Installation Installation Manual - CS Diesel Generators

InstallationInstallation ManualManualGenerator Setwith PowerCommand® 2100 Control

GGPA (Spec A-B)GGPB (Spec A-B)GGPC (Spec A-B)

EnglishOriginal Instructions 9-2015 A030G175 (Issue 5)

Table of Contents

1. IMPORTANT SAFETY INSTRUCTIONS ....................................................................................... 11.1 Warning, Caution, and Note Styles Used in This Manual ...................................................... 11.2 General Information ................................................................................................................ 1

1.2.1 General Safety Precautions ......................................................................................... 21.3 Generator Set Safety Code .................................................................................................... 4

1.3.1 Moving Parts Can Cause Severe Personal Injury or Death ........................................ 41.3.2 Positioning of Generator Set....................................................................................... 4

1.4 Electrical Shocks and Arc Flashes Can Cause Severe Personal Injury or Death.................. 51.4.1 AC Supply and Isolation............................................................................................... 61.4.2 Medium Voltage Equipment (601 V to 15 kV) ............................................................. 6

1.5 Fuel and Fumes Are Flammable ............................................................................................ 61.5.1 Spillage ....................................................................................................................... 71.5.2 Fluid Containment....................................................................................................... 71.5.3 Do Not Operate in Flammable and Explosive Environments ...................................... 7

1.6 Exhaust Gases Are Deadly..................................................................................................... 71.6.1 Exhaust Precautions ................................................................................................... 8

2. INTRODUCTION............................................................................................................................ 92.1 About This Manual.................................................................................................................. 9

2.1.1 Additional Installation Manual Information ................................................................... 92.2 Schedule of Abbreviations .................................................................................................... 102.3 Related Literature ................................................................................................................. 112.4 After Sales Services.............................................................................................................. 12

2.4.1 Maintenance.............................................................................................................. 122.4.2 Warranty..................................................................................................................... 122.4.3 How to Obtain Service ............................................................................................... 13

3. SPECIFICATIONS ....................................................................................................................... 153.1 Generator Set Specifications ................................................................................................ 15

4. SYSTEM OVERVIEW .................................................................................................................. 174.1 Generator Set Components.................................................................................................. 174.2 Generator Set Rating............................................................................................................ 184.3 Engine................................................................................................................................... 194.4 Sensors................................................................................................................................. 194.5 Heaters ................................................................................................................................. 19

4.5.1 Heater Supply and Isolation...................................................................................... 19

5. INSTALLATION OVERVIEW ....................................................................................................... 215.1 Application and Installation ................................................................................................... 215.2 Safety Considerations........................................................................................................... 215.3 Standby Heating Devices...................................................................................................... 215.4 Product Modifications............................................................................................................ 22

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Table of Contents 9-2015

6. INSTALLING THE GENERATOR SET ........................................................................................ 236.1 Location ................................................................................................................................ 236.2 Mounting ............................................................................................................................... 246.3 Access to Set........................................................................................................................ 256.4 Vibration Isolator Installation................................................................................................. 26

7. MECHANICAL CONNECTIONS .................................................................................................. 297.1 Overview ............................................................................................................................... 297.2 Fuel System.......................................................................................................................... 297.3 Fuel Lines Routing................................................................................................................ 297.4 Natural Gas/LPG Vapor/LPG Liquid Fuel System................................................................ 307.5 Fuel Pressure........................................................................................................................ 307.6 Check Gas Leaks and Correct.............................................................................................. 317.7 Exhaust System.................................................................................................................... 317.8 Ventilation and Cooling......................................................................................................... 347.9 Vents and Ducts.................................................................................................................... 347.10 Dampers ............................................................................................................................. 357.11 Radiator Set Requirements................................................................................................. 35

8. DC CONTROL WIRING ............................................................................................................... 378.1 PCCnet devices Belden cable .............................................................................................. 388.2 TB1 Remote Monitor / Control Connections......................................................................... 388.3 PCC 2100 TB1 Customer Connections ................................................................................ 398.4 TB1 Customer Inputs............................................................................................................ 398.5 TB1 Customer Outputs ......................................................................................................... 408.6 Switched B+.......................................................................................................................... 428.7 Run Relays (K10, K11, K12)................................................................................................. 42

9. AC ELECTRICAL CONNECTIONS ............................................................................................. 459.1 Transfer Switch ..................................................................................................................... 469.2 Alternator Voltage Connections ............................................................................................ 479.3 Load Connections ................................................................................................................. 489.4 Load Balancing ..................................................................................................................... 489.5 Current Transformers............................................................................................................ 48

9.5.1 CT Installation Requirements..................................................................................... 489.6 Grounding ............................................................................................................................. 489.7 Coolant Heater Connection................................................................................................... 519.8 Alternator Heater (Option)..................................................................................................... 51

10. PRE-START PREPARATION..................................................................................................... 5310.1 InPower Service Tool General Information......................................................................... 53

10.1.1 InPower Adjust Mode............................................................................................... 5310.1.2 InPower Capture File Description ............................................................................ 53

10.2 Electrical System ................................................................................................................ 5310.3 Battery Connections............................................................................................................ 5410.4 Controller Configuration Relays .......................................................................................... 5410.5 Adjust Menu ........................................................................................................................ 56

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10.5.1 Adjusting Values/Parameters................................................................................... 5810.5.2 Adjust Submenus..................................................................................................... 58

10.6 Starting................................................................................................................................ 58

11. INSTALLATION CHECKLIST ..................................................................................................... 59

12. MANUFACTURING FACILITIES ................................................................................................ 61

APPENDIX A. ALTERNATOR RECONNECT DRAWING ................................................................ 63A.0 GGPA/B/C Wiring Diagram with PowerCommand 2100 Control ......................................... 65

APPENDIX B. WIRING DIAGRAMS................................................................................................. 71B.0 Wiring Diagrams ................................................................................................................... 73

APPENDIX C. OUTLINE DRAWINGS.............................................................................................. 83C.0 Outline Drawings .................................................................................................................. 84C.1 Outline Drawing 0500-5070 (F177)...................................................................................... 85C.2 Outline Drawing 0500-5030 (F179)...................................................................................... 86C.3 Outline Drawing 0500-3278 (Circuit Breaker) ...................................................................... 88C.4 GGHE/GGHF Enclosure Outline Drawing 0500-4814 (F217).............................................. 91C.5 GGHE/GGHF Enclosure Outline Drawing 0500-4813 (F216).............................................. 92C.6 GGHE/GGHF Enclosure Outline Drawing 0500-3171 (F182).............................................. 94C.7 GGHE/GGHF Enclosure Outline Drawing 0500-3167 (F173).............................................. 96C.8 GGHE/GGHF Enclosure Outline Drawing 0500-3211 (F172).............................................. 97

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1 Important Safety InstructionsSave these instructions. This manual contains important instructions that should be followedduring installation and maintenance of the generator set.

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

1.1 Warning, Caution, and Note Styles Used in ThisManualThe following safety styles and symbols found throughout this manual indicate potentiallyhazardous conditions to the operator, service personnel, or equipment.

DANGERIndicates a hazardous situation that, if not avoided, will result in death or serious injury.

WARNINGIndicates a hazardous situation that, if not avoided, could result in death or seriousinjury.

CAUTIONIndicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

NOTICEIndicates information considered important, but not hazard-related (e.g., messages relating toproperty damage).

1.2 General InformationThis manual should form part of the documentation package supplied by Cummins PowerGeneration with specific generator sets. In the event that this manual has been supplied inisolation please contact your authorized distributor.

NOTICEIt is in the operator’s interest to read and understand all warnings and cautions contained withinthe documentation relevant to the generator set, its operation and daily maintenance.

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1. Important Safety Instructions 9-2015

1.2.1 General Safety PrecautionsWARNING

Hot Pressurized LiquidContact with hot liquid can cause severe burns.Do not open the pressure cap while the engine is running. Let the engine cool down beforeremoving the cap. Turn the cap slowly and do not open it fully until the pressure has beenrelieved.

WARNINGMoving PartsMoving parts can cause severe personal injury.Use extreme caution around moving parts. All guards must be properly fastened to preventunintended contact.

WARNINGToxic HazardUsed engine oils have been identified by some state and federal agencies to cause cancer orreproductive toxicity.Do not ingest, breathe the fumes, or contact used oil when checking or changing engine oil.Wear protective gloves and face guard.

WARNINGElectrical Generating EquipmentIncorrect operation can cause severe personal injury or death.Do not operate equipment when fatigued, or after consuming any alcohol or drug.

WARNINGToxic GasesSubstances in exhaust gases have been identified by some state and federal agencies to causecancer or reproductive toxicity.Do not breathe in or come into contact with exhaust gases.

WARNINGCombustible LiquidIgnition of combustible liquids is a fire or explosion hazard which can cause severe burns ordeath.Do not store fuel, cleaners, oil, etc., near the generator set.

WARNINGHigh Noise LevelGenerator sets in operation emit noise, which can cause hearing damage.Wear appropriate ear protection at all times.

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9-2015 1. Important Safety Instructions

WARNINGHot SurfacesContact with hot surfaces can cause severe burns.Wear appropriate PPE when working on hot equipment and avoid physical contact with hotsurfaces.

WARNINGElectrical Generating EquipmentIncorrect operation and maintenance can result in severe personal injury or deathMake sure that only suitably trained and experienced service personnel perform electrical and/ormechanical service.

WARNINGToxic HazardEthylene glycol, used as an engine coolant, is toxic to humans and animals.Wear appropriate PPE. Clean up coolant spills and dispose of used coolant in accordance withlocal environmental regulations.

WARNINGCombustible LiquidIgnition of combustible liquids is a fire or explosion hazard which can cause severe burns ordeath.Do not use combustible liquids like ether.

WARNINGAutomated MachineryAccidental or remote starting of the generator set can cause severe personal injury or death.Isolate all auxiliary supplies and use an insulated wrench to disconnect the starting batterycables (negative [–] first).

WARNINGFire HazardMaterials drawn into the generator set are a fire hazard. Fire can cause severe burns or death.Make sure the generator set is mounted in a manner to prevent combustible materials fromaccumulating under the unit.

