Script for High Horsepower Natural Gas Lean Burn Control Systems

CATEGORY SUBCATEGORY SCENE AUDIO

Overview Familiarization 10000 This program covers the engine and genset controls for the Cummins high
horsepower lean burn natural gas range of products.
This includes the QSK19G, QSK45G, QSK60G and the QSV81 and 91
products.
Overview Familiarization 10600 The control systems in this program cover both vee and in-line engine
powered gensets. The control system configuration and functionality for the in-
line gensets differs from that of the vee engine genset models. In addition the
vee engine controls may include one or two fuel control assemblies and
throttles depending on the engine type and model.
However, major system components and underlying principles are common
throughout.
Overview Familiarization 10700 Included with this program is a complete glossary of terms. Highlights from
that document are shown here, however it is recommended that you review
the entire glossary before continuing with the remainder of this training.
Overview Familiarization 20700 All Cummins high horsepower, lean burn natural gas engines are fitted with
knock sensors. These sensors are used to protect the engine from damage
should detonation occur. In-line engines have sensors fitted only to specific
cylinders. All vee engines are fitted with knock sensors on each cylinder head.
Output from these sensors is a nominal one volt DC.
Overview Familiarization 20800 Similarly, all Cummins lean burn natural gas engines are fitted with a closed
loop fuel system capable of monitoring and trimming the air/fuel ratio to
maintain exhaust emissions to a pre-set level. In-line engines achieve this by
simply monitoring the exhaust oxygen level using a heated oxygen sensor. An
exhaust back pressure sensor is used in this system to ensure accuracy over
a wide load range. Vee engine gensets more generally use a Torque over
Boost algorithm to maintain the air/fuel ratio and emission levels. This system
uses an engine output torque value obtained by measuring the Kilowatt
electrical output of the generator along with the inlet manifold boost pressure
and calculates the required air/fuel ratio to achieve the set emission level.
Overview Familiarization 30000 The complete engine and generator control system for vee engine lean burn
gas gensets consists of four main devices: the Power Command Supervisor,
the Human Machine Interface, the PLC and the engine control system. The
engine control system is further divided into the CM700, two CM558s, two
ignition modules, a CENSE module and the engine sensors. These main
devices communicate via network datalinks. There are also a number of hard
wire connections that maintain shutdown protection should the network
communication fail.
Overview Familiarization 30100 On in-line engines, such as the QSK19G, the complete engine and genset
control system is simplified to two main devices. The Power Command
Supervisor and the engine control system. The engine control system on in-
line engines is divided into just the CM700, one CM558 module, one ignition
module and the engine sensors. Current production release has network
communication between the CM700 and CM558 and a hard wire shutdown
link between the CM700 and the PCS. Future product release will include an
additional network connection between the CM700 engine controller and the
PCS genset controller.
Engine Familiarization 91100 The modules associated with the engine control for high horsepower lean burn
Controls gas engines consist of the CM700, the CM558, the ignition module, and the
CENSE module.
Engine Familiarization 91150 The engine control modules and components are 24 volt DC units and are
Controls powered from a wall mounted panel containing sealed lead acid batteries and
a charger. If the engine is equipped with an electric starter the starter batteries
are separate from the batteries that power the control modules.
Engine Familiarization 91200 The CM700 location is dependant on the engine model. It may be found in the
Controls DC terminal box that is mounted on the genset. It is a non-serviceable unit that
is easily recognized by the three 50 pin Deutsch connectors.

