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1. TABLE 22 PROPANE VAPOR PIPE CAPACITY CUBIC FEET OF GAS PER HOUR Nominal Iron Length of Pipe in Feet Pipe Size iss ep pee feo m mm mom m aa 27 wr h he mom s je de he n ee ina es2 so8 fass ae se5 3s3 sos 20 207 252 23o 204 Maximum pipe capacity in cubic feet per hour of Propane vapor with a pressure drop of 0 5 inches 1 27 mm WC over the length FIGURE 14 TYPICAL PROPANE VAPOR WITHDRAWL INSTALLATION 3 7 3 4 Converting From Natural Gas to Propane Vapor Withdrawal The generator set leaves the factory set up for Natural gas For use with Propane the generator must be converted by configuring the control for Propane An LPconversion kit AO30M445 must also be ordered and installed For US EPA and carburetor emission complianace the LP conversion kit is required to convert the 13GSBA 2010 models from natural gas to LP 3 7 4 Testing the Fuel System for Leaks A WARNING Fuel presents the hazard of explosion or fire which can result in severe personal injury or death Do not smoke or allow any flame spark pilot light arc producing equipment switch or other ignition sources around fuel or fuel components Before operating the generator set test the fuel system for leaks e Energize the fuel solenoid from a separate 12 volt DC source before testing the fuel system 32 A029V090 Issue 1 4 2010 3 Step By Step Outline of Installation CS NOTE Testing for
2. Ji 24 1 16 Or S3 SEE NOTES 1 3 J1 8 Uum S7 SEE NOTE 4 o 1 33 9S5 SWITCH IS N C D J112 8 2 Ji e3a A12 MODULE 56 J4 e u a o aya fn DISPLAY CONNECTOR n TO i TRANSFERSWITCH Je e J23 J127 Je 4 Je 5 Ji1 e8 Noa u 8 uuu J1 25 gt J118 J1 26 Ji1 328 19 1 14 Ji 7 J1 5 Ji 38 1 15 1 17 gt Ji iB gt 1 17 gt 1 3 Ji a 1 13 J1 1 1 34 1 35 3 A029V090 Issue 1 3 Pe o SEE NOTE 4 G1 MAIN ALTERNATOR a4 18 SERVICE TOOL CONNECTOR TO BONDING LINK ON TRANSFER SWITCH N 4 SWITCH IS NORMALLY OPEN 8 CHANGES TO THIS DIAGRAM SHEET MUST BE TRANSFEHED TO AG2B8W344 3 SWITCH IS OPTIONAL 4 ONLY USED ON GSBB TB2 GND N L2 cre 1 LINE LOAD L4 LINE E EN 2 LOAD FIGURE 68 WIRING DIAGRAM SHEET 1 OF 3 No Rev Appendix A Outline and System Drawings A029L912 B Sh 1 of 3 87 Appendix A Outline and System Drawings 88
3. Generator P7 UTILITY SENSE 1 UTILITY SENSE 2 TRANSFERHSWITCH CONTHOL B SWITCH POSITION UTILITY SWITCH POSITION GENEHRATOH LOAD CONTHRUL 1 LOAD CONTRHOL 2 NOTES 4 2010 1 ALL WIRING AND RELAYS ON THIS PAGE ARE CUSTOMER SUPPLIED 2 OPTIONAL Transfer Switch RELAY 4 tT RELAY2 v s gt 18 gt 115 12 gt TB4 1 UTILITY SENSE 1 TB4 2 UTILITY SENSE 2 TB4 3 TRANSFER_SWITCH CONTAOL TB4 4 B TB4 5 SWITCH POSITION UTILITY 4 TB4 6 SWITCH POSITION GENEHATOH TB4 7 Bt 120v EXAMPLE 25A amp 42vDCl 70nR8 4 EENS LOAD La H N 24 V EXAMPLE LOW VOLTAGE EXAMPLE 25A amp 42vDCl 7O08 4 INNAN we At CONTROL L4 w os SIGNAL L2 ME FIGURE 69 WIRING DIAGRAM SHEET 2 OF 3 No A029L912 Rev B A029V090 Issue 1 4 2010 A029V090 Issue 1 TO DISTRIBUTION PANEL OIL HEATER JUNCTION BOX HOT BA g o THEAMOSTAT E n HEATER NEUTRAL Qr GND Q ALTERNATOR HEATER FIGURE 70 WIRING DIAGRAM SHEET 3 OF 3 Appendix A Outline and System Drawings NOTES 1 FOR COLD WEATHER SPECS ONLY No A029L912 Rev B Sh 3 of 3 89 Appendix A Outline
4. 4 Replace the 4 small screws Load Shed Communications Wires The control cable has the load control wires brought out of the genset P7 7 and P7 8 Class 1 wiring methods should be used for the in home display Ethernet and transfer switch communication conductors between the generator set and transfer switch Separation of Class 2 and power circuits should be maintained per Article 725 136 of 2008 NFPA 70 National Electrical Code Use 300V 18 gauge 75 C wire for wiring the relay See the following figures for the different ways the relays can be wired A029V090 Issue 1 4 2010 3 Step By Step Outline of Installation Q Load control pin 8 or 9 No Description NO LA To air conditioner load Sa Relay Requirement e Input 12Vdc Max 0 5 Amp e Contact Low voltage lt 40 Amp e Mounting No restrictions FIGURE 8 LOW VOLTAGE RELAY SPDT A029V090 Issue 1 23 3 Step By Step Outline of Installation 4 2010 No Description No Description Pie a Cun en Relay Requirement e Input 12Vdc Max 0 5 Amp e Contact 120 V AC Amp rating for load e Mounting Typically in distribution panel FIGURE 9 HIGH VOLTAGE RELAY SPDT 120V AC LOAD 24 A029V090 Issue 1 4 2010 3 Step By Step Outline of Installation Load Control Pin 8 or 9 No Description NO Fl Sais ik SF amp 43x f Relay Requirements e Input 12Vdc Max 0 5 A
5. Genset Status Voltage 240V Frequency 60Hz Hr Meter 1234 6 FIGURE 52 GENERATOR SET STATUS SCREEN 7 8 Display Setup and Software Info 7 8 1 Brightness and Contrast To change the Brightness and Contrast of the display screen ils D O QUELLES Press the MENU button on the home screen Press the up or down arrow button on the menu screen to select Display Setup Press the ENTER button on the menu screen Press the NEXT button to select Brightness or Contrast Press the increase or decrease arrow button to increase or decrease brightness Change Contrast the same way as Brightness Press the BACK button to save the settings and return to the home screen A029V090 Issue 1 63 7 Operation 4 2010 Sun 10 35 AM Battery 12 5 Genset Load LIW 1288 EXCER CLOCK LOAD MENU Genset Status Event Log Fault Log Ethernet Setup Software Info GEN SW P N 3261234 SW VERSION 12 34 Dis SW P N 3261234 SW VERSION 10 23 FIGURE 53 DISPLAY SETUP AND SOFTWARE INFO SCREENS 7 8 2 Software Info To check on the generator set and display software 64 1 Press the MENU button on the home screen 2 Press the up or down arrow button on the menu screen to select Display Setup 3 4 Press the INFO button on the Display Setup screen and note the values displayed on the Press the ENTER button on the menu screen Software Info screen A029V090 Issue 1
6. Installation Manual Cummins Onan Performance you rely on Home Standby Generator Set GSBA Spec A English Original Instructions 4 2010 A029V090 Issue 1 Table of Contents 1 IMPORTANT SAFETY INSTRUC DOM Serene if PNE 1 1 Save These Instructions 1 2 General Precautions 1 3 Generator Voltage is Deadly 1 4 Engine Exhaust is Deadly d 5srueltisitlammablerandiExplosiVemeee m eee Ree RS 1 6 Batteries Can Explode 1 7 Moving Parts Can Cause Severe Personal Injury or Death seeessssessss T 8 Ehe Mazards or Carbomionoxidezs s m doe LIE ZOINEISODUCTHONSUTST B 2 1 About this Manual 2 2 Model Specifications 2 3 Information For After Installation 3 STEP BY STEP OUTLINE OF INSTALLA ION eerte nnns 3 1 Pre Installation Considerations 3 2 Generator Set Location Requirements cccccccccceeceeeceeeeeeeeeeeeeeneseeeeeaaaeaaaeaaeeaaeeaeeeeeeees 3 3 Preparing the Site 3 4 Lifting and Moving the Generato Eel MR RENATA AETERNE a LE 3 9 staking the Generator Set in PIaee estos eme aci tectae itta ess ct unte E buta inmate 3 6 Electrical Wiring Connections au FUA SOV SIEM ses ca 3 8 Engine Exhaust coc 4 OPTIONAL INTERNET EMAIL INTERFACE DESCRIPTIONS eee 4 1 Introduction
7. 4 2 Screen Descriptions 5 ETHERNET CONNECTION INSTALLATION WORKSHEET eee 5 1 Network Connectivity Options 5 2 Material Cable Routing 5 3 Network Information Needed For Setup sssssessseeneeee eene 6 OPTIONAL INTERNET EMAIL INTERFACE SETUP ssseeseeneeeenme eene 6 1 Ethernet Connections Optional A029V090 Issue 1 CQ OO MN NNa gt a N O1 O1 o 14 16 16 17 17 26 33 35 35 36 41 41 41 41 43 43 Table of Contents 4 2010 6 2 In Home Network Access to the Generator Set sseeeseeeeeee 44 6 3 Setting up E mail NotifiGatiori paint A a ned te uide rdeh 46 6 4 Email Setup Parameters cccccccecccecceeceseeeecececeeeceaseesensaneaaneaecaeceseceeceeeeeeeeeeeeeeeeeesenseties 47 6 5 Remote Internet Access to the Generator Set cee tenets 49 6 6 Help Hotline mm mU SET m 49 6 7 Frequent ys ie che Stm E ccr lcs nsi EE 49 7 OPERATIONE E MES S lm 53 PS ROON SVAN o een eene eee 53 e2sinzEiomexeperatonbarnelee mS eee ee a E eee 54 ESanvpicaliperationmeee euet eee TUM 55 VA TO nace Diae standby MEA hf 60 7 5 lo Manually Start Stop Generator amp eb e stre 60 7 6 Fault Maintenance and New Event Screens cccccccccccecccceeccseeeceseuceseueseeuceesuuceueuseeseunes 61 Lal GENEL SIE Saeco RRR eeu E EE E E 62 7 8 Display Setup and
8. Fi 1 SEE REF DES 10334_0757 CTI AD28X 144 TRANSFORMER CURRENT 6 WIRE TIES SHALL BE PLACED AT ALL TUBE ENDS AND AT BOTH SIDES OF BREAK OUTS WIRE TIES SHALL BE PLACED ALONG TUBE EVERY 100MM MAX IE I 16 0323 1614 01 3 1 1 SEE REF DES 0334 0756 cT A028X144 TRANSFORMER CURRENT W20 J4 1 0323 2063 1 2 6mm STRIP 03340156 106 z 6 ALL BREAK OUTS SHALL EXIT FROM THE TUBING SLIT REGARDLESS WHICH SIDE 2i sad ai n LUI LENS El A0062612 TERMINAL RECEPTICAL FUEL SHUTOFF 187 X 02 RCPT EY APPEAR IN THE GRAPHICS x ET 6ND 0062612 TERMINAL RECEPTICAL FUEL SHUTOFF 187 X 02 RCPT w23 P1 23 0323 1614 01 412 1 SEE REF DES 0334_0756 A E WRAP FUSE TO HARNESS WITH ITEM 0332 3388 FI 0332 1992 TERMINAL RECEPTICAL BRUSH BLOCK 14 X 03 TAB W24 PI 24 0323 1614 01 E1 1 SEE REF DES 0334 0156 CE 7S mea OI T U 103340757 F2 0332 1992 TERMINAL RECEPTICAL BRUSH BLOCK 1 4 X 03 TAB w27 J4 2 0323 2063 12 2 Gmm_STRIP 0334 0156 F3 0321 0311 HOLDER FUSE i23 1 28 0323 1614 01 P7 7 0323 1492 0334_0757 ND 0332_1194 TERMINAL RING ALTERNATOR FOOT 5 16 STUD wo HEN 0323 1614 01 Z3 2 Gmm STRIP 0334 0756 GND 2 0332 1194 TERMINAL RING ALTERNATOR FOOT 5 16 STUD W31 J4 3 0323 2063 13 2 Gmm STRIP 0334 0756 GND 3 0332 1302 TERMINAL W32 73 1 Sm STRIP PI 0323 1492 0334 0757 w33 P1 33 0323 1614 01 55 1 SEE REF DES 0334 0756 i easet CONNECTOR PLUG W34 1 32 0323 1614 01 52 3 0332 2928 0334 0756 5 0323 2644 CONNECTOR PLUG 435 PI 34 0323 1614 01 AC
9. 4 2010 7 Operation 5 Press the BACK button to return to the home screen 7 9 Event Log 7 9 1 To Check Log of Last 20 Events 1 Press the MENU button on the home screen 2 Press the up or down arrow button on the menu screen to select Event Log 3 Press the ENTER button on the menu screen 4 Scroll through the event log with the up and down double arrow buttons Each screen provides a brief description of the event along with the time and date of the event 5 Press the BACK button to return to the home screen Sun 10 35 AM Battery 12 5 Genset Load LIW 128 EXCER CLOCK LOAD MENU Genset Status Display Setup Fault Log Ethernet Setup Event Log Standby Enabled 05 04 2007 1 18PM FIGURE 54 EVENT LOG SCREEN 7 9 2 List of Recordable Events e Genset started manually Standby Ready Disabled e Genset stopped manually Standby Ready Disabled e Genset exercise started A029V090 Issue 1 65 7 Operation 4 2010 Genset exercise completed Genset started due to loss of utility Genset stopped with return of utility Switch on genset moved to remote position Switch on genset moved to run position Switch on genset moved to off position Standby ready disabled by user Standby ready enabled by user Utility lost not in Standby Ready Utility returned not in Standby Ready Maintenance reminder Change oil and check valve lash Maintenance reminder Cha
10. 88 ft Hr 191 ft Hr 7 11 inches WC 5 11 inches WC Tank Size 500 Gallon Contact your local gas company to verify the tank size required for your application TABLE 5 GENERATOR SPECIFICATIONS TABLE Brush Type 2 Pole Rotating Field Single Bearing Rated Voltage V 120 240 120 240 Rated Current Amps 106 53 92 46 Phase Type Single Phase Circuit Breaker Amps jo fo De rating Guidelines Maximum wattage or maximum current are subject to and limited by such factors as fuel Btu content ambient temperature altitude engine power and conditions etc Full rated power is available at 60 F 15 5 C at sea level De rate 3 5 for each 1000 ft 304 8 m above sea level and 3 for each 10 F 5 5 C increase in ambient temperature above 60 F 15 5 C This generator is rated in accordance with UL 2200 Stationary Engine Generator Assemblies or CSA C22 2 No 100 04 Motors and Generators The maximum continuous current values that are listed on the generator set nameplate and specification tables occur at the lower limit of acceptable voltage Maximum current occurs at 108 and 216 volts 10 below nominal voltage 120 240 The voltage set point of this generator set can be adjusted from the operator panel if desired Refer to the Operator Manual procedure To Adjust the Output Voltage TABLE 6 ENGINE SPECIFICATIONS TABLE Engine sid 2 Cylinder V Twin OHV Air Cooled 4 Stroke Spark Ignited 3600 RPM Displacement 720
11. I 1 SEE REF DES 0334 0756 LI 0332 2148 TERMINAL i36 1 35 0323 1614 01 amp C 2 1 SEE REF DES 0334 0756 Te 0332 2748 TERMINAL 437 S3 GND SEE REF DES EI GND SEE REF DES 0334_075T 5i EER COEP W38 S3 GND 1 SEE REF DES GND 1 1 SEE REF DES 0334 0757 P2 0323 2516 CONNECTOR PLUG W33 S5 GND 1 SEE REF DES GND 1 1 SEE REF DES 0334 0757 Wa AI2 GND l SEE REF DES GND I 1 SEE REF DES 0334 0756 qu 032351982 CONNECTOR PLUG wal S2 2 0332 2928 82 1 0332 2828 0334 0756 P8 4028x409 CONNECTOR PLUG 342 2 2 0332 2928 GND 2 1 SEE REF_DES 0334_0757 al 0332_2430 TERMINAL BLADE QUAD WINDING 1 4 03 RCPT m Prd 0323 1492 SND a SEE REF DES 9334 0757 7 03322430 TERWINAL BLADE QUAD WINDING 174 03 RCPT wad PI 2 0323 1614 01 6ND 2 1 SEE REF DES 0334 0757 32 0308 1019 CONNECTOR SWITCH WAS J4 5 0323 2063 15 2 Gmm STRIP 0334 0157 wa P2 2 0323 1614 01 P1 2 9323 1492 0334 0157 ad 0342 1997 TERMINAL RECEPTIEAE w47 P2 3 0323 1614 01 P7 3 0323 1492 0334 0151 S3 GND 0332 4041 TERMINAL RECEPTICAL i48 92 1 0323 1614 01 P1 5 0323 1492 0334 0757 5 0332 2571 TERMINAL RCPT wag LIT SEE REF DES 182 1 1 SEE REF DES 0334 1212 5 GND 0332 2571 TERMINAL RCPT W30 ry SEE REF DES 182 2 1 SEE REF DES 0334 1212 36 0323 2517 CONNECTOR RECEPTICAL STARTER W51 T82 1 SEE REF_DES GND 3 1 SEE REF DES 0334 1212 S1 0332 2571 TERMINAL RCPT W53 CTI 2 SEE NOTE 1 PI 15 0323 1614 01 0334_0757 W54 SE SEE_NOTE 14
12. and System Drawings 4 2010 NOTES LABEL SHOWN ON PRINT IS NOT ARTWORK VENDOR ART R PRODUCTION SAMPLE MUST BE SIGNED OFF BY CUMMINS OWER GENERATION PURCHASING Eco 2 ALL TEXT TO BE HELVETICA SANS SERIF OR EQUIVALENT 3 IF CSA AGENCY APPROVAL IS REQUIRED LOCATE VENDOR CSA IDENTIFICATION MARK IN LOWER RIGHT HAND CORNER 4 F CORNERS SHOWN SQUARE RADIUS IS OPTIONAL 9 MATERIAL THICKNESS 10 MIL 6 BACKGROUND COLOR WHITE TEXT COLOR BLACK 1 LOCATE PART NUMBER AND REV LETTER ON BACKING SHEET a 45 a E D e 8 LABELS ARE TO BE DIE CUT AND CONTAINED ON A BACKING SHEET CUSTOMER WIRING CUSTOMER WIRING i 1 GROUND B BLACK 1 UTILITY SENSE 1 WHITE 2 2 UTILITY SENSE 2 GREEN 3 Br RED 3 TRANS SWCH CTRL ORANGE 4 REMOTE START BLUE 4 B BLACK 7 0 5 5 SWCH POS UTILITY BLUE 6 SWCH POS GEN BROWN 6 SWCH POS GEN BROWN LOAD CTRL 1 YELLOW 7 B RED LOAD CTRL 2 VIOLET 8 LOAD CTRL 1 YELLOW 8 LOAD CTRL 2 VIOLET USE WITH RSS100 6634 USE WITH RSS100 6868 RSS200 6635 RSS200 6869 AO29U3I6 A No A029U316 sh 1 of 1 Rev A FIGURE 71 HARNESS LABEL 90 A029V090 Issue 1 4 2010 section A A A029V090 Issue 1 EL DETAIL A 3 WIRE FROM PIN WIRE COLOR FUNCTION REF WI 4 1 0323 2449 ORANGE RS485A
