Installation Manual Generator Set QSJ2.4 Engine with PowerCommand® 1.
Table of Contents 1. IMPORTANT SAFETY INSTRUCTIONS ....................................................................................... 1.1 Warning, Caution, and Note Styles Used in This Manual ..................................................... 1.2 Save These Instructions ........................................................................................................ 1.3 General Information ........................................................................................................
Table of Contents 7-2018 APPENDIX B. OUTLINE AND SYSTEM DRAWINGS...................................................................... 87 APPENDIX C. WIRING DIAGRAMS............................................................................................... 101 APPENDIX D. SEISMIC REQUIREMENTS.................................................................................... D.1 Seismic Installation Instructions (A044H911).....................................................................
1 IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS. This manual contains important instructions that should be followed during installation and maintenance of the generator set and batteries. 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. 1.
1. IMPORTANT SAFETY INSTRUCTIONS 7-2018 DANGER Alerts you to an immediate hazard that will result in severe personal injury or death. WARNING Alerts you to a hazard or unsafe practice that can result in severe personal injury or death. CAUTION Alerts you to a hazard or unsafe practice that can result in personal injury or equipment damage. 1.3 General Information This manual should form part of the documentation package supplied by Cummins Inc. with specific generator sets.
-2018 1. IMPORTANT SAFETY INSTRUCTIONS • Use caution when making adjustments when the generator set is running, hot, or when parts are electrically live, as all situations may cause personal injury or death. • Used engine oil has been identified by some state and federal agencies as causing cancer or reproductive toxicity. Do not ingest, inhale, or come into contact with used oil or its vapors. • Do not work on the generator set when mentally or physically fatigued or after consuming alcohol or drugs.
1. IMPORTANT SAFETY INSTRUCTIONS 7-2018 WARNING Electrical Generating Equipment Incorrect operation and maintenance can result in severe personal injury or death. Do not operate equipment when fatigued, or after consuming any alcohol or drug. Make sure that only suitably trained and experienced service personnel perform electrical and/or mechanical service. WARNING Toxic Gases Substances in exhaust gases have been identified by some state and federal agencies to cause cancer or reproductive toxicity.
7-2018 1. IMPORTANT SAFETY INSTRUCTIONS WARNING Combustible Gases Generator sets in operation have combustible gases under pressure, which if ignited can cause eye and ear damage. Wear appropriate eye and ear protection at all times. WARNING Combustible Gases Generator sets in operation have combustible gases under pressure, which if ignited can cause severe injury. Do not operate the generator set with any doors open.
1. IMPORTANT SAFETY INSTRUCTIONS 1.5 7-2018 Generator Set Voltage Is Deadly • Generator set output connections must be made by a trained and experienced electrician in accordance with all applicable codes. • This generator set and the public utility may only be connected to house circuits by means of the automatic transfer switch. CAUTION Improper connections can lead to electrocution of utility workers and damage to equipment.
7-2018 1.7 1. IMPORTANT SAFETY INSTRUCTIONS Starting Batteries WARNING Toxic Hazard The electrolyte in starting batteries is a dilute sulfuric acid that is harmful to the skin and eyes. It is also electrically conductive and corrosive. Always: 1. Wear full eye protection and protective clothing; 2. If the electrolyte contacts the skin, wash it off immediately with water; 3. If the electrolyte contacts the eyes, flush them thoroughly and immediately with water and seek medical attention; and 4.
1. IMPORTANT SAFETY INSTRUCTIONS 7-2018 NOTICE Servicing of batteries must be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries. • Wear safety glasses. • Do not smoke. • Do not charge frozen batteries. • To prevent arcing when disconnecting the battery: 1. Press the Off switch from the display and then press the E-Stop button. 2. Disconnect AC power from any battery chargers. 3.
7-2018 1. IMPORTANT SAFETY INSTRUCTIONS 1.10 Moving Parts Can Cause Severe Personal Injury or Death • Do not wear loose clothing or jewelry near moving parts, such as cooling fans. • Keep hands away from moving parts. • Keep guards in place over fans. 1.11 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.
1. IMPORTANT SAFETY INSTRUCTIONS 7-2018 The exhaust outlet may be sited at the top or bottom of the generator set. Make sure that the exhaust outlet is not obstructed. Personnel using this equipment must be made aware of the exhaust position. Position the exhaust away from flammable materials - in the case of exhaust outlets at the bottom, make sure that vegetation is removed from the vicinity of the exhaust. The exhaust pipes may have some insulating covers fitted.
2 Introduction 2.1 About This Manual WARNING Improper installation can result in severe personal injury, death and damage to equipment. The installation must comply with all applicable building codes (including project permits and inspections). The installer should be properly trained and licensed to perform electrical and mechanical equipment installations (including gaseous fuel installation). NOTICE Manuals are updated from time to time to reflect changes in the equipment and its specifications.