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 Script for High Horsepower Natural Gas Lean Burn Control Systems
Engine Familiarization 91225 On vee engine gensets the CM700's primary functions are engine starter
Controls control, speed governing and basic engine protection. In addition to sending
the signal to the CM558 to drive the engine throttles, the CM700 monitors
sensors for coolant temperature and pressure, lube oil temperature and
pressure, and crankshaft speed.
Engine Familiarization 91230 The in-line engine gensets are produced with the CM700's function simplified
Controls to starter control and engine speed governing. In these units all other basic
engine protection is performed by PCS.
Engine Familiarization 91235 The CM558 and ignition module mounting location varies with the engine
Controls family. On QSV engines the CM558 modules are located under covers in an
area of the engine called the hot box.
The ignition modules are mounted at the flywheel end of the engine.
On all QSK engines these modules are accessible without removing any
covers. CM558s are distinguished by their two 50 pin Deutsch connectors.
Engine Familiarization 91250 On QSV engines the CM558 combustion control module has primary control
Controls of the ignition timing and air fuel ratio. To do this the CM558 monitors the
engine parameters shown here. The QSV engines having two fuel control
assemblies, require identical inputs to each CM558. The CM558 uses this
information to control air fuel ratio by reference to its internal control maps.
The CM558 also uses this information to generate a reference pulse that is
sent to the ignition module to start the firing sequence. A pulse is delivered to
the ignition module to fire each individual cylinder. In this way it is possible for
the control system to advance or retard the timing on cylinders independently,
for knock, or globally for speed variation. If the CM558 detects a light knock on
any cylinder it will automatically retard the timing on that cylinder in two
stages. If, after retarding the timing, the knock persists, the system will shut
the engine down.
Note: QSV engines may be fitted with one or two throttles depending on
rating.
Engine Familiarization 91252 On vee engines with a single fuel control assembly, like the QSK, the right
Controls bank CM558 function is simplified to ignition timing and knock detection.
Engine Familiarization 91254 The QSK19G has only two knock sensors, one located on cylinder number
Controls five and one on cylinder number six. The timing on cylinder six runs slightly
advanced of the other cylinders to ensure knock is detected. If a knock is
detected that exceeds the set threshold the system does not retard timing but
shuts the engine down immediately.
Engine Familiarization 91260 The ignition module uses reference and fire signals received from the CM558
Controls to determine when to fire each spark plug. These reference and fire signals
are based on the engine speed and position.
A DC to DC converter in the ignition module takes the 24 volt, system battery
voltage and steps it up to 320 volts. This higher voltage is stored in a capacitor
until the ignition module receives the signal from the CM558. When the
ignition module receives the fire signal from the CM558, it closes an electronic
switch which discharges the capacitor into the primary windings of the ignition
coil. The current in the primary windings induces a high voltage in the
secondary windings. This secondary voltage (up to 36kV) fires the spark plug.
Engine Familiarization 91265 Essentially, there are two different systems that are used to monitor the engine
Controls speed and position for governing and timing. The actual system is dependent
on engine model.
On QSK engines the engine speed signal for the CM700 governing function is
generated by a magnetic pick-up monitoring the flywheel ring gear teeth.
Engine Familiarization 91270 In addition, engine speed and position information is required by the CM558
Controls for control of ignition timing. This signal is generated by a magnetic pick-up
monitoring a webbed wheel mounted on the end of the camshaft. The wheel
may have the webs arranged in a 6 plus 1 or a 24 plus 1 pattern. The
additional, plus one pulse, is used as the reference signal to reset the ignition
module counter so that the next negative going pulse it receives from the
CM558 fires cylinder number one.
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 Script for High Horsepower Natural Gas Lean Burn Control Systems
Engine Familiarization 91271 On QSV engines the speed and position reference signals are created using
Controls the information from three magnetic pick-ups. Two speed sensors mounted in
the flywheel housing and a camshaft position sensor on the Right-bank
camshaft drive.
The crankshaft sensors read a 72 minus 2 hole pattern drilled into a flange on
the flywheel. One provides speed information to the CM700 for the governing
function. The other provides speed and position information to both of the
CM558s. The camshaft position sensor provides a single pulse at TDC for the
firing reference by signaling the CM558s when the engine is on the exhaust
stroke.
Engine Familiarization 91272 When cranking, the camshaft and crankshaft signals are checked by the
Controls CM558s. Only when the CM558s have verified that the camshaft and
crankshaft are synchronized and a speed of approximately 50 rpm has been
reached will the signal be given to open the main twin solenoid gas supply
valve.
Engine Familiarization 91273 All QSV engines are fitted with two gas control assemblies. All other engines
Controls have only one. The gas control assembly consists of a fuel inlet pressure
sensor (P1), a gas mass flow sensor, a fuel control valve and a fuel outlet
pressure sensor (P2).
Engine Familiarization 91274 The gas control assembly is controlled and monitored by the CM558.
Controls
Engine Familiarization 91278 The gas mass flow sensor is a hot wire sensor. The CM558 sends a current
Controls through the wire, heating the wire. The natural gas flowing over the sensor
tends to cool the wire and lower its resistance. By monitoring the change the
CM558 determines the quantity of gas flowing. Positioning the sensor in the
bypass passage provides less turbulent flow over the sensor and improves
resolution.
Engine Familiarization 91280 The CM558 delivers a pulse width modulated, 24 volt square wave signal to
Controls the fuel control valve. The fuel control valve is a butterfly type valve that
controls the air/fuel ratio by controlling the volume of gas drawn through the
gas control assembly. The fuel control valve position is fed back to the CM558.
The feedback is a zero to five volt DC signal.
Engine Familiarization 91283 Each gas control assembly has two pressure sensors. One is located before
Controls the gas mass flow sensor and the other is located after the fuel control valve.
The CM558 monitors the input and output pressures to set up an orifice flow
equation. Under transient conditions the orifice flow equation provides faster
correction to the fuel control valve position than the gas mass flow sensor can
provide.
Engine Familiarization 91285 The CM558 receives a speed governing signal from the CM700. The CM558
Controls converts this into a torque output signal that is sent to the throttle driver.
In-line engines have one throttle and driver while vee engines are equipped
with one or two depending on the model. For in-line engines the signal from
the CM558 to the throttle driver is a 24 volt PWM signal. On vee engines this
signal is a 4 to 20 miiliamp signal.
The throttle driver and actuator convert the signal from the CM558 into a
specific throttle position thereby controlling the amount of fuel/air mixture
delivered to the engine. The system is a closed loop design with a position
feedback signal sent to the CM558 for diagnostic purposes. Extreme
variations between the commanded and actual throttle position will trigger an
automatic engine shutdown.
Engine Familiarization 91300 The CENSE module mounting position varies with engine family. In-line
Controls engines are not fitted with CENSE.

