CUMMINS С25 D6 Installation Manual

Installation Installation Manual Manual Generator Set with 4BT3.3 Engine and PowerCommand® 1.1 Control C25 D6 (Spec A) C30 D6 (Spec A) C35 D6 (Spec A) C40 D6 (Spec A) C50 D6 (Spec A) C60 D6 (Spec A)

Copyright © 2019 Cummins Inc. Table of Contents 1. IMPORTANT SAFETY INSTRUCTIONS ....................................................................................... 1 1.1 Warning, Caution, and Note Styles Used in This Manual ..................................................... 1 1.2 General Information ................................................................................................................ 1 1.3 Generator Set Voltage Is Deadly ........................................................................................... 4 1.4 Fuel and Fumes Are Flammable ............................................................................................ 5 1.5 Batteries Can Explode ............................................................................................................ 5 1.6 Moving Parts Can Cause Severe Personal Injury or Death .................................................. 6 1.7 Exhaust Gases Are Deadly..................................................................................................... 6 1.8 The Hazards of Carbon Monoxide.......................................................................................... 7 2. INTRODUCTION............................................................................................................................ 9 2.1 About This Manual.................................................................................................................. 9 2.2 Related Literature ................................................................................................................... 9 2.3 Before Installation ................................................................................................................. 10 2.4 Model Specifications............................................................................................................. 11 2.5 Transfer Switch Requirements.............................................................................................. 14 3. PRE-INSTALLATION CONSIDERATIONS.................................................................................. 17 3.1 Pre-Installation Considerations............................................................................................. 17 3.2 Installation Codes and Standards for Safety ........................................................................ 18 3.3 Required Items for Installation.............................................................................................. 19 3.4 Transfer Switch Mounting ..................................................................................................... 21 4. INSTALLATION............................................................................................................................ 23 4.1 Installation Introduction......................................................................................................... 23 4.2 Site Assessment and Preparation ........................................................................................ 23 4.3 Fuel System.......................................................................................................................... 26 4.4 Engine Exhaust..................................................................................................................... 31 4.5 Electrical Connections .......................................................................................................... 31 5. STARTUP AND CONFIGURATION............................................................................................. 43 5.1 Exercise Settings ................................................................................................................. 43 5.2 Time Setup (1-Phase ATS)................................................................................................... 47 5.3 Brightness and Contrast ....................................................................................................... 51 5.4 History and About Menu ....................................................................................................... 53 5.5 Startup ................................................................................................................................. 55 5.6 Installation Checklist ............................................................................................................. 56 5.7 InPower Service Tool............................................................................................................ 57 APPENDIX A. DIESEL FUEL PIPING .............................................................................................. 59 A.0 Diesel Fuel Piping Requirements......................................................................................... 60 APPENDIX B. OUTLINE AND SYSTEM DRAWINGS...................................................................... 63

8-2019 ii A047W865 (Issue 9) Copyright © 2019 Cummins Inc. APPENDIX C. SEISMIC REQUIREMENTS...................................................................................... 87 C.1 Seismic Installation Instructions ........................................................................................... 89

Copyright © 2019 Cummins Inc. 1 IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS. This manual contains important instructions that should be followed during installation and maintenance of the generator set and batteries. Safe and efficient operation can be achieved only if the equipment is properly operated and maintained. Many accidents are caused by failure to follow fundamental rules and precautions. 1.1 Warning, Caution, and Note Styles Used in This Manual The following safety styles and symbols found throughout this manual indicate potentially hazardous conditions to the operator, service personnel, or equipment. DANGER Indicates a hazardous situation that, if not avoided, will result in death or serious injury. WARNING Indicates a hazardous situation that, if not avoided, could result in death or serious injury. CAUTION Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury. NOTICE Indicates information considered important, but not hazard-related (e.g., messages relating to property damage). 1.2 General Information This manual should form part of the documentation package supplied by Cummins with specific generator sets. If this manual has been supplied in isolation, please contact your authorized dealer. NOTICE It is in the operator's interest to read and understand all warnings and cautions contained in the documentation relevant to the generator set operation and daily maintenance.

8-2019 2 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. General Safety Precautions WARNING Hot Pressurized Liquid Contact with hot liquid can cause severe burns. Do not open the pressure cap while the engine is running. Let the engine cool down before removing the cap. Turn the cap slowly and do not open it fully until the pressure has been relieved. WARNING Moving Parts Moving parts can cause severe personal injury. Use extreme caution around moving parts. All guards must be properly fastened to prevent unintended contact. WARNING Toxic Hazard Used engine oils have been identified by some state and federal agencies to cause cancer or reproductive toxicity. Do not ingest, breathe the fumes, or contact used oil when checking or changing engine oil. Wear protective gloves and face guard. WARNING Electrical Generating Equipment Incorrect operation and maintenance can result in severe personal injury or death. Do not operate equipment when fatigued, or after consuming any alcohol or drug. Make sure that only suitably trained and experienced service personnel perform electrical and/or mechanical service. WARNING Toxic Gases Substances in exhaust gases have been identified by some state and federal agencies to cause cancer or reproductive toxicity. Do not breathe in or come into contact with exhaust gases. WARNING High Noise Level Generator sets in operation emit noise, which can cause hearing damage. Wear appropriate ear protection at all times.

8-2019 3 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. WARNING Hot Surfaces Contact with hot surfaces can cause severe burns. The unit is to be installed so that the risk of hot surface contact by people is minimized. Wear appropriate PPE when working on hot equipment and avoid contact with hot surfaces. WARNING Toxic Hazard Ethylene glycol, used as an engine coolant, is toxic to humans and animals. Wear appropriate PPE. Clean up coolant spills and dispose of used coolant in accordance with local environmental regulations. WARNING Combustible Liquid Ignition of combustible liquids is a fire or explosion hazard which can cause severe burns or death. Do not store fuel, cleaners, oil, etc., near the generator set. Do not use combustible liquids like ether. WARNING Combustible Gases Generator sets in operation have combustible gases under pressure, which if ignited can cause eye and ear damage. Wear appropriate eye and ear protection at all times. WARNING Combustible Gases Generator sets in operation have combustible gases under pressure, which if ignited can cause severe injury. Do not operate the generator set with any doors open. WARNING Fire Hazard Materials drawn into the generator set, as well as accumulated grease and oil, are a fire hazard. Fire can cause severe burns or death. Keep the generator set and the surrounding area clean and free from obstructions. Make sure the generator set is mounted in a manner to prevent combustible materials from accumulating under the unit.

8-2019 4 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. WARNING Automated Machinery Accidental or remote starting of the generator set can cause severe personal injury or death. Isolate all auxiliary supplies and use an insulated wrench to disconnect the starting battery cables (negative [–] first). NOTICE Keep multi-type ABC fire extinguishers close by. Class A fires involve ordinary combustible materials such as wood and cloth. Class B fires involve combustible and flammable liquid fuels and gaseous fuels. Class C fires involve live electrical equipment. (Refer to NFPA No. 10 in the applicable region.) NOTICE Before performing maintenance and service procedures on enclosed generator sets, make sure the service access doors are secured open. NOTICE Stepping on the generator set can cause parts to bend or break, leading to electrical shorts, or to fuel leaks, coolant leaks, or exhaust leaks. Do not step on the generator set when entering or leaving the generator set room. 1.3 Generator Set Voltage Is Deadly • Generator set output connections must be made by a trained and experienced electrician in accordance with all applicable codes. • This generator set and the public utility may only be connected to house circuits by means of the automatic transfer switch. CAUTION Improper connections can lead to electrocution of utility workers and damage to equipment. Make sure that the connections are installed properly by a trained technician. • Use caution when working on live electrical equipment. Remove jewelry, and make sure clothing and shoes are dry. Stand on a dry wooden platform.

8-2019 5 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. 1.4 Fuel and Fumes Are Flammable Fire, explosion, and personal injury or death can result from improper practices. • Do not fill fuel tanks while the engine is running unless the tanks are outside the engine compartment. Fuel contact with hot engine or exhaust is a potential fire hazard. • Do not permit any flame, cigarette, pilot light, spark, arcing equipment, or other ignition source near the generator set or fuel tank. • Fuel lines must be adequately secured and free of leaks. Fuel connection at the engine should be made with an approved flexible line. Do not use copper piping on flexible lines as copper will become brittle if continuously vibrated or repeatedly bent. • Make sure all fuel supplies have a positive shutoff valve. • Make sure the battery area has been well-ventilated prior to servicing near it. Lead-acid batteries emit a highly explosive hydrogen gas that can be ignited by arcing, sparking, smoking, etc. 1.5 Batteries Can Explode Batteries can explode, causing severe skin and eye burns and can release toxic electrolytes. WARNING Combustible Gases Batteries can explode, causing severe skin and eye burns, and can release toxic electrolytes. Do not dispose of the battery in a fire, because it is capable of exploding. Do not open or mutilate the battery. Do not charge frozen batteries. WARNING Electric Shock Hazard Batteries present the risk of high short circuit current. When servicing the generator set: • Remove watches, rings, or other metal objects. • Use tools with insulated handles. NOTICE Servicing of batteries must be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries. • Wear safety glasses.

