Armstrong World Industries ACUM84 User's Manual
Contents
1. Amperes meter Volt meter Frequency meter Temperature meter Oil pressure level Battery charge meter To check the readings of volts amperes ad frequency of each phase the control panel has a toggle switch that will allow to change between the readings of each phase When it is on he of position no lecture will be received Posi tion number 1 will give the readings of the phase L1 posi AR EXP CUMMINS 07 00 Page 28 tion number 2 will give the readings of the phase L2 and position number 3 will give the reading of the phase L3 only on 3 phase equipments Single phase equipments will give no reading on this position 8 1 CHECKS DURING OPERATION While running make the following checks to see that all parts are working correctly Radiator Cooling water Coolant To avoid personal injury e Do not remove radiator cap until coolant temperature is well below its boiling point Then loosen cap slightly to the stop position to relieve any pressure before removing cap completely When the engine overheats and hot coolant overflows through the overflow pipe and cannot be stopped stop the engine immediately and make the following checks to deter mine the cause of trouble 1 Check to see if there is any coolant leak 2 Check to see if there is any obstacle around the cooling air inlet or outlet 3 Check to see if there is any dirt or dust between radiator fins and tube 4 Check to see if the fan belt2. PINK AWG 16 gt L BLUE AWG 16 6 ___ LIGHT BLUE 7 PURPLE AWG 16 ES WHITE AWG 16 S ij WHITE AWG 16 OIL PRESS SWITCH 9 uud BLUE AWG 16 WATER TEMP SWITCH 12 LIGHT GREEN AWG 16 GREEN AWG 16 GREEN AWG 16 13 N 1 Eo ORANGE AWG 16 46 ORANGE AWG 16 14 PURPLE AWG 16 ma RED AWG 12 From PART DESCRIPTION 111 4 emcur BREAKER DC 12 AMP ___ 2 3 jomer re Tr TP SEIN Pr dee ___ 5 71 CRANKSOLENOIDE STARTER rine REMOTE START CONTAC FROM TRANFER SWITCH WATER TEMP GAUGE E ____ 6 19 7 19 _____ ESC JjAcmszawe 140 1 ______ 24 PIN _____ 12 1 _______ __ rz m m ovo gt 10 25 07 DRAWING PROYECT COSTUMER FRANCISCO R LOJOS 5 1 4 BLACK AWG 16 1 t14 1 SQUARE RECEPTACLE 9 PIN T EA ron 5 WHTEAWG S 17 4 FuELHEATERRESISTOR 6 a 18 a 4 ROTARY CAM SWITCH 10 AMP ee tates eene rers iei 10 2507 DATE ARMSTRONG POWER SYSTEM d M CHECKED APPVD DATE TITLE FILENAME ELECTRICAL FUNCTION CUMMINS CUMMINS GENERATING SET OPERATION AND MAINTENAN
3. 9 Connect an accurate AC frequency meter across terminal lugs Voltage should be 1 5 of the specificated and frequency 4 0 of the specificated on the unit 10 Let the generator run at full rated load for 20 30 min utes Listen for unusual noises vibration or other indica tions of abnormal operation Check for oil leaks evidence of overheating etc 11 When testing under load is complete turn OFF electrical loads 12 Set the generator s main circuit breakers to their OFF Or open positions 13 Let the engine run at no load for a few minutes 14 Set the Start stop switch to stop The engine should shut down 6 3 CHECKING AUTOMATIC OPERATION To check the system for proper automatic operation pro ceed as follows 1 Check that the Start stop switch is set to stop 2 Manually set the transfer switch to the UTILITY position i e load terminals connected to the utility power source side 3 Turn ON the utility power supply to the transfer switch using the means provided such as a utility main line circuit breaker 4 Set the Start stop switch to manual The engine should crank and start when the remote start input is activated 5 Turn OFF the utility power supply to the transfer switch With the Start stop switch at AUTO the engine should crank and start when the utility source power is turned OFF After starting the transfer switch should connect load circuits to the standby side Le
4. by the cooling fan or intake system e Install and operate this generating set only in full compliance with relevant National local or federal codes standards or other requirements AR EXP CUMMINS 07 00 OWNERS MANUAL Page 6 Risk of serious injuries or death Fuels and fumes associated with generating sets can be flammable and potentially explo sive Proper care in handling these materials can dramatically limit the risk of fire or explo sion However safety dictates that fully charged BC and ABC fire extinguishers are kept on hand Personnel must know how to operate them e The acids in the battery can cause explosion e Avoid any contact between the tools and the terminals in the battery e Never use metallic objects on the neck or hands when handling the set A DAN 5 E R e Never connect the negative terminal from the battery to the positive terminal from the starter i Explosive e Don t smoke or allow sparks flames or other sources of ignition around the Y vapors fuel or batteries No smoking Use adequate equipment to take fuel from the set No open flames sparks Never test the battery by touching together the terminals Ensure the generating set room is properly ventilated Don t touch the battery charger or the connections during the battery charging proc ess e Always disconnect the negative terminal from the battery before to start any work on the unit Keep the room the floor and the gener
5. 3l WARNING Do not mix gasoline alcohol or gasohol with diesel fuel This mixture can cause an explosion CAUTION Due to the precise tolerances of diesel injection systems it is extremely important that the fuel be kept clean and free of dirt or water Dirt or water in the system can cause severe damage to both the fuel pump and the fuel injectors Cummins Inc recommends the use of ASTM number 2D fuel The use of number 2 diesel fuel will result in optimum en gine performance At operating temperatures below O C 32 F acceptable performance can be obtained by using blends of number 2D and number 1D NOTE Lighter fuels can reduce fuel economy NOTE Engines equipped with diesel particulate filters require the use of diesel fuel with 30 ppm sulfur maximum There are no acceptable substitutes The viscosity of the fuel must be kept above 1 3 cSt at 40 C 104 F to provide adequate pumping and lubricating char acteristics to fuel system components The following chart lists acceptable substitute fuels for this engine Acceptable Substitute Fuels Number AD Number Number 2D 1K Kero Jet A Jet A1 JP 5 JP 8 Jet B JP 4 CITE DieselG 2 E 3 Diesel An A means OK only if fuel lubricity is adequate This means the BOCLE number is 3100 or greater as measured by ASTM specification D6078 Scuffing Load Ball On Cylinder Evaluator SLBOCLE Lubricity can also be measured by ASTM specification D6079 ISO 12156 High Frequency Re
6. Drain Intervals section The lubricating oil and lubricating oil filter interval can be adjusted based on application fuel con sumption gross vehicle weight and idle time For engines whose aspiration is charge air cooled refer to Table in the Oil Drain Intervals section Antifreeze check interval is every oil change or 500 hours or 6 months whichever occurs first The operator must use a heavy duty year round antifreeze that meets the chemical composition of GM6038M The antifreeze change interval is 2 years 2000 hours or whichever occurs first Anti freeze is essential for freeze overheat and corro sion protection Follow the manufacturer s recommended mainte nance procedures for the starter alternator gen erator batteries electrical components charge air cooler radiator air compressor air cleaner refrig erant compressor and fan clutch Refer to the Component Manufacturers in Section M OWNERS MANUAL Page 30 Table Jacket Water Cooled Turbocharged Only or Naturally Aspirated Engines Cummins Engine Standard American Petroleum Institute ee P a International Classifications All Engine Ratings Classification Classification An ______ or CR API CI 4 SK API 1 4 API 20076 CES 20072 CES CH 4 S CES 20075 API CF 4 SG aren 150 Hours or 6 Weeks 4 5 API CD API Table 2 Charge Air Cooled Engines Cummins Engine Standard American Petroleum Instit