WARNINGFire HazardAccumulated grease and oil are a fire hazard. Fire can cause severe burns or death.Keep the generator set and the surrounding area clean and free from obstructions. Repair oilleaks promptly.

WARNINGFire HazardMaterials drawn into the generator set are a fire hazard. Fire can cause severe burns or death.Keep the generator set and the surrounding area clean and free from obstructions.

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NOTICEKeep multi-class ABC fire extinguishers handy. Class A fires involve ordinarycombustible materials such as wood and cloth. Class B fires involve combustible andflammable liquid fuels and gaseous fuels. Class C fires involve live electricalequipment. (Refer to NFPA No. 10 in applicable region.)

NOTICEBefore performing maintenance and service procedures on enclosed generator sets, make surethe service access doors are secured open.

NOTICEStepping on the generator set can cause parts to bend or break, leading to electricalshorts, or to fuel, coolant, or exhaust leaks. Do not step on the generator set whenentering or leaving the generator room.

1.3 Generator Set Safety CodeBefore operating the generator set, read the manuals and become familiar with them and theequipment. Safe and efficient operation can be achieved only if the equipment is properlyoperated and maintained. Many accidents are caused by failure to follow fundamental rules andprecautions.

WARNINGElectrical Generating EquipmentIncorrect operation and maintenance can result in severe personal injury or death.Read and follow all Safety Precautions, Warnings, and Cautions throughout this manual and thedocumentation supplied with the generator set.

1.3.1 Moving Parts Can Cause Severe Personal Injury or Death• Keep hands, clothing, and jewelry away from moving parts.

• Before starting work on the generator set, disconnect the battery charger from its ACsource, then disconnect the starting batteries using an insulated wrench, negative (–) cablefirst. This will prevent accidental starting.

• Make sure that fasteners on the generator set are secure. Tighten supports and clamps;keep guards in position over fans, drive belts, etc.

• Do not wear loose clothing or jewelry in the vicinity of moving parts or while working onelectrical equipment. Loose clothing and jewelry can become caught in moving parts.

• If any adjustments must be made while the unit is running, use extreme caution around hotmanifolds, moving parts, etc.

1.3.2 Positioning of Generator SetThe generator set should be placed on level ground with adequate open space around it. Theimmediate area around the generator set should be free of any flammable material.

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NOTICEOn an enclosed generator set, access or service doors must be closed and lockedbefore repositioning, and they must remain locked during transportation and siting.

NOTICEThe generator set is capable of operating at inclines of up to +/– 10 degrees, however,for optimal performance and reliability, any incline should be +/– 5 degrees.

1.4 Electrical Shocks and Arc Flashes Can CauseSevere Personal Injury or Death

WARNINGElectric Shock HazardVoltages and currents present an electrical shock hazard that can cause severe burns or death.Contact with exposed energized circuits with potentials of 50 Volts AC or 75 Volts DC or highercan cause electrical shock and electrical arc flash. Refer to standard NFPA 70E or equivalentsafety standards in corresponding regions for details of the dangers involved and for the safetyrequirements.

Guidelines to follow when working on de-energized electrical systems:

• Use proper PPE. Do not wear jewelry and make sure that any conductive items areremoved from pockets as these items can fall into equipment and the resulting short circuitcan cause shock or burning. Refer to standard NFPA 70E for PPE standards.

• De-energize and lockout/tagout electrical systems prior to working on them.Lockout/Tagout is intended to prevent injury due to unexpected start-up of equipment orthe release of stored energy. Please refer to the lockout/tagout section for moreinformation.

• De-energize and lockout/tagout all circuits and devices before removing any protectiveshields or making any measurements on electrical equipment.

• Follow all applicable regional electrical and safety codes.

Guidelines to follow when working on energized electrical systems:

NOTICEIt is the policy of Cummins Inc. to perform all electrical work in a de-energized state. However,employees or suppliers may be permitted to occasionally perform work on energized electricalequipment only when qualified and authorized to do so and when troubleshooting, or if de-energizing the equipment would create a greater risk or make the task impossible and all otheralternatives have been exhausted.

NOTICEExposed energized electrical work is only allowed as per the relevant procedures and must beundertaken by a Cummins authorized person with any appropriate energized work permit for thework to be performed while using proper PPE, tools and equipment.

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In summary:

• Do not tamper with or bypass interlocks unless you are authorized to do so.

• Understand and assess the risks - use proper PPE. Do not wear jewelry and make surethat any conductive items are removed from pockets as these items can fall into equipmentand the resulting short circuit can cause shock or burning. Refer to standard NFPA 70E forPPE standards.

• Make sure that an accompanying person who can undertake a rescue is nearby.

1.4.1 AC Supply and IsolationNOTICE

Local electrical codes and regulations (for example, BS EN 12601:2010 Reciprocating internalcombustion engine driven generating sets). Safety may require the installation of a disconnectmeans for the generator set, either on the generator set or where the generator set conductorsenter a facility.

NOTICEThe AC supply must have the correct over current and earth fault protection according to localelectrical codes and regulations. This equipment must be earthed (grounded).

It is the sole responsibility of the customer to provide AC power conductors for connection toload devices and the means to isolate the AC input to the terminal box; these must comply withlocal electrical codes and regulations. Refer to the wiring diagram supplied with the generatorset.

The disconnecting device is not provided as part of the generator set, and Cummins PowerGeneration accepts no responsibility for providing the means of isolation.

1.4.2 Medium Voltage Equipment (601 V to 15 kV)• Medium voltage acts differently than low voltage. Special equipment and training is

required to work on or around medium voltage equipment. Operation and maintenancemust be done only by persons trained and experienced to work on such devices. Improperuse or procedures will result in severe personal injury or death.

• Do not work on energized equipment. Unauthorized personnel must not be permitted nearenergized equipment. Due to the nature of medium voltage electrical equipment, inducedvoltage remains even after the equipment is disconnected from the power source. Plan thetime for maintenance with authorized personnel so that the equipment can be de-energizedand safely grounded.

1.5 Fuel and Fumes Are FlammableFire, explosion, and personal injury or death can result from improper practices.

• Do not fill fuel tanks while the engine is running unless the tanks are outside the enginecompartment. Fuel contact with hot engine or exhaust is a potential fire hazard.

• Do not permit any flame, cigarette, pilot light, spark, arcing equipment, or other ignitionsource near the generator set or fuel tank.

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• Fuel lines must be adequately secured and free of leaks. Fuel connection at the engineshould be made with an approved flexible line. Do not use copper piping on flexible linesas copper will become brittle if continuously vibrated or repeatedly bent.

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

• Make sure the battery area has been well-ventilated prior to servicing near it. Lead-acidbatteries emit a highly explosive hydrogen gas that can be ignited by arcing, sparking,smoking, etc.

1.5.1 SpillageAny spillage that occurs during fueling or during oil top-off or oil change must be cleaned upbefore starting the generator set.

1.5.2 Fluid ContainmentNOTICE

Where spillage containment is not part of a Cummins supply, it is the responsibility of theinstaller to provide the necessary containment to prevent contamination of the environment,especially water courses and sources.

If fluid containment is incorporated into the bedframe, it must be inspected at regular intervals.Any liquid present should be drained out and disposed of in line with local health and safetyregulations. Failure to perform this action may result in spillage of liquids which couldcontaminate the surrounding area.

Any other fluid containment area must also be checked and emptied, as described above.

1.5.3 Do Not Operate in Flammable and Explosive EnvironmentsFlammable vapor can cause an engine to over speed and become difficult to stop, resulting inpossible fire, explosion, severe personal injury, and death. Do not operate a generator setwhere a flammable vapor environment can be created, unless the generator set is equippedwith an automatic safety device to block the air intake and stop the engine. The owners andoperators of the generator set are solely responsible for operating the generator set safely.Contact your authorized Cummins Power Generation distributor for more information.

1.6 Exhaust Gases Are Deadly• Provide an adequate exhaust system to properly expel discharged gases away from

enclosed or sheltered areas, and areas where individuals are likely to congregate. Visuallyand audibly inspect the exhaust system daily for leaks per the maintenance schedule.Make sure that exhaust manifolds are secured and not warped. Do not use exhaust gasesto heat a compartment.

• Make sure the unit is well ventilated.

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1.6.1 Exhaust PrecautionsWARNING

Hot Exhaust GasesContact with hot exhaust gases can cause severe burns.Wear personal protective equipment when working on equipment.

WARNINGHot SurfacesContact with hot surfaces can cause severe burns.Wear appropriate PPE when working on hot equipment and avoid physical contact with hotsurfaces.

WARNINGToxic GasesInhalation of exhaust gases can cause asphyxiation and death.Pipe exhaust gas outside and away from windows, doors, or other inlets to buildings. Do notallow exhaust gas to accumulate in habitable areas.

WARNINGFire HazardContaminated insulation is a fire hazard. Fire can cause severe burns or death.Remove any contaminated insulation and dispose of it in accordance with local regulations.

The exhaust outlet may be sited at the top or bottom of the generator set. Make sure that theexhaust outlet is not obstructed. Personnel using this equipment must be made aware of theexhaust position. Position the exhaust away from flammable materials - in the case of exhaustoutlets at the bottom, make sure that vegetation is removed from the vicinity of the exhaust.

The exhaust pipes may have some insulating covers fitted. If these covers becomecontaminated they must be replaced before the generator set is run.

To minimize the risk of fire, make sure the following steps are observed:

• Make sure that the engine is allowed to cool thoroughly before performing maintenance oroperation tasks.

• Clean the exhaust pipe thoroughly.

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2 IntroductionWARNING

Hazardous VoltageContact with high voltages can cause severe electrical shock, burns, or death.Make sure that only a trained and experienced electrician makes generator electrical outputconnections, in accordance with the installation instructions and all applicable codes.

WARNINGElectrical Generating EquipmentFaulty electrical generating equipment can cause severe personal injury or death.Generator sets must be installed, certified, and operated by trained and experienced person inaccordance with the installation instructions and all applicable codes.

2.1 About This ManualThe purpose of this manual is to provide the users with sound, general information. It is forguidance and assistance with recommendations for correct and safe procedures. CumminsPower Generation (CPG) cannot accept any liability whatsoever for problems arising as a resultof following recommendations in this manual.

