Powercommand 2100 Series

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Installation Manual
PowerCommand Control
2100 Series
Generator Sets
Models
DFAB, DFAC, DFBF, DFCB, DFCC, DFCE
960-0634C 02-2004
Printed in U.S.A.
Redistribution or publication of this document,

by any means, is strictly prohibited.
Table of Contents
SECTION TITLE PAGE

IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
1 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
Aligning Generator with Engine (750 kW Gensets and Larger) . . . . . . . . . 3-5
4 MECHANICAL CONNECTIONS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Ventilation and Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
5 DC CONTROL WIRING
Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
TB1 Remote Monitor/Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
TB2 Power Transfer Control (PTC) Connections (Optional) . . . . . . . . . . . . 5-2
Control Relays (K11, K12, K13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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.

i by any means, is strictly prohibited.
SECTION TITLE PAGE
6 AC ELECTRICAL CONNECTIONS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
AC Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Control Heater (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Coolant Heater (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Generator Heater (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Fuel Transfer Pump (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Ground Fault Alarm Relay (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
7 ENCLOSURE ELECTRICAL CONNECTIONS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Optional AC Distribution Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Optional Motorized Inlet/Outlet Louvers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Optional Transfer Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
8 PRESTART PREPARATION
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
PCC Options Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
9 INSTALLATION CHECKLIST
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Generator Set Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Cooling Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Diesel Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
AC and DC Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Generator Set Prestart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
10 WIRING DIAGRAMS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

ii by any means, is strictly prohibited.
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 oper-
• Engine exhaust and some of its constituents are
known to the state of California to cause cancer,
ator, service personnel, or the equipment.
birth defects, and other reproductive harm.
This symbol warns of immediate
MOVING PARTS CAN CAUSE SEVERE
hazards which will result in severe personal in-
jury or death. PERSONAL INJURY OR DEATH
• Keep your hands, clothing, and jewelry away from
WARNING This symbol refers to a hazard or un- moving parts.
safe practice which can result in severe person-
al injury or death. • Before starting work on the generator set, discon-
nect battery charger from its AC source, then dis-
CAUTION 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 vicinity 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,
moving parts, etc.
• DO NOT permit any flame, cigarette, pilot light,
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 servicing 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 Cummins Power
ing, sparking, smoking, etc. Generation distributor for more information.
LS-14L
iii by any means, is strictly prohibited.
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, combustible
• Remove electric power before removing protective and flammable liquid fuels and gaseous fuels; Class
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 DIRECT-
LY TO ANY BUILDING ELECTRICAL SYSTEM. • Do not work on this equipment when mentally or
Hazardous voltages can flow from the generator set physically fatigued, or after consuming any alcohol
into the utility line. This creates a potential for elec- or drug that makes the operation of equipment un-
trocution 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 by any means, is strictly prohibited.
1. Introduction
ABOUT THIS MANUAL mance, and safe operation. Refer to Operators
Manual for troubleshooting information.
This manual provides installation instructions for
the generator set models listed on the front cover. Installation Checklist − reference checks
This includes the following information: upon completion of installation.
Mounting Recommendations - for fastening
generator set to base and space requirements This manual DOES NOT provide application infor-
for normal operation and service. mation for selecting a generator set or designing the
complete installation. If it is necessary to design the
Mechanical and Electrical Connections - various integrated systems (fuel, exhaust, cooling,
covers most aspects of the generator set instal- etc.), additional information is required. Review
lation. standard installation practices. For engineering
Prestart − checklist of items or procedures data specific to the generator set, refer to the Speci-
needed to prepare generator set for operation. fication and Data Sheets. For application informa-
Initial Startup − test complete system to en- tion, refer to Application Manual T-030, “Liquid
sure proper installation, satisfactory perfor- Cooled Generator Sets”.

1-1 by any means, is strictly prohibited.
INSTALLATION OVERVIEW installed, maintained, and operated. However, the
overall safety and reliability of the complete system
These installation recommendations apply to typi- is dependent on many factors outside the control of
cal installations with standard model generator the generator set manufacturer. To avoid possible
sets. Whenever possible, these recommendations safety hazards, make all mechanical and electrical
also cover factory designed options or modifica- connections to the generator set exactly as speci-
tions. However, because of the many variables in fied in this manual. All systems external to the gen-
any installation, it is not possible to provide specific erator (fuel, exhaust, electrical, etc.) must comply
recommendations for every situation. If there are with all applicable codes. Make certain all required
any questions not answered by this manual, contact inspections and tests have been completed and all
your nearest Cummins Power Generation distribu- code requirements have been satisfied before certi-
tor for assistance. fying the installation is complete and ready for ser-
vice.
Application and Installation
A standby power system must be carefully planned Standby Heating Devices
and correctly installed for proper operation. This in-
volves two essential elements: application and In accordance with NFPA 110, Cummins Power
installation. Generation recommends installing diesel standby
generator sets (life safety systems) equipped with
Application (as it applies to generator set installa- engine jacket water coolant heaters in locations
tions) refers to the design of the complete standby where the minimum ambient temperature is above
power system that usually includes power distribu- 40°F (4°C). NFPA also requires that the engine
tion equipment, transfer switches, ventilation equip- jacket water coolant be maintained at a minimum of
ment, mounting pads, and cooling, exhaust, and 90°F (32°C) and, for most applications, accept the
fuel systems. Each component must be correctly emergency load in 10 seconds or less. Although
designed so the complete system will function as in- most Cummins Power Generation generator sets
tended. Application and design is an engineering will start in temperatures down to −25°F (−32°C)
function generally done by specifying engineers or when equipped with engine jacket water coolant
other trained specialists. Specifying engineers or heaters, it might take more than 10 seconds to
other trained specialists are responsible for the de- warm the engine up before a load can be applied
sign of the complete standby system and for select- when ambient temperatures are below 40°F (4°C).
ing the materials and products required.
The Engine Cold (Code 1435) message, in con-
Installation refers to the actual set-up and assem-
junction with illumination of the Warning LED, is pro-
bly of the standby power system. The installers set
vided to meet the requirements of NFPA 110. The
up and connect the various components of the sys-
engine cold sensing logic initiates a warning when
tem as specified in the system design plan. The
the engine jacket water coolant temperature falls
complexity of the standby system normally requires
below 70°F (21°C). In applications where the ambi-
the special skills of qualified electricians, plumbers,
sheetmetal workers, etc. to complete the various ent temperature falls below 40°F (4°C), a cold en-
segments of the installation. This is necessary so all gine may be indicated even though the coolant
components are assembled using standard meth- heaters are connected. Under these conditions, al-
ods and practices. though the generator set may start, it may not be
able to accept load within 10 seconds. When this
Safety Considerations condition occurs, check the coolant heaters for
proper operation. If the coolant heaters are operat-
The generator set has been carefully designed to ing properly, other precautions may be necessary to
provide safe and efficient service when properly warm the engine before applying a load.
Copyright 2003 Cummins Power Generation. All rights reserved.

Cummins and PowerCommand are registered trademarks of Cummins Inc.