7. HUN 4no YI S3ueJJ u asnge an au e qisuodsau pu jo au uo su SUOLI Aew J9MOd duoJ3sulJv q yenuew SJo3e Jodo JnoA UO 3JInDoJ 99 JO 9DUP 12 4 Suoa3sulav SUILUJOJUOD JOU s3ueure e da4 4 4 sJredoJ redey e eu Au 49402 JOU eus 3 21134 gt 5143 Suome3luul 5 5 ct 3 2 y U v s lt a lt 2 ct 5 gt m 3 ct s 5 0 lt 2 Y y 3 ct UO y PUN JOM 5 UI S32 9 7 Jo porJed e senunuo 4 3ueuje2e dau J OTT LEO SW3ISAS 500 9NOULSWUV pue 34 q u2IUA diysu UM SJnou 005 40 sue y esne UJ jo esne o Jaye 222 SUOLI auinba syjueunsn pe pue seolAJes J pue e ue 35 11 JP 4edouduur 32 8 JO eu Sung rej IMPORTANT SAFETY INSTRUCTIONS AR EXP CUMMINS 07 00 OWNERS MANUAL Page 5 This manual provides general safety information for installing operating and maintenance of Armstrong Power equipments The purcha
8. MW 3 ESSO BEACON 3 9 3 VOLTAG REGULATOR EEH The generators are provided with automatic voltage regula tor The AVR is provided with potentiometers to adapt the characteristics of the AVR to different operating conditions The AVR is provided with adjustable stability circuitry to allow operations in a wide range of applications The AVR is equipped also with protecting circuit allowing the generator to operate underspeed if not loaded ATTENTIONI it is not advisable to have the generator oper ating loaded when the frequency speed is below the rated value this kind of operation is an overload for the whole generator excitation system CONNECTION OF AVR The AVR is connected to the terminals of the generator and to exciter FAST ON terminals USE OF POTENTIOMETERS C voltage DES voltage P1 VOLT Potentiometer for adjusting the output voltage of the generator it allows a wide range of voltage setting i e between 350 and 470 V or between 170 and 260 V de pending on winding connections When resetting the po tentiometer the voltage has to be set in the range 5 5 around the rated voltage of the machine In order to obtain AR EXP CUMMINS 07 00 Page 34 a finer regulation or to adjust the voltage from control panel or to limit the voltage range it is possible to insert an external potentiometer P2 FREQ Potentiometer for changing the low speed protec tion Usually it is se
9. Tank and Reservoirs Drain Cooling Fan Check Correct Crankcase Breather Tube Inspect Drive Belts Check Correct Engine Coolant Level Check Correct Engine Lubricating Oil Level Check Correct Fuel Water Separator Drain Every 250 Hours or 3 Months Maintenance Check 1 4 Air Cleaner Restriction Check Correct Air Compressor Mounting Hardware Check Correct Charge Air Cooler Check Correct Charge Air Piping Check Correct Fuel Injection Pump Mounting Hardware Check Correct Lubricating Oil and Filters Change Radiator Hoses Check Every 500 Hours or 6 Months Maintenance Check 2 3 4 Engine Coolant Antifreeze Check Fuel Filter Canister Type Replace Fuel Filter Spin on Type Replace Lubricating Oil and Filters Change Every 1000 Hours or 1 Year Maintenance Check 4 Cooling Fan Belt Tensioner Check Correct Fan Hub Belt Driven Check Correct Overhead Set Adjust Every 2000 Hours or 2 Years Maintenance Check 3 4 Air Compressor Discharge Line Check Correct Cooling System Drain Flush and Fill Vibration Damper Rubber Check Vibration Damper Viscous Check 1 NOTE The lubricating oil and lubricating oil filter interval can be adjusted based on application fuel consumption gross vehicle weight and idle time For engines whose aspiration is jacket water cooled turbocharged only or natural refer to AR EXP CUMMINS 07 00 Page 29 Table in the Oil
10. are NOT adjust able Crank disconnect Underspeed Overspeed Remote start delay Preheat Crank period Crank rest Safety delay Remote stop delay AR EXP CUMMINS 07 00 20Hz 20Hz 5 Hz 50Hz nominal 68 Hz 60Hz nominal 5S 10s 10s 10s 10s 30s PIN DESCRIP No TION 1 DC Plant Sup ply Input ve DC Plant Sup ply Input ve Fuel relay Out put Start relay Output Preheat Out put relay Remote Start Input Charge Fail Input Excita tion Output Low Oil Pres sure Input High Engine Temp Input 7 3 TERMINAL DESCRIPTION CABLE SIZE 1 0mm 1 0mm 0 5mm 0 5mm 0 5mm 0 5mm 1 0mm 0 5mm 0 5mm Page 27 NOTES Connected to plant battery negative Connected to plant battery positive Recommende d Fuse 2A Used to oper ate the fuel solenoid con trol relay Used to oper ate the crank ing control relay Used to oper ate the pre heat control relay Switch to negative to start set Must NOT be connected to plant supply negative if not used Switch to negative on fault Switch to negative on fault NOTE All the outputs are solid state rated at 1 2 Amps 8 Volts to 35 Volts DC and switch to battery negative when active OWNERS MANUAL 7 4 INSTRUMENTS READING Additional to the digital module the control panel has ana log capabilities hat provide more durability and low mainte nance cost Those instruments are
11. is too loose 5 Check to see if radiator water pipe is clogged and 6 Check to see if anti freeze is mixed into coolant in warm seasons Fuel To avoid personal injury Fluid escaping from pinholes may be invisible Do not use hands to search for suspected leaks Use a piece of card board or wood instead If injured by escaping fluid see a medical doctor at once This fluid can produce gangrene or a severe allergic reaction e Check any leaks from fuel pipes or fuel injection pipes Use eye protection when checking for leaks Be careful not to empty the fuel tank Otherwise air may enter the fuel system requiring fuel system bleeding While the engine is run within the rated output range The color of exhaust remains colorless If the output slightly exceeds the rated level exhaust may become a little colored with the output level kept constant e If the engine is run continuously with dark exhaust emis sion it may lead to trouble with the engine Immediately stop the engine if The engine suddenly slow down or accelerates Unusual noises suddenly appear e Exhaust fumes suddenly become very dark 8 2 MAINTENANCE SCHEDULE Perform maintenance at whichever interval that occurs first At each scheduled maintenance interval perform all previ ous maintenance checks that are due for scheduled main OWNERS MANUAL tenance Daily or Refueling Maintenance Check Air Intake Piping Inspect Air
12. minute e The site must permit engine exhaust gases to be piped away to an area that is uninhabited by people or ani mals Care must be given to ensure that exhaust gases do not re enter an occupied area e The outside site must provide access to the generator to allow for maintenance service and repair A three foot 914 meter service clearance around the unit is recommended e Fuelsupply and ease of refueling must be taken into consideration e Adequate normal and emergency lighting must be pro vided in any installation 1 1 GROUND FLOOR LOADING The foundation for the generator must support the total weight of the generator This includes fuel oil and the weight of any associated support systems Plan for 3 feet 1 Meters of access around the generator for maintenance service and repair When calculating the floor loading ensure the fuel weight cooling system fluids where applicable piping pumps power cables runways and supporting structures are in cluded in the calculations A concrete foundation with anchored mounting bolts is recommended Steel Beams are an acceptable alternative Foundations help in the servicing and repair of Gen Set s and protect the unit from moisture that could occur from seepage The concrete base that the generator is mounted to should be separate and independent from the surround ing structure The following applies to concrete bases A Single See Figure 1 or Double Se
13. you with CPR instructions 2 BLOW Tilt the head back and listen for breathing If not breathing normally pinch nose and cover the mouth with yours and blow until you see the chest rise Give 2 breaths Each breath should take 1 seconds 3 PUMP If the victim is still not breathing normally coughing or moving begin chest compressions Push down on the chest 11 2 to 2 inches 30 times right between the nipples Pump at the rate of 100 minute faster than once per second CONTINUE WITH 2 BREATHS AND 30 PUMPS UNTIL HELP ARRIVES In unconscious patient with intact breathing and pulse recovery position ensures the preven tion of tongue falling back and blocking the airway What to do e Place the patient on their back e Lift the chin to ensure the air way is open e Patient s arm on your side should be positioned so as to make a right angle with his body with elbow bent and palm facing out e Patient s other arm on opposite side should be placed across the chest with back of their hand against the cheek on your side of the patient e Pull up the patient s knee joint side away from you as it bends with the foot flat on the ground e Roll over the patient in this position towards your side e By tilting the patient s head back ensure that the airway is open AR EXP CUMMINS 07 00 OWNERS MANUAL Page 10 CAUTION The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically co
