QSK 60G & 60G High Efficiency Series

Gas Engines

Module 5 – IGNITION SYSTEMS

Cummins Corporate Training

1
HE -60G/ Ignition / BMG / 03 - 07 / REV 01.
 System Module - Ignition

Learning Objective
To give an introduction to the Ignition System. At the end of this
section of the module you will know the main Ignition System
Components and understand the operation of the Ignition System.

Agenda
• Ignition System Components:
- Spark Plug,
- Coil-on-Plug,
- Ignition Module (CCD / PDM Module),
- CM558 Modules.

2
 Ignition Components

The following components are provided on each engine:

Spark plug - one per cylinder

 COP (Coil on Plug)
 Ignition Module (Capacitor Discharge Type)
 CM 558 (Control Module 558) .

THE ABOVE MODULES ARE ONLY PART OF THE COMPLETE CONTROL

SYSTEM . MODULES ARE SUPPLIED WITH INFORMATION BY A NUMBER OF
SENSORS / SENDERS MOUNTED ON THE ENGINE. THE SENSORS AND
MODULE FUNCTIONS WILL BE COVERED IN THE CONTROL MODULE.

3
 Cummins QSK Gas Ignition System
 Fully Electronic Design to ensure precise timing and spark control.
 Has closed-loop Control capability - multi-strike capability based on
breakdown voltage of COP previous cycle, 6 maximum. (Not used in
Power Generation applications).
 Variable Energy System.
 Monitors In-Cylinder Pressure (by spark resistance).
 Varies Spark Energy based on In-Cylinder Pressure.

- At Low loads, Cylinder boost pressure lower, LESS spark energy required
- 12/18KV to start fuel burn.
- At High loads, Cylinder boost pressure higher, MORE spark energy
required - 26KV to start fuel burn.
Traditional Inductive Ignition Systems must address high load environment.
Therefore always fire the plug at max energy levels.
Result: Improved Spark Plug Life !
4
 Ignition Components

IGNITION
COP A SSM558 B
CCD / PDM
Assembly
Module

Spark Ignition Harness

Plug

5
 Control & Ignition Modules

 Ignition Module - one per bank,

ignition control, 9 cyl max. output
300 - 350v
 CM 558 - one per bank, ignition
& throttle control
CM 558 IGN.
Module Module
View on Face of SSM 558

SSM558
1
A 10 1
B 10 10
B 1 10
A 1

41 50 41 50 50 41 50 41
Front View - Male Connectors Face View of Connectors (When Removed) - Female
Male Pin Connectors Pin Connectors
6
 Ignition Modules

 Ignition Module (CCD) :

• Solid state fully encapsulated, controls up to 9
cylinders.
• Non-serviceable.
• Two Amphenol connectors:
- one 19 pin - input from CM558
 - one 17 pin - outputs to COPs
 Responsible for:
• Provides primary voltage signal to each coil on
its bank.

7
 Engine Ignition System -
Operating Principle
Knock Sensors

Inlet Pressure (IMT)

CM558
Inlet Temperature (IMT)
Timing Reference
Signal Signal

L.V. Signal
CCD
Primary
Ignition Module Coil
Crank
EPS/Cam
Speed
Sensors
Sensors

Secondary
H.T. Signal Coil
NOTE: Engine Speed is one of the main factors in determining Engine
Timing. Additionally, Intake Manifold Pressure (IMP) input gives the ability
to change the timing to compensate for varying Engine Loads and Intake
Manifold Temperature (IMT) input gives the ability to offset the timing to
compensate for ignitability due to changing intake temperatures.

