressure on the engine. Excessive exhaust re-striction will result in increased fuel consumption,abnormally high exhaust temperature and failuresrelated to high exhaust temperature.

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 4-1) 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.

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.

CAUTION Weight applied to the engine man-ifold can result in damage. Support the mufflerand exhaust piping so no weight or stress is ap-plied to engine exhaust.

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 to the exhaust system becomes the respon-sibility of the person installing the unapproved muf-fler or performing the modification. Contact a Cum-mins Power Generation distributor for approved ex-haust system parts.

4-4

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 4-2).

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

WALL OR PARTITION

HORIZONTAL

VERTICAL

9 INCH(230 mm)

HOLES INEND OF INNER

SLEEVE

9 INCH(230 mm)

FIGURE 4-1. MOUNTING EXHAUST THIMBLE

AVOIDSHARPBENDS

IF EXHAUST LINE MUST BEPITCHED UPWARD, CONSTRUCT

A TRAP AT POINT OF RISE

DRAIN CONDENSATIONTRAP PERIODICALLY

VALVE HANDLE SHOWNIN OPEN POSITION

FIGURE 4-2. CONDENSATION TRAP

4-5

VENTILATION AND COOLINGGenerator sets dissipate heat and fumes that mustbe removed by proper cooling and ventilation.

Generator sets in factory-mounted housings foroutdoor installation are designed for proper coolingand ventilation.

Indoor installations require careful design with re-spect to cooling and ventilation. In an indoor instal-lation, all radiator cooling air must be discharged tothe out-of-doors. Duct adapter kits are available.See Figure 4-4 for a typical indoor installation.

WARNING Engine or radiator cooling air maycarry deadly carbon monoxide gas which cancause asphyxiation and death. All engine or ra-diator cooling air must be discharged to the out-of-doors. Do not use it for heating a room orcompartment.

Vents and DuctsFor 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 4-3.

PREVAILING WINDS PREVAILING WINDS

NOT LESS THANHEIGHT OF OPENING

FIGURE 4-3. WIND BARRIER

4-6

Dampers

Dampers or louvres protect the generator set andequipment room from the outside environment.Their operation of opening and closing should becontrolled by operation of the generator set.

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 generatorset engine is still cold, increasing the engine effi-ciency.

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 4-4). Locate the air inlet to therear of the set. Make the inlet vent opening 1-1/2times 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 air outletopening using screws and nuts so duct can be re-moved for maintenance purposes. The duct pre-vents recirculation of heated air. Before installingthe duct, remove the radiator core guard.

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 engine coolant heater is available tokeep the engine warm for improved starting andcode compliance. Connect the heater to a powersource that will be energized when the engine isNOT running.

4-7

MUFFLER

THIMBLE

AIR OUT

COOLING AIR INLET MUST BE AT LEAST 1-1/2 TIMES LARGERTHAN RADIATOR DUCT OUTLET AREA ON RADIATOR-COOLED

MODELS.

FLOW OF COOLING AIR AND HEATED AIR MAY BECONTROLLED BY AUTOMATICALLY OPERATED LOUVRES.

IMPORTANT!

EXHAUSTLINE

SWEEPINGELBOW

CONTROLWIRING

FLEXIBLESECTIONS

POWERWIRING

VIBRATIONISOLATORS

LEVELCONCRETE

BASE

CONDENSATIONDRAIN PLUG

AIRIN

FLEXIBLEBELLOWS

FIGURE 4-4. TYPICAL GENERATOR SET INSTALLATION

4-8

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5-1

5. DC Control Wiring

CONTROL WIRING

The generator set control panel box contains con-nection points for remote control and monitor op-tions.

CAUTION Stranded copper wire must be usedfor all customer connections to the control pan-el. Solid copper wire may break due to gensetvibration.

Use flexible conduit for all wiring connections to thegenerator set. All conduit used for control wiring isattached to the control housing.

Route the control wiring through the control housingand into the access holes on the bottom of the con-trol panel box. Figure 5-1 also shows the accessholes that should be used according to where thewires are terminated inside the control box.

A compression type strain-relief connector shouldbe used to prevent dust, insects, etc. from enteringcontrol box.

Use cable ties to keep control wiring away fromsharp edges and AC power cables within the controlhousing.

TB1

TB2CONTROL RELAYS(K10, K11, K12) &CONTROL BOX

HEATER

STRAIN-RELIEFCONNECTOR

NETWORK COMMUNICATIONMODULE

FIGURE 5-1. SUGGESTED CUSTOMER WIRE ROUTING

5-2

TB1 REMOTE MONITOR/CONTROLCONNECTIONS

Customer monitor/control connections are at-tached to terminal block TB1 (Figure 5-2). Optionalequipment such as a remote annunciator panel,sensing devices used to monitor genset operation,remote start/stop switches, battery charger, etc. areattached to TB1. Refer to Customer Connectionsdiagram in Section 9.

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, otherthan 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 9 for the relay specifi-cations.

Network Connections: Refer to 900-0366 Power-Command Network Installation and Operationmanual for the type/gauge wire to use for these con-nections.

Switched B+: (Fused at 5 amps.) Same as RelayConnection description.

B+: (Fused at 10 amps.) Same as Relay Connec-tion description.

TB1 Customer Inputs

Refer to Page 9-2 for typical connections to TB1.

Remote Start: When the O/Manual/ Auto switch isin the Auto position, grounding this input initiatesthe engine cranking and start sequence. This circuitmust be opened to permit resetting a shutdown con-dition with the Reset input. (The remote stop is actu-ally the removal of the remote start signal to the con-trol.)

Remote Emergency Stop: Grounding this inputcauses an immediate shutdown. Emergency stopmust be reset at the front panel.

Remote Reset: When the O/Manual/ Auto switch isin the Auto position and the remote start switch isopen, grounding this input resets any warning andshutdown fault (except Emergency Stop, whichmust be reset at the genset front panel.)

Customer Fault Inputs 1 through 4: Groundingany one of these inputs activates the correspondingwarning or shutdown sequence.

All four customer inputs may not be available. Cus-tomer inputs can be prewired from the factory forgenset optional/standard features.

Beginning with spec J, customer input #4 is notavailable.

External sensing equipment must be connected tothe designated digital input.

