TM Cable Series Engine Control Module (ECM) Operation and Maintenance Manual Effective: October, 2003 ® TM
TM 744-862-C0-003 Rev.
TM Overview: The purpose of the AlphaGen ENGINE CONTROL MODULE(ECM) Operation and Maintenance Manual is to provide a high-level overview of the system and to detail the operation and maintenance of the module. Audience: This manual intended for the operator of the system. This Operation and Maintenance Manual is comprised of five sections: Section 1. Section 2. Section 3. Section 4. Section 5. 744-862-C0-003 Rev.C System Overview. This section describes the theory of operation of the ECM.
Engine Control Module (ECM) Table of Contents Section 1, System Overview 1.1 1.2 Introduction ............................................................................... Theory of Operation .................................................................... 1.2.1. Normal Operating Condition .................................................. 1.2.2. Standby Operating Condition (less than 3 minutes) .................. 1.2.3. Standby Operating Condition (more than 3 minutes) ................ 1.2.4.
Engine Control Module (ECM) List of Figures Section 1, System Overview Fig. 1-1 Fig. 1-2 Fig. 1-3 Fig.1-4 Front view, Engine Control Module (ECM) ................................... Run/Auto/Stop and Service/Reset switches ............................... Location of Engine Control Module (ECM) .................................. ECM Printed circuit boards ....................................................... 14 15 15 16 Section 2, ECM Indicators and Control Functions Fig.
Engine Control Module (ECM) IMPORTANT SAFETY INSTRUCTIONS CONTAINED IN THIS MANUAL CAUTION HAZARDOUS CONDITION To reduce the risk of electrical shock, injury or death caused by explosion of fuel or moving parts, and to ensure the safe operation of this unit, the following symbols have been placed throughout the manual. Where these symbols appear, servicing must be performed only by qualified personnel. DANGEROUS VOLTAGE This symbol indicates a “dangerous voltage” exists in this area of the product.
Engine Control Module (ECM) SAFETY PRECAUTIONS NOTE: Failure to follow these precautions could result in injury or death caused by the explosion of fuel, moving parts hazards or electrocution. CAUTION: This set of procedures will require the operation of the generator and should only be performed by qualified, experienced personnel in a well-ventilated area. • Technicians must have easy access to a fire extinguisher at all times. • Propane/Natural Gases are highly explosive.
Engine Control Module (ECM) SAFETY PRECAUTIONS • The Engine Control Module (ECM) must be serviced only by qualified personnel. • Remove all rings, watches and other jewelry before servicing batteries or installing the ECM. • Verify the voltage requirements of the equipment to be protected (load), the AC input voltage to the power supply (line), and the output voltage of the system prior to installation.
Engine Control Module (ECM) IMPORTANT INSTALLATION NOTES • The system must be installed ONLY by qualified service personnel. • Consult local utility codes for additional cabinet grounding and utility requirements. • ALPHA TECHNOLOGIES is not responsible for broken welds or other damage to the cabinet caused by improper installation. • All dimensions are given in inches. • For further information regarding this installation, contact ALPHA TECHNOLOGIES or your nearest ALPHA representative.
Engine Control Module (ECM) Auxiliary Power Unit (APU) Notes NOTE: When the engine is stopping, a small amount of unburned fuel may be detected by the odor of gas fumes. Fans are used to expel these fumes from the enclosure and may be detected outside the enclosure for a short period of time after engine shutdown. This is a normal condition and does not present a hazard.
Engine Control Module (ECM) Battery Safety Notes Chemical Hazards Any gelled or liquid emissions from a Valve-Regulated Lead-Acid (VRLA) battery is electrolyte which contains dilute sulfuric acid which is harmful to the skin and eyes; is electrically conductive; and is corrosive. If electrolyte contacts the skin, wash immediately and thoroughly with water.
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Engine Control Module (ECM) Section 1, System Overview 1.1 Introduction The primary purpose of Alpha’s Engine Control Module (ECM) is to control and monitor an AlphaGen Auxiliary Power Unit (APU) set, such as the CE-3X2 3.0kW and 5.0kW Series Engine-Generators. The ECM is used in conjunction with a Generator Remote Interface (GRI) PCBA, often referred to as the Power Board. The ECM/Power Board Assembly is mounted to the top of the EngineGenerator housing, to the left of the ignition battery.
