genset inst manual feb 08[1]

7/26/2019 Genset Inst Manual Feb 08[1]

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G enset Installation

R ecom m endations

Our energy wor king for you.TM


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1

Installation Recomm endations

About this m anual

Whatever the use of the on-site power is intended to be,

reliability of service from the on-site equipment,

performance, a nd c ost effectiveness a re prima ry

concerns of the users.

Any event or project needs a right start, which leads to

the w inning pos ition. G enerating s et/s insta lla tion a nd

commissioning recommenda tions mea ns exa ctly the

sa me The Right S ta rt. This is bo und to lead to a chieve

expec ted relia bility, durab ility, ec onomy, se rvice a bility,

eq uipment uptime, better aes thetics , sa fety and b etter

w orking c onditions .

The purpose o f this m a nual is to provide g uida nce to

system and facility designer for the right start. However,

this manual details typical installations and it is not

poss ible or pra ctical to co ver specific deta ils to ma ny

variables in an application. In such cases, the user isreq uested to conta ct C ummins or GOEMs (G enera ting s et

Original Equipment Manufacturers) at address given on

the ba ck cover.

Always keep in mind that the installations should comply

with Sta te /C entral Go vernment and other applica ble

statutory requirements.

This ma nual provides insta lla tion a nd c ommiss ioning

ge neral guidelines /recomm enda tions for Cummins Diesel

Generating Set housed in an Acoustic Enclosure. In thisma nual different types of insta lla tions (roof-top,

ba sement, room housed etc.) have b een co nsidered w hile

preparing the guidelines /recommendations. However,

any new, uncommon or critical installation needs to be

consulted with Cummins network.

The information is s upported b y d ifferent photo gra phs,

diag rams a nd reference information tab les . The iformation

has been c ompiled to gether for ad eq uate information but

still keeping in mind to ma ke this ma nual crisp, ha ndy a nd

use rs friend ly.

We a re sure, this ma nual w ill be us eful to the insta ller a nd

in-turn to equipment user to achieve desired performance

of the g enerating s et/s.

In order to ha ve insta nt a vaila bility of b a sic informa tion

which is needed during installation, operation and

maintenance of the generating set, the information is

compiled in a list form and should be available to the

opera tor /us er nea r the insta lla tion, preferab ly visible a llthe time.

Follow ing informa tion s hould be a vaila ble :

1. P rojec t Deta ils

2. Re ference Literature

A. Project Details:

User - Na me, Add ress , Co ntac t P erson,

Phone /Mobile Nos., Email

Consultant - Name, Address, Contac t Person,

Phone /Mobile Nos., Email Supplier - Na me, Add ress , Co ntac t P erson,


Se rvice P rovider - Name , Address , C ontac t P erson,


Equipment ma jor deta ils:

Engine number and make

AC G enerato r number a nd ma ke

Equipment number and make

Major s pec ifica tions

Major loads kVA/kW ratings, starting

type and normal loading sequence

Language for instructions

B. Reference L i terature / Informat ion:

S ite d ra wing

Installation and commissioning recommendations

plus Insta lla tion d raw ing

Operation and Maintenance ma nual

Logbook

Relevant approvals a nd certifica tes from the

concerned authorities like CPCB, SEB, Municipal

Corporation, Fuel Authority etc.

Benef ic ial purpose Basic reference informat ion

About this manual


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2


Prelim inary design

Loading and Unloading

A.P rovis ion for lifting isprovided on the a cous tic

enclosure. Unloaddamage free by lifting

w ith prope r lifting ta c kle

/nylon sling / ste el

rope of s uitab le c apa city.

B.Spreader bar /spac erpla te of s uitab le s ize ma y be required to a void

damages .

C.Ensure lifting o r hoisting eq uipment ha s a ppropria tetires for the terrain to a void b ec oming s tuck or tipping

over.

D.Use a suitable lift truck with arms longer than theacoustic width if ground is uneven or the hauling

distance to o far.

E.Ensure that lateral movement of the enclosure isminimum during transportation.

F. Us e lift points on thea coustic enclosure

which provide support to

the equipment when it is

moved . This ma kes it

ea sier to s et them up

on a trailer base or on the

ground.

G.Use a hoist a nd ana djusta ble lifting b ea m in

ord er to lift. All

supporting members

(chains and cables)

should b e pa ra llel to ea chother and a s perpendicula r as poss ible to the top of

the ob jec t be ing lifted.

H.Ship /transport dry genset including batteries i.e.without the lube oil and jacket water coolant.

I. Center of gravity calculation is important, especiallywhen the gensets are hoisted by overhead cranes.

Foundation

A. Do not insta ll acous tic enclosure on loose sa nd orclay.

B.Base /foundation should be designed consideringsa fe bea ring c apa city of soil.

C.The length a nd b readth of b a se /foundation shouldbe a t leas t 150-300 mm (6-12) more tha n a co ustic

enclosure length and breadth respectively.

D.Ensure that the conc rete is co mpletely s et a ndhardened before positioning the enclosure.

E. It is reco mmended to have b a se /foundation heighta bo ut 100-150 mm a bo ve ground level, it helps to

maintain cleanliness.

F. Chec k the ba se /foundation level diagona lly a s well a sa cross the length for even fla tness and sa me should beshould b e w ithin 0.5 degrees of a ny horizontal plane.

G.The insta lla tion de sign must provide a proper ba se /founda tion to support the a coustic w eight a nd to

prevent damaging or annoying levels of vibration

energy from migrating into the building structure. In

addition, the installation should assure that the

supporting infrastructure for the generator set does not

a llow vibra tion from the enc los ure to migra te into the

stationary portion of the equipment.

H.Whenever seismic events a re a cons ideration, aqualified structural engineer should be consulted.