The nature of the fault is an optional customerselection. Example inputs: Low Fuel Day Tank, Wa-ter In Fuel, Ground Fault, Low Starting HydraulicPressure, Low Starting Air Pressure, etc.

Each of the four fault functions can be programmed(using InPower), as follows:

Enable/disable input. Default setting:Enable 1 through 4

Status, Warning or Shutdown. Default setting:1 − None2 thru 4 − Warning

Active closed or open. Default setting:Closed [ground] 1 through 4

Change display name using up to 19 charac-ters. Default setting:

1 − Customer Fault 12 − Ground Fault3 − Low Fuel4 − Rupture Basin Fault

5-3

TB1 Customer Outputs

Refer to Page 9-2 for typical connections to TB1.

Customer Outputs 1 through 4: One set of nor-mally open (NO) contacts, rated for 2 amps at 30VDC for each of the four output signals. The relayscan be used to control small devices and indicatorlamps.

The nature of the customer output signal (contactsclosed) is an optional customer selection. Exampleoutputs: Genset running, common warning, com-mon fault, load shed, ready to load, etc.

Each relay can be independently programmed (us-ing InPower) to energize as follows.

Enable/disable output. Default setting:Enable 1 through 4

Status, Warning or Shutdown. Default setting:1 − Common warning2 − Common shutdown3 − Not in Auto4 − Ready to Load

The customer outputs can also be connected tothree control relays (optional) to operate larger

equipment, such as, fans, pumps and motorized airdampers. Refer to Control Relays in this section foradditional information.

B+: This is a fused 10 amp, 12/24 volt output. (FuseF1 is located on Base board.) Two terminals(TB1-17 and -18) are connected to this 10 amp cir-cuit.

Switched B+: This is a fused 5 amp, 12/24 voltswitched output. This output is activated when thecontrol receives a run command. (Fuse F2 is lo-cated on Base board.)

TB2 POWER TRANSFER CONTROL (PTC)CONNECTIONS (OPTIONAL)

TB2 is used to connect the optional PTC module tothe control. With this option installed, the control willmonitor the utility voltage (mains) and frequency forfailure. If power fails, the PTC control will start thegenerator, open the mains circuit breakers andclose the generator circuit breakers. Refer to Cus-tomer Connections diagram in Section 9 and instal-lation instructions sent with the PTC Module Kit.

5-4

TB2

TERMINALDIN RAIL

TERMINALEND BRACKET

TERMINALEND BRACKET

CONTROLRELAYS

SCREW

TB1

VOLTAGESUPPRESSOR

BASEBOARD

FIGURE 5-2. CONTROL PANEL BOX

5-5

CONTROL RELAYS (K10, K11, K12)

CAUTION Damage to the Base board can oc-cur if the voltage suppressors (Figures 5-2 and5-3) are not installed across relay coils (A1/A2)of control relays K11, K12 and K13 before con-necting genset battery cables.

The three optional control relays are rail mountedinside the control panel housing. Each relay is a

4-pole relay with 2 poles normally open and twopoles normally closed.

These relays (Figure 5-3) are used to control auxil-iary equipment, such as fans, pumps and motorizedair dampers. Energizing of the relays is user defin-able.

The contacts are rated at 10 amps at 600 VAC.

Refer to Customer Connections diagram in Sec-tion 9.

20 AWG Wire, UL Rated for 600 VAC

VOLTAGESUPPRESSOR

FIGURE 5-3. OPTIONAL CONTROL RELAYS (K10, K11, K12)

5-6

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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. Place the control panel run switch in theOFF position. Turn off or remove AC power from thebattery charger and then remove the negative (−)battery cable from the set starting battery.

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:

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. Do notconnect to any building electrical system ex-cept through an approved device and afterbuilding main switch is opened.

6-2

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

6-3

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 CT1, CT2 and CT3 on the reconnectionwiring diagram. (The Reconnection Diagram is lo-cated on the upper side cover of the control hous-ing.)

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. CT1 − U load leads (A phase),CT2 − V load leads (B phase)CT3 − W load leads (C phase)

C. Route the appropriate load wires through eachCT.

D. The CT’s have dual secondaries (3 posts). TheCT secondary wire marked 1 is connected topost 1 of the CT. CT secondary wire marked 2/3is connected to post 2 for high voltage gensetsor to post 3 for low voltage gensets. (Refer toReconnection Diagram.)

6-4

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.

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.

4-POLE ATSGENERATOR SETSERVICE ENTRANCE

LOAD

3-POLE ATSGENERATOR SETSERVICE ENTRANCE

LOADTHREE-PHASE, FOUR-WIRE UTILITY, THREE-POLE ATS

THREE-PHASE, FOUR-WIRE UTILITY, FOUR-POLE ATS

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

6-5

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

rior. It protects the components when the generatorset is subjected to varying ambient air conditionsduring extended periods of non-use.

HEATER

240V PLUG

THERMOSTAT

120V PLUG

FIGURE 6-3. OPTIONAL CONTROL HEATER

6-6

COOLANT HEATER (OPTIONAL)

Coolant heaters keep the 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 volt-age rating is correct for the heater element rating.

POWERPLUG

LOCATION

COOLANTHEATER

INLETHOSE

OUTLETHOSE

FIGURE 6-4. COOLANT HEATER

6-7

GENERATOR HEATER (OPTIONAL)A 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 may form within a generator, creatingflashing and shock hazards.

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) to a source of pow-er that will be on during the time the engine is notrunning. Power connections are made to the termi-nal block in the heater terminal box. Be sure the volt-age rating is correct for the heater element rating.

HEATER

HEATERTERMINAL BOX

(VIEW AA)

HEATERLEADS

FIGURE 6-5. TYPICAL GENERATOR HEATER INSTALLATION

6-8

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7-1

7. Prestart Preparation

GENERAL

Before attempting the initial start of the generatorset, be sure to complete the Installation Checklist inSection 8.

INPOWER SERVICE TOOLGENERAL INFORMATION

InPower is a PC based service tool for the Power-Command 2100 Control (PCC). Use InPower to:

Make adjustments to the control’s trims andsettings.

Perform diagnostics and monitoring.

Create a capture file of the controls trims andsettings.

Update control calibrations (InPower PRO ver-sion).