Engine Control Module (ECM) 1.1 Introduction, continued 1 3 5 10 2 4 11 6 12 7 8 13 14 15 9 16 Fig. 1-1, Front view, Engine Control Module (ECM) Engine Control Module LED Indicators and switches: 1. 2. 3. 4. 5. 6. 7. 8. 9. Communications Input (J4) Note: Pin #1 at bottom of connector.
Engine Control Module (ECM) 1.1 Introduction, continued 7 8 RUN AUTO STOP SRVC RESET Fig. 1-2, Run/Auto/Stop and Service/Reset switches Ignition Battery Shelf Engine Generator Fig. 1-3, Location of Engine Control Module (ECM) within the Engine-Generator Cabinet. 744-862-C0-003 Rev.
Engine Control Module (ECM) 1.1 Introduction, continued GRI (Power Board) Engine Control Module (ECM) PCB J2 10 11 J2 1 J1 3 J1 12 5 13 4 6 7 J3 J3 14 2 8 15 15 16 9 Fig.1-4 Open view, ECM Printed circuit boards Engine Control Module LED Indicators and switches: 1. 2. 3. 4. 5. 6. 7. 8. 9. Communications Input (J4) Note: Pin #1 at bottom of connector.
Engine Control Module (ECM) 1.2 Theory of Operation 1.2.1 Normal Operating Condition Under normal operating conditions (no alarms) the ECM's Run-Auto-Stop (RAS) three-position rocker switch will be in the "center" or AUTO position as shown in figure 1-2. The ECM has complete control over the APU while in the AUTO mode. Also, each time the RAS switch is moved from the STOP position, to the center or AUTO position, the ECM will run the APU for one minute after a short delay.
Engine Control Module (ECM) 1.2 Theory of Operation, continued Crank Cycle Crank Attempt 1 2 3 4 5 6 7 8 9 Cranking Engine 15 Sec 15 Sec 15 Sec 15 Sec 15 Sec 15 Sec 15 Sec 15 Sec 15 Sec Pause (no crank) 30 Sec 30 Sec 60 Sec 30 Sec 30 Sec 60 Sec 30 Sec 30 Sec Engine Overcrank Alarm Table 1-1 Normal Mode Crank Cycle 1.2.4.
Engine Control Module (ECM) 1.2 Theory of Operation, continued 1.2.6. ECM Operating Mode Summary The ECM monitors the status of the AC line and DC bus to make a determination when to start and stop the generator. The ECM also monitors APU status while the engine is running and will immediately shut down the unit if certain alarm conditions are detected. The ECM reports status information via a parallel data interface and/or an Alpha-Bus serial data (RS-485) interface.
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Engine Control Module (ECM) Section 2, ECM Indicators and Control Functions 2.1 Indicators Refer to the illustration on the following page: The ECM user interface consists of 5 LEDs (2-6), a three-position rocker switch (7), and a momentary contact, push-button switch (8). The COMM Interface (1) can be used to attach an Alpha Technologies system controller. Provisions are made for Transponder connections through the Interface connector (9).
Engine Control Module (ECM) 2.1 Indicators, continued 1 3 5 2 4 6 7 8 9 Pin 1 Fig. 2-1 Engine Control Module LED indicators and switches. Engine Control Module LED Indicators and switches: 1. 2. 3. 4. 5. 6. 7. 8. 9.
Engine Control Module (ECM) 2.2 Control Functions Refer to Figure 2-2 on the following page: The three positions of the rocker switch (7) are RUN - AUTO - STOP (RAS). The RAS switch is normally left in the center, AUTO, position so that the ECM has control of the generator set. A minor alarm is indicated when the RAS switch is not in the AUTO position. The STOP ("down") position is used to stop or prevent APU operation during maintenance.
Engine Control Module (ECM) 2.2 Control Functions, continued The service reset push-button is also used to obtain information about active alarms. The Major and Minor alarm LEDs are very general and a technician will need more detailed information upon arrival to the site of an alarming ECM. To retrieve details about an active alarm, the user presses and releases the service-reset switch. An active alarm (Major or Minor) will be indicated by the LEDs as indicated in Figure 3-1.
