HHP Natural Gas Engine & Generator Controls

MODULE 3
‘V’ Engine Controls
 Questions
1. Natural Gas is lighter than air. True or True
False?

2. The fuel inlet pressure at the engine is? 150mBar

3. Engine speed is governed by which CM700 (MCM700).

Control Module?

4. CM700 engine speed is measured by? Flywheel mounted speed

sensors.

5. CM558 engine position is measured by? Camshaft mounted position

sensors.

Do you need to review your Self-Study CD-ROM before the end of this
course? You WILL be tested on topics covered in the CD-ROM.

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 2
 Questions
1. Which engine module controls ignition CM558 (SSM558).
timing?

2. On ‘V’ engines, which module supplies The CCD module.

voltage to the Ignition Coils?

3. Approximately, what voltage does the 300vDc.

CCD Module supply to the Coil-on-Plug
units?
4. The definition of engine knock is? The uncontrolled combustion of
the air/fuel mixture BEFORE or
AFTER the spark event.

5. Engine position is measured by? Crankshaft and Camshaft

mounted position sensors.

Do you need to review your Self-Study CD-ROM before the end of this
course? You WILL be tested on topics covered in the CD-ROM.
CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 3
Engine Controls

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 4
 Controls
Network Line Diagram

AUX101 AUX101 AUX101

J1939 “PGI CAN” CENSE STCD
3 5 4 J1939 “PGI CAN”
250k Baud 250k Baud

STCB
STCC
PCCNet
19.2k Baud

REMOTE CM558 CM558 CM850 CM850

HMI320 & PCC3300 CM700
HMI114
A B A B

CAN 2.0B
LOCAL STCA 500k Baud
HMI320 &
HMI114 J1587
PCCNet 9.6k Baud RMS
19.2k Baud Customer
iWatch
Modbus
InPower Wireless

Modbus
RS232 – 19.2k Baud

Modbus
RS485 – 19.2k Baud

NOTE: CENSE OR CM850 are used, not

both as shown in the Network Line Diagram)
CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 5
 Engine Controls
COMPONENT OUTPUT SENSORS SENSORS SENSORS
- CCD Sync / Fire - Engine Speed - EGT’s - EGT’s
- Battery Conservation - Engine Position (A1 A8) (A9, B9)

C2000 N5C / N6C

Power Down Relay - Knock (B1 B8)

CM558 TC
CCD CENSE
(B) Converter

18 16 14 12 10 8 6 4 2 SENSORS
- Coolant Temperature (HT & LT)
- Coolant Pressure (HT & LT)
QSV91 PhII Single Turbo Alternator - Engine Lube Oil Temperature
- Engine Lube Oil Pressure
- Compressor Inlet Air Temperature
- Turbocharger Speed
17 15 13 11 9 7 5 3 1 - Crankshaft Speed
PCC3300 INPUT
- Speed Bias
- Shutdown
CM558 - Electrical Load (kW)
CCD CM700 PCC3300
(A) - Idle / Rated Command
- Start / Stop Command
SENSORS COMPONENT OUTPUT - Utility Breaker State
COMPONENT OUTPUT - Boost Pressure - Start Solenoid - Fuel Control Valve Position
- Throttle Driver - Intake Manifold Temperature
- Fuel Control Valve Driver - Intake Manifold Pressure COMPONENT INPUT
- CCD Sync / Fire - Fuel Inlet Pressure - Power Down Relay
- Fuel Outlet Pressure - ECM Keyswitch
- Engine Speed
- Engine Position
- Gas Mass Flow
- Knock
COMPONENT INPUT
- Throttle Actuator Position
- Fuel Control Valve Position
CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 6
 SENSORS
- Boost Pressure
- Intake Manifold Temperature
- Intake Manifold Pressure
- Fuel Inlet Pressure

Engine Controls
- Fuel Outlet Pressure
COMPONENT OUTPUT - Engine Speed
- Throttle Driver - Engine Position
- Fuel Control Valve Driver - Gas Mass Flow
- CCD Sync / Fire - Knock SENSORS
SENSORS
C1540 N5C / N6C
C1750 N5C / N6C
- Battery Conservation - EGT’s
COMPONENT INPUT - EGT’s
Power Down Relay (A1 A8) (A9, B9)
- Throttle Actuator Position
(B1 B8)
C1250 N6C
- Fuel Control Valve Position