Refer to INPOWER User’s Guide for specifics.

InPower Adjust Mode

The adjustment feature allows you to make adjust-ments to genset parameters, calibrations and set-tings. There are several groups of adjustment pa-rameters; note that not all gensets will have thesame adjustments available.

InPower Capture File Description

InPower provides a method of extracting (captur-ing) a device’s parameter values. Capturing savesdevice information in a file that is identified with a.CAP extension.

Capture files are used to store a copy of the gen-set’s parameter values. During genset installation,it is suggested that a capture file be made beforeand after changes are made to the genset operatingparameters. This information can be a very useful

when troubleshooting the genset (determine if pa-rameters/settings have been modified after installa-tion) and when replacement of the Base board isnecessary. The capture file can be used as a tem-plate to write the previous settings to the new Baseboard software.

ELECTRICAL SYSTEM

Verify 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 Connections

WARNING Accidental starting of the generatorset 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 a 12 volt battery. Connectpositive battery cable before connecting negativebattery cable to prevent arcing.

Service the batteries as necessary. If an automatictransfer switch is installed without a built-in chargecircuit, connect a separate battery charger. Properselection and maintenance of batteries and batterychargers is essential for system reliability.

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.

7-2

PCC OPTIONS PRESTART CHECKS

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

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

The Setup submenus are intended for qualified ser-vice personnel only and require a password tomodify these submenus. The Controller Configura-tion and Adjust submenus are intended for servicepersonnel and site personnel.

The Controller Configuration submenus are used tochange the default language, temperature units,and pressure units to be displayed in menus.

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.

Controller Configuration

Figure 7-1 shows a block representation of the Con-troller Configuration menus.

To view the first Controller Configuration menu,make sure Main Menu 1 is displayed and simulta-neously press the Home Menu and Previous MainMenu buttons.

As shown in the diagram, the Controller Configura-tion menu has three submenus.

Press the buttons next to the and symbols in thedigital display to navigate between the menus.

Press the button next to the symbol in the displayuntil the + and − symbols are displayed.

Press the button next to the + or − symbol to selectthe desired option.

After selecting option, pressing the symbol resultsin the changes being saved. If the Home button orPrevious Main Menu button is pressed beforepressing the symbol, the changes are not saved.

Language Selected submenu: Used to select de-sired language (default = English).

Temperature Units submenu: Used to selectFahrenheit or Centigrade for temperature readings.

Fluid Pressure Units submenu: Used to selectPSI or kPA for pressure readings.

7-3

CONTROLLER CONFIGURATION MENU

EngineAlternator

AdjustMore>>

+Language Selected− English

Language SelectedEnglish

Temperature UnitsDeg F +Temperature Units

− Deg C

Fluid Pressure UnitsPSI +Fluid Pressure Units

− kPa

Back

Back

Back

Main Menu 1

FIGURE 7-1. CONTROLLER CONFIGURATION MENU

7-4

Adjust Menu

Figure 7-2 shows a block representation of the Ad-just menu. If you press the button next to the word“Adjust” in the display, the first Adjust submenu isdisplayed.

As shown in the diagram, the Adjust menu has fivesubmenus. Each submenu includes a parameter orvalue that can be changed.

Press the buttons next to the and symbols in thedigital display to navigate between the menus.Press the Home button or the Previous Main Menubutton to return to Main Menu 1.

Adjusting Values/Parameters:

1.. Press the button next to the symbol in the dis-play until the + and − symbols are displayed.

2.. If necessary, press the button next to the or symbols to move to the numeric character youwish to change.

3.. Press the button next to the + symbol to in-crease the value or select parameter; press thebutton next to the − symbol to decrease the val-ue or select parameter.

4.. After adjusting values/selecting parameters,pressing the symbol results in the changesbeing saved. (When adjusting values, makesure the cursor is on the last numeric characterbefore pressing the symbol).

If the Home button or Previous Main Menu but-ton is pressed before pressing the symbol,the changes are not saved.

Voltage Adjust submenu: Voltage can be ad-justed to �5 percent of the nominal voltage. For ex-ample, if genset output voltage is 208 volts, the volt-age can be adjusted from 197 to 218 volts.

If the revised value is greater or less than the allowed(5%) range, the control will round off the displayedvalue (up or down). For example, if changing the val-ue by −5% (maximum) equals 197.6, the display willshow 197, but will display and change the output to198 when saved.

Frequency Adjust submenu: Frequency can beadjusted to �5 percent of the nominal frequency.For example, if the genset frequency is 60.0 Hz, thefrequency can be adjusted from 57.0 to 63.0 Hz.

Start Delay submenu: Start Delay can be set from0 to 300 seconds (default = 0). This function is by-passed during a manual start/stop sequence.

Stop Delay submenu: Stop Delay can be set from0 to 600 seconds (default = 0). This function is by-passed during a manual start/stop sequence andengine shutdown faults.

Rated To Idle (Beginning Version 2.303): RatedTo Idle delay can be set from 0 to 10 seconds (de-fault = 0). (Enter 1 or more to enable.) Entering anon-zero delay will cause the genset to delay thetransition to Cooldown At Idle.

Idle Start submenu (Only available on somemodels): Idle Start can be enabled or disabled (de-fault = Disable). This function is only enabled whenthe genset is started in manual mode. Idle Start canalso be enabled while the set is running in manualmode.

Enabling Idle Start will cause the genset to run inidle mode until Idle Start is disabled. A warning isdisplayed if genset is left in idle more than 10 min-utes. Long periods of engine idling can eventuallyaffect engine performance and may void enginewarranty.

7-5

Voltage Adjustnnn V

Frequency Adjustnn.n Hz

Start Delaynnn Sec

+Voltage Adjust− nnn V

+Frequency Adjust− nn.n Hz

+Start Delay− nnn Sec

Back

Back

Back

ADJUST MENU

EngineAlternator

AdjustMore>>

Main Menu 1

Idle Start Disable

+Idle Start− Enable

Back

Stop Delaynnn Sec +Stop Delay

− nnn SecBack

Rated To Idle Delaynn Sec +Rated To Idle Delay

− nn SecBack

FIGURE 7-2. ADJUST MENU

7-6

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 menus are displaying the cor-rect values.

8-1

8. 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.

