Table of Contents SECTION ” TITLE PAGE IMPORTANT SAFETY INSTRUCTIONS |... ..00.000ccccceeeeee iti INTRODUCTION ‘About this Manual aa Installation Overview ...... : 212 SPECIFICATIONS . MOUNTING THE GENERATOR SET General Location Mounting . Access to S Vibration Isolators Aligning Generator with Engine MECHANICAL CONNECTIONS General ... ; ode Fuel System at Exhaust System beens we Ventilation and Cooling . 46 Coolant... 49 DC CONTROL WIRING Control Wiring . et Remote Monitor/Gontral Conn 52 Run Relays (Ki1, K12, K13) - 54 Alarm Relay (K16) . 55 Power Transfer Control (Optional). 56 ‘AC ELECTRICAL CONNECTIONS General . et Insulation Resistance (Megger) & Polarization Index eo Testing... 6-2 Transfer Switch 64 AC Wiring .. 65 Control Heater - 67 Coolant Heater 68 Generator Heater x) California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. | |SECTION TITLE PAGE 7 PRESTART PREPARATION General .. . veces 7A InPower Service Tool General Information nee eeeee sevens Tl Electrical System . - ae BD Control Prestart Checks . . ae cece THB Adjust Submenu ........ wee cee THE Power Transfer Control Main Menus bee 77 UTILITY SENSORS Submenus . 78 I GENSET SENSORS Submenus ..... wee . 710 | TIMERS Submenu .... re | TEST/EXERCISE Submenu . 743 | PTC Detailed Field Descriptions 714 | Starting : 716 | 8 INSTALLATION CHECKLIST General ............ . BF Generator Set Support . . : Bi } Cooling Air Flow pte or . - Bt | Diesel Fuel System et Exhaust System . . 82 AC and DC Wiring ...... 82 Generator Set Prestart .. = wee 82 9 RADIATOR ASSEMBLY INSTALLATION | General ... ot | ‘Special Tools we Ot | Shipping Skid Removal ......... 82 Assemble Generator Set . 29.3 10 WIRING DIAGRAMS Customer Connections ......... vee 10-1/10-4IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS ~ This manual contains important instructions that should be followed during installation and maintonance of the generator set and batteries. Before operating the generator set (genset), read the Operator's Manual and become familiar with it and the equipment, Safe and efficient operation can be achieved only if the equipment is properly operated and maintained, Many accidents are caused by failure to follow fundamental rules and precautions. The following symbols, found throughout this manual, alert you to potentially dangerous conditions to the op- erator, service personnel, or the equipment. This symbol warns of immediate hazards which will result in severe personal in- jury or death, (GWABNING] This symbol refers to a hazard or un- safe practice which can result in severe per- sonal injury or death. [ACAUTION] This symbol refers to a hazard or un- ‘safe practice which can result in personal injury or product or property damage, FUEL AND FUMES ARE FLAMMABLE Fire, explosion, and personal injury or death can result {rom improper practices, ‘© DO NOT fill fuel tanks while engine is running, un- fess tanks are outside the engine compartment, Fuel contact with hot engine or exhaust is @ potential fire hazard, © DO NOT permit any flame, cigarette, pilot light, spark, arcing equipment, or other ignition source near the generator set or fuel tank, ¢ Fuel fines must be adequately secured and free of leaks. Fuel connection at the engine shoukd be made with an approved flexible line. Do not use zine ‘coated or copper fuel lines with diesel fuel. ‘© Be sure all fuel supplies have a positive shutoff valve. ‘© Be sure battery area has been wett-ventifated prior 0 servicing near it. Lead-acid batteries emit a highly explosive hydrogen gas that can be ignited by arc- ing, sparking, smoking, etc, EXHAUST GASES ARE DEADLY * Provide an adequate exhaust system to properly expel discharged gases away from enclosed or sheltered areas and areas where individuals are likely to congregate. Visually and audibly inspect the exhaust daily for leaks per the maintenance schedule, Make sure that exhaust manifolds are se- cured and not warped. Do not use exhaust gases to heat a compartment. ‘© Be sure the unit is well ventilated, © Engine exhaust and some of its constituents are known to the state of California to cause cancer, bitth defects, and other reproductive harm. MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH Keep your hands, clothing, and jewelry away trom moving parts, © Before starting work on the generator set, disoon- rnect battery charger from its AG source, then dis- connect starting batteries, negative (-) cable first. This will prevent accidental starting. ‘© Make sure that fasteners on the generator set are secure, Tighten supports and clamps, keep guards in position aver fans, drive belts, etc. ‘© Do not wear loose clothing or jewey inthe vicinity of moving parts, or while working on electrical equip- ment. Loose clothing and jewelry can become ‘caught in moving parts. ‘© adjustment must be made while the unit is run- ning, use extreme caution around hot manifolds, moving parts, etc, DO NOT OPERATE IN FLAMMABLE AND EXPLOSIVE ENVIRONMENTS: Flammable vapor can cause an engine to overspeed and become dificult to stop, resulting in possible fire, explo- sion, severe personal injury and death, Do not operate a genset where a flammable vapor environment can be created by fuel spill, leak, etc., unless the genset is equipped with an automatic safety device to block the ait intake and stop the engine. The owners and operators of the genset are solely responsible for operating the gen- set safely. Contact your authorized Cummins Power Generation distributor for more information, Ls-16mELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH © Remove electric power before removing protective shields or touching electrical equipment. Use rub- ber insulative mats placed on dry wood platforms ‘over floors that are metal or concrete when around electrical equipment. Do not wear damp clothing {particularly wet shoes) or allow skin surface to be damp when handling electrical equipment. Do not ‘wear jewelry. Jewelry can short out electrical con- tacts and cause shack or burning. ‘¢ Use extreme caution when working on electrical components. High voltages can cause injury or death, DO NOT tamper with interlocks. ‘* Follow all applicable state and local electrical codes. Have all electrical installations performed by a qualified licensed electrician, Tag and lock open switches to avoid accidental closure. © DO_NOT CONNECT GENERATOR SET DI- RECTLY TO ANY BUILDING ELECTRICAL SYS- TEM. Hazardous voltages can flow from the gen- ‘erator set into the utifty line. This creates a potential {or electrocution or property damage. Connect only through an approved isolation switch or an ap- proved paralleling device. MEDIUM VOLTAGE GENERATOR SETS (601V to 15kV) ‘© Medium voltage acts differently than low voltage, Special equipment and training is required to work (on of around medium voltage equipment. Operation and maintenance must be done only by persons trained and qualified to work on such devices. Im- proper use or procedures will result in severe per- sonal injury or death. ‘© Do not work on energized equipment. Unauthorized personnel must not be permitted near energized equipment, Due to the nature of medium vokage ‘electrical equipment, induced voltage remains even affer the equipment is disconnected from the power source. Plan the time for maintenance with author- ized personnel so that the equipment can be de-en- ergized and safely grounded. GENERAL SAFETY PRECAUTIONS Coolants under pressure have a higher boiling point than water. DO NOT open a radiator or heat ex- changer pressure cap while the engine is running To prevent severe scalding, let engine cool down before removing coolant pressure cap. Tum cap sslowiy, and do not open it fully until the pressure has been relieved. Used engine oils have been identified by some state or federal agencies as causing cancer or reproduc- tive toxicity, When checking or changing engine oll, take care not to ingest, breathe the fumes, or con- tact used oil, Keep multiclass ABC fire extinguishers handy. Class A fires involve ordinary combustible materials such as wood and cloth; Class B fires, combustible and flammable liquid fuels and gaseous fuels; Class fires, ve electrical equipment. (ref, NFPA No, 10). Make sure that rags or combustible material are not left on or near the generator set. Make sure generator set is mounted in a manner to prevent combustible materials from accumulating under or near the unit. Remove all unnecessary grease and oil from the unit. Accumulated grease and oil can cause over- heating and engine damage which present a poten- tial fire hazard. Keep the generator set and the surrounding area clean and free from