2. Specifications
MODEL DFAB/DFAC DFBF DFCB/DFCC DFCE

Cummins Diesel Series LTA10 NT855 NTA855 NTA855
Generator kW Rating See Genset Nameplate for rating information.
Cooling System
Capacity with Standard Radiator 13 Gal (49 L) 13.5 Gal (51 L) 13.5 Gal (51 L) 15 Gal (57 L)
Oil Capacity* 9.5 Gal (36 L) 10.5 Gal (40 L) 10.5 Gal (40 L) 10 Gal (38 L)
Engine Fuel Connection
Inlet/Oultet Thread Size Refer to Generator Outline Drawing
Fuel Flow
Max. Fuel Inlet Restriction 4 in. Hg. (13.5 kPa) 4 in. Hg. (13.5 kPa)
Max. Fuel Return Restriction 6.5 in. Hg. (22 kPa) 6 in. Hg. (20.3 kPa)
Exhaust
Outlet Size 4 in. NPT 5 in. NPT 6 in. NPT 6 in. NPT
Max. Allowable Back Pressure
H20 41 41 41 41
kPa 10.2 10.2 10.2 10.2
Electrical System
Starting Voltage 24 Volts DC
Battery Two, 12 Volt
Group number 8D
CCA (minimum)
Cold Soak @ 0° F (-18° C) 1400
* Refer to Cummins engine Operation and Maintenance Manual for lubricating oil recommendations/specifications.
FUEL CONSUMPTION (STANDBY/FULL LOAD/60HZ)

MODEL DFAB DFAC DFBF DFCB DFCC DFCE
US gph (L/hr) 15.6 (59) 16.8 (63.7) 20.4 (77.3) 22.5 (85.3) 24.4 (92.5) 29.1 (110.3)

THIS PAGE LEFT INTENTIONALLY BLANK

3. Mounting the Generator Set
GENERAL • Discharge of exhaust gases
• Electrical connections
Generator set installations must be engineered so
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 • Vibration isolation
consulting engineer when locating or installing any
components. The complete installation must com- LOCATION
ply with all local and state building codes, fire ordi-
nances, and other applicable regulations. Generator set location is decided mainly by related
systems such as ventilation, wiring, fuel, and ex-
haust. The set should be located as near as pos-
Requirements to be considered prior to installation:
sible to the main power service entrance. Exhaust
• Level mounting surface must not be able to enter or accumulate around in-
habited areas.
• Adequate cooling air
• Adequate fresh induction air Provide a location away from extreme ambient tem-
peratures and protect the generator set from ad-
• Discharge of generator set air verse weather conditions. An optional housing is
• Non-combustible mounting surface. available for outside operation.
WARNING
INCORRECT INSTALLATION, SERVICE OR PARTS REPLACEMENT CAN RESULT IN SEVERE

PERSONAL INJURY, DEATH, AND/OR EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST
BE TRAINED AND EXPERIENCED TO PERFORM ELECTRICAL AND MECHANICAL COM-
PONENT INSTALLATION.
IMPORTANT
DEPENDING ON YOUR LOCATION AND INTENDED USE, FEDERAL, STATE OR LOCAL LAWS
AND REGULATIONS MAY REQUIRE YOU TO OBTAIN AN AIR QUALITY EMISSIONS PERMIT
BEFORE BEGINNING INSTALLATION OF YOUR GENSET. BE SURE TO CONSULT LOCAL
POLLUTION CONTROL OR AIR QUALITY AUTHORITIES BEFORE COMPLETING YOUR
CONSTRUCTION PLANS.

MOUNTING
SUBBASE OR
Generator sets are mounted on a steel skid or fuel VIBRATION
tank that provides proper support. The engine-gen- ISOLATOR
erator assembly is isolated from the skid frame by FLANGE
rubber mounts that provide adequate vibration
isolation for normal installations. Where required by HEX NUT
building 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
Ç Ç
genset warranty.
Ç Ç
For fuel tank mounted generator sets, it is required
Ç Ç
that the tank be mounted such that an air space is
provided between the bottom of the tank and the
Ç
1-1/2 x 6 INCH
floor underneath to reduce corrosion and permit PIPE
visual inspections for leaks.
MOUNTING 12 IN.
Mount the generator set on a substantial and level BASE (305 mm)
base such as a concrete pad. A non-combustible CONCRETE
material must be used for the pad.
Use 5/8 inch or 16 mm anchored mounting bolts to
secure the vibration isolators to the base. Secure
the vibration isolators using flat or bevel washer and
hexagonal nut for each bolt (see Figure 3-1). The MOUNTING
1-1/2 x 6 inch pipe inserted over the mounting bolts BOLT
allows minor adjustment of the bolts to align them to
the holes in the subbase or vibration isolator.
FIGURE 3-1. BOLT DIAGRAM
Locate the isolators as shown on the generator set
Outline Drawing referenced in the Data Sheet.
ACCESS TO SET
Generally, at least 1 meter (3 feet) of clearance
should be provided on all sides of the generator set
for maintenance and service access. (Increase
clearance by width of door if optional housing is
used.) A raised foundation or slab of 150 mm (6
inches) or more above floor level will make servic-
ing 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.

DC CONTROL
WIRING
CONDENSATION
DRAIN TRAP
MUFFLER
SWEEPING
ELBOW
THIMBLE
AC POWER
WIRING
FLEXIBLE SECTION
AIR
IN
AIR OUTLET
DUCT
SHIPPING SCREW
(DFCE ONLY) EACH SIDE CONCRETE
BASE
VIBRATION IMPORTANT!
ISOLATORS COOLING AIR INLET MUST BE AT LEAST 1-1/2
TIMES LARGER THAN RADIATOR DUCT OUTLET
AREA ON RADIATOR COOLED MODELS
FLOW OR COOLING AIR AND HEATED AIR CAN

BE CONTROLLED BY AUTOMATICALLY
OPERATED LOUVRES
FIGURE 3-2. TYPICAL INSTALLATION

VIBRATION ISOLATORS The leveling bolt will adjust the clearance be-
tween the top plate and the isolator base. A
Installation and Adjustment Procedure nominal clearance of 0.25 inch (6 mm) or great-
er is desired. This will provide sufficient clear-
1. Place the vibration isolators (Figure 3-3) on the ance for the rocking that occurs during startup
genset support structure. The isolators should and shutdown. If the 0.25 inch (6 mm) clear-
be shimmed or grouted to ensure that all of the ance is not present, turn the leveling bolt until
isolator bases are within 0.25 inch (6 mm) the desired clearance is achieved.
elevation of each other. The surface that the
isolator bases rest on must also be flat and lev- 5. The genset may not be level yet; therefore, ad-
el. just the leveling bolts until the set is level and
sufficient clearance still remains. (Clearance
2. Loosen the side snubber lock nuts so that the on all isolators should be roughly equal). Once
top plate of the isolator is free to move vertically all isolators have been set, lock the leveling bolt
and horizontally. Be sure that the top plate is in place with the lock nut.
correctly aligned with the base and springs.
6. The snubber nuts may remain loose and there-
3. Place the genset onto the isolators while align- fore provide better isolation between the gen-
ing the skid’s mounting with the threaded isola- set and support structure.
tor hole. The top plates will move down and ap-
proach the base of the isolator as load is ap- 7. Model DFCE only: With the genset in position
plied. and secured to the isolators, remove the two
controller cabinet shipping screws (see Figure
4. Once the genset is in position, the isolators 3-2).
may require adjusting so that the set is level.
The isolators are adjusted by inserting the lev- CAUTION Remove shipping screws (two)
eling bolt through the skid and into the isolator prior to genset operation. Genset operation
(the leveling bolt’s locking nut should be with shipping screws in place will damage
threaded up towards the bolt head). control components.
GENSET SKID
LEVELING BOLT
LOCK NUT
CLEARANCE
SNUBBER
BASE
FIGURE 3-3. VIBRATION ISOLATORS

ALIGNING GENERATOR WITH ENGINE Misalignment Symptoms
(750 kW GENSETS AND LARGER)
If the assembly is allowed to run under these condi-
Proper alignment of the generator and engine as- tions, the discs must flex in alternate directions
semblies is necessary to avoid premature wear and twice for each engine revolution. It is important to
improper operation of the genset. Review the fol- minimize the amount of disc flexing since, if it is ex-
lowing alignment conditions and procedures for cessive, the drive disc will crack. Although perfect
aligning the generator assembly to engine flywheel bearing alignment is desirable, it is more important
housing. to keep disc deflection to the very minimum pos-
sible. This procedure assumes that the pilot bore of
the drive discs are in the exact center and the fly-
Angular Misalignment wheel counterbore (pilot) has no practical runout.
Under these conditions, perfect Angular alignment
Angular misalignment is the result of the generator will be attained when no deflection of the discs is
bearing center axis not aligning with axis of the en- measured.
gine crankshaft. This condition creates an angle
between the generator shaft axis and the crank- Excessive Axial alignment will cause more genera-
shaft axis. The cause of this type of misalignment is tor vibration than Angular misalignment.
usually shimming error.
Axial misalignment needs to be checked only when
an objectionable vibration is present.
Axial Misalignment
Either type off misalignment may be present in a
Axial misalignment is the result of the generator generator set assembly, with angular misalignment
shaft axis not aligning with engine crankshaft axis. being the most common problem. Angular align-
The tolerances in the bolted flywheel and drive disc ment may also be effected by set installation condi-
connection may add up to displace the generator tions and/or mishandling during shipping of the gen-
axially relative to the crankshaft axis. set.
SEE DETAIL A
CLAMP DIAL INDICATOR
FLEX
DISCS
GENERATOR MOUNTING BOLT

