ECP 4083935_o&m_ecpg

Operation & Maintenance Manual for ECPG

1

TABLE OF CONTENTS i.

Introduction ................................................................................................................................................... i-1

1.

Electronic Control Panel with Speed Governor .............................................................................................. 1-1

2.

ECPG Dimensions ....................................................................................................................................... 2-1

3.

Engine Start-up & Adjustments .................................................................................................................... 3-1

4.

Engine Protection ......................................................................................................................................... 4-1

5.

Fault Code Information ................................................................................................................................. 5-1

6.

Troubleshooting ............................................................................................................................................ 6-1

7.

Installation .................................................................................................................................................... 7-1

8.

Appendix ...................................................................................................................................................... 8-1

Operation & Maintenance Manual for ECPG

i-1

Operation & Maintenance Manual for ECPG

SECTION i - INTRODUCTION Section Contents Page About the Manual ................................................................................................................................................... i-2 To the Owner and Operator .................................................................................................................................... i-3 General Safety Instructions .................................................................................................................................... i-4 General Repair Instructions .................................................................................................................................... i-5 Graphic Symbols ................................................................................................................................................... i-6 Electrical Symbols ................................................................................................................................................. i-7 Acronyms and Abbreviations ................................................................................................................................. i-9 Foreword ............................................................................................................................................................... i-10 Important Reference Numbers ............................................................................................................................... i-11 Illustrations ........................................................................................................................................................... i-12

i-2

Operation & Maintenance Manual for ECPG

About the Manual This manual contains information needed to correctly operate and maintain the ECPG provided on your engine. Additional service literature (Shop Manual, Troubleshooting and Repair Manual) can be ordered from Authorised Dealers. Numerous illustrations and symbols are used to aid in understanding the meaning of the text. Refer to complete listing of symbols and their definitions. Each section is preceded by a “Section Contents” to aid in locating information more quickly. This manual contains information needed to understand, correctly operate and maintain the Electronic Control Panel with Governor (ECPG) as recommended by Cummins India Limited. This manual does not cover base engine maintenance procedures. Refer to the Operation and Maintenance Manual, Bulletin No. 3243773-03 for the specific engine information. Any base engine specific changes in the Software Calibration / Features will be covered in separate bulletins for that particular Engine / Rating. This manual does not cover generator equipment maintenance or repair procedures. Consult the generator equipment manufacturer for specific maintenance and repair recommendations. Both metric and U.S. customary values are listed in this manual. The metric value is listed first, followed by the U.S. customary in brackets. This manual does not cover the Installation / Operation of the Service Tool Software. Refer to the Installation & Operation manual for the ECP-G Service Tool (Bulletin No. 3243816).

Operation & Maintenance Manual for ECPG

To The Owner and Operator Preventative maintenance is the easiest and least expensive type of maintenance. Follow the maintenance schedule recommendations outlined in Maintenance Guidelines. Keep records of regularly scheduled maintenance. Use the correct fuel, oil and coolant in your engine as specified in Specifications and Torque Values. Cummins India Ltd. uses the latest technology and the highest quality components to produce its engines. Cummins recommends using only genuine Cummins parts and ReCon exchange parts. Personnel at Cummins Authorized Repair Locations have been trained to provide expert service and parts support. If you have a problem that cannot be resolved by a Cummins Authorized Repair Location, follow the steps outlined in the Service Assistance. NOTE: Discharge of oil or oily waste into or upon water is a direct violation of todays laws. Violators are subject to a penalty of various monetary charges. Dispose off these substances properly.

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Operation & Maintenance Manual for ECPG

General Safety Instructions Important Safety Notice

WARNING Read and understand all of the safety precautions and warnings before performing any repair. This list contains the general safety precautions that must be followed to provide personal safety. Special safety precautions are included in the procedures when they apply. • Make sure the work area surrounding the product is safe. Be aware of hazardous conditions that can exist. • Always wear protective glasses and protective shoes when working. • Do not wear loose-fitting or torn clothing. Remove all jewelry when working. • Disconnect the battery and discharge any capacitors before beginning any repair work. Disconnect the air starting motor if equipped to prevent accidental engine starting. Put a “Do Not Operate” tag in the operator’s compartment or on the controls. • Use ONLY the proper engine barring techniques for manually rotating the crankshaft. Do not attempt to rotate the crankshaft by pulling or prying on the fan. This practice can cause serious personal injury, property damage, or damage to the fan blade(s) causing premature fan failure. • If an engine has been operating and the coolant is hot, allow the engine to cool before you slowly loosen the filler cap and relieve the pressure from the cooling system. • Do not work on anything that is supported ONLY by lifting jacks or a hoist. Always use blocks or proper stands to support the product before performing any service work. • Relieve all pressure in the air, oil, and the cooling systems before any lines, fittings, or related items are removed or disconnected. Be alert for possible pressure when disconnecting any device from a system that utilizes pressure. Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal injury. • To avoid personal injury, use a hoist or get assistance when lifting components that weigh 23 kg [50 lb] or more. Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of the correct capacity. Make sure hooks are positioned correctly. Always use a spreader bar when necessary. The lifting hooks must not be side-loaded. • Corrosion inhibitor contains alkali. Do not get the substance in your eyes. Avoid prolonged or repeated contact with skin. Do not swallow internally. In case of contact, immediately wash skin with soap and water. In case of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN. • Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the manufacturer’s instructions to provide complete safety when using these materials. KEEP OUT OF REACH OF CHILDREN. • To avoid burns, be alert for hot parts on products that have just been turned OFF, and hot fluids in lines, tubes, and compartments. • Always use tools that are in good condition. Make sure you understand how to use them before performing any service work. Use ONLY genuine Cummins or Cummins Recon® replacement parts. • Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener of less quality if replacements are necessary.

Operation & Maintenance Manual for ECPG

i-5

General Repair Instructions This engine incorporates the latest diesel technology; yet, it is designed to be repaired using normal repair practices performed to quality standards. • Cummins India Ltd., does not recommend or authorize any modifications or repairs to engines or components except for those detailed in Cummins Ser vice Inf ormation. In par ticular ed Service Information. particular ticular,, un-authoriz un-authorized sonal injur y. Belo w is a par tial listing of components repair to saf ety-related components can cause per Below partial safety-related personal injury classified as safety-related: Air Compressor Fuel Shutoff Assemblies Cooling Fan Fuel Suppl y Tubes Supply Fan Hub Assembly Lifting Brackets Fan Mounting Bracket(s) Throttle Controls Fan Mounting Capscrews Turboc har ger Compressor Casing urbochar harg Fan Hub Spindle Turboc har ger Oil Drain Line(s) urbochar harg Flywheel Turboc har ger Oil Suppl y Line(s) urbochar harg Supply Flywheel Crankshaft Adapter Turboc har g er T urbine Casing urbochar harg Flywheel Mounting Capscrews Vibration Damper Mounting Capscrews • Follow All Safety Instructions Noted in the Procedures. Follow the manufacturer’s recommendations for cleaning solvents and other substances used during the repair of the engine. Always use good safety practices with tools and equipment. • Provide A Clean Environment and Follow the Cleaning Instructions Specified in the Procedures The engine and its components must be kept clean during any repair. Contamination of the engine and components will cause premature wear. • Perform the Inspections Specified in the Procedures. • Replace all Components or Assemb lies Whic h are Dama ged or Worn Be yond the Specifications Assemblies Which Damag Bey • Use Genuine Cummins New or ReCondD Service Parts and Assemblies The assembly instructions have been written to use again as many components and assemblies as possible. When it is necessary to replace a component or assembly, the procedure is based on the use of new Cummins India Ltd. or Cummins ReCon® components. All of the repair services described in this manual are available from all Cummins Distributors and most Dealer locations. Follow Disassemblly and Assemb Assemblly Pr Procedures Damag • Follo w The Specified Disassemb ocedures to Avoid Dama ge to the Components. Complete rebuild instructions are available in the shop manual which can be ordered or purchased from a Cummins Authorized Repair Location. ECPG DO’S AND DON’TS DON’Ts 1. DO NOT remove the ECPG connectors A, B and C when +24V supply is conected to ECPG. 2. DO NOT attempt to open the ECPG enclosure. 3. DO NOT attempt to remove or repair any of the ECPG electronic parts (components, cables etc.). There are no user serviceable parts inside ECPG. 4. Precaution during welding: i) DO NOT connect ground cable of welding machine to ECPG ii) DO NOT perform welding near Engine when ECPG harness is conected to ECPG. 5. DO NOT expose ECPG to sunlight, humidity, heat, water while in operation. 6. Servicing of ECPG is to be done by Authorized Cummins Personnel Only. DO’s 1. Precautions during welding : i) First, disconnect battery cables from battery terminals. ii) Then, disconnect the connectors A, B, C from the ECPG 2. Contact authorized service personnel in case of ECPG failure.

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Operation & Maintenance Manual for ECPG

GRAPHIC SYMBOL The following symbols have been used in this manual to help communicate the intent of the instructions. When one of the symbols appears, it conveys the meaning defined below :

WARNING - Serious personal injury or extensive property damage can result if the warning instructions are not followed. CAUTION - Minor personal injury can result or a part, an assembly, or the engine can be damaged if the caution instructions are not followed. Indicates a REMOVAL or DISASSEMBLY step. Indicates an INSTALLATION or ASSEMBLY step. INSPECTION is required.

CLEAN the part or assembly. PERFORM a mechanical or time MEASUREMENT. LUBRICATE the part or assembly. Indicates that a WRENCH or TOOL SIZE will be given. TIGHTEN to a specific torque. PERFORM an electrical MEASUREMENT. Refer to another location in this manual or another publication for additional information. The component weight 23 kg [50 lb] or more. To avoid personal injury, use a hoist or get assistance to lift the component.

Operation & Maintenance Manual for ECPG

i-7

ELECTRICAL SYMBOLS Name

Symbol

Battery

Name Transfer

Alternator (Frequency Source) Capacitor Resistor Fuse Variable Resistor (Potentiometer)

3 Terminal Device 2 Terminal Device

Circuit Breaker

Jumper Wire Terminal Strip Switches : (N.O.) Normally Open

Coil Magnetic Core

(N.C.) Normally Closed Transfer

Transfer 3 position

Transformer

Variable Reluctance Magnetic Pickup

Relay Contact : (N.O.) Normally Open (N.C.) Normally Closed

Female Contact

Male Contact

Symbol

i-8

Name

Operation & Maintenance Manual for ECPG

Symbol

Name

Shields:

Earth Safety Ground

Shielded Wire

**

Shielded Pair

** Crossing of Conductors (wires) not Connected

Junction of Connected Conductors (wires) Grounded Chassis or Frame Connection Conducting connection to a chassis or frame, or equivalent chassis connection of a printed wiring board. The chassis or frame (or equivalent chassis connection of a printed wiring board) may be at a different potential than the earth or structure in which this chassis or frame (or printed wiring board) is mounted. Direct Conducting Connection to Circuit Return. Conducting connection to a structure that services a function similar to that of an earth ground (that is, a structure such as a frame of an air, space or land vehicle that is not conductively connected to earth.)

This symbol may be used in place of symbol for direct conducting connection to circuit return to indicate a ground connection having a specified protective function (e.g., for protection against electrical shock in case of a fault). Ref. Electrical and Electronics Graphic Symbols and abbreviated names.

Symbol

Operation & Maintenance Manual for ECPG

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ACR ONYMS AND ABBREVIA TIONS ACRONYMS ABBREVIATIONS A

Ampere

Hz

Hertz

AC

Alternating Current

IP53

Ingress Protection - Dust-Protected &

AMF

Auto Mains Failure

AMPS

Amperes

Spraying Water IP54

Ingress Protection - Dust-Protected &

AWG

American Wire Gage

B+

Battery Positive

In

Inch

o

Degree Celsius

I/O

Input / Output

CTS

Coolant Temperature Sensor

kg

Kilogram

CW

Clockwise

kPa

Kilopascal

CCW

Counterclockwise

kW

Kilowatt

DC

Direct Current

lb

Pound

ECP

Electronic Control Panel

LED

Light-Emitting Diode

ECP+G / ECPG

Electronic Control Panel with Governor

LLOP

Low Lube Oil Pressure

EMC

Electro-Magnetic Compatibility

mA

Milli-Ampere

EMF

Electro-Motive Force

mW

Milli-Watts

EMI

Electro-Magnetic Interference

mm

Millimeter

EPROM

Erasable Programmable Read Only

MPU

Magnetic Pickup

Memory

N-m

Newton-meter

E-STOP

Emergency Stop

O/M

Owner-Operator Manual

C

Splashing Water

ESS

Engine Speed Sensor

OEM

Original Equipment Manufacturer

o

Degree Fahrenheit

OPS

Oil Pressure Sensor

FSOV

Fuel Shutoff Valve

OS

Over Speed

ft (FT)

Foot

PC

Personal Computer

GND

Ground

P-P

Peak to Peak

GOEM

G-Drive Original Equipment

P/N

Part Number

Manufacturer

psi

Pounds Per Square Inch

H2O

Water

rpm (RPM)

Revolutions Per Minute

HCT

High Coolant Temperature

PWM

Pulse Width Modulator

HE

Heat Exchanger

V

Volts

Hg

Mercury

PT

Pressure Time

hp

Horsepower

MS

Military Standard

F

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Operation & Maintenance Manual for ECPG

Foreword This manual contains information for the correct operation and maintenance of your Cummins engine. It also includes important safety information, engine and systems specifications, troubleshooting guidelines. Keep this manual with the equipment. If the equipment is traded or sold, give the manual to the new owner. The information, specifications, and recommended maintenance guidelines in this manual are based on information in effect at the time of printing. Cummins India Limited reserves the right to make changes at any time without obligation. If you find differences between your engine and the information in this manual, contact your local Cummins Authorized Dealer. The latest technology and the highest quality components were used to produce this engine. When replacement parts are needed, we recommend using only genuine Cummins or ReCon® exchange parts. These parts can be identified by the following trademarks:

Operation & Maintenance Manual for ECPG

i-11

Important Reference Numbers Fill in the part name and number in the blank spaces provided below. This will give you a reference whenever service or maintenance is required.

ECPG Sr. No.

