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Installation Manual Generator Set Cummins NPower GF Series English Version 03/2014 Doc 17855 This manual contains proprietary information to equipment produced by Cummins NPower LLC and Cummins Inc. and is being supplied solely for the purpose of operating, maintaining, and servicing the natural gas generator set purchased from Cummins NPower LLC. © Copyright 2013, Cummins Inc. Cummins NPower LLC Generator Sets Limited Warranty Commercial Generating Set This limited warranty applies to all Cummins NPower LLC (hereinafter referred to as “Cummins NPower” branded commercial generating sets and associated accessories (hereinafter referred to as "Product"). This warranty covers any failures of the Product, under normal use and service, which result from a defect in material or factory workmanship. Warranty Period: The warranty start date for stationary Product is the date of initial start up, demonstration or 18 months after factory ship date, whichever is sooner. The warranty start date for rental or oil and gas products is the date of receipt of Product by the end customer. See table for details. Base Warranty Duration (Whichever occurs first) Rating Months Emergency Standby Power (ESP) 12 Prime Power (PRP) 12 Maximum Hours 500 Unlimited Emergency Standby Power (ESP) is defined as the maximum power available during a variable electrical power sequence, under the stated operating conditions, for which a generating set is capable of delivering in the event of a reliable utility power outage. The permissible average power output over 24 hours of operation shall not exceed 70% of the ESP. For applications supporting an unreliable utility service, the Prime Power (PRP) rating should be used. Prime Power (PRP) is defined as being the maximum power which a generating set is capable of delivering continuously while supplying a variable electrical load. The permissible average power output over 24 hours of operation shall not exceed 70% of the PRP. Cummins NPower Responsibilities: In the event of a failure of the Product during the warranty period due to defects in material or workmanship, Cummins NPower will only be responsible for the following costs: x All parts and labor required to repair the Product. x Reasonable travel expenses to and from the Product site location. x Maintenance items that are contaminated or damaged by a warrantable failure. Owner Responsibilities: The owner will be responsible for the following: x Notifying Cummins NPower distributor or dealer within 30 days of the discovery of failure. x Installing, operating, commissioning and maintaining the Product in accordance with Cummins NPower’s published policies and guidelines. x Providing evidence for date of commissioning. x Providing sufficient access to and reasonable ability to remove the Product from the installation in the event of a warrantable failure. In addition, the owner will be responsible for: x Incremental costs and expenses associated with Product removal and reinstallation resulting from difficult or non-standard installations. x Costs associated with rental of generating sets used to replace the Product being repaired. x Costs associated with labor overtime and premium shipping requested by the owner. x All downtime expenses, fines, all applicable taxes, and other losses resulting from a warrantable failure. Cummins NPower LLC 1600 Buerkle Road White Bear Lake, MN 55110 Phone 651 636 1000 www.npower.cummins.com Limitations: This limited warranty does not cover Product failures resulting from: x Inappropriate use relative to designated power rating or application guidelines. x Normal wear and tear, negligence, accidents or misuse. x Improper and/or unauthorized installation. x Lack of maintenance or unauthorized repair. x Noncompliance with any Cummins NPower published guideline or policy. x Use of improper or contaminated fuels, coolants or lubricants. x Improper storage before and after commissioning. x Owner’s delay in making Product available after notification of potential Product problem. x Replacement parts and accessories not authorized by Cummins NPower. x Use of Battle Short Mode. x Owner or operator abuse or neglect such as: operation without adequate coolant or lubricants; over-fueling; over-speeding; lack of maintenance to lubricating, cooling or air intake systems; late servicing and maintenance; improper storage, starting, warm-up, run-in or shutdown practices, or for progressive damage resulting from a defective shutdown or warning device. x Damage to parts, fixtures, housings, attachments and accessory items that are not part of the generating set. This limited warranty does not apply to: x Costs of maintenance, adjustments, installation, commissioning or start-up. x Starting batteries, heating elements, trailers and enclosures. x Components added to the Product after shipment from Cummins NPower. Please contact your local Cummins NPower Distributor for clarification concerning these limitations. Extended Warranty Cummins NPower offers the Cummins ENCOMPASS Extended Coverage program for parts and labor as listed in Cummins Bulletin # 3624424 for a period of 5 years or 2000 hours. Cummins NPower Right to Failed Components: Failed components claimed under warranty remain the property of Cummins NPower. Cummins NPower has the right to reclaim any failed component that has been replaced under warranty. THE WARRANTIES SET FORTH HEREIN ARE THE SOLE WARRANTIES MADE BY CUMMINS NPOWER IN REGARD TO THE PRODUCT. CUMMINS NPOWER MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED, OR OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT IS CUMMINS NPOWER LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. This limited warranty shall be enforced to the maximum extent permitted by applicable law. This limited warranty gives the owner specific rights that may vary from state to state or from jurisdiction to jurisdiction. Cummins NPower LLC 1600 Buerkle Road White Bear Lake, MN 55110 Phone 651 636 1000 www.npower.cummins.com Table of Contents Warranty Information Section 1 - Safety 1.1 Advisory and Cautionary Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2 Safety/Data Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Section 2 - Introduction 2.1 About This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 Application and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Standby Heating Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 Product Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2-1 2-1 2-1 2-2 2-2 Section 3 - Installation 3.1 Mounting the Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1.1 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1.2 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1.3 Access To Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1.4 Mechanical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3.1.5 Base Drains (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3.2 Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3.2.1 Fuel Lines - Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3.2.2 Natural Gas/Propane Vapor/Propane Liquid Fuel System (Dual Fuel System). . . . . . . . . . . . . . . . 3-2 3.2.3 Fuel Supply Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.2.4 Check Gas Leaks and Correct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.2.5 Fuel Heater (Optional-MOH models only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.2.6 Regulator (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.2.7 Fuel Filters (Optional-MOH models only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.3 Battery Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.3.1 Battery Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.3.2 Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3.4 Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3.5 Installation of Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3.6 Air Fuel Ratio (AFR) Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3.7 Catalyst-Removable Elements (Only available on some models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3.8 Engine 3-Way Catalyst (Model Specific) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3.8.1 Installation and Applications Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3.8.2 Owner’s Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 3.8.3 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 3.8.4 3-Way Catalyst Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 3.9 Air Fuel Setting and Emission Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 3.10 Ventilation and Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 3.11 Vents and Ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 3.12 Oil Reservoir (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 3.13 Dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 TOC-i Table of Contents 3.14 Radiator Set Cooling Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 3.15 Remote Radiator Cooling Requirements (Available on All Models). . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11 Section 4 - Controls 4.1 Control System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.2 Control Wiring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.3 Remote Monitor/Control Connections (PCC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.4 Control Relays (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4.5 AC Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4.6 AC Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.6.1 Generator Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.6.2 Load Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5 4.6.3 Load Balancing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5 4.6.4 Current Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5 4.7 Coolant Heater (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 4.7.1 Battery Heater (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 4.7.2 Control Heater (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6 4.7.3 Breather Heater (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7 Section 5 - Pre-Start Preparation 5.1 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.2 Battery Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.3 InPower Service Tool General Information (PCC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.4 PCC Options Pre-Start Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.5 Start Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.6 Emissions Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2 5.7 Fuel Pressure and Mixture Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5.7.1 Fuel Supply Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5.7.2 Fuel System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 5.7.3 Fuel System Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 5.7.4 Fuel Mixture Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 5.7.4.1 Electronic Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 5.7.4.2 Non-Electronic Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Section 6 - Installation Checklist 6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 Generator Set Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 Cooling Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6 AC And DC Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7 Generator Set Pre-Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6-1 6-1 6-1 6-2 6-2 6-2 Section 7 - Wiring Diagrams 7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 Wiring Diagrams - Electronic Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 Wiring Diagrams - Hydro-Mechanical Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 TOC-ii Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 Table of Contents Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 TOC-iii Table of Contents TOC-iv Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 Section 1 - Safety IMPORTANT SAFETY INSTRUCTIONS - This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries. SAVE THESE INSTRUCTIONS. Before operating the generator set (genset), read the Operator’s Manual and become familiar with it and the equipment. 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. The following symbols, found throughout this manual, alert you to potentially dangerous conditions to the operator, service personnel, or the equipment. 1.1 Advisory and Cautionary Statements Advisory and Cautionary Statements are used throughout this manual to call attention to special information, correct operating procedures, and safety precautions. NOTE: A general advisory statement relating to equipment operation and maintenance procedures. IMPORTANT: A specific advisory statement intended to prevent damage to the equipment or associated components. Cautionary Statements consist of three levels: DANGER This symbol warns of immediate hazards which will result in severe personal injury or death. WARNING This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death. CAUTION This symbol refers to a hazard or unsafe practice which can result in personal injury or product or property damage. CAUTION 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 the 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. The 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 vibrated or repeatedly bent. • Natural gas is lighter than air, and will tend to gather under hoods. Propane is heavier than air, and will tend to gather in sumps or low areas. NFPA code requires all persons handling propane to be trained and qualified. • Be sure all fuel supplies have a positive shut-off valve. • Be sure the 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. Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 1-1 WARNING Exhaust Gases Are Deadly.The engine exhaust from this product contains chemicals known to the State of California and some of its constituents cause cancer, birth defects, or other reproductive harm. • Provide an adequate exhaust system to properly expel discharged gases away from enclosed or sheltered areas and areas where individuals are likely to congregate. Visually and audibly inspect the exhaust daily for leaks per the maintenance schedule. Make sure that exhaust manifolds are secured and not warped. Do not use exhaust gases to heat a compartment. • Disconnect electric power before removing protective shields or touching electrical equipment. 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 electrical components. High voltages can cause injury or death. DO NOT tamper with interlocks. • Follow all applicable state and local electrical codes. Have all electrical installations performed by a qualified licensed electrician. Tag and lock open switches to avoid accidental closure. • Be sure the unit is well ventilated. WARNING Moving Parts Can Cause Severe Personal Injury or Death. • Keep your hands, clothing, and jewelry away from moving parts. • DO NOT CONNECT GENERATOR SET DIRECTLY TO ANY BUILDING ELECTRICAL SYSTEM. Hazardous voltages can flow from the generator set into the utility line. This creates a potential for electrocution or property damage. Connect only through an approved isolation switch or an approved paralleling device. General Safety Precautions • Before starting work on the generator set, disconnect the battery charger from its AC source, then disconnect the starting batteries, negative (-) cable first. This will prevent accidental starting. • 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. • Make sure that fasteners on the generator set are secure. Tighten supports and clamps. Keep guards in position over fans, drive belts, etc. • 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. • Do not wear loose clothing or jewelry in the vicinity of moving parts, or while working on electrical 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 manifolds, moving parts, etc. WARNING Electrical Shock Can Cause Severe Personal Injury or Death. 