2. Introduction 7-2018 Abbr. Description Abbr. Description AC Alternating Current LED Light-Emitting Diode AMP AMP, Inc.
7-2018 2. Introduction Abbr. 2.3 Description Abbr.
2. Introduction 7-2018 CAUTION A generator set must be operated and maintained properly if you are to expect safe and reliable operation. The Operator Manual includes a maintenance schedule and a troubleshooting guide.
7-2018 2. Introduction ◦ The gas must be supplied to the generator set in sufficient volume to support operation of the generator set. This is normally a matter of selecting fuel line size to be large enough to transport the volume of fuel needed. For liquid propane vapor-withdrawal fuel systems the size and temperature of the fuel tank also affects this requirement. 2.5 Model Specifications TABLE 1. 2.
2. Introduction 7-2018 TABLE 4. FUEL SPECIFICATIONS 60 HZ, 3600 RPM C30 N6H C36 N6H C40 N6H C45 N6H C50 N6H C60 N6H Full Load (Propane) 195.5 scfh 490,000 BTU/hr 219.6 scfh 550,000 BTU/hr 236.2 scfh 595,000 BTU/hr 256.9 scfh 645,000 BTU/hr 289.5 scfh 725,000 BTU/hr 324.6 scfh 820,000 BTU/hr Full load (Natural Gas) 476.1 scfh 495,000 BTU/hr 533.3 scfh 555,000 BTU/hr 573.2 scfh 595,000 BTU/hr 623.0 scfh 645,000 BTU/hr 704.7 scfh 730,000 BTU/hr 814.
7-2018 2. Introduction TABLE 7. Sound Level 1 (Wet) GENERATOR SET WEIGHT 60 HZ, 1800 RPM C20 N6 C22 N6 C25 N6 C30 N6 C36 N6 C40 N6 kg 503 503 520 580 615 646 lb 1109 1109 1147 1279 1356 1424 TABLE 8. Sound Level 1 (Wet) GENERATOR SET WEIGHT 60 HZ, 3600 RPM C30 N6H C36 N6H C40 N6H C45 N6H C50 N6H C60 N6H kg 514 567 635 635 635 648 lb 1134 1249 1399 1399 1399 1429 TABLE 9.
2. Introduction 7-2018 C30 N6H C36 N6H C40 N6H C45 N6H C50 N6H C60 N6H 120/240 120/208 277/480 3-Phase NOTICE Maximum I2 = 8%. Copyright © 2018 Cummins Inc.
7-2018 2. Introduction TABLE 11. GENERATOR SET DERATING GUIDELINES Engine Power Available Up To... Fuel Elevation Ambient Temperature C20 N6 NG, LP 1005 m (3300 ft) 40 °C (104 °F) C22 N6 NG 670.
2. Introduction 7-2018 TABLE 13. DC SYSTEM SPECIFICATIONS (ALL MODELS) Specification Value Nominal Battery Voltage 12 VDC Battery Group 26 standard, 34 high capacity (a high capacity battery requires an accessory battery tray) Battery Type Maintenance free Minimum Cold Crank Amps 545 standard, 850 high capacity (a high capacity battery requires an accessory battery tray) Copyright © 2018 Cummins Inc.
3 Pre-Installation Considerations No. Description No. Description 1 Generator Set 4 Electrical Meter 2 Propane Tank 5 Natural Gas Meter 3 Transfer Switch FIGURE 1.
3. Pre-Installation Considerations 7-2018 • Minimum distance from the propane tank fill (verify the legal minimum distance with local code officials) • Accessories required (if any) for the customer's application (utility power may be required at the generator set; make plans accordingly) NOTICE Depending on the locality and use of the generator set, it may be necessary to obtain an air quality emissions permit before installation begins.
7-2018 3. Pre-Installation Considerations TABLE 14.
3. Pre-Installation Considerations 3.3 7-2018 Required Items for Installation Tools and materials are used for the installation of this generator set. These items are identified in the following sections. Please refer to local codes and standards, because they may affect the materials required. Materials Required NOTICE Refer to local codes and standards, which may affect material requirements.
7-2018 3.
3. Pre-Installation Considerations FIGURE 2. 7-2018 CUMMINS TRANSFER SWITCH (RA SERIES) Before beginning the installation of the transfer switch, verify that the unit was correctly selected. Check the following features: • Specifications (voltage, amperage, frequency, poles, and phases) • Enclosure (indoor vs. outdoor) • Model Refer to the RA Series Transfer Switch Owner Manual (A046S594) for more detailed information. The RA Series transfer switch is the recommended ATS for use with these generators.