____________________

Engine Model

____________________

Engine Serial Number

____________________

Engine Control Parts List (CPL) Number

____________________

Engine Oil Type and Viscosity Fuel Pump Part Number

SAE grade 15 W 40 ____________________

Filter Part Numbers: • Air Cleaner Element

____________________

• Coolant (C-Series)

____________________

• Lubricating Oil

____________________

• Fuel

____________________

Belt Part Number (Alternator)

____________________

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Operation & Maintenance Manual for ECPG

Illustrations Some of the illustrations throughout this manual are generic and will not look exactly like the engine or parts used in your application. The illustrations can contain symbols to indicate an action required and an acceptable or not acceptable condition.

The illustrations included in this manual are intended to illustrate procedures performed or location of particular items. ECPG The procedure performed or location of the item described will be the same even though the illustrations may vary.

Illustrations showing connector contact positions for connections to the Electronic Control Panel and Governor are shown as viewed looking at the connector on the ECPG, not the interfacing connector of the wiring harness.

ECPG Connector ‘A’

Illustrations showing connector contact positions for connections to the in-line connectors of the wiring harnesses are viewed looking at the corresponding connector on the factory supplied engine or extension wiring harness, not the connector of the interfacing harness.

Connector Fuel Actuator

1-1

Operation & Maintenance Manual for ECPG

SECTION 1 ECPG GENERAL INFORMATION Page Electronic Control Panel with Speed Governor ...................................................................................................... 1-2 Description ................................................................................................................................................... 1-2 Theory of Operation ...................................................................................................................................... 1-2 Introduction to Parts .............................................................................................................................................. 1-3 ECPG Front Panel ........................................................................................................................................ Harness ........................................................................................................................................................ Extension Harness (Option) .......................................................................................................................... Inputs ........................................................................................................................................................... Outputs ........................................................................................................................................................

1-5 1-5 1-5 1-6 1-6

Sensors ................................................................................................................................................................ Magnetic Pick-up .......................................................................................................................................... Coolant Temperature Sensor ........................................................................................................................ Intake Air Temperature Sensor ..................................................................................................................... Lube Oil Pressure Sensor ............................................................................................................................. Coolant Level Sensor ................................................................................................................................... Actuator and Actuator Housing .....................................................................................................................

1-6 1-6 1-7 1-7 1-7 1-7 1-8

Connector Details .................................................................................................................................................. Connector-A ................................................................................................................................................. Connector-B ................................................................................................................................................. Connector-C ................................................................................................................................................. Data Link Connector (9 Pin) ..........................................................................................................................

1-9 1-9 1-9 1-9 1-9

ECPG Hardwired Interconnections ...................................................................................................................... 1-10

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Operation & Maintenance Manual for ECPG

Electronic control panel with speed governor Description The Electronic control panel (ECPG) with built in governor is used on engines for governing engine speed, monitoring engine parameters and protecting the engine in catastrophic conditions. The ECPG with built in governor comprises of, ECPG with software to govern the engine speed, actuator mounted in an aluminum housing, mounting par ts, cable harness for interconnection, engine sensors. This ECPG eliminates the conventional electronic fuel controller (EFC) and the related harness. The ECPG is used on PT type fuel system.

ECPG

ECPG

The primary function of the ECPG is to govern the engine speed in isochronous or droop mode. The ECPG hardware and software provides the following additional features : • • • • • •

Engine Speed Governing Operator Control Interface Engine Monitoring Engine Protection System Fault Diagnostics. Electronic Service Tool

Theory of operation The magnetic pickup senses the engine speed at the flywheel ring gear and generates an AC voltage with its frequency proportional to the engine speed. The signal is sensed by the ECPG and is used as a speed feedback.

ECPG

The actuator mounted in the actuator housing is used to control the fuel flow from the fuel pump to the injectors. Actuator valve (with no current flowing in the actuator coil) is normally closed. Actuator opens depending upon the current through the actuator coil. The ECPG compares the electrical signal from the magnetic pickup with a preset speed reference point (for e.g. 1500 RPM). If there is a difference in the two signals, the controller will change the amount of current flowing through to the actuator coil. A change in the amount of current to the actuator coil makes the actuator shaft to linearly open/ close the fuel outlet port, and controls the amount of fuel flow to the engine. This in turn controls the engine speed. The ECPG controls the engine speed at the set reference speed (for e.g. 1500 RPM) from No load to Full load (For Isochronous operation). It also provides programmable speed droop function. It requires no special settings as the software in the ECPG controls the engine speed.

ECPG

Operation & Maintenance Manual for ECPG

1-3

INTRODUCTION TO PARTS The ECPG enclosure is made of glass reinforced plastic and is divided into two halves, the front enclosure and the rear enclosure.

&&&&

These two enclosures are sealed by a rubber seal. Six M5 x 0.5, 50mm length Phillips head screws are used for mounting it.

The ECPG comprises of two sub assemblies (printed circuit boards) : a. I/O board (Analog board) b. CPU board (Digital board) These boards are housed in the glass reinforced, plastic enclosure. The CPU board is mounted on the front and the I/O board is mounted on the rear half of the enclosure respectively.

The CPU board processes the input signals received from the I/O board and performs the calculation and displays the measured data on the digital display. It also checks for various safety limits and shuts off the supply to the fuel shut off valve if one of the engine parameters exceeds the set safety threshold. The CPU board also calculates the engine running time and displays it.

CPU Board

The I/O Board interfaces with the engine sensors and OEM connections, through three connectors called as Connector A (19-pin), Connector B (10-pin), and Connector C (7-pin). The CPU board interfaces with the service tool through D-type connector called as datalink connector.

I/O Board

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Operation & Maintenance Manual for ECPG

The Connector ‘A’ interfaces with the engine sensors and actuator. Connector ‘A’ is a male 19 position MS shell connector. It mates with female connector on the engine harness through a 19 position receptacle socket. Connector ‘B’ is a male 10 position MS shell connector. It interfaces with customer connections through 10 position MS shell receptacle socket. The following customer features are accessible via hardwired connections to Connector B :

CONNECTOR-A

• • • • • • • • • •

Alternate Frequency Switch Overspeed (OS) alarm relay driver High coolant temperature (HCT) alarm relay driver Low lube oil pressure (LOP) alarm relay driver Remote start Remote stop Raise contact Lower contact. Intake air temperature alarm relay driver. Customer Selection Output Alarm relay driver : Not ready to start, Engine running, Common warning, Common shutdown. • Speed bias input.

CONNECTOR-B

Connector ‘C’ is for future expansion. The datalink connector is 9 pin ‘D’ type connector interfacing with PC based service tool. The data link is intended to be used to connect single or multiple ECPG’s to a host computer acting as a supervisor for facilitating data acquisition and logging using a PC based service tool. There are many features of the ECPG that are configured using the service tool. Electronic service tool is a packaged software application that installs on a IBM compatible PC. The Service Tool is available as a Kit (Part No. 4105287) on a CD. The Service PC, running the ECP-G Tool is connected to the ECP-G via a RS-232 serial communication cable. The enclosed figure illustrates the method used to connect the Service PC via the engine harness to the ECP-G. The data link uses two wire RS-485 serial communication standard. A RS485 to RS-232 convertor (Part No. 4071717) is required for connecting the data link to a PC’s RS-232 serial communication port. The configurable features will be discussed in this manual, however, all functions of Service Tool are not covered. Refer to the Service Tool manual (Part No. 3243816) for more detailed information about using Service Tool. Note that the PC that has the Service Tool software installed requires a separate service cable to communicate with the ECPG through the RS-485 service datalink connector on the Engine Harness.

DATA LINK CONNECTOR

CONNECTOR-C 4105287 ECPG Service Tool

4073853 ECPG to data-link adapter cable, adapter side stub

○

4071851 PC to data-link adapter cable

○

○

○

4071935 ECPG

4071717 Data-link Adapter

4071852 ECPG to data-link adapter cable ECPG side stub

SERVICE TOOL

Operation & Maintenance Manual for ECPG

1-5

ECPG front panel The front operator interface panel comprises of the following: (i) Four digit “7 Segment Display”, to indicate the scanned engine parameters.

8 GREEN LED’s

&&&&

Three Position Key Switch

Idle/Rated Toggle Switch

8 RED LED’s

(ii) A column of green LED’s on the left hand side with legends to indicate the parameter being selected for display. (iii) A column of red LED’s on the right hand side with legends to indicate the fault condition. (iv) Scan Push button: The display is toggled between “All Parameters” and “Single Parameter” scan mode by the momentary pressing of the scan button. It is mounted on the front plate of the ECPG. (v) Three position key switch : The key switch on the front panel is used to ‘Wake up’ ECPG and start/ stop the engine. It is used to turn the 24 V DC battery ON/OFF and thus start the engine. Refer Section ECPG Features, Power down mode. (vi) Idle / Rated Toggle switch : The engine mode is toggled between idle and rated using this switch.

Harness The outputs from all the sensors are connected to the ECPG through the engine harness. This harness is connected to the ECPG through Connector ‘A’. The other harness, which is the OEM harness connects the OEM outputs like remote start, remote stop and alarm relay drivers through Connector ‘B’. Extension Harness (Option) The Extension Harness provides the means for mounting the ECPG off the engine, such as generator set or some other remote location. This is accomplished by extending the circuits from the engine harness connector to the ECPG mounting location. The maximum length of extension harness is 10 meters. CA UTION CAUTION No attempt should be made to bypass/tap existing engine sensors, actuators or to operate the engine using 3rd party governor control systems.

Following inputs / outputs are connected to the ECPG

ENGINE HARNESS

OEM HARNESS

Scan Push Button

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Operation & Maintenance Manual for ECPG

by two harnesses at the rear of the ECPG. Inputs 1. Battery Supply Voltage 2. Coolant Temperature sensor 3. Intake Air temperature sensor (only on KTA50G8 and KTA38G5 engine models) 4. Lube Oil Pressure sensor 5. Engine speed sensor i.e. magnetic pickup 6. Low coolant level sensor 7. Scan push button 8. Key switch 9. Remote start 10. Remote stop 11. Idle / Rated switch 12. Alternate Frequency switch 13. Speed bias input 14. Battery charging failure indication SENSOR FEEDBACK

15. Raise

AIR INTAKE TEMPERATURE

16. Lower Outputs 1. Fuel shut-off valve 2. Starter magnetic switch

MAGNETIC PICK-UP

ECP-G

FUEL PUMP LOP

3. High coolant temperature alarm relay driver ENGINE

4. Low lube oil pressure alarm relay driver

FUEL SHUTOFF VALVE, FUEL ACTUATOR

5. High Intake air temperature alarm relay driver

OEM INTERFACE

6. Engine overspeed relay driver 7. Fuel actuator The figure shows how various parts are functionally connected. Following major parts are included in the ECPG. SENSORS a. Magnetic pickup The magnetic pickup is an electromagnetic device. It is mounted on the flywheel housing. It senses the engine speed at the flywheel ring gear and generates AC voltage with its frequency proportional to the engine speed. A Two pin MS connector is provided to connect the magnetic pick up to the engine harness. The magnetic pickup is connected between pin ‘B’ (RPM –) and ‘T’ (RPM +) of Connector A through engine harness.

ECPG

Operation & Maintenance Manual for ECPG

1-7

b. Coolant temperature sensor

COOLANT TEMPERATURE SENSOR

A coolant temperature sensor is mounted on the thermostat housing. The sensor is fitted in an adapter. A two-pin connector is provided to connect the coolant temperature sensor to the engine harness. The sensor is connected between pin ‘P’ and ‘N’ of Connector ‘A’ through the engine harness.

c. Intake Air temperature sensor

Intake Air Temperature Sensor

The intake air temperature sensor is used to monitor the low temperature aftercooler performance for two-pump two-loop system only. The intake air temperature sensor is mounted on the aftercooler housing for the KTA –38- G5 and KTA-50-G8 engines. A two-pin connector is provided to connect the intake air temperature sensor to the engine harness. The sensor is connected between Pin ‘S’ and ‘U’ of Connector ‘A’ through the engine harness.

d. Lube oil pressure sensor LUBE OIL PRESSURE SENSOR

Lube oil pressure sensor is mounted on the engine block oil gallery. A three-pin connector is provided to connect lube oil pressure sensor to the engine harness. The sensor is connected between pin ‘J’, Pin ‘G’ and Pin ‘H’ of Connector ‘A’ through the engine harness.

COOLANT LEVEL COOLANT LEVELINDICATOR SENSOR

e. Coolant level sensor The coolant level sensor is a switch type sensor. It is used to detect the coolant level of the engine. The sensor is connected at Pin-R of Connector ‘A’ to the engine harness.

Note : The sensor locations shown in the figures are of VTA-28 engine as an example.

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f.

Operation & Maintenance Manual for ECPG

Actuator and actuator housing

The actuator is a linear proportional valve. The actuator is housed in the aluminum housing. This assembly is used as a valve for controlling the speed and horsepower of the engine by controlling the fuel flow. The actuator is connected between Pin-F and Pin-M of Connector ‘A’ to the engine harness. Actuator

Actuator is closed when no current is flowing through the actuator coil. When current is passed through the actuator coil, the actuator port opens proportional to the actuator current.

Housing

Operation & Maintenance Manual for ECPG

CONNECTOR DETAILS Connector-A Sr. No.

PIN

Description

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

A B C D E F G H J K L M N P R S T U V

Battery (24 VDC) Negative Engine speed sensor return Not Connected Fuel shut off valve output Starter magnetic switch output Fuel actuator output Lube oil pressure sensor supply Lube oil pressure sensor signal (output) Lube oil pressure sensor return Datalink start output relay driver (future expansion) Battery (24 VDC) Positive Fuel actuator return Coolant temperature sensor signal Coolant temperature sensor signal Coolant level sensor signal Intake Air temperature sensor signal Engine speed sensor signal Intake Air temperature sensor signal Battery charging failure signal

Connector-B Sr. No.

Letter

1 2 3 4 5 6 7 8 9 10

A B C D E F G H I J

Description Battery (24 VDC) Negative Speed raise / Alternate Frequency Speed lower Remote Start High intake air / Engine overspeed alarm relay driver Low lube oil pressure alarm relay driver High coolant temperature alarm relay driver Customer selectable output Speed bias signal Remote stop

Data Link Connector (9 pin) Sr. No.

Letter

1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8 9

Description Data link positive Data link negative Not connected Not connected Not connected Not connected Not connected Not connected Not connected

Connector - C (Future use) Sr. No.

