Application Engineering Bulletin: 1.0 Summary of Installation Requirements

Application
Engineering
Bulletin
Title: This AEB is for the following applications:
Cummins Tier 4 Aftertreatment System Exhaust Automotive Industrial Marine

Heater Application Guidelines
G-Drive Genset
Filtration Emission Solutions

Date: 14 November 2013 Refer to AEB 9.01 for Safety Practices, AEB Number: 227.03
Guidelines and Procedures
Generator sets utilizing engine models: QST30, QSK50, QSK60, and QSK78
Owner: Rumman Kabir Approver: per Procedure VPI-GAE-0001 Page 1 of 30
This AEB supersedes AEB 227.03 dated February 6, 2013.
1.0 Summary of Installation Requirements:

1. Installation of the system must comply with AEB 227.01.
2. The preheater must be supplied with 3 phase 480 V L-L 60 Hz power connection. A transformer
must be provided where Generator set output voltage of the system is different than 3 phase 480
V L-L 60 Hz.
3. The load monitoring current sensor (CS) must be connected to monitor the total load on the
generator – refer to Section 4.3 for details.
4. A circuit breaker with remote shunt trip capability is required for protection of the exhaust pre-
heater – refer to Section 4.4 for details.
5. Over current protective device (Fuse) is required to meet system SCCR rating.
6. The circuit breaker, cabling sizing, and installation method for the Internal Load Bank power
supply must follow NEC guidelines and applicable local codes.
2.0 Purpose:
This AEB outlines the application considerations of the T4 aftertreatment system exhaust preheater. The
application considerations are for both single and multiple genset applications.
3.0 Introduction:
The difference between a T4i certified and the T4F capable unit is the reduced amount of particulate
matter (PM) in the exhaust as regulated by the Environmental Protection Agency (EPA). T4F capable
systems have lower PM per EPA requirement. In a T4F capable system this is achieved through the
implementation of the Diesel Particulate Filter (DPF). The DPF incorporates multiple particulate filters
that trap PM within and reduce the amount that exits the DPF. Over time these filters become saturated
and a regeneration process is required to restore their effectiveness. Regeneration is also important to
keep the backpressure within the specified limits of the generator. The regeneration process involves
increasing the exhaust temperature to a minimum temperature where the PM captured in the DPFs can
be oxidized. The aftertreatment control system coordinates the regeneration process.
Regeneration process requires the exhaust temperature to reach a minimum required temp of 900 °F to
oxidize the soot accumulated in the DPFs. If the generator is running at a high load (typically 70% and
above), the exhaust temperature is high enough to perform regeneration. However if the load on the
generator is low, it requires the use of the heater supplied with CPG T4F solution to increase the exhaust
temperature to perform regeneration. During regeneration the aftertreatment control system monitors the
Cummins Tier 4 Aftertreatment System Exhaust Heater Application Guidelines AEB 227.03
exhaust gas temperature and modulates the heaters to maintain minimum required temperature.
The aftertreatment control always gives priority to the actual customer load. If it recognizes that the
customer load has increased, it modulates the preheater load to ensure that customer load is satisfied.
This is done via the aftertreatment control with signals received from the Current Sensors (CS). The
Current Sensors are used with specific genset models that are covered in the later sections. They
monitor the total load on the generator set including the heater load. If the customer load is high enough
to maintain the temperature required for regeneration, then the aftertreatment system may deactivate the
preheater completely. The preheater can also be used to manually load the genset for test and exercise
purposes. The Annunciator on the aftertreatment control panel can be used to control the preheater load.
Figures 3.1 and 3.2 show the components and the whole aftertreatment system. Item 4 contains the
heating elements that heats up the incoming exhaust gases to allow for the regeneration process to take
place. These preheater elements are controlled by rectifiers to modulate the heat inside the
aftertreatment system. When the exhaust gas temperature is high enough (close to 900 °F), the
aftertreatment control panel (item 6) signals the heater power panel (item 5) and modulates the exhaust
preheater (item 4) power to maintain the regeneration temperature in the DPF (item 2) for required time
(approximately 1 hour). After the regeneration is completed the control panel shuts off the heaters until
the next regeneration process.
CUMMINS PROPRIETARY: This information is confidential and classified PROPRIETARY per CORP-10-01-21-03, and shall not be disclosed to others in hard copy or
electronic form, reproduced by any means, or used for any purpose without the written consent of Cummins Inc.
Revision 03, 14 November 2013 Page 2 of 30 © Copyright 2013 Cummins Inc.

Figure 3.1: Typical Aftertreatment System
Figure 3.2: Cummins Power Generation T4 capable genset with DPF and Exhaust preheater
4.0 System Overview:
This section describes the major components of the aftertreatment heater system. The detail of their
connection requirements is discussed later in this document. The following diagram illustrates the
additional components required to be provided by the customer. The wires marked in blue are the
required customer connections.

