Product Manual A

ManualsBrandsCummins Power ManualsCommercial GeneratorsCummins Commercial Standby Generator — 80 kW, LP/NG, 277/480 Volts, 3-Phase

English

Original Instructions

7-2018 A051X873 (Issue 10)

InstallationInstallation ManualManual

Generator Set with QSJ5.9G Engine and

PowerCommand® 1.1/2.3 Control

C45 N6 (Spec A)

C50 N6 (Spec A)

C60 N6 (Spec A)

C70 N6 (Spec A)

C80 N6 (Spec A)

C100 N6 (Spec A)

Summary of content (170 pages)

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Installation Manual Generator Set with QSJ5.9G Engine and PowerCommand® 1.1/2.
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Table of Contents 1. IMPORTANT SAFETY INSTRUCTIONS ....................................................................................... 1.1 Warning, Caution, and Note Styles Used in This Manual ..................................................... 1.2 General Information ................................................................................................................ 1.3 Generator Set Voltage Is Deadly ........................................................................................
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Table of Contents 7-2018 6.5 Startup ................................................................................................................................. 87 APPENDIX A. FUEL LINE SELECTION........................................................................................... A.0 Fuel System Pipe Sizing Introduction................................................................................... A.1 Gas Pipe Sizing .......................................................................
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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.
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1. IMPORTANT SAFETY INSTRUCTIONS 7-2018 General Safety Precautions WARNING Hot Pressurized Liquid Contact with hot liquid can cause severe burns. Do not open the pressure cap while the engine is running. Let the engine cool down before removing the cap. Turn the cap slowly and do not open it fully until the pressure has been relieved. WARNING Moving Parts Moving parts can cause severe personal injury. Use extreme caution around moving parts.
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-2018 1. IMPORTANT SAFETY INSTRUCTIONS WARNING Hot Surfaces Contact with hot surfaces can cause severe burns. The unit is to be installed so that the risk of hot surface contact by people is minimized. Wear appropriate PPE when working on hot equipment and avoid contact with hot surfaces. WARNING Toxic Hazard Ethylene glycol, used as an engine coolant, is toxic to humans and animals. Wear appropriate PPE.
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1. IMPORTANT SAFETY INSTRUCTIONS 7-2018 WARNING Automated Machinery Accidental or remote starting of the generator set can cause severe personal injury or death. Isolate all auxiliary supplies and use an insulated wrench to disconnect the starting battery cables (negative [–] first). NOTICE Keep multi-type ABC fire extinguishers close by. Class A fires involve ordinary combustible materials such as wood and cloth. Class B fires involve combustible and flammable liquid fuels and gaseous fuels.
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7-2018 1.4 1. IMPORTANT SAFETY INSTRUCTIONS Fuel and Fumes Are Flammable Fire, explosion, and personal injury or death can result from improper practices. • Do not fill fuel tanks while the engine is running unless the tanks are outside the engine compartment. Fuel contact with hot engine or exhaust is a potential fire hazard. • Do not permit any flame, cigarette, pilot light, spark, arcing equipment, or other ignition source near the generator set or fuel tank.
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1. IMPORTANT SAFETY INSTRUCTIONS 7-2018 WARNING Combustible Gases Batteries can explode, causing severe skin and eye burns, and can release toxic electrolytes. Do not dispose of the battery in a fire, because it is capable of exploding. Do not open or mutilate the battery. Do not charge frozen batteries. WARNING Electric Shock Hazard Batteries present the risk of high short circuit current. When servicing the generator set: • Remove watches, rings, or other metal objects.
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7-2018 1.7 1. IMPORTANT SAFETY INSTRUCTIONS Vented Batteries WARNING Toxic Hazard The electrolyte in vented 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.
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1. IMPORTANT SAFETY INSTRUCTIONS 7-2018 WARNING Hot Surfaces Contact with hot surfaces can cause severe burns. The unit is to be installed so that the risk of hot surface contact by people is minimized. Wear appropriate PPE when working on hot equipment and avoid contact with hot surfaces. WARNING Toxic Gases Inhalation of exhaust gases can cause asphyxiation and death. Pipe exhaust gas outside and away from windows, doors, or other inlets to buildings.
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7-2018 1. IMPORTANT SAFETY INSTRUCTIONS Special Risks of CO near the Home WARNING Toxic Gases Carbon monoxide (CO) gas can cause nausea, fainting, or death. Residents can be exposed to lethal levels of CO when the generator set is running. Depending on air temperature and wind, CO can accumulate in or near the home.