Letter

1 2 3 4 5 6 7

A B C D E F G

Description Electrical STC valve return Not connected Not connected Fuel rail pressure sensor signal (output) Fuel rail pressure sensor supply Fuel rail pressure sensor return Electrical STC valve output

1-9

1-10

ECPG Hardwired Interconnections Data Link Connector Service Tool Interface Connector ‘A’ Ø Engine Sensors

Ø Ø Ø Ø

• Speed • Coolant Temperature • Intake Air Temperature • Lube Oil Pressure • Coolant Level FSO valve ECPG Power & Ground Fuel Actuator Starter magnetic S/W

Connector ‘C’ Ø Future Scope

ECPG Rear Vie w View

ECPG Fr ont Vie w Front View

Ø Ø Ø Ø

Remote Start Remote Stop Speed bias Switch Input • Raise • Lower • Alternate frequency Ø Lamp / Relay Driver • Low lube oil pressure alarm • Coolant Temperature Alarm • Air intake temperature/ Over Speed Alarm • Customer O/P

OFF / RUN / START Mode

Idle / Rated mode

Single Parameter / All parameters Scan mode

Operation & Maintenance Manual for ECPG

Connector ‘B’

Operation & Maintenance Manual for ECPG

2-1

SECTION 2 ECPG DET AILS DETAILS Page ECPG Dimensions ................................................................................................................................................ 2-2 ECPG Electronic Interfaces .................................................................................................................................. 2-3 ECPG Features .................................................................................................................................................... 2-4 Power Down Mode ........................................................................................................................................ Key Switch and Starter Protection ................................................................................................................ Over Cranking Prevention ............................................................................................................................. Parameter Selection Push Button ................................................................................................................. Idle / Rated Mode Selection ......................................................................................................................... Engine Running Hours .................................................................................................................................. FSO Supply / Fuel Actuator Command ......................................................................................................... Alarm Relay Drivers ..................................................................................................................................... Remote Start ................................................................................................................................................ Remote Stop ................................................................................................................................................ Battery Voltage ............................................................................................................................................ Battery Charging Indication ...........................................................................................................................

2-4 2-4 2-5 2-5 2-6 2-6 2-6 2-6 2-7 2-7 2-7 2-7

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Operation & Maintenance Manual for ECPG

ECPG DIMENSIONS (PART DESCRIPTION)

7 263.9

6 5 313.9

4

3875362

4071721

4084285

5

6

7

2

504975 4

1

4084219 3

3

4084218

4083975

1

2

REF. NO.

97.3

21

1

1

1

1

1

1 PLATE,COOLER

SWITCH,PUSH BUTTON

SWITCH,TOGGLE

SWITCH, IGNITION

PANEL BACK

1 PANEL DISPLAY

SEAL,FRONT COVER

ITEM DESCRIPTION ITEM NO.

QTY.

The ECPG measures 314 x 264 x 118 mm including the heat-sink. Refer to the section “Installation” for details and cautions before selecting a location for mounting the ECPG.

Operation & Maintenance Manual for ECPG

2-3

ECPG ELECTRONIC INTERFACES

(OEM Scope of Supply)

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Operation & Maintenance Manual for ECPG

ECPG FEA TURES FEATURES a. Power do wn mode down Unswitched 24 VDC volts is connected to the ECPG through Connector A. When the key switch is turned to Run position : -

ECPG wakes up from sleep mode and executes hardware check where the LEDs and Displays are checked. ECPG then enters into all parameters scan mode and is ready to start the engine.

When the key switch is turned to OFF position/key S/W is in ‘run position’ and engine is not running. -

-

ECPG will not turn off immediately but the power down mode will be enabled. ECPG will turn Off after the set power down time, thus minimising the battery drain during engine off condition.



Power down mode can be disabled temporarily using the service tool as per the attached illustration.

b. Key switch and starter protection The key switch on the front panel is used to turn on or off the 24 volts DC battery supply to the ECPG. The key switch is a three-position switch which controls the three modes as off, run, start. i)

OFF

Off mode : The key switch in off mode disconnects the supply to the FSOV and fuel actuator, resulting in engine shut down. It also transits the ECPG to “power down” mode.

ii)

Run mode : When the key switch is turned to “Run” position, the controller wakes up. Carries out self check and is ready to start the engine. RUN

iii) Start mode : Turn and hold the key switch to “Start” position, for controller to energize the starter magnetic switch. A built in software mechanism disengages the supply to the starter magnetic switch after six seconds and prevents the starter from damage. The controller also ramps up the engine speed from crank to idle/rated mode in a predetermined time period. Note : For Amf application, key switch should always be in ‘R UN’ position to star ‘RUN’ startt the engine through remove start input.

START

Operation & Maintenance Manual for ECPG

2-5

c. Over cranking prevention Starter disengage speed

> 300 RPM

Engine Speed

300

Starter solenoid condition

Fail to start / crank 6 sec. ON

6 sec. ON

ON 6 sec. OFF

6 sec. OFF

Crank Speed

When the key switch is held in Start position, the starter magnetic switch will turn on, causing the starter to engage to the flywheel ring gear teeth and rotate the engine. As the engine picks up speed, the starter magnetic switch is de-activated by the ECPG automatically. This disengages the starter from the flywheel ring gear, preventing the starter from Over cranking. As long as the engine is running, taking the key switch to Start position will not activate the starter key switch. This prevents starter damage that can be caused by an attempt to engage the starter with flywheel ring gear when an engine is already running.

OFF

TIME (seconds)

There is a built in timer mechanism which prevents starter damage due to over cranking. After six seconds from the instant the key switch is turned to Start position, the starter magnetic switch will automatically de activate and remain de activated for six more seconds even if the key is in start position.



The starter protection is based on engine speed and not on lubricating oil pressure. Releasing the key switch from Start position will reset the starter engage/disengage time. OFF

d. Scan push button The scan push button is used to select the following display scan modes : (a) Single parameter scan mode (b) All parameters scan mode. 

The parameter selection switch acts as a toggle to select these two modes. These two modes are toggled by momentarily pressing and releasing the parameter scan push button. PARAMETER SELECTION

{

All parameters scanned sequentially



In ‘all parameters scan’ mode, all the parameters are scanned sequentially and the corresponding green LED for the parameter on the left hand column, glows and the value of the parameter is displayed on the 7-segment digital display. The value of the parameter is displayed for two seconds after which the next parameter is scanned. The user can toggle to the Single Scan Mode from the All Parameters Scan mode by momentarily pressing and releasing the scan push button.

Toggle between Single scan / all parameters scan mode.

The value of the selected parameter is displayed continuously on the 7-segment digital display.

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Operation & Maintenance Manual for ECPG

e. Idle / Rated Mode Selection The idle / rated switch is used to select the base running speed of the engine. When the idle / rated switch is in Idle Position, Idle speed is selected. Whereas Rated speed is selected if the switch is in Rated Position. For e.g. Idle speed = 1100 rpm (Idle position) Rated speed = 1500 rpm (Rated position) Note : For AMF application, Idle/Rated switch should al wa ys be in ‘RA TED’ position so that on alwa ways ‘RATED’ Remote Start, engine goes to rated speed. f.

Engine Running Hours

The hour meter shows the number of hours for which the engine has been running at Rated Speed. 

The reading is refreshed after every hour on the display.

g. FSO supply / Fuel actuator command The percentage duty cycle of the actuator PWM command is indicated on the front display. This fuel actuator command is proportional to the current flowing through the actuator.

RUN

The supply to the fuel shut off valve is turned on the moment the key switch is set to “Run” position, and remains ON continuously till the engine trips because of a fault condition or the user stops the engine manually or the controller receives a Remote Stop command.



RUN

h. Alarm Relay Drivers Relays are connected between point E or F or G or H and point A of the OEM harness for alarm indication. Use suitable relays as shown in OEM connector wiring diagram OR use suitable interface circuits to make use of the alarm relay driver outputs.. Refer Section 8-2 for specification of relays to be used.

HCT ALARM G

LLOP ALARM OS/HIGH IMT ALARM CUSTOMER SELECTION OUTPUT OEM INTERFACE PANEL

F

H I

A B

A1;

C

J E

D

OEM CONNECTOR "B ON CONTROLLER

Operation & Maintenance Manual for ECPG

OEM "B" CONNECTOR

I

B

J C

F D

E

Remote start

Note that the Starter magnetic switches (2 Nos. in case of KV engines) draw current from this 24 V source. The cables and the contact must therefore be appropriately rated. Recommend 10 amps capability. It also includes starter protection and over cranking preventation.

PIN ‘D’

N/O CONTACT

i.

Applying +24 volts DC (with respect to engine battery negative) through an external contact at Pin D of the Connector B, would start the engine with this remote start command. +24 volts DC should be applied continuously at this input till engine starts.

A

H

G

2-7

+ 24 V D C (+24)

Note : Use ‘potential free contact’ for this input. j. OEM "B" CONNECTOR

A

H I

Note : Applying +24 volts DC to Remote Start and Remote Stop inputs at the same time shall not start the engine.

J C

F E

On applying 24 volts DC is externally applied to pin J of the Connector B, the supply to the fuel shut off valve is removed and fuel actuator is closed the engine is shut down remotely.

B

G

+ 24 V DC

Remote stop

D

PIN ‘J’ N/O CONTACT

Note : Use ‘potential free contact’ for this input. CAUTION Do not connect ‘+24V’ from battery to pin A (ground) of OEM connector connector.. k. Battery voltage  "

A 24V battery is connected to power up the ECPG. This battery voltage is measured and displayed on the digital display.

Battery Voltage

l.



Battery Charging failure

Battery Charging Indication

With no charging current flowing to the battery from the charging alternator, the charging failure LED glows . Hence this LED glows when the engine is not running. As the engine starts running and the charging alternator starts supplying charging current to the batteries, the LED turns OFF. If this LED glows when the engine is running, it indicates that the charging alternator is not generating voltage.

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Operation & Maintenance Manual for ECPG

NOTES _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________

Operation & Maintenance Manual for ECPG

3-1

SECTION 3 ENGINE STARTUP AND ADJUSTMENTS Page Engine Startup and Adjustments ........................................................................................................................... 3-2 Governor Gain Adjust ................................................................................................................................... 3-2 Droop Adjust ................................................................................................................................................ 3-2 Isochronous Mode ........................................................................................................................................ 3-3 Frequency Adjust ......................................................................................................................................... 3-3 Raise/Lower Switches .......................................................................................................................... 3-3 Speed Bias Input ................................................................................................................................. 3-3 Alternate Frequency ............................................................................................................................. 3-4

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Operation & Maintenance Manual for ECPG

ENGINE STARTUP AND ADJUSTMENTS

Service Tool Configurable Feature

a. Governor gain adjust The governor gain can be set by changing the value using the PC based service tool. Caution Improper configuration or adjustment of governor gain feature can cause unstable engine operation. The customer is responsible for performing the necessary system tests to ensure that the feature is properly configured.

Data Link Convertor

To ECPG

Feature = Governor Trim = Governor Gain Adjust

b. Droop adjust The droop can be set by changing the value electronically using the PC based service tool.

Service Tool Configurable Feature

Caution Improper configuration or adjustment of Droop feature can cause unstab le engine operation. The unstable customer is responsible for performing the necessary system tests to ensure that the feature is properly configured.

Data Link Convertor

Feature Trim

= Reference Speed = Droop

To ECPG

The amount of droop can be calculated using the formula. Droop engine gensets which are set to 50 Hz operation at full load, need to have the engine no load governed speed adjusted to: 51.5 Hz (1545 RPM) for 3 % Speed droop 52.5 Hz (1575 RPM) for 5 % Speed droop

(No. Load Speed - Full Load Speed) % Droop = ————————————————– x 100 Full Load Speed

If the rated kW is not available, use the available kW to get the engine speed, as computed by the formula : 3 % DROOP

{

Note : The default Droop is factory set to 3%.

{

51.50 51

FREQUENCY (Hz)

Available kW load S = NLS – ———————— x (NLS - FLS) (Rated kW load) Where, S = Speed at available load NLS = No load speed (Same as high idle speed) FLS = Full load speed (Rated speed normally 1500 RPM)

50 49

0%

50 %

LOAD

100%

Operation & Maintenance Manual for ECPG

3-3

c. Isochronous mode

ISOCHRONOUS SPEED MODE

FREQUENCY (Hz)

For Isochronous speed operation, the droop setting needs to be set at 0 %. 51

The droop setting can be adjusted using the service tool. 50 49

0%

50 %

100%

LOAD OEM “B” CONNECTOR

d. Frequency Adjust The ‘Frequency adjust’ can be effected through ‘Speed Raise’ to ‘Speed Lower’ Inputs, or through ‘Speed bias Input’ one of these sources can be selected through PC Based tool settable trim.

SPEED RAISED

i)

Two switch input contacts called as “Speed Raise” and “Speed Lower” are provided on the Connector B to adjust the generator set frequency. The frequency is adjusted within +/- 4 Hz of rated operating frequency.

SPEED LOWER (+) 24 VDC

OEM / CUSTOMER PANEL

The customer can implement the frequency adjust feature by connecting the speed Raise / speed Lower push buttons on the Connector B to (+) 24 Volts.

Service Tool Configurable Feature

The engine speed will increase or decrease at a pre programmed rate depending upon the switch selected. The Raise / Lower ramp rate can be programmed through the service tool as shown in the enclosed figure.. Data Link Convertor

Feature Parameter

= Reference Speed = Speed Adjust Source

Note : Use ‘potential free contacts’ for these inputs. ii) Speed Bias input

To ECPG

Service Tool Configurable Feature

Feature Parameter

Raise / Lower Switches

The speed bias input can be implemented by connecting a 0 –5 Volts analog input at pin number ‘I’ Connector B with reference to engine battery negative. Note : The speed bias signal and the signal return conductors must be protected from EMI by using a twisted, shielded cable. One end of the shield must be connected at Pin ‘A’ of Connector “B” at the ECP-G end and the other end to be left open.

= Reference Speed = Speed Adjust Ramp Rate

Data Link Convertor

Caution

To ECPG

The Voltage input must not exceed 5 Volts DC for the speed bias input. Improper configuration or adjustment of speed bias input feature can cause

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Operation & Maintenance Manual for ECPG

unstable engine operation. The customer is responsible for performing the necessary system tests to ensure that the feature is properly configured. The Speed bias Trim feature can be enabled using the service tool as described in the enclosed figure.

