Loading...
Generator Manual.pdfInstallation Manual, GENERATOR SET Printed U.S.A. 928-0602 12-95 i + +�u GriGaua�su,o� dug. g�s��ai�r °,�R'�ark s t,6 G# is t6uaa ruaazr�°�i by any rn l b, v"'A sftkAHy puoMiboc(L Table of Contents SECTION TITLE PAGE SAFETY PRECAUTIONS . ............................................ ii 1 INTRODUCTION ...... ................. .................. .........1-1 About this Manual ....................... .................,.,,..1-1 Installation Overview ... . ..... . ... ................ , ...... 1-1 2 SPECIFICATIONS.................ro................................ 2-1 3 MOUNTING THE GENERATOR SET .................................. 3-1 General...........................................<............3-1 Location...... ............................. ......... ........... .3-1 Mounting.......................... ........... ........... ....,3-2 Access to Set ..................................... .............. 3-2 4 MECHANICAL CONNECTIONS .............. . ......... ...... 4-1 General......... .................. ............. ............ ..... 4-1 FuelSvstem......................... ........................... .4-1 Exhaust System .......... ............... ......... ............... 4-2 Ventilation and Cooling ............................ .............. 4-3 5 ELECTRICAL CONNECTIONS ...................... ........ 5-1 General......................................... ......... 5-1 Transfer Switch ................................................. 5-1 AC Wiring ...................................................... 5-2 Control Wiring .............. ....................... .............. 5-3 Engine Control Monitor Board (A11) .... . ...... . ........ . .... . ....... 5-4 Auxiliary Relay Board (Optional) ............................ . ...... 5-6 Time -Delay Module (A15) ............................ . .. . ........ 5-8 The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. i IRe6sfiiriilkuaatloaaus Aau publlua;aafisaun of 4paks doa.aauri°oeuat ion by any means, os .>tlrocHy IprolrnubRed: SECTION TITLE u 07 PAGE 6 PRESTART PREPARATIONS .. . . .. . . ............................. « . 6-1 General............... ................................ ,«..... – 6-1 Lubrication...................................................... 6-1 Coolant.............................................«.......... 6-1 Fuel......«...........«............................««.......... 6-1 Ventilation ,....... ........................... ............. 6-1 Exhaust System ................. .......«,«............ 6-1 Electrical System«.....,..««............................«,...,...6-1 Mechanical Checks ..................«.................. ........6-1 7 INITIAL START AND CHECKS .. . ........ . .................. « ... —. . 7-1 Starting....................«................................... 7-1 EngineGauges ..............«.......«,.................«.«........ 7-1 AC Meters (If Equipped) ........ . ... . .. , ... « ...... « . « .......... , « , « 7-1 Engine Monitor Indicator Lamps ...... , «„ , , ..... « « . .... . ....... . ... 7-1 Exhaust System ...... ...............................«.,.........«. 7-2 FuelSystem ........................«,,...,........,.....,....,. 7-2 DC Electrical System... «........................................ « . 7-2 Cooling System .................... _ ... ,.................. .... 7-2 Mechanical Adjustments ....... . .. . . . . . . ......... .............. « . , 7-2 8 INSTALLATION CHECKLIST ................ « .......... « « « .... « . , ... 8-1 General........................................................ 8-1 Genset Support ................«,.........«.,................... 8-1 CoolingAir Flow ......,...«.......,..............«.«....«..,.«.... 8-1 FuelSystem .....................«.......«.............,«,,....... 8-1 Exhaust System ...,.,.,...«,. ........................,.«... 8-2 ACand DC Wiring .............«,...........,.................... 8-2 GensetPrestart .................................«.,«,,....... .«. 8-2 9 WIRING DIAGRAMS ...........................«...«,...«.......... 9-1 Redistribution or publication of this document by any means, is strictly prohibited. Before operating the generator set, read the Op- erator's Manual and become familiar with it and the equipment. Safe and efficient operation can be achieved only If the equipment is properly oper- ated and maintained. Many accidents are caused by failure to follow fundamental rules and precau- tions. The following symbols, found throughout this man- ual, alert you to potentially dangerous conditions to the operator, service personnel, or the equipment. j IN This symbol warns of Immediate hazards which will result In severe personal in- jury or death. �vThis symbol refers to a hazard or un- safe practice which can result in severe per- sonal injury or death. �o This symbol refers to a hazard or un- safe practice which can result in personal injury or product or property damage. FUEL AND FUMES ARE FLAMMABLE Fire, explosion, and personal injury or death can re- sult from improper practices. • DO NOT fill fuel tanks while engine is running, unless tanks are outside the engine compart- ment. 