Product Manual

ManualsBrandsCummins ManualsGenerator AccessoriesAuxiliary Output Relays for Big Connect RS Standby Generator

InstructionInstruction SheetSheet

7-2013

A045H692 (Issue 1)

Installation Instructions for Customer Relay Kit A044Z053

1 Introduction

The information contained within is based on information available at the time of going to print.

In line with Cummins Power Generation policy of continuous development and improvement,

information may change at any time without notice. The users should therefore make sure that

before commencing any work, they have the latest information available. The latest version of

this manual is available on QuickServe Online (https://qsol.cummins.com/info/index.html).

2 Safety Precautions

2.1 General Safety Precautions

WARNING

Coolants under pressure can cause severe scalding. Do not open a radiator or heat

exchanger pressure cap while the engine is running. Let the engine cool down before

removing the coolant pressure cap. Turn the cap slowly and do not open it fully until

the pressure has been relieved.

WARNING

Moving parts can cause severe personal injury or death and hot exhaust parts can

cause severe burns. Make sure all protective guards are properly in place before

starting the generator set.

WARNING

Used engine oils have been identified by some state and federal agencies to cause

cancer or reproductive toxicity. Do not ingest, breathe the fumes, or contact used oil

when checking or changing engine oil.

WARNING

Operation of equipment is unsafe when mentally or physically fatigued. Do not operate

equipment in this condition, or after consuming any alcohol or drug.

WARNING

Substances in exhaust gases have been identified by some state and federal agencies

to cause cancer or reproductive toxicity. Do not breath in or come into contact with

exhaust gases.

English

A045H692 (Issue 1)

- Original Instructions

Page 1 of 11

Summary of content (11 pages)

PAGE 1
Instruction Sheet A045H692 (Issue 1) 7-2013 Installation Instructions for Customer Relay Kit A044Z053 1 Introduction The information contained within is based on information available at the time of going to print. In line with Cummins Power Generation policy of continuous development and improvement, information may change at any time without notice. The users should therefore make sure that before commencing any work, they have the latest information available.
PAGE 2
WARNING Flammable liquids can cause fire or explosion. Do not store fuel, cleaners, oil, etc. near the generator set. WARNING Wear hearing protection when going near an operating generator set . WARNING Hot metal parts can cause severe burns. Avoid contact with the radiator, turbo charger, and exhaust system. WARNING Maintaining or installing a generator set can cause severe personal injury.
PAGE 3
CAUTION Before performing maintenance and service procedures on enclosed generator sets, make sure the service access doors are secured open. CAUTION Keep the generator set and the surrounding area clean and free from obstructions. Remove any debris from the set and keep the floor clean and dry. NOTICE Keep multi-class ABC fire extinguishers handy. Class A fires involve ordinary combustible materials such as wood and cloth. Class B fires involve combustible and flammable liquid fuels and gaseous fuels.
PAGE 4
• De-energize and lockout/tagout electrical systems prior to working on them. Lockout/Tagout is intended to prevent injury due to unexpected start-up of equipment or the release of stored energy. Please refer to the lockout/tagout section for more information. • De-energize and lockout/tagout all circuits and devices before removing any protective shields or making any measurements on electrical equipment. • Follow all applicable regional electrical and safety codes.
PAGE 5
WARNING Incorrect service or replacement of parts can result in severe personal injury or death, and/or equipment damage. Service personnel must be trained and experienced to perform electrical and mechanical service. WARNING High voltages can cause electrical shock, resulting in severe personal injury or death. Voltages of up to 600 VAC are present inside the control box. The control box must be opened only by technically qualified personnel.
PAGE 6
WARNING Ignition of explosive battery gases can cause severe personal injury. Do not smoke or cause any spark, arc, or flame while servicing batteries. 2. Remove the roof panel (dome) of the electrical control box. 3. The customer relays are rail mounted inside the control box (see the figures below). Remove the right control cover from the control box.
PAGE 7
No. Description No. Description 1 PCC-TB1 Connector 4 Customer Relays 2 Harness Wire Route 5 Pan Head Screws (A043Y727) 3 TB-DC Terminal Block FIGURE 1.
PAGE 8
No. 1 Description Screw In A043E872 FIGURE 2. No. 2 Description Harness Wire Route CUSTOMER RELAY INSTALLATION (REAR VIEW) 4. The relay harness (see figure below) comes with relay assembly mounted to the din rail. Install the din rail in the box using the pan head screws (A043Y727) as shown in Figure 1. Torque to 8 - 9 Nm (5.92 - 6.66 ft-lb).
PAGE 9
FIGURE 3. RELAY HARNESS 5. The B+ extension harness (see figure below) comes with a TB-DC terminal block. Snap the block in above the relays. FIGURE 4. B+ EXTENSION HARNESS 6. Screw in the pan head screw (A043E872) behind the box where the block gets mounted. See Figure 1 and Figure 2. Torque to 8 - 9 Nm (5.92 - 6.66 ft-lb). 7. Refer to the wiring diagrams (shown below) to connect the relay harness and B+ extension wires to the TB-DC block and PCC-TB1 connector.
PAGE 10
FIGURE 5.
PAGE 11
FIGURE 6. WIRING DIAGRAM FOR CUSTOMER CONNECTIONS (SHOWING TB-DC BLOCK) 8. Route the harness wires to the back of the box into the PCC-TB1 connector as shown in Figure 1 and Figure 2. 9. Secure the wires using wire ties. 10. Re-install the control cover on control box. 11. Re-install the roof panel. 12. Reconnect the battery cables (positive [+] cable first). 13. Connect the battery charger (if applicable). 14. A qualified technician should configure the relays to the desired customer outputs.