OEM "B" CONNECTOR

I

B

G

ANALOG OUTPUTS

I

A

H

(0 - 5 V D C )

J C

F E

D

e. Alternate Frequency Input (50/60 Hz) An alternate frequency input is provided for selection between one of the two generator set frequency settings (50 Hz or 60 Hz).

OEM / CUSTOMER PANEL

This feature can be set through the service tool as shown in the enclosed figure. Note : The alternate frequency selection feature is only enabled for engines rated for dual speed operation. For engines rated for single speed operation, the alternate frequency input is non operational and no service tool related settings need to be made. If the frequency selection using the alternate frequency input changes for dual speed engine operation while the engine is running, the selected frequency setting will not take effect until the engine is shut down and restarted. The frequency adjust feature using Speed Raise / Speed Lower inputs is ineffective for dual speed operation. All software calibrations in the ECP-G shipped out of the factory have a default setting of 50 Hz ONLY operation. Separate software calibration(s) needs to be “downloaded” into the controller if the genset is to be operated @ 60 Hz ONLY or 50 Hz / 60Hz (Dual speed operation). Note : For the Dual speed operation (50 Hz or 60 Hz) the Raise / lower feature(s) are disabled in the software calibration. Note : Alternate frequency feature can be used for single g enset application onl y. genset only

Service Tool Configurable Feature

Data Link Convertor

Feature Parameter

= Reference Speed = Genset Operating Mode

To ECPG

Operation & Maintenance Manual for ECPG

4-1

SECTION 4 ENGINE PROTECTION Page Engine Protection .................................................................................................................................................. 4-2 Fault Diagnosis ............................................................................................................................................ 4-2 Fault Codes .................................................................................................................................................. 4-2 Service Tool ................................................................................................................................................. 4-3 Alarm Relay / Lamp Drivers .......................................................................................................................... 4-4 Fault Acknowledge / Reset ........................................................................................................................... 4-4

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Operation & Maintenance Manual for ECPG

ENGINE PROTECTION The engine protection parameters shown on the right can be configured within preset limits using the service tool. The service tool does not allow to set the values of the parameter beyond the minimum and maximum limits. The service tool does not allow the setting of parameter values beyond the minimum and maximum limits.

Engine Speed Coolant Temperature Lube Oil Pressure Air Inlet Temperature Coolant Level

a. Fault Diagnosis There are eight red colour LED’s on the front display of the ECPG. These LED’s light up individually when a fault is reported active by the ECPG.

#

Fault diagnosis is displayed next to the LED which is illuminated.

}

Individual LED glow when fault is detected.

Note : Only active faults are displayed on ECPG digital display. ECPG service tool shall be used to view all active as well as inactive faults. b. Fault Codes The ECPG can record and report certain detectable diagnostic conditions. These conditions are recorded as fault codes. These can be used to assist in trouble shooting engine and controller failure. Refer to the fault code list and trouble shooting tree in the manual for further details.

#

If fault condition is detected, ECPG Fault Code detected LED glows

Fault codes recorded in the ECPG can be accessed in following way : 1) ECPG Front Panel. When a fault is detected by the ECPG, the red LED on the right hand side row “ECPG Fault detected” lights up. The user can use the scan push button to view all the active faults detected by the ECPG displayed in sequence.

#

}

LED glow when a fault occurs.

Operation & Maintenance Manual for ECPG

4-3

Fault Code Viewing :

{

All parameters scanned sequentially

Procedure for viewing fault code varies slightly depending on whether user is in Single parameter or continuous scan mode. #

Single Parameter Mode :

Toggle between Single scan / all parameters scan mode.

Example : Consider that user is monitoring Coolant Temperature and Green LED for Coolant temperature is glowing with value of coolant temperature displayed on Digital display. If a fault occurs at this time, 1. Red LED will glow next to the fault condition. 2. RED LED will glow next to “ECP fault code detected” and Fault code will be stored in ECPG memory. 3. Push the scan push button to invoke continuous scan mode until scan reaches ECP fault code. Push and release the scan push button, at this position to select ECP fault code. 4. The display will show at fault codes stored in memory sequentially. Continuous Scan Mode : If a fault occurs at this time, 5. Red LED will glow next to the fault condition. 6. Red LED will glow next to “ECP fault code detected” and Fault code will be stored in ECPG memory.

{

All parameters scanned sequentially

7. Wait until scan reaches ECP fault code. Push and release the scan push button, at this position to select ECP fault code.

#

8. The display will show all fault codes stored in memory sequentially. Toggle between Single scan / all parameters scan mode.

Service Tool Configurable Feature

When ECP fault code is selected for display, any new fault code will be displayed, when it is registered in the ECPG. When engine has shut down as a response to fault, ECPG may power down in the stipulated time before the user has viewed the fault code. In this case, fault codes can be viewed even at next power ON the ECPG following the above procedure. c. Ser vice Tool Service The engine protection parameters and the fault codes are available to the user using the service tool.

Data Link Convertor

Feature Trim

= Reference Speed = Droop

To ECPG

4-4

Operation & Maintenance Manual for ECPG

d. Alarm Relay / Lamp Drivers Four (4) output drivers are provided to annunciate the specific engine protection alarm conditions that have occurred. Individual output of these drivers can be used to drive either a lamp or a relay. Following relay / lamp drivers are provided : Engine Warning conditions : (1) High Coolant Temperature (2) Low Lube Oil Pressure (3) Engine Overspeed / High Intake Air Temp. shutdown (4) Customer output.

HCT ALARM G

LLOP ALARM OS/HIGH IMT ALARM CUSTOMER SELECTION OUTPUT OEM INTERFACE PANEL

F

H I

A B

A1;

C

J E

D

OEM CONNECTOR "B ON CONTROLLER

Each relay / lamp driver is capable to handle a rated maximum continuous voltage equal to Battery (+) and 80mA sink Current. The recommended Relay for the Relay driver is O/E/N 57 DP-12-106 coil : 12 Volts / 150 ohms. Refer to the ECPG Fault Response threshold table for the Warning and Shutdown. Note : Intake Air Temperature Sensor is pr ovided ffor or pro specific engine models only for these engine High Intake Air Temp. Alarm and Engine o ver speed alarm over verspeed are provided on a common output. (Connector B-Pin E). FAULT ACKNOWLEDGE

e. Fault Acknowledge / Reset The ECPG does not have a separate fault reset switch. All the faults which are detected “active” by ECPG will be displayed on the digital display. The ECPG will not shut off the engine for faults with a response of ‘Warning”. It will shut off the engine for faults with response of “Shutdown”. If ECPG powers off with active faults, the fault codes will be displayed at next ECPG startup. If the engine trips because of a fault with a response of “Shutdown”, it can be restarted immediately. If the fault condition persists, the engine will be shutoff again. All the “active” faults are stored in the ECPG non volatile memory. They are retained permanently, in the nonvalatile memory of ECPG.

Turn key switch to ‘OFF’ position.

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Operation & Maintenance Manual for ECPG

SECTION 5 ECPG - FAULT CODE INFORMATION Page ECPG Fault Code Information ............................................................................................................................... 5-2 ECPG Fault Response Threshold ......................................................................................................................... 5-5

5-2

Electronic Control Panel + Governor (ECPG) Fault Code Information Engine Protection/ System Fault

Default Fault Response

Fault Description

Effect (Only when fault is active)

135

System

Warning

Engine Lube Oil Pressure sensor signal is shorted high

No engine protection for Lube Oil Pressure. No effect on engine performance.

141

System

Warning

Engine Lube Oil Pressure sensor signal is shorted low

No engine protection for Lube Oil Pressure. No effect on engine performance.

143

Engine Protection

Warning

Engine Lube Oil Pressure has dropped below the warning threshold for Low Lube Oil Pressure

Low Lube Oil Pressure warning relay driver is energized. No effect on engine performance.

144

System

Warning

Engine Coolant Temperature sensor signal is shorted high

No engine protection for Coolant Temperature. No effect on engine performance.

145

System

Warning

Engine Coolant Temperature sensor signal is shorted low

No engine protection for Coolant Temperature. No effect on engine performance.

146

Engine Protection

Warning

Engine Coolant Temperature has exceed the warning threshold for High Coolant Temperature

High Coolant Temperature warning relay driver is energized. No effect on engine performance.

151

Engine Protection

Shutdown

Engine Coolant temperature has exceed the shutdown threshold for high Coolant Temperature

Engine will shutdown.

153

System

Warning

Engine Intake Air Temperature sensor signal is Shorted high

No engine protection for Intake Air Temperature. No effect on engine performance.

154

System

Warning

Engine Intake Air Temperature Sensor signal is shorted low

No engine protection for Intake Air Temperature. No effect on engine performance.

Operation & Maintenance Manual for ECPG

Fault Code

Fault Code

Engine Protection/ System Fault

Default Fault Response

Fault Description

Effect (Only when fault is active)

155

Engine Protection

Warning

Engine Intake Air Temperature has exceed the warning threshold for High Intake Air Temperature

High Intake Air Temperature warning relay driver is energized. No effect on engine performance.

234

Engine Protection

Shutdown

Engine Speed Signal indicates that engine speed is greater than Overspeed threshold

Engine will shutdown. Fuel Shut-Off Valve (S.D. Coil) is de-energized (valve closed). Overspeed shutdown relay driver is energized.

235

Engine Protection

Shutdown

Engine Coolant Level has dropped below the shutdown threshold for Low Coolant Level.

Engine will shutdown.

359

System

Warning

Engine cranked but failed to start

No effect on engine performance

415

Engine Protection

Shutdown

Engine Lube Oil Pressure has dropped below the shutdown threshold for Low Oil Pressure

Engine will shutdown.

441

System

Warning

Low voltage has been detected for battery during engine crank.

Engine may not crank. Possible loss of ECPG functionality.

1411

System

Warning

Speed Bias Analog Input signal is shorted high

The Speed Bias Analog Input signal feature will be disabled. Possible loss of engine performance.

1416

System

Warning

Engine fail to shutdown

Engine failed to stop even after a stop command was issued by the system. No engine protection feature.

Operation & Maintenance Manual for ECPG

Electronic Control Panel + Governor (ECPG) Fault Code Information

5-3

5-4

Electronic Control Panel + Governor (ECPG) Fault Code Information Engine Protection/ System Fault

Default Fault Response

Fault Description

Effect (Only when fault is active)

1438

System

Warning

Engine fail to crank

No effect on engine performance.

3111

System

Warning

Speed Bias Analog Input signal is shorted low

The speed bias analog input signal feature will be disabled. Possible loss of engine performance.

3112

System

Warning

Speed Raise Switch is shorted high

The Speed Raised Switch feature will be disabled. Possible loss of engine performance.

3113

System

Warning

Speed Lower switch is shorted high

The Speed Lower Switch feature will be disabled. Possible loss of engine performance.

3115

System

Shutdown

Speed signal was lost while engine running.

Engine will shutdown.

3116

System

Warning

Fuel Actuator PWM signal is close to maximum for long enough time due to possibly stuck actuator or insufficient fuel supply.

Possible loss of engine performance at higher loads.

3118

System

Warning

Powerdown hardware within ECPG malfunctioning.

1) No effect on engine performance. 2) ECPG will not powerdown. Potential battery drain.

Operation & Maintenance Manual for ECPG

Fault Code

Operation & Maintenance Manual for ECPG

5-5

ECPG FAULT RESPONSE THRESHOLD Engine Parameter

Fault Response (default values)

Threshold (default values)

Engine Overspeed

Shutdown

110% of rated RPM for 1500 RPM 110% of rated RPM for 1800 RPM

Warning

90oC (194 oF) 93oC (199 oF)

Shutdown

96oC (205 oF)

High Intake Manifold Temperature Warning

Warning

75oC (167 oF)

Low Lube Oil Pressure Warning

Warning

RPM 0 500 1100 1500

Threshold (bar) 0 0.5 1.0 2.7

Low Lube Oil Pressure Shutdown

Shutdown

RPM 0 500 1100 1500

Threshold (bar) 0 0.3 0.6 2.4

Low Coolant Level

Shutdown

Low Coolant Level

High Coolant Temperature Warning

High Coolant Temperature Shutdown

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Operation & Maintenance Manual for ECPG

NOTES _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________

Operation & Maintenance Manual for ECPG

6-1

SECTION 6 TROUBLESHOOTING Page Fault Code 135 ...................................................................................................................................................... 6-2 Fault Code 141 ...................................................................................................................................................... 6-3 Fault Code 143 ...................................................................................................................................................... 6-4 Fault Code 144 ...................................................................................................................................................... 6-6 Fault Code 145 ...................................................................................................................................................... 6-7 Fault Code 146 ...................................................................................................................................................... 6-8 Fault Code 151 .................................................................................................................................................... 6-10 Fault Code 153 .................................................................................................................................................... 6-12 Fault Code 154 .................................................................................................................................................... 6-13 Fault Code 155 .................................................................................................................................................... 6-14 Fault Code 234 .................................................................................................................................................... 6-15 Fault Code 235 .................................................................................................................................................... 6-16 Fault Code 359 .................................................................................................................................................... 6-17 Fault Code 415 .................................................................................................................................................... 6-18 Fault Code 441 .................................................................................................................................................... 6-20 Fault Code 1411 .................................................................................................................................................. 6-21 Fault Code 1416 .................................................................................................................................................. 6-22 Fault Code 1438 .................................................................................................................................................. 6-23 Fault Code 3111 .................................................................................................................................................. 6-24 Fault Code 3112 .................................................................................................................................................. 6-25 Fault Code 3113 .................................................................................................................................................. 6-26 Fault Code 3115 .................................................................................................................................................. 6-27 Fault Code 3116 .................................................................................................................................................. 6-28 Fault Code 3118 .................................................................................................................................................. 6-29

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Operation & Maintenance Manual for ECPG

TR OUBLESHOO TING TROUBLESHOO OUBLESHOOTING Fault Code 135

Reason Engine Lube Oil Pressure sensor signal is shorted high.

Cause

Lube Oil Pressure sensor short

OK

Engine harness defective

OK

ECPG Malfunctioning

Effect (Only when fault code is active Warning No engine protection for Lube Oil Pressure. No effect on engine performance.