13. and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform Generator Set service Possible Causes Bad connections or bad communications Corrective Actions 1 Check connections a Verify that the Ethernet cable is plugged into the generator set control and the router b Verify that the computer is connected to the same router as the generator set via an Ethernet cable c Verify that the wireless card on the computer is turned off d Check to see if both ends of the Ethernet cable are assembled and crimped as described in the installation instructions If not reassemble and crimp as described in the installation instructions e Verify that the Ethernet cable connections between the generator set and the router are solid and correct f Proceed to Check communications 2 Check communications a Check to see if you can access a standard web page with the computer connected to the same router as the generator set If not contact your router manufacturer for troubleshooting information b Check to see if the green and orange lights are illuminated at the Ethernet connection port on the generator set control board If not disconnect the Ethernet cable from the generator control board and connect it to the computer Check to see if you can access a standard web page with the computer connected to the generator side of the Ethernet cable a If you can access a standard web pag
14. arrow button on the Config Menu screen to select Generator Config 4 Press Enter on the Config Menu to go to the Generator Config screen 5 Press the NEXT button on the Generator Config Menu screen to select the Config Frequency or Rating field 6 Press the up or down arrow button to increase or decrease the configuration parameter a Config Select appropriate configuration depending on model and fuel from the table shown below b Frequency Select 60 Hz or 50 Hz c Rating Rating will be filled in based on the configuration selected This value can be lowered in order to correctly de rate for high altitude or hot climates Selecting the correct Amps value will also allow the correct genset load to be displayed on the Operator Panel 7 Press the BACK button to save the setting and return to the home screen TABLE 25 CONFIGURATIONS BASED ON MODEL AND FUEL TYPE Mode Ful Configuration Propane 16 72 A029V090 Issue 1 4 2010 8 5 A029V090 Issue 1 Sun 10 35 AM Battery 12 5 Genset Load LIW 128 EXCER CLOCK LOAD MENU Genset Status Display Setup Event Log Fault Log Ethernet Setup hold blank button for 5 seconds Generator Adjustments TS Config TS Adjustments Config Frequency fi Hz Ef Amps FIGURE 59 GENERATOR CONFIGURATION Transfer Switch Configuration To configure the generator set for the transfer switch being used 1 Press the MENU button on the
15. death It is extremely important that bonding and equipment grounding be properly done All metallic parts that could become energized under abnormal conditions must be properly grounded A029V090 Issue 1 19 3 Step By Step Outline of Installation 4 2010 GROUNDING WITH MODEL RSS 100 6634 AND RSS 200 6635 TRANSFER SWITCHES SERVICE ENTRANCE GENERATOR SET L 2 POLE TRANSFER I SWITCH T A I A EE x I I nl e 3 3 45 TO UTILITY e B A SERVICE N T l I i ee a 6 LOADS GROUNDING WITH MODEL RSS 100 6868 AND RSS 200 6869 TRANSFER SWITCHES COMBINED SERVICE ENTRANCE AND 2 POLE TRANSFER SWITCH GENERATOR SET I Wi M o i TO UTILITY 5 I I SERVICE N LOADS FIGURE 7 TYPICAL SYSTEM GROUNDING ONE LINE DIAGRAMS 3 6 3 Automatic Transfer Switch The generator set is intended for installation with Cummins Onan model RSS automatic transfer switches only Install the transfer switch in accordance with its Installation Manual and make connections to the generator set in accordance with the Electrical Connections section of this manual 20 A029V090 Issue 1 4 2010 3 Step By Step Outline of Installation 3 6 3 4 Transfer Switch Communications Wires A WARNING Interconnecting the generator set and the public utility can lead to the electrocution of personnel working on th
16. enter the username and password Help Hotline 1 800 888 6626 option 1 Technical support for setup and troubleshooting of the hardware used for in home network access to the generator set is available through the selling Cummins Onan dealer distributor The owner may be required to contact their ISP and or email provider for technical support of the e mail notification feature setup and troubleshooting Due to the variations in network equipment network configurations and ISPs the owner is responsible for acquiring the needed support service from a qualified network specialist to properly and securely set up the owner s network for remote monitoring of the generator set Cummins Onan does not provide technical support for setup and troubleshooting of the owner s network and email service e f you can t remember your password reset it to cummins by selecting Reset Password on the Network Setup screen on the in home Operator Panel and pressing the up or down arrow e The customer s public IP Address must be a static IP Address If the customer s public IP Address is dynamic the customer must either obtain a static IP Address from their service provider or set up a domain name that manages the dynamic IP Address Frequently Asked Questions Question Do need another router A029V090 Issue 1 49 6 Optional Internet Email Interface Setup 4 2010 50 Answer Yes a router or switch is required to allow for the connectio
17. for proper operation and maintenance instructions A029V090 Issue 1 7 2 Introduction 4 2010 This page is intentionally blank 8 A029V090 Issue 1 3 1 ee Step By Step Outline of Installation WARNING The installer is responsible for complying with all applicable installation codes and safety requirements See the Installation Codes and Standards section of this manual for more information The following sections create 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 NOTE For information on pre installation considerations tools materials locating the genset codes and standards and specifications see the Introduction chapter of this manual Pre Installation Considerations Before installation begins certain actions must be considered Prior coordination will reduce delays and the amount of time power has to be interrupted Areas of consideration e The location of the generator set is one of the first decisions to be made as it affects all other aspects of the installation such as e the length of electric wiring e the length of gas lines e Natural Gas or Propane both of which must be inspected by the gas utility inspectors and building inspectors e the site preparation e access to the site e trenches e site preparation materials needed e The i
18. fuel system installations cleanliness is extremely important e Make every effort to prevent fuel contamination of e moisture e dirt e excess thread sealant e contaminants of any kind e Clean all fuel system 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 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 an electric battery powered shutoff valve included CS NOTE It is recommended that a shutoff valve be located near the generator set as well for emergency shut off or servicing the generator set 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 inadvertently 3 7 1 Fuel Line Connections A WARNING Fuel presents the hazard of fire or explosion that can result in severe personal injury or death Do not smoke or allow any flame spark pilot light or other ignition sources near fuel or in the installation area Read the important safety precautions in the Fuel System section of this manual Refer to the Outline and System Drawings for the location of the fuel supply connection through the side of the generator se
19. function or a fault shutdown has occurred N CAUTION When STANDBY is disabled the generator set will NOT automatically start to supply power if utility power is interrupted To enable or disable generator set standby 1 Press the STANDBY ON OFF button on the operator panel which takes you to the Standby ON OFF screen 2 Press the up or down arrow button to select ON or OFF 3 To enable STANDBY select ON and press the BACK button The STANDBY OFF lamp will go out and the display will state Standby ready enabled by user 4 To disable STANDBY select OFF and press the BACK button The STANDBY OFF lamp will come on and the display will state Standby ready disabled by user Standby required for automatic start stop Standby f S9 E orr FIGURE 47 ENABLE DISABLE STANDBY SCREEN 7 5 To Manually Start Stop Generator Set Normally only the maintenance service technician has to manually start and stop the generator set e Starting the generator set will result in the generator powering the house loads N CAUTION Manually starting or stopping the generator set disables generator set STANDBY The generator set will not automatically start to supply power if utility power is interrupted Manually start and stop the generator set once every 3 months to test that these functions are working properly To manually start or stop the generator set 1 Press the START STOP button on the operator panel which takes yo
20. gas leaks with a flame can cause a fire or explosion that can lead to severe personal injury or death Use approved methods only After assembly and before initial operation all fuel system connections hose valves regulators and fittings must be tested and proven free of leaks using a soap and water or 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 e Apply the soap and water solution to all fuel system connections hose valves regulators and fittings e When the system is running bubbles will form where air pressure is leaking from the system Other approved methods of detecting leaks can be used if appropriate DO NOT use a flame to test for gas leaks 3 8 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 A WARNING EXHAUST GAS IS DEADLY The exhaust system must terminate away from building vents windows doors and sheltered spaces that may not have ample fresh air ventilation A WARNING Engine discharge air and exhaust carry carbon monoxide gas odorless and invisible which can cause asphyxiation and death Never use engine discharge air or exhaust for heating a room or enclosed space A029V090 Issue 1 33 3 Step By Step Outline of Installation 4 2010 This page is intentionally blank 34 A029V
21. home screen 8 Startup and Configuration 73 8 Startup and Configuration 4 2010 2 Press and hold the blank button on the menu screen for at least 5 seconds to go to the Config Menu 3 Press the up or down arrow button on the Config Menu screen to select TS Config 4 Press Enter on the Config Menu to go to the Transfer Switch screen 5 Press the up or down arrow button to select between two choices RSS100 6868 and RSS200 6869 or RSS100 6634 and RSS200 6635 which must match the model number of the transfer switch being used CS NOTE For non Cummins Onan transfer switches select RSS100 6634 and RSS100 6635 6 Press the BACK button to save the setting and return to the home screen 74 A029V090 Issue 1 4 2010 8 6 Transfer Switch Parameter Adjustments 8 Startup and Configuration Sun 10 35 AM Battery 1255 Genset Load LIW LAW EXCER CLOCK LOAD MENU Genset Status Display Setup Event Log Fault Log Ethernet Setup hold blank button for 5 seconds Config Menu Generator Config Generator Adjustments TS Adjustments Model RSS100 6868 o RSS200 6869 FIGURE 60 TRANSFER SWITCH CONFIGURATION Model RSS100 6634 and RSS200 6635 Transfer Switches Refer to Transfer Switch Installation Manual 962 0620 to set the parameters inside the transfer switch A029V090 Issue 1 75 8 Startup and Configuration 4 2010 76 Model RSS100 6868 and RSS200 6869 Transfer Switc
22. remotely via the Internet Question used the IP Addresses shown on the front of this guide but why was not able to access the generator set Answer The IP Addresses shown in this guide are only examples and are not likely to be the ones that will work on your network setup Question The IP Address consists of four numbers ranging from 0 to 255 which are separated by dots 179 168 052 094 for example Are leading zeros necessary Answer No the IP Address 192 168 0 1 for example is equivalent to 192 168 000 001 The address can be entered either way Question How do get my IP Number Subnet Mask and Gateway Answer On a PC 1 Disable the PC s wireless function 2 Establish an Ethernet connection between the computer and generator set via a common modem 3 On the computer Click Start gt Run 4 On the run menu that appears type cmd and click OK 5 Type ipconfig on the DOS window that appears Question Why do need two IP Addresses to access my generator set Answer You can access your generator set from two networks your in home or local network and from the World Wide Web thus requiring two addresses e Your local IP Address is different from your World Wide Web IP Address e From your in home network you use the generator set s Static IP Address e From the World Wide Web you first need to access your modem which is accomplished by typing in the Static IP Address of your Internet connection
23. the finger guard cover from the terminal block compartment Connections e Use minimum 8 AWG 75 C conductors for the four AC power output wires L1 L2 N and GND wire size is determined by the length of the run e Connect them to the AC output terminal block TB 2 e Torque the terminals per the table on the side of TB 2 e The wires must be routed to the transfer switch in approved liquid tight conduit e The conduit can be stubbed up through the bottom stub up opening or connected to the conduit opening on the side of the generator set e f the stub up opening is used fill in the stub up opening with duct seal or mastic tape to keep out insects and rodents N CAUTION AC wiring can induce false signals in control and communications wiring Do not route in the same conduit 3 6 2 Grounding Use the Typical System Grounding One Line Diagrams in this section to be sure that the generator set transfer switch power supply wiring and all connected electrical equipment are bonded to a common grounding point in accordance with the applicable codes and standards A WARNING The generator set grounding terminal TB2 4 must be connected to the grounding terminal in the transfer switch Do not provide a separate grounding rod for the generator set CE NOTE Generator neutral is not grounded at the generator set but at the common system grounding point A WARNING Contact with electrical equipment can result in severe personal injury or