Figure 4.1: Customer Connection points & additional components for Heater application
Components that need to be supplied and connected by installer (**Except the Optional CS):
4.1 Power cable to provide 3 Phase 480 V AC 60 Hz power to the Heater (Customer Supplied)
4.2 Transformer to step down/up the generator set output voltage to 480 V AC 60 Hz to the
individual heater ducts (Customer Supplied)
4.3 Circuit Breaker (CB) appropriately sized for AT system protection as guided by NEC
(Customer Supplied)
4.4 Current Sensor (CS) to Monitor the total load on the genset (**CPG supplied)
4.5 Arc flash analysis
4.6 CS and CB connection alternate locations
4.1 Power Cables for Heater: The Heater needs to be supplied with 3 phase 480 V AC 60 Hz for
powering the heating elements. This can be tapped directly off the genset if the voltage matches.
For any other voltage connections, the customer needs to provide a step down/up transformer to
supply the heater with rated voltage and current.
i. Code Considerations: The power cable connections must be sized and installed
according to NEC/NFPA 70 or local code guidelines. The considerations include but are
not limited to
 NEC240 Location to Circuit: Use this section to determine how long the taps can be
before an Over current protective device needs to be used.

 The cables must be sized to meet NEC Article 310 (NEC 2011), conductors for
general wiring. Tables in article 310.15 provide size and derate factors for up to 2000
V. Above that article 310.60 should be followed.
Figure 4.1.1: Exhaust preheater and Heater power panel (on right)
4.2 Transformers: The power source to the heater must be rated at 480 V AC at 60 Hz 3 Phase.
For any application where the generator set output voltage is over or under 480 V, a transformer
is needed to be used for power supply to the heater. If a 480 V power connection from the
emergency circuit of the load bus is available, it can be used to power the heaters without a
transformer. The transformer needs to be appropriately sized per the heater size. The size of the
heater loads are given in Table 4.2.1.
i. Code Considerations: The transformer needs to be protected per NEC/local Code
guidelines. Both primary and secondary sides of the transformer need protection. For
the primary side a fuse or a circuit breaker can be used per NEC guidelines. For the
secondary side the circuit breaker needed for the heater installation is sufficient.
ii. Heater load: The total heater load varies by genset model. The power factor of the
exhaust preheater loads is almost unity since the elements are resistive type. If there is
more than one heater on a single transformer, it must be sized and protected accordingly.
Calculate current per heater duct by the following formula.
Current per duct I (ampere) = (kWe*1000) / (1.73205 * VL-L)
For example, a 480VL-L, 3 phase, 2000KW DQKxx T4i certified set has two aftertreatment
duct, with 250 kWe heater load on each duct.
So current per duct I = (250*1000)/(1.73205*480) = 301 ampere.
Genset Genset Engine Heater load (kWe) Heater Load (kWe)

Model Rating (kWe) Model T4i Certified T4 Final capable
DQFAE-H 750-1000 QST30-G17 250 kW 250 kW
DQGAR-S 1250-1500 QSK50-G8 2 x 250 kW 2 x 250 kW
(total 500 kW) (total 500 kW)
DQKAK-L 1750-2000 QSK60-G16 2 x 250 kW 2 x 250 kW
DQKAM 2250 QSK60-G17 2 x 250 kW 2 x 250 kW
DQLG-H 2500 QSK78-G14 2 x 330 kW 2 x 330 kW
2750 (total 660 kW) (total 660 kW)
Table 4.2.1: Exhaust preheater size by genset Model

4.3 Current Sensor: A single Current Sensor is needed for properly monitoring the total load on the
gensets equipped with Cummins PCC 3201 and PCC3.3 controls. Current Sensor must be
installed in a location that allows the aftertreatment control panel to monitor the total load on the
generator set, including the heater loads. The ideal location to install the CS would be around the
bus bars in the alternator set top box as shown by Figure 4.3.1. The CS can be installed on any
one of the phases, typically the phase with the most loads. If the loads on all phases are
balanced, then the CS can be installed on either of the three. The CSs polarity must be such that
it reads the current flowing out of the genset. The CS wires have to be connected in the
customer connection terminal block in the aftertreatment control panel according to the wiring
diagram.
The aftertreatment control must know the exact characteristics of the CSs; therefore the installer
must follow the instructions to set up the CS appropriately in the aftertreatment system. See CS
connection example (Figures 4.3.2 and 4.3.3).
Generator
G
TERMINAL BLOCK
N W V U
CT Genset Control
AT
Control CT-AT
Circuit Breaker or
Entrance Box
Figure 4.3.1: CS installation for the aftertreatment system (PCC 3201 and PCC3.3 Control)

Figure 4.3.2: CS connection example. (1: CS, 2: Load cables, 3: Heater Power Cables).
The 4th phase is not shown in this picture.
Notice below that the CS is connected before the customer load and heater power cables. This is
ensuring that the CS is monitoring total current which is the sum of customer load and heater load.
Figure 4.3.3: CS connection example. (1: CS, 2: Load Cables, 3: Heater Power Cables)