Preliminary design


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Prelim inary design

Site location

A.Determine whether the location of the acousticenclos ure w ill be inside a building or outs ide in a

shelter or housing. The overall co st a nd ea se ofinsta llation of the pow er system depend upon the

layout and physical location of all elements of the

system generator set, fuel tanks, ventilation ducts

and louvers, accessories, etc.

B.Road and a cces s to site needs to be checked beforetrans port. Roa d c losure or tra nsport esco rt also needs

to be cons idered be fore physical movement.

C.Crane reac h or crane height needs to be c hecked oralternatively rolling needs or fork lift arrangements are

to be made.

D.Fuel supply tank design and installation in many areasis controlled by regulations that are generally written for

two sepa ra te purposes : environmental protection andfire protection. Reg ula tions , their enforcement a nd

exemptions va ry by loca tion, it is neces sa ry to resea rch

a nd understand loca l req uirements.

E.Acoustic enclosure should be located considering winddirection ensuring that there is no obstruction to natural

wind flow and the prevailing wind do not enter into the

radiator /exhaust outlet. If this is not possible, install a

w ind b a rrier. Dista nce of the w ind b a rrier from the

enclosure should be atleast 2.5 - 3 times radiator side

opening height.

F. Enclosure should be loca ted a wa y from pollutedatmo sphere like a cidic fumes, cement d ust, s tone dust

cotton fibres, furnac e c hemica ls etc. wherever

poss ible. In ca se loca tion is dusty or polluted, co ntac t

OEM/Cummins. Heavy duty air cleaner is must forsuch insta lla tions. Hea t excha nger cooled s ystem is

recommend ed for such insta llations a s ra diator gets

clogged in dusty atmos phere.

G.For humid /co as tal a tmospheric applica tions, a nticonde nsa tion heaters are ma nda tory for alternator.

H.Co nsider iss ues of s ec urity from flood ing, fire, icing,and vandalism.

I. P roper ac ces s is important for- Initial product delivery and installation.

- Service i.e. for general maintenance and inspections.

- Working space for major work such as overhauls or

co mponent remova l/repla ce ment.

J . Roo ftop insta lla tions require further pla nning a ndstructural des ign co nsideration. Vibra tion a nd fuel

storag e / delivery ma y b e problematic with rooftop

installations.

K. For a esthetic rea sons , co nsider exhaust pla cement inrelation to the b uilding. Over a period of time, exha ust

gas carbon deposits will tend to accumulate on any

nearby wall or structure.

Preliminary design

Wind b a rrier


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Prelim inary design

Enclosure placement / Enclosure room

A. Ensure sufficient lighting /illumination at theinsta lla tion spa ce.

B. P rovide s uitable , sa fe ac cess /sta ging to elevateditems.

C. P rovide a uxilia ry AC supply tog ether w ith thea ss ociated AC distribution pa nel a nd ma y be with

moto r co ntrol unit (MCC ) w here a pplica ble.

D. S tand ard too l kit should b e a vaila ble eas ily a ndq uickly. It should be protecte d from co rros ion and

stored in a d ry plac e.

E. If spares are supplied alongwith the equipment, theyshould be protected from corrosion and stored in a

dry pla ce.

F. In case of multiple enclosures provide minimum 2meters or sufficient clea rance to open a dja cent d oors

simultaneously of two enclosures.G. While ma king the layo ut, provision s hould be ma de

for :

I. CablesII. Fuel linesIII. Brea ther ventIV. C oolant / lube o il dra inV. Oil storageVI. Spa res storage

H. Norma lly, a ll entry /e xit provisions of a bo ve a reco nsidered in enclos ure de sign. Try to a void a dd itions .

If it is req uired to have a dd itiona l entry / exit

provisions, ensure for proper sea ling o f noise ,

tempera ture a nd entry/exit o f foreign pa rticles.

I. Acces s a nd clearancei. Enough opening /shutters should be provided

so that entry and plac ement of the enclosure is

easily possible.

ii. G enerato r sets will req uire a cc ess for service toboth s ides of the engine as well a s the c ontrol/

alternator end of the machine. Local electrical

cod es ma y require s pecific wo rking s pac e for

electrical equipment. Allow for working space equal

to the w idth of the gens et on bo th sides and rear.

Also ensure sufficient overhead clearances are

provided.

J . P lea se refer table for typica l acous tic enclos ure s izes.K. Future expansion plans should be considered while

dec iding tota l area .

L. The genera tor room / a rea a round enclosure shouldnot be used for storage purposes.

M.Avoid insta lling the enclos ure b es ide hea t g eneratingeq uipment, or directly b elow wa ter or stea m pipes or

in the vicinity of corrosive substances or vapours,

meta l pa rticles a nd dust.