24. when a scheduled maintenance operation is due e The warning does not time out A029V090 Issue 1 61 7 Operation 4 2010 7 6 3 T T 62 e Perform the maintenance Press the BACK button to return to the home screen Maintenance Due Air Filter FIGURE 50 TYPICAL MAINTENANCE DUE SCREEN New Event Screen A New Event screen appears whenever system status changes such as when there is an interruption of utility power The screen provides a brief description of the event along with the time and date of the event e The message does not time out unless superseded by a new event e Press the BACK button to return to the home screen See the Event Log section of this manual to review the log of the last 20 events New Event Auto Start Loss of Utility 07 10 2007 4 08PM FIGURE 51 TYPICAL NEW EVENT SCREEN Genset Status To check generator set output voltage and frequency and the total numbers of hours run 1 Press the MENU button on the home screen 2 Press the up or down arrow button on the menu screen to select Genset Status 3 Press the ENTER button on the menu screen and note the values displayed on the Genset Status screen 4 Press the BACK button to return to the home screen A029V090 Issue 1 4 2010 7 Operation Sun 10 35 AM Battery 1255 Genset Load LIW I2NMN J EXCER CLOCK LOAD MENU 1 Genset Status Display Setup Event Log Fault Log Ethernet Setup
25. 090 Issue 1 4 1 s Optional Internet Email Interface Descriptions Introduction This feature allows for in home or remote access to your generator set through a web page On this web page you can start or stop the generator set adjust the exerciser day and time determine if utility power is available and view the last 20 events faults on the generator set This feature is useful for homeowners who travel or have a second home and want to be able to remotely interface with their generator set This feature can also help to reduce troubleshooting time and service calls when the service technician has access to the same web page Use of the Ethernet is not required if you do not use web access To set up your generator set for web access complete installation instructions are included in the Network Setup Guide instruction sheet included with your generator set literature package The Internet Email Interface can make the same fault maintenance and event notices available to you and to your generator set service contract agency with appropriate Internet Service and email account NOTE Technical support for setup and troubleshooting of the hardware used for in home network access to the generator set is available through the selling Cummins Onan dealer distributor The owner may be required to contact their ISP and or email provider for technical support of the email notification feature setup and troubleshooting Due to the var
26. 10 7 3 2 7 Operation Cummins Onan UTILITY PRESENT Sun 10 35 AM RUNNING STANDBY OFF ACTION REQUI FIGURE 45 UTILITY PRESENT AND CONNECTED STANDBY OFF LAMP ON Emergency Operation Utility Power Interrupted If utility power is interrupted 1 The green UTILITY PRESENT lamp will go out 2 The generator set will start automatically and the green GENERATOR RUNNING lamp will turn on 3 The UTILITY CONNECTED light will go out when the generator set is connected to supply power The LCD screen will provide a visual indication of Genset Load bar graphs The bar graphs indicate how much of the available power is being used in each supply line L1 and L2 If the red ACTION REQUIRED light comes on either the generator shut down or periodic maintenance has come due The LCD screen will indicate what maintenance is due or which fault occurred Cummins Onan UTILITY PRESENT CONNECTED Sun 10 35 AM GENERATOR Battery 12 5 RUNNING Genset Load STANDBY Q SEMEN cn ACTION EXCER CLOCK LOAD MENU FIGURE 46 GENERATOR SET RUNNING ACTION REQUIRED LAMP ON A029V090 Issue 1 59 7 Operation 4 2010 7 4 To Enable Disable Standby Normally you should not have to disable generator set STANDBY e STANDBY should always be enabled ON except during maintenance service e STANDBY will have to be re enabled STANDBY OFF light on if the generator set is started or stopped manually normally a maintenance service
27. 2 Smm_STRIP 0334 0751 Wet EELE TERMINAL w55 CT2 1 SEE NOTE 1 74 2 Smm STRIP 0334 0757 T82 2 0332 0913 TERMINAL W56 CT2 2 SEE_NOTE_1 PI 18 0323 1614 01 0334 075T TB2 4 0332 0913 TERMINAL 457 7 1 Smn STRIP PIT 0323 1814 01 0334 0157 ETE TOAN w58 PIS 0323 1614 01 F3 2 SEE REF DES 0334 0158 nu 0332 3058 SPLICE BUTT W53 P2 6 0323 1614 01 P8 2 0323 0488 0334 0756 Wad 8 1 0323 0488 Al2 GND 1 SEE REF DES 0334 0756 SEAL FUSE WS F3 I SEE REF DES BI BAT I SEE REF DES 0334_0759 0332 3368 TIE CABLE Wes I H 0323 1614 01 BI SW I SEE REF DES 0334 0157 Wed 7 2 Smn STRIP J5 1 0323 2449 0334 0157 Wes 7 1 Sm STRIP PI 18 0323 1614 01 0334_0757 i66 12 2 Smn STRIP 35 2 0323 2449 0334 0151 y 72 1 mn STRIP 1 26 0323 1614 01 0334 0157 i68 18 2 Sm STRIP J5 4 0323 2448 0334 0151 No A028X141 sh 1 of 2 W63 75 1 Sm STRIP GND 2 1 SEE REF DES 0334_0757 Rev D FIGURE 74 WIRING HARNESS CONNECTIONS SHEET 3 OF 4 A029V090 Issue 1 93 4 2010 Appendix A Outline and System Drawings oema B SCALE 17 16 0898 1185 07 0898 1185 07 161 53 1 3 GND 2K 78 peTAIL A SCALE 11 16 0858 1195 08 0898 1 195 04 n x
28. 5 pe E 12 7 10 4 174 i 6 8 EM L ACCESS TO ALL jue m i SERVICE POINTS H 228 258 5 10 2 lb 863 34 5 IN CONDULT ACCESS m ise E is JE 1 25 IN CONDUI I ACCESS 35 3 No A0297911 sh1of2 Rev A FIGURE 76 OUTLINE DRAWING A029V090 Issue 1 95 Appendix A Outline and System Drawings 4 2010 This page is intentionally blank 96 A029V090 Issue 1 Cummins Power Generation 1400 73rd Ave NE Minneapolis MN 55432 USA Phone 1 763 574 5000 Toll free 1 800 888 6626 Fax 1 763 574 5298 Copyright 2010 Cummins Power Generation Inc All rights reserved Cummins Onan the C logo and Performance you rely on are trademarks of Cummins Inc
29. 6 Check to see if you are using an email account capable of using port 25 with plain authentication SMTP server setup If necessary obtain an email account capable of using port 25 with plain authentication SMTP and enter detail into the network setup screen 7 Verify that the domain name is included in the user name field of the Network Setup screen i e username domainname A029V090 Issue 1 81 9 Communication Troubleshooting 4 2010 8 Verify with your ISP that the Static DNS Domain Name Server 1 and 2 are correct 9 If the previous steps do not correct the problem contact a computer network specialist to diagnose No authentication is possible by leaving the username and password fields blank IMPORTANT NOTE Changes are not saved unless you navigate through all three Network Setup screens and click on Done The message Settings Saved Successfully is then displayed Network Setup DHCP Off On IP Number 192 168 Subnet Mask 255 255 0 1255 Gateway 192 168 0 Static DNS 1 192 168 Static DNS 2 134 amp FIGURE 64 NETWORK SETUP PAGE 1 82 A029V090 Issue 1 4 2010 Event Control Log Exercise Load Schedule Genset Time Date Genset Status Stopped Battery Voltage 13 8 VDC Genset Load 95 Line 11 Line 21 Output Voltage Frequency 0 VAC 0 Hz Engine Hours 389 Hours
30. 8 C The heater wraps around the battery The heater cord is connected to the 120V accessory connection block Install the heater in accordance with the kit instructions To prevent injury due to accidental start up do not connect the battery cables to the battery until the installation has been completed and it is time to start the set A WARNING Before working on the generator set move the Switch S2 to the Stop Position disconnect the remote harness P7 to disable the ATS mounted charger and remove the negative battery cable from the battery to prevent starting FIGURE 11 BATTERY LOCATION 3 7 Fuel System 26 A WARNING 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 This generator set has a convertible fuel system The generator may run on Natural Gas or Propane depending on the preferences of the owner A WARNING 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 A029V090 Issue 1 4 2010 3 Step By Step Outline of Installation In all
31. 9 Communication Troubleshooting Fault Network Log Setup Genset Clock 6 11 PM March 10 2008 Utility Utility Present Utility Connected Running Standby Off Action Required FIGURE 65 GENERATOR SET HOME PAGE Network Setup Email Setup Alert Level All Events Outgoing Server SMTP Server Name max 42 chars yourservername User Name max 48 chars yourusername domainname Password max 16 chars yourpassword FIGURE 66 NETWORK SETUP PAGE 2 A029V090 Issue 1 83 9 Communication Troubleshooting 4 2010 Network Setup Destination Email Addresses max 48 chars each Address 1 youremail youremail com Address 2 yourCumminsOnanDealer theiremail com Address 3 yourCumminsOnanServiceTech theiremail com FIGURE 67 NETWORK SETUP PAGE 3 84 A029V090 Issue 1 Appendix A Outline and System Drawings Table of Contents Figure 68 Wiring Diagram Sheet 1 of 3 ccccessesceeseseeeceeeeeeeeeseseeeeseeesneeeeeeeeneesesesenaeseseeneeseeseeneeseeneenaees 87 Figure 69 Wiring Diagram Sheet 2 of 3 seeseeeeseeeeeeneeeenenennee nennen nennen nennen nennen nnn nennen 88 Figure 70 Wiring Diagram Sheet 3 of 3 eeeeeeeeseeeeneneneeeenen nennen nennen nnn nnne nnn nnn nennen 89 Figure Ti Harness labeli deest omee ta aa aa ens Eh naan an aa a iier e e ee t eR S e eem 90 Figure 72 Wiring Harn
32. DDRESSES Settings saved successfully FIGURE 38 RETURN TO HOME PAGE 48 A029V090 Issue 1 4 2010 6 5 6 6 6 7 6 Optional Internet Email Interface Setup Remote Internet Access to the Generator Set WARNING Opening ports in your firewall can pose network security risks The following instructions require forwarding port 80 NOTE It is highly recommended that a professional computer and network support specialist be hired to complete this part of the setup for proper connections and proper firewall protection to the in home network 1 Follow the modem and router setup instructions to forward port 80 to the IP address that was previously assigned to the generator set Typically this is done on a Port Forwarding or Virtual Server setup screen NOTE To maintain connections to all devices connected to the modem router do not turn off modem router DHCP NOTE If the router is capable of being set up as a switch plug the input from the modem into one of the open router outputs instead of accomplishing this step 2 To access the generator set s web page on any computer or wireless device not connected to the same modem router as the generator set type in the owner s public IP address and enter the user name and password 3 To access the generator set s web page on any computer or wireless device connected to the same modem router as the generator set type in the unique in home network address of the generator set and
33. E GAS METER GENERATOR SET FIGURE 13 TYPICAL NATURAL GAS INSTALLATION gt NOTE Typically 1 ft hr 1000 BTU hr When the fuel delivery value falls between two columns use the larger value TABLE 20 NATURAL GAS PIPE CAPACITY CUBIC FEET OF GAS PER HOUR Normal Iron Length of Pipe in Feet Pipe Size Genes m m e e oo oo m e Jeo roo es e ws 200 oa qso 0 P PF L Jeo fass 375 320 28 260 20 11a t4o0 oso 770 eeo sso s3o 490 460 430 aoo seo 325 300 280 Maximum pipe capacity in cubic feet per hour of 0 60 specific gravity Natural Gas with a pressure drop of 0 5 inches 1 27 mm WC over the length A029V090 Issue 1 29 3 Step By Step Outline of Installation 4 2010 3 7 3 Propane Fuel System A WARNING NFPA Standard No 58 requires all persons handling and operating Propane to be trained in proper handling and operating procedures A WARNING 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 3 7 3 1 Recommended Fuel Propane A WARNING Propane presents the hazard of fire or explosion that can cause severe personal injury or death Do not permit any flame spark arc prod
34. IDUALLY PACKAGED AND WU SEES ieee rs GREEN UII SENSE INCLUDE F N 5 LABEL INFORMATION W3 PT 3 0323 149 ORANGE TRANSFER SWITCH CONTROL 2 HARNESS MUST BE PROCURED FROM A SUPPLIER QUALIFIED AS WA P1 4 10323 149 BLACK B A UL RECOGNIZED HARNESS MANUFACTURER CATEGORY ZPFW2 PACKAGING OR PARTS TO BE MARKED IN ACCORDANCE WITH W5 Da 229 at BLUE EAE IEEE SEO POS ETT ON REQUIREMENTS SPECIFIED BY SUPPLIERS UL PROGRAM we P7 6 0323 149 BROWN GENERATOR SWITCH POSITION w eral ee ae YELLOW LOAD CONTROL W8 P7 8 0323 149 VIOLET LOAD CONTROL 2 i W9 P7 11 0323 149 RED Bt 9 4 10 3 fl 2 12 1 section A A LENGTH A 4 PT TABULATION PART NUMBER CURRENT_ER LENGTH A0290298 ECO 105593 FT A lt a A029U302 ECOQ 105593 50 FT co A029U303 ECO 105593 100 FT Ce A029U304 ECO 105593 200 FT No A029U299 sh 1 of 1 Rev A FIGURE 73 WIRING HARNESS CONNECTIONS SHEET 2 OF 4 92 A029V090 Issue 1 4 2010 Appendix A Outline and System Drawings NOTES TO FROM WI RE L ST THIS PART I MANUFACTURER SOURCE CONTRO
35. K button to return to the home screen Adjust percent load to match the de rate A029V090 Issue 1 69 7 Operation 4 2010 7 13 2 Manual Load Management N CAUTION To reduce unnecessary loss of service it is highly recommended that manual load management be undertaken only by an authorized Cummins Onan dealer When set to manual mode the user is able to view connect and disconnect loads If the connection of loads L1 and L2 exceeds generator capacity the AC circuit breaker trips To select manual load management when the generator is running 4 Battery Genset Load 1 Disconnected LIN EXCER CLOCK LOAD MENU Press the LOAD button on the home screen 2 Press the up or down arrow button to select Manual 3 Note which loads are connected or disconnected 4 5 Connect or disconnect Load 1 or Load 2 as necessary by pressing either button under Press the double down arrow button to go the load connect disconnect screen Load 1 or Load 2 Press the BACK button to save the setting and return to the home screen Load Management 12 5 Mode Memen 2 Connnected L288 4 Load Management When running Mode ENSE Disconnected 70 Disconnected Connected Connnected Connect Disconnect Load 1 Load 2 AUTOMATIC MODE MANUAL MODE FIGURE 58 LOAD MANAGEMENT SCREEN A029V090 Issue 1 8 Startup and Configuration 8 1 Installa
