Witness Test Proc For QSK With MCRS

Subject: This AEB is for the following applications:
Witness Test Procedure for Automotive Industrial G-Drive Marine
QSK Series Engines with

MCRS
Date Created: 03/24/2008 File Name : 0.15.00 MAB No.
Revision Date: 03/24/2008 Controls Gauges & 0.15.00-03/24/2008

Expire Date: 05/21/2009 Alarms
Engine Class : Multiple Engines
Engine Model : Multiple
Document Owner : Frank Ruggiero Page 1 of 37
Purpose
The purpose of this document is to describe a test procedure required to

demonstrate the Alarm System and Safety System functionality of the QSK
Series Engines with MCRS and the C Command Panel System.
Introduction
The demonstration of the Alarm and Safety systems is required by most all of
the agencies that regulate marine engines (e.g. CG, ABS, and DNV). The
intent of this procedure is to demonstrate the alarm functions of the Cummins
supplied Alarm and Safety systems for QSK Series Engines with MCRS.
The Cummins supplied Alarm and Safety systems consist of three basic parts:
1. Engine mounted sensors monitored by the engine ECM and displayed
on all C Command alarm panels
2. Engine mounted sensors monitored directly by the C Command Elite
Plus Alarm System module (not the ECM) and displayed by the C
Command Elite Plus alarm panel only
3. Engine mounted sensors monitored directly by the C Command Elite
Plus Safety System module (not the ECM) and displayed by the C
Command Elite Plus alarm panel only
Cummins Confidential Page 1 of 37

The alarm panel alerts the operator of parameters which exceed pre-defined
thresholds for pre-defined time periods, whether from the ECM sensors or the
separate (non-ECM) sensors. The alarm panel also alerts the operator when
the engine has been shutdown due to inputs from the independent safety
system sensors.
Table of Contents
Purpose ................................................................................................................1
Introduction ...........................................................................................................1
Table of Contents..................................................................................................2
Required Tools ..................................................................................................3
ECM Monitored Sensors................................................................................3
Alarm and Safety System Monitored Sensors: ..............................................3
Discussion ............................................................................................................3
Important: ..........................................................................................................4
Procedure .............................................................................................................7
I. Alarms Demonstration Using Calterm III .......................................................7
Example Alarm Demonstration Procedure:....................................................8
Demonstration of Engine Overspeed Protection (ECM Controlled): ............10
II. Alarms Demonstration Using INSITE™.......................................................12
Summary of Engine Protection Settings ......................................................13
Example Alarm Demonstration Procedure Using INSITE: ...........................13
III. Alarms Demonstration Using External Sources..........................................15
A. Fuel Leakage from High Pressure Fuel Lines Alarm Demonstration......16
B. Sea water Cooling System Pressure Alarm Demonstration ..................17
C. Intake Manifold Temperature
Alarm Demonstration (QSK38 IMT 2/3/4) .............................................19
D. Lube Oil Temperature Alarm Demonstration (QSK19 Only)...................21
E. Low Coolant Pressure Alarm Demonstration (QSK19 Only) ..................22
IV. Alarm and Shutdown Demonstration Procedure
for Sensors Monitored by the Safety System ............................................24
A. Low Lube Pressure LSR (Low Speed Range)
Shutdown Demonstration [SDU Switch 3 input].....................................25
B. Low Lube Pressure HSR (High Speed Range)
Shutdown Demonstration [SDU Switch 4]..............................................28
C. Low Coolant Pressure Switch
Shutdown Demonstration [SDU Switch 2]..............................................30
D. High Coolant Temperature Switch
Shutdown Demonstration [SDU Switch 1].............................................32
E. Overspeed Shutdown ............................................................................34
Attachments ........................................................................................................37

Required Tools
The following equipment is needed to perform this demonstration.
ECM Monitored Sensors

• Field Calterm v3.0 or later
-OR-
INSITE Service Tool version 7.1 or later for propulsion engine
models, version 7.0 or later for auxiliary engine models
• Datalink adapter and connecting harness between laptop and
engine harness.
Alarm and Safety System Monitored Sensors:

• Fuel leakage detector
o Suitable tube to insert fuel into the tank.
o 1 pint US (473 cc, 2 cups, 16.6 fl ounces UK) of diesel fuel.
• Pressure Sensors and Switches
o Regulated pressure source providing between 0 and 50 psig
o Mating connector for male M14 fitting
o Mating connector for Danfoss pressure manifold (Stauff p/n
SMD 20 - G ¼ - V-OR)
• Temperature Sensors and Switches
o Variable temperature liquid bath capable of up to 230 F for a
6 mm diameter probe.
Discussion
There are a maximum of 24 sensor inputs to the alarm & safety system that can
trigger an alarm indication that can be demonstrated during a surveyor witness
test, depending on the Cummins engine model. The proportion of ECM-
monitored alarm sensors to separately-monitored alarm sensors also varies
depending on engine model. The independent safety system includes 5
sensors in all cases.
The demonstration of the Alarm and Safety system sensors depends upon the
monitoring device. There are 3 categories of sensors to be tested in this
procedure:
A. Sensors used by the ECM and shared with the Alarm system
B. Sensors used only by the Alarm system
C. Sensors used only by the Safety system