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2 Introduction WARNING Hazardous Voltage Contact with high voltages can cause severe electrical shock, burns, or death. Make sure that only a trained and experienced electrician makes generator set electrical output connections, in accordance with the installation instructions and all applicable codes. WARNING Electrical Generating Equipment Faulty electrical generating equipment can cause severe personal injury or death.
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2. Introduction 7-2018 See the generator set's specific operator manual for operation and maintenance and specific service manual for service. Refer to the Model Specifications section for specific information about the system and its components. Refer to the Outline and System Drawings appendix and the Wiring Diagrams appendix for specific information about installation and wiring connections. 2.
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7-2018 2. Introduction • RA Series Transfer Switch Owner Manual (A046S594) - if applicable • PowerCommand® 1302 Controller Owner's Manual (0900-0661) • PowerCommand® 2300 Operator Manual (A029M413) • Service Tool Manual (A043D529) • Standard Repair Times - HL Family (A053K365) • T-030: Liquid Cooled Generator Set Application Manual (A040S369) - for application information 2.3 Before Installation Before beginning the installation of the generator set, verify that the unit was correctly selected.
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2. Introduction 7-2018 Temperature Battery Type Description Group 1 CCV heaters are provided as part of the cold and extreme cold coolant heater packages. The cold weather starter is provided as part of the extreme cold coolant heater package. 2 NOTICE For NFPA 110 applications, a coolant heater is required. A factory option is available. TABLE 3.
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7-2018 2. Introduction Type Specification Engine Weight (Dry, Long Block 413 kg (911 lb) Only) Valve Clearance (Intake) 0.305 mm (0.012 in) Valve Clearance (Exhaust) 0.610 mm (0.024 in) • 50/50 coolant solution (50% pure water and 50% antifreeze) Coolant • 16 L (4.23 gal) capacity Oil Capacity 15 L (4 gal) • Must adhere to Cummins® Engineering Standard (CES) 20085 • Use of improper oils can result in engine damage.
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2. Introduction 7-2018 TABLE 6. GENERATOR SET SIZE SPECIFICATIONS Enclosure Type Size (L x W x H) Open/Weather 2489 x 1016 x 1473 mm (98 x 40 x 58 in); does not include exhaust discharge elbow Sound Level 1 3023 x 1016 x 1473 mm (119 x 40 x 58 in) Sound Level 2 3454 x 1016 x 1473 mm (136 x 40 x 58 in) TABLE 7.
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7-2018 2. Introduction NOTICE Maximum I2 = 8%. Generator set load unbalance must not exceed 25% between any phases. TABLE 9. GENERATOR SET DERATING GUIDELINES Engine Power Available Up To...
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3 Pre-Installation Considerations Areas of consideration: No. Description No. Description 1 Generator Set 4 Electrical Meter 2 Propane Tank 5 Natural Gas Meter 3 Transfer Switch FIGURE 1.
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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.
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7-2018 3. Pre-Installation Considerations TABLE 12.
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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.
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7-2018 3. Pre-Installation Considerations • Code compliant conduit for all wires Mounting Materials: • Four base tie-down bolts NOTICE Seismic zone installations require compliance to specific mounting configurations. Fuel Materials: • Flexible fuel line (provided with the generator set, attached to the radiator guard) • UL listed pipe thread sealant • Fuel line at generator set (natural gas and propane: 6-13 inches of water column [1.5 - 3.
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4 Installation 4.1 Site Assessment and Preparation Proper component location and site preparation have a very important impact on completing a successful installation. The major components and sources of power needed for installation include the following items: • Generator set • Transfer switch • Electrical utility • Fuel source • Accessories (may be required under certain conditions) Picking a Location WARNING Exhaust gas is deadly.
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4. Installation 7-2018 The generator set location is critical for safety and performance. Follow the guidelines below: • Must comply with applicable codes (NFPA, NEC, IBC, etc.). • This manual only covers outdoor installations with Cummins factory installed enclosures. For other installation types, contact your local Cummins dealer or reference the Application Manual at the following link: http://www.cumminspower.com/www/literature/applicationmanuals/t030.