4.4 Circuit Breaker: For the protection of the exhaust preheater a circuit breaker is required. For
dual duct systems, there are two heaters. One circuit breaker per duct must be used in dual duct
aftertreatment systems. The circuit breaker size can be selected based on the heater load size
per Table 4.2.1 in unity power factor. The location of the circuit breaker is discussed in Section 5
in the bulletin when we discuss topologies for multiple genset applications. An 80% or 100%
rated breaker can be used according to the code guidelines.
i. Code Consideration: The circuit breaker must follow NEC guidelines for location in the
circuit. NEC allows different lengths of wires for tapped branches.
ii. Fuse Protection: The control panel, heater DEF and power panel installation must follow
the NEC Article 409 including overcurrent protection and short circuit current rating. The
short circuit current rating for the components can be found in Appendix B.
iii. Shunt Trip: The circuit breaker(s) must have a shunt trip unit that is connected to the
aftertreatment control. The specifications of the AT control outputs for the shunt trip units
are listed below and are also found in the system wiring diagram (refer to Installation
Manual).
Shunt Trip Output for Duct A breaker:

Terminal connections (AT Control Panel): See wiring diagram
Output Voltage: 24VDC
Max. Continuous Current: 1A
Max. Inrush Current: 2A @ 100ms
Shunt Trip Output for Duct B breaker:

Terminal connections (AT Control Panel): See wiring diagram
Output Voltage: 24VDC
Max. Continuous Current: 1A
Max. Inrush Current: 2A @ 100ms
If current requirements for circuit breaker shunt trip coil is higher than above, add
interposing relay to operate shunt trip.
iv. Lock-out/Tag-out: The circuit breaker must allow or include provisions required for lock-
out/tag-out procedures according to OSHA regulations and any other applicable codes.
4.5 Arc Flash Analysis: Arc Flash analysis has to be performed by the system installer on the whole
system. After the analysis, required labels must be placed also by the analyst in accordance to
NEC article 110.16.

4.6 CS and CB connection: The circuit breaker and Current Sensors can be connected to genset in
one of the following ways.
i. CS and CB connected to the alternator bus bar. The CS is installed around the phase
with the most loads. The heater power cables can be used with compression lugs to
connect to the alternator bus bar slots.
Exhaust Heater
(Load Bank)
Mixer DPF SCR
Heater Heater Exhaust

panel panel
Heater output
command
PCC
Modbus Genset
Generator
AT Control CT
Shunt Trip Gen CB or

Entrance Box
Fuse
AT 480 V 60Hz
CB
Par
CB
AT
CB

ii. CS connected to alternator bus bars. Heater connected to the Gen CB/ Entrance box
lugs
Exhaust Heater
(Load Bank)
Mixer DPF SCR

panel panel
Heater output
command
PCC
Modbus Genset
Generator
CT
AT Control
Gen CB or
Entrance Box
Shunt Trip
Fuse
AT
CB 480 V 60Hz
AT Par
CB CB
iii. CS and CB both connected to the Gen CB or Entrance box lugs
Exhaust Heater
(Load Bank)
Mixer DPF SCR

panel panel
Heater output
command
PCC
Modbus Genset
Generator
AT Control
Gen CB or
Entrance Box
Shunt Trip CT
Fuse
AT 480 V 60Hz
CB
AT Par
CB CB

5.0 System Topologies for multi genset application:

Based on the multiple types of connection schemes, we can arrange multi genset applications in one
of the following topologies. The circuit breaker location should be determined and installed per NEC
guidelines as discussed earlier. The transformer should be sized according to the load available, and
protection should be ensured per NEC guidelines for both primary and secondary side of the
transformer.
5.1 Multiple gensets with bus voltage at 480 V AC 3 Phase 60 Hz

5.2 Multiple gensets with bus voltage above 480 V AC 3 Phase 60 Hz
5.2.1 Individual transformers per genset
5.2.2 Large central transformer
5.1 Multiple gensets with bus voltage at 480 V AC 3 Phase 60 Hz: For multiple gensets with
heaters attached, the preference is that the heater power cables connect at the output of the
genset. This typically is the circuit breaker output lugs or entrance box bus bars.
5.1.1 CS connection: The Current Sensor should be connected so that it monitors the
total load of the genset on the phase with highest loads. Which means it should
monitor the customer load and the heater load together. It can be installed in the
circuit breaker box or entrance box where the heater power cables connect. The
CS cables should be routed back to the aftertreatment control and connected per
the description in Section 4.4.
Exhaust Heater Exhaust Heater Exhaust Heater

(Load Bank)
Mixer DPF SCR (Load Bank)
Mixer DPF SCR
Heater Heater Heater

panel Exhaust panel Exhaust panel Exhaust
PCC PCC PCC

Gen 1 Gen 2 Gen x
Modbus Generator Modbus Generator Modbus Generator
AT AT AT
control control Control
Gen Gen Gen

CB CB CB
CT CT 480 V 60Hz CT
AT 480 V 60Hz AT 480 V 60Hz AT
CB CB CB
Shunt trip Shunt trip Shunt trip
Par Par Par

CB CB CB
Gen Bus
480 V 60 Hz output from Gen, No transformer required.

