Вы находитесь на странице: 1из 38

QSV 81/91 Series Gas Engines

Module 5 - Control System

Cummins Corporate Training

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
Control System

Learning Objective
Participants will be able to locate and identify base engine control
components and describe their operation within a total system.
Agenda
• Engine Control System - Capability & Integration.
• Control Components:
- Master Control Module,
- Sub Systems Module,
- Capacitor Coil Driver,
- CENSE.
• Ignition System.
• Engine Sensors and Speed Probes.
• Engine Panel Layout.
• Engine Panel Connections.

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
2
Engine Control System Capability
• Continuous Monitoring of:
– Lubrication System
– Cooling
– Air/Fuel handling
– By cylinder (detects in-cylinder problems)
– Others (operation hours/duty cycle, etc.)
– Over 1200 fault codes !
• Diagnostics and Prognostics:
– Directs Service technician to specific problem
– Continuous engine operating status/predict durability
• Information Management for future analysis:
– Trend Data for Engine performance, durability, and
maintenance intervals

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
3
QSV Gas Engine Control System

Fully Integrated Controls: Fuel System-Ignition System-Governing-Genset


CUMMINS
CENSE Sensor Bank 1
SERVICE
TOOL
Signal COP’S 1 - 9
J 1939
PDM Ref . Gnd.

* PDM - Prognostic Ref


8 Bit Bus
-320v
Diagnostic Module MCM-700
Master
Fire
CCD Gnd.

CAN 2.0B
CCD - Capacitor
Coil Driver Combustion
Combustion
Controller
Controller
SSM-558
CM - 5XY Bank 2
Sensor
Signal
COP’S 10 - 18

PDM Ref. Gnd .

8 Bit Bus
Ref -320v
Control System Schematic Fire CCD Gnd.

* Future development feature.

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
4
System Components
CENSE
module

COP

MOD Bus
Interface
Connection
IGNITION RELATED:-
SSM 558, CCD, COP.
FUEL RELATED:-
MCM 700, SSM558.
MONITORING ONLY:-
CENSE

SSM CCD / CAN 2.0 &


MCM 700 558 PDM J1939 bus

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
5
Control System Line diagram

SSM Fire Ign.


MODBUS MCM 558 Sync CCD
PLC
700 COP

MODBUS link
(1900 baud) Engine
CAN 2.0 B
(500K baud)
COP
J 1939
(250K baud) Sync
CENSE SSM Fire Ign.
Possible future 1
CAN 2.0 B 558 CCD
data link.

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
6
Master Control Module

MCM700 - Master Control


Module:
• Solid state fully encapsulated,
one module required per
system.
• Located in engine interface
panel (door mounted).
• Recognised by it’s 3 x 50 pin
Deutsch connectors.
• Non serviceable.

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
7
MCM 700
Monitors / Sensors for:
SSM
Ign.
Resistive Temperatures: MODBUS MCM 558
HT coolant temp engine outlet PLC 700
LT coolant temp engine inlet
Lube oil temp after oil cooler Engine
Pressures (ratiometric sensor):
Lube oil pressure before filters
Lube oil pressure after filters CENSE SSM
1 Ign.
Ambient pressure 558
HT coolant pressure (pump outlet )
LT coolant pressure (pump outlet ) Switches: *Lube oil sump level, *coolant level,
Start air pressure turning gear engaged.
Crankshaft speed Drivers: Control air solenoid, starter solenoid, safety
Crankshaft speed back-up wire loop.
* Not available to-date.Standard.Genset arrangement;
sump level via Murphy lube oil make-up switch, 12v 3KHz PWM Inputs: KW genset load, speed
coolant via header tank switch wired to customer bias from genset.
controlled shutdown terminals in GCP.
4 - 20 mA Outputs: Intake throttle drivers.
PWM - pulse width modulated

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
8
Hot Box Modules

CCD - Capacitor Coil Driver:


• Solid state fully encapsulated, controls up
to 9 cylinders
• Non-serviceable.
• Two Amphenol connectors;
one 19 pin - input from SM558,
one 17 pin - outputs to COP’s.