The tool required to test each of the available sensors for the Alarm System is
show in Table 1. The demonstration of the alarm sensors monitored by the
engine ECM can be performed with a Cummins service tool. (INSITE or
Calterm III) The demonstration of the alarm and safety sensors connected
directly to the independent Alarm and Safety Systems must be performed with
an external source (See Table 2). The details of each these test methods will
be described in the following sections of this document.
Important Information:
• Never demonstrate engine protection for an auxiliary/generator

drive application under load; it can cause a black out or relevant
risk exposure to personnel and machinery if engine protection
based shutdowns are enabled.
• Never demonstrate engine protection for a propulsion application

under way without captain’s consent.
• Derates limit the rated speed or the maximum engine fueling to

70%. If the engine protection for a propulsion application is
demonstrated at idle speed, the fuel or speed derate will not be
observed, although the associated fault codes will be annunciated.
• Override values should be chosen above the threshold for

temperature and below the threshold for pressure.
• Ensure that the witness is familiar with the electronic displays on

board, in terms of locating desired parameters and accessing the
list of active / inactive fault codes.
• For safety reasons, the demonstration of the engine overspeed

protection will be performed by lowering the RPM thresholds rather
than actually exceeding the predefined limits.

Table 1 –Summary of Alarm System Sensors & Demonstration Method
Required Tool
QSK19
QSK38
QSK50
QSK60
Alarm Sensor Alarm Type Action
Engine Speed (Cam & Crank) Overspeed AN, DR, SD ○ ○ ○ ○

Intake Manifold Temperature High Alarm AN, DR, SD ○ ○ ○ ○
Intake Manifold Temperature 2 High Alarm AN, DR, SD ● ○ ○
Lube Oil Pressure Low Alarm AN, DR, SD ○ ○ ○ ○
Fuel Temperature High Alarm AN, SD ○ ○ ○ ○
Lube Oil Temperature High Alarm AN, DR, SD ● ○ ○ ○
Crankcase Pressure High Alarm AN, DR, SD ○ ○ ○ ○
Coolant Temperature High Alarm AN, DR, SD ○ ○ ○ ○
Coolant Level Low Level Alarm AN, DR, SD ○ ○ ○ ○
Coolant Pressure Low Alarm AN, DR, SD ● ○ ○ ○
Fuel Supply Pressure Low Alarm AN ○ ○ ○ ○
Gear Oil Pressure (If installed) Low Alarm AN, DR, SD ○ ○ ○ ○
Fuel Leakage from HP Lines High Level Alarm AN ● ● ● ●
Sea Water Pressure (HX Only) Low Alarm AN ● ● ● ●
Lube Oil Differential Pressure High Alarm AN ● ○ ○ ○
Exhaust Stack Temperature – Left High Alarm AN, DR ○ ○ ○ ○
Exhaust Stack Temperature - Right High Alarm AN, DR ○ ○ ○
LEGEND: ○ - INSITE/Calterm III AN – Annunciation

● - External Source Required DR – Derate
SD – Shutdown*
* - ECM controlled engine shutdowns will only occur if they are enabled in
the calibration and the Engine Protection Override switch is not active
Table 2 –Summary of Safety System Sensors

Sensor Shutdown Type
Engine Speed Overspeed

Lube Oil Pressure – Low Range Low Limit
Lube Oil Pressure – High Range Low Limit
Coolant Pressure Low Limit
Coolant Temperature High Limit
NOTE: Safety System sensors are only connected at the Shutdown Unit
(SDU). No Engine ECM connections are present.

One of the main roles of the engine ECM is to protect the engine. The engine
ECM is programmed to take appropriate action depending on the type and
severity of the fault. The first course of action for the ECM, in the event of a fault,
is an engine derate. The derate will reduce the available RPM and /or torque
available from the engine during the fault condition. If the fault condition is
severe enough, the ECM also has the capability of shutting down the effected
engine. The strategy that these engine protection functions are applied varies
depending on engine type. This strategy is outlined in the following table.
Table 3 - Engine Protection Strategy for MCRS Marine Engines

(Cummins ECM Monitored Sensors Only)
Engine Model Derates Shutdowns

If sensor value exceeds
the predefined
conditions, an engine
ECM controlled engine
derate will occur along
shutdowns are user
with fault code
Propulsion selectable and can be
annunciation over the
enabled using INSITE.
datalink.
The ECM default setting
Derates cannot be
is engine shutdowns
disabled.
disabled.
There are no derates in
auxiliary product line. A
If shutdowns are
greater risk is posed if
disabled, the ECM will
engine speed is reduced
not shut down the engine
in a prime mover
Auxiliary/Generator even if shutdown
application.
Drive conditions are met,
except for Overspeed, E-
Note: The fault codes
Stop, or Key switch off.
associated with derate
conditions will still be
annunciated

Demonstration Procedures
I. Alarms Demonstration Procedure Using Calterm III
Calterm III can be used to demonstrate engine protection alarms for

sensors monitored by the engine ECM. The following procedure outlines
the method used to perform this demonstration for a surveyor.
This method allows you to override a sensor’s value to the ECM with a
demonstration value. It must be entered manually using the selected
Calterm parameter and the ECM will alarm for that value accordingly.
Once the selected parameter override is disabled, the ECM will report the
value received from the sensor. Refer to Figure 1 for an overview of how
this demonstration method functions.
Figure 1: Calterm III Alarm Demonstration Overview
‘0’ default
Sensor
Value
ECM
Logic
Override
Value Display Value
‘1’ Override (Electronic
Display / Calterm)
Override
Enable
(Using Calterm)
Override Value:
This is the intended value of a parameter in particular, it has to be above

