MODULE 1

INTRODUCTION
HHP LBNG Generator Controls

Module Objective
To prepare participants for learning and set background information relevant to the later modules in
this course.

After Completion – Participants should be able to:

• Specifically identify their Genset, engine & alternator
• Understand the product background and nomenclature
• Understand the gas Genset design & identify component location

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 Cummins Energy Solutions Business

ESB EMEA
• Daventry, Northamptonshire, UK
• Ramsgate, Kent, UK
• Mechelen, Belgium

ESB America’s
• Columbus, IN, USA
• New Jersey, NJ, USA
• Miami, FL, USA ESB India
• Minneapolis, MN, USA • Pune, Maharashtra, India
• Sao Paulo, Brazil

ESB Asia / China

• Beijing, PRC

ESB S. Pacific
• Scoresby, VIC, AUS

CUMMINS, INC TRAINING – LBNG ‘V’ Genset Controls / Introduction / KDL / 05 - 2010 / REV 2.0
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What is Cummins Energy Solutions Business (ESB)?

…A unique line of business within Cummins Power Generation. Our genset electrical power output
offerings range from 300kW up to 2000kW in applications from basic power generation to
cogeneration – all while being fueled by some good pipeline natural gas to low energy content (low
Btu) gaseous fuels. These unique applications lead to the need for greater business and
engineering support from smaller regional coverage areas. The result is the ESB Project Company
structure which hosts everything from business development managers to applications and service
engineers available to support regional distributors and channel partners as required.

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 HHP Gas Genset Design

CUMMINS, INC TRAINING – LBNG ‘V’ Genset Controls / Introduction / KDL / 05 - 2010 / REV 2.0
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Basic Genset Design

Our natural gas fueled, high horsepower Genset’s employing lean burn technology are extremely
complex power generation systems designed to be a reliable and efficient source of energy.

Although complex, significant engineering effort is dedicated to ensure systems have easy access
for maintenance. Features like crankshaft and camshaft inspection covers, cylinder heads that can
be removed individually without removing a lot of other components, and main & centrifugal oil filters
that can be serviced while the engine is running. Using the most advanced control systems
Cummins has to offer affords simplified control system interface and a reduced number of
components.

One of the most significant differences between the ESB’s Gensets and most every other Cummins
Power Generation offering is the fact that we do not provide a engine coolant to air heat exchanger
(radiator). Commonly, the engine coolant is either plumbed into a customer’s building heating
system or into a remote radiator. We do offer as standard either a PID control & valve system or
wax-thermostat system that regulates coolant flow from our Gensets so-as to maintain optimum
operating temperatures.

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 Background: Genset + GCP
(est. 2006)

GCP (v.2) Contents:

GIB (v.1) Contents:
• Generator Control (PCS3100)
• A/C MCB’s & Contactors
• HMI (PP420)
• VDC Interfaces & Controls
• PLC (Customer I/O)
• Engine Control (CM700)
• Customer Connections
• Remotely Located (up to 40m)

CUMMINS, INC TRAINING – LBNG ‘V’ Genset Controls / Introduction / KDL / 05 - 2010 / REV 2.0
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Genset History: Genset + GCP

The significant items dating our Gensets can be visually identified as the GCP & GIB.
The Genset’s GIB, as shown here as version 1, is a skid mounted container with all connection
points for the Genset’s VAC & VDC auxiliaries, the control modules for the cooling system and the
CM700 master engine control module. The GCP, version 2 shown here, is a free-standing container
that can be remotely located (up to 40m away from the Genset) and contains the Genset’s control
interfaces – one PCS3100 & one HMI (PP420) touchscreen that presented the control parameter
states such as EGT, gas system state, engine speed & many more. The GIB is also home to the
customer connection points – where a customer can connect their balance of plant items such as
cooling louvre & radiator fan relays for our Genset control to manage.

NOTE: This Genset control system is NOT covered as part of this training. Courses covering this
control system are available on request.

