HHP Natural Gas Engines - Controls

Module 3 – Fuel Systems

Cummins, Inc Training

 2

Fuel Systems
Learning Objective
To understand Fuel System Components and Sensors not previously covered in the
Cummins, Inc. Virtual College Engine Controls ‘Self-Study’ CD-ROM. At the end of this
module you will understand the operation of HHP Gas Fuel Systems.
Agenda
• Virtual College CD-ROM - Any Questions?
• CM700 Functions
• CM558 Function
• CENSE Functions and Location
• Air, Fuel and Exhaust Handling System.
• Gas Supply Train.
• Valve Proving System.
• Throttle Drivers and Actuators.
• FloTech Assembly.
• Open and Closed-Loop Control.
• Torque-over-Boost Control - ‘V’ Engines.
• Engine Sensors.
QSK60G – rev 2.0 Our energy working for you™.
 3

Virtual Training CD-ROM

The following Fuel System Components have been extensively covered in

the Cummins, Inc. Virtual Training CD-ROM ‘self-study’ program for the
High Horsepower Natural Gas Lean Burn Controls:

• Crankshaft / Camshaft Sensors (Speed, Position, etc.).

• CM700,
• CM558,
• Gas Control Assembly.

ANY QUESTIONS???
QSK60G – rev 2.0 Our energy working for you™.
 4

Questions

1. Natural Gas is lighter than air. True or True

False?

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

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

Control Module?

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

sensors.

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

sensors.

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

QSK60G – rev 2.0 Our energy working for you™.

 5

CM700 Functions
HT Coolant LT Coolant Lube Oil Compressor Inlet Crankcase Blow-by
Temperature Temperature Temperature Air Temperature ( when fitted )
(45/60 only )
HT Coolant LT Coolant Lube Oil Crankshaft
Pressure Pressure Pressure Speed

MODBUS to Genset PLC

Speed Bias Signal CM
From PCS CM700 Ignition
Ignition
Shutdown Signal 558
Speed
Engine Management
Governing
Switch
+
Genset Load (kW Load)
Base Engine
Idle / Rated switch (PLC) Protections Engine
Stop / Start Switch (PLC)
Utility Breaker Status (PLC)
Start Solenoid
Fuel Shut Off Valve
CM
Safety Wire Loop / Power CENSE Ignition
Ignition
558
Down Relay Exhaust
Thermocouples
• Output Torque Command (throttle driver signal) to CM558 Modules via CAN 2.0B data Link.
• Exhaust Temperature information sent to CM700 from CENSE Module via J1939 data link.
• Total system data sent to Genset Programmable Logic Controller via RS485 data link.
QSK60G – rev 2.0 Our energy working for you™.
 6

CM558 Functions
Intake Manifold Exhaust
Boost Fuel Inlet & Engine Speed Gas Mass
Temperature & Knock O2 & Back
Pressure Outlet Pressures & Position Flow
Pressure Pressure

LEFT BANK SENSORS

Throttle (Driver Signal)

CM CM558 Throttle (actuator Position Feedback)
700 Ignition Fuel Control Valve (Driver Signal)
(Left Bank) Ignition
Fuel Control Valve (Position Feedback)
Ignition Module (Sync / Fire Signals)
Safety Wire Loop / Power Down Relay

Engine LEFT BANK COMPONENTS

To Generator
Control Panel
(PLC)
RIGHT BANK COMPONENTS
CM558 Ignition
Ignition Ignition Module (Sync / Fire Signals)
CENSE (Right Bank)

RIGHT BANK SENSORS

Engine Speed Knock

QSK60G – rev 2.0 & Position Our energy working for you™.
 7

CENSE Functions

To Generator Control CM CM
Panel (PLC) 558 Ignition
Ignition
700
Exhaust Port Temperatures (Left Bank)
TH1 TH2 TH3 TH4 TH5 TH6 TH7 TH8

Engine

CENSE MODULE
CM Ignition
Ignition
558
TH9 TH10 TH11 TH12 TH13 TH14 TH15 TH16

Exhaust Port Temperatures (Right Bank)

• Thermocouples signals are connected to CENSE module K - Type inputs.