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.

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

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

8-2

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.

9-1

9. Wiring Diagrams

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

Page 9-3 − Customer Connections Diagram

9-2

THIS PAGE LEFT INTENTIONALLY BLANK

9-3

No. 620-0247 sh 1 of 1Rev. AModified 4-18-02

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

DEFAULT SETTING

CUSTOMER FAULTS:1 CUSTOMER FAULT 12 GROUND FAULT3 LOW FUEL4 RUPTURE BASIN FAULT

CUSTOMER RELAYS:1 COMMON WARNING2 COMMON SHUTDOWN3 NOT IN AUTO4 READY TO LOAD

DEFAULT SETTING

TB1-CUSTOMER FAULTS:1 CUSTOMER FAULT 12 GROUND FAULT3 LOW FUEL4 RUPTURE BASIN FAULT

TB1-CUSTOMER RELAYS:1 COMMON WARNING2 COMMON SHUTDOWN3 NOT IN AUTO4 READY TO LOAD

CUSTOMER CONNECTIONS DIAGRAM

9-2

THIS PAGE IS LEFT BLANK INTENTIONALLY.

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

Phone 1 763 574 5000Toll-free 1 800 888 6626Fax 1 763 574 5298Email [email protected]�, the “C” logo, and “Our energy working for you.”are trademarks of Cummins Inc.

�2010 Cummins Power Generation, Inc. All rights reserved.

Installation Manual

Generator Set

GGFDGGFE

with PowerCommand� 2100 Controller

English 04-2008 928-0616 (Issue 3)

i

Table of Contents

SECTION TITLE PAGE

IMPORTANT SAFETY PRECAUTIONS iii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 INTRODUCTIONAbout 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 MECHANICAL CONNECTIONSGeneral 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust System 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ventilation and Cooling 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 DC CONTROL WIRINGControl Wiring 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB1 Remote Monitor/Control Connections 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . TB2 Power Transfer Control (PTC) Connections (Optional) 5-3. . . . . . . . . . . . Control Relays (K11, K12, K13) 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The engine exhaust from this productcontains chemicals known to the State

of California to cause cancer, birth defects or other reproductive harm.

! !

ii

SECTION TITLE PAGE

6 AC ELECTRICAL CONNECTIONSGeneral 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Switch 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Wiring 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Heater (Optional) 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant Heater (Optional) 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Heater (Optional) 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 PRESTART PREPARATIONGeneral 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . InPower Service Tool General Information 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . Electrical System 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PCC Options Prestart Checks 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 INSTALLATION CHECKLISTGeneral 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Set Support 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling Air Flow 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust System 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC and DC Wiring 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Set Prestart 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 WIRING DIAGRAMSGeneral 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MS-5iii

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 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 usecopper piping on flexible lines as copper will be-come brittle if continuously vibrated or repeatedlybent.

Natural gas is lighter than air, and will tend to gatherunder hoods. Propane is heavier than air, and willtend to gather in sumps or low areas. NFPA code re-

quires all persons handling propane to be trainedand qualified.

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. Jewelry can short out elec-trical contacts and cause shock or burning.

If adjustment must be made while the unit is run-ning, use extreme caution around hot manifolds,moving parts, etc.

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.

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.

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.

Benzene and lead, found in some gasoline, havebeen identified by some state and federal agenciesas causing cancer or reproductive toxicity. Whenchecking, draining or adding gasoline, take care notto ingest, breathe the fumes, or contact gasoline.

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.

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

1-1

1. Introduction

ABOUT THIS MANUAL

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 and Electrical Connections -covers most aspects of the generator set instal-lation.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 Sheet and Data Sheet. For application infor-mation, refer to Application Manual T-030, “LiquidCooled Generator Sets”. To find this manual online:

4. Go to http://www.cumminspower.com

5. Click on “Application Engineering” under head-ing Technical Information

6. Click on “Liquid Cooled Genset ApplicationManual.

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 so allcomponents are assembled using standard meth-ods 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.

Copyright 2003 Cummins Power Generation. All rights reserved.

Cummins and PowerCommand are registered trademarks of Cummins Inc.

2-1

2. Specifications

MODEL GGFD/GGFE

EngineOnan Modified Ford V-6 ESG-642

Generator kW Rating See Genset Nameplate for rating information.

Engine Fuel ConnectionInlet/Outlet Size Refer to Generator Outline Drawing

Fuel or a combination of two fuels Propane (Liquid or Vapor)Natural Gas

Fuel Flow (Inlet Pressure)Minimum:

NG/LPG

Maximum:NG/LPG Vapor withdrawalLPG Liquid withdrawal

7.0 inch H2O (1.7 kPa)

13.6 inch H2O (3.4 kPa)312 psi (2,153 kPa)

ExhaustConnectionBackpressure (Max. Allowed)

3 inch NPT30 inch H2O (7.5 kPa)

Electrical SystemStarting VoltageBattery Charging Alternator (Max. Rating)

12 Volts DC37 A

Cooling SystemCapacity with Standard Radiator 7.0 Gal (26.5 L)

Lubricating SystemOil Capacity with Filters

Standby Power (Normal Oil Filter)Prime Power (Heavy Duty Oil Filter)

6.0 Qts (5.7 L)9.7 Qts (9.2 L)

Tune-up SpecificationsSpark Plug Gap 0.044

(1.1 mm)

BatteryGroundRequired Battery VoltageGroup NumberCCA (minimum)

Cold Soak @ 0 F (-18 C)

Negative12 Volts DC

31

660

FUEL CONSUMPTION (STANDBY/PRIME/60HZ)

MODEL GGFD GGFE

Standbycfh (m3/hr)

LPG (Vapor or Liquid)Natural Gas

191 (5.41)488 (13.82)

246 (6.97)579 (16.4)

Primecfh (m3/hr)

LPG (Vapor or Liquid)Natural Gas

172 (4.87)436 (12.35)

225 (6.37)507 (14.36)

2-2

THIS PAGE LEFT INTENTIONALLY BLANK

3-1

3. Mounting the Generator Set

GENERALGenerator 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. Considerthese requirements before installation: Level mounting surface Adequate cooling air Adequate fresh induction air Discharge of generator set air Non-combustible mounting surface Discharge of exhaust gases

Electrical connections

Accessibility for operation and servicing

Noise levels

Vibration isolation

LOCATIONGenerator 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. An optional housing isavailable for outside operation.