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. • Fuel lines must be adequately secured and free of leaks. Fuel connection at the engine should be made with an approved flexible line. Do not use copper piping on flexible lines as copper will become brittle if continuously vi- brated or repeatedly bent. • Be sure all fuel supplies have a positive shutoff valve. • Be sure battery area has been well -ventilated prior to servicing near it. Lead -acid batteries emit a highly explosive hydrogen gas that can be ignited by arcing, sparking, smoking, etc.. EXHAUST GASES ARE DEADLY • Provide an adequate exhaust system to prop- erly expel discharged gases away from en- closed or sheltered areas and areas where in- dividuals are likely to congregate. Visually and audibly inspect the exhaust daily for leaks per the maintenance schedule. Make sure that ex- haust manifolds are secured and not warped. Do not use exhaust gases to heat a compart- ment. • Be sure the unit is well ventilated. • Engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm. MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH • Keep your hands, clothing, and jewelry away from moving parts. • Before starting work on the generator set, dis- connect battery charger from its AC source, then disconnect starting batteries, negative (-) cable first. This will prevent accidental starting. • Make sure that fasteners on the generator set are secure. Tighten supports and clamps, keep guards in position over fans, drive belts, etc. • Do not wear loose clothing or jewelry in the vi- cinity of moving parts, or while working on elec- trical equipment. Loose clothing and jewelry can become caught in moving parts. Jewelry can short out electrical contacts and cause shock or burning. • If adjustment must be made while the unit is running, use extreme caution around hot mani- folds, moving parts, etc. LS -11 b III Redistribution or publication of this document by any means, is strictly prohibited. ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH • Remove electric power before removing pro- tective shields or touching electrical equip- ment. Use rubber insulative mats placed on dry wood platforms over floors that are metal or concrete when around electrical equipment. Do not wear damp clothing (particularly wet shoes) or allow skin surface to be damp when handling electrical equipment. • Use extreme caution when working on electri- cal components. High voltages can cause in- jury or death. DO NOT tamper with interlocks. • Follow all applicable state and local electrical codes. Have all electrical installations per- formed by a qualified licensed electrician. Tag and lock open switches to avoid accidental closure. • DO NOT CONNECT GENERATOR SET DI- RECTLY TO ANY BUILDING ELECTRICAL SYSTEM. Hazardous voltages can flow from the generator set into the utility line. This cre- ates a potential for electrocution or property damage. Connect only through an approved isolation switch or an approved paralleling device. HIGH VOLTAGE GENERATOR SETS (1.9kV to 15kV) High voltage acts differently than low voltage. Special equipment and training is required to work on or around high voltage equipment. Op- eration and maintenance must be done only by persons trained and qualified to work on such devices. Improper use or procedures will result in severe personal injury or death. Do not work on energized equipment. Un- authorized personnel must not be permitted near energized equipment. Due to the nature of high voltage electrical equipment, induced voltage remains even after the equipment is disconnected from the power source. Plan the time for maintenance with authorized person- nel so that the equipment can be de -energized and safely grounded. GENERAL SAFETY PRECAUTIONS Coolants under pressure have a higher boiling point than water. DO NOT open a radiator or heat exchanger pressure cap while the engine is running. Allow the generator set to cool and bleed the system pressure first. Benzene and lead, found in some gasoline, have been identified by some state and federal agencies as causing cancer or reproductive toxicity. When checking, draining or adding gasoline, take care not to ingest, breathe the fumes, or contact gasoline. Used engine oils have been identified by some state or federal agencies as causing cancer or reproductive toxicity. When checking or changing engine oil, take care not to ingest, breathe the fumes, or contact used oil. Provide appropriate fire extinguishers and in- stall them in convenient locations. Consult the local fire department for the correct type of ex- tinguisher to use. Do not use foam on electrical fires. Use extinguishers rated ABC by NFPA. Make sure that rags are not left on or near the engine. Remove all unnecessary grease and oil from the unit. Accumulated grease and oil can cause overheating and engine damage which present a potential fire hazard. Keep the generator set and the surrounding area clean and free from obstructions. Re- move any debris from the set and keep the floor clean and dry. Do not work on this equipment when mentally or physically fatigued, or after consuming any alcohol or drug that makes the operation of equipment unsafe. • Substances in exhaust gases have been iden- tified by some state or federal agencies as causing cancer or reproductive toxicity. Take care not to breath or ingest or come into contact with exhaust gases. KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE Powe�w iv Redistribution or publication of this document Generation by any means, is strictly prohibited. ABOUT THIS MANUAL This manual provides installation instructions for the EK / EM Series generator sets. This includes the following information: Mounting Recommendations — Instructions for fastening generator set to base and space requirements for normal operation and service. Mechanical Connections — Location of con- nection points for fuel, exhaust, ventilation, and cooling. Electrical Connections — Location of electri- cal connection points for the control, generator, and starting system. Prestart — Checklist of items or procedures needed to prepare generator set for operation. Initial Startup—Test complete system to make sure of proper installation, satisfactory per- formance, and safe operation. Refer to Opera- tors Manual for troubleshooting information. Installation Checklist — Reference checks upon completion of installation. This manual DOES NOT provide application infor- mation for selecting a generator set or designing the complete installation. If it is necessary to design the various integrated systems (fuel, exhaust, cooling, etc.), review standard installation practices, or specify system materials, additional information is required. For engineering data specific to the gen- erator set, refer to the specification and product data sheets. For application information, refer to Application Manual T-030, "Liquid Cooled Genera- tor Sets". INSTALLATION OVERVIEW These installation recommendations apply to typi- cal installations with standard model generator sets. Whenever possible, these recommendations also cover factory designed options or modifica- tions. However, because of the many variables in any installation, it is not possible to provide specific recommendations for every situation. If there are any questions not answered by this manual, contact your nearest Cummins/Onan dealer or distributor for assistance . 