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7-2018 4. Installation NOTICE Seismic installation may require a different pad and securing devices. NOTICE Local codes and standards may have different requirements. 4. Lift the generator set onto the pad, and secure it. No. Description No. Description 1 Pad Length (Must Extend Minimum 152 mm/6 in Beyond Skid) 6 Circuit Breaker 3 Stub-Up (Optional) 2 Pad Width (Must Extend Minimum 152 mm/6 in Beyond Skid) 7 1.
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4. Installation 7-2018 Lifting and Moving the Generator Set WARNING Heavy Load The generator set is heavy. Handle with care. Dropping the generator set can cause severe personal injury or death. Use appropriate lifting techniques to move the generator set. Keep feet and hands clear when lifting the generator set. CAUTION The generator set is shipped with oil in the engine crankcase. Keep the generator set upright.
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7-2018 4. Installation WARNING Gaseous fuels are flammable, explosive, and can cause severe personal injury or death. Do not smoke if you smell gas, are near fuel tanks for fuelburning equipment, or are in an area sharing ventilation with such equipment. Keep flames, sparks, pilot lights, electrical arcs, arc-producing equipment and all other sources of ignition well away. Keep a type ABC fire extinguisher handy. In all fuel system installations, cleanliness is extremely important.
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4. Installation 7-2018 NOTICE Iron pipe must be a minimum of schedule 40 subject to the authority having jurisdiction. • Cummins flexible fuel line (attached to the radiator guard) to protect the fuel system from vibration, expansion, and contraction • Manual shutoff valve WARNING Fuel leaks can lead to explosive accumulations of gas. Prevent gas leaks and the accumulation of gaseous fuel in the event of a leak. No. Description No.
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7-2018 4. Installation An older site might require upgrading and repair of the gas supply system. Schedule an upgrade or repair to minimize power and gas supply interruptions. Make sure the full load fuel supply pressure at the inlet to the generator fuel shutoff valves matches the requirements in the Model Specifications section.
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4. Installation 7-2018 Component Description Cummins Flexible Fuel Line No. Attached to radiator guard. Protects the fuel system from vibration, expansion, and contraction. Description No. Description 1 Flexible Fuel Line (Attached to Radiator Guard) 4 Shutoff Valve 2 Generator Set 5 Propane Tank 3 Service Regulator FIGURE 5. TYPICAL PROPANE INSTALLATION Propane Fuel Requirements WARNING Propane presents the hazard of fire or explosion that can cause severe personal injury or death.
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7-2018 4. Installation NOTICE NFPA Standard No. 58 requires all persons handling and operating propane to be trained in proper handling and operating procedures. 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.
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4. Installation 7-2018 • Fit the propane tanks with a pressure reducing regulator before connection to the generator set to prevent fuel system damage. • Locate the propane tanks and all other fuel system components at least 10 feet (3 meters) from any source of combustion (including the generator set). The fuel supplier or local code may require a larger distance between the tank and source of combustion.
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7-2018 4. Installation To calculate the minimum pipe size: 1. Make a list of all the fittings and valves in a proposed system and add their equivalent lengths. 2. Add all lengths of straight pipe to arrive at a total equivalent length to the fittings/valves total. 3. Choose the applicable table based on the fuel system and fuel line material. 4. Obtain the maximum fuel requirements for the specific generator set from the Model Specifications section. 5.
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4. Installation 7-2018 NOTICE Follow any local codes and standards, as they may require a different method or documentation of a leak test. Perform the following fuel piping system leak check: 1. After assembly and before initial operation of generator set, test all fuel system components as required per the National Fuel Gas Code (NFPA 54). 2. The National Fuel Gas Code requires that the generator set be isolated from the piping system by disconnecting it and capping the outlet prior to test.
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7-2018 4.4 4. Installation Electrical Connections WARNING Improper installation can lead to electrocution and damage to property. Electrical connections must be made by a licensed electrician. WARNING Automatic startup of the generator set during installation can cause severe personal injury or death. Make sure the generator set is shut down and disabled: 1. Press the generator set's "O" (Off) button to stop the generator set. Allow the generator set to thoroughly cool to the touch. 2.