SM558 - Sub Systems Module:


• Solid state fully encapsulated, controls up
to 9 cylinders.
• Non-serviceable.
• Two Deutsch 50 pin connectors, one input
from MCM 700 one outputs to CCD.

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
9
SSM558 Bank ‘A’ and Bank ‘B’

SSM
Ign.
Monitors / Sensors for: MODBUS MCM 558
PLC 700
• Crankshaft speed
• Camshaft speed Engine
• Ambient air temp
• Pressure before throttle
• FloTech position CENSE SSM
1 Ign.
• Throttle plate position 558
• Fuel in pressure - down stream
• Fuel in pressure - up stream
• Intake manifold pressure Switches: Bank-A / B, Power on / off.
• Intake manifold temperature Ign. Sync & Fire: Spark reference, spark timing.
• Bosch knock sensors - one per cyl
Actuators: FloTech fuel system.
• Hitachi gas mass flow sensor
• NGK Lambda sensor (when fitted) Safety: Safety wire loop, fuel shut-off (via double
(exhaust gas oxygen), 4 - 20 mA solenoid gas valve).
closed loop on A or B-bank

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
10
Duty Cycle Valve (FloTech)

• Part of the gas control assembly.


• Operates on the mark space ratio (duty cycle) of a 5v square wave signal from SSM558.
• Controls the gas supply to the mixer.
• This electronic butterfly valve effectively controls the air / fuel ratio (mixture) for any
given volume of fuel drawn through the gas control assembly as directed by the SSM558.

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
11
Open / Closed Loop Control
Air / Fuel ratio control on the engine in 3 basic modes: Open loop:
1. Open Loop. Has advantage of simpler
set-up, calibration and
2. Closed Loop (with O2 feedback). trouble-shooting.
Closed Loop (with torque over boost feedback). Closed loop:
Engines will be shipped in Open Loop mode. will ensure emissions do
not drift outside spec.

Procedure for switching Air / Fuel ratio control mode:


A calibration will be used in the SSM558 to select which bank will do closed loop air / fuel
ratio. If bank identification matches Air / fuel ratio close loop selector, then that bank will
handle the oxygen sensor signal in order to do closed loop air / fuel ratio control.
SSM558 Parameters table
Name Description Unit min max. accuracy default
C_AFCLSL close loop selector bit 0 1 NA 1
(0 = Bank-B does closed loop A/F, 1 = Bank-A does closed loop A/F)

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
12
Closed Loop Control

The SSM558 shall use the following table to determine what bank controls the
closed loop portion of the air fuel ratio.
A-Bank ID Connector.

Harness pins Bank Selection


Bank-A/B Diagnostic Decrement Switch
0 0 Bank-B
0 1 Fault
1 0 Fault
ID CONNECTOR:
1 1 Bank-A
A-Bank - 1 & 3
Linked

WARNING: B-Bank - 2 & 3


Incorrect fitment can cause exhaust explosion. Linked

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
13
Open / Closed Loop Control
Procedure for switching Air / Fuel ratio control mode:
1. Closed Loop (with O2 feedback). Turned on by intake manifold algorithm,
Adjustment via Calterm value C_LMDOFF (by a maximum of +/- 0.2)
Make small adjustments of +/- 0.03 (this will give a large change in A/F desired, Calterm
parameter AF_AFDES).
O2 FEEDBACK NOT USED IN THE FIELD.
2. Closed Loop (with torque over boost feedback),
On/off via Calterm gain parameter C_ TBGN (0 = open loop, 1 = closed loop).
The 558 with this parameter at 1 will determine which bank 558 is controlling the closed
loop.
Adjustment via C_TBOFF, 0.01 = 25ppm NOx. (maximum range +/- 0.05).
TA LUFT = 175ppm @ 92°C HT (or 500 mg/ Nm³ - NOx).
Engines will be shipped in Open Loop mode.