Correction Inspect the sensor for damaged, corroded, bent, broken, expanded or pushed back pins. If sensor pins are found damaged, replace the sensor. Also inspect the sensor for dirt, debris, moisture in or on the sensor pins. If observed, flush the dirt, debris, moisture from the sensor pins. Check the lube oil pressure sensor as per sensor specification. If it is not as per sensor specification, replace the sensor. Check the sensor supply voltage between pin ‘G’ and pin ‘J’ of engine harness. If no sensor supply voltage is observed, check the engine harness for continuity. Check supply voltage = 5V if the lube oil pressure sensor signal wire (pin ‘H’) is shorted to + 5V sensor supply wire pin ‘G’ in the engine harness. If short is observed in the harness, repair the wires, that have short circuits or replace the engine harness. Replace the ECPG.

Operation & Maintenance Manual for ECPG

Fault Code 141

Reason Engine Oil pressure sensor signal is shorted low.

Cause

Lube Oil Pressure sensor open

OK

Engine harness defective

OK

ECPG Malfunctioning

6-3

Effect (Only when fault code is active) Warning No engine protection for Lube Oil Pressure. No effect on engine performance. Correction Inspect the sensor for damaged, corroded, bent, broken, expanded or pushed back pins. If sensor pins are found damaged, replace the sensor. Also inspect the sensor for dirt, debris, moisture in or on the sensor pins. If observed, flush the dirt, debris, moisture from the sensor pins. Check the lube oil pressure sensor as per sensor specification. If it is not as per sensor specification, replace the sensor. Check the sensor supply voltage between pin ‘G’ and pin ‘J’ of engine harness. If no sensor supply voltage is observed, check the engine harness for continuity. Check supply voltage = 5V if the lube oil pressure sensor signal wire (pin ‘H’) is shorted to + 5V sensor supply wire pin ‘G’ in the engine harness. If short is observed in the harness, repair the wires, that have short circuits or replace the engine harness. Replace the ECPG.

6-4

Operation & Maintenance Manual for ECPG

Fault Code

Reason Engine Oil Pressure has dropped below the warning threshold for low lube oil pressure.

143

Cause Insufficient lube oil in engine

Effect (Only when fault code is active) Warning Low lube oil pressure warning relay driver is energized. No effect on engine performance. Correction Check the dipstick calibration. Check the oil level in the engine. Add oil if level below dipstick mark.

OK

Lube Oil Pressure sensor not at correct location on engine

Check the mounting location of lube oil pressure sensor on engine. Refer to engine specification. If location is incorrect, relocate sensor and check operation.

OK

Lube oil diluted with fuel or coolant

OK

Full flow lube oil filter(s) plugged

Check for fuel or coolant contamination in the lube oil. If contaminated, remove the cause. Drain all the oil in engine and fill the fresh lube oil in the engine.

Replace lube oil filter(s).

OK

Lube oil suction tube broken or tube seals leaking

Remove oil sump. Inspect/replace the suction tube.

OK

Malfunction lube oil pressure regulator in lube oil filter head.

Remove oil sump. Inspect/replace suction tube.

OK

Lubricating oil pump malfunction

Inspect lubricating oil pump. repair or replace the pump if necessary.

Operation & Maintenance Manual for ECPG

Fault Code

Reason Engine Oil Pressure has dropped below the warning threshold for low lube oil pressure.

143 Contd.

Cause

Lube oil pressure sensor defective

6-5

Effect (Only when fault code is active) Warning Low lube oil pressure warning relay driver is energized. No effect on engine performance. Correction Check the lube oil pressure sensor as per sensor specification. If it is not as per specification, replace the sensor.

OK

Sensor getting + 5 V supply

Check the sensor supply voltage between pin ‘G’ and pin ‘J’ of engine harness. If not, check the engine harness.

OK

Engine harness defective

OK

ECPG Malfunctioning

Check the continuity between connector ‘A’ and engine harness (pin ‘G’, pin ‘H’ or pin ‘J’). If no continuity is observed, repair the wires that have short circuits or replace the engine harness.

Replace the ECPG.

6-6

Operation & Maintenance Manual for ECPG

Fault Code

Reason

144

Engine coolant temperature sensor signal is shorted high.

Cause Coolant Temperature sensor short

OK

Engine harness defective

OK

ECPG Malfunctioning

Effect (Only when fault code is active Warning No engine protection for coolant temperature. No effect on engine performance. Correction Check the Coolant Temperature sensor resistance as per sensor specification. If it is not as per sensor specification, replace the sensor.

Check the Coolant Temperature sensor signal wire (pin ‘N’) shorted to + 24 V battery supply in the engine harness. If short is observed, repair the wires that have short circuits, or replace the engine harness. Replace the ECPG.

Operation & Maintenance Manual for ECPG

Fault Code

Reason

145

Engine Coolant Temperature sensor signal is shorted low.

Cause Coolant Temperature sensor open

OK

Engine harness defective

OK

ECPG Malfunctioning

6-7

Effect (Only when fault code is active Warning No engine protection for coolant temperature. No effect on engine performance.

Correction Check the Coolant Temperature sensor resistance as per sensor specification. If it is not as per sensor specification, replace the sensor.

Check the Coolant Temperature sensor signal wire (pin ‘N’) shorted to ground in the engine harness. If short is observed, repair the wires that have short circuits, or replace the engine harness.

Replace the ECPG.

6-8

Operation & Maintenance Manual for ECPG

Fault Code

Reason Engine Coolant Temperature has exceeded the warning threshold for high coolant temperature

146

Cause

Coolant Level low

Effect (Only when fault code is active) Warning High Coolant Temperature warning relay driver is energized. No effect on engine performance. Correction Check level. Add Coolant if necessary.

OK

Intake Air temperature too high

Disconnect underhood air. Check for air recirculation from radiator entering air cleaner

OK

Radiator/Heat Exchanger fins obstructed or damaged

Check fins for damage and debris.

OK

Pipe coupling or hose collapsed

Check the pipe coupling or hose if damaged.

OK

Fan shroud damaged

Inspect shroud for damage.

OK

Fan belt slipping or viscous fan malfunction

Check fan RPM.

OK

Radiator Cap Malfunction

Check / replace radiator cap.

Operation & Maintenance Manual for ECPG

Fault Code

Reason Engine Coolant Temperature has exceeded the warning threshold for high coolant temperature

146 Contd.

Cause Loss of Raw water supply to HE

6-9

Effect (Only when fault code is active) Warning High Coolant Temperature warning relay driver is energized. No effect on engine performance. Correction Check the raw water flow pressure and see whether it is in the specified limit.

OK

Radiator core obstructed or damaged (internal)

Inspect radiator and clean if necessary.

OK

Water pump malfunctioning

Check the water pump and replace it if incase found defective.

OK

Coolant Temperature sensor defective

Check the Coolant Temperature sensor as per sensor specification. If it is not as per specification, replace the sensor.

OK

Engine harness defective

OK

ECPG Malfunctioning

Check the sensor supply voltage (+ 12 V) between pin ‘N’ and pin ‘A’ of engine harness. If not, repair the wires that have short circuits / open circuits or replace the engine harness.

Replace the ECPG.

6-10

Operation & Maintenance Manual for ECPG

Fault Code

Reason

151

Engine coolant temperature has exceeded the shutdown threshold for high coolant temperature

Cause

Coolant Level low

Effect (Only when fault code is active) Shutdown Engine will shutdown

Correction Check level. Add coolant, if necessary.

OK

Intake Air temperature too high

Disconnect underhood air. Check for air recirculation from radiator entering air cleaner

OK

Radiator/HE fins obstructed or damaged

Check fins for damage and debris.

OK

Pipe coupling or hose collapsed

Check the pipe coupling or hose if damaged.

OK

Fan shroud damaged

Inspect shroud for damage.

OK

Fan belt slipping or viscous fan malfunction

Check fan RPM.

OK

Radiator Cap Malfunction

Check /replace radiator cap.

Operation & Maintenance Manual for ECPG

Fault Code 151 Contd.

Reason Engine coolant temperature has exceeded the shutdown threshold for high coolant temperature

Cause Loss of Raw water supply to HE

6-11

Effect (Only when fault code is active) Shutdown Engine will shutdown

Correction Check the raw water flow pressure and see whether it is in the specified limit.

OK

Radiator core obstructed or damaged (internal)

Inspect radiator and clean if necessary.

OK

Water pump malfunctioning

Check the water pump and replace it if incase found defective.

OK

Coolant Temperature sensor defective

Check the Coolant Temperature sensor as per sensor specification. If it is not as per specification, replace the sensor.

OK

Engine harness defective

OK

ECPG Malfunctioning

Check the sensor supply voltage (+ 12 V) between pin ‘N’ and pin ‘A’ of engine harness. If not, repair the wires that have short circuits / open circuits or replace the engine harness.

Replace the ECPG.

6-12

Operation & Maintenance Manual for ECPG

Fault Code

Reason

153

Engine Intake air temperature sensor signal is shorted high.

Cause Intake Air Temperature sensor short

OK

Engine harness defective

OK

ECPG Malfunctioning

Effect (Only when fault code is active) Warning No engine protection for Intake Air Temperature. No effect on engine performance.

Correction Check the Intake Air Temperature sensor resistance as per sensor specification. If it is not as per sensor specification, replace the sensor.

Check if the Intake Air Temperature sensor signal wire (pin ‘S’) is shorted to + 24 V battery supply in the engine harness. If short is observed, repair the wires that have short circuits or replace the engine harness.

Replace the ECPG.

Operation & Maintenance Manual for ECPG

Fault Code

Reason

154

Engine Intake Air Temperature sensor signal is shorted low.

Cause Intake Air Temperature sensor open

OK

Engine harness defective

OK

ECPG Malfunctioning

6-13

Effect (Only when fault code is active) Warning No engine protection for Intake Air Temperature. No effect on engine performance.

Correction Check the Intake Air Temperature sensor resistance as per sensor specification. If it is not as per sensor specification, replace the sensor.

Check the Intake Air Temperature sensor signal wire (pin ‘S’) shorted to ground in the engine harness. If short is observed, repair the wires that have short circuits or replace the engine harness.

Replace the ECPG.

6-14

Operation & Maintenance Manual for ECPG

Fault Code

Reason Engine Intake Air Temperature has exceeded the warning threshold for high intake air temperature.

155

Cause

Intake Air Temperature Sensor defective.

OK

LTA Pump failure

Effect (Only when fault code is active) Warning High intake air temperature warning relay driver is energized. No effect on engine performance.

Correction Check the nominal resistance with DMM (Digital multimeter) of Intake Air temperature sensor by referring sensor specification. If it is not as per specification, replace the sensor.

Check for LTA pump working. If not, replace the pump. Also check LTA raw water pump operation.

OK

Incorrect engine installation or mechanical problem

OK

ECPG Malfunctioning

Check : - CAC plumbing. - Engine compartment temperature - Lack of insulation on exhaust manifold or turbocharger.

Replace the ECPG.

Operation & Maintenance Manual for ECPG

Fault Code

Reason Engine speed signal indicates that engine speed greater than overspeed threshold.

234

Cause Incorrect calibration

OK

Fuel Actuator stuck in open position

6-15

Effect (Only when fault code is active) Shutdown Engine will shutdown. Overspeed shutdown relay driver is energized. Correction Use proper calibration and check engine overspeed limit is set sufficiently higher than the rated engine speed.

Clean or replace the fuel actuator.

OK

Fuel actuator getting +24V battery supply continuously

OK

Check other engine related factors referring to engine T & R Manual

If +24 V supply is present on actuator, 1) check the engine harness for actuator connection shorting to supply voltage. If short, repair the wires that have short circuits or replace the engine harness. 2) If supply voltage is still present on actuator, replace the ECPG.

Refer T & R Manual.

6-16

Operation & Maintenance Manual for ECPG

Fault Code

Reason Engine coolant level has dropped below the shutdown threshold for low coolant level.

235

Cause Coolant is low

Effect (Only when fault code is active) Shutdown Engine will shutdown. Correction Check the coolant level. Add coolant, if necessary.

OK

Coolant level sensor faulty

OK

Engine harness defective

Inspect the coolant level sensor for damaged, corroded, bent, broken, expanded or pushed back pins. If sensor pins are found damaged, replace the sensor. Also inspect the sensor for dirt, debris, moisture in or on the sensor pins. If observed, flush the dirt, debris, moisture from the sensor pins.

Check Pin ‘R’ of engine harness shorted to + 24 V battery supply. If short is observed, repair the wires or replace the engine harness.

OK

ECPG malfunctioning

Replace the ECPG.

Operation & Maintenance Manual for ECPG

Fault Code 359

Reason Engine cranked but failed to start

6-17

Effect (Only when fault code is active) Warning No effect on engine performance.

Cause Fuel in the tank is low

Correction Add fuel.

OK

Fuel filter choked

Clean or replace the fuel filters.

OK

Fuel inlet restriction excessive

Inspect the fuel line and remove the obstructions and clean the line.

OK Check air in the fuel. Tighten the fuel line connections. Tighten filter. Check tank stand pipe

Air in fuel

OK

Fuel shut off valve not getting the + 24 V battery supply

OK

Fuel Shut Off Valve not operating

Check the engine harness for FSO valve connection open or short, if faulty, repair the wires that have short circuits / open circuits or replace the engine harness. If voltage is still not preset, replace the ECPG. Check the resistance of FSO Valve. If resistance as per specification, check for mechanical operation. If not, replace the FSO Valve.

OK

Actuator not getting supply

OK

Actuator coil open / short or sticky

Check the engine harness for actuator connection, short or open, if faulty, repair the wires that have short circuits / open circuits or replace the engine harness. If voltage is still not preset, replace the ECPG. Check the fuel actuator coil resistance. If as per specification, check actuator for stickiness. If sticky, clean / replace the actuator. If coil resistance not as per specification, replace the actuator.

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Operation & Maintenance Manual for ECPG

Fault Code

Reason

415

Engine Lube Oil Pressure has dropped below the shutdown threshold for low oil pressure

Cause

Incorrect Oil level

Effect (Only when fault code is active) Shutdown Engine will shutdown.

Correction Check the dipstick calibration. Check the oil level. Add oil if necessary.

OK

Lube Oil pressure sensor not at correct location

Check location. Refer to engine specification. Relocate sensor, and check operation.