8-2019 6 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. • Do not smoke. • Do not charge frozen batteries. • To prevent arcing when disconnecting the battery: 1. Press the Off switch from the display and then press the E-Stop button (if equipped). 2. Disconnect AC power from any battery chargers. 3. Remove the negative (-) battery cables to prevent starting. • To prevent arcing when reconnecting the battery: 1. Reconnect the positive (+) cables. 2. Reconnect the negative (-) cables. 3. Reconnect the battery charger to AC power supply. • When replacing the generator set battery, always replace it with a battery as specified in this manual. 1.6 Moving Parts Can Cause Severe Personal Injury or Death • Do not wear loose clothing or jewelry near moving parts, such as cooling fans. • Keep hands away from moving parts. • Keep guards in place over fans. 1.7 Exhaust Gases Are Deadly • Provide an adequate exhaust system to properly expel discharged gases away from enclosed or sheltered areas, and areas where individuals are likely to congregate. Visually and audibly inspect the exhaust system daily for leaks per the maintenance schedule. Make sure that exhaust manifolds are secured and not warped. Do not use exhaust gases to heat a compartment. • Make sure the unit is well ventilated. Exhaust Precautions WARNING Hot Exhaust Gases Contact with hot exhaust gases can cause severe burns. Wear personal protective equipment when working on equipment.

8-2019 7 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. WARNING Hot Surfaces Contact with hot surfaces can cause severe burns. The unit is to be installed so that the risk of hot surface contact by people is minimized. Wear appropriate PPE when working on hot equipment and avoid contact with hot surfaces. WARNING Toxic Gases Inhalation of exhaust gases can cause asphyxiation and death. Pipe exhaust gas outside and away from windows, doors, or other inlets to buildings. Do not allow exhaust gas to accumulate in habitable areas. WARNING Fire Hazard Contaminated insulation is a fire hazard. Fire can cause severe burns or death. Remove any contaminated insulation and dispose of it in accordance with local regulations. The exhaust outlet may be sited at the top or bottom of the generator set. Make sure that the exhaust outlet is not obstructed. Personnel using this equipment must be made aware of the exhaust position. Position the exhaust away from flammable materials - in the case of exhaust outlets at the bottom, make sure that vegetation is removed from the vicinity of the exhaust. The exhaust pipes may have some insulating covers fitted. If these covers become contaminated they must be replaced before the generator set is run. To minimize the risk of fire, make sure the following steps are observed: • Make sure that the engine is allowed to cool thoroughly before performing maintenance or operation tasks. • Clean the exhaust pipe thoroughly. 1.8 The Hazards of Carbon Monoxide Carbon monoxide (CO) is an odorless, colorless, tasteless and non-irritating gas. You cannot see it or smell it. Red blood cells, however, have a greater affinity for CO than for oxygen. Therefore, exposure even to low levels of CO for a prolonged period can lead to asphyxiation (lack of oxygen) resulting in death. Mild effects of CO poisoning include eye irritation, dizziness, headaches, fatigue and the inability to think clearly. More extreme symptoms include vomiting, seizures and collapse. Engine-driven generator sets produce harmful levels of carbon monoxide that can injure or kill you.

8-2019 8 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. Special Risks of CO near the Home WARNING Toxic Gases Carbon monoxide (CO) gas can cause nausea, fainting, or death. Residents can be exposed to lethal levels of CO when the generator set is running. Depending on air temperature and wind, CO can accumulate in or near the home. To protect yourself and others from the dangers of CO poisoning, it is recommended that reliable, approved, and operable CO detector alarms are installed in proper locations in the home as specified by their manufacturer. Protecting Yourself from CO Poisoning • Locate the generator set in an area where there are no windows, doors, or other access points into the home. • Make sure all CO detectors are installed and working properly. • Pay attention for signs of CO poisoning. • Check the exhaust system for corrosion, obstruction, and leaks every time you start the generator set and every eight hours when you run it continuously.

Copyright © 2019 Cummins Inc. 2 Introduction 2.1 About This Manual WARNING Improper installation can result in severe personal injury, death and damage to equipment. The installation must comply with all applicable building codes (including project permits and inspections). The installer should be properly trained and licensed to perform electrical and mechanical equipment installations (including gaseous fuel installation). NOTICE Manuals are updated from time to time to reflect changes in the equipment and its specifications. The most up-to-date version of this manual is found on the QuickServe website (https://quickserve.cummins.com/info/index.html). This manual is a guide for the installation of the generator set models listed on the front cover. Proper installation is essential for top performance, reliable operation, and safety. Read through this manual before starting the installation. This manual covers outdoor applications only; for other installations, refer to the T-030: Liquid- Cooled Generator Set Application manual available from your Cummins distributor. NOTICE The installation must comply with all applicable building codes. See the generator set's specific operator manual for operation and maintenance and specific service manual for service. Refer to the Model Specifications section for specific information about the system and its components. Refer to the Outline and System Drawings appendix and the Wiring Diagrams appendix for specific information about installation and wiring connections. 2.2 Related Literature Before any attempt is made to operate the generator set, the operator should take time to read all of the manuals supplied with the generator set and familiarize themselves with the warnings and operating procedures.

Copyright © 2019 Cummins Inc. A generator set must be operated and maintained properly if you are to expect safe and reliable operation. The Operator Manual includes a maintenance schedule and a troubleshooting guide. The Health and Safety Manual must be read in conjunction with the Operator Manual for the safe operation of the generator set. The literature provided with the generator set is as follows: • Health and Safety Manual (0908-0110-00) • Warranty Statement (A028U870) • Emissions Component Defect Warranty Statement (A054N449) • Generator Set Installation Manual (A047W865) • Generator Set Operator Manual (A047W873) • 4BT3.3 Engine Operator Manual (3666417) • Installation Quick Start Guide (A050N805) • Operator Quick Start Guide (A050N807) The relevant manuals appropriate to your generator set are also available. The documents below are in English: • Generator Set Service Manual (A047W877) • 4BT3.3 Engine Service Manual (4021540) • Generator Set Parts Manual (A048W980) • 4BT3.3 Engine Parts Manual (25 kW, 30 kW, 35 kW, 40 kW) (A049Y673) • 4BT3.3 Engine Parts Manual (50 kW, 60 kW) (A054A174) • RA Series Transfer Switch Owner's Manual (A046S594) - if applicable • PowerCommand® 1302 Controller Owner's Manual (900-0661) • Standard Repair Times (SRT) Manual - GH Family (A049J592) • Application Manual T-030 - for application information (A040S369) • Service Tool Manual (A043D529) • Universal Annunciator Operator Manual (0900-0301) 2.3 Before Installation Before beginning the installation of the generator set, verify that the unit was correctly selected. Check the following features: • Model • Specifications • Options • Fuel Supply

Copyright © 2019 Cummins Inc. 2.4 Model Specifications TABLE 1. MODEL VARIATIONS (60 HZ, 1800 RPM) Models 4BT3.3 Engine C25 D6, C30 D6, C35 D6, C40 D6 G5 C50 D6, C60 D6 G7 TABLE 2. COLD WEATHER SPECIFICATIONS (ALL MODELS) Temperature Starting Aids Battery Factory Options Above 4 °C (40 °F) Not required Standard battery (group 26) -- -17 to 4 °C (0 to 40 °F) Coolant heater and battery charger recommended. Standard battery (group 26) Available Below -17 °C (0 °F) All (battery heater, coolant heater, battery charger) recommended. Larger battery (group 34) Available NOTICE For NFPA 110 applications, a coolant heater is required. Factory option is available. TABLE 3. FUEL CONSUMPTION (FULL LOAD) Rating C25 D6 C30 D6 C35 D6 C40 D6 C50 D6 C60 D6 Standby 9.16 L/ hr (2.42 gal/hr) 10.63 L/ hr (2.81 gal/hr) 11.95 L/ hr (3.16 gal/hr) 13.85 L/ hr (3.66 gal/hr) 16.08 L/ hr (4.25 gal/hr) 19.07 L/ hr (5.04 gal/hr) Prime 8.32 L/ hr (2.2 gal/hr) 9.65 L/ hr (2.55 gal/hr) 10.86 L/ hr (2.87 gal/hr) 12.6 L/ hr (3.33 gal/hr) 14.61 L/ hr (3.86 gal/hr) 17.33 L/ hr (4.58 gal/hr)