CM558 TC
CCD CENSE
(B) Converter

18 16 14 12 10 8 6 4 2 SENSORS
- Coolant Temperature (HT & LT)
- Coolant Pressure (HT & LT)
QSV91 PhI Multi Turbo Alternator - Engine Lube Oil Temperature
- Engine Lube Oil Pressure
- Compressor Inlet Air Temperature
- Turbocharger Speed
17 15 13 11 9 7 5 3 1 - Crankshaft Speed
PCC3300 INPUT
- Speed Bias
- Shutdown
CM558 - Electrical Load (kW)
CCD CM700 PCC3300
(A) - Idle / Rated Command
- Start / Stop Command
SENSORS COMPONENT OUTPUT - Utility Breaker State
COMPONENT OUTPUT - Boost Pressure - Start Solenoid - Fuel Control Valve Position
- Throttle Driver - Intake Manifold Temperature
- Fuel Control Valve Driver - Intake Manifold Pressure COMPONENT INPUT
- CCD Sync / Fire - Fuel Inlet Pressure - Power Down Relay
- Battery Conservation - Fuel Outlet Pressure - ECM Keyswitch
Power Down Relay - Engine Speed
- Engine Position
- Gas Mass Flow
- Knock
COMPONENT INPUT
- Throttle Actuator Position
- Fuel Control Valve Position CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 7
 SENSORS
- Boost Pressure
- Intake Manifold Temperature
- Intake Manifold Pressure
- Fuel Inlet Pressure

Engine Controls
- Fuel Outlet Pressure
- Engine Speed
COMPONENT OUTPUT - Engine Position
- Throttle Driver

C1160 N5C
- Gas Mass Flow
- Fuel Control Valve Driver - Knock
- CCD Sync / Fire

C1000 N6C
- Battery Conservation COMPONENT INPUT
Power Down Relay - Throttle Actuator Position SENSORS
- Fuel Control Valve Position - EGT’s
C1100 N6C
CM558
CCD CENSE
(A)
A1

A2

A3

A4

A5

A6

A7

A8
SENSORS
2 4 6 8 10 12 14 16 - Coolant Temperature (HT & LT)
- Coolant Pressure (HT & LT)
- Engine Lube Oil Temperature
QSK60G PhII Multi Turbo Alternator - Engine Lube Oil Pressure
- Compressor Inlet Air Temperature
- Turbocharger Speed
- Crankshaft Speed
B1

B2

B3

B4

B5

B6

B7

B8
1 3 5 7 9 11 13 15
- Crankcase Blow-By
PCC3300 INPUT
- Speed Bias
CM558 - Shutdown
CCD CM700 PCC3300 - Electrical Load (kW)
(B)
- Idle / Rated Command
- Start / Stop Command
COMPONENT OUTPUT SENSORS COMPONENT OUTPUT - Utility Breaker State
- Throttle Driver - Boost Pressure - Start Solenoid - Fuel Control Valve Position
- Fuel Control Valve Driver - Intake Manifold Temperature COMPONENT INPUT
- CCD Sync / Fire - Intake Manifold Pressure - Power Down Relay
- Battery Conservation - Fuel Inlet Pressure - ECM Keyswitch
Power Down Relay - Fuel Outlet Pressure
- Engine Speed
- Engine Position
- Gas Mass Flow
- Knock
COMPONENT INPUT
- Throttle Actuator Position
- Fuel Control Valve Position CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 8
 SENSORS
- Boost Pressure
- Intake Manifold Temperature
- Intake Manifold Pressure
- Fuel Inlet Pressure

Engine Controls
- Fuel Outlet Pressure
- Engine Speed
COMPONENT OUTPUT - Engine Position
- Throttle Driver
- Fuel Control Valve Driver
- Gas Mass Flow
- Knock C995 N5C
- CCD Sync / Fire
- Battery Conservation Power
COMPONENT INPUT
- Throttle Actuator Position
C1400 N5C / N6C
Down Relay
- Fuel Control Valve Position SENSORS
- Compressor By-Pass Driver
- Compressor By-Pass Position - EGT’s (A1 A8)