Preliminary design

Typical acoustic enc losure dim ensions*

Genset Model Prime Rating Engine Model Enclosure Dimensions

(kVA) Length (mm) Width (mm) Height (mm)C 15 D5 P 15 X 1.7 G 1 2200 900 1375

C 20 D5 P 20 X 2.5 G 1 2200 900 1375

C 25 D5 P 25 X 2.5 G 2 2200 900 1375

C 30 D5 P 30 S 3.8 G 2 2800 1150 1450

C 35 D5 P 35 S 3.8 G 3 2800 1150 1450

C 40 D5 P 40 S 3.8 G 4 2800 1150 1575

C 50 D5 P 50 S 3.8 G 6 2800 1150 1575

C 62.5 D5 P 62.5 S 3.8 G 7 2950 1150 1575

C 75 D5 P 75 6B T5.9 G 1 3850 1150 1700

C 82.5 D5 P 82.5 6B T5.9 G 1 3850 1150 1700C 100 D5 P 100 6B TA 5.9 G 1-I 4000 1150 1700

C 125 D5 P 125 6B TA 5.9 G 2-I 4000 1150 1700

C 140 D5 P 140 6B TAA 5.9 G 1-I 4000 1150 1700

C 160 D5 P 160 6CTA 8.3 G 1-I 4500 1500 1850

C 180 D5 P 180 6CTA 8.3 G 2-I 4500 1500 1850

C 200 D5 P 200 6CTAA 8.3 G 1-I 4500 1500 1850

C 250 D5 P 250 6CTAA 8.3 G 4 4850 1700 2050

C 320 D5 P 320 NTA 855G 2-I 5500 2000 2450

C 380 D5 P 380 NTA 14 G 3 5500 2000 2450

C 500 D5 P 500 KTA 19 G 9 6500 2000 2300

C 600 D5 P 600 VTA28 G 3-I 7000 2500 2925

C 625 D5 P 625 VTA28 G 5-I 7000 2500 2925

C 750 D5 P 750 KTA 38 G 2-I 7500 2500 2925

C 800 D5 P 800 KTA 38 G 3-I 7500 2500 2925

* Dimensions of the enclosure are excluding the silencer.


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Prelim inary design

Normal precautions and safeties

A. Safety involves three aspects: human safety, safeoperation of the generator set itself (and its

ac ces sories) and reliab le ope ra tion of the s ystem.Relia ble operation of the s ystem is related to s afety

bec aus e eq uipment a ffecting life a nd hea lth is often

dependent on the generator set e.g. hospital life

suppo rt sys tems , building ventila tors, e leva tors, fire

pumps, s ecurity etc.

B. Ensure that equipment is correctly and safely installed,fully complies with all central, state and local codes

and a ny person opera ting this eq uipment has been

properly trained.

C. The fire protection s yst em mus t c omply w ith therequirements of the a uthority.

D. Hot exhaust gasses must never be directed toward

anything tha t ma y c atc h fire or explode.E. Never operate the generator unless all gua rds, c overs,

shields and other safety items are properly installed.

F. Never operate the engine when the air cleaner isremoved. An engine backfire can cause serious burns.

G. Never jump sta rt a generator to s tart the engine.If the battery charge is insufficient to start the engine,

cha rge or repla ce the ba ttery a nd try to restart. J ump

starting a battery can cause the battery to explode.

H. Unauthorized modifica tion of a generator set maymake the unit unsafe for operation or may impair the

operation of the unit. Never start a generator set that

has been mod ified or tampered w ith. Be sure that a ll

covers a nd gua rds are properly insta lled a nd that the

unit is safe before starting the engine.

I. Keep generato r a wa y from fla mmab le or ha za rdousmaterials (trash, rags, lubricants, explosives, paints

etc.) and grass or leaf build up.

J . Opera tor should use s a fety gla ss es w ith side s hieldsand hearing protection.

K. Disc onnect a ll connections to the c ontrol system onengine /g enset b efore d oing a ny we lding wo rk.

L. Do not tampe r control system in ca se o f any problem.There are no user s ervice a ble pa rts inside the va rious

controls supplied along with Cummins engine /genset.

Call the nearest Cummins office /dealer for help.M.Disc onnect the ba tterys ground terminal beforew orking in the vicinity of the ba ttery or ba ttery w ires

during installation and maintenance.

N. Be sure a ll wiring / ca bling c omplies w ith the a llregional and local codes /regulations /standards.

O. Be sure the system is properly grounded beforea pplying po w er.

P. P hysica lly s epara te the generator feeders from thenormal wiring feed ers to p revent poss ible

simultaneous des truction a s a result of a loca lized

ca tas trophe such a s a fire, flood ing, or shea r force.

Bypa ss isolation transfer switch eq uipment so tha ttra nsfer switches c a n be ma intained o r repa ired

w ithout d isruption o f critica l loa d eq uipment.

Q. Large s tiff ca bles ma y not provide sufficient a bilityto bend even though they are considered flexible.

This is a lso true o f so me c onduit types . Fa ilure to

allow sufficient flexibility will result in damage to

enclosures, lea ds , c a bles, insula tion, or c onnection

points.

R. Seismic Areas: In seismic risk areas, special electricalinsta lla tion prac tice s a re req uired, including s eismic

mounting of eq uipment contac t c oncerned

co nsultant/s.

Preliminary design


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Prelim inary design

Ventilat ion

A. Cross ventila tion a nd free flow of co ol, c lea n a ndfresh air should flow from alternator end to engine.

B. Add itiona l ventila tion a rra ngem ent ma y be required forradiator cooled engines installed in acoustic enclosure

beca use a coustic enclosure traps rad iated heat,

dec rea sing cooling ca pab ilities. Hence thes e sets may

need bigger ventilation fans. Rad ia tor cooled engines

may create slight nega tive pressure inside the gens et

room /enclosure. Maximum static restriction should

not increase 6-mm of water column.

C. For basement installations, supply of fresh air andforced ventila tion through a ir ducts is req uired to

remove hea t.

D. Refer to table for values of air required and fan flowsfor various gens ets ra ted a t 1500 rpm.

Va lues mentioned in ta ble are with la gg ed exha ustpiping in the room a nd s ilence r fitted outside the

room.

E. Maximum allowed temperature rise above ambient ingens et enclosure is :

Max. ambient allowable temp. rise upto 40 oC is 10 oC

and a bove 40 oC is 5 oC

F. Adeq uate c a pac ity natural ventila tors ca n be usedfor ac oustic enclos ure room.

Natura l Ventilato rs

Preliminary design

G. Field Check for Proper Ventilation1. Run the engine on full load /typical load for about 1

hour so that temperature in the enclosure gets

stabilized.

2. Measure the ambient air temperature (ambienttempera ture s hould b e mea sured outside the

enclosure in sha de ).

3. Measure the temperature inside the enclosure.Enclosure temperature should be measured near air

clea ner inlet of e ngine.

4. Ca lcula te temperature difference betw een e nclos uretempera ture a nd a mbient i.e. d elta T.

Sometimes to ensure proper ventilation, it may be

necessary to measure actual airflow by

anemometer.