Copyright © 2019 Cummins Inc. TABLE 4. ENGINE SPECIFICATIONS Specification Value Engine 4 Cylinder-in-line, liquid-cooled, 4-stroke Aspiration Turbocharged Displacement 3300 cc (199 in3) Compression Ratio 4BT3.3-G5: 20.8:1 4BT3.3-G7: 17.3:1 Fuel ASTM number 2D fuel (Refer to the Engine Operator Manual) Coolant 50/50 coolant solution (50% pure water and 50% ethylene glycol) Fuel Flow Maximum fuel flow: 56.4 L/hr (14.9 gal/hr) Maximum fuel inlet restriction with clean filter: 58.4 mm hg (2.3 in hg) Maximum return restriction: 375.9 mm hg (14.8 in hg) Lube Oil Capacity 7.9 L (8.35 qt) Oil Recommendation 15W40 (Refer to the Engine Operator Manual) TABLE 5. GENERATOR SET SIZE SPECIFICATIONS (25-60 KW 1800 RPM) Size Dimensions (L x W x H) With Sound Level 1 Enclosure, Without Fuel Tank 2384 x 864 x 1156 mm (93.8 x 34 x 45.5 in) TABLE 6. GENERATOR SET WEIGHT (60 HZ, 1800 RPM, SOUND LEVEL 1, WET) C25 D6 C30 D6 C35 D6 C40 D6 C50 D6 C60 D6 Minimum 574 kg (1265 lb) 575 kg (1288 lb) 611 kg (1348 lb) 622 kg (1371 lb) 710 kg (1556 lb) 738 kg (1626 lb) Maximum 575 kg (1288 lb) 622 kg (1371 lb) 636 kg (1402 lb) 718 kg (1584 lb) 668 kg (1742 lb) 668 kg (1742 lb)

Copyright © 2019 Cummins Inc. TABLE 7. ALTERNATOR SPECIFICATIONS (60 HZ, 1800 RPM) Model Alternator Power (kVA) 1 Phase/3 Phase Rated Voltages (V) Standby Prime 1 Ph 3 Ph C25 D6 Brushless, 4- pole rotating field, single bearing 25/31.3 22.5/28.1 120/240 277/480 120/208 120/240 347/600 C30 D6 30/37.5 27/33.8 C35 D6 35/43.8 31.5/39.4 C40 D6 40/50 36/45 C50 D6 50/42.5 45/37.5 C60 D6 60/75 56/67.5 NOTICE Maximum I2= 8%. TABLE 8. GENERATOR SET DERATING GUIDELINES Model Mode Engine Power Available Up to... Derate at... Elevation Ambient Temperature Elevation per 300 m (985 ft) Temperature per 10 °C (18 °F) C25 D6 Standby 3048 m (10000 ft) 50 °C (122 °F) 3% 6% Prime 3048 m (10000 ft) 3% 6% C30 D6 Standby 3048 m (10000 ft) 3% 6% Prime 2200 m (7220 ft) 5% 9% C35 D6 Standby 2896 m (9500 ft) 40 °C (104 °F ) 3% 6% Prime 2399 m (7870 ft) 5% 9% C40 D6 Standby 1677 m (5500 ft) 3% 6% Prime 1677 m (5500 ft) 5% 9%

Copyright © 2019 Cummins Inc. Model Mode Engine Power Available Up to... Derate at... Elevation Ambient Temperature Elevation per 300 m (985 ft) Temperature per 10 °C (18 °F) C50 D6 Standby 1677 m (5500 ft) 50 °C (122 °F) 3% 10% Prime 1677 m (5500 ft) 3% 10% C60 D6 Standby 1280 m (4200 ft) 3% 10% Prime 1280 m (4200 ft) 3% 10% TABLE 9. DC SYSTEM SPECIFICATIONS (ALL MODELS) Specification Value Nominal Battery Voltage 12 VDC Battery Group 26 standard, 34 high capacity (high capacity battery requires an accessory battery tray) Battery Type Maintenance free Minimum Cold Crank Amps 530 standard, 850 high capacity (high capacity battery requires an accessory battery tray) 2.5 Transfer Switch Requirements A transfer switch must be a part of every generator set installation. Transfer switches transfer loads to the generator set during power outages. NOTICE Cummins offers a variety of transfer switches, including residential and light commercial options. FIGURE 1. CUMMINS TRANSFER SWITCH (RA SERIES)

Copyright © 2019 Cummins Inc. Before beginning the installation of the transfer switch, verify that the unit was correctly selected. Check the following features: • Specifications (voltage, amperage, frequency, poles, and phases) • Enclosure (indoor vs. outdoor) • Model Refer to the RA Series Transfer Switch Owner Manual (A046S594) for more detailed information. The RA Series transfer switch is the recommended ATS for use with these generators.

2. Introduction 8-2019 16 A047W865 (Issue 9) Copyright © 2019 Cummins Inc.

Copyright © 2019 Cummins Inc. 3 Pre-Installation Considerations 3.1 Pre-Installation Considerations Before installation begins, certain items must be considered. Prior coordination reduces delays and the amount of time power has to be interrupted. Areas of consideration: No. Description No. Description 1 Generator Set 3 Transfer Switch 2 Electrical Meter FIGURE 2. SITE PREPARATION EXAMPLE • Location of the generator set - this is one of the first decisions to be made, as it affects all other aspects of the installation, such as: ◦ Length of electric wiring ◦ Length of fuel lines

8-2019 18 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. ◦ Site preparation: ▪ Access to the site ▪ Trenches ▪ Site preparation materials needed • Automatic transfer switch location and connections • Tools and materials required • Accessories required (if any) for the customer's application (utility power may be required at the generator set; make plans accordingly) NOTICE Depending on the locality and use of the generator set, it may be necessary to obtain an air quality emissions permit before installation begins. Check with local pollution control or air quality authority to determine permit requirements. 3.2 Installation Codes and Standards for Safety NOTICE The generator set installer bears sole responsibility for following all applicable local codes and regulations. The following list of codes and standards may apply to the installation and operation of the generator set. This list is for reference only and not intended to be inclusive of all applicable codes and standards. The address of each agency is listed so that copies of the codes may be obtained for reference. Installation codes and recommendations are subject to change, and may vary by location or over time. TABLE 10. INSTALLATION CODES AND STANDARDS FOR SAFETY RECOMMENDATIONS NFPA 70 - National Electrical Code NFPA 37 - Installation and Use of Stationary Combustion Engines and Gas Turbines NFPA 110 - Standard for Emergency and Standby Power Systems National Fire Protection Association 470 Atlantic Avenue Boston, MA 02210 CSA Electrical Bulletin CSA 22.1 Canadian Electrical Code CSA B139 Installation Code for Oil-Burning Equipment CSA C22.2 No. 100 Motors and Generators CSA C22.2 No. 14 Industrial Control Equipment Canadian Standards Association Housing and Construction Materials Section 178 Rexdale Blvd. Rexdale, Ontario, Canada M9Q 1R3

8-2019 19 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. California Administrative Code - Title 25 Chapter 3 State of California Documents Section P.O. Box 1015 North Highlands, CA 95660 3.3 Required Items for Installation Tools and materials are used for the installation of this generator set. These items are identified in the following sections. Please refer to local codes and standards, because they may affect the materials required. Materials Required NOTICE Refer to local codes and standards, which may affect the material requirements. NOTICE If a 100% rated breaker is used, 90 °C wire must be used for L1, L2, and L3 with the wire size determined by the 75 °C ampacity tables. NOTICE A UL-listed grounding electrode terminal within its ratings and suitable for the application must be installed and labeled “Grounding Electrode Terminal”. Electrical Materials: NOTICE Class 1 wiring methods must be used for connecting the generator set. • Four code compliant AC power wires; L1, L2, N and Gnd (add another wire for 3-phase for a total of 5 AC wires) • For RA switches, 4 DC control wires will be needed from the generator to the transfer switch. • Wire sizes (DC control and power and AC sense only): ◦ DC control or AC sense wires under 1000 feet circuit length => 18-14 AWG of the insulation type above