Fdr Fdr Fdr
CB CB CB
Load 1 Load 2 Load x

5.2 Multiple gensets with bus voltage other than 480 V AC 3 Phase 60 Hz: Gensets with
base voltage 480 V or above require the use of a transformer to power the heaters. In a
multiple genset configuration, there could be either individual transformers for each genset or
one central transformer.
5.2.1 Individual transformers per genset: If each genset has its own individual
transformers, it is the best to connect them to the genset power terminals
(illustrated by the drawing on top). The primary side of the transformer for each
genset can be connected directly to the alternator output. The primary side of
the transformer can also be connected to the genset bus (Illustrated by the
bottom drawing). In the latter case, isolation of the single T4 system would
require opening the paralleling circuit breaker and also the primary side of the
transformer.
Exhaust Heater Exhaust Heater Exhaust Heater

(Load Bank)
Mixer DPF SCR

PCC PCC PCC

Gen n Gen n Gen n
Generator Generator Generator
Modbus Modbus Modbus
AT CT AT AT CT
CT
Control Control Control
Gen Gen Gen

Shunt trip CB Shunt trip CB Shunt trip CB
Fuse Fuse
Fuse AT AT
AT
CB 480 V 60Hz CB
CB 480 V 60Hz
480 V 60Hz
Par Par Par

CB CB CB
MV/HV bus (600V, 4.2KV, 13.2 KV at 60 Hz, etc)
Voltage Greater than 480 V from Gen, Transformer required (individual

connected at the Alternator output).
Fdr Fdr Fdr
CB CB CB
Load n Load n Load n
Exhaust Heater
Exhaust Heater
Mixer DPF SCR Exhaust Heater
Mixer DPF SCR
(Load Bank) (Load Bank)

PCC PCC PCC

Gen n Gen n Gen n
Generator
Modbus Generator
Modbus Generator
Modbus
AT AT AT
Control Control Control
Gen Gen Gen

CT CB CT CB CT CB
AT 480 V 60Hz AT 480 V 60Hz AT 480 V 60Hz

CB CB CB
Par Par Par

Fuse Fuse CB Fuse CB
CB
Voltage Greater than 480 V from Gen, Transformer required (individual

connected at the Genset Bus). Fdr Fdr Fdr
CB CB CB

5.2.2 Large central transformer: In multiple genset application, one large transformer
can also be used to power multiple exhaust preheaters. Designer must make
sure that during testing and exercising the genset, the heater of the respective
genset has power available for regeneration process. Proper transformer and
cable protection must meet local code guidelines. With this topology, one should
also be careful about operator safety since the heater power cable would be
energized even if the genset paralleling circuit breaker is in open state.
5.2.2.1 Alternatively, if the load bus has an emergency circuit that has a stepped
down voltage of 480 V 3 Phase 60 Hz, then the heater power can be
derived from the same emergency bus. This might be a less expensive
upfront cost if the emergency bus already has a large enough
transformer for all heaters in the system.
Exhaust Heater
Exhaust Heater
Mixer DPF SCR Exhaust Heater
Mixer DPF SCR
(Load Bank) (Load Bank)

Exhaust Exhaust panel Exhaust
panel panel
PCC PCC PCC

Gen n Gen n Gen n
Generator
Modbus Generator
Modbus Generator
Modbus
PLC PLC PLC

CT CT
Control Control CT Control
AT
CB
Shunt trip
Shunt trip
Shunt trip
480 V 60Hz
AT Distribution AT
CB Panel
CB
Par Par Par
CB CB CB
Fdr Fdr Fdr

CB CB CB
6 Switchgear system level protection consideration

In multiple genset paralleling applications there are special considerations in the switchgear and built
in protection schemes. There are different levels of protection that are implemented for each genset,
bus, and feeder breakers in the switchgear sections. The protections which can be affected are the
differential types of protections. The location of protection and considerations may vary by
application as well as device type and manufacturer. Therefore for each application they may need to
be considered separately. The following are examples of possible protective relays that would be
affected based on where the heater loads are located.
6.1 Genset Differential protection: Individual gensets within the switchgear system may have
additional protective relays such as a differential protection relay. One of the methods of fault
detection used by this device is a set of differential CTs. These CTs monitor current going
out and back in to the genset. During normal operation and without any fault in the system,
this should cancel each other out. The figure below illustrates a typical genset differential

protection scheme in a multi genset application with switchgear. There are 2 Sets of CTs that
monitor the genset output with the current coming back through the neutral side of the
phases. The relay activates a shunt trip to the paralleling breaker when it detects a fault.
CT 1 (1 per phase)
Heater
Panel
Gen
Heater added
Genset CB
Paralleling CB SEL 700G
CT 2 (1 per phase)
Figure 6.1.1: Typical genset differential protection
If the exhaust preheaters required power is drawn in between the zone of protection then
there is some imbalance when the heater is active. Figure 6.1.1 shows an example of typical
drawing of the differential protection on the left (A snapshot from an actual application
drawing) and A exhaust preheater added to that system on the right. When the heater is on,
there is current flowing through the exhaust preheater. As a result, the two sets of Differential
CTs on the Differential protective relay has a current imbalance. CT 1 has a higher amount
of current flowing than CT 2 (since the Heater is taking a significant amount) and it is likely
trigger the Differential protective relay causing the paralleling CB to trip and lock out.
Therefore to ensure protection and also avoid nuisance trips the designer must work with the
switchgear supplier to accommodate a solution. One of the solutions can be adding a set of
CTs (one per phase, highlighted in yellow). They can be the same polarity as the supply side
breaker that adds up to the current drawn by the actual loads and thereby balance the whole
system. These CTs have to be the same ratio as the CTs used for the differential protective
relays. This also ensures that during testing the generator with load and paralleling breakers
open, the current is balanced. To ensure proper protection the designer must work closely
with the switchgear supplier and discuss the possible effect on the protective devices in the