7-2018 3. Pre-Installation Considerations FIGURE 3. TRANSFER SWITCH CONNECTIONS FOR PARTIAL COVERAGE LOAD FIGURE 4. TRANSFER SWITCH CONNECTIONS FOR FULL COVERAGE LOAD Loose Parts Shipped with the Generator Set The following loose parts are shipped with the generator set: • Flexible fuel hose assembly (attached to the radiator guard) A045R241 (Issue 13) 27 Copyright © 2018 Cummins Inc.
3. Pre-Installation Considerations 7-2018 • One enclosure key (where applicable) • Battery tie-down • Sound level 2 baffle (where applicable) • Weather enclosure exhaust elbow (where applicable) • Literature (operator manual, installation manual, health and safety manual, and warranty statements) Copyright © 2018 Cummins Inc.
4 Installation 4.1 Site Assessment and Preparation Proper component location and site preparation have a very important impact on completing a successful installation.
4. Installation 7-2018 No. Description 1 Cool Air In 2 Hot Air Out FIGURE 5. No. 3 Description Hot Air Out (Weather Enclosure) EXAMPLE OF GENERATOR SET LOCATION The generator set location is critical for safety and performance. Follow the guidelines below: • Must comply with applicable codes (NFPA, NEC, IBC, etc.). • Use this manual for outdoor installations only. For other applications, contact your local Cummins dealer or refer to the application manual at the following link: http://www.
7-2018 4. Installation • Position the generator set so that cooling air is free to enter and leave the area. • Locate and position the generator set so that prevailing winds carry exhaust gases and potential fuel leaks away from the house or occupied area. NOTICE For all clearance requirements, refer to the Outline and System Drawings section. Laying the Foundation When laying the foundation: 1. Clear obstructions, and make sure that there is adequate clearance for access. 2.
4. Installation 7-2018 Mounting the Generator Set Mount the generator set on a substantial and level base such as a concrete pad. A non-combustible material must be used for the pad. Verify that the mounting pad is level by length, by width, and diagonally. NOTICE Seismic installation may require specific anchorage. 4.2 Fuel Selection and Fuel System Connection This generator set has a convertible fuel system. The generator may run on natural gas or propane, depending on the preferences of the owner.
7-2018 4. Installation Gaseous-fuel supply system design, materials, components, fabrication, assembly, installation, testing, inspection, operation, and maintenance must comply with the applicable codes. See NFPA Standards No. 37, 54, and 58. If this is a seismic installation, refer to IBC codes and standards. Where seismic installation is required, there may be specific anchorage requirements for the generator set and other installed components.
4. Installation 7-2018 NOTICE A shutoff valve is recommended and often required by local and state codes. Natural Gas Fuel System Requirements for a natural gas generator set are as follows: TABLE 15.
7-2018 4. Installation No. Description No. Description 1 Shutoff Valve 3 Meter 2 Flexible Fuel Line (Attached to Radiator Guard) 4 Secondary Regulator FIGURE 6. TYPICAL NATURAL GAS INSTALLATION Natural Gas Supply Line Size The natural gas supply meter may need to be exchanged for a higher capacity meter to supply the additional gas consumed by the generator set. Use the total load requirement of the generator set to determine the size of the fuel supply pipe.
4. Installation 7-2018 NOTICE NFPA Standard No. 58 requires all persons handling and operating propane to be trained in proper handling and operating procedures. The required components in a propane vapor fuel system are as follows: Component Description Propane Tank Make sure to identify and use the correct tank size based on fuel flow requirements and the lowest average temperature for your region. If the tank is sized incorrectly, the generator set could run out of fuel.
7-2018 4. Installation No. Description No. Description 1 Generator Set 4 Secondary Regulator 2 Flexible Fuel Line (Attached to Radiator Guard) 5 Propane Tank 3 Shutoff Valve FIGURE 7. TYPICAL PROPANE INSTALLATION Propane Fuel Requirements WARNING Propane presents the hazard of fire or explosion that can cause severe personal injury or death. Do not permit any flame, spark, arc-producing equipment, switch, pilot light, cigarette, or other ignition source near the fuel system.
4. Installation 7-2018 NOTICE Commercial propane may contain more than 2.5% butane, which can result in poor fuel vaporization and low tank pressure, resulting in poor engine starting and operation in below 32 °F (O °C) temperatures. Propane Tank Size When propane is used, size the tank correctly to ensure successful generator set operation. Considerations when figuring the proper propane tank size: • Temperature is a critical factor that affects the size of the tank.