14. 5 0 18 9 gal L 6 3 23 8 Cartridge SAE 15W 40 12V negative Fuel Consumption 75 Power gal hr L hr L hr 75 Fuel Consumption 100 Power gal hr gt Air Intake Restriction clean filter Air Require ment Air Intake Restriction dirty filter Exhaust Temperature Lubrication System Total Engine Oil Cap w filter Oil Filter Type Lube oil specifications grade Battery Charging Alternator Volts Ground al Baterry Charging Alternator 777 1200 0 F 18 Starter Motor Volts Ground 12V negative Temperature and Altidtude Losses 4 per 1000 ft 300 m and 1 per 10 F 2 per 11 Rated amps Engine Elec tricals AR EXP CUMMINS 07 00 OWNERS MANUAL ACUM210 INSTALLATION AND APPLICATION Type of Operation and Application Standby 1800 Standby Rated Speed 1500 Gross Engine Output bhp kWm 285 213 317 237 245 183 272 203 BMEP psi kPa 248 1710 276 1902 213 1470 237 1632 Mean Piston Speed Ft s m s 26 57 8 1 22 30 6 8 Ambient Air Temperature F C 122 50 Engine Heat Reject to Coolant 4250 74 4725 83 4090 72 4420 78 Maximum Pressure Cap Psi kpa 10 69 Maximum coolant friction Psi kpa 5 35 4 28 Maximum fuel flow gal h L h 55 208 Diesel 2 3 39 3 21 6 42 10 18 9 63 18 57 12 83 Fuel Type Fuel Fuel Consumption 25 P
15. 50 ratio 40 to 60 percent working range A 50 50 mixture of antifreeze and water gives a 36 C 33 F freezing point and a 108 C 226 F boiling point which is adequate for locations in North America The actual lowest freezing point of ethylene glycol antifreeze is at 68 percent Using higher concentrations of antifreeze will raise the freezing point of the solution and increase the possibility of a silica gel problem Do not use sealing additives in the cooling system The use of sealing additives will e Buildup in coolant low flow areas Plug the radiator and oil cooler Possibly damage the water pump seal Do not use soluble oils in the cooling system The use of soluble oils will e Corrode brass and copper e Damage heat transfer surfaces e Damage seals and hoses For safety purposes it is necessary that any testing or maintenance carried out on electrical machine are performed by qualified and authorized personnel and all operation must be performed when the machine is stopped at ambient tem perature and disconnected from any supply source including the auxiliary circuits such as the anti condensation heaters Furthermore all measures must be taken to avoid restarting the gen set during maintenance 9 1 INSPECTION AND MAINTENACE INTERVALS Inspection and maintenance should take into account the importance of the plant ambient conditions dust etc and op erating conditions As a general rule the machine should be subj
16. CE A s MS Laat watt iLL mm AR EXP CUMMINS 07 00 OWNERS MANUAL Before starting complete the following 1 Set the generator s Start stop switch to the Stop position STOP 2 Turn OFF the utility power supply to the transfer switch using the means provided such as the utility main line circuit breaker 3 Check the engine crankcase oil level and if necessary fill to the dipstick FULL mark with the recommended oil Do not fill above the FULL mark 4 Check the fuel supply All fuel shutoff valves in the fuel supply lines must be open Never operate the engine with the oil level below the Add mark on the dipstick Doing this could damage the engine 6 1 Electrical Checks Complete electrical checks as follows 1 Turn on the utility power supply to the transfer switch using the means provided such as a utility main line circuit breaker The transfer switch is now electrically hot Contact with hot parts will result in extremely hazardous and possibly fatal electrical shock Proceed with caution 2 Use an accurate AC voltmeter to check utility power source voltage across terminals 3 Check utility power source voltage across terminals and the transfer switch neutral lug then across second terminal and neutral Nominal line to neutral voltage should be 120 volts AC 4 When certain that utility supply voltage is compatible with transfer switch and
17. Date 10 01 07 OWNERS MANUAL CUMMINS SERIES MODELS ACUM65 ACUM84 ACUMIIO ACUMI40 185 ACUM21IO AR EXP CUMMINS 07 00 OWNERS MANUAL Page 2 SAVE THESE INSTRUCTIONS This manual contains important instructions regarding for all Armstrong Power Systems LLC power generator Models The information contained here must be followed during installation and maintenance of the genera tor and batteries Keep this manual with the equipment If the equipment is traded or sold give the manual to the new owner You are now the owner of a Armstrong Power generator powered by CUMMINS engine All our components keep the highest standards in quality efficiency and durability Each unit pass thru a complete test and inspection to guarantee the quality of your unit We provide warranty on every component subject to the warranty coverage and limitations To get the best results from your new generator please read carefully this document before starting the unit and follow the instructions If you have any question regarding your equipment please call your dealer or contact us Please have the generator model and serial num bers when you call Parts may be obtained directly from our distributors Once again thank you for your trust in Armstrong Power and welcome to our family AR EXP CUMMINS 07 00 OWNERS MANUAL sey ued noA yl Idoq J 4
18. ake Restriction clean filter In H2O kPa 10 2 49 In H20 kPa 25 6 22 F C 947 508 991 533 1041 560 1073 578 Maximun Allowable Back Pressure In H20 kPa 40 78 10 15 Maximum oil temperature F C 250 121 Oil Pan Capacity gal L 3 8 14 2 Total Engine Oil Cap w filter gal L 4 3 16 4 Oil Filter Type Lube oil specifications grade Air Require en Air Intake Restriction dirty filter Exhaust Temperature Lubrication System Cartridge SAE 15W 40 12V negative Battery Charging Alternator Volts Ground al al Baterry Charging Alternator A Battery Cold CCA amps 800 0 F 18 Starter Motor Volts Ground 12V negative Temperature and Altidtude Losses 4 per 1000 ft 300 m and 1 per 10 F 2 per 11 C Rated amps Engine Elec tricals AR EXP CUMMINS 07 00 OWNERS MANUAL ACUM185 INSTALLATION AND APPLICATION Type of Operation and Application Rated Speed 1800 1500 Maximum fuel flow gal h L h 55 208 Fuel Type Diesel 2 Fuel Fuel Consumption 25 Power 171 a System Fuel Consumption 50 Power gal hr L hr 5 92 10 56 8 88 12 81 14 08 10 76 11 85 Combustion Air Flow ft min L s 540 255 550 259 407 192 437 206 In H20 kPa 10 2 49 In H20 kPa 25 6 22 F C 955 513 1055 569 996 536 1046 563 Maximun Allowable Back Pressure In H20 kPa 3 10 13 Maximum oil temperature F 9C 250 121 Oil Pan Capacity gal L
19. anels a 3 foot clearance is re quired and the use of an emergency light to illuminate the unit during operation is typically required Power for the emergency light should be from both the primary utility and the generator This is highly recommend so that in the event of a malfunction there is a light source to see to work on the unit Refer to your local building and electrical codes to ensure compliance 4 2 CONDUCTOR SIZING CONNECTION This information is dependent upon your generator output and intended load When connecting cables to the genera tor make connections at the generator first Make the con nections at the load last Failure to do so may constitute a fire or safety hazard All ampacities are typically calculated at 75 C Celsius 167 o F Fahrenheit in the conductor size charts Building wire conductors should be rated at 90 C 194 F to allow for different ambient temperatures that these conductors may pass through All conductors are typically required by electrical code to be copper The recommended conductor sizes are based on maximum current Ampacities are found in NEC Article 310 Table 310 16 Conductor resistances are found in NEC Ta ble 8 Conductor Properties 4 3 CONNECTING THE GENERATOR Please the refer to the electrical drawing of the unit and your transfer switch documentation for information related Leave the installation only to a trained personnel and don t forget to observe the local law
