11828 QSX15/C/60 DSheet
Power
Generation
Diesel Powered
Generating Sets
410 kW - 500 kW 60 Hz
QSX15 Series Engine
RM
BSI
FI
ST
ERED
NATIONAL
ACCREDITATION
OF CERTIFICATION
BODIES
Quality Assurance
Registered Firm Certificate Number FM509 in accordance with:
BS EN ISO 9001
Quality Assurance Schedule 3420/1
Sourc
e
One
ernator
Alt
ntrols
Co
en
e r a ti n g S e
One
Name
t
G
Prime
kW (kVA)
410 (513)
455 (569)
PowerCommand Control System
PCC II
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Microprocessor control
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Integrates governor and voltage
regulation systems
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Superior alternator and genset
protection system
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Accurate battery monitoring system
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Totally reliable and proven system
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CE Compliant
I
Model
Prime
410 DFEJ
455 DFEK
Alternator
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Brushless Group made machine
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Close voltage regulation
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Rotor and exciter impregnated with
oil and acid resisting resin
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12 lead reconnectable
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Exceptional short circuit capability
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Low waveform distortion with non
linear loads
Ratings
All kW Power ratings based on a 40°C
ambient temperature reference
Chassis
Built-in anti-vibration system
Bonded rubber units fitted as standard
eliminates need for rubber mats or
spring mountings
Low Emissions
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Integral cooling systems which
deliver low NOx, CO, HC, PM and
SO2 exhaust emissions
REG
Single Source Responsibility
●
Design, manufacturer and test of all
components and accessories are
made by Cummins Power
Generation and Cummins companies
International Integrity
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Assurance and strength of a
worldwide, world class corporation
Global Backing
●
24 hour spares and service support –
in 72 countries
Single Source Warranty
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Complete genset covered by
Cummins Power Generation
comprehensive warranty
Packaged Self-Contained Units
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Units with built in antivibration
systems with provision for base fuel
tank and other accessories
Cummins Engine
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Heavy duty 4 cycle water cooled
engine
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Electronic governor control
Cooling System
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40°C cooling package (50°C option)
Ready Filled
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Every set comes filled with lube oil
and anti-freeze
Engine
Standard Genset Features
Typical model with optional sub-base
fuel tank and circuit breaker
Cummins Power Generation, Cummins Engines and
Newage Alternators are all part of the same group
60 Hz Ratings
Model
Standby
450 DFEJ
500 DFEK
Standby
kW (kVA)
450 (563)
500 (625)
Engine
Model
QSX15G9
QSX15G9
A Single Source for all Power System Solutions
Specifications May Change Without Notice
01/02 CPG QSX15/C/60
Specifications
Generator Set Performance
Voltage Regulation
Maintains voltage output to within ±1.0%.
At any power factor between 0.8 lagging and
unity.
At any variations from No load to Full load.
At any variations from Cold to Hot.
At speed droop variations up to 4.5%.
Frequency Regulation
Isochronous under varying loads from no
load to 100% full load.
Random Frequency Variation
Will not exceed ±0.25% of its mean value for
constant loads – no load to full load.
Generator Set Options
Waveform
Total harmonic distortion open circuit voltage
waveform in the order of 1.5%. Three-phase
balanced load in the order of 5.0%.
Telephone Influence Factor (TIF)
TIF better than 50.
THF to BS4999 Part 40 better than 2%.
Alternator Temperature Rise
Class H insulation. Temperature rise up to
125°C permitted.
Radio Interference
In compliance with BS800 and VDE levels
G and N.
Engine
Cummins QSX15G9 direct injection engines.
Six-cylinder, in-line. 14.9 litres.
Type
Water cooled, four cycle, turbo charged and
aftercooled.
Construction
Four valves per cylinder, forged steel
crankshaft and connecting rods, cast iron
block, replaceable wet liners.
Starting
24 volt negative earth. Battery charging
35 amp alternator. Cranking current
900 amps at 0°C.
Fuel System
24 volt fail safe fuel actuator. Spin-on
element fuel filters. Cummins HPI - TP fuel
injection system with integral electronic
governor. Dual flexible fuel lines and
connectors. Fuel/water separator.
Filters
Dry element air filters with restriction
indicator and spin-on combination element
oil filter with full flow and bypass filteration.
Spin on corrosion resistor filter.
Cooling
40°C radiator as standard with 50°C ambient
as option.
