Cummins QSK60 Tier II Installation Impact

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Presentation transcript:

Cummins QSK60 Tier II Installation Impact

27 September 2005 Cummins Confidential Modified cost reduced turbo mounting frame New turbochargers New exhaust transfer connection for turbo mounting New injectors New exhaust manifold sections for turbo mounting New single piece thermostat housing with large diameter water manifold New exhaust gas temperature sensor thermistors New air crossover Modified flywheel & housing for crank position sensor Modified head and valve cover – remove injector rocker lever and cam follower lever New Breather Combined jacket and LTA water pump & new aftercooler and intercooler plumbing 3 New ECM’s, mounting & harness Cast iron intake manifolds and covers for improve robustness New fuel pump and drive Westport engine gear housing & cam gear for cam position sensor New fuel feed and drain plumbing New fuel filter and head inc. prime pump (not shown) 27 September 2005 Cummins Confidential

Overview Tier 2 QSK60 production start date is Jan 1, 2006, in compliance with US EPA emission requirement. Ratings from 1785-3000hp: 1 or 2 stage turbocharging. Altitude capability reduced (with respect to comparable ratings.) Engine performance Impacts Increased fuel consumption Increased mass air flow 2 Pump 2 Loop aftercooling Minimal installation impacts

Ratings and Altitude Capability Single Stage Turbocharging (hp @ rpm) Turbocharger Arrangement Altitude Capability (ft) 1800@1800 Single Stage 12,500 1875@1800 1875@1900 2000@1800 11,000 2000@1900 *2300@1900 5,000 *Note: Restricted Rating 27 September 2005 Cummins Confidential

Ratings and Altitude Capability Two Stage Turbocharging (hp @ rpm) Turbocharger Arrangement Altitude Capability (ft) 2250@1800 Two Stage 13,000 2500@1900 12,000 2700@1900 10,000 **3000@1900 6,000 *Note: Restricted rating **Note: Restricted to electric drive haul truck 27 September 2005 Cummins Confidential

Performance Impact Fuel consumption will be approximately equivalent to Tier 1 ratings Air mass flow is expected to increase by approximately 4% when compared to equivalent Tier I ratings 27 September 2005 Cummins Confidential

Cooling System and Heat Rejection Impacts 2 Pump 2 Loop aftercooling Engine coolant heat rejection is expected increase by 2.5% Water outlet connections will remain in the same location Water inlet connections for both the LTA coolant circuit and Engine coolant circuit are on the right bank side of the engine. NOTE: All comparisons made to Tier I QSK60. 27 September 2005 Cummins Confidential

Air Handling Impacts Turbocharger inlet and exhaust outlet connections will remain in the same location when comparing similar turbocharging arrangements. Due to the rating and altitude offerings, customers that previously received single stage QSK60’s may elect to move to the two stage configuration for Tier 2. See following page for example. Options for customer air handling connections may vary. Refer to installation drawings for specifics. NOTE: All comparisons made to Tier I QSK60 except where noted. 27 September 2005 Cummins Confidential

Air Handling Impacts Two Stage Turbocharging Single Stage 27 September 2005 Cummins Confidential

Fuel System Impacts Fuel inlet connection will remain located on the filter head by the pan rail towards the front of the engine Fitting options include ORFS (1 3/16-12), 37 deg flare (1 1/16-12), Ermetto flareless (M30x2) Fuel drain location will move to the left bank side of the engine on the front aftercooler cover. Please use drawing on the next pages for coordinates. The preliminary installation drawing does not reflect production hardware. Heat rejection to fuel has been dramatically reduced. This may allow some customers avoid the use of fuel coolers. Fuel inlet temperature requirements on the datasheets must be met.

