Home

Installation Manual

1. 75 Foundation Outline 30 40 kW 1800 RPM 36 60 kW 3600 RPM Sheet 1 of 1 76 Enclosure Outline 20 25 kW 1800 RPM 30 kW 3600 RPM Sheet 1 of 2 77 Enclosure Outline 20 25 kW 1800 RPM 30 kW 3600 RPM Sheet 2 of 2 78 Enclosure Outline 30 40 kW 1800 RPM 36 60 kW 3600 RPM Sheet 1 of 2 79 Enclosure Outline 30 40 kW 1800 RPM 36 60 kW 3600 RPM Sheet 2 of 2 80 Circuit Breaker Outline Sheet 1 of 1 81 Wiring Diagram Sheet 1 6 82 Wiring Diagram Sheet 2 of 6 83 Wiring Diagram Sheet 3 of 6 84 Wiring Diagram Sheet 4 of 6 85 Wiring Diagram Sheet 5 0 66 86 Wiring Diagram Sheet 6 of 6 87 A045R241 Issue 2 69 Appendix Outline and System Drawings 10 2013 This page is intentionally blank 70 A045R241 Issue 2 10 2013 A045R241 Issue 2 Appendix B Outline and System Drawings 5 4 i 3 2 PRODUCTION RELEASE D GILLE
2. SERVICE MENU 1 Setup Menus 2 History About 3 Screen Adjust More Options 1 2 3 ADJUST SCREEN Contrast mm Brightness Units F PSI 25705 7 ADJUST SCREEN Contrast Brightness Units FIGURE 19 BRIGHTNESS AND CONTRAST MENU NAVIGATION NOTICE Adjusting the brightness on the Operator Panel adjusts the brightness of both the LCD backlight and the LEDs on the display The contrast should never be 0 or 100 on any of the screens The default value for Brightness is 50 50 A045R241 Issue 2 10 2013 5 Startup and Configuration 5 2 History and About Menu To access the History About Menu 1 From any Information Menu hold down the up and down arrows simultaneously for two seconds The Service Menu appears 2 Select History About 3 Advance through the screens to view information about the generator set control and display NOTICE The following screens represent the standard operator panel HMI211 If using an in home operator panel which may be additionally purchased as an option the screens may look slightly different This procedure applies to both operator panels A045R241 Issue 2 51 5 Startup and Configuration 52 10 2013 SERVICE MENU 1 Setup Menus 2 History About 3 Screen Adjust More Options 1 2 3 h HISTORY Starts 1234567 Hours 123456 7 Control Hours 123456 7 _____
3. 18JUL13 COILS ECM POWER 2 2 POWER 0 USED POWER I I 52 im p DISPLAY PI E FUSED POWER TO COILS 25 STARTER SWITCH W 50 KEVSWITCH FUSED POWER SOLENOIDS 2 FLASH BATT CHARG ALT E POWER TO 1302 Weld BGRAPH P6 PCC 1302 TO PAGE 2 GENSET CONTROL m FOR EBS OPTION 6 4 ESTOP OPTION FOR INSTRUCTIONS GO TO PAGE SECTION FOR INSTRUCTIONS GO TO PAGE 6 SECTION A 5 f gt TO PAGE 2 STARTER SECTION 20 FUSED BATTERY 8 KEYSWITCH TO B POWER RELAY OUTPUT B GND GND GND GND GND CHASSIS LOW COOLANT LEVEL LOW FUEL LEVEL CANS CAN PCC PII CAN SHIELD Fiz 10A FUSE FOR ENGINE CONTROL MODULE ECM FOR EBS OPTION 2 FOR INSTRUCTIONS GO TO PAGE 5 A F2 15A FUSE FOR ENGINE SMART COILS SECTION B4 A F3 20A FUSE FOR 1302 GENSET CONTROL CAN wel HARNESS LEGEND F4 10A FUSE FOR SOLENOIDS 4 CHARGING ALTERNATOR 9 CONTROL 55 PT AN SHIELD A0436986 K2 POWER RELAY ENABLES SMART COILS NONE R TAMBOL KA STARTER RELAY ENABLES STARTER 5 imr m POWER GENERATION KS RUN RELAY ENABLES SOLENOIDS AND FLASHES BATTERY CHARGING ALTERNATOR a rec DIAGRAM WIRING K6 KEYSWITCH RELAY PROVIDES BATTERY POWER TO 5 AND SIGNALS Ene mm 45 AT
4. A299 2 RADIATOR FILL ENGINE COOLANT 50 50 MIXTURE H669 2 ENGINE COOLING HIGH AMBIENT AIR TEMPERATURE 125 2 11 5 pan m il THOS 44 2 D otra 1M he 2 31 227 DIP STICK 638 1 51 FUEL LINE PORT 2 1649 64 9 2X 2119 85 81 2204 SKID 87 61 20 0 11 0 00 5 4 T 3 FIGURE 31 meau Cumas Pow GEERATON 5 aro D_GILLETT 2 10 00 17 49 GILL OUTLINE GENSET 17 50 24 99 0 30 0 13 22MAYI3 _______ cot 1 1 APP CO 134616 1 LIMITED PRODUCTION RELEASE 22MAT13 NOTES 1 DIMENSIONS SHOWN IN ARE IN INCHES 2 REFER TO CIRCUIT BREAKER OUTLINE DRAWING FOR ELECTRICAL STUB UP AREA FOR SPECIFIC BREAKERS 3 CONTROL INTERFACE CONNECTIONS SHOULD BE MADE WITH FLEXIBLE CONNECTIONS 20 65 0 8 HOLES MARKED BY ror 4 POINT ISOLATION OR SECURING TO MOUNTING SURFACE 5 FUEL SUPPLY LINE AND RETURN LINE 1 INCH HOSE 10 BARB WITH 1 00 NPT CONNECTOR OIL DRAIN EXTENSION 3 8 INCH HOSE ID lt 4X 25 t 2X 814 321 864 SKID 341 GENERATOR SET OUTLINE 30 40 KW 1800 RPM 36 60 KW 3600 RPM SHEET 1 OF 2 73 74 Appendix Outline and System Drawings 10 2013 4 L 5
5. NI Lubricate the part or assembly Indicates a mechanical or time measurement Refer to another publication for additional information Indicates a removal or disassembly step Tighten to a specific torque Indicates parts or tools required Indicates that the component is heavy 50 Ib or 23 kg or more To reduce the possibility of personal injury use a hoist or get assistance to lift AOV NS er 2 3 Related Literature EES The literature provided with the generator set is as follows Installation Manual A045R241 Operator Manual A045R242 A generator set must be operated and maintained properly if you are to expect safe and reliable operation The Operator Manual includes a maintenance schedule and a troubleshooting guide The Health and Safety Manual must be read in conjunction with this manual for the safe operation of the generator set Health and Safety Manual 0908 0110 Warranty Statement A028U870 10 A045R241 Issue 2 10 2013 2 Introduction Emissions Component Defect Warranty Statement 028 278 The relevant manuals appropriate to your generator set are also available The documents below are in English Service Manual 0458243 Parts Manual 0462674 E Controls Inc Service Manual A035C596 Global Control Platform GCP Engine Display Interface Software EDIS Training Manual A035C608 RA Series Transfer Switch Owner s Manual 0465594 i
6. 5 4 T 3 FIGURE 29 GENERATOR SET OUTLINE 20 25 KW 1800 RPM 30 KW 3600 RPM SHEET 1 OF 2 71 Appendix Outline and System Drawings 10 2013 Creo Parametric 6 5 4 4 3 2 1 wis im vision e Wr ECO 134616 1 LIMI TED PRODUCT ION RELEASE tv 22 713 1 mim 1 1 1 __ ALTERNATOR BATTERY CHARGE FUEL SYSTEM NG LPV 4333 2 SINGLE FUEL C284 2 D D ENGINE AIR CLEANER HOSE FUEL NORMAL DUTY 0041 2 SEE NOTE 5 gt lt COOLANT RECOVERY BOTTLE B B 8 36 5 902 135 833 32 ENGINE CRANKSHAFT OIL DRAIN EXTENSION ENGINE STARTER 12 VDC MOTOR H268 2 SEE NOTE 5 M422 2 A 8 ODAMEES IONS aa CUMMINS POWER GENERATION 1 6 0 00 4 99 0 15 0 08 2 aaen OUTLINE GENSET 0 00 17 50 24 99 0 30 0 13 22MAYI3 22MAY13 SITE CODE Por 8 A045C2 1 6 5 4 ED 3 2 1 FIGURE 30 GENERATOR SET OUTLINE 20 25 KW 1800 RPM 30 KW 3600 RPM SHEET 2 OF 2 72 A045R241 Issue 2 10 2013 A045R241 Issue 2 Appendix B Outline and System Drawings Creo Parametric 6 ELECTRICAL LOWER STUB UP 125 X 470 151 18 5 831 32 1 CONTROL PCI I H700 2 5 4 3 DIM RACK BATTERY F065 2 5 AIR FLOW EXHAUST CONNECTOR
7. 1 9 2 3 2 9 3 0 4 0 4 6 6 4 7 9 M 14 3 Elbow 46 54 6 8 11 13 18 22 26 32 35 40 1 4 1 6 2 1 3 4 4 0 5 5 6 7 7 9 5 422 2 6 8 8 5 10 14 17 20 24 26 31 1 1 1 3 1 6 A 2 1 2 6 3 0 4 3 5 2 6 1 7 3 7 9 9 4 45 29 3 64 2 4 28 PN 17 19 22 Elbow 0 9 1 1 1 3 1 4 1 8 2 2 as ge 5 2 5 8 6 7 12 16 48 20 25 31 44 56 67 78 89 110 3 0 3 7 4 9 5 5 6 1 7 6 9 4 13 17 20 E i 18 Inch ad E dS 5 is tt T3 a a io oo 24 Inch T n 12 T za A m m me s TO ube 68 A045R241 Issue 2 Appendix Outline and System Drawings Table of Contents Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 Figure 36 Figure 37 Figure 38 Figure 39 Figure 40 Figure 41 Figure 42 Figure 43 Figure 44 Figure 45 Generator Set Outline 20 25 kW 1800 RPM 30 kW 3600 RPM Sheet 1 of 2 71 Generator Set Outline 20 25 kW 1800 RPM 30 kW 3600 RPM Sheet 2 of 2 72 Generator Set Outline 30 40 kW 1800 RPM 36 60 kW 3600 RPM Sheet 1 of 2 73 Generator Set Outline 30 40 kW 1800 RPM 36 60 kW 3600 RPM Sheet 2 of 2 74 Foundation Outline 20 25 kW 1800 RPM 30 kW 3600 RPM Sheet 1 of 1
8. 10 43 95 175 680 1400 2100 3950 6300 11000 23000 20 29 65 120 250 465 950 1460 2750 4350 7700 15800 30 24 52 97 200 375 770 1180 2200 3520 6250 12800 40 20 45 82 170 320 660 990 1900 3000 5300 10900 so 18 40 73 151 285 580 900 1680 2650 4750 9700 60 16 36 66 138 260 530 1520 2400 4300 8800 80 14 57 118 220 460 690 1300 2050 3700 7500 _9 13 29 53 110 205 430 650 1220 1950 3450 7200 100 12 27 50 103 195 400 620 1150 1850 3250 6700 125 11 24 44 93 175 360 550 1020 1650 2950 6000 150 10 22 40 84 160 325 500 950 1500 2650 5500 9 20 37 77 145 300 460 850 1370 2450 5000 8 19 72 135 280 430 1280 2280 4600 TABLE 18 NATURAL GAS SEMI RIGID COPPER TUBING SIZING Gas Natural Inlet Pressure 0 5 psi or less Pressure Drop 0 5 in w c Specific Gravity 0 6 Gas Natural Inlet Pressure 0 5 psi or less Pressure Drop 0 5 in w c Specific Gravity 0 6 Tube Size in toman sen ae Tae Outside 0375 inside __ 0 305 0 402 0 527 0 652 0 745 0 995 1 245 1 481 1 959 2 435 64 A045R241 Issue 2 10 2013 Appendix Fuel Line Selection Gas Natural
9. ABOUT GENSET Model Number ABCDEZS ASG 222 Control PCC1302 ABOUT GENSET KVA Standby Rating 1200 kVA ABOUT CONTROL P N 3260000 S N 0123456789 SW P N 3260000 SW Version 0 24 ABOUT DISPLAY SW P N 3260000 SCRNE Ver FAR Pah SCRN VER 1 50 DISP DEVICE ID 68 FIGURE 20 HISTORY ABOUT MENU A045R241 Issue 2 10 2013 5 3 Time Setup NOTICE When battery power is lost these settings must be reset To set up the generator set clock for the current date and time 1 Access the Time Setup Menu by selecting Clock Exerciser on the Genset Service Menu 2 Select Adjust When updating these settings the function of the keys are as follows settings on the screen Select the left arrow to return to the previous screen Menu the Adjust button TIME SETUP Date 00 00 00 mm dd yy Time 00 00 AM ADJUST P TIME SETUP Date 08 00 00 yy Time 00 00 AM SAVE FIGURE 21 TIME SETUP SCREEN Updating Daylight Saving Adjust Menu To update the Savings Time and Adjustment on the Daylight Saving Adjust Menu 1 Press the down key on the Time Setup Menu to access the Daylight Saving Adjust Menu 2 Select Adjust A045R241 Issue 2 5 Startup and Configuration The horizontal right arrow key is used to select successive blocks for editing Adjust values by using the or keys on the Adjust Menu of the Time Setup Press Save to s
10. ALTERNATOR SS m 10 hora lt __ 11 5 ADD NOTE EBS JACK 18JUL13 1 21 HARNESS LEGEND 6 EBS HARMESS A0422044 D PCCI302 ALTERNATOR FIELD PLUG gt a 185 FIELD 7 c EBS 1 PCC PI7 GENSET CONTROL 5 5 5 25 8 22 lt LINH Js RELAY COIL lt ELECTRONIC BOOST SYSTEM EXCITATION CONFIGURATION eR WIRI Por 8 044 5 2 1 MONE R TAMBOLI POWER GENERATION 5 4 3 FIGURE 44 WIRING DIAGRAM SHEET 5 OF 6 A045R241 Issue 2 10 2013 Appendix Outline and System Drawings A045R241 Issue 2 Creo Parametric AUXIOI PIA4 AUXIOI PI AUXI0 OPTIONAL 6 5 4 3 2 1 efe we 0 136413 12 2 6 UPDATE E STOP PIN DETAILS wr 1801 3 ae ALTERNATOR JS OPTIONS HARNESS LEGEND OPTIONAL AUXIO HARNESS A043A230 1302 0 AUXILIARY BELAY HARNESS ALTERNATOR HEATER X X XT 1 X fun READY TO LOAD OP