AND ENGINE TO DISC
CRANKSHAFT MEASUREMENT AXIAL
CENTERLINE
SHIMS ALIGNMENT DETAIL A
FIGURE 3-4. ANGULAR ALIGNMENT MEASUREMENT

Angular Alignment Procedure -.015”.) The indicator is closer to the top and further
away at the bottom. This example indicates that the
WARNING Accidental starting of the generator generator bearing is high. Since the side readings
set during this procedure presents the hazard are equal, the generator is centered side to side. To
of severe personal injury or death. Make sure to lower the generator, remove equal shims from un-
disconnect the negative (-) battery cable(s) be- der both generator mounting feet. To approximate
fore beginning. the amount of shims to remove or add:
Fasten a dial indicator to either the generator shaft 1. Measure the distance between the center of
or the cooling fan with the sensing point resting on the generator shaft to the point the indicator is
the capscrew head or the flat surface of the drive measuring at. (For example; a SAE 18 Disc
disc at the bolt circle diameter, see Figure 3-4. Bar coupling distance is 10.7”).
the engine over in a clockwise rotation as viewed
2. Measure the distance from the generator side
from engine flywheel. Do not allow it to roll back on
of the flex discs to the center of the generator
compression at the end of the travel of each read-
mounting bolt, refer to Figure 3-4. (For exam-
ing. It is unnecessary to zero the indicator since the
ple; a HC6 Frame’s distance is 28.4”.)
total indicator reading (T.I.R.) of the deflection mea-
surement to the bolt heads is what is required. T.I.R. 3. Compare the distance measured in steps 1 and
will be the sum of the maximum positive and nega- 2. (28.4” vs 10.7” or a 2.65 to 1 ratio.) Multiply
tive dial indicator readings as the engine completes this ratio times one half the T.I.R. (In our exam-
one revolution. ple, .025” divided by 2 is .0125”. This, times
2.65 equals .033”. Therefore, remove .033” of
CAUTION Do not bar engine over by prying on shims from under both mounting feet.)
fan blade. This may damage the blade and result
in premature, sudden blade failure. In general, the T.I.R. should not be more than .001”
for each inch of radius (center of shaft to indicator
Sample Generator Runout Readings: When taking axis). If we use our example of 10.7 inches, then the
the deflection readings described, make a diagram maximum T.I.R. would be .011”. This would only re-
similar to the example shown in Figure 3-5, with a quire a correction of .014” from the T.I.R. of .025”. (A
total indicator reading of .025”. (The highest posi- reading of +.002 at the top and −.009 at the bottom
tive value of +.010” and the largest negative value of would fall within the satisfactory range.)
+.010
+.010
MEASURED AT
BOLT CIRCLE −.002
DIAMETER
−.004
10.7 IN.
−.010
−.010
−.015 −.015
FIGURE 3-5. ANGULAR ALIGNMENT MEASUREMENT READINGS (EXAMPLE)

Axial Alignment Procedure to the varying surface quality of the generator
shaft’s drive disc mounting hub.
Axial misalignment needs to be checked only when
an objectionable vibration is present. The goal of the Axial alignment is to reduce the
vibration level of the genset while it is operating. A
If excessive vibration remains after the angular small improvement in the T.I.R. runout may have
alignment, check for concentric alignment of the dramatic effects in the mechanically measured or
generator shaft/engine crankshaft axis. physically observed vibration levels.
Fasten dial indicator holding device to skid base,
engine block, or generator shell with a magnetic To correct for an out-of-tolerance T.I.R. indication,
base or clamp and position so the sensor point of in- remove the capscrews connecting drive discs and
dicator rests on the generator shaft hub, see Figure flywheel. Mark the drive discs and flywheel with re-
3-6. Bar the engine over in a clockwise rotation as spect to each other. Rotate either the engine or gen-
viewed from engine flywheel, through a couple of erator so that drive discs holes are repositioned 180
rotations. Record indicator readings in eight equal- degrees from their original location. Put the drive
ly spaced points around the shaft diameter. This will discs capscrews back in and retorque. Recheck
provide a T.I.R. for Axial shaft misalignment. shaft alignment as before. If shaft T.I.R. runout re-
mains unchanged then discs should be rotated to
The maximum allowable T.I.R. runout is subjective, either 30, 60 or 90 degrees from original location to
the optimal T.I.R. for runout would be .000 inches, correct the out-of-tolerance condition. If the T.I.R.
however that may not be attainable. The recom- does not improve after repositioning, a closer in-
mendation of this procedure will be to reduce the spection of the flywheel pilot and drive disc runouts
measured T.I.R. runout by one half. Specific out-of- is required. This will help determine the cause of the
tolerance runout levels are difficult to establish due Axial misalignment.
ANGULAR ALIGNMENT
GENERATOR
SHAFT
HUB
DIAL
INDICATOR
SEE DETAIL A
GENERATOR
AND ENGINE
CRANKSHAFT CLAMP
CENTERLINE
FAN HOUSING
DETAIL A
FIGURE 3-6. AXIAL ALIGNMENT MEASUREMENT


4. Mechanical Connections
GENERAL CAUTION Never use galvanized or copper fuel
lines, fittings or fuel tanks. Condensation in the
The generator set mechanical system installation tank and lines combines with the sulfur in diesel
includes connecting the fuel, exhaust, ventilation fuel to produce sulfuric acid. The molecular
and cooling systems. Before starting any type of structure of the copper or galvanized lines or
fuel installation, all pertinent state and local codes tanks reacts with the acid and contaminates the
must be complied with and the installation must be fuel.
inspected before the unit is put in service.
An electric solenoid valve in the supply line is rec-
ommended for all installations and required for in-
FUEL SYSTEM door automatic or remote starting installations.
Connect the solenoid wires to the genset “Switched
Cummins engines normally use ASTM No. 2 diesel B+” circuit to open the valve during generator set
fuel. They will, however, operate on alternate diesel operation.
fuels within the specifications shown in the Cum-
mins engine Operation and Maintenance Manual. Separate fuel return lines to the day tank or supply
tank must be provided for each generator set in a
multiple-set installation to prevent the return lines of
In all fuel system installations, cleanliness is of the
idle sets from being pressurized. Fuel return lines
upmost importance. Make every effort to prevent
must not contain a shutoff device. Engine damage
entrance of moisture, dirt or contaminants of any
will occur if the engine is run with the return fuel lines
kind into the fuel system. Clean all fuel system com-
blocked or restricted.
ponents before installing.
CAUTION Never install shutoff device in fuel
A fuel filter/strainer/water separator of 100-120 mesh return line(s). If fuel return line(s) is blocked or
or equivalent (approximately 150 microns nominal) exceeds fuel restriction limit, engine damage
must be fitted between either the main tank and day will occur.
tank or between the main tank and the engine.
Fuel Return Restriction (or Pressure) Limit: Fuel
return drain restriction (consisting of friction head
Use only compatible metal fuel lines to avoid elec- and static head) between the engine injector return
trolysis when fuel lines must be buried. Buried fuel line connection and the fuel tank must not exceed
lines must be protected from corrosion. the limit stated in the Specification section.

