Power

Generation

Installation Manual
PowerCommand® Control
3100 Series
Generator Sets

Models
DQAD. DQAE. DQAF

Printed in U.S.A. 960-0624 5-2001

Table of Contents
SECTION TITLE PAGE
IMPORTANT SAFETY INSTRUCTIONS iii
INTRODUCTION
About this Manual 1-1
Installation Overview 1-2
2 SPECIFICATIONS 2-1
3 MOUNTING THE GENERATOR SET
General 3-1
Location 3-1
Mounting 3-2
Access to Set 3-2
Vibration Isolators 3-4
MECHANICAL CONNECTIONS
General 4-1
Fuel System 4-1
Exhaust System 4-4
Ventilation and Cooling 4-6
DC CONTROL WIRING
Control Wiring .* 5-1
TB1 Remote Monitor/Control Connections 5-1
Run Relays (K11,K12, Kl 3) 5-3
Alarm Relay (K14) 5-4

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.
6 AC ELECTRICAL CONNECTIONS
General 6-1
Transfer Switch 6-2
AC Wiring 6-3
Control Heater (Optional) 6-5
Coolant Heater 6-6
Generator Heater 6-7
Fuel Transfer Pump 6-8
Ground Fault Alarm Relay (Optional) 6-9
7 PRESTART PREPARATION
General 7-1
PCC Power On/Standby Mode 7-1
Electrical System 7-2
PCC Options Prestart Checks 7-3
Starting 7-5
8 INSTALLATION CHECKLIST
General ..8-1
Generator Set Support 8-1
Cooling Air Flow 8-1
Diesel Fuel System 8-1
Exhaust System 8-2
AC and DC Wiring 8-2
Genset Prestart 8-2
9 WIRING DIAGRAMS
General .• 9-1
 IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS - This manual contains EXHAUST GASES ARE DEADLY
important instructions that should be followed during
installation and maintenance of the generator and batter- • Provide an adequate exhaust system to properly
ies. expel discharged gases away from enclosed or
sheltered areas and areas where individuals are
Before operating the generator set (genset), read the likely to congregate. Visually and audibly inspect
Operator's Manual and become familiar with it and the the exhaust daily for leaks per the maintenance
equipment. Safe and efficient operation can be schedule. Make sure that exhaust manifolds are se-
achieved only if the equipment is properly operated cured and not warped. Do not use exhaust gases to
and maintained. Many accidents are caused by failure heat a compartment.
to follow fundamental rules and precautions.
• Be sure the unit is well ventilated.
The following symbols, found throughout this manual,
alert you to potentially dangerous conditions to the op- • Engine exhaust and some of its constituents are
erator, service personnel, or the equipment. known to the state of California to cause cancer,
birth defects, and other reproductive harm.
ri^ij'isMazd This symbol warns of immediate
hazards which will result in severe personal in- MOVING PARTS CAN CAUSE SEVERE
jury or death. PERSONAL INJURY OR DEATH
• Keep your hands, clothing, and jewelry away from
IAWARNINGI This symbol refers to a hazard or un-
moving parts.
safe practice which can result in severe per-
sonal injury or death. • Before starting work on the generator set, discon-
nect battery charger from its AC source, then dis-
IACAUTIONI This symbol refers to a hazard or un- connect starting batteries, negative (-) cable first.
safe practice which can result in personal injury This will prevent accidental starting.
or product or property damage. • Make sure that fasteners on the generator set are
secure. Tighten supports and clamps, keep guards
FUEL AND FUMES ARE FLAMMABLE in position over fans, drive belts, etc.
Fire, explosion, and personal injury or death can result • Do not wear loose clothing or jewelry in the vidnity of
from improper practices. moving parts, or while working on electrical equip-
ment. Loose clothing and jewelry can become
• DO NOT fill fuel tanks while engine is running, un-
caught in moving parts.
less tanks are outside the engine compartment.
Fuel contact with hot engine or exhaust is a potential • If adjustment must be made while the unit is run-
fire hazard. ning, use extreme caution around hot manifolds,
• DO NOT permit any flame, cigarette, pilot light, moving parts, etc.
spark, arcing equipment, or other ignition source DO NOT OPERATE IN FLAMMABLE AND
near the generator set or fuel tank.
EXPLOSIVE ENVIRONMENTS
• Fuel lines must be adequately secured and free of
leaks. Fuel connection at the engine should be Flammable vapor can cause an engine to overspeed and
made with an approved flexible line. Do not use zinc become difficult to stop, resulting in possible fire, explo-
coated or copper fuel lines with diesel fuel. sion, severe personal injury and death. Do not operate a
genset where a flammable vapor environment can be
• Be sure all fuel supplies have a positive shutoff created by fuel spill, leak, etc., unless the genset is
valve. equipped with an automatic safety device to block the air
• Be sure battery area has been well-ventilated prior intake and stop the engine. The owners and operators of
to sen/icing near it. Lead-acid batteries emit a highly the genset are solely responsible for operating the gen-
explosive hydrogen gas that can be ignited by arc- set safely. Contact your authorized Onan/Cummins deal-
ing, sparking, smoking, etc. er or distributor for more information.

LS-13L
in
ELECTRICAL SHOCK CAN CAUSE Keep multi-class ABC fire extinguishers handy.
SEVERE PERSONAL INJURY OR DEATH Class A fires involve ordinary combustible materials
such as wood and cloth; Class B fires, combustibli
• Remove electric power before removing protective and flammable liquid fuels and gaseous fuels; Clas
shields or touching electrical equipment. Use rub- C fires, live electrical equipment, (ref. NFPA No. 10).
ber insulative mats placed on dry wood platforms
over floors that are metal or concrete when around Make sure that rags are not left on or near the en-
electrical equipment. Do not wear damp clothing gine.
(particularly wet shoes) or allow skin surface to be
damp when handling electrical equipment. Do not Make sure generator set is mounted in a manner to
wear jewelry. Jewelry can short out electrical con- prevent combustible materials from accumulating
tacts and cause shock or burning. under the unit.
• Use extreme caution when working on electrical Remove all unnecessary grease and oil from the
components. High voltages can cause injury or * unit. Accumulated grease and oil can cause over-
death. DO NOT tamper with interlocks. heating and engine damage which present a poten-
• Follow all applicable state and local electrical tial fire hazard.
codes. Have all electrical installations performed by Keep the generator set and the surrounding area
a qualified licensed electrician. Tag and lock open clean and free from obstructions. Remove any de-
switches to avoid accidental closure. bris from the set and keep the floor clean and dry.
• DO NOT CONNECT GENERATOR SET DI-
RECTLY TO ANY BUILDING ELECTRICAL SYS- Do not work on this equipment when mentally or
TEM. Hazardous voltages can flow from the gen- physically fatigued, or after consuming any alcohol
erator set into the utility line. This creates a potential or drug that makes the operation of equipment un-
for electrocution or property damage. Connect only safe.
through an approved isolation switch or an ap- Substances in exhaust gases have been identified
proved paralleling device. by some state or federal agencies as causing can-
GENERAL SAFETY PRECAUTIONS cer or reproductive toxicity. Take care not to breath
or ingest or come into contact with exhaust gases
• Coolants under pressure have a higher boiling point
than water. DO NOT open a radiator or heat ex- Do not store any flammable liquids, such as fuel,
changer pressure cap while the engine is running. cleaners, oil, etc., near the generator set. A fire or
Allow the generator set to cool and bleed the system explosion could result.
pressure first.
Wear hearing protection when going near an oper-
• Used engine oils have been identified by some state ating generator set.
or federal agencies as causing cancer or reproduc-
tive toxicity. When checking or changing engine oil, To prevent serious burns, avoid contact with hot
take care not to ingest, breathe the fumes, or con- metal parts such as radiator, turbo charger and ex-
tact used oil. haust system.

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

IV
 1. Introduction
ABOUT THIS MANUAL Prestart - Checklist of items or procedures
needed to prepare generator set for operation.
This manual covers models produced under the Initial Startup - Test complete system to en-
Cummins®/Onan® and Cummins Power Genera- sure proper installation, satisfactory perform-
tion brand names. ance, and safe operation. Refer to Operators
Manual for troubleshooting information.
This manual provides installation instructions for This manual DOES NOT provide application infor-
the generator set models listed on the front cover. mation for selecting a generator set or designing the
This includes the following information: complete installation. If it is necessary to design the
various integrated systems (fuel, exhaust, cooling,
Mounting Recommendations - for fastening etc.), additional information is required. Review
generator set to base and space requirements standard installation practices. For engineering
for normal operation and service. data specific to the generator set, refer to the gener-
Mechanical Connections and Electrical ator set Specifications and Data sheets. For appli-
connections - covers most aspects of the gen- cation information, refer to Application Manual
erator set installation. T-030, "Liquid Cooled Generator Sets".