Engine Control Module (ECM) Section 3, ECM Alarms and Notifications 3.1 Alarms Classifications The ECM is capable of reporting 9 "Major" alarms, 8 "Minor" alarms and 2 "Notifications". The following are detailed descriptions of each. Major Alarm: A Major alarm indicates failure of a critical component or some other situation (pad shear, for example) where the system either has gone offline, or system failure and/or shutdown is imminent.
Engine Control Module (ECM) 3.1 Alarms Classifications, continued MAJOR ALARMS (continued): Alternator Over-voltage (Latching) The generator set has detected that the alternator output voltage is too high. Depending on generator type, this likely means that the voltage regulator or the engine speed governor has failed. Operation of the unit has been suspended. The alarm is cleared when the Reset command is issued or when the manual stop switch is activated.
Engine Control Module (ECM) 3.1 Alarms Classifications, continued Minor Alarm: These alarms indicate a system fault which, though not indicative of imminent system failure or shutdown, require service attention as the fault condition could worsen to shut down the system. A site check by service personnel is recommended. MINOR ALARMS: Control Fail (Latching - after 5 activations) Indicates a control failure between the ECM and the generator set.
Engine Control Module (ECM) 3.1 Alarms Classifications, continued Auto Mode Disabled Indicates the position of the ECM control select switch. When the Run-Auto-Stop (RAS) switch is in a manual (STOP or RUN) position, the ECM has no control over engine operation and therefore raises an alarm. This is a hardware ‘lockout’ input and cannot be changed via status monitoring. Tamper One of the doors on enclosure is open. The alarm clears when the door is closed.
Engine Control Module (ECM) 3.3 Alarm and Notification Indications Alarms are indicated in three ways: ECM LEDs, RS-485 communications and alarm contact closures on ECM transponder interface. Alarm indication on the ECM LEDs is obtained by pressing the service reset button momentarily and noting the combination of illuminated LEDs. Pressing the service reset switch again will reveal the next alarm in the list.
Engine Control Module (ECM) 3.4 ECM Transponder Interface The ECM also provides a transponder interface for remote status monitoring as shown in figure 2-1, item 9. The transponder interface consists of a 12-position terminal block with 8 optically-isolated output signals and one switch closure input signal. The wiring diagram for the transponder interface is shown in Figure 3-2, with the following signals mapped to the transponder interface terminal block as shown in below.
Engine Control Module (ECM) 3.
Engine Control Module (ECM) 3.5 Standard ECM-Transponder Interconnection, cont’d Top view Plug-side view Terminal 1 Terminal 1 Wire-insertion-side view Terminal 1 Fig. 3-4 ECMconnector arrangement 1 2 3 4 Unused SCM COMM PIN 2, BLACK Wire PIN 3, RED Wire Unused Fig. 3-5 SCM-to-ECM interconnect cable Plug-side view Top view Terminal 1 Terminal 1 Wire-insertion-side view Terminal 1 Fig. 3-6 ECM-to-SCM connector arrangement 32 TM 744-862-C0-003 Rev.
Engine Control Module (ECM) 3.6 Transponder System Block Diagram Alpha XMS2 USM-2 Transponder Enclosure Tamper Switc h USM Interface Connector APU Interface 'Alpha' Side 'Transponder' Side Power Supply Enclosure Transponder to ECM Interface cable Enclosure Sensors Alpha ECM Battery Pack, 36 VDC or 48VDC Auxiliary Power Unit Enclosure CE-3X2 Alpha Auxiliary Power Unit (APU) Pin 1 on bottom 744-862-C0-003 Rev.
Engine Control Module (ECM) Section 4, ECM Configuration/System Interface 4.1 ECM Configuration DIP Switch, Fuses The ECM has an 8 position DIP switch (SW5) which is used to configure the type of Generator Interface, APU output voltage (AC or DC), and the utility voltage. Please refer to Section 4.4, "Input Voltage and Line Sense", prior to configuring utility voltage and line sense voltage. Also, the ECM power board contains three fuses, F1, F2, and F3.
