Low Range Generator Set - Startup Checklist

Instructions: the following form should be completed for each Arrow pilot product installation. There are 4 sections.
It is important to complete the information to provide valuable market data to the team and to validate the completion of
generator set startup procedure under Cummins Power Generation recommendations. Please email completed form to Caroline
Njogu, email: caroline.njogu@cummins.com

SECTION I - GENERAL INFORMATION

Cummins Authorized Representative Performing Startup
Name:
Distributor/Dealer:
Branch/Dealer Location:
Branch/Dealer Address:
Branch/Dealer Phone Number:
Customer Information Installation Contractor (if not done by dealer)
Name: Name:
Address: Address:
City, State & Zip Code: City, State & Zip Code:
Office Phone #: Office Phone #:
Product Information
Genset Model: Automatic Transfer Switch (ATS) Model:
Serial Number: Serial Number:
Sales Information
Dealer price ($): Lead Source:
Customer Price ($): Date sold:
Customer Installed Cost ($):
Application Information
Market Segment: Residential Light Commercial Other:

SECTION II - INSTALLATION (see Appendix I for guidelines)

Genset
Safety & Installation Checks Exhaust System inspected
Cooling System Inspection Electrical System inspected
Lubrication System checked Control System checked
Starting System connected & operational
Fuel System Diesel LP Natural Gas
Tank Size (gallons/liters)
Fuel Line Length (ft/m)
Fuel Line I.D. (inches/mm)
Fuel Level (Empty, 1/4, 1/2, 3/4, Full)
Automatic Transfer Switch
Remote start wiring to Engine / Generator Visual check main contactors
Remote battery charger installed Contactor block removed
Sized & torqued terminals AC load , generator & utility All safety covers in place
General Inspection (Final Check before Startup)
Wiring Clearances Fluids/Leaks
Hoses Supports Ready for Startup
SECTION III - COMMISSIONING (see Appendix II for guidelines)
Start and Warm Up Period NO LOAD
Check phase rotation (only if 3 phase): Clockwise Counter Clockwise
Warm up Period (Add Load)
Air-Fuel Ratio (AFR) setting (gaseous fuel only)
Frequency (Hz)
Voltage (VAC): L1-L2 L1-N L2-N N-Ground
Check local stop / emergency stop control checked
Remote start / stop / emergency stop checked
Test Underload
Customer Loads Yes No Load achieved (Amps):
Load Bank Test: Yes No Load achieved (Amps):
Complete Automatic Restart Period: Selector switch in "remote"
Simulate power failure "Main Breaker disconnect"
Generator set operational Automatic operations checked
Transfer switch operational All safety shutdowns and warnings operational
Automatic Load Transfers: Transfer to emergency ok
Retransfer to normal ok
Engine shut down ok
Ensure time delays and setpoints are to customer request
Set exerciser clock
Day Duration With Load Without Load
Make sure start switch is in "automatic"
Make sure customer is aware of exerciser time delays

SECTION IV - CPG WARRANTY INITIATION

Product Registered http://now.cumminspower.com/?elqPURLPage=263

Special notes or comments:

Technician performing Startup & Product Registration:

Name:

Signature: Date:
 Low Range Generator Set - Startup Checklist
APPENDIX I - INSTALLATION GUIDELINES
Safety & Installation Checks
Generator set is level - mounting bolts secure
Pipework and cables are secure with no trip hazards
Overhead obstructions clearly marked and labeled
Electrical bonding complete
Ensure starting is inhibited until startup is required
Set clean and fully assembled
No loose materials near genset
Air ducts clear and clean
Access & egress routes unobstructed and labeled
Control & maintenance positions unobstructed
Room secure - no unauthorized access
Personnel warned of start-up process

Cooling System Inspection

Liquid cooled - appropriate coolant level
Air cooled or Radiator air flow outlet free from obstructions
Air cooled or Radiator air flow inlet free from obstructions
Radiator overflow clear and routed to avoid blockeage or pollution
Radiator filled with correct coolant & cap secured
Belts checked for alignment , tension , and damage
Guards in place and secure
Energize coolant heater supplies and check function
Coolant heater if equiped energized and operational, fitted and valves open
Radiator , engine & pipe work checked for leaks
Coolant heater operational

Diesel Fuel System (only for diesel units)

Bulk Storage Facility
Bulk storage tank filled
Tank contents gauge and alarm contacts checked
Electrical bonding complete
Bulk system checked for leaks
Vent and overflow pipes open
Isolating valves correctly positioned
Transfer pump & controls operational
Pipeline / tank heating system operational
Fill point alarm operational
Storage facility secure
Flexible fuel connections checked supply and return
Check fuel return line to main tank (one size larger)
Day Tank
Isolating and solenoid valves checked for operation
Engine fuel return open
Tank filled
Air purged from system
Spillage containment & alarms operational
Transfer pump operational
Leak check
Fire valves & release tested and operational
Wiring properly landed

Gas Fuel System (only for gas units)

Isolating valves correctly positioned and checked
Flexible fuel connections checked
Gas present at shut off valves
Regulator set to correct pressure
Gas leak detection equipment operational
Leak test complete
Purging complete
Correct pipe sizing

Lubrication System
Type and weight of oil
Engine oil pan filled to correct level
Level alarms checked

Starting System
Battery Starting
Batteries installed , filled & connected
Proper battery size and voltage
Correct polarity
Batteries isolated from floor
Electrolyte level
Battery charger operational
Boost / float controls & instruments checked, set to correct specs

Exhaust System
Check security of piping & muffler
Check all flanges , joints & welds
Check stack /tail pipe and rain cap are clear and operational
Check exhaust condensation trap
Check for correct exhaust pipe sizing
Check for long-radius exhaust elbows
Check for hot air recirculation
Electrical System
Engine water jacket heater wired to normal source
Fuel solenoid valve wired to ignition system
Remote start wiring to Transfer Switch
Operation selector switch to proper position
Proper generator AC wiring connections
Wiring to remote display or annunciator
Ethernet cable run for local or remote monitoring
System grounded properly

Control Systems
Visual check completed
Energize set controls and check functionality
Energize system controls and check functionality
Download capture file
Control system calibration checked
Customer remote indication / controls checked
Generator output connections proper for desired voltage
Set parameters on set / system control
Enter / verify engine & alternator protection settings
 APPENDIX II - COMMISSIONING GUIDELINES
Start and Warm Up Period NO LOAD
Field circuit breaker "off"/reset/not tripped
Start engine (Selector switch in "run" position)
Field circuit breaker "on"
Check high leg placement
Check phase rotation (3-phase only)
Unusual noises / vibrations
Allow for proper no load warm-up

Warm up Period (Add Load)

Selector switch in the "run" position
Apply load
Air-Fuel Ratio (AFR) setting
Check for overload
Check local stop / emergency stop control checked
Remote start / stop / emergency stop checked

Generator Set Load Test

Load test completed using customer load

Load Bank Test

Check load bank voltage and power capability
Check cables installed correctly & tightened
Energize auxiliary supplies and check functionality
Load test completed
Record load achieved

Complete Automatic Restart Period

Selector switch in "remote"
Simulate power failure " Main breaker disconnect"

Engine / Generator
Generator set operational
Changeover / transfer switch operational
Automatic operations checked
All safety shutdowns and warnings operational
Automatic Load Transfer Switch
Transfer to emergency ok
Return load to normal "Main breaker on to restore line power
to Transfer Switch
Retransfer to normal ok
Time delays time out properly
Engine shut down ok
Make sure start switch is in "automatic"