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 Script for High Horsepower Natural Gas Lean Burn Control Systems
Engine Familiarization 91400 On vee engines the CENSE system's main function is to monitor the cylinder
Controls exhaust temperatures. It does this for each individual cylinder on the engine.
The exhaust port temperature information is used to determine cylinder
misfire. The information gathered by the CENSE module is sent to the CM700
on the J1939 datalink for fault processing. Low and high cylinder temperatures
or cylinder temperature deviations will cause the engine to shutdown.
In-line engines such as the QSK19G are not fitted with exhaust temperature
monitoring.
Engine Familiarization 91450 The Cense module has 16 K-type input channels for thermocouple
Controls connections. On the QSV91, 18 cylinder engine a two channel K-type
converter allows the thermocouples for the front cylinder on each bank to
connect to a standard Cense input channel.
Engine Familiarization 91475 System control devices use data links to communicate and share data; a
Controls Cummins proprietary CAN 2.0B link, a SAE J1939 public data link and a
MODBUS data link. The J1939 data link is CAN based and uses CAN 2.0B
protocol and interface specifications. MODBUS is an industrial automation
communication protocol. An RS485 interface is used for the MODBUS data
link.
The rate at which data, bits of information, can be communicated is the baud
rate. The baud rate indicates the number of bits per second transmitted.
Engine Familiarization 91500 The CM700 communicates with the CM558s through two datalinks; a J1939
Controls datalink and a CAN 2.0 B link.
The J1939 link operates at 250K baud while the CAN 2.0 B link operates at
500K baud.
Information on the CAN 2.0 B datalink is a high speed real time
communications protocol that is used for control only. CENSE communicates
with the CM700 over the J1939 datalink. Note that on vee engine systems the
engine control is linked to the genset PLC via a modbus communication data
link, this link operates at 19,200 baud.
Engine Familiarization 91550 On in-line engine control systems the communications are simplified to a Can
Controls 2.0B and a J1939 link between the CM700 and the CM558. There is currently
no datalink between the CM700 and the PCS genset controller, only hard wire
common shutdown and a speed bias connections exist. An optional Modbus
datalink connection from the CM700 is available on in-line control systems that
can be used to communicate with a digital fault display.
Engine Familiarization 91560 The J1939 data link is primarily used as a service network. The service
Controls network allows technicians to monitor engine control module signal levels in
the CM700 and CM558s. The service network is also used to download
software calibrations to these modules.
To connect to the service network a laptop loaded with the Cummins
proprietary service tool software and INLINE II interface adapter are required.
Engine Familiarization 91575 A simplified diagram of the Cummins lean burn natural gas engine control
Controls system is shown here.
Hardware/ Familiarization 30050 Once the alternator is coupled to the engine a number of hardware items are
Software assembled to complete the genset build.
Hardware/ Familiarization 30075 It is important to recognize that some of the genset control components
Software covered in this program will have part numbers that differ from the usual
Cummins Engine numbers. Unlike the seven digit Cummins Engine part
numbers the Cummins Power Generation genset part numbers are eight digits
with an optional two digits. These last two digits, where used, indicate
component options or revisions.
When ordering parts, the engine and genset part orders must be placed
separately.
Now let's look at the hardware and software that make up the genset package.

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 Script for High Horsepower Natural Gas Lean Burn Control Systems
Hardware/ Familiarization 30100 The genset hardware generally includes the AC terminal box, DC terminal
Software box, alternator auxiliary box and control panel. The control panel is free
standing on vee engine gensets. On in-line engine gensets the AC, DC and
alternator auxiliary boxes are integrated with the skid mounted genset control
panel.
Hardware/ Familiarization 30200 The AC terminal box houses the circuit breakers that control any AC auxiliary
Software equipment that may be fitted. This equipment varies with the engine model
and options, but may include such items as the engine coolant heaters with
circulating pump, alternator heater, and pre-lubricating pump. An under-
voltage protection unit is included to provide protection for these components.
The power to the AC box is customer supplied. The standard format is three-
phase, four wire.
Hardware/ Familiarization 30300 The DC terminal box houses the terminals for interconnections between the
Software genset and the Generator Control Panel.
Vee engine genset controls are fitted with a torque over boost emission control
system. A kilowatt transducer fitted in the DC terminal box supplies a 4 to 20
milliamp load reference signal to the CM700. This signal is passed to the
CM558 via the Can 2.0B datalink and used to hold emissions within the
desired operating window when operating in torque over boost closed loop
mode. In closed loop mode the CM558 relates the output torque of the engine
as indicated by the load reference signal to the level of boost pressure. With
this information the system calculates the required air/fuel ratio and adds or
subtracts fuel as necessary to keep the engine operating at the set emissions
point. On vee engines the closed loop control monitoring is carried out only by
the left bank CM558.
The kilowatt transducer is a three phase 4 wire unbalanced load unit that is
pre-set to allow the control system's current transformers to be used as the
current source. Signal output from the transducer must be calibrated using the
electronic service tool if the transducer is replaced.
Hardware/ Familiarization 30400 The alternator auxiliary box contains the voltage regulator output module. This
Software module uses the Pulse Width Modulated signal from the PowerCommand
Supervisor to control the power supplied from the permanent magnet
generator to the exciter windings.
The alternator auxiliary box also houses a Potential Transformer/Current
Transformer PT/CT module. This board converts generator voltage output to
approximately 18 volts AC and current output to approximately 1.65 volts AC
at full load. These signals are then used as inputs to the PowerCommand
Supervisor.
Hardware/ Familiarization 30600 On QSV gensets the generator wiring is achieved by way of four pre-
Software fabricated harnesses: the AC harness, the DC harness, the AVR PT/CT
harness and the Alternator heater harness. The engine harness is combined
with the AC and DC harnesses on these engines.
Hardware/ Familiarization 30700 The AC harness runs through a square aluminum conduit down the right-bank
Software side of the engine. It connects the AC terminal box to all the engine and
genset auxiliaries installed.
Hardware/ Familiarization 30800 The DC harness runs through an square aluminum conduit down the left-bank
Software side of the engine. It connects the DC terminal box to the various DC switches
and sensors located around the engine and genset.
Hardware/ Familiarization 30900 The Automatic Voltage Regulator (AVR) and PT/CT in the alternator auxiliary
Software box are connected to the DC box by a flexible plastic harness.
Hardware/ Familiarization 31000 The Alternator heater, when fitted, is connected by a flexible plastic harness
Software that connects the AC auxiliary box to the alternator heater. Use caution when
working around this harness as single phase AC voltage is present.
Hardware/ Familiarization 31101 The QSK 45 and 60G harness layout to the AC, DC, Alternator auxiliary and
Software alternator heater boxes is similar to the QSV.
Hardware/ Familiarization 31150 In-line gensets have all of the boxes integrated with the skid mounted control
Software panel. This simplifies the wiring layout.