1-2 • 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; Class C fires involve live electrical equipment. (Ref. NFPA No. 10). • Make sure that rags are not left on or near the engine. • Make sure the generator set is mounted in a manner to prevent combustible materials from accumulating under the unit. Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 • Substances in exhaust gases have been identified 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. • 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. Remove any debris from the set and keep the floor clean and dry. • Do not store any flammable liquids, such as fuel, cleaners, oil, etc., near the generator set. A fire or explosion could result. • Wear hearing protection when going near an operating generator set. • 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. • To prevent serious burns, avoid contact with hot metal parts such as the radiator, turbo charger, and exhaust system. 1.2 Safety/Data Labels 10 9 5 WARNING CAUTION FOR PROPER FILL PETCOCK MUST BE OPEN DURING COOLING SYSTEM FILL DISCONNECT BOTH POSITIVE AND NEGITIVE BATTERY CABELS BEFORE WELDING ON VEHICLE. ATTACH GROUND CABEL ON WELDER NO MORE THAN 2 FEET FROM PART BEING WELDED. DO NOT WELD ON ENGINE OR ENGINE MOUNTED COMPONENTS 6940-04 REFER TO SERVICE MANUAL BEFORE REMOVING COVERS 12 2 DANGER 6940-01 *Some units may also have this decal on the engine. STARTS AUTOMATICALLY 6940-07 7 ! 5 CAUTION CAUTION DISCONNECT BOTH POSITIVE AND NEGITIVE BATTERY CABELS BEFORE WELDING ON VEHICLE. ATTACH GROUND CABEL ON WELDER NO MORE THAN 2 FEET FROM PART BEING WELDED. DO NOT WELD ON ENGINE OR ENGINE MOUNTED COMPONENTS HOT 6940-02 1 6940-01 1 4 2 3 DANGER 3 DANGER 4 DANGER STARTS AUTOMATICALLY HIGH VOLTAGE WILL CAUSE SEVERE INJURY OR DEATH. DO NOT OPERATE GENERATOR SET WITHOUT COVER IN PLACE. 6940-03 HIGH VOLTAGE WILL CAUSE SEVERE INJURY OR DEATH. DO NOT OPERATE GENERATOR SET WITHOUT COVER IN PLACE. 6940-03 6940-07 6 1 WARNING 11 8 ! CAUTION HOT 6940-13 *One per side on center post of enclosure. 1. 2. 3. 4. 5. 6. 7. ROTATING FAN CAN CAUSE SEVERE INJURY. STAY CLEAR OF FAN WHEN ENGINE IS RUNNING. Decal, Caution Decal, Danger Auto Start (P/N 6940-07) Decal, Danger High Voltage (P/N 6940-03) Decal, Caution Shock Hazard Decal, Caution Welding (P/N 6940-01) Decal, Warning Rotating Fan (P/N 6940-06) Decal, Caution Hot, Sm (P/N 6940-02) 6940-06 8. 9. 10. 11. 12. Decal, Caution Hot, Lg (P/N 6940-13) (Enclosed Units Only) Decal, Caution Cover Decal, Warning Petcock (P/N 6940-04) (KTA19 Only) Decal, Ground Data Tag, Genset (P/N 24588) Figure 1-1 Generator Decal Locations (typical) Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 1-3 KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE 1-4 Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 Section 2 - Introduction 2.1 About This Manual 2.3 Application and Installation This manual provides installation instructions for the generator set models listed on the front cover. This includes the following information: A power generation system must be carefully planned and correctly installed for proper operation. This involves two essential elements: application and installation. Mounting Recommendations - for fastening the generator set to the base and space requirements for normal operation and service. Mechanical and Electrical Connections - covers most aspects of the generator set installation. Pre-start - checklist of items or procedures needed to prepare generator set for operation. Initial Startup - tests the complete system to ensure proper installation, satisfactory performance, and safe operation. Refer to Operator Manual for troubleshooting information. Installation Checklist - reference checks upon completion of installation. This manual DOES NOT provide application information for selecting a generator set or designing the complete installation. If it is necessary to design the various integrated systems (fuel, exhaust, cooling, etc.), additional information is required. Review standard installation practices. For engineering data specific to the generator set, refer to the Specification and Data Sheets. For application information, refer to Cummins Application Manual T-030, Liquid Cooled Generator Sets. 2.2 Installation Overview These installation recommendations apply to typical installations with standard model generator sets. Whenever possible, these recommendations also cover factory designed options or modifications. 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 distributor for assistance. Application (as it applies to generator set installations) refers to the design of the complete power generation system that usually includes power distribution equipment, transfer switches, ventilation equipment, mounting pads, and cooling, exhaust, and fuel systems. Each component must be correctly designed so the complete system will function as intended. Application and design is an engineering function generally done by specifying engineers or other trained specialists. Specifying engineers or other trained specialists are responsible for the design of the complete standby system and for selecting the materials and products required. Installation refers to the actual set-up and assembly of the power generation system. The installers set up and connect the various components of the system as specified in the system design plan. The complexity of the system normally requires the special skills of qualified electricians, plumbers, sheet metal workers, etc. to complete the various segments of the installation. This is necessary so all components are assembled using standard methods and practices. 2.4 Safety Considerations The generator set has been carefully designed to provide safe and efficient service when properly installed, 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 specified in this manual. All systems external to the generator (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 certifying the installation is complete and ready for service. Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 2-1 2.5 Standby Heating Devices 2.6 Product Modifications In accordance with NFPA 110, Cummins NPower recommends installing generator sets (life safety systems) equipped with engine jacket water coolant heaters in locations where the minimum ambient temperature is below 4°C (40°F). NFPA also requires that the engine jacket water coolant be maintained at a minimum of 32°C (90°F) and, for most applications, accept the emergency load in 10 seconds or less. Agency certified products purchased from Cummins NPower comply only with those specific requirements and as noted on company product specification sheets. Subsequent modifications must meet commonly accepted engineering practices and/or local, state and national codes and standards. Product modifications must be submitted to the local authority having jurisdiction for approval. The Engine Cold (Code 1435) message, in conjunction with illumination of the warning light is provided to meet the requirements of NFPA 110. The engine cold sensing logic initiates a warning when the engine jacket water coolant temperature falls below 21°C (70°F). In applications where the ambient temperature falls below 4°C (40°F), a cold engine may be indicated even though the coolant heaters are connected. Under these conditions, although the generator set may start, it may not be able to accept load within 10 seconds. When this condition occurs, check the coolant heaters for proper operation. If the coolant heaters are operating properly, other precautions may be necessary to warm the engine before applying a load. The information, specifications, and recommended guidelines in this manual are based on information in effect at the time of printing. Cummnis Npower, LLC. and Cummins, Inc. reserves the right to make changes at any time without obligation. If you find differences between your engine and the information in this manual, contact your local Cummins Authorized Repair Location or call 1-800-DIESEL (1-800-3437357) toll free in the U.S. and Canada. 2-2 2.7 Product Inquiries (Model 150 GFPA) For Model 150 GFPA engine related inquires, contact a PSI representative at the service department technical support line at 1-888-331-5764 or e-mail [email protected]. For questions relating to the generator controls on this model, please contact Npower Service at 1-866-831-7620 or www.cumminsnpower.com for more information. Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 Section 3 - Installation 3.1 Mounting the Generator Set Generator set installations must be engineered so the generator set will function properly under the expected load conditions. Use these instructions as a general guide only. Follow the instructions of the consulting engineer when locating or installing any components. The complete installation must comply with all local and state building codes, fire ordinances, and other applicable regulations. Consider these requirements before installation: • Level mounting surface • Adequate cooling air • Adequate fresh induction air • Discharge of generator set air • Non-combustible mounting surface • Discharge of exhaust gases • Electrical connections • Accessibility for operation and servicing • Noise levels • Vibration isolation 3.1.1 Location Generator set location is decided mainly by related systems such as ventilation, wiring, fuel, and exhaust. The set should be located as near as possible to the main power service entrance. Exhaust must not be able to enter or accumulate around inhabited areas. Provide a location away from extreme ambient temperatures and protect the generator set from adverse weather conditions. An optional housing is available for outside operation. WARNING Incorrect installation, service, or parts replacement, can result in severe personal injury, death, and/or equipment damage. Service personnel must be trained and experienced to perform electrical and mechanical component installation. IMPORTANT: Depending on location and intended use, federal, state, or local laws and regulation may require the customer to obtain an air quality emissions permit before beginning installation of the genset. Be sure to consult local pollution control or air quality authorities before completing construction plans. 3.1.2 Mounting Generator sets are mounted on a steel skid that provides proper support. The engine-generator assembly is isolated from the skid frame by rubber mounts that provide adequate vibration isolation for normal installations. Where required by building codes or special isolation needs, generator sets may be mounted on rubber pads or mechanical spring isolators. The use of unapproved isolators may result in harmful resonances and may void the genset warranty. Mount the generator set on a substantial and level base such as a concrete pad. A non-combustible material must be used for the pad. Use 16 mm or (5/8) inch anchored mounting bolts to secure the generator set skid to the floor to prevent movement. 3.1.3 Access To Set Generally, at least 1 meter (3 ft) of clearance should be provided on all sides of the generator set for maintenance and service access. (Increase clearance by width of door if optional housing is used.) A raised foundation or slab of 150 mm (6 in) or more above floor level will make servicing easier. Lighting should be adequate for operation, maintenance and service operations and should be connected on the load side of the transfer switch so that it is available at all times. Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 3-1 3.1.4 Mechanical Connections 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. IMPORTANT: All pipe threaded fuel system fittings, including container fittings, must be assembled using a pipe joint sealing compound designed for use with natural gas or propane as applicable per industry standards. 3.1.5 Base Drains (Optional) Some units are equipped with drain extensions that allow for oil or coolant (or both) drains to be brought out to the base edge for convenient maintenance. These drains have an in-line ball valve or Fumoto valve installed for control. Factory drains require no further installation at site. 3.2 Fuel System These gensets can be equipped to operate on: Support fuel lines to restrain movement and prevent chaffing or contact with sharp edges, electrical wiring and hot exhaust parts. CAUTION Sparks and hot surfaces can ignite fuel, leading to severe personal injury or death. Do not route fuel lines near electrical wiring or hot exhaust parts. Fuel lines must be routed and secured per local, state and national codes. Install a dry-type fuel filter ahead of the service pressure regulator to protect the sensitive pressure regulating components and orifices downstream from rust, scale and other solid substances carried along in the gas stream. 3.2.2 Natural Gas/Propane Vapor/Propane Liquid Fuel System (Dual Fuel System) • Natural gas • Combination of natural gas and propane (Dual Fuel for select models) In all fuel system installations, cleanliness is of the upmost importance. Make every effort to prevent entrance of moisture, dirt or contaminants of any kind. Clean all fuel system components before installing 3.2.1 Fuel Lines - Routing A flexible fuel hose(s) or section of flexible fuel hose(s) must be used between the engine’s fuel system and fuel supply line to protect the fuel system from damage caused by vibration, expansion and contraction. Genset fuel supply line must be dedicated supply line from utility. CAUTION Fuel leaks create fire and explosion hazards which can result in severe personal injury or death. Always use flexible tubing between engine and fuel supply to avoid line failure and leaks due to vibration. The fuel system must meet applicable codes. 3-2 Installation of the fuel hose must be done according to all applicable codes and standards, and installation recommendations provided by the manufacturer. The flexible hose used must be approved by the hose manufacture for use with the genset fuel type and product application. WARNING Gaseous fuels are flammable and explosive and can cause severe personal injury or death. Do not smoke if you smell gas or are near fuel tanks or fuel-burning equipment or are in an area sharing ventilation with such equipment. Keep flames, sparks, pilot lights, electrical arcs and arc-producing equipment and all other sources of ignition well away from genset and areas sharing ventilation. Keep a type ABC fire extinguisher handy. WARNING NFPA No. 58 requires all persons handling and operating propane to be trained in proper handling and operating procedures. Gaseous-fuel supply system design, materials, components, fabrication, assembly, installation, testing, inspection, operation and maintenance must comply with the applicable codes. See NFPA No. 37, No. 54, and No. 58. Most codes require both manual and electric (batterypowered) shutoff valves ahead of the flexible fuel hose(s). The manual valve should be of the indicating Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 type. The electric valve should be wired so that the valve is closed when the genset is off. The recommendations in Cummins Application Manual T-030 should be followed in regard to fuel supply system pipe sizes, manual shut-off valves, fuel filters, and gas pressure regulators. 3.2.3 Fuel Supply Pressure WARNING High gas supply pressure can cause gas leaks which can lead to fire and severe personal injury or death. Gas supply pressure must be adjusted to Specifications by qualified personnel. For propane (vapor withdrawal) and natural gas, the maximum permissible fuel supply pressure is 5.0 kPa (20 in WC) and the recommended minimum is 3.7 kPa (15 in WC). For propane (liquid withdrawal), the maximum permissible fuel supply pressure is 2,153 kPa (312 psi) under any operating condition. WARNING Gaseous fuel leaks into an inadequately ventilated space can lead to explosive accumulations of gas. Natural gas rises when released into the air and can accumulate under overhanging hoods and inside housings and buildings. Propane sinks when released into the air and can accumulate inside housings, basements and other belowgrade spaces. Precautions must be taken to prevent gas leaks and the accumulation of gaseous fuel in the event of a leak. 3.2.6 Regulator (Optional) Prime regulators are available on some models for fuel pressure reduction from source. Regulators vary by manufacturer and model. Check with your distributor or service technician for details on use and settings of your Regulator. Factory Regulator requires no further installation at site, connect fuel supply. 