20. ating set clean When spills of fuel oil battery electrolyte or coolant occur they should be cleaned up immediately Never store flammable liquids near the engine Store oily rags in covered metal containers Avoid refilling the fuel tank while the engine is running Do not attempt to operate the generating set with any known leaks in the fuel system e Make electrical connections in compliance with relevant electrical codes standards or other requirements This in cludes requirements for grounding and ground earth faults e For stationary generating sets with remote fuel storage systems make sure such systems are installed in compliance with relevant codes standards or other requirements e Engine exhaust emissions are hazardous to personnel The exhaust for all indoor generating sets must be piped out doors via leak free piping in compliance with relevant codes standards and other requirements Ensure hot exhaust silencers piping and turbochargers if equipped are clear of combustible material and are guarded for personnel protection per safety requirements Ensure that fumes from the exhaust outlet will not be hazard e Never lift the generating set by attaching to the engine or alternator lifting lugs Use a sling with a spreader bar connected to the base frame e Ensure the lifting rigging and supporting structure is in good condition and has capacity suitable for the load e Keep all personnel away from the generati
21. ation Standby Standby Rated Speed rom 1800 1500 Gross Engine Output bhp kWm 155 115 170 127 130 97 143 107 BMEP psi kPa 189 1308 208 1435 159 1097 175 1207 Mean Piston Speed Ft s m s 23 6 7 2 19 66 6 0 Ambient Air Temperature F C 122 50 Engine Heat Reject to Coolant BTU min kW 3640 64 3950 69 3080 54 3450 61 Coolant Capacity Gal L 2 4 9 1 Standard Thermostat Range F C 180 203 82 95 Psi kpa 10 69 Psi kpa gal h L h Cooling Sys tem Maximum Pressure Cap Maximum coolant friction 2 2 5 2 Total drain flow 8 30 Diesel 2 1 88 1 73 3 75 3 46 5 63 5 20 7 51 6 93 f min L s 315 150 240 113 In H20 kP 10 2 49 Air Intake Restriction dirty filter In H20 kPa 25 6 22 Exhaust Temperature F C 955 513 995 535 1025 552 1080 582 Maximun Allowable Back Pressure In H2O kPa 3 10 13 Maximum oil temperature F C 250 121 gal L 3 8 14 2 gal L 4 3 16 4 Cartridge SAE 15W 40 12V negative Fuel Type TEN gt SS Fuel Fuel Consumption 25 Power gal hr L h System Fuel Consumption 50 Power gal hr L hr gal hr L h Fuel Consumption 100 Power gal hr L hr AS Fuel Consumption 75 Power gt Combustion Air Flow Air Intake Restriction clean filter Air Require ment Oil Pan Capacity m Lubrication System Total Engine Oi
22. ciporating Rig HFRR in which the fuel must have a wear scar di ameter of 0 45 mm 0 02 in or less Any adjustment to compensate for reduced performance with a fuel system using alternate fuel is not warrantable Winter blend fuels such as found at commercial fuel dispensing outlets are combinations of number 1D and 2D diesel fuels and are acceptable CAUTION A sulfated ash limit of 1 85 percent has been placed on all engine lubricating oils recommended for use in Cummins engines Higher ash oils can cause valve and or piston damage and lead to excessive oil consumption CAUTION The use of a synthetic base oil does not justify extended oil change intervals Extended oil change intervals can decrease engine life due to factors such as corrosion deposits and wear AR EXP CUMMINS 07 00 OWNERS MANUAL Page 32 The use of quality engine lubricating oils combined with appropriate oil drain and filter change intervals is a critical factor in maintaining engine performance and durability Cummins Inc recommends the use of high quality SAE 15W 40 heavy duty engine oil such as Valvoline Premium Blue which meets performance specifications as listed below Cummins Engineering Stan American Petroleum Institute A dard Classification CES Classification API NENNEN CD API CE API CG 4 SH ACEA uc em hha CES 20075 API CF 4 SG ACEA E 2 ACEA E 3 JAMA Minimum acceptable oil classi DH fication fo
23. e Figure 2 pedestal base may be used A height of at least 6 inches higher than floor level is recommended OWNERS MANUAL Page 13 Figure 1 Single Pedestal Concrete Mount Figure 2 Double Pedestal Concrete Mount A double pedestal base allows easier cleaning under most generator s Double pedestals provide better access for inspecting for oil or fuel tank leaks The generator should be retained to the pedestal base with fasteners that are recommended by the generator set manufacturer The concrete base should extend beyond the genera tor s Footprint by at least 12 Inches 305 mm on all sides The higher the mounting base is made the easier the unit will be to work on when performing maintenance service or repairs Typically bases are required to be raised at least 6 inches 153 mm above floor level Placing the unit higher than 6 inches sometimes has the advantage of making it easier to change the unit s oil Passing fuel lines and electrical conduit for a stub up through the concrete base is a standard practice of gen set installers Concrete foundations are typically mixed by volume AR EXP CUMMINS 07 00 The typical ratio of cement sand and aggregate is 1 2 3 with a maximum 4 inch 102 mm slump and 28 day compressive strength of 2500 psi 173 kPa e generator can typically be mounted to a combustible floor or roof dependent upon code however the sur face beneath the engine and beyo
24. e e followed Keep access doors on enclosures if equipped closed and locked when not required to be open e Avoid contact with hot oil hot coolant hot exhaust gases hot surfaces and sharp edges and corners Wear protective clotting including gloves and hat when working around the generating set Do not attempt to remove the radiator filler cap until the coolant has cooled Then loosen the cap slowly to relive any excess pressure before removing the cap completely Ethyl ether starting aids must not be used on engines with combustion air preheating devises These starting aids will reduce the efficient working life of the engine SAFETY FIRS Fuels oils coolants lubricants and battery electrolyte used in this generating set are typical of the industry However they can be hazardous to personnel if not If you get treated properly chemicals on your body or eyes wash thoroughly with plenty of e Do not swallow or have skin contact with fuel oil coolant lubricants and battery electrolyte If swallowed seek medical treatment immediately Do not induce vomiting if fuel is swallowed For skin contact wash with soap and water e Donot wear clothe that has been contaminated by fuel or lube oil Eye protection must be worn when working on batteries Carbon monoxide may be present AR EXP CUMMINS 07 00 e Wearan acid resistant apron and face shield or goggles when servicing the battery If electr
25. ected to a first inspection after approx 500 operating hours in any case not more than 1 year and subsequent inspections when performing maintenance on prime mover When performing inspection check that e The generator operates smoothly without noise or irregular vibrations due to bearing deterioration The operating data complies with that detailed on the rating plate The air inlet openings are not obstructed The supply cables show no signs of deterioration and connections are firmly tight The electrical connections are in perfect condition undamaged Screws and nuts are firmly tightened 9 2 MAINTENNCE OF BEARINGS The lifetime of bearings is determined by multiple factors and specifically by e lifetime of the grease e heenvironmental conditions and working temperature e The external loads and vibrations The bearings D E and N D E side are prelubricated sealed type life lubrication with sufficient grease quantity for a long operating time The life expected time is in case of normal operating condition of about 20000 hours for all bearings AR EXP CUMMINS 07 00 OWNERS MANUAL In case of complete overhaul of genset the bearing of the generator should be changed On request prelubricated bearings with regreasing system can be mounted When regreasing use 20 30 grams of grease Following types of grease are to be recommended for nor mal application MOBIL OIL MOBILUX 3 SHELL ALVANIA 3 AGIP GR