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 Script for High Horsepower Natural Gas Lean Burn Control Systems
Hardware/ Familiarization 31200 On Vee engines the Generator control panel is a separate unit that gives the
Software operator control of the genset.
The GCP houses the Power Command Supervisor, Programmable Logic
Controller and the Human Machine Interface. These items are covered in
detail later in the training.
Hardware/ Familiarization 31300 Also located in the GCP are the customer terminals, control panel batteries,
Software battery charger, panel auxiliary supply isolator and the service tool connector.
Hardware/ Familiarization 31325 Vee engine genset control panels include two datalinks. One connects the
Software Power Command Supervisor to the PLC. The other connects the Human
Machine Interface to the PLC.
Interface and protocol details are shown here.
Hardware/ Familiarization 31350 The complete vee engine genset arrangement is shown here. Note that all
Software engine and generator control components are interconnected. The PLC relays
fault and operating data from any control component to the HMI for display.
Hardware/ Familiarization 31400 In-line gensets, such as the QSK19G, have simplified functionality and do not
Software have a free standing GCP. These units are supplied with a plant mounted
control panel as shown. On these gensets the control panel also houses the
CM700, service tool connector and the throttle driver.
Hardware/ Familiarization 31500 The complete in-line genset arrangement is shown here. Only hard wire
Software connections exist between the CM700 and PCS. Generator fault and
operating data will be displayed on the power command supervisor LED
display. Engine fault data can be read from the optional display or via the
service tool.
Protection Familiarization 40000 A fully integrated engine protection system is built into each Cummins lean
burn, natural gas genset. This system alerts the operator to problems and will
shut down the engine to prevent damage. Each module of the control system
has a unique set of protective features.
Protection Familiarization 40100 On vee engine genset controls there are three levels of protection:
A warning alarm is used to alert the operator of a problem. While the engine
continues to run the system notifies the operator by sounding the alarm and
illuminating the alarm lamps on the PCS and HMI.
An urgent shutdown activates the audible and visible alarms. In addition it puts
the system into cooling run mode. This cooling run mode is the same as that
used for a normal control stop, the engine will unload and then run off load to
cool down before the engine is brought to rest.
Critical shutdown is activated when the fault is severe enough to cause engine
damage during the cooling run stage. For a critical shutdown the engine is
shut down without a cooling run and the audible and visible alarms are
activated.
The in-line engine genset controls such as fitted to the QSK19G have only two
protection levels, warning and critical.
Protection Familiarization 40200 The generator sensors mounted on the genset are identified by two letters and
two numbers. The first letter indicates the system according to the following
code:
A is for the start air system
C is for the air induction system
E is exhaust
G is for gas
I is the ignition
L lube oil
R regulation and W is for the cooling system.
Protection Familiarization 40300 The second letter gives an indication of the type of sensor.
C is used for a control
F is for a flow
L is level
O outlet, P pressure, S spark or speed, T temperature and V valve.
The two numbers are used to distinguish multiple sensors within the same
category.

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 Script for High Horsepower Natural Gas Lean Burn Control Systems
Protection Familiarization 40400 In addition there are sensor identifiers that begin with the letters MX and MY.
These letters are used to designate miscellaneous items that fall outside the
identification system. For example, emergency stop.
Protection Familiarization 40500 Examples of the signal and logic flow for some vee engine critical shutdown
faults are shown here.
In this case high engine oil temperature is detected. The CM700 sends a
critical shutdown signal to the PLC and PCS via the hard wire connection. The
specific fault information (high oil temperature) is sent to the PLC and then to
the HMI via the network. This shutdown message is displayed on the Human
Machine Interface and stored in its internal alarm log. PCS displays "common
shutdown.
If the network communications fail the system is still protected by the hardwire
connection that initiates the shutdown. Only the specific fault data will be lost.
Protection Familiarization 40600 A knock sensor reading can also cause an immediate shutdown. The
shutdown is always initiated by the first control / detection device, in this case
its the CM558
Protection Familiarization 40700 Engine overspeed is another cause for immediate shutdown. In this case the
Power Command Supervisor initiated a shutdown because it detected
overspeed using the backup speed sensor.
Protection Familiarization 40750 The fault protection provided by the program logic includes an ignition power
down relay. When a critical fault is detected, in addition to the shutdown
message transmitted over the datalink, the CM700 sends the shutdown signal
to a relay that de-energizes the ignition modules. Notice that the E-stop
button, battery conservation relay, PCS and PLC, are also capable of dropping
out relays that initiate an emergency stop by cutting off the power to the
ignition module. After a critical shutdown the operator must follow the critical
shutdown reset procedure given later in this training. This will reset the control
modules and ignition power down relay.
Note that the emergency shutdown system interrupts the power to the ignition
modules and the fuel shut off relays, stopping both fuel flow and ignition. For a
normal shutdown the CM700 and left bank CM558 will only shut off the fuel.
Protection Familiarization 40775 Inline shutdown and isolation is simplified as shown here.
Protection Familiarization 40800 In place of the hardwire shutdown link just mentioned, the QSV control
systems have an extended backup protection circuit known as the safety wire
loop. If the Loop is broken it causes an immediate emergency shutdown. The
CM700, CM558s and the PLC each drive a safety wire loop relay. Any one of
these devices can therefore initiate an emergency stop. On QSV gensets the
emergency shutdown and isolation circuit is scheduled to be converted to
match the QSK system.
Protection Familiarization 40900 The CM700 and CM558 control modules can be in any one of the six states
show here. This diagram indicates the logic flow for normal and emergency
shutdowns and restarts.
For a normal shutdown the Cummins gas controls will ramp the load off of the
generator, open the generator circuit breaker, initiate a cooling run and then
shut off the fuel at the 24 volt twin solenoid fuel valves. The ignition is not
disabled during a normal shutdown. Fuel in the intake system is drawn into the
engine and burnt as the engine runs down.
For emergency shutdowns the fuel and ignition are disabled immediately. Vee
engine control systems always initiate a vent cycle on the next start attempt.
During the vent cycle the engine cranks with no fuel or ignition. This purges
any unbent gas from the engines exhaust, minimizing the risk of fire or
explosion. Following a short rest period a normal start cycle begins. In-line
engines like the QSK19G have purge cycle capability, but due to their smaller
cylinder volume these engines have the default vent cycle option set to
inactive.