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
14
Ignition System

• DC to DC converter steps up the


supply voltage to approx 300 v
which charges the capacitor.
CCD
• Signal from SSM 558 closes an
DC TO DC
P PRIMARY &
electronic switch in the CCD, the
CONVERTER CAPACITOR D SECONDARY
capacitor charge discharges into M WINDINGS
+
the primary windings of the COP.
• The voltage induced into the
secondary winding of the COP is COP
supplied directly to the spark plug
and rises (up to 40Kv) until it 24V SSM558
overcomes the resistance of the PLUG
electrode to ground strap air gap.
• The PDM monitors the COP and
determines charge required, plus
diagnostics for CCD/COP.

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
15
CCD Output Harness
The CCD output pins for firing sequence are fixed as shown in the table below.
The harness connections therefore determine the cylinder firing order!
CCD/PDM - 17 Pin Output Connector
Pin Type Comments To
A -Vdc 1 Ignition Coil Power *COP#1
B -Vdc 2 Ignition Coil Power * Dependant on firing order V16/18. *COP#2
C -Vdc 3 Ignition Coil Power *COP#3
D -Vdc 4 Ignition Coil Power *COP#4
E -Vdc 5 Ignition Coil Power *COP#5
F -Vdc 6 Ignition Coil Power *COP#6
R -Vdc 7 Ignition Coil Power *COP#7
P -Vdc 8 Ignition Coil Power *COP#8
N -Vdc 9 Ignition Coil Power *COP#9
G IGN-COP Ignition Coil Ground COP
J HVS-S High Voltage Sensor shield. Connected to CCD-CDM case None
K HVS-GND High Voltage Sensor Ground ref. Connected to GND at COP COP
L HVS-SIG High Voltage Sensor Input Signal COP
WARNING: Incorrect fitment can cause exhaust explosion.

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
16
Position Sensor & Speed Probes

For Cummins Genset systems


only (PCS). Position
Sensor
One off B-
bank camshaft,
flywheel-end

LB RB

Dual Output Speed Probe: Dual Output Speed Probe:


1 to MCM700, 1 not used. SSM558’s (output to A & B-bank units).

Speed probe Part No. 3865350


** When installing check probe is NOT over one of 72-2 flywheel hole
flywheel holes, set clearance to 0.8mm (back-off 3flats). pattern

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
17
Engine Position Sensor
Determines stroke position by ‘Clocking’
Camshaft TDC. Probe Part No. 3865350 Incorrect clearance can
cause loss of cam sync.
Fitting & Adjustment:
OK WRONG

• Remove cover plate


• Turn engine so that probe IS over tooth
• Back off lock-nut, screw in sensor until it
touches tooth
Output from speed sensor
• Set gap to 0.4 mm using feeler gauge, tighten feeds both SM558’s
lock-nut.

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
18
Speed & Position Detection

SSM558 ‘A’ - Intake half cycle


EPS2
- Exhaust half cycle
Single ‘Tooth’ SSM558 ‘B’
cam position INT.
plate - B-bank ROTATION
cam only A1 TDC
360º / cycle)
EPS1
EXH. ( 60º BTDC B1 - centre of
hole)
270º cam rotation.
BTDC - B1

B1 - TDC
72 - 2 Hole Pattern ROTATION
Flywheel (720º / cycle)

70 Teeth plus 2 spaces


on flywheel

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
19
Sensor Output

TDC BDC TDC BDC TDC


Intake Valve Position. Cylinder Pressure Exhaust Valve Position.
20 80
18 70
16
60
14
12 50
10 40 BAR
8 30
6
20
4
2 10
0 0
-90 810

Crank sensor

1,5
1
0,5 VOLTS
0
-90 810

Cam sensor

2
0
VOLTS
-2
-90 Comp. stroke Power Stroke 810

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
20
Engine Sensors

IMPORTANT: Torque
to 20Nm +/- 2

Heated Oxygen Sensor (if fitted): Knock Sensor:


1-off, fitted in exhaust ‘Y’ One per cylinder, fitted to head,
A-bank side pizzo electric crystal.
OUTPUT: 0 - 5vdc NOM OUTPUT: 1v dc.
> 1.8 v IGN retarded 3º ( x2)
(Also requires 12v dc heater supply)
> 2.8 v Engine Shutdown

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
21
Engine Sensors
Gas Mass Flow Sensor:
• Located in the Gas Control assembly.
• Operates on a 12v dc “hot wire” system, the
output is up to 7.8v although the SM558 can only
read up to 5.0v.
• ‘V’ engines have two identical units, one located
at each end of the engine.
• The information is then fed to the SSM 558
module which adjusts the duty cycle to give the
correct gas flow as defined in the 558 control map.
Temperature & Pressure:
• Temperature and pressure switches are mounted
in each air filter housing to monitor both ambient
temperature and air filter restriction.
• These switches are used as warning devices only.
.
QSV Gas CUMMINS CORPORATION
CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
22
Engine Sensors

A - BANK SENSORS B - BANK SENSORS DETAIL

P1

LAYOUT
• P1 - Pressure before throttle actuator
• P2 - Pressure after throttle actuator
T1
• T1 - Temperature after throttle actuator
P2
A-bank sensors feed A-bank SSM558,
B-bank sensors feed B-bank SSM558.

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
23
Proact Drivers & Cense Module

The ProAct III Actuators are


mounted on the air intake plenum
duct, the actuators never open
beyond 70 % under any conditions.

The actuators operate on a closed


loop feedback system with the driver
module in order to determine
actuator position.

Both ProAct drivers and the CENSE


module are located on the B-bank
side of the charge air cooler as
shown.

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
24
CENSE
Monitors / Sensors For:
SSM
Ign.
Resistive temperatures: MODBUS MCM 558
PLC 700
Compressor inlet temp - free-end
Compressor inlet temp - f/w-end Engine
Gas line temp - engine
Thermocouples:
CENSE SSM
Cyl. exhaust temp (up to 16 cyl max) 1 Ign.
558
Pressures ( Ratiometric sensor ):
Compressor inlet pressure - free-end
Compressor inlet pressure - f/w-end Switches:
Lube oil pressure after filters (backup)
Coolant level, (as required, optional).
Note: CENSE has the capability of being programmed to
monitor coolant level although it is not used in our Crankshaft speed (backup - not fitted).
standard Genset arrangement. Installing the header tank
is part of the installation work.The switch in the header Alternative input on / off.
tank is wired directly into the customer controlled
shutdown terminals in the GCP.

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
25
Harness Schematic & Data Link Protocol

Harness Protocol
Layout R Used R

Service

R = 120 ohm
Termination Resistor
R
R

J1587 / J1939 - General Communication and


Service Protocol. NOTE: Service Connector
operates on J1939, MUST use INLINE II
adapter to convert to RS232 for PC.
CAN - High speed communication protocol,
control only.

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
26
MCM700 Control Architecture
Isolated Battery (+24v)
HT COOLANT LT COOLANT OIL OUTLET OIL PRESSURE OIL PRESSURE
PRESSURE PRESSURE TEMPERATURE BEFORE FILTER AFTER FILTER
(HCP) (LCP) (OLT) (OIP) (OOP)
Battery (+24v)
) Isolated Battery (+24v)
0-5V
C8 E8
MODBUS
EPS (crank) PLC
MCM700 &
CAN 2.0B
Key Switch MMI

THIS IS WHERE THE PLC WILL


MONITOR THE SAFETY WIRE
LOOP. (TO DETECT EMERGENCY B10
HT COOLANT LT COOLANT START AIR TURBO TURBO
PRESSURE SPEED #1 SPEED #2 SHUTDOWNS)
TEMPERATURE TEMPERATURE
(TS1) (TS2) PIN NUMBERS ARE FROM
(COT) (CIT) (SAP)
HUBERT’S GENSET INTERFACE B12
SPECIFICATION.