1 i �� 52 Ge^nei,ation ;61 Application and Installation A standby power system must be carefully planned and correctly installed for proper operation. This in- volves two essential elements: application and in- stallation. Application (as it applies to generator set installa- tions) refers to the design of the complete standby power system that usually includes power distribu- tion equipment, transfer switches, ventilation equip- ment, mounting pads, and cooling, exhaust, and fuel systems. Each component must be correctly designed so the complete system will function as in- tended. Application and design is an engineering function generally done by specifying engineers or other trained specialists. Specifying engineers are responsible for the design of the complete standby system and for selecting the materials and products required. Installation refers to the actual setup and assem- bly of the standby power system. The installers set up and connect the various components of the sys- tem as specified in the system design plan. The complexity of the standby system normally requires the special skills of qualified electricians, plumbers, sheetmetal workers, etc. to complete the various segments of the installation. This is necessary so all components are assembled using standard methods and practices. Safety Considerations The generator set has been carefully designed to provide safe and efficient service when properly in- stalled, maintained, and operated. However, the overall safety and reliability of the complete system is dependent on many factors outside the control of the generator set manufacturer. To avoid possible safety hazards, make all mechanical and electrical connections to the generator set exactly as speci- fied in this manual. All systems external to the gen- erator (fuel, exhaust, electrical, etc.) must comply with all applicable codes. Make certain all required inspections and tests have been completed and all code requirements have been satisfied before certi- fying the installation is complete and ready for serv- ice. 1-1 Redistribution or publication of this document by any means, is strictly prohibited. mWQW-.4 No 40 Fecif 1cations, MODEL EK EM Engine Onan Modified Ford In-line 6 CSG -649 CSG -649 Fuel System Inlet Size Natural Gas 3/4 inch NPT 3/4 inch NPT Propane Vapor 3/4 inch NPT 3/4 inch NPT Propane Liquid 1/4 inch NPT 1/4 inch NPT Gasoline 1/8 inch NPT 1/8 inch NPT Exhaust Connection 2 inch NPT 2 inch NPT Backpressure (Max. Allowed) 20.4 inch H2O 20.4 inch H2O Electrical System Starting Voltage 12V 12V Battery Charging Current 65 amp 65 amp Cooling System Coolant Capacity with 5 gal 5 gal Standard Radiator (19 L) (19 L) Lubricating System Oil Capacity with Filter 7 qt (7 L) 7 qt (7 L) Battery Required Battery Voltage 12 VDC 12 VDC SAE Number 60 60 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 GENERATOR SET. BE SURE TO CONSULT WITH LOCAL POLLUTION CONTROL OR AIR QUALITY AUTHORITIES BEFORE COMPLET- ING YOUR CONSTRUCTION PLANS. PllDwillr"uvr 2-1 Redistribution or publication of this document e,Itrl'er ion by any means, is strictly prohibited. I Mounting the Generator Set GENERAL Most generator set installations must be engi- neered so the generator set will function properly under the expected load conditions. Use these in- structions as a general guide only. Follow the in- structions of the consulting engineer when locating or installing any components. The complete instal- lation must comply with all local and state building codes, fire ordinances, and other applicable regula- tions. Refer to Onan Application Manual, T-030, for further installation information. Requirements to be considered prior to installation: • Level mounting surface • Adequate cooling air • Adequate fresh induction air Power Generation sailllmio • Discharge of circulated air • Discharge of exhaust gases • Electrical connections • Accessibility for operation and servicing • Noise levels • Vibration isolation LOCATION 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 possi- ble to the main power fuse box. Provide a location away from extreme ambient tem- peratures and protect the generator set from ad- verse weather conditions. An optional housing is available for outside operation. 