CM558 CM850
CCD
(A) (A)

SENSORS
2 4 6 8 10 12 14 16 - Coolant Temperature (HT & LT)
- Coolant Pressure (HT & LT)
- Engine Lube Oil Temperature
QSK60G PhIV Single Turbo Alternator - Engine Lube Oil Pressure
- Compressor Inlet Air Temperature
- Turbocharger Speed
- Crankshaft Speed
1 3 5 7 9 11 13 15
- Crankcase Blow-by
PCC3300 INPUT
- Speed Bias
- Shutdown
CM558 CM850 CM700 PCC3300 - Electrical Load (kW)
CCD - Idle / Rated Command
(B) (B)
- Start / Stop Command
COMPONENT OUTPUT - Utility Breaker State
- Start Solenoid - Fuel Control Valve Position
COMPONENT OUTPUT SENSORS
- CCD Sync / Fire - Engine Speed SENSORS COMPONENT INPUT
- Battery Conservation - Engine Position - EGT’s (B1 B8) - Power Down Relay
Power Down Relay - Knock - ECM Keyswitch

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 9
 Engine Controls
CM700 Operational State Control
Transient
Stop / Start STOP Conditions From
Switch Stop / Start Stop / Start
Authorized
STOP Engine RPM = 0 Normal Shutdown No Shutdown
Reset E - Shutdown Transient
Normal Shutdown Condition Occurred Signals, No
Key Switch Conditions From
Condition Not Active Previous System
OFF and Engine RPM = 0, Stop / Start VENT Condition
Authorized Then Key Switch ON No Shutdown Signals,
E - Shutdown Previous System
OR Power Cycle
Condition Occurred Vent Condition
Engine Modules

Start Cycle
Authorized Authorized Finished OR Authorized
Normal Shutdown
Authorized
Normal Shutdown N_SHUTD E_SHUTD VENT START
Condition Active
Vent Cycle
Finished
Authorized
Normal Shutdown Authorized
Condition Occurred E- Shutdown Condition Occurred

Authorized
Normal Shutdown Condition Occurred
Authorized
E - Shutdown
Condition Occurred

Authorized Engine Speed > 200 RPM

Normal Shutdown RUN
Condition Active
CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 10
 Engine Controls
Shutdown Controls
CM558A

Isolated Battery (+24v) A49 + 24volts

Isolated Battery (+24v) A50 FS FS
CM558A O 1 O2
Fuel Shut Off + A43 FSO Relay VPS
Fuel Shut Off – A44 (KM14)
CM700
CM558B FSO Relay
+ 24volts
Isolated Battery (+24v) A49 (KM15) Fuel Shut-off
Isolated Battery (+24v) A50 Valve with Valve
Proving System
CAN 2.0B
(FSO)
CM700 Datalink

FSO Control (HSD) A43

Throttle Driver +24 Volts
IGNITION
(Enable) MODULE
L-BANK
Compressor
Bypass IGNITION
Fuel Control MODULE
R-BANK
Valve (FCV)

+24 Volts Battery

Battery Conservation (lsd) B39 Conservation
Relay
+24 Volts (KM13)
PCC 3.3
PCC 3.3
FSO
Stop
Relay
(LSD)
AUX 101-3 (KM20)
Isolated Battery (+24v) A49 (Vent Fan Louvre cont).
Local / Remote
Isolated Battery (+24v) A50 E-Stop Push B’s
E-Stop Input (Bis 20) C27 ( via KM17/18/AUX101)
E-
A3 Stop
A13
E-Shutdown
J1939 System Bus Status
(A3+ / A13- / A4 A4 (KM1
screen) 1)
Normal & Emergency Shutdown +24 Volts +24 Volts
Requests to / from PCC3300
CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 11
 Engine Controls
CCD & CM558 Modules

CM558
Capacitive Coil Driver (CCD)

The Ignition System operating principle is the same for all Cummins HHP LBNG Gensets

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 12
 Engine Controls
>A>
CCD Wiring
COP # 1 >B>

