
10
Installation Recommendations
Electrical design
Electrical design
Genset / Engine Controls
The generator set is controlled locally by a dedicated
Generator Control Panel. This incorporates the control
systems, metering, alarm indications and customer
connections.
Two types of control system are currently available;
Engine Governing, Control System and Power Command
Control.
A. Make sure that the polarity of the battery connections
are correct before applying power to the all Electronic
Controls.
B.Do not test wire leads to see if they are ‘live’ by
flashing them on either engine body or the Control
mounting stand.
C.Disconnect all connections to the control system on
engine / genset before doing any welding work on set.
D.There are no user serviceable parts inside the various
controls supplied along with Cummins engine / genset.
Call the nearest Cummins office / dealer for help.
E. Turn off or remove AC power from the battery charger
and then remove –ve battery cable from the engine /
genset battery. This will avoid possible damage and
someone else starting engine / Genset accidentally.
F. Make sure the battery area is well ventilated before
servicing the battery. Arcing can cause explosion due
to hydrogen gas given off by batteries.
G.Always refer to the wiring diagram and product manual
supplied with the engine / genset for details.
Electrical protection
If the overload and short circuit protection is provided by
a circuit breaker, care must be taken with the protection
settings. Circuit breakers are designed for operation with
the utility supply, which can provide much higher and
longer fault levels than a generator. The circuit breaker
overcurrent and short circuit settings should therefore be
set according to the overcurrent/short circuit curves of
the circuit breaker and not the overcurrent/short circuit
dials on the circuit breaker. The generator overload and
short circuit settings on the protection should be set so
that they are below the thermal damage curve for the
generator.
Cabling
A. Overheating due to loose thumbing / undersize
cables causes most of electrical failures, hence
power cabling between alternator and control panel
and control panel and change over switch to mains
should be done with correct size of cables and
thimbles.
B.While terminating cables avoid any tension on the
bolts / busbars.
C.While terminating R.Y.B. phase notations should be
maintained in the alternator and control panel for easy
maintenance.
D.Crimped cables should be connected to alternator
and control panel through cable glands.
E. For AMF application, use 8/10 core 2.5 sq. mm
armoured copper cable for control cabling.
F. Typical cable sizes for 415 V application are provided in
the table which are indicative, please refer to cable
manufacturers for details. For HT installations, kindly
contact GOEM’s for details on sizing.
Proper cable terminations
Earthed cable glands for
crimped cables
Typical Cable Sizes for DG Sets
kVA Rating Amp Rating Cable size Sq. mm x Runs
2000 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 6
600 835 240 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 (Single Phase) 125 50 x 2 -- --
20 (Single Phase) 80 35 x 2 -- --
15 (Single Phase) 63 25 x 2 -- --
Notes:
1. Use 3 1/2 core armoured power cables woth aluminium conductor (AYFY).
2. Current rating of cables are taken based on operating temperature of 70
0
C.
3. For multiple runs of cables, deration factor of 0.75 is considered i.e. 25% deration applied.
4. AYFY: Aluminium conductor, PVC insulation, Steel strip armour, PVC outer sheath.
5. Cable sizes mentioned are in square mm.
6. For sets above 1000 kVA, use of proper busbars in bus ducts is recommended.
7. Earthing as per IEC rules to be provided.
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