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4. Installation 7-2018 NOTICE When using a circuit breaker with an adjustable, electronic trip unit, the amperage and trip curve settings may need adjustment to match the generator set load wiring, or downstream loads and circuit breakers. An accessory seal kit (part number A026M166) is available to tamper-proof the adjustable settings. 1. Make sure the generator set is shut down and disabled: a. Press the Off switch from the display and then press the E-Stop button to stop the generator set.
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7-2018 4. Installation FIGURE 7. 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. A051X873 (Issue 10) 39 Copyright © 2018 Cummins Inc.
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4. Installation 7-2018 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 RA Series Transfer Switch Owner Manual. Copyright © 2018 Cummins Inc.
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7-2018 4. Installation FIGURE 8. RA SERIES TRANSFER SWITCH AC CONNECTIONS LOCATION Factory Option and Accessory Connections The AC-powered options or accessories available include the battery charger, engine coolant heater, alternator heater, oil heater, battery warmer, and CCV heater (included with coolant heater). A051X873 (Issue 10) 41 Copyright © 2018 Cummins Inc.
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4. Installation 7-2018 NOTICE The CCV heater requires power from a 120 VAC, 20 Amp protected circuit from the Main Distribution Panel. The CCV needs to be powered even during utility outages. Use 12 AWG 167 °F (75 °C) conductors to connect to the generator set AC distribution connector. FIGURE 9. Copyright © 2018 Cummins Inc.
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7-2018 4. Installation DC Connections NOTICE When selecting and installing conduit to the generator set, account for any needed accessories, such as a remote display, etc. FIGURE 10. A051X873 (Issue 10) DC CUSTOMER CONNECTIONS 43 Copyright © 2018 Cummins Inc.
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4. Installation 7-2018 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. Install the transfer switch in accordance with the RA Series Transfer Switch Owner Manual.
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4. Installation No. 7-2018 Description No. Description 1 DC Circuit Connectors 5 Remote Start 2 DC Customer Connections (within Dotted Line Box) 6 Fuse B+ (5A) 3 PCC 1.1 or PCC 2.3 7 Ready to Load 4 Ground (B-) 8 RA Transfer Switch Terminal Block FIGURE 12. GENERATOR SET TO RA TRANSFER SWITCH DC CUSTOMER CONNECTIONS Grounding NOTICE The generator set is shipped from the factory with the neutral and equipment ground not bonded together. Copyright © 2018 Cummins Inc.
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7-2018 4. Installation 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. When the generator set is running, the battery is charged from the engine-driven battery alternator. When the set is not running, an AC powered battery charger is needed to keep the battery charged.
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4. Installation 7-2018 FIGURE 13. BATTERY LOCATION Refer to the Model Specifications section for battery specifications. An optional thermostatically controlled battery heater is available for more reliable starting in ambient temperatures below –18 °C (0 °F).
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5 Startup and Configuration PCC 1.1 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.
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5. Startup and Configuration PCC 1.1 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.
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7-2018 5. Startup and Configuration PCC 1.1 TABLE 14. 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 16. DAYLIGHT SAVING ADJUST START SCREEN Update the Daylight Saving Adjust End Screen 1.
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5. Startup and Configuration PCC 1.1 FIGURE 17. 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.
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5. Startup and Configuration PCC 1.1 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.
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7-2018 5. Startup and Configuration PCC 1.1 FIGURE 19. 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.
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5. Startup and Configuration PCC 1.1 7-2018 • Press Save to save any changes. After saving, the Save button changes to the Adjust button. FIGURE 20. 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.
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7-2018 5. Startup and Configuration PCC 1.1 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 21. A051X873 (Issue 10) BRIGHTNESS AND CONTRAST SCREEN NAVIGATION 57 Copyright © 2018 Cummins Inc.
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5. Startup and Configuration PCC 1.1 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.
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5. Startup and Configuration PCC 1.1 5.5 7-2018 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.
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7-2018 5. Startup and Configuration PCC 1.1 Tick Item Wire sizes, wire types, 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 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.