Engine Model Rating Total Air Radiator(0.8 pf) (Ventilation + Breathing) Fan flow

requirement for Genset in

Max. amb. Max. amb. Genset

above below room

400C 400C

(rise 5 0C) (rise 100C)

kVA lt./sec lt./sec lt./sec

QS K60 - G 4 2000 41915 22090 32285

QS K60 - G 3 1875 38525 20310 32285

KTA50 - G 8 - I 1500 34955 18275 28400

KTA50 - G 3 1250 31475 16420 27375

KTA38 - G 5 1000 26980 14050 23855

KT38 - G 2 - I (2300) 750 21795 11395 22655

VTA28 - G 5 625 17770 9270 22655

VTA28 - G 3 600 17405 9060 18880

KTA19 - G 4 500 14410 7480 20280

KTA19 - G 3 450 13110 6800 13000

KTA1150 - G 380 12070 6255 10385

NTA14 - G 3 380 11110 5750 10385

NTA855 - G 2 B C 320 9385 4855 10070

NT855 - G 6 B C 285 8975 4650 10070

NT855 - G 5 B C 250 8285 4300 10070

NT855 - G 4 B C 225 7305 3795 10070

6C TAA8.3 - G 1 - I 200 6245 3225 7385

6C TA8.3 - G 2 - I 180 6035 3115 5540

6C TA8.3 - G 1 - I 160 5565 2880 5540

6C T8.3 - G 2 - I 140 4955 2555 5540

6B TA5.9 - G 2 - I 125 4920 2525 4000

6B T5.9 - G 2 - I 82.5 3420 1760 2880

S 3.8 - G 7 62.5 2450 1260 1880

S 3.8 - G 6 50 2090 1075 1880

S 3.8 - G 5 45 2090 1075 1880

S 3.8 - G 4 40 1715 890 1880

S 3.8 - G 3 35 1420 730 1880

S 3.8 - G 2 30 1240 640 1880

X2.5 - G 2 25 1060 542 1250

X2.5 - G 1 20 930 475 1250

X1.7 - G 1 15 670 345 1050


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M echanical design

Air System

A.Va cuum indica tor is supplied w ith a ll engines toindicate choked filter. Max air intake restriction with

clean and choked filter is as follows :

B. Heavy duty air cleaners shouldbe used for dusty environment.

Contact OEM /Cummins if

enclosure is to be kept in dusty

environment. P lea se note tha t

gens ets are s upplied withmedium duty a ir clea ners as

standard scope.

C. If fibrous conditions exist, care should be taken toprevent the fibers ge tting e ntered into the enclosure /

air cleaner and no such fibre element shall enter/block

the a ir flow of a lternato r.

Mechanical design

Exhaust System

A.Exha ust s ystem should c rea te minimum total ba ckpressure.

B.Limits for exhaust back pressure

Mod el mm (In.) of Hg

KTA50G 8/QS K60/S S eries /G a s Eng ines 51 (2)

KTA50G 3/KT2300G /VTA28/K19/NT/N14/B /C /X 76 (3)

New insta llations s hould have ba ck pressure low er by

12 mm (0.5) of Hg tha n limit me ntioned a bo ve.

C.Exha ust piping o utside the enclosure s hould be la gg eda long w ith a luminum shee t c la dd ing. Typica l thicknes s

of lagging is 50 mm.

D.If exhaust pipe length is more than 7 m, then additional

flexible b ellow /provision for expa nsion s hould beprovided.

E.It is recommende d to use S chedule B MS /prefab rica ted sta inless steel pipes a nd long bend

elbow s. P lea se refer Ta ble for pipe s izes . If number of

bends are more than 4 or pipe length is more than 10

meters than contact OEM /Cummins for piping

arrangement.

(See table in next co lumn)

F. The exha ust outlet s hould be in the direc tion o fprevailing w inds .

G.There should be rain tra p to a void rain wa ter entry.If ra in ca p is used the d ista nce b etwee n exhaust pipe

and rain cap should be higher than diameter of pipe. It

is also recommended that horizontal run of exhaust

piping s hould s lope do wnw a rds aw a y from engine to

the co ndensa te trap. S ilencer should be insta lled with

drain plug a t bo ttom.

Location : Optimum Silencer (when fitted outsideenclosure) Location of the silencer in exhaust system hasvery definite influence on b oth s ilencing a nd b a ck

press ure impose d o n the s yst em. The preferred s ilence r

loc a tions a re given in the Ta ble w here L is length o f the

tota l exhaust s ystem mea sured from exhaus t ma nifold in

meters.

Please note that locating t he silencer as per opt imum silencer location is

not mandatory. For high rise buildings suitable arrangements m ay have

to b e provided in consultation w ith acoustic engineer.

(See table in next page

Engine Model Rating Exhaust pipe Exhaust

(0.8 pf) size max. 4 Gas flow

Bends (No. of banks

Max. Lenght x

10 mtrs. flow per bank)

