Cense Cakibration Manul

Service/Parts Date: Application:
26.04.2007 Generator Unit

Topics
No: Fuel Type: File Group
ESB-SPB 10 Natural Gas 19
CUMMINS CONFIDENTIAL
ESB Internal Circulation, Approved Distributors and Partners Only
Author: David McNeil & Kevin Leonard
Subject: CENSE Module Calibration Download
Publications Affected by This Service/Parts Topic

Engine Operation and Troubleshooting Shop Other
Maintenance and Repair
QSV81G 4021314
QSV91G 4021314
QSV60G 4021396
NOTE: Publications identified as Other include the following: ¹Parts
Catalogue, ²Wiring Diagram, ³Electrical Troubleshooting and Repair Manual.
This Service Bulletin applies to QSV81G, QSV91G, QSV91G 18Bar BMEP

2MWe, QSK60G natural gas and low Btu/Biogas fuelled Gensets and all
model variants.
Warranty Impact
None – The information in this document does not have any effect on current
warranty coverages or repair practices, nor does it authorize TRP or
Campaign practices.
The following procedure can be used to download CENSE Module calibrations

via a PC to either a new or used CENSE Module.
Cummins Inc. Box 3005, Columbus, Indiana 47202-3005

Cummins Engine Co. Ltd., Daventry, Northants, England, NN11 8NU
Registered Office: Unit 1-B Uniongate, Ridgeway Trading Estate, Iver, Buckinghamshire SL0 9HX, England
Registered No. 573951 England
Copyright © 2007 Cummins Inc.
All rights reserved Page 1 of 9
Topics
Equipment Required:
IBM compatible laptop PC loaded with INSITE 6.5.1 (or later) and INSITE
CENSE. INSITE CENSE is available on all INSITE installation CD-ROMs.
Applicable RS232 Communication Lead:
3162850 – 9-pin serial to 9-pin serial lead (QSV81/91G <04.02)

3885817 – 9-pin serial to 3-pin RS232 lead (QSV81/91G (>04.02) &
QSK60G)
For QSV81/91G Gensets (from build >04.02 – pre-synergy models) the RS232
communication network is terminated to a terminal strip located in the Engine
Interface (DC) Box (see wiring diagram bulletin 4021370). It is necessary to
assemble a connection socket using Deutsch Connector Receptacle p/n
3824020 and female connector wires p/n 3822920 (see wiring diagram and
picture below).
All parts required to assemble the above RS232 connector are available from the
Cummins Wiring Harness Repair kits, such as 3824904.
A similar arrangement may be required for QSK60G ‘pre-synergy’ Gensets, refer

to Engine Interface Panel drawings to determine correct wiring configuration.
Engine Panel (<04.02)
NOTE: The 9-pin serial lead RS232 connector socket may be located in two
possible locations within the Engine Panel (as indicated).

Topics
Engine Interface (DC) Box
Assembled CENSE RS232 Connector installed into

Engine Interface Box (QSV 81/91G >04.02)
CENSE RS232 Connector Wiring Diagram (>04.02)
Cable to be assembled
Comms Lead
3885817 C C 382xxxx 17 BLUE 33
2 A-Plug
B B 382xxxx 18 RED 22
3
A A 382xxxx 19 YELLOW 13
5 B-Plug
Engine
PC Interface Box CENSE
9-Pin Serial
Module
3824020

Topics
Generator Interface Box (GIB) (>01/06)
Location of CENSE RS232 Connector Socket – Generator Interface Box

(QSV81/91G and QSK60G >01.06)
NOTE: QSV91G 18Bar BMEP, 2MWe (single turbocharger) arrangement is

similar to that shown above.
CENSE Calibration Procedure:
1. Ensure that INSITE and INSITE CENSE has been loaded onto the PC
being used for the CENSE re-calibration.
2. Connect the appropriate RS232 communication cable. The INLINE

adapter and associated leads are NOT required for this procedure.
3. Open INSITE. Insert the latest INCAL Calibration DVD into the DVD
drawer on the PC.
4. Click on the ‘Calibration Selection’ icon located in the left-hand menu bar.

Topics
5. When the INCAL Calibration DVD has been detected, expand the INCAL
options (shown as Feb07INCAL (E:\) on the example below) by clicking
on the (+) symbol.
Locate CENSE and expand the CENSE options by clicking on the (+)
symbol.