3.2.7 Fuel Filters (Optional-MOH models only) Our in-line fuel filters are designed for optimal performance of the generator set. They provide the best choice for Customers who want to extend service intervals and increase Genset uptime. Optional pressure indicators and automatic drains are available on some models. Check the installation and service manuals for your specific filter (models vary by unit) for details. Factory Fuel Filter require no further installation at site, connect fuel supply. 3.3 Battery Selection The minimum recommended reserve capacity (SAE RC) and cold cranking ampere (SAE CCA) values for a particular engine can be found on the Model specific Genset specification sheet is provided with the genset (visit www.cumminsnpower.com for genset specifications). RC and CCA definitions can be found in SAE Standard J537. All battery information is for lead/acid batteries. 3.3.1 Battery Requirements For battery replacement information, refer to Figure 3-1. Batteries may be supplied by Cummins Distribution as an option, or may be supplied by the customer. 3.2.4 Check Gas Leaks and Correct All fuel-system connections, including the container with associated valves and fittings, must be tested for leaks with a soap and water solution or equivalent, while the system is under pressure. 3.2.5 Fuel Heater (Optional-MOH models only) PECO fuel heaters are available on some MOH models. They are designed to provide heating of engine fuel for optimal performance of the Genset. The PECO Fuel Heater is designed to provide uninterrupted fuel flow in cold temperature environments when it is needed most. Factory Fuel Heater requires power source to be wired. See owner’s manual for instructions. _ _ NG-00045 Figure 3-1 Series Battery Connection - 24 VDC Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 3-3 3.4 Exhaust System WARNING Battery electrolyte (sulfuric acid) is highly caustic and can burn clothing and skin. Wear acid impervious neoprene gloves and safety goggles, or full face shield, when working with the batteries. Always disconnect the negative (-) battery cable first and attach the negative (-) battery cable last. CAUTION DO NOT connect battery charging cables to any electronic control system component. This can damage the electronic control system. 3.3.2 Battery Installation 1. Provide adequate room for servicing or replacing the batteries. Provide protection from extremes of temperature and weather. 2. Locate the batteries near the engine or increase the size of the conductors as required by applicable codes. Ensure that the batteries are configured properly for 24 VDC standard operations. Refer to Figure 3-1. 3. Check the battery cables and connections to ensure they are installed correctly and in good condition. NOTE: Coat the terminals with NOCO/Anti-OX to prevent corrosion. Install the cables and tighten the battery connections. WARNING Batteries can emit explosive gases during charging. Always ventilate the compartment before servicing the batteries. Remove sources of spark or open flame. To avoid arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. 3-4 WARNING Inhalation of exhaust gases can result in severe personal injury or death. Do not use exhaust heat to warm a room, compartment or storage area. 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 conditions such as extreme heat, infrequent operation and light loads. Regularly inspect the exhaust system both visually and audibly to see that the entire system remains fume tight and safe for operation. WARNING Inhalation of exhaust gasses can result in severe personal injury or death. Use extreme care during installation to provide a tight exhaust system. Terminate exhaust pipe away from enclosed or sheltered areas, windows, doors and vents. For indoor installation, the exhaust system shall use sealed joint type fittings, (for example NPT fittings) to provide a tighter exhaust system. Use of slip type fittings (secured with a muffler clamp) may allow leakage of exhaust gases into the building. The exhaust system design should meet Federal, State and local code requirements. Use an approved thimble (Figure 3-2) where exhaust pipes pass through walls or partitions. Insulated wall/ roof thimbles are used where exhaust pipes pass through a combustible roof or wall. This includes structures, such as wood framing or insulated steel decking, etc. Uninsulated wall/roof thimbles are used where exhaust pipes pass through a non-combustible wall or roof, such as concrete. Refer to NFPA 37 Stationary Combustion Engines and Gas Turbines” for accepted design practices. Build according to the code requirements in effect at the installation site. Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 11 22 33 55 44 Weight applied to the engine exhaust components can result in damage. Support the muffler and exhaust piping so no weight or stress is applied to engine exhaust. IMPORTANT: Liability for injury, death, damage, and warranty expense due to use of unapproved mufflers or modifications to the exhaust system becomes the responsibility of the person installing the unapproved muffler or performing the modification. Contact a Cummins NPower distributor for approved exhaust system parts. Avoid sharp bends by using sweeping, long radius elbows and provide adequate support for muffler and tailpipe. Pitch a horizontal run of exhaust pipe DOWNWARD (away from engine) to allow any 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. Refer to Figure 3-3. 66 1. 2. 3. 4. 5. 6. 7. CAUTION 77 Rain Cap Drip Cap Holes in End of Inner Sleeve Roof Thimble in Vertical Orientation Thimble in Horizontal Orientation Wall of Partition NG-00038 NG-00038 Figure 3-2 Mounting Exhaust Thimble WARNING Hot exhaust pipes can start a fire and cause severe injury or death if improperly routed through walls. Use an approved thimble where exhaust pipes pass through walls or partitions. Rain caps are available for the discharge end of vertical 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. Use a section of flexible exhaust pipe between the engine and remainder of exhaust system. Support exhaust system to prevent weight from being applied to engine exhaust outlet. Shield or insulate exhaust lines if there is danger of personal contact. Allow at least 305 mm (12 in) of clearance if the pipes pass close to a combustible wall or partition. Before installing insulation on exhaust system components, check the exhaust system for leaks while operating the genset under full load and correct all leaks. WARNING Exhaust pipes are very hot and they can cause severe personal injury or death from direct contact or from fire hazard. Shield or insulate exhaust pipes if there is danger of personal contact or when routed through walls or near other combustible materials. 3.5 Installation of Sensors On select model specific engines the natural gas, O2 and temp sensors to be mounted in exhaust ports located pre and post catalyst. See Figure 3-4 and Figure 3-5. Customer is responsible for installation of sensors. Reference AEB 10.124 NOTE: 4.00’ clearance for insulation and other items around sensors is required. Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 3-5 3.8 Engine 3-Way Catalyst (Model Specific) 11 The natural gas 3-way catalyst reduces the oxides of nitrogen (NO, NO2), and hydrocarbons (HC) from the natural gas exhaust. Read this manual before installing, operating or servicing the engine equipped with a natural gas catalytic converter. The natural gas 3-way catalyst, when installed properly, meets state and local emission reduction requirements on NO, NO2, CO, and HC as OEM technology on stoichiometric natural gas engine. Removal of these devices without prior approval from the state and regulatory agencies can be constituted as tampering. 22 33 1. 2. 3. NG-00039 NG-00039 Exhaust Line Condensation Trap Valve Handle (shown in open position) Figure 3-3 Condensation Trap 3.6 Air Fuel Ratio (AFR) Controller Select model specific natural gas engines are equipped with an air fuel ratio controller, and are designed to meet emission requirements for EPA, SI, and NSPS codes. The engines are also capable of meeting NSPS emissions standards with an AFR controller and factory supplied catalyst. The AFR control system uses a O2 sensor architecture with catalyst, if applicable, to control exhaust emissions. The AFR control system controls fuel flow based on exhaust O2. The controller opens or closes the fuel control valve (FCV) in the fuel line based on feedback from the O2 sensor(s). 3.7 Catalyst-Removable Elements (Only available on some models) Some Gensets require a 3-way or Oxidation catalyst to meet emission requirements. There is a precious metals element inside the housing of the catalyst that converts exhaust to EPA requirements. Some catalysts have a removable body that can be replaced with a new element when required. Most catalysts come installed on Genset from factory. Some catalysts require customer mounting. Check with your distributor or service technician for details on your product. 3-6 CAUTION Handle the natural gas 3-way catalyst with care. Do not hammer or drop the unit. Do not weld or drill holes in the body of the natural gas 3-way catalyst without prior approval of Cummins® or its distributors. 3.8.1 Installation and Applications Guidelines The following are recommendations for installation and application of natural gas 3-way catalyst for select models of natural gas engines. It is recommended that systems incorporating natural gas 3-way catalyst be designed by, or in conjunction with Cummins Engineering. In order to receive Cummins approval of the 3-way catalyst installation, the installation shall meet the following requirements. (Exceptions to these requirements shall be approved by Cummins Engineering.) 1. The 3-way catalyst and housing shall be the correct part number for the application. 2. The 3-way catalyst shall be mounted with a mounting system strong enough to support both the additional weight and dynamic loads. 3. It is recommended to use exhaust piping material compatible with the 3-way catalyst housing material, either cold-rolled steel or appropriate grade of stainless steel. 4. The exhaust piping shall be supported separately from the 3-way catalyst. 5. The 3-way catalyst is designed to be supported by the piping to which it is attached. See Figure 3-4 and Figure 3-5. Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 6. Do not impose external force(s) on the catalyst housing greater than 22.7 kg (50 lb) in any direction. 12. The catalyst can be installed either upstream or downstream of the silencer to obtain sufficient exhaust inlet temperatures. 7. It is required to put a flexible tubing (i.e. bellows or flex pipe) between the engine and the beginning of the exhaust piping. This will isolate the 3way catalyst and other downstream components from engine vibration. 3.8.2 Owner’s Responsibilities 1. The owner is responsible for keeping the natural gas 3-way catalyst system on the equipment because the removal of the system may cause a violation of the local emission regulations. 8. For vertical flow mounting, ensure that the stack above the catalyst is independently supported. See Figure 3-5. 9. Avoid cantilevering loads off the end of the 3way catalyst. 10. The engine oil shall meet CES 20074 or better specifications as required by the engine manufacturer. 11. The catalyst must be installed to guarantee air exhaust temperature into the catalyst of 482°649° C (900°-1200° F). Any temperature outside this range may affect catalyst performance or life. 2. The owner is responsible for periodic inspection of the system in accordance with these and other operational instructions. 3. The owner is responsible for maintaining the operation of the engine in a way that would NOT adversely affect the natural gas 3-way catalyst system. Any misfire, stack detonations, oil or debris in the exhaust system, shall be recorded in the equipment’s service record. 4. The owner is responsible for maintaining complete oil consumption and service records, as well as software files, where applicable, and to make them available to a requesting Cummins® authorized repair location for troubleshooting purposes. Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 3-7 2. Depress E-Stop. 3.8.3 Preparation 3. Disconnect the equipment batteries. WARNING Do not touch the surface of the existing silencer during or up to 30 minutes after operation. All surfaces are hot and can cause personal injury. 4. Turn off the fuel supply. 5. Ensure the engine and auxiliary equipment are safely locked out and can not be engaged. 1. Ensure the engine ignition system and air-fuel ratio controller system is functioning properly per the manufacturer's specifications prior to starting installation of the 3-way catalyst. 1 7 8 D 3xD MAX HANGER SPACING 3xD MAX HANGER SPACING 5 4 3 2 6 NG-00035 1. 2. 3. 4. Hangers 3-Way Catalyst (Model specific) Air Exhaust Temperature 482°-649° C (900°1200° F) Silencer 5. 6. 7. 8. Expansion Joint Engine Pre O2 and Temp Sensor Port (180° offset) Post O2 and Temp Sensor Port Figure 3-4 Recommended Horizontal Mounting Configuration (Typical) 3-8 Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 2. Install the customer supplied mounting clamps to the natural gas 3-way catalyst housing. Tighten the mounting clamps enough to hold them in place (per Figure 3-4 and Figure 3-5) and to allow movement to connect the inlet and outlet exhaust pipes. 3.8.4 3-Way Catalyst Installation WARNING To reduce the possibility of personal injury, use a hoist or get assistance to lift the assembly. 3. Connect the inlet and outlet exhaust pipes to the catalyst inlet and outlet. CAUTION The existing exhaust pipe silencer hangers can not hold the weight of a natural gas catalyst. Install appropriate customer supplied natural gas 3-way catalyst mounting brackets. 4. Connect the customer supplied mounting clamps to the catalyst mounting bracket. 5. Tighten the natural gas catalyst mounting clamps. 1. Bolt the natural gas 3-way catalyst mounting bracket (supplied by the customer according to the application), to a solid structure. 2 3 1 8 4 7 3xD MAX HANGER SPACING 6 5 9 NG-00036 1. 2. 3. 4. 5. Hangers Fixed Support Expansion Joint (optional) 3-Way Catalyst Silencer 6. 7. 8. 9. Expansion Joint Pre O2 and Temp Sensor Port (180° offset) Post O2 and Temp Sensor Port Engine Figure 3-5 Recommended Vertical Mounting Configuration (Typical) Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 3-9 3.9 Air Fuel Setting and Emission Measurement This procedure shall be performed at the time of installation of the natural gas 3-way catalyst, after any re-assembly, and periodically per schedule provided by manufacturer throughout the life of the 3-way catalyst. Follow the air fuel ratio controller’s instructions and engine manufacturer’s instructions to set the air fuel ratio. Analyze the engine exhaust gases with a Nox, CO, or HC analyzer down stream of the 3-way catalyst. If the emissions do not meet specifications, replace the catalyst module(s) as needed. 3.10 Ventilation and Cooling Generator sets dissipate heat and fumes that must be removed by proper cooling and ventilation. Generator sets in factory-mounted housings for outdoor installation are designed for proper cooling and ventilation. Indoor installations require careful design with respect to cooling and ventilation. In an indoor installation, all radiator cooling air must be discharged outdoors. Duct adapter kits are available. See Figure 3-6 for a typical indoor installation. WARNING Engine or radiator cooling air may carry deadly carbon monoxide gas which can cause asphyxiation and death. All engine or radiator cooling air must be discharged outdoors. Do not use it for heating a room or compartment. 