11. Exro MoOHEBLY Tue 02 00 SAVE FIGURE 26 EXERCISE FREQUENCY NAVIGATION Updating Exercise Duration To update the exercise duration on the Clock Exerciser Menu 1 Press the down key on the Exercise Schdr Menu 2 Press Adjust When updating these settings the functions of the keys are as follows The horizontal right arrow key is used to select the duration block for editing exercise duration 58 A045R241 Issue 2 10 2013 5 Startup and Configuration Use the or keys to edit the exercise duration minutes Press Save to save any changes After savings the Save button changes to the Adjust button Exercise Schdr Exercise Duration ADJUST 5 MIN Exercise Schdr Exercise gt Duration SAVE gt FIGURE 27 EXERCISE DURATION NAVIGATION 5 5 Commissioning Checklist The commissioning checklist should be completed for each installation There are a four sections It is important to complete the information to validate the completion of the generator set startup procedure under Cummins Power Generation recommendations For a copy of the commissioning checklist download it from ChannelOne Portal or contact your local dealer 5 6 Startup Automatic startup of the generator set during installation can cause severe personal injury or death Push the control switch OFF and disconnect the negative cable from the battery to keep the generator set from sta
12. FIGURE 38 ENCLOSURE OUTLINE 30 40 KW 1800 RPM 36 60 KW 3600 RPM SHEET 2 OF 2 A045R241 Issue 2 10 2013 Appendix Outline and System Drawings 6 5 4 3 2 1 CC CC Eo B f aac Tet pw m xn DRAWING HAS BEEN PICTORIALLY UPDATED PL P LARSON 13MATI3 __________3 03 ADD PHRASE J FRAME 4 ZONE 05 ADD PHRASE J FRAME SHOWN SP PL P_LARSON 3MAYI3 _ 5 10 03 ADD PHRASE 8 POSITION SP PL P LARSON 3MAYI3 HOH IDE ADD PASE a POSTION 06 ADD PHRASE POSITION ONLY SP PL AT EuN POSITION ADD CII LABEL FINA I POSITION ONLY AT 06 DIM 444 1 WAS 417 2 SP PL JP LARSON 13MAY13 E A POSITION tot bn sec ie ep tans D _________ 1 02 DIM 438 8 was 4012 26 5 SP PL P LARSON 134AY13 D LT rjavo sim ro wone PY JP LARSON i3wav 3 444 1 438 8 2X 318 2 318 2 H SHUNT TRIP MX 12 VOC COIL BURDEN lt 5 WATTS 10 IN RUSH AUXILIARY CONTACTS OPEN CLOSED OF TRIP INDICATION SD FORM C CONTACTS RATING 6 AMPS 24 VAC 48 VAC 110 VAC 6 AMPS AT 24 VOC 2 5 AMPS AT 48 VDC 0 6 AMPS AT 110 VOC MAXIMUM OF 4 CONTACTS PER CIRCUIT BREAKER gt lt COPPER CONDUCTOR SDE 1 H FRAME AL 150 HD 1 14 3 0 THERMAL MAGNETIC 14 810 50 LB IN
13. 9 Install the circuit breaker cover Automatic Transfer Switch AC Connections Failure to use an approved transfer switch can lead to the electrocution of personnel working on the utility lines damage to equipment fire or personal injury An approved switching device must be used to prevent interconnection to the public utility GES Install the transfer switch in accordance with the Transfer Switch Installation Manual FIGURE 11 RA SERIES TRANSFER SWITCH CONNECTIONS LOCATION A045R241 Issue 2 39 4 Installation 10 2013 Factory Option and Accessory Connections NOTICE Use copper conductors only AC powered options or accessories available Battery charger Engine coolant heater e Alternator heater Battery warmer No Description AC Distribution Connector s FIGURE 12 AC ACCESSORY CONNECTIONS Th The battery charger engine coolant heater alternator heater and battery warmer require power from 120 20 amp protected circuit from the Distribution Panel Use 12 AWG 167 F 75 C conductors to make connection to the generator set AC distribution connector 40 A045R241 Issue 2 10 2013 4 Installation DC Connections NOTICE When selecting and installing conduit to the generator set account for any needed accessories such as a remote display etc Description DC Circuit Connector s FIGURE 13 DC CUSTOMER CON
14. Actual 0 622 0 824 1 049 2 067 3 068 3 548 4 026 Length ft Maximum Cs in Thousands of Btu per Hour A045R241 Issue 2 65 Appendix Fuel Line Selection 10 2013 Gas Propane Inlet Pressure 11 0 in w c Pressure Drop 0 5 in w c Specific Gravity 1 50 Special Use Pipe sizing between single or second stage low pressure regulator and appliance 3 ___ 80 94 197 372 100 84 175 330 677 1014 5 __ 250 94 74 155 292 600 899 1730 4876 7139 9945 42 89 167 515 991 2793 4090 5698 TABLE 22 PROPANE VAPOR SEMI RIGID COPPER TUBING SIZING Gas Undilute Propane Inlet Pressure 11 0 in w c Pressure Drop 0 5 in w c Specific Gravity 1 50 Special Use Sizing between single second stage low pressure regulator appliance Tube Size in P e a 0 375 0 500 0 625 0 750 d 1 375 1 625 2 125 2 625 5 0 305 0 402 0 527 0 652 das d 1 245 1 481 1 959 2 435 5 66 A045R241 Issue 2 10 2013 Appendix Fuel Line Selection Gas Undilute Propane Inlet Pressure 11 0 in w c Pressure Drop 0 5 in w c Specific Gravity 1 50 Special Use Sizing between single second stage low pressure regulator appliance 310
15. Inlet Pressure 0 5 psi or less Pressure Drop 0 5 in w c Specific Gravity 0 6 __ 18 38 134 190 406 730 1151 2398 4242 30 15 30 107 152 326 586 925 1926 3407 19 26 53 92 131 279 502 797 1648 2016 47 82 116 247 445 701 1461 2584 __ 10 21 42 74 105 224 403 635 1323 2341 ___7 19 39 68 96 206 371 585 1218 2154 80 86 18 36 63 90 192 345 544 1133 2004 90 17 59 84 180 324 510 1063 1880 10 76 16 32 56 79 170 306 482 1004 1776 ___125 68 14 28 50 70 151 271 427 890 1574 1580 6 1 13 26 45 64 136 245 387 806 1426 ___200 52 1 22 39 55 117 210 690 1221 ___250 47 20 34 48 103 186 294 612 1082 300 42 87 18 44 94 169 266 554 Table capacities are based on Type K copper tubing inside diameter shown which has the smallest inside diameter of the copper tubing products TABLE 20 PROPANE VAPOR SCHEDULE 40 IRON PIPE SIZING Gas Undiluted Propane Inlet Pressure 11 0 in w c Pressure Drop 0 5 in w c Specific Gravity 1 50 Special Use Pipe sizing between single second stage low pressure regulator 5 Pipe Size o 1 2 3 4 1 1 4 1 1 2 3 1 2
16. When the set is not running an AC powered battery charger is needed to keep the battery charged As part of the installation make sure that the battery is secured to the battery tray with the strap provided A045R241 Issue 2 45 4 Installation 10 2013 46 FIGURE 18 BATTERY LOCATION To connect the battery 1 Connect the positive battery terminal 2 Connect the negative battery terminal 3 Make sure that the black and red battery cable boots are in place Refer to the Model Specifications section for battery specifications An optional thermostatically controlled battery heater is available for more reliable starting in ambient temperatures down to 40 F 40 C To prevent injury due to accidental startup do not connect the battery cables to the battery until the installation has been completed tools rags and body parts are away from any rotating parts or electrically live parts and it is time to start the set NOTICE Ensure that the AC power to the battery charger is disconnected when installing the battery NOTICE Wear proper safety protection when working around batteries Keep open flames and sparks away from the equipment A045R241 Issue 2 10 2013 4 Installation NOTICE Only personnel knowlegable of batteries and required precautions should perform or supervise battery servicing A045R241 Issue 2 47 4 Installation 10 2013 This page is intentionally blank 48
17. at ambient temperatures up to 40 104 F Above these elevations derate at 496 per 305 m 1000 ft and 296 per 10 above 40 C 104 F Engine power available up to 0 m 0 ft at ambient temperatures up to 25 C 77 F Above these elevations derate 4 305 m 1000 ft and 2 per 10 above 40 104 F Engine power available up to 114 m 375 ft at ambient temperatures up to 25 C 77 F Above these elevations derate at 4 per 305 m 1000 ft and 2 per 10 above 25 Engine power available up to 762 2500 ft at ambient temperatures up to 40 C 104 F Above these elevations derate at 4 per 305 m 1000 ft and 2 per 10 above 40 104 F Engine power available up to 945 m 3100 ft at ambient temperatures up to 40 C 104 F Above these elevations derate at 4 per 305 m 1000 ft and 2 per 10 above 40 104 F A045R241 Issue 2 15 2 Introduction 10 2013 NG LP Guidelines NG LP Engine power available up to 914 m 3000 ft at ambient temperatures up to 40 C 104 F Above these elevations derate at 4 per 305 1000 ft and 2 10 above 40 C 104 F TABLE 12 CONTROL SPECIFICATIONS All Models Integrated microprocessor based engine generator transfer switch control TABLE 13 DC SYSTEM SPECIFICATIONS Models Nominal 12 VDC battery voltage Battery group 26 standard 24 high capacity
18. 0 65 INCH 15 150 AMP 8 3 0 120 LB IN J FRAME 1 4 4 0 THERMAL MAGNETIC 1 00 INCH 175 AMP 225 LB IN THERMAL MAGNET IC 2 1 00 INCH 200 250 AMP J FRAME ELECTRONIC TRIP 1 1 0 300 KCMIL 1 00 INCH ADJUSTABLE RANGE 70 250 250 LB IN 100 RATED ASSEMBLY A A UMLESS OTERIISE SPECIFIED NONE R WEHRENBERG 1 LE e Cummins POWER GENERATION ate sees OUTLINE CIRCUIT BREAKER BOTTOM VIEW 17 50 24 99 0 30 0 13 wt 19 12 ______ sirt CONFDENTAL rat sir ESSE A Row Por 6 5 4 ay 3 2 1 FIGURE 39 CIRCUIT BREAKER OUTLINE SHEET 1 OF 1 A045R241 Issue 2 81 Appendix Outline and System Drawings 10 2013 Creo Parametric 6 CUSTOMER TERMINAL CONNECTORS gt 1302 PROGRAMMING CONNECTION TO BE USED ONLY BY AUTHORIZED PERSONNEL 82 CUSTMR GND CUSTMR IN 1 T RETURN CUSTMR IN 2 REMOT TART 1 0 71 0 T OUTPUTI NO PROTECTED B READY TO LOAD L CUST OUTPUT 2 COM CUST OUTPUT2 NO PCCNe SYSTEM WAKEUP ns 48 a welt SERVICE J3 1302 GENSET CONTROL URRENT SENSING 2 DASHED LINES NOT PRESENT IN SINGLE PHASE VOLTAGE SENSING 9 EQUIPMENT GROUND FIGURE 40 WIRING DIAGRAM SHEET 1 OF 6 NOTES ALL CIRCUIT ARE SHOWN DE ENERGIZED
19. 000 BTU hr BTU hr BTU hr BTU hr BTU hr BTU hr 6 14 inch water column TABLE 5 ENGINE SPECIFICATIONS All Models Engine 4 Cylinder in line SOHC liquid cooled 4 stroke spark ignited Displacement 144 in 2351 cc 0 040 inch 1 0 mm NA 0 030 inch 0 76 mm T TAA Spark plug torque 15 ft lb 20 N m Approximately 4 5 quarts 4 3L i 5W30 API SM recommendation TABLE 6 GENERATOR SET SIZE SPECIFICATIONS 20 25 kW 1800 RPM and 30 kW 30 40 kW 1800 RPM and 36 60 kW 3600 RPM 3600 RPM Propane Vapor Natural Gas Propane Vapor Natural Gas Size with L x W x 72 x 34 x 45 2 in L x W x H 94 x 34 x 45 2 in sound level 1 1830 x 864 x 1152 mm 2384 x 864 x 1152 mm enclosure TABLE 7 GENERATOR SET WEIGHT POUNDS 60 HZ 1800 RPM C20 C22 N6 C25 C30 N6 C36 N6 C40 6 Sound level 1 1109 1109 1147 1279 1356 1424 wet A045R241 Issue 2 13 2 Introduction 10 2013 TABLE 8 GENERATOR SET WEIGHT POUNDS 60 HZ 3600 RPM C30 C36N6H C40N6H C45N6H 50 C60 Sound level 1 1134 1249 1399 1399 1399 1429 wet TABLE 9 GENERATOR SPECIFICATIONS 60 HZ 1800 RPM C20 N6 C22 N6 25 6 C30 N6 C36 N6 C40 6 Brushless 2 pole rotating field single bearing Power kVA 20 25 22 275 25 31 3 30 37 5 36 45 40 50 1phase 3 phase Rated voltages 120 240 120 240 120 240 120 240 120 240 120 240 V 1 Ph 1 Ph 1 Ph 1 Ph 1 Ph 1 Ph 120 240 120 240 120 240 120 240 120 240 1
20. DISCHARGE AREA DIMENSION WITH ACCESS DOOR OPEN c DISTANCE REQUIRED TO LIFT OFF SERVICE PANELS TOP VIEW lt ACCESS DOOR FOR OPERATOR PANEL AND ENTER OF GRAVITY AIR INTAKE AREAS CIRCUIT BREAKER HANDLE LATCHES ARE KEY LOCKABLE B 802 31 6 SERVICE PANEL FUEL CONNECTION SERVICE PANEL 115 1 SERVICE PANEL 80 GAS ONLY 4 51 13 21 OF GRAVITY 13 8 46 1 RIGHT SIDE OUTLET VIEW LEFT SIDE VIEW INLET VIEW F231 2 ENCLOSURE CONFIGURATION Cams OBST 0 00 4 99 0 15 0 08 2 50 9 99 0 20 0 5 EA 17 30 24 99 RA ARROW POF 6 5 4 d 3 2 1 FIGURE 37 ENCLOSURE OUTLINE 30 40 KW 1800 RPM 36 60 KW 3600 RPM SHEET 1 OF 2 A045R241 Issue 2 79 Appendix Outline and System Drawings 10 2013 Creo Parametric 6 0 gt 6 80 5 4 2 1 ue om CO 137084 AK NK MATTHEWS 10SEP 13 AIR INTAKE AREA p o x D INTAKE AREA lt AIR INTAKE AREA F217 2 ENCLOSURE CONFIGURATION REFER TO PAGE 1 231 2 ENCLOSURE FOR A OTHER F217 2 ENCLOSURE DIMENSIONS Y i 9 00 4 99 0 15 0 08 T RADKE Tm IESE names OUTLINE ENCLOSURE 0 38 17 50 24 99 60 30 0 13 oare 17JANI3 ieee 8 043 729 Pe 2 1 m D ae I 5 4 Ak 3