3-1 Redistribution or publlication of this document by any means, is strictly prohibited. MOUNTING Generator sets are mounted on a steel skid that pro- vides proper support. The engine -generator as- sembly is isolated from the skid frame by rubber mounts that provide adequate vibration isolation for normal installations. For critical installations, install vibration isolators between the skid base and foun- dation. Mount the generator set on a substantial and level base such as a concrete pad. Use 3/4 -inch diameter, anchored mounting bolts to secure the generator set skid to the floor to prevent movement. Secure the skid using a flat washer and hex nut for each bolt (Figure 3-1). For proper spac- ing of mounting bolts and set mounting dimensions, see your generator set outline drawing. ACCESS TO SET Plan for access to the generator set for servicing and provide adequate lighting around the unit. For convenience in general servicing such as the radia- tor, fan belt and changing the crankcase oil, the sur- face of the mounting base should be at least 6 inches (152 mm) above the floor. % 0Power 21AW Generation HEX NUT FLAT WASHER SKID 12 INCH (305 mm) i MOUNTING BOLT M1627 FIGURE 3-1 BOLT DIAGRAM 3-2 Redistribution or publication of this document by any means, is strictly prohibited. ionsi .4, Mechanical Connect" GENERAL The generator set mechanical system installation includes connecting the fuel, exhaust, ventilation and cooling systems. Before starting any type of fuel installation, all pertinent state and local codes must be complied with and the installation must be inspected before the unit is put in service. FUEL SYSTEM Sets can be equipped to operate on gasoline only, LPG (propane), gasoline/natural gas, gasoline/ LPG and LPG/natural gas combinations. A fuel se- lector switch may be provided for fuel changeover. (The position of the switch determines which fuel valve will open when the set is operated.) Gasoline Fuel ABh Fuel presents the hazard of fire or explosion which can result in severe personal injury or death. Do not smoke or allow any flame, spark, pilot light, arc producing equip- ment, or switch, or other ignition sources around fuel or fuel components, or in the instal- lation area or areas with shared ventilation. Keep a type ABC fire extinguisher nearby. The gasoline-carbureted fuel system delivers a mixture of fuel and air to the combustion chamber. The system draws fuel from a tank, delivers it through a filter and fuel pump, to the carburetor float chamber. Air passing through the carburetor venturi draws fuel from the the float chamber. See Specifications section for gasoline inlet size. Fuel lift should not exceed 6 feet (1.83 m). The rec- ommendations in Onan publication T030, the Ap- plication Manual for Liquid -Cooled Generator Sets, should be followed in regard to fuel supply system pipe sizes and manual shutoff valves. Natural Gas/LPG Vapor/LPG Liquid Fuel System EVAHNl:N:G Natural gas and LPG vapor are highly flammable. LPG vapor is heavier than air. Do not bleed lines so fumes can collect in low areas. Do not smoke or allow any flame, spark, arcing switch or equipment, pilot light, or other source of Ignition around fuel lines. A combination gasoline -gaseous fuel carburetor or straight gaseous fuel carburetors are available for use with gaseous fuels. A gaseous fuel system uses a fuel regulator to control the flow of gas from the lines to the carburetor. At the carburetor, the gaseous fuel is mixed with the incoming air. Gaseous -fuel supply system design, materials, components, fabrication, assembly, installation, testing, inspection, operation and maintenance must comply with the applicable codes. See NFPA Standards No. 30, No. 37, No. 54 and No. 58. See Specifications section for natural gas/LPG fuel inlet size. The recommendations in Onan publica- tion T030, the Application Manual for Liquid -Cooled Generator Sets, should be followed in regard to fuel supply system pipe sizes, manual shutoff valves, fuel filters and gas pressure regulators. Gas Pressure: The fuel regulators in each line pro- vide constant gas pressure at the gas mixer under varying load conditions (approximately 5 inches WC for natural gas and 1.5 inches WC for LPG). There is a pressure test port on the supply side of the gas mixer for measuring fuel inlet pressure. The maximum permissible fuel supply pressure Is 20 inches WC and the minimum is 7 inches WC. This applies to LPG as well as to natural gas. The minimum pressure refers to supply pressure under rated load (maximum gas flow). There is a pressure test port on the supply side of each fuel regulator for measuring fuel supply pressure. 41 Redistribution or publication of this document by any means, is strictly prohibited. EXHAUST SYSTEM Pipe exhaust gases to the outside of any enclosure. Locate the exhaust outlets away from any air inlets to avoid gases re-entering the enclosure. Exhaust installations are subject to various detrimental con- ditions such as extreme heat, infrequent operation and light loads. Regularly inspect the exhaust sys- tem both visually and audibly to see that the entire system remains fume tight and safe for operation. Inhalation of exhaust gases can re- sult in severe personal injury or death. Use ex- treme care during installation to provide a tight exhaust system. Terminate exhaust pipe away from enclosed areas, windows, doors and vents. Use an approved thimble (Figure 4-1) where ex- haust pipes pass through wall or partitions. Refer to NFPA 37, Section 6-3. "Stationary Combustion En- gines and Gas Turbines" for accepted design prac- tices. Build according to the code requirements in effect at the installation site. lull+ inhalation of exhaust gases can re- sult in severe personal injury or death. Do not use exhaust heat to warm a room, compartment or storage area. Rain caps are available for the discharge end of ver- tical exhaust pipes. The rain cap clamps onto the end of the pipe and opens due to exhaust discharge force from the generator set. When the generator set is stopped, the rain cap automatically closes, protecting the exhaust system from rain, snow, etc. Check the rain cap periodically for proper operation (cap is not stuck open or closed). Use a section of flexible exhaust pipe between the engine and remainder of exhaust system. Support exhaust system to eliminate weight applied to en- gine exhaust outlet elbow/turbocharger connec- tion. The flexible exhaust pipe section is used to eliminate vibration. Do not use to compensate for misalignment of exhaust components. �Weight applied to the engine mani- fold can result In turbocharger damage. Sup- port the muffler and exhaust piping so no weight or stress is applied to engine exhaust el- bow. C Pomrer Generation atiiD'JIT RAIN CAP DRIP CAP HOLES IN END OF INNER SLEEVE 9 INCH MIN 4 (230 mm) VERTICAL ROOF a 9 INCH MIN (230 mm) HORIZONTAL WALL OR PARTITION EXS1036 FIGURE 4-1. MOUNTING EXHAUST THIMBLE 4-2 Redistribution or publication of this docum lent by any means, is strictly prohibited. 