8-2019 20 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. ◦ DC control or AC sense wires 1000-2000 feet circuit length => 16-14 AWG of the insulation type above • All AC and DC wires and cables must be rated 75 °C minimum, stranded copper, and rated for wet locations. ◦ For wire sizes 14 AWG and larger, use insulation types: RHW, RHW-2, THHW, THW, THW-2, THWN, THWN-2, XHHW, XHHW-2, USE-2, ZW-2 ◦ For wire sizes 16 and 18 AWG, use insulation types: FFH-2, KFF-2, PAFF, PFF, PGFF, PTFF, RFH-2, RFHH-2, RFHH-3, SFF-2, TFF, TFFN, ZFF • Code compliant 20 A, 120 VAC, GFCI protected circuit for alternator heaters/battery charger/coolant heater/oil heater/battery heater (if equipped) • Code compliant conduit for all wires Mounting Materials: • Four base tie-down bolts NOTICE Regional fuel tanks require six bolts to attach to the ground. NOTICE Seismic zone installations require compliance to specific mounting configurations, as determined by the structural engineer of record. Fuel Materials: • Flexible fuel line • UL listed pipe thread sealant • Fuel pipe to the remote tank Loose Parts Shipped With the Generator Set The following loose parts are shipped with the generator set: • One enclosure key (where applicable) • Battery tie-down • Sound level 2 baffle (where applicable) • Fuel tank vent extensions (where applicable) • Fuel tank riser blocks (where applicable) • Literature - Operator Manual, Installation Manual, Health and Safety Manual, and Warranty Statements

8-2019 21 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. 3.4 Transfer Switch Mounting 1. Consider the location before mounting the transfer switch. • Consider the proximity to the utility service entrance and breaker panel. There must be a service disconnect (circuit breaker or fuses) in the power line ahead of the transfer switch, unless a service entrance rated automatic transfer switch is being used. • Keep safety concerns in mind. Never mount the transfer switch near hazardous chemicals or gases. • Avoid high humidity areas or areas prone to excessive heat or dust. 2. Make sure that the wall is stable and able to support the weight of the transfer switch. 3. Make sure that the transfer switch is mounted according to all applicable building code requirements. 4. Mount the transfer switch per the instructions in the RA Series Transfer Switch Owner Manual. NOTICE Seismic zone installations require compliance to specific mounting configurations.

3. Pre-Installation Considerations 8-2019 22 A047W865 (Issue 9) Copyright © 2019 Cummins Inc.

Copyright © 2019 Cummins Inc. 4 Installation 4.1 Installation Introduction NOTICE The installer is responsible for complying with all applicable installation codes and safety requirements. See the Installation Codes and Standards for Safety section of this manual for more information. The following sections cover a step-by-step overview of a typical generator set installation. Review these sections to become familiar with specific procedures and important safety precautions before beginning the installation. 4.2 Site Assessment and Preparation Proper component location and site preparation have a very important impact on completing a successful installation. The major components and sources of power needed for installation include the following items: • Generator set • Transfer switch • Electrical utility • Fuel source (diesel) • Accessories (may be required based on certain conditions) Picking a Location WARNING Exhaust gas is deadly. Locate the generator set away from doors, windows, and other openings to the house and where exhaust gases will disperse away from the house. Generator set location is critical for safety and performance. Follow the guidelines below: • Must comply with applicable codes (NFPA, NEC, IBC, etc.). • This manual only covers outdoor installations with Cummins factory installed enclosures. For other installation types, contact your local Cummins dealer or reference the Application Manual at the following link: http://www.cumminspower.com/www/literature/applicationmanuals/t030.pdf • Consider access to utilities (electric meters, transfer switch, remote fuel tank location, etc.).

Copyright © 2019 Cummins Inc. • Call the local utilities to mark the locations of buried utility services (gas, electric, or telephone) before digging. • Verify the locations of any other buried components (gas, electric or telephone) with the homeowner before digging. Clearances: • The exhaust side of the generator set must be located at a minimum of 5 feet from combustible materials (NFPA 37) and any openings in a wall (window, door, vent, etc.). • The generator must be located such that the exhaust is not able to accumulate in an occupied area. • The generator must have enough room for installation, service, and maintenance. • The generator must be located to ensure ventilation openings are not blocked. • Position the generator set so that cooling air is free to enter and leave the area. • Locate and position the generator set so that prevailing winds carry exhaust gases and potential fuel leaks away from the house or occupied area. No. Description 1 5 ft Clearance (shaded area) FIGURE 3. CLEARANCES Laying the Foundation When laying the foundation: 1. Clear obstructions, and make sure that there is adequate clearance for access.

Copyright © 2019 Cummins Inc. 2. Level the ground, and make sure that the ground is compact and settled. Ensure that it is stable ground, not subject to flooding. 3. Prepare the concrete pad. • The pad should be constructed of reinforced concrete with a 28-day compressive strength of at least 2500 psi (17,237 kPa). • The pad dimensions should be the same as those indicated in the Outline and System Drawings appendix. NOTICE Seismic installations may require a different pad and securing devices. NOTICE Local codes and standards may have different requirements. 4. Lift the generator set onto the pad, and secure it. Lifting and Moving the Generator Set WARNING Heavy Load The generator set is heavy. Handle with care. Dropping the generator set can cause severe personal injury or death. Use appropriate lifting techniques to move the generator set. Keep feet and hands clear when lifting the generator set. CAUTION The generator set is shipped with oil in the engine crankcase. Keep the generator set upright. Mounting the Generator Set Mount the generator set on a substantial and level base such as a concrete pad. A non-combustible material must be used for the pad. Verify that the mounting pad is level by length, by width, and diagonally. NOTICE Seismic installation may require specific anchorage.

Copyright © 2019 Cummins Inc. 4.3 Fuel System NOTICE The factory-installed sub-base fuel tanks meet the fuel system requirements. Please verify that they also meet local codes and standards. Cummins engines normally use a diesel fuel specified to ASTM D975 grade 2. Refer to the Engine Operator Manual for additional information. In all fuel system installations, cleanliness is of the utmost importance. Make every effort to prevent entrance of moisture, dirt, or contaminants of any kind into the fuel system. Clean all fuel system components before installing. NOTICE A fuel filter/strainer/water separator of 100-120 mesh or equivalent (approximately 150 microns nominal) must be fitted between the main tank and day tank if a factory sub-base tank is used as a day tank. Use only compatible metal fuel lines to avoid electrolysis when fuel lines must be buried. Buried fuel lines must be protected from corroding. NOTICE Never use galvanized or copper fuel lines, fittings, or fuel tanks. Condensation in the tank and lines combines with the sulfur in diesel fuel to produce sulfuric acid. The molecular structure of the copper or galvanized lines or tanks reacts with the acid and contaminates the fuel, resulting in possible engine damage. An electric solenoid valve in the supply line is recommended for all installations and required for indoor automatic or remote starting installations that do not use the factory sub-base fuel tank. Connect the solenoid wires to the generator set “Switched B+” circuit to open the valve during generator set operation. NOTICE Never install a shutoff device in fuel return line(s). If the fuel return line(s) is blocked or exceeds fuel restriction limit, engine damage will occur. NOTICE A base mounted fuel tank may be part of the generator set build. An additional external fuel system may be required if the onboard fuel capacity is not sufficient for the application. Fuel Selection and Recommendations For fuel specifications, see the Model Specifications section.

Copyright © 2019 Cummins Inc. NOTICE Fuel systems must be installed by qualified service technicians. Improper installation presents hazards of fire and improper operation, resulting in severe personal injury or property damage. In all fuel system installations, cleanliness is extremely important. • Make every effort to prevent fuel contamination from: ◦ Moisture ◦ Dirt ◦ Excess thread sealant ◦ Contaminants of any kind • Clean all fuel system components before installing. Refer to the Engine Operator Manual for complete fuel requirements. WARNING The generator set is heavy. Dropping the generator set can cause severe injury or death. Do not lift the generator set with fuel in the tank (where applicable). Keep hands and feet clear when lifting the generator set. WARNING Do not mix gasoline, alcohol, or gasohol with diesel fuel. This 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 from dirt or water. Dirt or water in the system can cause severe damage to both the fuel pump and fuel injectors. Fuel Return Restrictions (or Pressure) Limit Fuel return drain restriction (consisting of friction head and static head) between the engine injector return line connection and the fuel tank must not exceed the limit stated in the Model Specifications. Fuel return lines must not contain a shutoff device. Engine damage will occur if the engine is run with the return fuel lines blocked or restricted.