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 Script for High Horsepower Natural Gas Lean Burn Control Systems
PowerComma Familiarization 50000 The Power Command Genset Supervisor -- PCS -- has been developed for
nd Supervisor the high horsepower, lean burn, natural gas gensets. PCS is a direct derivative
of the standard PCC and has similar construction and functionality. The main
differences are the software contained in the E-E-PROM chip on the digital
board and on vee engine controls the removal of the emergency stop
pushbutton from the front panel. However, most components are
interchangeable between PCS and PCC.
PowerComma Familiarization 50100 Key features and functions of Power Command Supervisor include:
nd Supervisor Panel construction
Front Panel components
Function of PCS internal boards and external control modules
Alarm and status message display
AC output metering
Voltage regulation
AmpSentry protection
Advanced paralleling features for set to set and utility paralleling applications
On vee engines the speed governing and base engine protections are not part
of PCS. They are controlled by the CM700.
On in-line gensets speed governing is not part of PCS, however, the base
engine protections are.
PowerComma Familiarization 50200 The PCS is designed as a sealed membrane, gasketed enclosure. It is
nd Supervisor designed to operate in temperatures ranging from -40 degrees C to +70
degrees C. It can operate in environments of 95% humidity without allowing
condensation in the cabinet.
PowerComma Familiarization 50300 The front panel contains a percent kilowatt meter, frequency meter, AC
nd Supervisor voltmeter and percent AC ammeter.
Status indicators light up to indicate a warning, shutdown or non-automatic
mode of operation.
The Run/Off/Auto switch, reset switch, self test switch, and other switches and
indicators are all contained on the panel. The panel also houses a two line, 32
character LED and menu selection buttons.
PowerComma Familiarization 50400 Behind the front panel, functions of PCS are divided onto separate boards for
nd Supervisor ease of troubleshooting and repair. These boards are common to all Power
Command Supervisors and also the former Power Command Control.
PowerComma Familiarization 50500 The digital board contains an Intel 8186 processor and an E-PROM chip that
nd Supervisor contains the operational software. It is only the software information stored on
the E-PROM chip that distinguishes this board from the digital board on Power
Command Control.
PowerComma Familiarization 50600 The analog board interprets all analog signals for the digital board.
nd Supervisor
PowerComma Familiarization 50700 The engine interface board interprets user control inputs. It also connects with
nd Supervisor engine sensors and the voltage regulator driver module.
PowerComma Familiarization 50800 The display board drives the meters and front panel display.
nd Supervisor
PowerComma Familiarization 50900 The customer interface provides signal conditioning of AC sensing and status
nd Supervisor monitoring of all customer signals such as remote start, circuit breaker open or
close, etc.
PowerComma Familiarization 51000 On vee engine gensets the PCS network interface board connects to the PLC
nd Supervisor in the genset control panel for the transfer of data and status information. The
interface board is used for communication to the PLC. This communication is
via an RS232 interface. On in-line genset controls only simple hard wire
connections exist between the CM700 and PCS for engine shutdown signals.