QSK60G – rev 2.0 Our energy working for you™.

 8

CENSE Module - Location

CENSE Module - Located on

Right-Bank, Flywheel-End just
above starter motors.

QSK60G – rev 2.0 Our energy working for you™.

 9

Air, Fuel & Exhaust Handling System

O2 TPP

P P1 T
Closed P2
T
FOP
FIP
T
Open Open
SSV GMF FCV

Legend
Note: Gas
Although two turbochargers are used, the gas Air
mixture is common at the Charge Air Cooler. Gas Mixture
Exhaust Gas
Only a single Fuel Control Module is used.
Air Filter
Therefore, data points are all single and do not Charge Air Cooler
need to show left or right bank reference.

QSK60G – rev 2.0 Our energy working for you™.

 10

Gas Supply Line

Gas Supply System option - EXTERNAL to Engine - Supplied pre-assembled according
to data submitted by CPGK, operating pressures set and assembly tested by supplier.

Gas Supply Line as Gas Pressure Gas Pressure Safety Blow Double
shown normally 80mm Regulator Switch Off Valve Solenoid
diameter up to 3.0Bar Only fitted if Main Gas
Supply exceeds 5psi
Valve
inlet pressure, 50mm
diameter over 3.0Bar.

P1 P2

Manual Gas Safety Shut Valve Fuel Supply

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

Ensure ALL gas pipe work is Earthed! Clamp type Earth straps should also be fitted to
flexible supply line. Ensure components comply to local regulations / legislation.
QSK60G – rev 2.0 Our energy working for you™.
 11

Filter

GF Type - general fine filter for all

gasses and air, 50 micron rating.
Body cast - Aluminium & Silicon
(ALSi).
Flanges to DIN 2533.
Filter pad - removable polypropylene
fleece.
Can be fitted in horizontal and
vertical indoor pipes.
Maximum operating temp + 80º C. Note: Direction of gas flow

Maximum pressure 2 or 4Bar.

QSK60G – rev 2.0 Our energy working for you™.

 12

Pressure Regulator
Pressure
Regulator
Setting Screw
Gas pressure regulator with high level safety
shut-off valve at approximately 50mBar
above regulator output pressure, manual Main Diaphragm Load Spring

reset only. Vent

Pressure
Regulator output pressure setting - Compensation
selectable by spring and adjustment screw to Valve

give 180 - 200mBar output, irrespective of SSV Valve

Seat Pulse
inlet pressure or flow rate. Connection
SSV Valve
Spring selection dependent on Gas Inlet Pipe Plate Intermediate
Diaphragm
diameter. Valve Seat
SSV pressure range set by spring and
adjustment screw. P1 P2
Differential between set and response Closing
Valve Plate
pressure of the SSV should be not less than Spring

20mBar to prevent sporadic tripping. Ball Pulse

Connection Closing Cover
Regulator and SSV spring selection will be Meter
Vent
Maximum
determined by Cummins prior to delivery. Pressure Spring SSV Diaphragm

SSV - Mandatory requirement if gas supply Maximum Pressure Minimum Pressure Spring
Setting
pressure greater than 75mBar. Reset Button
Minimum Pressure Setting

QSK60G – rev 2.0 Our energy working for you™.

 13

SSV Reset Procedure - Dungs® Regulator

• Equalize pressure across

valve via the By-Pass Valve.
Close valve.
• Remove the closing cover.
• Ensure good ventilation, a
small quantity of gas can
escape when removing the
closing cover.
• Move the valve bar by
pulling out the lever until the
ball lock shut-off re-
engages.
• Refit the closing cover and
seal.
• Perform a leak test on the
closing cover.
• The SSV is again ready to
operate.

QSK60G – rev 2.0 Our energy working for you™.

 14

DSSV – Valve Proving System

The Fuel shutoff Valve (FSOV) may

be equipped with either a Validation
Module or position switches to
confirm proper operation.
Note: The Fuel Shutoff Valve (FSOV)
may be engine or remote mounted.
The Validation Module, if equipped, is
mounted on the Fuel Shutoff Valve
(FSOV).
The Validation Module is an automatic
test feature that verifies the two
normally-closed valves within the Fuel
Shutoff Valve are gas tight when the
engine is stopped.
The Validation Module test runs
automatically after a normal engine
shutdown and whenever the engine
control system is reset. Engine Mounted Fuel Shutoff Valve
Fitted with Fuel Validation Module.