(for temperature) or below (for pressure) the trigger value for the
parameter in consideration, as described in the engine protection table.
The engine protection table is contained in MCRS Engine Protection
Settings found in the Appendix of this document. (Refer to MAB 0.19.00-
12/07/2006 QSK Series with MCRS Electronic Controls System for more
detail)

Override Enable:
This is the digital switch (flag) in the calibration which is defaulted to “0”
(disable); it needs to be “1” (enabled) for the processor to read the
“Override value” as the surrogate “sensor value.”
Display Value:
This is the output of the ECM on the datalink which is communicated to

the operator through Cummins-provided display panel(s) or other datalink
monitoring device. Ideally, this is the processed value of the sensor signal,
and can also be referred to as the sensor value.
Example Alarm Demonstration Procedure:
Channel: Coolant Temperature
Engine Condition: Running at idle or above
Calterm III: Connected and reading from engine
1. For selected Calterm III screen, add display value, override value
and override enable parameters from Table 4
a. Coolant_Temperature
b. AIP_Cool_Tmptr_Override_Value
c. T_AIP_CT_User_Override
2. Check the display value of Coolant_Temperature parameter on

Calterm screen. Note value shown.
3. Using the attached MCRS Engine Protection Settings document,

find the shutdown or protection threshold defined for the alarm state
being demonstrated.
4. Add 5 deg. above the threshold to that value and enter it into the
AIP_Cool_Tmptr_Override_Value parameter
5. To demonstrate the alarm/shutdown for Coolant Temperature,

change the value from 0 to 1 in the T_AIP_CT_User_Override
parameter to override the sensor value with the input value from
Step 4.

6. The display value on Calterm screen and also on the Cummins-
provided display panel(s) connected to the engine will change to
the value from Step 4.
7. Once the persistence time for Coolant Temperature has been

exceeded, the Calterm screen and the Cummins-provided display
panel(s) will show the appropriate alarm state. If shutdowns are
enabled, and the shutdown threshold is exceeded, the engine will
shutdown.
8. To end the demonstration, change the value from 1 to 0 in the

T_AIP_CT_User_Override parameter to revert back to the actual
sensor value.
9. The Calterm screen and the Cummins-provided display panel(s)

will show the actual sensor value for Coolant Temperate and the
alarm state will become inactive.
10. The test is complete for this parameter.
Similarly any other sensor channel can be demonstrated with the method
described above. The only exception to this method is the demonstration
of Engine Overspeed. The procedure for this demonstration is covered in
the next section.

Demonstration of Engine Overspeed Protection (ECM Controlled):
The engine overspeed feature works differently than all other engine
protection channels because of the software layout and the fact that this
protection is always enabled and cannot be disabled.
Since the feature is permanently enabled, the change of limits temporarily

allows the overspeed trip to be demonstrated. The overspeed protection
works in two layers, the first one being the engine protection based
parameter referred to as “engine protection value” and second layer being
the secondary processor monitoring the engine speed referred to as
“secondary processor value” shown in Table 4.
The “engine protection value” is the limit that, when exceeded, will cutoff
the fueling to the engine, thus causing a shutdown. This condition will
also generate a fault code indication to inform the operator of the
shutdown. The “secondary processor value” is the limit, when exceeded,
will cutoff the fueling to the engine but it will not generate a fault code.
To properly demonstrate the overspeed shutdown feature, set the “engine

protection value” to a value within the throttle controlled range (below
rated speed). The “secondary processor” value should be set above the
“engine protection value” but still below engine rated speed for correct
demonstration. This method will generate an engine shutdown with the
associated fault code.
NOTE: This is not for the Safety System shutdown demonstration.

This method is only for ECM controlled engine shutdowns. For
Safety System shutdowns please refer to Section IV of this
document
.

Table 4 - Calterm III Parameters for Demonstrating Engine Protection
Sensor Channel Display Value Override Value Override Enable
Coolant Temperature Coolant_Temperature AIP_Cool_Tmptr_Override_Value T_AIP_CT_User_Override

Coolant Pressure Coolant_Pressure AIP_Cool_Press_Override_Value T_AIP_CP_User_Override
Crankcase Pressure Crankcase_Press C_AIP_CrankcasePress_Ovrd_Valu T_AIP_CrankcasePress_Usr_Ovr_En
e
Oil Pressure Oil_Pressure AIP_Oil_Press_Override_Value T_AIP_OP_User_Override
Coolant Level Coolant_Level AIP_Cool_Lev_Override_Value T_AIP_Cool_Lev_User_Override_En
Oil Temperature Oil_Temperature AIP_Oil_Tmptr_Override_Value T_AIP_OT_User_Override
Intake Manifold Temp 1 Charge_Tmptr_1 C_AIP_CHT_Override_Value_1 T_AIP_CHT_User_Override_En_1
Fuel Temp Fuel_Temperature H_FSI_t_FuelTempOverrideValue C_FSI_s_FuelTempUserOverrideEnabl
e
Gear Oil Pressure OEM_Pressure AIP_OEMPress_Ovrd_Val T_AIP_OEMPress_Ovrd_En
Stack Temp L Stack_Tmptr_1 C_AIP_StackTmptr_Ovrd_Val_1 T_AIP_StackTmptr_Ovrd_En_1
Stack Temp R Stack_Tmptr_1 C_AIP_StackTmptr_Ovrd_Val_2 T_AIP_StackTmptr_Ovrd_En_2
Engine Speed Override (read exception section before demonstration)