obstructions, Remove any de- bris from the set and keep the floor clean and dry, Do not work on this equipment when mentally or physically fatigued, or after consuming any alcohol ‘or drug that makes the operation of equipment un- safe. ‘Substances in exhaust gases have been identified by some state of federal agencies as causing can- ‘cer or reproductive toxicity, Take care not to breath ‘r ingest or come inta contact with exhaust gases, Do not store any flammable liquids, such as fuel, cleaners, oil, etc., near the generator set. A fire or explosion could resut. Wear hearing protection when near an operating generator set. To prevent serious burns, avoid contact with hot metal parts such as radiator system, turbo charger system and exhaust system. KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE1. Introduction ABOUT THIS MANUAL This manual provides installation instructions for the generator set models listed on the front cover. ~ This includes the following information: Mounting Recommendations - for fastening generator set to base and space requirements for normal operation and service, Mechanical and Electrical Connections - covers most aspects of the generator set instal- lation, Prestart — checklist of items or procedures needed to prepare generator set for operation. Initial Startup ~ test complete system to en- sure proper installation, satisfactory perfor- mance, and safe operation. Refer to Operators Manual for troubleshooting information, Installation Checklist - reference checks upon completion of installation. This manual DOES NOT provide application infor- mation for selecting a generator set or designing the complete installation. If it is necessary to design the various integrated systems (fuel, exhaust, cooling, etc.), additional information is required. Review standard installation practices. For engineering data specific to the generator set, refer to the Speci fication and Data Sheets. For application informa tion, refer to Application Manual T-030, "Liquid ‘Cooled Generator Sets". INSTALLATION OVERVIEW ‘These installation recommendations apply to typl- cal installations with standard model generator ‘sets. Whenever possible, these recommendations also caver factory designed options or modifica- 14 tions. However, because of the many variables in any installation, it is not possible to provide specific recommendations for every situation, if there are any questions not answered by this manual, contact your nearest Cummins Power Generation distribu- tor for assistance, Application and installation A power system must be carefully planned and cor- rectly installed for proper operation. This involves two essential elements: application and installa- tion, Application (as it applies to generator set installa- tions) refers to the design of the complete power system that usually includes power distribution equipment, transfer switches, ventilation equip- ment, mounting pads, and cooling, exhaust, and fuel systems. Each component must be correctly designed so the complete system will function as in- tended. Application and design is an engineering function generally done by specifying engineers or other trained specialists. Specifying engineers or other trained specialists are responsible for the de- sign of the complete power system and for selecting the materials and products required, Installation refers to the actual set-up and assem- bly of the power system. The installers set up and ‘connect the various components of the system as ‘specified in the system design plan, The complexity of the system normally requires the special skills of qualified electricians, plumbers, sheet metal work- ers, etc, to complete the various segments of the installation, This is necessary so all components are assembled using standard methods and prac- tices. |Safety Considerations The generator set has beer carefully designed to provide safe and efficient service when properly installed, maintained, and operated. However, the overall safety and reliability of the complete system is dependent on many factors outside the control of the generator set manufacturer. To avoid possible safely hazards, make all mechanical and electrical connections to the generator set exactly as speci- fied in this manual. All systems externel to the gen- erator (fuel, exhaust, electrical, etc,) must comply with all applicable codes, Make certain all required inspections and tests have been completed and all code requirements have been satisfied before certi- fying the installation Is complete and ready for ser- vice. Standby Heating Devices In accordance with NFPA 110, Cummins Power Generation recommends installing diesel standby generator sets (life safety systems) equipped with engine jacket water coolant heaters in locations where the minimum ambient temperature is above 40°F (4°C). NFPA also requires that the engine be heated as necessary to maintain the water jacket temperature determined by the manufacturer for cold start and load acceptance for the type of sys- tem. Although most Cummins Power Generation generator sets will start in temperatures down to =25°F (82°C) when equipped with engine jacket CCopytighté 2003 Cummins Power Generation. Al rights reserved, water coolant heaters, it might take more than 10 seconds to warm the engine before a load can be applied when ambient temperatures are below 40°F (4°C). The Engine Cold (Code 1435) message, in con- junction with illumination of the Warning LED, is pro- vided to meet the requirements of NFPA 110. The ‘engine cold sensing logic initiates a warning when the engine jacket water coolant temperature falls below 70°F (21°C). In applications where the ambi- ‘ent temperature falls below 40°F (4°C), a cold en- gine may be indicated even though the coolant heaters are connected and operating correctly. Un- der these conditions, although the generator set may start, it may not be able to accept load within 10 seconds, When this condition occurs, check the ‘coolant heaters for proper operation. If the coolant heaters are operating properly, other precautions may be necessary to warm the engine before apply- ing aload. Product Modifications Agency certified products purchased from Cum- mins Power Generation comply only with those specific requirements and as noted on company product specification sheets, Subsequent modifica tions must meet commonly accepted engineering practices and/or local and national codes and stan- dards. Product modifications must be submitted to the local authority having jurisdiction for approval. ‘Cummins and PowerCommand are registered tademarks of Cummins ine 122. Specifications MODEL DQKB/DGKC DQKD DaKH ‘Cummins Diesel Series ‘QSK6O (60/60 Hz) | _QSK60(S0H2) | GSK6O (60/60 Hz) Generator KW Rating ‘See Genset Nameplate for rating information. ‘Cooling System Radiator-Cooled Models 40°C Jacket Water Cooling System 80 Gal (303 L) 80 Gal (303 L) 110 Gal (417 L) Low-Temp Aftercooling System 40 Gal (182 L) 40 Gal (152 L) 40 Gal (152 L) ‘50°C Jacket Water Cooling System 110 Gal (417) 110 Gal (417 L) Low-Temp Aftercooling System 40 Gal (152 L) 40 Gal (182 L) ‘Oil Capacity, Maximum (eee Figure 2-1) Ol Pan Only Standard Capacity 68 Gal (417 L) 69 Gal (261 L) 48.5 Gal (176 L) igh Capacity 100 Gal (378) 100 Gal (379 L) NA ‘System (w/Std. Fitters) Standard Capacity 74 Gal (280 L) 74 Gal (280 L) 51.5 Gal (195) High Capacity 105 Gal (398 L) 105 Gal (988 L) NA *OW Type Engine Fuel Connection Inle/Outlet Thread Size Refer to Generator Set Outline Drawing Fuel Consumption ‘Standby/Full Load/60Hz GPH(LHR) 117 (443) 118.8 (487) 150 (569) Exhaust ‘Outlet Size ASME B16.1 Class 125 NPS 10 Maximum Allowable Back H0 27 in (686 mm) ka 67 Hg 2.0 in (61 mm) Electrical System ‘Starting Voltage 24 Volts DC Battery Four, 12 Volt Group Number @D ‘GGA (minimum) Gold Soak @ 0° F (-18° C) 1800 * Refer to Cummins GSKE0 Series Engine Operation and Maintenance Manual for lubricating ol! recommendations/specifcations. ** Refer to Data Sheet for ather applications, 24‘STANDARD CAPACITY (PQKH) STANDARD CAPACITY (BKB, DQKC, DaKD) wy i F o ou I 9-90 i id ze O ! HIGH CAPACITY (BKB, DaKC, DaKD) FIGURE 2-1. OIL PAN TYPES. 