3.11 Vents and Ducts For indoor installations, locate vents so incoming air passes through the immediate area of the installation before exhausting. Install the air outlet higher than the air inlet to allow for convection air movement. Size the vents and ducts so they are large enough to allow the required flow rate of air. The ”free area” of ducts must be as large as the exposed area of the radiator. Refer to the genset data sheet for the airflow requirements and allowed airflow restriction. 3-10 3.12 Oil Reservoir (Optional) 5 or 10 gallon Oil Tanks are optional on some units to allow for extended service intervals between maintenance. These tanks are typically plumbed to an Oil Maintainer Switch that controls the flow into the engine oil pan. It is imperative the switch is functioning properly without obstruction and if the switch is vented, the vent is not obstructed as well. The tank should be filled with oil per Engine Manufacturer guidelines. 3.13 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 are used. These dampers allow the air to be recirculated back to the equipment room. This enables the equipment room to be heated while the generator set engine is still cold, increasing the engine efficiency. 3.14 Radiator Set Cooling Requirements Radiator set cooling air is drawn past the control end of the set by a pusher fan that blows air through the radiator (Figure 3-6). Locate the air inlet to the rear of the set. Make the inlet vent opening 1-1/2 times larger than the radiator area. NOTE: Louvers and screens over air inlet and outlet openings restrict air flow and vary widely in performance. A louver assembly with narrow vanes, for example, tends to be more restrictive than one with wide vanes. The effective open area specified by the louver or screen manufacturer should be used. Locate the cooling air outlet directly in front of the radiator 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. Attach a canvas or sheet metal duct to the air outlet opening using screws and nuts so duct can be removed for maintenance purposes. The duct prevents recirculation of heated air. Before installing the duct, remove the radiator core guard. Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 3.15 Remote Radiator Cooling Requirements (Available on All Models) Remote radiator plumbing will vary with installation. Follow recommendations given in Cummins Application Manual T-030. See product Data Sheet provided with the genset (visit www.cumminsnpower.com for genset specifications) for friction head and static head limits. The remote radiator cooling system substitutes a remote mounted radiator and an electrically driven fan in place of mounted components. Removal of the radiator and the fan from the set reduces noise levels without forcing dependence on a continuous cooling water supply (necessary with heat exchanger cooling). The remote radiator installation must be completely protected against freezing. 1 2 3 IMPORTANT: Before filling cooling system, check all hardware for security. This includes hose clamps, capscrews, fittings and connections. Use flexible coolant lines with heat exchanger or remote mounted radiator options. 8 4 6 7 9 5 10 14 13 11 12 1. 2. 3. 4. 5. 6. 7. Thimble 3-Way Catalyst Exhaust Line Silencer Condensation Drain Plug Sweeping Elbow Flexible Sections 8. 9. 10. 11. 12. 13. 14. NG-00041 Control Wiring Power Wiring Air Inlet Level Concrete Base Seismic Isolators (Optional) Flexible Bellows Air Outlet Figure 3-6 Generator Set Installation (Typical) Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 3-11 3-12 Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 Section 4 - Controls 4.1 Control System Overview The PowerCommand Control (PCC) which is a microprocessor-based control can be provided in a mechanical and electronic version. All generator set control functions are contained on one circuit board (Base board). The Base board provides engine speed governing (optional), main alternator voltage output regulation, and complete generator set monitoring. The operating software provides control of the Description generator set and its performance characteristics and displays performance information on a digital display panel. It accepts menu-driven control and set-up input from the push button switches on the front panel. For specific information on the control panel for your unit, please refer to the following documentation provided separately from this manual. Application Part Number PCC 1.1 (1302) Owner’s Manual Standby/Prime 900-0661 PCC 2.2 (2300) Operator Manual Standby/Prime 900-0665 PCC 3.3 (3300) Owner’s Manual Standby/Prime/Paralleling A029M414 Table 4-1 4.2 Control Wiring Installation The generator set control panel box contains connection points for remote control and monitor options. Use cable ties to keep control wiring away from sharp edges and AC power cables within the control housing. 4.3 Remote Monitor/Control Connections (PCC) CAUTION Stranded copper wire must be used for all customer connections to the control panel. Solid copper wire may break due to genset vibration. Use flexible conduit for all wiring connections to the generator set. All conduit used for control wiring is attached to the control housing. Route the control wiring through the control housing and access holes. Access holes should be used according to where the wires are terminated inside the control box. A compression type strain-relief connector should be used to prevent dust, insects, etc. from entering the control box. Customer monitor/control connections are attached to terminal block TB-1. Optional equipment such as a remote annunciator panel, sensing devices used to monitor genset operation, remote start/stop switches, battery charger, etc. are attached to TB-1. Refer to the customer connections diagram in Section 7 Wiring Diagrams. CAUTION Always run control circuit wiring in a separate metal conduit from AC power cables to avoid inducing currents that could cause problems within the control. Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 4-1 Table 4-2 Temperature rating of wire that is intended to be used for connection of the unit. Copper conductors only Aluminum conductors or copper-clad conductorsa Row 1 60 or 75° C Use either b AWG, 60° C or c AWG, 75° C copper wire. Use 60° C wire, either b AWG copper or b AWG aluminum; or 75° C wire, either c AWG copper or c AWG aluminum. Row 2 60° C Use b AWG, 60° C copper wire. Use 60° C wire, either b AWG copper or b AWG aluminum. Row 3 75° C Use c AWG, 75° C copper wire. Use 75° C wire, either c AWG copper or c AWG aluminum. Row 4 90° C Use c AWG, 90° C copper wire. Use 90° C wire, either c AWG copper or c AWG aluminum. a Reference to copper wire is not to be included when wiring terminals are intended for only the conductors specified in the code. b The wire size for 60° C wire is not required to be included in the marking; however, when it is included, it shall be based on the ampacities given in Table 310-16 of the National Electrical Code, ANS/NFPA 70, for 60° C wire and the derating factor described in 12.1.3. c The conductor size shall be no smaller than the larger of the following: 1. The conductor size used for the temperature test; or 2. The 75° C wire size based on the ampacities given in Table 310-16 of the National Electrical Code, ANSI/NFPA 70, and the derating factor described in 12.1.3. Digital Connections: Connection points, other than relayed outputs, network, switched B+ and B+ are considered digital connections to terminal strip TB-1. The type/gauge wire to use for these connections are: • Less than 305 m (1000 ft), use 20 gauge stranded copper wire. • 305 to 610 m (1000 to 2000 ft), use 18 gauge stranded copper wire. 4-2 Relay Connections: Due to the wide variety of devices that can be attached to the relay outputs of TB1, the electrical contractor must determine the gauge of the stranded copper wire that is used at this installation site. Refer to PCC Customer Connections diagram in Section 7 - Wiring Diagrams. Network Connections: Refer to 900-0366 PowerCommand Network Installation and Operation Manual for the type/gauge wire to use for these connections or refer to Figure 4-1. Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 NG-00052 NG-00052 Figure 4-1 Switched B+: (Fused at 5 amps.) Same as Relay Connection description. B+: (Fused at 10 amps.) Same as Relay Connection description. 4.4 Control Relays (Optional) CAUTION Damage to the base board can occur if the voltage suppressors are not installed across relay coils (A1/A2) of control relays K11, K12 and K13 before connecting genset battery cables. The three optional control relays are rail mounted inside the control panel housing. Each relay is a 4pole relay with 2 poles normally open and two poles normally closed. These relays are used to control auxiliary equipment, such as fans, pumps and motorized air dampers. Energizing of the relays is user definable. The contacts are rated at 10 amps at 600 VAC. Refer to Customer Connections diagram in Section 7 - Wiring Diagrams. 4.5 AC Electrical Connections This section provides the procedure that is used to connect the AC electrical system of the genset. Before making any AC electrical connections, make certain the generator set cannot be accidentally started. Place the control panel run switch in the OFF position. Turn off or remove AC power from the battery charger, depress the E-Stop, and then remove the negative (-) battery cable from the set starting battery. WARNING Ignition of explosive battery gases can cause severe personal injury or death. Arcing at battery terminals, light switch or other equipment, flame, pilot lights and sparks can ignite battery gas. Do not smoke, or switch trouble light ON or OFF near battery. Discharge static electricity from body before touching batteries by first touching a grounded metal surface. Ventilate battery area before working on or near battery—Wear goggles—E-Stop gen set and disconnect charger before disconnecting battery Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 4-3 cables—Disconnect negative (-) cable first and reconnect last. Check that the load cables from the genset are properly connected. CAUTION Disconnect battery charger from AC source before disconnecting battery cables. Otherwise, disconnecting cables can result in voltage spikes damaging to DC control circuits of the set. WARNING Accidental starting of the generator set can cause severe personal injury or death. Prevent accidental starting by disconnecting the negative (-) cable from the battery terminal. WARNING Each of the operations described in this section should be done only by persons trained and experienced in electrical maintenance. Improper procedures may result in property damage, bodily injury or death. Socket Size Across Flats Tightening Torque mm inch N-m lb inches 3.2 1/8 5.1 45 4.0 5/32 11.4 100 4.8 3/16 13.8 120 5.6 7/32 17.0 150 6.4 1/4 22.6 200 7.9 5/16 31.1 275 9.5 3/8 42.4 375 12.7 1/2 56.5 500 14.3 9/16 67.8 600 Connecting the genset AC electrical system involves: Table 4-3 • • • • Installation of transfer switch Generator output voltage selection Load cable connection Standard and optional AC equipment connections (e.g., control box heater, coolant heater, etc.). Local regulations often require that wiring connections be made by a licensed electrician, and that the installation be inspected and approved before operation. All connections, wire sizes, materials used, etc. must conform to the requirements of electrical codes in effect at the installation site. Contractor guidelines for appropriate conduit and wire sizing for this generator set can be found by referring to Figure 4-1. WARNING Improper wiring can cause a fire or electrocution, resulting in severe personal injury or death and/ or property and equipment damage. Before starting the genset, check to make sure that all electrical connections are secure, and that all wiring is complete. Replace and secure any access panels that have been removed during installation. 4-4 WARNING Backfeed to utility system can cause electrocution or property damage. Do not connect to any building electrical system except through an approved device and after building main switch is opened. 4.6 AC Wiring 4.6.1 Generator Voltage Connections The available generator output voltages and maximum current ratings 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 to the nameplate voltages as shown on the Reconnection Diagram located in the generator manual supplied with this equipment. Many of the voltages listed will require reconfiguration of the generator output leads on the connection terminal block. This reconfiguration must only be done by service personnel that are trained and experienced to perform electrical installation. The generator set was adjusted to produce a specified voltage during production verification testing Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 prior to shipment. The installer must always check the stator lead terminal block connections and perform any necessary reconnect to obtain the voltage required. Refer to applicable Alternator Installation, Service & Maintenance Manual as identified in Table 4-4 . Description Application Part Number Alternator Installation, Service and Maintenance Manual UCI, UCM, UCD 224 & 274 UCH-027 Alternator Installation, Service and Maintenance Manual HCI Series UCI-056 Table 4-4 Some generator sets are capable of producing a wide range of voltages and connection configurations, others have specific limited capabilities. Refer to wiring diagram and generator voltages (from the nameplate) when reviewing the voltage connection information and use the wiring diagram supplied with your generator set when actually performing load connections. CAUTION Reconfiguring generator sets to higher voltages can exceed the voltage capability of the specific generator windings. This will damage the generator, decrease line current, and render line circuit breakers too large. Consult with your distributor before performing reconnection for a different voltage. All loads are connected to the generator by bolting stranded load wires to the appropriate terminals on the generator reconnection terminal block or circuit breaker lugs. The terminals are stamped U, V, W and N to indicate the line and neutral connections. (Reference: U, V, and W correspond with L1, L2 and L3; and N with L0 respectively). 4.6.3 Load Balancing When connecting loads to the generator set, balance the loads so the current flow from each line terminal (L1, L2 and L3) is about the same. This is especially important if both single phase and three phase loads are connected. Any combination of single phase and three phase loading can be used as long as each line current is about the same, within 10 percent of median value and no line current exceeds the nameplate rating of the generator. Check the current flow from each line after connections by observing the control panel display. 4.6.4 Current Transformers The CT’s must be installed as noted in the following CT Installation Requirements. Refer to the reconnection diagram to identify the output leads/phase that must be routed through each CT, and also appropriate transformer post selection for meter sensing leads. The transformers are labeled CT1, CT2 and CT3 on the reconnection wiring diagram. (The reconnection diagram is located on the upper side cover of the control housing.) CT Installation Requirements: The CT has a dot on one side. This dot must be facing toward the generator (conventional current flowing into the dot). A dot is also used to indicate pin 1 of the CT. a. CT1 - U load leads (A phase) CAUTION Reconfiguring generator sets to lower voltages can reduce generator set ratings, and also increase line current, rendering line circuit breakers too small. Consult with your distributor before performing reconnection for a different voltage. 