Min. ID

kVA No. x mm No. x lt. /sec

QS K60 - G 4 2000 2 x 325 2 x 2805

QS K60 - G 3 1875 2 x 325 2 x 2700

KTA50 - G 8 - I 1500 2 x 250 2 x 2220

KTA50 - G 3 1250 2 x 250 2 x 1910

KTA38 - G 5 1000 2 x 250 2 x 1460

KT38 - G 2 - I (2300) 750 2 x 200 2 x 1245

VTA28 - G 5 625 2 x 125 2 x 945

VTA28 - G 3 600 2 x 125 2 x 930

KTA19 - G 4 500 1 x 200 1 x 1600

KTA19 - G 3 450 1 x 200 1 x1460

KTA1150 - G 380 1 x 125 1 x 1095

NTA14 - G 3 380 1 x 125 1 x 1055

NTA855 - G 2 B C 320 1 x 125 1 x 990NT855 - G 6 B C 285 1 x 125 1 x 1160

NT855 - G 5 B C 250 1 x 125 1 x 960

NT855 - G 4 B C 225 1 x 125 1 x 860

6C TAA8.3 - G 1 - I 200 1 x 100 1 x 610

6C TA8.3 - G 2 - I 180 1 x 100 1 x 550

6C TA8.3 - G 1 - I 160 1 x 100 1 x 540

6C T8.3 - G 2 - I 140 1 x 100 1 x 470

6B TA5.9 - G 2 - I 125 1 x 100 1 x 225

6B T5.9 - G 2 - I 82.5 1 x 100 1 x 225

S 3.8 - G 7 62.5 1 x 75 1 x 190

S 3.8 - G 6 50 1 x 75 1 x 150

S 3.8 - G 5 45 1 x 75 1 x 150

S 3.8 - G 4 40 1 x 75 1 x 150

S 3.8 - G 3 35 1 x 75 1 x 115

S 3.8 - G 2 30 1 x 75 1 x 115

X2.5 - G 2 25 1 x 50 1 x 75X2.5 - G 1 20 1 x 50 1 x 75

X1.7 - G 1 15 1 x 50 1 x 50

X Series S Series S Series All Engines All Engines Gas(Nat ural ly (Tu rbo w it h m ed ium wit h heavy engi ne

Asp irat ed) char ged) duty A/c dut y A/c

mm/wc ( in/wc) mm/wc ( in/wc) mm/wc ( in/wc) mm/wc ( in/wc) mm/wc ( in/wc) mm/wc ( in/wc)

Clean filter 250 (10) 250 (10) 250 (10) 250 (10) 380 (15) 200 (8)

Choked filter 400 (15.7) 380 (15) 500 (20) 635 (25) 635 (25) 380 (15)


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M echanical design

Fuel system

A.Ensure that fill point is accessible and clean all thetime. P rovide proper lid a nd loc k. Ensure tha t a ll piping

is leak free.B.Service storage tank should be located such that

piping will have minimum and controlled restriction.

This is mo re impo rtant a nd d ifficult in ca se of roof-top

installation.

C.Fuel transfer pump, preferably automatic isrecommend ed tha n manual.

D.Avoid fuel spillage. Do not overfill the fuel tank.Fuel expands when w a rm a nd ma y overflow.

E.Ensure proper fuel disposal arrangement.F. Ensure that fuel dilution a nd theft d oes not oc cur.

Ca re should be ta ken in the purcha se of fuel a nd filling

of tanks to prevent ingress of dirt and moisture into the

diesel fuel system.G.Insta ll fuel treatme nt pla nt dep ending upon a vaila ble

q uality of the fuel (mixed with w a ter or se diments like

rust, sc ale, weld slag , dirt a nd other debris.

H.Ensure tha t ca vitation does not ta ke place in thesystem.

Cooling system

A.Ensure initia l fill + top up w a ter used in co oling s yste mhas reco mmended properties a s mentioned in

operation and ma intenance ma nual.

B.Water softening /demineralizing plants should be used,if wa ter quality is not ac cepta ble.

Poor routing of fuel hoses

I. Common exhaust system for multiple sets is notrecommended due to soot, condensation, excessive

suction press ure, entry of exhaus t ga ses in non

wo rking eng ine, increas ed ba ck pressure and la ck of

fail sa fe sys tem a vaila bility. However exhaust of two

banks of V-engines can be connected, after silencer.

Ensure tha t a rea of c ommon pipe is greater than s umof the areas of individual pipes. Exhaust of engines can

be directly connected to chimney at different levels as

shown.

J . Insta lla tion of explos ion relief valve is recomme nded ,pa rticularly for bigg er sets .

K.The exha ust s ys tem outlet direction should a lso beca refully co nsidered. Hot exhaust g as ses must never

be directed towards undesirable locations like

cafteria, play ground, school or public place etc. or

towa rds c ombustible s urfac e. Exha ust from a diesel

engine is hot and will contain soot and other

conta minants tha t ca n ad here to surrounding surfa ces .

It is highly recommended that the exha ust s ystem b e

ca rried up a s high as pra ctical on the dow nwind s ide ofbuildings in order to discharge straight up to maximize

dispersal.

Co mmon e xhaust piping (not

recommended) Exhaust Rain Ca p

Mechanical design

Optimum Location of Silencer

In-line Engine V Engine

B es t 2L /5 4L - 5

5

S ec ond bes t 2L /5 2L - 4.5

5

Worst Location of Silencer

In-line Engine V Engine

Wors t L or 3L 3L -10

5 5 5

Where L = Length


10/16

9


M echanical design

Start ing system

Cranking torque a nd s tarting time is affected by the

following:

A.Auxilia ry loa ds vary d epend ing upo n the type ofa pplic a tion. The a uxiliary torq ue c urve will a ffec t the

time to a cc elerate c ra nking s peed.

B.Fuel w ith low energy c ontent w ill need more time tocrank because of slower burning and erratic firing.

C.Colder a mbient temperature increa se sta rting torquereq uirement. G low plugs a nd/or ether sta rting a ids a re

recomme nded when tempera tures fall below certain

levels, refer O &M. Insta ll ja cket w a ter hea ters to

maintain the ja cket w ater a t a tempera ture high enough

to allow for easy starting of the engine.

D.Increas ed lube oil visc osity bec a use o f cold c onditions,

increas e s tarting torq ue dema nd a nd in turn increas ingstarting time. Lube heaters may used if required.

E.P arasitic load s affect sta ting torque needs.F. Ba tteries supplied with genset are g enera lly dry a nd

uncharged. First cha rging of uncharged ba tteries is

very important and should be done from authorized

battery charging center. It takes about 72-80 hours to

completely charge a new battery.