2-23. Mounting the Generator Set GENERAL Generator set installations must be engineered so the generator set will function properly under the ex- pected load conditions. Use these instructions as a general guide only. Follow the instructions of the consulting engineer when locating or installing any components. The complete installation must com- ply with all local and state building codes, fire ordi- ances, and other applicable regulations, Requirements to be considered prior to installation: @ Level mounting surface Adequate cooling air © Adequate fresh induction air © Discharge of generator set air © Discharge of exhaust gases © Non-combustible mounting surface, ‘* Electrical connections © Accessibility for operation and servicing Noise levels ‘© Vibration isolation AWARNING The set mounted radiator cooling system can be shipped installed or as a separate item. If shipped separately, the radiator cooling system must be Installed before the genset Is mounted. For radiator assembly instruction, refer to Section 9 of this manu- al. (AEAUTION] If the set mounted radiator cooling system is shipped INSTALLED, the alignment of the cooling system fan drive must be checked after the genset is mounted. Fallure to check fan drive alignment can result in severe fan/radiator damage. Refer to Section 9 for alignment proce- dure. LOCATION Generator set location is decided mainly by related systems such as ventilation, wiring, fuel, and ex- haust. The set should be located as near as pos- sible to the main power service entrance. Exhaust must not be able to enter or accumulate around in- habited areas. Provide a location away from extreme ambient tem- peratures and protect the generator set from ad- verse weather conditions, INCORRECT INSTALLATION, SERVICE OR PARTS REPLACEMENT CAN RESULT IN SEVERE PERSONAL INJURY, DEATH, AND/OR EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST BE TRAINED AND EXPERIENCED TO PERFORM ELECTRICAL AND MECHANICAL COM- PONENT INSTALLATION. IMPORTANT DEPENDING ON YOUR LOCATION AND INTENDED USE, FEDERAL, STATE OR LOCAL LAWS AND REGULATIONS MAY REQUIRE YOU TO OBTAIN AN AIR QUALITY EMISSIONS PERMIT BEFORE BEGINNING INSTALLATION OF YOUR GENSET. BE SURE TO CONSULT LOCAL POLLUTION CONTROL OR AIR QUALITY AUTHORITIES BEFORE COMPLETING YOUR CONSTRUCTION PLANS. kMOUNTING Generator sets are mounted on a stee! skid that pro- vides proper support. The engine-generator as- sembly is hard mounted directly to a skid-base. Vibration isolation between the skid-base and the supporting structure is always required, whether that supporting structure is a foundation, building, or sub-base fuel tank. The use of unapproved isola- tors may result in harmful resonances and may void the genset warranty. Mount the generator set on a substantial and level base such as a concrete pad. A non-combustible material must be used for the pad. Use 3/4 inch anchored mounting bolts to secure the vibration isolators to the base, Secure the vibration isolators to the skid using flat washer and hexago- nal nut for each bo (see Figure 3-1). The 1-1/2 x 6 inch pipe inserted over the mounting bolts allows minor adjustment of the bolts to align them to the holes in the subbase or vibration isolator. Locate the isolators as shown on the generator set Outline Drawing referenced in the Data Sheet. ACCESS TO SET Generally, at least 1 meter (8 feet) of clearance ‘should be provided on all sides of the generator set for maintenance and service access, A raised foundation or slab of 150 mm (6 inches) or more above floor level will make servicing easier. Lighting should be adequate for operation, mainte- nance and service operations and should be con- nected on the load side of the transfer switch so that itis available at all times. 3-2 ‘SUBBASE OR VIBRATION ISOLATOR. ance Lo gs FLAT WASHER 7-126 INCH PIPE MOUNTING 12 IN. BASE (05 mm) ‘CONCRETE MOUNTING BOLT FIGURE 3-1. BOLT DIAGRAMSWEEPING MUFFLER ew THIMBLE DC CONTROL WIRING AC POWER CONDENSATION a WIRING DRAIN TRAP FLEXIBLE SECTION AIR OUTLET bucT ‘CONCRETE VIBRATION a ISOLATORS FIGURE 3-2. TYPICAL INSTALLATION 33 | | |VIBRATION ISOLATORS Installation and Adjustment Procedure 1. Place the vibration isolators (Figure 3-3) on the genset support structure. The isolators should be shimmed or grouted to ensure that all of the isolator bases are within 0.25 inch (6 mm) elevation of each other. The surface that the isolator bases rest on must also be flat and lev- al. 2. Loosen the side snubber lock nuts so that the top plate of the isolator is free to move vertically and horizontally. Be sure that the top plate is correctly aligned with the base and springs. 8. Place the genset onto the isolators while align- ing the skid's mounting with the threaded isola- tor hole. The top plates will move down and ap- proach the base of the isolator as load is ap- plied. 4. Once the genset is in position, the isolators may require adjusting so that the set is level, The isolators are adjusted by inserting the lev- ling bott through the skid and into the isolator (the leveling bolt's locking nut should be threaded up towards the bolt head). The leveling bolt will adjust the clearance be- tween the top plate and the isolator base. A nominal clearance of 0.25 inch (6 mm) or great- er Is desired. This will provide sufficient clear- ance for the rocking that occurs during startup and shutdown. If the 0.25 inch (6 mm) clear- ance is not present, turn the leveling bolt until the desired clearance is achieved ‘Set mounted radiator-cooled generator sets: Make ure radiator skid and engine/atternatar skid are level with each other after adjusting leo- lators, If nat level, proper fan bett alignment can- not be achieved (Section 9). 5. The genset may not be level yet; therefore, ad- just the leveling bolts until the set is level and sufficient clearance still remains. (Clearance on all isolators should be roughly equal). Once all isolators have been set, lock the leveling bolt in place with the lock nut. 6. The snubber nuts must remain loose and therefore provide better isolation between the genset and support structure. (ACAUTION] Fan belt alignment for set mounted radiators must be performed after genset is lev- eled. This includes a genset shipped with pre- installed radiator cooling system. Refer to Sec- tion 9 for fan belt alignment procedure. GENSET SKID. SNUBBER, LEVELING BOLT FIGURE 3-3. VIBRATION ISOLATORS 3-4ALIGNING GENERATOR WITH ENGINE Proper alignment of the generator and engine as- semblies is necessary to avoid premature wear and improper operation of the genset. Checking the an- gular alignment of the generator set must be per- formed before initial start-up. Review the following alignment conditions and pro- cedures for aligning the generator assembly to en- gine flywheel housing. Angular Misalignment: |s the result of the genera- tor bearing center axis not aligning with axis of the engine crankshaft. This condition creates an angle between the generator shaft axis and the crank- shaft axis. The cause of this type of misalignment is usually shimming error. Axial Misalignment: |s the result of the generator shaft axis not aligning with engine crankshaft axis, The tolerances in the bolted flywheel and drive disc connection may add up to displace the generator axially relative to the crankshaft axis. Misalignment Symptoms: If the assembly is al- lowed to run under these conditions, the discs must 35 flex in alternate directions twice for each engine rev- olution. It is important to minimize the amount of disc flexing since, if itis excessive, the drive disc will crack. Although perfect bearing alignment is desir- able, it is more important to keep disc deflection to the minimum possible. This procedure assumes that the pilot bore of the drive discs are in the exact ‘center and the flywheel counterbore (pilot) has no practical runout. Under these conditions, perfect Angular alignment will be attained when no defiec- tian of the disks is measured. Excessive Axial misalignment will cause more gen- erator vibration than Angular misalignment. ‘Axial misalignment should be checked only when an objectionable vibration Is present. Either type of misalignment may be present in a generator set assembly, with angular misalignment being the most common problem. Angular align- ment may also be effected by set installation condi- tions and/or mishandling during shipping of the gen- set. |Angular Alignment Procedure Accidental starting of the generator set during this procedure presents the hazard of severe personal injury or death. Make sure to disconnect the negative (-) battery cable(s) be- fore beginning. Fasten a dial indicator to either the generator shaft or the cooling fan with the sensing point resting on the capscrew head or the flat surface of the drive disc at the bolt circle diameter, see Figure 3-4. Bar the engine over in a clockwise rotation as viewed from engine flywheel. Do not allow it to roll back on compression at the end of the travel of each read- ing, Its unnecessary to zero the indicator since the tolal indicator reading (T.1.R.) of the deflection mea- surement to the bolt heads is what is required. TLR will be the sum of the maximum positive and nega- tive dial indicator readings as the engine completes one revolution. DIAL INDICATOR (GENERATOR AND ENGINE ‘CRANKSHAFT (CENTERLINE SHIMS FIGURE 3-4. ANGULAR ALIGNMENT MEASUREMENT |Sample Generator Runout Readings When taking the deflection readings described, make a diagram similar to the example shown in Figure 3-5, where the total indicator reading is 025”. (The highest positive value of +.010 and the largest negative value of -.015".) The indicator is ‘closer at the top and further away at the bottom, This example indicates that the generator bearing is high. Since the side readings are equal, the genera- tor is centered side to side. To lower the generator, remove equal shims from under the four generator mounting feet. To approximate the amount of shims to remove or add: 1. Measure the distance between the center of the generator shaft to the point the indicator is measuring at. (For example; a SAE 18 Disc coupling distance is 10.7"). 