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

MOUNTING

Generator 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 generator set skid to the floor to preventmovement. Secure the skid using a flat washer anda hex nut for each bolt (Figure 3-1). The 1-1/2 x 6inch pipe inserted over the mounting bolts allowsminor adjustment of the bolts to align them to theholes in the subbase or vibration isolator.

ACCESS TO SET

Generally, at least 1 meter (3 feet) of clearanceshould be provided on all sides of the generator setfor maintenance and service access. (Increaseclearance by width of door if optional housing isused.) A raised foundation or slab of 150 mm (6inches) or more above floor level will make servic-ing 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

ÇÇÇ

ÇÇ

FIGURE 3-1. BOLT DIAGRAM

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.

All pipe threaded fuel system fittings, including con-tainer fittings, must be assembled using a pipe jointsealing compound designed for use with LPG/NG.

FUEL SYSTEM

Gensets can be equipped to operate on:

LPG (vapor or liquid withdrawal)

NG (natural gas) or

Combination (NG/LPG)

In all fuel system installations, cleanliness is of theupmost importance. Make every effort to prevententrance of moisture, dirt or contaminants of anykind. Clean all fuel system components beforeinstalling

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 line to protect the fuel sys-tem from damage caused by vibration, expansionand contraction.

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.

Installation of the fuel hose must be done accordingto all applicable codes and standards, and installa-

tion recommendations provided by the manufactur-er. The flexible hose used must be 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 a2 inch (51 mm) minimum clearance from electricalwiring and hot exhaust parts.

Natural Gas/LPG Vapor/LPG Liquid FuelSystem

WARNING Gaseous fuels are flammable andexplosive and can cause severe personal injuryor death. Do not smoke if you smell gas or arenear fuel tanks or fuel-burning equipment or arein an area sharing ventilation with such equip-ment. Keep flames, sparks, pilot lights, electri-cal arcs and arc-producing equipment and allother sources of ignition well away from gensetand areas sharing ventilation. Keep a type ABCfire extinguisher handy.

NFPA Standard No. 58 requires all persons han-dling and operating LPG to be trained in properhandling and operating procedures.

Gaseous-fuel supply system design, materials,components, fabrication, assembly, installation,testing, inspection, operation and maintenancemust comply with the applicable codes. See NFPAStandards No. 37, No. 54 and No. 58.

4-2

Most codes require both manual and electric (bat-tery-powered) shutoff valves ahead of the flexiblefuel hose(s). The manual valve should be of the in-dicating type. The electric valve should be wired sothat the valve is closed when the genset is off.

Install a dry-type fuel filter ahead of the servicepressure regulator to protect the sensitive pressureregulating components and orifices downstreamfrom rust, scale and other solid substances carriedalong in the gas stream.

See Specifications section for natural gas/LPG fuelinlet size. The recommendations in ApplicationManual T-030, should be followed in regard to fuelsupply system pipe sizes, manual shutoff valves,fuel filters and gas pressure regulators.

Fuel Pressure

WARNING High gas supply pressure can causegas leaks which can lead to fire and severe per-sonal injury or death. Gas supply pressure mustbe adjusted to Specifications by qualified per-sonnel.

The gas pressure regulators in each line provideconstant gas pressure at the gas mixer under vary-ing load conditions. There are pressure test portson both sides of the regulator for measuring supplyand regulated fuel pressures (NG or LPG systems).When measuring supply pressure, the most accu-rate reading would be on the input side of the sole-noid valve.

Mixer side: The NG gas pressure should beapproximately 5 inches WC (1.3 kPa) at full load.

The LP gas pressure will be approximately negative0.5 inches WC (0.13 kPa) at no load and a negativepressure of 1.0 inch WC (0.249 kPa) at full load.

Supply side: The minimum pressure refers to sup-ply pressure under rated load (maximum gas flow).

For LPG (vapor withdrawal) and NG, the maximumpermissible fuel supply pressure is 13.6 inches WC(3.4 kPa) and the recommended minimum is 7 inch-es WC (1.7 kPa).

For LPG (liquid withdrawal), the maximum permis-sible fuel supply pressure is 312 psi (2,153 kPa) un-der any operating condition.

WARNING Gaseous fuel leaks into an inade-quately ventilated space can lead to explosiveaccumulations of gas. Natural gas rises whenreleased into the air and can accumulate underoverhanging hoods and inside housings andbuildings. LPG sinks when released into the airand can accumulate inside housings, base-ments and other below-grade spaces. Precau-tions must be taken to prevent gas leaks and theaccumulation of gaseous fuel in the event of aleak.

Check Gas Leaks and Correct

All fuel-system connections, including the containerwith associated valves and fittings, must be testedfor leaks with a soap and water solution or equiva-lent, while the system is under pressure. LP gaspressure should not be less than 90 psi (621 kPa) atthe inlet of the primary regulator for this test.

4-3

EXHAUST SYSTEM

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.

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.

The exhaust system must be designed to minimizebackpressure on the engine. Excessive exhaust re-striction will result in increased fuel consumption,abnormally high exhaust temperature and failuresrelated to high exhaust temperature.

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 4-1) 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.

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.

CAUTION Weight applied to the engine man-ifold can result in damage. Support the mufflerand exhaust piping so no weight or stress is ap-plied to engine exhaust.

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 to the exhaust system becomes the respon-sibility of the person installing the unapproved muf-fler or performing the modification. Contact a Cum-mins Power Generation distributor for approved ex-haust system parts.

4-4

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 4-2).

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

WALL OR PARTITION

HORIZONTAL

VERTICAL

9 INCH(230 mm)

HOLES INEND OF INNER

SLEEVE

9 INCH(230 mm)

FIGURE 4-1. MOUNTING EXHAUST THIMBLE

AVOIDSHARPBENDS

IF EXHAUST LINE MUST BEPITCHED UPWARD, CONSTRUCT

A TRAP AT POINT OF RISE

DRAIN CONDENSATIONTRAP PERIODICALLY

VALVE HANDLE SHOWNIN OPEN POSITION

FIGURE 4-2. CONDENSATION TRAP

4-5

VENTILATION AND COOLINGGenerator sets dissipate heat and fumes that mustbe removed by proper cooling and ventilation.