7-2018 4. Installation • Install the propane tanks according to all national and local codes and standards, and as required by the fuel tank and fuel supplier. Refer to the Fuel Line Selection appendix for propane figures and tables. Propane Vapor Fuel Supply Line Size and Pressure Fuel line size depends on the amount of fuel needed to run the generator set at full load at the distance the fuel must be moved.
4. Installation 7-2018 b. Edit the Fuel System using the horizontal arrow key. Change the field value by using the +/- keys. FIGURE 8. Copyright © 2018 Cummins Inc.
7-2018 4. Installation 3. Update the Gas Fuel Type on the Fuel System Menu. a. When changing the Fuel System, a second Fuel System Menu is enabled. Advance to this menu by pressing the down arrow after saving any changes. b. Press Adjust on the Fuel System Menu. c. Edit the Gas Fuel Type by using the horizontal arrow key. See the figure below. FIGURE 9. GAS FUEL TYPE d. Change the field value to Natural Gas, Liquid Propane, or Dual by using the +/- keys. e. Select Save to save the changes.
4. Installation 7-2018 Testing the Fuel System for Leaks After assembly and before initial operation, all of the fuel system components must be tested and proven free of any leaks. WARNING Fuel presents the hazard of explosion or fire which can result in severe personal injury or death. Do not use an open flame to check for leaks. Do not smoke or allow any flame, spark, pilot light, arc-producing equipment, switch or other ignition sources around fuel or fuel components.
7-2018 4.3 4. Installation Engine Exhaust The exhaust system for this generator set is complete and was designed specifically for this generator set. Do not modify or add to the exhaust system of this generator set. WARNING Exhaust gas is deadly. Make sure that the exhaust system terminates away from building vents, windows, doors, and sheltered spaces that may not have ample fresh air ventilation.
4. Installation 7-2018 Electrical Preparations 1. Run all wires through a single conduit (unless prohibited by the authority having jurisdiction). NOTICE Be sure to account for any needed accessories, such as a remote display, etc. 2. Connect the conduit to the generator set. Refer to the specific outline drawing in the Outline and System Drawings section for the size and location of the hole provided for electrical conduit connection. The existing hole may be increased in size to match conduit used.
7-2018 4. Installation 4. Remove the four bolts holding the circuit breaker cover. 5. Connect the conductors to the circuit breaker load-side terminals, neutral lug, and equipment grounding lug. For grounding and neutral connections, look for the symbols on the generator set circuit breaker box (shown below, and in the next image at the bottom). Equipment Grounding Conductor Symbol FIGURE 10.
4. Installation 7-2018 FIGURE 11. CIRCUIT BREAKER AC LOAD CONNECTIONS LOCATION (SYMBOLS SHOWN AT BOTTOM) 6. Torque the circuit breaker terminals per specifications on the circuit breaker label. 7. Torque the neutral lug to 31.1 Nm (275 in-lb). 8. Torque the equipment grounding lug to 13.8 Nm (120 in-lb). 9. Fill in the stub-up openings with an approved duct seal or mastic tape to keep out insects and rodents. 10. Install the circuit breaker cover. Copyright © 2018 Cummins Inc.
7-2018 4. Installation Automatic Transfer Switch AC Connections WARNING Failure to use an approved transfer switch can lead to the electrocution of personnel working on the utility lines, damage to equipment, fire, or personal injury. An approved switching device must be used to prevent interconnection to the public utility. Install the transfer switch in accordance with the appropriate RA Series Transfer Switch Owner Manual. Factory Option and Accessory Connections NOTICE Use copper conductors only.
4. Installation No. 1 7-2018 Description No. Description AC Distribution Connector(s) FIGURE 12. AC ACCESSORY CONNECTIONS The battery charger, engine coolant heater, alternator heater, CCV heater, and battery warmer require power from a 120 VAC, 20 Amp protected circuit from the Main Distribution Panel. Use 12 AWG 75 °C (167 °F) conductors to make connection to the generator set AC distribution connector.
7-2018 4. Installation FIGURE 13. DC CUSTOMER CONNECTIONS Automatic Transfer Switch DC Connections WARNING Failure to use an approved transfer switch can lead to the electrocution of personnel working on the utility lines, damage to equipment, fire, or personal injury. An approved switching device must be used to prevent interconnection to the public utility. A045R241 (Issue 13) 49 Copyright © 2018 Cummins Inc.
4. Installation 7-2018 Install the transfer switch in accordance with the appropriate RA Series Transfer Switch Owner Manual. The following image is an example that shows the location of the connectors in the generator set where the ATS DC control wires terminate. This is also the location of the connectors where load management control wires (if applicable) terminate. NOTICE Load management is only availble with air cooled product.