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 Script for High Horsepower Natural Gas Lean Burn Control Systems
PowerComma Familiarization 51100 PCS connects to three external modules.
nd Supervisor A potential transformer/current transformer (PT/CT module) for generator
voltage detection and overcurrent protection.
A voltage regulator driver module that controls the output voltage of the
generator. And a bus potential transformer (Bus PT module) for common bus
bar voltage sensing.
PowerComma Familiarization 51200 The PT/CT module mounted on the alternator transforms the genset AC output
nd Supervisor voltage to an 18 volt AC input signal to PCS. There are different PT/CT part
numbers for different voltage ranges. Gensets with output voltages of over 600
volts require an additional external Potential Transformer.
PowerComma Familiarization 51225 Special current transformers with 0.55 amp output at genset full load current
nd Supervisor are installed in the alternator terminal box. It is important that all connections
between the genset and the panel are checked prior to running the generator.
Crossed CT wiring can lead to the incorrect phasing of the generator and the
utility bus.
PowerComma Familiarization 51250 The PT/CT module converts this 0.55 amp signal into a 1.5 volt ac signal for
nd Supervisor use by the customer interface and analog boards.
PowerComma Familiarization 51275 This signal is filtered on the customer interface board and further filtered and
nd Supervisor rectified on the analog board before it is split and sent on to the digital board.
When the digital board receives these signals it uses the heavily filtered signal
from the multiplexer (MUX) for display and power calculations. The lightly
filtered signal is used for short circuit regulation.
PowerComma Familiarization 51400 Mounted on the alternator the voltage regulator driver controls the output
nd Supervisor voltage of the genset.
PowerComma Familiarization 51425 The microprocessor in PCS compares the output voltage from the PT/CT
nd Supervisor module to the set reference voltage and calculates the difference. PCS then
uses this information to generate a pulse width modulated signal for the
voltage regulator driver module. The voltage regulator driver module switches
the connection between the permanent magnet generator and the main
generator field on and off in time with the PWM signal. In this way the
excitation of the generator is controlled to regulate output.
PowerComma Familiarization 51500 On the vee engine control systems the Bus PT module is mounted in the
nd Supervisor generator control panel. In-line engines will have it mounted on either the
alternator auxiliary box or with the switchgear. The Bus PT transforms the
common bus bar AC voltage signal to 18 volt ac input for the PCS. Four
different part numbers are used for different voltage ranges. If the generator is
more than 600 volt line to line, the genset is fitted with an additional external
potential transformer. The Bus PT module relays the common bus information
to the PCS for Synchronization and display purposes.
PowerComma Familiarization 51550 On Cummins lean burn, natural gas engines the base speed governing is
nd Supervisor done by the engine's master control module the CM700. To synchronize the
genset to another genset or utility the PCS provides a speed/load bias signal
to the CM700. This signal changes engine speed up or down to match the
genset's frequency with the other supply.
Once synchronized this signal is used to regulate the load level between the
paralleled gensets operating in island mode or, between the genset and utility
when operating in utility parallel mode.
PowerComma Familiarization 51600 The speed/load bias signal generated by the PCS is a 3 kHz 12 volt pulse
nd Supervisor width modulated signal. The duty cycle of the signal ranges from 10 to 90
percent. This signal can influence the base engine speed from minus 10% to
plus 10%. If the CM700 does not receive a speed bias signal it will interpret
that as zero percent duty cycle and a request for maximum bias to slow. As a
result engine speed will be reduced by 10% to 1,350 rpm for a 1,500 rpm
engine.

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 Script for High Horsepower Natural Gas Lean Burn Control Systems
PowerComma Familiarization 51700 A 74% duty cycle signal is interpreted as a null bias request by the CM700. In
nd Supervisor other words at 74% duty cycle the CM700 provides no speed correction from
its base speed set point. While this signal is capable of changing the engine
speed from minus 40 to plus 10 percent of rated speed the CM700 limits any
change to minus 10 to plus 10 percent.
PowerComma Familiarization 51800 The Bus PT signal is used by the PCS as a voltage reference for
nd Supervisor synchronization .
PowerComma Familiarization 51900 PCS uses the phase detector on the analog board to check this signal against
nd Supervisor the PT/CT module's voltage signal. It then verifies the genset is properly
phased to the main bus before allowing the circuit breaker connecting the
genset to the bus to close.
PowerComma Familiarization 52000 In automatic mode, the integrated synchronizer in PCS signals the CM700 to
nd Supervisor vary genset frequency from minus 10 to plus 10 percent of nominal using the
speed bias signal. This brings the generator and bus into phase. PCS also
matches the genset voltage to the bus and when PCS has established
synchronization, it sends out the circuit breaker close signal.
In manual mode the PCS still checks for synchronization. If the genset is not
synchronized to the bus it will not allow the breaker to close.
Once the genset breaker is closed the synchronizer is disabled.
PowerComma Familiarization 52100 A master first start unit is a separate module that is used in multiple genset
nd Supervisor installations to give first genset ready, first breaker close authority. The master
first start unit supplies sequenced pulses to all of the gensets in turn. When a
PCS senses a low to high transition from the master first start unit, and its
voltage and frequency are greater than 90 percent of rated and the main bus
is dead, the breaker is commanded to close. When the first genset breaker
closes and energizes the bus, the other genset's breakers are inhibited from
closing until synchronous conditions are met.
PowerComma Familiarization 52200 PCS has a built in isochronous load sharing controller that is used for multiple
nd Supervisor gensets in island mode applications. With this feature the PowerCommand
Supervisors from each genset are interconnected. Each unit supplies the
kilowatt (kW) and kilovolt amp reactive (kVAR) load as a percentage of its
rating and the total demand.
The control system can also be operated in a number of utility paralleling
modes. Utility parallel operation is activated when a contact on the utility
breaker connects the utility parallel enable terminals in the control panel.
When utility paralleling, the load share lines are not active. Each genset
supplies a percentage of its rated power based on a zero to five volt DC signal
applied to the system's load demand terminals.
PowerComma Familiarization 52250 When utility paralleling, the system can be configured for base load, peak
nd Supervisor shave or import/export operation.
In base load mode the generators run continuously, providing power up to a
pre-determined level to meet internal demand. When the internal demand
exceeds the capacity of the generators the shortfall is made up by the utility.
In peak shave mode the utility provides the base load power. The generators
are commanded to run only after a pre-determined level of utility power is
being consumed.
In import/export mode the generators run continuously. When the total power
of the generators is less than the base load requirement the utility supplies the
difference. When the total genset power ratings exceed the base load, the
excess power is sold to the utility.