Display Value Engine Protection Value Secondary Processor Value
Engine_Speed C_EPD_Overspeed_Limit C_EPS_n_ASICOverspeedLimit
NOTE: A Calterm III screen file of the values in this table is available in the Attachments section of this document.
(EP_Witness_Test.scr.xml)
II. Alarms Demonstration Procedure Using INSITE™
INSITE™ can be used to demonstrate engine protection alarms for sensors

monitored by the engine ECM. The following procedure outlines the method
used to perform this demonstration for a surveyor.
This feature is already available with INSITE™ v 7.0 for Auxiliary engine
models. A similar function for use on propulsion engine models will be
available the next INSITE software release.
It allows the customer to prove the operation of the engine protection feature by
using the tool to temporarily override sensor values. By overriding a sensor to
a value that exceeds an engine protection threshold, the desired engine
protection response can be observed.
This feature is available on electronic service tool v7.0 onwards and resides in
the ECM diagnostic test section. The following figure shows the window users
will be able to access with INSITE™. The engine protection channel and the
severity of fault can be selected through a drop down box. Pushing the “start”
executes the algorithm which demonstrates the function. All parameters
discussed in Table 1 are available for this witness testing.
Figure - 2 Screen Shot of INSITE™ for Witness testing
Cummins Confidential
12 of 37
Summary of Engine Protection Settings
The selection for “Engine Protection Settings” is an INSITE™ view that displays
the dialog screen for the Engine Protection feature. Within this view the user
can determine how the engine will react when an engine protection fault is
logged.
The user can know if the engine protection derate has been suppressed or not.
In addition, the user can see all or some of the following information for each of
the critical parameters being monitored for engine protection through torque or
time derate or both:
• If the derate is applicable (and enabled) or not
• Fault Code
• Type of Derate (time or severity based)
• Parameter thresholds that triggers the derate
• Delays before the onset of derate.
Conditions and enable parameters for time based Torque and RPM shutdowns
such as the thresholds and warning periods for lamp flashes are also visible to
the user. Similar information for severity-based shutdowns is also given.
Example Alarm Demonstration Procedure Using INSITE:
Channel: Engine Oil Pressure
Engine Condition: Running at idle or above
INSITE: Connected and reading from engine
1. Select ECM Diagnostics Tests from the left side of the screen in the
INSITE tool.
2. Select the Engine Protection Witness Test feature from the list of tests.
3. Select the parameter Oil Pressure from the drop-down list.
4. Select a severity of “moderate” from the drop-down list.
5. With the engine running at desired speed, click “start” on the INSITE
screen to begin the test.
Page 13 of 37
6. Observe the test value of Oil Pressure displayed on the INSITE screen;
this value is now being supplied to the ECM for engine protection
functions in place of the value measured by the oil pressure sensor.
Note: the Cummins-provided display panel(s) will continue to

display the value of Oil Pressure as measured by the sensor.
7. Observe the alarm threshold value for Oil Pressure as displayed on the
INSITE screen, below which the alarm will occur after the programmed
persistence time. This value is a function of engine speed (rpm).
8. Observe that within approximately one minute of clicking “start”, a yellow

low Oil Pressure alarm is indicated both visually and audibly on the
Cummins-provided display panel(s) (and by the vessel alarm system if
connected to the panel).
9. Approximately 2 minutes (indicated on the INSITE screen) after clicking

“start”, observe that the INSITE tool indicates the test has concluded.
10. Observe that approximately 3 minutes after clicking “start”, the low Oil
Pressure alarm goes inactive (and can be cleared from the display by
Acknowledge command) on the Cummins-provided display panel(s).
11. At this point, the test is complete and normal use of the Oil Pressure
sensor output by the ECM has resumed.
Page 14 of 37
III. Alarms Demonstration Procedure Using External Sources
For Alarm System sensors not shared by the engine ECM, an external source
is required to simulate the alarm condition. The external sources are used to
generate pressures, temperatures, and high level conditions that would trigger
a system alarm during normal operation. These sensors report to the Alarm
System monitoring panel. For C Command Elite Plus, this module is called the
Remote Input/Output Module (RIO).
The RIO is an independent sensor monitoring device included with C

