Oprator Manual_cummins WTP PC

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Operator Manual

KTA50 Engine with PowerCommand Contro3100

C1100 D5eC1250 D6

C1400 D5

C1400 D5e

C1500 D6

C1675 D5

C1675 D5A

English - Original Instructions 10-2009 A030F394 (Issue


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Table of Contents

1. ENGINE OVERVIEW ...................................................................................................................... 1

1.1 Engine Data ............................................................................................................................. 1

2. CONTROL SYSTEM - PCC 3100................................................................................................. 11

2.1 Control System Description ................................................................................................... 11

3. GLOBAL ADDRESSES................................................................................................................. 13

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Table of Contents 10-2009

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1 Engine Overview

This section provides an overview of the engine.

1.1 Engine Data1.1.1 Engine Identification Plate

Each engine is provided with a Data Plate as shown below. This provides information unique to

the engine.

The engine data plate shows specific information about your engine.

The Engine Serial Number (ESN) (1) and Control Parts List (CPL) (2) provide information for

ordering parts and service needs.

NOTE: The engine data plate must not be changed unless approved by CumminsEngine Company Inc.

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1. Engine Overview 10-2009

Key Description

1. Engine Serial Number (ESN)

2. Control Parts List (CPL)

3. Model

4. Horsepower and rpm Rating

1.1.2 Engine Diagrams

The following illustrations show the locations of the major external engine components, filters,

and other service and maintenance points on a typical QSX15 engine. Some external

components will be at different locations for different engine models.

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10-2009 1. Engine Overview

1.1.2.1 Engine Views

1.1.2.1.1 Front View

Key Description

1. Left-bank water outlet

2. Left-bank thermostat housing

3. Coolant filter head

4. Coolant filters

5. Fan pulley

6. Front gear cover

7. Accessory drive pulley

8. Direction of rotation

9. Crankshaft pulley

10. Vibration damper

11. Alternator drive pulley

12. Fan idler pulley

13. Fan hub

14. Rocker lever cover

15. Air crossover

16. Right-bank thermostat housing

17. Right-bank water outlet

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1.1.2.1.2 Right View

Key Description

1. Air transfer housing

2. Turbocharger

3. Air crossover connection


5. Lifting bracket

6. Air intake connection

7. Intake manifold

8. Cam follower cover

9. Flywheel housing

10. Hand hole cover

11. Oil pan adapter

12. Plate, oil pan adapter

13. Oil pan

14. Water inlet connection

15. Water pump

16. Water pump drive

17. Water bypass tube

18. Fan belt idler pulley

19. Crankcase breather

20. Fan belt idler assembly

21. Thermostat housing

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22. Water outlet connection

1.1.2.1.3 Left View

Key Description

1. Turbocharger

2. Thermostat housing support

3. Thermostat housing

4. Fan hub support5. Front gear cover

6. Front gear housing

7. Dataplate

8. Air compressor drive

9. Air compressor

10. Fuel pump

11. Fuel filter head

12. Fuel filter

13. Full-flow lubricating oil filter

14. Crankcase breather

15. Oil level gauge

16. Oil fill port

17. Lubricating oil filter head

18. Flywheel housing

19. Cam follower cover

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20. Intake manifold

21. Lifting bracket

22. Exhaust manifold


1.1.2.1.4 Rear View

Key Description

1. Oil cooler cover

2. Cylinder block


4. Right-bank exhaust manifold

5. Water outlet passage

6. Air crossover


8. Rocker lever housing

9. Fuel manifold

10. Cylinder head

11. Flywheel

12. Oil pan adapter

13. Oil pan


15. Left-bank exhaust manifold

16. Turbocharger

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1.1.2.1.5 Top View

Key Description

1. Alternator

2. Right-bank water outlet

3. Right-bank thermostat housing

4. Fan hub bracket

5. Fan hub shaft

6. Thermostat housing support

7. Left-bank thermostat housing

8. Left-bank water outlet

9. Turbocharger

10. Left-bank exhaust manifold



13. Intake manifold

14. Water transfer tube

15. Right-bank exhaust manifold


17. Rocker lever housing

18. Air crossover

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1.1.3 Acoustic Information

1.1.3.1 Acoustic Information (1500 rpm)

TABLE 1. ACOUSTIC DATA (1500 RPM)

Model C1100 D5e C1400 D5 C1400 D5e C1675 D5 C1675 D5AEngine KTA50G7 KTA50G3 KTA50G7 KTA50G8 KTA50GS8

Enclosed Set N/A 105 105 108 108Acoustic Data LWA

(Based on using astandardCumminscanopy, and 50Hz set operatingwith doors closed)1, 2

Open Set 110.6 110.6 110.6 110.6 100.9Acoustic Data dB(A) at 1m 3 SPL (or enclosedset with doorsopen)

1. Doors closed figures are measured using 2000/14/EC guaranteed sound power levels

2. Based on 75% load


For Noise Spectrum Figures, refer also to your authorised distributor.

In line with the Cummins Power Generation policy of continuous improvement, these figures are subject to change.