21. PAGE 1 CUSTOMER CONNECTIONS FOR CONTROL POWER CONNECTIONS TO CIRCUIT BREAKER PAGE 2 ENGINE CONTROL MODULE ECM INTERFACE TO ENGINE SENSORS COILS STARTER BATTERY BATTERY CHARGING ALTERNATOR LOW COOLANT LEVEL OPTIONAL FUEL PRESSURE SWITCH OPTIONAL PAGE 3 1302 INTERFACE DISPLAY AND BARGRAPH OPTIONAL PAGE 4 ALTERNATOR INTERFACE SHUNT EXCITATION 4 PERMANENT MAGNET EXCITATION PMG PAGE 5 ALTERNATOR INTERFACE ELECTRONIC BOOST SYSTEM EBS EXCITATION PAGE 6 OPTIONS AUXIOI AC RELAYS BATTERY CHARGER _Cuams Pom fear Dei TULADHAR ves Por 1 SECONDARY CIRCUIT BREAKER COOLANT HEATER amp ALTERNATOR HEATER ALTERNATOR VOLTAGE WIRING SEE DIAGRAMS A044D428 FOR AW2 amp AW3 ALTERNATORS A044D432 FOR AW ALTERNATORS USE OUTER CIRCUIT BREAKER POLES FOR SINGLE PHASE SEE INSIDE THE BREAKER BOX AND ON THE BREAKER FOR LUG TORQUE DIAGRAM WIRING DIAGRAM WIRING A045R241 Issue 2 10 2013 Appendix Outline and System Drawings Creo Parametric A045R241 Issue 2 5 SPK SMARTIb 135 ROUND 136413 c 2 ZONE Bi Ruv w 158 01 UPDATE NOTE PIN 6 wr 18JUL 13 pus _____ POWER TO KE
22. PERIMETER SEE 1030 APPLICATION MANUAL FUEL SIDE INLET CLEARANCE INSTALLATION 4 REMOVAL LIFTING AND SERVICE ACCESS CLEARANCE SUGGESTED MINIMUM FOR IOC SEISMIC CERTIFIED INSTALLATIONS SEE GENSET 18 SEISMIC INSTALLATION REQUIREMENTS DRAWING GENSET CONTROL 4 WIRE STUB UP DC 4 ACCESSORY xd 120V AC 204 wiR STUB UP 2 4 80 C 12 8 A 13 21 DUCT INLET END CAP ENCLOSURE ENCLOSURE gt 321 A mm 200 11 91 150 25 129 51 tT COOLING AIR INLET LEARA SUGGESTED MINIMUM CIRCUIT BREAKER 1 4x Ui MIG OR 5 8 STANDARD BOLT OR STUD CIRCUIT BREAKER UP GENSET MODEL DUAL CIRCUIT BREAKER APPLICATION Omm fam mum A Tc ium E OUTLINE GENSET 1 ib 3 i 5 Exe DISQUES FIGURE 34 FOUNDATION OUTLINE 30 40 KW 1800 RPM 36 60 KW 3600 RPM SHEET 1 OF 1 76 A045R241 Issue 2 10 2013 Appendix Outline and System Drawings 6 5 4 T 3 2 1 __ so ferio d 137084 C DRAWING HAS BEEN PICTORIALLY UPDATED AK NOTE _______ AK LISEPI3 _ __ 3 A00 NOTE 4 AK LISEPI3 1 DIM IN INCHES LT 1 566 tco FoR attics 15913 ZX 120 AND 170 ARE DETENTED OPEN ANGLE OF HINGE 3 WHEN HOUSING IS INSTALLED ON AN OPEN GENERAT
23. ROW Por 5 A044K 485 vie der 6 5 4 1 3 2 1 FIGURE 42 WIRING DIAGRAM SHEET 3 OF 6 84 A045R241 Issue 2 10 2013 A045R241 Issue 2 Appendix B Outline and System Drawings 6 1302 7 GENSET CONTROL PCC PII 5 4 3 2 1 Tw To Eco 136413 C 8 20 CS C2 ADD NOTE ALTERNATOR G 65 C3 __ E 7771177 ______ 1l __ D ALTERNATOR PCC1302 V 17 5 L1 L2 L3 N U v GROUND 11 12 13 N FELD PLUG B OPTIONAL GENSET CONTROL a PCC PII RELAY COIL Be WOT USED 2 5 2 2 are AC TNPUT SHUNT EXCITATION CONFIGURATION PERMANENT MAGNET EXCITATION CONFIGURATION DIAGRAM WIRING 10JANI3 5116 NATURAL GAS GENSET Be 5 4 T 3 FIGURE 43 WIRING DIAGRAM SHEET 4 OF 6 85 Appendix Outline and System Drawings 10 2013 Creo Parametric 6 86 5 4 3 2 1 H 136413 ONE C5 ADD NOTE
24. SHOWN FOUNDATION SHOULD BE EXTENDED BEYOND THis PERIMETER SEE 1030 APPLICATION MANUAL N FUEL SIDE INLET CLEARANCE INSTALLATION amp REMOVAL LIFTING SERVICE ACCESS CLEARANCE SUGGESTED MINIMUM 6 FOR IBC SEISMIC CERTIFIED INSTALLATIONS SEE GENSET IBC SEISMIC INSTALLATION REQUIREMENTS DRAWING woe 11 GENSET CONTROL 2 WIRE STUB UP 00 4 ACCESSORY 120V AC 20 WIRE 5708 0 gt n 12 81 3 21 DUCT INLET END CAP ENCLOSURE ENCLOSURE 2x 814 32 m o 2 690 21 16 91 25 129 51 COOLING AIR INLET LEARAI SUGGESTED MINIMUM CIRCUIT BREAKER I 41 108 MIG OR 5 8 A STANDARD BOLT OR STUD CIRCUIT BREAKER Li uP GENSET MODEL DUAL CIRCUIT BREAKER APPLICATION ax 102 cow 19 cw 43 03 0 Pom ETENN oo OUTLINE GENSET x 1 4 3 m 2 FIGURE 33 FOUNDATION OUTLINE 20 25 KW 1800 RPM 30 KW 3600 RPM SHEET 1 OF 1 A045R244 Issue 2 75 Appendix Outline and System Drawings 10 2013 4 3 D 2 NOTES D V DIMENSIONS IN 1 ARE IN INCHES D LN SKID BASE A FLANGE THICKNESS OF 3 42mm ALLOW CXTRA LENGTH ON HARDWARE FOR UNEVENESS OF MOUNTING SURFACE SKID BASE PERIMETER 15 SHOWN FOUNDATION SHOULD BE EXTENDED BEYOND THIS
25. conditions Picking a Location Exhaust gas is deadly Locate the generator set away from doors windows and other openings to the house and where exhaust gases will disperse away from the house A045R241 Issue 2 23 4 Installation Em 24 10 2013 Description No Description Cool Air In Hot Air Out FIGURE 3 GENERATOR SET LOCATION Generator set location is critical for safety and performance Follow the guidelines below Must comply with applicable codes NFPA NEC IBC etc Install outdoors only For other applications contact your local Cummins dealer or reference the Application Manual at following link http www cumminspower com www literature applicationmanuals t030 pdf Consider access to utilities electric gas meters transfer switch remote fuel tank location etc Call the local utilities to mark the locations of buried utility services gas electric or telephone before digging Verify the locations of any other buried components gas electric or telephone with the homeowner before digging Clearances The exhaust side of the generator set must be located 5 feet from combustible materials NFPA 37 The exhaust side of the generator must be located 5 feet from any opening wall window door vent etc The generator must be located such that the exhaust is not able to accumulate in an occupied area The generator must have en
26. high capacity battery require an accessory battery tray Battery Type Maintenance free Minimum cold 545 standard 850 high capacity high capacity battery require an accessory crank amps battery tray 2 6 Transfer Switch Requirements A transfer switch must be a part of every generator set installation Transfer switches transfer loads to the generator set during power outages NOTICE Cummins residential and light commercial transfer switches are available FIGURE 1 CUMMINS TRANSFER SWITCH RA SERIES 16 A045R241 Issue 2 10 2013 Gr 2 Introduction Before beginning the installation of the transfer switch verify that the unit was correctly selected Check the following features Specifications voltage amperage frequency poles and phases Enclosure indoor vs outdoor Model Refer to the Transfer Switch Installation Manual for more detailed information A045R241 Issue 2 17 2 Introduction 10 2013 This page is intentionally blank 18 A045R241 Issue 2 3 Pre Installation Considerations Before installation begins certain items must be considered Prior coordination ZS reduces delays and the amount of time power has to be interrupted Areas of consideration No Description No Description Generator Set Electrical Meter Propane Tank Natural Gas Meter 3 Transfer Switch FIGURE 2 SITE PREPARATION EXAMPLE Location of the generator set this is one of the fi
27. keep the generator set from starting NOTICE Use copper conductors only 250 amp 100 rated circuit breaker assembly requires 194 F 90 C conductors For grounding and neutral connections look for the following symbols on the generator set circuit breaker cabinets A044F269 REV FIGURE 8 EQUIPMENT GROUNDING CONDUCTOR SYMBOL A044H599 REV B FIGURE 9 EQUIPMENT NEUTRAL CONNECTION SYMBOL A045R241 Issue 2 37 4 Installation 10 2013 A a 74 y e FIGURE 10 CIRCUIT AC LOAD CONNECTIONS LOCATION Cal For connection to the generator set AC load connections are made in the circuit 6 breaker box To access 5 Remove enclosure side panel to gain access to main circuit breaker box Place the circuit breaker handle in the OFF position Remove the four bolts holding the circuit breaker cover WO N Install the conductors to the circuit breaker load side terminals neutral lug and equipment grounding lug 5 Torque the circuit breaker terminals per specifications on the circuit breaker label 6 Torque the neutral lug to 275 inch pounds 31 1 Nm 7 Torque the equipment grounding lug to 120 inch pounds 13 8 Nm 38 A045R241 Issue 2 10 2013 4 Installation 8 Fill in the stub up openings with an approved duct seal or mastic tape to keep out insects and rodents
28. may contain more than 2 5 butane which can result in poor fuel vaporization and low tank pressure resulting in poor engine starting and operation in below 32 F O C temperatures Propane Tank Size When propane is used size the tank correctly to ensure successful generator set operation 32 A045R241 Issue 2 10 2013 4 Installation Considerations when figuring the proper propane tank size Temperature is a critical factor that affects the size of the tank o Ambient temperatures can affect how quickly liquid is converted to gas Generator set fuel consumption is the same regardless of the surrounding temperatures Colder weather climates require larger fuel tanks Larger tanks have greater surface area allowing more liquid propane to vaporize and maintain the required fuel rate Propane is stored as liquid Keep the fuel tank at least 50 full to operate properly Fuel tanks that are less than 50 full may not have the capacity to vaporize enough propane to operate the generator set and other LP applicances Propane tanks are sized by their internal volume in gallons not the amount of fuel they can hold which is less Propane tanks are generally filled to only 80 of their capacity Therefore a 500 gallon tank results in 400 gallon tank capacity Low ambient temperatures affect the amount of fuel available from the propane tank Approximately 60 of the fuel in gallons fil
29. of the transfer switch unless a service entrance rated automatic transfer switch is being used Keep safety concerns in mind Never mount the transfer switch near hazardous chemicals or gases Avoid high humidity areas or areas prone to excessive heat or dust 2 Make sure that the wall is stable and able to support the weight of the transfer switch 3 Make sure that the transfer switch is mounted according to all applicable building code requirements 4 Mount the transfer switch per the instructions in the Transfer Switch Installation Manual 22 A045R241 Issue 2 4 Installation NOTICE The installer is responsible for complying with all applicable installation codes and safety requirements See the Installation Codes and Standards for Safety section of this manual for more information The following sections cover a step by step overview of a typical generator set installation Review these sections to become familiar with specific procedures and important safety precautions before beginning the installation 41 Site Assessment and Preparation Proper component location and site preparation have a very important impact on completing a successful installation The major components and sources of power needed for installation include the following items Generator set Transfer switch Electrical utility Fuel source natural gas or propane vapor Accessories may be required based on certain
30. should extend at least 6 Circuit Breaker 2 Stub Up dual circuit inches beyond skid breaker pad should extend at least 6 7 Circuit Breaker 1 Stub Up standard inches beyond skid 4 Generator Set Control Wire Stub Up DC FIGURE 5 CONCRETE PAD PREPARATION 26 A045R241 Issue 2 10 2013 4 2 4 Installation Lifting and Moving the Generator Set The generator set is heavy Dropping the generator set can cause severe personal injury or death Keep feet and hands clear when lifting the generator set The generator is shipped with oil in the crankcase Keep the generator set upright The generator set is heavy Handle with care Use appropriate lifting techniques to move the generator set Do not use the lifting eyes on the engine and alternator to lift the entire generator set NOTICE Only a certified and trained person should lift from above the generator set Mounting the Generator Set Positioning of cast in bolts can be problematic since even small errors in location can cause time consuming redrilling of the skid base Some generator set designs allow use of concrete anchor bolts requiring the mounting points to be carefully laid out based on actual location of the mounting points on the generator set and isolators 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 Verify that the mounting pad is level le