Copyright © 2019 Cummins Inc. Fuel Lines Routing WARNING Explosive hazard. Fuel leaks create fire and explosion hazards which can result in severe personal injury or death. Always use flexible tubing between the engine and fuel supply to avoid line failure and leaks due to vibration. The fuel system must meet all application codes. WARNING Sparks and hot surfaces. Sparks and hot surfaces can ignite fuel, leading to severe personal injury or death. Do not route fuel lines near electrical wiring or hot exhaust parts. NOTICE Fuel lines must be routed and secured to maintain a 12.7 mm (½ inch) minimum clearance from electrical wiring and a 51 mm (2 inch) minimum clearance from hot exhaust parts. A flexible fuel hose(s) or section of flexible fuel hose(s) must be used between the engine’s fuel system and fuel supply and return line(s) to protect the tank's fuel system from damage caused by vibration, expansion, and contraction. The fuel hose must be installed according to all applicable codes and standards.

Copyright © 2019 Cummins Inc. No. Description No. Description 1 Day Tank (Sub-Base) 7 Fill Pipe 2 Engine Fuel Pump 8 Main Fuel Tank 3 Supply Line 9 Supply Line 4 Float Switch 10 Overflow Line 5 Return Line 11 120 Mesh Fuel Strainer 6 Vent Pipe 12 Fuel Transfer Pump Electric Motor Driven FIGURE 4. TYPICAL FUEL SUPPLY INSTALLATION (USING FACTORY SUB-BASE TANK AS DAY TANK) Engine Fuel Connections Identification tags are attached to the fuel supply line and fuel return line connections. All models require a fuel return line from the injectors to the tank. Supply Tank Locate the fuel tank as close as possible to the generator set and within the restriction limitations of the fuel pump. Install a fuel tank that has sufficient capacity to supply the generator set operating continuously at full rated load for the planned period of operation or power outage.

Copyright © 2019 Cummins Inc. If the fuel inlet restriction exceeds the defined limit due to the distance/customer- supplied plumbing between the generator set and the main fuel tank, a transfer tank (sometimes referred to as a day tank) and auxiliary pump will also be required. If an overhead main fuel tank is installed, a transfer tank and float valve will be required to prevent fuel head pressures from being placed on the fuel system components. Fuel Inlet Pressure/Restriction Limit Engine performance and fuel system durability is compromised if the fuel inlet pressure or restriction limits are not adhered to. Fuel inlet pressure or restriction must not exceed the limits stated in the model-specific generator set Specification Sheet. Day Tank Some generator set installations may include a fuel day tank. They are used when fuel inlet restriction limits cannot be met, or the supply tank is overhead and presents problems of high fuel head pressure for the fuel inlet and return lines. Supply Tank Lower Than Engine WARNING Fuel spillage. Spilled fuel presents the hazard of fire or explosion which can result in severe personal injury or death. Provide an overflow line to the supply tank from the day tank. NOTICE The supply tank top must be below the day tank top to prevent siphoning from the fuel supply to the day tank. With this installation, the day tank is installed near the generator set, below the fuel injection system and within the fuel inlet restriction limit. Install a fuel transfer pump, to pump fuel from the supply tank to the day tank. A float switch in the day tank controls operation of the auxiliary fuel pump. Provide a return line from the engine injection system return connection to the day tank. Plumb the return line to the bottom of day tank. Provide a day tank overflow line to the supply tank in case the float switch fails to shut off the fuel transfer pump. Supply Tank Higher Than Engine With this installation, the day tank is installed near the generator set, above the fuel injection system and within the fuel return restriction limit. Include an automatic fuel shutoff valve in the fuel line between the fuel supply tank and the day tank to stop fuel flow when the generator set is off. Provide a return line from the engine injection system return connection to the day tank. Plumb the return line to the bottom of day tank.

Copyright © 2019 Cummins Inc. NOTICE Spilled fuel can create environmental hazards. Check local requirements for containment and prevention of draining to sewer and ground water. 4.4 Engine Exhaust The exhaust system for this generator set is complete and was designed specifically for this generator set. Do not modify or add to the exhaust system of this generator set. WARNING Exhaust gas is deadly. Make sure that the exhaust system terminates away from building vents, windows, doors, and sheltered spaces that may not have ample fresh air ventilation. WARNING Engine discharge air and exhaust carry carbon monoxide gas (odorless and invisible) which can cause asphyxiation and death. Never use engine discharge air or exhaust for heating a room or enclosed space. 4.5 Electrical Connections WARNING Improper installation can lead to electrocution and damage to property. Electrical connections must be made by a licensed electrician. WARNING Automatic startup of the generator set during installation can cause severe personal injury or death. Make sure the generator set is shut down and disabled: 1. Press the generator set's "O" (Off) button to stop the generator set. Allow the generator set to thoroughly cool to the touch. 2. Turn off and disconnect the battery charger from the AC source before disconnecting the battery cables. 3. Disconnect the negative (–) cable from the battery and secure it from contacting the battery terminals to prevent accidental starting. NOTICE Refer to regional codes and the National Electrical Code (NFPA 70) for all electrical installation requirements.

Copyright © 2019 Cummins Inc. NOTICE Class 1 wiring methods must be used for connecting the generator set. AC Connections WARNING Automated Machinery Accidental or remote starting of the generator set can cause severe personal injury or death. Isolate all auxiliary supplies and use an insulated wrench to disconnect the starting battery cables, negative (–) cable first. NOTICE If a 100% rated breaker is used, 90 °C wire must be used for L1, L2, and L3 with the wire size determined by the 75 °C ampacity tables. NOTICE When using a circuit breaker with an adjustable, electronic trip unit, the amperage and trip curve settings may need adjustment to match the generator set load wiring, or downstream loads and circuit breakers. An accessory seal kit (part number A026M166) is available to tamper-proof the adjustable settings. 1. Make sure the generator set is shut down and disabled: a. Press the Off switch from the display and then press the E-Stop button to stop the generator set. Allow the generator set to thoroughly cool to the touch. b. Turn off and disconnect the battery charger from the AC source before disconnecting the battery cables. c. Disconnect the negative (–) cable from the battery and secure it from contacting the battery terminals to prevent accidental starting. 2. Remove the enclosure side panel to access the main circuit breaker box. 3. Place the circuit breaker handle in the OFF position. 4. Remove the four bolts holding the circuit breaker cover. 5. Connect the conductors to the circuit breaker load-side terminals, neutral lug, and equipment grounding lug. For grounding and neutral connections, look for the symbols on the generator set circuit breaker box (shown below, and in the next image at the bottom).

Copyright © 2019 Cummins Inc. Equipment Grounding Conductor Symbol Equipment Neutral Connection Symbol FIGURE 5. SYMBOLS ON CIRCUIT BREAKER BOX FIGURE 6. CIRCUIT BREAKER AC LOAD CONNECTIONS LOCATION (SYMBOLS SHOWN AT BOTTOM) 6. Torque the circuit breaker terminals per specifications on the circuit breaker label.

Copyright © 2019 Cummins Inc. 7. Torque the neutral lug to 31.1 Nm (275 in-lb). 8. Torque the equipment grounding lug to 13.8 Nm (120 in-lb). 9. Fill in the stub-up openings with an approved duct seal or mastic tape to keep out insects and rodents. 10. Install the circuit breaker cover. Automatic Transfer Switch AC Connections WARNING Failure to use an approved transfer switch can lead to the electrocution of personnel working on the utility lines, damage to equipment, fire, or personal injury. An approved switching device must be used to prevent interconnection to the public utility. Install the transfer switch in accordance with the appropriate RA Series Transfer Switch Owner Manual. Factory Option and Accessory Connections NOTICE Use copper conductors only. AC powered options or accessories available: • Battery charger • Engine coolant heater • Alternator heater • Battery warmer • CCV heater

Copyright © 2019 Cummins Inc. No. Description No. Description 1 AC Distribution Connector(s) FIGURE 7. AC ACCESSORY CONNECTIONS The battery charger, engine coolant heater, alternator heater, CCV heater, and battery warmer require power from a 120 VAC, 20 Amp protected circuit from the Main Distribution Panel. Use 12 AWG 75 °C (167 °F) conductors to make connection to the generator set AC distribution connector. DC Connections NOTICE When selecting and installing conduit to the generator set, account for any needed accessories, such as a remote display, etc.

Copyright © 2019 Cummins Inc. No. Description 1 DC Circuit Connector(s) FIGURE 8. DC CUSTOMER CONNECTIONS Automatic Transfer Switch DC Connections WARNING Failure to use an approved transfer switch can lead to the electrocution of personnel working on the utility lines, damage to equipment, fire, or personal injury. An approved switching device must be used to prevent interconnection to the public utility.