switchgear system. The Cummins parallel system design incorporates provisions taking into
account properly matched CT’s. The diagram below outlines where the additional CTs
(highlighted in yellow) can be connected in the protective differential relay (the lines in blue
outline the additional CT wires, and the red arrows show the typical current flow of the
system).
Heater
Panel
Gen
Genset CB
Paralleling CB SEL 700G
Figure 6.1.2: Differential protection consideration for the genset
6.2 Bus Differential protection: A multiple genset application with switchgear system may also
have protective relays for bus protection. Bus protection is also achieved through differential
relays. There are CTs for each Feeder breaker and genset. The CTs total current between
supply and loads should always add up to zero. The polarity of the CTs is very important and
they typically are arranged the same way for all the Feeders. Figure 6.2.1 illustrates the zone
of protection for the bus. The zone of protection is highlighted in blue, whereas the
differential protection relays are in yellow. They feed into a bus differential relay in this
example. The bus differential relay controls the trip relay (86z) highlighted in Green which
can trip all the Feeder and genset breakers also highlighted in green.
Now consider when the heater power is drawn from the common bus. If the bus voltage is
different than 480 V, a central transformer can be used to convert to 480 V AC. Now this can
affect the bus differential protection. To solve this, a set of CTs with the same spec as the
feeder line CTs can be added to the Transformers supply feed. The CT polarity has to be
same as the feeder line CTs. This is to ensure that the differential bus protection relay is
monitoring all the loads on the system.

Figure 6.2.1: Bus differential protection consideration


Appendix A: Current Sensor Sizing Guidelines

Current Sensor selection process:
Based on the
current rating,
1. Identify Genset
Use Table A.2 to identify the proper Order 1 or 2
2. Identify Feature Code Install and Verify
identify current Current sensor Current Sensor
3. Identify Alternator voltage code Current sensor per
rating of the from table A.3 based on number
4. Identify number of Entrance guideline below
Genset Verify current of CB on the set
Boxes on the Genset
sensor window
opening.
1. Generator model information:

a. Identify the genset model
b. Ensure that one of the following features are selected
i. L177-2 EPA T4 Interim Certified (2011) w/ILB
ii. L178-2 EPA T4 Interim Certified, Tier 4 Final Capable
c. Find the alternator voltage code. It will have a Rxxx-2 format (for example R107-2 is the
voltage feature code for 4160 VAC L-L)
d. Identify the number of entrance boxes on the genset
2. Identifying rated current:
a. Based on the Genset model and the voltage feature code, identify the rated current of
the current sensor in Amps

Current Sensor rated current of the current sensor in Amps for 10 VDC
output
R098-2 R099-2 R114-2 R107-2 R144-2
R020-2 R029-2 R132-2
Feature codes R076-2 R003-2 R130-2
R023-2
R002-2
Min Volts >120 >240 >480 >600 >12470
Max Volts =240 =480 =600 =4160 =13800
Genset Rating
LV MV HV
Model (kW)
DQFAA, DQFAE 750
DQFAB, DQFAF 800
3500 2000 1500
DQFAC, DQFAG 900
DQFAD, DQFAH 1000
DQGAA, DQGAE, DQGAR 1250
3000 2000 300
DQGAB, DQGAF, DQGAS 1500
DQKAA, DQKAD, DQKAK 1750
DQKAB, DQKAE, DQKAL 2000 4500 3000 400 150
DQKAC, DQKAF, DQKAM 2250
DQLE, DQLG 2500
5500 3500 500 200
DQLF, DQLH 2750
Table A.2: Identifying rated current output of the genset
3. Selecting correct Current Sensor:

a. Based on the genset full rated amps, identify the proper Current Sensor size for the
application from Table A.3.
b. If there are two entrance boxes (two circuit breakers) then order two same sized current
sensors selected in the previous step. With two paths for current from the genset, the
two current sensors with a special harness sum up the current for correct load control in
the heater power panels.

Current Transformer Dimensions

Window Square Outside Dimensions
Rated current Cummins Cal Pacific
Line Voltage Length x Width Length x Width x
@ 10 VDC Part Numbers
(inch) Depth (inch)
120 to 600 1500 4x4 7.5 x 7.5 x 1.5 01-1-000591
120 to 600 2000 4x4 7.5 x 7.5 x 1.5 01-1-000592
120 to 600 3000 5x5 8.25 x 8.25 x 1.5 01-1-000593
120 to 600 3500 5x5 8.25 x 8.25 x 1.5 01-1-000594
120 to 600 4500 8x8 10.8 x 10.8 x 1.2 01-1-000595
120 to 600 5500 10 x 10 14 x 14 x 1.8 01-1-000596
12.47 kV to 13.80 kV 150 5.8 x 3 x 1.5 01-1-000597