J1939
Service Tool
Exhaust Port Temperatures (Bank A)
TH1 TH2 TH3 TH4 TH5 TH6 TH7 TH8 R4 Isolated Battery (+24v)

FLY-WHEEL END
AIR FILTER PRESSURE
SSM558
BANK A
FREE WHEEL END
AIR FILTER PRESSURE CENSE
COOLANT LEVEL MODULE Isolated Battery (+24v)

CRANKCASE SSM558
BLOWBY PRES.
BANK B
TH9 TH10 TH11 TH12 TH13 TH14 TH15 TH16 R5
Exhaust Port Temperatures (Bank B)

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
27
CABINET
224001 ACTUATOR A DRIVER A DRIVER B 222007 ACTUATOR B
221002 222007 224008 224008 221003
Thermocouple converter FLOTEC B
224004 166012

MCM700 NGK Controller FSO VALVE


224002 224003 166006

PT242 -1 223038
TE601-1 223010
PT622-1 223009
PT601-1 223011

PT622-2 223022

TE601-2 223024

PT601-2 223025
PT903B 223026
PT902B 223027
FT901B 223023
TE652 223001
PT652 223002

PT401 223034
PT451 223035
TE402 223036
TE451 223037
HARNESS

VENT EV
A BANK

CV601A

CV164B

CV601B
GT673A

GT901B

GT673B
222003

CV902
CV903

PT651
FREE END HARNESS 222001
Module IC2 IC1
CENSE
MCM700 B BANK HARNESS 222004 224007
SSM558 A IC4
SSM558 B TE509A 223007 TE509B 22300
CENSE TE501A 223007 TE501B 22300
OPTIONAL SE614A 223017 TE502A 223007 SE614B 223017 TE502B 22300
SSM558 A SE624A 223017 TE503A 223007 SSM558 B SE624B 223017 TE503B 22300
224005 SE634A 223017 TE504A 223007 224005 SE634B 223017 TE504B 22300
SE644A 223017 TE505A 223007 SE644B 223017 TE505B 22300
SE654A 223017 TE506A 223007 SE654B 223017 TE506B 22300
IGNITION SE664A 223017 TE507A 223007 IGNITION SE664B 223017 TE507B 22300
Harness HARNESS CCD A SE674A 223017 TE508A 223007 HARNESS CCD B SE674B 223017 TE508B 22300
127005 127004 SE684A 223017 127005 127004 SE684B 223017
FREE END HARNESS SE694A 223017 SE694B 223017
FREE END HARNESS UT700 223019 UT700 223032
B BANK HARNESS FLOTEC A
A BANK HARNESS BANK ID A IC8 166012 BANK ID B
NGK SENSOR HARNESS 1 2 3 4 5 6 NGK SENSOR QT517 1 2 3 4 5 6
AIR STARTER HARNESS IC3 HARNESS 222005
IGNITION HARNESS
PT242-2 223005

PT903A 223013
PT902A 223014
ST175A 223015
ST173A 223016
ST175B 223029
ST173B 223030
FT901A 223012
GS792 223041
TE653 223003

PT653 223004

ST173 223039
ST174 223040

TE232 223042
PT241 223043
FT700 223006

CV321-2
CV164A
GT901A

FLYWHEEL HARNESS
222002 IC7 PT301 AIR STARTER
PNEUMATIC CV321-1 218002
STARTER HARNESS
222006

QSV Gas Control Diagram & SPC’s (Refer to Handout)


MCM 700 System State Control

STOP
Stop/start switch = start
and MXSRCNEN = 0 Stop/start switch transition
and ENGRPM = 0 from stop to start and
Stop/start switch = stop MMVENTSS = VENTED
and ENGRPM = 0 and and MXSRCNEN = 1 and
Authorized N_SHUTD Stop/start switch transition MMSTOKFG = 1
authorized N_SHUTD Keyswitch off and
condition occurred from stop to start and OR
condition is not active ENGRPM = 0 then MMVENTSS = MUSTVENT Stop/start switch = start and
Authorized E_SHUTD keyswitch on OR and MXSRCNEN = 1 and MXSRCNEN = 0 and
condition occurred power cycle MMSTOKFG = 1 MMSTOKFG = 1 and
ENGRPM > 0
Start cycle finished OR
Authorized N_SHUTD
Authorized Authorized
condition occurred and
E_SHUTD E_SHUTD
MXSRCNEN = 1
Authorized condition condition
N_SHUTD occurred occurred
condition N SHUTD E SHUTD VENT START
active
Vent cycle finished