4.6.2 Load Connections Flexible conduit and stranded conductors must be used for connections to take up movement of the generator set. b. CT2 - V load leads (B phase) c. CT3 - W load leads (C phase) d. Route the appropriate load wires through each CT. The CT’s have dual secondaries (3 posts). The CT secondary wire marked 1 is connected to post 1 of the CT. CT secondary wire marked 2/3 is connected to post 2 for high voltage gensets or to post 3 for low voltage gensets. (Refer to the Reconnection Diagram in Section 7 - Wiring Diagrams.) Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 4-5 4.7 Coolant Heater (Optional) 2 CAUTION The coolant heater must not be operated while the cooling system is empty or damage to the heater will occur. 1 Coolant heaters keep the engine coolant warm when the engine is shut down. It heats and circulates the coolant within the engine. This reduces startup time and lessens engine wear caused by cold starts. It is electrically operated and thermostatically controlled. Figure 4-2 shows a typical coolant heater. Connect the heater to a source of power that will be on during the time the engine is not running. Be sure the voltage rating is correct for the heater element rating and that the thermostat is set to the correct temperature prior to starting. 2 1 NG-00033 1. 2. Coolant Outlet Coolant Inlet Figure 4-2 Coolant Heater 1 1 2 2 NG-00042 3 1. 2. Heater Leads Heater Terminal Box 3. Heater Figure 4-3 Generator Heater Installation (Typical) 4.7.1 Battery Heater (Optional) 4.7.2 Control Heater (Optional) Battery heaters ensure the batteries are ready for starting the engine in cold standby conditions. They also protect against condensation during standby and prevent corrosive damage of electrical components in high humidity environments. Factory Battery Heater requires power source to be wired. See owner’s manual for instructions. Control heaters protect the control cabinet components from condensation during standby and prevent corrosive damage of electrical and mechanical components in high humidity environments. Heaters are available for most PowerCommand Controls models. Factory Control heater is wired and requires no further installation at site. 4-6 Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 4.7.3 Breather Heater (Optional) This heater is designed to prevent crankcase breather freezing. The heater has a set point of 50° F. If the ambient temperature inside the enclosure drops below 50° F, the heater will automatically switch on. Factory Breather heater is wired and requires no further installation at site. 4.8 Generator Heater (Optional) WARNING Water or moisture inside a generator increases the possibility of flashing and electrical shock, which can cause equipment damage and severe personal injury or death. Do not use a generator which is not dry inside and out. A generator heater(s) is used to help keep the generator free of condensation when the generator set is not running. During cool and humid conditions, condensation may form within a generator, creating flashing and shock hazards. Figure 4-3 illustrates the installation of two heater elements. Connect the heater(s) to a source of power that will be on during the time the engine is not running. Power connections are made to the terminal block in the heater terminal box. Be sure the voltage rating is correct for the heater element rating. Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 4-7 4-8 Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 Section 5 - Pre-Start Preparation Before attempting the initial start of the generator set, be sure to complete the Installation Checklist in Section 6. 5.1 Electrical System Verify all electrical connections are secure and all wiring is complete and inspected. Replace and secure any access panels that may have been removed during installation. 5.2 Battery Connections WARNING Accidental starting of the generator set can cause severe personal injury or death. Make sure that the Run/Off/Auto switch on the control panel is set to the Off position before connecting the battery cables. Starting the unit requires batteries per the model specific genset data sheet as provided with the genset (visit www.cumminsnpower.com to locate specifications). E-Stop the genset before the connection or disconnection of battery cables. Connect positive battery cable before connecting negative battery cable to prevent arcing. Service the batteries as necessary. If an automatic transfer switch is installed without a built-in charge circuit, connect a separate battery charger. A battery charger is required when the PowerCommand Controller is set to the Awake mode. 5.3 InPower Service Tool General Information (PCC) InPower is a PC based service tool for the PowerCommand Controller (PCC) to be used by Cummins authorized factory service technicians. InPower is used to: • Make adjustments to the controls trims and settings. WARNING Ignition of explosive battery gases can cause severe personal injury or death. Always connect negative (-) battery cable last to prevent arcing. WARNING Ventilate battery area before working on or near battery. Arcing at battery terminals, light switch or other equipment, flame, pilot lights and sparks can ignite battery gas. Do not smoke, or switch trouble light ON or OFF near battery. Discharge static electricity from body before touching batteries by first touching a grounded metal surface. 5.4 PCC Options Pre-Start Checks All generator set configuration options are set at the factory except for site related options, (e.g., Language, Start/Stop Time Delays, Cycle Crank, Customer Fault 1 and 2, etc. Adjustment of these options are divided into two categories within the menu driven system. These two categories are Setup and Controller Configuration/ Adjust. The Setup submenus are intended for qualified service personnel only and require a password to modify these submenus. The Controller Configuration and Adjust submenus are intended for service personnel and site personnel. The Controller Configuration, submenus are used to change the default language, temperature units, and pressure units to be displayed in menus. The Adjust submenus allow site personnel to calibrate the generator set voltage/frequency, idle speed and start/stop time delays. For the pre-start checks, adjustment of only the start/stop delays is required. Refer to the model specific Power Controller (PCC) Manual for installation, operator, and service information per Table 4-1 . • Perform diagnostics and monitoring. 5.5 Start Up Procedure • Create a capture file of the controls trims and settings. Refer to the appropriate Operator Manual for important safety precautions and recommended procedures for starting the genset and verifying proper operation. Start the generator set and verify all engine and generator menus are displaying the correct values. • Update control calibrations (InPower PRO version). Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 5-1 5.6 Emissions Requirements WARNING It is the owner/operator’s responsibility to complete site specific emission requirements to ensure compliance with the US EPA SI NSPS. Emissions on this Generator Set must be dialed-in at the job-site per the following requirements before operation: GTA855E refer to manual 4325956 and AEB 10.124 and 24.52 KTA19SLB and QSK19 refer to AEB 28.07 the ignition system are functioning properly. Especially check air cleaner restriction due to dirt accumulation. IMPORTANT: Read the warranty statement provided with the genset for US Environmental Protection Agency (EPA) restrictions on servicing specific components. 5.7.1 Fuel Supply Pressure The fuel supply pressure must be 3.75-5 kPa (15-20 inches WC) under full-load operation not to exceed 5.0 kPa (20 inches WC) under any condition. See Figure 5-1 for the pressure test ports. 5.7 Fuel Pressure and Mixture Adjustments WARNING Gaseous fuels are flammable and explosive and can cause severe personal injury or death. Do not allow cigarettes, flame, pilot lights, arcing switches or equipment in area or areas sharing ventilation. Keep a type ABC fire extinguisher nearby. WARNING Natural gas is lighter than air, and will tend to gather under hoods. LPG is heavier than air, and will tend to gather in sumps or low areas. NFPA Standard No. 58 requires all persons handling and operating LPG to be trained in proper handling and operating procedures. 1 WARNING Do not attempt to correct power by adjusting fuel system before determining that the engine and 5-2 1. NG-00044 NG-00044 Pressure Test Port (2) Figure 5-1 Demand Regulator (Natural Gas) Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 1 2 3 4 5 7 6 NG-00043 1. 2. 3. 4. Air-Fuel Mixture Test Port Solenoid Valve Demand Regulator Carburetor 5. 6. 7. Fuel Mixture Adjuster Natural Gas Supply Pressure Test Port Throttle Body/Governor Actuator Figure 5-2 Natural Gas Fuel System (Typical) 5.7.2 Fuel System Components Engine is equipped with one shut-off solenoid valve and a demand pressure regulator. Gensets for optional liquid withdrawal of propane are equipped with a converter that vaporizes the fuel with hot engine coolant. See Figure 5-2 for a typical fuel system. A genset equipped for dual fuel, natural gas and propane, has a gas mixer that serves both fuels. A fuel pressure switch to detect loss of natural gas pressure is provided for automatic changeover to propane while the engine is running. Manual shut-off valves are provided in each supply line for manual changeover systems. 5.7.3 Fuel System Operation During normal operation, the engine fuel/air ratio is determined by the fuel trim valve operating in conjunction with the oxygen sensor and the air/fuel control module. Your authorized Cummins distributor can monitor fuel system/oxygen sensor operation using the service tool. Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 5-3 5.7.4 Fuel Mixture Adjustments IMPORTANT: Always use Nox and CO test equipment to set emission levels. 1. Check for recommended fuel supply pressure 3.7-5.0 kpa (15-20 inches WC) at engine mounted regulator 2. Check the operation of fuel shut-off solenoids. 5.7.4.1 Electronic Engines For electronic engines: • Model GTA855E see Cummins AEB 24.51. • Model KTA19 SLB and QSK19, see Cummins AEB 28.07. Model 150 GFPA, GFMC, and GCDC are self adjusting per engine manufacturer. Visit www.psiengines.com for additional information and updates. 5.7.4.2 Non-Electronic Engines Some engines are site compliant capable. Generator set certification is per local, regional and national codes and may require frequent site testing. A summary of the testing procedure is listed here. For non-electric engines, apply 100% load. 1. Install the emission tester in the exhaust post catalyst. The emission tester needs to read Nox and CO in grams per break horsepower (g/bhp). Install an O2 meter per catalyst in port on turbo exhaust elbow. 2. Connect the laptop to RS232 connection at the Gill air-fuel ratio controller module. Start the engine. Click on the Gill icon when connected, click on View, then click on Fuel Valve Control. (The engine has to be running for the laptop to connect to the air-fuel ratio controller.) 3. On the screen, go to the Mode column, and click on Open Loop. The air-fuel valve will go to the closed position. 4. Apply full generator name plate load. 5. All adjustments and emission readings need to be at full load of the generator rating. 6. Run at full load for 5 minutes. Check O2 at the turbo exhaust elbow. It should be at 0.5. If O2 is not at 0.5, proceed to step 7. If at 0.5, proceed to 5-4 step 10. THIS READING NEEDS TO BE WITH AFR IN OPEN LOOP. 7. Adjust the carburetor air-fuel mixing screw. If O2 is above 0.5, turn screw out. This will lower the O2 setting. If O2 is below 0.5, adjust the carburetor screw in, this will raise the O2. 8. Run the engine for 5 minutes and check the O2 setting. Repeat adjustment until O2 is at 0.5. 9. Under the Mode column, click on Close Loop, and the fuel valve will open. 10. Run the engine for 5 minutes. Check the exhaust emissions. Emission should be under 4 g/hp for CO and under 2 g/hp for Nox. O2 reading, post catalyst should be 0.0 to -0.3. 11. O2 reading at the turbo exhaust elbow should drop to about 0.1. 12. If the emission readings are not correct, the airfuel ratio controller will need to be adjusted. 13. Under the Control column, record the number in the set point box. (This is in case you need to go back and start from the beginning). 14. Double click on the set point box. It will turn red. Now you can change the set point value. 15. Change the set point value in small increments (sample if the set point is -0.1550, change to 0.1750), click Enter on the laptop. This will save the new set point and the box will change back to white. 16. Wait 5 to 10 minutes after every adjustment before taking the emission readings. Be very patient doing this part of the set up. Making a change to the setting before emissions have stabilized will make it very difficult to get AFR adjusted correctly. 17. As the set point value goes up, the valve will open more. 18. Under output, you will see % Open and Steps. This is the amount the valve is open. The maximum opening is 200 steps. 19. The CO and NOx reading will fluctuate. Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 Section 6 - Installation Checklist 6.1 General □ Generator set wattage capacity is sufficient to handle maximum anticipated load. □ At least.91 m (3 ft) of clearance (or greater for housing door) is provided around entire generator set for servicing and ventilation. □ Generator set is located in an area not subject to flooding. □ All operating personnel have read and are familiar with Operator Manual. □ All operators have been thoroughly briefed on preventive maintenance procedures. □ All operators have read and understand all Important Safety Instructions in Operator Manual. 6.2 Generator Set Support □ Floor, roof or earth on which the generator set rests is strong enough and will not allow shifting or movement. Observe local codes on soil bearing capacity due to freezing and thawing. □ Generator set is properly supported and retained to approved base. □ Supporting base is large enough and is of non-combustible materials. 6.3 Cooling Air Flow □ Generator set air inlet is faced into direction of strongest, prevailing winds. □ Air inlet openings are unrestricted and at least 1-1/2 times larger than air outlet area. □ Cooling air outlet is on downwind side of building (if not, wind barrier is constructed). □ Proper ducting material (sheet metal, canvas) is used between radiator and air outlet. 6.4 Fuel System □ Fuel tanks meet or exceed all Local, State or National codes. □ Fuel lines are properly installed, supported and protected against damage. □ Approved flexible fuel line is installed between main fuel supply line and generator set’s fuel system, near the generator set, to protect the fuel system from damage caused by vibration, expansion and contraction. □ Fuel supply line shutoff valve is installed to prevent fuel flow in case of leaks. □ No fuel leaks are found in supply line or engine fuel system. Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 6-1 6.5 Exhaust System □ Operators are thoroughly briefed on the dangers of carbon monoxide gas. □ Areas around set are well ventilated. No possibility of exhaust fumes entering building doors, windows, or intake fans. □ Exhaust gases are piped safely outside and away from building. □ The correct length of approved rigid pipe is connected to the generator set flexible pipe using approved securing methods with no weight resting on engine exhaust components. There are no bends in flex section. □ Condensation drain is provided in lowest section of exhaust piping. □ Exhaust piping is insulated to guard against burns to personnel. □ Exhaust piping passing through walls or ceilings have approved fire-proof materials and are in compliance with all codes. □ Exhaust piping is large enough in diameter to prevent excessive back pressure on engine. □ For model GTA855E, verify O2 and temperature sensors are installed pre and post catalyst. 