Fuel Lines − Routing Install a fuel tank that has sufficient capacity to sup-
ply the genset operating continuously at full rated
A flexible fuel hose(s) or section of flexible fuel load for the planned period of operation or power
hose(s) must be used between the engine’s fuel outage. Refer to Data Sheet for fuel consumption
system and fuel supply and return line(s) to protect data.
the fuel system from damage caused by vibration,
expansion and contraction. Flexible lines for con- WARNING Fuel leaks create fire and explosion
necting between the engine and the stationary fuel hazards which can result in severe personal in-
lines are supplied as standard equipment. jury or death. Always use flexible tubing be-
Installation of the fuel hose must be done according tween engine and fuel supply and return to
to all applicable codes and standards, and installa- avoid line failure and leaks due to vibration. The
tion recommendations provided by the manufactur- fuel system must meet applicable codes.
er. The supplied flexible hose is approved by the
hose manufacture for use with the genset fuel type If the fuel inlet restriction exceeds the defined limit
and product application. due to the distance/customer-supplied plumbing
between the genset and the main fuel tank, a trans-
Support fuel lines to restrain movement and prevent fer tank (referred to as a day tank) and auxiliary
chaffing or contact with sharp edges, electrical wir- pump will also be required. If an overhead main fuel
ing and hot exhaust parts. tank is installed, a transfer tank and float valve will
WARNING Sparks and hot surfaces can ignite be required to prevent fuel head pressures from be-
fuel, leading to severe personal injury or death. ing placed on the fuel system components.
Do not route fuel lines near electrical wiring or
hot exhaust parts. For critical start applications, where generator sets
are paralleled or must satisfy emergency start-time
Fuel lines must be routed and secured to maintain a requirements, it is recommended that a fuel tank or
1/2 inch (12.7 mm) minimum clearance from electri- reservoir be located such that the lowest possible
cal wiring and a 2 inch (51 mm) minimum clearance fuel level is not less than 6 inches (150 mm) above
from hot exhaust parts. the fuel pump inlet. This will prevent air from accu-
mulating in the fuel line while the set is in standby,
Engine Fuel Connections eliminating the period during startup when it has to
be purged.
Identification tags are attached to the fuel supply
line and fuel return line connections. Fuel Inlet Pressure/Restriction Limit:: Engine
Supply Tank performance and fuel system durability will be com-
promised if the fuel inlet pressure or restriction limits
Locate the fuel tank as close as possible to the gen- are not adhered to. Fuel inlet pressure or restriction
erator set and within the restriction limitations of the must not exceed the limits stated in the Specifica-
fuel pump. tion section.

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. Also, the overflow line should be
and presents problems of high fuel head pressure one pipe diameter larger than the supply line.
for the fuel inlet and return lines.
WARNING Spilled fuel presents the hazard of
Supply Tank Lower Than Engine: With this instal-
lation, the day tank is installed near the generator
fire or explosion which can result in severe per-
set, below the fuel injection system and within the
sonal injury or death. Provide an overflow line
fuel inlet restriction limit. Install an auxiliary fuel
to the supply tank from the day tank.
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
The supply tank top must be below the day tank top pump inlet. The engine fuel return line must enter
to prevent siphoning from the fuel supply to the day the day tank.
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.
WARNING Spilled fuel can create environmental hazards. Check local requirements for containment
and prevention of draining to sewer and ground water.
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
SHUTOFF
VALVE
VENT LINE
DAY TANK
1 INCH
BAFFLE FILL PIPE
FLOAT
SWITCH
SUPPLY
LINE
FUEL TRANSFER
PUMP ELECTRIC
MOTOR DRIVEN
120 MESH FUEL

STRAINER
FUEL TANK
LARGER OVER-
FLOW LINE
FIGURE 4-1. TYPICAL FUEL SUPPLY INSTALLATION

EXHAUST SYSTEM 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 WARNING 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
and light loads. Regularly inspect the exhaust sys- partitions.
tem both visually and audibly to see that the entire
system remains fume tight and safe for operation. WARNING Inhalation of exhaust gases can re-
sult in severe personal injury or death. Do not
WARNING 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
For indoor installation, the exhaust system must set is stopped, the rain cap automatically closes,
use sealed joint type fittings, (for example NPT fit- protecting the exhaust system from rain, snow, etc.
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
WARNING Inhalation of exhaust gases can re-
connection.
sult in severe personal injury or death. Use ex-
treme care during installation to provide a tight CAUTION Weight applied to the engine man-
exhaust system. Use NPT or equivalent type fit- ifold can result in turbocharger damage. Sup-
tings for all indoor installations. port the muffler and exhaust piping so no
weight or stress is applied to engine exhaust el-
Use an approved thimble (Figure 4-2) where ex- bow.
haust pipes pass through wall or partitions. Insu-
lated wall/roof thimbles are used where exhaust The exhaust system design should meet local code
pipes pass through a combustible roof or wall. This requirements.
includes structures, such as wood framing or insu-
Liability for injury, death, damage, and warranty ex-
lated steel decking, etc. Uninsulated wall/roof pense due to use of unapproved mufflers or modifi-
thimbles are used where exhaust pipes pass cations becomes the responsibility of the person
through a non-combustible wall or roof, such as installing the unapproved muffler or performing the
concrete. Refer to NFPA 37, Section 6-3. “Station- modification. Contact a Cummins Power Generation
ary Combustion Engines and Gas Turbines” for ac- distributor for approved exhaust system parts.

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

VENTILATION AND COOLING
Generator sets dissipate heat and fumes that must
be removed by proper cooling and ventilation.
Generator sets in factory-mounted housings for
outdoor installation are designed for proper cooling
and ventilation. PREVAILING WINDS PREVAILING WINDS
Indoor installations require careful design with re-
spect to cooling and ventilation. In an indoor instal-
lation, all radiator cooling air must be discharged to
the out-of-doors. Duct adapter kits are available.
See Figure 4-5 for a typical indoor installation.
WARNING Engine or radiator cooling air may
carry deadly carbon monoxide gas which can
cause asphyxiation and death. All engine or ra-
diator cooling air must be discharged to the out-
of-doors. Do not use it for heating a room or
compartment.
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
FIGURE 4-4. WIND BARRIER
than the air inlet to allow for convection air move-
ment.
Size the vents and ducts so they are large enough to
allow the required flow rate of air. The ”free area” of
ducts must be as large as the exposed area of the
radiator. Refer to the genset Data Sheet for the air-
flow requirements and allowed airflow restriction.
Wind will restrict free airflow if it blows directly into
the air outlet vent. Locate the outlet vent so the ef-
fects of wind are eliminated. See Figure 4-4.

Dampers Louvers and screens over air inlet and outlet open-
ings restrict air flow and vary widely in performance.
A louver assembly with narrow vanes, for example,
Dampers or louvres protect the genset and equip- tends to be more restrictive than one with wide
ment room from the outside environment. Their op- vanes. The effective open area specified by the lou-
eration of opening and closing should be controlled ver or screen manufacturer should be used.
by operation of the genset. Locate the cooling air outlet directly in front of the ra-
diator and as close as possible. The outlet opening
must be at least as large as the radiator area.
In cooler climates movable or discharge dampers Length and shape of the air outlet duct should offer
are used. These dampers allow the air to be recircu- minimum restriction to airflow.
lated back to the equipment room. This enables the
equipment room to be heated while the genset en- Attach a canvas or sheet metal duct to the flange
gine is still cold, increasing the engine efficiency. and the air outlet opening using screws and nuts so
duct can be removed for maintenance purposes.
The duct prevents circulation of heated air. Before
Radiator Set Requirements installing the duct, remove the radiator core guard.
Standard Radiator Cooling uses a set mounted

Radiator set cooling air is drawn past the control radiator and engine pusher fan to cool engine water
end of the set by a pusher fan that blows air through jacket. Air travels from the generator end of the set,
the radiator (Figure 4-5). Locate the air inlet to the across the engine and out through the radiator. An
rear of the set. Make the inlet vent opening 1-1/2 to 2 integral discharge duct adapter flange surrounds
times larger than the radiator area. the radiator grille.]
THERMOSTATIC AIR RE-