Authorized N_SHUTD Authorized E_SHUTD


condition occurred condition occurred

Authorized N_SHUTD
condition occurred and
Authorized E_SHUTD MXSRCNEN = 0
condition occurred

Authorized N_SHUTD
condition occurred ENGRPM > MMMNRNES
RUN

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
29
Engine State Control Drivers

MCM700 SSM558 Controlled (see SSM558 SPS)


Controlled
State Starter Safety Wire Fuel Shut Spark Throttle Fuel
Driver Off Valve Position Control
Valve
Position
STOP off on on closed off C SPTHPS C SPDC
VENT on on on closed off C VTTHPS C VTDC
START on on on open on between between
C THMNSR C AFDCLL
and and
C THMXSR C AFDCLU
RUN off on on open on between between
C THMNRN C AFDCLL
and and
C THMXRN C AFDCLU
N SHUTD off on on closed on, for between between
SHSKIHTM C THMNRN C AFDCLL
after entering and and
N SHUTD C THMXRN C AFDCLU
state
E SHUTD off off off closed off closed closed

Table of Essential Control Drivers Which are Tied to Engine State

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
30
Engine Panel
S2 S3 S4

S2 = MCM700 Calibration Switch.


S3 = J1939 Bus termination resistor
Internal / External. Note; set to external
for GCP service connection.
S4 = J1587 / 1939 Service connection.
S4 Switch positions;
1 = off, (2 & 3 not used CCD ‘A’ & ‘B’ diagnostics)
4 = MCM700, 5 = 558 ‘A’, 6 = 558 ‘B’

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
31
Engine Panel Layout
* CENSE Connector
(9 pin ‘D’ - RS232), may be
incorporated into service
connector
S2 S3 S4

S1
Power
(24v) A A/B/C Fuses
Harness
on / off
connector
MCM B

Terminal Block - XR
700 Relays
K1 - 5
K11-18 NGK Oxygen sensor
C o / p converter
0 - 5v, plus heater
supply.
XEA - A -bank harness
XEB - B -bank harness NGK
THA

S1 THB V18 Only


XGEN - OEM harness Thermocouple
24v DC /12v DC converters, CENSE
XEFE - Free-End
converter. Supply for covers V16
harness
NGK Oxygen sensor .

* H1 - H8 Service Indicator Lamps, Service Connector, use INLINE II Link Box


NOT used, flash to show unit to interface with PC. * Early models have
Service Connector powered ONLY. May be removed. separate CENSE connector.

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
32
Safety Wire Loop

SAFETY LOOP ENERGISE TO RUN NOTE: The total system uses 2 x 24v power supplies:
+24V-1 (switched) and +24V-2 (un-switched).
+ 24 - 1 (v dc).
F15 SM558 ‘A’
OEM/ B10 (5A)
R1/1 R2/1 R3/1 R4/1 R5/1
R11

SM558 ‘B’
‘E’

Thermocouple converter.
MCM700 and
Isolates : 24 - 1,

(Proact) 1 and 2
Isolates :Actuator drivers
SM558 A / B.
Isolates : 24 - 2 and

valve (FloTech) A and B.


Isolates : Duty cycle

(CCD) A and B
Isolates : Ignition drivers
Stop
R12
to
OEM MCM 700
PLC
R13
OEM/ B12
‘E’ OEM’
700/C27
Stop
from R14
OEM
PLC GND /1
R1 R2 R3 R4 R5

GND -1 (0 v dc).