1-1
 INSTALLATION OVERVIEW system and for selecting the materials and products
required.
These installation recommendations apply to typi-
cal installations with standard model generator Installation refers to the actual set-up and assem-
sets. Whenever possible, these recommendations bly of the standby power system. The installers set
also cover factory designed options or modifica- up and connect the various components of the sys-
tions. However, because of the many variables in tem as specified in the system design plan. The
any installation, it is not possible to provide specific complexity of the standby system normally requires
recommendations for every situation. If there are the special skills of qualified electricians, plumbers,
any questions not answered by this manual, contact sheetmetal workers, etc. to complete the various
your nearest Cummins Power Generation distribu- segments of the installation. This is necessary so
tor for assistance. all components are assembled using standard
methods and practices.
Application and Installation
Safety Considerations
A standby power system must be carefully planned
and correctly installed for proper operation. This in- The generator set has been carefully designed to
volves two essential elements: application and in- provide safe and efficient service when properly in-
stallation. stalled, maintained, and operated. However, the
overall safety and reliability of the complete system
Application (as it applies to generator set installa- is dependent on many factors outside the control of
tions) refers to the design of the complete standby the generator set manufacturer. To avoid possible
power system that usually includes power distribu- safety hazards, make all mechanical and electrical
tion equipment, transfer switches, ventilation equip- connections to the generator set exactly as speci-
ment, mounting pads, and cooling, exhaust, and fied in this manual. All systems external to the gen-
fuel systems. Each component must be correctly erator (fuel, exhaust, electrical, etc.) must comply
designed so the complete system will function as in- with all applicable codes. Make certain all required
tended. Application and design is an engineering inspections and tests have been completed and all
function generally done by specifying engineers or code requirements have been satisfied before certi-
other trained specialists. Specifying engineers are fying the installation is complete and ready for serv-
responsible for the design of the complete standby ice.

Copyright® 2001 Cummins Power Generation. All rights reserved.

Cummins, Onan and PowerCommand are registered trademarks of Cummins Inc.

1-2
2. Specifications
MODEL DQAD/DQAE/DQAF
Cummins Diesel Series QSM11
Generator kW Rating See Genset Nameplate for rating information.
Cooling System
Capacity with Standard Radiator 10.5 Gal (40 L)
Oil Capacity* 9.7 Gal (36.7 L)
Engine Fuel Connection
Inlet/Outlet Thread Size Refer to Generator Outline Drawing
Fuel Flow
Max. Fuel Inlet Pressure 10PSI(69kPa)
Max. Fuel Inlet Restriction 4 in. Hg. (13.5 kPa)
Max. Fuel Return Restriction 2.5 in. Hg. (8.5 kPa)
Exhaust
Outlet Size 5 in. NPT
Maximum Allowable Back Pres. 41 in. H20(10.2kPa)
Electrical System
Starting Voltage 24 Volts DC
Battery Two, 12 Volt
Group Number 8D
Cold Cranking Amps (minimum)
o o
Cold Soak@0 F(-18 C) 900
* Referto Cummins engine Operation and Maintenance Manual for lubricating oil recommendations/specifications.

FUEL CONSUMPTION (STANDBY/FULL LOAD/60Hz)

MODEL DQAD DQAE DQAF
US gph (L/hr) 17.3 (65.5) 19.4 (73.4) 21.4(81.0)

2-1
 3. Mounting the Generator Set
GENERAL • Discharge of exhaust gases
Generator set installations must be engineered so • Electrical connections
the generator set will function properly under the ex- • Accessibility for operation and servicing
pected load conditions. Use these instructions as a • Noise levels
general guide only. Follow the instructions of the
consulting engineer when locating or installing any • Vibration isolation
components. The complete installation must com-
ply with all local and state building codes, fire ordi- LOCATION
nances, and other applicable regulations. Consider
these requirements before installation: Generator set location is decided mainly by related
systems such as ventilation, wiring, fuel, and ex-
Requirements to be considered prior to installation: haust. The set should be located as near as possi-
ble to the main power service entrance. Exhaust
• Level mounting surface must not be able to enter or accumulate around in-
• Adequate cooling air habited areas.
• Adequate fresh induction air
Provide a location away from extreme ambient tem-
• Discharge of generator set air peratures and protect the generator set from ad-
• Non-combustible mounting surface. verse weather conditions.
IAWARNING

INCORRECT INSTALLATION, SERVICE OR PARTS REPLACEMENT CAN RESULT IN S E V E R E

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. B E S U R E TO CONSULT LOCAL
POLLUTION CONTROL OR AIR QUALITY AUTHORITIES BEFORE COMPLETING YOUR CON-
STRUCTION PLANS.

3-1
 MOUNTING SUBBASE OR
Generator sets are mounted on a steel skid that pro- VIBRATION
vides proper support. The engine-generator as- ISOLATOR
FLANGE
sembly is isolated from the skid frame by rubber
mounts that provide adequate vibration isolation for
normal installations. Where required by building HEX NUT
codes or special isolation needs, generator sets
may be mounted on rubber pads or mechanical FLAT OR BEVEL
spring isolators. The use of unapproved isolators WASHER
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. 1-1/2x6 INCH
PIPE
Use 5/8 inch or 16 mm anchored mounting bolts to
MOUNTING 12 IN.
secure the vibration isolators to the base. Secure BASE (305 mm)
the vibration isolators to the skid using flat or bevel
CONCRETE
washer and hexagonal nut for each bolt (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 MOUNTING
BOLT
Outline Drawing referenced in the Data Sheet
A C C E S S TO S E T
Generally, at least 1 meter (3 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 FIGURE 3-1. BOLT DIAGRAM
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
it is available at all times.

3-2
 AC POWER
DC CONTROL WIRING
WIRING

CONDENSATION
DRAIN TRAP

MUFFLER

THIMBLE

FLEXIBLE
SECTION

AIR OUTLET
DUCT (FLEXIBLE
BELLOWS)

LEVEL
CONCRETE IMPORTANT!
BASE COOLING AIR INLET MUST BE AT LEAST 1-1/2
TIMES LARGER THAN RADIATOR DUCT OUTLET
AREA ON RADIATOR COOLED MODELS

FLOW OF COOLING AIR AND HEATED AIR CAN

BE CONTROLLED BY AUTOMATICALLY
OPERATED LOUVRES

FIGURE 3-2. TYPICAL INSTALLATION

3-3
 VIBRATION ISOLATORS The isolators are adjusted by inserting the lev-
eling bolt through the skid and into the isolator
Installation and Adjustment Procedure (the leveling bolt's locking nut should be
threaded up towards the bolt head).
1. Place the vibration isolators (Figure 3-3) on the The leveling bolt will adjust the clearance be-
genset support structure. The isolators should tween the top plate and the isolator base. A
be shimmed or grouted to ensure that all of the nominal clearance of 0.25 inch (6 mm) or
isolator bases are within 0.25 inch (6 mm) ele- greater is desired. This will provide sufficient
vation of each other. The surface that the isola- clearance for the rocking that occurs during
tor bases rest on must also be flat and level. startup and shutdown. If the 0.25 inch (6 mm)
2. Loosen the side snubber lock nuts so that the clearance is not present, turn the leveling bolt
top plate ofthe isolator is free to move vertically until the desired clearance is achieved.
and horizontally. Be sure that the top plate is 5. The genset may not be level yet; therefore, ad-
correctly aligned with the base and springs. just the leveling bolts until the set is level and
3. Place the genset onto the isolators while align- sufficient clearance still remains. (Clearance
ing the skid's mounting with the threaded isola- on all isolators should be roughly equal). Once
tor hole. The top plates will move down and ap- all isolators have been set, lock the leveling bolt
proach the base of the isolator as load is ap- in place with the lock nut. -
plied. 6. The snubber nuts may remain loose and there-
4. Once the genset is in position, the isolators fore provide better isolation between the gen-
may require adjusting so that the set is level. set and support structure.