Generator sets in factory-mounted housings foroutdoor installation are designed for proper coolingand ventilation.

Indoor installations require careful design with re-spect to cooling and ventilation. In an indoor instal-lation, all radiator cooling air must be discharged tothe out-of-doors. Duct adapter kits are available.See Figure 4-4 for a typical indoor installation.

WARNING Engine or radiator cooling air maycarry deadly carbon monoxide gas which cancause asphyxiation and death. All engine or ra-diator cooling air must be discharged to the out-of-doors. Do not use it for heating a room orcompartment.

Vents and DuctsFor 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 4-3.

PREVAILING WINDS PREVAILING WINDS

NOT LESS THANHEIGHT OF OPENING

FIGURE 4-3. WIND BARRIER

4-6

Dampers

Dampers or louvres protect the generator set andequipment room from the outside environment.Their operation of opening and closing should becontrolled by operation of the generator set.

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 generatorset engine is still cold, increasing the engine effi-ciency.

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 4-4). Locate the air inlet to therear of the set. Make the inlet vent opening 1-1/2times 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 air outletopening using screws and nuts so duct can be re-moved for maintenance purposes. The duct pre-vents recirculation of heated air. Before installingthe duct, remove the radiator core guard.

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 engine coolant heater is available tokeep the engine warm for improved starting andcode compliance. Connect the heater to a powersource that will be energized when the engine isNOT running.

4-7

MUFFLER

THIMBLE

AIR OUT

COOLING AIR INLET MUST BE AT LEAST 1-1/2 TIMES LARGERTHAN RADIATOR DUCT OUTLET AREA ON RADIATOR-COOLED

MODELS.

FLOW OF COOLING AIR AND HEATED AIR MAY BECONTROLLED BY AUTOMATICALLY OPERATED LOUVRES.

IMPORTANT!

EXHAUSTLINE

SWEEPINGELBOW

CONTROLWIRING

FLEXIBLESECTIONS

POWERWIRING

VIBRATIONISOLATORS

LEVELCONCRETE

BASE

CONDENSATIONDRAIN PLUG

AIRIN

FLEXIBLEBELLOWS

FIGURE 4-4. TYPICAL GENERATOR SET INSTALLATION

4-8

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5-1

5. DC Control Wiring

CONTROL WIRING

The generator set control panel box contains con-nection points for remote control and monitor op-tions.

CAUTION Stranded copper wire must be usedfor all customer connections to the control pan-el. Solid copper wire may break due to gensetvibration.

Use flexible conduit for all wiring connections to thegenerator set. All conduit used for control wiring isattached to the control housing.

Route the control wiring through the control housingand into the access holes on the bottom of the con-trol panel box. Figure 5-1 also shows the accessholes that should be used according to where thewires are terminated inside the control box.

A compression type strain-relief connector shouldbe used to prevent dust, insects, etc. from enteringcontrol box.

Use cable ties to keep control wiring away fromsharp edges and AC power cables within the controlhousing.

TB1

TB2CONTROL RELAYS(K10, K11, K12) &CONTROL BOX

HEATER

STRAIN-RELIEFCONNECTOR

NETWORK COMMUNICATIONMODULE

FIGURE 5-1. SUGGESTED CUSTOMER WIRE ROUTING

5-2

TB1 REMOTE MONITOR/CONTROLCONNECTIONS

Customer monitor/control connections are at-tached to terminal block TB1 (Figure 5-2). Optionalequipment such as a remote annunciator panel,sensing devices used to monitor genset operation,remote start/stop switches, battery charger, etc. areattached to TB1. Refer to Customer Connectionsdiagram in Section 9.

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, otherthan 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 9 for the relay specifi-cations.

Network Connections: Refer to 900-0366 Power-Command Network Installation and Operationmanual for the type/gauge wire to use for these con-nections.

Switched B+: (Fused at 5 amps.) Same as RelayConnection description.

B+: (Fused at 10 amps.) Same as Relay Connec-tion description.

TB1 Customer Inputs

Refer to Page 9-2 for typical connections to TB1.

Remote Start: When the O/Manual/ Auto switch isin the Auto position, grounding this input initiatesthe engine cranking and start sequence. This circuitmust be opened to permit resetting a shutdown con-dition with the Reset input. (The remote stop is actu-ally the removal of the remote start signal to the con-trol.)

Remote Emergency Stop: Grounding this inputcauses an immediate shutdown. Emergency stopmust be reset at the front panel.

Remote Reset: When the O/Manual/ Auto switch isin the Auto position and the remote start switch isopen, grounding this input resets any warning andshutdown fault (except Emergency Stop, whichmust be reset at the genset front panel.)

Customer Fault Inputs 1 through 4: Groundingany one of these inputs activates the correspondingwarning or shutdown sequence.

All four costomer inputs may not be available. Cus-tomer inputs can be prewired from the factory forgenset optional/standard features.

External sensing equipment must be connected tothe designated digital input.

The nature of the fault is an optional customerselection. Example inputs: Low Fuel Day Tank, Wa-ter In Fuel, Ground Fault, Low Starting HydraulicPressure, Low Starting Air Pressure, etc.

Each of the four fault functions can be programmed(using InPower), as follows:

Enable/disable input. Default setting:

Enable 1 through 4

Status, Warning or Shutdown. Default setting:

1 − None2 thru 4 − Warning

Active closed or open. Default setting:

Closed [ground] 1 through 4

Change display name using up to 19 charac-ters. Default setting:

1 − Customer Fault 12 − Ground Fault3 − Low Fuel4 − Rupture Basin Fault

5-3

TB1 Customer Outputs

Refer to Page 9-2 for typical connections to TB1.

Customer Outputs 1 through 4: One set of nor-mally open (NO) contacts, rated for 2 amps at 30VDC for each of the four output signals. The relayscan be used to control small devices and indicatorlamps.

The nature of the customer output signal (contactsclosed) is an optional customer selection. Exampleoutputs: Genset running, common warning, com-mon fault, load shed, ready to load, etc.

Each relay can be independently programmed (us-ing InPower) to energize as follows.