6.6 AC And DC Wiring □ Wire sizes, insulation, conduits and connection methods all meet applicable codes. □ AC and DC wires are separated in their own conduit to prevent electrical induction. □ All load, line and generator connections are proper and correct. □ Flexible conduit between generator set and building or surrounding structure. 6.7 Generator Set Pre-Start □ Generator set engine is properly serviced with oil and coolant. □ E-Stop is depressed. □ Batteries are properly installed, serviced and charged. □ Battery charger and engine coolant heater are connected and operational. □ All generator set covers and safety shields are installed properly. 6-2 Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rel. 03/2014 Section 7 - Wiring Diagrams 7.1 General This section consists of the schematic and connection wiring diagrams referenced in the text. The following drawings are included. Wiring Diagrams - Electronic Engines Drawing Title Drawing No. Rev. Schematic, Controls Interface GFBC GTA855E w/ PCC 1302 GFBC-PCC1.3-Wiring B Schematic, Controls Interface GFBC GTA855E w/ PCC 2300 GFBC-PCC 2.3-Wiring B Schematic, Controls Interface GFBC GTA855E w/ PCC 3300 GFBC-PCC 3.3-Wiring B Schematic, Controls Interface GFEB KTA19SLB w/ PCC 1302 GFEB-PCC1.3-Wiring A Schematic, Controls Interface GFEB KTA19SLB w/ PCC 2300 GFEB-PCC 2.3-Wiring A Schematic, Controls Interface GFEB KTA19SLB w/ PCC 3300 GFEB-PCC 3.3-Wiring A 22726 - Schematic, Overall GFPA Model 150 w/PCC 1.1/PCC 2.2 Wiring Diagrams - Hydro-Mechanical Engines Drawing Title Drawing No. Rev. Schematic, Controls Interface HM ENG w/PCC 1302 25538 - Schematic, Controls Interface HM ENG w/PCC 3300 25539 - Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rev. 03/2014 7-1 7-2 Natural Gas Generator Set Installation Manual-GF Series Doc. 17855, Rev. 03/2014 ALTERNATOR 2 RECONNECT TERMINAL BLOCK N 3B C28 CR11 PMG C26 1 U V W ENGINE INTERFACE HARNESS (C1 MATES UP TO 47 PIN ON ENGINE HARNESS CONNECTOR) E-STOP MAIN CONTROL PANEL (SEE SHEET 2 FOR LAYOUT) 3 8 C27 12 F2 (6A) 3A (F1) X+ CR4 3 C26 8 1B FIELD (F2) XX- WINDING 9 12 2 4 4 8 5 5 6 6 7 7 6 10 8 MAIN BREAKER MCB_1 4 CUSTOMER LOAD CT1 X1 V V CT1 COM CT2 CT2 X1 W W CT2 COM CT3 CT3 X1 CT3 COM 4 J12 G G 1 CT1 K K 4 CT1 COM H H 2 CT2 L L 5 CT2 COM J J 3 CT3 M M 6 CT3 COM STARTER RELAY DRIVER J20 STARTER 15 CR10 1 L1 L2 C C 2 L2 L3 B B 3 L3 B+ INPUT (FUSED B+) 9 N A A 4 N B+ INPUT (FUSED B+) 10 B+ INPUT (FUSED B+) 20 J17 PMG 2 PMG 3 SWITCHED B+ LOW SIDE DRIVER 3 B+ INPUT (FUSED B+) 21 F F 2 FIELD - CHASSIS GROUND 1 E E 1 FIELD + BATT - 2 BATT - 4 J18 F9 (10A) P P O O N N Q Q 2 PMG 1 PMG 2 3 PMG 3 1 F8 (10A) 1 1 C3 8 4 9 5 CR6 4 12 CR7 5 5 1 4 5 BATT - 7 BATT - 12 13 9 CR8 5 1 C8 CR3 1 14 3 3 GND 5 5 AUTO COMMAND MANUAL COMMAND TERMINAL BLOCK, RELAY AND FUSE DESCRIPTIONS 1 +24VDC SUPPLY 2 +24VDC SUPPLY 3 +24VDC SUPPLY 5A FUSED B+ FROM F5 4 -24VDC RETURN 6 -24VDC RETURN 6 7 6 1 PCC NET B 2 2 SYSTEM WAKEUP 4 4 J6 HMI 114 DISCRETE INPUT RETURN 2 LOCAL E-STOP 11 SPL C SPL C SPL A PCC NET A 1 SPL B 10 19 ENG SHUTDOWN LAMP 21 21 22 22 23 23 24 24 C23 41 41 44 44 28 43 6 46 46 5 47 47 5 7 5 1 SPEED ADJUST 5VDC SUPPLY IGN SHUTDOWN SIGNAL STOP/START SWITCH ENG WARNING LAMP CD200 OVERSPEED IDLE/RATED SWITCH CR2 8 13 CR4 14 F1 (20A) 1 30 30 31 31 34 34 36 36 8 14 14 7 11 11 27 27 29 29 CR3 4 3 35 J1939 + J1939 SHIELD SPEED ADJUST 0-5VDCSPEED ADJUST 0-5VDC+ IGN GND IGN GND FSO DRIVER + 35 IGNITION +24VDC ECM KEY SWITCH PRE/POST CAT OXYGEN SHIELD PRE/POST CAT TEMPERATURE SHIELD PRE/POST CAT OXYGEN HEATER POST CAT OXYGEN HEATER + PRE CAT OXYGEN HEATER + CR1 SW BATT +24VDC 3 AUTO COMMAND MANUAL COMMAND PCC NET SHIELD BATT -24VDC 4 PCC NET A 3 PCC NET B 5 SYSTEM WAKEUP 4 THROTTLE GROUND 5 ECM GROUND 6 ECM +24VDC 7 FCV +24VDC 8 FCV GROUND 9 EGO PRE CAT POWER UP RELAY LSD 16 SWITCH RET GND 19 ENG SHUTDOWN LAMP 20 SPEED ADJUST 5VDC SUPPLY 21 IGN SHUTDOWN SIGNAL 22 STOP/START SWITCH 23 ENG WARNING LAMP 24 CD200 OVERSPEED 25 IDLE/RATED SWITCH 32 EGO POST CAT RELAY 26 J1939 - 41 J1939 + 44 J1939 SHIELD 28 SPEED ADJUST 0-5VDC- 43 SPEED ADJUST 0-5VDC+ 46 IGN GND 47 IGN GND 30 FSO DRIVER + 31 BATTERY CONSERVATION RELAY 34 IGNITION +24VDC BATTERY CONSERVATION RELAY 7 9 THROTTLE +24VDC J1939 - PE BATT +24VDC 10 19 SWITCH RET GND 4 4 5 36 ECM KEY SWITCH 29 PRE CAT TEMPERATURE SUPPLY 35 PRE CAT TEMPERATURE SIGNAL 45 POST CAT TEMPERATURE SIGNAL 42 POST CAT TEMPERATURE SUPPLY 27 PRE CAT OXYGEN RETURN 14 PRE CAT OXYGEN SIGNAL 37 POST CAT OXYGEN SIGNAL 38 POST CAT OXYGEN RETURN ECM C5 J6 C3 SPL A POST CAT OXYGEN RETURN PRE CAT OXYGEN RETURN A A PRE CAT OXYGEN SIGNAL B B POST CAT OXYGEN SIGNAL C POST CAT OXYGEN HEATER + D POST CAT OXYGEN HEATER - FUSED B+ 1 1 PRE CAT OXYGEN HEATER + C GND 2 2 PRE CAT OXYGEN HEATER - D J1 P1 PCC NET A 3 3 PCC NET B 4 4 5 5 SYSTEM WAKEUP 5 7 BATT - 9 16 26 C25 J25 6 9 16 26 13.8VDC OUT+ 8 EGO PRE CAT POWER UP RELAY LSD C24 13.8VDC OUTSPL D 8 32 PE 9 FCV GROUND 25 5 9 J1 FUSED B+ FCV +24VDC 32 24VDC TO 13.8VDC CONVERTOR J1 ECM +24VDC 25 C21 HMI 211 ECM GROUND 1 EGO POST CAT RELAY 7 CR11 C1 THROTTLE +24VDC THROTTLE GROUND 20 SWITCHED B+ D PMG 1 CR5 5 CR9 C8 J22 ALT. GROUND BOLT 1 CR9 D FIELD + 8 C8 L1 FIELD - CR1 5 PCC1302 C1 C6 CT1 TO 1 6 CR4 F4 (6A) U U C2 1 F3 (10A) 1A ALTERNATOR HARNESS C4 SPL C SPL C PRE CATALYST O2 POST CATALYST O2 SPL B C6 C4 PRE CAT TEMPERATURE SUPPLY 1 1 POST CAT TEMPERATURE SUPPLY PRE CAT TEMPERATURE SIGNAL 2 2 POST CAT TEMPERATURE SIGNAL E-STOP POST CATALYST TEMP PRE CATALYST TEMP 2B 7 -24VDC RETURN 8 -24VDC RETURN 9 20A FUSED B+ FROM F6 2A 10 SYSTEM WAKEUP C1 FUEL SHUTOFF VALVE CONTROL CONTACT C2 FUEL SHUTOFF VALVE CONTROL CONTACT 120 OHM POWER AND SENSOR HARNESS J11 C3 B C23 20 J1939 CAN HIGH A C24 19 J1939 CAN LOW C C25 17 J1939 CAN SHIELD C6 A C5 9 PIN ECM DIAGNOSTIC 4 B ECM SWITCH COMMON A C C23 J1939 CAN HIGH C8 IDLE/RATED INPUT D C24 J1939 CAN LOW E C25 J1939 CAN SHIELD ECM KEYSWITCH C21 +24VDC ED3 DISPLAY POWER (SWITCHED) 8 CR7 F1 (20A) BATT + C3 C20 1 10 BATT - CR2 6 3 4 CR5 3 CR8 4 4 3 CR5 8 6 5 CR9 10 CR7 12 CR11 C1 6 8 ED3 DISPLAY GROUND C23 J1939 DATA LINK+ C24 J1939 DATA LINK- C25 J1939 DATA LINK SHIELD C26 5A FUSED B+ FROM F5 C27 CUSTOMER NORMAL SHUTDOWN (FSO) C28 CUSTOMER IGNITION SHUTDOWN (FSO AND SPARK) 6 10 C1 C1 A A 6 5 C2 C C C2 SPL D A CR2 SPL E "FSO" B W4 GND CR10 2 C22 "FSO #2" B 3 4 C F F W5 SW B+ W3 B+ W6 S TERM STARTER S TERM C3 ALTERNATOR LAMP 22 C2 CR11 ED3 DISPLAY 2 1 C21 SWITCHED B+ 7 C23 J1939 CAN HIGH 8 C24 J1939 CAN LOW C22 ED3 GROUND STARTER DISCONNECT INPUT 11 LOW COOLANT LEVEL SWITCH 2 18 5 9 S S B LAMP T T D SENSE MOT C4 F7 (5A) 3 P C25 J1939 CAN SHIELD P F10 (1A) LOW COOLANT LEVEL SWITCH 1 "ALT" 17 C C D D B B C5 SPL C H H C C L L D D B B SPL A ECM RESET S1 8 U U 8 G G 8 E E 3 R R 2 B B 1 D D M M "LCL2" ENGINE ALTERNATOR "LCL1" SPL A C20 ECM KEYSWITCH C26 +24VDC C26 F5 (5A) 4 SPL B F6 (20A) 9 + - BATTERY REFERENCE: 1) SEE CPG DRAWING #0630-3440 FOR PCC SCHEMATICS AND INTERFACE 2) SEE CUMMINS DRAWING #4021936-02 FOR ENGINE SIDE WIRING AND INTERFACE LEGEND CR# - - = RELAY COIL CR# - 10 = RELAY CONTACT = TERMINAL BLOCK AUTO CAD S1 E-STOP "RESET" "E-STOP" "C3" TERMINATING RESISTOR C3 PCC1302 "C2" ED3 DISPLAY C2 J18 "P1" J17 P1 TB1 C6 J22 "J6" J6 "J1" J1 J12 J25 TB15 J11 J20 F5 F4 F3 F2 F1 F10 F9 F8 F7 F6 13 "F7" F8 "F8" F9 "F9" F10 CR1 CR2 CR3 CR4 CR5 CR6 CR7 CR8 CR9 CR10 F7 C28 "F6" C27 F6 C26 "F1" C25 F1 C25 "F2" C24 F2 C24 "F3" C23 F3 C23 "F4" C22 F4 C21 "F5" C20 F5 1 2 3 4 PE 5 6 7 8 8 8 9 9 10 C1 C2 C3 C8 REAR VIEW OF FUSE PANEL DEPICTING WIRE ROUTING 12 CR11 "F10" SPLICE DETAILS STAGGER SPLICES IN SHIELDED CABLE C5 C1 C4 SPL A SPL B SPL D C28 C27 C26 C25 C25 C24 C24 C23 C23 C22 C21 C20 C8 C3 C2 C1 10 9 9 8 8 8 7 6 5 PE 4 3 2 1 SPL C TERMINAL STRIP DETAIL AUTO CAD ALTERNATOR C1 3 A B 2 RECONNECT TERMINAL BLOCK A 1 U V C MAG SWITCH C2 PMG B (F1) X+ FIELD (F2) XX- WINDING "FSO" C4 STARTER C C D D B B S TERM "LCL1" MOT C C D D B B "LCL2" C1 C1 C6 C1 C5 C3 B LAMP D SENSE "ALT" B+ + - ENGINE ALTERNATOR BATTERY C4 C5 9 PIN SERVICE C1 POST CAT TEMP C4 A B PRE CAT TEMP C6 A B C2 W C N "FSO #2" C3 POST CAT O2 C D B C5 PRE CAT O2 C D B AUTO CAD ALTERNATOR 2 RECONNECT TERMINAL BLOCK N 3B C28 F2 (6A) CR11 PMG C26 1 U V W ENGINE INTERFACE HARNESS (C1 MATES UP TO 47 PIN ON ENGINE HARNESS CONNECTOR) E-STOP MAIN CONTROL PANEL (SEE SHEET 2 FOR LAYOUT) 3 8 3A C27 12 CR4 3 C26 8 12 6 (F1) X+ 9 8 CR4 F4 (6A) 6 10 8 4 MAIN BREAKER MCB_1 CUSTOMER LOAD CT1 X1 CT1 COM CT2 CT2 X1 W W PCC2300 C1 C6 CT1 CT2 COM CT3 CT3 X1 CT3 COM 4 J12 G G 1 CT1 K K 4 CT1 COM H H 2 CT2 L L 5 CT2 COM J J 3 CT3 M CR1 5 1 6 M CT3 COM CR5 5 1 8 CR9 C8 J20 STARTER RELAY DRIVER 15 1 4 STARTER 1 CR10 C3 9 5 CR6 4 12 CR7 5 5 9 1 4 CR8 5 5 L1 SWITCHED B+ LOW SIDE DRIVER 3 C C B B 3 L3 B+ INPUT (FUSED B+) 9 N A A 4 N B+ INPUT (FUSED B+) 10 B+ INPUT (FUSED B+) 20 B+ INPUT (FUSED B+) 21 L2 J17 FIELD + PMG 1 PMG 2 F F 2 FIELD - CHASSIS GROUND 1 E 1 FIELD + BATT - 2 BATT - 4 BATT - 7 BATT - 12 PMG 3 P P O O J18 N N Q Q 2 PMG 1 PMG 2 3 PMG 3 1 F8 (10A) 1 1 13 CR11 GND 3 3 TERMINAL BLOCK, RELAY AND FUSE DESCRIPTIONS AUTO COMMAND 4 4 MANUAL COMMAND 6 6 1 +24VDC SUPPLY PCC NET A 1 PCC NET B 2 2 2 +24VDC SUPPLY SYSTEM WAKEUP 3 3 3 +24VDC SUPPLY J6 J6 1 1 4 5A FUSED B+ FROM F5 5 -24VDC RETURN FUSED B+ -24VDC RETURN 6 7 -24VDC RETURN 8 -24VDC RETURN GND SPL C SPL A 1 HMI 114 SPL C 2 2 J1 J1 PCC NET A 3 3 PCC NET B 4 4 SYSTEM WAKEUP 5 5 SPL B 10 19 19 21 21 22 22 23 23 24 24 26 26 3 C23 41 41 F12 (4A) 3 F13 (4A) F14 (4A) C25 5 44 3 43 PE 6 5 46 5 7 1 CR2 47 8 BATT - 6 DISCRETE INPUT RETURN 2 LOCAL E-STOP 11 AUTO COMMAND 10 MANUAL COMMAND 9 PCC NET SHIELD 4 PCC NET A 3 PCC NET B 5 SYSTEM WAKEUP ENG SHUTDOWN LAMP SPEED ADJUST 5VDC SUPPLY IGN SHUTDOWN SIGNAL STOP/START SWITCH ENG WARNING LAMP CD200 OVERSPEED IDLE/RATED SWITCH 4 THROTTLE GROUND 5 ECM GROUND 6 ECM +24VDC 7 FCV +24VDC 8 FCV GROUND 9 EGO PRE CAT POWER UP RELAY LSD 16 SWITCH RET GND 19 ENG SHUTDOWN LAMP 20 SPEED ADJUST 5VDC SUPPLY 21 IGN SHUTDOWN SIGNAL 22 STOP/START SWITCH 23 ENG WARNING LAMP 24 CD200 OVERSPEED 25 IDLE/RATED SWITCH 32 EGO POST CAT RELAY 26 46 47 30 30 31 31 34 34 J1939 + J1939 - 41 J1939 SHIELD J1939 + SPEED ADJUST 0-5VDC- 44 J1939 SHIELD 28 SPEED ADJUST 0-5VDC+ SPEED ADJUST 0-5VDC- 43 IGN GND SPEED ADJUST 0-5VDC+ 46 IGN GND IGN GND FSO DRIVER + 47 IGN GND 30 FSO DRIVER + 31 BATTERY CONSERVATION RELAY 34 IGNITION +24VDC 36 ECM KEY SWITCH 29 PRE CAT TEMPERATURE SUPPLY 35 PRE CAT TEMPERATURE SIGNAL 45 POST CAT TEMPERATURE SIGNAL 42 POST CAT TEMPERATURE SUPPLY 27 PRE CAT OXYGEN RETURN 14 PRE CAT OXYGEN SIGNAL 37 POST CAT OXYGEN SIGNAL 38 POST CAT OXYGEN RETURN BATTERY CONSERVATION RELAY 7 13 CR4 14 F1 (20A) 1 36 36 8 14 14 7 11 11 27 27 29 29 CR3 13.8VDC OUT+ 8 44 28 5 SWITCH RET GND THROTTLE +24VDC J1939 - 3 J25 J29 J29 9 16 C24 1 14 C21 SPL D 9 16 1 EGO POST CAT RELAY PE 9 EGO PRE CAT POWER UP RELAY LSD 32 J28 J28 1 8 25 13.8VDC OUTFUSED B+ FCV GROUND 32 CR3 24VDC TO 13.8VDC CONVERTOR HMI 220 FCV +24VDC F11 (4A) E F9 (10A) 7 25 7 L3 2 7 ECM +24VDC SWITCHED B+ L2 FIELD - ALT. GROUND BOLT D 6 ECM GROUND 20 C8 D 5 CR9 J22 L1 5 C1 THROTTLE +24VDC THROTTLE GROUND 4 6 8 C8 ALTERNATOR HARNESS V V 1 4 F3 (10A) 2 1A TO C2 1 1B FIELD (F2) XX- WINDING U U C4 4 3 35 35 IGNITION +24VDC ECM KEY SWITCH PRE/POST CAT OXYGEN SHIELD PRE/POST CAT TEMPERATURE SHIELD PRE/POST CAT OXYGEN HEATER POST CAT OXYGEN HEATER + PRE CAT OXYGEN HEATER + CR1 SW BATT +24VDC 3 4 4 BATT +24VDC BATT -24VDC 5 ECM C5 C3 SPL A POST CAT OXYGEN RETURN PRE CAT OXYGEN RETURN A A PRE CAT OXYGEN SIGNAL B B POST CAT OXYGEN SIGNAL C POST CAT OXYGEN HEATER + D POST CAT OXYGEN HEATER - PRE CAT OXYGEN HEATER + C PRE CAT OXYGEN HEATER - D SPL C PRE CATALYST O2 SPL C POST CATALYST O2 SPL B C6 C4 PRE CAT TEMPERATURE SUPPLY 1 1 POST CAT TEMPERATURE SUPPLY PRE CAT TEMPERATURE SIGNAL 2 2 POST CAT TEMPERATURE SIGNAL POST CATALYST TEMP PRE CATALYST TEMP E-STOP 2B 9 20A FUSED B+ FROM F6 10 SYSTEM WAKEUP C1 FUEL SHUTOFF VALVE CONTROL CONTACT 2A 120 OHM C2 FUEL SHUTOFF VALVE CONTROL CONTACT C3 ECM SWITCH COMMON C8 IDLE/RATED INPUT POWER AND SENSOR HARNESS J11 C3 B C23 20 J1939 CAN HIGH A C24 19 J1939 CAN LOW C C25 17 J1939 CAN SHIELD C6 A "FSO #2" B C5 9 PIN ECM DIAGNOSTIC B 4 BATT + 8 BATT - C20 ECM KEYSWITCH A C C23 J1939 CAN HIGH C21 +24VDC ED3 DISPLAY POWER (SWITCHED) D C24 J1939 CAN LOW E C22 ED3 DISPLAY GROUND C25 J1939 CAN SHIELD CR7 F1 (20A) 1 10 CR2 6 3 4 CR5 3 CR8 4 4 3 CR5 8 6 5 CR9 10 6 CR7 12 CR11 C1 8 6 10 C1 C1 A A C C A CR2 6 5 C2 C2 SPL D SPL E "FSO" B W4 GND CR10 C23 J1939 DATA LINK+ C24 J1939 DATA LINK- C25 J1939 DATA LINK SHIELD C26 5A FUSED B+ FROM F5 C27 CUSTOMER NORMAL SHUTDOWN (FSO) C28 CUSTOMER IGNITION SHUTDOWN (FSO AND SPARK) 2 3 4 C F W5 F SW B+ W3 B+ W6 S TERM STARTER S TERM C3 ALTERNATOR LAMP 22 C2 CR11 ED3 DISPLAY 2 1 C21 SWITCHED B+ 7 C23 J1939 CAN HIGH 8 C24 J1939 CAN LOW C22 ED3 GROUND STARTER DISCONNECT INPUT 11 LOW COOLANT LEVEL SWITCH 2 19 5 9 S S B LAMP T T D SENSE MOT C4 F7 (5A) 3 P C25 J1939 CAN SHIELD P F10 (1A) LOW COOLANT LEVEL SWITCH 1 "ALT" 17 C C D D B B C5 SPL C H H C C L L D D B B SPL A ECM RESET S1 8 U U 8 G G 8 E E 3 R R 2 B B "LCL2" ENGINE ALTERNATOR "LCL1" SPL A C20 ECM KEYSWITCH C26 +24VDC C26 F5 (5A) 4 SPL B F6 (5A) 9 1 D D M M + - BATTERY REFERENCE: 1) SEE CPG DRAWING #0630-3440 FOR PCC SCHEMATICS AND INTERFACE 2) SEE CUMMINS DRAWING #4021936-02 FOR ENGINE SIDE WIRING AND INTERFACE LEGEND CR# - - = RELAY COIL CR# - 10 = RELAY CONTACT = TERMINAL BLOCK AUTO CAD S1 E-STOP "RESET" "E-STOP" "C3" TERMINATING RESISTOR C3 "C2" ED3 DISPLAY C2 TB15 TB8 J17 F5 F13 F4 F12 F11 F3 F10 F2 F9 "J1" F1 J1 PCC2300 C6 J18 "J6" J6 "J29" J29 J12 F8 "J28" J28 TB1 REAR VIEW OF FUSE PANEL DEPICTING WIRE ROUTING J25 J22 J11 F7 "F7" F6 "F6" F5 "F5" F4 "F4" F3 "F3" F2 "F2" F1 "F1" J20 GND F9 CR1 CR2 CR3 CR4 CR5 CR6 CR7 CR8 CR9 CR10 C28 C27 C26 C25 C25 C24 C24 C23 C23 C22 C21 C20 "F8" 1 2 3 4 PE 5 6 7 8 8 8 9 9 10 C1 C2 C3 C8 F8 CR11 "F9" F10 "F10" F11 "F11" F12 "F12" F13 "F13" F14 "F14" SPLICE DETAILS STAGGER SPLICES IN SHIELDED CABLE C5 C1 C4 SPL A SPL B SPL D C28 C27 C26 C25 C25 C24 C24 C23 C23 C22 C21 C20 C8 C3 C2 C1 10 9 9 8 8 8 7 6 5 PE 4 3 SPL C 2 F14 F6 1 F7 TERMINAL STRIP DETAIL AUTO CAD ALTERNATOR C1 3 A B 2 RECONNECT TERMINAL BLOCK A 1 U V C MAG SWITCH C2 PMG B (F1) X+ FIELD WINDING (F2) XX- "FSO" C4 STARTER C C D D B B S TERM "LCL1" MOT C C D D B B "LCL2" C1 C1 C6 C1 C5 C3 B LAMP D SENSE "ALT" B+ + - ENGINE ALTERNATOR BATTERY C4 C5 9 PIN SERVICE C1 POST CAT TEMP C4 A B PRE CAT TEMP C6 A B C2 W C N "FSO #2" C3 POST CAT O2 C D B C5 PRE CAT O2 C D B AUTO CAD ALTERNATOR N C26 PMG C28 8 12 C27 3A C26 1 U V W 3B CR11 2 RECONNECT TERMINAL BLOCK ENGINE INTERFACE HARNESS (C1 MATES UP TO 47 PIN ON ENGINE HARNESS CONNECTOR) E-STOP MAIN CONTROL PANEL (SEE SHEET 2 FOR LAYOUT) 3 (F1) X+ F2 (6A) CR4 3 1B FIELD (F2) XX- WINDING 8 9 1A 12 4 4 5 5 6 6 7 7 6 MAIN BREAKER MCB_1 U U CT1 X1 V V CT1 COM CT2 CT2 X1 W W CT2 COM CT3 CT3 X1 CT3 COM 4 PCC3300 C1 C6 CT1 TO CUSTOMER LOAD 10 8 ALTERNATOR HARNESS J12 G G 1 CT1 K K 4 CT1 COM H H 2 CT2 L L 5 CT2 COM J J 3 CT3 M M 6 CT3 COM 4 STARTER RELAY DRIVER J20 STARTER 15 CR10 1 D D 1 L1 C C 2 L2 L3 B B 3 L3 B+ INPUT (FUSED B+) 9 N A A 4 N B+ INPUT (FUSED B+) 10 B+ INPUT (FUSED B+) 20 PMG 3 5 FSO LOW SIDE DRIVER 14 13 CR11 F11 (4A) F12 (4A) F14 (4A) 3 1 PE E E 1 FIELD + BATT - 2 BATT - 4 BATT - 7 BATT - 12 N N Q Q 2 PMG 1 PMG 2 3 PMG 3 1 CR8 5 1 1 CR3 5 C23 C25 GND AUTO COMMAND +24VDC SUPPLY 2 +24VDC SUPPLY 3 +24VDC SUPPLY 4 5A FUSED B+ FROM F5 5 -24VDC RETURN 6 -24VDC RETURN 7 -24VDC RETURN 8 -24VDC RETURN 9 20A FUSED B+ FROM F6 3 3 1 CR2 8 7 13 CR4 14 F1 (20A) MANUAL COMMAND 4 6 4 SPL C SPL C SPL A 1 1 PCC NET B 2 2 SYSTEM WAKEUP 3 3 2 LOCAL E-STOP 11 6 PCC NET A DISCRETE INPUT RETURN SPL B 10 10 PCC NET SHIELD PCC NET A 3 PCC NET B 5 SYSTEM WAKEUP 24 25 25 32 32 26 26 41 44 