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 to allow any moisture condensation to drain away from the engine. If an exhaust pipe must be turned upward, install a condensation trap at the point where the rise begins (Figure 4-2). Shield or insulate exhaust lines if there is danger of personal contact. Allow at least 12 inches (305 mm) of clearance if the pipes pass close to a combustible wall or partition. IIv� Exhaust pipes are very hot and they can cause severe personal injury or death from direct contact or from fire hazard. Shield or in- sulate exhaust pipes if there is danger of per- sonal contact or when routed through walls or near other combustible materials. VENTILATION AND COOLING Generator sets create considerable heat that must be removed by proper ventilation. Outdoor installa- tions rely on natural air circulation but indoor instal- lations need properly sized and positioned vents for required airflow. Vents and Ducts For indoor installations, locate vents so incoming air passes through the immediate area of the installa- tion before exhausting. Install the air outlet higher than the air inlet to allow for convection air move- ment. Size the vents and ducts so they are large enough to allow the required flow rate of air. The "free area" of ducts must be as large as the exposed area of the radiator. Refer to the Product Data Sheet for the air- flow requirements. 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 4-3. Pr er" Genenatiorij AVOID SHARP BENDS IF EXHAUST LINE MUST BE PITCHED UPWARD, CONSTRUCT A TRAP AT POINT OF RISE DRAIN CONDENSATION TRAP PERIODICALLY EXS1046S FIGURE 4-2. CONDENSATION TRAP C81we FIGURE 4-3. WIND BARRIER 4-3 Redistribution or publication of this document by any means, is stridy prohibited. Dampers Dampers or louvres protect the generator set and equipment room from the outside environment. Their operation of opening and closing should be controlled by operation of the generator set. In cooler climates movable or discharge dampers can be used. These dampers allow the air to be recirculated back to the equipment room. This en- ables the equipment room to be heated by the gen- erator set when operating. Radiator Set Requirements Radiator set cooling air is drawn past the rear of the set by a pusher fan that blows air through the radia- tor (Figure 4-4). Locate the air inlet to the rear of the set. Make the inlet vent opening a minimum of 1-1/2 times larger than the radiator area. It is important that the inlet and outlet (louvers) do not restrict the cooling air flow beyond the capability of the engine cooling fan. If this capability is exceed- ed, engine will overheat. 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. Length and shape of the air outlet duct should offer minimum restriction to airflow. Maximum restriction is 0.25 inches WC. The radiator has an air discharge duct adapter flange. Attach a canvas or sheet metal duct to the flange and the air outlet opening using screws and nuts so duct can be removed for maintenance pur- poses. The duct prevents recirculation of heated air. Before installing the duct, remove the radiator core guard. t ; Po'win Standard Radiator Cooling uses a set mounted radiator and engine pusher fan to cool engine water jacket. Air travels from the generator end of the set, across the engine and out through the radiator. An integral discharge duct adapter flange surrounds the radiator grille. Set Mounted Heat Exchanger Cooling uses a liq- uid -to -liquid heat exchanger that requires a connec- tion to a supply of pressurized cold water and to a drain to discharge the water when it has passed through the heat exchanger. The engine coolant pump pumps coolant through the closed, pressur- ized loop between the engine and heat exchanger. The cold water supply line should have a manual shutoff valve, water strainer and 12 VDC water sole- noid valve to shut off the water supply when the en- gine is not running. A thermostatic water flow valve is also recommended. See Application Manual T-030 for more information. A powered ceiling vent will probable be required for ventilating the generator room. Remote Radiator Cooling (Optional) substitutes a remote mounted radiator and an electrically driven fan for the set mounted components. Re- moval of the radiator and the fan from the set re- duces noise levels without forcing dependence on a continuous cooling water supply. The remote radia- tor installation must be completely protected against freezing. Remote radiator plumbing will vary with installation. Follow recommendations given in Application Man- ual T-030. See Product Data Sheet for friction head and static head limits. Before filling cooling system, check all hardware for security. This includes hose clamps, capscrews, fit- tings and connections. Use flexible coolant lines with heat exchanger, standpipe or remote mounted radiator. 4-4 Redistribution or publication o9 this document by any means, is strictly prohibited. FIGURE 4-4. TYPICAL INSTALLATION !Dlowe4.5 Redistribution or publication of this document Gerieration by any means, is strictly prohibited. 