31. 0 Iron Pipe Sizing Table 22 Propane Vapor Semi Rigid Copper Tubing Sizing eere Table 24 Equivalent Lengths of Pipe Fittings in Feet A045R241 Issue 2 61 Appendix Fuel Line Selection 10 2013 62 A 0 Gas Pipe Sizing Sizing of gas piping for proper fuel delivery both flow and pressure can become quite complex However a simplified method is to convert all fittings valves etc to equivalent lengths of pipe in the diameter s being considered The total equivalent length can then be related to flow capacity Tables are included for natural gas propane liquid withdrawal and propane vapor withdrawal under specified conditions Consult NFPA 54 or other applicable codes for other operating conditions or other fuel system installation requirements The tables displayed in this section are reprinted with permission from NFPA 54 2002 National Fuel Gas Code Copyright 2002 National Fire Protection Association Quincy MA 02169 This reprinted material is not the complete and official position of the NFPA on the referenced subject which is represented only by the standard in its entirety A calculation of minimum pipe size is fairly straightforward Make a list of all the fittings and valves in a proposed system and sum their equivalent lengths using the table Add to this total all lengths of straight pipe to arrive at a to
32. 20 240 3 Ph 3 Ph 3 Ph 3 Ph 3 Ph 3 Ph 120 208 120 208 120 208 120 208 120 208 120 208 3 Ph 3 Ph 3 Ph 3 Ph 3 Ph 3 Ph 277 480 277 480 277 480 277 480 277 480 277 480 3 Ph 3 Ph 3 Ph 3 Ph 3 Ph 3 Ph 347 600 347 600 347 600 347 600 347 600 347 600 3 Ph 3 Ph 3 Ph 3 Ph 3 Ph 3 Ph TABLE 10 GENERATOR SPECIFICATIONS 60 HZ 3600 RPM C36 C40N6H C45 C50N6H C60 Brushless 2 pole rotating field single bearing Power kVA 30 37 5 36 45 40 50 45 56 3 50 62 5 60 75 1Phase 3 Phase Rated Voltages 120 240 120 240 120 240 120 240 120 240 120 240 V 1 Ph 1 Ph 1 Ph 1 Ph 1 Ph 1 Ph 120 240 120 240 120 240 120 240 120 240 120 240 3 Ph 3 Ph 3 Ph 3 Ph 3 Ph 3 Ph 120 208 120 208 120 208 120 208 120 208 120 208 3 Ph 3 Ph 3 Ph 3 Ph 3 Ph 3 Ph 277 480 277 480 277 480 277 480 277 480 277 480 3 Ph 3 Ph 3 Ph 3 Ph 3 Ph 3 Ph 14 A045R241 Issue 2 10 2013 2 Introduction NOTICE Maximum I 8 TABLE 11 GENERATOR SET DERATING GUIDELINES Model NG LP Guidelines C20 N6 NG LP Engine power available up to 1005 m 3300 ft at ambient C22 N6 LP temperatures up to 40 104 F Above these elevations derate at 4 per 305m 1000 ft and 2 10 C above 40 C 104 Engine power available up to 670 5 m 2200 ft at ambient temperatures up to 40 C 104 F Above these elevations derate at 496 per 305 m 1000 ft and 296 per 10 above 40 104 F Engine power available up to 114 m 375 ft
33. 45 188 329 467 997 1795 2830 5895 10429 2202 31 64 129 226 685 1234 1945 4051 7168 30 51 104 182 258 550 991 1562 3253 5756 40 21 44 89 155 220 471 848 1337 2784 4926 50 19 79 138 195 417 752 1185 2468 4366 ___ 17 35 7t 125 177 378 681 1074 2236 3956 TO 16 32 66 115 163 626 988 2057 3639 15 6t 107 152 324 583 919 1914 3386 ___ 14 28 57 100 142 304 547 862 1796 3177 100 __ 13 27 54 95 134 287 517 814 1696 3001 tas __ 11 48 254 458 722 1503 2660 40 10 21 44 76 108 230 415 654 1362 2410 _10 20 40 70 99 212 382 602 1253 2217 89 18 37 65 92 197 355 560 1166 2062 1935 1828 275 1736 300 7 15 52 74 158 265 449 936 1656 Table capacities are based on Type K copper tubing inside diameter shown which has the smallest inside diameter of the copper tubing products A045R241 Issue 2 67 Appendix Fuel Line Selection 10 2013 TABLE 24 EQUIVALENT LENGTHS OF PIPE FITTINGS IN FEET METERS TYPE NOMINAL INCH PIPE SIZE 2 2 1 2 14 16 18 OF FITTING 50 65 180 ADS VES ES E gon E 400 450 90 5 2 6 2 7 7 9 6 10 13 15 21 26 42 47 Stand 1 6
34. A045R241 Issue 2 5 1 Startup and Configuration Brightness and Contrast The Screen Adjust Menu allows the contrast brightness and units to be set To access the Screen Adjust Menu 1 From any Information screen hold down the up and down arrows simultaneously for two seconds to gain access to the Service Menu screen 2 Select Screen Adjust To adjust the contrast brightness or units from the Screen Adjust screen 1 From the Screen Adjust Menu select Adjust to access the screen variables 2 Press the right arrow to move between the variables 3 Adjust settings and press Save to save any changes When updating these settings the function of the keys are as follows The horizontal right arrow key is used to select successive blocks for editing settings on the screen Select the left arrow to return to the previous screen Adjust values by using the or keys on the Adjust Menu of the Display Setup Menu Press Save to save any changes After savings the Save button changes to the Adjust button NOTICE The following screens represent the standard operator panel HMI211 If using an in home operator panel which may be additionally purchased as an option the screens may look slightly different This procedure applies to both operator panels A045R241 Issue 2 49 5 Startup and Configuration 10 2013 Battery 12 4 VDC Eng Temp 180 F Oil Press 75 PSI Eng Hours 2222 h AUTO MAN
35. AKE AREA ETT INTAKE AREA AIR INTAKE AREA 12 8 F217 2 ENCLOSURE CONFIGURATION REFER TO PAGE 1 F23 2 ENCLOSURE FOR UNLESS SPECIFIED AL OTHER F217 2 ENCLOSURE DIMENSIONS MIO C D qmm imme __ OUTLINE ENCLOSURE 17 50 24 99 0 307 0 1 site cove _ ema ere 5 1 4 3 2 1 78 FIGURE 36 ENCLOSURE OUTLINE 20 25 KW 1800 RPM 30 KW 3600 RPM SHEET 2 OF 2 A045R241 Issue 2 10 2013 Appendix Outline and System Drawings 6 are m Tw el we ECO 137084 C 1 DRAWING HAS BEEN PICTORIALLY UPDATED NK J MATTHEWS NOTE 2 wort 3 J MATTHEWS 3 ADD NOTE 4 1 DIM IN INCHES AX 120 AND 170 ARE DETENTED OPEN ANGLE FOR HINGE 3 WHEN THE HOUSING INSTALLED ON AN OPEN GENERATOR SET THE TOTAL WEIGHT WILL INCREASE BY 98 KG 216 LBS THIS INCLUDES THE MUFFLER D 4 THE CENTER GRAVITY CG OF THE GENERATOR SET WHEN EQUIPPED WITH THIS HOUSING SHIFTS APPROXIMATELY 8MM 0 31 INCH TOWARDS THE AIR DISCHARGE END OF THE HOUSING AND 38MM 1 5 INCH HIGHER FROM THE GROUND COMPARED TO THE EQUIVALENT NON HOUSED PRODUCT WITH THE FI79 SKID SEE HOUSING READY SKID BASE OUTLINE DRAWING FOR CG LOCATION OF NON HOUSED PRODUCT AIR AND EXHAUST RADIATOR FILL ACCESS 445 17 5 F
36. NECTIONS A045R241 Issue 2 41 4 Installation 10 2013 Automatic Transfer Switch DC Connections An approved switching device must be used to prevent interconnection to the public utility Failure to do so can lead to the electrocution of personnel working on the utility lines damage to equipment fire or personal injury GX Install the transfer switch in accordance with its Installation Manual The following images shows the location of the Cummins RA Series Transfer Switch customer connections Class 1 wiring methods should be used for connecting generator set and transfer switch signal wiring NE FIGURE 14 RA SERIES TRANSFER SWITCH CONNECTIONS LOCATION 42 A045R241 Issue 2 10 2013 4 Installation 26 2067 eal No Description No Description DC Circuit Connectors 5 Remote Start 2 DC Customer Connections within Fuse B 5A dotted line box 1302 Control Ready to Load Ground B RA Transfer Switch Terminal Block FIGURE 15 GENERATOR SET TO RA TRANSFER SWITCH DC CUSTOMER CONNECTIONS Drilling Locations for Electrical Connections Preferred routing of electrical leads is vertically through conduit that is installed in the mounting pad that terminates in the electrical connection areas Refer to the generator set Foundation Outline drawing in the Outline and System Drawings Appendix for location of electrical connection areas In som
37. OR SET THE TOTAL WEIGHT WILL INCREASE BY 84 KG 185 LBS D THIS INCLUDES THE MUFFLER D 4 THE CENTER OF GRAVITY CG OF THE GENERATOR SET WHEN EQUIPPED WITH THIS HOUSING SHIFTS APPROXIMATELY SIMM 2 INCH TOWARDS THE AIR DISCHARGE END OF HOUSING AND 42MM 1 5 INCH FROM THE GROUND COMPARED TO THE EQUIVALENT NON HOUSED PRODUCT WITH THE F179 SKID SEE HOUSING READY SKID BASE OUTLINE DRAWING FOR CG LOCATION OF NON HOUSED PRODUCT AIR AND EXHAUST DISCHARGE AREA RADIATOR FILL ACCESS 445 17 5 DIMENSION WITH ACCESS OPEN DOOR DISTANCE REQUIRED LIFT OFF SERVICE PANELS gt ACCESS DOOR FOR OPERATOR PANEL AND CIRCUIT BREAKER HANDLE 610 610 124 124 AIR INTAKE AREAS 7 7 8 1156 45 5 802 31 6 L i ENTER LATCHES ARE ENTER OF GRAVITY ee 7 LATCHES ARE FUEL CONNECTION SERVICE PANEL GAS ONLY A A RIGHT SIDE VIEW OUTLET VIEW LEFT SIDE VIEW INLET VIEW SS arr TEN lan mr MATTHEWS F231 2 ENCLOSURE CONFIGURATION lovin ENCLOSURE 6 5 4 3 ture os 1010 E PGF 4043604 2 1 FIGURE 35 ENCLOSURE OUTLINE 20 25 KW 1800 RPM 30 KW 3600 RPM SHEET 1 OF 2 0458241 Issue 2 77 Appendix Outline and System Drawings 10 2013 137084 AIR INT
38. Power om Generation Installation Manual Standby Power Generator Set C20 N6 Spec A C22 N6 Spec A C25 N6 Spec A C30 N6 Spec A C36 N6 Spec A C40 N6 Spec A C30 N6H Spec A C36 N6H Spec A C40 N6H Spec A C45 N6H Spec A C50 N6H Spec A C60 N6H Spec A English Original Instructions 10 2013 A045R241 Issue 2 Table of Contents 1 IMPORTANT SAFETY INSTRUCTIONS 1 1 Warning Caution and Note Styles Used In This 1 2 General 1 3 General Precautions 1 4 Generator Voltage is Deadly 1 5 Engine Exhaust is Deadly 1 6 Fuel is Flammable and Explosive 1 7 Batteries Can 1 8 Moving Parts Can Cause Severe Personal Injury or Death 1 9 The Hazards of Carbon Monoxide 2 1 About this Manual 222 COINS ERR coca ajc Memes 2 4 Before Installation 2 5 Model Specifications 2 6 Transfer Switch Requirements 3 PRE INSTALLATION CONSIDERATIONS 3 1 Installation Codes and Standards for Sa
39. TI 22 ELECTRICAL LONER p 14 X 480 15 51 118 9 F065 2 DIMENSIONS SHOWN IN ARE IN INCHES REFER TO CIRCUIT BREAKER OUTLINE DRAWING FOR ELECTRICAL STUB UP AREA FOR SPECIFIC BREAKERS AIR FLOW CONTROL INTERFACE CONNECTIONS SHOULD BE MADE WITH FLEXIBLE CONNECTIONS A 20 65 10 81 HOLES MARKED ev A FOR 4 POINT ISOLATION OR SECURING TO MOUNTING SURFACE RER RN uP 00000000000000000000000000 5 FUEL SUPPLY AND RETURN LINE 3 4 INCH HOSE ID BARB 7 T 4 tit WITH 3 4 NPT CONNECTORS 22 7 MM E OIL DRAIN EXTENSION s INCH HOSE 1D 18 9 EXHAUST CONNECTOR NPT A299 2 RADIATOR FILL ENGINE COOLANT 50 50 MIXTURE H669 2 ENGINE COOLING HIGH AMBIENT AIR TEMPERATURE 125 2 CONTROL PCI I gt 8100 2 728 mS ee E aN 5 D NH hui coy D 1 sae IN 7 27 9 5 tp RET icine ys o CRANKSHAFT sg M m TS 2 31 i 6 8 jJ 38 1 51 DIP STICK FUEL LINE PORT LIFTING HOLES 840 33 1 2 43 1 UNLESS OTHERWISE SPECIFIED NONE RET See Hm 641 meum OUTLINE GENSET 1670 SKID xe 0 00 17 50 20 99 0 307 0 13 rt 22MAYI3 cone T 3 zm ee suc 106 POF 0 n 2