36. LLED VIRES DIE E TON aam M ST Is ZAN COMPONENTS CTI AND CT2 ARE PART OF ASSEMBLY A028X144 ADJUST LEAD LENGTHS AS REQUIRED APPLY UL RECOGNIZED Wl PIG 9323 1814 01 F2 1 SEE RET DES 0334 0757 VINYL SELF LAMINATING LABEL SYSTEM TO CTI AND CT2 LEADS 402 1 2 0323 1614 01 0I 1 SEE REF DES 0334 0757 ECINECTORT MT TERMINALS LN OVERLAP BUNDLE ENDS A MINIMUM OF 25 W03 PI 3 0323 1614 01 2 1 SEE_REF_DES 0334_0757 REF_DES PART NUMBER DESCRIPTION GOES TO DESC GOES TO PART APPLY 2 WIRE TIES TO THE OVERLAP AI 03321903 TERMINAL RECEPTICAL ACTUATER GOVERNOR 4 X 03 TAB Lis s Pared Rene eae prie 4 HARNESS MUST BE PROCURED FROM A SUPPLIER QUALIFIED AS A UL wos PIS 5823 16 14 01 87 1 0332 2928 0334 0156 AT2 GND 03324045 TERIINAL RECEPTACLE ECOGNIZED HARNESS MANUFACTURER CATEGORY ZPFW2 PACKAGING OR Wo6 PI 6 0323 1614 01 87 1 SEE_REF_DES 0334_0756 AC 0332 0804 TERHINAL RING ARTS TO BE MARKED IN ACCORDANCE WITH REQUIREMENTS SPECIFIED BY SUPPLIERS UL PROGRAM 407 PIT 0323 1614 01 52 8 0332 2928 0334 0756 nm o357 0804 TERHINAESRTRG Wo8 I 8 0323 1614 0 F3 2 SEE_REF_DES 0334 0158 9 A VALUE OF 0 ZERO IS USED IN THE BILL OF MATERIAL BI BAT 0332 1194 TERMINAL RING STARTER 5 16 STUD E QUANTITY OF THE AFFECTED ITEMS SHALL BE DERIVED FROM 403 2 1 9323 1614 01 P7 1 0323 1492 0334 0757 E DRAWING REQUIRMENTS m EIE mECGTODCOUES TS INE BI SW 0332_1993 TERMINAL RECEPTICAL STARTER 14 X 03 TAB i d Wiz Pi i3 0323 161401
37. OR SAFETY RECOMMENDATIONS NFPA 70 National Electric Code National Fire Protection Association NFPA 37 Installation and Use of Stationary Combustion Engines 470 Atlantic Avenue and Gas Turbines Boston MA 02210 NFPA 54 National Fuel Gas Code NFPA 58 Storage and Handling of Liquefied Petroleum Gases CSA Electrical Bulletin Canadian Standards Association CSA C22 2 No 100 Housing and Construction Materials Section CSA C22 2 No 14 178 Rexdale Blvd Rexdale Ontario Canada M9Q 1R3 California Administrative Code Title 25 Chapter 3 State of California Documents Section P O Box 1015 North Highlands CA 95660 Underwriters Laboratories Underwriters Laboratories Inc UL2200 333 Pfingsten Road Northbrook IL 60062 2096 3 1 2 Required Items for Installation Specific tools and materials are required for the installation of this generator set These items are identified in the following sections 3 1 2 1 Materials Required TABLE 10 ELECTRICAL MATERIALS pt Required Optional Appropriately sized gauge and length AC wires with 75 C insulation 4 wires L1 L2 N and Gnd Appropriate conduit for all AC wires EINEN J Cummins Onan Plug n Play harness from Genset to ATS 1 50 and 100 lengths X available for purchase Appropriate conduit for DC communications wires x Cummins Onan Plug n Play harnesses for Generator Set to in home display if installing in the house 1 50 and 100 lengths available
38. RATOR SOURCE UTILITY SOURCE CIRCUIT CIRCUIT BREAKER BREAKER MAIN BREAKER PANEL ALLLOADS FIGURE 4 FULL COVERAGE LOAD CONNECTIONS TRANSFER SWITCH WITH CONTROLLER 3 2 Generator Set Location Requirements A WARNING EXHAUST GAS IS DEADLY Install the generator set out doors only The generator set must be located away from doors windows and other openings to the house and where exhaust gases will disperse away from the house 14 A029V090 Issue 1 4 2010 3 Step By Step Outline of Installation Generator set location is critical for safety and good performance Follow the guidelines below e Install out doors only e Call the local utilities to mark the locations of buried utility services gas electric or telephone before digging drenches for fuel and electric lines e Ask the homeowner for the location of any other buried components electrical wires drainage tiles cable etc e Locate and orient the genset such that the prevailing winds will carry exhaust gases and fuel leaks away from the house e The genset MUST be at least 5 feet 1600 mm away from all openings to the house e Do not locate the genset in a tree sided niche of the house under an overhang in a low lying area or next to a basement e Do not locate the genset where snow drifts plant growth lawn clippings and other objects are likely to block the ventilation openings e Locate the genset as far away
39. RESENT CONNECTED sun 10 35 AN GENERATOR Battery RUNNING Genset Stopped STA OFF ACTION REQUIRED EXCER CLOCK LOAD MENU No Description E Back Button When navigating through the LCD menus press this button to return to the main operating Screen 2 Standby On Off Button See the To Enable Disable Standby section of this manual Start Stop Button See the To Manually Start Stop Generator Set section of this manual Navigation Buttons The function of these buttons change as different screens appear FIGURE 40 IN HOME OPERATOR PANEL 7 2 1 BACK Button When navigating through the LCD menus press the BACK button to return to the main operating screen 7 2 2 START STOP Button See To Manually Start Stop Generator Set 7 2 3 Standby ON OFF Button See To Enable Disable Standby 54 A029V090 Issue 1 4 2010 7 Operation 7 3 Typical Operation CS NOTE The following diagrams are based on an APPROXIMATE time duration Your genset may vary slightly from the timing diagrams in this manual Typical Power Outage Cycle Green Utility Pi t ility Presen Of Utility Green Connected Off Display LED Green Generator Running Flashing Off Generator Red Standby Off Off Available Utility Power Trot Available On Generator Of l l l l l Transfer Utility Switch Generator On Load Con
40. Software Info cccccccccccceeeceeee cece eee eeee ee eeeeceeeeeeeeeseeaaseesaeeaaeaaeeaeeeaeeees 63 UL EVAN LAC oioi a A 65 C 1O FENA LORS 7 66 e ene S ela CAI BN 67 V APIS SWS ioooososcosoccocosooo oc ccsvccsccscesescsgcsssseseueedenendauscenscenscsenaucsnancebaasedensecescedeaeeesendaeserends 68 T1 34Load Management PERENNE 69 8 STAJSIDEESSTIBNEEPIERSUNS EODI eeeeeceeenneer enhn nnne 71 Salil Stall AUOMROV IG Weenie RRO a oaaae aenea dte aeaa 71 a 25Start pess t e eer ce ncaa EU E E A E NONU UGA TAREE EIOS 71 avasruelisolenoid skirstetahtsee e E I I TM 71 8 4 Generator Set Configuration esre etr RENE IR EE EHE EE ERIT SEES 72 6 0 ErAanSten Switcho COnmngurator ocn cec eerie Hd eee eee Aloe see SUO eee Ku EE REDE ETE 73 8 6 Transfer Switch Parameter Adjustments ecce metee eene tente 75 S Xaeneratorsdustienitss ce ore E C Lr e Re E De LEM 77 9 COMNIUNIGETIONSEROUBEESPIOOEING n saree eee ee T MEE 79 9 1 In Home Network Access to Generator Set Troubleshooting sseeesssss 79 9 2 Remote Internet Access to Generator Set Troubleshooting ssseessssss 80 9 3 Email Alert TrouDl sShioo mgo ee er E tively aa ne eee a Sean 81 APPENDIX A OUTLINE AND SYSTEM DRAWINGS eeesessseseeeeneenen nnne nnne 85 ii A029V090 Issue 1 1 IMPORTANT SAFETY INSTRUCTIONS 1 4 Save These Instructions This manual contains important inst
41. WHEN KEPT AT LEAST HALF FULL Withdrawal Lowest Average Winter Temperature Rat ate 32 F 0 C 20 F 7 C 10 F 12 0 F 18 C 10 F 23 20 F 29 30 F 34 C C C C 100 cfg 250 250 250 400 500 1000 1500 250 000 945 945 945 1515 1890 3785 5675 BUT hr 945 945 945 2 8 m hr 264 MJ hr 30 A029V090 Issue 1 4 2010 3 Step By Step Outline of Installation 200 cfg 500 000 BUT hr 5 7 m hr 527 5 MJ hr 300 cfg 5000 A 18925 8 5 m hr 791 2 MJ hr 3 7 3 3 Propane Vapor Fuel Supply Line Size and Pressure Insert the body content of the topic Fuel line size depends on the amount of fuel needed to run the generator set at full load at the distance the fuel must be moved e See the Fuel Specifications Table for fuel system specifications such as the amount of propane vapor at certain loads The following figure shows a typical Propane vapor installation and the table below lists fuel capacity for given distances and pipe size Size the fuel line so that the Propane vapor pressure drops no more than 2 inches WC from no load to full load A029V090 Issue 1 31 3 Step By Step Outline of Installation 4 2010 PRIMARY REGULATOR GENERATOR L mae oa SHUTORF D ow b IL EA ave SECONDARY MEM ah REGULATOR d PROPANE c TANK S Ie im li
42. We 4 2 0323 24498 WHITE RS485B W3 4 3 0323 2449 RED Bt W4 J4 4 0323 2449 BLACK Bs WS J4 5 0323 2449 GREEN DISPLAY WAKEUP W6 JS 1 0323 2063 ORANGE RS4854 ESI S2 IOS WHITE RS485B W8 Dos SS CIO RED B W9 J5 4 0323 2063 BLACK D WIO J5 5 0323 2063 GREEN DISPLAY WAKEUP J4 Appendix A Outline and System Drawings NOTE HARNESS MUST BE PROCURED FROM A SUPPLIER QUALIFIED AS A UL RECOGNIZED HARNESS MANUFACTURER CATEGORY ZPFW2 PACKAGING OR PARTS TO BE MARKED IN ACCORDANCE WITH REQUIREMENTS SPECIFIED BY SUPPLIERS UL PROGRAM BE m lolololol m J5 lolololol BS LE DETAIL B SCALE 2 l STRIP JACKET D m 10 5X STRIP WIRE T den pr EE a 304 8410 p n D SEE DETAIL B section B B PLUG HARNESSES TOGETHER A TABULATION PART NUMBER CURRENT ER L 40290306 Hum 05593 FT A029U308 ECQ 105593 50 FT A029U310 EC 105593 100 FT A029U31 EC 105593 200 FT No A029US307 sh 1 of 1 Rev A FIGURE 72 WIRING HARNESS CONNECTIONS SHEET 1 OF 4 91 Appendix A Outline and System Drawings 4 2010 WIRE FROM PIN WIRE COLOR FUNCTION REF NOTES wi ieee ie WHITE UTILITY SENSE HARNESSES TO BE INDIV
43. Your modem will then automatically forward you to your generator set on the local network A029V090 Issue 1 51 6 Optional Internet Email Interface Setup 4 2010 This page is intentionally blank 52 A029V090 Issue 1 7 Operation T 1 3 Position Switch A three position Start Stop switch is located at the genset control panel Switch positions available e Manual Start Normally only the maintenance service technician has occasion to manually start and stop the generator set Push the switch down at the thick end to start the set immediately e Stop middle position This switch disables the set e Remote For automatic operation the Start Stop switch must be in the Remote position and Standby On must be activated on the In Home Display Push the switch down at the thin end to put into the Remote position No Description No Description O E Manual Start Position m Remote Position 3 Stop Position 7 770 FIGURE 39 3 POSITION SWITCH STOP SWITCH A029V090 Issue 1 53 7 Operation 4 2010 7 2 In Home Operator Panel The operator panel must be hard wired to the generator set in order for the generator system to operate CS NOTE The in home operator panel and Internet Email interface can be used simultaneously The operator panel consists of two UTILITY status lamps three GENERATOR status lamps three action buttons and an LCD display screen with four navigation buttons UTILITY P
44. age password max 8 chars cummins MAC address 00 1C E8 23 00 01 Software Part Number 3267344 Software Version 0 56 FIGURE 31 NETWORK SETUP SCREEN Network Setup DHCP Off On IP Number 92 168 o 150 SubnetMask 255 255 255 0 Gateway 192 168 0 Static DNS 1 192 168 Static DNS 82 134 171 111 FIGURE 32 NETWORK SETUP PAGE 1 6 3 Setting up E mail Notification 1 See In Home Network Access to the Generator Set to set up the in home network 2 Click on the Network Setup Tab 46 A029V090 Issue 1 4 2010 6 4 6 4 1 6 4 2 6 Optional Internet Email Interface Setup Click Click here to start Network Setup Set up in home computer access to the generator set Click Network Setup on the home page Click Click here to start Network Setup Continue to the Email Setup screen Select the Alert Level you would like to receive o ON Oa bh o Enter your e mail Server Name User Name inclusive of domain for example usename yahoo com and Password Typically it will be necessary to contact the customer s e mail service provider NOTE The email account must allow SMTP via port 25 verify with your ISP 10 Continue to the Destination Email Addresses screen 11 Enter up to three different email addresses to receive generator set alerts 12 Press Done Network Setup Destination Email Addresses max 48 chars each Address 1 yow A
45. and machinery hazards should perform Generator Set service Possible Causes An improper setup the alert level is not set to all events emails cannot be received the outgoing email address is not included in your contact list the email account is not capable of using port 25 with plain SMTP for the outgoing SMTP server setup the domain name is not included in the user name filed of the Network Setup screen or the DNS 1 and 2 values are incorrect on the Network Setup screen Corrective Actions 1 Check to see if you are able to access the generator set with your in home computer If not refer to In Home Computer Access Troubleshooting 2 Verify that you followed the network setup instructions Refer to the Network Setup Guide 3 Verify that the alert level is set to All Events a To verify that your generator set can send emails select Disable Standby and wait several minutes to verify that you did receive an email b Select Enable Standby and wait a few more minutes to verify that you did receive a second email 4 Send an email to the destination email address and check to see if you received this email If not contact your email service provider or your ISP Internet service provider to diagnose 5 Check to see if the destination email accounts have spam filtering a If spam filtering is present add the outgoing email address to your contact list b If spam filtering is not present proceed to step 6
46. arts Shipped With the Generator The following loose parts are shipped with the generator set e Oil drain hose e Flexible fuel hose assembly e Four base spikes ground stakes e In home display e Two keys e LP orifice accessory kit required e Literature Operator Manual A029V091 Installation Manual A029V090 Setup Guide and Warranty Statement A029V090 Issue 1 11 3 Step By Step Outline of Installation 4 2010 3 1 2 2 Tools Required Use a forklift to move the generator set and set it in place Alternatively a one man hand dolly designed to fit the generator set base is available to move the generator set and set it in place Hand tools required include the following e Wire stripper and lug crimper e Torque wrench e Jewelers screwdriver e Allen wrench e Rachet set with 10 mm socket and extension e Two pipe wrenches for gas connections e Phillips head and flat blade screwdrivers 3 1 3 Choosing A Transfer Switch Block diagrams showing partial or full load coverage are shown on the following pages e CSA Approved and UL 1008 listed with controller e RSS 100 6634 e RSS 200 6635 e UL 1008 listed Service Entrance Rated without controller e RSS 100 6868 e RSS 200 6869 CS NOTE If the transfer switch is connected for full load coverage which exceeds the generator set rating it may be necessary to shed large loads such as air conditioners NOTE e The RSS 100 transfer switch models can be connec