Alternator
Type
Brushless, single bearing, revolving field,
4-pole, drip proof, screen protected.
Class H insulation.
Enclosed to IP22 (NEMA 1) standard.
IC 01 cooling system.
Fully interconnected damper winding.
AC exciter and rotating rectifier unit.
Epoxy coated stator winding.
Rotor and exciter impregnated with tropical
grade insulating oil and acid resisting
polyester resin. Dynamically balanced rotor
to BS5625 grade 2.5.
Sealed for life bearings.
Layer wound mechanically wedged rotor.
Compliance Standards
To BS4999/5000 pt 99,
VDE 0530, UTE5100,
NEMA MG1-22, CEMA,
IEC 34, CSA A22.2,
AS1359, BSS5514,
ISO 3046, ISO 8528
Specifications May Change Without Notice
Exciter
Triple dipped in moisture, oil and acid
resisting polyester varnish and coated with
anti-tracking varnish.
Sealed solid state automatic voltage
regulator – self-exciting, self-regulating.
Output windings with 2/3 pitch for improved
harmonics and paralleling ability.
Close coupled engine/alternator for perfect
alignment.
Engine
o Heavy duty air cleaner
o Coolant heater and thermostat
o Tool kit
o Lead acid batteries, cable and fitted tray
o NiCad batteries
o Sump drain pump
o Oil and water drain taps
o CE Compliance (guarding)
o Exhaust temperature monitoring
Cooling
o Oil temperature indication
Alternator
o Anti-Condensation heater
o Thermistors
o PMG Exciter and MX321 AVR
Exhaust System
o Industrial type silencer
o Residential type silencer
o Length of flexible exhaust and bellows
Fuel System
o Sub-base tanks
o Hand fuel transfer pump
o Automatic fuel transfer pump
o Free-standing 450, 900 and 1350 litre
fuel tanks with stand
o Fuel tank level switch
o High fuel level warning
o Low fuel level warning
o Low fuel level shutdown
Generator Set
o Silenced enclosures
o Super silenced enclosures
Control Panel
o See separate list on Control Panel pages
o 3 or 4 pole circuit breaker
o Battery charger 5 amp or 10 amp
o Cable entrance box
Chassis
Fabricated and welded steel chassis
Built-in anti-vibration mountings
Optional sub-base fuel tank with eight hour
capacity, dual flexible fuel lines, dial type
fuel gauge and drain bung
Finish
Etch undercoated and finished in high gloss
durable green
General
Complete set of operating and instruction
manuals
01/02 CPG QSX15/C/60
PowerCommand
Digital
Generator Set
Control
PCC II
Operator Panel Features
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Emergency stop switch
Indicating lamps for remote start, not in
auto, common shutdown, and common
warning
Fault reset switch
Panel lamp/lamp test switch
Exercise switch and indicating lamp
Manual run/stop switch
Off/Manual/Auto mode select switch
Graphical display panel with pushbutton
switches capable of displaying up to 9
lines of data approximately 26 characters
wide, as well as graphical characters
Analog AC metering panel for
simultaneous monitoring of 3-phase AC
voltage and current, kW, powerfactor, and
frequency. Voltage, current and kW are
scaled in % of nominal values, and all
values are color coded to indicate normal,
warning, and abnormal operating
conditions
Single membrane front panel with
enclosure rated NEMA 3R/IP53
Control Functions
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Isochronous governing
3-phase sensing voltage regulation with
single and three phase fault current
regulation
AC output protection including over/under
voltage, over/under frequency,
overcurrent, short circuit, and over load
(kW)
Engine control and monitoring system
with displays for oil pressure, oil
temperature, engine coolant temperature,
engine speed, battery voltage and other
values
Generator set protection system including
AC output protection alarms, engine
pressure, temperature warning,
Shutdown functions, low coolant
temperature, low coolant level, low fuel
level, failure to crank, failure to start and
overspeed
Operator adjustments for time delay,
start/stop, engine speed, and overspeed
Technician setup menu
Status and data display functions
including engine operating hours, kW
hour productions, AC metering functions
and fault history
Major Control Features
Include:
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Alternator temperature alarms
Audible alarm module
Automatic mains failure control
Control anti-condensation heater
Digital paralleling controls
Echelon LonWorks interface
Generator running relay contacts
Key-type mode control switch
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OFF/MANUAL/AUTO Mode Control
Switch
MANUAL RUN/STOP Control Switch and
Indicating LED
EXERCISE Control Switch and Indicating
LED
PANEL LAMP/LAMP TEST Control
Switch
EMERGENCY STOP Control Switch
Graphical Operator Panel
Graphical Display Panel
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Specifications May Change Without Notice
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Generator Set Hardware Data
Data Logs
Adjustment History
Fault History
Load Profile Data
Generator Set Output Voltage
Generator Set Output Current
Generator Set Output Frequency
Generator Set Power Output
Generator Set kWh Power Output
Digital Synchroscope
Engine Starting Battery Voltage
Engine Lube Oil Pressure
Engine Coolant Temperature
Engine Coolant Pressure
Engine Fuel Rail Temperature and
Pressure