>A>
COP # 2 J1939 (+)
>B>
• <P<
J1939 (–)
CM558 A Plug Pin 03
<R< CM558 A Plug Pin 13
J1939 Shield
>A> <U< CM558 A Plug Pin 04
Spark Timing A
>A> >R> <K< CM558 B Plug Pin 28
COP # 3 >B>
• <T<
Spark Reference A
CM558 B Plug Pin 27
>D> 1708 Com (+)
<H< Manual Selector Switch
>P> 1708 Com (–)
Manual Selector Switch
Capacitive Coil <J<
Keyswitch
>A> >B> <F<
COP # 4 Driver (CCD)
>B>
• >E> <D<
>N> <E<
(B Bank) ECM Ground
<B<
>F> Battery (–)
>A> <N<
COP # 5 >B>
• >C>
<A<
Battery (+)

• >G> <C<
Battery (+)
Battery (–)
<L<
ECM Ground
>A> <S<
COP # 6 >B>
•
>A>
COP # 7 >B>
• •
>A>
>B>
>A>
>B>

COP # 8 COP # 9
NOTE: QSV91G Wiring Example shown

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 13
 Engine Controls
CENSE / CM850 Module Location

CENSE
or
CM850

QSV91G

Thermocouple QSK60G
Converter

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 14
 Engine Controls
QSK60G HE – EGT THERMOCOUPLES – CM850
• CM850 modules have no K-Type inputs. Temp ( C) V (out)
Therefore Thermocouples with combined 0 4.2
K - Type signal converters are connected
to the CM850 modules. 50 3.95
100 3.7
• The signal converter is built into the 3-pin
harness plug. 150 3.45
200 3.2
• Temperature Vs sensor output is shown in
the table. The lower the output the higher 250 2.95
the temperature. 300 2.7

• Harness pin-out is : 350 2.45

Pin Layout 400 2.2

Pin 1 –Sensor Supply from ECM.
450 1.95
5.0 v dc.
500 1.7
Pin 2 - Sensor ground. 1 2 550 1.45
0 v. 600 1.2
Pin 3 – Sensor output voltage 3 4 650 0.95

0.2 to 4.2 v dc. 700 0.7

750 0.45
Pin 4 – not fitted / used.
800 0.2

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 15
 CENSE FCP
Connector B Connector
29 29 A Exhaust Port
39 28 B Temp Cyl 1
● ● ● ● ● ●
09 31 A Exhaust Port
19 30 B Temp Cyl 3
● ● ● ● ● ●
10 33 A Exhaust Port
40 32 B Temp Cyl 5
● ● ● ● ● ●
20 36 A Exhaust Port
30 35 B Temp Cyl 7
● ● ● ● ● ●
26 38 A Exhaust Port
36 37 B Temp Cyl 9
● ● ● ● ● ●
16 40 A Exhaust Port
06 B Temp Cyl 11
39
● ● ● ● ● ●
27 42 A Exhaust Port
37 B Temp Cyl 13
● ● ● 41
● ● ●
22 44 A Exhaust Port
32 43 B Temp Cyl 15
● ● ● 20 ● ● ●
J1939 Return (-)
08 ● 45
120 Ohm Resistor Auxiliary CM700
03 ● J1939 Signal (+)
46 Connector (C26) Connector A
23 ●
J1939 Shield
● 47 ● 02 13
31 A Exhaust Port
Temp Cyl 2 03 03
21 B
● ● ● ● 07 ● ● 04
01 A Exhaust Port
11 B Temp Cyl 4
● ● ●
12 A Exhaust Port 25 Power
02 B Temp Cyl 6 Connector
● ● ● (C27)
24 A Exhaust Port Key:
34 B Temp Cyl 8
● ● ● L Signal:
14 A Exhaust Port
04 B Temp Cyl 10
● ● ● Return:
25 A Exhaust Port
35 B Temp Cyl 12 Shield:
● ● ●
07 A Exhaust Port

Engine Controls
17 B Temp Cyl 14
● ● ●
05 A Exhaust Port

Exhaust Temperature Monitoring

15 B Temp Cyl 16
● ● ●
18 ● Battery Return (-)
– CENSE Module (CM530)
CUMMINS, INC TRAININGExample: QSK60G
- Gas Engine Controls Multiple
/ Engine Controls /Turbocharger)
KDL / 10 - 2009 / REV 1.1 16
 Engine Controls
Exhaust
CM850 60-Pin CM850 60-Pin
Left Bank
03 03
Exhaust Port Right Bank Exhaust Port
Connector (C23) 02 Connector (C23) 02