26. esigned to be safe when used in the correct manner The following safety precautions if fol lowed will minimize the possibility of accidents Before performing any procedure or operating technique it is up to the user to ensure that it s safe The generating set should only be operated by personnel who are authorized and trained Warning e Read and understand all safety precautions and warnings before operating the generating set e Failure to follow the instructions procedures and safety precautions in this manual may increase the possibility of accidents and injuries e Never start the generating set unless it is safe to do so e attempt to operate the generating set with a know unsafe condition e fthe generating set is unsafe fit danger notices and disconnect the battery negative lead so that it cannot be started until the condition is corrected e Disconnect the battery negative lead prior to attempting any repairs or cleaning inside the enclosure if equipped e Appropriate firefighting equipment is to hand e The metal work on every part of the generating set must be connected by means of an earth continuity conduc tor to an effective earth point Care must be taken to avoid spillage from the batteries No loose items or combustible material should be left on or against any part of the generator Do not risk injury by coming into contact with moving parts of the plant or by allowing anything to be draw in
27. essure will be low with the engine at rest FAIL TO START if the engine does not fire after the pre set 3 attempts at starting a shutdown will be initiated The icon will illuminate t r LOW OIL PRESSURE if the module detects that the engine oil pressure has fallen below the low oil pressure switch after the Safety On timer has expired a shutdown will oc cur The icon will illuminate Qr a HIGH ENGINE TEMPERATURE if the module detects that the engine coolant temperature has exceeded the high engine temperature switch after the Safety On timer has expired a shutdown will occur The icon will illuminate E OVERSPEED if the engine speed exceeds the pre set trip 1496 above the nominal frequency a shutdown is initiated Overspeed is not delayed it is an immediate shutdown The icon will illuminate Lo NOTE During the start up sequence the overspeed trip level is extended to 24 above the normal fre quency for the duration of the safety timer to allow an extra trip level margin This is used to prevent nuisance tripping on start up UNDERSPEED if the engine speed falls below 20Hz fixed OWNERS MANUAL after the Safety On timer has expired a shutdown is initi NOTE The lt icon is used to indicate both underspeed ated The icon will flash and overspeed A flashing icon indicates underspeed A steady icon indicates overspeed 7 2 SETTINGS 1 2 1 FIXED SETTINGS The following settings are factory set and
28. ipe and walls is also required by most local codes e Low points in horizontal runs of piping should be pro vided with condensation traps as well as condensation drains eo Piping and mufflers must be properly supported and connected e A flexible length of exhaust pipe is required between the engine exhaust manifold and rigid exhaust piping e Exhaust piping must be terminated safely outside structure that houses a generator in such a way that hot gases and sparks will be discharged harmlessly and will not blow against any combustible surface or material e Exhaust piping must not terminate under loading plat forms structures or near any opening in a building Where necessary exhaust piping must be guarded and or insulated to prevent burns e Provide a clearance of at least 9 inches 229mm 10 inches 250mm recommended between exhaust piping and any combustible material Keep exhaust piping well clear of fuel tanks fuel lines etc 5 9 RAIN CAP A rain cap is recommended on the end of the exhaust pipe The rain cap is attached to the end of the pipe and opens due to the pressure from the exhaust discharge force The rain cap protects the exhaust system from the environment when the system is not running 5 4 SPARK ARRESTOR Use of a spark arrestor is required by the U S Department of Forestry if located on lands under their jurisdiction The spark arrestor is recommended in areas where combustible mate
29. l Cap w filter Oil Filter Type Lube oil specifications grade Volts Ground Rated amps Battery Charging Alternator BA Baterry Charging Alternator Recommended Battery Cold CCA amps 650 Crank Starter Motor Volts Ground 12V negative Temperature and Altidtude Losses 4 per 1000 ft 300 m and 1 per 10 F 2 per 11 C Engine Elec tricals AR EXP CUMMINS 07 00 OWNERS MANUAL INSTALLATION AND APPLICATION NM Type of Operation and Application 6Hz CT 5ohz Prime Standby Standby Gross Engine Output bhp kWm 188 140 207 154 181 135 BMEP psi kPa 230 1587 253 1747 201 1384 221 1527 Mean Piston Speed Ft s m s 23 6 7 2 19 66 6 0 F C 122 50 BTU min kW 4205 73 9 4534 79 7 3587 63 3843 67 5 Cooling Sys Ambient Air Temperature Engine Heat Reject to Coolant Coolant Capacity Gal L 2 6 9 9 Standard Thermostat Range F C 180 203 82 95 Maximum Pressure Cap Psi kpa 10 69 tem Maximum coolant friction Psi kpa gal h L h Tw M A TO 23 Total drain flow Fuel Type Diesel 2 Fuel Fuel Consumption 25 Power gal hr L hr 2 30 2 22 System Fuel Consumption 50 Power gal h 4 61 4 44 Fuel Consumption 75 Power gal hr L hr 6 91 6 65 Fuel Consumption 100 Power gal hr L hr 9 21 10 15 8 87 Combustion Air Flow ft min L s 391 181 409 190 284 135 302 144 D Air Int
30. load circuit ratings turn OFF the utility power supply to the transfer switch 5 Set the generator s main circuit breaker to its OFF or open position Initial tests will be conducted at no load condition 6 On the generator panel Start stop switch to the to start position The engine should crank and start when the re mote start input is activated 7 Let the engine warm up for about five minutes to allow internal temperatures to stabilize Then set AR EXP CUMMINS 07 00 Page 18 the generator s main circuit breaker to its ON or closed position Proceed with caution Generator power voltage is now supplied to the transfer switch Contact with live transfer switch parts will result in dangerous and possibly fatal electrical shock 8 Connect an accurate AC voltmeter and an AC frequency meter across transfer switch terminal lugs and voltage and frequency of the unit must be accord to the specifications of the generator 9 Connect the AC voltmeter test leads across terminal Lugs and neutral one by one 10 Set the generator s main circuit breaker to its OFF or open position Let the engine run at no load for a few min utes to stabilize internal engine generator temperatures 11 Set the generator s Start stop switch to stop position The engine should shut down NOTE It is important that you DO NOT proceed until you are cer tain that generator AC voltage and frequency are correct and within the stated li
31. mbient temperatures below 5 C 23 F However continuous use of low viscosity oils can decrease engine life due to wear Refer to the accompanying chart If an engine is operated in ambient temperatures consistently below 23 C 9 F and there are no provisions to keep the engine warm when it is not in operation use a synthetic CH SI or CH SK or higher API classification engine oil with ade quate low temperature properties such as 5W 20 or 5W 30 The oil Supplier is responsible for meeting the performance service specifications represented with its product Use low silicate antifreeze that meets ASTM4985 GM6038M specification criteria Fully formulated coolant must meet ASTM D 6210 D 6211 Cummins Inc recommends using either a 50 50 mixture of good quality water and fully formu lated antifreeze or fully formulated coolant when filling the cooling system Good quality water is important for cooling system performance Excessive levels of calcium and magnesium contribute to scaling problems and excessive levels of chlorides and sulfates cause cooling system corrosion AR EXP CUMMINS 07 00 OWNERS MANUAL Water Quality Calcium Magnesium Maximum 170 ppm as hardness Chloride 40 ppm as Sulfur 100 ppm as SO Cummins Inc recommends using Fleetguard Compleat It is available in both glycol forms ethylene and propylene Fully formulated antifreeze must be mixed with good quality water at a 50