7-2018 4. Installation FIGURE 14. EXAMPLE OF RA SERIES TRANSFER SWITCH DC CONNECTIONS LOCATION Drilling Locations for Electrical Connections Preferred routing of electrical leads is vertically through conduit that is installed in the mounting pad that terminates in the electrical connection areas. • Refer to the generator set foundation outline drawing in the Outline and System Drawings appendix for location of electrical connection areas.
4. Installation 7-2018 • Comply with NEC and local codes and standards for installation of wires for electrical circuits. Refer to NEC standards for required wire bend radius and ampacity of load leads. No. Description 1 Circuit Breaker Side 2 DC (Left) and AC (Right) Connection Area FIGURE 15. No. 3 Description Drilling Allowed (Shaded Areas) DRILLING LOCATIONS FOR SIDE ELECTRICAL CONNECTIONS Copyright © 2018 Cummins Inc.
7-2018 4. Installation No. 1 Description No. Circuit Breaker FIGURE 16. 2 Description Maximum 7.6 cm (3 in) Bend Radius Gap CABLING ROOM FOR CIRCUIT BREAKER Grounding NOTICE The generator set is shipped from the factory with the neutral and equipment ground not bonded together. Refer to local codes and standards for grounding procedures. Battery The generator set requires a 12V battery (negatively grounded) for engine cranking and powering the electronic control system.
4. Installation 7-2018 To prevent injury due to accidental startup: • Do not connect the battery cables to the battery until the installation has been completed; • Make sure tools, rags, and body parts are kept away from any rotating parts or electrically live parts; and • Make sure it is time to start the generator set. NOTICE Ensure that the AC power to the battery charger is disconnected when installing the battery. NOTICE Wear proper safety protection when working around batteries.
7-2018 4. Installation FIGURE 17. A045R241 (Issue 13) BATTERY LOCATION 55 Copyright © 2018 Cummins Inc.
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5 Startup and Configuration 5.1 Time Setup (1-Phase ATS) NOTICE When battery power is lost, these settings must be reset. NOTICE Not applicable without a single phase RA series transfer switch. To set up the generator set clock for the current date and time: 1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears. 2. Access the Time Setup screen by selecting Clock Exerciser on the Genset Service Menu. 3. Select Adjust.
5. Startup and Configuration 7-2018 Updating Daylight Saving Adjust Screens Update Values on the Daylight Saving Adjust Screen 1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears. 2. Navigate to the Genset Service Menu. 3. Select Clock Exerciser to access the Time Setup screen. 4. Press the down key on the Time Setup screen to access the Daylight Saving Adjust screen. 5. Select Adjust.
7-2018 5. Startup and Configuration TABLE 17. KEY FUNCTIONS ON THE DAYLIGHT SAVING ADJUST START SCREEN Key/Button Function Horizontal right arrow key Select successive blocks for editing settings on the screen + or - keys Adjust Month, Week, Day or Hour Save button Save any changes; after saving, the Save button changes to the Adjust button FIGURE 20. DAYLIGHT SAVING ADJUST START SCREEN Update the Daylight Saving Adjust End Screen 1. Press the down key on the Daylight Saving Adjust Start screen.
5. Startup and Configuration FIGURE 21. 5.2 7-2018 DAYLIGHT SAVING ADJUST END SCREEN Exercise Settings NOTICE When battery power is lost, these settings must be reset. NOTICE Not applicable without a single phase RA series transfer switch. To access the Clock/Exerciser Menu: 1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears. 2. Navigate through the screens to find and select Clock/Excr in the Service Menu.
7-2018 5. Startup and Configuration FIGURE 22. A045R241 (Issue 13) CLOCK/EXERCISER MENU NAVIGATION 61 Copyright © 2018 Cummins Inc.
5. Startup and Configuration 7-2018 Updating Exercise Frequency (1-Phase ATS) NOTICE Not applicable without a single phase RA series transfer switch. To update the exercise frequency and dates on the Clock/Exerciser Menu: 1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears. 2. Access the Time Setup screen by selecting Clock Exerciser on the Genset Service Menu. 3.
7-2018 5. Startup and Configuration FIGURE 23. EXERCISE FREQUENCY NAVIGATION Updating Exercise Duration (1-Phase ATS) NOTICE Not applicable without a single phase RA series transfer switch. To update the exercise duration on the Clock/Exerciser Menu: 1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears. 2. Access the Time Setup screen by selecting Clock Exerciser on the Genset Service Menu. 3.
5. Startup and Configuration 7-2018 • Press Save to save any changes. After saving, the Save button changes to the Adjust button. FIGURE 24. 5.3 EXERCISE DURATION NAVIGATION Brightness and Contrast The Screen Adjust screen allows the contrast, brightness, and units to be set. To access the Screen Adjust screen: 1. From any Information screen, hold down the up and down arrows simultaneously for two seconds to gain access to the Service Menu screen. 2. Select Screen Adjust.