12.47 kV to 13.80 kV 200 5.8 x 3 x 1.5 01-1-000598
4.16 kV 300 3x3 5.8 x 3 x 1.5 01-1-000599
4.16 kV 400 5.8 x 3 x 1.5 01-1-000600
4.16 kV 500 5.8 x 3 x 1.5 01-1-000601
Table A.3: Identifying correct Current Sensors
4. Verifying Current Sensor size:

a. Based on the dimensions provided in Table A.3, please verify that the power carrying
cables to the loads fits inside the window. It is critical to note that the Current Sensor
must monitor all the loads being fed from the generator set (See Section 4.3 and 4.6 for
reference).
b. If the selected Current Sensor above does not fit the all the power carrying cables, a
custom Current Sensor may be required. Please contact Cummins Pacific.
Current Sensor Installation Procedure
1. Installation of a Single Current Sensor

a. Materials required:
i. Current Sensor, 0-10VDC output matching the ratings outlined in the sections
above.
b. Instructions
a) Record, mark one end of current sensor body and split core as shown in Figure 1 for
correct reinstalling (if Low Voltage).
b) BY HAND: unscrew nylon thumbscrews and remove split core from the current
sensor as shown in Figure 2.

Figure 1 (Low Voltage) Figure 2 (Low Voltage)
Figure 1 (High Voltage) Figure 2 (High Voltage)
c) Install current sensor on one phase of power cable as shown in wiring diagram.
i) IMPORTANT NOTE: the current sensor does not perform as intended if any
of the cables do not pass through the current sensor or if cables from
another phase are included.
d) Align mark on CS and reinstall split core and nylon thumbscrews.
i) IMPORTANT NOTE: do not substitute nylon thumbscrews for any conductive
material.
ii) DO NOT USE TOOLS as the current senor housing or nylon screws may be
damaged.

e) Ensure the current sensor is perpendicular to the power cables passing through the
current sensor. Also, ensure that no medium or high voltage cables run parallel to
any side of the current sensor. Support or tie wrap current sensor to the power
cables. This is to make sure that the current carrying cables for the genset do not
rub against the current sensor and wear the insulation of the cables.
f) Connect the current sensor to the Wiring Harness PCC to AT control per wiring
diagram. Ensure current sensor wires are well clear of and do not run parallel to the
current carrying cables.
2. Installation of Dual Current Sensors for Left and Right Entrance Boxes
a. This section applies to the following feature codes:
i. KP81-2
b. Materials required:
i. Two Current Sensors, 0-10VDC output matching the ratings outlined in the
sections above. Both sensors should have the same rating.
ii. Dual Current Sensor Junction Box kit
c. Instructions:
a) Review the single current sensor procedure from the previous step.
b) Install current sensor on left and right entrance or circuit breaker power cables as
outlined in single current sensor installation. Ensure the same phase is used for
both entrance boxes and combined, both current sensors monitor all the loads
being fed from the generator set.
c) Connect Dual Current Sensor Junction Box with pigtail wires and Wiring Harness PCC
to AT control per Figure A.2.b.

Figure A.2.b: Dual Current sensor installation

3. Check Procedure: Calibration

a. Test Equipment:
i. Fully installed Tier 4 service tool
ii. External Load bank (rating must be equivalent to or exceed the genset rating)
b. Instructions: (Current calibration is factory loaded in control panel)
a) Verify Genset model & Voltage vs Current sensor part number in accordance
with Table A.2
b) Connect the Tier 4 service tool to the after treatment PLCs inside the after
treatment control panel.
c) Disable the integrated load bank through the service tool.
d) Start the genset and verify genset load 50% & 100% in KVA from the PCC control
vs current sensor kVA from the service tool.
Genset Load % PCC control -KVA Current sensor -KVA

50%
100%
e) Confirm the current sensor measurement in kVA is within 50kVA of the genset
load in kVA from the PCC controller. Also confirm that for a fixed external load
the current sensor measurement remains static within +/-3% of the load.
f) Change to normal operation (enable) of integrated load bank through the
service tool.
g) Start integrated load bank to manual regeneration and apply external load at
full and zero power kVA as listed in load shed algorithm and record ILB load
from service tool.
a. At Max External load for ILB at full power (in kVA – Table A.4), approximate
ILB kW shall be at full load (accepting temperature dependency).
b. At Max External load for ILB at zero power (in kVA – Table A.4), ILB kW shall
be at no load.
h) Cool/Shut down the genset.

Genset Model Genset Rating Max External load for ILB Max External load for ILB
(kW) at full power at zero power
(kVA) (kVA)
DQFAE 750 400 650
DQFAF 800 450 700
DQFAG 900 550 800
DQFAH 1,000 650 900
DQGAR 1,250 650 1,150
DQGAS 1,500 900 1,400
DQKAK 1,750 1,150 1,650
DQKAL 2,000 1,400 1,900
DQKAM 2,250 1,637 2,137
DQLG 2,500 1,715 2,375
DQLH 2,750 1,952 2,612
Table A.4: Load Shed Schedule
4. Troubleshooting Procedure: Significant Current Sensor Error

a. Test Equipment:
a) Fully installed Tier 4 service tool
b) External Load bank (rating must be equivalent to or exceed the genset rating)
c) Volt meter (optional)
b. Instructions: (Current sensors calibration are factory loaded in control panel)
Fault Symptom: Measurement varies by more than +/-3% of nominal during steady
state with integrated load bank only.
a) Photograph the current sensor installation for trouble shooting purposes
b) Take a capture file of the aftertreatment control for record and trouble shooting
c) Replace current sensor
Fault Symptom: Total load measurement between the Genset control and the
aftertreatment control (viewable by AT service tool) differs by 50 kVA
a) Verify Genset model & Voltage vs Current sensor part number in accordance
with Table A.2.
b) Verify the current sensor is perpendicular to the power cables passing through
the current sensor window.
c) Verify that the current sensor and power cables are securely supported and tie
wrapped to each other.
d) Verify that no medium or high voltage cables run parallel to any side of the
current sensor. Support or tie wrap current sensor to the power cables.
e) Verify current sensor wires are well clear of and do not run parallel to the
current carrying cables.