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 Background: Genset + GCP
(est. 2006)

GENSET ENGINE
MODEL POWER FREQUENCY CONTROL MODEL CONFIGURATION
kWe Hz
1370GQMA 1370 50 PCS3100 QSV81 V-16, Multi Turbo
1570GQMB 1570 50 PCS3100 QSV81 V-16, Multi Turbo
1250GQNA 1250 60 PCS3100 QSV91 V-18, Multi Turbo
1540GQNA 1540 50 PCS3100 QSV91 V-18, Multi Turbo
1750GQNB 1750 50 PCS3100 QSV91 V-18, Multi Turbo
1750GQPB 1750 60 PCS3100 QSV91 V-18, Multi Turbo
2000GQNC 2000 50 PCS3100 QSV91 V-18, Single Turbo
2000GQPC 2000 60 PCS3100 QSV91 V-18, Single Turbo
1160GQKA 1160 50 PCS3100 QSK60 V-16, Multi Turbo
1400GQKA 1400 60 PCS3100 QSK60 V-16, Multi Turbo
1000GQKB 1000 60 PCS3100 QSK60 V-16, Single Turbo
1100GQKC 1100 50 PCS3100 QSK60 V-16, Single Turbo
1400GQKC 1400 60 PCS3100 QSK60 V-16, Single Turbo

CUMMINS, INC TRAINING – LBNG ‘V’ Genset Controls / Introduction / KDL / 05 - 2010 / REV 2.0
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Genset History: Genset + GCP (Cont’d)

This Genset configuration was available from 2006 through early 2009.

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 Background: Genset
(est. 2009)

Remote Panel Contents:

ƒ HMI (HMI320 + HMI114)
ƒ Start, Stop, E-Stop (no breaker control in Manual Mode)
ƒ Remotely Located (up to 1200m)

GIB (v.2) Contents:

ƒ VAC MCB’s & Contactors
ƒ VDC Interfaces & Controls
ƒ Engine Control (CM700)
ƒ Genset Control (PCC3300)
ƒ VDC Primary Supply
ƒ Customer Connections
ƒ HMI (HMI320 & HMI114)
ƒ Customer I/O Modules
(AUX101’s)
ƒ Alternator Mains Decoupling
Relay (Optional)

CUMMINS, INC TRAINING – LBNG ‘V’ Genset Controls / Introduction / KDL / 05 - 2010 / REV 2.0
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Genset History: Genset

Advances in Cummins control offerings lead to the redesign of our GIB – resulting in a consolidation
of all components that were housed in both the predecessor’s GIB & GCP. In addition to the
consolidation, a simplified customer connection chamber was added to the end of the GIB that
eases the Genset commissioning.

As not everyone is comfortable standing next to such a Genset during operation – one remote panel
offering was released that can be located up to 1200m from the GIB.

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 Background: Genset
(est. 2009)

GENSET ENGINE
MODEL POWER FREQUENCY CONTROL MODEL CONFIGURATION
kWe Hz
1370GQMA N/A N/A N/A QSV81 N/A

1570GQMB N/A N/A N/A QSV81 N/A

C1250 N6C 1250 60 PC3.3 QSV91 V-18, Multi Turbo
C1540 N5C 1540 50 PC3.3 QSV91 V-18, Multi Turbo
C1750 N5C 1750 50 PC3.3 QSV91 V-18, Multi Turbo
C1750 N6C 1750 60 PC3.3 QSV91 V-18, Multi Turbo
C2000 N5C 2000 50 PC3.3 QSV91 V-18, Single Turbo
C2000 N6C 2000 60 PC3.3 QSV91 V-18, Single Turbo
C1160 N5C 1160 50 PC3.3 QSK60 V-16, Multi Turbo
C1400 N6C 1400 60 PC3.3 QSK60 V-16, Multi Turbo
C1000 N6C 1000 60 PC3.3 QSK60 V-16, Single Turbo
C1100 N5C 1100 50 PC3.3 QSK60 V-16, Single Turbo
C995 N5C 995 50 PC3.3 QSK60 V-16, Single Turbo
C1400 N5C 1400 60 PC3.3 QSK60 V-16, Single Turbo