Engine Fuel Input and Output
Temperature
Intake Manifold Temperature and
Pressure
Engine Fuel Consumption
Ambient Air Pressure
Crankcase Blowby Flow
Aftercooler Inlet Coolant Temperature
Engine Exhaust Temperature (optional)
Internal Control Functions
General Functions
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Control Switches and
Functions
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Control Options
Digital full authority electronic engine
controls for Cummins HPI-PT fuel system,
including engine monitoring and
protection, and governing. These
functions are integrated with voltage
regulation, synchronizing, and load
sharing controls, including import/export
controls for paralleling with an infinite
(utility/mains) bus
AmpSentry™ Protection for true
alternator overcurrent protection
Analog and Digital AC Output Metering
Battery Monitoring System to sense and
warn against a weak battery condition
Digital Alarm and Status Message Display
Generator set Monitoring: Displays status
of all critical engine and alternator
generator set functions
Smart Starting Control System: Integrated
fuel ramping to limit black smoke and
frequency overshoot, in addition to
optimized cold weather starting
Advanced Serviceability using InPower, a
PC-based software service tool
PowerCommand Communications
Network Capability (optional)
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Emergency Start Mode
Non-Emergency Start Mode
Sleep Mode
Data Logging
Fault Simulation Mode
Built In Test
First Start Sensor System
Synchronizer
Load Demand Mode
Load Govern Mode
Manual (Semi-Automatic) Parallel Mode
Engine Control
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Engine Starting
Cycle Cranking
Programmable Idle Speed Control
Time Delay Start and Stop (cooldown)
Engine Governing
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Isochronous Governing
Droop Governing
Temperature Dynamics
Idle Mode
Isochronous (kW) Load Sharing Control
01/02 CPG QSX15/C/60
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Low Oil Level warning
Low coolant temperature (warning)
Low Fuel – Daytank (warning,
external input signal)
High coolant temperature (shutdown)
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Control Interface
Alternator Control
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Digital Output Voltage Regulation
Torque-Matched Volts/Hz Overload
Control
Fault Current Regulation
Isochronous (kVar) Load Sharing
Control
Droop (kVar) Load Sharing Control
Protective Functions
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Ground Fault Warning (option600VAC class generator sets)
Configurable Alarm and Status Inputs
Breaker Fail To Close and Breaker
Auxiliary Contact Warning or
Shutdown
Breaker Fail To Open Warning
Bus or Generator Set PT Input
Calibration Error
Emergency Stop
AmpSentry™
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Over Current Warning
Over Current Shutdown
Short Circuit Shutdown
High AC Voltage Shutdown
Low AC Voltage Shutdown
Under Frequency Shutdown
Over Frequency Shutdown/Warning
Over Load (kW) Warning
Reverse Power Shutdown
Sync Check
Fail To Synchronize Warning or
Shutdown
Phase Sequence Sensing Shutdown
Reverse Var Shutdown
Breaker Fail to Close
High Alternator Temperature (Option)
Engine Protection
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Overspeed Shutdown
Low Lube Oil Pressure Shutdown
Low Lube Oil Pressure Warning
High Lube Oil Temperature
Warning/Shutdown
High Coolant Temperature Shutdown
High Coolant Temperature Warning
Low Coolant Pressure
Warning/Shutdown
Low Coolant Level
Warning/Shutdown
Low and High Battery Voltage
Warning
Discharged Battery Protection
Weak battery warning
Fail to Start (Overcrank) Shutdown
Fail to Crank Shutdown
Redundant Starter Disconnect
Redundant Speed Sensors
Low Fuel – Day Tank and Low Fuel –
Main Tank warning
Cranking Lockout
Sensor Failure Indication
High Crankcase Blowby Level
warning
High Fuel Temperature Warning
High Intake Manifold
Temperature/Pressure
Aftercooler Cooler Inlet Over
Temperature
Specifications May Change Without Notice
Input signals to the PowerCommand
control include:
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Remote Start signal
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Remote Emergency Stop
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Configurable Customer Inputs
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Low Main Fuel Level warning
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Remote Alarm Reset
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Load Demand Stop
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Utility Parallel (Load Govern) Mode
command
Output signals from the control include:
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Generator Set Running signal
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Generator Set Common Shutdown
signal
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Load Shed signal
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Ready to Load signal
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Modem Control signal
Network connections include:
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Serial Interface.