40. TIONAL CUSTMR GNO GENSET CONTROL FOR 1302 INTERFACE AC TERMINAL 1 212 CUSTMR IN CONNECTORS 4 WITH ALTERNATOR ess CUST RETURN CUST OUTPUT COM KII K10 REFER CUSTOMER n CUST OUTPUT NQ o SHUNT CONNECTION PAGE 4 gy FoR connect ion Pace 4 FOR EBS 5 OPTIONAL ESTOP PE 1 BATTERY CHARGER 120VAC INPUT 4 GROUND 120VAC lt CUSTOMER PROVIDED FOLLOW NATIONAL ELECTRIC CODE FOR INSTALLATION m OIL PRESSURE OPTIONAL OIL PRESSURE SENDER FACTORY INSTALLED ee E STOP HARNESS 043 232 5 NEUTRAL FOR INSTALLATION SECOND UNPLUG CONNECTOR PAIR PE JE IN CONTROL HARNESS 40436986 GROUND CIRCUIT BREAKER RECONNECT PE TO RECONNECT JE TO ESTOP PE ee zi PE JE PAIR IN PAGE 3 SECTION C2 E WOME CEAL OPTIONAL EMERGENCY STOP ERREUR Era DIAGRAM WIRING FACTORY INSTALLED i MS EUM srt NATURAL GAS coL A ERIS Sk TE 5 4 3 2 FIGURE 45 WIRING DIAGRAM SHEET 6 OF 6 87 Appendix Outline and System Drawings 10 2013 This page is in
41. YSWITCH 0115 POWER FUSED POWER TO ECM FUSED POWER TO COILS STARTER SWITCH FUSED POWER TO SOLENOIDS FLASH BATT CHARG ALT POWER TO 1302 STARTER W 123 BATTERY CHRG ALT BATT B 1 CHARGING ALTERNATOR LOW COOLANT LEVEL OPTIONAL 3 COOLANT TEMP ENGINE GND 3 SECTION D 6 SWITCH ENG GND 2 FUSED BATTERY KEYSWITCH TO ECM POWER RELAY OUTPUT ENG GND 4 GND CHASSIS LOW COOLANT LEVEL ENG GND 1 LOW FUEL LEVEL C 5011 1 CAN CAN SHIELD FUEL PRESSURE SENSOR OPTIONAL FOR SINGLE FUEL TO PAGE 3 SECTION B 6 END SHIELD LEGEND ENGINE HARNESS A042Y601 um ow W TULADIAR DIAGRAM WIRING PROGRAMMING CONNECTION wt 1QJANI3 _______ coot NATURAL GAS GENSET TO BE USED ONLY BY AUTHORIZED PERSONNEL C ECM PROGM CER ARROW eer A044K485 1 5 4 3 2 FIGURE 41 WIRING DIAGRAM SHEET 2 OF 6 83 Appendix Outline and System Drawings 10 2013 6 5 4 3 2 __ ce ECO 136413 C 4 ZONE D6 UPDATE NOTE EJI PIN 6 PT WT AI TULADIAT 184013 TS t4 UPDATE NOTE PCC PI1 PIN 22 TULADU 18JUL13 POWER ADD NOTE ALTERNATOR PT MT 18JUL13 TT 0 45 UPDATE NOTE ECM PT WT
42. ad to asphyxiation lack of Oxygen resulting in death Mild effects of CO poisoning include eye irritation dizziness headaches fatigue and the inability to think clearly More extreme symptoms include vomiting seizures and collapse Engine driven generators produce harmful levels of carbon monoxide that can injure or kill you Special Risks of CO Near the Home Residents can be exposed to lethal levels of CO when the generator set is running Depending on air temperature and wind CO can accumulate in or near the home A045R241 Issue 2 10 2013 1 IMPORTANT SAFETY INSTRUCTIONS To protect yourself and others from the dangers of CO poisoning it is recommended that reliable approved and operable CO detector alarms are installed in proper locations in the home as specified by their manufacturer Carbon Monoxide CO gas can cause nausea fainting or death Protecting Yourself From CO Poisoning Locate the generator in an area where there are no windows doors or other access points into the home Make sure all CO detectors are installed and working properly Pay attention for signs of CO poisoning Check the exhaust system for corrosion obstruction and leaks every time you start the generator set and every eight hours when you run it continuously 0458241 Issue 2 7 1 IMPORTANT SAFETY INSTRUCTIONS 10 2013 This page is intentionally blank 8 A045R241 Issue 2 2 Introduction This generator set is i
43. ave any changes After savings the Save button changes to 5 Startup and Configuration 10 2013 When updating these settings the functions of the keys are as follows The horizontal right arrow key is used to select successive blocks for editing settings on the screen Select the left arrow to return to the previous screen Adjust values by using the or keys on the Adjust Menu of the Daylight Saving Adjust Menu Press Save to save any changes After savings the Save button changes to the Adjust button Daylight Saving Adjust Saving Time Disabled Adjust 60 MIN ADJUST a Daylight Saving Adjust Saving Time Disabled Adjust 60 MIN SAVE Em FIGURE 22 DAYLIGHT SAVING ADJUST MENU NAVIGATION To access and update the Daylight Saving Adjust Start Menu 1 Press the down key on the Daylight Saving Adjust Menu 2 Press Adjust When updating these settings the functions of the keys are as follows The horizontal right arrow key is used to select successive blocks for editing settings on the screen Use the or keys to edit the following settings Month Week Day o Hour Press Save to save any changes After savings the Save button changes to the Adjust button 54 A045R241 Issue 2 10 2013 5 Startup and Configuration Daylight Saving Adjust Start Mth Wk Day Hr O 1 Sun AM ADJUST Daylight Saving Adjust Start Mth Wk Day Hr Ow SAVE
44. cer or reproductive toxicity Do not ingest breathe the fumes or contact used oil when checking or changing engine oil Operation of equipment is unsafe when mentally or physically fatigued Do not operate equipment in this condition or after consuming any alcohol or drug Substances in exhaust gases have been identified by some state and federal agencies to cause cancer or reproductive toxicity Do not breathe in or come into contact with exhaust gases Flammable liquids can cause fire or explosion Do not store fuel cleaners oil etc near the generator set Wear hearing protection when going near an operating generator set Hot metal parts can cause severe burns Avoid contact with the radiator turbo charger and exhaust system Maintaining or installing a generator set can cause severe personal injury Wear personal protective equipment such as safety glasses protective gloves hard hats steel toed boots and protective clothing when working on equipment Ethylene glycol used as engine coolant is toxic to humans and animals Clean up coolant spills and dispose of used antifreeze in accordance with local environmental regulations A045R241 Issue 2 3 1 IMPORTANT SAFETY INSTRUCTIONS 10 2013 Starting fluids such as ether can cause explosion and generator set engine damage Do not use Stepping on the generator set can cause parts to bend or break leading to electrical shorts or to fuel coolant or exhau
45. dels For NFPA 110 applications a coolant heater is required Factory option is available a 40 F 4 starting aids required Standard battery group 26 0 to 40 F 17 Additional coolant heater and battery charger recommended for starting to 4 Factory options available Standard battery group 26 Below 0 17 starting aides battery heater coolant heater battery charger C recommended Factory options available Larger battery group 24 TABLE 3 FUEL SPECIFICATIONS 60 HZ 1800 RPM C22 N6 C25 N6 C30 C36 N6 C40 6 Full load 105 1 scfh 112 7 scfh 125 4 scfh 1164 1 scfh 182 7 193 6 scfh propane 265 000 285 000 315 000 410 000 460 000 490 000 BTU hr BTU hr BTU hr BTU hr BTU hr BTU hr Full load 259 6 scfh 278 8 scfh 1309 5 scfh 380 9 472 3 scfh 519 scfh natural gas 270 000 290 000 320 000 395 000 490 000 540 000 BTU hr BTU hr BTU hr BTU hr BTU hr BTU hr 6 14 inch water column 12 A045R241 Issue 2 10 2013 2 Introduction TABLE 4 FUEL SPECIFICATIONS 60 HZ 3600 RPM C30 C36N6H C40N6H C45N6H 50 C60 Full load 195 5 scfh 219 6 236 2 scfh 1256 9 scfh 289 5 scfh 324 6 scfh propane 490 000 550 000 595 000 645 000 725 000 820 000 BTU hr BTU hr BTU hr BTU hr BTU hr BTU hr Full load 476 1 scfh 533 3 573 2 scfh 1623 0 scfh 704 7 814 2 scfh natural gas 495 000 555 000 595 000 645 000 730 000 840
46. e cases it may be necessary to route electrical leads horizontally in conduits that pass through the A045R241 Issue 2 43 4 Installation 10 2013 generator set chassis Refer to the figure below for available drilling space for conduit holes in the side of the chassis Holes up to 3 inches in diameter can be made in the chassis in the areas shown Exceeding 3 inches in diameter may cause failure of the chassis Comply to NEC and local codes and standards for installation of wires for electrical circuits Refer to NEC standards for required wire bend radius and ampacity of load leads No Description No Description EN Circuit Breaker Side shaded areas Drilling Allowed shaded sections DC left and AC right Connection ee areas FIGURE 16 DRILLING LOCATIONS FOR SIDE ELECTRICAL CONNECTIONS 44 A045R241 Issue 2 10 2013 4 Installation No Description No Description Circuit Breaker Maximum 3 in Bend Radius Gap FIGURE 17 CABLING ROOM FOR CIRCUIT BREAKER Grounding NOTICE The generator set is shipped from the factory with the neutral and equipment ground not bonded together Refer to local codes and standards for grounding procedures Battery Tm The generator set requires a 12V battery negatively grounded for engine cranking LOT and powering the electronic control system When the generator set is running the battery is charged from the engine driven battery alternator
47. e generator set 1 Press the Stop Switch and disable AUTO mode 2 Disconnect AC power from any battery chargers 3 Remove the negative battery cable from the battery to prevent it from contacting the battery terminal post Use caution when making adjustments when the generator set is running hot or when parts are electrically live as all situations may cause personal injury or death Used engine oil has been identified by some state and federal agencies as causing cancer or reproductive toxicity Do not ingest inhale or come into contact with used oil or its vapors Do not work on the generator set when mentally or physically fatigued or after consuming alcohol or drugs NOTICE Only trained and authorized personnell shall maintain or service the generator set General Safety Precautions Coolants under pressure can cause severe scalding Do not open a radiator or heat exchanger pressure cap while the engine is running Let the engine cool down before removing the coolant pressure cap Turn the cap slowly and do not open it fully until the pressure has been relieved A045R241 Issue 2 10 2013 1 IMPORTANT SAFETY INSTRUCTIONS Moving parts can cause severe personal injury or death and hot exhaust parts can cause severe burns Make sure all protective guards are properly in place before starting the generator set Used engine oils have been identified by some state and federal agencies to cause can
48. em components before installing Gaseous fuel supply system design materials components fabrication assembly installation testing inspection operation and maintenance must comply with the applicable codes See NFPA Standards No 37 54 and 58 For seismic installation refer to IBC codes and standards Where seismic installation is required there may be specific anchorage requirements for the generator set and other installed components Most codes require a manual shutoff valve ahead of a flexible fuel hose The manual valve should be of the indicating type The generator set has electric battery powered shutoff valves included NOTICE It is recommended that a shutoff valve be located near the generator set for emergency shut off or servicing the generator set Follow applicable codes A045R241 Issue 2 10 2013 4 Installation Until the generator set is connected cap the fuel line stub up at the generator set to prevent dirt from entering and gas from discharging if the gas supply shutoff valve is opened accidentally To determine the required capacity add generator set consumption to the gas consumed for heating cooking clothes drying etc A typical natural gas installation might require a 400 000 BTU meter Consideration should also be given to utilizing high pressure gas supply if available This reduces the required size and cost of gas piping especially if the location of the generator set requires a long supp