2. Measure the distance from the generator side of the flex discs to the center of the generator mounting bolt, refer to Figure 3-4. (For exam- ple; a HC6 Frame's distance is 28.4”,) 3. Compare the distance measured in steps 1 and 2. (28.4" vs 10.7" of a 2.65 to 1 ratio.) Multiply this ratio times one half the [Link]. (In our exam: ple, .025" divided by 2 is .0125". This, times 2.65 equals .033". Therefore, remove .033" of shims from under the four mounting feet of the generator.) In general, the [Link]. should not be more than .001” for each inch of radius (center of shaft to indicator axis). If we use our example of 10.7", then the maxi- mum [Link]. would be .011", This would only require ‘a correction of 014" from the T.L.R. of .025". (A read- ing of +.002 at the top and -.009 at the bottom would fall within the satisfactory range.) MEASURED AT BOLT CIRCLE DIAMETER FIGURE 3-5. ANGULAR ALIGNMENT MEASUREMENT READINGS (Example) 3-7Axial Alignment Procedure Axial misalignment needs to be checked only when an objectionable vibration is present. If excessive vibration remains after the angular alignment, concentric alignment of the generator shaft/engine crankshaft axes may be at fault. The goal of the axial realignment is to reduce the vibration level of the genset while it is operating, A small improvement in the axial alignment may have dramatic effects in the measured or physically ob- served vibration levels. 38 To correct for possible axial misalignment, remove the capscrews connecting drive discs and flywheel. Mark the drive discs and flywheel with respect to each other. Rotate either the engine or generator so that drive discs holes are repositioned two bolt holes from their original location. Put the drive discs capscrews back in and retorque. Recheck/record vibration levels as before, Repeat this test until the drive disos holes are repositioned 180 degrees from their original location, Review vibration data and position drive disc in law- est recorded level location,4. Mechanical Connections GENERAL The generator set mechanical system installation includes connecting the fuel, exhaust, ventilation and cooling systems. Before starting any type of fuel installation, all pertinent state and local codes must be complied with and the installation must be inspected before the unit is put in service, FUEL SYSTEM ‘Cummins engines normally use ASTM No, 2 Diese! fuel. They will, however, operate on alternate diesel fuels within the specifications shown in the Cum- mins QSK60 Series Engine Operation and Mainte- nance Manual, In all fuel system installations, cleanliness is of the upmost importance. Make every effort to prevent entrance of moisture, dirt or contaminants of any kind into the fuel system. Clean all fuel system com- ponents before installing, A fuel fiter/strainer/Water separator of 100-120 mesh oF equivalent (approximately 150 microns nominal) ‘must be fitted between olther the main tank and day tank or between the main tank and the engine, Use only compatible metal fuel lines to avoid elec- trolysis when fuel ines must be buried. Buried fuel lines must be protected from corrosion. Never use galvanized or copper fuel lines, fittings or fuel tanks. Condensation in the tank and lines combines with the suitur in diesel fuel to produce sulfuric acid. The molecular structure of the copper or galvanized lines or tanks reacts with the acid and contaminates the fuel. An electric solenoid valve in the supply line is rec- ommended for all installations and required for in- door automatic or remote starting installations, ‘Connect the solenoid wires to the genset “Switched B+ circuit to open the valve during generator set operation. Separate fuel return lines to the day tank or supply tank must be provided for each generator set in a ‘multiple-set installation to prevent the return lines of idle sets from being pressurized. Fuel retum lines ‘must not contain a shutoff device. Engine damage at will occur ifthe engine is run with the return fuel lines blocked or restricted. (ACAUTION] Never install shutoft device in fuel return line(s). If fuel return lines) is blocked or exceeds fuel restriction limit, engine damage will occur, Fuel Return Restriction (or Pressure) Limit: Fuel return drain restriction (consisting of friction head and static head) between the engine injector return line connection and the fuel tank must not exceed the limit stated in the Generator Set Data Sheet. Fuel Lines - Routing A flexible fuel hose(s) or section of flexible fuel hose(s) must be used between the engine's fuel system and fuel supply and return line(s) to protect the fuel system from damage caused by vibration, expansion and contraction, Flexible lines for con- necting between the engine and the stationary fuel lines are supplied as standard equipment, Fuel leaks create fire and explosion hazards which can result in severe personal in- jury or death. Always use flexible tubing be- tween engine and fuel supply and return to avoid line failure and leaks due to vibration. The fuel system must meet all applicable codes. Installation of the fuel hose must be done according to all applicable codes and standards, and installa- tion recommendations provided by the manufactur- er. The supplied fiexible hose is approved by the hose manufacture for use with the genset fuel type and product application, ‘Support fuel lines to restrain movement and prevent chafing or contact with sharp edges, electrical wir- ing and hot exhaust parts. [AWABHING] Sparks and hot surfaces can ignite fuel, leading to severe personal injury or death. Do not route fuel lines near electrical wiring or hot exhaust parts. Fuel lines must be routed and secured to maintain a 1/2 inch (12.7 mm) minimum clearance from electri- cal wiring and a 2 inch (61 mm) minimum clearance from hot exhaust parts. |ENGINE vente rue Fi CaP PuMe / | SHUTOFF arm YT TINCH = tt. | [oir ont site FUEL TRANSFER: PUMP ELECTRIC. MOTOR DRIVEN INJECTOR FUEL. RETURN UNE CONNECT TO ‘AC OUTPUT ‘All models require a fuel retum line. from injectors to tenk. VENT LINE FILL PIPE 420 MESH FUEL, STRAINER, LARGER OVER- FUEL TANK FLOW LINE, FIGURE 4-1, TYPICAL FUEL SUPPLY INSTALLATION Engine Fuel Connections Identification tags are attached to the fuel supply line and fuel return line connections. Supply Tank Locate the fuel tank as close as possible to the gen- erator set and within the restriction limitations of the fuel pump. Install a fuel tank thet has sufficient capacity to sup- ply the genset operating continuously at full rated load for the planned period of operation or power ‘outage. Refer to Data Sheet for fuel consumption data. If the fuel inlet restriction exceeds the defined limit due to the distance/customer-supplied plumbing between the genset and the main fuel tank, a trans- fer tank (sometimes referred to as a day tank) and auxiliary pump will also be required. If an overhead 42 main fuel tank is installed, a transfer tank and float valve will be required to prevent fuel head pres- sures from being placed on the fuel system compo- nents, For critical start applications, where generator sets are paralleled or must satisfy emergency start-time requirements, It ls recommended that a fuel tank or regervolr be located such that the lowest possible fuel level is not less than 6 Inches (150 mm) above the fuel pump inlet. This will prevent air from acou- mulating In the fuel line while the set Is not running, eliminating the period during startup when It has to be purged. Fuel Inlet Pressure/Restriction Limit: Engine performance and fuel system durability will be com- promised if the fuel infet pressure or