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5. Startup and Configuration PCC 1.1 7-2018 The following information applies to C70 N6, C80 N6, and C100 N6 generator set models only: Adaptive learn is an engine ECM function that allows the generator set to "learn" its environment. There are small differences in the performance of each engine and fuel system component, so the ECM uses inputs from the engine sensors to adjust running conditions to operate more consistently for each individual generator set.
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7-2018 5. Startup and Configuration PCC 1.1 NOTICE These steps cannot be performed with the HMI211; they can only be performed with the InPower service tool. 1. Connect to the PCC 1.1 or PCC 2.3 via InPower. 2. Navigate to the Adjustments->Features->Automatic Transfer Switch folder. 3. Select the Auto Mains Failure Enable parameter. 4. Double-click on Enabled in the Value field. 5. A pop-up will appear with available choices. Select Disabled. 6. Select Device->Save Adjustments from the top menu bar. 7.
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6 Startup and Configuration PCC 2.3 6.1 Operator Panel The figure below shows the features of the front panel. It includes five lamp indicators; the graphical display with four menu select and seven menu navigation buttons; and six control mode buttons. This display panel enables the operator to look at the status, adjust the settings, and start and stop the generator set. No. Description No.
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6. Startup and Configuration PCC 2.3 7-2018 Operator Panel - Initial Operator Menu Figure 24 on page 67 shows the initial menu which is displayed over two pages. Use the soft-key buttons below the up and down arrows (▲ and ▼) to toggle between the two pages. Use the soft-key buttons below Genset, Alternator, or Engine to short-cut to those menus. Pressing the Home button menu screens.
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7-2018 6. Startup and Configuration PCC 2.3 Name Description Adjust The use of these screens is restricted to authorized personnel only. Genset Setup Paralleling Basic Setup OEM Setup PCCnet Setup Modbus Setup Display Options Clock Setup Configurable IO Calibration Save/Reserve FIGURE 24. INITIAL OPERATOR MENU • Press the Home Button A051X873 (Issue 10) to return to the main menu at any time. 67 Copyright © 2018 Cummins Inc.
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6. Startup and Configuration PCC 2.3 7-2018 • Press the C Button to return to the previous menus. Settings will not be saved when this button is pressed. Operator Panel - Engine Data Operator Menu The Engine Data Menu - Typical Data figure shows a block representation of a typical Engine Data menu. To navigate from the Home menu (HOME [1/2]), press the soft-key button below the function button indicating Engine. This will take you directly to the Engine menu.
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7-2018 6. Startup and Configuration PCC 2.3 Name Batt Voltage Description Allowed Values Battery voltage value FIGURE 25. ENGINE DATA MENU - TYPICAL DATA • Press the Home Button to return to the main menu at any time. • Press the C Button to return to the previous menus. Settings will not be saved when this button is pressed. History/About Menu Figure 26 on page 71 shows a block representation of a typical History/About menu.
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6. Startup and Configuration PCC 2.3 TABLE 18. 7-2018 HISTORY/ABOUT MENU Name Description Starts Total number of start attempts. Runs Total number of generator set runs. Engine Hours Total engine run time. Control Hours Controller ON time in seconds. Upper limit is 136 years. Kw Hours Generator set total net kWh accumulation. Gen Mod # Number identifying the model of the generator set. (Password level: 2) Gen Ser # Serial number identifying the generator set.
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7-2018 6. Startup and Configuration PCC 2.3 FIGURE 26. HISTORY/ABOUT MENU - TYPICAL DATA • Press the Home Button to return to the main menu at any time. • Press the C Button to return to the previous menus. Settings will not be saved when this button is pressed. Contrast The Display Options screen allows the contrast to be set. 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 Display Options. 3.
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6. Startup and Configuration PCC 2.3 7-2018 5. Adjust the setting and press Save to save any changes. When updating this setting, the functions of the keys are as follows: TABLE 19.
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7-2018 6. Startup and Configuration PCC 2.3 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. When updating these settings, the functions of the keys are as follows: TABLE 20.
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6. Startup and Configuration PCC 2.3 TABLE 21. 7-2018 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 29. DAYLIGHT SAVING ADJUST START SCREEN Update the Daylight Saving Adjust End Screen 1.