49. f applicable PowerCommand 1302 Controller Owner s Manual 900 0661 Standard Repair Times SRT Manual 0462094 Application Manual T 030 for application information A040S369 Service Tool Manual A043D529 2 4 Before Installation Before beginning the installation of the generator set verify that the unit was correctly selected Check the following features Model Specifications Options Fuel Supply The gas supplied to the generator set must of acceptable quality The gas supply must have sufficient pressure Care must be taken to be sure that the gas supply at the generator set not just at the source is of proper pressure for operation The specified pressure must be available while the generator set is starting and running at full load The gas must be supplied to the generator set in sufficient volume to support operation of the generator set This is normally a matter of selecting fuel line size to be large enough to transport the volume of fuel needed For liquid propane vapor withdrawal fuel systems the size and temperature of the fuel tank also affects this requirement A045R241 Issue 2 11 2 Introduction 10 2013 2 5 Model Specifications TABLE 1 2 4L MODEL VARIATIONS Model Description C20 N6 C22 N6 C25 N6 C30 N6 C36 N6 60 Hz 1800 RPM C40 6 C30 N6H C36 N6H C40 N6H C45 N6H 60 Hz 3600 RPM C50 N6H C60 N6H TABLE 2 COLD WEATHER SPECIFICATIONS Mo
50. fety 3 2 Required Items for Installation 3 3 Transfer Switch Mounting 4 e eee 4 1 Site Assessment and Preparation 4 2 Fuel Selection and Fuel System Connection 4o EngieExhausi s c rU 4 4 Electrical Connections 5 STARTUP AND CONFIGURATION 5 1 Brightness and 5 2 History and About Menu 5 5 5 Commissioning Checklist 5 6 APPENDIX A FUEL LINE SELECTION 0 Gas Pipe Sizing et APPENDIX B OUTLINE AND SYSTEM DRAWINGS A045R241 Issue 2 10 11 12 16 19 20 21 22 23 23 27 36 36 49 49 51 53 56 59 59 61 62 69 Table of Contents 10 2013 This page is intentionally blank ii A045R241 Issue 2 1 1 1 1 2 IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions for the generator set Follow these instructions during installation operation and maintenance of the generator set and batteries Thoroughly read the Operator Manual before operating the generator set Safe operation and top performance can only be obtained when the equipment is
51. gt FIGURE 23 DAYLIGHT SAVING ADJUST START MENU To access and update the Daylight Saving Adjust End Menu 1 Press the down key on the Daylight Saving Adjust Start Menu 2 Press Adjust When updating these settings the functions of the keys are as follows The horizontal right arrow key is used to select successive blocks for editing settings on the screen Use the or keys to edit the following settings o Month Week Day o Hour Press Save to save any changes After savings the Save button changes to the Adjust button A045R241 Issue 2 55 5 Startup and Configuration 10 2013 Daylight Saving Adjust End Mth Wk Day Hr 1 Sun ADJUST Daylight Saving Adjust End Mth Wk Day Hr Sum JOE SAVE m FIGURE 24 DAYLIGHT SAVING ADJUST END MENU 5 4 Exercise Settings NOTICE When the battery power is lost these settings must be reset To access the Clock Exerciser Menu 1 From any Information Menu hold down the up and down arrows simultaneously for two seconds The Service Menu appears 2 Navigate through the screens to find and select Clock Excr in the Service Menu NOTICE The following screens represent the standard operator panel HMI211 If using an in home operator panel which may be additionally purchased as an option the screens may look slightly different This procedure applies to both operator panels 56 A045R241 I
52. i mo tte o cr wit ECO 134616 LIMITED PRODUCTION RELEASE tv 22 7 13 aaa pon TI 0 51 ALTERNATOR BATTERY CHARGE FUEL SYSTEM NG LPV LLL A333 2 SINGLE FUEL C284 2 D T adl zu CES LLE fh imi 631 Theos 25 1 2821 34 1 SEE NOTE 5 ENGINE AIR CLEANER NORMAL DUTY 0041 2 lt COOLANT RECOVERY BOTTLE i IE B 969 4 38 2 34 41 t 4 C o 2 5 OIL DRAIN EXTENSION ENGINE 12 VDC MOTOR H268 2 SEE NOTE 5 A422 2 25 4 UNLESS OFWERWISE SPECIFIED ALL NOME DIMENSIONS ARE IN MILLIMETERS 3 z d VOLET e c POWER GENERATION x 3 H E are D_GILLETT EA puras Tt GENSET 176 EA ARROW 9 3045211 6 5 4 2 1 FIGURE 32 GENERATOR SET OUTLINE 30 40 KW 1800 RPM 36 60 KW 3600 RPM SHEET 2 OF 2 A045R241 Issue 2 10 2013 Appendix Outline and System Drawings 4 3 Y 2 Sat 4 0 308 BAT m 7 T s 179577 tiima iE 5 1 DIMENSIONS IN ARE IN INCHES D SKID BASE MAS FLANGE THICKNESS 3 4 ALLOW ELTRA LENGTH ON HARDWARE FOR UAE VERESS OF MOUNTING SURFACE SkiD BASE PERIMETER 15
53. in the maximum fuel requirements for the specific generator set from the manufacturer s specification sheets Convert to ft hr as needed Refer to the fuel line sizing charts in the Fuel Line Selection Appendix Locate the equivalent length of pipe or next larger equivalent length in the left hand column Move across the row to where the maximum capacity number is as large as or larger than the maximum fuel consumption or next larger At the top of that column is the minimum nominal pipe size or tubing size required for the system as designed A045R241 Issue 2 10 2013 4 Installation Installing Fuel Lines The basic components required for fuel line installation are as follows Flexible connection Fuel line e Shutoff valve Fuel supply To install the fuel lines 1 Connect a flexible fuel line to the fuel connection ports on the generator set 2 Connect the opposite end of the flexible fuel line to the fuel source line NOTICE A shutoff valve is recommended and often required by local and state codes Testing the Fuel System for Leaks After assembly and before initial operation all of the fuel system components must be tested and proven free of any leaks Fuel presents the hazard of explosion or fire which can result in severe personal injury or death Do not use an open flame to check for leaks Do not smoke or allow any flame spark pilot light arc producing equipment switch or other ignition so
54. ings elbows tees valves in the installation in addition to the fuel line length Longer lengths require larger diameters Fuel line type e g copper tubing or iron pipe Most fuel line types are iron pipe or copper tubing Be sure to use the sizing chart for the line type when sizing the fuel line There are some basic but very important steps all installers must follow to make sure that fuel lines are sized correctly 1 Verify adequate fuel flow quality and pressure available from utility connection 4 Determine fuel requirements at full load See the Fuel Specifications table in the Model Specifications section to determine the fuel flow requirements Determine equivalent length of fuel line fittings required See the Fuel Line Size Based on Fitting table in the Fuel Line Selection Appendix to determine the equivalent lengths for elbows tees and valves Add this length to fuel line length to determine total equivalent length Determine required fuel line size at full load See the Fuel Line Sizing table in the Fuel Line Selection Appendix to determine the fuel line size To calculate the minimum pipe size Make a list of all the fittings and valves in a proposed system and add their equivalent lengths Add all lengths of straight pipe to arrive at a total equivalent length to the fittings valves total Choose the applicable table based on the fuel system and fuel line material Obta
55. ize NOTICE Make sure the fuel supply pressure at the inlet to the generator fuel shutoff valves is set between 6 14 inch water column for all operating loads no load to full load 30 A045R241 Issue 2 10 2013 4 Installation Propane Fuel System Propane vapor can be used as a primary fuel source or as a backup fuel source for the generator sets with two independent fuel sources connected to the generator set NOTICE NFPA Standard No 58 requires all persons handling and operating propane to be trained in proper handling and operating procedures Fuel leaks can lead to explosive accumulations of gas Propane sinks in air and can accumulate inside housings basements and other below grade spaces Prevent gas leaks and the accumulation of gaseous fuel in the event of a leak The required components in a propane vapor fuel system are as follows Propane tank Make sure to identify and utilize the correct tank size based on fuel flow requirements and the lowest average temperature for your region If the tank is sized incorrectly the generator set could run out of fuel Refer to the Minimum LPG Tank Size figure in the Fuel Line Selection Appendix Shutoff valve Useful during installation or in the event of a leak may be required to meet local codes Primary regulator Located at the tank outlet the primary regulator reduces the tank pressure to the working pressure in the fuel supply line P
56. led in the tank can be effectively used Therefore a 500 gallon tank results in 240 gallon usable capacity To assist in the proper installation of the propane tank follow the guidelines below Fit the propane tanks with a pressure reducing regulator before connection to the generator set to prevent fuel system damage Locate the propane tanks at least 10 feet 3 meters from any source of combustion including the generator set Install the propane tanks according to all national and local codes and standards Refer to the Fuel Line Selection Appendix for propane figures and tables Sizing Fuel Lines Incorrect fuel line size may may cause the generator set to not run or provide a full load Fuel line sizes for installations typically range from 1 4 in to 2 or more inches in diameter To determine the optimal fuel line size the following information is needed Fuel flow requirements for the generator set Larger kW generator sets generally have higher fuel consumption and fuel line size requirements A045R241 Issue 2 33 4 Installation 34 IN 4 WM 10 2013 The fuel source natural gas or propane vapor Fuel sources can affect fuel line size Natural gas installations generally require a higher fuel flow rate compared to propane vapor installations since propane has a higher energy content Fuel line length including fittings Factor in the equivalent lengths of all of the fitt
57. ly line Natural Gas Fuel System Requirements for a natural gas generator set are as follows Adequate fuel supply to operate correctly and run at full load Pipeline quality gas The length of the fuel supply pipe from the gas service entrance to the generator set must be known to determine the correct fuel pipe size refer to the Fuel Line Selection charts NOTICE Iron pipe must be a minimum of schedule 40 subject to the authority having jurisdiction Cummins flexible fuel line to protect the fuel system from vibration expansion and contraction Manual shutoff valve Fuel leaks can lead to explosive accumulations of gas Prevent gas leaks and the accumulation of gaseous fuel in the event of a leak A045R241 Issue 2 29 4 Installation 10 2013 No Description No Description Shutoff Valve Meter Flexible Fuel Line Regulator FIGURE 6 TYPICAL NATURAL GAS INSTALLATION Natural Gas Supply Line Size NOTICE The Natural Gas supply meter may need to be exchanged for a higher capacity meter to supply the additional gas consumed by the generator set NOTICE An older site might require upgrading and repair of the gas supply system Schedule an upgrade or repair to minimize power and gas supply interruptions Use the total load requirement of the generator set to determine the size of the fuel supply pipe Use the Fuel Line Selection tables and charts in the Appendix to determine the correct pipe s