Temperature
Temp Cyl 15 Temp Cyl 16
01 01

●
03
02
Exhaust Port
●
03
02
Exhaust Port Monitoring
● Temp Cyl 13
● Temp Cyl 14
CM850 Module
01 01

50 03 50 03
● 02 Exhaust Port
● 02 Exhaust Port (Example: QSK60G Single
● 01
Temp Cyl 11
● 01
Temp Cyl 12
Turbocharger)

43 03 03
43
● 02 Exhaust Port
● 02 Exhaust Port
● 01
Temp Cyl 9
● 01
Temp Cyl 10
Key:
30 03 30 03
● 02 Exhaust Port
● 02 Exhaust Port 5vdc Supply:
● 01
Temp Cyl 7
● 01
Temp Cyl 8
Signal:
23 03 23 03 Return:
● 02
Exhaust Port
● 02
Exhaust Port
● 01
Temp Cyl 5
● 01
Temp Cyl 6

17 03 17 03
● 02
Exhaust Port
Temp Cyl 3 ● 02
Exhaust Port Connector
● 01 ● 01
Temp Cyl 4
Pin-Out
15 03 15 03
47 ● 02 Exhaust Port
47 ● 02 Exhaust Port 1 2
37 ● 01
Temp Cyl 1
37 ● 01
Temp Cyl 2

08 08 ● 120 Ohm Resistor

06 06 ● 3 4
07 ● 07 ●
CM850 50-Pin CM850 50-Pin
Left Bank Right Bank
Connector (C24) Connector (C24)
31 31

19 19
Front
Crossover Pipe
Proprietary Datalink Supply
● 10
Proprietary Datalink Return CM700
● 09 DC1 Connector A
Proprietary Datalink Shield 18
● ● 11 ● 18

Proprietary Datalink Supply 19 19

Proprietary Datalink Return
● 20 ● ● 20
CUMMINS,
Proprietary Datalink Shield INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 17
 Engine Controls
Spark Ignition Systems
Basic Layout

CCD CM558

Coil on Plug (COP) CENSE

CCD

CM558

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 18
 Engine Controls
Spark Ignition Systems
COP Assembly

COP Assembly
(HT Insulator Section removable)

C B COP Installed in QSV91G

COP Connector
Pin-Out

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 19
 Engine Controls
Spark Ignition Systems
Knock Sensors

Knock Sensor QSK60G Bank-A NDE Knock Sensor

QSV91G Knock Sensors

Knock Sensor Function:

ƒ Monitor each cylinder for uncontrolled combustion events
ƒ Monitor each cylinder during non-combustion cycle for
abnormal mechanical noise
Knock Sensors MUST be correctly torqued!!

QSK60G Bank-B Knock Sensors

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 20
 Gas Control Network
Unique Protection – De-Rate
QSK60G PhIV & QSV91G PhII

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 21
 Gas Control Network
Unique Protection
Rapid De-Rate

100%
1400

1200
Load (kWe)

70%
1000
800 Rapid
De-Rate
600 Event
400

200

0
0 5 10 1
Time (min) Time (
CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 22
 Engine Controls
Spark Ignition Systems
Engine Speed & Position – QSV91G

SSM558 ‘A’
EPS2
SSM558 ‘B’
INT.

TDC: A1
EPS1
EXH.

B-Bank Camshaft
60o

TDC: B1

Flywheel 72-2 Hole Pattern

Flywheel

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 23
 Engine Controls
Spark Ignition Systems
Engine Speed & Position – QSV91G

Position Sensor
One off B-bank
camshaft, free-end

A- Bank B Bank
Dual Output Speed Probe: Dual Output Speed Probe:
1 to CM700, 1 for Output to A & B-bank
Speed Bias (Synchronisation). CM558 Modules.

72-2 Hole Flywheel Configuration

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 24
 Engine Controls
Spark Ignition Systems
Engine Speed & Position – QSV91G

Determines stroke position by ‘Clocking’ Incorrect clearance can

Camshaft TDC. cause loss of cam sync.