46 47 47 30 30 31 31 34 34 36 14 7 11 11 27 27 4 THROTTLE GROUND ECM GROUND ECM +24VDC FCV +24VDC FCV GROUND EGO PRE CAT POWER UP RELAY LSD SWITCH RET GND ENG SHUTDOWN LAMP SPEED ADJUST 5VDC SUPPLY IGN SHUTDOWN SIGNAL STOP/START SWITCH ENG WARNING LAMP CD200 OVERSPEED IDLE/RATED SWITCH EGO POST CAT RELAY 3 29 29 35 35 J1939 + J1939 SHIELD SPEED ADJUST 0-5VDCSPEED ADJUST 0-5VDC+ IGN GND IGN GND FSO DRIVER + BATTERY CONSERVATION RELAY IGNITION +24VDC ECM KEY SWITCH PRE/POST CAT OXYGEN SHIELD PRE/POST CAT TEMPERATURE SHIELD PRE/POST CAT OXYGEN HEATER POST CAT OXYGEN HEATER + PRE CAT OXYGEN HEATER + CR1 SW BATT +24VDC MANUAL COMMAND 4 24 14 CR3 AUTO COMMAND 9 23 36 13.8VDC OUT+ BATT - 23 8 13.8VDC OUT- 6 22 46 5 5 7 8 22 44 6 J25 SPL D 21 5 24VDC TO 13.8VDC CONVERTOR 9 21 43 PE J29 J29 TERMINAL BLOCK, RELAY AND FUSE DESCRIPTIONS 1 1 19 28 J28 J28 1 19 41 C21 FUSED B+ 16 C1 THROTTLE +24VDC 3 4 4 BATT +24VDC BATT -24VDC 5 C5 2 PRE CAT OXYGEN HEATER + C PRE CAT OXYGEN HEATER - D 5 5 SPL C SYSTEM WAKEUP C1 FUEL SHUTOFF VALVE CONTROL CONTACT C2 FUEL SHUTOFF VALVE CONTROL CONTACT ENG SHUTDOWN LAMP 20 SPEED ADJUST 5VDC SUPPLY 21 IGN SHUTDOWN SIGNAL 22 STOP/START SWITCH 23 ENG WARNING LAMP 24 CD200 OVERSPEED 25 IDLE/RATED SWITCH 32 EGO POST CAT RELAY 26 J1939 - 41 J1939 + 44 J1939 SHIELD 28 SPEED ADJUST 0-5VDC- 43 SPEED ADJUST 0-5VDC+ 46 IGN GND 47 IGN GND 30 FSO DRIVER + 31 BATTERY CONSERVATION RELAY 34 IGNITION +24VDC 36 ECM KEY SWITCH 29 PRE CAT TEMPERATURE SUPPLY 35 PRE CAT TEMPERATURE SIGNAL 45 POST CAT TEMPERATURE SIGNAL 42 POST CAT TEMPERATURE SUPPLY 27 PRE CAT OXYGEN RETURN 14 PRE CAT OXYGEN SIGNAL 37 POST CAT OXYGEN SIGNAL 38 POST CAT OXYGEN RETURN C3 SPL A SPL C PRE CATALYST O2 POST CATALYST O2 SPL B C6 E-STOP C4 PRE CAT TEMPERATURE SUPPLY 1 1 POST CAT TEMPERATURE SUPPLY PRE CAT TEMPERATURE SIGNAL 2 2 POST CAT TEMPERATURE SIGNAL 2B 10 SWITCH RET GND 19 POST CAT OXYGEN HEATER - 2 SYSTEM WAKEUP EGO PRE CAT POWER UP RELAY LSD 16 POST CAT OXYGEN HEATER + GND 4 FCV GROUND 9 C B 3 8 D PRE CAT OXYGEN SIGNAL 4 FCV +24VDC POST CAT OXYGEN SIGNAL 1 3 ECM +24VDC 7 B 1 PCC NET B ECM GROUND 6 POST CAT OXYGEN RETURN FUSED B+ PCC NET A THROTTLE GROUND 5 A J6 J1 4 A J6 J1 THROTTLE +24VDC ECM PRE CAT OXYGEN RETURN HMI 114 1 J1939 - C24 1 HMI 320 16 3 21 J18 9 1 3 F13 (4A) CR7 5 3 CHASSIS GROUND F8 (10A) 5 12 5 7 B+ INPUT (FUSED B+) P 9 14 FIELD - O 8 9 20 C8 2 P 9 CR6 4 4 F O C3 4 F F9 (10A) PMG 2 C8 PCC FSO L2 PMG 1 1 8 CR9 J17 ALT. GROUND BOLT 5 CR5 8 CR9 J22 FIELD + 1 C8 L1 FIELD - 5 CR1 1 8 CR4 F4 (6A) C2 1 6 F3 (10A) 2 C4 POST CATALYST TEMP PRE CATALYST TEMP 2A ECM SWITCH COMMON C3 IDLE/RATED INPUT C8 C20 ECM KEYSWITCH C21 +24VDC ED3 DISPLAY POWER (SWITCHED) C22 ED3 DISPLAY GROUND POWER AND SENSOR HARNESS C5 9 PIN ECM DIAGNOSTIC B 4 BATT + C6 A 8 BATT - A C C23 J1939 CAN HIGH D C24 J1939 CAN LOW E C25 J1939 CAN SHIELD F1 (20A) 1 CR7 10 6 CR2 3 CR5 4 3 4 CR5 8 6 5 CR8 4 3 CR7 12 8 C1 C1 CR9 10 6 C1 A A C2 C C F F A CR2 6 5 C2 SPL D SPL E "FSO" B J1939 DATA LINK+ C23 "FSO #2" B W4 GND CR10 C24 J1939 DATA LINK- C25 J1939 DATA LINK SHIELD 2 3 4 C W5 SW B+ W3 B+ W6 S TERM STARTER S TERM 5A FUSED B+ FROM F5 C26 C27 CUSTOMER NORMAL SHUTDOWN (FSO) C28 CUSTOMER IGNITION SHUTDOWN (FSO AND SPARK) C3 ALTERNATOR LAMP J26 15 9 120 OHM CR11 KEY SWITCH STARTER DISCONNECT INPUT 11 LOW COOLANT LEVEL SWITCH 2 19 C3 B C23 11 ECM CAN HIGH A C24 10 ECM CAN LOW C C25 1 ECM CAN SHIELD 2 BACKUP START DISCONNECT 7 FIELD CURRENT - 14 FIELD CURRENT + C2 ED3 DISPLAY 2 1 C21 SWITCHED B+ 7 C23 J1939 CAN HIGH 8 C24 J1939 CAN LOW C22 ED3 GROUND 3 AVR PWM - 16 AVR PWM + 5 LOW COOLANT LEVEL SWITCH 1 B+ RETURN (B-) 9 AVR FUSED B+ AUX 103 (AVR) 1 AVR FUSED B+ 8 B+ RETURN (B-) 2 AVR PWM + 9 AVR PWM - 4 FIELD CURRENT + 10 FIELD CURRENT - 3 CR# - - CR12 2 4 C20 ECM KEYSWITCH C26 +24VDC B LAMP T T D SENSE "ALT" MOT C4 F7 (5A) 3 P P F10 (1A) 17 C C D D B B H C C L L D D B B 8 U U 8 G G 8 E E 3 R R "LCL2" C5 SPL C H SPL A ENGINE ALTERNATOR "LCL1" SPL A C26 4 9 PE S1 9 S SPL B F6 (5A) J19 ECM RESET 5 S F5 (5A) C25 J1939 CAN SHIELD LEGEND 22 14 2 B B 1 D D M M + - BATTERY BACKUP START DISCONNECT GND CHASSIS REFERENCE: 1) SEE CPG DRAWING #0630-3440 FOR PCC SCHEMATICS AND INTERFACE 2) SEE CUMMINS DRAWING #4021936-02 FOR ENGINE SIDE WIRING AND INTERFACE = RELAY COIL CR# - 10 = RELAY CONTACT = TERMINAL BLOCK AUTO CAD CONNECTOR WIRE INSERTION VIEW C1 C2 6 C4 C3 C5 C6 C13 A 7 J1,TB15 1 J6 5 J12 J17 J18 J19 J20 3 1 1 3 11 6 4 2 1 22 J22 J25 1 4 J26 6 J28 1 J29 5 1 2 1 4 3 15 B 1 12 C S1 E-STOP 12 12 1 7 11 "RESET" "E-STOP" "C3" TERMINATING RESISTOR C3 "C2" ED3 DISPLAY C2 TB15 TB9 J14 TB7 TB10 TB8 PCC3300 CT1 "J1" J18 J17 J1 C6 CT2 "J6" REAR VIEW OF FUSE PANEL DEPICTING WIRE ROUTING F7 F6 F5 F4 F3 J6 J19 TB5 CT3 F2 "J29" J29 "J28" J28 AUX103 AVR J12 F1 TB3 TB1 J25 J22 "F3" F2 "F2" F1 "F1" GND F8 "F8" F9 "F9" F10 "F10" F11 "F11" F12 "F12" F13 "F13" F14 "F14" CR1 CR2 CR3 CR4 C5 CR5 CR6 CR7 CR8 CR9 C1 CR11 CR12 F3 CR10 "F4" C28 F4 C27 "F5" C26 F5 C25 "F6" C25 F6 C24 "F7" J20 J26 C24 F7 F8 C23 F9 C23 F10 C22 F11 C21 F12 C20 F13 1 2 3 3 3 4 PE 5 6 7 8 8 8 9 9 9 10 C1 C2 C3 C8 F14 C4 SPLICE DETAILS STAGGER SPLICES IN SHIELDED CABLE C28 C27 C26 C25 C25 C24 C24 C23 C23 C22 C21 C20 C8 C3 C2 C1 10 9 9 9 8 8 8 7 6 5 PE 4 3 3 3 2 1 SPL A SPL B TERMINAL STRIP DETAIL SPL C SPL D AUTO CAD ALTERNATOR C1 3 A B 2 RECONNECT TERMINAL BLOCK A 1 U V C MAG SWITCH C2 PMG B (F1) X+ FIELD WINDING (F2) XX- "FSO" C4 STARTER C C D D B B S TERM "LCL1" MOT C C D D B B "LCL2" C1 C1 C6 C1 C5 C3 B LAMP D SENSE "ALT" B+ + - ENGINE ALTERNATOR BATTERY C4 C5 9 PIN SERVICE C1 POST CAT TEMP C4 A B PRE CAT TEMP C6 A B C2 W C N "FSO #2" C3 POST CAT O2 C D B C5 PRE CAT O2 C D B AUTO CAD ALTERNATOR 2 RECONNECT TERMINAL BLOCK N 3B C28 C4 CR11 PMG C26 8 1 U V W ENGINE HARNESS MATES DIRECTLY UP TO CONNECTORS C4 AND C13 ON MAIN CONTROL PANEL. E-STOP MAIN CONTROL PANEL (SEE SHEET 2 FOR LAYOUT) 3 3A C27 12 8 C26 (F1) X+ F3 (10A) 2 1B FIELD (F2) XX- WINDING CR4 F4 (6A) 9 6 1A 10 8 4 CR1 5 1 C8 4 MAIN BREAKER MCB_1 ALTERNATOR HARNESS U U CUSTOMER LOAD CT1 X1 TO V V CT1 COM CT2 CT2 X1 W W CT3 CT2 COM X1 CT3 CT3 COM G G 1 CT1 K 4 CT1 COM H H 2 CT2 CT2 COM L L 5 J J 3 CT3 M M 6 CT3 COM D D 1 C8 15 ALT. GROUND BOLT SWITCHED B+ LOW SIDE DRIVER 1 3 C C 2 L2 B B 3 L3 B+ INPUT (FUSED B+) 9 N A A 4 N B+ INPUT (FUSED B+) 10 B+ INPUT (FUSED B+) 20 J17 F F 2 E E 1 FIELD + J18 F9 (10A) PMG 1 PMG 2 PMG 3 B+ INPUT (FUSED B+) FIELD - P P O O N N Q Q F8 (10A) 1 PMG 1 2 PMG 2 3 PMG 3 H ECM +24VDC P FCV +24VDC N FCV GROUND V EGO SENSOR POWER RELAY DRIVER b SWITCH RETURN GROUND f ENGINE SHUTDOWN RELAY DRIVER 1 BATT - 2 BATT - 4 BATT - 7 BATT - 12 CR7 5 5 CR6 5 9 1 CR10 7 5 CR3 1 5 U IGNITION SHUTDOWN SIGNAL e STOP/START SWITCH g ENGINE WARNING RELAY DRIVER M RSVD 13 CR11 14 4 CR8 5 C24 Z J1939 LOW C23 T J1939 HIGH C25 a J1939 SHIELD L CD200 RELAY DRIVER C8 Y IDLE/RATED SWITCH 6 h IGNITION CASE GROUND 5 c IGNITION CASE GROUND B FSO RELAY DRIVER I ECM KEYSWITCH 1 9 21 CHASSIS GROUND 12 STARTER J20 STARTER RELAY DRIVER L3 FIELD + 9 4 L2 FIELD - C3 4 SWITCHED B+ L1 ECM GROUND CR9 J12 K 1 8 CR9 J22 L1 5 PCC1302 C1 C6 CT1 CR5 G PE 7 CR2 1 5 8 C21 F1 (20A) 1 5 7 13 CR4 14 A IGNITION +24VDC m BATTERY CONSERVATION RELAY + W EGO SENSOR GROUND C EGO SENSOR B+ 13.8VDC 24VDC TO 13.8VDC CONVERTOR PE 13.8VDC OUTCR3 13.8VDC OUT+ J1 HMI 211 TERMINAL BLOCK, RELAY AND FUSE DESCRIPTIONS +24VDC SUPPLY 1 +24VDC SUPPLY 2 3 3 GND 5 5 AUTO COMMAND 7 7 MANUAL COMMAND 6 6 1 1 PCC NET B 2 2 4 4 J6 J6 FUSED B+ 1 1 GND 2 2 J1 P1 PCC NET A 3 3 PCC NET B 4 4 SYSTEM WAKEUP 5 5 +24VDC SUPPLY 3 5A FUSED B+ FROM F5 4 9 J25 SPL D SPL C SPL C SPL A PCC NET A HMI 114 SPL B 10 CR1 SW BATT +24VDC 8 BATT - 6 DISCRETE INPUT RETURN BATT +24VDC 2 LOCAL E-STOP BATT -24VDC 11 AUTO COMMAND 10 MANUAL COMMAND 9 PCC NET SHIELD 4 PCC NET A 3 PCC NET B 5 SYSTEM WAKEUP 3 -24VDC RETURN 6 4 4 5 C13 PWM DRV+ TB1-1 P THROTTLE PWM+ PWM DRV- TB1-2 N THROTTLE PWM- FEED BACK+ TB2-1 L THROTTLE FEEDBACK+ FEED BACK0 TB2-2 A THROTTLE FEEDBACK FEED BACK- TB2-3 B THROTTLE FEEDBACK- FEED BACK SHIELD TB2-4 M THROTTLE FEEDBACK SHIELD PWM - TB4-5 F THROTTLE PWM 2 COMMAND - PWM + TB4-4 E THROTTLE PWM 2 COMMAND + SHIELD TB4-3 D SHIELD FEEDBK - TB4-2 J THROTTLE POSITION FEEDBACK - FEEDBK + TB4-1 I THROTTLE POSITION FEEDBACK + WOODWARD PROACT II DRIVER BOX F2 (6A) SPL C CR4 3 8 12 6 TB3-2 POWER+ TB3-1 POWER- -24VDC RETURN 5 3 J1 FUSED B+ SYSTEM WAKEUP 4 E-STOP SPL E 2B 7 -24VDC RETURN 8 -24VDC RETURN 9 20A FUSED B+ FROM F6 2A 120 OHM SYSTEM WAKEUP 10 C1 FUEL SHUTOFF VALVE CONTROL CONTACT C2 FUEL SHUTOFF VALVE CONTROL CONTACT POWER AND SENSOR HARNESS J11 C3 B C23 20 J1939 CAN HIGH A C24 19 J1939 CAN LOW C C25 17 J1939 CAN SHIELD C6 A C5 9 PIN ECM DIAGNOSTIC B 4 BATT + 8 BATT - C3 ECM SWITCH COMMON A C C23 J1939 CAN HIGH C8 IDLE/RATED INPUT D C24 J1939 CAN LOW E C25 J1939 CAN SHIELD C20 ECM KEYSWITCH C21 +24VDC ED3 DISPLAY POWER (SWITCHED) CR7 F1 (20A) 1 10 CR2 6 3 4 CR5 3 CR8 4 4 3 CR5 8 6 5 CR9 10 6 CR7 12 CR11 C1 8 ED3 DISPLAY GROUND C23 J1939 DATA LINK+ C24 J1939 DATA LINK- C27 CUSTOMER NORMAL SHUTDOWN (FSO) C28 CUSTOMER IGNITION SHUTDOWN (FSO AND SPARK) A 6 5 C2 C C C2 SPL D A SPL E "FSO" B W4 GND 3 4 C F F W5 SW B+ W3 B+ W6 S TERM STARTER S TERM C3 ALTERNATOR LAMP 22 C2 CR11 ED3 DISPLAY 5A FUSED B+ FROM F5 C26 10 A CR10 J1939 DATA LINK SHIELD C25 6 C1 C1 CR2 2 C22 "FSO #2" B 2 1 C21 SWITCHED B+ 7 C23 J1939 CAN HIGH 8 C24 J1939 CAN LOW C22 ED3 GROUND STARTER DISCONNECT INPUT 11 LOW COOLANT LEVEL SWITCH 2 18 5 9 S S B LAMP T T D SENSE MOT C4 F7 (5A) 3 P C25 J1939 CAN SHIELD P F10 (1A) LOW COOLANT LEVEL SWITCH 1 "ALT" 17 C C D D B B C5 SPL C H H C C L L D D B B SPL A ECM RESET S1 8 U U 8 G G 8 E E 3 R R 2 B B 1 D D M M "LCL2" ENGINE ALTERNATOR "LCL1" SPL A C20 ECM KEYSWITCH C26 +24VDC C26 F5 (5A) 4 SPL B F6 (20A) 9 + - BATTERY REFERENCE: 1) SEE CPG DRAWING #0630-3440 FOR PCC SCHEMATICS AND INTERFACE 2) SEE CUMMINS DRAWING #4021667-01 FOR ENGINE SIDE WIRING AND INTERFACE LEGEND CR# - - = RELAY COIL CR# - 10 = RELAY CONTACT = TERMINAL BLOCK AUTO CAD S1 E-STOP "RESET" "E-STOP" "C3" TERMINATING RESISTOR C3 "C2" ED3 DISPLAY C2 PCC1302 J18 J17 TB1 C6 J22 "J1" J1 "J6" J6 J12 J25 "J29" J29 TB15 J11 J20 "J28" J28 F5 F4 F3 F2 F1 F10 F9 F8 F7 F6 REAR VIEW OF FUSE PANEL DEPICTING WIRE ROUTING F4 "F4" F3 "F3" F2 "F2" F1 "F1" F6 "F6" F7 "F7" F8 "F8" F9 "F9" CR1 CR2 CR3 CR4 CR5 CR6 CR7 CR8 CR9 CR10 C28 C27 C26 C25 C25 C24 C24 C23 C23 C22 C21 C20 5 6 7 8 8 8 9 9 10 C1 C2 C3 C8 "F5" 1 2 3 4 F5 CR11 SPLICE DETAILS STAGGER SPLICES IN SHIELDED CABLE C5 SPL A SPL B F10 C1 C4 C13 "F10" C28 C27 C26 C25 C25 C24 C24 C23 C23 C22 C21 C20 C8 C3 C2 C1 10 9 9 8 8 8 7 6 5 PE 4 3 2 SPL D 1 SPL C TERMINAL STRIP DETAIL AUTO CAD ALTERNATOR C1 3 A B 2 RECONNECT TERMINAL BLOCK A 1 U V MAG SWITCH C2 PMG B (F1) X+ FIELD WINDING (F2) XX- "FSO" C4 STARTER C C D D B B S TERM "LCL1" MOT C C D D B B "LCL2" C1 C1 C6 C1 C5 C3 B LAMP D SENSE "ALT" B+ + - ENGINE ALTERNATOR BATTERY C4 C13 C5 9 PIN SERVICE C2 C1 C2 W C C1 N "FSO #2" AUTO CAD ALTERNATOR 2 RECONNECT TERMINAL BLOCK N V W 3B C28 C4 CR11 PMG C26 8 1 U ENGINE HARNESS MATES DIRECTLY UP TO CONNECTORS C4 AND C13 ON MAIN CONTROL PANEL. E-STOP MAIN CONTROL PANEL (SEE SHEET 2 FOR LAYOUT) 3 3A C27 12 8 C26 (F1) X+ G ECM GROUND H ECM +24VDC P FCV +24VDC N FCV GROUND V EGO SENSOR POWER RELAY DRIVER b SWITCH RETURN GROUND f ENGINE SHUTDOWN RELAY DRIVER U IGNITION SHUTDOWN SIGNAL e STOP/START SWITCH g ENGINE WARNING RELAY DRIVER M RSVD C24 Z J1939 LOW C23 T J1939 HIGH C25 a J1939 SHIELD L CD200 RELAY DRIVER C8 Y IDLE/RATED SWITCH 6 h IGNITION CASE GROUND 5 c IGNITION CASE GROUND B FSO RELAY DRIVER I ECM KEYSWITCH A IGNITION +24VDC m BATTERY CONSERVATION RELAY + W EGO SENSOR GROUND C EGO SENSOR B+ 13.8VDC F3 (10A) 2 1B FIELD (F2) XX- WINDING CR4 F4 (6A) 9 6 1A 10 8 4 CR1 5 1 C8 4 MAIN BREAKER MCB_1 ALTERNATOR HARNESS U U X1 TO CUSTOMER LOAD CT1 V V CT1 COM CT2 CT2 X1 W W CT2 COM CT3 CT3 X1 CT3 COM G 1 CT1 K 4 CT1 COM H H 2 CT2 L L 5 CT2 COM J J 3 CT3 6 CT3 COM M C8 D 1 15 L1 SWITCHED B+ LOW SIDE DRIVER 1 CR10 3 C C 2 L2 B B 3 L3 B+ INPUT (FUSED B+) 9 N A A 4 N B+ INPUT (FUSED B+) 10 B+ INPUT (FUSED B+) 20 J17 PMG 2 PMG 3 B+ INPUT (FUSED B+) 2 FIELD - CHASSIS GROUND 1 E E 1 FIELD + BATT - 2 BATT - 4 BATT - 7 P O O J18 N N Q Q 2 PMG 1 PMG 2 3 PMG 3 1 F8 (10A) 5 CR6 5 7 5 13 CR11 CR3 1 5 BATT - F12 (4A) 4 3 CR8 5 1 3 F13 (4A) F14 (4A) 3 3 PE 7 CR2 1 5 8 C21 F1 (20A) 12 1 5 7 13 CR4 14 24VDC TO 13.8VDC CONVERTOR PE 13.8VDC OUT- CR3 13.8VDC OUT+ FUSED B+ 1 1 GND 3 3 9 J25 SPL D J29 J29 1 2 3 4 5 6 +24VDC SUPPLY +24VDC SUPPLY +24VDC SUPPLY 5A FUSED B+ FROM F5 AUTO COMMAND 4 4 MANUAL COMMAND 6 6 1 1 PCC NET B 2 2 3 3 SYSTEM WAKEUP J6 J6 FUSED B+ 1 1 GND 2 2 HMI 114 7 -24VDC RETURN 8 -24VDC RETURN SPL C SPL C SPL A PCC NET A -24VDC RETURN -24VDC RETURN 4 3 J28 J28 HMI 220 TERMINAL BLOCK, RELAY AND FUSE DESCRIPTIONS 9 1 14 21 F P CR7 F11 (4A) F F9 (10A) PMG 1 12 5 SWITCHED B+ L3 FIELD + 9 4 STARTER J20 STARTER RELAY DRIVER L2 FIELD - ALT. GROUND BOLT D C3 4 J22 L1 8 CR9 G 1 CR9 J12 K M 5 PCC2300 C1 C6 CT1 CR5 J1 J1 PCC NET A 3 3 PCC NET B 4 4 SYSTEM WAKEUP 5 5 SPL B 10 CR1 8 BATT - 6 DISCRETE INPUT RETURN 2 LOCAL E-STOP 11 AUTO COMMAND 10 MANUAL COMMAND 9 PCC NET SHIELD 4 PCC NET A 3 PCC NET B 5 SYSTEM WAKEUP SW BATT +24VDC 3 4 4 BATT +24VDC BATT -24VDC 5 C13 PWM DRV+ TB1-1 P THROTTLE PWM+ PWM DRV- TB1-2 N THROTTLE PWM- FEED BACK+ TB2-1 L THROTTLE FEEDBACK+ FEED BACK0 TB2-2 A THROTTLE FEEDBACK FEED BACK- TB2-3 B THROTTLE FEEDBACK- FEED BACK SHIELD TB2-4 M THROTTLE FEEDBACK SHIELD PWM - TB4-5 F THROTTLE PWM 2 COMMAND - PWM + TB4-4 E THROTTLE PWM 2 COMMAND + SHIELD TB4-3 D SHIELD FEEDBK - TB4-2 J THROTTLE POSITION FEEDBACK - FEEDBK + TB4-1 I THROTTLE POSITION FEEDBACK + WOODWARD PROACT II DRIVER BOX F2 (6A) SPL C CR4 3 8 12 6 TB3-2 POWER+ TB3-1 POWER- E-STOP SPL E 2B 9 20A FUSED B+ FROM F6 10 SYSTEM WAKEUP C1 FUEL SHUTOFF VALVE CONTROL CONTACT 2A 120 OHM C2 FUEL SHUTOFF VALVE CONTROL CONTACT C3 ECM SWITCH COMMON C8 B C23 20 J1939 CAN HIGH A C24 19 J1939 CAN LOW C C25 17 J1939 CAN SHIELD 9 PIN ECM DIAGNOSTIC B 4 BATT + 8 BATT - ECM KEYSWITCH A C C23 J1939 CAN HIGH C21 +24VDC ED3 DISPLAY POWER (SWITCHED) D C24 J1939 CAN LOW E C25 J1939 CAN SHIELD C22 ED3 DISPLAY GROUND C24 J1939 DATA LINK- C25 J1939 DATA LINK SHIELD C26 5A FUSED B+ FROM F5 C27 CUSTOMER NORMAL SHUTDOWN (FSO) C28 CUSTOMER IGNITION SHUTDOWN (FSO AND SPARK) A "FSO #2" B C20 J1939 DATA LINK+ C6 C5 IDLE/RATED INPUT C23 POWER AND SENSOR HARNESS J11 C3 CR7 F1 (20A) 1 10 CR2 6 3 4 CR5 3 CR8 4 4 3 CR5 8 6 5 CR9 10 6 CR7 12 CR11 C1 8 6 10 C1 C1 A A C C F F A CR2 6 5 C2 C2 SPL D SPL E "FSO" B W4 GND CR10 2 3 4 C W5 SW B+ W3 B+ W6 S TERM STARTER S TERM C3 ALTERNATOR LAMP 22 C2 CR11 ED3 DISPLAY 2 1 C21 SWITCHED B+ 7 C23 J1939 CAN HIGH 8 C24 J1939 CAN LOW C22 ED3 GROUND STARTER DISCONNECT INPUT 11 LOW COOLANT LEVEL SWITCH 2 19 5 9 S S B LAMP T T D SENSE MOT C4 F7 (5A) 3 P C25 J1939 CAN SHIELD P F10 (1A) LOW COOLANT LEVEL SWITCH 1 "ALT" 17 C C D D B B C5 SPL C H H C C L L D D B B SPL A ECM RESET S1 8 U U 8 G G 8 E E 3 R R "LCL2" ENGINE ALTERNATOR "LCL1" SPL A C20 ECM KEYSWITCH C26 +24VDC C26 F5 (5A) 4 SPL B F6 (5A) 9 2 B B 1 D D M M + - BATTERY REFERENCE: 1) SEE CPG DRAWING #0630-3440 FOR PCC SCHEMATICS AND INTERFACE 2) SEE CUMMINS DRAWING #4021667-01 FOR ENGINE SIDE WIRING AND INTERFACE LEGEND CR# - - = RELAY COIL CR# - 10 = RELAY CONTACT = TERMINAL BLOCK AUTO CAD S1 E-STOP "RESET" "E-STOP" TB15 "C3" TERMINATING RESISTOR C3 TB8 F7 F6 F5 F4 F3 F2 F1 "C2" ED3 DISPLAY J17 C2 PCC2300 F13 F12 F11 F10 F9 "J1" J1 "J6" J6 F8 J12 "J29" J29 REAR VIEW OF FUSE PANEL DEPICTING WIRE ROUTING TB1 "J28" J28 J25 J22 F7 "F7" F6 "F6" F5 "F5" F4 "F4" F3 "F3" F2 "F2" F1 "F1" J11 J20 GND F9 CR1 CR2 CR3 CR4 CR5 CR6 CR7 CR8 CR9 CR10 C28 C27 C26 C25 C25 C24 C24 C23 C23 C22 C21 C20 5 6 7 8 8 8 9 9 10 C1 C2 C3 C8 "F8" 1 2 3 4 F8 CR11 "F9" F10 "F10" F11 "F11" F12 "F12" F13 "F13" F14 "F14" SPLICE DETAILS STAGGER SPLICES IN SHIELDED CABLE C5 SPL A C1 C4 C13 SPL B C28 C27 C26 C25 C25 C24 C24 C23 C23 C22 C21 C20 C8 C3 C2 C1 10 9 9 8 8 8 7 6 5 PE 4 3 SPL D 2 SPL C 1 F14 C6 J18 TERMINAL STRIP DETAIL AUTO