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 Script for High Horsepower Natural Gas Lean Burn Control Systems
PowerComma Familiarization 52300 Minimum connections for load sharing include:
nd Supervisor Breaker position and control
Bus voltage from the Bus PT
Load share lines
Master First Start
Remote Start
An example of the connections for island mode parallel operation is shown
here..
Connections for other modes will be different.
Programmabl Familiarization 70000 In this section of the training we introduce the Programmable Logic Controller
e Logic or PLC. The PLC is only fitted as part of the vee engine genset control system.
Controller In addition to having its own specific functions, the PLC integrates the
operation of all system components.
Programmabl Familiarization 70200 The functions of the PLC include:
e Logic control the stop/start sequence of the genset
Controller control engine auxiliary equipment
respond to numerous digital inputs to extend genset protection
provide analog monitoring of alternator RTDs for temperature data and
protection
link hardware using a common fault hard wired interface
communicate with the other main hardware components for data and fault
information
provide a data reservoir that the customer can use to obtain information
Programmabl Familiarization 70300 The hardware architecture for the PLC is as shown in the diagram. The
e Logic hardware consists of a power supply, central processing unit, communications
Controller cards and digital and analog input and output cards.
Programmabl Familiarization 70400 The PLC main program operates the common fault logic, the engine
e Logic auxiliaries and communicates with the engine control, PCS, and the Human
Controller Machine Interface. Some typical auxiliaries that may be fitted and come under
PLC control include: engine pre-heaters, alternator pre-heaters, water
circulating pump, radiator fans, oil pre-lubrication pump, ventilation fans and
motorized louvers.
Programmabl Familiarization 70500 All protective features are brought to the PLC as digital or analog inputs.
e Logic These faults are grouped into system categories depending on severity. For a
Controller more complete description of the system fault categories see the Human
Machine Interface section of this training.
Human Familiarization 80000 The Human Machine Interface or HMI is fitted as part of the standard vee
Machine engine genset control system. The HMI is a touchscreen device that functions
Interface as a user interface.
It displays real time data about the genset; it reports fault conditions and the
operator can initiate or control the operation of certain functions such as the
manual pre-lube on QSV gensets.
Human Familiarization 80100 The HMI treats the Programmable Logic Controller as a data reservoir. The
Machine HMI therefore has access to data and fault code information from the PLC,
Interface PCS, and the engine control system.
Human Familiarization 80200 If the HMI should fail the set will still operate. Emergency shutdown protection
Machine will be ensured by the hard wired connections but, the visual indication of the
Interface fault will be lost.
Human Familiarization 80300 The HMI hardware consists of two pieces: a Provit 2200 touchscreen and an
Machine industrial PC mounted on the back of the touchscreen.
Interface The Screen is a 640 by 480 monochrome unit with a resistive touch
membrane.
The PC is a 486 SX with 256 kB of static RAM and 20 MB flashdisk.
Human Familiarization 80400 Shown here is a typical set of connections to the PC. The actual position of the
Machine connections may differ.
Interface

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 Script for High Horsepower Natural Gas Lean Burn Control Systems
Human Familiarization 80500 The HMI software consists of MSDOS v6.22 and Interact v5.2 touchscreen
Machine software.
Interface NOTE: the MSDOS operating system is loaded and the installation discs are
shipped inside the panel. The customer is required to register the software
package.
Human Familiarization 80600 The display can show several different screens.
Machine
Interface
Human Familiarization 80700 Several features are shared by every HMI screen.
Machine
Interface
Human Familiarization 80800 On the top of every screen is the screen name.
Machine
Interface
Human Familiarization 81000 Below the screen name is the Status/Mode report.
Machine On this line the Operating Mode is displayed. The mode will be indicated as
Interface run, off, or auto.
Also shown is the Status. For the gas engines this is stopped, purge, cranking,
idle, running or cool down.
The breaker status is displayed as open or closed.
The access level, viewer, user or engineer is shown in the box marked access.
Units can be set to American (psi and Fahrenheit) or S.I. units (Bar and
centigrade)
Touching the exit box on any screen returns the operator to the main screen.
Human Familiarization 81100 The bottom line of the screen is used to display fault and alarm information.
Machine Touching the fault display box brings up the fault management screens. Here
Interface the operator can obtain information about the individual faults and control how
that fault information is displayed. The operator can also manage faults by
acknowledging or clearing them. The hardware device that detected the fault
is identified and the operator can use the fault management screens to view
historical files once the fault has been corrected and reset.
Human Familiarization 81200 In addition to the Fault display selection box, this line also displays alarm and
Machine shutdown information.
Interface
Human Familiarization 81300 The various data and information screens are shown in the center of the
Machine display.
Interface
Human Familiarization 81400 The Main Screen is the home page for the system. As such it displays the
Machine principal data, alternator information on the left side of the screen and
Interface genset/engine data on the right.
Human Familiarization 81500 The alternator voltage and current for each phase are displayed in the box on
Machine the left. The operator can select to view output voltage from phase to phase (L
Interface to L) or from phase to ground (L to N).
Human Familiarization 81600 On the right side of the main screen the Kilowatt and megawatt hours are
Machine displayed along with the engine oil pressure coolant temperature and speed.
Interface
Human Familiarization 81700 An exception to the common features is made on the main screen. Since the
Machine exit button is always used to return to the main screen, on the main screen the
Interface exit button is replaced by a "Gas System" screen button.
Human Familiarization 81800 The change user level button allows the operator to select the proper user
Machine level.
Interface The choices are viewer, user, engineer and developer.
Human Familiarization 81900 The viewer level (code 100) is the default level. It allows the operator to
Machine monitor system operation only. The system should always be returned to this
Interface level following the completion of service work.