OK

Lube Oil diluted in the engine with fuel or coolant

Check for fuel or coolant contamination in the engine oil. If contaminated remove the cause. Drain the oil. Fill the fresh oil.

OK

Full flow Lube Oil filter plugged

Replace oil filter.

OK

Oil suction tube broken or tube seals leaking.

Remove oil sump. Inspect/replace suction tube.

OK

Malfunction Oil pressure regulator in Oil Filter head.

Remove oil sump. Inspect/replace suction tube.

OK

Lubricating Oil pump malfunction

Inspect lubricating oil pump. Replace or repair the pump if possible.

Operation & Maintenance Manual for ECPG

Fault Code

Reason

415 Contd.

Engine Lube Oil Pressure has dropped below the shutdown threshold for low oil pressure Cause

Lube oil pressure sensor defective

6-19

Effect (Only when fault code is active) Shutdown Engine will shutdown. Correction Check the lube oil pressure sensor as per sensor specification. If it is not as per specification, replace the sensor.

OK

Sensor getting + 5 V supply

Check the sensor supply voltage between pin ‘G’ and pin ‘J’ of engine harness. If not, check the engine harness.

OK

Engine harness defective

OK

ECPG Malfunctioning

Check the continuity between connector ‘A’ and engine harness (pin ‘G’, pin ‘H’ or pin ‘J’). If no continuity is observed, repair the wires that have short circuits or replace the engine harness.

Replace the ECPG.

6-20

Operation & Maintenance Manual for ECPG

Fault Code 441

Reason Low voltage has been detected during engine crank

Cause Battery charge low

Effect (Only when fault code is active) Warning 1) Engine may not crank. 2) Possible loss of ECPG functionality. Correction Check electrolyte level and specific gravity of battery cells. If low, charge or replace the battery.

OK

Battery rating too low

Replace battery with correct rating.

OK

ECPG Malfunctioning

Replace the ECPG.

Operation & Maintenance Manual for ECPG

Fault Code 1411

Reason Speed Bias Analog Input signal is shorted high.

Cause

The Speed Bias Analog Input Signal shorted to high

OK

Source of signal delivering Speed Bias voltage from O.E.M. equipment stuck to high.

6-21

Effect (Only when fault code is active) Warning The Speed Bias Analog Input Signal feature will be disabled. Possible loss of engine performance. Correction Check the O.E.M. harness for short circuit the signal wire to + 5 V or + 24 V battery supply. If short is observed, repair the wires that have short circuits or replace the O.E.M. harness.

Isolate the ECPG. Check and rectify the source of signal from O.E.M. equipment. If problem still persists, replace the O.E.M. source of signal equipment.

OK

ECPG malfunctioning

Replace the ECPG.

6-22

Operation & Maintenance Manual for ECPG

Fault Code 1416

Reason Engine fail to shutdown

Cause Fuel Shut Off valve permanently ‘ON’ after turning the key switch from ‘Run’ position to ‘Off’ position.

OK

Fuel Shut Off valve is in manual override mode

Effect (Only when fault code is active) Warning Engine failed to stop even after a stop command was issued by the system. No engine protection feature. Correction Check engine harness for FSO valve wire short to + 24 V battery supply. If short is observed, repair the wires or replace the engine harness. If problem still persists, replace the ECPG.

Check and be sure that the manual override screw on fuel shutoff valve is out to maximum travel.

OK

Fuel Shut Off valve malfunctioning

OK

Engine fuel drain line restricted

Check that the Fuel Shut Off valve is turned ‘off’ when 24 Volts from ECPG is removed by turning the key switch from ‘Run’ position to ‘Off’ position.

Check restriction. Replace or reroute engine fuel drain line.

OK

Engine injector(s) malfunctioning or injector(s) O-ring(s) damaged.

Please refer T & R manual of the engine for mechanical and fuel systems repair problems.

Operation & Maintenance Manual for ECPG

Fault Code 1438

Reason Engine fail to crank

Cause MPU not operative (fault occurs even if engine cranks)

6-23

Effect (Only when fault code is active) Warning No effect on engine performance.

Correction Refer to ‘Speed Signal Lost’ fault diagnosis. See fault code 3115.

OK

Battery connections are broken, loose or corroded

Clean and tighten the Battery connections.

OK

Battery charge low

Check electrolyte level and specific gravity of battery cells. If low, charge or replace the battery.

OK

Battery rating too low

Replace battery with correct rating.

OK

Engine starting circuit component Malfunctioning. OK

Check whether engine drive unit engages OK

Engine starting Motor pinion or ring gear on pinion damage

Check if +24 V battery supply appears at starter magnetic switch during start. If +24V battery supply does not appear, check for engine harness continuity. Check for continuity : Check the continuity between Pin ‘E’ of Connector ‘A’ and starter magnetic switch connections. If no continuity is observed, repairs the wires or replace the engine harness. If continuity is observed, and problem still persists, replace the ECPG. Check if the starter solenoid gets supply voltage. If not, change the starter magnetic switch. If problem still persists, check if the starter solenoid is working properly. Remove engine starting motor and check for damage

OK

Hydraulic Lock in engine cylinder

Check intake or exhaust valve operation.

6-24

Operation & Maintenance Manual for ECPG

Fault Code

Reason Speed Bias Analog Input signal is shorted low.

3111

Cause

The Speed Bias Analog Input Signal shorted to ground

Effect (Only when fault code is active) Warning The Speed Bias Analog Input signal feature will be disabled. Possible loss of engine performance. Correction Check the O.E.M. harness for short circuit the signal wire to ground. If short is observed, repair the wires that have short circuits or replace the O.E.M. harness.

OK

Source of signal delivering Speed Bias voltage from O.E.M. equipment stuck to low.

Isolate the ECPG. Check and rectify the source of signal from O.E.M. equipment. If problem still persists, replace the O.E.M. source of signal equipment.

OK

ECPG malfunctioning

Replace the ECPG.

Operation & Maintenance Manual for ECPG

Fault Code 3112

Reason Speed Raise switch is shorted High

6-25

Effect (Only when fault code is active) Warning The Speed Raise Switch feature will be disabled. Possible loss of engine performance.

Cause

Correction

The Speed Raise Switch on the A.M.F. or Customer panel shorted to high.

Check the speed raise switch on the A.M.F. or customer panel for short. If short is observed, repair or replace the switch.

OK

OEM harness defective

OK

ECPG malfunctioning

Check the O.E.M. harness for speed raise input short to +24 V battery supply. If short circuit is observed, repair the wires that have short circuits or replace the O.E.M. harness.

Replace the ECPG.

6-26

Operation & Maintenance Manual for ECPG

Fault Code 3113

Reason Speed Lower switch is shorted high

Effect (Only when fault code is active) Warning The Speed Lower Switch feature will be disabled. Possible loss of engine performance.

Cause

Correction

The Speed Lower Switch on the A.M.F. or customer panel shorted to high.

Check the speed lower switch on the A.M.F. or customer panel for short. If short is observed, repair or replace the speed lower switch.

OK

O.E.M. harness defective

Check the O.E.M. harness for speed lower input short to + 24 V battery supply. If short circuit is observed in the O.E.M. harness, repair the wires that have short circuits or replace the harness.

OK

ECPG malfunctioning

Replace the ECPG.

Operation & Maintenance Manual for ECPG

Fault Code

Reason Speed signal was lost while engine running.

3115

Cause Loose MPU connection

6-27

Effect (Only when fault code is active) Shutdown Engine will shutdown. Correction Check whether MPU connector is properly secured to the engine harness.

OK

MPU coil resistance as per sensor specification

OK

MPU tip damaged

Check the resistance of the MPU coil. Refer sensors specifications, if not within specification, replace the MPU.

Check the tip of the MPU for damage. If the tip is damaged, replace the MPU.

OK

Gap between MPU tip and engine flywheel ring gear teeth more than the engine specification

Check the gap between MPU tip and engine flywheel ring gear teeth. If gap is more, adjust the gap as per engine specification.

OK

Engine harness defective

Check the continuity between Connector A (Pin ‘B’ and Pin ‘T‘) and MPU connector. If no continuity is observed repair the wires or replace the engine harness. If continuity is observed and the problem still persists, replace the ECPG.

6-28

Operation & Maintenance Manual for ECPG

Fault Code 3116

Reason Fuel actuator PWM signal is close to maximum for long enough time due to possibly stuck actuator or insufficient fuel supply.

Cause

Fuel is not available

Effect (Only when fault code is active) Warning Possible loss of engine performance at higher loads. Correction Check the engine fuel supply and ensure that air lock has not occured.

OK

Fuel filter(s) choked

Check the fuel filter(s) and clean or replace it, if necessary.

OK

Fuel Actuator sticky

Remove the fuel actuator located on engine fuel pump and clean it with clean diesel (not compressed air) or replace it, if necessary.

OK

Fuel actuator not getting supply

Check the engine harness for short circuits or open circuits. For short circuits : If short or open circuits observed between Connector A and actuator connector, repair the wires that have short or open circuits or replace the engine harness. For open circuits : Check the continuity between Connector A (pin ‘F’ and pin ‘M’) and the fuel actuator connector. If no continuity is observed, repair the wires or replace the engine harness. If continuity is observed, and the problem still persists, replace the ECPG.

Operation & Maintenance Manual for ECPG

Fault Code 3118

Reason Powerdown hardware within ECPG malfunctioning

Cause Powerdown hardware within ECPG failed

6-29

Effect (Only when fault code is active) Warning 1) No effect on engine performance. 2) Potential battery drain. Correction Replace ECPG

6-30

Operation & Maintenance Manual for ECPG

NO TES NOTES _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________

Operation & Maintenance Manual for ECPG

7-1

SECTION 7 ECPG INSTALLATION Page Installation ............................................................................................................................................................ 7-2 Magnetic Pick up .......................................................................................................................................... 7-2 Actuator ....................................................................................................................................................... 7-3 Actuator Removal from the Housing ............................................................................................................. 7-5 Actuator Housing .......................................................................................................................................... 7-5 ECPG Controller ........................................................................................................................................... 7-6 Power Source ............................................................................................................................................... 7-7 Isolating Grounding ....................................................................................................................................... 7-7 Replacement of Parts ................................................................................................................................... 7-8 Removal of I/O Board ................................................................................................................................. 7-10 Removal of CPU Board .............................................................................................................................. 7-10

7-2

Operation & Maintenance Manual for ECPG

INSTALLATION

Note : Normally magnetic pickup, actuator housing, actuator, engine harness, ECP-G controller are mounted on the engine at the time of the shipment. However, the installation procedure for these parts is given below to aid retro fitting / replacement in field. a. Magnetic pick up A magnetic pickup is an electromagnetic device. It is mounted on the flywheel housing so that the ring gear teeth are sensed by the pickup. Two pin MS connector is provided to connect the magnetic pick up to the engine harness. The magnetic pickup is connected between pin ‘B’ and ‘T’ of engine connector through harness. Installation: 1. Remove the magnetic pickup from the engine harness if connected. Then screw the magnetic pickup downwards till it contacts a flywheel gear tooth. 2. Unscrew the pickup by 1/2 - 3/4 of a turn to maintain a proper gap between pickup and flywheel teeth. Sensing distance should be between 0.71 to 1.07mm (0.042 inch) from the flywheel gear tooth. Screw the pickup all the way down until it contacts the flywheel gear tooth. The pickup will screw in very easy, do not use excessive pressure to install the pickup. Note : If the pickup does not screw in with finger pressure, check the hole and the pickup threads. Tap the hole again, if required. Refer to the previous page for the chip removal procedure.

Back the pickup out 1/2 to 3/4 of a turn. If you can get a feeler gauge between the magnetic pickup and the flywheel gear tooth, back the pickup out 0.028 to 0.71 to 1.07mm (0.042 inch) from the flywheel gear tooth.

Operation & Maintenance Manual for ECPG

7-3

Tighten the locknut down on the flywheel housing. Plug the electrical connection into the pickup, when required. Install the main generator, if it was removed.

When the flywheel gear teeth pass the pickup, an A.C. voltage is induced. One cycle is induced for each gear tooth.

If the pickup signal is less than 2.5 volts A.C. when cranking the engine, screw the pickup in 1/8 to 1/4 turn.

b. Actuator Two “O” rings are used for mounting the actuator in the housing. 1) Part number : 3865398 Seal “O” Ring 2) Part number : 3042542 Seal “O” Ring

1

2

7-4

Operation & Maintenance Manual for ECPG

Two “O” rings and four Allen screws and washers are used to clamp the housing on the fuel pump. The actuator cable is used to connect actuator terminals to a connector in the engine harness at connector ‘A’ at pin ‘F’ & pin ‘M’.

Caution Actuator is a delicate part and should be handled with care, while removing, cleaning or putting back in the housing.

Installation Lubricate the two-barrel “O” rings with clean engine oil. Insert the actuator in the housing and rotate it clockwise till it is inserted completely. Using a 1,1/4-inch spanner, tighten the actuator, (torque of 5.6 N•m).

Connect the connector to the actuator. The connector is “keyed”, so that it connects in one direction only.

Operation & Maintenance Manual for ECPG

7-5

c. Actuator removal from the housing Actuator may be needed to be removed from the housing for cleaning the fuel filter, replacing or for diagnostic purpose. Remove the actuator connector. Using the 1,1/4" spanner, remove the actuator from the housing. Note : Always shut off the supply to the ECPG by turning the key switch to “Off”, before servicing the actuator.

Cleaning the fuel Screen There is a 10-micron fuel screen in the inlet side of the actuator; the filter screen should be periodically cleaned. Pull the two smallest fuel filter windows outwards. Hold the actuator in both the hands, with the connector pointed outwards. Pull the two fuel filter windows which are smallest outwards, the fuel filter screen opens. Clean the filter screen with shop air at pressure ~1Kg/cm2 (0.980 bar). Snap the filter back into place by pushing the filter windows together.

d. Actuator Housing The actuator housing is mounted on the fuel pump as per following procedure:

Retrofitting preparation: a) Remove the copper tube/rubber hose connecting the fuel shutoff valve to the injectors from the fuel shutdown valve side. b) Remove the shutdown valve with the “O” ring. c) Remove the fuel pump return line along with the elbow, if used. d) Remove the tacho drive, if it is on the top of the pump. e) Plug it with an aluminum plug. f)

Clean the top of the fuel pump. The fuel pump is ready for mounting the actuator housing.