Command Elite Plus. The information from the Alarm System sensor are
connected to the RIO and the data collected by these sensors is broadcast for
display on C Command Elite RP display panel(s) or by a vessel supplied
monitoring system.
The RIO is also responsible for triggering alarms when an Alarm System
sensor has exceed a pre-defined threshold. This alarm state is also broadcast
by the RIO to the C Command Elite RP display panel(s) or by a vessel supplied
monitoring system. As shown in Table 1, the component responsible for
monitoring the Alarm System sensors varies depending upon engine model.
The following section will outline the alarm demonstration procedures for the
each of the possible monitoring channels.
For this document, the QSK60 was chosen to be the example engine model.
Please refer to the QSK Series Engines with MCRS Sensor Locations
document in the appendix for a complete list of sensor locations.
Page 15 of 37
A. Fuel Leakage from High Pressure Fuel Lines Alarm Demonstration
1. Disconnect the input tube at the lower fitting on the leak tank. (See
Figure 3 for location)
Figure 3 – Fuel Leakage Detector
2. Using suitable tubing to assist, pour at least 266 cc (1 cup) of diesel

fuel into the lower port of the leak tank, more if necessary to achieve
the next step.
3. Observe the alarm indication for fuel leakage from high pressure lines
on the Cummins-provided display panel, both visual and audible
Note: if alarm does not occur after 30 seconds, try adding

additional fuel.
4. Using a pressurized air source, blow out the fuel from the leak tank
(the drain fitting is on opposite side of tank from inlet fitting).
5. Observe that the alarm for fuel leakage from high pressure lines
becomes inactive on the Cummins-provided display panel.
6. Reconnect the input line to the leak tank.
7. This completes the test of the Fuel Leakage detector.
Page 16 of 37
B. Sea water Cooling System Pressure Alarm Demonstration
1. Loosen the hold-down screw and remove the electrical connector from the
pressure sensor
Note: The alarm system will indicate an open circuit fault for
seawater pressure
Figure 4 – Sea Water Pressure Sensor
Hex Head Screws
Electrical Connector
Check Valve
2. Loosen the two hex head screws holding the pressure sensor in place.
3. Hold the check valve with a wrench to prevent it from rotating, and use
another wrench to rotate the pressure sensor counter-clockwise to
remove it from the check valve.
Note: the check valve prevents seawater from spraying out as the
sensor is removed.
4. Connect a regulated pressure source to the male M14 fitting on the

pressure sensor.
Page 17 of 37
5. Apply an appropriate pressure to simulate normal operating conditions
(use a value above the line in Table 2 corresponding to the actual engine
rpm).
Figure 5 - Seawater Pressure Alarm Threshold vs. Engine RPM

10
7
Seawater Pressure (psig)
0
0 500 1000 1500 2000 2500 3000
Engine RPM
6. Reinstall the electrical connector to the sensor, tighten the hold-down

screw, and observe that the open circuit alarm for seawater pressure
goes inactive on the Cummins-supplied display panel.
7. Reduce the regulated pressure source to a desired value (below the line
in Table 2) in order to test the alarm system; observe that a low
seawater pressure alarm is indicated on the Cummins-supplied display
panel (and on the vessel alarm system if connected).
8. Once the alarm has been suitably demonstrated, re-install the sensor by
a. Removing the electrical connector
b. Screwing the sensor into the check valve
c. Tightening the 2 hex head screws to hold the sensor in place
d. Reconnecting the electrical connector and tightening the screw
e. Confirming no faults are active for seawater pressure
Page 18 of 37
C. Intake Manifold Temperature Alarm Demonstration (QSK38 IMT 2/3/4)
1. Remove the intake manifold sensing element from the thermo-well (do
not remove the thermo-well), located on the left underside of intake
manifold to be tested.
Figure 6 – Example Temperature Probe
Thermo-well
Sensor Element
Figure 7 – Example Temperature Sensor
Temperature Sensor
Harness Connector
Page 19 of 37
2. Remove the P-clip bolt(s) as needed to gain sufficient free length of the
armored capillary to enable the sensing element to reach the heat bath.
3. Set the temperature of the heat bath to a value less than 93 C (200 F) and
allow to stabilize.
4. Insert the sensing element into the heat bath.
5. Start the engine.
6. Raise the temperature of the bath to 107 C (225 F).
7. The DCU will alarm for high intake manifold temperature after 10 seconds.
8. Press the Alarm button on the DCU (Engine room panel on front of CIB
door) to cancel the buzzer.
9. Confirm that the DCU displays a yellow alarm for high intake manifold
temperature.
10. Remove the temperature sensing bulb from the heat bath.
11. Acknowledge any faults appearing on the DCU by pressing the

Acknowledge button at bottom left of screen.
12. Viewing the DCU alarm list, confirm that no faults remain active (Active
faults have red or yellow backgrounds, inactive faults have grey
backgrounds).
13. Press the Alarm button on the DCU again to return to the engine
parameter display.
14. Replace the sensing element in the pocket (removed in Step 1 above)
15. Replace the P-clip bolt(s) removed in Step 2 above.
16. Repeat procedure for remaining IMT sensors (if necessary).
Page 20 of 37
D. Lube Oil Temperature Alarm Demonstration (QSK19 Only)
1. Remove the intake manifold sensing element from the thermo-well (do
not remove the thermo-well), located on the left underside of intake
manifold to be tested. (Refer to Figures 5 and 6 for images of an
example sensor)
3. Set the temperature of the heat bath to a value less than 120 C (250 F)
and allow temperature to stabilize.
7. The DCU will alarm for high lube oil temperature after 5 seconds.
door) to cancel the buzzer.
9. Confirm that the DCU displays a yellow alarm for high intake lube oil
temperature.
11. Acknowledge any faults appearing on the DCU by pressing the