47. as practical from noise sensitive areas such as bedrooms living room windows and neighbors e Locate the genset where it will be protected from vehicular traffic and vandalism e Locate the genset as close as practical to the electrical service meter to reduce the length of electric wiring and fuel lines e Locate the genset on stable ground not subject to flooding e Locate the genset the minimum legal distance form the Propane fill valve e Minimum distance to be verified by local code officials CS NOTE The area should be leveled and compacted with sand or pea gravel 3 2 1 Generator Set Clearances The generator set must e be located at least 3 ft 915 mm from combustible material NFPA 37 e have at least 3 ft 915 mm of open space all around the generator set enclosure for access to the inside NEC Art 110 26a Art 110 26b e beatleast 5 ft 1524 mm from any opening in a wall window door vent etc e be located in an area where exhaust is not able to accumulate A029V090 Issue 1 15 3 Step By Step Outline of Installation 4 2010 5 FT 1524 MM MIN TO ANY OPENING FIGURE 5 GENERATOR SET CLEARANCES 3 3 Preparing the Site Steps to preparing a proper safe generator set site 1 Create a level area Add a layer of sand or pea gravel that is deep enough that the generator set will sit level 2 Be sure that the area is at least 48 in by 34 in 1219 mm by 864 mm Sites on an incline require more area 3 B
48. ate Apply FIGURE 18 GENSET LOAD MANAGEMENT 4 2 4 Event Log Select the Event Log Tab on the Home Screen to review the last 20 events See the Event Log screen capture below for a list of all of the recordable events A029V090 Issue 1 37 4 Optional Internet Email Interface Descriptions 4 2010 Home Genset Excicise vU Network lime Date Schedule Log Setup Event Log Cvent Description Time Date Genset started manually Standby Ready Disabled September 13 200 amp cot PM Standby ready enabled by user September 14 2007 3 21 PM Genser stopped manually Standby Ready Dl shind Srpremher 14 2007 3 24 PM Censer started manually Standby Ready Disabled Seprember 14 2007 2 22 PM Standby ready enabled by user September 14 2007 2 08 PM Genset stopped manually Standby Ready Disabled September 14 2007 2 02 PM Gensel starte manually Standby Ready Disabled Septeniber 14 200 1308 PM Standby ranky elisssdilised ly war E Suplumiun 14 2027 4 58 PM Standhy rearly enabled by user Snprember 14 2077 1 37 PM Censet stopped manually Standby Ready Disabled September 14 2007 1 37 PM Genset started manually Standby Ready Disabled January 4 2006 4 20 AM Standby ready enabled by user January 2 2006 7 11 FM Gensel stopped manually Slandby Ready Disabled January 2 2006 14 EM Morini ers amie Chotruge ail and chick vaka kesh dsauanny 2 2006 42 25 PIA Genser started manually Sra
49. cc 6 A029V090 Issue 1 4 2010 2 Introduction Spark Plug Gap 0 7 to 0 8 mm Spark Plug Torque 10 ft lb 13 5 N m Cylinder Leak Down Pressure 75 PSI 517 kPa Intake and Exhaust Valve Lash 0 7 to 0 13 mm Measure at 0 25 6 35mm past top dead center Oil Capacity 1 7 quarts 1 6L Oil Recommendation OW 40 Synthetic Engine Oil See Operator Manual Cylinder Compression 12 kg cm 470 rpm TABLE 7 CONTROL SPECIFICATIONS TABLE Controller Integrated Microprocessor Based Engine Generator Transfer Switch Controller TABLE 8 DC SYSTEM SPECIFICATIONS TABLE DC System E Nominal Battery Voltage 12 Volts DC Battery Group Battery Type Minimum Cold Crank Amps 2 3 Information For After Installation A WARNING Improper installation can result in severe personal injury death and damage to equipment The installation must comply with all applicable building codes It is strongly recommended that the installer be properly trained and licensed to perform electrical and mechanical equipment installations however a person with the proper knowledge and experience in installing electrical and mechanical equipment installations may also install this genset Refer to the Specification Tables for specific information about the system and it s components Refer to the Outline and System Drawings for specific information about the installation and wiring connections See the Operator Manual A029V091
50. ddress 2 your ins alergtheiremail com Address 3 yourCumminsOnanSemteeTechathelremall com Eme FIGURE 33 EMAIL ADDRESSES PAGE 3 Email Setup Parameters Outgoing Server SMTP Settings Ask your Internet Service Provider ISP and or e mail provider for the Server Name User Name and Password to enter NOTE An Email account capable of SMTP authentication via port 25 is required The User Name must include the domain name Example username domainname Email Addresses You may enter up to three Email addresses to whom to send generator set status and event messages A029V090 Issue 1 47 6 Optional Internet Email Interface Setup 4 2010 Genset Exercise Load Fault Network tup Time Date Schedule Control Log Network Setup Click here to start Network Setup Enter new webpage password max 8 chars cummins Save Password MAC address 00 1C E8 23 00 01 Software Part Number 3267344 Software Version 0 56 FIGURE 34 NETWORK SETUP SCREEN Network Setup Subnet Mask Gateway Static DNS 1 Static DNS 2 FIGURE 35 NETWORK SETUP PARAMETERS Network Setup Email Setup Alert Level Maintenance and Attention Required x Outgoing Server SMTP Server Name max 42 chars User Name max 48 chars Password max 16 chars Network Setup Destination Email Addresses max 48 chars each FIGURE 37 EMAIL A
51. e call Cummins Support at 1 800 888 6626 and select option 1 b If you cannot access a standard web page go to Check connections above c Check to see if the correct generator IP Address has been entered as described in the Network Setup Guide If not enter the correct IP Address d Check to see if you can access the generator set via the in home network If not call Cummins Support at 1 800 888 6626 and select option 1 A029V090 Issue 1 79 9 Communication Troubleshooting 4 2010 FIGURE 63 NETWORK CONNECTIONS CONTROL BOARD AND ETHERNET CONNECTION 9 2 80 A Remote Internet Access to Generator Set Troubleshooting WARNING Some Generator Set service procedures present hazards that can result in severe personal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform Generator Set service Possible Causes An improper setup no high speed internet connection the public IP address is not active or properly set up an incorrect IP address is entered the computer is connect to the same router or network and the generator set or the internet connection is bad Corrective Actions 1 Check to see if you are able to access the generator set with your in home computer If not refer to the In Home Network Access Troubleshooting procedures Verify that you followed the network setup procedures Refer to the Networ
52. e additional gas consumed by the generator set See the Fuel Specifications Table for fuel specifications such as BTU To determine the required meter capacity generator set consumption must be added to the gas consumed for heating cooking clothes drying etc e A typical installation might require a 400 000 BTU meter Consideration should also be given to utilizing high pressure gas supply 2 psi if available This will reduce the required size and therefore cost of gas piping especially if the location of the generator set requires a long supply line CS NOTE An older site might require upgrading and repair of the gas supply system which should be scheduled to minimize power and gas supply interruptions 28 A029V090 Issue 1 4 2010 3 Step By Step Outline of Installation 3 7 2 2 Natural Gas Supply Line Size See the Generator Set Specifications Table for fuel specifications such as BTU hr The Natural Gas meter may not be adequate if the meter serves other gas appliances such as a e Furnace e Water heater e Stove To correctly size the fuel pipe you must also take other loads operated from the fuel supply line into consideration such as e Space heating equipment e Water heating equipment Use the total load requirement of the fuel supply line to determine the size of the fuel supply pipe Use the Natural Gas Pipe Capacity Cubic Feet of Gas Per Hour table to determine the correct pipe size SHUTOFF VALV
53. e sure that the area is on firm ground 4 Remove any combustible material that would be under and around the generator set 3 4 Lifting and Moving the Generator Set A WARNING 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 N CAUTION The generator is shipped with oil in the crankcase Keep the generator set upright The generator set is heavy and must be handled with care e Use a fork lift to move the generator set and set it in place e The lifting eyes on the engine and alternator should not be used for lifting the entire generator set e Alternatively a one person hand dolly designed to fit the generator set base is available to move the generator and set it in place 16 A029V090 Issue 1 4 2010 3 5 3 6 3 Step By Step Outline of Installation Staking the Generator Set in Place WARNING Pounding the stakes into electric gas or telephone service lines can result in severe personal injury or death Observe the utility company markings and discuss any other buried lines with the home owner Set the generator set in place and pound the four corner stakes into the ground to secure the generator set in place Electrical Wiring Connections Refer to the Outline and System Drawings for the locations of the electrical conduit openings on the side of the generator set and the alternative stub up opening in the base
54. e utility lines damage to equipment and fire An approved switching device must be used to prevent interconnections Install the transfer switch in accordance with its Installation Manual Wiring harnesses are available in various lengths for quick connection between the generator set and transfer switch See the Outline and System Drawings for harness details 3 6 4 Heater and Outlet Connections 3 6 4 1 120 Volt Optional Accessories NOTE To supply 120 VAC to power the following accessories connect 12 AWG 75 C wires to the accessory wires in the 120 volt junction box from a 15 amp protected circuit in the main distribution panel in the house e Optional battery heater e Optional engine heater and alternator drier assembly e Optional installer supplied GFCI outlet e Optional carburetor heater NOTE The wires my be run through the same conduit as the AC power output wires 3 6 5 Operator Panel 3 6 5 1 Operator Panel Communication Wires Wiring harnesses are available in various lengths for quick connection between the generator set and in home display See the Outline and System Drawings for harness details Class 1 wiring methods should be used for the in home display Ethernet and transfer switch communication conductors between the generator set and transfer switch Separation of Class 2 and power circuits should be maintained per Article 725 136 of 2008 NFPA 70 National Electrical Code See the Operator Manua
55. ess Connections Sheet 1 of 4 eccessccesseeeeeeseeeeeeeeseeeseeeseeeseeeeseeeeeeeeseaeeeensees 91 Figure 73 Wiring Harness Connections Sheet 2 of 4 ccscsscecesseceeeeseeeeeeesseeeeeeseeeeeeesseaeeeeeeseaeeeensees 92 Figure 74 Wiring Harness Connections Sheet 3 of 4 cccsssesccssseeeeeeseeeeeeeeseeneeeeseeeseeeesnenseeeeseaneeensnees 93 Figure 75 Wiring Harness Connections Sheet 4 of 4 csecscccesseeceeeeseeeeeeeseeeeeeeeseeeeeeeeseeeeeeesseeeeeenseae 94 EigurezzexOutlineDrawing m ree eese eee es 95 A029V090 Issue 1 85 Appendix A Outline and System Drawings 4 2010 This page is intentionally blank 86 A029V090 Issue 1 4 2010 GENERATOR CONTROL FOR REFERENCE ONLY EH INPUT STARTER SOLENOID FUEL SOLENOID FUEL_PRESSURE OIL_PRESSURE SWITCH AMBIENT TEMP IGNITION KILL GOVENOR HIGH UTILITY SENSE 1 UTILITY SENSE 2 TRANSFEHSWITCH CONTHOL B SWICTCH POSITION UTILITY SWITCH POSITION GENERATOH LOAD_CONTROL_ 1 LOAD CONTHOL 2 RS4B5 A RS4B85 B BHT TO DISPLAY DISPLAY_WAKEUP LOCAL STATUS REMOTE GENSET ON CUHRENT SENSE 1 CUHRENT SENSE 1 CUHRENT SENSE 2t CUHRENT SENSE 2 QUAD 2 GUAD 1 FIELDt FIELD ALTERNATOR SENSE 1 ALTERNATOR SENSE 2 ETHERNET OPTIONAL NG LP CONVERSTION J18 gt BATTERY CHARGER REGULATOR G2 FLYWHEEL ALTERNATOR J1 8 J1 11 BAT
56. ess in the address bar of the web browser of a computer established on the same in home network as the generator set 4 Enter the default User Name and Password User Name Admin A029V090 Issue 1 4 2010 Password Cummins 6 Optional Internet Email Interface Setup The following screen will be displayed after a few seconds amp NOTE It may take a few seconds for the screen and screen updates to load FIGURE 29 GENERATOR SET HOME B Standby Power by Cummins Microsoft Internet Explorer File Edt View Favortes Tools Help Qe m a JO seh fg Favorites O B b z3 J a 3 Address htp 192 168 1 100 G Search amp 39 fedlortons S Exercise Luad Event Schedule Control Log Genset Time Date Genset Status Running Rattery Voltage 11 7 Vnc Genset Load 4 Line 1 Mum Line 2 Mmm 0 2 0 75 100 Output Voltage Frequency 240VAC 60Hz Engine Hours 105 4 Hours Network Sctup Gensct Clock 8 12 AM September 16 2007 Utility Connected Action Required Start Genset Stop Genset Enable Standby A029V090 Issue 1 Disable Standby 45 6 Optional Internet Email Interface Setup 4 2010 Sun 10 35 AM Battery Genset Load Genset Status Display Setup Event Log Fault Log Ethernet Setup DHCP IP 192 168 000 002 Reset Password Exercise Load Time Date Schedule Control Network Setup Cli ri rt Net Enter new webp
57. for all power and communications wiring connections between the generator set and transfer switch Route the wires from the transfer switch through the conduit and connect the wires to the mating terminals on the generator set terminal block Two separate conduits are required e One is for all AC voltage connections on TB2 or in the AC junction box e One is for all communications cables on P7 J4 or Ethernet cables A029V090 Issue 1 17 3 Step By Step Outline of Installation 4 2010 Number FIGURE 6 STUBUP OPENING 3 6 1 AC Power Supply Connections A WARNING Electrical connections must be made by a licensed electrician Improper installation can lead to electrocution and damage to property A WARNING 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 starting 3 6 1 1 Main Wiring A WARNING Refer to the requirements of The National Electrical Code NFPA No 70 for all AC wiring connections For access to the wiring connection terminal block TB2 e Open the top of the generator set 18 A029V090 Issue 1 4 2010 3 Step By Step Outline of Installation e Swing the service door wide open or gently lift up on each side of the front cover to remove it completely e Remove
58. for purchase Three conductor 75 C 300V minimum rated wiring appropriately sized to 120 volt GFCI installation or to Alternator Oil heaters if equipped 10 A029V090 Issue 1 4 2010 3 Step By Step Outline of Installation Appropriately sized junction box and cover for heater GFCI wiring if installing Provided on cold weather model Code compliant GFCI outlet and While in Use Wet Location cover Cat 5e for Internet installation Two conductor 300V wire 18AWG per Load Management relay Low Voltage SPDT relay min 1A 24VAC High Voltage SPDT relay sized to load amp and voltage TABLE 11 MOUNTING MATERIALS Requires Optional Four base mounting spikes Provided with generator gt Cummins Onan Installation Wheel Kit is available for easy on site generator X transportation TABLE 12 FUEL MATERIALS o Required Optional 12 Flexible fuel line Provided with generator o x UL Listed pipe thread sealant x Size Fuel line NG 5 11 H20 LP 7 11 H20 fuel pressure See Installation Manual X guidelines Fuel regulator as required uc Manual fuel shut off at Genset preferred i S TABLE 13 IN HOME DISPLAY MATERIALS b P Required Optional In home display One 1 provided with generator EZ CAES NENNEN Four wall anchors and screws no 6 if mounting on stud wall Ee Standoffs and mounting fasteners if mounting on block or brick wall hes 3 1 2 1 1 Loose P