CIRCULATING DAMPER
*
WIND/NOISE
BARRIER
INLET AIR
DAMPER
HOT AIR
COOL AIR
D
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

Remote Radiator Cooling (Optional) substitutes engine warm for improved starting and code com-
a remote mounted radiator and an electrically driv- pliance. Connect the heater to a power source that
en fan in place of mounted components. Removal will be energized when the engine is NOT running.
of the radiator and the fan from the set reduces
noise levels without forcing dependence on a con- Heat Exchanger (Optional)
tinuous cooling water supply (necessary with heat
exchanger cooling). The remote radiator installa- The optional heat exchanger (Figure 4-6) uses a
tion must be completely protected against freezing. shell and tube type heat exchanger instead of the
standard radiator and fan. Engine jacket coolant cir-
Remote radiator plumbing will vary with installation. culates through the shell side of the heat exchanger
Follow recommendations given in Application while the cooling water is pumped through the
Manual T-030. See product Data Sheet for friction tubes. Engine coolant and raw water do not mix.
head and static head limits. This system may reduce set enclosure airflow re-
quirements and noise levels. Proper operation de-
Before filling cooling system, check all hardware for
pends on a constant supply of raw water for heat re-
security. This includes hose clamps, capscrews, fit-
tings and connections. Use flexible coolant lines moval. Adjust the flow to maintain engine coolant
with heat exchanger or remote mounted radiator. temperature between165° F and 195° F (74° C and
91° C) while viewing the water temperature gauge.
Engine Coolant Heater (Optional) The engine coolant side of the system can be pro-
tected from freezing; the raw water side cannot be
An optional coolant heater is available to keep the protected.
VENTILATING
FAN
WATER WARM FLEXIBLE WA-

SOLENOID AIR TER
VALVE CONNECTIONS
MOUNTED HEAT
COOL AIR EXCHANGER
RAW WATER
SUPPLY
RAW WATER
DISCHARGE
FIGURE 4-6. TYPICAL HEAT EXCHANGER INSTALLATION

5. DC Control Wiring
CONTROL WIRING Route the control wiring through the control housing
and into the access holes on the bottom of the con-
The generator set control panel box contains control panel box. Figure 5-1 also shows the access
nection points for remote control and monitor op- holes that should be used according to where the
tions. wires are terminated inside the control box.
CAUTION Stranded copper wire must be used
for all customer connections to the control pan- A compression type strain-relief connector should
el. Solid copper wire may break due to genset be used to prevent dust, insects, etc. from entering
vibration. control box.
Use flexible conduit for all wiring connections to the Use cable ties to keep control wiring away from
generator set. All conduit used for control wiring is sharp edges and AC power cables within the control
attached to the control housing. housing.
NETWORK COMMUNICATION
MODULE
TB1
CONTROL RELAYS
(K10, K11, K12) & TB2 STRAIN-RELIEF
CONTROL BOX CONNECTOR
HEATER
FIGURE 5-1. SUGGESTED CUSTOMER WIRE ROUTING

TB1 REMOTE MONITOR/CONTROL Relay Connections: Due to the wide variety of de-
CONNECTIONS vices that can be attached to the relay outputs of
TB1, the electrical contractor must determine the
Customer monitor/control connections are at- gauge of the stranded copper wire that is used at
tached to terminal block TB1 (Figure 5-2). Optional this installation site. Refer to PCC Customer Con-
equipment such as a remote annunciator panel, nections diagram in Section 9 for the relay specifi-
sensing devices used to monitor genset operation, cations.
remote start/stop switches, battery charger, etc. are
Network Connections: Refer to 900-0366 Power-
attached to TB1. Refer to Customer Connections
Command Network Installation and Operation
diagram in Section 9.
manual for the type/gauge wire to use for these con-
nections.
TB1 Wiring
Switched B+: (Fused at 5 amps.) Same as Relay
CAUTION Always run control circuit wiring in Connection description.
a separate metal conduit from AC power cables
B+: (Fused at 10 amps.) Same as Relay Connec-
to avoid inducing currents that could cause
tion description.
problems within the control.
TB2 POWER TRANSFER CONTROL (PTC)
Digital Connections: Connection points, other
than relayed outputs, network, switched B+ and B+
CONNECTIONS (OPTIONAL)
are considered digital connections to terminal strip TB2 is used to connect the optional PTC module to
TB1. The type/gauge wire to use for these connec- the control. With this option installed, the control will
tions are: monitor the utility voltage (mains) and frequency for
failure. If power fails, the PTC control will start the
• Less than 1000 feet (305m), use 20 gauge generator, open the mains circuit breakers and
stranded copper wire.
close the generator circuit breakers. Refer to Cus-
• 1000 to 2000 feet (305 to 610m), use 18 gauge tomer Connections diagram in Section 9 and instal-
stranded copper wire. lation instructions sent with the PTC Module Kit.

BASE
BOARD
TB1
TB2
MACHINE
SCREW
TERMINAL
END BRACKET
CONTROL
RELAYS
VOLTAGE
SUPPRESSOR
TERMINAL
DIN RAIL
TERMINAL
END BRACKET
FIGURE 5-2. CONTROL PANEL BOX

CONTROL RELAYS (K11, K12, K13) 4-pole relay with 2 poles normally open and two
poles normally closed.
CAUTION Damage to the Base board can oc- These relays (Figure 5-3) are used to control auxil-
cur if the voltage suppressors (Figures 5-2 and iary equipment, such as fans, pumps and motorized
5-3) are not installed accross relay coils (A1/A2) air dampers. Energizing of the relays is user defin-
of control relays K11, K12 and K13 before con- able.
necting genset battery cables.
The contacts are rated at 10 amps at 600 VAC.
The three optional control relays are rail mounted Refer to Customer Connections diagram in Sec-
inside the control panel housing. Each relay is a tion 9.
VOLTAGE
SUPPRESSOR
20 AWG Wire, UL Rated for 600 VAC
FIGURE 5-3. OPTIONAL CONTROL RELAYS (K10, K11, K12)

6. AC Electrical Connections
GENERAL Connecting the genset AC electrical system in-
volves:
This section provides the procedure that is used to
connect the AC electrical system of the genset. • Generator insulation check
Before making any AC electrical connections, make • Installation of transfer switch
certain the generator set cannot be accidentally
started. Place the control panel run switch in the • Generator output voltage selection
OFF position. Turn off or remove AC power from the
battery charger and then remove the negative (−) • Load cable connection
battery cable from the set starting battery. • Standard and optional AC equipment connec-
WARNING Ignition of explosive battery gases tions (e.g., control box heater, coolant heater,
can cause severe personal injury or death. Arc- etc.
ing at battery terminals, light switch or other • Optional enclosure electrical connections (re-
equipment, flame, pilot lights and sparks can ig- fer to Section 7).
nite battery gas. Do not smoke, or switch
trouble light ON or OFF near battery. Discharge Local regulations often require that wiring connec-
static electricity from body before touching bat- tions be made by a licensed electrician, and that the
teries by first touching a grounded metal sur- installation be inspected and approved before op-
face. eration. All connections, wire sizes, materials used,
Ventilate battery area before working on or near etc. must conform to the requirements of electrical
battery—Wear goggles—Stop genset and dis- codes in effect at the installation site.
connect charger before disconnecting battery
cables—Disconnect negative (−) cable first and WARNING Improper wiring can cause a fire or
reconnect last. electrocution, resulting in severe personal inju-
ry or death and/or property and equipment dam-
CAUTION Disconnect battery charger from AC
age.
source before disconnecting battery cables.
Otherwise, disconnecting cables can result in
voltage spikes damaging to DC control circuits Before starting the genset, check to make sure that
of the set. all electrical connections are secure, and that all
wiring is complete. Replace and secure any access
WARNING Accidental starting of the generator panels that have been removed during installation.
set can cause severe personal injury or death. Check that the load cables from the genset are
Prevent accidental starting by disconnecting properly connected.
the negative (−) cable from the battery terminal.
WARNING Each of the operations described in WARNING Backfeed to utility system can
this section should be done only by persons cause electrocution or property damage. Do
trained and experienced in electrical mainte- not connect to any building electrical system
nance. Improper procedures may result in prop- except through an approved device and after
erty damage, bodily injury or death. building main switch is opened.