QSK60G – rev 2.0 Our energy working for you™.

 15

DSSV – Valve Proving System

ƒ System introduced since publication of
Cummins Virtual College CD-ROMs. Valve Proving
System
ƒ NO CHANGE to Gas Control Valve - 24v dc
solenoid operated twin shut-off valves (for
isolation and safety). Maximum inlet
pressure: 500mBar.
ƒ Valve Proving System (VPS) – Automatic
test feature to check the integrity of the
valves within the DSSV.
ƒ HP and LP protection levels set via CM700
module. Monitored via Danfoss pressure
sensor mounted on rear of DSSV assembly.
ƒ High and Low Pressure Switches and Vent
Valve removed from this system.
ƒ Valve operation can be checked by opening
the p2 test point (simulates leak condition).

THE CONTROL VALVE THEN SUPPLIES THE GAS CONTROL ASSEMBLY ON THE ENGINE

QSK60G – rev 2.0 Our energy working for you™.

 16

Valve Proving System – VPS504

Manual Test/Reset Button

and Test ‘Fail’ Lamp

Test ‘Pass’ Lamp

Engine Stop – Valves V1 and V2 are closed.

Top View of Valve Proving System
Pressure Build-up – The internal pump increases the gas
pressure P1 in the section by approximately 20mBar (P2)
compared with the input pressure at valve V1. During the test time,
the integrated differential pressure sensor monitors the test section
for leaks. When the test pressure is attained (20mBar), the pump
switches off (end of test period). The test time is dependant upon
gas volume and pressure and is set between 10-26 seconds. If the
test section has no leaks within the specified test period, the
contact is released to the control box and the YELLOW LED is lit. If
the test section leaks, or if the pressure increase of 20mBar is not
attained during the test period, the VPS504 generates a fault and
the RED LED is lit. Test takes place at every SHUTDOWN and
repeats at a calibratable period (TBD).

QSK60G – rev 2.0 Engine Running: The internal valveworking

Our energy of the VPS504 is closed.
for you™.
 17

Valve Proving System – VPS504

The VPS requires regular servicing.
Valve
Proving ƒ Inlet and Outlet filters require
System replacement – frequency
dependant upon gas quality
(aggressiveness).
VPS Outlet ƒ O-rings also require replacement
Filter & O-Ring at the same time.
ƒ On first service, the VPS
mounting screws also require
replacement. The new screws
should be torqued to
manufacturers specification.
ƒ Mounting screws DO NOT require
replacement at any other service
VPS Inlet Filter interval.
& O-Ring
ƒ Filter servicing is vital as blocked
filters will cause the VPS to pass
NOTE: VPS servicing MUST be undertaken
the test, regardless of condition of
by a CORGI registered technician.
the DSSV valves.

QSK60G – rev 2.0 Our energy working for you™.

 18

FSOV Validation Module – Manual Test

A Test button is located on the Validation Module.

If the test shows the valves to be tight (no leakage) the amber light on top of the
Validation Module will be illuminated.
Pressing the Manual Test button with the plug removed from P2 test port will
allow a small amount of natural gas to leak from the Validation Module.

ƒ Remove the plug from the P2 test port and press the Manual Test button.
ƒ The Validation Module will run through its normal automatic test cycle and fail
to build pressure. The red light on top of the Validation Module will be
illuminated indicating a failed test (leaking valve). The engine should be
inhibited from starting.
ƒ Reinstall the plug in P2 test port. TEST
Press the Manual Test button. The amber light
should now illuminate indicating a successful test.
P2
NOTE: The VPS is fitted with an internal Fuse.
Should the unit fail to operate check this fuse before Front View of Validation Module
undertaking further tests.
QSK60G – rev 2.0 Our energy working for you™.
 19

ProAct III Throttle Drivers & Actuators

The ProAct III Actuators are mounted

on the air intake plenum duct, the
actuators never open beyond 70%
under any conditions.
The actuators operate on a closed loop
feedback system with the driver module
in order to determine actuator position.
Both ProAct driver modules are located
on the B-bank side of the charge air
cooler as shown.
On the QSK45 and 60 Gas Engines
there is only one ProAct III fitted.