GENSET SKID.

SNUBBER CLEARANCE

FIGURE 3-3. VIBRATION ISOLATORS

3-4
 4. Mechanical Connections
GENERAL must not contain a shutoff device. Engine damage
will occur if the engine is run with the return fuel lines
The generator set mechanical system installation
blocked or restricted.
includes connecting the fuel, exhaust, ventilation
and cooling systems. Before starting any type of IA CAUTION I Never install shutoff device in fuel
fuel installation, all pertinent state and local codes retum line(s). If fuel return linefs) is blocked or
must be complied with and the installation must be exceeds fuel restriction limit, engine damage
inspected before the unit is put in service. will occur.

FUEL SYSTEM Fuel Retum Restriction (or Pressure) Limit: Fuel

return drain restriction (consisting of friction head
Cummins engines normally use ASTM No. 2 diesel and static head) between the engine injector return
fuel. They will, however, operate on alternate diesel line connection and the fuel tank must not exceed
fuels within the specifications shown in the Cum-the limit stated in the Specification section.
mins engine Operation and Maintenance Manual.
Fuel Lines - Routing
In all fuel system installations, cleanliness is ofthe
upmost importance. Make every effort to prevent A flexible fuel hose(s) or section of flexible fuel
entrance of moisture, dirt or contaminants of any hose(s) must be used between the engine's fuel
kind into the fuel system. Clean all fuel system com- system and fuel supply and return line(s) to protect
ponents before installing. the fuel system from damage caused by vibration,
expansion and contraction. Flexible lines for con-
A fuel filter/strainer/water separator of 100-120 mesh necting between the engine and the stationary fuel
or equivalent (approximately 150 microns nominal) lines are supplied as standard equipment.
must be fitted between either the main tank and day
tank or between the main tank and the engine. Installation of the fuel hose must be done according
to all applicable codes and standards, and installa-
Use only compatible metal fuel lines to avoid elec- tion recommendations provided by the manufactur-
trolysis when fuel lines must be buried. Buried fuel er. The supplied flexible hose is approved by the
lines must be protected from corrosion. hose manufacture for use with the genset fuel type
and product application.
IACAUTIONI Never use galvanized or copper fuel
lines, fittings or fuel tanks. Condensation in the Support fuel lines to restrain movement and prevent
tank and lines combines with the sulfur in diesel chaffing or contact with sharp edges, electrical wir-
fuel to produce sulfuric acid. The molecular ing and hot exhaust parts.
structure of the copper or galvanized lines or
tanks reacts with the acid and contaminates the IAWARNINGI Sparks and hot surfaces can ignite
fuel. fuel, leading to severe personal injury or death.
Do not route fuel lines near electrical wiring or
An electric solenoid valve in the supply line is rec- hot exhaust parts.
ommended for all installations and required for in-
door automatic or remote starting installations. Fuel lines must be routed and secured to maintain a
Connect the solenoid wires to the genset "Switched 1/2 inch (12.7 mm) minimum clearance from electri-
B+" circuit to open the valve during generator set cal wiring and a 2 inch (51 mm) minimum clearance
operation. from hot exhaust parts.
Separate fuel return lines to the day tank or supply Engine Fuel Connections
ank must be provided for each generator set in a
multiple-set installation to prevent the return lines of Identification tags are attached to the fuel supply
idle sets from being pressurized. Fuel return lines line and fuel return line connections.

4-1
 ENGINE VENTED INJECTOR FUEL
RETURN LINE All models require a fuel return
FUEL FILL CAP line from injectors to tank.
PUMP
CONNECT TO
AC OUTPUT

VENT LINE
DAY TANK

. FILL PIPE

FUEL TRANSFER•
PUMP ELECTRIC '
MOTOR DRIVEN
120 MESH FUEL
STRAINER
FUELTANK
LARGER OVER-
FLOW LINE

FIGURE 4-1 TYPICAL FUEL SUPPLY INSTALLATION

Supply Tank fer tank (referred to as a day tank) and auxiliary

pump will also be required. If an overhead main fuel
Locate the fuel tank as close as possible to the gen- tank is installed, a transfer tank and float valve will
erator set and within the restriction limitations of the be required to prevent fuel head pressures from be-
fuel pump. / ing placed on the fuel system components.
Install a fuel tank that has sufficient capacity to sup- For critical start applications, where generator sets
ply the genset operating continuously at full rated are paralleled or must satisfy emergency start-time
load for the planned period of operation or power requirements, it is recommended that a fuel tank or
outage. Refer to product Specification Sheet for reservoir be located such that the lowest possible
fuel consumption data. fuel level is not less than 6 inches (150 mm) above
the fuel pump inlet This will prevent air from accu-
IAWARNINGI Fuel leaks create fire and explosion mulating in the fuel line while the set is in standby,
hazards which can result in severe personal in- eliminating the period during startup when it has to
jury or death. Always use flexible tubing be- be purged.
tween engine and fuel supply to avoid line fail-
Fuel Inlet Pressure/Restriction Limit:: Engine
ure and leaks due to vibration. The fuel system
performance and fuel system durability will be com-
must meet applicable codes.
promised ifthe fuel inlet pressure or restriction limits
If the fuel inlet restriction exceeds the defined limit are not adhered to. Fuel inlet pressure or restriction
due to the distance/customer-supplied plumbing must not exceed the limits stated in the Specifica-
between the genset and the main fuel tank, a trans- tion section.

4-2
Day Tank (If Used) turn line to the bottom of day tank as shown in Fig-
ure 4-1. Provide a day tank overflow line to the sup-
Fuel day tanks are used when fuel inlet restriction ply tank in case the float switch fails to shut off the
limits can not be met, or the supply tank is overhead fuel transfer pump.
and presents problems of high fuel head pressure
for the fuel inlet and return lines.
IAWARNINGI Spilled fuel presents the hazard of
Supply Tank Lower Than Engine: With this instal- fire or explosion which can result in severe per-
lation, the day tank is installed near the generator sonal injury or death. Provide an overflow line
set, below the fuel injection system and within the to the supply tank from the day tank.
fuel inlet restriction limit. Install an auxiliary fuel
pump, to pump fuel from the supply tank to the day Supply Tank Higher Than Engine: Install the day
tank. A float switch in the day tank controls opera- tank near the generator set, but below the fuel injec-
tion of the auxiliary fuel pump. tion system. Use fuel line at least as large as the fuel
pump inlet. The engine fuel return line must enter
The supply tank top must be below the day tank top the day tank.
to prevent siphoning from the fuel supply to the day
tank.
Include a shutoff valve in the fuel line between the
Provide a return line from the engine injection sys- fuel supply tank and the day tank to stop fuel flow
tem return connection to the day tank. Plumb the re- when the generator set is off.

IAWARNINGISpilled fuel can create environmental hazards. Check local requirements for containment
and prevention of draining to sewer and ground water.

4-3
 EXHAUST S Y S T E M cepted design practices. Build according to the
code requirements in effect at the installation site.
Pipe exhaust gases to the outside of any enclosure.
Locate the exhaust outlets away from any air inlets I AWARNING I Hot exhaust pipes can start a fire
to avoid gases re-entering the enclosure. Exhaust and cause severe injury or death if improperly
installations are subject to various detrimental con- routed through walls. Use an approved thimble
ditions such as extreme heat, infrequent operation where exhaust pipes pass through walls or par-
and light loads. Regularly inspect the exhaust sys- titions.
tem both visually and audibly to see that the entire
system remains fume tight and safe for operation. IAWARNINGI Inhalation of exhaust gases can re-
sult in severe personal injury or death. Do not
IAWARNINGI Inhalation of exhaust gases can re- use exhaust heat to warm a room, compartment
sult in severe personal injury or death. Use ex- or storage area.
treme care during installation to provide a tight Rain caps are available for the discharge end of ver-
exhaust system. Terminate exhaust pipe away tical exhaust pipes. The rain cap clamps onto the
from enclosed or sheltered areas, windows, end of the pipe and opens due to exhaust discharge
doors and vents. force from the generator set. When the generator
set is stopped, the rain cap automatically closes,
For indoor installation, the exhaust system must protecting the exhaust system from rain, snow, etc.
use sealed joint type fittings, (for example NPT fit-
tings) to provide a tighter exhaust system. Use of Use a section of flexible exhaust pipe between the
slip type fittings (secured with a muffler clamp) may engine and remainder of exhaust system. Support
allow leakage of exhaust gases into the building. exhaust system to prevent weight from being ap-
plied to engine exhaust outlet elbow/turbocharger
IAWARNINGI Inhalation of exhaust gases can re- connection.
sult in severe personal injury or death. Use ex- IACAUTIONI Weight applied to the engine mani-
treme care during installation to provide a tight fold can result in turbocharger damage. Sup-
exhaust system. Use NPT or equivalent type fit- port the muffler and exhaust piping so no
tings for all indoor installations. weight or stress is applied to engine exhaust el-
bow.
Use an approved thimble (Figure 4-2) where ex-
haust pipes pass through wall or partitions. Insu- The exhaust system design should meet local code
lated wall/roof thimbles are used where exhaust requirements.
pipes pass through a combustible roof or wall. This
includes structures, such as wood framing or insu- Liability for injury, death, damage, and warranty ex-
pense due to use of unapproved mufflers or modifi-
lated steel decking, etc. Uninsulated wall/roof cations to the exhaust system becomes the respon-
thimbles are used where exhaust pipes pass sibility of the person installing the unapproved muf-
through a non-combustible wall or roof, such as fler or performing the modification. Contact a Cum-
concrete. Refer to NFPA 37, Section 6-3. "Station- mins Power Generation distributor for approved ex-
ary Combustion Engines and Gas Turbines" for ac- haust system parts.