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

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 L1, L2 and
set nameplate. Line-to-neutral voltage is always the L3; and N with L0 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 (L1, 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
connection terminal block. This reconfiguration single phase and three phase loading can be used
must only be done by service personnel that are as long as each line current is about the same, with-
trained and experienced to perform electrical instal- in 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
Current Transformers
and perform any necessary reconnect to obtain the
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 (from Refer 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 CT1, CT2 and CT3 on the reconnection
wiring diagram. (The Reconnection Diagram is lo-
CAUTION Reconfiguring generator sets to cated on the upper side cover of the control hous-
higher voltages can exceed the voltage capabil- ing.)
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.
CAUTION Reconfiguring generator sets to
B. CT1 − U load leads (A phase),
lower voltages can reduce generator set rat- CT2 − V load leads (B phase)
ings, and also increase line current, rendering CT3 − 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 for a 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.)

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 impor- ground lug provided in the circuit breaker box.
tant to follow the requirements of the local electrical
WARNING Electric current can cause severe
code.
personal injury or death. Bonding and ground-
ing must be done properly. All metallic parts
Figure 6-2 illustrates typical system grounding for a that could become energized under abnormal
3-pole and a 4-pole automatic transfer switch conditions must be properly grounded.
(ATS). In the 3-pole ATS, note that the generator
neutral is connected to the ATS and is NOT bonded Typical requirements for bonding and grounding
to ground at the generator. In the 4-pole ATS sys- are given in the National Electrical Code, Article
tem, a grounding electrode conductor and a bond- 250. All connections, wire sizes, etc. must conform
ing jumper are used to connect the generator neu- to the requirements of the electrical codes in effect
tral to ground. at the installation site.
SERVICE ENTRANCE GENERATOR SET

3-POLE ATS
LOAD
THREE-PHASE, FOUR-WIRE UTILITY, THREE-POLE ATS
SERVICE ENTRANCE GENERATOR SET

4-POLE ATS
LOAD
THREE-PHASE, FOUR-WIRE UTILITY, FOUR-POLE ATS
FIGURE 6-2. TYPICAL SYSTEM GROUNDING ONE-LINE DIAGRAMS

CONTROL HEATER (OPTIONAL) rior. It protects the components when the generator
A control heater (Figure 6-3) provides a means of set is subjected to varying ambient air conditions
humidity/temperature control of the control box inte- during extended periods of non-use.
THERMOSTAT
HEATER
120V PLUG
240V PLUG
FIGURE 6-3. OPTIONAL CONTROL HEATER

COOLANT HEATER the time the engine is not running. Be sure the sup-
ply voltage and circuit amperage is correct for the
The coolant heater keeps engine coolant warm heater element rating.
when the engine is shut down. It heats and circu-
lates the coolant within the engine. This reduces
A battery charger is required to prevent battery dis-
startup time and lessens engine wear caused by charge. The heater control relay draws 83 mA of cur-
cold starts. It is electrically operated and thermo- rent when the heater(s) is off. The heater is off when
statically controlled. the engine has reached the proper temperature or
the engine is running.
CAUTION The coolant heater must not be op-
erated while the cooling system is empty or
CAUTION Do not connect AC power to the
damage to the heater will occur.
heater before connecting battery cables. Heater
Figure 6-4 shows a typical coolant heater. Connect will run continuously without DC power and
the heater to a source of power that will be on during can overheat and damage heater.
THERMOSTAT
COOLANT
FLOW
COOLANT
FLOW
DC SUPPLY
DRAIN
LINE
AC ELECTRICAL CONNECTION
BOX (ELECTRICAL DIAGRAM
INSIDE COVER) AC POWER
DC CONTROL LINE
LINE
FIGURE 6-4. TYPICAL COOLANT HEATER

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-
flashing and a shock hazard. ment rating.
WARNING Water or moisture inside a genera-
tor increases the possibility of flashing and
electrical shock, which can cause equipment
damage and severe personal injury or death. Do
not use a generator which is not dry inside and
out.
HEATER LEADS
HEATER LEADS
HEATERS
HEATER
TERMINAL BOX
HEATER
VOLT/WATTS
LABEL
TERMINAL
BLOCK
FIGURE 6-5. TYPICAL GENERATOR HEATER INSTALLATION

FUEL TRANSFER PUMP WARNING Diesel fuel is highly combustible.
Improper installation of this kit can lead to spill-
age of large quantities of fuel and loss of life and
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 au- lation and service must be performed by trained
tomatic control operates the fuel pump to maintain a and experienced persons in accordance with
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

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- TB1-5 and TB1-6, and TB1-7 and TB1-8
tion to 240 VAC. in the control box and connect the two
jumpers between terminals TB1-6 and
1. To convert the day tank controller from 240
TB1-7.
VAC to 120 VAC, perform the following steps.
B. Move selector switch S103 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
TB1-5 and TB1-6 and the other between H1 and H3, and H2 and H4 and connect
terminals TB1-7 and TB1-8. 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 TB1-8 and TB1-5 are available for
C. If the control is equipped with a transform- connection of a 120 or 240 VAC electric fuel
er, remove the two jumpers between ter- shutoff valve rated not more than 0.5 amps.
minals H2 and H3 and connect one be- The voltage rating of the valve must corre-
tween H1 and H3 and the other between spond with the voltage utilized for the pump.
H2 and H4. See Item 2 above.
FIGURE 6-7. FUEL PUMP CONTROL TERMINAL BOARD

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
A. Verify that the N-G Fault Indicator on the
housing grille. The ground fault relay continuously
GFR is not lit. If lit, it indicates that the
monitors the neutral to ground connection and acti-
bonding jumper circuit (neutral to ground)
vates a fault alarm when the connection is broken.
is open. If genset does not require bonding
During genset operation, the relay continuously
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 B. Move the control switch to the Run posi-
the genset control to provide a “Ground Fault tion.
Alarm” indication.
C. 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 D. Verify that the control panel warning mes-
second and a current setting of 5 to 1200 amperes. sage is displayed and the Fault Indicator
(>I) on the GFR is lit.
Adjust the Current and the Time Delay controls on
the ground fault relay to the customers specifica- E. Reset the control panel fault (this will also
tions. reset the ground fault relay).

CONTROL
HOUSING
GRILLE
GROUND FAULT
RELAY
ASSEMBLY
ON INDICATOR
TEST BUTTON RESET BUTTON
(N.U., FACTORY SET
TO AUTO RESET)
TIME DELAY CONTROL

FAULT INDICATORS
>I
(OVER CURRENT)
N−G
(OPEN CIRCUIT)
CURRENT CONTROL
FIGURE 6-8. GROUND FAULT ALARM RELAY


7. Enclosure Electrical Connections
GENERAL CAUTION Flexible conduit and stranded con-
ductors must be used for connections to take
Generator sets configured with an enclosure can up movement of the genset. Solid copper wire
contain one or more optional features. The optional
may break due to genset vibration.
features that require electrical connections when
installing the generator set are described in this
section. For wiring diagrams of enclosure options, Figure 7-1 shows the location of the optional fea-
refer to Section 10, Enclosure/Options Wiring. tures within the enclosure.
OVERFILL FUEL FUEL SYSTEM

ALARM FILL CONTROL
FUEL ALARM EMERGENCY

PANEL STOP SWITCH
EXTERNAL
FUEL FILL BOX 120 VAC
EXTERNAL
RECEPTACLE
MOTORIZED
INLET LOUVER
AC DISTRIBUTION
PANEL
FIGURE 7-1. OPTIONAL ENCLOSURE FEATURES (WEATHER ENCLOSURE SHOWN)