f) Verify that ALL of the cables from the desired phase and ONLY cables from the
desired phase pass through the current sensor window.
g) Connect the Tier 4 service tool to the after treatment PLCs inside the after
treatment control panel.
h) Take a capture file of the aftertreatment control for record and trouble shooting
i) Disable the integrated load bank through the service tool.
j) Use the Current Sensor Calibration utility in the service tool to calibrate the
current sensor.
k) Start the genset and verify genset load 50% & 100% in KVA from the PCC control
vs current sensor kVA from the service tool.
Genset Load % PCC control -KVA Current sensor -KVA

50%
100%
l) Confirm the current sensor measurement in kVA is within 50 kVA of the genset
load in kVA from the PCC controller. Also confirm that for a fixed external load
the current sensor measurement remains static within +/-3% of the load.
m) Change to normal operation (enable) of integrated load bank through the
service tool.

Appendix B: Specifications
AFTERTREATMENT SYSTEM SPECIFICATION

Model CA451 CA452 CA542
T4i w/ILB or T4i wILB or
T4i T4i T4i wILB or T4fc T4i
T4fc T4fc
CONTROL PANEL (TO BE INSTALLED INDOOR)
Volts 120 VAC
Phase 1PH
Amps 21A
Frequency 60 Hz
Largest Motor 0.5HP @ 1.9A
DC Volts, Amps 24 VDC, 10 Amps (max)
SCCR 5kA

T4fc T4fc
POWER PANEL
Volts 480 VAC 480 VAC 480 VAC
Amps 300 A 300 A (2X) 396 A (2X)
Phase NA 3PH NA 3PH NA 3PH
Frequency 60 Hz 60 Hz 60 Hz
Enclosure TYPE 3R TYPE 3R TYPE 3R
HEATER (AT INTERNAL LOAD BANK)
Volts 480 VAC 480 VAC 480 VAC
330 kW
Amps 250 kW 250 kW (2X)
(2X)
Phase 3PH 3PH 3PH
Frequency 60 Hz 60 Hz 60 Hz
Enclosure Rain tight w/gasket cover

POWER PANEL SCCR

MAX MAX OVERCURRENT
MAX LOAD CONTINUOUS CONDUCTOR*
CURRENT SCCR RMS PROTECTION DEVICE*
(kW) CURRENT (A) (kcmil/AWG)
(A) ( kA ) (OCPD)
330 396 246 350 500A FUSE (J OR T TYPE) 100
250 300 186 4/0 400A FUSE (J OR T TYPE) 100
*CONDUCTOR AMACITY AND FUSE CURRENT RATING SHALL MEET OR EXCEED NEC 70 REQUIREMENTS.

T4fc T4fc
HEATER DEF (TO BE INSTALLED INDOOR)
Volts 120 VAC
kW 2 kW
Phase 1 PH
Full Load
17 A
current
Frequency 60 Hz
SCCR 5kA

Current Sensor Specifications:
Current Sensor specification Requirements

1 For applications Line Voltage Up to 600V 600 < V < 13,800
2 Frequency 60Hz
3 Insulation Level Up to 600V Up to 13,800V
4 Basic Impulse Insulation Level (BIL) Meet or exceeds IEEE C57.13 clauses 4.5
5 Current Sensor rated current for 10 VDC See Table A.2 and Table A.3
6 Current Sensor output 0 to 10 VDC
7 Minimum Input Impedance 20 K ohms
8 Rating factor 1.25
Response time, Genset No load to Full
9 100 ms
load step change
10 Accuracy 1% up to full scale rated output
No damage to current sensor during 3x genset rated
11 Maximum current
current or short circuit fault.
12 Output connections #10 Screw terminals
13 Ambient Temperature Range -30 deg F to 175 deg F
IEEE C57.13-2008 or IEC Std 60044-1
14 Code & Standard Compliance
UL & CSA certified or listed.
Must withstand genset vibration Swept sine test :
15 Vibration & Shock +/- 0.125 inch. 20 to 100 Hz,
5.0 g from 100 Hz to 300 Hz
Vertical and horizontal direction
16 Application Installation Indoor, Inside circuit breaker box or Enclosure
17 Current Sensor design Split-core
18 Current sensor window size
See Table A.2 and Table A.3
19 Current sensor size
Ordering Information:
Cummins Pacific
Attn: Tier 4 Sales
1939 Deere Ave
Irvine, CA 92606
(949) 253-6000