4-4
Avoid sharp bends by using sweeping, long radius
elbows and provide adequate support for muffler
and tailpipe. Pitch a horizontal run of exhaust pipe DRIP CAP
DOWNWARD (away from engine) to allow any RAIN CAP
moisture condensation to drain away from the en- HOLES IN END
gine. If an exhaust pipe must be turned upward, in- OF INNER
stall a condensation trap at the point where the rise SLEEVE
begins (Figure 4-3).
9 INCH MIN
Shield or insulate exhaust lines if there is danger of (230 mm)
personal contact. Allow at least 12 inches (305 mm) ROOF
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-
9 INCH MIN
tem for leaks while operating the genset under full (230 mm)
load and correct all leaks.
IAWARNINGI 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.

WALL OR PARTITION

FIGURE 4-2. MOUNTING EXHAUST THIMBLE

IF EXHAUST LINE MUST BE

\ PITCHED UPWARD, CONSTRUCT
A TRAP AT POINT OF RISE

AVOID ^ L M
SHARP M
BENDS

^ f l DRAIN CONDENSATION
j l TRAP PERIODICALLY

FIGURE 4-3. CONDENSATION TRAP

4-5
 VENTILATION AND COOLING
Generator sets create considerable heat that must
be removed by proper ventilation. Outdoor installa- PREVAILING WINDS PREVAILING WINDS
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 air
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 model-specific Specification FIGURE 4-4. WIND BARRIER
Sheet for the airflow requirements and allowed air-
flow 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. See Figure 4-4.

4-6
Dampers Locate the cooling air outlet directly in front of the ra-
diator and as close as possible. The outlet opening
Dampers or louvres protect the genset and equip- must be at least as large as the radiator area.
ment room from the outside environment. Their Length and shape of the air outlet duct should offer
operation of opening and closing should be con- minimum restriction to airflow.
trolled by operation of the genset.
Attach a canvas or sheet metal duct to the flange
In cooler climates movable or discharge dampers and the air outlet opening using screws and nuts so
are used. These dampers allow the air to be recircu- duct can be removed for maintenance purposes.
lated back to the equipment room. This enables the The duct prevents circulation of heated air. Before
equipment room to be heated while the genset en- installing the duct, remove the radiator core guard.
gine is still cold, increasing the engine efficiency.
Standard Radiator Cooling uses a set mounted
Radiator Set Requirements radiator and engine pusher fan to cool the engine.
Air travels from the generator end of the set, across
Radiator set cooling air is drawn past the control the engine and out through the radiator. An integral
end of the set by a pusher fan that blows air through discharge duct adapter flange surrounds the radia-
the radiator (Figure 4-5). Locate the air inlet to the to tor grille.
the rear of the set. Make the inlet vent opening 1-1/2
to 2 times larger than the radiator area.
Engine Coolant Heater (Optional)
Louvers and screens over air inlet and outlet open-
ings restrict air flow and vary widely in performance. An optional engine coolant heater is available to
A louver assembly with narrow vanes, for example, keep the engine warm for starting under adverse
tends to be more restrictive than one with wide weather conditions. Connect the heater to a power
vanes. The effective open area specified by the lou- source that will be energized when the engine is
ver or screen manufacturer should be used. NOT running.

THERMOSTATIC AIR
RECIRCULATING
DAMPER *

WIND/NOISE
BARRIER

INLET AIR
DAMPER I
HOT AIR
)
COOL AIR

RADIATOR FLEXIBLE DUCT DISTANCE SHOULD NOT

Louvers should close when room CONNECTOR BE LESS THAN HEIGHT
ambient is above 60° F (16° C) OF RADIATOR

FIGURE 4-5. TYPICAL RADIATOR SET INSTALLATION

4-7
 5. DC Control Wiring
CONTROL WIRING Digital Connections: Connection points, other
then relayed outputs, network, switched B+ and B+
The generator set accessory box (Figure 5-1), are considered digital connections to terminal strip
which is located on the backside of the control hous- TB1. The type/gauge wire to use for these connec-
ing, contains connection points for remote control tions are:
and monitor options.
• Less than 1000 feet (305m), use 20 gauge
IACAUTIONI Stranded copper wire must be used stranded copper wire.
for all customer connections to the Accessory
Box. Solid copper wire may break due to genset • 1000 to 2000 feet (305 to 610m), use 18 gauge
vibration. stranded copper wire.
Relay Connections: Due to the wide variety of de-
TB1 REMOTE MONITOR/CONTROL vices that can be attached to the relay outputs of
CONNECTIONS TB1, the electrical contractor must determine the
gauge of the stranded copper wire that is used at
Customer monitor/control connections are at- this installation site. Refer to Customer Connec-
tached to terminal block TB1 (Figure 5-1). Optional tions diagram in Section 9 for the relay
equipment such as sensing devices used to monitor specifications.
genset operation, remote start/stop switches, con-
trol box heater, battery charger and etc. are at- Network Connections: Refer to 900-0366 Power-
tached to TB1. Refer to PCC Customer Connec- Command Network Installation and Operation
tions diagram in Section 9. manual for the type/gauge wire to use for these con-
nections.
TBI Wiring
Switched B+: (Fused at 10 amps.) Same as Relay
Always run control circuit wiring in Connection description.
a separate metal conduit from AC power cables
to avoid inducing currents that could cause B+: (Fused at 20 amps.) Same as Relay Connec-
problems within the control. tion description.

5-1
 OPTIONAL OPTIONAL RUN
COMMON ALARM RELAYS K11, K12 &
RELAY K14 K13

TBI-1

TBI-62

FIGURE 5-1. ACCESSORY BOX

5-2
 RUN RELAYS (Kl 1, K12, 13) fans, pumps and motorized air dampers. The run
relays are energized when the generator set control
The optional run relays are rail mounted inside the receives a start signal.
accessory box (Figure 5-1). The rail mount allows
you to easily remove and replace the snap-on re- The contacts are rated:
lays. The generator set can be equipped with one,
two or three run relays. • 10 amps at 28 VDC or 120 VAC, 80%PF
The three-pole, double-throw run relays (Figure • 6 amps at 240 VAC, 80%PF
5-2) are used to control auxiliary equipment such as • 3 amps at 480/600 VAC, 80%PF

I
K11,K12, K13 7
4

2
K11,K12, K13 8 CUSTOMER
CONNECTIONS
5

3
K11, K12, K13 9
6

K11 K12 K13

RUN RELAY RUN RELAY RUN RELAY

© NO © © © NO © © © NO
® © NC © © NC © © © NC

5 5
ffl C O
A40-TB1-8 _ "- A40-TB1-12
(SWITCHED B+) © © COM (B-) © r-®
I® © © © © © © © ©

3-

FIGURE 5-2. OPTIONAL RUN RELAYS (Kll, K12, K13)

5-3
 ALARM RELAY (K14) as audible alarms. Any generator set warning or
shutdown will energize the alarm relay.
The optional alarm relay is rail mounted inside the
accessory box (Figure 5-1). The rail mount allows The contacts are rated:
you 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 • 6 amps at 240 VAC, 80%PF
5-3) is often used to energize warning devices such • 3 amps at 480/600 VAC, 80%PF