12. Viewing the DCU alarm list, confirm that no faults remain active (Active
faults have red or yellow backgrounds, inactive faults have grey
backgrounds).
parameter display.
14. Replace the sensing element in the pocket (removed in Step 1 above)
Page 21 of 37
E. Low Coolant Pressure Alarm Demonstration (QSK19 Only)
1. Rotate the top-most isolation valve 90 degrees clockwise to closed

position on the manifold block mounted on the left front corner of the
engine. Arrow heads should be pointed 90 degrees away from the
pressure fitting when in the closed position.
Figure 8 – Example Coolant Pressure Test Block (QSK19)
Isolation Valve
Pressure Fitting
2. Remove pressure fitting cap nearest the engine from the manifold block
3. Connect a regulated pressure source to the manifold port uncovered in

Step 2. (See Required Tools section above for details of appropriate
adapter fitting).
4. Adjust the regulated pressure source to provide at least 70 kPa (10 psig)
into the manifold.
5. Start the engine and run at idle or above.
6. Lower the regulated pressure to 7 kPa (1 psig).
7. The DCU will alarm after 5 seconds below approximately 14 kPa (2

psig).
door) to cancel the buzzer (the SDU buzzer will continue)
Page 22 of 37
9. Confirm that the DCU displays yellow alarm for low coolant pressure.
10. Reduce the applied pressure to 0 kPa (0 psig).
11. Acknowledge any faults appearing on the DCU by pressing

12. Viewing the DCU alarm list, confirm that no related faults remain active
(Active faults have red or yellow backgrounds, inactive faults have grey
backgrounds).
parameter display.
14. Remove the regulated pressure source, and replace the cap on the
manifold.
15. Open the isolation valve (Closed in Step 1 above) by rotating it 90

degrees counterclockwise, so that the arrow heads are pointing up and
down. CU.
Page 23 of 37
IV. Alarm and Shutdown Demonstration Procedure for Sensors Monitored
by the Safety System
The System sensors are monitored by an independent monitoring device called

the Shutdown Unit (SDU). These sensors are not shared by the engine ECM.
An external input is required to simulate the shutdown conditions driven by the
SDU. As with the RIO, the external inputs are used to generate pressures,
temperatures, and high level conditions that would trigger a safety system
shutdown during normal operation.
The SDU is an independent sensor monitoring device included with C Command

Elite Plus. The information from the Safety System sensor are connected to the
SDU and the data collected by these sensors is broadcast for display on C
Command Elite RP display panel(s) or by a vessel supplied monitoring system.
The SDU is also responsible for triggering alarms and providing an engine
shutdown when a Safety System sensor has exceeded a pre-defined threshold.
This alarm state is also broadcast by the RIO to the C Command Elite RP display
panel(s) or by a vessel supplied monitoring system.
All engines delivered with C Command Elite Plus monitoring systems are
delivered with the sensors and connectors according to Table 2 above. The
following section will outline the alarm and shutdown demonstration procedures
for the each of the Cummins Supplied SDU monitoring channels.
Be advised that the switch locations, orientations, and size will vary from engine
to engine. For this document, the QSK60 was chosen to be the example engine
model. Please refer to the QSK Series Engines with MCRS Sensor Locations
document in the appendix for a complete list of sensor locations.
Page 24 of 37
A. Low Lube Pressure LSR (Low Speed Range) Shutdown Demonstration
[SDU Switch 3 input]
1. Rotate the upper-most isolation valve 90 degrees clockwise to the

closed position on the manifold block mounted on the right rear corner of
the engine. Arrow heads should be pointed 90 degrees away from the
pressure fitting when in the closed position. (In Figure 9, the top three
valves are shown in open position; the bottom valve is shown closed.)
Figure 9 – Example Oil Pressure Switch Test Block (QSK60)
LSR Pressure Fitting LSR Isolation Valve
HSR Pressure Fitting HSR Isolation Valve
2. Remove the upper-most pressure fitting cap from the manifold block
3. Connect a regulated pressure source to the upper-most manifold port

uncovered in Step 2 (see Required Tools section above for details of
appropriate adapter fitting).
4. Adjust the regulated pressure source to provide at least 138 kPa (20
psig) into the manifold port.
5. Run the engine at idle (Must be less than 1400 rpm to operate in low
speed range).
Page 25 of 37
7. The SDU will shut down the engine after 5 seconds below approximately
104 kPa (15 psig).
8. After the engine has shut down, confirm that the red “Shutdown” LED on
the SDU is illuminated as well as the red LED for “Switch 3” indicating
low lube pressure.
Figure 10 – Shutdown Unit (SDU) Switch Indication
door) to cancel the DCU buzzer (The SDU buzzer has an auto-off
feature that will silence the alarm after 5 seconds.)
10. Confirm that the DCU displays a red SDU alarm for low lube oil pressure
(low speed range).
12. Press the Alarm button on the DCU to return to the screen displaying
gauges.
13. Attempt to start the engine using the Start button on the DCU, to
demonstrate it will not start (Prior to Acknowledging the SDU).
14. Press the “Acknowledge” (upper) pushbutton on the face of the SDU
inside the CIB.
15. Confirm that the SDU buzzer ceases, and that there are no faults
indicated on the SDU via illuminated yellow LEDs.
16. Confirm the red LED for switch 3 is no longer illuminated on the SDU.
Page 26 of 37
17. Acknowledge any SDU related faults appearing on the DCU by pressing
the Alarm button on the DCU, then pressing the Acknowledge button at
bottom left of screen.
18. Viewing the DCU alarm list, confirm that no SDU related faults remain
active (Active faults have red or yellow backgrounds, inactive faults have
grey backgrounds).
parameter display.
manifold.
21. Open the isolation valve (Closed in Step 1 above) by rotating it 90