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7-2018 6. Startup and Configuration PCC 2.3 FIGURE 30. DAYLIGHT SAVING ADJUST END SCREEN Genset Setup Menu Use the Genset Setup menu to view generator setup data. The figure below shows block representations of the Genset Setup menu and sub-menus. 1. Use the two soft-key buttons below the up and down arrows (▲ and ▼) to page down to the second page of the HOME (2/2) menu. 2. In the HOME (2/2) menu, use the up and down arrows (▲ and ▼), to highlight the Genset Setup text. 3.
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6. Startup and Configuration PCC 2.3 7-2018 Press the Home Button to return to the main menu at any time. Press the C Button to return to the previous menus. Settings will not be saved when this button is pressed. FIGURE 31. Copyright © 2018 Cummins Inc.
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7-2018 6.2 6. Startup and Configuration PCC 2.3 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. 6.3 Checklist Tick General Items Generator set output is sufficient to handle maximum anticipated load. At least 0.
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6. Startup and Configuration PCC 2.3 7-2018 Tick General Items Fuel lines are properly installed, supported, and protected against damage. The fuel filters have been installed. Approved flexible fuel line is installed between the main fuel supply and the generator set’s fuel system near the generator set, to protect it against damage caused by vibration, expansion, and contraction.
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7-2018 6. Startup and Configuration PCC 2.3 Tick General Items 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 compliance with all codes. Exhaust piping is large enough in diameter to prevent excessive back pressure on engine. Verify that the pyrometer meters are functioning. AC and DC Wiring For bottom entry circuit breaker installations, the cable chute has been installed (if applicable).
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6. Startup and Configuration PCC 2.3 6.4 7-2018 Before Starting NOTICE One operator should be in complete charge, or working under the direction of someone who is in charge. Remember that, upon starting the engine, cables and switchgear will become energized, possibly for the first time. Furthermore, equipment that does not form part of the generator set installation may become electrically charged. Only authorized and competent personnel should carry out this work.
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7-2018 6. Startup and Configuration PCC 2.3 NOTICE The number of starting cycles, and the crank and rest times are set from within the Setup menu. Trained and experienced service personnel are required to change the default setting. Contact your authorized Cummins distributor. Initial Pre-Start Checks WARNING Electric Shock Hazard Voltages and currents present an electrical shock hazard that can cause severe burns or death.
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6. Startup and Configuration PCC 2.3 TABLE 23. 7-2018 INITIAL PRE-START CHECKS Check Description Generator Set Grounding Grounding (earthing) must be checked prior to performing service or inspection procedures that may expose personnel to conductors normally energized with voltages greater than 600 Volts. Contact your authorized Cummins distributor.
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7-2018 6. Startup and Configuration PCC 2.3 WARNING Hot Pressurized Liquid Contact with hot liquid can cause severe burns. Do not open the pressure cap while the engine is running. Let the engine cool down before removing the cap. Turn the cap slowly and do not open it fully until the pressure has been relieved. NOTICE Radiators with two fill necks only: Both fill necks must be filled when the cooling system has been drained. TABLE 24.
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6. Startup and Configuration PCC 2.3 7-2018 Check Description Make sure that the batteries are charged, and that all connections are clean, correct and tight (if applicable). Batteries Auxiliary Powered Make sure that all auxiliary equipment is receiving power from the AC Supplies customer’s supply. Emergency Stop Make sure that the emergency stop button is fully operational.
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7-2018 6. Startup and Configuration PCC 2.3 To clear a Fail to Start shutdown: a. Press the Stop button. b. Press the Reset button. 4. Before attempting to re-start, wait a minimum of two minutes for the starter motor to cool and then repeat the starting procedure. If the engine does not run after a second attempt, refer to the Troubleshooting section of the operator manual. DISABLING MANUAL MODE To disable Manual mode, change to Auto or Off mode.
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6. Startup and Configuration PCC 2.3 7-2018 Cold Starting with Loads NOTICE Make sure that all pre-start checks are carried out before starting the generator set. Do not attempt to start the generator set until it is safe to do so. Warn all others in the vicinity that the generator set is about to start. Use a coolant heater if a separate source of power is available. The optional heater available from Cummins will help provide reliable starting under adverse weather conditions.