Mechanical design

Model Battery Cable Electrical

Capacity Size System

AH mm2 VoltsKV a nd a bove 360 70 24

V28 /K19 180 70 24

N14 /855 /N8 /C 180 50 24

B 5.9 150 50 12

S 3.8 120 50 12

X S eries 88 35 12


11/16

10


Electrical design

Electr ical design

Genset / Engine Contr ols

The ge nerator se t is c ontrolled loca lly by a ded ica ted

G enerato r C ontrol P a nel. This incorporates the co ntrol

sys tems, metering, a larm indica tions a nd c ustomerconnections.

Tw o type s of co ntrol sys tem a re currently a vaila ble;

Engine Governing, Control System and Power Command

Control.

A.Make sure that the polarity of the battery connectionsare correct before applying power to the all Electronic

Controls.

B.Do not test wire leads to see if they are live byflashing them on either engine body or the Control

mounting s tand .

C.Disc onnect a ll connections to the control sys tem onengine /ge nset b efore do ing a ny welding w ork on set.

D.There a re no user s ervice a ble pa rts inside the variouscontrols supplied along with Cummins engine /genset.

Call the nearest Cummins office /dealer for help.

E.Turn off or remove AC pow er from the b a ttery c harge ra nd then remove ve b a ttery c ab le from the engine /

gens et ba ttery. This will avoid poss ible da ma ge a nd

some one else sta rting engine /Gens et a cc identa lly.

F. Make sure the battery area is well ventilated beforeservicing the battery. Arcing can cause explosion due

to hydrogen ga s g iven off by ba tteries.

G.Always refer to the wiring diagram and product manualsupplied with the engine /genset for details.

Electr ical pr otect ion

If the overloa d a nd s hort circuit protec tion is provided by

a circuit breaker, care must be taken with the protection

settings. Circuit breakers are designed for operation with

the utility s upply, w hich c a n provide much higher and

long er fault levels tha n a ge nerator. The c ircuit b reaker

overcurrent a nd s hort circuit settings s hould therefore be

se t a cc ording t o the overcurrent/sho rt circuit curves of

the c ircuit brea ker a nd no t the o vercurrent/sho rt circ uit

dials on the c ircuit brea ker. The g enerato r overloa d a ndshort circuit settings on the protection should be set so

that they a re below the thermal da ma ge c urve for the

generator.

Cabling

A.Overheating due to loose thumbing /undersizeca bles ca uses most of electrica l failures, henc e

pow er cab ling be tween a lternator a nd co ntrol panel

a nd control panel and c hange over switch to mains

should be done w ith correct s ize of ca bles a nd

thimbles.

B.While terminating cables avoid any tension on thebolts /busba rs.

C.While termina ting R.Y.B . pha se nota tions sho uld b emaintained in the alternator and control panel for easy

maintenance.

D.Crimped c ab les s hould b e co nnected to a lternato ra nd c ontrol panel through ca ble gla nds.

E.For AMF app lic a tion, use 8/10 co re 2.5 sq . mm

a rmoured copper c a ble for control ca bling.F. Typica l ca ble s izes for 415 V a pplic a tion a re provide d in

the table which are indicative, please refer to cable

ma nufac turers for deta ils . For HT insta lla tions, kindly

conta ct G OEMs for details on sizing.

Proper cable terminationsEarthed ca ble glands forcrimped c ables

Typical Cable Sizes for DG Sets

kVA Rating Amp Rating Cable size Sq. mm x Runs2000 2782 500 x 10 -- --

1800 2504 400 x 10 -- --

1500 2087 400 x 8 300 x 9 240 x 10

1250 1739 400 x 7 300 x 8 240 x 9

1000 1397 300 x 6 225 x 7 --

750 1043 400 x 4 240 x 5 185 x 6

650 904 300 x 4 225 x 5 150 x 6

625 870 300 x 4 185 x 5 120 x 6600 835 240 x 4 185 x 5 120 x 6

500 696 300 x 3 185 x 4 120 x 5

450 626 240 x 3 150 x 4 95 x 5

380 529 400 x 2 185 x 3 120 x 4

320 445 300 x 2 150 x 3 95 x 4

285 396 225 x 2 120 x 3 70 x 4

250 348 400 x 1 185 x 2 95 x 3

225 313 400 x 1 185 x 2 95 x 3

200 278 300 x 1 -- --

180 250 240 x 1 -- --

160 223 185 x 1 -- --

140 195 150 x 1 -- --

125 174 120 x 1 -- --

100 139 95 x 1 -- --

82.5 115 70 x 1 -- --

75 104 50 x 1 -- --

62.5 87 35 x 1 -- --

50 70 25 x 1 -- --30 42 16 x 1 -- --

25 40 10 x 4 -- --

20 40 10 x 4 -- --

15 32 6 x 4 -- --

25 (S ing le P ha s e) 125 50 x 2 -- --

20 (S ing le P ha s e) 80 35 x 2 -- --

15 (S ing le P ha s e) 63 25 x 2 -- --

Notes:

1. Use 3 1/2 core a rmoured power ca bles woth a luminium conduc tor (AYFY).2. Current rating of cables are taken bas ed on operating temperature of 700C.3. For multiple runs of cab les, deration factor of 0.75 is co nsidered i.e. 25% deration applied.4. AYFY: Aluminium conductor, P VC insulation, Steel strip armour, PVC outer sheath.5. Cable sizes mentioned are in square mm.6. For sets ab ove 1000 kVA, use of proper busbars in bus ducts is recommend ed.7. Earthing as per IEC rules to be provided.


12/16

11

Earthing

A.The genera ting s et sho uld b e co nnecte d to ea rth ina cc ordanc e w ith loca l regula tions.

B.All metal-work of the generating set should be bondedso that there is a continuous low impedanc e pa th from

all parts of it, including the engine and bed-plate, back

to the earth point.

C.The s ize o f the ca ble used for the main ea rthconnection should be of adequate size.