restriction limits are not adhered to, Fuel inlet pressure or restriction must not exceed the limits stated in the Generator ‘Set Data Sheet.Day Tank (If Used) Fuel day tanks are used when fuel inlet restriction limits can not be met, or the supply tank is overhead and presents problems of high fuel head pressure for the fuel inlet and return lines. ‘Supply Tank Lower Than Engine: With this instal- lation, the day tank is installed near the generator set, below the fuel injection system and within the fuel inlet restriction limit, Install a fuel transfer pump, to pump fuel from the supply tank to the day tank, A float switch in the day tank controls operation of the fuel transfer pump. ‘When using a fuel transfer pump, the supply tank top must be below the day tank top to prevent siphoning from the fuel supply to the day tank, Provide a réturn line from the engine injection sys- tem retum connection to the day tank. Plumb the re- tum line to the bottom of day tank as shown in Fig- ure 4-1. Provide a day tank overflow ine to the sup- ply tank in case the fioat switch fails to shut off the fuel transfer pump. Spilled fuel presents the hazard of fire or explosion which can result in severe per- sonal injury or death. Provide an overflow line to the supply tank from the day tank. Supply Tank Higher Than Engine: With this installation, the day tank is installed near the gener- ator set, below the fuel injection system and within the fuel inlet restriction limit. Include a automatic fuel shutoff valve in the fuel line between the fuel supply tank and the day tank to stop fuel flow when the generator set is off, Provide a return line from the engine injection sys- tem return connection to the day tank, Plumb the re- turn line to the bottom of day tank as shown in Fig- ure 4-1. Spilled fuel can create environmental hazards. Check local requirements for containment and prevention of draining to sewer and ground water. 43EXHAUST SYSTEM Pipe exhaust gases to the outside of any enclosure. Locate the exhaust outlets away from any air inlets to avoid gases re-entering the enclosure. Exhaust installations are subject to various detrimental con- ditions such as extreme heat, infrequent operation and light loads. Regularly inspect the exhaust sys- tem both visually and audibly to see that the entire system remains fume tight and safe for operation. Inhalation of exhaust gases can re- ‘sult in severe personal injury or death. Use ex- treme care during installation to provide a tight exhaust system. Terminate exhaust pipe away from enclosed or sheltered areas, windows, doors and vents. For indoor installation, the exhaust system must use sealed joint type fittings, (for example NPT fit- tings) to provide a tight exhaust system, Use of slip type fittings (secured with a muffier clamp) may al- low leakage of exhaust gases into the building. Inhalation of exhaust gases can re- sult in severe personal injury or death. Use ex- treme care during installation to provide a tight exhaust system. Use NPT or equivalent type fit- tings for all indoor installations. Use an approved thimble (Figure 4-2) where ex- haust pipes pass through wall or partitions, Insu- lated wall/roof thimbles are used where exhaust pipes pass through a combustible roof or wall. This includes structures, such as wood framing or insu- lated steel decking, etc. Uninsulated wall/roof thimbles are used where exhaust pipes pass through @ non-combustible wall or roof, such as concrete, Refer to NFPA 37, Section 6-3, “Station- ary Combustion Engines and Gas Turbines" for ao- 4-4 cepted design practices. Build according to the code requirements in effect at the installation site. Hot exhaust pipes can start a fire and cause severe injury or death if improperly routed through walls. Use an approved thimble where exhaust pipes pass through walls or partitions. Inhalation of exhaust gases can re- sult in severe personal injury or death. Do not use exhaust heat to warm a room, compartment or storage area. Rain caps are available for the discharge end of ver- tical exhaust pipes. The rain cap clamps onto the end of the pipe and opens due to exhaust discharge force from the generator set, When the generator set is stopped, the rain cap automatically closes, protecting the exhaust system from rain, snow, etc. Use a section of flexible exhaust pipe between the engine and remainder of exhaust system. Support exhaust system to prevent weight from being ap- plied to engine exhaust outlet elbow/turbocharger connection, (AGAUTION] Weight applied to the engine man- ifold can result in turbocharger damage. Sup- port the muffler and exhaust piping so no weight or stress Is applied to engine exhaust el- bow. The exhaust system design should meet local code requirements. Liability for Injury, death, damage, and warranty ex pense due to use of unapproved mufflers or modifl- cations to the exhaust system becomes the respon- sibility of the person installing the unapproved muf- fer of performing the modification. Contact a Cum- ming Power Generation dietributor for approved ex- hhaust system parts,Avoid sharp bends by using sweeping, long radius elbows and provide adequate support for muffler and tailpipe. Pitch a horizontal run of exhaust pipe DOWNWARD (away from engine) to allow any moisture condensation to drain away from the en- gine. If an exhaust pipe must be tured upward, install a condensation trap at the point where the rise begins (Figure 4-3). ‘Shield or insulate exhaust lines if there is danger of Personal contact. Allow at least 12 inches (305 mm) of clearance if the pipes pass close to a combustible wall or partition, Before installing insulation on ex- haust system components, check the exhaust sys- tem for leaks while operating the genset under full load and correct all leaks. [AWABNING] Exhaust pipes are very hot and they can cause severe personal injury or death from direct contact or from fire hazard. Shield or in- sulate exhaust pipes if there is danger of per- sonal contact or when routed through walls or near other combustible materials. 45 DRIP CAP HOLES IN END OF INNER ROOF Y HoRZONTAL IC a WALL OF PARTITION FIGURE 4-2. MOUNTING EXHAUST THIMBLE. IF EXHAUST LINE MUST BE PITCHED UPWARD, CONSTRUCT ATRAP AT POINT OF RISE DRAIN CONDENSATION TRAP PERIODICALLY FIGURE 4-3. CONDENSATION TRAPVENTILATION AND COOLING Generator sets create considerable heat that must be removed by proper ventilation. Outdoor installa tions normally rely on natural air circulation but in- door installations need properly sized and posi- tioned vents for required airflow. Vents and Ducts For indoor installations, locate vents so incoming alr passes through the immediate area of the installa- tion before exhausting. Install the air outlet higher than the air inlet to allow for convection air move- ment. Size the vents and ducts so they are large enough to allow the required flow rate of air. The “free area’ of ducts must be as large as the exposed area of the radiator. Refer to the genset Data Sheet for the air- flow requirements and allowed airflow restriction. Wind will restrict free airflow if it blows directly into the air outlet vent, Locate the outlet vent so the ef- fects of wind are eliminated, or if outlet vent cannot be located as mentioned, install wind barier, See Figure 4-4, Dampers Dampers or louvres protect the generator set and equipment room from the outside environment. Their operation of opening and closing should be controlled by operation of the generator set. In cold climates, the radiator exhaust air can be re- circulated to modulate the ambient air temperature in the generator set room. This will help the genera- tor set warm up faster, and help to keep fuel temper- atures higher than the cloud point ofthe fuel. If recir- culation dampers are used, they should be de- ined to “fail closed”, with the main exhaust damp- ers open, so that the generator set can continue to, operate when required. Designers should be aware that the generator set room operating temperature will be very close to the outdoor temperature, and either not route water piping through the generator set room, or protect it from freezing. 