1.1.3.2 Acoustic Information (1800 rpm)

TABLE 2. ACOUSTIC DATA (1800 RPM)

Model C1250 D6 C1500 D6

Engine KTA50G3 KTA50G9

Enclosed Set Acoustic Data LWA 114 114

(Based on using a standard Cummins canopy, and 60 Hz setoperating with doors closed) 1, 2

Open Set Acoustic Data dB(A) at 1m 3 SPL (or enclosed set 124 124with doors open)




For Noise Spectrum Figures, refer also to your authorised distributor.In line with the Cummins Power Generation policy of continuous improvement, these figures are subject to change.

1.1.4 Engine Fuel Consumption (L/hr)

Model C1100 D5e C1400 D5 C1400 D5e C1675 D5 C1675 D5A

Engine KTA50G7 KTA50G3 KTA50G7 KTA50G8 KTA50GS8

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Engine 238 293 303 345 345Performance Dataat 50Hz1

1. Standby/Full Load

Refer to Data Sheets for other applicationsIn line with the CPGK policy of continuous improvement these figures aresubject to change.

Model C1250 D6 C1500 D6

Engine KTA50G3 KTA50G9

Engine Performance Data at 60Hz1 330 392

1. Standby/Full Load

Refer to Data Sheets for other applicationsIn line with the CPGK policy of continuous improvement these figures aresubject to change.

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2 Control System - PCC 3100

2.1 Control System Description

The main control panel and its associated equipment are located in the Control Housing, whichis mounted on the bedframe at the rear of the genset. A Load Terminal Box will be mounted on

either the left or right side of the housing, as required for the site.

The PCCP is a microprocessor-based control for gensets. It provides fuel control and engine

speed governing, main alternator voltage output regulation, and complete genset control and

monitoring. It also provides controls for automatic and semi-automatic synchronising and

automatic load sharing for both isolated bus and utility (mains) paralleling applications. The

control also monitors the health of the engine, alternator and auxiliary systems continuously,

and will affect an Automatic Shutdown if a serious fault occurs. All indicators, control

switches/buttons and alphanumeric display are located on the face of the control panel as

illustrated in Figure 1.

The PCCP operates in conjunction with an array of sensors and senders located on the engine,alternator and auxiliary systems. Data is passed between components over a digital data link.

An important function of the control system is to continuously monitor the genset for faults. If a

fault occurs during engine running, the PCCP will provide an indication for the operator and, if

the fault is serious, affect an automatic, fully programmed, Shutdown. One of three fault level

signals will be generated by the PCCP. The three fault levels are:

1. Warning, signals an imminent or non-fatal engine fault. The PCCP provides an indication

only for this condition.

2. Fault, signals a potentially damaging condition. The PCCP will automatically subject the

engine to an off-load, cool-down run, and will then shut it down.

3. Shutdown, signals a potentially fatal fault for the engine. The PCCP will automatically take

the engine off-load and shut it down immediately, without a cool-down run.

The control systems operate on 12 or 24VDC battery power. Data backup is taken care of by a

small rechargeable battery installed within the PCCP enclosure. Auxiliary equipment operates

on LV AC power.

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2. Control System - PCC 3100 10-2009

1. % Kilowatt Meter

2. Frequency Meter

3. AC Voltmeter

4. % AC Ammeter

5. System Control Selection Switches

6. Voltage Meter Scale Indicator Lamp

7. Phase Selector Switch + Indicators

8. Emergency Stop Switch

9. Menu Home Switch

10. Panel Lights Switch

11. Self-test Switch

12. Run / Off / Auto Switch (Mode switch) (This may be a Key Switch)

13. Breaker Control Push- buttons

14. Reset Switches

15. Status Indicators

16. Digital Display & Status Panel

FIGURE 1. CONTROL PANEL

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3 Global Addresses

NORTH AMERICA EMEA, CIS ASIA PACIFIC

Cummins Power Generation Limited Cummins Power Generation Limited Cummins Power Generation Limited

1400 73rd Ave. NE Columbus Avenue 10 Toh Guan Road #07-01Minneapolis, MN 55432 USA Manston Park TT International Tradepark

Manston, Ramsgate Singapore 608838

Kent CT12 5BF

United Kingdom

Phone 1 763 574 5000 Phone 44 1843 255000 Phone 65 6417 2388

Toll Free 1 800 888 6626 Fax 44 1843 255902 Fax 65 6417 2399

Fax 1 763 574 5298

BRAZIL CHINA INDIA

Rua Jati, 310, Cumbica 8 Wanyuan Street 35A/1/2, Erandawana

Guarulhos, SP 07180-900 Beijing Econiomic and Technological Pune 411 038Dev. AreaBrazil IndiaBeijing 100176

P.R. China

Phone 55 11 2186 4195 Phone 86 10 6788 2258 Phone 91 020 6602 7525

Fax 55 11 2186 4729 Fax 86 10 6788 2285 Fax 91 020 6602 8090

LATIN AMERICA MEXICO

3350 Southwest 148th Ave. Eje 122 No. 200 Zona Industrial

Suite 205 San Luis Potosi, S.L.P. 78395

Miramar, FL 33027 Mexico

USA

Phone 1 954 431 551 Phone 52 444 870 6700

Fax 1 954 433 5797 Fax 52 444 824 0082

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3. Global Addresses 10-2009


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