7-2018 5. Startup and Configuration NOTICE The following screens represent the standard operator panel (HMI211). If using an in-home operator panel, which may be additionally purchased as an option, the screens may look slightly different. This procedure applies to both operator panels. FIGURE 25. A045R241 (Issue 13) BRIGHTNESS AND CONTRAST SCREEN NAVIGATION 65 Copyright © 2018 Cummins Inc.
5. Startup and Configuration 7-2018 NOTICE Adjusting the brightness on the operator panel adjusts the brightness of both the LCD backlight and the LEDs on the display. The contrast should never be 0 or 100% on any of the screens. The default value for Brightness is 50%. 5.4 History and About Menu To access the History/About screen: 1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears. 2. Select History/About. 3.
7-2018 5. Startup and Configuration FIGURE 26. A045R241 (Issue 13) HISTORY/ABOUT MENU 67 Copyright © 2018 Cummins Inc.
5. Startup and Configuration 5.5 7-2018 InPower Service Tool The InPowerTM service tool can be used in troubleshooting to perform tests, verify control inputs and outputs, and test protective functions. Refer to the InPower User's Guide, provided with the InPower software for test procedures. Disabling the AMF Feature NOTICE This procedure must be performed by a qualified technician. On single-phase units, the control is shipped with the Automatic Mains Failure (AMF) feature enabled.
7-2018 5.6 5. Startup and Configuration Installation Checklist Tick Item General Generator set wattage capacity is sufficient to handle maximum anticipated load. At least 5 feet of clearance to combustible materials is provided. At least 3 feet of clearance is provided around the entire generator set for service and ventilation. The generator set is located in an area not subject to flooding.
5. Startup and Configuration 7-2018 Tick Item AC and DC wires are separated in their own conduit to prevent electrical induction. All load, line and generator connections are well made and correct. Generator Set Pre-Start A safety check was performed just before starting. The generator set engine is properly serviced with oil and coolant. The battery is properly installed, serviced and charged. The battery charger and engine coolant heater are connected and operational, if applicable.
7-2018 5. Startup and Configuration The generator set is shipped from the factory with the proper level of engine oil and coolant, but each should be checked before the generator set is started. Start and operate the generator set following all the instructions and precautions in the Operator Manual. Ensure that the bonding bolts are installed into the service panels before leaving the site.
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Appendix A. Fuel Line Selection Table of Contents Table 20. Required Information for Determining Fuel Line Size ............................................................. 74 Table 22. NFPA Equivalent Lengths of Pipe Fittings and Valves in Feet (Meters) ................................ 75 Table 24. Natural Gas Schedule 40 Metallic Pipe Sizing in Inches ......................................................... 77 Table 27. Natural Gas Semirigid Copper Tubing Sizing .........................................
Appendix A. Fuel Line Selection A.0 7-2018 Fuel System Pipe Sizing Introduction Incorrect fuel line size may cause the generator set to not run or provide full power output. Tables are included in this section to help calculate pipe sizing for natural gas and propane vapor withdrawal under specified conditions. Consult NFPA 54 or other applicable codes for other operating conditions or other fuel system installation requirements.
7-2018 Appendix A. A.1 Fuel Line Selection Gas Pipe Sizing NOTICE The following tables in this section are reprinted with permission from NFPA 54-2015, National Fuel Gas Code, Copyright © 2014, National Fire Protection Association.
Appendix A. Fuel Line Selection 7-2018 Nominal Inch (Millimeters) Pipe Size Type of Fitting 1/2 (15) 1 (25) 1-1/4 (32) 1-1/2 (40) 2 (50) 2-1/2 (65) 3 (80) 4 (100) Foot Valve and Strainer 3.7 4.9 7.5 (1.1) (1.5) (2.3) 8.9 (2.7) 11.0 (3.4) 15.0 (4.6) 18.0 (5.5) 22.0 (6.7) 29.0 (8.8) Swing Check Valve, Fully Open 6.0 8.0 10.0 (1.8) (2.4) (3.0) 14.0 (4.3) 16.0 (4.9) 20.0 (6.1) 25.0 (7.6) 30.0 (9.1) 40.0 (12.2) Globe Valve, Fully Open 18.0 22.0 29.0 (5.5) (6.7) (8.8) 38.0 (11.
7-2018 Appendix A. Fuel Line Selection TABLE 24. NATURAL GAS SCHEDULE 40 METALLIC PIPE SIZING IN INCHES Gas: Natural Inlet Pressure: Less than 2 psi Pressure Drop: 0.5 in. water column Specific Gravity: 0.6 Pipe Size Nominal: Actual ID: 1⁄2 3⁄4 1 11⁄4 11⁄2 2 21⁄2 3 4 5 6 8 10 12 0.622 0.824 1.049 1.38 1.61 2.067 2.469 3.068 4.026 5.047 6.065 7.981 10.02 11.