degrees counterclockwise, so that the arrow heads are pointing left and
right rather than up and down.
22. Confirm that the engine can be started using the Start button on the
DCU.
Page 27 of 37
B. Low Lube Pressure HSR (High Speed Range) Shutdown Demonstration
[SDU Switch 4]
1. Rotate the second-upper-most isolation valve 90 degrees clockwise to

the closed position on the manifold block mounted on the right rear
corner of the engine. (See Figure 9) Arrow heads should be pointing up
and down rather than fore and aft.
2. Remove the second-upper-most pressure fitting cap from the manifold

block

Step 1 (See Required Tools section above for details of appropriate
adapter fitting).
4. Adjust the regulated pressure source to provide at least 240 kPa (35
psig) into the manifold.
5. Start the engine and run it at rated (Must be at least above 1400 rpm to
operate in high speed range).
200 kPa (29 psig).
8. After the engine has shut down, confirm that the Red “Shutdown” LED
on the SDU is illuminated as well as the red LED for “Switch 4” indicating
low lube oil pressure HSR.
door) to cancel the DCU buzzer (The SDU buzzer has an auto-off
feature that will silence the alarm after 5 seconds)
10. Confirm that the DCU displays a red SDU alarm for low oil pressure
(high speed range).
gauges.
inside the CIB.
Page 28 of 37
16. Confirm the red LED for Switch 4 is no longer illuminated on the SDU.
grey backgrounds).
parameter display.
manifold.
21. Open the isolation valve (closed in step a above) by rotating it 90

degrees counterclockwise, so that the arrow heads are pointing left and
right as shown in the photo.
DCU.
Page 29 of 37
C. Low Coolant Pressure Switch Shutdown Demonstration
[SDU Switch 2]
1. Rotate the rear-most isolation valve 90 degrees clockwise to closed

position on the manifold block mounted on the right front corner of the
engine. Arrow heads should be pointed 90 degrees away from the
pressure fitting when in the closed position.
Figure 11 – Example Coolant Pressure Test Block (QSK60)
Isolation Valve
Pressure Fitting
2. Remove pressure fitting cap nearest the engine from the manifold block

Step 2. (See Required Tools section above for details of appropriate
adapter fitting).
4. Adjust the regulated pressure source to provide at least 70 kPa (10 psig)
into the manifold.
5. Start the engine and run at idle or above.
14 kPa (2 psig).
Page 30 of 37
the SDU is illuminated as well as the red LED for “Switch 2” indicating low
coolant pressure.
door) to cancel the buzzer (The SDU buzzer has an auto-off feature that
will silence the alarm after 5 seconds)
10. Confirm that the DCU displays a red SDU alarm for low coolant pressure.
gauges.
inside the CIB.
grey backgrounds).
parameter display.
manifold.
21. Open the isolation valve (Closed in Step 1 above) by rotating it 90 degrees
counterclockwise, so that the arrow heads are pointing up and down.
22. Confirm that the engine can be started using the Start button on the DCU.
Page 31 of 37
D. High Coolant Temperature Switch Shutdown Demonstration
[SDU Switch 1]
1. Remove the coolant sensing element from the thermo-well (do not
remove the thermo-well), located on the left underside of thermostat
housing.
Figure 12 – Example Temperature Switch (QSK60)
Thermo-well
Sensor Element
P-Clip Bolt
3. Set the temperature of the heat bath to a value less than 100 C (212 F)
and allow temperature to stabilize.
7. The SDU will shut down the engine after 5 seconds above approximately
105 C (221 F).
Page 32 of 37
the SDU is illuminated as well as the red LED for “Switch 1” indicating
high coolant temperature.
10. Confirm that the DCU displays a red SDU alarm for high coolant
temperature.
gauges.
inside the CIB.
grey backgrounds).
parameter display.
20. Replace the sensing element in the pocket (removed in Step 1 above).
DCU.
Page 33 of 37
E. Overspeed Shutdown
1. With the engine running at Idle, disconnect the electrical connector from
the speed sensor for the Safety System, located on the flywheel housing
as shown in Figure 13.
Note: This unit contains two sensors with two connectors in one
assembly.
Figure 13 – Example Speed Sensor Location (QSK60)
Page 34 of 37
2. Confirm that the SDU indicates a fault for both Tacho 1 and Tacho 2 via
two illuminated yellow LEDs.
Figure 14 – Shutdown Unit (SDU) Status Indication
3. Press the alarm button on the DCU to observe that an active yellow SDU
alarm is present for both Tacho 1 and Tacho 2.
4. Reconnect the speed sensor disconnected in Step 1 above.
5. Press the Acknowledge button on the SDU and observe that the yellow
LEDs for Tacho 1 and Tacho 2 are extinguished.
6. On the DCU alarm screen, observe that the SDU Tacho alarms are
inactive (grey background)
7. Press the Acknowledge button on the DCU and observe that the two
SDU Tacho faults disappear.
8. Press and hold for more than 2 seconds the “Overspeed Test” button on
the SDU. This button is found beneath the “Acknowledge” button.
Observe the red “Overspeed” LED blinks rapidly to confirm that
overspeed test mode is active.
Note: to deactivate Overspeed Test mode prior to the automatic