K14
I 7
4
2
8 CUSTOMER,
K14 CONNECTIONS
5
3
K14 9
6

JUMPER WIRE
REQUIRED FOR K14 K14
RELAY OPTION COMMON ALARM
A40-TB1-11
(GND) © © NO
© © NC
A40-TB1-31 — 3
(COMMON ALARM) "51
2 9. lei

C 0 1 1
A40-TB1-1 - A40-TB1-30
(B+) © © COM (COMMON ALARM)
© © ©

FIGURE 5-3. OPTIONAL ALARM RELAY (K14)

5-4
 6. AC Electrical Connections
GENERAL 2. Press the Emergency Stop button and wait at
least 30 seconds before completing Step 3.
This section provides the procedure that is used to
connect the AC electrical system of the genset. 3. Turn off or remove AC power from the battery
IACAUTIONI Before disconnecting battery charger.
cablefs), press the Emergency Stop button and
wait at least 30 seconds. Engine performance 4. Remove the negative (-) battery cable from the
may be affected (e.g., engine dying or hard generator set starting battery.
starting) if battery cablefs) is removed during
the 30 second waiting period. Service person- Connecting the genset AC electrical system in-
nel may be required to correct fault. volves:
IAWARNINGI Ignition of explosive battery gases • Installation of transfer switch
can cause severe personal injury or death. Arc- • Generator output voltage selection
ing at battery terminals, light switch or other
equipment, name, pilot lights and sparks can ig- • Load cable connection
nite battery gas. Do not smoke, or switch • Standard and optional AC equipment connec-
trouble light ON or OFF near battery. Discharge tions (e.g., control box heater, coolant heater,
static electricity from body before touching bat- etc.
teries by first touching a grounded metal sur-
face. Local regulations often require that wiring connec-
tions be made by a licensed electrician, and that the
Ventilate battery area before working on or near installation be inspected and approved before op-
battery—Wear goggles—Stop genset and dis- eration. All connections, wire sizes, materials used,
connect charger before disconnecting battery etc. must conform to the requirements of electrical
cables—Disconnect negative (-) cablefirstand codes in effect at the installation site.
reconnect last.
IAWARNINGI Improper wiring can cause a fire or
IACAUTIONI Disconnect battery charger from AC electrocution, resulting in severe personal inju-
source before disconnecting battery cables. ry or death and/or property and equipment dam-
Otherwise, disconnecting cables can result in age.
voltage spikes damaging to DC control circuits
of the set Before starting the genset, check to make sure that
all electrical connections are secure, and that all
IAWARNINGI Accidental starting of the generator
wiring is complete. Replace and secure any access
set can cause severe personal injury or death. panels that have been removed during installation.
Prevent accidental starting by disconnecting Check that the load cables from the genset are
the negative (-) cable from the battery terminal. properly connected.
Before making any AC electrical connections, make
certain the generator set cannot be accidentally IAWARNINGI Backfeed to utility system can
started as follows: cause electrocution or property damage. Do
not connect to any building electrical system
1. Move the Run/Off/Auto switch on the control except through an approved device and after
panel to the OFF position. building main switch is opened.

6-1
 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). NORMAL
Follow the installation instructions provided with the SOURCE GENSET
transfer switch when connecting the load and con-
trol wiring.

•
FIGURE 6-1. TYPICAL LOAD TRANSFER
FUNCTION

1
i
i . . . . J

6-2
 AC WIRING All loads are connected to the generator by bolting
stranded load wires to the appropriate terminals on
Generator Voltage Connections the generator reconnection terminal block or circuit
breaker lugs. The terminals are stamped U, V, W
The available generator output voltages and maxi- and N to indicate the line and neutral connections.
mum current ratings are specified on the generator (Reference: U, V, and W correspond with L l , L2 and
set nameplate. Line-to-neutral voltage is always the L3; and N with LO respectively).
lower voltage shown and line-to-line voltage is the
higher rating. Load Balancing

These generators can be configured to the name- When connecting loads to the generator set, bal-
plate voltages as shown on the Reconnection Dia- ance the loads so the current flow from each line ter-
gram located on the side access cover of the control minal (Ll, L2 and L3) is about the same. This is es-
housing. Many of the voltages listed will require re- pecially important if both single phase and three
configuration of the generator output leads on the phase loads are connected. Any combination of sin-
connection terminal block. This reconfiguration gle phase and three phase loading can be used as
must only be done by service personnel that are long as each line current is about the same, within
trained and experienced to perform electrical instal- 10 percent of median value and no line current ex-
lation. The generator set was adjusted to produce a ceeds the nameplate rating of the generator. Check
specified voltage during production verification test- the current flow from each line after connections by
ing prior to shipment. The installer must always observing the control panel ammeter.
check the stator lead terminal block connections
and perform any necessary reconnect to obtain the Current Transformers
voltage required. Current transformers (CT's) are required on gen-
sets that contain AC meters. The CT's must be
Some generator sets are capable of producing a installed as noted in the following CT Installation
wide range of voltages and connection configura- Requirements.
tions, others have specific limited capabilities. Re-
fer to wiring diagram and generator voltages (fromRefer to the Reconnection Diagram to identify the
the nameplate) when reviewing the voltage connec- output leads/phase that must be routed through
tion information and use the wiring diagram sup- each CT, and also appropriate transformer post
plied with your generator set when actually perform-
selection for meter sensing leads. The transformers
ing load connections. are labeled CT21, CT22 and CT23 on the recon-
nection wiring diagram. (The Reconnection Dia-
Reconfiguring generator sets to gram is located on the upper side cover of the con-
higher voltages can exceed the voltage capabil- trol housing.)
ity of the specific generator windings and dam-
age the generator and also decrease line cur- CT Installation Requirements:
rent, rendering line circuit breakers too large. A. The CT has a dot on one side. This dot must be
Consult with your distributor before performing facing toward the generator (conventional cur-
reconnection for a different voltage. rent flowing into the dot). A dot is also used to
indicate pin 1 of the CT.
IACAUTIONI Reconfiguring generator sets to
B. CT21 - U load leads (A phase),
lower voltages can reduce generator set rat- CT22 - V load leads (B phase)
ings, and also increase line current, rendering CT23 - W load leads (C phase)
line circuit breakers too small. Consult with
your distributor before performing reconnec- C. Route the appropriate load wires through each
tion fora different voltage. CT.
D. The CT's have dual secondaries (3 pins). The
Load Connections CT secondary wire marked 1 is connected to
pin 1 of the CT. CT secondary wire marked 2/3
Flexible conduit and stranded conductors must be is connected to pin 2 for high voltage gensets or
used for connections to take up movement of the to pin 3 for low voltage gensets. (Refer to Re-
generator set. connection Diagram.)

6-3
Grounding Make sure the genset is grounded to earth in one
location only. On generators without a circuit break-
The following is a brief description of system and er, ground to the point indicated on the top of the
equipment grounding of permanently installed AC generator. On gensets with circuit breakers, use the
generators within a facility wiring system. It is ground lug provided in the circuit breaker box.
important to follow the requirements of the local
electrical code. IAWARNINGI Electric current can cause severe
Figure 6-2 illustrates typical system grounding for a personal injury or death. Bonding and ground-
3-pole and a 4-pole automatic transfer switch ing must be done properly. All metallic parts
(ATS). In the 3-pole ATS, note that the generator that could become energized under abnormal
neutral is connected to the ATS and is NOT bonded conditions must be properly grounded.
to ground at the generator. In the 4-pole ATS sys-
tem, a grounding electrode conductor and a bond- Typical requirements for bonding and grounding
ing jumper are used to connect the generator neu- are given in the National Electrical Code, Article
tral to ground. In some installations, a CT may be 250. All connections, wire sizes, etc. must conform
required for ground fault monitoring (refer to Figure to the requirements of the electrical codes in effect
6-2 for CT location). at the installation site.