Fitting & Adjustment:

OK WRONG

• Remove cover plate

• Turn engine so that probe IS NOT
over hole
Dual output sensor.
• Back off lock-nut, set gap to 0.4 mm Output from position sensor
using feeler gauge, tighten lock-nut. feeds both CM558’s
CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 25
 Engine Controls
Spark Ignition Systems
Engine Position – QSK60G

Cyl. # 1 2 3 4

Ref Pulse ‘Fire’ on falling

edge of signal

CM558 ‘Fire’ signal to CCD w/

Cyl #3 Ignition Timing retard.

Bank B Cam Gear

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 26
 Engine Controls
Spark Ignition Systems
Engine Position – QSK60G

Engine Position Sensor

Position Sensor Adapter

QSK60G Bank B

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 27
 Engine Controls
Spark Ignition Systems
Engine Speed – QSK60G

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 28
 Gas Supply Network

Gas Pressure Gas Pressure Safety Blow Double

Regulator Switch Off Valve Solenoid
Only fitted if Main Gas
Supply exceeds 5psi
Valve

P1 P2

Manual Gas Safety Shut Valve Fuel Supply

Gas Valve Filter Off Valve Proving System Pressure Sensor
(Mounted on rear of assembly)

Ensure ALL gas pipe work is Earthed!

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 29
 Gas Supply Network
SSV Reset Procedure - Dungs® Regulator

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 30
 Gas Supply Network
Gas Valve Proving System (VPS)

TEST/
Reset
Engine Mounted FSOV w/ Validation Module P2

Front View of Top View of

Validation Module Validation Module

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 31
 Gas Supply Network
Gas Valve Proving System (VPS)
Maintenance

VPS VPS Outlet Filter

& O-Ring

VPS Inlet Filter

& O-Ring

VPS servicing MUST be undertaken by a gas registered or certified technician.

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 32
Gas Control Network
Gas Metering

QSK60G Multiple Turbocharger Models

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 33
Gas Control Network
Gas Metering

QSK60G Single Turbocharger Models

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 34
Gas Control Network
Gas Metering

QSV81/91G Multiple Turbocharger Models

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 35
 Gas Control Network
Gas Metering

QSV91G Single Turbocharger Models

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 36
 Torque-over-Boost Control –
‘V’ Engines

The CM700 utilizes the kW Customer GIB Alt box

value calculated by the Inteface Inteface Inteface

PCC3300 for Torque-over- AUX101 AUX101 AUX101

Boost algorithm calculation. PCC3300 I/O I/O I/O
This algorithm is used to MODBUS /
InPower
provide “Closed-Loop” Air/Fuel (MON) System Bus J1939 (250KBPS)
Ratio feedback. “Closed Loop” Tool Con.
(on board)
operation will ensure that
J1587 (250KBPS)
changes in mixture PWM
CM700
automatically take place to AUX103
maintain the desired emissions AVR J1587 Service
operating point. CM558L Tool Connector
CAN
2.0B
The kW reference is relayed to
the CM700 over the System CM558R
Bus J1939 data link. The
CM700 then calculates the CENSE or J1939 Service
Tool ConnectorCM850
appropriate gain for the closed 2 x CM850 core 2 module ONLY
loop fueling to maintain the
desired emission set point.

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 37
Gas Control Network
Gas Control Logic

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 38
 Gas Control Network
Gas Metering
(D) CM558 Plug B Pin xx - Sensed Gas Mass Flow Signal

(A) CM558 Plug B Pin xx - Sensor (+24 v dc supply from CM558)

(B) CM558 Plug B Pin xx - Sensor (–)
FOP - Located on outlet pipe work to mixer

FIP

GMF
(C) Battery 24V (–)

FCV

QSV Gas Control Assembly Shown

GMF Pin-out
CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 39
 Gas Control Network
Gas Metering

AIR GAS +
GAS MIXER AIR TO
INTAKE
TURBO

ΔP
GMF FCV
FIP
FOP
GAS
IN
VENTURI
FIT
(T2)