59. g 3 z g 7 V 2 Z 0898 1195 02 E1 GND Tn T We m ll m A El 51413 60 5935 5 0898 1 195 02 440 TB2 4 Ss T82 2 m EN 782 1 279 3X FINGER TIGHT 306 TOLERANCES MM 1 olor Beg a in 0 x 610 E poeg panacee T lo 520 5 dO Coram PEETA fe VIEW A A VIEW B B VIEN C C VIEW D D FIGURE 75 WIRING HARNESS CONNECTIONS SHEET 4 OF 4 A029V090 Issue 1 94 4 2010 Appendix A Outline and System Drawings ECO 107350 A P ELECTRICAL STUB UP AREA THROUGH PLASTIC SKID 16 GNA 4 5 D A 100 l L aS 3 9 o C 193 7 6 si s s 65 OFF RUN SWITCH 3l co C INSTALLER EA 1 F S E REMOVEABLE SERVICE PANEL Em amp amp gt E ONG S KA L_BATTERY LOCATION 1339 FUEL CONNECTION FEMALE 1037 52 7 3 4 NPT NG amp LP 40 81 T VEN Da is i aa 4 all Hi eig f l ex S fia D ONA mias E S 7 LOAD CIRCUIT BREAKER ur i z 889 GFCI OUTLET eant soa 4X ANCHORING SPIKE POWER CONNECTIONS i y Par a 4 323 26
60. hes To make transfer switch parameter adjustments 1 2 Press the MENU button on the home screen Press and hold the blank button on the menu screen for at least 5 seconds to go to the Config Menu 3 Press the up or down arrow button on the Config Menu screen to select TS Adjustments Press Enter on the Config Menu to go to the Transfer Switch screen 5 Press the NEXT button on the Generator Config Menu screen to select the Pickup Dropout or Nominal field To set Nominal Press the up or down double arrow button to increase or decrease the nominal utility voltage parameter to match actual Present utility voltage The Pickup and Dropout parameters are percentages of the nominal voltage parameter To set Pickup Press the up or down double arrow button to increase or decrease the minimum utility voltage to which the transfer switch will connect Default is 9096 of nominal It can be increased to 9596 of nominal To set Dropout Press the up or down double arrow button to increase or decrease the minimum utility voltage at which the transfer switch will disconnect Default is 85 of nominal It can be decreased to 80 75 7096 of nominal Press the BACK button to save the setting and return to the home screen A029V090 Issue 1 4 2010 8 Startup and Configuration Sun 10 35 AM Battery 12 5 Genset Load LIW I28MN EXCER CLOCK LOAD MENU Genset Status Display Setup Event Log Fault Log E
61. iations in network equipment network configurations and ISPs the owner is responsible for acquiring the needed support service from a qualified network specialist to properly and securely set up the owner s network for remote monitoring of the generator set Cummins Onan does not provide technical support for setup and troubleshooting of the owner s network and email service A029V090 Issue 1 35 4 Optional Internet Email Interface Descriptions 4 2 Screen Descriptions d Standby Power by Cummins Microsoft Internet Explorer File Edit View Favorites Tools Help O O x la GD s 3X pe carentes a E E lad a address httpit92 168 000 002 v G Search amp Portions S Cummins Onan Genset Exercise Load Time Date Event Schedule Control Log Genset Status Running Battery Voltage 11 7 VDC Genset Load Line 1 Mm Line 2 ME M 0 25 50 75 100 Output Voltage Frequency 240VAC 60Hz Engine Hours 105 4 Hours Start Genset Stop Genset Network Setup Genset Clock 8 12 AM September 16 2007 Utility Utility Present Utility Connected enerator Running Standby Off Action Required Enable Standby Disable Standby FIGURE 15 HOME PAGE 4 2 1 Setting Time and Date 4 2010 Select the Genset Time Date Tab on the Home Screen to set the time and date for the generator set control Genset Time Date Datu Sep
62. ice Provider assigns a dynamic IP Address to your Internet connection This is the IP Address you type into your Internet browser to access your generator set from the World Wide Web A static IP Address is required for you to establish a constant address you can always access from the World Wide Web Contact your ISP to set up a static IP Address for your Internet connection Question What is DHCP Answer DCHP or Dynamic Host Configuration Protocol automatically assigns IP Addresses subnet masks and gateways to devices allowing them to communicate with each other e Your router and generator set are equipped with DHCP e Default is for DHCP to be on Question What is a UPS device and why is it recommended Answer A UPS Uninterruptible Power Supply device is battery backup to keep devices such as computers and modems powered during short term power outages e We recommend that the modem router be powered through a UPS device to ensure that your generator set is able to send emails and be remotely accessed at all times e For example if your generator set shuts down during a utility power outage the generator set can still send you an email letting you know that the power has failed and that the generator set shut down Question When do need to use a Static IP Address A029V090 Issue 1 4 2010 6 Optional Internet Email Interface Setup Answer Static IP addresses are required if you plan to access your generator set
63. k Setup Guide 3 Verify that you are using a high speed internet connection Verify that the public IP Address is active and set up properly with the ISP Internet Service Provider If necessary contact the ISP to verify your setup Verify that the correct public IP Address is entered into the web browser of the computer i e XXX XXX XXX XXX Verify that the computer is not connected to the same router or network as the generator set e The computer used for internet access must be connect to a different internet connection than the generator set A029V090 Issue 1 4 2010 9 3 9 Communication Troubleshooting 7 Check to see if you can access a standard web page from a computer e f not contact the ISP to troubleshoot the internet connection 8 Verify all settings as described in the Network Setup Guide 9 If the previous steps do not correct the problem contact a computer network specialist to diagnose To verify your IP Address access whatismyipaddress com from the browser of a computer connected to the internet and on the same network as the generator set This web page displays your current IP Address which should match the IP Address assigned to you by your ISP Email Alert Troubleshooting WARNING Some Generator Set service procedures present hazards that can result in severe personal injury or death Only trained and experienced service personnel with knowledge of fuels electricity
64. l A029V091 for information regarding using the operator panel to operate and monitor the generator set 3 6 5 2 Operator Panel Installation In The Home Mount the generator set operator panel on a wall in a convenient location such as next to the house thermostat To install the operator panel e n drywall or paneled walls 1 Drill a hole that is large enough to clear the harness connector on the back of the operator panel 2 Route the wires inside the wall to hide the wires A029V090 Issue 1 21 3 Step By Step Outline of Installation 4 2010 3 6 5 2 1 3 6 5 3 22 3 Mount the operator panel with four No 6 wood screws or wall anchors e On brick stone or block walls 1 Mount with spacers to clear the harness connector on the back of the operator panel 2 Mount with the appropriate wall anchors 3 Connect the operator panel to the generator set Refer to the Outline and System Drawings of this manual for guidelines on how to connect the operator panel to the generator set Operator Panel Installation In The Generator Set The operator panel may be installed inside of the generator set To install the operator panel in the generator set 1 Remove the bushing in the 1 hole on the control panel 2 Remove the 4 small screws from the control panel 3 Pulling the harness through the 1 hole connect J4 directly to the back of the operator panel into the connector that lines up with the hole in the metal panel
65. l Interface Descriptions Network Setup DHCP Off On IP Number Subnet Mask Gateway Static DNS 1 205 i Static DNS 2205 FIGURE 22 NETWORK SETUP PARAMETERS 4 2 7 Email Setup Screen Descriptions The user must determine what events will trigger an email notification of the event e Never e All Events e Maintenance and Attention Required or Attention Required Only This screen is also used to set up e mail configuration The user may enter up to three email addresses for receiving notifications of the home standby generator set status See the Email Addresses figure below Network Setup Email Setup Alert Level Maintenance and Attention Required v Outgoing Server SMTP Server Name max 42 chars User Name max 48 chars Password max 16 chars Network Setup Destination Email Addresses max 48 chars each Address 1 Address 2 Address 3 FIGURE 24 EMAIL ADDRESSES 4 2 8 Saving Changes After the email addresses are added and Done is selected this screen will appear verifying that all changes have been saved A029V090 Issue 1 39 4 Optional Internet Email Interface Descriptions 4 2010 Settings saved successfully FIGURE 25 SAVE SCREEN 40 A029V090 Issue 1 5 Ethernet Connection Installation Worksheet NOTE IMPORTANT Leave a filled out copy of this sheet chapter with the customer for future reference This generator set provides in home ne
66. lay 1Delay 2 Delay ATSx fer l ressa Enabled FIGURE 43 MANUAL START STOP TIMING DIAGRAM A029V090 Issue 1 57 7 Operation 4 2010 Utility Present Teen G Q Utility Connected Generator Running Generator Standby Off ES Available UH Power ot AVallsbS On Generator OF Transfer Utility Switch Generator On I Load Control 1 Of On Load Control 2 Off i Time Duration 5 3mi 3min i 3min 3min i i i 10 ipecon Ee j Wi j d d d Transfer iLoad Control Load Control iLoad Control Load ControfLoad Control i ln tility ma Control Delay f 1 Delay T 2 Delay f i 182 de 1 Delay i 2 Delay i i i 182 ii Load lt 70 lt 70 lt 95 gt 95 lt 50 lt 50 lt 95 gt 95 FIGURE 44 LOAD MANAGEMENT TIMING DIAGRAM 7 3 1 Normal Operation Utility Power Available and Connected As long as utility power is available and connected both of the green UTILITY lamps PRESENT and CONNECTED will stay on and the LCD screen will indicate Genset Stopped If the red GENERATOR STANDBY OFF light is on the generator set will not start up automatically if utility power is interrupted See the To Enable Disable Standby section of this manual to enable STANDBY so that the generator set will automatically supply power if utility power is interrupted 58 A029V090 Issue 1 4 20
67. lect changes in the equipment and its specifications The most up to date version of this manual will be found on the QuickServe website https quickserve cummins com info index html 2 2 Model Specifications The generator set consists of three model variations These variations are defined in the table below TABLE 1 MODEL VARIATIONS Product Description S 13GSBA 6712 60 Hz Warm 13GSBA 6711 60 Hz Cold 13GSBA 6718 60 Hz CSA Includes an alternator dryer oil heater kit and intake warmer CS NOTE See the Cold Weather Specifications Table for recommendations TABLE 2 COLD WEATHER SPECIFICATIONS TABLE Operating Temperature Range o Above 32 F 0 C and low No dryers or starting aids required humidity Any temperature with high Alternator drying heater recommended humidity Below 32 F 0 C Additional oil and intake heater recommended for starting Factory installed model available A029V090 Issue 1 5 2 Introduction 4 2010 Below 10 F 23 C Additional accessory battery blanket recommended for starting Below 20 F 29 C Not warranted See warranty statement TABLE 3 GENERATOR SET SPECIFICATIONS TABLE Weight With Oil 460 Ibs 209 kg Size L x W x H 48 x 43 x 34 6 in 1219 x 864 x 880 mm 64 dB A at 23 ft 7 m at normal load TABLE 4 FUEL SPECIFICATIONS TABLE 1 2 Load 132 500 Btu Hr 122 000 Btu Hr 53 ft Hr 122 ft Hr Full Load 220 000 Btu Hr 191 000 Btu Hr
68. led in the home A WARNING Carbon Monoxide CO gas can cause nausea fainting or death A029V090 Issue 1 3 1 IMPORTANT SAFETY INSTRUCTIONS 4 2010 1 8 3 Only You Can Protect Yourself From CO Poisoning e Locate the generator in an area where there are no windows doors or other access points into the home e Make sure all CO detectors are working properly e Pay attention to the signs of CO poisoning e Check the exhaust system for corrosion obstruction and leaks each time you start the generator set and every eight hours if you run it continuously 4 A029V090 Issue 1 2 Introduction Important note for Brazil applications The manufacturer warns that the installation operation and maintenance of equipment by the user must fully comply with the Manual s guidelines and current Brazilian laws including those of the Brazilian Agency of Petroleum Natural Gas and Fuels ANP and the Brazilian Energy Agency ANEEL 2 1 About this Manual This manual is a guide for the installation of the generator set models listed on the front cover Proper installation is essential for top performance reliable operation and safety Read through this manual before starting the installation NOTE The installation must comply with all applicable building codes See the generator set Operator Manual A029V091 for operation and maintenance and the Service Manual A030A240 for service NOTE Manuals are updated from time to time to ref
69. load the generator set This requires the installation of relays to the load management signals which allow for the disconnection of loads Load management can be set to operate in automatic or manual mode Whether in automatic or manual mode there is a delayed start Load 1 is enabled three minutes after the generator set is connected to the house loads and Load 2 is enabled six minutes after the generator set is connected to the house loads 7 13 1 Automatic Load Management When set to automatic mode the user takes no action and can only view which loads are connected Three minutes after the generator starts the load that is connected to genset load L1 is connected After a delay of three more minutes the load that is connected to genset load L2 is connected If the connection of loads L1 and L2 exceeds 95 of the generator s load capacity they are disconnected by the generator Following another three minute delay the control reconnects both loads following the same connection sequence used in the first attempt three minutes apart If generator load capacity is exceeded again both loads are disconnected and no further reconnection is tried To select automatic load management and view whether the selected loads are connected while the generator set is running 1 Press the LOAD button on the home screen 2 Press the up or down arrow button to select Automatic 3 Note which loads are connected or disconnected 4 Press the BAC