QSK60G – rev 2.0 Our energy working for you™.

 20

ProAct III Throttle Drivers - ‘V’ Engines

4-20mA A
36
THROTTLE PLATE
POSITION FEEDBACK 37 B J3
(CM558’s - Connector ‘A’) C

DRIVER
+ A
49 & 50
24V SUPPLY
((+) CM700 Connector ‘A’) – GCP D
J2 J1 J3 F
J1
4-20mA + B
40
THROTTLE PLATE
POSITION CONTROL 50
– C
(CM558’s - Connector ‘B’)
E

ACTUATOR
+ A A
– D D
RED
B
+ B
+ WHITE
J2
– C C
0 BLACK
E – E
FEEDBACK
NOTE: Wiring shown is for QSV 81 / 91 Engines, F F
ALWAYS check wiring diagram for specific engine

QSK60G – rev 2.0 Our energy working for you™.

 21

ProAct III Throttle Actuator

Charge Air Cooler

Gas / Air Flow

x1 Throttle Actuator
(Woodward ProAct)

QSK60G – rev 2.0 Our energy working for you™.

 22

Fuel Control Assembly

Gas Mass Flow Sensor:
• Low maintenance.
• Samples only a small percentage of the
fuel.
• Same sensor as used on the QSV series
engines.
FCV (FloTech):
• Regulates fuel flow into the mixing
chamber.
• Opens proportional to the duty cycle of
the 4 - 20mA PWM signal sent from the
CM558 for precise fuel control.
• Closes when no signal is applied to it.
Fuel Inlet and Outlet Pressure Sensors:
• Two fuel pressure sensors - before (FIP)
and after (FOP) the fuel control valve. QSK19 G Gas Control Assembly Shown

QSK60G – rev 2.0 Our energy working for you™.

 23

Fuel Control Assembly - FloTech

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

Pin Numbering Shown for QSK19 G - ALWAYS

refer to engine specific wiring diagram
System / Engine
A - Power Supply (+).
B - Power Supply (–).
D - Fuel Control Valve Command (+).
E - Fuel Control Valve Command (–).
F - Fuel Control Valve Position Feedback (+).
Ground
NOTE:
Position Feedback is reference to the Supply
Power (–), wire B. Feedback output signal
will vary from 0.5Vdc (± 0.1) at minimum
actuator position to 4.5Vdc (± 0.1) nominal at
maximum actuator position.

QSK60G – rev 2.0 Our energy working for you™.

 24

Fuel Control Assembly - GMF Sensor - All Gas Engines

Gas Mass Flow Sensor:

o Measures the amount of gas being
delivered to the engine.
o Delivers a voltage signal to the ECM which
is proportional to Gas Mass Flow.
Key diagnostic tool
(D) CM558 Plug B Pin 17 - Sensed Gas Mass Flow Signal
GMF
(B) CM558 Plug B Pin 18 - Sensor (–)
Sensor
(A) CM558 Plug B Pin 08 - Sensor (+24 v dc supply from CM558)

(C) Battery 24V (–)

QSK19 G Engine Shown

QSK60G – rev 2.0 Our energy working for you™.

 25

Gas Control Assembly

Pressure Sensor (FOP)

Gas Mass Flow Sensor (GMF)

Control ‘Butterfly’

Pressure Sensor (FIP) Duty Cycle Valve

(FloTech)
Temperature Sensor (FIT)

QSK60G – rev 2.0 Our energy working for you™.

 26

Open / Closed Loop Control

Air / Fuel ratio control on the engine in 2 basic modes:

1. Open-Loop - Has advantage of simpler set-up, calibration and trouble-shooting.
However, emissions are only correct at time of setting.
2. Closed-Loop - Will ensure emissions do not drift outside of specification, as
closed-loop system monitors ambient temperatures, pressures, gas quality, etc.
and makes adjustments to fuelling accordingly.
Engines will be shipped in Open-Loop mode.
Note: Some QSK 60G Engines currently have an O2 sensor fitted, but it is
redundant and NOT used to control air/fuel ratio.