8
 Capacitive Coil Driver Module (CCD)

• The transformer converts 24vdc to

CCD Coil approximately 300vdc.
Secondary
Winding • The primary windings of the coils are
Capacitor
Switch
powered on and off by the capacitive
Transformer discharge process in the CCD
Module.
300V
• When the spark timing signal is sent
(5v switched earth within CM558
Primary Magnetic
Module), the switch is closed causing
CM558 Winding Core the current to flow in the primary
winding of the coil, creating a
magnetic field.
24V
Supply • As the magnetic field is created, it
induces a higher voltage in the
WARNING: The ignition system can secondary windings, jumping the
deliver up to 40,000 VDC to the spark spark plug gap when enough energy
plugs. Extreme care needs to be taken is available to overcome spark plug
when working with this high-voltage and combustion chamber
resistances.
system or bodily injury can occur.
9
 Engine Controls
CCD Wiring

>A>
COP # 1 >B>

>A>
COP # 2 J1939 (+)
>B>
• <P<
J1939 (–)
CM558 A Plug Pin 03
<R< CM558 A Plug Pin 13
J1939 Shield
>A> <U< CM558 A Plug Pin 04
Spark Timing A
>A> >R> <K< CM558 B Plug Pin 28
COP # 3 >B>
• >D>
<T<
Spark Reference A
1708 Com (+)
CM558 B Plug Pin 27
<H< Manual Selector Switch
>P> 1708 Com (–)
<J< Manual Selector Switch
Capacitive Coil Keyswitch
>A> >B> <F<
COP # 4 Driver (CCD)
>B>
• >E> <D<
>N> <E<
(B Bank) ECM Ground
<B<
>F> Battery (–)
>A> <N<
COP # 5 >B>
• >C>
<A<
Battery (+)

• >G> <C<
Battery (+)
Battery (–)
<L<
<S< ECM Ground
>A>
COP # 6 >B>
•
>A>
COP # 7 >B>
•
>A>
>B>

NOTE: Always refer to engine specific wiring diagram.

10 COP # 8
 Coil-On-Plug

 One COP per cylinder.

Eliminates high-tension leads. Coils designed for 40,000 hr + life


Output range 12,000 to 36,000 v.

 Improves ignition system

reliability and output.

 Liquid Polymer insulation / Ignition Harness

cooled construction.

11
 Engine Controls
Spark Ignition Systems
COP Assembly

COP Assembly
(HT Insulator Section removable)

C B COP Installed in QSV91G

COP Connector
Pin-Out

12
 Engine Controls –
2-Pin Connector COP Assembly (from Jan ‘09)
Removable HT
Insulator Section

Removable O-Ring, must be Coil Housing

replaced when changing Easily identified by
spark plug its integral harness
and 2-pin Deutsch
Connector.

IMPORTANT! The coil has a liquid polymer insulation. Do NOT energise the coil in a horizontal position as
it is possible to get an internal flash-over between the LV and HV circuits.
13
 Engine Controls
Spark Ignition Systems
Knock Sensors

Knock Sensor

QSK60G Left-Bank NDE Knock Sensor

Knock Sensor Function:
 Monitor each cylinder for uncontrolled combustion events
 Monitor each cylinder during non-combustion cycle for abnormal mechanical noise
 Knock level is displayed on the PCC3300 as a % value, where 0.5vDc = 0% (no Knock)
and 5.0vDc = 112.5%. Therefore, Heavy Knock (4.5vDC) = 100% (Critical Shutdown).
Knock Sensors MUST be correctly torqued!!
14
 Gas Control Network
Unique Protection
Rapid De-Rate

100%
1400

1200
Load (kWe)

70%
1000

800 Rapid
De-Rate
600 Event
400

200

0
0 5 10 1
Time (min) Time (
15
 Engine Controls
Spark Ignition Systems
Engine Position – QSK60G

Cyl. # 1 2 3 4

Ref Pulse ‘Fire’ on falling

edge of signal

CM558 ‘Fire’ signal to CCD w/

Cyl #3 Ignition Timing retard.

Bank B Cam Gear

16
 Engine Controls
Spark Ignition Systems
Engine Position – QSK60G

Engine Position Sensor

Position Sensor Adapter

QSK60G Bank B
17
 Engine Controls
Spark Ignition Systems
Engine Speed – QSK60G

Speed Probe:
When installing check probes are over one of the teeth, set clearance to 0.8mm
(back-off 3flats).
18
 QSK 60G & 60G High Efficiency Series
Gas Engines

Module 5 – IGNITION SYSTEM

End
Cummins Corporate Training
19
HE -60G/ Ignition / BMG / 03 - 07 / REV 01.