OPTIONAL AC DISTRIBUTION PANEL panel are not needed for generator set opera-
tion.)
The AC distribution panel (Figure 7-2) provides a
centralized power source (120/220VAC) for all op- All connections to the AC distribution panel are to be
tional enclosure features. done in compliance with the National Electric Code
and all applicable local codes and standards using
CAUTION Make sure all circuit breakers are in
60 or 75 degree conductors.
the OFF position before applying power to the
AC distribution panel. Other options may re- The AC distribution panel is designed to be fed with
quire additional installation before connecting a 100AMP, 120/240VAC, single phase feeder. The
to power. two line conductors connect into the 100AMP main
breaker that is listed for #4 to 2/0 conductors, AL or
CAUTION When the generator set contains
CU when torqued to 50 in-lbs.
the fuel transfer pump option, power to the AC
distribution panel must be fed from a transfer The neutral conductor connects into the neutral bus
switch and step-down transformer to maintain which is listed for #5 to 300KCMIL conductors, AL or
120V power to the pump when utility power is in- CU when torqued to 21 ft-lbs.
terrupted. If the transfer pump option is not
installed, power to the AC distribution panel can The grounding conductor, if used, connects into the
be fed from a non-emergency source. (Other op- ground bar which is listed for #1 to 2/0 conductors,
tional features connected to the AC distribution AL or CU when torqued to 17 ft-lbs.
2
1/3
4
GFCI SERVICE
6 RECEPTACLE
5/7
8
CIRCUIT BREAKERS
1/3: 100A MAIN COOLANT HEATER
2: 20A J1/J2 RECEPTACLES CONTROL AC SUPPLY
4: 20A J3/J4 RECEPTACLES
5/7: 40A COOLANT HEATERS
6: 20A INLET/OUTLET LOUVERS
8: 20A INTERNAL/EXTERNAL J1 J2 J3 J4
SERVICE RECEPTACLES
120VAC RECEPTACLES
FOR OPTIONAL FEATURES
J1: ENGINE OIL HEATER 24 VAC
J2: BATTERY HEATER TRANSFORMERS
J3: ALTERNATOR /CONTROL (LOUVER MOTORS)
CABINET HEATERS
J4: BATTERY CHARGER/TRANS-
FER PUMP CONTROLLER
FIGURE 7-2. AC DISTRIBUTION PANEL FEATURES

OPTIONAL MOTORIZED INLET/OUTLET Without the AC distribution panel, the 24VAC lou-
LOUVERS vers are not prewired. Louvers operating on 24VAC
require 30VAC, 24 volt class 2 transformer(s).
Louvers (inlet and/or outlet) are powered by either (Transformers are not supplied with genset that
24VDC supplied by genset control switched B+ or does not contain an AC distribution panel.) Mount
24VAC transformer connected to shore power. and connect the transformer(s) to the 18 gauge
wires terminated at the AC distribution panel loca-
With switched B+ or gensets having the AC distribution. Connect the transformer(s) to a source of pow-
tion panel, the motorized louvers are prewired and er that will be on during the time the engine is not
require no further installation (Figure 7-3). running.
MOTORIZED MOTORIZED
INLET LOUVER OUTLET LOUVER
30VAC AC DISTRIBUTION
TRANSFORMER(S) PANEL
FIGURE 7-3. MOTORIZED LOUVER

OPTIONAL FUEL TRANSFER PUMP tomatically go to the power on mode (functions the
same as pressing the ON switch). The pump will start
A fuel transfer pump and control are available when if the control detects low fuel in sub-base tank.
a sub-base fuel tank is provided. The automatic
control operates the fuel pump to maintain a reser- CAUTION Do not connect AC power to the fuel
voir of fuel in the sub-base tank. transfer pump control without having fuel in the
supply tank. Damage to the pump can occur if
CAUTION Power to the fuel transfer pump
pump operates with no fuel in supply tank.
must be fed from a transfer switch and step-
down transformer to maintain 120V power to the
Supply Tank
pump when utility power is interrupted. Power
must be supplied to the transfer pump during Refer to Section 4 for information regarding the
the time the genset is running or not running. installation/plumping of the supply tank to the sub-
The fuel transfer pump/controller is prewired and base fuel tank.
ready to connect to a 120VAC source.
The fuel transfer pump has a maximum inlet restric-
NOTE: When power is applied to the control or is re- tion capability of 16 inch Hg (which is approximately
stored after a power interruption, the control will au- equivalent to 20 feet of diesel).
FUEL SYSTEM
CONTROL
FUEL
FILL
OVERFILL
ALARM
TO 120 VAC
EMERGENCY SUPPLY
FIGURE 7-4. FUEL TRANSFER PUMP/CONTROL LOCATION

8. Prestart Preparation
GENERAL when troubleshooting the genset (determine if pa-
rameters/settings have been modified after installa-
Before attempting the initial start of the generator tion) and when replacement of the Base board is
set, be sure to complete the Installation Checklist in necessary. The capture file can be used as a tem-
Section 9. plate to write the previous settings to the new Base
board software.
INPOWER SERVICE TOOL
GENERAL INFORMATION ELECTRICAL SYSTEM
Verify all electrical connections are secure and all
InPower is a PC based service tool for the Power- wiring is complete and inspected. Replace and se-
Command 2100 Control (PCC). Use InPower to: cure any access panels that may have been re-
moved during installation.
• Make adjustments to the controls trims and set-
tings. Battery Connections
• Perform diagnostics and monitoring. WARNING Accidental starting of the generator
• Create a capture file of the controls trims and set can cause severe personal injury or death.
settings. Make sure that the Run/Off/Auto switch on the
control panel is set to the Off position before
• Update control calibrations (InPower PRO ver- connecting the battery cables.
sion).
Starting the unit requires a 12 volt battery. Connect
Refer to INPOWER User’s Guide for specifics.
positive battery cable before connecting negative
InPower Adjust Mode battery cable to prevent arcing.
The adjustment feature allows you to make adjust- Service the batteries as necessary. If an automatic
ments to genset parameters, calibrations and set- transfer switch is installed without a built-in charge
tings. There are several groups of adjustment pa- circuit, connect a separate battery charger. A bat-
rameters; note that not all gensets will have the tery charger is required when the PowerCommand
same adjustments available. control is set to the Awake mode.
WARNING Ignition of explosive battery gases
InPower Capture File Description can cause severe personal injury or death. Al-
ways connect negative (−) battery cable last to
InPower provides a method of extracting (captur- prevent arcing.
ing) a device’s parameter values. Capturing saves
device information in a file that is identified with a WARNING Ventilate battery area before work-
.CAP extension. ing on or near battery. Arcing at battery termi-
nals, light switch or other equipment, flame, pi-
Capture files are used to store a copy of the gen- lot lights and sparks can ignite battery gas. Do
set’s parameter values. During genset installation, not smoke, or switch trouble light ON or OFF
it is suggested that a capture file be made before near battery. Discharge static electricity from
and after changes are made to the genset operating body before touching batteries by first touching
parameters. This information can be a very useful a grounded metal surface.

PCC OPTIONS PRESTART CHECKS Controller Configuration
Figure 8-1 shows a block representation of the Con-
All generator set configuration options are set at the troller Configuration menus.
factory except for site related options, (e.g., Lan-
To view the first Controller Configuration menu,
guage, Start/Stop Time Delays, Idle Start, Cycle make sure Main Menu 1 is displayed and simulta-
Crank, Customer Fault 1 and 2, etc.. neously press the Home Menu and Previous Main
Menu buttons.
Adjustment of these options are divided into two As shown in the diagram, the Controller Configura-
categories within the menu driven system. These tion menu has three submenus.
two categories are Setup and Controller Configura-
tion/Adjust. Press the buttons next to the and symbols in the
digital display to navigate between the menus.
The Setup submenus are intended for qualified ser- Press the button next to the symbol in the display
vice personnel only and require a password to until the + and − symbols are displayed.
modify these submenus. The Controller Configura- Press the button next to the + or − symbol to select
tion and Adjust submenus are intended for service the desired option.
personnel and site personnel.
After selecting option, pressing the symbol results
in the changes being saved. If the Home button or
The Controller Configuration, submenus are used Previous Main Menu button is pressed before
to change the default language, temperature units, pressing the symbol, the changes are not saved.
and pressure units to be displayed in menus.
Language Selected submenu: Used to select de-
sired language (default = English).
The Adjust submenus allow site personnel to cali-
brate the generator set voltage/frequency, idle Temperature Units submenu: Used to select
speed and start/stop time delays. For the prestart Fahrenheit or Centigrade for temperature readings.
checks, adjustment of only the start/stop delays is Fluid Pressure Units submenu: Used to select
required. PSI or kPA for pressure readings.