CUMMINS, INC TRAINING – LBNG ‘V’ Genset Controls / Introduction / KDL / 05 - 2010 / REV 2.0
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Genset History: Genset (Cont’d)

This Genset configuration was available starting early 2009 and will supersede the predecessor.
With the introduction, a new Genset model nomenclature was also introduced to add consistency for
nomenclature across all of CPG’s lines of business.

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 Genset Identification
QSV91G Driven Gensets

Genset
Data Plate

Alternator
Data Plate

Engine
Data Plate

CUMMINS, INC TRAINING – LBNG ‘V’ Genset Controls / Introduction / KDL / 05 - 2010 / REV 2.0
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Genset Identification:
The QSV91G driven Genset data plates are located:
• Engine = Below Crankshaft Access Covers, A Bank
• Alternator = NDE, Rear of AVR Control Box
• Genset = Left side of Alternator Terminal Box

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 Genset Identification
QSK60G Driven Gensets

CUMMINS, INC TRAINING – LBNG ‘V’ Genset Controls / Introduction / KDL / 05 - 2010 / REV 2.0
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Genset Identification:
The QSK60G driven Genset data plates are located:
• Engine = NDE, A Bank
• Alternator = NDE, Rear of AVR Control Box
• Genset = Left side of Alternator Terminal Box

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 Genset Data Plate

The Genset data plate shows specific information about your Genset.

Genset Identification Information

• Genset Parts Ordering Reference
• Technical Publications Association…

Genset Rated Electrical

Performance, Weight & Control
Configuration

NOTE: The Genset data plate MUST NOT be changed or removed unless approved by Cummins Inc.

CUMMINS, INC TRAINING – LBNG ‘V’ Genset Controls / Introduction / KDL / 05 - 2010 / REV 2.0
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Identifying Your Genset:

The Genset data plate contains the information required for reference during service parts ordering.
It also contains the electrical performance information rated to ISO 8528 international standards.

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 Alternator Data Plate

The alternator data plate shows specific information about your alternator.

The Alternator Model #

code as located on the
alternator’s nameplate

NOTE: The alternator data plate MUST NOT be changed or removed unless approved by Cummins, Inc.

CUMMINS, INC TRAINING – LBNG ‘V’ Genset Controls / Introduction / KDL / 05 - 2010 / REV 2.0
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Identifying Your Alternator:

In addition to the alternator’s rated performance, the alternator model information is contained on
the alternator data plate.

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 Engine Data Plate

The engine data plate shows specific information about your engine. The Engine Serial
Number (ESN) (1), Model (2) and Rating (3) provide information for ordering parts and
service needs. Other important engine information is also detailed.
The Engine Data Plate location is specific to each engine type - location shown in
relevant engine O&M manual .

1 3 5

2 4
Always check specific engine type as specifications are different between engines of
different ratings within the same engine range, i.e. QSV91 14Bar and 16Bar engines
have different valve lash settings (4). The engine timing code is also shown (5).

NOTE: The engine data plate MUST NOT be changed or removed unless approved by Cummins, Inc.

CUMMINS, INC TRAINING – LBNG ‘V’ Genset Controls / Introduction / KDL / 05 - 2010 / REV 2.0
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 Team Task

1. Locate key control components on the training school’s hardware /

Genset.
2. Identify where the same components would be on a QSK60G
driven Genset.
(REFER TO HANDOUTS)

CUMMINS, INC TRAINING – LBNG ‘V’ Genset Controls / Introduction / KDL / 05 - 2010 / REV 2.0
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 MODULE 1
END

HHP LBNG Generator Controls

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