The information contained within the manual is based on information available at the time ofgoing to print. In line with Cummins Power Generation policy of continuous development andimprovement, information may change at any time without notice. The users should thereforemake sure that before commencing any work, they have the latest information available. Thelatest version of this manual is available on QuickServe Online(https://qsol.cummins.com/info/index.html).

Users are respectfully advised that, in the interests of good practice and safety, it is theirresponsibility to employ competent persons to carry out any installation work. Consult yourauthorized distributor for further installation information. It is essential that the utmost care istaken with the application, installation, and operation of any engine due to their potentiallyhazardous nature. Careful reference should also be made to other Cummins Power Generationliterature. A generator set must be operated and maintained properly for safe and reliableoperation.

For further assistance, contact your authorized distributor.

2.1.1 Additional Installation Manual InformationThe purpose of this manual is to provide the Installation Engineer with sound, generalinformation for the installation of the generator set. Refer to the Generator Set Operator Manualfor additional information which must also be read before operating the set.

This manual provides installation instructions for the generator set models listed on the frontcover. This includes the following information:

• Mounting Recommendations - for fastening the generator set to a base and spacerequirements for normal operation and service.

• Mechanical and Electrical Connections - covers most aspects of the generator setinstallation.

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2. Introduction 9-2015

• Prestart - checklist of items or procedures needed to prepare the generator set foroperation.

• Installation Checklist - reference checks upon completion of the installation.

This manual DOES NOT provide application information for selecting a generator set ordesigning the complete installation. If it is necessary to design the various integrated systems(fuel, exhaust, cooling, etc.), additional information is required. Review standard installationpractices. For engineering data specific to the generator set, refer to the Specification and DataSheets. For application information, refer to Application Manual T-030, "Liquid Cooled GeneratorSets." To find this manual online:

1. Go to www.powersuite.cummins.com

2. Click on "Application & Technical Manuals" on the Home page.

3. Click on "Liquid Cooled Genset Application Manual"

2.2 Schedule of AbbreviationsThis list is not exhaustive. For example, it does not identify units of measure or acronyms thatappear only in parameters, event/fault names, or part/accessory names.

AmpSentry, INSITE, and InPower are trademarks of Cummins Inc. PowerCommand is aregistered trademark of Cummins Inc.

ABBR. DESCRIPTION ABBR. DESCRIPTION

AC Alternating Current LED Light-emitting Diode

AMP AMP, Inc., part of Tyco Electronics LTS Long Term Storage

ANSI American National Standards LVRT Low Voltage Ride ThroughInstitute

ASOV Automatic Shut Off Valve MFM Multifunction Monitor

ASTM American Society for Testing and Mil Std Military StandardMaterials (ASTM International)

ATS Automatic Transfer Switch MLD Masterless Load Demand

AVR Automatic Voltage Regulator NC Normally Closed

AWG American Wire Gauge NC Not Connected

CAN Controlled Area Network NFPA National Fire Protection Agency

CB Circuit Breaker NO Normally Open

CE Conformité Européenne NWF Network Failure

CFM Cubic Feet per Minute OEM Original Equipment Manufacturer

CGT Cummins Generator Technologies OOR Out of Range

CMM Cubic Meters per Minute OORH / ORH Out of Range High

CT Current Transformer OORL / ORL Out of Range Low

D-AVR Digital Automatic Voltage PB Push ButtonRegulator

DC Direct Current PCC PowerCommand® Control

DEF Diesel Exhaust Fluid PGI Power Generation Interface

DPF Diesel Particulate Filter PGN Parameter Group Number

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9-2015 2. Introduction

ABBR. DESCRIPTION ABBR. DESCRIPTION

ECM Engine Control Module PI Proportional/Integral

ECS Engine Control System PID Proportional/Integral/Derivative

EMI Electromagnetic interference PLC Programmable Logic Controller

EN European Standard PMG Permanent Magnet Generator

EPS Engine Protection System PPE Personal Protective Equipment

E-Stop Emergency Stop PT Potential Transformer

FAE Full Authority Electronic PTC Power Transfer Control

FMI Failure Mode Identifier PWM Pulse-width Modulation

FRT Fault Ride Through RFI Radio Frequency Interference

FSO Fuel Shutoff RH Relative Humidity

Genset Generator Set RMS Root Mean Square

GCP Generator Control Panel RTU Remote Terminal Unit

GND Ground SAE Society of Automotive Engineers

LCT Low Coolant Temperature SCR Selective Catalytic Reduction

HMI Human-machine Interface SPN Suspect Parameter Number

IC Integrated Circuit SWL Safe Working Load

ISO International Organization for SW_B+ Switched B+Standardization

LBNG Lean-burn Natural Gas UL Underwriters Laboratories

LCD Liquid Crystal Display UPS Uninterruptible Power Supply

2.3 Related LiteratureBefore any attempt is made to operate the generator set, the Operator should take time to readall of the manuals supplied with the generator set, and to familiarize themselves with Warningsand Operating Procedures.

CAUTIONA generator set must be operated and maintained properly if you are to expect safe and reliableoperation.

The relevant publications appropriate to your generator set are also available:

• Operator Manual (A030G173)

• Service Manual (A030G174)

• Engine Service Manual (A030M990)

• Specification and Data Sheet (For engineering data specific to the generator set)

• Application Manual T-030, Liquid Cooled Generator Sets (For application information)

• Parts Manual (A030F464)

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NOTICERead the warranty statement provided with the genset for US Environmental ProtectionAgency (EPA) restrictions on servicing specific components.

Contact your authorized distributor.

2.4 After Sales ServicesCummins Power Generation offers a full range of maintenance and warranty services.

2.4.1 MaintenanceWARNING

Electrical Generating EquipmentIncorrect operation and maintenance can result in severe personal injury or deathMake sure that only suitably trained and experienced service personnel perform electrical and/ormechanical service.

For expert generator set service at regular intervals, contact your local distributor. Each localdistributor offers a complete maintenance contract package covering all items subject to routinemaintenance, including a detailed report on the condition of the generator set. In addition, thiscan be linked to a 24-hour call-out arrangement, providing year-round assistance if necessary.Specialist engineers are available to maintain optimum performance levels from generator sets.Maintenance tasks should only be undertaken by trained and experienced technicians providedby your authorized distributor.

2.4.2 WarrantyFor details of the warranty coverage for your generator set, refer to the Global CommercialWarranty Statement listed in the Related Literature section.

Extended warranty coverage is also available. In the event of a breakdown, prompt assistancecan normally be given by factory trained service technicians with facilities to undertake all minorand many major repairs to equipment on site.

For further warranty details, contact your authorized distributor.

NOTICEDamage caused by failure to follow the manufacturer's recommendations will not be covered bythe warranty. Please contact your authorized distributor.

2.4.2.1 Warranty LimitationsFor details of the warranty limitations for your generator set, refer to the warranty statementapplicable to the generator set.

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9-2015 2. Introduction

2.4.3 How to Obtain ServiceWhen the generator set requires servicing, contact your nearest Cummins Power Generationdistributor. To contact your local Cummins Power Generation distributor refer to the GlobalAddresses section contained within this document. When contacting your distributor, alwayssupply the complete Model, Specification, and Serial Number as shown on the nameplate.

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3 Specifications

3.1 Generator Set SpecificationsTABLE 1. SPECIFICATIONS

MODELS GGPA/GGPB/GGPC

Engine GM 5.0 LOnan Modified GM V-8

Generator kW Rating See generator set nameplate for rating information.

Engine Fuel Connection Refer to Generator Outline DrawingInlet/Outlet Thread Size

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

Fuel Flow (Inlet Pressure)Minimum:NG/LPG 7.0 inch H2O (1.7 KPA)Maximum:NG/LPG Vapor Withdrawal 13.6 inch H2O (3.4 kPa)LPG Liquid Withdrawal 312 psi (2,153 kPa)

ExhaustConnection 3 inch NPTBackpressure (Max. Allowed) 20 inch WC (5.0 kPa)

Electrical SystemStarting Voltage 12 Volts DCBattery Charing Alternator (Max. 37 ARating)

Cooling SystemCapacity with Standard Radiator 6.9 Gallons (26.1 L)

Lubricating SystemOil Capacity with Filters 5.75 Quarts (5.5 L)

Tune-up SpecificationsSpark Plug Gap 0.030 inch (0.762 mm)

BatteryGround NegativeRequired Battery Voltage 12 Volts DCGroup Number 31CCA (minimum)Cold Soak @ 0o F (-18o C) 625

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3. Specifications 9-2015

TABLE 2. FUEL CONSUMPTION (STANDBY/PRIME/60 HZ) AT FULL LOAD

Model GGPA GGPB GGPC

Standbycfh (m3/hr)LPG (Vapor or Liquir) 204 (5.8) 225 (6.4) 270.2 (7.7)Natural Gas 528 (14.9) 590 (16.7) 646 (18.3)

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4 System OverviewThis section provides an overview of the generator set.

4.1 Generator Set ComponentsFigure 1 shows a typical generator set installation.

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4. System Overview 9-2015

No. Description No. Description

1 Thimble 7 Control Wiring

2 Exhaust Line 8 Power Wiring

3 Muffler 9 Level Concrete Base

4 Condensation Drain Plug 10 Vibration Isolators

5 Sweeping Elbow 11 Flexible Bellows

6 Flexible Sections

FIGURE 1. TYPICAL GENERATOR SET

4.2 Generator Set RatingFor details of the generator set rating, refer to the generator set nameplate. For operation attemperatures or altitudes above those stated on the nameplate, a de-rate may be necessary.

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9-2015 4. System Overview

4.3 EngineFor additional engine specific information, refer to the relevant engine manual for your generatorset.


1 Temperature Sensor 4 Oil Pressure Sender

2 Oil Filler Cap 5 Fan Belt

3 Dipstick 6 Battery Cables

FIGURE 2. TYPICAL ENGINE COMPONENTS

4.4 SensorsVarious generator set parameters are measured by sensors, and the resulting signals areprocessed by the control board.

Engine-mounted sensors monitor a number of different systems, such as:

• Lube Oil Pressure

• Cooling System Temperature

4.5 Heaters4.5.1 Heater Supply and Isolation

An external power supply is required for the operation of the generator set heaters.