D.If residual current protection is required for personnelprotect ion it should no t be fitted to the ge nerator c ircuit

brea ker. This ca n ca use spurious tripping, b ut should

be fitted to the s ub c ircuits requiring the protection.

E.If residual current protec tion is fitted to the ge neratorcircuit breaker, care should be taken for the earth cable

connection, as the connection point will determine

whether the genera tor windings a nd the loa d a reprotected, o r only the load is protected .

F. When fitting residual current protec tion c a re s houldbe taken to ensure that there is only ONE earth path to

the ma in ea rth point.

G.Ea rthing a ll meta l-wo rk WITHOUT c onne ct ing it to thege nerator s ta r point w ill not g ive ea rth protec tion for

the generator loa d.

H.If the generators are operating in parallel the starpoints c an be connected in pa rallel provided this does

not cause parallel paths for the earth protection, or

cause excessive circulating currents

I. The generating set and all as soc ia ted eq uipment,control a nd sw itch gea r panels must b e ea rthed before

the set is put into operation.

J . 4 numbers earth pits are required as per IndianElectricity rules or local electricity board.

2 earthing pits for genset /control panel body

2 ea rthing pits for neutra l

K.GI strips of suitable size may be used for earthing.Earthing should be c hecked at ea rth strip and the

resista nce s hould b e less than 1 ohm. For gensets

with AVMs between engine /alternator and base rail,

the ea rthing MUS T be d one a t the engine /alternator

a nd NOT a t ba se rail.

L. The neutral of the genera tor is no t bo nded to thegenerator frame as supplied from the factory. An earthterminal is provided inside the terminal box adjacent to

the main terminals. If the set is required to operate

with the neutra l ea rthed, a subs tantia l earth conductor

(normally eq uiva lent to one ha lf of the s ec tion of the

line cond uctors) must be connected betw een the

neutral and the ea rth termina l inside the terminal

bo x.Add itiona l ea rth termina ls a re provide d o n the

generator feet.


Electrical design

H.The termina l bo x is mos t c onveniently g la nded oneither right or left hand side. Both panels are

remo va ble for d rilling /punc hing to suit g la nds /or

glanding b oxes. If single core ca bles a re ta ken through

the terminal box side panel, an insulated or non-ma gnetic gland plate s hould b e fitted.

I. Incoming cables should be supported from eitherbelow or a bove the b ox level and a t a sufficient

distance from the centre line of the generating set.

This w ould a void a tight ra dius a t the po int of entry into

the terminal box panel, and allow move ment of the

generator set on its anti-vibration mountings without

exces sive stress on the ca ble. Before ma king

final connections, test the insulation resistance of the

w indings. The AVR s hould be disc onnec ted during

this tes t. When ma king

connections to the

terminals theincoming ca ble

termination s hould b e

pla ced on top of the

winding lead

termination/s a nd

clamped with the nut

provided.

J . Care to be taken, that weights of cables should notfall on alternator /base rail. It is recommended to

support output ca bles on s epa ra te structure on g round.

K.Externa l wirings , w hen provided for remotevoltag e /exc ita tion monitoring /d roop C T etc . sha ll be

sc reened s heathed type. Maximum length of such

wiring should not exceed 5 meters.

L. P ow er cab les s hould b e type insta lled in a duct or acable tray.

Electr ical design

Ca ble acc ess from either side orabove

Overhead Cables


13/16

12


Electrical design

Earthing str ip data

DG Set Rating Recommended Earth Strips / Wir e

30 kVA 8 S WG C opper



62.5 kVA 8 S WG C opper

75 kVA 8 S WG C opper82.5 kVA 25 x 3mm CU /25 x 6 mm G I

100 kVA 25 x 3mm CU /25 x 6 mm G I

125 kVA 25 x 3mm CU /25 x 6 mm G I

140 kVA 25 x 3mm CU /25 x 6 mm G I

160 kVA 25 x 3mm CU /25 x 6 mm G I

180 kVA 25 x 3mm CU /25 x 6 mm G I

200 kVA 25 x 3mm CU /25 x 6 mm G I

250 kVA 32 x 3mm CU 1 Run /25 x 6 mm G I 2 Runs



437.5 kVA 25 x 6mm CU 2 Runs /25 x 6 mm G I 2 Runs

500 kVA 25 x 6mm CU 2 Runs /25 x 6 mm G I 2 Runs








14/16


Log sheet


15/16

14


Installation C hecklist

This c hecklist s hould b e use d to valida te the c ompletion

of a generator set installation, prior to commissioning.

A checklist should be completed for each generator of a

multiple inst a llation.

Project DetailsP roject na me

....... ...........

. ......

Customer (End User)

....... .......

. ......

Address of Site

..........................................................................................

.......................................

Tel.No. .. .......

Mo bile . .. .. .. .. .. ... .. .. .. .. .. .. .. .. .. .. .Ema il. .. ...... ...

-------------------------------------------------------------------

Generator Set DetailsG enera tor S et Mod el. .. ...... ...

Generator Set Serial No. ... .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. .

S et No..................................................................................

Controller Type ... .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .

Eng ine S r. No. ....... .....

A C G e ne ra to r S r. No . .. .. . .. .. .. .. .. .. .. ..

Con tro lle r Sr. No . . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .

-------------------------------------------------------------------

Site Information Yes or NoSite clean &clear from obstruction &secure......................

S ite services complete &commissioned.............................

(lighting, auxiliary supply, water etc)

Installation - open air or closed room..................................

Insta lla tion o n level &firm ground....... ............. ............ ........

No loose material near generating set ... .. . . .. . . .. . . .. .

P ipes &cab les sec ured .......................................................

Air intake &exit paths clear &clean ...................................

Ele c tric a l b o nd ing c o m ple te . .. .. .. .. .. .. ..

Comments /Any other irregularity ... .. . . .. . . .. . . .

.. . .