46 PREVAILING WINDS PREVAILING WINDS FIGURE 4-4. WIND BARRIERSet Mounted Radiator Cooling Set mounted radiator cooling uses a set mounted radiator and engine pusher fan to cool engine wa- fer. Air-travels from the generator end of the set, across the engine and out through the radiator. An integral discharge duct adapter flange surrounds the radiator grille. (AGAUTION) The set mounted radiator cooling system can be shipped installed or as a sepa- rate item. If shipped INSTALLED, the alignment of the cooling system fan drive must be checked before genset operation. Failure to check fan drive alignment can result in severe fan/radiator damage. Refer to Section 9 for alignment procedure. Radiator Set Requirements: Radiator set cooling air is drawn past the control end of the set by a push- ‘er fan that blows air through the radiator (Figure 4-5). Locate the air inlet to the rear of the set. Make the inlet vent opening 1-1/2 to 2 times larger than the radiator area. Louvers and screens over air inlet and outlet open- ings restrict airflow and vary widely in performance. Alouver assembly with narrow vanes, for example, tends to be more restrictive than one with wide vanes. The effective open area specified by the lou- ver or screen manufacturer should be used. Locate the cooling air outlet directly in front of the ra- diator and as close as possible. The outlet openit must be at least as large as the radiator area. Length and shape of the air outlet duct should offer minimum restriction to airflow. Attach a canvas or sheet metal duct to the flange and the air outlet opening using screws and nuts 80 duct can be removed for maintenance purposes. The duct prevents circulation of heated air. Before installing the duct, remove the radiator core guard. ‘THERMOSTATICALLY ‘CONTROLLED Euan Ove ee RECIRCULATING DAMPER WINDY J) NOISE BARRIER g X ~ Xx X NS S i \ ‘ DIsTANGE sHoULD REXBE — oumieTAR —_NOTBELESS THAN cot chon DAMPER HEGHTOF RADIATOR FIGURE 4-5. TYPICAL RADIATOR SET INSTALLATION a7Remote Radiator Cooling (Optional) Remote radiator cooling substitutes a remote mounted radiator and an electrically driven fan in place of the set mounted components. Removal of the radiator and the fan from the set reduces noise levels without forcing dependence on a continuous cooling water supply (necessary with heat ex- changer cooling). The remote radiator installation must be completely protected against freezing, 48 Remote radiator plumbing will vary with installation. Follow recommendations given in Application Manual T-030. See product Data Sheet for friction head and static head limits. Before filling cooling system, check all hardware for ‘security, This includes hose clamps, capscrews, fit- tings and connections. Use flexible coolant lines with heat exchanger or remote mounted radiator.COOLANT The cooling system of radiator type gensets can be shipped installed or as a separate item. If shipped with the cooling system installed, both radiators are filled with the proper fluids at the factory. Make sure that the coolant levels of both radiators are correct before starting. The procedure for checking and filling the cooling system of a set mounted radiator is provided in Seo- tion 9 of this manual. Coolant Filters Two spin-on type corrosion filters (Figure 4-7) are standard equipment. To prevent coolant loss during filter replacement, a coolant shut off valve is pro- vided (Figure 4-7). Make sure shutoff valve is in the ON position before operating the generator set. 49 COOLANT FILTER, SHUTOFF VALVE, NOTE: OPEN COOLANT FILTER SHUTOFF VALVE BEFORE OPERATING GENERATOR SET. FIGURE 4-7, TYPICAL COOLANT FILTER iTHIS PAGE LEFT INTENTIONALLY BLANK 4-105. DC Control Wiring CONTROL WIRING generator set. All conduit used for control wiring is attached to the lower left corner of the control box The generator set contro| box assembly, which can assembly as shown in Figure 5-1, be located on either side of the genset, contains -- connection points for remote control and monitor [AGAUTION] Stranded copper wire must be used options. for all customer connections to the control box assembly. Solid copper wire may break due to Use flexible conduit forall wiring connections tothe genset vibration. CONTROL BOX CONTROL 80x ‘ASSEMBLY | LEFT SIDE PANEL ci = eG fo t 4 KNooKOUTS FOR CUSTOMER WIRING FIGURE 5-1. CONTROL BOX - SIDE MOUNTREMOTE MONITOR/CONTROL CONNECTIONS Customer monitor/control connections are at- tached to terminal blocks TB3 and TBS (see Figure 5-2). Optional equipment such as a remote annun- ciator panel, sensing devices used to monitor gen- set operation, remote start/stop switches, control box heater, and etc, are also attached to these ter- minal blocks. Driver signals for customer supplied relays are also provided for several alarm and shut down conditions. Refer to Customer Connections diagram in Section 10. When removing terminal block con- nector TB8 from Base card, note orientation of connector. This terminal block connector is not keyed and can be installed incorrectly, which will cause control failures. Terminal Block Wiring ‘Always run control circuit wiring in a separate metal conduit from AC power cables to avoid inducing currents that could cause problems within the control. Digital Connections: Connection points, other then relayed outputs, network, switched B+ and B+ are considered digital connections to the terminal blocks. The type/gauge wire to use for these con- nections are: * Less than 1000 feet (305m), use 20 gauge stranded copper wire. ‘+ 1000 to 2000 feet (305 to 610m), use 18 gauge stranded copper wire. Relay Connections: Due to the wide variety of de- vices that can be attached to the relay outputs of ter- minal blocks, the electrical contractor must deter- mine the gauge of the stranded copper wire that is. used at this installation site. Refer to Customer Connections diagram in Section 10 for the relay specifications, ‘Switched B+: (Fused at 10 amps.) Same as Relay Connestion description. Delayed Switched B+: (Fused at 10 amps. with a 10 second dropout) Use for external fuel shut-off solenoid. Same as Relay Connection description, Bs: (Fused at 10 amps.) Same as Relay Connec- tion description. Network Connections: Refer to Cummins 900-0366 PowerCommand Network Installation and Operation manual for the type/gauge wire to use for these connections, 5-2OPTIONAL RUN RELAYS Kit, IZ 8 KIS Tete cova. Tor ener ‘MEET O8 CGrtional Kit #12] K13 UN AND ALAT BELTS (OPIOHAL TEoe 66 TOO TIONIZ {928 21282030 31 9293.34 26 96 149 50 St 52 53545556 57 505960, CONTROL WIRING OPTIONAL, ACCESS: SHUTDOWN ALARM RELAY K16 outa ‘ean ‘GROUND FAULT 16] eur OPTIONAL (OPTIONAL ate 18 161718102021 22.2894 37 88 3040 a1 42 44 a5 464748 CBSSST GS | Lonworts pce 11 263 62 65 6567 en Ga WHT oT} | censervparatter pce CTs) sf Biase ce ‘CARD CAGE FIGURE 5-2. CONTROL BOX ASSEMBLY INTERIOR 5-3RUN RELAYS (K11, K12, K13) The optional run relays are rail mounted inside the control box (Figure 5-2). The rail mount allows you to easily remove and replace the snap-on relays. The generator set can be equipped with one, two or three run relays. The three-pole, double-throw run relays (Figure 5-3) are used to control auxiliary equipment such as fans, pumps and motorized air dampers. The run relays are energized when the generator set control receives a start signal. The contacts are rated: © 10 amps at 28 VDC or 120 VAC, 80%PF ‘¢ G amps at 240 VAC, 80%PF ‘© 3 amps at 480/600 VAC, 80%PF £—, ka, 12, Kia. 7 Le 4 _— [Link] E—— = = customer (CONNECTIONS posi xanga, 2 —— pg ee Kz RUN RELAY @ Sel] no | BG] ne Ta85 1837 (SMITCHED Bs) ; com (GND) AA FIGURE 5-3. OPTIONAL RUN RELAYS (K1, K12, Ki3) 5-4ALARM RELAY (K16) as audible alarms. Any generator set shutdown will energize the alarm relay. The optional alarm relay is rail mounted inside the control box (Figure 5-2). The rail mount allows you ‘The contacts are rated: to easily remove and replace the snap-on relay. + 10 amps at 28 VDC or 120 VAC, 80%PF The three-pole, double-throw alarm relay (Figure eee aera eat 5-4) is offen used to energize warning devices such ‘+ 3 amps at 480/600 VAC, 80%PF CUSTOMER ——— 7 - 2) wie F—— 8 > oSieerons THs | kis SHUTDOWN ALARM [S|] [S| no 2 No Sl ale isl el |S fet IF) Te0-17 Hel| |fi| 20 es8 (COM ALARI Gi « mM) Ileal} om oN) FIGURE 5-4. OPTIONAL ALARM RELAY (K16) 55POWER TRANSFER CONTROL (OPTIONAL) The optional Power Transfer Control (PTC) feature requires connecting the control relays of the PTC circuit to the generator set and utility circuit break- ers, These relays are used to control the opening and closing of these circuit breakers via the PCC, for transfer and retransfer of the load to the genera- tor set or the utility. A typical PTC installation is shown in Figure 6-5. Relay Connections: Due to a wide verity of circuit breakers that can be attached to the relay outputs of PCC terminal block TB3, the system designer must determine if the electrical requirements of the instal- lation does not exceed the limits of the PTC contro! relays. Relays that can handle larger switching cur- rent/voltage will need to be connected to the PTC. control relays if the electrical