32. mits Generally if both AC frequency and voltage are high or low the engine governor requires adjustment If frequency is correct but voltage is high or low the generator s voltage regulator requires adjustment 6 2 GENERATOR TESTS UNDER LOAD To test the generator set with electrical loads applied pro ceed as follows 1 Set generator s main circuit breaker to its OFF or open position 2 Set the generator s Start stop switch to OFF 3 Turn OFF the utility power supply to the transfer switch using the means provided such as a utility main line circuit breaker Do not attempt manual transfer switch operation until all power voltage supplies to the transfer switch have been positively turned off Failure to turn off all power voltage supplies will result in extremely hazardous and possibly fatal electrical shock 4 Manually set the transfer switch to the STANDBY posi tion i e load terminals connected to the generator s termi nals The transfer switch operating lever should be down 5 Set the generator s Start stop switch to MANUAL The engine should crank and start immediately 6 Let the engine stabilize and warm up for a few minutes 7 Set the generator s main circuit breaker to its ON or closed position Loads are now powered by the standby OWNERS MANUAL generator 8 Turn ON electrical loads Apply an electrical load equal to the full rated wattage amperage capacity of the installed generator
33. nd the engine to a minimum distance of 12 inches 305 mm must be covered with a non combustible insulation and a mini mum of 24 gage sheet metal between the insulation Insulation Mounting Anchors 4 12 Inch Minimum and the generator See Figure 3 Figure 3 Combustible Floor and Roof e Optional vibration isolators beyond those already built in the generator also help reduce transmitted noise however it is recommended that one verify that the generator manufacturer recommends the use of an isolator e Insulation must be a non combustible material typi cally a Fiberglas mat S L OUTDOOR INSTALLATIONS AIR COOLED UNITS If your generator is expected to be in temperatures lower than 20 F 29 C a cold weather package may be required The following general rules apply Where strong prevailing winds are anticipated face the engine end away from the wind e Planthe installation carefully to prevent the cooling air vents on the generator from becoming clogged by leaves grass snow etc OWNERS MANUAL There are a number of different generator systems and typical loads in the context of electrical systems Most sys tems unless they contain automated switch gear have a means of disconnect between the generator and the load This is typically a transfer switch or discon nect Ensure the contacts on the switch are rated for the size of your system 4 1 GENERAL ELECTRICAL SYSTEM When mounting electrical p
34. nductive and corrosive The following procedures are to be observed 1 Wear full eye protection and protective clothing 2 Where electrolyte contacts the skin wash it off immediately with water 3 Where electrolyte contacts the eyes flush thoroughly and immediately with water and seek medical attention and 4 Spilled electrolyte is to be washed down with an acid neutralizing agent common practice is to use a solution of one pound 500 grams bicarbonate of soda to one gallon 4 liters of water The bicarbonate of soda solution is to be added until the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried Lead acid batteries present a risk of fire because they generate hydrogen gas The following procedures are to be followed 1 DO NOT SMOKE when near batteries 2 DO NOT cause flame or spark in battery area and 3 Discharge static electricity from body before touching batteries by first touching a grounded metal surface AR EXP CUMMINS 07 00 OWNERS MANUAL TEMAS GENERATING SET INSTALLATION The generating set sub base tank or frame if it s the case is Specifically designed for ease of moving the set Improper handling can cause serious damage to the generator and components Never lift the generating set by attaching lugs to the engine or alternator Shackles and chains of suitable length and lifting capacity must be used A spreade
35. ng set when it is Suspended e sure all personnel are out of the generating set canopy or container if equipped before closing and latching enclosure doors e When towing a mobile generating set observe all codes standards or other regulations and traffic laws These in clude those regulations specifying required equipment and maximum and minimum speeds Ensure brakes if fitted are in good order e Do not permit personnel to ride or on the mobile generating set Do not permit personnel to stand or ride on the drawbar or to stand or walk between the generating set and the towing vehicle e Donotinstall or use the generating set in any classification of hazardous environment unless it has been specifically designed for that environment AR EXP CUMMINS 07 00 OWNERS MANUAL Page 7 The generating set is designed with guards for protection from moving parts Care must still be taken to protect personnel and equipment from other mechanical hazards when working around the generating set e Do not attempt to operate the generating set with safety guards removed While the generating set is running do not attempt to reach under or around the guards to do maintenance or for any other reason e Keep hands arms long hair loose clothing and jewellery away from pul leys belts and other moving parts Attention Some moving parts con not be seen clearly when Proper hot the set is running work procedures must b
36. o fire during this cranking attempt then the starter motor is disengaged for a 10 second rest period Should this sequence continue beyond the 3 starting attempts the start sequence will be terminated and Fail to Start fault will be illuminated M AR EXP CUMMINS 07 00 Page 26 When the engine fires the starter motor is disengaged and locked out at 20 Hz measured from the Alternator output After the starter motor has disengaged the Safety On timer is activated allowing Oil Pressure High Engine Tempera ture Under speed and Charge Fail to stabilise without trig gering the fault On removal of the Remote Start signal the Stop delay timer is initiated Once this timer has expired the Fuel Solenoid is de energised bringing the generator to a stop 7 1 3 WARNINGS Warnings are used to warn the operator of an impending fault BATTERY CHARGE FAILURE if the module does not detect a voltage from the warning light terminal on the aux iliary charge alternator the icon will illuminate 1 1 4 SHUTDOWNS Shutdowns are latching and stop the Generator The alarm must be cleared and the fault removed to reset the mod ule In the event of a shutdown the appropriate LED will be illuminated NOTE The alarm condition must be rectified before a reset will take place If the alarm condition remains it will not be possible to reset the unit The exception to this is the Low Oil Pressure alarm and similar delayed alarms as the oil pr
37. o start the set press the e button begin indicated by the 8 LED Preheating will NOTE There is no Start Delay in this mode of operation Starting will commence as soon as the start button is pressed The Fuel Solenoid is energised then the Starter Motor is engaged The engine is cranked for a 10 second period If the engine fails to fire during this cranking attempt then the starter motor is disengaged for a 10 second period Should this sequence continue beyond the 3 starting attempts the start sequence will be terminated and Fail to Start fault will be illuminated When the engine fires the starter motor is disengaged and locked out at 20 Hz measured from the Alternator output After the starter motor has disengaged the Safety On timer is activated which is fixed at 10 seconds allowing Oil Pres sure High Engine Temperature Under speed and Charge Fail to stabilise without triggering the fault Selecting stop O de energises the FUEL SOLENOID bringing the generator to a stop 7 1 2 AUTOMATIC MODE OF OPERATION To initiate a start sequence in AUTO turn the key to the posi The start sequence is initiated when the remote start input is activated After a fixed 5 second start delay Preheating will occur fixed at 10s indicated by the 55 LED The Fuel Solenoid is energised then one second later the Starter Motor is engaged The engine is cranked for a 10 second period If the engine fails t