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Echelon LonWorks Interface (Option)
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Paralleling Breaker Interface
Certifications
PowerCommand meets or exceeds the
requirements of the following codes and
standards:
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NFPA110 for level 1 systems.
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UL508 Listed, Category NIWT7 for
US and Canada.
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CSA C282-M1999 Compliance
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CSA 22.2 No. 14 M91 Industrial
Controls.
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ISO 8528-4: 1993 Compliance,
Controls and Switchgear
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NFPA99: Standard for Health Care
Facilities
EC Marking
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EN 50081-1 Residential, commercial,
light industrial
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EN 50081-2 Industrial
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EN 50082-1 Residential, commercial,
light industrial
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EN 50082-2 Industrial
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ISO 7637, pulses #2b, 4; DC supply
surge voltage test
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Mil Std 202C, Method 101 Salt Fog
test
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ANSI C62.41 Surge Withstand
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Mil Std 461
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IEC 801.2, 3, 4, 5
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IEEE 587
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Verify functional operation of the
control by simulating fault conditions
within the control, and manipulating
input parameters in the control
Conveniently adjust operating
parameters of the generator set, and
protective equipment set points
Generate standard reports describing
generator set settings, test report
data
Establish and maintain passwords for
users and system administrators.
InPower also offers the ability to
bypass passwords (by qualified user)
in the event that a password is lost or
forgotten
Allows the active testing of all
warning and shutdown devices.
Provide control simulations to allow
testing of the generator set or transfer
switch without operation of the device
Allows operation of the engine with
the excitation switched off for some
service modes
PowerCommand for Windows
Features include:
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Ability to locally or remotely monitor
on-site power systems from a
personal computer
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Data logging
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Notifies user of alarm conditions in
the power system, and forwards
alarm conditions to a paging system
when needed
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Provides multiple level security
access
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Stores system data in encrypted
secure formats
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Allows easy report generation
Options and Accessories
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Key-type Mode Select Switch
Ground Fault Alarm Module
Semi-Automatic Paralleling
Isolated Bus Paralleling
Full Function Paralleling
Exhaust Temperature Monitoring
Alternator Temperature Monitoring
Digital Remote Annunciator
Digital Output Relay Module
Software
InPower
Software Functions:
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View active and inactive faults, time
stamp for last fault, number of times
each fault has occurred. Clear
inactive faults (this also can be done
with the control operator interface, but
is easier to do with the service tool.)
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Display snapshot data for all the
latest active and inactive faults.