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4. System Overview 9-2015

NOTICEIf not already provided, it is the sole responsibility of the customer to provide the powersupply and the means to isolate the AC input to the terminal box. Cummins PowerGeneration accepts no responsibility for providing the means of isolation.

20 A030G175 (Issue 5)

5 Installation OverviewThese installation recommendations apply to typical installations with standard model generatorsets. Whenever possible, these recommendations also cover factory designed options ormodifications. However, because of the many variables in any installation, it is not possible toprovide specific recommendations for every situation. If there are any questions not answeredby this manual, contact your nearest authorized distributor for assistance.

5.1 Application and InstallationA power system must be carefully planned and correctly installed for proper operation. Thisinvolves two essential elements.

• Application (as it applies to generator set installations) refers to the design of thecomplete power system that usually includes power distribution equipment, transferswitches, ventilation equipment, mounting pads, cooling, exhaust, and fuel systems. Eachcomponent must be correctly designed so the complete system will function as intended.Application and design is an engineering function generally done by specifying engineersor other trained specialists. Specifying engineers or other trained specialists areresponsible for the design of the complete power system and for selecting the materialsand products required.

• Installation refers to the actual set-up and assembly of the power system. The installersset up and connect the various components of the system as specified in the systemdesign plan. The complexity of the system normally requires the special skills of qualifiedelectricians, plumbers, sheet-metal workers, etc. to complete the various segments of theinstallation. This is necessary so that all components are assembled using standardmethods and practices.

5.2 Safety ConsiderationsThe generator set has been carefully designed to provide safe and efficient service whenproperly installed, maintained, and operated. However, the overall safety and reliability of thecomplete system is dependent on many factors outside the control of the generator setmanufacturer. To avoid possible safety hazards, make all mechanical and electrical connectionsto the generator set exactly as specified in this manual. All systems external to the generator(fuel, exhaust, electrical, etc.) must comply with all applicable codes. Make certain all requiredinspections and tests have been completed and all code requirements have been satisfiedbefore certifying the installation is complete and ready for service.

5.3 Standby Heating DevicesCummins Power Generation requires installing standby generator sets (life safety systems) withengine jacket water coolant heaters in order to ensure a 10 second start. Jacket water coolantheaters are also recommended in prime and continuous applications where time and loadacceptance is to be minimized.

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5. Installation Overview 9-2015

The jacket water coolant heater provided by Cummins Power Generation is rated to provide theabove requirements in ambient temperatures as low as 4 °C (40 °F). Although most CumminsPower Generation generator sets will start in temperatures down to –32 °C (–25 °F) whenequipped with engine jacket water coolant heaters, it might take more than 10 seconds to warmthe engine before a load can be applied when ambient temperatures are below 4 °C (40 °F).

On generator sets equipped with a graphic display, the Low Coolant Temperature message,in conjunction with illumination of the Warning LED, is provided to meet the currentrequirements. The engine cold sensing logic initiates a warning when the engine jacket watercoolant temperature falls below 21 °C (70 °F). In applications where the ambient temperaturefalls below 4 °C (40 °F), or there exists a high amount of cold airflow, the jacket water coolantheater may not provide the necessary heating. Under these conditions, although the generatorset may start, it may not be able to accept load within 10 seconds. When this condition occurs,check the coolant heaters for proper operation. If the coolant heaters are operating properly,other precautions may be necessary to warm the engine before applying a load.

5.4 Product ModificationsAgency certified products purchased from Cummins Power Generation comply only with thosespecific requirements and as noted on company product specification sheets. Subsequentmodifications must meet commonly accepted engineering practices and/or local and nationalcodes and standards. Product modifications must be submitted to the local authority havingjurisdiction for approval.

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6 Installing the Generator SetGenerator set installations must be engineered so that the generator set will function properlyunder the expected load conditions. Use these instructions as a general guide only. Follow theinstructions of the consulting engineer when locating or installing any components. Thecomplete installation must comply with all local and state building codes, fire regulations, andother applicable regulations.

Requirements to be considered prior to installation are:

• 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

NOTICEDepending on the location and intended use, ensure that international, national or local laws andregulations regarding Air Quality Emissions have been observed and complied with. Be sure toconsult local pollution control or air quality authorities before completing construction plans.

6.1 LocationWARNING

Electrical Generating EquipmentIncorrect operation and maintenance can result in severe personal injury or deathMake sure that only suitably trained and experienced service personnel perform electrical and/ormechanical service.

WARNINGIncorrect installationIncorrect installation of the generator set, service or parts replacement, can result in severepersonal injury, death, and/or equipment damage.Service personnel must be trained and experienced to perform electrical and mechanicalcomponent installation.

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6. Installing the Generator Set 9-2015

NOTICEDepending on your location and intended use, additional laws and regulations mayrequire for you to obtain an air quality emissions permit before beginning installation ofyour generator set. Be sure to consult local pollution control or air quality authoritiesbefore completing your construction plans.

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

Provide a location away from extreme ambient temperatures and protect the generator set fromadverse weather conditions.

Use the following information to locate the generator set for optimal operating conditions:

Surface: Concrete or compacted gravel with container resting on solid, poured concrete blocks,or timber blocks spaced at reasonable intervals around the perimeter of the container.

Leveling: Level the container from side-to-side within + 35°, and end-to-end within +25°.

Placement:

• Generators should be a minimum of 16.4 ft (5 m) apart to allow for adequate access toentry doors.

• Make sure that the air inlets are not obstructed by surrounding trees, buildings, or otherobstructions.

• Make sure noise distribution (to prevent echoing) is kept to a minimum.

• Consider exhaust for immediate neighbors.

• The prevailing wind direction should be considered so that the engine combustion air inletis upwind and the exhaust discharge is downwind.

• The immediate area around the proposed location of the mounting surface should beevaluated for proper drainage so that moisture run-off is sufficient to prevent pondingaround the unit(s).

6.2 MountingGenerator sets are mounted on a steel skid that provides proper support. The engine-generatorassembly is isolated from the skid frame by rubber mounts that provide adequate vibrationisolation for normal installations. Where required by building codes or special isolation needs,generator sets may be mounted on rubber pads or mechanical spring isolators.

NOTICEThe use of unapproved isolators may result in harmful resonances and may void the generatorset warranty.

Mount the generator set on a substantial and level base such as a concrete pad. A non-combustible material must be used for the pad.

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9-2015 6. Installing the Generator Set

Use 16 mm (5/8 inch) or anchored mounting bolts to secure the generator set bedframe to thebase. Use a flat washer and hexagonal nut for each bolt (see Figure 3). The 38 mm x 152 mm(11/2 x 6 inch) pipe inserted over the mounting bolts allows minor adjustment of the bolts to alignthem to the holes in the bedframe.

The fixing centers for the mounting bolts can be found on the generator set Outline Drawing.


1 Generator Bedframe Flange 5 38 mm x 152 mm Pipe (1½ inch x 6 inch)

2 Hexagonal Nut 6 Mounting Bolt Set in Concrete

3 Flat or Bevel Washer 7 305 mm (12 inch)

4 Mounting Base on Concrete

FIGURE 3. BOLT DIAGRAM

6.3 Access to SetGenerally, at least 1 meter (3.3 feet) of clearance should be provided on all sides of thegenerator set for maintenance and service access. (Increase clearance by width of door ifoptional housing is used.) A raised foundation or slab of 152 mm (6 inches) or more above floorlevel will make servicing easier. Lighting should be adequate for operation, maintenance andservice operations and should be connected on the load side of the transfer switch so that it isavailable at all times.

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6.4 Vibration Isolator InstallationNOTICE

Ensure that the equipment is stable before installation of the vibration isolator.

1. Place the vibration isolator (FSR Mounting - Free Standing Restrain) under the supportpoint of the equipment, ensure that the load is uniformly distributed over the top plate of thevibration isolator as shown in Figure A & B see Figure 4.

2. Adjust the FSR Mounting.

NOTICEThe FSR Mounting shown is pre-assembled with a suitable spacer (6mm). Do notmake any adjustment before installation. Adjustment of the FSR Mounting shouldbe done when the equipment is at its operating weight. (Refer to Figure A of Figure4.)

a. With the 6 mm spacer in position as shown, tighten the positioning nut.

b. Turn, the adjusting bolt of the spring counter-clockwise to load the spring. Load all theFSR at the same time to ensure that the total load is uniformly spread onto all theFSR mounts.

c. Continue the previous step until the spring load equal to the load of the equipment.

d. When equilibrium point is reached, the 6 mm spacer can be removed from the FSRmount. (Refer to Figure B of Figure 4.)

NOTICEBolting the equipment to the floor is optional, the vibration isolators (FS - FreeStanding, FSR - Free Standing Restrain, FSB - Free Standing Bolted) haveacoustical non-slip pads which prevent excessive movements.

CAUTIONWhen bolting is required, direct metal contact between the bolts must beavoided. This will prevent transmission or acoustical frequency.

CAUTIONFor safety reason, it is recommended to lift up the equipment whilepositioning the vibration isolators.

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FIGURE 4. VIBRATION ISOLATORS

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7 Mechanical ConnectionsThe generator set mechanical system installation includes connecting the fuel, exhaust,ventilation and cooling systems. Before starting any type of fuel installation, all pertinent stateand local codes must be complied with and the installation must be inspected before the unit isput in service.

7.1 OverviewThe generator set mechanical system installation includes connecting the fuel, exhaust,ventilation and cooling systems. Before starting any type of fuel installation, all pertinent stateand local codes must be complied with and the installation must be inspected before the unit isput in service.

NOTICEAll pipe threaded fuel system fittings, including container fittings, must be assembledusing a pipe joint sealing compound designed for use with LPG/NG.

7.2 Fuel SystemGensets can be equipped to operate on:

• LPG (vapor or liquid withdrawal)

• NG (natural gas) or

• Combination (NG/LPG)

In all fuel system installations, cleanliness is of the upmost importance. Make every effort toprevent entrance of moisture, dirt or contaminants of any kind. Clean all fuel systemcomponents before installing

7.3 Fuel Lines RoutingA flexible fuel hose(s) or section of flexible fuel hose(s) must be used between the engine's fuelsystem and fuel supply line to protect the fuel system from damage caused by vibration,expansion and contraction.