Note: In case of retrofitting, the fuel pump needs recalibration along with the actuator housing, using proper code for calibration.

Fuel Pump

7-6

Operation & Maintenance Manual for ECPG

1.

Place the actuator housing with two “O” rings, these “O” rings act as a face seal in fuel outlet and fuel return path respectively.

2.

Clamp the housing on the fuel pump using four Allen screws. Torque of 5.6 N•m (50.4 in-lb) should be given.

3. Mount fuel shutoff valve on the actuator housing as per standard procedure. 4.

Connect the fuel pump return line on the actuator housing.

5.

Connect the copper tubing going to injectors from the fuel shut off valve.

e. ECPG Controller

&&&&

Normally all ECP-G controllers are engine mounted on a bracket with the help of four vibration isolators. If it is not so, then a suitable provision for mounting the controller needs to the provided by the user. It can be fixed on a bracket or on a separate stand near the alternator. The controller should be mounted such that the front and rear sides are accessible and convenient for any kind of adjustment and connections. The mounting place should be such that, the cable routing length is not more than the length of the extension cable provided. The mounting location should be such that the controller is not directly exposed to Sun, heat, humidity, water, while in operation. Four mounting holes are provided on the ECPG to connect it on vibration isolators. Warning To avoid personal injury, or death, it is important that all electrical equipment be properly bonded or grounded. All metallic parts that could become energized under abnormal conditions must also be properly bonded or grounded.

Operation & Maintenance Manual for ECPG

f.

Power Sour ce Source

The ECP-G is designed to operate between 20 and 30 volts D.C.

Caution a) Do not connect the ECPG to a batter yc har ger battery char harg er.. Due to the circuitry and method of operation of the chargers, the controller will not function pr operl y. Connect the batter y c har ger to the properl operly battery char harg batter y . battery b) To disconnect the +24VDC supply to ECPG, do not remove the 19 pin connector (Connector A) of the harness. Disconnect the battery cables from the battery terminals. Caution To a void dama ge to the ECPG, connect all electrical av damag connections to the ECPG and remove the ECPG from the generator set prior to using any type of welding equipment that requires electrical power to operate. Caution To pre vent loss of v aluab le inf ormations suc h as fault prevent valuab aluable informations such codes, power must be available to the ECPG at all times during normal engine operation. g.

Isolated Grounding

When using a grounding method other than negative ground system, where electrical system ground is not connected to battery (-ve), take into consideration the following : 1) The load sharing / paralleling equipment interfacing to the ECPG should have the same grounding method and is isolated electrically. 2) Starter wiring harness, battery charging alternator and other components like free wheeling diode must be designed to operate properly when connected using the grounding method being implemented.

7-7

7-8

Operation & Maintenance Manual for ECPG

h. Replacement of Parts ed Cummins (T o be perf ormed b y authoriz (To performed by authorized personnel only) This section describe the procedure for removal and installation of circuit boards and parts that are contained in the ECPG. Turn off or remove AC power from the battery charger and then remove the negative (-) battery cable from the set starting battery. This is to make sure that the set will not start while working on it and to avoid circuit board damage caused by voltage spikes when removing and replacing circuit board connectors. CAUTION Always disconnect the battery charger from its AC source before disconnecting the battery cables. Otherwise, disconnecting the cables can result in voltage spikes high enough to damage the DC control circuits of the set. 1) Turn the key switch to off position.

OFF

2) Remove the two mating connectors in the harness from Connector “A” and Connector “B”.

CA UTION CAUTION

ENGINE HARNESS

OEM HARNESS

No user serviceable parts inside ECPG. Do not attempt to ope the ECPG enclosure while battery and ECPG harness is connected to ECPG. P otential risk Potential of electrical shock. 3) Remove the six Phillips head screws (M5 x 50 mm) on the back of the plastic enclosure.

Operation & Maintenance Manual for ECPG

7-9

4) Gently pull out the rear plastic enclosure half. This gives access to the two boards and the flat ribbon cable.

5) The plastic enclosure houses the two printed circuit boards, (1) CPU Board, (2) Input/Output (I/O) Board.

I/O board

26 pin FRC cable

CPU board

6) Remove the 26 pin FRC cable from the I/O and CPU board by pulling out the locking wedges and gently pulling out the flat ribbon cable. Take care not to bend the pins.

7) Remove the 14 pin FRC cable from the I/O and CPU board by pulling out the locking wedges and gently pulling out the flat ribbon cable. Take care not to bend the pins.

26 pin FRC cable

7-10

Operation & Maintenance Manual for ECPG

i.

Removal of the I/O board a) Remove the two M8 x 1.5 hex screws connecting the I/O board heat sink.

b) Remove the four M4 x 0.5 screws on the three MS connectors.

c) Remove the three nuts on the three position key switch.

j.

Removal of CPU Board The CPU Board is attached to the front plastic enclosure with the help of four M3 x 0.5 screws. a) Remove the four M3 x 0.5 screws using a screw driver. b) Pull out the CPU Board from the plastic enclosure.

Operation & Maintenance Manual for ECPG

8-1

SECTION 8 APPENDIX Page Appendix-A - Operating, Electrical & Environmental Specifications ....................................................................... 8-2 Appendix-B - Glossary of Power Terms ................................................................................................................. 8-3 Appendix-C - Electrical Wiring Diagram ................................................................................................................. 8-9 Wiring diagram for Engines with Single Starter ............................................................................................. 8-9 Wiring diagram for Engines with Two Starter ............................................................................................... 8-10 Appendix-D - ECPG Sensor Specifications ......................................................................................................... 8-11 Appendix-E - List of Replacement Parts .............................................................................................................. 8-12 Customer Literature Comments ........................................................................................................................... 8-13

8-2

Operation & Maintenance Manual for ECPG

Appendix - A OPERATING, ELECTRICAL & ENVIRONMENTAL SPECIFICATIONS Operation Governor Mode .................................................................................. Isochronous to 6% Droop Governor Gain Adjust ........................................................................ 0.9 to 1.1 Frequency Adjust Range .................................................................... ±4Hz Power Nominal Operating Voltage ................................................................ +24VDC Operating Voltage Range ................................................................... +20 to +32VDC Maximum Continuous Voltage ........................................................... +32VDC Ground Polarity ................................................................................. Negative Ground Nominal Operating Current ................................................................. 1.5A @ +24VDC Maximum Operating Current .............................................................. 4.5A @ +18VDC Sleep Mode Operating Current ........................................................... 100mA (nominal) Ready Mode Operating Current .......................................................... 850mA (nominal) [ECPG On & Engine Not Running] Environmental Ambient ECPG Housing Operating Temp. ......................................... 0° to 70°C (0° to158°F) Storage Temperature ......................................................................... 0° to 70°C (0° to158°F) Vibration Limits ................................................................................. 20-100Hz, 93.6mm/sec: Physical Dimensions (Including Heat Sink; ...................................................... 314 mm (L) x 264 mm (H) x 118.3 mm (D) excluding mounting brackets) ............................................................ (12.34 x 10.37 x 4/64”) Weight ............................................................................................... 2.53 kg (5.596 lbs.) Housing Enclosure ............................................................................ Glass Filled Plastic Heat Sink Metal ................................................................................. Aluminum Protection Reverse Polarity Protection ............................................................... +28VDC Maximum Electrical Interface Characteristics Lamp/Relay Driver Supply Supply Voltage .................................................................................. +12VDC Nominal @ 80 mA Lamp/Relay Drivers Driver Type. ....................................................................................... Low-Side (switched GND/Open) Driver Voltage Rating ......................................................................... +24VDC Nominal Maximum Sink Current (Driver On) .................................................... 80mA Analog (Adjustable) Inputs Nominal Input Voltage Adjustment Range .......................................... 0-5VDC Maximum Input Voltage ..................................................................... 5VDC Speed (Frequency) Bias Reference & Voltage Supply 0-5 VDC Reference Voltage ............................................................... +5VDC

Operation & Maintenance Manual for ECPG

8-3

Appendix - B GLOSSARY OF POWER TERMS A.C. - See Alternating Current. Alternating Current - Electrical current which repeatedly varies from zero to a positive maximum value to zero to a negative maximum value and back to zero at a periodic rate. Since the applied voltage continually reverses polarity, the resultant current flow alternates in direction within the circuit.

Capacitance - The property of a device which resists changes in voltage. In an A.C. circuit, a capacitive load will cause the voltage to lag behind the current flow. Stated more conventionally, the current leads the applied voltage. A capacitive load is, therefore, a leading power factor load (see Power Factor).

Alternating Current Leading Applied Voltage Caused by Capacitive Load Alternating Current = I Applied Voltage = V AMP — An abbreviation for the term Ampere. Ampere - The unit of measure of electrical current flow. One ampere of current will flow when one volt of electrical potential is applied across one ohm of resistance. Auto-Transformer — A transformer of single coil construction in which both the primary and secondary connections are made on the same coil but use different taps. Bi-State - Refers to the type of electrical device, or the signal supplied by such a device, that has two discrete and mutually exclusive states. For example, a twoposition toggle switch is a bi-state switching device that is either ‘open’ or ‘closed’. B- — Symbol used to designate the negative polarity of a D.C. voltage supply. B+ — Symbol used to designate the positive polarity of a D C voltage supply.

Capacitor ~ A device possessing the property of capacitance. A typical capacitor consists of two conducting surfaces separated by an insulating material. A capacitor stores electrical energy, blocks the flow of D.C. and permits the flow of A.C. to a degree largely dependent on the capacitance and the frequency of the applied A.C. Circuit - An electrical path through which an electric current may flow from a voltage supply to a load and return. A closed or complete circuit is one where current is flowing. An open circuit is where the path has been disrupted, such as an open switch or circuit breaker, thus stopping current flow. Circuit Breaker - A protective device for opening a circuit where current flow exceeds a predetermined value. Circulating Current - Also called Cross Current. Current which flows between paralleled generators, most apparent with no external load on the paralleled generators. Circulating current is caused (1) by unequal excitation of the generators (reactive current, which may be reduced by changing the voltage regulator adjustment or connections); and (2) by unequal power from the engines that are driving the generators real current (and power) which can be eliminated by governor adjustments. Conductor - A wire cable, bus, or other device intended to distribute current from the supply to the load. Technically, a conductor is any device which will permit the flow of current.

8-4

Operation & Maintenance Manual for ECPG

Contactor - A device for opening and closing an electric circuit. Contactors are normally used in motor circuits where large amounts of current are controlled. Cross Current - See Circulating Current. Cross Current Compensation - A term, no longer approved, for a circuit arrangement that made paralleled generators share the reactive component of load current in proportion to the generator ratings. The circuit arrangement could also essentially eliminate the reactive component of circulating current flowing between paralleled generators See Reactive Differential (Cross Current) Compensation and Reactive Droop Compensation). Current (Electrical, Symbol I) - The rate of transfer of electricity from one point to another. Current is usually a movement of electrons, but may also be a movement of positive ions, negative ions, or holes. Current is usually measured in amperes. Cycle 00 - A complete set of events before repetition occurs. In alternating current or voltage, a cycle starts at zero, continues to a maximum positive value returns to zero, continues to a maximum negative value, and is completed at zero.

Diode - A two terminal solid-state device which permits current to flow in one direction, but not in the other. In alternating current circuits, a diode will permit one half cycle to flow but will resist the flow of the opposite half cycle of current. Thus, alternating current is converted to direct current by a diode.

Direct Current (D.C.) - An electric current that flows in one direction only. Conventional direct current is defined as flowing from positive to negative in the circuit outside the source (example: a battery or combination of diodes). Conventional current flows in the direction of the arrow through a diode.

Direct Current I Applied Voltage V Distribution Panel — A control panel containing circuit breakers, transfer switches, and other control devices which distribute the electrical power, such as from a generator set to the loads. Double Pole Switch - A switch which has two sets of contacts which operate on two independent circuits at the same time.

Typical Alternating Current or Voltage Cycle D.C. - See Direct Current. Typical Double Pole Switch Shown as a Single Throw Type in the “Off” Position

Operation & Maintenance Manual for ECPG

E - Symbol used to represent electrical potential (voltage). Earth Ground - An intentional connection made between the earth and the metallic frame of electrical equipment as a means to eliminate possible voltage hazards to personnel. Earth Ground also serves, in some cases, to reduce electrical interference in sensitive circuits such as television and radio equipment. EMI - An abbreviation for the term electromagnetic interference which is sometimes caused by SCR type devices and evident in radio and television operation. Energy - The capability of performing work. Frequency - The number of complete cycles of alternation current per unit of time. Typically, frequency is expressed in cycles per second or Hertz (Hz). Frequency Droop - A decrease in steady state frequency output of a generator caused by an increase in load. This decrease in frequency from the no load frequency is expressed as a percentage of the full load frequency or:

(FNL - FFL) X 100 %F Droop = ———————— FFL Where: % F Droop = Percent Frequency Droop FNL = No Load Frequency FFL = Full Load Frequency Frequency droop may be used to provide governor stability and for load sharing between paralleled generator sets. Frequency Meter - An instrument designed to measure the frequency of an alternating current system. Gain - The increase in signal power that is produced by an amplifier, usually given as the ratio of output to input voltage, current, or power. In generator set systems, a low gain setting on the electric governor or voltage regulator provides a relatively small signal to correct variations of frequency or voltage. The frequency and/or voltage may wander or be slow in recovering to stable conditions after a load change. A high gain setting provides a relatively large signal to correct variations of frequency and/or voltage. If the gain is set too high, the electric governor or voltage regulator may over-correct.

8-5

This may produce unacceptable hunting of the frequency and/or voltage. Gate - The third terminal of an SCR to which a voltage must be applied before the SCR will conduct. Governor - A device which controls engine speed and thus the generator output frequency. Ground - A connection, either accidental or intentional, between an electrical potential and the earth or some conducting body serving in place of the earth. Heat Sink - A device which absorbs heat from electrical devices such as diodes and SCR’s and dissipates the heat to the surrounding air. Hertz - A term equivalent to cycles per second (See Frequency). Hunting - Oscillation in frequency or in voltage where steady state conditions are not reached, particularly after a load transient change. I - Symbol used to represent current. Impedance - The opposition to the flow of alternating current. Induced Voltage - The voltage which is produced by relative motion between a wire and a magnetic field. Inductance - The property of a device which resists changes in current. In an A.C. circuit, an inductive load will cause the current to lag behind the applied voltage. Stated more conventionally, the current lags the applied voltage. An inductive load is therefore a lagging power factor load (see Power Factor).