58. ngthwise widthwise and diagonally NOTICE Seismic installation may require specific anchorage Fuel Selection and Fuel System Connection For fuel specifications such as BTU hr see the Model Specifications section A045R241 Issue 2 27 4 Installation 10 2013 28 NOTICE This generator set has a convertible fuel system The generator may run on natural gas or propane depending on the preferences of the owner All generator sets come preconfigured from the factory for natural gas fuel For more information on converting the fuel system type contact your Cummins dealer or reference the Service Manual A045R243 NOTICE Fuel systems must be installed by qualified service technicians Improper installation presents hazards of fire and improper operation resulting in severe personal injury or property damage Gaseous fuels are flammable explosive and can cause severe personal injury or death Do not smoke if you smell gas are near fuel tanks for fuel burning equipment or are in an area sharing ventilation with such equipment Keep flames sparks pilot lights electrical arcs arc producing equipment and all other sources of ignition well away Keep a type ABC fire extinguisher handy In all fuel system installations cleanliness is extremely important Make every effort to prevent fuel contamination from gt Moisture o Dirt Excess thread sealant Contaminants of any kind Clean all fuel syst
59. ntended for stationary installation for emergency use only 21 About this Manual GES This manual is a guide for the installation of the generator set models listed on the NO ae front cover Proper installation is essential for top performance reliable operation and safety Read through this manual before starting the installation This manual covers outdoor applications only For other applications such as indoor applications contact your local Cummins dealer or reference the Application Manual at the following link http www cumminspower com www literature applicationmanuals t030 paf NOTICE The installation must comply with all applicable building codes GX See the generator set Operator Manual A045R242 for operation and maintenance NY the Service Manual A045R243 for service NOTICE Manuals are updated from time to time to reflect changes in the equipment and its specifications The most up to date version of this manual is found on the QuickServe website https quickserve cummins com info index html 2 2 Icons The following symbols may have been used in this manual to help communicate the intent of the instructions They are defined below Description Clean the part or assembly Indicates an electrical measurement Indicates that an inspection is required 0458241 Issue 2 9 2 Introduction 10 2013 5 Description Indicates an installation or assembly procedure
60. o that copies of the codes may be obtained for reference Installation codes and recommendations are subject to change and may vary by location or over time TABLE 14 INSTALLATION CODES AND STANDARDS FOR SAFETY RECOMMENDATIONS NFPA 70 National Electric Code National Fire Protection Association NFPA 37 Installation and Use of Stationary 470 Atlantic Avenue Combustion Engines and Gas Turbines Boston MA 02210 NFPA 54 National Fuel Gas Code NFPA 58 Storage and Handling of Liquefied Petroleum Gases NFPA 110 Standard for Emergency and Standby Power Systems CSA Electrical Bulletin Canadian Standards Association CSA 22 2 No 100 Housing and Construction Materials CSA 22 2 No 14 Section 178 Rexdale Blvd Rexdale Ontario Canada M9Q 1R3 20 A045R241 Issue 2 10 2013 3 Pre Installation Considerations California Administrative Code Title 25 Chapter 3 State of California Documents Section P O Box 1015 North Highlands CA 95660 3 2 Required Items for Installation Tools and materials are used for the installation of this generator set These items are identified in the following sections Please refer to local codes and standards as they may affect the materials required Materials Required NOTICE Refer to local codes and standards as they may affect the material requirements Electrical Materials Appropriately sized gauge and length AC wires with 75 C insulation Four wire
61. ough room for installation service and maintenance The generator must be located to ensure ventilation openings are not blocked Position the generator set so that cooling air is free to enter and leave the area A045R241 Issue 2 10 2013 4 Installation Locate and position the generator set so that prevailing winds carry exhaust gases and potential fuel leaks away from the house or occupied area No Description 5 ft Clearance shaded area FIGURE 4 CLEARANCES Laying the Foundation Cal When laying the foundation 1 Clear obstructions and make sure that there is adequate clearance for access 2 Level the ground and make sure that the ground is compact and settled Ensure that it is stable ground not subject to flooding 3 Prepare the concrete pad The pad should be constructed of reinforced concrete with a 28 day compressive strength of at least 2500 psi 17 236 89 kPa The pad should be at least 5 inches 127 mm deep and extend at least 6 inches 150 mm beyond the skid on all sides NOTICE Seismic installation may require a different pad and securing devices A045R241 Issue 2 25 4 Installation 10 2013 NOTICE Local codes and standards may have different requirements 4 Lift the generator set onto the pad and secure it No Description No Description 1 Thickness at least 5 inches 5 120 V 20 A Max Wire Stub Up 2 Width pad
62. properly operated and maintained Warning Caution and Note Styles Used In This Manual The following safety styles and symbols found throughout this manual indicate potentially hazardous conditions to the operator service personnel or the equipment DANGER Indicates a hazardous situation that if not avoided will result in death or serious injury Indicates a hazardous situation that if not avoided could result in death or serious injury Indicates a hazardous situation that if not avoided could result in minor or moderate injury NOTICE Indicates information considered important but not hazard related e g messages relating to property damage General Information This manual should form part of the documentation package supplied by Cummins Power Generation with specific generator sets In the event that this manual has been supplied in isolation please contact your authorized dealer A045R241 Issue 2 1 1 IMPORTANT SAFETY INSTRUCTIONS 10 2013 1 3 NOTICE Its is in the operator s interest to read and understand all warnings and cautions contained in the documentation relevant to the generator set operation and daily mainteance General Precautions Keep ABC fire extinguishers accessible Make sure that all fasteners are secure and torqued properly Keep the generator set and its compartment clean Do not store any items in the generator set compartment Before working on th
63. rimary and secondary regulators must be properly matched for a safe and functional system Consult with your propane supplier to ensure that the regulators are properly sized Secondary regulator Located near the generator set the secondary regulator reduces the higher line pressure to a working pressure of 6 14 inch water column Higher pressure before the secondary regulator is necessary to ensure that there is enough fuel available at the secondary regulator for a fully loaded generator set Fuel line Connects to the fuel supply It must be sized properly using the propane fuel line sizing charts see the Fuel Line Selection Appendix Installation must comply with all national state and local codes Cummins flexible fuel line Protects the fuel system from vibration expansion and contraction A045R241 Issue 2 31 4 Installation 10 2013 No Description No Description Flexible Fuel Line Shutoff Valve Generator Set Propane Tank Regulator FIGURE 7 TYPICAL PROPANE INSTALLATION Recommended Fuel Propane Propane presents the hazard of fire or explosion that can cause severe personal injury or death Do not permit any flame spark arc producing equipment switch pilot light cigarette or other ignition source near the fuel system Keep an ABC type fire extinguisher nearby Use clean fresh HD 5 grade propane or equivalent product consisting of at least 90 propane NOTICE Commercial propane
64. rst decisions to be made as it affects all other aspects of the installation such as Length of electric wiring Length of gas lines natural gas or propane both must be inspected by the gas utility inspectors and building inspectors Site preparation Access to the site Trenches Site preparation materials needed Fuel supply pressure Automatic transfer switch location and connections A045R241 Issue 2 19 3 Pre Installation Considerations 10 2013 Tools and materials required Minimum distance from the propane tank fill verify the legal minimum distance with local code officials Accessories required if any for the customer s application utility power may be required at the generator set make plans accordingly NOTICE Depending on the locality and use of the generator set it may be necessary to obtain an air quality emissions permit before installation begins Check with local pollution control or air quality authority to determine permit requirements 3 1 Installation Codes and Standards for Safety NOTICE The generator set installer bears sole responsibility for following all applicable local codes and regulations The following list of codes and standards may apply to the installation and operation a of the generator set This list is for reference only and not intended to be inclusive of all applicable codes and standards The address of each agency is listed s
65. rting After verifying that the installation was completed correctly start and test the system Make sure to connect the battery cables to the battery with the positive cable first A045R241 Issue 2 59 5 Startup and Configuration 10 2013 Zs Read through the Operator Manual and perform the maintenance and pre start checks as instructed The generator is shipped from the factory with the proper level of engine oil and coolant but should be checked before it is started Start and operate the generator set following all the instructions and precautions in the Operator Manual Ensure that the bonding bolts are reinstalled into the service panels before leaving the site NOTICE Before leaving the site if the generator set is ready to be placed in service set the control switch to the AUTO position to provide automatic standby power NOTICE Contact your local Cummins service representative if you encounter a fault code 60 A045R241 Issue 2 Appendix A Fuel Line Selection Table of Contents Figure 28 Minimum LPG Tank Size 50 Full Required to Maintain 5 PSIG at Specific Withdrawal Rate and Minimum Expected Winter Temperature Table 16 Natural Gas Schedule 40 Iron Pipe Sizing eese Table 18 Natural Gas Semi Rigid Copper Tubing Sizing Table 20 Propane Vapor Schedule 4