Air / Fuel ratio control mode:

The automated calibration in QUEST defaults to the table in the A-Bank CM558 to
perform open-loop air / fuel ratio control. This default cannot be changed.

QSK60G – rev 2.0 Our energy working for you™.

 27

Air/Fuel Ratio Control

Engine Coolant Engine

Speed Temperature Speed

Manifold Desired
Temperature Volumetric Air Flow Desired Air Flow Gas Flow
Efficiency Air / Fuel
Air / Fuel
Table Ratio Table Desired
Ratio
Air / Fuel
Ratio

Manifold Manifold
Pressure Pressure

QSK60G – rev 2.0 Our energy working for you™.

 28

Gas Mass Flow Control

Open-Loop
Fuel Inlet Fuel Outlet
Pressure Pressure

Desired Gas Flow Fuel Control % Fuel Control Valve

Valve Position

Measured
FCV Gas Flow
Correction

GMF
Deviation Desired Gas Flow
Adjust FCV
minus
Position
Measured Gas Flow

QSK60G – rev 2.0 Our energy working for you™.

 29

Air/Fuel Ratio Control

Closed-Loop
Fuel Inlet Fuel Outlet
Pressure Pressure

Desired Gas Flow Fuel Control % Fuel Control Valve

Valve Position

A/F Gas Flow

Compensation Control Loop

A/F
Desired A/F Ratio
Adjusted Desired Deviation
minus ToB Engine
Gas Flow
Measured A/F Flow

QSK60G – rev 2.0 Our energy working for you™.

 30

Torque-over-Boost Control

Plant Interface Box

The kW transducer shown is utilised on the ‘V’

Engine Gas products to provide the kW load
reference for the CM700. The CM700 uses this for
the Torque-over-Boost algorithm calculation for
Air/Fuel Ratio Closed-Loop Feedback. The kW
reference is a 4 - 20mA signal.

It is a 3-phase, 4-wire unbalanced load unit.

It is pre-calibrated to allow the panel control system
CT’s to be connected in series.
Two configurations are available:
• For HV sets - voltage input routed via a PT,
• For LV sets - direct voltage input up to 480V.
Wiring Configuration Shown is for LV Genset
REMEMBER! On later build Gensets, the kW
Transducer is no longer used. The kW signal is taken
directly from the PCS.

QSK60G – rev 2.0 Our energy working for you™.

 31

Engine Sensors

Intake Manifold Temperature (IMT):

ƒ Measures the temperature of the
air/fuel mixture.
ƒ Relays a signal to the ECM relative
to the temperature of the mixture.

QSK60G – rev 2.0 Our energy working for you™.

 32

Engine Sensors - MAP Sensor

Manifold Absolute Pressure (MAP):

ƒ Monitors the absolute pressure in the intake
manifold.
ƒ Transmits an electrical voltage to the ECM
which is proportional to the pressure being
sensed.

Pin A sensor (+) from CM558 Plug A

Pin B sensor (–) from CM558 Plug A
Pin C sensor feedback to CM558 Plug A

QSK60G – rev 2.0 Our energy working for you™.

 33

Engine Sensors - QSK 60G Engines

Intake Air
Temperature Sensor
FloTech Fuel Gas Mass Fuel Inlet
Control Valve Flow Sensor Pressure Sensor
(FCV) (GMF) (FIP)

Exhaust Back
Pressure Sensor
(Not Used)
Fuel Outlet
Pressure Sensor
(FOP)

Fuel Inlet
Temperature Sensor

QSK60G – rev 2.0 Our energy working for you™.

 34

Engine Sensors - QSK 60G Engines

Turbo Outlet
Pressure Sensor
(P1 - before Throttle)

Intake Manifold
Temperature Sensor

HT Coolant
Pressure Sensor Intake Manifold
Pressure Sensor Mounted on Right
(P2 - After Throttle) Bank Inlet
Manifold Elbow
Woodward Throttle
Actuator

QSK60G – rev 2.0 Our energy working for you™.

Module 3 – Fuel Systems

END

Cummins, Inc Training