Engine Control Module (ECM) 4.2 ECM Configuration The ECM configuration is required for interface type, output voltage, input voltage and reserved functions. The following should be used to configure the ECM: E C M S w i tc h 5 S e t t in g s 1 2 M e a n in g 3 4 5 6 7 8 1 = ON, 0 = O FF N o n s ta n d a r d G R I in te r fa c e ( 7 .
Engine Control Module (ECM) 4.3 System Interface The illustration below shows the interconnection between the ECM, engine-generator controller, and enclosure safety sensors. PIN 1 Fig. 4-3 ECM/APU Interconnection, 2.7kW/3.0 kW configuration 36 TM 744-862-C0-003 Rev.
Engine Control Module (ECM) 4.3 System Interface, continued The illustration below shows the interconnection between the ECM, engine-generator controller, and enclosure safety sensors.
Engine Control Module (ECM) 4.4 ECM input voltage and line sense configurations The ECM has 120/240VAC input voltage and line sense capabilities, which must be configured separately. The ECM PCBA part number 704-630-XX must be configured for 120/208/240VAC line sense via DIP Switch SW5-5 and SW5-6 as shown in table 4-1. The default setting is 120VAC.
Engine Control Module (ECM) 4.5 ECM System Parameters The following is a listing of programmable parameters used by the ECM. They may be changed via the Telecom Power Monitor (TPM). Refer to the Telecom Power Monitor Technical Manual (p/n 744-781-B0) for additional information. 4.5.1 Low DC Bus Level Description: Range: Default setting: If the power system battery voltage goes below this threshold voltage for a certain period of time, the ECM will start the generator. 0V to 127VDC 1.95 volts/cell 4.5.
Engine Control Module (ECM) 4.5 ECM System Parameters, continued 4.5.6 Auto-test Interval Description: Range: Default setting: Interval between automatic self tests in days. Auto-test Countdown is reset to this value (multiplied by 24 hours) when this parameter is written or upon completion of an automatic self test. Setting this value to zero will disable the automatic self-test. 0 to 65535 days 0 days (automatic self tests disabled) See table 4-1 for Autotest enable. 4.5.
Engine Control Module (ECM) Section 5, System Self-test and Maintenance 5.1 Self-Test Generator testing can be initiated in four ways: 1. 2. 3. 4. The ECM can be programmed to periodically run an automatic test (Default OFF). A Self-Test can be commanded via status communications. Momentary activation of the Engine Run command will cause the ECM to effectively run a test. Note that this method is the least desirable because the Self-Test Fail alarm will not be set if an alarm condition arises.
Engine Control Module (ECM) 5.1 Self-Test, continued If AC line should fail during a test, the test will terminate normally but the engine will continue to run until line returns. If the test fails because the DC Bus alarm activates, the test will terminate, the self-test fail alarm will activate but the generator will continue to run until the DC Bus alarm clears. The Self-Test Fail alarm may be cleared via a reset command or by successfully running a subsequent test.
Engine Control Module (ECM) 5.2 System Maintenance The ECM monitors time between periodic maintenance of the enginegenerator. The Service Interval internal ECM variable represents the number of hours of engine-run-time between periodic services. When the engine runs for a number of hours equal to Service Interval, the ECM sets the Service Required Alarm and turns on the amber notification LED. The default value of Service Interval is 100 hours but may be programmed from 0 to 250.
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Engine Control Module (ECM) Engine Control Module Alarm Table Remove page and use for quick reference Alarms are indicated in three ways: ECM LEDs, RS-485 communications and alarm contact closures on ECM transponder interface. Alarm indication on the ECM LEDs is obtained by pressing the service reset button momentarily and noting the combination of illuminated LEDs. Pressing the service reset switch again will reveal the next alarm in the list.
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Engine Control Module (ECM) Power Node/ECM Certification Power Node Location___________Node____________ Model#____________ Technician______________Date ____________ Serial #___________ Ignition Battery Check (Record Results) Verify correct Ignition Battery and Charger cables attachment ........................ Verify Battery Terminal surfaces clean, tight, and covered with approved corrosion inhibitor (NCP-2) ........................................................... Battery Voltage Range 12.5-14.1Vdc. .
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