OEM Fuel Fittings y x z Drain Inlet

Front Gear Train Impacts A gear driven air compressor will no longer be an option Space for left bank hydraulic drive on the rear of the gear cover is limited. Larger pump may have to utilize the drive on the from on the gear cover. 27 September 2005 Cummins Confidential

Electrical Wiring Interface Three OEM connectors will be required with the new configuration Signal Connector #1 (Deutsch 31-pin connector) Signal Connector #2 (Deutsch 23-pin connector) Power Connector (Deutsch 16-pin connector) OEM connection points located on the left bank near the intake manifold, pointing toward the rear. 27 September 2005 Cummins Confidential

Electrical Wiring Interface Power Connector Deutsch HD36-24-16SE-059 (OEM Side) Sixteen 12 Gauge (AWG) Contacts, 100 AMP Capacity Discrete connections for all module power, grounds plus keyswitch Signal Connector #1 Deutsch HD36-24-23PE-059 (OEM Side) Twenty Three 16 Gauge Contacts Signal Connector #2 Deutsch HD36-24-31SE-059 (OEM Side) Thirty One 16 Gauge Contacts OEM Cense Connector Removed – Functionality in Advanced Engine Monitoring but RS232 and R422 not supported J1708 Communication Protocol not supported

Advanced Engine Monitoring (AEM) Features Cylinder Health (EGTS Monitoring) High Temperature Faults High and Low Temperature Deviation Faults Trend Data-log Calibrate-able Parameter List Sample @ Rated Condition Shutdown Data-log Store Data-log when Engine Stops Saves the last two engine stops 27 September 2005 Cummins Confidential 10/6/2003

Advanced Engine Monitoring (AEM) Features Fault Snapshot Data-log Calibrate-able Parameter List Store Data-log pre and post Fault Start-Stop Data-log Real Time Stamp of Engine Starts and Stops Data-logs Save Most Recent Data and Discard Old Data Data-logs Exportable to Excel for Post Analysis and Graphing Uses best features of CENSE Integrated into base engine software Standard on QSK50 and QSK60 Tier 2 mining engines Uses standard electronic diagnostic tool 27 September 2005 Cummins Confidential 10/6/2003

Current Product Cense QSK45/60/78 J1939 Public Vehicle Communication J1708 Proprietary RS422 Quantum/ CM500 Cense/ CM530 Modular Mining/ Dispatch/ Vehicle Communication J1939 Public Quantum Insite RS232 Quantum Sensors (engine controlling and protection) Addt’l Cense Sensors (no redundant) Insite Cense Short range RF (Mining Gateway) Engine Operator Panel Lamps 27 September 2005 Cummins Confidential 10/6/2003

X X Tier 2 AEM QSK50/60 Challenges: 27 September 2005 Insite (Contains functionality of INSITE Cense) J1939 Public Vehicle Communication RS422 CM850 Child 2 Modular Mining/ Dispatch/ Vehicle Communication X Challenges: RF Interface RS422 Interface for existing systems Data Storage/Streaming Sensors (engine controlling and protection) CM850 Child 1 RS232 X Although current modular mining set up supports RS422, the next generation of their product will support J1939. CM850 Master Short range RF (Mining Gateway) Engine Operator Panel Lamps 27 September 2005 Cummins Confidential 10/6/2003

Installation Impact summary QSK60 (Tier 1) QSK60 (Tier 2) Fuel System HPI MCRS Performance Power – Hp (KW) 2700 (2013) Torque – ft-lb (Nm) 7840 (10,630) Speed Range – RPM 600 – 2150 Fuel Consumptions, rated/min – lb/bhp*hr 0.339 / 0.329 Approximately equal Heat Rejection to Coolant @ rated – BTU/hr 65605 +2.5% Air Flow – ft3/min 5988 +4% Altitude Capability 12,000 (3658) 10,000 (3048) Application Electronic Features Quantum Supported Communication Protocols J1708/J1939 J1939 Electronics Connectors 2 – Deutsch (31/21 pin) 3 – Deutsch (31/23/16 pin) Size (with 69 gallon sump) Height – in (mm) 91 (2314) Length – in (mm) 115 (2931) Width – in (mm) 66 (1663) 64 (1635) Wet Weight – lbs (kg) 21210 (9621) TBD (approximately equal)

Information Availability Preliminary application information available Installation Drawings Tech Package (Available on Request) Curves and Datasheets QSK60 Tier 2 link on GCE is now Live Will be updated regularly Contains: Prototype ordering information Latest application information This presentation Final application information available in Q3-Q4 2005 27 September 2005 Cummins Confidential