Change Log
Revision Date Author Description Page(s)
02 14Nov13 R. Kabir Changed text from “CT” to “current sensor (CS)”. 1
Added text “– refer to Section 4.3 for details”. 1
Added text “A circuit breaker with remote shunt trip 1
capability is required for protection of the exhaust
pre-heater – refer to Section 4.4 for details. Over
current protective device (Fuse) is required to meet
system SCCR rating.”
Changed text from “preheater” to “Internal Load 1
Bank”.
Added text “and applicable local codes”. 1
Changed text from “Transformers (CT)” to “Sensors 2, 5
(CS)”.
Changed text from “Transformers” to “Sensors”. 2,5,7,10,12
Deleted text from Section 4.0 “The CTs for load 4
monitoring will be provided as a part of the solution
from Cummins.”
Changed text from “CT” to “CS”. 5, 7, 8, 10,
11, 12
Updated Table 4.2.1. 6
Changed text from “will be” to “are”. 9
Added “Fuse Protection” section. 9
Added text “circuit”. 9
Changed text from “For single/double heater with one 9
circuit breaker the shunt trip should be connected to
the designated terminal in the wiring diagrams.” to
“The specifications of the AT control outputs for the
shunt trip units are listed below and are also found
in the system wiring diagram (refer to Installation
Manual).”
Added information to Shunt Trip section. 9
Added “Lock-out/Tag-out” section. 9
Added Appendix A and Appendix B. 18-29

01 06Feb13 R. Kabir Added Section 4.5 Arc Flash Analysis. 4, 8
Deleted “(PCC 3201 Control Only)” from Section 4.3. 6
Added “and PCC3.3” to Section 4.3. 6
Added “and PCC3.3 Control” to Figure 4.3.1. 6
Deleted “CS only required for Generators with 10
PCC3201 Control” from Section 5.1.1.
00 12Nov12 R. Kabir Initial Release All

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Application

Cummins Tier 4 Aftertreatment System Exhaust Automotive Industrial Marine

Filtration Emission Solutions

This AEB supersedes AEB 227.03 dated February 6, 2013.

1.0 Summary of Installation Requirements:

Revision 03, 14 November 2013 Page 2 of 30 © Copyright 2013 Cummins Inc.

Figure 3.1: Typical Aftertreatment System

4.0 System Overview:

Revision 03, 14 November 2013 Page 3 of 30 © Copyright 2013 Cummins Inc.

Revision 03, 14 November 2013 Page 4 of 30 © Copyright 2013 Cummins Inc.

Genset Genset Engine Heater load (kWe) Heater Load (kWe)

Revision 03, 14 November 2013 Page 5 of 30 © Copyright 2013 Cummins Inc.

Revision 03, 14 November 2013 Page 6 of 30 © Copyright 2013 Cummins Inc.

Revision 03, 14 November 2013 Page 7 of 30 © Copyright 2013 Cummins Inc.

Shunt Trip Output for Duct A breaker:

Shunt Trip Output for Duct B breaker:

Revision 03, 14 November 2013 Page 8 of 30 © Copyright 2013 Cummins Inc.

Heater Heater Exhaust

Shunt Trip Gen CB or

Revision 03, 14 November 2013 Page 9 of 30 © Copyright 2013 Cummins Inc.

Heater Heater Exhaust

iii. CS and CB both connected to the Gen CB or Entrance box lugs

Heater Heater Exhaust

Revision 03, 14 November 2013 Page 10 of 30 © Copyright 2013 Cummins Inc.

5.0 System Topologies for multi genset application:

5.1 Multiple gensets with bus voltage at 480 V AC 3 Phase 60 Hz

Exhaust Heater Exhaust Heater Exhaust Heater

Heater Heater Heater

PCC PCC PCC

Gen Gen Gen

Par Par Par

480 V 60 Hz output from Gen, No transformer required.

Load 1 Load 2 Load x

Revision 03, 14 November 2013 Page 11 of 30 © Copyright 2013 Cummins Inc.

Exhaust Heater Exhaust Heater Exhaust Heater

Heater Heater Heater

PCC PCC PCC

Gen Gen Gen

Par Par Par

MV/HV bus (600V, 4.2KV, 13.2 KV at 60 Hz, etc)

Voltage Greater than 480 V from Gen, Transformer required (individual

Load n Load n Load n

Heater Heater Heater

PCC PCC PCC

Gen Gen Gen

AT 480 V 60Hz AT 480 V 60Hz AT 480 V 60Hz

Par Par Par

MV/HV bus (600V, 4.2KV, 13.2 KV at 60 Hz, etc)

Voltage Greater than 480 V from Gen, Transformer required (individual

Load n Load n Load n

Revision 03, 14 November 2013 Page 12 of 30 © Copyright 2013 Cummins Inc.

Heater Heater Heater

PCC PCC PCC

PLC PLC PLC

MV/HV bus (600V, 4.2KV, 13.2 KV at 60 Hz, etc)

Fdr Fdr Fdr

Load n Load n Load n

6 Switchgear system level protection consideration

Revision 03, 14 November 2013 Page 13 of 30 © Copyright 2013 Cummins Inc.

Paralleling CB SEL 700G

Figure 6.1.1: Typical genset differential protection

Revision 03, 14 November 2013 Page 14 of 30 © Copyright 2013 Cummins Inc.

Paralleling CB SEL 700G