5, Electrical Connections GENERAL The generator set electrical system includes con- necting the load, installing the control wiring and connecting the batteries. Connect the batteries last to avoid accidental starting of the unit during instal- lation. AhtTlar To prevent arcing, always discon- nect a battery charger from its AC source before disconnecting the battery cables. Otherwise, disconnecting the cables can result in voltage spikes high enough to damage the DC control circuits of the set. LOAD NORMAL SOURCE GENSET --------------- NOTE: SHOWN WITH LINE CONNECTED TO LOAD A bulgy Accidental starting of the generator FIGURE 5-1. TYPICAL LOAD TRANSFER SWITCH set while working on it can cause severe per- sonal injury or death. Prevent accidental start- ing by disconnecting the starting battery cables (negative [-] first) - Arcing can ignite the explosive hydrogen gas given off by batteries, causing severe personal Injury. Arcing can occur if the negative H bat- tery cable is connected and a tool being used to connect or disconnect the positive (+) battery cable accidentally touches the frame or other grounded metal part of the set. To prevent arc- ing, always remove the negative H cable first, and reconnect it last. Most local regulations require that wiring connec- tions be made by a licensed electrician and the in- stallation be inspected and approved before opera- tion. All connections, wire sizes, etc. must conform to the requirements of all electrical codes in effect at the installation site. �� improper wiring can cause a fire or electrocution, resulting In severe personal in- jury or death and/or property and equipment damage. TRANSFER SWITCH If the installation is for standby service, a transfer switch is required for switching the load from the normal power source to the generator set (Figure 5-1). Either a manual or automatic switch can be used. Follow the installation instructions provided with the transfer switch when connecting the load and control wiring. 5 Pouvier 5-1 Redistribution or publication of this document %il Gereeration by any means, is strictly prohibited. AC WIRING Generator Voltage Connections The generator output voltage and maximum current rating are specified on the generator set nameplate. Line -to -neutral voltage is always the lower voltage shown and line -to -line voltage is the higher rating. These generators can be configured for the volt- ages shown in the Reconnection Diagram. Most of these voltages must be reconnected by the installer to give the voltage required by the installation. Be- fore shipping, the factory tests the generator set output by connecting the generator to produce a particular test voltage. The generator may be con- nected at the factory to produce a specified voltage per customer order. The installer must always check the stator lead terminal connections and per- form any necessary reconnect to obtain the voltage desired. Note that some voltages are available only on certain specific generators. Refer to Reconnection Diagram when reviewing the voltage connection information and use the electri- cal schematic supplied with your generator set when actually performing load connections. �ori Reconnecting factory connected generator sets to lower voltages can reduce set ratings, and also render line circuit breakers too small. Consult with your distributor before per- forming reconnection for a different voltage. Load Connections Flexible conduit and stranded conductors must be used for connections to take up movement of the set. When installing sets with AC meters, the generator output leads must be routed through current trans- formers for proper meter operation. The transform- ers are labeled CT21, CT22, and CT23. Refer to cW P;vwer, ir6l_ r ev atlovii Reconnection Diagram to identify the output leads that must be routed through each current trans- former, and also appropriate transformer post se- lection for meter sensing leads. Load Balancing When connecting loads to the generator set, bal- ance the loads so the current flow from each line ter- minal (L1, L2, and L3) is about the same. This is es- pecially important if both single phase and three phase loads are connected. Any combination of sin- gle phase and three phase loading can be used as long as each line current is within 10 percent of me- dian value and no line current exceeds the name- plate rating of the generator. Check the current flow from each line by observing the control panel am- meter. Grounding Grounding involves making a conducting connec- tion between the metal parts of the generator set or one of its electrical circuits and the earth. The de- sign and installation of a grounding system is af- fected by many factors such as the use of multiple transformers, ground fault protection requirements and physical location of the generator. Follow the recommendations of the consulting engineer when installing the grounding system. 'IMARNINO Contact with electrical equipment can result in severe personal Injury or death. It Is extremely important that bonding and equip- ment grounding be properly done. All metallic parts that could become energized under ab- normal conditions must be properly grounded. Typical requirements for bonding and grounding are given in the National Electrical Code, Article 250. All connections, wire sizes, etc. must conform to the requirements of the electrical codes in effect at the installation site. 5.2 Redistribution or publicatbn of this document by any means, is strictVy prohibited. CONTROL WIRING The generator set control panel box contains con- nection points for remote control and monitor op- tions. These connection points are located on the Engine Control Monitor board (ECM), the time - delay module and the optional Auxiliary Relay Board (ARB). (Note that if the optional ARB is installed, no remote monitor connections are at- tached to the ECM. The ARB provides all remote monitor connection points.) If the distance between the generator set and the re- mote station is less than 1000 feet (305 m), use 18 gauge stranded copper wire. H the distance is 1000 to 2000 feet (305 to 610 m), use 16 gauge stranded cop- per wire. Always run control circuit wiring in a sepa- ti tiPovve%i rate metal conduit from AC power cables to avoid in- ducing currents that could cause problems within the control. IFIVARNIA DANGEROUS VOLTAGE Touching uninsulated live