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7-2018 6.5 6. Startup and Configuration PCC 2.3 Startup WARNING Automated Machinery Accidental or remote starting of the generator set can cause severe personal injury or death. Isolate all auxiliary supplies and use an insulated wrench to disconnect the starting battery cables, negative (–) cable first. • After verifying that the installation was completed correctly, start and test the system. Make sure to connect the battery cables to the battery with the positive (+) cable first.
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Appendix A. Fuel Line Selection Table of Contents Table 26. Required Information for Determining Fuel Line Size ............................................................. 90 Table 28. NFPA Equivalent Lengths of Pipe Fittings and Valves in Feet (Meters) ................................ 91 Table 30. Natural Gas Schedule 40 Metallic Pipe Sizing in Inches ......................................................... 93 Table 33. Natural Gas Semirigid Copper Tubing Sizing .........................................
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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.
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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.
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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.
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7-2018 Appendix A. Fuel Line Selection TABLE 30. 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.
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Appendix A.
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7-2018 Appendix A.
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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.
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7-2018 Appendix A.
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Appendix A. Fuel Line Selection 7-2018 TABLE 39. 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.
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7-2018 Appendix A.
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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.
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7-2018 Appendix A. Fuel Line Selection FIGURE 32. MINIMUM LPG TANK SIZE (50% FULL) REQUIRED TO MAINTAIN 5 PSIG AT SPECIFIC WITHDRAWAL RATE AND MINIMUM EXPECTED WINTER TEMPERATURE A051X873 (Issue 10) 101 Copyright © 2018 Cummins Inc.
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Appendix B. Outline and System Drawings Table of Contents Figure 33. Generator Set Outline, 45-50 kW (Sheet 1 of 2) .................................................................... 105 Figure 34. Generator Set Outline, 45-50 kW (Sheet 2 of 2) .................................................................... 106 Figure 35. Generator Set Outline, 60 kW (Sheet 1 of 2) ......................................................................... 107 Figure 36. Generator Set Outline, 60 kW (Sheet 2 of 2) ....
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Appendix C. Wiring Diagrams Table of Contents Figure 45. Wiring Diagram for PCC 1302 (56 Pin ECM) (Sheet 1 of 7) .................................................. 121 Figure 46. Wiring Diagram for PCC 1302 (56 Pin ECM) (Sheet 2 of 7) .................................................. 122 Figure 47. Wiring Diagram for PCC 1302 (56 Pin ECM) (Sheet 3 of 7) .................................................. 123 Figure 48. Wiring Diagram for PCC 1302 (56 Pin ECM) (Sheet 4 of 7) .................................
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Appendix C. Wiring Diagrams 7-2018 Figure 79. Circuit Card Harness (Sheet 1 of 1) ....................................................................................... 155 Figure 80. Relay Harness (Sheet 1 of 1) .................................................................................................. 156 Figure 81. Generator Electrical Harness (Sheet 1 of 1) .......................................................................... 157 Copyright © 2018 Cummins Inc.
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7-2018 Appendix C. Wiring Diagrams The drawings included in this section are representative. For current complete information, refer to the drawing package that was shipped with the unit. A051X873 (Issue 10) 119 Copyright © 2018 Cummins Inc.
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Appendix D. Seismic Requirements Table of Contents Figure 82. Seismic Installation Requirements (Sheet 1 of 4) ................................................................ 161 Figure 83. Seismic Installation Requirements (Sheet 2 of 4) ................................................................. 162 Figure 84. Seismic Installation Requirements (Sheet 3 of 4) ................................................................. 163 Figure 85. Seismic Installation Requirements (Sheet 4 of 4) ............
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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.
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power.cummins.com Copyright © 2018 Cummins Inc. All rights reserved. Cummins, the "C" logo, PowerCommand, AmpSentry, and InPower are trademarks of Cummins Inc. Other company, product, or service names may be trademarks or service marks of others. Specifications are subject to change without notice.