Enable/disable output. Default setting:Enable 1 through 4

Status, Warning or Shutdown. Default setting:1 − Common warning2 − Common shutdown3 − Not in Auto4 − Ready to Load

The customer outputs can also be connected tothree control relays (optional) to operate larger

equipment, such as, fans, pumps and motorized airdampers. Refer to Control Relays in this section foradditional information.

B+: This is a fused 10 amp, 12/24 volt output. (FuseF1 is located on Base board.) Two terminals(TB1-17 and -18) are connected to this 10 amp cir-cuit.

Switched B+: This is a fused 5 amp, 12/24 voltswitched output. This output is activated when thecontrol receives a run command. (Fuse F2 is lo-cated on Base board.)

TB2 POWER TRANSFER CONTROL (PTC)CONNECTIONS (OPTIONAL)

TB2 is used to connect the optional PTC module tothe control. With this option installed, the control willmonitor the utility voltage (mains) and frequency forfailure. If power fails, the PTC control will start thegenerator, open the mains circuit breakers andclose the generator circuit breakers. Refer to Cus-tomer Connections diagram in Section 9 and instal-lation instructions sent with the PTC Module Kit.

5-4

TB2

TERMINALDIN RAIL

TERMINALEND BRACKET

TERMINALEND BRACKET

CONTROLRELAYS

SCREW

TB1

VOLTAGESUPPRESSOR

BASEBOARD

FIGURE 5-2. CONTROL PANEL BOX

5-5

CONTROL RELAYS (K10, K11, K12)

CAUTION Damage to the Base board can oc-cur if the voltage suppressors (Figures 5-2 and5-3) are not installed across relay coils (A1/A2)of control relays K11, K12 and K13 before con-necting genset battery cables.

The three optional control relays are rail mountedinside the control panel housing. Each relay is a

4-pole relay with 2 poles normally open and twopoles normally closed.

These relays (Figure 5-3) are used to control auxil-iary equipment, such as fans, pumps and motorizedair dampers. Energizing of the relays is user defin-able.

The contacts are rated at 10 amps at 600 VAC.

Refer to Customer Connections diagram in Sec-tion 9.

20 AWG Wire, UL Rated for 600 VAC

VOLTAGESUPPRESSOR

FIGURE 5-3. OPTIONAL CONTROL RELAYS (K10, K11, K12)

5-6

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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. Place the control panel run switch in theOFF position. Turn off or remove AC power from thebattery charger and then remove the negative (−)battery cable from the set starting battery.

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:

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. Do notconnect to any building electrical system ex-cept through an approved device and afterbuilding main switch is opened.

6-2

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

6-3

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

The CT’s must be installed as noted in the followingCT Installation Requirements.

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 CT1, CT2 and CT3 on the reconnectionwiring diagram. (The Reconnection Diagram is lo-cated on the upper side cover of the control hous-ing.)

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. CT1 − U load leads (A phase),CT2 − V load leads (B phase)CT3 − W load leads (C phase)

C. Route the appropriate load wires through eachCT.

D. The CT’s have dual secondaries (3 posts). TheCT secondary wire marked 1 is connected topost 1 of the CT. CT secondary wire marked 2/3is connected to post 2 for high voltage gensetsor to post 3 for low voltage gensets. (Refer toReconnection Diagram.)

6-4

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.

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.

4-POLE ATSGENERATOR SETSERVICE ENTRANCE

LOAD

3-POLE ATSGENERATOR SETSERVICE ENTRANCE

LOADTHREE-PHASE, FOUR-WIRE UTILITY, THREE-POLE ATS

THREE-PHASE, FOUR-WIRE UTILITY, FOUR-POLE ATS

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

6-5

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

rior. It protects the components when the generatorset is subjected to varying ambient air conditionsduring extended periods of non-use.

HEATER

240V PLUG

THERMOSTAT

120V PLUG

FIGURE 6-3. OPTIONAL CONTROL HEATER

6-6

COOLANT HEATER (OPTIONAL)

Coolant heaters keep the 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 volt-age rating is correct for the heater element rating.

COOLANTHEATER

INLETHOSE

OUTLETHOSE

FIGURE 6-4. COOLANT HEATER

6-7

GENERATOR HEATER (OPTIONAL)A 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 may form within a generator, creatingflashing and shock hazards.

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) to a source of pow-er that will be on during the time the engine is notrunning. Power connections are made to the termi-nal block in the heater terminal box. Be sure the volt-age rating is correct for the heater element rating.

HEATER

HEATERTERMINAL BOX

(VIEW AA)

HEATERLEADS

FIGURE 6-5. TYPICAL GENERATOR HEATER INSTALLATION

6-8

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7-1

7. Prestart Preparation

GENERAL

Before attempting the initial start of the generatorset, be sure to complete the Installation Checklist inSection 8.

INPOWER SERVICE TOOLGENERAL INFORMATION

InPower is a PC based service tool for the Power-Command 2100 Control (PCC). Use InPower to:

Make adjustments to the control’s trims andsettings.

Perform diagnostics and monitoring.

Create a capture file of the controls trims andsettings.

Update control calibrations (InPower PRO ver-sion).

Refer to INPOWER User’s Guide for specifics.

InPower Adjust Mode

The adjustment feature allows you to make adjust-ments to genset parameters, calibrations and set-tings. There are several groups of adjustment pa-rameters; note that not all gensets will have thesame adjustments available.

InPower Capture File Description

InPower provides a method of extracting (captur-ing) a device’s parameter values. Capturing savesdevice information in a file that is identified with a.CAP extension.

Capture files are used to store a copy of the gen-set’s parameter values. During genset installation,it is suggested that a capture file be made beforeand after changes are made to the genset operatingparameters. This information can be a very useful

when troubleshooting the genset (determine if pa-rameters/settings have been modified after installa-tion) and when replacement of the Base board isnecessary. The capture file can be used as a tem-plate to write the previous settings to the new Baseboard software.

ELECTRICAL SYSTEM

Verify 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 Connections

WARNING Accidental starting of the generatorset 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 a 12 volt battery. Connectpositive battery cable before connecting negativebattery cable to prevent arcing.

Service the batteries as necessary. If an automatictransfer switch is installed without a built-in chargecircuit, connect a separate battery charger. Properselection and maintenance of batteries and batterychargers is essential for system reliability.