70. may cause personal injury or death e 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 it s vapors e Do not work on the generator set when mentally or physically fatigued or after consuming alcohol or drugs 1 3 Generator Voltage is Deadly e Generator output connections must be made by a trained and experienced electrician in accordance with all applicable codes A029V090 Issue 1 1 1 IMPORTANT SAFETY INSTRUCTIONS 4 2010 e This standby generator set and the public utility may only be connected to the house circuits by means of the automatic transfer switch e Improper connections can lead to electrocution of utility workers and damage to equipment e Use caution when working on live electrical equipment Remove jewelry make sure clothing and shoes are dry and stand on a dry wooden platform 1 4 Engine Exhaust is Deadly e See What Is Carbon Monoxide Poisoning to learn the symptoms of Carbon Monoxide poisoning e This generator set is for outdoor installation only e t must be located well away from doors windows other openings into the house and where the exhaust gases will disperse away from the house 1 5 Fuel is Flammable and Explosive e Keep flames cigarettes sparks pilot lights electrical arc producing equipment switches and all other sources of ignition well away from areas whe
71. mp e Contact 120 V AC Amp rating for load e Mounting Typically in distribution panel FIGURE 10 HIGH VOLTAGE RELAY DPDT 220V AC LOAD 3 6 5 4 Ethernet Connections Wire The generator set control board has a connector for Cat 5 Ethernet cable for connection to a remote modem router See Ethernet Email Interface for setup and operation Use Cat 5 Ethernet cable and 300V 18 gauge 75 C wire for wiring the relay Class 1 wiring methods should be used for the in home display Ethernet and transfer switch communication conductors between the generator set and transfer switch Separation of Class 2 and power circuits should be maintained per Article 725 136 of 2008 NFPA 70 National Electrical Code CS NOTE The Internet Email interface requires high speed or broadband cable or DSL service to the house See Ethernet Email Interface for a full list of requirements 3 6 5 5 Battery The generator set has a 12 VDC negative ground control and engine cranking system The engine has a battery charger for recharging during generator set operation A battery charger located in the transfer switch keeps the battery charged during generator set standby Refer to the Specifications Table for battery specifications A029V090 Issue 1 25 3 Step By Step Outline of Installation 4 2010 An optional thermostatically controlled battery heater is available for more reliable starting in ambient temperatures down to 20 F 28
72. n in the Ethernet RJ 45 Connector Wiring illustration Utilize an appropriate Ethernet stripping and crimping tool for these connections PIN 1 8 gGo BbO bBR gGoBbOLhr BR g Green and White G Green 0 Orange and White O Orange b Blue and White B Blue br Brown and White BR Brown FIGURE 27 ETHERNET RJ 45 CONNECTOR WIRING A029V090 Issue 1 43 6 Optional Internet Email Interface Setup 4 2010 UPS RECOMMENDED INTERNET WORLD WIDE WEB Public IP 176 196 052 094 Forward Port 80 to 192 168 000 001 Device IP 192 168 000 001 Forward Port 80 to 192 168 000 150 CAT 5 CABLE Sisie p 192168000150 b NOTE IPs mentioned in these instructions are samples only i k uu E WE ix RE 4 a o T CONTROL BOARD PERSONAL COMPUTER FIGURE 28 NETWORK CONNECTIONS 6 2 In Home Network Access to the Generator Set 44 1 Connect an Ethernet cable from the generator set control board to a router that has enough ports to connect the generator set and a computer 2 Write down the IP Address shown on the Network Setup screen below on the generator set s in home operator panel CE NOTE Leave the DHCP ON 3 Type the generator set IP Addr
73. n of more than one device computer generator set etc with each other and the Internet e Typically your Internet modem also serves as a router e f you have an available Ethernet connection on your router enabled modem you may not need to add an additional router Question Do need another modem Answer A modem is required if you want to utilize the email and remote Internet access features of the generator set e Only one modem is required e f you already have an Internet connection you have a modem Question What is an IP Address Answer An IP Address or Internet Protocol Address is a unique address that devices such as a computer or your home generator set use to communicate with each other both on your in home network LAN network or with the World Wide Web Question What is the difference between Static and Dynamic IP Addresses Answer Dynamic IP Address On your in home network the router with DHCP enabled will assign a dynamic IP Address to all devices computer home generator set etc connected to the router As devices are added and removed from the router the devices are automatically updated with new IP Addresses This means that your computer and generator set IP Addresses will not always be the same unless static IP Addresses are assigned Static IP Address A static IP Address is an unique address that is permanently assigned to a device On the World Wide Web your typical ISP Internet Serv
74. nge oil amp filter air filter adjust valve lash clean and check battery amp engine cooling fins Genset fault Fault description appended Genset warning Transfer Switch Signal Failure Genset warning Transfer Switch Failed to Transfer to Utility Genset warning Low Battery or Battery Charger Failure 7 10 Fault Log To check the log of the last 5 faults 66 s ij 5 Press the MENU button on the home screen 2 Press the up or down arrow button on the menu screen to select Fault Log 3 4 Scroll through the fault log with the up and down double arrow buttons Each screen Press the ENTER button on the menu screen provides a brief description of the fault the fault code number and the time and date of the fault Press the BACK button to return to the home screen NOTE If there are no faults recorded the No Stored Faults screen will appear A029V090 Issue 1 4 2010 7 Operation Battery 12 5 Genset Load LIW 1288 EXCER CLOCK LOAD MENU Genset Status Display Setup Event Lo Ethernet Setup Fault Log 1 of 5 Speed Sense Lost Fault No 27 Hour 10000 1 Fault History No Stored Fault FIGURE 55 FAULT LOG SCREEN 7 11 Exercise Settings To set the generator set exercise schedule 1 Press the EXCER button on the home screen 2 Press the NEXT button on the Exerciser Clock screen to select the field to change 3 Press the up or down arrow button
75. nriby Ready Disabled January 1 2006 4 74 PM Genset stopped manually Standby Ready Disabled Jenuery 1 2006 4 22 PM Genset stopped with return of utility zm January 1 2006 4 21 PM E Standby ready enabled by user January 1 2006 4 21 EM Genset slarled manually Slanuby Ready Disabled January 12006 4 20 PM 1 Switeh on genant maved ro remote pasitian Wanuary 1 2006 42 00 ALA FIGURE 19 EVENT LOG 4 2 5 Fault Log Select the Fault Log Tab on the Home Screen to review the last 5 faults Genset Exercise Time Date Schedule Fault Log Fault Description Engine Hours FIGURE 20 FAULT LOG 4 2 6 Network Setup Screen Descriptions An owner custom password can be defined in the Network Setup screen shown below The user will be prompted to enter the User Name and Password to access this screen The Network Setup Parameters screen allows dynamic addresses to be changed to static addresses This screen allows the user to configure the static address for the in home network See the Network Setup Parameters screen shown below Genset Exercise Load Network Time Date Schedule Control Setup Network Setup Click here to start Network Setup Enter new webpage password max 8 chars cummins Save Password MAC address 00 1C E8 23 00 01 Software Part Number 3267344 Software Version 0 56 FIGURE 21 NETWORK SETUP SCREEN 38 A029V090 Issue 1 4 2010 4 Optional Internet Emai
76. nstallation cannot be completed without connections to an automatic transfer switch Decide where to locate the automatic transfer switch e Decide what tools and materials will be needed e Maintain the minimum distance from the Propane tank fill e Verify the legal minimum distance with local code officials e Determine what if any accessories will be required for the customer s application Utility power may be required at the generator set make plans accordingly NOTE 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 whether or not a permit is needed A029V090 Issue 1 9 3 Step By Step Outline of Installation 4 2010 3 1 4 Installation Codes and Standards for Safety A WARNING The generator set installer bears sole responsibility for following all applicable local codes and regulations The following list of Installation Codes and Standards for Safety applies to the installation and operation of standby generator sets 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 so 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 9 INSTALLATION CODES AND STANDARDS F
77. re fuel fumes are present and areas sharing ventilation e Fuel lines must be secured free of leaks and separated or shielded from electrical wiring e Leaks can lead to explosive accumulations of gas Prevent leaks and the accumulation of gas e A rotten egg smell indicates a possible Natural Gas or Propane leak e Natural Gas rises when released and can accumulate under hoods and inside housings and buildings e Propane sinks when released and can accumulate inside housings and basements and other below grade spaces 1 6 Batteries Can Explode Batteries can explode causing severe skin and eye burns and can release toxic electrolytes e Wear safety glasses e Do not smoke e Do not dispose of the battery in a fire e The battery is capable of exploding e Do not open or mutilate the battery e Released electrolytes have been known to be harmful to the skin and eyes and to be toxic e Batteries present the risk to high short circuit current e Remove watches rings or other metal objects and use tools with insulated handles 2 A029V090 Issue 1 4 2010 1 7 1 8 1 8 1 1 8 2 1 IMPORTANT SAFETY INSTRUCTIONS e To prevent arcing when disconnecting the battery e Move the Stop Switch S2 to the Stop position disconnect the remote harness P7 to disable the ATS mounted charger and then remove the negative battery cable to prevent starting e To prevent arcing when reconnecting the battery e First
78. reconnect the positive cable then the negative cable and finally reconnect the battery charger e 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 e Do not wear loose clothing or jewelry near moving parts such as fans e Keep hands away from moving parts e Keep guards in place over fans The Hazards of Carbon Monoxide Engine driven generators can produce harmful levels of carbon monoxide that can injure or kill you What Is Carbon Monoxide Poisoning Carbon Monoxide CO is an odorless colorless tasteless and non irritating gas You cannot see it or smell it Red blood cells however have a greater affinity for CO than for Oxygen Therefore exposure even to low levels of CO for a prolonged period can lead 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 What Are the Special Risks of CO Near the Home Residents can be exposed to lethal levels of CO when the genset is running Depending on air temperature and wind CO can accumulate in or near the home To protect yourself and others from the dangers of CO poisoning it is recommended that reliable and approved CO detector alarms be instal
79. ructions for the generator set that should be followed during installation operation and maintenance of the generator and batteries Thoroughly read the Operator Manual before operating the generator set Safe operation and top performance can only be obtained when equipment is properly operated and maintained The following symbols in this manual alert you to potential hazards to the operator service person and equipment DANGER Alerts you to an immediate hazard that will result in severe personal injury or death WARNING Alerts you to a hazard or unsafe practice that can result in severe personal injury or death gt p e CAUTION Alerts you to a hazard or unsafe practice that can result in personal injury or equipment damage 1 2 General Precautions e Keep ABC fire extinguishers handy e Make sure all fasteners are secure and torqued properly e Keep the generator set and its compartment clean Do not store any items in the genset compartment e Excess oil oily rags etc can catch fire e Dirt and gear stowed in the compartment will restrict cooling air flow e Before working on the generator set move the Stop Switch S2 to the Stop position disconnect the remote harness P7 to disable the ATS mounted charger and then remove the negative battery cable to prevent starting e Use caution when making adjustments while the generator set is running hot moving or when parts are electrically live as all situations
80. t A flexible fuel hose is packaged inside the generator set The section of flexible fuel hose supplied with the generator set must be used between the engine s fuel system and fuel supply line to protect the fuel system from damage caused by vibration expansion and contraction The fuel hose must be installed according to all applicable codes and standards Connect it between the 3 4 NPT fitting on the generator set and the fuel supply line A029V090 Issue 1 27 3 Step By Step Outline of Installation 4 2010 Air e o Out Callout Component Number Fuel Connection Female 3 4 NPT amp NG amp LPV 4x Anchoring Spike FIGURE 12 FUEL LINE CONNECTIONS 3 7 2 Natural Gas Fuel System The generator set requires an adequate fuel supply to operate correctly at full load 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 Natural Gas Pipe Capacity Cubic Feet of Gas Per Hour table located within the Natural Gas Supply Line Size section of this manual to find the fuel supply requirement for your generator set The Pipe must be a minimum of schedule 40 subject to the authority having jurisdiction 3 7 2 1 Natural Gas Supply NOTE The Natural Gas supply meter may need to be exchanged for a higher capacity meter to supply th