......................................................................................

-------------------------------------------------------------------Cooling System Yes or NoRadiator air outlet clean, free from obs truction .. . .. . .

Coolant overflow well routed for spillag e ... .. . . .. . . ..

Pos sibility o f hot air recirculat ion .. .. . . . .. . .

-------------------------------------------------------------------

Fuel System Yes or NoBulk storage tank installation complete ..............................

Transfer pump installed &connected .. . .. . . . .. . .. . .

P iping co rrect materia l, cleaned &lea k-free .............. .

S pillag e c ontainment co mplete ...................................

Vent insta lled, piped to s afe a rea and open ....................

Day tank f ill point clean &clear . . .. . .. . .. . .. .. . .

Electrica l bonding completed .. . .. . . .. . . .. . . .. . . .. . . .. . . .. ..

S to rage fac ility secured . .. .. .. .. .. .. .. .. .. .. .. . . .

-------------------------------------------------------------------

Exhaust System Yes or NoInsta lla tion prevents exha ust recircula tion ...... .....

Insta lla tion allow s for pipewo rk expans ion ............ ..

Welded joints &flanges secured w ith gas kets .. . .. . ..

P ip ing c orre ctly s up po rte d .. .. .. . .. .

S ta c k preve nts ra in ing re ss .. ...... .

C o nd ens a te d ra in pro vid ed . . .. .. .. .

Exit dire c te d away fro m b uild ing . . .. .. . .

S y ste m la g g ed & c la d d ed p ro pe rly . .. .. .. .

Flammable material properly protected .. .. . .. .

-------------------------------------------------------------------

Ventilation Yes or NoInsta lla tion prevents hot air recircula tion ............. .

Installation ac counts for prevailing wind . . . . . . ... .. . . .Air exit directed aw ay from building .. . .. . . ... .. . .

Forced ventilation if in plac e wired ... .. . . .. . . .. . . .. . .

Moving Louvers if any connected to system .. . . .. . .. . .

Inlet, outlet &enclosure bird protected ... .. . . .. . . ..

-------------------------------------------------------------------

Electrical System Yes or NoContro l system

Field w iring to s et mounted control complete ... ......

Customer wiring to control complete .. .. . .. . .. . .

Interconnection to remote co ntrol complete ............. ..

Remote emergency stop controls wired .. .. . .. . .. . .. . .

Generator / Swi tchgear / Changeover / transfer

Means o f disconnection /isolation provided ........ .......

Sw itchgea r insta lla tion &pre-testing co mplete ...........

Ca bles insta lled c orrectly, marked &flexible ...............

P o we r c o nne c tio ns c o m ple te . .. .. .. . . .. .. .. . .

Enclosure penetration properly sea led .......... .......

Enclosure

All electrica l boxes clean&covers replac ed .. .. . .. . .

Auxiliary electrica l supply complete ........... .......

Grounding system complete &tested .. .. .. . . . .. . . .

Utility supply a vailab le a s required .. . .. . . .. . . .. .. . .. .

-------------------------------------------------------------------

Any other comment /observation if any

.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... .. .. .. . .

.......

-------------------------------------------------------------------

Checklist completed by

.......

...... .................................

Da te ........ .

Company ... .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . .. . .

-------------------------------------------------------------------

Note : C ompletion of this c hecklist do es not relieve

The Ins ta ller of contra c tua l ob liga tion.

-------------------------------------------------------------------

Generator set Installat ion checklist (Enclosed or Containerized Generating Sets)


16/16

Cummins India Limited

Po wer Generation Business Unit

35A/1/2, Era nda w a na ,

Pune 411 038. India

Tel.: (91) 020-6602 7525

Fax: (91) 020-6602 8090

Cummins Power Generation Offices:

Location: Tel: Fax:

B a nga lore: (080) 2361 3831/2361 1958 (080) 2361 4552

Ch enna i: 098400 88717/098402 07633 (044) 2491 1120

Delhi: Telefa x: (011) 4161 8357/ 61

Hyde rab a d: (040) 2766 3017 (040) 2767 8892

Ind ore: (0731) 645 1042

J a ipur: (0141) 236 4944 (0141) 236 3746

Kolkot a : (033) 2287 8065/2247 2481 (033) 2290 3839

Lucknow : (0522) 278 6718/278 7514 (0522) 278 7880

Moha li: (0172) 224 0373 (0172) 224 0371/72

Mumbai: (022) 2756 6351/52/53/54 (022) 27566355

Va do da ra: (0265) 232 4207/654 0390 (0265) 234 0623www.cumminsindia.com

Cummins Sales & Service (I) Ltd.

35A/1/2, Era nda w a na ,

Pune 411 038. India

Tel.: (91) 020-2543 1234/2543 0066

Fax: (91) 020-2543 9490

Powerica Limited

74 - A Mitta l C ourt, Nariman P oint,

Mumbai - 400 021

Tel.: (022) 6656 2525

Fax: (022) 2204 3782

Email: [email protected]

Website: www.powericaltd.com

Our author ised GOEMs

Sudhir Gensets Limit ed

Plot No. 1, Sec tor 34,

Gurgaon - 122 001

P ho ne : (0124) 416 8000 (30 lines )

Fax: (0124) 416 8010


Website: www.sudhirgensets.com

Jaksons Limited

A-43, P ha se -II (Extn.), Opp. NEP Z,

Noida - 201305 (U.P )

Tel: (0120) 430 2600/256 8923-27Fax : (0120) 430 2646/256 8930

Email: conta [email protected] om

Website: www.jakson.com

24 x 7 Customer Assistance Cell

Tel.: (91) 020-2543 6680

Fax: (91) 020-2544 5916

Call Toll Free: 1-800-2332000


Cummins ha s a lways been a pioneer in product improvement. Thus spe cifications may change without notice.

Our energy w orking for you.TM

genset inst manual feb 08[1]

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