38. of the generating set and or inter connecting cables or conductors with any part of the body or with any non insulated conductive object e Place the control panel cover as soon as connection or disconnection of the load cables is complete Do not operate the generating set without the cover securely on place e Connect the generating set only to loads and or electrical systems that are com patible with it s electrical characteristics and that are within it s rated capacity e Besure all power is disconnected from the electrical equipment being serviced e Keep all electrical equipment clean and dry Replace any wiring where the insulation is cracked cut abraded or oth erwise degraded Replace terminals that are worm discolored or corrode Keep terminals clean and tight e Insulate all connections and disconnected wires e Use only class BC or Class ABC extinguishers on electrical fires AR EXP CUMMINS 07 00 OWNERS MANUAL Page 9 Identification look out for e Unconsciousness and Burns e Establish site of entry and exit of electric shock What to do e Switch off the main switch e Break the contact between electrical source and patient using dry non conductive object like wooden stick e Callfor help e If breathing and heartbeat has stopped begin CPR 1 CALL Check the victim for unresponsiveness If there is no response Call 911 and return to the victim In most locations the emergency dispatcher can assist
39. olyte is spilled on skin or clotting flush immediately with large quantities of water Always keep good ventilation when the equipment is working Carbon Monoxide inhalation cause death Always maintain inspection routine of the exhaust system OWNERS MANUAL Page 8 Generating sets that are not equipped with sound attenuating enclosures can produce noise levels in excess of 105 dBA Prolonged exposure to noise levels above 85 dBA is hazardous to hearing Ear protection must be worn when operating this equipment e Ear protection must be worn when operating or working around an operating set Safe and efficient operation of electrical equipment can be achieved only if the equip ment is correctly installed operated and maintained Never remove e The generating set must be connected to the load only by trained and quali panel while fied electricians who are authorized to do so and in compliance with rele switchgear is vant electric codes standards and other regulations energized e Ensure the generating set is effectively grounded earthed in accordance with all relevant regulations prior operation e he generating sets should be shutdown with the battery negative termi nal disconnected prior to attempting to connect or disconnect load connec tions e Do attempt to connect or disconnect load connections while standing water or on wet or soggy ground e Donottouch electrical energized parts
40. oolant friction Psi kpa 5 35 4 28 Total drain flow gal h L h 8 30 Diesel 2 144 1 33 2 88 2 65 Fuel Type Fuel Fuel Consumption 25 Power h System Fuel Consumption 50 Power Fuel Consumption 75 Power gal h gal hr L L gal h h gt xe gt 4 31 3 58 3 98 5 75 TT Fuel Consumption 100 Power gal hr L Combustion Air Flow ft min L s 247 117 261 123 169 80 181 85 Air Intake Restriction clean filter In H20 kPa 10 2 49 Air Require ment Air Intake Restriction dirty filter In H20 kPa F C 889 476 919 501 1045 563 1053 567 In H20 kPa 3 10 13 Maximum oil temperature F C 250 121 Oil Pan Capacity gal L 2 5 9 5 Total Engine Oil Cap w filter gal L 2 88 10 9 Oil Filter Type Lube oil specifications grade No Oi o nis Exhaust Temperature Maximun Allowable Back Pressure Lubrication System Cartridge SAE 15W 40 Volts Ground 12V negative Rated amps Battery Charging Alternator Baterry Charging Alternator Recommended Battery Cold Crank Starter Motor Temperature and Altidtude Losses Engine Elec tricals CCA amps 650 Volts Ground 12V negative al 5 4 per 1000 ft 300 m and 1 per 10 F 2 per 11 AR EXP CUMMINS 07 00 OWNERS MANUAL ACUM110 INSTALLATION AND APPLICATION Type of Operation and Applic
41. ower System Fuel Consumption 50 Power Fuel Consumption 75 Power gal h gal hr L h L L hr gal h gt xe 00 Fuel Consumption 100 Power gal hr L h Combustion Air Flow ftz min L s 610 289 666 314 425 200 465 220 Air Intake Restriction clean filter In H20 kPa 10 2 49 Air Require ment Air Intake Restriction dirty filter In H20 kPa 25 6 22 F C 886 474 920 493 1037 553 1059 571 In H20 kPa 3 10 13 Maximum oil temperature F C 250 121 Oil Pan Capacity gal L 5 0 18 9 Total Engine Oil Cap w filter gal L 6 3 23 8 Oil Filter Type Lube oil specifications grade Exhaust Temperature Maximun Allowable Back Pressure Lubrication System Cartridge SAE 15W 40 Volts Ground 12V negative Rated amps Battery Charging Alternator Baterry Charging Alternator Recommended Battery Cold Crank Starter Motor Engine Elec tricals CCA amps 1200 0 F 18 C e 5 JJ D o di Volts Ground 12V negative or 4 per 1000 ft 300 m and 3 3 per 10 6 per 10 C 5 Operation Temperature and Altidtude Losses For 1500 RPM 4 per 1000 ft 800 m and 8 3 per 10 F 15 per 10 C AR EXP CUMMINS 07 00 OWNERS MANUAL 7 1 DESCRIPTION OF OPERATION 7 1 1 MANUAL MODE OPERATION To initiate a start sequence in MANUAL turn the key to the position T
42. r bar is required to prevent damaging the set See the drawings The location for a generator is dependent on applicable codes and associated support systems for the generator such as ventilation wiring fuel and exhaust The following factors should be considered e The ideal location for any generator is away from ex treme ambient temperatures and where the generator is protected from adverse weather conditions It is recommended that generator be as close to the load it is Supporting as possible e The structure where the Generator Set will be set upon must be strong enough to support the weight of the Gen Set its auxiliary equipment and other equipment mounted on the structure e The structure must meet 1 hour non combustion fire rating e The installation site must be clean dry and not subject to flooding e Because of excessive ambient temperatures associ ated with the use of stand alone metal sheds from exposure to sunlight a concrete pad with a supported AR EXP CUMMINS 07 00 Page 12 roof and an outside security enclosure fence to pro tect the unit from vandalism birds rodents and other small animals is recommended e The Gen Set generates heat while running Installing the Gen Set in a tightly enclosed building or shed is not recommended The site must provide for adequate cooling and ventilation with a minimum of duct work Adequate ventilation for a generator is specified in cubic feet per
43. r midrange engines Acceptable oil classification CES 2007 CES 20076 4 5 API CH 4 Global DHD E for midrange engines Similar in performance to CES 20071 but validated un CES 20072 CES 20077 ACEA E 5 Global DHD der European test standards Excellent oil for midrange engines CES 20078 API Cl 4 SK Cl 4 Excellent oil for midrange engines NOTE In areas where CH 4 SJ or CG 4 SH oils are not available refer to Oil Drain Intervals in Section 2 A sulfated ash limit of 1 0 mass percent is suggested for optimum valve and piston deposit and oil consumption control As the engine oil becomes contaminated essential oil additives are depleted Lubricating oils protect the engine as long as these additives are functioning properly Progressive contamination of the oil between oil and filter change intervals is normal The amount of contamination will vary depending on the operation of the engine kilometers or miles on the oil fuel consumed and new oil added Extending oil and filter change intervals beyond the recommendations will decrease engine life due to factors such as corrosion deposits and wear Special break in engine lubricating oils are not recommended for new or rebuilt Cummins engines Use the same type of oil during the break in as is used in normal operation The use of low viscosity oils such as 10W 10W 30 can be used to aid in starting the engine and in providing sufficient oil flow at a