SERVICE ENTRANCE GENERATOR SET

3-POLE AUTOMATIC

30
r TRANSFER SWITCH

TO UTILITY 45
SERVICE N

L --X —L.. IS
4 WIRES & GROUND
TO LOAD

SERVICE ENTRANCE GENERATOR SET

4-POLE AUTOMATIC
r TRANSFER SWITCH
30
-O O- BONDING
N .JUMPER
TO UTILITY
SERVICE r-ob- CT LOCATION IF
REQUIRED FOR

1
GFI MONITORING
L ___r—1_.
GROUNDING
4 WIRES & GROUND ELECTRODE
TO LOAD CONDUCTOR

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

6-4
 CONTROL HEATER (OPTIONAL) terior. It protects the components when the genera-
A control heater (Figure 6-3) provides a means of tor set is subjected to varying ambient air conditions
humidity /temperature control of the control box in- during extended periods of non-use.

TO ACCESSORY BOX
A40-TB1-36 & 37
(PCC CONTROL)

nn
k lur = . j
-ELJ

BOTTOM VIEW OF
CONTROL BOX
HEATER

R G U R E 6-3. OPTIONAL CONTROL HEATER

6-5
 COOLANT HEATER ply voltage and circuit amperage is correct for the
heater element rating.
The coolant heater keeps engine coolant warm Refer to the electrical diagram located inside the AC
when the engine is shut down. It heats and circu- electrical connection box cover (Figure 6-4) for
lates the coolant within the engine. This reduces coolant heater power connections/voltage selec-
startup time and lessens engine wear caused by tions.
cold starts. It is electrically operated and thermos-
tatically controlled. A battery charger is required to prevent battery dis-
charge. The heater control relay draws 83 mA of cur-
IACAUTIONI TTie coolant heater must not be op- rent when the heater(s) is off. The heater is off when
the engine has reached the proper temperature or
erated while the cooling system is empty or the engine is running.
damage to the heater will occur.
IACAUTIONI DOnot connect AC power to the
Figure 6-4 shows a typical coolant heater. Connect heater before connecting battery cables. Heater
the heater to a source of power that will be on during will run continuously without DC power and can
the time the engine is not running. Be sure the sup- overheat and damage heater.

THERMOSTAT

COOLANT
FLOW

DRAIN

AC ELECTRICAL CONNECTION
BOX (ELECTRICAL DIAGRAM
INSIDE COVER) AC POWER
DC CONTROL LINE
LINE

FIGURE 6-4. TYPICAL COOLANT HEATER

6-6
 GENERATOR HEATER Figure 6-5 illustrates the installation of two heater
A generator heater(s) is used to help keep the gen- elements. Connect the heater(s) terminals to a
erator free of condensation when the generator set source of power that will be on during the time the
is not running. During cool and humid conditions, engine is not running. Be sure the supply voltage
condensation can form within a generator, creating and circuit amperage is correct for the heater ele-
ment rating.
flashing and a shock hazard.
IAWARNINGI Water or moisture inside a genera-
tor increases the possibiUty 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.

HEATER LEADS

1 3

HEATER LEADS
HEATERS
HEATER
TERMINAL BOX
HEATER
VOLT/WATTS
- LABEL
TOTAUHATT8

TERMINAL.
BLOCK

FIGURE 6-5. TYPICAL GENERATOR HEATER INSTALLATION

6-7
 F U E L TRANSFER PUMP IAWARNINGI Diesel fuel is highly combustible.
Improper installation of this kit can lead to spill-
age of large quantities of fuel and loss of life anc
A fuel transfer pump and control are available when property if the fuel is accidentally ignited. Instal-
a sub-base or in-skid day tank are provided. The lation and service must be performed by trained
automatic control operates the fuel pump to main- and experienced persons in accordance with
tain a reservoir of fuel in the day tank. the applicable codes.
Do not smoke near fuel and keep flames,
sparks, pilot lights, arcing switches and equip-
ment, and other sources of ignition well away.

CONTROL FLEXIBLE FUEL FLEXIBLE FUEL

RETURN LINE SUPPLY LINE

FUEL PUMP FLOAT SWITCH DAY FUEL FUEL FILL

AND MOTOR ASSEMBLY TANK GAUGE CAP

FIGURE 6-6. TYPICAL IN-SKID DAY TANK INSTALLATION

6-8
Fuel Pump Control AC Connections , 2. To convert the day tank controller from 120
VAC to 240 VAC, perform the following steps.
The control can be powered by 120 VAC or 240 A. Remove the jumpers between terminals
VAC. The control is set up at the factory for connec- TBI-5 and TBI-6, and TB1-7 and TB1-8
tion to 240 VAC. in the control box and connect the two
jumpers between terminals TBI-6 and
1. To convert the day tank controller from 240 TBI-7.
VAC to 120 VAC, perform the following steps.
B. Move selector switch SI 03 on the control
A. Remove the two jumpers between termi- PCB to the down position for 240 VAC.
nals TB1-6 and TB1-7 in the control box C. If the control is equipped with a transform-
and connect one between terminals er, remove the jumpers between terminals
TBI-5 and TB1-6 and the other between H1 and H3, and H2 and H4 and connect
terminals TBI-7 and TBI-8. the two jumpers between H2 and H3.
3 Attach a tag to the control box indicating the
B. Move selector switch S103 on the control supply voltage.
PCB to the up position for 120V.
4 Terminals TBI-8 and TBI-5 are available for
C. If the control is equipped with a trans- connection of a 120 or 240 VAC electric fuel
former, remove the two jumpers between shutoff valve rated not more than 0.5 amps.
terminals H2 and H3 and connect one be- The voltage rating of the valve must corre-
tween HI and H3 and the other between spond with the voltage utilized for the pump.
H2 and H4. See Item 2 above.

PI03-GND
PI 03-4
AC (240V) PI03-WHITE
EARTH GND PI 03-3
NEUTRAL (I20V)- PI 03-I
AC (I20/240V) -
-SI + USED W/O
-GND TRANSFORMER

I 2 3 4 5 6 7 8 9 I 0 I I I 2 I 3 I 4 I 5 I 6 I 7 I 8 I 9 20 2I
T
00 0 00

o o
to
CD
J5
oooooooooo J4
J6
(ooooooooooooo
J3
o r°°)
PCB ASSY-DAYTANK 300-3464

FIGURE 6-7. FUEL PUMP CONTROL TERMINAL BOARD

6-9
 GROUND FAULT ALARM RELAY After the installation of the genset is complete, per-
(OPTIONAL) form the following procedure to test the operation of
the ground fault relay.
The optional Ground Fault Relay (GFR) (Figure
6-8) is typically located behind the lower control
housing grille. The ground fault relay continuously A. Verify that the N-G Fault Indicator on the
monitors the neutral to ground connection and acti- GFR is not lit. If lit, it indicates that the
vates a fault alarm when the connection is broken. bonding jumper circuit (neutral to ground)
During genset operation, the relay continuously is open. If genset does not require bonding
monitors the line to neutral and activates a fault jumper, a bonding jumper must be
alarm when a ground fault is sensed. installed at the facility service entrance.

The relay alarm contacts are typically connected to A. Move the control switch to the Run posi-
the genset control to provide a "Ground Fault tion.
Alarm" indication.
B. Press the TEST switch on the ground fault
A control reset will clear the fault at the control panel relay.
and will also reset the ground fault relay.
The relay has a time delay setting of zero to one se- C. Verify that the control panel warning mes-
cond and a current setting of 5 to 1200 amperes. * sage is displayed and the Fault Indicator
(>l) on the GFR is lit.
Adjust the Current and the Time Delay controls on
the ground fault relay to the customers specifica- D. Reset the control panel fault (this will also
tions. reset the ground fault relay).