Alternating Current Lagging Applied Voltage Caused by Inductive Load

8-6

Inductor - A device possessing the property of inductance. An inductor stores electrical energy, passes D.C., and opposes the flow of A.C. to a degree largely dependent on the inductance and the frequency of the applied A.C. A typical inductor consists of a coil of wire. In Phase - Alternating currents or voltages are in phase with respect to each other if they cross through zero and reach their positive and negative maximum values together. Insulation - A non-conductive material such as rubber or plastic intended to prevent current from flowing. Technically, insulation is any material which stops the flow of current. Isochronous - As it applies to engine governors, maintaining constant steady state speed regardless of the load within the rating of the engine. Thus, a generator set is said to be isochronous if the frequency remains the same regardless of load. Normally Closed (Symbol N.C.) - As applied to a magnetically operated device such as a valve or the contacts of a relay, Normally Closed indicates that the valve or the relay contacts are closed when no power is supplied to the operating magnet. Normally Open (Symbol N.O.) - As applied to a magnetically operated device such as a valve or the contacts of a relay, Normally Open indicates that the valve or the relay contacts are open when no power is supplied to the operating magnet. Ohm - The unit of measure of electrical resistance. One ohm of resistance will allow a current of one ampere to flow with an applied potential of one volt. Ohmmeter - An instrument for measuring electrical resistance. Ohm’s Law - A fundamental law expressing the relationship between voltage, current, and resistance in electrical circuits. The law states that E = IR or voltage is equal to current times resistance. Open Circuit - 1) A circuit that does not provide a complete path for the flow of current. 2.) A condition of an electrical circuit caused by the breaking of continuity of one or more conductors of the circuit; often an

Operation & Maintenance Manual for ECPG

undesired condition. 3) An arrangement of conductors and equipment that depends upon lack of continuity for operation, as open-circuit telegraphy; a circuit in which continuity is incomplete or interrupted. Oscillogram - The permanent record produced by an oscillograph, or a photograph of the trace produced by an oscilloscope. Oscillograph - A measurement device for determining waveform by recording the instantaneous values of a quantity such as voltage as a function of time. Oscilloscope - An instrument primarily for making visible the instantaneous value of one or more rapidly varying electrical quantities as a function of time or of another electrical or mechanical quantity. Oscilloscope, Dual Beam - An oscilloscope in which the cathode-ray tube produces two separate electron beams that may be individually or jointly controlled. Parallel Connection - An electrical connection in which the input of one element is connected to the input of another element. The output connections are similarly connected together thus providing two or more paths for current to flow.

Parallel Connection Parallel Operation - The method by which two or more generators having the same voltage and frequency characteristics are connected to a common load. Permanent Magnet Generator - A generator which uses permanent magnets to create a magnetic field. As applied to Cummins Generators: a permanent magnet generator, within the main generator, supplies the power to the voltage regulator which in turn supplies the power to the exciter field. The permanent magnet generator still supplies power during a short circuit of the main generator. This permits the main generator to sustain high short circuit currents. The output of the permanent magnet generator is electrically isolated from the main generator output and is not adversely affected by main generator output waveform distortion such as from SCR type loads.

Operation & Maintenance Manual for ECPG

PMG - See Permanent Magnet Generator. Polarity - An electrical term which indicates the direction in which current flows in a conductor. In a direct current system, current flows in the same direction. In an alternating current system, current changes direction as the polarity of the A.C. voltage source changes. Potential - Another term to indicate voltage. Potential Difference - The difference in voltage between two points in a circuit. Power - Defined as the rate of performing work. Mechanical power is measured in horsepower or kilowatts. Electrical power is measured in Kilowatts. Power Factor - The ratio of the true power (KW) requirements of a load to the apparent power (KVA) requirements of a load. The combined loads applied to a power source may have a resistive, capacitive, or inductive effect. Resistive loads such as incandescent lighting or resistive heating elements cause no shift in the voltage/current wave forms and are, therefore, unity (1.0) power factor loads. Inductive and capacitive loads, however, cause the voltage and current waveforms to shift with respect to one another. These types of loads are commonly called power factor loads (i.e., the power factor is less than 1.0). See INDUCTANCE and CAPACITANCE for more information. Power factor is frequently multiplied by 100 and expressed as a percentage.

8-7

Resistor (Symbol R) - A device or component designed to have a definite amount of resistance. Resistors are used in circuits to limit current flow or to provide a voltage drop. Resistor, Fixed - A component which is used to control voltage and current by introducing a constant resistance of known value into the circuit. Resistor, Variable - Similar to a fixed resistor except the resistance value can be adjusted. The voltage adjust rheostat is a variable resistor. Rheostat - A variable resistor. Series Connection - An electrical connection in which the input of one element is connected to the output of another element providing only one path for current to flow.

Series Connection Short Circuit - An abnormal connection (including an arc of relatively low resistance, whether made accidentally, or intentionally, between two points of different potential in a circuit. Equipment, not protected by fuse or circuit breakers, may be damaged by a short circuit. Single Pole Switch - A switch which has only one set of contacts.

The formula for power factor is: True Power (KW) Power Factor = —————————— Apparent power (KVA) R - Symbol used to represent resistance. Relay - An electromechanical device having a magnetic coil which, when energized, opens or closes several sets of contacts. Resistance - Opposition to the flow of current.

Typical Single Pole Switch Shown as a Single Throw Type in the “Off” Position Single Throw Switch - A switch which opens a set of contacts in one switch position and closes the contacts in the other position.

Typical Single Throw Switch Shown as a Single Pole Type in the “Off” Position

8-8

Operation & Maintenance Manual for ECPG

Speed Droop - A decrease in steady state speed of an engine due to an increase in applied load. This decrease in speed from the no load speed is expressed as a percentage of full load speed or:

(SNL - SFL) X 100 %S Droop = ————————— SFL Where : %SDroop = Percent Speed Droop SFL = Full Load Speed SNL = No Load Speed Solenoid - An electromechanical device which when energized, acts on a movable core or plunger in the center of the energizing coil to perform mechanical work. Solid-State - A term which applies to electronic devices which are constructed using semiconductor material. Such devices include transistors, SCR’s, and diodes. Stability - Freedom from undesired variations or oscillation. In generator set systems, the generator set is stable if it can maintain or quickly re-establish steady state conditions of voltage and frequency after a sudden load change. Tachometer - An instrument for measuring the rate of rotation expressed in revolutions per minute. Temperature Drift - A change in the value of a component caused by changes in operating temperature. Terminal - A mechanical device for making electrical connections. Thyristor (SCR) - A Silicon-Controlled Rectifier is a structure with an external connection (gate) to one of the inter layer. With no gate current, the SCR characteristic is that of a four-level diode. Transformer - A device using a laminated iron core with a primary and secondary winding. A transformer changes some level of input (primary) voltage or current to a proportional output (secondary) voltage or current (see Current Transformer and Potential Transformer). Transient - A temporary change from the steady state conditions. V - Symbol used to represent voltage. Volt - The unit of measure of electrical potential (voltage).

One Volt of electrical potential will force a current of one Ampere to flow through a resistance of one Ohm. Voltage - Electrical potential or pressure which forces current to flow through a circuit. Voltage Dip - A temporary reduction in voltage generally resulting from an increase in load. Voltage Droop - A decrease in steady state voltage of a generator due to an increase in load applied. This decrease in voltage from the no load voltage is expressed as a percentage of the full load voltage or

(VNL- VFL) X 100 %VDroop = ———————— VFL Where: % VDroop = Percent Voltage Droop VNL = No Load Voltage VFL = Full Load Voltage Voltmeter - An instrument designed to measure electrical potential or voltage.

LCL

+ Ve

26

33E

R

W

V

+ Ve

25

M

F

STARTER 45

26

EARTH WIRE

A

BATTERY 24 V.D.C.

- Ve + Ve

36

39E

25

LOW COOLANT LEVEL SENSOR

35 +Ve

ALTERNATOR

- Ve

36 -Ve

*

GND

OUTPUT

+5V

ECPG ACTUATOR

SHUT DOWN COIL

D

- Ve

45

17

38 35

L

39E 38

17 E

MAGNETIC SWITCH

39E

DATALINK START

INTAKE AIR TEMP. SENSOR

MAG. PICK-UP

COOLANT TEMP. SENSOR

A1;

-Ve

V

U

T

S

R

P

N

M

L

K

J

H

G

F

E

D

B

A

CIRCUIT NO.

B,T

SHIELDED 1 SQ. MM CABLE

P.V.C. 95 SQ. MM

1 SQ. MM 200

11 26,45

G,H,J,N,P,S,U,R

1.5 SQ. MM 4.5 SQ. MM 30

14

AMP. CAPACITY WIRE GAUGE

25,33E,38,17

G,E,V,A,L,F,M 39E,D

V

U

T

S

R

P

N

M

L

K

J

H

G

F

E

D

C

B

A

19 PIN CONNECTOR

WIRING DIAGRAM FOR ENGINES WITH SINGLE STARTER

S0.C7A5L0E

WIRING DIAGRAM FOR ENGINES WITH SINGLE STARTER

1. 24 VOLT NEGATIVE GROUND SYSTEM

2. TURN THE STARTING KEY SWITCH TO START POSITION TO CRANK THE ENGINE.

Operation & Maintenance Manual for ECPG 8-9

APPENDIX - C

ELECTRICAL WIRING DIAGRAMS

8-10

WIRING DIAGRAM FOR ENGINES WITH TWO STARTERS WIRING DIAGRAM FOR ENGINES WITH TWO STARTERS D

SHUT DOWN COIL 19 PIN CONNECTOR

F

-Ve

A B

D

ECPG ACTUATOR

F

G H J K L M

35 +Ve R

N

36 -Ve

P LOW COOLANT LEVEL SENSOR

33E

E

F

OUTPUT

DATALINK START

+ Ve

R A1;

S

AIR INTAKE TEMP. SENSOR

T U

25

W

V V

D

E

+5V

GND

- Ve

B C

M

*

A

G H J K L M N P

S0C.A7L5E0

R S T U V

COOLANT TEMP. SENSOR

CIRCUIT NO. 26

A 36

25

38 35

45 17

STARTER

17

39E

EARTH WIRE 45 - Ve - Ve + Ve

26

L

17

17 STARTER 45 39E

26 + Ve

38

E 38

38

MAGNETIC SWITCH

BATTERY 24 V.D.C.

AMP. CAPACITY WIRE GAUGE

G,E,V,A,L,F,M 39E,D

14

1.5 SQ. MM

25,33E,38,17

30

4.5 SQ. MM

1. 24 VOLT NEGATIVE GROUND SYSTEM

G,H,J,N,P,S,U,R

11

26,45

200

EARTH WIRE B,T

2. TURN THE STARTING KEY SWITCH TO START POSITION TO CRANK THE ENGINE.

1 SQ. MM P.V.C. 95 SQ. MM

SHIELDED 1 SQ. MM CABLE

Operation & Maintenance Manual for ECPG

ALTERNATOR

Operation & Maintenance Manual for ECPG

8-11

APPENDIX - D DATALINK

ECPG CONNECT OR CONNECTOR

•

•

RS-485 Serial Communication Standard

Retaining capscrew torque=1 N•m [9 in-lb]

SHORT CIRCUIT TO EXTERNAL VOLTAGE ALL CONTINUITY CHECKS •

OK if < 1.5 VDC

• OK (no open circuit) if < 10 Ω ALL SHORTS TO GROUND ESS circuits

ECPG POWER SUPPLY

•

• 20 to 32 VDC

OK (no short circuit) if > 10MΩ

All other circuits • OK (no short circuit) if > 100kΩ

ECPG SENSOR SPECIFICA TIONS SPECIFICATIONS OIL PRESSURE SENSOR Torque = 14 N•m [124 in-lb]

ALL TEMPERA TURE SENSORS TEMPERATURE Torque = 15 N•m [133 in-lb]

Pressure (kPa)

Pressure [psia]

Voltage (VDC)

Temperature (oC)

Temperature (oF)

Resistance (Ω)

0 207 414 621 827

0 30 60 90 120

0.5 1.5 2.5 3.5 4.5

0 25 50 75 100

32 77 122 167 212

30k to 36k 9k to 11k 3k to 4k 1350 to 1500 600 to 675

ENGINE SPEED SENSOR Torque = 34 to 47 N•m [25 to 35 ft-lb] Coil Resistance = 750 to 1600 Ω

8-12

Operation & Maintenance Manual for ECPG

APPENDIX - E LIST OF REPLACEMENT PARTS Sr. No.

Part name

Part Number

ECP-G Assembly 1 2 3 4 5 6

ECP-G Assembly Key switch Parameter selection push button Toggle switch (for Idle/Rated mode selection) Vibration Isolator Mounting bracket

4083935 504975 4071721 3875362 3229922 4084240

Sensors 1 2 3 4 5 6 7 8 9

Coolant temperature sensor Air Intake temperature sensor Lube oil pressure sensor Coolant level sensor Adapter for Coolant temperature sensor Adapter for Air intake temperature sensor Magnetic pick up Lube Oil Pressure sensor adaptor (V 28 engine) Lube Oil Pressure sensor adaptor (495, 743, 855 series engines)

3865346 3408345 3408560 4072714 4084218 4084219 3879986 4104562 3814448

Actuator and Actuator housing 1 2 3 4 5

Fuel Actuator with O ring Fuel actuator housing Fuel actuator filter screen Fuel actuator ‘O’ rings (1) Fuel actuator ‘O’ rings (2)

3330601 4071944 3867393 3865398 3642542

Harness

1 2 3 4 5 6 7 8 9

Engine harness KT/KTA 1150/KTA 19 G4/G3 engines NT 495 NTA 495 NT/NTA 743 NT/NTA 855 VT/VTA 28 Extension harness 10 meters Extension harness 5 meters OEM harness

4084232 4085697 4085698 4085700 4085692 4085693 4072993 4072992 4054744

Operation & Maintenance Manual for ECPG

8-13

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8-14

Operation & Maintenance Manual for ECPG

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