44. rials may ignite such as dry grass leaves or other combustible materials OWNERS MANUAL Page 15 Battery is connected properly Recommended battery is installed Cables are clean and tight Terminals are coated with anti corrosion grease and terminal covers are positioned FUEL SYSTEM Complies with local and NFPA codes Fuel is connected and checked for leaks Correct fuel pressure 11 14 inches of water 0 6 psi at all load ranges Load block adjusted for maximum power for natural gas fuel LOCATION Unit is fastened to the appropriate mounting pad Louvers are free from obstruction Exhaust is clear of flammable objects and debris ELECTRICAL CONNECTIONS Complies with local code requirements and all National Electrical Codes Utility is connected and present Transfer switch is connected All wires running outside of the generator are in NEC approved conduit Note Utility wires and transfer switch control wires must be in separate conduit Unit is grounded to an approved earth ground COOLING AND VENTILATING All inlets and outlets are free from obstruction OTHER Verify that the unit is filled to the proper level with the proper break in oil Adjust as required AR EXP CUMMINS 07 00 OWNERS MANUAL ____ RAE SA BLACK AWG 14 Es BLACK AWG 14 T 2 a RED AWG 14 RED AWG 14 4 1 gt Arm YELLOW AWG 16 3 YELLOW AWG 16 Ei ET 4 FUEL RED AWG 16 16 k 5 5
45. s and permit requirements Errors during the installation may damage the equipment and electrical devices connected to the unit and may create fire and electrocution risks 5 1 GENERAL EXHAUST SYSTEM Generator engines give off deadly carbon monoxide gas through their exhaust systems Carbon monoxide gas if breathed in sufficient concentra tions can cause unconsciousness or death Exhaust gases must be piped safely away from any room or enclosure that houses a generator and to a well ventilated area where people will not be endangered Besides the possibility of carbon monoxide poisoning ex AR EXP CUMMINS 07 00 Page 14 haust piping becomes extremely hot during operation and remains hot for a long time after shutdown For that reason the following precautions are necessary Avoid contact with hot engines exhaust manifolds exhaust piping and mufflers Any of these can cause severe burns e Where piping must pass through combustible walls or ceilings special precautions must be taken to prevent fire or heat damage such as using heat thimbles through walls and ceilings 5 2 GENERAL RULES FOR EXHAUST SYSTEM When installing an exhaust system for a generator the fol lowing rules should be considered Exhaust piping should be of wrought iron or steel hav ing adequate strength and durability e Exhaust fittings may be of cast iron inch spacing 10 inches 250mm recommended from the exhaust p
46. ser should comply with the instructions and information in this manual and is strongly ad vised that all personnel to be associated with the equipment supplied should be made familiar with the information contained herein It is essential that the personnel engaged in the installation commissioning and maintenance of this equipment are both competent and experienced in these fields and that they comply with the relevant statutory requirements and regulations including he provisions of the Health and Safety act 1974 and any such modifications and amendments which may subsequently become a legal requirement The equipment supplied by Armstrong Power should be installed by or under the supervision of competent person nel in accordance with good engineering practice established codes of practice those statutory requirements appli cable to the installation site the IEE regulations as applicable and where the appropriate in accordance with any instructions specifically advised by the company You are requested in accordance with the needs of safe operation and the provisions of the act to take such steps as are necessary to ensure that the appropriate information on the proper use and handling of our equipment is made available by yourself to all those concerned Similarly this information must be available to anyone who may purchase or otherwise acquire from your self such products for use in their own premises The generating set is d
47. t in order to reduce the excitation when the speed is 10 below the rated value at 50 Hz By re moving the bridge which is normally shorting the auxiliary terminals 60 Hz of the regulator the low speed protection acts properly for 60 Hz P3 STAB Potentiometer for stability adjust By rotating it clockwise the stability of the regulator increases but the response time becomes longer PA AMP Potentiometer for chancing the overexcitation limit device The overexcitation limit device helps to protect the excitation system This device is delayed to avoid transitory conditions in case of overexcitation On the AVR there is a protecting fuse In case it should be necessary to replace it high speed fuses should be used in addition they should have high breaking resistance with a rated voltage of 5OOV and rated current of 10A The AVR is connected to the terminals of the generator and to exciter using FAST ON terminals ARMSTRONG POWER SYSTEMS OWNERS MANUAL
48. t the system go through its entire auto matic sequence of operation With the generator running and loads powered by generator AC output turn ON the utility power supply to the transfer switch The following should occur AR EXP CUMMINS 07 00 Page 19 e After about six seconds the switch should transfer loads back to the utility power source e About one minute after retransfer the engine should shut down Check the installation and application data charts for any additional information OWNERS MANUAL ACUM65 INSTALLATION AND APPLICATION tee ______ 5ohz O Prime Standby Standby em au O Bid Fore pe e ube ol speciicaions grade SAE19N 40 Temperature and Altidtude Losses 4 per 1000 ft 300 m and 1 per 10 F 2 per 11 C AR EXP CUMMINS 07 00 OWNERS MANUAL INSTALLATION AND APPLICATION Type of Operation and Application ______ 50H ____ Prime Standby Standby Rated Speed 1500 1800 Gross Engine Output bhp kWm 130 97 145 108 117 87 130 97 BMEP psi kPa 239 1648 266 1838 215 1483 239 1648 Mean Piston Speed Ft s m s 23 6 7 2 19 66 6 0 Ambient Air Temperature F C 122 50 BTU min kW 2633 46 3 2973 52 2 2141 37 6 2423 42 6 Engine Heat Reject to Coolant tem Standard Thermostat Range F C Maximum Pressure Cap Psi kpa 10 69 Maximum c
49. ute fg cat Pe International Classifications All Engine Ratings Classification Classification cm em ULL Don A CEEI CR API CI 4 SK API 4 API 20076 CES 20072 CES API CH 4ls CES 20075 API CF 4 SG CUN ES ACEA EL 250 Hours or 3 Weeks API CG 4 SH API CD API 8 3 CUMMINS FLEETGUARDO FILTER SPECIFICATIONS ACEA E 5 Global DHD 250 Hours or 3 Months ACEA E 5 Global DHD 500 Hours or 6 Months Fleetguard amp is a subsidiary of Cummins Inc Fleetguard filters are developed through joint testing at Cummins and Fleetguard Fleetguard filters are standard on new Cummins engines Cummins Inc recommends their use Fleetguard amp products meet all Cummins Source Approval Test standards to provide the quality filtration necessary to achieve the engine s design life If other brands are substituted the purchaser should insist on products that the supplier has tested to meet Cummins high quality standards Cummins can not be responsible for problems caused by non genuine filters that do not meet Cummins performance or durability requirements Filter Part Numbers Lubricating Oil Lubricating Oil Lubricating Oil Filter B3 9 Filter B4 5 Filter B5 9 Fuel Filter B3 9 Fuel Filter B4 5 Fuel Filter B5 9 Cummins Part 3634499 3934429 3934430 3966139 3991350 3900632 Number Fleetguard Pare Number _ LFI 00 LF9100 LF9098 FF9413 FS19608 FF9417 AR EXP CUMMINS 07 00 OWNERS MANUAL Page
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