parts Inside the control panel box can result in severe personal injury or death. Control wire Installation must be done with care to avoid touching uninsulated live parts. For your protection, stand on a dry wooden plat- form or rubber insulating mat, make sure your clothing and shoes are dry, remove jewelry from your hands and use tools with insulated han- dles. 5-3 Redistribution or trubNcation of this document by any means, is stricHy prohibited. ENGINE CONTROL MONITOR BOARD (A11) The heart of the engine control system is the Engine Control Monitor board (ECM). It is a printed circuit board assembly mounted on the back wall of the control box (Figure 5-2). It starts and stops the en- gine in response to the control panel switches, en- gine sensors and remote control signals. Remote Monitor Connections The optional Detector 12 Control (12 light panel) provides the capability of attaching a remote moni- tor panel. Connections are made on the terminal blocks T191 and TB2 located on the ECM board. A detailed connection diagram for the ECM board is provided in Section 9. (If the optional ARB is installed, remote monitor connections attach to the ARB, not the ECM board.) Function Selection Jumpers The ECM board has six selection jumpers that can be repositioned to provide the following timed or non -timed warnings or timed or non -timed shut- downs with warnings: W1 Jumper Position (jumper WS must be in the B position): A Non -timed warning under FLT 2 condi- tions. B Non -timed shutdown and warning under FLT 2 conditions. C Timed warning under FLT 2 conditions. D Timed shutdown and warning under FLT 2 conditions. W2 Jumper Position (jumper W9 must be in the B position): A Non -timed warning under FLT 1 condi- tions. B Non -timed shutdown and warning under FLT 1 conditions. C Timed warning under FLT 1 conditions. D Timed shutdown and warning under FLT 1 conditions. W6 Jumper Position: A Warning under Pre -High Engine Tem- perature conditions. B Shutdown and warning under Pre -High Engine Temperature conditions. W7 Jumper Position: A Warning under Pre -Low Oil Pressure conditions. B Shutdown and warning under Pre -Low Oil Pressure conditions. W8 Jumper Position: A Warning while running or during standby under FLT 2 conditions. B Allows selection of functions with W1 jumper. W9 Jumper Position: A Warning while running or during standby under FLT 1 conditions. B Allows selection of functions with W2 jumper. 5-4 Redistribution or publication of this document by any means, is strictly prohibited, T82 FIGURE 5-2. ENGINE CONTROL MONITOR BOARD (ECM) , M d P" ' o 5-5 Redistribution or publication of this document Generation by any means, is strictly prohibited. AUXILIARY RELAY BOARD (OPTIONAL) The following describes the design/functional crite- ria for the Auxiliary Relay Board (ARB) with a Detec- tor -7 or -12 Generator set control. When provided, the board is mounted on the right wall of the control box. See Figure 5-3. There are two versions of the ARB; with and without the set of 12 Fault relays. A detailed connection diagram for the ARB is pro- vided in Section 9. Terminal Blocks: • TB1 — ARB T131 and ECM board T131 are iden- tically numbered and provide the same remote control connection points. Note that additional terminals are provided for terminals 5, 7, and 10 of ARB T131. TB2 through T135 — Connection points for re- lays K1 through K3. TB2 provides the N/O and N/C connections (three form `C' contacts for each relay). TB3 through TB5 provide the com- mon connection points (TB3 for K1, TB4 for K2 and TB5 for K3). • TB6 and T197 — Connection points for fault re- lays K4 through K15. Three terminals are pro- vided for each relay, which are labeled COM, N/C, N/O. Plug-in Relays (K1, K2, K3): The ARB can be equipped with one to three 3 -pole, double -throw re- lays. These relays (K1, K2, K3) are field changeable plug-in relays for easy field addition and replace- ment. Each relay can be operated as a RUN, COMMON ALARM, or ISOLATED COIL with the changing of a jumper. The relay contact ratings are: • 10 amps at 28 VDC or 120 VAC, 80% PF • 6 amps at 240 VAC, 80% PF • 3 amps at 480 VAC, 80% PF Jumper Positions for Plug-in Relays: Jumpers W1, W2 and W3 perform the same functions for their respective relays, W1 for relay K1, W2 for relay K2, and W3 for relay K3. They can be located in any of 3 positions (A, B, C) independently of each other. Pt w wed "mlr Gwrieratiort • Jumper Position A (Run) — The relay oper- ates as a Run relay, energizing when SW B+ is applied from the engine monitor. • Jumper Position B (Common Alarm) — The relay operates as a Common Alarm relay. The relay energizes any time there is an engine fault shutdown. This fault signal is provided from the engine. Jumper Position C (Isolated) — The relay op- erates as an Isolated relay. The relay coil is en- ergized by a customer applied B+ signal through the terminal block; T133-1 for relay K1, TB4-1 for relay K2, and T135-1 for relay K3. Jumpers W11, W12, and W13 perform the same functions for their respective relays; W11 for relay K1, W12 for relay K2, and W13 for relay K3. They can be located in two different positions (A, B) inde- pendently of one another. • Jumper Position A — The relay operates iso- lated from the board. The customer provides the circuit completion through terminal block; T133 for relay K1, TB4-5 for relay K2, and T135-5 for relay K3. The customer can operate the re- lay with switched ground logic or use this relay in the middle of more complex logic circuits if needed. • Jumper Position B — The relays operate with the coils connected to ground through the board connections. The coil will require a B+ signal to energize with the jumper in this posi- tion. Fault Relays (K4 through K15): These optional re- lay modules are used to operate a remote alarm an- nunciator that has an independent power source. This allows the use of either AC or DC for alarm drives. The relays are energized through the latch- ing relays on the engine monitor and provided N/O and N/C contacts for each external alarm connec- tion. The 12 relays with form 'C' contacts are rated: • 10 Amp, 120 VAC • 10 Amp. 30 VDC 55-6 Redistribution or publication of this docurnent by any means, is strictly prohibited. OR JUMPERS ■ z w 0 �ACOMNON . ............................ ........ ..... . , """ , , - - -- " ... ..... .... ..... .............................. Jl, J2 WIRE 4 Al AW N/C N, N/0 N/C N/0 N/C N/01 W,r_rjil�M WE N11) N/C N/0 N/C F— , _ _., , - —\ —1 F— M U i�� HARNESS PLUG PLIN 3 (11M CIM 111M I 1 10 1 1 M, A I 11M 10M 1011 A CONNECTIONS FROM All KI K5 K6 K KO K9 .....K1K4 (11 K x (M K�S ii 1 . . . ............. ... . ...... . ..... . ... .......... . ...... 0 0 FIGURE 5-3. AUXILIARY RELAY BOARD (ARB) JUMPERS TI36, TI37 AND RELAYS K4 THROUGH K15 ARE OPTIONAL Povver 5-7 Redistribution or pubfication of this document Generaticni by any means, is strictly prohibited. TIME -DELAY MODULE (A15) The start delay is adjustable from 5 to 15 seconds and the stop delay from 30 seconds to 30 minutes. Turn the delay adjusting potentiometers clockwise to increase delay and counterclockwise to de- crease delay. Remote Control Connections Remote control connections are made at the termi- nal block (TB1) that is located on the time -delay module (Figure 5-4). Connect one or more remote switches across the remote terminal (TB1-5)of the time -delay module and the B+ terminal of the ECM board. - START DELAY STOP DELAY POTENTIOMETER POTENTIOMETER z .41_� �r ley Q 0 0 a o 0 0 l7-71 TB1 1 2 3 4 5 6 PRIMARY START -DISCONNECT L RUN SIGNAL OUT (Ail - T131 -6A11 - TBi-2 SECONDARY START -DISCONNECT RUN SIGNAL IN (REMOTE (All T131 -3 START/STOP CONTROL B- (All - TB1-5 B+ (Ail - TB1-7) FIGURE 5-4. TIME -DELAY MODULE ,i ������� cv,rei 55-8 Redi>tribUtion Or pUblicati®n of this dOCLIment `ne"I P"atio G by any means, is strir°tiy prohibited. 6. Prestart Preparations GENERAL EXHAUST SYSTEM Before attempting the initial start of the generator Check the exhaust system for proper installation. set, be sure it is serviced and ready for operation. Verify there is at least 12 inches (305 mm) clear - Refer to the Maintenance section of the Operator's ance between exhaust pipes and combustible ma - Manual for the recommended procedures for add- terials. ing oil, coolant or fuel. Generator sets are shipped with oil and coolant add- ed. Be sure to check these systems to make sure they are at proper operating levels before starting. LUBRICATION Before starting, check the engine dipstick and if re- quired, fill the crankcase with the recommended oil. COOLANT Before starting, check the coolant recovery tank on the radiator and fill (between LOW and FULL mark) with the recommended coolant. FUEL Open all manual shutoff valves. VENTILATION Verify all air vents and ducts are open and free from any obstructions. Verify dampers, if used, operate properly. meIr Gel erat ian ELECTRICAL SYSTEM Verify all electrical connections are secure and all wiring is complete and inspected. Replace and se- cure any access panels that may have been re- moved during installation. Battery Connections Use one 12 volt battery for a normal installation. Connect positive battery cable before connecting negative (GND) battery cable to prevent arcing. Service the battery as necessary. If an automatic transfer switch is installed without a built-in charge circuit, connect a separate trickle charger. MECHANICAL CHECKS Check the generator set for loose or damaged com- ponents and repair or replace as required. 6-1 Redistribution or publication of this document by any means, is strictly prohibited. EXHAUST SYSTEM With the generator set operating, inspect the entire exhaust system including the exhaust manifold, muffler and exhaust pipe. Visually and audibly check for leaks at all connections, welds, gaskets and joints. Make sure exhaust pipes are not heating surrounding areas excessively. If any leaks are de- tected, have them corrected immediately. Inhalation of exhaust gases can re- sult in severe injury or death. Inspect exhaust system visually and audibly for leaks dally. Shut down generator set and repair any leaks Imme- diately. FUEL SYSTEM With the generator set operating, inspect the fuel supply lines, filters and fittings for leaks. Check any flexible sections for cuts, cracks and abrasions and make sure they are not rubbing against anything that could cause breakage. I Leaking fuel will create a fire hazard that can result in severe personal injury or death if Ignited by a spark. If any leaks are de- tected, shut down generator set and have them corrected immediately. DC ELECTRICAL SYSTEM With the generator set off, check the terminals on the battery for clean and tight connections. Loose or corroded connections create resistance that can hinder starting. Clean and reconnect the battery ca- bles if loose. Always connect the negative battery cable last. ARNINGygnition of explosive gases can cause severe personal injury. Do not smoke while servicing the batteries. COOLING SYSTEM Before starting the engine for the first time, remove the radiator pressure cap and monitor the coolant level. As trapped air is expelled from the system, the coolant level will drop and additional coolant must be added. Replace the pressure cap when the cool- ant level is stable. MECHANICAL ADJUSTMENTS With the generator stopped, check for loose belts and fittings, leaking gaskets and hoses, or any signs of mechanical damage. If any problems are found, have them corrected immediately. With the set running, listen for any unusual noises that can indicate mechanical problems. Check the oil pressure frequently. Refer to Operator's or Serv- ice Manual for required adjustments. 7-2 Redistribution or publication of this document by any means, is strictly prohibited.