Copyright © 2019 Cummins Inc. Install the transfer switch in accordance with the appropriate RA Series Transfer Switch Owner Manual. The following image is an example that shows the location of the connectors in the generator set where the ATS DC control wires terminate. This is also the location of the connectors where load management control wires (if applicable) terminate. NOTICE Load management is only availble with air cooled product. Refer to the Wiring Diagrams appendix for generator set to RA transfer switch DC customer connections. NOTICE Class 1 wiring methods should be used for connecting the generator set and transfer switch signal wiring.

Copyright © 2019 Cummins Inc. FIGURE 9. EXAMPLE OF RA SERIES TRANSFER SWITCH DC CONNECTIONS LOCATION Drilling Locations for Electrical Connections Preferred routing of electrical leads is vertically through conduit that is installed in the mounting pad that terminates in the electrical connection areas. • Refer to the generator set foundation outline drawing in the Outline and System Drawings appendix for location of electrical connection areas. • In some cases, it may be necessary to route electrical leads horizontally in conduits that pass through the generator set chassis. • Refer to the figure below for available drilling space for conduit holes in the side of the chassis. Holes up to 7.6 cm (3 in) in diameter can be made in the chassis in the areas shown. Exceeding 7.6 cm (3 in) in diameter may cause failure of the chassis.

Copyright © 2019 Cummins Inc. • Comply with NEC and local codes and standards for installation of wires for electrical circuits. Refer to NEC standards for required wire bend radius and ampacity of load leads. No. Description No. Description 1 Circuit Breaker Side 3 Drilling Allowed (Shaded Areas) 2 DC (Left) and AC (Right) Connection Area FIGURE 10. DRILLING LOCATIONS FOR SIDE ELECTRICAL CONNECTIONS

Copyright © 2019 Cummins Inc. No. Description No. Description 1 Circuit Breaker 2 Maximum 7.6 cm (3 in) Bend Radius Gap FIGURE 11. CABLING ROOM FOR CIRCUIT BREAKER Grounding NOTICE The generator set is shipped from the factory with the neutral and equipment ground not bonded together. Refer to local codes and standards for grounding procedures. Battery CAUTION Ensure that the AC power to the battery charger is disconnected when installing the battery. CAUTION Wear proper safety protection when working around batteries. Keep open flames and sparks away from the equipment. NOTICE Only personnel knowledgeable of batteries and required precautions should perform or supervise battery servicing.

Copyright © 2019 Cummins Inc. NOTICE See the Important Safety Instructions section for complete battery-related safety information. The generator set requires a 12V battery (negatively grounded) for engine cranking and powering the electronic control system. When the generator set is running, the battery is charged from the engine-driven battery alternator. When the set is not running, an AC powered battery charger is needed to keep the battery charged. As part of the installation, make sure that the battery is secured to the battery tray with the strap provided. To connect the battery: 1. Connect the positive battery terminal. 2. Connect the negative battery terminal. 3. Make sure that the black and red battery cable boots are in place. Refer to the Model Specifications section for battery specifications. An optional thermostatically controlled battery heater is available for more reliable starting. To prevent injury due to accidental startup: • Do not connect the battery cables to the battery until the installation has been completed; • Make sure tools, rags, and body parts are kept away from any rotating parts or electrically live parts; and • Make sure it is time to start the generator set.

Copyright © 2019 Cummins Inc. FIGURE 12. TYPICAL BATTERY LOCATION

Copyright © 2019 Cummins Inc. 5 Startup and Configuration 5.1 Exercise Settings NOTICE When battery power is lost, these settings must be reset. NOTICE Not applicable without a single phase RA series transfer switch. To access the Clock/Exerciser Menu: 1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears. 2. Navigate through the screens to find and select Clock/Excr in the Service Menu. NOTICE The following screens represent the standard operator panel (that is, HMI211). If using an in-home operator panel, which may be additionally purchased as an option, the screens may look slightly different. This procedure applies to both operator panels.

8-2019 44 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. FIGURE 13. CLOCK/EXERCISER MENU NAVIGATION

8-2019 45 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. Updating Exercise Frequency (1-Phase ATS) NOTICE Not applicable without a single phase RA series transfer switch. To update the exercise frequency and dates on the Clock/Exerciser Menu: 1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears. 2. Access the Time Setup screen by selecting Clock Exerciser on the Genset Service Menu. 3. Press the down key on the Time Setup screen to access the Daylight Saving Adjust screen. 4. Select Adjust. 5. Press the down key on the Daylight Saving Adjust Start screen. 6. Select Adjust. 7. Press Exercise Schdr on the Daylight Saving Adjust End screen. 8. Press Adjust. When updating these settings, the functions of the keys are as follows: • The horizontal right arrow key is used to select successive blocks for editing settings on the screen. • Use the + or - keys to edit the following settings: ◦ Schdr Enable: Enable or Disable ◦ Exercise Schedule: Semi-Annual (every six months), Quarterly, Monthly, Bi-Monthly (the first and third week of every month based on the time set when the Bi-Monthly option is selected), or Weekly ◦ Exercise Schedule: Day, Hours, Minutes, AM/PM • Press Save to save any changes. After saving, the Save button changes to the Adjust button.

8-2019 46 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. FIGURE 14. EXERCISE FREQUENCY NAVIGATION Updating Exercise Duration (1-Phase ATS) NOTICE Not applicable without a single phase RA series transfer switch. To update the exercise duration on the Clock/Exerciser Menu: 1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears. 2. Access the Time Setup screen by selecting Clock Exerciser on the Genset Service Menu. 3. Press the down key on the Time Setup screen to access the Daylight Saving Adjust screen. 4. Select Adjust. 5. Press the down key on the Daylight Saving Adjust Start screen. 6. Select Adjust. 7. Press Exercise Schdr on the Daylight Saving Adjust End screen. 8. Press the down key on the Exercise Schdr Menu. 9. Press Adjust. When updating these settings, the functions of the keys are as follows: • The horizontal right arrow key is used to select the duration block for editing exercise duration. • Use the + or - keys to edit the exercise duration minutes.

8-2019 47 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. • Press Save to save any changes. After saving, the Save button changes to the Adjust button. FIGURE 15. EXERCISE DURATION NAVIGATION 5.2 Time Setup (1-Phase ATS) NOTICE When battery power is lost, these settings must be reset. NOTICE Not applicable without a single phase RA series transfer switch. To set up the generator set clock for the current date and time: 1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears. 2. Access the Time Setup screen by selecting Clock Exerciser on the Genset Service Menu. 3. Select Adjust. When updating these settings, the functions of the keys are as follows: • The horizontal right arrow key is used to select successive blocks for editing settings on the screen. • Select the left arrow to return to the previous screen. • Adjust values by using the + or - keys on the Adjust Menu of the Time Setup screen.

8-2019 48 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. • Press Save to save any changes. After saving, the Save button changes to the Adjust button. FIGURE 16. TIME SETUP SCREEN Updating Daylight Saving Adjust Screens Update Values on the Daylight Saving Adjust Screen 1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears. 2. Navigate to the Genset Service Menu. 3. Select Clock Exerciser to access the Time Setup screen. 4. Press the down key on the Time Setup screen to access the Daylight Saving Adjust screen. 5. Select Adjust. When updating these settings, the functions of the keys are as follows: TABLE 11. KEY FUNCTIONS ON THE DAYLIGHT SAVING ADJUST SCREEN Key/Button Function Horizontal right arrow key Select successive blocks for editing settings on the screen Left arrow key Return to the previous screen + or - keys Adjust values on the Adjust screen of the Daylight Saving Adjust screen Save button Save any changes; after saving, the Save button changes to the Adjust button

8-2019 49 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. FIGURE 17. "DAYLIGHT SAVING ADJUST SAVING TIME" SCREEN NAVIGATION Access and Update the Daylight Saving Adjust Start Screen 1. Press the down arrow key on the Daylight Saving Adjust screen. 2. Press Adjust. When updating these settings, the functions of the keys are as follows: TABLE 12. KEY FUNCTIONS ON THE DAYLIGHT SAVING ADJUST START SCREEN Key/Button Function Horizontal right arrow key Select successive blocks for editing settings on the screen + or - keys Adjust Month, Week, Day or Hour Save button Save any changes; after saving, the Save button changes to the Adjust button