WARNINGFuel leaks create fire and explosion hazards which can result in severe personal injury or death.Always use flexible tubing between engine and fuel supply to avoid line failure and leaks due tovibration. The fuel system must meet applicable codes.

Installation of the fuel hose must be done according to all applicable codes and standards, andinstallation recommendations provided by the manufacturer. The flexible hose used must beapproved by the hose manufacture for use with the genset fuel type and product application.

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

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7. Mechanical Connections 9-2015

WARNINGSparks and hot surfaces can ignite fuel, leading to severe personal injury or death. Do not routefuel lines near electrical wiring or hot exhaust parts.

Fuel lines must be routed and secured to maintain a 2 inch (51 mm) minimum clearance fromelectrical wiring and hot exhaust parts.

7.4 Natural Gas/LPG Vapor/LPG Liquid Fuel SystemWARNING

Gaseous fuels are flammable and explosive and can cause severe personal injury or death. Donot smoke if you smell gas or are near fuel tanks or fuel-burning equipment or are in an areasharing ventilation with such equipment. Keep flames, sparks, pilot lights, electrical arcs andarc-producing equipment and all other sources of ignition well away from genset and areassharing ventilation. Keep a type ABC fire extinguisher handy.

NFPA Standard No. 58 requires all persons handling and operating LPG to be trained inproper handling and operating procedures.

Gaseous-fuel supply system design, materials, components, fabrication, assembly, installation,testing, inspection, operation and maintenance must comply with the applicable codes. SeeNFPA Standards No. 37, No. 54 and No. 58.

Most codes require both manual and electric (battery-powered) shutoff valves ahead of theflexible fuel hose(s). The manual valve should be of the indicating type. The electric valveshould be wired so that the valve is closed when the genset is off.

Install a dry-type fuel filter ahead of the service pressure regulator to protect the sensitivepressure regulating components and orifices downstream from rust, scale and other solidsubstances carried along in the gas stream.

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

7.5 Fuel PressureWARNING

High gas supply pressure can cause gas leaks which can lead to fire and severe personal injuryor death. Gas supply pressure must be adjusted to Specifications by qualified personnel.

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The gas pressure regulators in each line provide constant gas pressure at the gas mixer undervarying load conditions. There are pressure test ports on both sides of the regulator formeasuring supply and regulated fuel pressures (NG or LPG systems). When measuring supplypressure, the most accurate reading would be on the input side of the solenoid valve.

• Mixerside: The NG gas pressure should be approximately negative 0.4" WC (0.1 kPa) andno load and negative 1.5" WC (0.48 kPa) at full load. The LP gas pressure should beapproximately negative 0.4" WC (0.1 kPa) and no load and negative 1.5" WC (0.48 kPa) atfull load.

• Supply side: The minimum pressure refers to supply pressure under rated load (maximumgas flow).

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

For LPG (liquid withdrawal), the maximum permissible fuel supply pressure is 312 psi(2,153 kPa) under any operating condition.

WARNINGGaseous fuel leaks into an inadequately ventilated space can lead to explosive accumulations ofgas. Natural gas rises when released into the air and can accumulate under overhanging hoodsand inside housings and buildings. LPG sinks when released into the air and can accumulateinside housings, basements and other below-grade spaces. Precautions must be taken toprevent gas leaks and the accumulation of gaseous fuel in the event of a leak.

7.6 Check Gas Leaks and CorrectAll fuel-system connections, including the container with associated valves and fittings, must betested for leaks with a soap and water solution or equivalent, while the system is underpressure. LP gas pressure should not be less than 90 psi (621 kPa) at the inlet of the primaryregulator for this test.

7.7 Exhaust SystemPipe exhaust gases to the outside of any enclosure. Locate the exhaust outlets away from anyair inlets to avoid gases re-entering the enclosure. Exhaust installations are subject to variousdetrimental conditions such as extreme heat, infrequent operation and light loads. Regularlyinspect the exhaust system both visually and audibly to see that the entire system remains fumetight and safe for operation.

WARNINGInhalation of exhaust gasses can result in severe personal injury or death. Use extreme careduring installation to provide a tight exhaust system. Terminate exhaust pipes away fromenclosed or sheltered areas, windows, doors and vents.

For indoor installation, the exhaust system should use sealed joint type fittings where possibleto provide a tight exhaust system. Use of slip type fittings (secured with a clamp) may allowleakage of exhaust gases into the building if not fitted correctly fitted. Check there are noexhaust leaks.

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WARNINGInhalation of exhaust gasses can result in severe personal injury or death. Use extreme careduring installation to provide a tight exhaust system.

Use an approved thimble (see Figure 5) where exhaust pipes pass through wall or partitions.Insulated wall/roof thimbles are used where exhaust pipes pass through a combustible roof orwall. This includes structures, such as wood framing or insulated steel decking, etc. Uninsulatedwall/roof thimbles are used where exhaust pipes pass through a non-combustible wall or roof,such as concrete. When a unit is provided with a partially installed or incomplete exhaustsystem, exhaust piping and chimneys shall be designed, constructed, and installed inaccordance with the Standard for the Installation and Use of Stationary Combustion Enginesand Gas Turbines, NFPA 37 or applicable local standards. Build according to the coderequirements in effect at the installation site.

WARNINGHot exhaust pipes can start a fire and cause severe injury or death if improperly routed throughwalls. Use an approved thimble where exhaust pipes pass through wall or partitions.

WARNINGInhalation of exhaust gases can result in severe personal injury or death. do not use exhaustheat to warm a room, compartment or storage area.

Rain caps are available for the discharge end of vertical exhaust pipes. The rain cap clampsonto the end of the pipe and opens due to exhaust discharge force from the generator set.When the generator set is stopped, the rain cap automatically closes, protecting the exhaustsystem from rain, snow, etc.

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

CAUTIONWeight applied to the engine manifold can result in turbocharger damage. Support the silencerand exhaust piping so no weight or stress is applied to the engine exhaust elbow.

The exhaust system design should meet local code requirements.

NOTICELiability for injury, death, damage, and warranty expense due to use of unapproved silencers ormodifications to the exhaust system becomes the responsibility of the person installing theunapproved silencer or performing the modification. Contact your authorized distributor forapproved exhaust system parts.

Avoid sharp bends by using sweeping, long radius elbows and provide adequate support for thesilencer and tailpipe. Pitch a horizontal run of exhaust pipe downward (away from engine) toallow any moisture condensation to drain away from the engine. If an exhaust pipe must beturned upward, install a condensation trap at the point where the rise begins see Figure 6.

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Shield or insulate exhaust lines if there is danger of personal contact. Allow at least 305 mm (12inches) of clearance if the pipes pass close to a combustible wall or partition. Before installinginsulation on exhaust system components, check the exhaust system for leaks while operatingthe generator set under full load and correct all leaks.

If the exhaust line must be pitched upward, construct a condensation trap at the point of rise.Avoid sharp bends and drain the trap periodically.

WARNINGExhaust pipes are very hot and they can cause severe personal injury or death from directcontact or from fire hazard. Shield or insulate exhaust pipes if there is danger of personalcontact or when routed through walls or near other combustible materials.

1 Rain Cap 6 230mm (9 inches)

2 Drip Cap 7 Vertical Alignment

3 Holes in End of Inner sleeve 8 Wall or Partition

4 Roof 9 Horizontal Alignment

5 230mm (9 inches)

FIGURE 5. MOUNTING EXHAUST THIMBLE

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FIGURE 6. CONDENSATION TRAP

7.8 Ventilation and CoolingWARNING

Toxic GasesEngine and radiator cooling air may carry carbon monoxide gas, which can cause asphyxiationand death.Pipe exhaust gas outside and away from windows, doors, or other inlets to buildings. Do notallow exhaust gas to accumulate in habitable areas.

Generator sets create considerable heat that must be removed by proper ventilation.

Generator sets in factory-mounted housings for outdoor installation are designed for propercooling and ventilation.

Indoor installations require careful design with respect to cooling and ventilation. In an indoorinstallation, all radiator cooling air must be discharged to the out-of-doors. Duct adapter kits areavailable.

Outdoor installations normally rely on natural air circulation but indoor installations need properlysized and positioned vents for required airflow.

7.9 Vents and DuctsFor indoor installations, locate vents so incoming air passes through the immediate area of theinstallation before exhausting. Install the air outlet higher than the air inlet to allow for convectionair movement.

Size the vents and ducts so they are large enough to allow the required flow rate of air.

NOTICEThe "free area" of ducts must be as large as the exposed area of the radiator. Refer to thegenerator set Specification Sheet for the airflow requirements and allowed airflow restriction.

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Wind will restrict free airflow if it blows directly into the air outlet vent. Locate the outlet vent sothe effects of wind are eliminated, or if outlet vent cannot be located as mentioned, install a windbarrier, see Figure 7.


1 Prevailing Wind Away from Air Outlet Vent 2 Prevailing Wind Towards Air Outlet Vent, WindBarrier Installed

FIGURE 7. WIND BARRIER

7.10 DampersDampers or louvers protect the generator set and equipment room from the outsideenvironment. Their operation of opening and closing should be controlled by operation of thegenerator set.

In cold climates, the radiator exhaust air can be recirculated to modulate the ambient airtemperature in the generator set room. This will help the generator set warm up faster, and helpto keep fuel temperatures higher than the cloud point of the fuel. If recirculation dampers areused, they should be designed to 'fail closed', with the main exhaust dampers open, so that thegenerator set can continue to operate when required. Designers should be aware that thegenerator set room operating temperature will be very close to the outdoor temperature, andeither not route water piping through the generator set room, or protect it from freezing.

7.11 Radiator Set RequirementsLouvers and screens over air inlet and outlet openings restrict air flow and vary widely inperformance.

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

Radiator set cooling air is drawn past the control end of the set by a pusher fan that blows airthrough the radiator. Locate the air inlet to the rear of the set. Make the inlet vent opening 1½inches times larger than the radiator area.

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

A flexible duct connector must be provided at the radiator to prevent exhaust air recirculationaround the radiator, to take up generator set movement and vibration, and prevent transmissionof noise. Attach a canvas or sheet metal duct to the air outlet opening using screws and nuts sothat the duct can be removed for maintenance purposes. Before installing the duct, remove theradiator core guard.