limits of the PTC relays are exceeded, The four PTC control relays are each rated at 16 amps at 250 VAG or 24 VDC. GENERATOR SET asia armen ) PTC CONTROL RELAYS (4) Pc 8201 I+ REMOTE (TEST) START Lt} ‘TRANSFER INHIBIT. H RETRANSFER INHIBIT H MANUAL MODE BUS PT MODULE GENSET caRCUIT BREAKER TO SERVICE umuiTy ‘oIRcUIT BREAKER ‘OPEN COMMAND. LOAD FIGURE 5-5. TYPICAL POWER ‘TRANSFER CONTROL INSTALLATION 566. AC Electrical Connections GENERAL This section provides the procedure that is used to ‘connect the AC electrical system of the genset, Before making any AC electrical connections, make _ certain the generator set cannot be accidentally started, Move the O/Manual/Auto switch on the control panel to the O (off) position, Tur off or re- move AC power from the battery charger and then remove the negative (-) battery cable from the set starting battery. Ignition of explosive battery gases can cause severe personal injury or death. Arc- ing at battery terminals, light switch or other equipment, flame, pilot lights and sparks can ig- nite battery gas. Do not smoke, or switch trouble light ON or OFF near battery. Discharge static electricity from body before touching bat- teries by first touching a grounded metal sur- face. Ventilate battery area before working on or near battery—Wear goggles—Stop genset and dis- connect charger before disconnecting battery cables—Disconnect negative (-) cable first and reconnect last. Disconnect battery charger from AG source before disconnecting battery cables. Otherwise, disconnecting cables can result in voltage spikes damaging to DC control circuits of the set. [AWABNING] Accidental starting of the generator ‘set can cause severe personal injury or death. Prevent accidental starting by disconnecting the negative (-) cable from the battery terminal. 64 Each of the operations described in this section should be done only by persons trained and experienced in electrical mainte- nance. Improper procedures may result in prop- erty damage, bodily injury or death. Connecting the genset AG electrical system in- volves: «Generator insulation check Installation of transfer switch Generator output voltage selection Load cable connection Standard and optional AC equipment connec- ions (e.g., control box heater, coolant heater, ete. Local regulations often require that wiring connec- tions be made by a licensed electrician, and that the installation be inspected and approved before op- eration. All connections, wire sizes, materials used, etc. must conform to the requirements of electrical codes in effect at the installation site, Improper wiring can cause a fire or electrical hazard, resulting in severe personal Injury or death and/or property and equipment damage. Before starting the genset, check to make sure that all electrical connections are secure, and that all ig is complete, Replace and secure any access panels that have been removed during installation. ‘Check that the load cables from the genset are properly connected. (AWARNING] Backfeed to utility system can cause electrocution or property damage. Do not connect to any building electrical system ‘except through an approved device and after building main switch is opened. |INSULATION RESISTANCE (MEGGER) & POLARIZATION INDEX (P!) TESTING Megger and PI testing must be performed on all medium voltage (601 through 15,000 volts) genera- tor sets before initial start-up. PI testing for low volt- age (less than 600 volts) generator sels is recom- mended by Cummins Power Generation. These tests are used to verify that the windings are dry before the generator set is operated and devel- ‘ops a base line for future test comparison, Before these tests can be performed on medium voltage generator sets, you must first perform the generator grounding procedure, Generator Set Grounding Procedure Prior to performing service or inspection proce- dures that may expose personnel to conductors normally energized with voltages greater than 600 volts, the following generator set grounding proce- dure must be followed. FMGENIE Do not perform these procedures unless fully trained in medium voltage ground- ing procedures and have necessary safety equipment. Severe injury or death due to high voltage electrical shock may result. 1. Open, lock-out and tag-out all sources of power to the immediate work area. 2, Disable the starting system of the generator a. Move the 0/Manual/Auto switch to the 0 (Of) position and wait for the controller to power down (approximately 10 minutes). bb, Disconnect the battery charger from its AC source, ©, Remove the negative battery cable from the battery, 4. Install a lockout device on the battery cable end. (For engines equipped with an air-powered starting system, close air valve and install valve locking device.) 3. Put on high voltage gloves with leather protec- tors. 4, Using two pre-tested voltage detection devices (of the proper rating), verify de-energized con- dition in the work area. (Retest voltage detec- tion devices immediately after verification of de-energized condition.) 5, Remove the metal cover from the generator ‘output box to gain access to generator load ter- minals. 6, Securely install the Grounding Cluster ground clamp to a verified “grounded” conductor, Hazardous voltage. Can cause severe personal injury or death. After DC voltage from the test equipment has been applied to the windings and ground, there will be a definite static charge on the wind- ings. Reconnect Grounding Cluster to re- move static charge from the winding after each generator test. 7. With the Grounding Cluster in place, you are protected from static and/or induced charges that may have been present in the generator stator. Leave grounds connected for at least one min- Ute so static charge can dissipate, Remove ground cluster and perform Pl and/or any other tests required on the stator winding. Reconnect grounds if additional generator service is nec- essary. 8, When work on the generator set is complete, remove the Grounding Cluster in the reverse order of installation, 9. After getting clearance from all personnel in- volved in the lock-out/tag-out procedure, re- move all lock-out devices in reverse order of installation,Megger and PI Test Medium-voltage, 601 to 15,000 volts, present special hazards of severe person- al injury or death. Even after genset shutdown, an electrical shock hazard may still exist, caused by induced voltage within the generator ‘or cables. Service personne! must be well- trained/qualified to work with distribution volt- * ages. (See Generator Set Grounding Proce- dures, Page 4-2.) The windings of medium-voltage (601 through 15,000 volts) generator sets must be dry before the generator is operated. Failure to make sure windings are dry before start-up may result in catastrophic equipment failure, ‘severe personal injury or death. Megger Test: The megger test consists of applying voltage for up to one minute. The highest resistance values shown in Table 6-1 should be obtained for a new generator with dry windings. For a set that has been in service, the resistance reading should not be less than the lower value shown. PI Test: The Pl test consists of applying a voltage between the winding and ground for ten minutes and recording resistance values at one minute and at ten minutes. The PI is the ratio of a ten minute reading in megohms divided by a one minute read- ing in megohms. A ratio of two or greater is consi ered good for new and in service sets. If low readings are obtained, the cause should be in- vestigated and corrected before the generator set is returned to service. If moisture is determined to be the cause of low test readings, a winding drying pro- cess will be required (refer to genset Service manu- al for drying procedure). 6-3 1. Perform the Generator Set Grounding Proce- dure in this section. 2. Open the control box door and remove connec: tor 10 from the AVR module. 3. Disconnect the AC voltage sense leads from the generator output terminals. The AC voltage sense leads are marked 5, 6, 7 and 8, 4. If the RTD (resistance temperature detector) ‘option is installed, ground all six RTD tempera- ture leads, Each RTD has three leads, one red and two white leads, Total of 18 leads must be grounded. Main Stator: 5. Remove and separate the neutral leads of the generator from the generator load terminal marked "N’, 6, Connect the megger between one phase of the stator and ground while grounding the other two phases and conduct the test, Refer to Table 6-1 for megger voltage selection and required resistance values. Repeat this step in turn for the other two phases. Main Rotor: 7. Disconnect the main rotor and voltage sup- pressor leads from terminals F1+ and F2- on the rotating rectifier assemblies and isloate them from ground, Tag and mark each lead with its terminal number (F1+ or F2-). 