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 Script for High Horsepower Natural Gas Lean Burn Control Systems
Human Familiarization 82000 The user level (code 200) gives the operator access to most of the control
Machine features of the system. Off load and on load testing and initiation of a manual
Interface oil prime require user access.
Human Familiarization 82100 The engineer level requires a special code. With engineer access it is possible
Machine to change the setpoints for the alternator temperature alarm and shutdown
Interface activation. Some information, such as the engineer data screens, are only
available with this or developer level of access.
Human Familiarization 82200 The developer level also requires its own special code. With developer level
Machine access it is possible to gain full access and also to reconfigure the system.
Interface
Human Familiarization 82300 The gas system screen shows the position of the gas control valves such as
Machine the shut off valves, fuel control valves and throttles. Also displayed are the gas
Interface flow rate and the pressures and temperatures at various locations throughout
the intake system.
The shutoff valve information comes from microswitches mounted on the valve
while the other data comes from the engine control system.
Human Familiarization 82400 The alternator statistics screen displays alternator phase voltages and
Machine currents. It also shows the alternator winding temperatures.
Interface The alternator temperatures are monitored by the PLC, with engineer level
access at this screen the protection temperature settings can be changed.
All other information shown on this screen is monitored by PCS.
Human Familiarization 82500 On the engine statistics screen the operation data comes from PCS. All other
Machine data on this screen comes from the CM700 and CENSE.
Interface
Human Familiarization 82600 The systems data screen displays genset control data and communication
Machine status information from the PLC. The other data shown on this screen comes
Interface from the PCS.
Human Familiarization 82650 The two engineer data screens are restricted access. These screens provide
Machine information about spark timing, knock sensor output and air/fuel ratio.
Interface
Human Familiarization 82700 The auxiliaries mimic screen shows the status of auxiliary systems such as the
Machine engine heaters, alternator heaters, coolant circulating pump and the lube oil
Interface priming pump. It also shows the status of individual auxiliary circuit breakers.
Human Familiarization 82800 On the fault management screen the faults are divided into four categories.
Machine Three fault conditions and a Notifiable Occurrence or Notice.
Interface Notifiable occurrences are conditions that are not significant enough to be
considered faults. These are message only, low priority conditions that do not
sound an alarm and do not require resetting.
System Warning alarms will not affect a running genset. They are the lowest
priority fault condition and set an alarm siren and message only.
Controlled or urgent shutdowns are urgent or serious conditions that will
initiate a genset shutdown after a cooling run. A fault message and alarm
accompany the shutdown.
Critical or emergency system shutdowns are caused by a condition so severe
that the engine must shutdown immediately. A fault message and alarm
accompany the shutdown.
Human Familiarization 82825 When a fault occurs on a vee engine genset the user must first acknowledge
Machine the fault to silence the audible alarm.
Interface If the fault has caused a controlled shutdown turn the run/off/auto switch to off.
When the problem has been identified and corrected the operator can reset
the alarm by pressing the PCS reset button. If the reset is successful the time
off appears in the HMI alarm screen window.
Clear the fault listing from the HMI and if the engine is shutdown restart it by
turning the PCS run/off/auto switch to the run or auto position.

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 Script for High Horsepower Natural Gas Lean Burn Control Systems
Human Familiarization 82850 If the fault has caused an immediate shutdown the engine modules will also
Machine need to be reset.
Interface Follow the same procedure as the controlled shutdown: Acknowledge the
alarm, turn the run/off/auto switch to off and make the necessary repairs.
Toggle the engine management switch to the reset position for at least 8
seconds. This powers down and resets the engine modules. Set the engine
management switch back to normal. Press the reset button on the PCS. Clear
the alarm from the HMI screen and restart the engine.
Remember, following a critical shutdown, vee engines will go through a vent
cycle on the next start attempt.
Human Familiarization 82875 To reset alarms on in-line engine gensets check the PCS Alpha Numeric
Machine display for fault and status messages, warning or Shutdown. CM700 derived
Interface engine faults will only indicate Engine Fault. Specific engine faults such as
knock, fuel pressure, battery voltage out of limits, communications failure,
throttle plate position error etc. will not be identified unless the optional
modbus display module is fitted or the control system is interrogated using the
Cummins electronic service tool.
Once normal operating status is restored Alarms can then be reset as follows;
Warning alarm, press the PCS re-set button.
Critical Shutdowns will bring an engine to an immediate stop and require
power to the engine control modules to be cycled off for 8 seconds in order to
reset them. Turn the run/off/auto switch to the off position and activate the
PCS reset switch. This will automatically power down and reset the engine
modules.
Following a successful reset, the fault code and description disappears from
the Alpha Numeric display.
Re-start the engine by turning the PCS run, off, auto switch back to Run or
Auto as required.
Human Familiarization 82900 On the fault summary screen the operator can highlight an individual fault
Machine event. This allows the operator to read information about which device
Interface detected the fault.
The operator can also sort events by priority or time and can confirm the date
and time that the event became active or inactive.
Human Familiarization 83000 Information for the fault history screen is provided by the HMI software. The
Machine HMI automatically creates a new file every eight hours and updates the file
Interface every three minutes. Up to 10 files are stored in memory so the operator can
recall up to 80 hours of historical information about the system.

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