1 Cool Air Inlet Damper 5 Flexible Duct Connector

2 Engine Driven Fan 6 Hot Air Outlet Damper

3 Radiator 7 Distance Should Not be Less Than Height ofRadiator

4 Thermostat Controlled Re-circulating Damper 8 Wind / Noise Barrier

FIGURE 8. TYPICAL RADIATOR SET INSTALLATION

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8 DC Control WiringThe generator set control box contains connection points for remote control and monitor options.

CAUTIONStranded copper wire must be used for all customer connections to the control panel. Solidcopper wire may break due to the generator set vibration.

Use flexible conduit for all wiring connections to the generator set.

WARNINGHazardous voltage! Touching uninsulated high voltage parts inside the control box can result insevere personal injury or death. Make sure all power is off before performing control wireinstallation.

WARNINGTo prevent accidental electrocution stand on a clean dry wooden platform or clean rubberinsulating mat, make sure your clothing and shoes are dry, remove jewlery and use tools withinsulated handles.

Route the control wiring through the bottom of the control housing, keep DC wiring away fromhigh voltage AC wiring.

Use cable ties to keep control wiring away from sharp edges and AC power cables within thecontrol housing.

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8. DC Control Wiring 9-2015

NO DESCRIPTION

1 Network Communication Module

2 Control Relays (K10, K11, K12) & control Box Heater

3 Strain–Relief Connector

FIGURE 9. SUGGESTED CUSTOMER WIRE ROUTING

8.1 PCCnet devices Belden cableNOTICE

When using any PCCNet device on a generator set control application, the wiring used toconnect ALL devices in the network must be Belden 9729 Two Pair, Stranded, Shielded TwistedPair Cable (24 AWG).

8.2 TB1 Remote Monitor / Control ConnectionsCustomer monitor/control connections are attached to terminal block TB1. Optional equipment,such as sensing devices used to monitor generator set operation, remote start/stop switches,etc. are also attached to TB1.

Available options will vary between controller models.

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8.3 PCC 2100 TB1 Customer Connections


1 Remote start 12 Configurable output 3

2 Remote emergency stop 13 Configurable output 3 (common)

3 Remote fault reset 14 Configurable output 4

4 Configurable input 1 15 Configurable output 4 (common)

5 Configurable input 2 16 Not used

6 Configurable input 3 17 B+

7 Configurable input 4 18 B+

8 Configurable output 1 19 Switched B+

9 Configurable output 1 (common) 20 Ground

10 Configurable output 2 21 Ground

11 Configurable output 2 (common) 22 Ground

FIGURE 10. PCC 2100 TB1 CUSTOMER CONNECTIONS

8.4 TB1 Customer InputsRemote Start: When the control is in Auto/Remote mode, grounding this input initiates theengine cranking and start sequence. This circuit must be opened to permit resetting a shutdowncondition with the Reset input. (The remote stop is actually the removal of the remote startsignal to the control.)

Remote Emergency Stop: Opening this input causes an immediate shutdown. Emergency stopmust be reset at the front panel.

Customer Fault Inputs 1 through 4: Grounding any one of these inputs activates thecorresponding warning or shutdown sequence.

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NOTICEAll four customer inputs may not be available. Customer inputs can be prewired from the factoryfor genset optional/standard features.

External sensing equipment must be connected to the designated digital input.

The nature of the fault is an optional customer selection. Example inputs: Low Coolant Level,Low Fuel Pressure, Low Fuel Day Tank, Water In Fuel, Ground Fault, Low Starting HydraulicPressure, Low Starting Air Pressure, etc.

Each of the two fault functions can be programmed as follows:

Status, Warning or Shutdown. Default = Warning.

NOTICEThe InPower Service Tool or access to the Setup Submenus is required to modify the customerfault inputs. Contact your authorized distributor for assistance.

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 - None

2 through 4 - Warning

• Active closed or open. Default setting:

Closed [ground] 1 through 4

• Change display name using up to 19 characters. Default setting:

1 - Customer Fault 1

2 - Ground Fault

3 - Low Fuel

4 - Rupture Basin Fault

8.5 TB1 Customer OutputsCustomer Outputs 1 through 4: One set of normally open (NO) contacts, rated for 2 amps at30 VDC for each of the four output signals. The relays can be used to control small devices andindicator lamps.

The nature of the customer output signal (contacts closed) is an optional customer selection.Example outputs: Genset running, common warning, common fault, load shed, ready to load,etc.

Each relay can be independently programmed (using InPower) to energize as follows.

• Enable/disable output. Default setting:

Enable 1 through 4

• Status, Warning or Shutdown. Default setting:

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1 - Common warning

2 - Common shutdown

3 - Not in Auto

4 - Ready to Load

The customer outputs can also be connected to three control relays (optional) to operate largerequipment, such as, fans, pumps and motorized air dampers. Refer to Control Relays foradditional information.

B+: This is a fused 10 amp, 12/24 volt output. (Fuse F1 is located on Base board.) Twoterminals (TB1-17 and -18) are connected to this 10 amp circuit.

Switched B+: This is a fused 5 amp, 12/24 volt switched output. This output is activated whenthe control receives a run command. (Fuse F2 is located on Base board.)


1 Customer Output Relay 1 (NO) 7 Customer Output Relay 4

2 Customer Output Com 1 8 Customer Output Com 4

3 Customer Output Relay 2 (NO) 9 Spare

4 Customer Output Com 2 10 B+ Fused Out

5 Customer Output Relay 3 (NO) 11 Switched B+

6 Customer Output Com 3 12 Ground

FIGURE 11. SUGGESTED CUSTOMER WIRE ROUTING

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8.6 Switched B+Switched B+ is fused at 5 Amps. Wiring is the same as the Relay Connection description.

8.7 Run Relays (K10, K11, K12)CAUTION

Damage to the Base board can occur if the voltage suppressors (Figures 5-2 and 5-3) are notinstalled across relay coils (A1/A2) of control relays K11, K12 and K13 before connecting gensetbattery cables.

The three optional control relays are rail mounted inside the control panel housing. Each relay isa 4-pole relay with 2 poles normally open and two poles normally closed.

These relays are used to control auxiliary equipment, such as fans, pumps and motorized airdampers. Energizing of the relays is user definable.

The contacts are rated at 10 amps at 600 VAC.

Refer to Customer Connections diagram.

FIGURE 12. OPTIONAL CONTROL RELAYS (K10, K11, K12)

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1 Base Board 5 Terminal End Bracket

2 Terminal Din Rail 6 Control Relays

3 Terminal End Bracket 7 Voltage Suppressor

4 Screw

FIGURE 13. CONTROL PANEL BOX

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9 AC Electrical ConnectionsWARNING

Arc Flash and Shock HazardVoltages and currents present an electrical shock hazard that can cause severe burns or death.Make sure that only service personnel who are trained and experienced perform electrical andmechanical component installations. The AC sensing harness and other cabling will becomeenergized when the generator set is in operation.

WARNINGHazardous VoltageContact with high voltages can cause severe electrical shock, burns, or death.Make sure that only personnel who are trained and qualified to work on this equipment areallowed to operate the generator set and perform maintenance on it.

WARNINGAutomated MachineryAccidental or remote starting of the generator set can cause severe personal injury or death.Isolate all auxiliary supplies and use an insulated wrench to disconnect the starting batterycables (negative [–] first).

WARNINGCombustible GasesIgnition of battery gases is a fire and explosion hazard which can cause severe personal injury ordeath.Do not smoke, or switch the trouble light ON or OFF near a battery. Touch a grounded metalsurface first before touching batteries to discharge static electricity. Stop the generator set anddisconnect the battery charger before disconnecting battery cables. Using an insulated wrench,disconnect the negative (–) cable first and reconnect it last.

WARNINGElectric Shock HazardVoltages and currents present an electrical shock hazard that can cause severe burns or death.Avoid contact with the voltage sense and bus sense leads; voltages of up to 600 VAC may stillbe present. These voltages could be live even when the generator set is switched off.

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

Before making any AC electrical connections, make certain the generator set cannot beaccidentally started. Make sure the Operator Panel is in OFF mode. Turn off or remove ACpower from the battery charger and then remove the negative (–) battery cable from the setstarting battery using an insulated wrench.

If the generator set is being installed in an application where it may parallel with othergenerators or utility sources, the generator set control system may be energized from anexternal source. Lock out tag out any external source that can provide AC power to thegenerator set.

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9. AC Electrical Connections 9-2015

NOTICEVentilate the battery area before working on or near battery. Wear goggles. Stop the generatorset and disconnect the battery charger before disconnecting battery cables. Disconnect negative(–) cable first and reconnect last using an insulated wrench.

Connecting the generator set AC electrical system involves:

• Installation of transfer switch

• Installation or verification of paralleling switchboard

• Generator output voltage selection

• Load cable connection

• Standard and optional AC equipment connections (e.g., control box heater, coolant heater,etc.).

When field connection is made at the alternator terminations, installation should be completedwith UL (or local code) listed conductors and connectors of appropriate size and rating. Strainrelief, bending space, raceway, and other installation features should be completed incompliance with local code.

Local regulations often require that wiring connections be made by a licensed electrician, andthat the installation be inspected and approved before operation. All connections, wire sizes,materials used, etc. must conform to the requirements of electrical codes in effect at theinstallation site.

Before starting the generator set, check to make sure that all electrical connections are secure,and that all wiring is complete. Replace and secure any access panels that have been removedduring installation. Check that the load cables from the generator set are properly connected.

NOTICEBackfeed to a utility system can cause electrocution or property damage. Do not connect to anybuilding electrical system except through an approved device and after the building main switchis opened.

9.1 Transfer SwitchA transfer switch must be used for switching the load from the normal power source to thegenerator set (see Figure 14). Follow the installation instructions provided with the transferswitch when connecting the load and control wiring.