6-10
 CONTROL
HOUSING

GRILLE
GROUND FAULT
RELAY
ASSEMBLY

ON INDICATOR
TEST BUTTON RESET BUTTON
(N.U., FACTORY SET
TO AUTO RESET)

0-S 4 - 5 0 8-&00
1 • 10
2 • 20
5 • IOO 9 - 1200
6 - 200
TIME DELAY CONTROL
FAULT INDICATORS 3 • 23 7 = 300

>l
(OVER CURRENT)

N-G
(OPEN CIRCUIT)
CURRENT CONTROL

FIGURE6-8. GROUND FAULT ALARM RELAY

6-11
 7. Prestart Preparation
GENERAL IACAUTIONI Disconnect battery charger from AC
source before disconnecting battery cables.
Before attempting the initial start of the generatorOtherwise, disconnecting cables can result in
set, be sure to complete the Installation Checklist voltage
in spikes damaging to DC control circuits
Section 8. of the set.
PCC POWER ON / STANDBY MODE IAWARNINGI Accidental starting of the generator
IACAUTIONI Before disconnecting battery set can cause severe personal injury or death.
cablefs), press the Emergency Stop button and Prevent accidental starting by disconnecting
wait at least 30 seconds. Engine performance the negative (-) cable from the battery terminal.
may be affected (e.g., engine dying or hard
starting) if battery cablefs) is removed during Before opening the PCC control cabinet to make
the 30 second waiting period. Service person- the following Power On/Standby Mode selection,
nel may be required to correct fault. remove the negative (-) battery cable(s) from the
generator set starting battery as follows:
IAWARNINGI Ignition of explosive battery gases
can cause severe personal injury. Arcing at bat- 1. Move the Run/Off/Auto switch on the control
tery terminals, light switch or other equipment, panel to the OFF position.
flame, pilot lights and sparks can ignite battery
gas. Do not smoke, or switch trouble light ON or
OFF near battery. Discharge static electricity 2. Press the Emergency Stop button and wait at
from body before touching batteries by first least 30 seconds before completing Step 3.
touching a grounded metal surface.
Ventilate battery area before working on or near 3. Turn off or remove AC power from the battery
battery—Wear goggles—Stop genset and dis- charger.
connect charger before disconnecting battery
cables—Disconnect negative f-) cable first and 4. Remove the negative (-) battery cable from the
reconnect last. generator set starting battery.

7-1
Selecting Power On or Standby Mode • moving the Run/Off/Auto switch to the Run
position,
IACAUTIONI Electrostatic discharge will damage
circuit boards. To prevent this damage, always • pressing the Self Test button,
wear a grounding wrist strap when working in- • a remote start input signal (genset in Auto
side control box.
mode), or
Set the Power On / Standby Mode switch (S5 in Fig- • any one of several "wake-up" signals from ex-
ure 7-1) to the desired position.
ternal switches.
Power On Mode: Slide the switch to the left to se-
lect the Power On (awake) mode. It is recom- With the switch set to Standby mode, pressing the
mended that switch S5 be left in the Power On mode Self Test button will allow you to activate and view
in all applications, except those where battery the menu displays without starting the generator
charging is not available. set. If no menu selections are made, a software tim-
er will shut down the power after 30 seconds.
The PCC will initialize the operating software and
permit operation of the menu display panel. Power
When left in the Standby Mode, and a "Warning"
will stay on until the switch is reset to the Standby signal is sensed by the PCC (for example, low
Mode. engine temp), the control will wake up and display
Standby Mode: Slide the switch to the right to se- the warning message. The control will remain active
lect the Standby (sleep) Mode. In this mode, the until the warning condition is corrected and the Re-
PCC operating software will be initiated by: set button is pressed to clear the warning message.

PCC POWER ON / STANDBY

MODE SWITCH (S5)

DIGITAL BOARD
(A32)
DISPLAY BOARD g,
(A35)
\ ANALOG BOARD

LA (A33)

ENGINE INTERFACE CUSTOMER INTERFACE

(A31) (A34)

FIGURE 7-1. CABINET INTERIOR (PCC 3100)

7-2
 ELECTRICAL SYSTEM Service the batteries as necessary. If an automatic
transfer switch is installed without a built-in charge
Verify all electrical connections are secure and all
wiring is complete and inspected. Replace and se- circuit, connect a separate battery charger. A bat-
cure any access panels that may have been re- tery charger is required when the PowerCommand
moved during installation. control is set to the Power On (awake) mode.

Battery Connections IAWARNINGI Ignition of explosive battery gases

can cause severe personal injury. Always con-
IAWARNINGI Accidental starting of the generator nect negative (-) battery cable last to prevent
set can cause severe personal injury or death. arcing.
Make sure that the Run/Off/Auto switch on the
control panel is set to the Off position before IAWARNINGI Ventilate battery area before work-
connecting the battery cables. ing on or near battery. Arcing at battery termi-
nals, light switch or other equipment, flame, pi-
Starting, the unit requires 24 volt battery current, us- lot lights and sparks can ignite battery gas. Do
ing two 12 volt batteries (see Specification section). not smoke, or switch trouble light ON or OFF
Connect the batteries in series (negative post of first near battery. Discharge static electricity from
battery to the positive post of the second battery) as body before touching batteries byfirsttouching
shown in Figure 7-2. a grounded metal surface.

POSITIVE

NEGATIVE

TWO, 12 VOLT
BATTERIES

FIGURE 7-2. GENSET BATTERY CONNECTIONS

7-3
 P C C OPTIONS P R E S T A R T C H E C K S START DELAY submenu: This delay applies only
All generator set configuration options are set at the to remote starting in the Auto mode. Use the buttons
factory except for site related options, (e.g., Start/ next to the "ff" a n d ' T symbols to set the start delay.
Stop Time Delays, Cycle Crank, Customer Fault 1 The start delay adjustment range is 0 to 300 sec-
and 2, etc.. onds.
Adjustment of these options are divided into two
categories within the menu driven system. These
two categories are Adjust and Setup/Calibrate. STOP DELAY submenu: This delay applies only
The Setup/Calibrate submenus are intended for to remote stopping in the Auto mode. From the
qualified service personnel only and require a pass- START DELAY submenu, press the button next to
word to modify these submenus. The Adjust sub- t h e " » " in the display to move to the STOP DELAY
menus are intended for service personnel and site submenu. Use the buttons next to the "tt" and
personnel. symbols to set the stop delay. The stop delay adjust-
The Adjust submenus allow site personnel to cali- ment range is 0 to 600 seconds.
brate the generator set voltage/frequency, and
start/stop time delays. For the prestart checks, ad-
justment of only the start/stop delays is required. SAVE/EXIT submenu: From the STOP DELAY
Adjust Menu 'submenu, press the button next to the " » " ' in the
display to move to the SAVE/EXIT submenu. Select
To adjust the start and stop delays, press the button
next to the word "ADJUST' in the Main Menu. Fig- SAVE to save your changes. At the CHANGES
ure 7-3 shows a block representation of the AD- SAVED submenu, select EXIT to return to the Main
JUST menu. After you press the button next to the menu.
word "ADJUST' in the display, the VOLTAGE sub-
menu will appear.
If you select SAVE, the adjustments will be retained
As shown in the diagram, the ADJUST menu has after shutdown, and will be in effect when the set is
four submenus, including a save/exit procedure. To restarted. If you select EXIT without saving first, the
move through the VOLTAGE and FREQUENCY adjustments will remain in effect until the genset is
submenus, press the button next to t h e " » ' to dis- shut down and return to the previous settings when
play the STOP DELAY submenu. the set is restarted.

7-4
•<

•<
•<
•
< ENGINE
ADJUST

ft VOLTAGE
11
GEN
>>

»
>•
>•
I ADJUST MENU

<••
<>•>•
•< tt FREQUENCY
•<

•< tt START DELAY •

•< Ji SEC > >

•< tt STOP DELAY

•< U SEC > >

SAVE • • CHANGES SAVED • • < ENGINE GEN >•

EXIT >> EXIT >> >U ADJUST >> >•
u<
: • CHANGES SAVED • •< tt VOLTAGE •
EXIT >> >> >•
u<
•
•< SAVE • •< ENGINE GEN >•
EXIT >> >IJ ADJUST >> >•
u<
j
•< SAVE • •< tt VOLTAGE •
•< EXIT >> ii- >> >•
u<

Indicates "OR" ConditiorTI

FIGURE 7-3. ADJUST MENU

7-5
•<
 STARTING
Refer to the generator set Operator's manual for im-
portant safety precautions and recommended pro-
cedures for starting the genset and verifying proper
operation. Start the generator set and verify all en-
gine and generator gauges are displaying the cor-
rect values.