CAD ALTERNATOR C1 3 A B 2 RECONNECT TERMINAL BLOCK A 1 U V MAG SWITCH C2 PMG B (F1) X+ FIELD WINDING (F2) XX- "FSO" C4 STARTER C C D D B B S TERM "LCL1" MOT C C D D B B "LCL2" C1 C1 C6 C1 C5 C3 B LAMP D SENSE "ALT" B+ + - ENGINE ALTERNATOR BATTERY C4 C13 C5 9 PIN SERVICE C2 C1 C2 W C C1 N "FSO #2" AUTO CAD ALTERNATOR N C26 PMG 8 12 C28 C27 C4 3A 8 C26 1 U V W 3B CR11 2 RECONNECT TERMINAL BLOCK ENGINE HARNESS MATES DIRECTLY UP TO CONNECTORS C4 AND C13 ON MAIN CONTROL PANEL. E-STOP MAIN CONTROL PANEL (SEE SHEET 2 FOR LAYOUT) 3 F3 (10A) 2 (F1) X+ CR4 F4 (6A) 1B FIELD (F2) XX- WINDING 9 6 10 8 1A 4 CR1 5 1 C8 4 MAIN BREAKER MCB_1 ALTERNATOR HARNESS U U X1 TO CUSTOMER LOAD CT1 V V CT1 COM CT2 CT2 X1 W W CT2 COM CT3 CT3 X1 CT3 COM G 1 CT1 K 4 CT1 COM H H 2 CT2 L L 5 CT2 COM J J 3 CT3 6 CT3 COM M C8 D 15 L1 FSO LOW SIDE DRIVER 1 CR10 14 C C 2 L2 B B 3 L3 B+ INPUT (FUSED B+) 9 N A A 4 N B+ INPUT (FUSED B+) 10 B+ INPUT (FUSED B+) 20 B+ INPUT (FUSED B+) 21 J17 AUX 103 (AVR) PMG 1 PMG 2 F 2 FIELD - CHASSIS GROUND 1 E E 1 FIELD + BATT - 2 BATT - 4 BATT - 7 BATT - 12 PMG 3 P P O O J18 N N Q Q 2 PMG 1 PMG 2 3 PMG 3 1 F8 (10A) 9 CR6 5 7 13 CR11 CR7 9 1 CR3 1 P FCV +24VDC N N FCV GROUND V V EGO SENSOR POWER RELAY DRIVER b b SWITCH RETURN GROUND f f ENGINE SHUTDOWN RELAY DRIVER U U IGNITION SHUTDOWN SIGNAL e e STOP/START SWITCH g g ENGINE WARNING RELAY DRIVER M M RSVD C24 Z Z J1939 LOW C23 T T J1939 HIGH C25 a a J1939 SHIELD L L CD200 RELAY DRIVER 5 14 F12 (4A) F13 (4A) F14 (4A) 4 3 AVR FUSED B+ 1 9 AVR FUSED B+ B+ RETURN (B-) 8 5 B+ RETURN (B-) AVR PWM + 2 16 AVR PWM + AVR PWM - CR8 5 1 3 C8 Y Y IDLE/RATED SWITCH 3 6 h h IGNITION CASE GROUND 5 c c IGNITION CASE GROUND B B FSO RELAY DRIVER I I ECM KEYSWITCH A A IGNITION +24VDC m m BATTERY CONSERVATION RELAY + 13.8VDC OUT- W W EGO SENSOR GROUND 13.8VDC OUT+ C C EGO SENSOR B+ 13.8VDC 3 PE 7 CR2 1 8 5 C21 F1 (20A) 1 5 J26 J19 12 5 7 PE 4 5 5 F11 (4A) F F9 (10A) ECM +24VDC P PCC FSO 1 L3 FIELD + ECM GROUND H STARTER J20 STARTER RELAY DRIVER L2 FIELD - ALT. GROUND BOLT D C3 4 J22 L1 G H CR9 J12 G 1 8 CR9 K M 5 PCC3300 C1 C6 CT1 CR5 G 13 CR4 14 24VDC TO 13.8VDC CONVERTOR AVR PWM - 9 3 FIELD CURRENT + 4 14 FIELD CURRENT + FIELD CURRENT - 10 7 FIELD CURRENT - BACKUP START DISCONNECT 3 2 BACKUP START DISCONNECT GND CHASSIS 14 CR1 TERMINAL BLOCK, RELAY AND FUSE DESCRIPTIONS SW BATT +24VDC BATT -24VDC 120 OHM C13 WOODWARD PROACT II DRIVER BOX B 5A FUSED B+ FROM F5 4 -24VDC RETURN 5 6 -24VDC RETURN 7 -24VDC RETURN 8 -24VDC RETURN SYSTEM WAKEUP C1 FUEL SHUTOFF VALVE CONTROL CONTACT C2 FUEL SHUTOFF VALVE CONTROL CONTACT ECM SWITCH COMMON C3 IDLE/RATED INPUT C8 C20 ECM KEYSWITCH C21 +24VDC ED3 DISPLAY POWER (SWITCHED) 11 C23 A C24 10 C C25 1 ECM CAN HIGH ECM CAN SHIELD F2 (6A) FUSED B+ 1 1 3 3 9 J29 J29 AUTO COMMAND 4 4 MANUAL COMMAND 6 6 PCC NET A 1 1 PCC NET B 2 2 SYSTEM WAKEUP 3 3 J6 J6 SPL C HMI 114 SPL A FUSED B+ 1 1 GND 2 2 J1 J1 PCC NET A 3 3 PCC NET B 4 4 SYSTEM WAKEUP SPL C 5 SPL B 10 12 6 8 BATT - 6 DISCRETE INPUT RETURN 2 TB1-1 P P THROTTLE PWM+ PWM DRV- TB1-2 N N THROTTLE PWM- FEED BACK+ TB2-1 L L THROTTLE FEEDBACK+ FEED BACK0 TB2-2 A A THROTTLE FEEDBACK THROTTLE FEEDBACK- FEED BACK- TB2-3 B FEED BACK SHIELD TB2-4 M M THROTTLE FEEDBACK SHIELD PWM - TB4-5 F F THROTTLE PWM 2 COMMAND - PWM + TB4-4 E E THROTTLE PWM 2 COMMAND + SHIELD TB4-3 D D SHIELD CR4 8 J25 SPL D PWM DRV+ B ECM CAN LOW 3 20A FUSED B+ FROM F6 10 KEY SWITCH J28 J28 HMI 320 GND 9 15 C3 +24VDC SUPPLY 3 5 PE 9 +24VDC SUPPLY 2 TB3-2 POWER+ TB3-1 POWER- SPL E LOCAL E-STOP FEEDBK - TB4-2 J J THROTTLE POSITION FEEDBACK - 11 AUTO COMMAND FEEDBK + TB4-1 I I THROTTLE POSITION FEEDBACK + 10 MANUAL COMMAND 9 PCC NET SHIELD 4 PCC NET A 3 PCC NET B 5 SYSTEM WAKEUP POWER AND SENSOR HARNESS C6 A SPL C F1 (20A) 1 5 CR7 10 6 CR2 3 CR5 4 3 4 CR5 8 6 5 CR8 4 3 CR7 12 8 C1 C1 CR9 10 6 C1 A A C2 C C F F A CR2 6 5 C2 SPL D SPL E "FSO" B 2B C23 J1939 DATA LINK+ C24 J1939 DATA LINK- C27 CUSTOMER NORMAL SHUTDOWN (FSO) C28 CUSTOMER IGNITION SHUTDOWN (FSO AND SPARK) GND 3 4 C W5 C5 SW B+ W3 B+ W6 S TERM STARTER 9 PIN ECM DIAGNOSTIC B 5A FUSED B+ FROM F5 C26 W4 CR10 2 2A J1939 DATA LINK SHIELD C25 "FSO #2" B E-STOP C22 4 4 BATT +24VDC +24VDC SUPPLY 1 3 A S TERM 4 BATT + 8 BATT - C C23 J1939 CAN HIGH D C24 J1939 CAN LOW E C25 J1939 CAN SHIELD C3 ALTERNATOR LAMP 22 CR11 STARTER DISCONNECT INPUT 11 LOW COOLANT LEVEL SWITCH 2 19 5 9 S S B LAMP T T D SENSE MOT C4 F7 (5A) 3 P P F10 (1A) LOW COOLANT LEVEL SWITCH 1 "ALT" 17 C C D D B B C5 SPL C H H C C L L D D B B SPL A 8 U U 8 G G 8 E E 3 R R "LCL2" ENGINE ALTERNATOR "LCL1" SPL A C26 F5 (5A) 4 SPL B F6 (5A) 9 2 B B 1 D D M M + - BATTERY S1 LEGEND ECM RESET CR# - - CR12 2 4 C20 ECM KEYSWITCH C26 +24VDC REFERENCE: 1) SEE CPG DRAWING #0630-3440 FOR PCC SCHEMATICS AND INTERFACE 2) SEE CUMMINS DRAWING #4021667-01 FOR ENGINE SIDE WIRING AND INTERFACE = RELAY COIL CR# - 10 = RELAY CONTACT = TERMINAL BLOCK AUTO CAD S1 E-STOP "RESET" "E-STOP" TB15 "C3" TERMINATING RESISTOR TB9 C3 J14 TB7 TB10 TB8 F7 F6 F5 F4 F3 F2 "C2" ED3 DISPLAY F1 PCC3300 C2 CT1 J18 J17 C6 CT2 "J1" J1 J19 TB5 CT3 "J6" F13 F12 F11 F10 F9 J6 J12 F8 "J29" J29 TB3 TB1 REAR VIEW OF FUSE PANEL DEPICTING WIRE ROUTING "J28" J28 J25 J22 J20 J26 F7 "F7" F6 "F6" F5 "F5" F4 "F4" F3 "F3" F2 "F2" F1 "F1" F9 CR1 CR2 CR3 CR4 CR5 CR6 CR7 CR8 CR9 CR12 C28 C27 C26 C25 C25 C24 C24 C23 C23 C22 C21 C20 5 6 7 8 8 8 9 9 9 10 C1 C2 C3 C8 "F8" 1 2 3 4 F8 CR10 GND CR11 "F9" F10 "F10" F11 "F11" F12 "F12" F13 "F13" F14 "F14" SPLICE DETAILS C5 STAGGER SPLICES IN SHIELDED CABLE C1 C4 C13 SPL A SPL B C28 C27 C26 C25 C25 C24 C24 C23 C23 C22 C21 C20 C8 C3 C2 C1 10 9 9 9 8 8 8 7 6 5 PE 4 3 2 SPL C 1 F14 AUX103 AVR TERMINAL STRIP DETAIL SPL D AUTO CAD ALTERNATOR C1 3 A B 2 RECONNECT TERMINAL BLOCK A 1 U V MAG SWITCH C2 PMG B (F1) X+ FIELD WINDING (F2) XX- "FSO" C4 STARTER C C D D B B S TERM "LCL1" MOT C C D D B B "LCL2" C1 C1 C6 C1 C5 C3 B LAMP D SENSE "ALT" B+ + - ENGINE ALTERNATOR BATTERY C4 C13 C5 9 PIN SERVICE C2 C1 C2 W C C1 N "FSO #2" AUTO CAD CNP 22801 CNP 22692 C4 (F2) XX- ALTERNATOR UCI274 (F1) X+ ALT. GROUND BOLT FIELD WINDING RECONNECT TERMINAL BLOCK L2(V) B B LP SOLENOID A A B B C7 L1(U) C4 C B 120 OHM CT1 COM CT2 CT2 X1 CT2 COM CT3 CT3 X1 CT3 COM J12 G G 1 CT1 K K 4 CT1 COM H H 2 CT2 L L 5 CT2 COM J J 3 CT3 M M 6 CT3 COM D 1 L1 L2 C C 2 L2 L3 B B 3 L3 N A A N J17 E F 2 E 1 PMG 2 PMG 3 F2 (10A) N O Q 2 3 PMG N O Q F3 (10A) PE A A A 20 16 16 N N CAN HIGH 19 17 17 P P CAN LOW J1939 CAN SHIELD 17 18 18 S S CAN SHIELD KEYSWITCH LOW SIDE DRIVER 21 10 10 F F START COMMAND 9 9 A A KEYSWITCH 11 11 C C SECONDARY FUEL LOCKOFF GND B B PRIMARY FUEL LOCKOFF GND G G FAULT LAMP GND H H FUEL SELECT (OPEN = NG / CLOSED = LP) K K OPTIONAL SWITCH INPUT (GND TO RUN) SPL B KEYSWITCH 1 5 CR3 SPL C CR1 3 KEYSWITCH RELAY COIL B+ 4 CR3 22 FIELD - 3 J20 B+ INPUT (FUSED B+) 9 B+ INPUT (FUSED B+) 10 B+ INPUT (FUSED B+) 20 B+ INPUT (FUSED B+) 21 B+ B+ B+ 4 4 T26 F1 (20A) 6 6 STARTER 1 5 CR1 FIELD + STARTER RELAY DRIVER SHUNT APPLICATION C B 15 J18 2 PMG 2 PMG 3 3 PMG 4 1 SWITCHED B+ 1 5 CR2 SWITCHED B+ LOW SIDE DRIVER 3 RELAY COIL B+ 13 CHASSIS GROUND 1 PE BATT - 2 BATT - 4 BB- BATT - 7 BATT - 12 SPL B SPL C - F C B 120 OHM CR2 D FIELD - C B C9 J1939 CAN LOW J22 L1 FIELD + C8 J1939 CAN HIGH 3 4 A C2 ENGINE INTERFACE C2 C1 SPL A B + CT1 X1 J11 PCC1302 / PCC2300 C1 C1 CT1 C B C6 A CNP 17995 C A BATTERY L3(W) A C5 SPL A N NG SOLENOID A 7 7 NOTE: IF USING A BATTERY CHARGER, DC OUT WIRES SHALL BE CONNECTED DIRECTLY TO THE BATTERY, OR STARTER, AND NOT TO THE CONTROL PANEL. (OPTIONAL) C3 4 17 LOW GAS PRESSURE SWITCH 18 2 LCL INPUT 2 B+ SUPPLY SPL D TB1 3 3 4 4 BATT - A A D D C C B B 5 C10 OUTPUT 1-A 6 A OUTPUT 1-B 7 OUTPUT 2-A 8 OUTPUT 2-B 9 REMOTE START RETURN 10 REMOTE START 11 INPUT #1 12 INPUT COMMON 13 INPUT #2 14 REMOTE E-STOP RETURN 15 REMOTE E-STOP 16 COOLANT LEVEL SENSOR - + DC OUT B+ OUTPUT (3A) L N AC IN BATTERY CHARGER A LOW GAS PRESSURE SWITCH B B CR2 6 5 CNP 22725 C3 E-STOP 1 9 2 8 C3 J25 DISCRETE INPUT RETURN 6 9 LOCAL E-STOP 2 8 J1 J1 3 3 7 HMI 211 HMI B+ BATT - 12 1 8 7 2 IF PCC1302 OPTION SELECTED 4 AUTO COMMAND 11 6 MANUAL COMMAND 10 5 PCC NET SHIELD 9 5 10 PCC NET A 4 3 11 PCC NET B 3 4 12 SYSTEM WAKEUP 5 6 3 OR ACC HARN 0338-4804 BARGRAPH J2 J2 J6 J6 3 3 1 1 FUSED B+ 2 2 GND FUSED B+ 4 5 5 GND 5 5 6 7 7 AUTO COMMAND 7 7 5 6 6 MANUAL COMMAND 6 6 J1 J1 11 1 1 PCC NET A 1 1 3 3 PCC NET A 12 2 2 PCC NET B 2 2 4 4 PCC NET B 3 4 4 SYSTEM WAKEUP 4 4 5 5 SYSTEM WAKEUP 10 AUDIBLE ALARM 1 2 IF PCC2300 OPTION SELECTED 1 2 CNP 22727 E-STOP C3 1 9 2 8 SPL D 7 SPL E 4 CNP 22894 CNP 22895 CNP 22896 FAULT RELAY 13 21 31 41 A1 J14 J5 J6 2 J1 4 5 14 22 32 42 A2 J1 3 4 5 NOT IN AUTO RELAY 13 PCC NET B 2 SYSTEM WAKEUP 1 PCC NET A J14 14 21 22 31 32 41 42 14 21 22 31 32 41 42 3 3 GND 4 AUTO COMMAND 6 6 MANUAL COMMAND 1 1 PCC NET A 2 2 PCC NET B 3 3 SYSTEM WAKEUP J6 J6 1 1 FUSED B+ 2 2 GND J1 J1 3 3 PCC NET A 4 4 PCC NET B 5 5 SYSTEM WAKEUP 12 2 SPL A SPL B SPL C BARGRAPH A2 RUN RELAY 13 FUSED B+ 4 1 A1 1 5 11 3 HMI 220 1 6 3 GND AUX101 MODULE 1 J28 J28 J29 J29 10 FUSED B+ NOTE: IF USING SHUNT APPLICATION, USE ALTERNATOR CENTER TAPS OR A TRANSFORMER IF L-L VOLTAGE IS > 240 VAC. LOW COOLANT LEVEL SWITCH 1 A1 A2 AUDIBLE ALARM AUX102 MODULE NOTES: 1) ALL ITEMS IN DASHED LINES ARE OPTIONAL. AUTO CAD ALTERNATOR 2 RECONNECT TERMINAL BLOCK N PMG 1 U V W POWER AND SENSOR HARNESS MAIN CONTROL PANEL (SEE SHEET 2 FOR LAYOUT) 3 (F1) X+ FIELD (F2) XX- WINDING MAIN BREAKER MCB_1 PCC1302 ALTERNATOR HARNESS U U C1 C6 CT1 CT1 X1 TO V V CUSTOMER LOAD CT1 COM CT2 CT2 X1 W W CT2 COM CT3 CT3 X1 CT3 COM J12 G G 1 CT1 K K 4 CT1 COM H H 2 CT2 L L 5 CT2 COM J J 3 CT3 M 6 M CT3 COM J11 C1 C1 OIL PRESSURE SENDER +5V 1 23 23 B OIL PRESSURE SENDER RETURN 2 12 12 A OIL PRESSURE SENDER 3 13 13 C MAGNETIC PICK UP SHIELD 8 14 14 MAGNETIC PICK UP SUPPLY 9 15 15 A MAGNETIC PICK UP RETURN 10 16 16 B OIL PRESSURE SENSOR PC TOOL 5 3 2 ENGINE SPEED SENSOR F-SERIES THROTTLE BODY J22 L1 D D 1 L1 L2 C C 2 L2 L3 B B 3 L3 N A A 4 N FIELD - F E F 2 E 1 P PMG 2 PMG 3 P O O N N Q Q J2 J2 FUSED B+ 3 3 GND 5 5 2 -24VDC RETURN 3 RELAY AND FSO FUSED B+ THROUGH E-STOP 4 2 3 PMG 3 C2 J25 8 9 12 B+ FOR HMI 8 BATT - 6 DISCRETE INPUT RETURN 2 LOCAL E-STOP 6 PCC NET B 7 SYSTEM WAKEUP 8 HMI's B+ SUPPLY FROM PCC PWM+ PWM- 1 FUSED B+ 16 B- PWM INVERTOR MODULE 5 PWM + (TO F-SERIES THROTTLE BODY) 4 PWM - (TO F-SERIES THROTTLE BODY) 3 GROUND 2 PWM - INPUT FROM PCC 1 B+ 4 4 2 4 5 5 6 6 24 24 AUTO COMMAND MANUAL COMMAND B+ RETURN (B -) 9 PCC NET SHIELD B+ RETURN (B -) 7 PCC NET A 1 1 4 PCC NET A B+ RETURN (B -) 12 PCC NET B 2 2 3 PCC NET B SYSTEM WAKEUP 4 4 5 SYSTEM WAKEUP J6 J6 STARTER DISCONNECT INPUT 11 ALTERNATOR LAMP 22 B+ INPUT 21 5 6 7 B+ J1 J1 B+ INPUT 9 PCC NET A 3 3 B+ INPUT 10 PCC NET B 4 4 B+ INPUT 20 SYSTEM WAKEUP 5 5 FSO RELAY DRIVER 14 3 3 2 2 28 28 11 11 GND SPL 1A STARTER RELAY LOW SIDE DRIVER 15 SWITCHED B+ LOW SIDE DRIVER 3 CONFIGURABLE INPUT 3 17 CONFIGURABLE INPUT 4 RELAY COIL B+ SUPPLY + BATT2 (12V) - + BATT1 (12V) B+ SPL A E-STOP 1B B 1 1 7 7 C 8 8 D 18 9 9 B 13 29 29 30 30 FSO LCL1 C 31 D LCL2 B A S TERM AFR POWER C HMI's GND FROM PCC B+ MAG SWITCH B AUX 101 INPUT 3- 10 AUX 101 INPUT 3+ 11 OIL TEMPERATURE SENSOR RETURN 13 OIL TEMPERATURE SENSOR SUPPLY BMOT STARTER PCC NET B 3 PCC NET A J14 1 27 27 ALTERNATOR SENSE B P11 SYSTEM WAKEUP 4 2 D AUX 101 P1 5 12 ENGINE ALTERNATOR IGNITION MODULE - 31 9 AUX POWER OUT 10 1 11 PCC NET A 5 RUN INPUT 2 18 B+ RETURN (B -) PCC NET SHIELD 4 5 22 CHASSIS GROUND 10 1 GND 22 10 7 2 RX 15 21 10 6 1 B 11 21 J20 6 2 18 COOLANT TEMPERATURE SENSOR A - 7 GND 17 2 AUTO COMMAND FUSED B+ 18 FIELD + +24VDC SUPPLY 1 12 MANUAL COMMAND HMI 114 17 TX FIELD - PMG 1 PMG 2 1 F8 (10A) 4 TERMINAL BLOCK, RELAY AND FUSE DESCRIPTIONS GOVERNOR - 11 J18 F9 (10A) PMG 1 HMI 211 COOLANT TEMP SENDER RETURN J17 FIELD + ALT. GROUND BOLT COOLANT TEMP SENDER 3 C INPUT 3- 5 20 20 INPUT 3+ 6 19 19 INPUT 4- 7 26 26 A INPUT 4+ 8 25 25 B OIL TEMPERATURE SENSOR J10 GND GND 9 CS1 3 FUSED B+ CS2 4 GND 10 LEGEND CR# - - = RELAY COIL REFERENCE: 1) SEE CPG DRAWING #0630-3440 FOR PCC SCHEMATICS AND INTERFACE CR# - 10 = RELAY CONTACT = TERMINAL BLOCK AUTO CAD E-STOP "E-STOP" AUX101 PCC1302 J4 J17 J18 TB1 J3 J10 J22 C6 J2 "J1" J1 "J6" J6 P11 J14 P1 J12 J25 TB15 J20 "J2" J11 J2 F14 12 11 9 10 8 7 6 5 4 3 3 2 2 2 13 CR3 13 12 11 10 9 8 7 6 5 "F13" 4 F13 CR1 CR2 C1 3 "F12" 3 F12 2 "F11" 2 F11 2 "F10" 1 F10 2 "F9" 2 F9 2 "F8" 1 F8 1 "F1" 2 F1 1 "F4" 1 F4 1 "F5" 1 F5 1 PWM CONVERTOR TERMINAL STRIP DETAIL "F14" AUTO CAD POWER AND SENSOR HARNESS J11 AUX105 C1 C1 OIL PRESSURE SENDER +5V 1 23 23 B OIL PRESSURE SENDER RETURN 2 12 12 A OIL PRESSURE SENDER 3 13 13 C MAGNETIC PICK UP SHIELD 8 14 14 OIL PRESSURE SENSOR MAGNETIC PICK UP SUPPLY 9 15 15 A MAGNETIC PICK UP RETURN 10 16 16 B OIL TEMP SENDER 13 25 25 A OIL TEMP SENDER RETURN 14 26 26 B COOLANT TEMP SENDER 11 17 17 COOLANT TEMP SENDER RETURN 12 18 18 PC TOOL 5 2 3 ENGINE SPEED SENSOR F-SERIES THROTTLE BODY OIL TEMPERATURE SENSOR COOLANT TEMPERATURE SENSOR A B 2 N U V W 19 19 5 RUN INPUT 16 20 20 2 AUX POWER OUT GOVERNOR - 4 21 21 18 PWM+ 22 22 10 PWM- ECM FUSED B+ 9 KEYSWITCH IN (WAKEUP) 11 BATTERY - IN 5 BATTERY - IN 6 PMG BATTERY - IN 1 BATTERY + IN 10 PCCNET RS485 A (F1) X+ FIELD (F2) XX- WINDING GND 15 MAIN CONTROL PANEL (SEE SHEET 2 FOR LAYOUT) 1 RX 15 INTAKE MANIFOLD TEMP SENDER ALTERNATOR RECONNECT TERMINAL BLOCK TX INTAKE MANIFOLD TEMP SENDER RETURN J21 3 3 11 8 PCCNET RS485 B 12 PCCNET RS485 SHIELD 7 J1939 CAN (+) 2 J1939 CAN (-) 3 J1939 CAN (SHIELD) 4 1 16 C2 5 PWM + (TO F-SERIES THROTTLE BODY) 4 PWM - (TO F-SERIES THROTTLE BODY) 3 GROUND 2 PWM - INPUT FROM PCC 1 B+ FUSED B+ B- MAIN BREAKER MCB_1 ALTERNATOR HARNESS U U CT1 X1 TO V V CUSTOMER LOAD CT1 COM CT2 CT2 X1 W W CT2 COM CT3 CT3 X1 J12 G G 1 CT1 K K 4 CT1 COM H H 2 CT2 L L 5 CT2 COM J CT3 COM M J M 3 CT3 6 CT3 COM J22 L1 D D L2 C L3 B N A J1939 (+) 11 J1939 (-) 10 PCCNET A 12 PCCNET B 13 PCCNET SHIELD 4 KEYSWITCH LOW SIDE DRIVER 15 KEYSWITCH B+ OUT / B + OUT 18 B+ RETURN (B -) 8 1 L1 C 2 L2 B 3 L3 B+ A 4 N - J17 FIELD FIELD + ALT. GROUND BOLT J26 PCC3300 C1 C6 CT1 F F 2 FIELD - E E 1 FIELD + J18 F9 (10A) PMG 1 PMG 2 PMG 3 P P O O N N Q Q 10 10 CHASSIS GROUND 1 4 4 B+ RETURN (B -) 2 B+ RETURN (B -) 4 5 5 2 PMG 1 PMG 2 B+ RETURN (B -) 7 6 6 3 PMG 3 B+ RETURN (B -) 12 24 24 3 3 B+ INPUT 21 B+ INPUT 9 B+ INPUT 10 B+ INPUT 20 1 F8 (10A) J20 IGNITION MODULE GND SPL 2 - J25 J28 J28 HMI 320 FUSED B+ GND 1 3 8 1 12 9 3 J29 J29 AUTO COMMAND 4 4 MANUAL COMMAND 6 6 4 TERMINAL BLOCK, RELAY AND FUSE DESCRIPTIONS 1 +24VDC SUPPLY 2 -24VDC RETURN PCC NET A 1 1 PCC NET B 2 2 SYSTEM WAKEUP 3 3 J6 HMI 114 1 1 GND 2 2 J1 RELAY AND FSO FUSED B+ THROUGH E-STOP 3 4 PCC NET SHIELD 5 PCC NET A J6 FUSED B+ J1 PCC NET A 3 3 PCC NET B 4 4 SYSTEM WAKEUP 5 5 ENGINE ALTERNATOR 8 BATT - 6 DISCRETE INPUT RETURN 2 LOCAL E-STOP 11 AUTO COMMAND 10 MANUAL COMMAND 9 5 6 7 B+ FOR HMI FSO RELAY DRIVER + BATT2 (12V) 2 2 28 28 11 11 - + BATT1 (12V) B+ SPL 14 A B STARTER RELAY LOW SIDE DRIVER 15 SWITCHED B+ LOW SIDE DRIVER 3 CONFIGURABLE INPUT 5 17 CONFIGURABLE INPUT 12 RELAY COIL B+ SUPPLY 1 1 7 7 C 8 8 D 19 9 9 B 13 29 29 30 30 FSO PCC NET SHIELD 4 PCC NET A 3 PCC NET B 5 SYSTEM WAKEUP LCL1 C STARTER DISCONNECT INPUT ALTERNATOR LAMP D 11 22 31 31 C 27 27 LCL2 B A S TERM AFR POWER B B+ MAG SWITCH STARTER E-STOP 6 PCC NET B 7 SYSTEM WAKEUP 8 HMI's B+ SUPPLY FROM PCC 9 HMI's GND FROM PCC 1B D B ALTERNATOR SENSE C 1A LEGEND CR# - - = RELAY COIL CR# - 10 = RELAY CONTACT = TERMINAL BLOCK REFERENCE: 1) SEE CPG DRAWING #0630-3440 FOR PCC SCHEMATICS AND INTERFACE AUTO CAD BMOT E-STOP "E-STOP" TB15 TB9 TB15 J14 J17 TB7 TB10 TB8 AUX105 PCC3300 CT1 J18 C6 CT2 "J1" J1 TB5 CT3 "J6" J6 J12 "J29" TB3 J29 TB1 "J28" J28 J25 J21 J22 J11 J20 J26 F14 9 8 7 6 "F13" 5 F13 9 8 7 6 5 4 3 3 2 2 CR3 C1 4 "F12" CR1 CR2 3 F12 3 "F11" 2 F11 2 "F10" 1 F10 2 "F9" 2 F9 2 "F8" 2 F8 2 "F1" 1 F1 1 "F3" 2 F3 1 "F4" 1 F4 1 "F5" 1 F5 1 PWM CONVERTOR TERMINAL STRIP DETAIL "F14" AUTO CAD Cummins NPower, LLC 1600 Buerkle Rd White Bear Lake, MN 55110 Customer Assistance Center: 1 866 831 7620 www.cumminsnpower.com