46 A030G175 (Issue 5)

9-2015 9. AC Electrical Connections


1 Normal Power Source 3 Load

2 Overcurrent Protective Device 4 Emergency Power Source

FIGURE 14. TYPICAL LOAD TRANSFER FUNCTION

9.2 Alternator Voltage ConnectionsThese alternators can be configured to the nameplate voltages as shown on the ReconnectionDiagram decal, attached to the backside of the control box cover. Many of the voltages listedwill require reconfiguration of the alternator output leads on the connection terminal block. Thisreconfiguration must only be done by service personnel that are trained and experienced toperform electrical installation. The generator set was adjusted to produce a specified voltageduring production verification testing prior to shipment. The installer must always check thestator lead terminal block connections and perform any necessary reconnect to obtain thevoltage required.

Some generator sets are capable of producing a wide range of voltages and connectionconfigurations; others have specific limited capabilities. Refer to wiring diagram and generatorvoltages (from the nameplate) when reviewing the voltage connection information and use thewiring diagram supplied with your generator set when actually performing load connections.

NOTICEReconfiguring generator sets to higher voltages can exceed the voltage capability of the specificgenerator windings and damage the generator and also decrease line current, rendering linecircuit breakers too large. Consult with your authorized distributor before performingreconnection for a different voltage.

NOTICEReconfiguring generator sets to lower voltages can reduce generator set ratings, and alsoincrease line current, rendering line circuit breakers too small. Consult with your authorizeddistributor before performing reconnection for a different voltage.

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9.3 Load ConnectionsNOTICE

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

All loads are connected to the alternator by bolting stranded load wires to the appropriateterminals on the alternator reconnection terminal block or circuit breaker lugs. The terminals aremarked U, V, W, and N to indicate the line and neutral connections. (Reference: U, V, and Wcorrespond with L1, L2 and L3; and N with L0 respectively). See Appendix C on page 83 fordetails about the following:

• Load connections

• Conduit

• Cable Size

9.4 Load BalancingWhen connecting loads to the generator set, balance the loads so that the current flow fromeach line terminal (L1, L2, and L3) is about the same. This is especially important if both singlephase and three phase loads are connected. Any combination of single phase and three phaseloading can be used as long as each line current is about the same, within 10 percent of medianvalue and no line current exceeds the name plate rating of the generator. Check the current flowfrom each line after connections by observing the Operator Panel ammeter.

9.5 Current TransformersCurrent transformers (CTs) reduce high voltage currents (AC) to enable safe monitoring.

9.5.1 CT Installation RequirementsThe CT has a dot on one side. This dot must be facing toward the alternator reconnectionterminal block (conventional current flowing into the dot). A dot is also used to indicate pin 1 ofthe CT.

Route the load lead through the appropriate CT (refer to the Reconnection Diagram inAppendix A on page 63.

The CTs have dual secondarys (3 pins). The CT secondary wire marked 1 is connected to pin 1of the CT. CT secondary wire marked 2/3 is connected to pin 3 for low voltage generator sets.

9.6 GroundingWARNING

Electric Shock HazardVoltages and currents present an electrical shock hazard that can cause severe burns or death.Make sure that only service personnel who are trained and experienced perform electrical andmechanical component installations. Bonding and grounding must be done properly. All metallicparts that could become energized under abnormal conditions must be properly grounded.

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System and equipment grounding of permanently installed AC generators within a facility wiringsystem.

NOTICEIt is important to follow the requirements of the local electrical code.

Figure 15, Figure 16 and Figure 17 illustrate typical system grounding for a 2-pole, 3-pole, and4-pole Automatic Transfer Switcsh (ATS). In the 2-pole and 3-pole ATS, note that the generatorneutral is connected to the ATS and is NOT bonded to ground at the generator. In the 4-poleATS system, a grounding electrode conductor and a bonding jumper are used to connect thegenerator neutral to ground.

Make sure the generator set is grounded to earth in one location only. On generator sets withouta circuit breaker, ground to the point indicated on the top of the generator. On generator setswith circuit breakers, use the ground lug provided in the circuit breaker box.

No. Description

1 Service Entrance

2 2-Pole ATS

3 Generator Set

4 Load

FIGURE 15. TYPICAL SYSTEM - ONE-PHASE, THREE WIRE UTILITY, TWO-POLE ATS

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No. Description

1 Service Entrance

2 3-Pole ATS

3 Generator Set

4 Load

FIGURE 16. TYPICAL SYSTEM - THREE-PHASE, FOUR WIRE UTILITY, THREE-POLE ATS

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No. Description

1 Service Entrance

2 4-Pole ATS

3 Generator Set

4 Load

FIGURE 17. TYPICAL SYSTEM - THREE-PHASE, FOUR WIRE UTILITY, FOUR-POLE ATS

9.7 Coolant Heater ConnectionNOTICE

The coolant heater must not be operated while the cooling system is empty or damage to theheater will occur.

A coolant heater keeps the engine coolant warm when the engine is shut down. It heats andcirculates the coolant within the engine. This reduces start-up time and lessens engine wearcaused by cold starts. It is electrically operated and thermostatically controlled.

Refer to Appendix B for electrical connections.

9.8 Alternator Heater (Option)An alternator heater(s) is used to help keep the alternator free of condensation when thegenerator set is not running. During cool and humid conditions, condensation can form within aalternator, creating flashing and shock hazards.

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WARNINGWater or moisture inside an alternator increases the possibility of flashing and electrical shock,which can cause equipment damage and severe personal injury or death. Do not use a alternatorwhich is not dry inside and out.

The figure below shows the installation of two heater elements. Connect the heater(s) terminalsto a source of power that will be on during the time the engine is not running. Be sure the supplyvoltage and circuit amperage is correct for the heater element rating.

NO DESCRIPTION NO DESCRIPTION

1 Heater 3 Heater Leads

2 Heater Terminal Box (View AA)

FIGURE 18. ALTERNATOR HEATER

52 A030G175 (Issue 5)

10 Pre-Start PreparationBefore attempting an initial start of the generator set, be sure to complete the InstallationChecklist, see Chapter 11 on page 59.

WARNINGMake sure that all items listed in the Installation Checklist are carried out beforestarting the generator set. The failure to do a complete installation can result inequipment damage and severe personal injury or death.

10.1 InPower Service Tool General InformationInPower is a PC based service tool for the PowerCommand 2100 Control (PCC). Use InPowerto:

• Make adjustments to the control's trims and settings.

• Perform diagnostics and monitoring.

• Create a capture file of the controls trims and settings.

• Update control calibrations (InPower PRO version).

NOTICERefer to the InPower User's Guide for specifics.

10.1.1 InPower Adjust ModeThe adjustment feature allows you to make adjustments to genset parameters, calibrations andsettings. There are several groups of adjustment parameters; note that not all gensets will havethe same adjustments available.

10.1.2 InPower Capture File DescriptionInPower provides a method of extracting (capturing) a device's parameter values. Capturingsaves device information in a file that is identified with a .CAP extension.

Capture files are used to store a copy of the genset's parameter values. During gensetinstallation, it is suggested that a capture file be made before and after changes are made to thegenset operating parameters. This information can be a very useful when troubleshooting thegenset (determine if parameters/settings have been modified after installation) and whenreplacement of the Base board is necessary. The capture file can be used as a template to writethe previous settings to the new Base board software.

10.2 Electrical SystemVerify all electrical connections are secure and all wiring is complete and inspected. Replaceand secure any access panels that may have been removed during installation.

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10. Pre-Start Preparation 9-2015

10.3 Battery ConnectionsWARNING

Automated MachineryAccidental or remote starting of the generator set can cause severe personal injury or death.Make sure that the generator set can not be started accidentally or remotely before starting workon the generator.

WARNINGCombustible GasesIgnition of battery gases is a fire and explosion hazard which can cause severe personal injury ordeath.Do not smoke, or switch the trouble light ON or OFF near a battery. Touch a grounded metalsurface first before touching batteries to discharge static electricity. Stop the generator set anddisconnect the battery charger before disconnecting battery cables. Using an insulated wrench,disconnect the negative (–) cable first and reconnect it last.

Starting the unit requires one or more batteries. For more information on batteries, refer toChapter 3 on page 15. To prevent arcing, use an insulated wrench to connect the positivebattery cable, then connect the negative battery cable.

If an automatic transfer switch is installed without a built-in charge circuit, connect a separatebattery charger. Proper selection and maintenance of batteries and battery chargers is essentialfor system reliability.

10.4 Controller Configuration RelaysThe figure below shows a block representation of the Controller Configuration menus.

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9-2015 10. Pre-Start Preparation

FIGURE 19. CONTROLLER CONFIGURATION MENU

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

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As shown in the diagram, the Controller Configuration menu has three submenus.

Press the buttons next to the up and down symbols in the digital display to navigate betweenthe menus.

Press the button next to the symbol in the display until the + and - symbols are displayed.

Press the button next to the + or - symbol to select the desired option.

After selecting option, pressing the symbol results in the changes being saved. If the Home

button or Previous Main Menu button is pressed before pressing the symbol, the changesare not saved.

Language Selected submenu: Used to select desired language (default = English).

Temperature Units submenu: Used to select Fahrenheit or Centigrade for temperaturereadings.

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

10.5 Adjust MenuThe figure below shows a block representation of the Adjust Menu. If you press the button nextto the word "Adjust" in the display, the first Adjust submenu option is displayed.

As shown in the diagram, the Adjust Menu has five submenus. Each submenu includes aparameter or value that can be changed.

Press the buttons next to the up and down symbols in the digital display to navigate betweenthe menus. Press the Home button or the Previous Main Menu button to return to Main Menu 1.

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9-2015 10. Pre-Start Preparation

FIGURE 20. ADJUST MENU

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10.5.1 Adjusting Values/Parameters1. Press the button next to the arrow symbol in the display until the + and - symbols are

displayed.

2. If necessary, press the button next to the or symbols to move to the numeric characteryou wish to change.

3. Press the button next to the + symbol to increase the value or select parameter; press thebutton next to the - symbol to decrease the value or select parameter.

4. After adjusting values/selecting parameters, pressing the arrow symbol results in thechanges being saved. (When adjusting values, make sure the cursor is on the last numericcharacter before pressing the arrow symbol).

If the Home button or Previous Main Menu button is pressed before pressing the arrowsymbol, the changes are not saved.

10.5.2 Adjust Submenus• Voltage Adjust submenu: Voltage can be adjusted to ±5 percent of the nominal voltage.

For example, if genset output voltage is 208 volts, the voltage can be adjusted from 197 to218 volts.