7-6
 8. Installation Checklist
GENERAL
• Generator set wattage capacity is sufficient to handle maximum anticipated load.
• At least 3 feet of clearance (or greater for housing door) is provided around entire generator set for servic-
ing and ventilation.
• Generator set is located in an area not subject to flooding.
• All operating personnel have read and are familiar with Operator's Manual.
• All operators have been thoroughly briefed on preventive maintenance procedures.
• All operators have read and understand all Important Safety Instructions in Operator's Manual.
GENERATOR S E T SUPPORT
• Floor, roof or earth on which the generator set rests is strong enough and will not allow shifting or move-
ment. Observe local codes on soil bearing capacity due to freezing and thawing.
• Generator set is properly supported and retained to approved base.
• Supporting base is large enough and is of non-combustible material - extends 6-inches all around set.
COOLING AIR FLOW
• Generator set air inlet is faced into direction of strongest, prevailing winds.
• Air inlet openings are unrestricted and at least 1-1/2 times larger than air outlet area.
• Cooling air outlet is on downwind side of building (if not, wind barrier is constructed).
• Proper ducting material (sheet metal, canvas) is used between radiator and air outlet.
DIESEL FUEL SYSTEM
• Fuel tanks meet or exceed all Local, State or National codes.
• Fuel lines are properly installed, supported and protected against damage.
• Approved flexible fuel line is installed between main fuel supply line and generator set's fuel system, near
the generator set, to protect the fuel system from damage caused by vibration, expansion and contrac-
tion.
• Strainer or fuel screen (100 to 120 mesh) is installed in the fuel supply line to protect the fuel lift pump, day
tank transfer pump or float valve seat from fuel supply tank debris.
• Fuel supply line shutoff valves are installed to prevent fuel flow in case of leaks.
• No shutoff valves are installed on engine fuel return line.
• External fuel pumps are connected and operational at all times (generator set started or shut down).
• Fuel system is properly primed.
• No fuel leaks are found in supply line or engine fuel system.

8-1
 EXHAUST SYSTEM
• Operators are thoroughly briefed on the dangers of carbon monoxide gas.
• Areas around set are well ventilated. No possibility of exhaust fumes entering building doors, windows, or
intake fans.
• Exhaust gases are piped safely outside and away from building.
• The correct length of approved rigid pipe is connected to the generator set flexible pipe using approved
securing methods with no weight resting on engine exhaust components. There are no bends in flex sec-
tion.
• Condensation drain is provided in lowest section of exhaust piping.
• Exhaust piping is insulated to guard against burns to personnel.
• Exhaust piping passing through walls or ceilings have approved fire-proof materials and are in com-
pliance with all codes.
• Exhaust piping is large enough in diameter to prevent excessive back pressure on engine.
AC AND DC WIRING
• Wire sizes, insulation, conduits and connection methods all meet applicable codes./, w . .
• AC and DC wires are separated in their own conduit to prevent electrical induction.
• All load, line and generator connections are proper and correct.
• Flexible conduit between generator set and building or surrounding structure.
GENERATOR S E T PRESTART
• Generator set engine is properly serviced with oil and coolant.
• Batteries are properly installed, serviced and charged.
• Battery charger and engine coolant heater are connected and operational.
• All generator set covers and safety shields are installed properly.
• All fuel and coolant shutoff valves are operational.

8-2
TBI-PIA (TOP)
TBI-PIB (SIDE)
_P2l4 (N/O) NOTE:
(N/O)
•B+ (20A FUSED) -w- PZ-12
CONT HEATER I
CUSTOMER RTN
HEATER I A APPLY GROUND TO ACTIVE INPUT. CUSTOMER FAULT 2 AND CUSTOMER FAULT 3
'WAKE UP' CONTROL. USE COPPER STRANDED WIRE. 20 GA FOR RUNS LESS THAN
1000 FT. 18 GA FOR RUNS FROM IOOO TO 2000 FT. (LESS THAN 50mA CURRENT)
CONT HEATER 2 HEATER 2
2-U
P2-I3
P2-I2
(N/O) READY TO LOAD
(N/O) LOAD DUMP A 2A 0 30VDC RELAY CONTACTS. THIS RELAY PICKS UP SHUT DOWNS ONLY.

•SWITCHED B+ (IOA FUSED) -Ih

2-8
P2-7
COMM
(N/O)
(N/O)
A SA • 30VDC RELAY CONTACTS. THIS RELAY PICKS UP CLOSE THE BREAKER AND
DROPS OUT TO THE OPEN THE BREAKER.

-yf- P2-5
PZli.
(N/C)
(N/C) A REFER TO ONAN 900-0366 POWER COMMAND NETWORK AND OPERATION MANUAL FOR
INTERCONNECTION INSTRUCTIONS (OPTIONAL PCC NETWORK INTERFACE MODULE).

-CHASSIS GROUND
P3-9
SPARE
UTILITY CB AUX
UTILITY CB AUX
A IA « 30VDC ISOLATED RELAY CONTACTS. THESE RELAYS PICK UP ON ASSIGNED
CMSTO ENGINE CONTROL MODULE FAULTS ALLOWING FOR MONITORING OF CMSTO FAULTS.
N/C
H*—I at N/C
MASTER START/SYNC ENAB1
I20VAC OR 240VAC 0 SO WATTS (OPTIONAL).
& 2A 0 30VDC ISOLATED RELAY CONTACTS. THIS RELAY PICKS UP WHEN GENERATOR
P -3 LOAD DEMAND/UTILITY SINGLE AC VOLTAGE AND FREQUENCY EXCEED 901 OF NORMAL.
NET POWER +
NET POWER -
NET DATA I
-4
CB OPEN/CLOSE INHIBIT
CB POSITION
KVAR *
A 2A 0 30VDC RELAY CONTACTS. THIS RELAY PICKS UP IF AN OVERLOAD OR UNDER-
FROUENCY CONDITION OCCURS.
NET DATA 2
RUPTURE BASIN
-23
-8
KVAR -
KW • A TERMINAL BLOCK RATING
20A, 600V
CMSTO IDLE/RATED
CMS70 EMERG STOP
CMSTO FAULT ACKN
P -
PF~5
KW -
SHIELD
EXTERNAL LOAD SET •
A 22 TO 12 GA WIRE
TOROUE TERMINAL SCREWS TO T IN-LBS (0.8 NM)
CMSTO WARNING
CMSTO SHUTDOWN
P2-23 EXTERNAL LOAD SET -
SPARE A SA 0 30 VDC RELAY CONTACTS. THIS RELAY PICKS UP WHEN A WARNING CONDITION
OCCURS.
CUSTOMER FAULT I
CUSTOMER FAULT 2
FAULT RESET
SPARE
A APPLY Bt AND A GROUND TO CIRCUIT BRAKER AUXILARY TO INDICATE A
UTILITY BREAKER CLOSURE (LESS THAN 50 mA).

ENGINE IDLE
LOW FUEL A SA 0 30VDC RELAY CONTACTS. THIS RELAY PICKS UP TO CLOSE AND DROPS OUT
TO OPEN THE GENERATOR CIRCUIT BREAKER.
REMOTE START
REMOTE EMERG STOP TERMINAL BLOCK POSITIONS A PULSED INPUT TO ENABLE GENSET AS FIRST ON LINE FOR MULTIPLE UNITS.
IN SINGLE/UTILITY PARALLEL MODE. APPLY 24V0C TO ENABLE SYNCHRONIZER.
(N/O)
COMM
(N/C) > COMMON
ALARM A TBI-41 THROUGH TBI-60 ARE
FOR PARALLELING ONLY
A
A
IN MULTIPLE UNIT OPERATION MODE APPLY GROUND TO CAUSE LOAD DEMAND STOP.
IN SINGLE MODE. GROUND TERMINAL TO ENABLE BREAKER CLOSURE.
APPLY A GROUND TO REMOTELY OPEN OR INHIBIT CLOSURE OF THE GENERATOR
CIRCUIT BREAKER WHEN PCC IS IN AUTO MODE (LESS THAN SOmA).
APPLY A GROUND TO INDICATE GENERATOR CIRCUIT BREAKER IS CLOSED
A (LESS THAN 50mA).

A PARALLEL LOAD SHARE LINES (0 - ImA). USE 4 CONDUCTOR SHIELDED CABLE.

18 GA STRANDED. MAXIMUM RUN SOO FT.

A ANALOG 0-5VDC INPUTS TO CONTROL GENERATOR LOAD IN UTILITY PARALLELING

MODE.

No. 612-6759 sh 4 of 4
Rev. B
Modified 3-01

CUSTOMER CONNECTIONS DIAGRAM (PCC)

9-2
 9- Wiring Diagrams
GENERAL
This section contains the Customer Connections
Diagram referenced in text.

9-1
Cummins Power Generation
1400 73rd Avenue N.E.
Minneapolis, MN 55432
1-800-888-6266
763-574-5000 International Use Power
Fax: 763-574-8087 Generation
Cummins is a registered trademark of Cummins Inc.