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.

7-2

PCC OPTIONS PRESTART CHECKS

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

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

The Setup submenus are intended for qualified ser-vice personnel only and require a password tomodify these submenus. The Controller Configura-tion and Adjust submenus are intended for servicepersonnel and site personnel.

The Controller Configuration submenus are used tochange the default language, temperature units,and pressure units to be displayed in menus.

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.

Controller Configuration

Figure 7-1 shows a block representation of the Con-troller Configuration menus.

To view the first Controller Configuration menu,make sure Main Menu 1 is displayed and simulta-neously press the Home Menu and Previous MainMenu buttons.

As shown in the diagram, the Controller Configura-tion menu has three submenus.

Press the buttons next to the and symbols in thedigital display to navigate between the menus.

Press the button next to the symbol in the displayuntil the + and − symbols are displayed.

Press the button next to the + or − symbol to selectthe desired option.

After selecting option, pressing the symbol resultsin the changes being saved. If the Home button orPrevious Main Menu button is pressed beforepressing the symbol, the changes are not saved.

Language Selected submenu: Used to select de-sired language (default = English).

Temperature Units submenu: Used to selectFahrenheit or Centigrade for temperature readings.

Fluid Pressure Units submenu: Used to selectPSI or kPA for pressure readings.

7-3

CONTROLLER CONFIGURATION MENU

EngineAlternator

AdjustMore>>

+Language Selected− English

Language SelectedEnglish

Temperature UnitsDeg F +Temperature Units

− Deg C

Fluid Pressure UnitsPSI +Fluid Pressure Units

− kPa

Back

Back

Back

Main Menu 1

FIGURE 7-1. CONTROLLER CONFIGURATION MENU

7-4

Adjust Menu

Figure 7-2 shows a block representation of the Ad-just menu. If you press the button next to the word“Adjust” in the display, the first Adjust submenu isdisplayed.

As shown in the diagram, the Adjust menu has fivesubmenus. Each submenu includes a parameter orvalue that can be changed.

Press the buttons next to the and symbols in thedigital display to navigate between the menus.Press the Home button or the Previous Main Menubutton to return to Main Menu 1.

Adjusting Values/Parameters:

1.. Press the button next to the symbol in the dis-play until the + and − symbols are displayed.

2.. If necessary, press the button next to the or symbols to move to the numeric character youwish to change.

3.. Press the button next to the + symbol to in-crease the value or select parameter; press thebutton next to the − symbol to decrease the val-ue or select parameter.

4.. After adjusting values/selecting parameters,pressing the symbol results in the changesbeing saved. (When adjusting values, makesure the cursor is on the last numeric characterbefore pressing the symbol).

If the Home button or Previous Main Menu but-ton is pressed before pressing the symbol,the changes are not saved.

Voltage Adjust submenu: Voltage can be ad-justed to �5 percent of the nominal voltage. For ex-ample, if genset output voltage is 208 volts, the volt-age can be adjusted from 197 to 218 volts.

If the revised value is greater or less than the allowed(5%) range, the control will round off the displayedvalue (up or down). For example, if changing the val-ue by −5% (maximum) equals 197.6, the display willshow 197, but will display and change the output to198 when saved.

Frequency Adjust submenu: Frequency can beadjusted to �5 percent of the nominal frequency.For example, if the genset frequency is 60.0 Hz, thefrequency can be adjusted from 57.0 to 63.0 Hz.

Start Delay submenu: Start Delay can be set from0 to 300 seconds (default = 0). This function is by-passed during a manual start/stop sequence.

Stop Delay submenu: Stop Delay can be set from0 to 600 seconds (default = 0). This function is by-passed during a manual start/stop sequence andengine shutdown faults.

Rated To Idle (Beginning Version 2.303): RatedTo Idle delay can be set from 0 to 10 seconds (de-fault = 0). (Enter 1 or more to enable.) Entering anon-zero delay will cause the genset to delay thetransition to Cooldown At Idle.

Idle Start submenu (Only available on somemodels): Idle Start can be enabled or disabled (de-fault = Disable). This function is only enabled whenthe genset is started in manual mode. Idle Start canalso be enabled while the set is running in manualmode.

Enabling Idle Start will cause the genset to run inidle mode until Idle Start is disabled. A warning isdisplayed if genset is left in idle more than 10 min-utes. Long periods of engine idling can eventuallyaffect engine performance and may void enginewarranty.

7-5

Voltage Adjustnnn V

Frequency Adjustnn.n Hz

Start Delaynnn Sec

+Voltage Adjust− nnn V

+Frequency Adjust− nn.n Hz

+Start Delay− nnn Sec

Back

Back

Back

ADJUST MENU

EngineAlternator

AdjustMore>>

Main Menu 1

Idle Start Disable

+Idle Start− Enable

Back

Stop Delaynnn Sec +Stop Delay

− nnn SecBack

Rated To Idle Delaynn Sec +Rated To Idle Delay

− nn SecBack

FIGURE 7-2. ADJUST MENU

7-6

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 menus are displaying the cor-rect values.

8-1

8. 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.

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.

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

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

8-2

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.

9-1

9. Wiring Diagrams

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

Page 9-2 − Customer Connections Diagram

9-2

No. 620-0247 sh 1 of 1Rev. AModified 4-18-02

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

DEFAULT SETTING

CUSTOMER FAULTS:1 CUSTOMER FAULT 12 GROUND FAULT3 LOW FUEL4 RUPTURE BASIN FAULT

CUSTOMER RELAYS:1 COMMON WARNING2 COMMON SHUTDOWN3 NOT IN AUTO4 READY TO LOAD

DEFAULT SETTING

TB1-CUSTOMER FAULTS:1 CUSTOMER FAULT 12 GROUND FAULT3 LOW FUEL4 RUPTURE BASIN FAULT

TB1-CUSTOMER RELAYS:1 COMMON WARNING2 COMMON SHUTDOWN3 NOT IN AUTO4 READY TO LOAD

CUSTOMER CONNECTIONS DIAGRAM

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Phone 1 763 574 5000Toll-free 1 800 888 6626Fax 1 763 574 5298Email [email protected]�, the “C” logo, and “Our energy working for you.”are trademarks of Cummins Inc.

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