8, Connect the megger between one of the rotor leads and ground and conduct the test. Refer to Table 6-1 for megger voltage selection and re- ‘quired resistance values.TABLE 6-1. GENERATOR INSULATION RESISTANCE MINIMUM REST FRaME| Generator | MEGGER | sl it —_= size | voutace | .v9Nq| MAN, MAIN ROTOR PMG STATOR pr | s0ovAGor | 500 io-1 10-1 1-7 0-7 less 600 VAG or | 1000 tons or P80 ee 500 200-100 5-3 10-5 {Combined rators) 2500 100-50 7 ‘601 thru 5000 Pao VAC 500 200 - 100 3-8 10-5 (Combined rators) r soot tu |_5000 | S00 750 Peo | isooovac | 500 200 - 100 3-3 70-8 (Combined rators) TRANSFER SWITCH If the installation is for standby service, a transfer LoaD ‘switch must be used for switching the load from the normal power source to the genset (see Figure 6-1). ae Either a manual or automatic transfer switch may be SOURCE GENSET used. Follow the installation instructions provided —_— with the transfer switch when connecting the load and control wiring. FIGURE 6-1. TYPICAL LOAD TRANSFER FUNCTIONAC WIRING Generator Voltage Connections The generator output voltage and maximum current rating are specified on the generator set nameplate. Line-to-neutral voltage is always the lower voltage shown and line-to-tine voltage is the higher rating. The generator is connected at the factory to pro- duce a specified voltage per customer order (they ~ cannot be reconfigured for different voltages in the field). Before shipping, the factory tests the genera- tor set at the specified voltage. Load Connections Flexible conduit and stranded conductors must be used for connections to take up movement of the generator set. All loads are connected to the generator by bolting the stranded load wires to the appropriate termi- nals on the generator reconnection terminal block, The terminals are stamped U, V, W and N to indicate the line and neutral connections. (Reference: U, V, and W correspond with L1, L2 and L3; and N with LO respectively) Load Balancing When connecting loads to the generator set, bal- ‘ance the loads so the current flow from each line ter- minal (L1, L2 and L3) is about the same, This is es- pecially important if both single phase and three phase loads are connected. Any combination of single phase and three phase loading can be used as long as each line current is about the same, with- in 10 percent of median value and no line current ex- ceeds the nameplate rating of the generator. Check the current flow from each line after connections by ‘observing the control panel ammeter. 6-5Grounding The following is a brief description of system and equipment grounding of permanently installed AC generators within a facility wiring system. Itis impor. tant to follow the requirements of the local electrical code. Figure 6-2 illustrates typical system grounding for a S-pole and a 4-pole automatic transfer switch (ATS). In the 3-pole ATS, note that the generator neutral is connected to the ATS and is NOT bonded to ground at the generator. In the 4-pole ATS sys- tem, a grounding electrode conductor and a bond- ing jumper are used to connect the generator neu- tral to ground, Make sure the genset is grounded to earth in one location only, On generators without a circuit break- €, ground to the point indicated on the top of the generator. On gensets with circuit breakers, use the Ground lug provided in the circuit breaker box. Electric current can cause severe personal injury or death. Bonding and ground- ing must be done properly. All metallic parts that could become energized under abnormal conditions must be properly grounded. Typical requirements for bonding and grounding are given in the National Electrical Code, Article 250. All connections, wire sizes, etc. must conform to the requirements of the electrical codes in effect at the installation site. GENERATOR SET SERVICE ENTRANCE THREE-PHASE, FOUR-WIRE UTILITY, THREE-POLE ATS. LoaD GENERATOR SET Loap THREE-PHASE, FOUR-WIRE UTILITY, FOUR-POLE ATS FIGURE 6-2. TYPICAL SYSTEM GROUNDING ONE-LINE DIAGRAMS 66CONTROL HEATER (OPTIONAL) control de-energizes the heater when the control box interior reaches 75° F (24° C). A control heater (Figure 6-3) provides a means of humidity /temperature control of the control box in- Connect the heater to a source of power that will be terior, It protects the components when the genera- _on during the time the engine is not running. Be sure tor set is subjected to varying ambient air conditions the supply voltage and circuit amperage is correct during extended periods of non-use. Thermostat __for the heater rating Le = To120\VAc == supply INPUT POWER B10 (240/120 VAC) 75: F (24° 0) THERMOSTAT 150W STRIP HEATER FIGURE 6-3, OPTIONAL CONTROL HEATER 6-7COOLANT HEATER Coolant heaters keep the engine coolant warm when the engine is shut down. It heats and citcu- lates the coolant within the engine. This reduces startup time and lessens engine wear caused by cold starts. It is electrically operated and thermo- statically controlled. The coolant heater must not be op- erated while the cooling system is empty, when the ball valves are closed or when the engine is running or damage to the heater will occur. Figure 6-4 shows a typical coolant heater, Connect, the time the engine is not running. Be sure the sup- ply voltage and circuit amperage is correct for the heater element rating Make sure that both ball valves are opened before connecting power to the heaters. With ball valves closed, heated coolant will not citculate through the ‘engine. Extended operation with ball valves closed can damage coolant heaters. A battery charger Is required to prevent battery dic- charge, The heater control relay draws 83 mA of cur- rent when the heater(s) Is off. The heater is off when the engine has reached the proper temperature or the heater to a source of power that will be on during the engine is running. THERMOSTAT — BALL VALVE AC POWER UNE ‘COOLANT HEATER 1 PRESSURE RELIEF VALVE HEATER CONTROL/AG ELECTRICAL ‘CONNECTION BOX (ELECTRICAL DIAGRAM INSIDE COVER) FIGURE 6-4. TYPICAL COOLANT HEATER, 6-8 | | | | |GENERATOR HEATER ‘A generator heater(s) is used to help keep the gen- erator free of condensation when the generator set is not running. During coo! and humid conditions, condensation can form within a generator, creating flashing and a shock hazard. Water or moisture inside a genera- tor increases the possibility of flashing and - electrical shock, which can cause equipment damage and severe personal injury or death. Do not use a generator which is not dry inside and - out. Figure 6-5 illustrates the installation of two heater elements. Connect the heater(s) terminals to a source of power that will be on during the time the ‘engine is not running. Be sure the supply voltage and circuit amperage is correct for the heater ele- ment rating TERMINAL. BLOCK _ HEATER | HEATERS VOLT WATTS LABEL FIGURE 6-5. TYPICAL GENERATOR HEATER INSTALLATIONTHIS PAGE LEFT INTENTIONALLY BLANK 6-107. Prestart Preparation GENERAL Before attempting the initial start of the generator _ Set, be sure to complete the Installation Checklist in Section 8. INPOWER SERVICE TOOL GENERAL INFORMATION InPower is a PC based service tool for the Power Command® 3201 Gontrol (PGC). Use InPower to: + Make adjustments to the controls trims and set- tings. * Perform diagnostics and monitoring. « Review event history. © Create a capture file of the controls trims and settings, * Update control calibrations (InPower PRO ver- sion). Refer to INPOWER User's Guide for specifics, TA InPower Adjust Mode The adjustment feature allows you to make adjust- ments to genset parameters, calibrations and set- tings. There are several groups of adjustment pa- rameters; note that not all gensets will have the same adjustments available. InPower Capture File Description InPower provides a method of extracting (captur- ing) a device's parameter values. Capturing saves device informatior € file that is identified with a .CAP extension. Capture files are used to store a copy of the gen- set's parameter values. During genset installation, It is suggested that a capture file be made before and after changes are made to the genset operating parameters. This information can be a very useful When troubleshooting the genset (determine if pa- rameters/settings have been modified after installa- tion) and when replacement of the Base board is necessary. The capture file can be used as a tem- plate to write the previous settings to the new Base board software,