5v
GMF
0v
SENSOR
(Hot Wire) Duty Cycle
GAS MIXER

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 40
 Gas Control Network
Gas Metering
Fuel Control Valve (FCV)

OEM CM22m - 5 + A
Battery (24v) – B
Not Used C
CM558-B Plug Pin 45 – D
CM558-B Plug Pin 35 + E
CM558-B Plug Pin 16 + F

System / Engine Ground

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 41
Gas Control Network
Throttles

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 42
 Gas Control Network
Throttles – QSV91G PhI & II

Gas / Air Flow

Gas / Air Flow

Driver
Module

Blanking
Plate

Throttle
Actuator(s)

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 43
 Gas Control Network
Throttles – QSK60G PhII & IV

Gas / Air Flow

Throttle
Actuator

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 44
 Gas Control Network
Engine Sensors
Intake Manifold Absolute Pressure

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 45
Gas Control Network
Engine Sensors

Compressor Inlet
Temperature

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 46
 Gas Control Network
Engine Sensors
Intake: QSV91G Multiple Turbocharger

B - BANK SENSORS A - BANK SENSORS Compressor Outlet Pressure (P1)

Intake Manifold Temperature (T1) Intake Manifold Pressure (P2)

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 47
 Gas Control Network
Engine Sensors
Intake: QSV91G HE 2MWe / Single Turbocharger

Assembly mounted on B-Bank

B - BANK SENSORS A - BANK SENSORS
MAP (P2)
side of engine, flywheel end.

Fuel Inlet
Pressure Sensor

IMT COP (P1)

Duty Cycle
Valve (FloTech)

ƒ IMT: Intake Manifold Temperature Fuel Inlet

Pressure Sensor
ƒ COP (P1): Compressor Outlet Pressure
Gas Mass
(before throttle). Flow Sensor
ƒ MAP (P2): Manifold Absolute Pressure Fuel Inlet
(after throttle) – B-Bank side of engine Temperature Sensor
adjacent cylinder 7. CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 48
 Gas Control Network
Engine Sensors
Exhaust: QSV91G HE 2MWe / Single Turbocharger

The Turbocharger Turbine Speed is

monitored by the CM700. There are two
speed thresholds:
ƒ A WARNING ALARM is flagged if turbine
speed exceeds 39720 rpm for 60 seconds.
A ‘Controlled Shutdown’ will be initiated
ƒ Engine will SHUTDOWN if turbine speed
exceeds 41500 rpm for 5 seconds.
An ‘E-Stop’ will be initiated

Turbine Speed Sensor

connects to engine
harness via socket in
A-Bank harness
located in hot-box.

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 49
 Gas Control Network
Engine Sensors
Intake: QSK60G

Compressor Outlet Pressure (P1) Intake Manifold Temperature (T1)

Ref: HT Coolant Pressure Sensor

Intake Manifold Pressure (P2)

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 50
 Gas Control Network
Engine Sensors - QSK60G PhII

Compressor Inlet
Air Temperature
FIP
GMF

FOP
Exhaust Back Pressure Sensor Fuel Inlet Temperature Sensor
(Not Used)
CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 51
 Gas Control Network
Engine Sensors - QSK60G HE
Fuel Outlet Temperature Fuel Inlet Temperature

Mixer Housing
Compressor Air
Inlet Temp

GMF

FIP

CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 52
 Gas Control Network
Unique Protection - QSK60G HE

• CM558 supplies 5v PWM drive

position signal.
• Actual position confirmation -
0 to 5vdc position feedback
Compressor by pass valve & associated pipe work signal supplied from by-pass
valve back to CM558.

The compressor by pass valve is controlled via the CM558 module and is used to
divert air/fuel mixture back to the mixer intake.
This butterfly valve is fitted on the QSK60 H/E model only and acts much like a waste
gate to match turbo performance to requirement over a wide speed range. Boost is
by-passed (reduced) at higher turbo rpm.
Operates on the mark space ratio (duty cycle) of a 5v square wave signal from
CM558.
CUMMINS, INC TRAINING - Gas Engine Controls / Engine Controls / KDL / 10 - 2009 / REV 1.1 53
HHP Natural Gas Engine & Generator Controls

MODULE 3

‘V’ Engine Controls

END