Appendix A.
7-2018 Appendix A.
Appendix A. Fuel Line Selection 7-2018 1,400 NA NA NA 13 19 41 73 116 241 1,500 NA NA NA 13 18 39 71 111 232 1,600 NA NA NA 13 18 38 68 108 224 1,700 NA NA NA 12 17 37 66 104 217 1,800 NA NA NA 12 17 36 64 101 210 1,900 NA NA NA 11 16 35 62 98 204 2,000 NA NA NA 11 16 34 60 95 199 NA: A flow of less than 10 cfh. Note: All table entries are rounded to 3 significant digits.
7-2018 Appendix A.
Appendix A. Fuel Line Selection 7-2018 TABLE 33. PROPANE VAPOR SEMIRIGID COPPER TUBING SIZING Gas: Undiluted Propane Inlet Pressure: 11.0 in. water column Pressure Drop: 0.5 in. water column Specific Gravity: 1.5 INTENDED USE: Tube Sizing Between Single- or Second-Stage (Low-Pressure) Regulator and Appliance Tube Size (in.) Nominal K& L: 1⁄4 3⁄8 1⁄2 5⁄8 3⁄4 1 11⁄4 11⁄2 2 Nominal ACR: 3⁄8 1⁄2 5⁄8 3⁄4 7⁄8 11⁄8 13⁄8 — — Outside: 0.375 0.5 0.625 0.75 0.875 1.125 1.375 1.
7-2018 Appendix A.
Appendix A. Fuel Line Selection Equivalent Length of Pipe (ft.) 7-2018 Schedule 40 Iron Pipe Size (in.): Nominal (Inside Diameter) 1/2 3/4 1 (0.622) (0.824) (1.049) 1 1/4 (1.38) 1 1/2 (1.61) 2 3 3 1/2 4 (2.067) (3.068) (3.548) (4.
7-2018 Appendix A. Fuel Line Selection FIGURE 27. MINIMUM LPG TANK SIZE (50% FULL) REQUIRED TO MAINTAIN 5 PSIG AT SPECIFIC WITHDRAWAL RATE AND MINIMUM EXPECTED WINTER TEMPERATURE A045R241 (Issue 13) 85 Copyright © 2018 Cummins Inc.
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Appendix B. Outline and System Drawings Table of Contents Figure 28. Generator Set Outline, 20-25 kW 1800 RPM, 30 kW 3600 RPM (Sheet 1 of 2) ..................... 89 Figure 29. Generator Set Outline, 20-25 kW 1800 RPM, 30 kW 3600 RPM (Sheet 2 of 2) ..................... 90 Figure 30. Generator Set Outline, 30-40 kW 1800 RPM, 36-60 kW 3600 RPM (Sheet 1 of 2) ................ 91 Figure 31. Generator Set Outline, 30-40 kW 1800 RPM, 36-60 kW 3600 RPM (Sheet 2 of 2) ................ 92 Figure 32.
Appendix B. Outline and System Drawings 7-2018 The drawings included in this section are representative. For current complete information, refer to the drawing package that was shipped with the unit. Copyright © 2018 Cummins Inc.
7-2018 Appendix B. FIGURE 28. A045R241 (Issue 13) Outline and System Drawings GENERATOR SET OUTLINE, 20-25 KW 1800 RPM, 30 KW 3600 RPM (SHEET 1 OF 2) 89 Copyright © 2018 Cummins Inc.
Appendix B. Outline and System Drawings 7-2018 FIGURE 29. Copyright © 2018 Cummins Inc.
7-2018 Appendix B. FIGURE 30. A045R241 (Issue 13) Outline and System Drawings GENERATOR SET OUTLINE, 30-40 KW 1800 RPM, 36-60 KW 3600 RPM (SHEET 1 OF 2) 91 Copyright © 2018 Cummins Inc.
Appendix B. Outline and System Drawings 7-2018 FIGURE 31. Copyright © 2018 Cummins Inc.
7-2018 Appendix B. FIGURE 32. A045R241 (Issue 13) Outline and System Drawings FOUNDATION OUTLINE, 20-25 KW 1800 RPM, 30 KW 3600 RPM (SHEET 1 OF 1) 93 Copyright © 2018 Cummins Inc.
Appendix B. Outline and System Drawings 7-2018 FIGURE 33. Copyright © 2018 Cummins Inc.
7-2018 Appendix B. FIGURE 34. A045R241 (Issue 13) Outline and System Drawings ENCLOSURE OUTLINE, 20-25 KW 1800 RPM, 30 KW 3600 RPM (SHEET 1 OF 2) 95 Copyright © 2018 Cummins Inc.