66. s L1 L2 N and Gnd add another wire for 3 phase Appropriate conduit for all AC wires Four 18 AWG 60 75 copper DC control wires and conduit for ATS interface RA Series Code compliant 20A GFCI circuit for alternator heaters battery charger coolant heater if equipped M Mounting Materials Four base tie down bolts NOTICE Seismic zone installations require compliance to specific mounting configurations M Fuel Materials e Flexible fuel line provided with generator e UL listed pipe thread sealant A045R241 Issue 2 21 3 Pre Installation Considerations 10 2013 Fuel line natural gas and propane 6 14 inch water column fuel pressure at generator set Fuel pressure regulator as required Manual fuel shut off at generator set ahead of automatic valves on generator set fuel system Loose Parts Shipped With the Generator The following loose parts are shipped with the generator set Flexible fuel hose assembly Two enclosure keys where applicable Battery tie down Sound level 2 where applicable Literature Operator Manual Installation Manual Health and Safety Manual and Warranty Statements 3 3 Transfer Switch Mounting IN 4 1 Consider the location before mounting the transfer switch Consider the proximity to the utility service entrance and breaker panel There must be a service disconnect circuit breaker or fuses in the power line ahead
67. sing severe skin and eye burns and can release toxic electrolytes A045R241 Issue 2 5 1 IMPORTANT SAFETY INSTRUCTIONS 10 2013 1 8 1 9 Do not dispose of the battery in a fire because it is capable of exploding Do not open or mutilate the battery Released electrolytes have been known to be harmful to the skin and eyes and to be toxic Batteries present the risk to high short circuit current Remove watches rings or other metal objects and use tools with insulated handles Wear safety glasses Do not smoke To prevent arcing when disconnecting the battery 1 Press the Stop Switch 2 Disconnect AC power from any battery chargers 3 Remove the negative battery cable to prevent starting To prevent arcing when reconnecting the battery 1 Reconnect the positive cable 2 Reconnect the negative cable 3 Reconnect the battery charger to AC power supply When replacing the generator set battery always replace it with a battery as specified in the Model Specifications section of this manual Moving Parts Can Cause Severe Personal Injury or Death Do not wear loose clothing or jewelry near moving parts such as fans Keep hands away from moving parts Keep guards in place over fans The Hazards of Carbon Monoxide Carbon Monoxide CO is an odorless colorless tasteless and non irritating gas you cannot see it or smell it Exposure even to low levels of CO for a prolonged period can le
68. ssue 2 10 2013 5 Startup and Configuration Battery 12 4 VDC Eng Temp 180 F Oil Press 75 PSI Hours 2222 h AUTO MAN 772 SERVICE MENU 1 Setup Menus 2 History About 3 Screen Adjust 7 More Options 1 2 3 SERVICE MENU 4 Fault History 5 Status 6 Lamp Test 7 More Options 4 5 6 v SERVICE MENU 7 Network Status 8 Clock Excr 7 More Options 7 8 TIME SETUP Date 00 00 00 mm dd yy Time 00 00 AM ADJUST FIGURE 25 CLOCK EXERCISER MENU NAVIGATION A045R241 Issue 2 57 5 Startup and Configuration 10 2013 Updating Exercise Frequency To update the exercise frequency and dates on the Clock Exerciser Menu 1 Press Exercise Schdr on the Daylight Saving Adjust End Menu 2 Press Adjust When updating these settings the functions of the keys are as follows The horizontal right arrow key is used to select successive blocks for editing settings on the screen Use the or keys to edit the following settings Schdr Enable Enable or Disable Exercise Schedule Semi Annual every six months Quarterly Monthly Bi Weekly every two weeks or Weekly Exercise Schedule Day Hours Minutes AM PM Press Save to save any changes After savings the Save button changes to the Adjust button Exercise Schdr Schdr Enable Dis Monthly Tue 02 00 PM ADJUST v Exercise Schdr Schdr Enable
69. st for heating a room or enclosed space Electrical Connections NOTICE Refer to regional codes and the National Electrical Code NFPA 70 for all electrical installation requirements Improper installation can lead to electrocution and damage to property Electrical connections must be made by a licensed electrician Automatic startup of the generator set during installation can cause severe personal injury or death Assure the generator set operation switch is in the OFF position Disconnect the negative cable from the battery and secure it to prevent contact of the cable to the battery terminal and from starting the generator set Separate conduits are required for Main wiring for generator AC voltage conductors between the generator set breaker and transfer switch 120 60 Hz utility house power power to operate the optional battery charger coolant heater or alternator heater Communications low voltage signals between generator set and transfer switch data signals between the control and optional remote display auxiliary input output signals to from the control A045R241 Issue 2 10 2013 4 Installation AC Connections Automatic startup of the generator set during installation can cause severe personal injury or death Push the control switch OFF and disconnect the negative cable from the battery and prevent the cable any electrical connection from contacting the battery B terminal to
70. st leaks Do not step on the generator set when entering or leaving the generator room To prevent accidental or remote starting while working on the generator set disconnect the negative battery cable at the battery using an insulated wrench Make sure that rags are not left on or near the engine Make sure the generator set is mounted in a manner to prevent combustible materials from accumulating under the unit Accumulated grease and oil can cause overheating and engine damage presenting a potential fire hazard Keep the generator set clean and repair any oil leaks promptly Before performing maintenance and service procedures on enclosed generator sets make sure the service access doors are secured open Keep the generator set and the surrounding area clean and free from obstructions Remove any debris from the set and keep the floor clean and dry NOTICE Keep multi class ABC fire extinguishers handy Class A fires involve ordinary combustible materials such as wood and cloth Class B fires involve combustible and flammable liquid fuels and gaseous fuels Class C fires involve live electrical equipment Refer to NFPA No 10 in applicable region 4 A045R241 Issue 2 10 2013 1 IMPORTANT SAFETY INSTRUCTIONS 1 4 Generator Voltage is Deadly Generator output connections must be made by a trained and experienced electrician in accordance with all applicable codes This generator set and the public utili
71. tal equivalent length Choose the applicable table based on the fuel system Obtain the maximum fuel requirements for the specific generator set s from the manufacturer s specification sheets Convert to ft hr as needed Locate the equivalent length of pipe or next larger equivalent length in the left hand column Move across the row to where the maximum capacity number is as large as or larger than the maximum fuel consumption or next larger At the top of that column is the minimum nominal pipe size or tubing size required for the system as designed A045R241 Issue 2 10 2013 Appendix Fuel Line Selection 100 000 50 000 LPG TANK SIZE GALLONS LPG VAPORIZATION RATE CUBIC FEET PER HOUR FIGURE 28 MINIMUM LPG TANK SIZE 50 FULL REQUIRED TO MAINTAIN 5 PSIG AT SPECIFIC WITHDRAWAL RATE AND MINIMUM EXPECTED WINTER TEMPERATURE TABLE 16 NATURAL GAS SCHEDULE 40 IRON PIPE SIZING Gas Natural Inlet Pressure 0 5 psi or less Pressure Drop 0 5 in w c Specific Gravity 0 60 Pipe Size in 1 4 3 8 1 2 3 4 1 1 1 4 1 1 2 2 1 2 0 364 0 493 0 622 0 824 1 049 1 380 1 610 2 067 2 469 3 068 4 026 2 9 2 lt c Maximum Capacity in Cubic Feet of Gas per Hour A045R241 Issue 2 63 Appendix Fuel Line Selection 10 2013 Gas Natural Inlet Pressure 0 5 psi or less Pressure Drop 0 5 in w c Specific Gravity 0 60
72. tentionally blank 88 A045R241 Issue 2 www cumminspower com Cummins the C logo and Our energy working for you are trademarks of Cummins Inc Copyright 2013 Cummins Power Generation Inc All rights reserved
73. ty may only be connected to house circuits by means of the automatic transfer switch Improper connections can lead to electrocution of utility workers and damage to equipment Make sure that the connections are installed properly by a trained technician Use caution when working on live electrical equipment Remove jewelry and make sure clothing and shoes are dry Stand on a dry wooden platform 1 5 Engine Exhaust is Deadly See The Hazards of Carbon Monoxide to learn the symptoms of Carbon Monoxide poisoning Locate the generator set away from doors windows other openings into the house and where exhaust gases will disperse away from the house 1 6 Fuel 1 Flammable and Explosive Keep flames cigarettes sparks pilot lights electrical arc producing equipment switches and all other sources of ignition away from areas where fuel fumes are present and areas sharing ventilation Fuel lines must be secured free of leaks and separated or shielded from electrical wiring Leaks can lead to explosive accumulations of gas Prevent leaks and the accumulation of gas A rotten egg smell indicates a possible natural gas or propane leak Natural gas rises when released and can accumulate under hoods and inside housings and buildings Propane sinks when released and can accumulate inside housings and basements and other below grade spaces 1 7 Batteries Can Explode Batteries can explode cau
74. urces around fuel or fuel components NOTICE Follow any local codes and standards as they may require a different method or documentation of a leak test Cal After assembly and before initial operation all fuel system connections hose 6 valves regulators and fittings must be tested and proven free of leaks using soap and water equivalent solution while the system is under gas or air pressure of at least 1 5 times the supply pressure or 3 psi 20 7 kPa minimum 1 Pressurize the system to a minimum of one and a half times the required fuel supply pressure 2 Use a mixture of dish soap and water Spray on all the joints 3 Inspect all of the joints and monitor the line pressure If bubbles appear there is a leak A045R241 Issue 2 35 4 Installation 10 2013 4 3 4 4 36 4 leak is found tighten the joints recheck for leaks and repair or replace component s as needed Engine Exhaust The exhaust system for this generator set is complete and was designed specifically for this engine Do not modify or add to the exhaust system of this generator set Exhaust gas is deadly Make sure that the exhaust system terminates away from building vents windows doors and sheltered spaces that may not have ample fresh air ventilation Engine discharge air and exhaust carry carbon monoxide gas odorless and invisible which can cause asphyxiation and death Never use engine discharge air or exhau

Installation Manual

Contents

Download Pdf Manuals

Related Search

Related Contents