deactivation after 4 minutes, press and hold the “Overspeed Test” button
for more than 2 seconds again.
Page 35 of 37
9. While the “Overspeed” LED is blinking (Within 4 minutes of completing
Step 8), increase the engine speed toward 1500 rpm, which is 75 rpm
above the Overspeed Test threshold while the SDU is in Overspeed Test
mode.
10. Observe that the engine shuts down immediately after exceeding 1425
rpm, and that the red “Overspeed” LED is illuminated solidly.
11. Press the Alarm button on the DCU (engine room panel on front of CIB
12. Confirm that the DCU displays a red SDU shutdown alarm for
overspeed.
13. Press the Stop button on the DCU, return the throttle to zero and/or
remove any automatic engine start command from the DCU.
gauges.
16. Press the “Acknowledge” button on the SDU inside the CIB.
18. Confirm the red LED for “Overspeed” is no longer illuminated on the
SDU.
grey backgrounds).
parameter display.
DCU.
Page 36 of 37
Attachments
MCRS Engine QSK Series with EP_Witnes_Test.scr.

Protection Settings.doMCRS Sensor Locatio xml
Change Log
Revising Author’s
Date Change Page
Name
5/21/2008 Published to the Web ddc
Distribution of this document is intended for Cummins personnel and distributors. The information contained in this
document is only considered valid while published on the Marine Website. Copies and archived documents are not
considered current.
Page 37 of 37

Witness Test Proc For QSK With MCRS

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Witness Test Proc For QSK With MCRS

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Subject: This AEB is for the following applications:

Witness Test Procedure for Automotive Industrial G-Drive Marine

QSK Series Engines with

Revision Date: 03/24/2008 Controls Gauges & 0.15.00-03/24/2008

The purpose of this document is to describe a test procedure required to

Cummins Confidential Page 1 of 37

Cummins Confidential Page 2 of 37

ECM Monitored Sensors

Alarm and Safety System Monitored Sensors:

Cummins Confidential Page 3 of 37

• Never demonstrate engine protection for an auxiliary/generator

• Never demonstrate engine protection for a propulsion application

• Derates limit the rated speed or the maximum engine fueling to

• Override values should be chosen above the threshold for

• Ensure that the witness is familiar with the electronic displays on

• For safety reasons, the demonstration of the engine overspeed

Cummins Confidential Page 4 of 37

Engine Speed (Cam & Crank) Overspeed AN, DR, SD ○ ○ ○ ○

LEGEND: ○ - INSITE/Calterm III AN – Annunciation

Table 2 –Summary of Safety System Sensors

Engine Speed Overspeed

Cummins Confidential Page 5 of 37

Table 3 - Engine Protection Strategy for MCRS Marine Engines

Engine Model Derates Shutdowns

Cummins Confidential Page 6 of 37

I. Alarms Demonstration Procedure Using Calterm III

Calterm III can be used to demonstrate engine protection alarms for

Figure 1: Calterm III Alarm Demonstration Overview

This is the intended value of a parameter in particular, it has to be above

Cummins Confidential Page 7 of 37

This is the output of the ECM on the datalink which is communicated to

Example Alarm Demonstration Procedure:

Channel: Coolant Temperature

Engine Condition: Running at idle or above

Calterm III: Connected and reading from engine

2. Check the display value of Coolant_Temperature parameter on

3. Using the attached MCRS Engine Protection Settings document,

5. To demonstrate the alarm/shutdown for Coolant Temperature,

Cummins Confidential Page 8 of 37

7. Once the persistence time for Coolant Temperature has been

8. To end the demonstration, change the value from 1 to 0 in the

9. The Calterm screen and the Cummins-provided display panel(s)

10. The test is complete for this parameter.

Cummins Confidential Page 9 of 37

Since the feature is permanently enabled, the change of limits temporarily

To properly demonstrate the overspeed shutdown feature, set the “engine

NOTE: This is not for the Safety System shutdown demonstration.

Cummins Confidential Page 10 of 37

Sensor Channel Display Value Override Value Override Enable

Coolant Temperature Coolant_Temperature AIP_Cool_Tmptr_Override_Value T_AIP_CT_User_Override

Engine Speed Override (read exception section before demonstration)

INSITE™ can be used to demonstrate engine protection alarms for sensors

Figure - 2 Screen Shot of INSITE™ for Witness testing

Example Alarm Demonstration Procedure Using INSITE:

Channel: Engine Oil Pressure

Engine Condition: Running at idle or above

INSITE: Connected and reading from engine

3. Select the parameter Oil Pressure from the drop-down list.

4. Select a severity of “moderate” from the drop-down list.

Note: the Cummins-provided display panel(s) will continue to

8. Observe that within approximately one minute of clicking “start”, a yellow

9. Approximately 2 minutes (indicated on the INSITE screen) after clicking

The RIO is an independent sensor monitoring device included with C