Information on the last 20 fault
conditions is displayed. Produce "strip
chart" recordings for up to 6
monitored functions at a time
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Perform control simulations
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Download calibrations and feature
changes. Allows the user to save
generator set configuration data for
use in other machines. This is
particularly useful in transfer switch
and paralleling applications where
multiple machines may be set up in
the same way
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Display generator set data plate
information, including model, serial
number
01/02 CPG QSX15/C/60
Technical Data
QSX15G9 Generating Sets – 60 Hz
Model
Ratings
Engine Model
Aspiration: Turbo-charged with air-to-air
aftercooling
Gross Engine Power
Break Mean Effective Pressure
Bore
Stroke
Piston Speed
Compression Ratio
Lubricating Oil Capacity
Overspeed Limit
Dry Weight
Wet Weight
Fuel Consumption Load
Fuel Consumption L/hr
Maximum Fuel Flow
Maximum Fuel Inlet Restriction
Maximum Fuel Return Restriction
Fan Load
Coolant Capacity
Coolant Flow
Heat Rejection to Eng Jacket Coolant
Heat Rejected to Ambient
Combustion Air
Maximum Air Cleaner Restriction
Alternator Cooling Air
Radiator Cooling Air
Minimum Air Opening to Room
Minimum Discharge Opening
Maximum Static Restriction
Exhaust Gas Flow (Full Load)
Exhaust Gas Temperature
Maximum Exhaust Back Pressure
Derate
Prime
410 DFEJ
410 kW
513 kVA
QSX15G9
Yes
Standby
450 DFEJ
450 kW
563 kVA
QSX15G9
Yes
506 kWm
562 kWm
2006 kPa
2213 kPa
137 mm
137 mm
169 mm
169 mm
10.1 m/s
10.1 m/s
17:1
17:1
83 Litres
83 Litres
2150 rpm ±50
2150 rpm ±50
4082 kg
4082 kg
4218 kg
4218 kg
1/4 1/2 3/4 Full 1/4 1/2 3/4 Full
37 60 81 104 40 55 88 114
424 L/hr
424 L/hr
127 mm Hg
127 mm Hg
77 mm Hg
77 mm Hg
26 kW
26 kW
58 Litres
58 Litres
485 L/Min
485 L/Min
144 kW
155 kW
54 kW
60 kW
34 m3/min
36 m3/min
6.2 kPa
6.2 kPa
62 m3/min
62 m3/min
707 m3/min
707 m3/min
2
2.3 m
2.3 m2
1.6 m2
1.6 m2
13 mm Wg
13 mm Wg
82 m3/min
89 m3/min
468°C
477°C
6.7 kPa
6.7 kPa
RTF
RTF
Prime
455 DFEK
455 kW
569 kVA
QSX15G9
Yes
Standby
500 DFEK
500 kW
625 kVA
QSX15G9
Yes
506 kWm
2193 kPa
137 mm
169 mm
10.1 m/s
17:1
83 Litres
2150 rpm ±50
4309 kg
4445 kg
1/4 1/2 3/4 Full
41 65 89 115
424 L/hr
127 mm Hg
77 mm Hg
26 kW
58 Litres
485 L/Min
153 kW
59 kW
36 m3/min
6.2 kPa
62 m3/min
707 m3/min
2.3 m2
1.6 m2
13 mm Wg
88 m3/min
473°C
6.7 kPa
RTF
562 kWm
2433 kPa
137 mm
169 mm
10.1 m/s
17:1
83 Litres
2150 rpm ±50
4309 kg
4445 kg
1/4 1/2 3/4 Full
42 59 96 132
424 L/hr
127 mm Hg
77 mm Hg
26 kW
58 Litres
485 L/Min
182 kW
67 kW
41 m3/min
6.2 kPa
62 m3/min
707 m3/min
2.3 m2
1.6 m2
13 mm Wg
102 m3/min
498°C
6.7 kPa
RTF
Typical figures only, based on an engine at full working temperature.
Load acceptance performance varies with site conditions.
Ratings
Standby
Applicable for supplying emergency power for the duration of normal power interruption. No sustained overload capability is available for this rating.
Nominally Rated (equivalent to fuel stop power in accordance with ISO 3046).
Prime
Applicable for supplying power in lieu of commercially purchased power. Prime power is the maximum power available at a variable load for an
unlimted number of hours. A 10% overload capability is available for limited time. Nominally rated.
Specifications May Change Without Notice
01/02 CPG QSX15/C/60
Dimensions and Weights – 50 Hz
C
A
Model
DFEJ
DFEK
Engine
QSX15G9
QSX15G9
A
3868
3868
B
Dimensions and Weights (mm/kg)
B
1524
1524
C
1534
1534
Set Weight
kg Dry
4082
4309
Set Weight
kg Wet
4218
4445
RTF = Refer to Factory.
Set weights are without sub-base tank.
Dimensions and weights are for guidance only. Do not use for installation design. Ask for certified drawings on your specific application.
Specifications may change without notice.
Power
Generation
See your distributor for more information.
Cummins Power Generation Limited
Manston Park, Columbus Avenue
Manston, Ramsgate
Kent CT12 5BF, UK
Telephone: +44 (0)1843 255000
Fax: +44 (0)1843 255902
Email: cpg.uk@cummins.com
www.cumminspower.com
www.cummins.com
Cummins is a registered trademark of Cummins Inc.
Specifications May Change Without Notice
01/02 CPG QSX15/C/60
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