8-2019 50 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. FIGURE 18. DAYLIGHT SAVING ADJUST START SCREEN Update the Daylight Saving Adjust End Screen 1. Press the down key on the Daylight Saving Adjust Start screen. 2. Press Adjust. When updating these settings, the functions of the keys are as follows: TABLE 13. KEY FUNCTIONS ON THE DAYLIGHT SAVING ADJUST END SCREEN Key/Button Function Horizontal right arrow key Select successive blocks for editing settings on the screen + or - keys Adjust Month, Week, Day or Hour Save button Save any changes; after saving, the Save button changes to the Adjust button

8-2019 51 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. FIGURE 19. DAYLIGHT SAVING ADJUST END SCREEN 5.3 Brightness and Contrast The Screen Adjust screen allows the contrast, brightness, and units to be set. To access the Screen Adjust screen: 1. From any Information screen, hold down the up and down arrows simultaneously for two seconds to gain access to the Service Menu screen. 2. Select Screen Adjust. To adjust the contrast, brightness, or units from the Screen Adjust screen: 1. From the Screen Adjust screen, select Adjust to access the screen variables. 2. Press the right arrow to move between the variables. 3. Adjust settings, and press Save to save any changes. When updating these settings, the functions of the keys are as follows: • The horizontal right arrow key is used to select successive blocks for editing settings on the screen. • Select the left arrow to return to the previous screen. • Adjust values by using the + or - keys on the Adjust screen of the Display Setup screen. • Press Save to save any changes. After saving, the Save button changes to the Adjust button.

8-2019 52 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. NOTICE The following screens represent the standard operator panel (HMI211). If using an in-home operator panel, which may be additionally purchased as an option, the screens may look slightly different. This procedure applies to both operator panels. FIGURE 20. BRIGHTNESS AND CONTRAST SCREEN NAVIGATION

8-2019 53 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. NOTICE Adjusting the brightness on the operator panel adjusts the brightness of both the LCD backlight and the LEDs on the display. The contrast should never be 0 or 100% on any of the screens. The default value for Brightness is 50%. 5.4 History and About Menu To access the History/About screen: 1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears. 2. Select History/About. 3. Advance through the screens to view information about the generator set, control, and display. NOTICE The following screens represent the standard operator panel (HMI211). If using an in-home operator panel, which may be additionally purchased as an option, the screens may look slightly different. This procedure applies to both operator panels.

8-2019 54 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. FIGURE 21. HISTORY/ABOUT MENU

8-2019 55 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. 5.5 Startup WARNING Automated Machinery Accidental or remote starting of the generator set can cause severe personal injury or death. Isolate all auxiliary supplies and use an insulated wrench to disconnect the starting battery cables, negative (–) cable first. After verifying that the installation was completed correctly, start and test the system. Make sure to connect the battery cables to the battery with the positive (+) cable first. Read through the Operator Manual and perform the maintenance and pre-start checks as instructed. The following information applies to C70 N6, C80 N6, and C100 N6 generator set models only: Adaptive learn is an engine ECM function that allows the generator set to "learn" its environment. There are small differences in the performance of each engine and fuel system component, so the ECM uses inputs from the engine sensors to adjust running conditions to operate more consistently for each individual generator set. After installation is complete and while testing the overall system function, the generator set must be run with no active faults under load (that is, transfer switch connected to maximum customer load available) until the engine temperature reaches 80 °C (175 °F) to allow the adaptive learn function to initialize. The generator set is shipped from the factory with the proper level of engine oil and coolant, but each should be checked before the generator set is started. Start and operate the generator set following all the instructions and precautions in the Operator Manual. Ensure that the bonding bolts are installed into the service panels before leaving the site. NOTICE Before leaving the site, if the generator set is ready to be placed in service, put the generator set in Auto mode to provide automatic standby power. NOTICE Contact your local Cummins service representative if you encounter a fault code.

8-2019 56 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. 5.6 Installation Checklist Tick General Items Generator set wattage capacity is sufficient to handle maximum anticipated load. At least 5 feet of clearance (or greater for housing door) is provided around the entire generator set for service and ventilation. The generator set is located in an area not subject to flooding. All operating personnel have read and are familiar with the generator set Operator manual, all health and safety procedures, warnings, cautions, precautions, and the other documentation supplied with the generator set. All operators have been thoroughly briefed on preventative maintenance procedures. All operators have read and understand all important safety instructions. Generator Set Support The floor, roof, or earth on which the generator set rests is strong enough and will not allow shifting or movement. Observe local codes on soil bearing capacity due to freezing and thawing. The generator set is properly supported and retained to an approved base The supporting base is large enough and is of non-combustible material, extending 6 inches (152.4 mm) all around the generator set. Cooling Air Flow Generator set air inlet is faced into direction of strongest, prevailing winds. Cooling air outlet is on downwind side of building (if not, wind barrier is constructed). Diesel Fuel System Fuel tanks meet or exceed all local, state, or national codes (if applicable). Fuel lines are properly installed, supported, and protected against damage. The fuel filters have been installed (if applicable). Strainer or fuel screen (100 to 200 mesh) is installed in the fuel supply line to protect the day tank transfer pump, or float valve seat from fuel tank debris (if applicable). The fuel filter assembly shipped with the generator set is installed and operational (if applicable). Fuel supply shutoff valves are installed to prevent fuel flow in case of leaks (if applicable). No shutoff valves are installed on engine fuel return line. External fuel pumps are connected and operational at all times - generator set started or shut down (if applicable). Fuel tanks are filled with the correct grade / type of fuel.

8-2019 57 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. Tick General Items Fuel system is properly primed. No fuel leaks are found in supply line or engine fuel system. Exhaust System The breather tube routing is set up to blow the fumes away from the generator set (if applicable) Operators are thoroughly briefed on the dangers of carbon monoxide gas. Areas around generator set are well ventilated. No possibility of exhaust fumes entering building doors, windows, or intake fans. Exhaust gases are piped safely outside and away from building. AC and DC Wiring Wire sizes, insulation, conduits and connection methods all meet applicable codes. AC and DC wires are separated in their own conduit to prevent electrical induction. All load, line and generator connections are well made and correct. Phase rotation is correct. Generator Set Pre-Start Generator set engine is properly serviced with oil and coolant. Battery charger is installed using the appropriate cable size and is operational (if applicable). Battery charger is configured for the proper DC battery voltage, battery type, and float voltage (if applicable). Batteries are properly installed, serviced and charged. Engine coolant heater is connected and operational (if applicable). All generator set covers and safety shields are installed correctly. All fuel and coolant shutoff valves are operational (if applicable). 5.7 InPower Service Tool The InPowerTM service tool can be used in troubleshooting to perform tests, verify control inputs and outputs, and test protective functions. Refer to the InPower User's Guide, provided with the InPower software for test procedures. Disabling the AMF Feature NOTICE This procedure must be performed by a qualified technician.

8-2019 58 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. On single-phase units, the control is shipped with the Automatic Mains Failure (AMF) feature enabled. This feature has logic to control the RA Automatic Transfer Switch (ATS), including a 5-minute retransfer to utility delay. If you are not using an RA ATS, you can eliminate the 5-minute retransfer to utility delay by disabling the AMF feature using the instructions below. NOTICE This procedure is optional. If you do not disable the AMF feature, the generator set will just run for an additional 5 minutes after the utility has been restored. NOTICE These steps cannot be performed with the HMI211; they can only be performed with the InPower service tool. 1. Connect to the PCC 1.1 or PCC 2.3 via InPower. 2. Navigate to the Adjustments->Features->Automatic Transfer Switch folder. 3. Select the Auto Mains Failure Enable parameter. 4. Double-click on Enabled in the Value field. 5. A pop-up will appear with available choices. Select Disabled. 6. Select Device->Save Adjustments from the top menu bar. 7. A pop-up will appear asking if the change is to be saved. Click the Save button. 8. After a pop-up appears confirming that the change has been saved, disconnect InPower from the PCC1302.