CONTROLLER CONFIGURATION MENU
Main Menu 1
Engine Adjust
Alternator More>>
Language Selected
English
+Language Selected
− English
Back
Temperature Units
Deg F
+Temperature Units
− Deg C
Back
Fluid Pressure Units

PSI
+Fluid Pressure Units
− kPa
Back
FIGURE 8-1. CONTROLLER CONFIGURATION MENU

Adjust Menu Voltage Adjust submenu: Voltage can be ad-
justed to 5 percent of the nominal voltage. For ex-
ample, if genset output voltage is 208 volts, the volt-
Figure 8-2 shows a block representation of the Ad-
age can be adjusted from 197 to 218 volts.
just menu. If you press the button next to the word
“Adjust” in the display, the first Adjust submenu is If the revised value is greater or less than the allowed
displayed. (5%) range, the control will round off the displayed
value (up or down). For example, if changing the val-
ue by −5% (maximum) equals 197.6, the display will
As shown in the diagram, the Adjust menu has five show 197, but will display and change the output to
submenus. Each submenu includes a parameter or 198 when saved.
value that can be changed.
Frequency Adjust submenu: Frequency can be
adjusted to 5 percent of the nominal frequency.
Press the buttons next to the and symbols in the For example, if the genset frequency is 60.0 Hz, the
digital display to navigate between the menus. frequency can be adjusted from 57.0 to 63.0 Hz.
Press the Home button or the Previous Main Menu
Start Delay submenu: Start Delay can be set from
button to return to Main Menu 1.
0 to 300 seconds (default = 0). This function is by-
passed during a manual start/stop sequence.
Adjusting Values/Parameters:
Stop Delay submenu: Stop Delay can be set from
1.. Press the button next to the symbol in the dis- 0 to 600 seconds (default = 0). This function is by-
play until the + and − symbols are displayed. passed during a manual start/stop sequence and
engine shutdown faults.
2.. If necessary, press the button next to the or
symbols to move to the numeric character you Rated To Idle (Beginning Version 2.303): Rated
wish to change. To Idle delay can be set from 0 to 10 seconds (de-
fault = 0). (Enter 1 or more to enable.) Entering a
3.. Press the button next to the + symbol to in- non-zero delay will cause the genset to delay the
crease the value or select parameter; press the transition to Cooldown At Idle.
button next to the − symbol to decrease the val-
Idle Start submenu (Only available on some
ue or select parameter.
models): Idle Start can be enabled or disabled (de-
fault = Disable). This function is only enabled when
4.. After adjusting values/selecting parameters,
the genset is started in manual mode. Idle Start can
pressing the symbol results in the changes also be enabled while the set is running in manual
being saved. (When adjusting values, make mode.
sure the cursor is on the last numeric character
before pressing the symbol). Enabling Idle Start will cause the genset to run in
idle mode until Idle Start is disabled. A warning is
displayed if genset is left in idle more than 10 min-
If the Home button or Previous Main Menu but- utes. Long periods of engine idling can eventually
ton is pressed before pressing the symbol, affect engine performance and may void engine
the changes are not saved. warranty.

ADJUST MENU
Main Menu 1
Engine Adjust
Alternator More>>
Voltage Adjust
nnn V
+Voltage Adjust
− nnn V
Back
Frequency Adjust
nn.n Hz
+Frequency Adjust
− nn.n Hz
Back
Start Delay
nnn Sec
+Start Delay
− nnn Sec
Back
Stop Delay
nnn Sec
+Stop Delay
− nnn Sec
Back
Rated To Idle Delay

nn Sec
+Rated To Idle Delay
− nn Sec
Back
Idle Start
Disable
+Idle Start
− Enable
Back
FIGURE 8-2. ADJUST MENU

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 menus are displaying the cor-
rect values.

9. 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 SET 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.

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.
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 SET 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.
Created capture file of the genset’s parameter values before and after modifications.

10. Wiring Diagrams
GENERAL • Page 10-2 − Customer Connections Diagram
This section consists of the schematic and connec- • Page 10-3 and 4 − Enclosure/Options Wiring
tion wiring diagrams referenced in the text. The fol-
lowing drawings are included.

THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.
DEFAULT SETTING
TB1-CUSTOMER FAULTS:
1 CUSTOMER FAULT 1
2 GROUND FAULT
3 LOW FUEL
4 RUPTURE BASIN FAULT
TB1-CUSTOMER RELAYS:
1 COMMON WARNING
2 COMMON SHUTDOWN
3 NOT IN AUTO
4 READY TO LOAD
No. 620-0247 sh 1 of 1
Rev. A
Modified 4-18-02
CUSTOMER CONNECTIONS DIAGRAM

10-2
No. 630-2672 sh 2 of 4
Rev. B
Modified 10-03
ENCLOSURE/OPTIONS WIRING (SHEET 1 OF 2)

No. 630-2672 sh 4 of 4
Rev. B
Modified 10-03
ENCLOSURE/OPTIONS WIRING (SHEET 2 OF 2)

10-4
Cummins Power Generation
1400 73rd Avenue N.E.
Minneapolis, MN 55432
1-800-888-6626
763-574-5000 International Use
Fax: 763-528-7229
Cummins is a registered trademark of Cummins Inc.


Powercommand 2100 Series

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SECTION TITLE PAGE

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KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

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Copyright 2003 Cummins Power Generation. All rights reserved.

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MODEL DFAB/DFAC DFBF DFCB/DFCC DFCE

FUEL CONSUMPTION (STANDBY/FULL LOAD/60HZ)

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INCORRECT INSTALLATION, SERVICE OR PARTS REPLACEMENT CAN RESULT IN SEVERE

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FLOW OR COOLING AIR AND HEATED AIR CAN

FIGURE 3-2. TYPICAL INSTALLATION

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FIGURE 3-3. VIBRATION ISOLATORS

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CLAMP DIAL INDICATOR

GENERATOR MOUNTING BOLT

FIGURE 3-4. ANGULAR ALIGNMENT MEASUREMENT

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FIGURE 3-5. ANGULAR ALIGNMENT MEASUREMENT READINGS (EXAMPLE)

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FIGURE 3-6. AXIAL ALIGNMENT MEASUREMENT

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ENGINE VENTED INJECTOR FUEL

120 MESH FUEL

FIGURE 4-1. TYPICAL FUEL SUPPLY INSTALLATION

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FIGURE 4-2. MOUNTING EXHAUST THIMBLE

IF EXHAUST LINE MUST BE

FIGURE 4-3. CONDENSATION TRAP

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Standard Radiator Cooling uses a set mounted

THERMOSTATIC AIR RE-

RADIATOR FLEXIBLE DUCT DISTANCE SHOULD NOT

FIGURE 4-5. TYPICAL RADIATOR SET INSTALLATION

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WATER WARM FLEXIBLE WA-

FIGURE 4-6. TYPICAL HEAT EXCHANGER INSTALLATION

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FIGURE 5-1. SUGGESTED CUSTOMER WIRE ROUTING

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FIGURE 5-2. CONTROL PANEL BOX

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20 AWG Wire, UL Rated for 600 VAC

FIGURE 5-3. OPTIONAL CONTROL RELAYS (K10, K11, K12)

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FIGURE 6-1. TYPICAL LOAD TRANSFER

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