If the revised value is greater or less than the allowed (5%) range, the control will round offthe displayed value (up or down). For example, if changing the value by -5% (maximum)equals 197.6, the display will show 197, but will display and change the output to 198when saved.

• Frequency Adjust submenu: Frequency can be adjusted to ±5 percent of the nominalfrequency. For example, if the genset frequency is 60.0 Hz, the frequency can be adjustedfrom 57.0 to 63.0 Hz.

• Start Delay submenu: Start Delay can be set from 0 to 300 seconds (default = 0). Thisfunction is bypassed during a manual start/stop sequence.

• Stop Delay submenu: Stop Delay can be set from 0 to 600 seconds (default = 0). Thisfunction is bypassed during a manual start/stop sequence and engine shutdown faults.

• Rated To Idle (Beginning Version 2.303): Rated To Idle delay can be set from 0 to 10seconds (default = 0). (Enter 1 or more to enable.) Entering a non-zero delay will cause thegenset to delay the transition to Cooldown At Idle.

• Idle Start submenu (Only available on some models): Idle Start can be enabled ordisabled (default = Disable). This function is only enabled when the genset is started inmanual mode. Idle Start can also be enabled while the set is running in manual mode.

Enabling Idle Start will cause the genset to run in idle mode until Idle Start is disabled. Awarning is displayed if genset is left in idle more than 10 minutes. Long periods of engineidling can eventually affect engine performance and may void engine warranty.

10.6 StartingRefer to the generator set Operator manual for important safety precautions and recommendedprocedures for starting the generator set and verifying proper operation. Start the generator setand verify all engine and generator set menus are displaying the correct values.

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11 Installation ChecklistTick General Items

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 the entire generator set forservice and ventilation.

The generator set is located in an area not subject to flooding.

All operating personnel have read and are familiar with Generator Set Operator manual and Health AndSafety manual.

All operators have been thoroughly briefed on preventative maintenance procedures.

All operators have read and understand all important safety instructions.

Generator Set Support

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

Generator set is properly supported and retained to approved base

Supporting base is large enough and is of non-combustible material, extending 6 inches all around thegenerator 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 to 11/2 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.

Natural Gas/LP Vapor/LPG Liquid Fuel System

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

Approved flexible fuel line is installed between main fuel supply and generator set’s fuel system near thegenerator set, to protect it against damage caused by vibration, expansion and contraction.

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

Fuel system is properly primed.

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

Check the fuel line and use equations to verify that it has proper volume capability.

Check if fuel pressure is between 7-13 inches water column.

Make sure fuel pressure does not drop below 7 inches water column under full load.

If necessary, perform initial demand regulator adjustment procedure.

Exhaust System

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

Areas around generator set are well ventilated. No possibility of exhaust fumes entering building doors,windows, or intake fans.

Exhaust gases are piped safely outside and away from building.

The correct length of approved rigid pipe is connected to the generator set flexible pipe using approvedsecuring methods with no weight resting on engine exhaust components. There are no bends in flex section.

Condensation drain is provided in lowest section of exhaust piping.

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11. Installation Checklist 9-2015

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 compliancewith 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 well made and correct.

Flexible conduit is used between generator and building or surrounding structure.

Generator Set Pre-Start

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 correctly.

All fuel and coolant shutoff valves are operational.

Radiator Fan and other external moving parts including drive belts are unrestricted.

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12 Manufacturing FacilitiesNORTH AMERICA EMEA, CIS ASIA PACIFIC

Cummins Power Generation Limited Cummins Power Generation Limited Cummins Power Generation Limited1400 73rd Ave. NE Columbus Avenue 10 Toh Guan Road #07-01Minneapolis, MN 55432 USA Manston Park TT International Tradepark

Manston, Ramsgate Singapore 608838Kent CT12 5BFUnited Kingdom

Phone +1 763 574 5000 Phone +44 1843 255000 Phone +65 6417 2388Toll Free +1 800 888 6626 Fax +44 1843 255902 Fax +65 6417 2399Fax +1 763 574 5298

BRAZIL CHINA INDIA

Rua Jati, 310, Cumbica Cummins Power Generation Cummins India Ltd,Guarulhos, SP 07180-900 2 Rongchang East Street, Power Generation Business Unit,Brazil Beijing Economic – Technological Plot No B-2, SEZ Industrial Area,

Development Area Village-Nandal & Surwadi, Taluka-PhaltanBeijing 100176, P.R.ChinaDist- Satara, Maharashtra 415523India

Phone +55 11 2186 4195 Phone +86 10 5902 3000 Phone +91 021 66305514Fax +55 11 2186 4729 Fax +86 10 5902 3199

LATIN AMERICA MEXICO

3350 Southwest 148th Ave. Eje 122 No. 200 Zona IndustrialSuite 205 San Luis Potosi, S.L.P. 78395Miramar, FL 33027 MexicoUSA

Phone +1 954 431 551 Phone +52 444 870 6700Fax +1 954 433 5797 Fax +52 444 824 0082

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12. Manufacturing Facilities 9-2015


62 A030G175 (Issue 5)

Appendix A. Alternator Reconnect Drawing

Table of ContentsFigure 21. A029P864 Sheet 1 ...................................................................................................................... 65Figure 22. A029P864 Sheet 2 ...................................................................................................................... 66Figure 23. A029P864 Sheet 3 ...................................................................................................................... 67Figure 24. A029P864 Sheet 4 ...................................................................................................................... 68Figure 25. A029P864 Sheet 5 ...................................................................................................................... 69

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Appendix A. Alternator Reconnect Drawing 9-2015


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9-2015 Appendix A. Alternator Reconnect Drawing

A.0 GGPA/B/C Wiring Diagram with PowerCommand 2100 Control

FIGURE 21. A029P864 SHEET 1

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Appendix B. Wiring Diagrams

Table of ContentsFigure 26. AC Reconnect Wiring Diagram (Sheet 1 of 2) ......................................................................... 74Figure 27. AC Reconnect Wiring Diagram (Sheet 2 of 2) ......................................................................... 75Figure 28. Customer Connections .............................................................................................................. 76Figure 29. Wiring Diagram - Generator Reconnect (Sheet 1 of 5) ........................................................... 77Figure 30. Wiring Diagram (Sheet 2 of 5) ................................................................................................... 78Figure 31. Wiring Diagram (Sheet 3 of 5) ................................................................................................... 79Figure 32. Wiring Diagram (Sheet 4 of 5) ................................................................................................... 80Figure 33. Wiring Diagram (Sheet 5 of 5) ................................................................................................... 81Figure 34. Genset Wiring Harness ............................................................................................................. 82

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Appendix B. Wiring Diagrams 9-2015


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9-2015 Appendix B. Wiring Diagrams

B.0 Wiring DiagramsNote: This section contains basic (generic) wiring diagrams and schematics for the controller and generator set.

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FIGURE 26. AC RECONNECT WIRING DIAGRAM (SHEET 1 OF 2)

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FIGURE 27. AC RECONNECT WIRING DIAGRAM (SHEET 2 OF 2)

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FIGURE 28. CUSTOMER CONNECTIONS

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FIGURE 29. WIRING DIAGRAM - GENERATOR RECONNECT (SHEET 1 OF 5)

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FIGURE 30. WIRING DIAGRAM (SHEET 2 OF 5)

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FIGURE 34. GENSET WIRING HARNESS

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Appendix C. Outline Drawings

Table of ContentsFigure 35. Outline Drawing (0500-5070) ..................................................................................................... 85Figure 36. Outline Drawing (0500-5030 Sheet 1) ....................................................................................... 86Figure 37. Outline Drawing (0500-5030 Sheet 2) ....................................................................................... 87Figure 38. Outline Circuit Breaker (0500-3278 Sheet 1) ........................................................................... 88Figure 39. Outline Circuit Breaker (0500-3278 Sheet 2) ........................................................................... 89Figure 40. Outline Circuit Breaker (0500-3278 Sheet 3) ........................................................................... 90Figure 41. Outline Drawing (0500-4814) .................................................................................................... 91Figure 42. Outline Drawing (0500-4813 Sheet 1) ....................................................................................... 92Figure 43. Outline Drawing (0500-4813 Sheet 2) ....................................................................................... 93Figure 44. Outline Drawing (500-3171) Sheet 1 ......................................................................................... 94Figure 45. Outline Drawing (500-3171) Sheet 2 ....................................................................................... 95Figure 46. Outline Drawing (0500-3167) ..................................................................................................... 96Figure 47. Outline Drawing (0500-3211) ..................................................................................................... 97

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Appendix C. Outline Drawings 9-2015

C.0 Outline DrawingsSee the applicable outline drawing in Appendix C on page 83 to check forinstallation details such as:

• mounting bolt hole locations• connection points (fuel, battery, raw water, exhaust, remote control, AC output)• sizes and types of fittings• overall dimensions

See your Cummins Onan Distributor for large-scale copies of the applicabledrawings.

WARNINGImproper installation can result in severe personal injury, death, andequipment damage. The installer must be qualified to perform installation ofelectrical and mechanical equipment.

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9-2015 Appendix C. Outline Drawings

C.1 Outline Drawing 0500-5070 (F177)

FIGURE 35. OUTLINE DRAWING (0500-5070)

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C.2 Outline Drawing 0500-5030 (F179)

FIGURE 36. OUTLINE DRAWING (0500-5030 SHEET 1)

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C.3 Outline Drawing 0500-3278 (Circuit Breaker)

FIGURE 38. OUTLINE CIRCUIT BREAKER (0500-3278 SHEET 1)

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C.4 GGHE/GGHF Enclosure Outline Drawing 0500-4814 (F217)


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FIGURE 44. OUTLINE DRAWING (500-3171) SHEET 1

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FIGURE 45. OUTLINE DRAWING (500-3171) SHEET 2

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power.cummins.comCopyright © 2015 Cummins Power Generation Inc. All rights reserved.Cummins Power Generation, the "C" logo, and Cummins are registeredtrademarks of Cummins Inc. PowerCommand, AmpSentry, InPower and "Ourenergy working for you." are trademarks of Cummins Power Generation.Other company, product, or service names may be trademarks or servicemarks of others. Specifications are subject to change without notice.

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