Copyright © 2019 Cummins Inc. Appendix A. Diesel Fuel Piping Table of Contents Table 15. Minimum Fuel Hose and Pipe Sizes; Up to 50 Feet (15 Meters) Equivalent Length. ............ 61

8-2019 60 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. A.0 Diesel Fuel Piping Requirements • Diesel fuel lines should be constructed from black iron pipe. Cast iron and aluminum pipe and fittings must not be used because they are porous and can leak fuel. Galvanized fuel lines, fittings, and tanks must not be used because the galvanized coating is attacked by the sulfuric acid that forms when the sulfur in the fuel combines with tank condensate, resulting in debris that can clog fuel pumps and filters. Copper lines should not be used because fuel polymerizes (thickens) in copper tubing during long periods of disuse and can clog fuel injectors. Also, copper lines are less rugged than black iron, and thus more susceptible to damage. NOTICE Never use galvanized or copper fuel lines, fittings or fuel tanks. Condensation in the tank and lines combines with the sulfur in the diesel fuel to produce sulfuric acid. The molecular structure of the copper or galvanized lines or tanks reacts with the acid and contaminates the fuel. • Approved flexible fuel hose must be used for connections at the engine to take up generator set movement and vibration. • Piping from a day tank to the engine should run “downhill" all the way from the tank to the engine, with no overhead loops that can allow air to be entrained in the system. • Fuel system piping should be properly supported to prevent vibration and breakage due to vibration. The piping should not run close to heating pipes, electrical wiring, or engine exhaust system components. The piping system design should include valves at appropriate locations to allow isolation of system components for repair without draining the entire fuel system. • Piping systems should be regularly inspected for leaks and general condition. The piping system should be flushed before operation of the engine to remove dirt and other impurities that could damage the engine. Use of plugged “T" connections rather than elbows allows for easier cleaning of the piping system. • The engine manufacturer's data indicates the maximum fuel inlet and return restrictions, the maximum fuel flow, supply and return, and the fuel consumption. The table below indicates minimum hose and pipe sizes for connections to a supply tank or day tank when it is within 50 feet (15 meters) of the set and at approximately the same elevation. Hose and pipe size should be based on the maximum fuel flow rather than on the fuel consumption. It is highly recommended that the fuel inlet and return restrictions be checked before the generator set is placed in service.

8-2019 61 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. TABLE 15. MINIMUM FUEL HOSE AND PIPE SIZES; UP TO 50 FEET (15 METERS) EQUIVALENT LENGTH. Max Fuel Flow Rate GPH (L/hr) Flex Hose No.* NPS Pipe Size (in) DN Pipe Size (mm) Less than 80 (303) 10 ½ 15 81-100 (304-378) 10 ½ 15 101-160 (379-604) 12 ¾ 20 161-230 (605-869) 12 ¾ 20 231-310 (870-1170) 16 1 25 311-410 (1171-1550) 20 1-1/4 32 411-610 (1550-2309) 24 1-1/2 40 611-920 (2309-3480) 24 1-1/2 40 * Generic fuel hose suppliers' size specification.

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Copyright © 2019 Cummins Inc. Appendix B. Outline and System Drawings Table of Contents Figure 22. Generator Set Outline, Open (25 kW, 30 kW, 35 kW, 40 kW) (Sheet 1 of 2) ......................... 65 Figure 23. Generator Set Outline, Open (25 kW, 30 kW, 35 kW, 40 kW) (Sheet 2 of 2) ......................... 66 Figure 24. Generator Set Outline, Open (50 and 60 kW) (Sheet 1 of 2) .................................................. 67 Figure 25. Generator Set Outline, Open (50 and 60 kW) (Sheet 2 of 2) .................................................. 68 Figure 26. Short Enclosure Outline, Sound Attention Level 1 and Level 2 (Sheet 1 of 2) .................... 69 Figure 27. Short Enclosure Outline, Sound Attention Level 1 and Level 2 (Sheet 2 of 2) .................... 70 Figure 28. Foundation Outline, Without Fuel Tank (Sheet 1 of 1) ........................................................... 71 Figure 29. Foundation Outline, With Regional Fuel Tank (Sheet 1 of 1) ................................................ 72 Figure 30. Foundation Outline, With Basic Fuel Tank (Sheet 1 of 1) ...................................................... 73 Figure 31. Circuit Breaker Outline (Sheet 1 of 1) ...................................................................................... 74 Figure 32. Wiring Diagram (Sheet 1 of 8) ................................................................................................... 75 Figure 33. Wiring Diagram (Sheet 2 of 8) ................................................................................................... 76 Figure 34. Wiring Diagram (Sheet 3 of 8) ................................................................................................... 77 Figure 35. Wiring Diagram (Sheet 4 of 8) ................................................................................................... 78 Figure 36. Wiring Diagram (Sheet 5 of 8) ................................................................................................... 79 Figure 37. Wiring Diagram (Sheet 6 of 8) ................................................................................................... 80 Figure 38. Wiring Diagram (Sheet 7 of 8) ................................................................................................... 81 Figure 39. Wiring Diagram (Sheet 8 of 8) ................................................................................................... 82 Figure 40. Outline Drawing (Sheet 1 of 1) .................................................................................................. 83 Figure 41. Outline Drawing (Sheet 1 of 2) .................................................................................................. 84 Figure 42. Outline Drawing (Sheet 2 of 2) .................................................................................................. 85

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8-2019 65 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. FIGURE 22. GENERATOR SET OUTLINE, OPEN (25 KW, 30 KW, 35 KW, 40 KW) (SHEET 1 OF 2)

8-2019 66 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. FIGURE 23. GENERATOR SET OUTLINE, OPEN (25 KW, 30 KW, 35 KW, 40 KW) (SHEET 2 OF 2)

8-2019 67 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. FIGURE 24. GENERATOR SET OUTLINE, OPEN (50 AND 60 KW) (SHEET 1 OF 2)

8-2019 68 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. FIGURE 25. GENERATOR SET OUTLINE, OPEN (50 AND 60 KW) (SHEET 2 OF 2)

8-2019 69 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. FIGURE 26. SHORT ENCLOSURE OUTLINE, SOUND ATTENTION LEVEL 1 AND LEVEL 2 (SHEET 1 OF 2)

8-2019 70 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. FIGURE 27. SHORT ENCLOSURE OUTLINE, SOUND ATTENTION LEVEL 1 AND LEVEL 2 (SHEET 2 OF 2)

8-2019 71 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. FIGURE 28. FOUNDATION OUTLINE, WITHOUT FUEL TANK (SHEET 1 OF 1)

8-2019 72 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. FIGURE 29. FOUNDATION OUTLINE, WITH REGIONAL FUEL TANK (SHEET 1 OF 1)

8-2019 73 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. FIGURE 30. FOUNDATION OUTLINE, WITH BASIC FUEL TANK (SHEET 1 OF 1)

8-2019 74 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. FIGURE 31. CIRCUIT BREAKER OUTLINE (SHEET 1 OF 1)

8-2019 75 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. FIGURE 32. WIRING DIAGRAM (SHEET 1 OF 8)

8-2019 76 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. FIGURE 33. WIRING DIAGRAM (SHEET 2 OF 8)

8-2019 77 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. FIGURE 34. WIRING DIAGRAM (SHEET 3 OF 8)

8-2019 78 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. FIGURE 35. WIRING DIAGRAM (SHEET 4 OF 8)

8-2019 79 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. FIGURE 36. WIRING DIAGRAM (SHEET 5 OF 8)

8-2019 80 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. FIGURE 37. WIRING DIAGRAM (SHEET 6 OF 8)

8-2019 81 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. FIGURE 38. WIRING DIAGRAM (SHEET 7 OF 8)

8-2019 82 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. FIGURE 39. WIRING DIAGRAM (SHEET 8 OF 8)

8-2019 83 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. FIGURE 40. OUTLINE DRAWING (SHEET 1 OF 1)

8-2019 84 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. FIGURE 41. OUTLINE DRAWING (SHEET 1 OF 2)

8-2019 85 A047W865 (Issue 9) Copyright © 2019 Cummins Inc. FIGURE 42. OUTLINE DRAWING (SHEET 2 OF 2)

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Copyright © 2019 Cummins Inc. Appendix C. Seismic Requirements Table of Contents Figure 43. Seismic Installation Specifications .......................................................................................... 89 Figure 44. Seismic Installation Notes ........................................................................................................ 90 Figure 45. Seismic Installation Requirements .......................................................................................... 91

Copyright © 2019 Cummins Inc. The drawings included in this section are representative. For current complete information, refer to the drawing package that was shipped with the unit.

Copyright © 2019 Cummins Inc. C.1 Seismic Installation Instructions FIGURE 43. SEISMIC INSTALLATION SPECIFICATIONS

Copyright © 2019 Cummins Inc. FIGURE 44. SEISMIC INSTALLATION NOTES

Copyright © 2019 Cummins Inc. FIGURE 45. SEISMIC INSTALLATION REQUIREMENTS

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Cummins, the "C" logo, PowerCommand, AmpSentry, and InPower are trademarks of Cummins Inc. Other company, product, or service names may be trademarks or service marks of others. Specifications are subject to change without notice.