Appendix B. Outline and System Drawings 7-2018 FIGURE 35. Copyright © 2018 Cummins Inc.
7-2018 Appendix B. FIGURE 36. A045R241 (Issue 13) Outline and System Drawings ENCLOSURE OUTLINE, 30-40 KW 1800 RPM, 36-60 KW 3600 RPM (SHEET 1 OF 2) 97 Copyright © 2018 Cummins Inc.
Appendix B. Outline and System Drawings 7-2018 FIGURE 37. Copyright © 2018 Cummins Inc.
7-2018 Appendix B. FIGURE 38. A045R241 (Issue 13) Outline and System Drawings CIRCUIT BREAKER OUTLINE (SHEET 1 OF 1) 99 Copyright © 2018 Cummins Inc.
Appendix B. Outline and System Drawings 7-2018 This page is intentionally blank. Copyright © 2018 Cummins Inc.
Appendix C. Wiring Diagrams Table of Contents Figure 39. Wiring Diagram (Sheet 1 of 7) ................................................................................................. 103 Figure 40. Wiring Diagram (Sheet 2 of 7) ................................................................................................. 104 Figure 41. Wiring Diagram (Sheet 3 of 7) ................................................................................................. 105 Figure 42.
Appendix C. Wiring Diagrams 7-2018 The drawings included in this section are representative. For current complete information, refer to the drawing package that was shipped with the unit. Copyright © 2018 Cummins Inc.
7-2018 Appendix C. FIGURE 39. A045R241 (Issue 13) Wiring Diagrams WIRING DIAGRAM (SHEET 1 OF 7) 103 Copyright © 2018 Cummins Inc.
Appendix C. Wiring Diagrams 7-2018 FIGURE 40. Copyright © 2018 Cummins Inc.
7-2018 Appendix C. FIGURE 41. A045R241 (Issue 13) Wiring Diagrams WIRING DIAGRAM (SHEET 3 OF 7) 105 Copyright © 2018 Cummins Inc.
Appendix C. Wiring Diagrams 7-2018 FIGURE 42. Copyright © 2018 Cummins Inc.
7-2018 Appendix C. FIGURE 43. A045R241 (Issue 13) Wiring Diagrams WIRING DIAGRAM (SHEET 5 OF 7) 107 Copyright © 2018 Cummins Inc.
Appendix C. Wiring Diagrams 7-2018 FIGURE 44. Copyright © 2018 Cummins Inc.
7-2018 Appendix C. FIGURE 45. A045R241 (Issue 13) Wiring Diagrams WIRING DIAGRAM (SHEET 7 OF 7) 109 Copyright © 2018 Cummins Inc.
Appendix C. Wiring Diagrams 7-2018 This page is intentionally blank. Copyright © 2018 Cummins Inc.
Appendix D. Seismic Requirements Table of Contents Figure 46. Seismic Installation Specifications ........................................................................................ 113 Figure 47. Seismic Installation Specifications ........................................................................................ 114 Figure 48. Seismic Installation Notes ...................................................................................................... 115 Figure 49.
Appendix D. Seismic Requirements 7-2018 The drawings included in this section are representative. For current complete information, refer to the drawing package that was shipped with the unit. Copyright © 2018 Cummins Inc.
7-2018 Appendix D. D.1 Seismic Installation Instructions (A044H911) FIGURE 46. A045R241 (Issue 13) Seismic Requirements SEISMIC INSTALLATION SPECIFICATIONS 113 Copyright © 2018 Cummins Inc.
Appendix D. Seismic Requirements 7-2018 FIGURE 47. Copyright © 2018 Cummins Inc.
7-2018 Appendix D. FIGURE 48. A045R241 (Issue 13) Seismic Requirements SEISMIC INSTALLATION NOTES 115 Copyright © 2018 Cummins Inc.
Appendix D. Seismic Requirements 7-2018 FIGURE 49. Copyright © 2018 Cummins Inc.
7-2018 Appendix D. FIGURE 50. A045R241 (Issue 13) Seismic Requirements SEISMIC INSTALLATION REQUIREMENTS 117 Copyright © 2018 Cummins Inc.
Appendix D. Seismic Requirements 7-2018 FIGURE 51. Copyright © 2018 Cummins Inc.
7-2018 Appendix D. FIGURE 52. A045R241 (Issue 13) Seismic Requirements SEISMIC INSTALLATION REQUIREMENTS 119 Copyright © 2018 Cummins Inc.
Appendix D. Seismic Requirements 7-2018 This page is intentionally blank. Copyright © 2018 Cummins Inc.
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