81. t 4 2010 5 3 2 s qe 42 Email Internet Service Provider ISP DSL Cable Satellite etc This will support Email Notification The service provider must be contacted to verify and provide the following information NOTE If these items cannot be verified or provided email communication and or remote Internet access may not work If the service provider will not verify or provide the installer with this information it is the responsibility of the customer to provide this information Email Account ISP Provider Email Account ISP Contact Number ISP allows SMTP via port 25 yes no circle one ISP supports Authenticated and Unauthenticated email yes no circle one ISP static address To identify the public IP address go to www whatismyip com Server Name smpt Example smpt hughes net When you call the Internet Service Provider ask them how to access log into the modem and if the modem is rented from the ISP or owned by the ISP User Name Example hughes hughes net Password Email Notification Who the customer wants notified Address 1 Address 2 Address 3 NOTE Some email accounts will not accept unauthenticated emails NOTE The ISP may take several days to establish the IP address and an additional service cost may be incurred A029V090 Issue 1 6 Optional Internet Email Interface Setup 6 1 Ethernet Connections Optional Wiring connections to the Ethernet RJ 45 plug are show
82. ted Start and operate the genset following all the instructions and precautions in the Operator Manual Perform Generator Set Configuration CS NOTE Before leaving the site if the genset is ready to be placed in service set the control switch to the AUTO position to provide automatic standby power 86 3 Fuel Solenoid First Startup First Start Upon first connection of the fuel especially in LP systems it is possible for a spike of pressure greater than the operating strength of the fuel solenoid to pass through the main regulator and to lock the solenoid into an inoperable position This issue can be reduced by using a two stage regulator at the tank A029V090 Issue 1 71 8 Startup and Configuration 4 2010 If the situation occurs close the main valve at the tank and vent the fuel from the line at the tank After reconnecting the lines start the crank cycle at the genset and then turn on the fuel at the tank while the engine is cranking Multiple crank attempts may be required to purge the fuel line depending on the length of the run 8 4 Generator Set Configuration The operator panel has a menu with four generator set transfer switch parameters that must be configured for the installation To configure the generator set 1 Press the MENU button on the home screen 2 Press and hold the blank far left solid black button on the menu screen for at least 5 seconds to go to the Config Menu 3 Press the up or down
83. ted for full or partial load coverage equal to the capacity of the generator set e The RSS 200 transfer switch models can be connected for full load coverage greater than the capacity of the generator set TABLE 14 TRANSFER SWITCH CONNECTION VS LOAD COVERAGE Transfer Switch Model Full Load Full or Partial Load Greater Than Capacity of Genset Equal to Capacity of Genset RSS 100 6634 O o E RSS 200 6635 RSS 100 6868 E EN RSS 200 6869 CES NOTE Model RSS 100 6634 and RSS 200 6635 transfer switches do not incorporate a utility circuit breaker and therefore must be connected through a Service Entrance Utility Panel incorporating the utility circuit breaker X 12 A029V090 Issue 1 3 Step By Step Outline of Installation 4 2010 Perform Generator Set Configuration when ready to start up the generator set UTILITY SOURCE gt GENERATOR CIRCUIT CIRCUIT ria BREAKER FIGURE 1 PARTIAL COVERAGE LOAD CONNECTIONS TRANSFER SWITCH WITHOUT CONTROLLER TRANSFER SWITCH GENERATOR SOURCE UTILITY SOURCE CIRCUIT BREAKER CIRCUIT BREAKER ALLLOADS FIGURE 2 FULL COVERAGE LOAD CONNECTIONS TRANSFER SWITCH WITHOUT CONTROLLER ONE CIRCUIT BREAKER A029V090 Issue 1 13 3 Step By Step Outline of Installation 4 2010 UTILITY PANEL UTILITY TRANSFER SWITCH SOURCE amp 5 GENERATOR CIRCUIT SEURE BREAKER TRANSFER SWITCH GENE
84. tember x 15 v 2007 Time 0 20 vl An Apply FIGURE 16 36 Nelwurk Setup SET GENSET TIME AND DATE A029V090 Issue 1 4 2010 4 Optional Internet Email Interface Descriptions 4 2 2 Set Exercise Schedule Select the Exercise Schedule Tab on the Home Screen to set the generator set exercise schedule CS NOTE The generator set will exercise on the first scheduled day for which it is programmed After that it exercises on that day at the scheduled interval For example if the generator set is scheduled on a Wednesday for Saturdays with a monthly interval the generator set starts on the next available Saturday After that it exercises on Saturdays one month apart Network Setup Exercise Schedule Frequency Neus v Sunday 12 v 6 v AM v Apply Lxercise Now FIGURE 17 SET EXERCISE SCHEDULE 4 2 3 Load Control Management Select the Load Control Tab on the Home Screen to enable Automatic or Manual Load Control In Automatic mode the user can only view which loads are connected In Manual mode the user can view loads and also connect or disconnect them See Load Management for details Home Genset Exercise Loac Fault Time i Date Schedule Cantal lon Genset Load Management ace 4 Connessi Load 2 Connected Nowe Taare arn always dlecannentod for n warm ip period when the nenerarr stris oven when In Mani Mads Luuus are enubled ore ai u fiume wilh a delay betwee eucit Mudu Autom
85. thernet Setup hold blank button for 5 seconds Generator Config Generator Adjustments TS EER FIGURE 61 TRANSFER SWITCH ADJUSTMENTS 8 7 Generator Adjustments 8 7 1 To Adjust the Output Voltage Use the following procedure 1 Connect an accurate AC volt meter across L1 and L2 while the generator set is running 029V090 Issue 1 77 8 Startup and Configuration 4 2010 2 With Output Volts selected on the Adjustments Menu screen press the up or down arrow button to adjust the voltage to the desired setting 3 The control allows an adjustment of 240 VAC x 796 17 VAC 4 Press the BACK button to save the settings and return to the home screen 8 7 2 To Calibrate the Display Meter Use the following procedure 1 Connect an accurate AC volt meter across L1 and L2 while the generator set is running 2 Press the NEXT button to select the Display Cal field screen not shown 3 Press the up or down arrow to adjust the voltage reading on the screen until it matches the meter reading 4 Press the BACK button to save the settings and return to the home screen Adjustments Use Meter to Set Output Volts E Hr Meter Loz FIGURE 62 ADJUSTMENT MENU SCREEN 78 A029V090 Issue 1 9 Communication Troubleshooting 9 1 In Home Network Access to Generator Set Troubleshooting A WARNING Some Generator Set service procedures present hazards that can result in severe personal injury or death Only trained
86. tion Review Before starting the genset inspect the installation and check off each of the following questions if it can be answered YES If a question cannot be checked off review the appropriate section in the manual e Can the top maintenance and service access doors be swung fully open for operation maintenance and service e Are the cooling air inlet and outlet openings free of obstructions e Have the AC output connections been made properly e Has the transfer switch been installed properly to prevent connecting the generator set to the utility e Has a properly sized battery been installed e Are all fuel connections tight e Is fuel supply pressure correct e Are electrical and fuel lines properly separated e Does engine exhaust disperse away from buildings e Have all fuel connections been checked for leaks 8 2 Startup When all installation requirements have been met connect the battery cables to the battery positive cable first A WARNING 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 starting Read through the Operator s Manual and perform the maintenance and pre start checks instructed The genset is shipped from the factory with the proper level of engine oil but should be checked before the genset is star
87. to increase or decrease the frequency of exercise and the day of the week and time of day for exercise Frequency selections are A029V090 Issue 1 67 7 Operation 4 2010 Weekly Bimonthly Monthly Never 4 Press the BACK button to save the settings and return to the home screen 5 If you want to exercise the generator set now select Exercise Now and press either the up or down arrow CS NOTE Scheduled or prompted exercise does not transfer the house loads to the generator set Sun 10 35 AM Battery 1245 Genset Load LIW 128 EXCER CLOCK LOAD MENU 4 Exerciser Clock Exercise Weekly Mon FIGURE 56 EXERCISE CLOCK SCREEN 7 12 Time Setup To set up the generator set clock for the current date and time 1 Press the CLOCK button on the home screen 2 Press the NEXT button on the Time Setup screen to select the field to change 3 Press the up or down arrow button to increase or decrease or change the date or time 4 Press the BACK button to save the settings and return to the home screen 68 A029V090 Issue 1 4 2010 7 Operation Sun 10 35 AM Battery 12 5 Genset Load LIW L2 EXCERICLOCK LOAD MENU 4 Time Setup Date Time FIGURE 57 TIME SETUP SCREEN 7 13 Load Management The generator set may have been set up at installation to connect and disconnect certain large loads such as air conditioners to manage the total load so as not to over
88. trol 1 Of Load Control 2 i Time Duration i i i TUNE te th wee 41 249 5 38min 3min 5min 5min seconds i i E H H H H Engine Start Engine Start Transfer Load Control Load Control Transfer Engine Cool Generator Ei allure Baes O uou D dy 2 Jide D Uus duni keun Delay Down off FIGURE 41 TYPICAL POWER OUTAGE CYCLE TIMING DIAGRAM A029V090 Issue 1 55 7 Operation Utility Present Off Utility Connected Dispay S i LED Generator Runni Flashing unning Generator Red Standby Off UA is Available BILE Not Aabi UR Rau On c i EC M 1 Transfer Utility Switch Load Control 1 Load Control 2 on Time Duration seconds 4 2010 Exercise 2 19 20 min 5 min Engine Start Generator Engine Cool Generator upTime Exercise Down Off FIGURE 42 EXERCISE TIMING DIAGRAM 56 A029V090 Issue 1 4 2010 7 Operation Manual Start Stop Utility Present eae Utility Connected Off Display LED Generator Running Generator Red Standby Of si ae m Available VU PONT lee available ees ee Generator en Ss RET Transfer Switch Time Duration seconds Start Stop l l Generator Start Stop Button Engine Starts Transfer Load Control Load Control Stopped Button Standby Pressed upTime De
89. twork capability and Internet connectivity It is the owner s responsibility to provide a network specialist for these connections and setup The following gives guidance for gathering information and materials needed for a network specialist to enable all features CS NOTE Prior to installation please review and verify that all requirements are met 5 1 Network Connectivity Options Network connectivity includes in home Network access to the generator set e mail notification and remote internet access 5 2 Material Cable Routing Route the Cat 5 Ethernet cable from the generator with the control lines and display cable display may be mounted in the house to the transfer switch and into the house Be sure to make the cable long enough to reach the network router Install connectors on both ends of the cable 5 3 Network Information Needed For Setup The following sections will help with gathering information required for a successful installation 5 3 14 Network Router This will support in home network access to the generator set The following information is needed to configure the genset from dynamic addressing to static e Router User Name e Router User Password e Range of dynamic address reserved or IP pool e Starting address for static address e P addresses from the Ethernet Setup Screen In Home Operator Panel e Static address to be used A029V090 Issue 1 41 5 Ethernet Connection Installation Workshee
90. u to the Genset START STOP screen e The screen will display Genset Stopped or Genset Running as appropriate 60 A029V090 Issue 1 4 2010 7 Operation 2 Press START to manually start the generator set and connect it to supply power to the house The STANDBY OFF lamp will come on and the display will state Genset started manually Standby Ready Disabled 3 Press STOP to manually stop the generator set and disconnect it The STANDBY OFF lamp will come on and the display will state Genset stopped manually Standby Ready Disabled CS NOTE To start the generator set without connecting loads pick Exercise Now on the Exerciser Clock screen Manual Operation Disables Standby Genset Stopped FIGURE 48 GENSET START STOP SCREEN 7 6 Fault Maintenance and New Event Screens Various warning and event screens may appear on the operator panel during Normal or Emergency Operation 7 6 1 Fault Screen If a generator set shutdown fault occurs a FAULT warning appears with the following information e Brief description of the warning or fault e The two digit Fault Code Number e The time of occurrence of the fault Press the BACK button to reset the fault and return to the home screen See the Fault Log section of this manual to review the log of the last 5 faults Starting Fault Fault Number 32 Hour 10000 1 FIGURE 49 TYPICAL FAULT SCREEN 7 6 2 Maintenance Due Screen A Maintenance Due screen appears
91. ucing 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 CS NOTE Commercial Propane may contain more than 2 5 butane which can result in poor fuel vaporization and low tank pressure resulting in poor engine staring in below 32 F O C temperatures 3 7 3 2 Propane Tank Size First some Propane tank facts to bear in mind when figuring the proper Propane tank size e Propane tanks are sized by the number of gallons of water they can hold not the amount of fuel they can hold e Propane tanks are generally filled to only 80 of their water capacity Therefore a 500 Ib tank results in 400 Ib tank capacity e Low ambient temperatures affect the amount of fuel available from the Propane tank e Approximately 60 of the fuel in gallons filled in the tank can be effectively used Therefore a 500 Ib tank results in 300 gallon capacity To assist in the proper selection of the Propane tank follow the guidelines below e Propane tanks must be fitted with a pressure reducing regulator before connection to the generator set to prevent fuel system damage e Propane tanks must be located at least 10 ft 3048 mm from any source of combustion including the generator set TABLE 21 REQUIRED PROPANE TANK SIZE IN GALLONS LITERS FOR INDICATED TEMPERATURES

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