Topics
6. Highlight the second CENSE option – 3098771 – by clicking on the option.

The available CENSE calibrations will be displayed on the right of the
screen.
7. Locate the applicable CENSE calibration for your model/specification of

Genset. Highlight the required option by clicking on it. When the
appropriate calibration is highlighted, right-click on the mouse to display a
drop-down menu. Select ‘Transfer to ECM’,

Topics
8. The calibration process will now begin. INSITE CENSE is automatically

started for this procedure. Follow ALL on-screen instructions shown on the
‘Calibration Download Wizard’. Select [NEXT].
NOTE: The following 3 screens (9 through to 11) will only appear when
downloading a calibration to a new CENSE module.
9. The ‘Communications Status’ screen appears.
10. After approximately 60 seconds, the following screen will appear. Select
[CANCEL].

Topics
11. The following screen will then appear. Select [OK].
12. The ‘Calibration Download Process’ commences.
NOTE: This can take up to 5 minutes to complete. Once started, it cannot be

cancelled. If the incorrect CENSE calibration has been selected, allow the
download process to finish and repeat the entire calibration procedure,
selecting the correct calibration.

Topics
13. You will be informed when INSITE CENSE has completed the calibration
download. Click on [FINISH] to close the wizard.
14. The screen will automatically return to INSITE. Close INSITE. e procedure
is now complete.
NOTE: If the Engine Management Reset (Key Switch) is in the ‘OFF’ or

‘RESET’ position when performing the CENSE module calibration download,
then the procedure will stick at the ‘PREPARING MODULE’ screen. Turn the
Engine Management Reset (Key Switch) to the ‘ON’ position and the
procedure will continue as normal.
IMPORTANT NOTE:
When selecting the CENSE calibration from the INCAL CD-ROM/DVD, the
following should be noted. The top 6 calibration options are for Gensets fitted
with the CMR harnesses.
The bottom 2 calibration options are for Gensets fitted with TVAB harnesses.


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Service/Parts Date: Application:

26.04.2007 Generator Unit

Author: David McNeil & Kevin Leonard

Subject: CENSE Module Calibration Download

Publications Affected by This Service/Parts Topic

This Service Bulletin applies to QSV81G, QSV91G, QSV91G 18Bar BMEP

The following procedure can be used to download CENSE Module calibrations

Cummins Inc. Box 3005, Columbus, Indiana 47202-3005

3162850 – 9-pin serial to 9-pin serial lead (QSV81/91G <04.02)

A similar arrangement may be required for QSK60G ‘pre-synergy’ Gensets, refer

Engine Panel (<04.02)

Cummins Inc. Box 3005, Columbus, Indiana 47202-3005

Engine Interface (DC) Box

Assembled CENSE RS232 Connector installed into

CENSE RS232 Connector Wiring Diagram (>04.02)

Cummins Inc. Box 3005, Columbus, Indiana 47202-3005

Generator Interface Box (GIB) (>01/06)

Location of CENSE RS232 Connector Socket – Generator Interface Box

NOTE: QSV91G 18Bar BMEP, 2MWe (single turbocharger) arrangement is

CENSE Calibration Procedure:

2. Connect the appropriate RS232 communication cable. The INLINE

Cummins Inc. Box 3005, Columbus, Indiana 47202-3005

Cummins Inc. Box 3005, Columbus, Indiana 47202-3005

6. Highlight the second CENSE option – 3098771 – by clicking on the option.

7. Locate the applicable CENSE calibration for your model/specification of

Cummins Inc. Box 3005, Columbus, Indiana 47202-3005

8. The calibration process will now begin. INSITE CENSE is automatically

9. The ‘Communications Status’ screen appears.

Cummins Inc. Box 3005, Columbus, Indiana 47202-3005

11. The following screen will then appear. Select [OK].

12. The ‘Calibration Download Process’ commences.

NOTE: This can take up to 5 minutes to complete. Once started, it cannot be

Cummins Inc. Box 3005, Columbus, Indiana 47202-3005

NOTE: If the Engine Management Reset (Key Switch) is in the ‘OFF’ or

Cummins Inc. Box 3005, Columbus, Indiana 47202-3005

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