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
33
Panel OEM Connector (1 of 3)
(wire size : 1.0 mm except when stated)
1.5
MOD + C3
MOD - C2 1.5 to PLC
MOD SHLD C1 SERVICE TOOL CONNECTOR
F
(on OEM / GCP)
MCM 700 J1587 + F1
E
MCM 700 J1587 - F2 120 Ohm.
To be connected with Cummins
SSM 558 A J1587 + F3 J service cable 3162848 and data link
3 twisted pairs converter INLINE II Part No.
SSM 558 A J1587 - F4
3162846.
SSM 558 B J1587 + F5 H
SSM 558 B J1587 - F6 Use Deutsch connector:
G
Service Selector Sw. Receptacle HD 10-9-96 P. Pin 16
1.5 AWG. 0460-202-16141.
J1939 + A7 A -
J1939 - A8 1.5
B+
J1939 SHILD A9
CENSE RS232 FOR SERVICE
CENSE RS232 TX F7 2
CENSE RS 232 RX F8 3 9 pin ‘D’ sub - male connector.
CENSE RS 232 GND F9 (available on OEM / GCP)
5
CENSE RS 422 TX - A4
Available to
CENSE RS 422 TX + B4
OEM / GCP
CENSE RS 422 RX - A5
(not used)
CENSE RS 422 RX+ B5
4.0
E3 F1 - 10 A +
CCD BAT + from OEM 4.0
BAT + from OEM E4 F2 - 30 A + BATTERY
E1 4.0
BAT - from OEM -
E2 4.0 24 V - 30A/hr.
CCD BAT - from OEM -

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
34
Panel OEM Connector (2 of 3)
( wire size : 1.0 mm except when stated)
FSO to OEM / GCP B2 Gas Valve Switch (closed = gas valve closed)
FSO from OEM / GCP C7

SWL / E STOP to PLC B10 Normally Closed Volt Free contact (open E stop-spare)
SWL / E STOP to PLC B12

+ 24v to OEM / GCP E5 E Stop from PLC (N/C Contact)


SWL/E STOP from PLC C8 RESET (closed = system power up)
Key sw. from OEM + B1
closed = Electric, Open = air starter
Starter Select C6
Derate LSD closed = TBD
B9
Stop Request LSD B11 closed = TBD
100 % Load LSD D7 closed = TBD
Start Fail LSD C11 lamp = TBD
Start Ready LSD lamp = TBD
C12
lamp = TBD
Spare LSD D11
lamp = TBD
Com. Shutdown LSD D12
close to start
Start / Stop BSW B3
close = rated
Idle / Rated BSW C10
close = TBD
Stop / Override BSW B8
closed = override
Start Block O.ride BSW D9
N/A
Ext. Shutdown BSW D9
closed = breaker closed
Alternator Status BSW D10
BSW Return C5
Coolant tank level switch (option 1, available 99).
Coolant / Oil Level BSW A3

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
35
Panel OEM Connector (3 of 3)
( wire size : 1.0 mm except when stated)
CENSE Level sig B7 A Coolant tank level switch
B
C (option 2 , available 99).
CENSE Gas pressure sig C4 A
CENSE Sensor return - A1 B Gas pressure sensor
CENSE Sensor + A2 C (before pressure reducer, available 99).

KW + A6 4 -20 mA signal for KW load


KW - A10 (signal calibration TBD)

Speed Ref. + A11 PWM 3 KHz , 5V a.c. for speed set point
Speed Ref. - A12

ILS Woodward B6 N/A (not used)

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
36
Control System Demonstration

Using the Cummins QSV Gas control simulator, demonstrate normal system
operation while pointing or activating the following;

• Safety wire loop (lamp operation)


• Idle mode (desired / rated)
• state control
(must vent, venting, post vent,start, stop)
• OEM remote start / stop operation
• E-STOP
• Overspeed shutdown

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.
37
Module 5 - Control System

End
Cummins Corporate Training

QSV Gas CUMMINS CORPORATION


CUMMINS CORPORATE TRAINING
G / Control System / BMG / 01 - 01 / REV. 03.