Ecg PDF
Ecg PDF
Ecg PDF
08 March 2007
Special Instruction
Operation of the ECG Software ........................ 18
Hardware requirements ................................. 18
Installation of the Hardware ........................... 19
Installation of the ECG Software ................... 19
Basic Software Operation ................................. 20
Operating the ECG Software ......................... 20
Progress Display Screen ............................. 21
Navigating Around the ECG Software ........... 21
Software Menus and Options ............................ 21
File Menu ....................................................... 21
Save ECG to Cal to File .............................. 22
View Cal File Comments ............................. 24
View Text File ................................................ 25
Convert Commands ....................................... 25
Convert ECG Cal to Text ............................. 25
Convert Cal File to Text ............................... 25
Convert Cal File to Strategy ........................ 26
Calibrate Menu .................................................. 27
Download Cal File to ECG .......................... 27
Compare ECG Cal to File ........................... 28
Calibration Wizard ....................................... 29
Monitor Menu .................................................. 32
Parameter View ........................................... 32
Parameter Plot ............................................ 33
Make PID Gain Adjustment from the Plot
Display window ........................................... 34
Change Plot Setup ...................................... 35
Display Faults .............................................. 35
Control Strategy .......................................... 36
Parameter List ............................................. 36
Configure Menu .............................................. 38
Configure the Serial Port ............................. 38
Configure the Demonstration Mode ............ 38
Configure a Custom Serial Port ..................... 39
Help Menu ...................................................... 39
Help Topics .................................................. 39
About ACT ................................................... 40
User Manual .................................................. 40
Calibrating the Features of the ECG ................. 40
The Calibration Guide ....................................... 40
Calibration Categories ................................... 41
Calibrating the Controller ............................... 41
Saving a Calibration Set to a File .................. 42
Calibrating the Controller with a Saved
Calibration File ............................................. 42
Understanding the Calibration Parameters of the
ECG ................................................................. 42
Configuration Modes for the Switch ................. 43
Engine Start Calibration Parameters .............. 45
Glow Plug Control .......................................... 45
i02589674
Table of Contents
Introduction ........................................................... 2
Understanding the System ................................... 2
Components of the Electronic Controlled Governor
(ECG) .................................................................. 2
Controller ........................................................... 2
Speed Sensor ................................................... 3
Actuator ............................................................. 3
ECG Software ................................................... 3
Programmable Features ................................... 4
Selection Options for Engine Speed .............. 4
Installing the Hardware ..................................... 4
Wiring Guidelines .......................................... 5
Wiring Lengths ............................................... 5
Installation of the Controller .............................. 5
Controller Wiring ............................................ 6
Basic Installation for the Control System for 1500
rpm and 1800 rpm ....................................... 8
Installation of the Speed Sensor ....................... 8
Engine Speed Setpoint Wiring Trim Analog
Input ................................................................ 9
Switched Inputs for the Engine Speed
Setpoints ......................................................... 10
Switch Wiring .................................................... 11
Single Switch Mode ....................................... 11
Two-Speed Mode .......................................... 11
Three-Speed Mode ........................................ 12
Four-Speed Mode .......................................... 12
Glow Plug Control Wiring .................................. 13
Installation of the Wiring for the Glow Plug
Control ......................................................... 13
Autocrank Wiring ............................................... 14
Installation of the Autocrank Wiring ............... 15
Auxiliary Output Wiring ...................................... 16
Engine Protection Input Wiring .......................... 17
Autocrank ....................................................
Diagnostic Calibration Parameters ....................
Engine Protection Input .................................
Actuator Calibration Parameters .......................
Auxiliary Outputs ...........................................
Droop Governing ...........................................
Troubleshooting .................................................
Governor Gain Calibration Parameters ..........
PID Gain Settings Response Plots ................
Troubleshooting Guidelines ...........................
Fault Codes ...................................................
Flow Chart for the Calibration Setup and
Configuration Parameters ...........................
Glossary of Terms .............................................
Speed sensor
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46
46
47
47
48
48
48
48
49
50
Actuator
Calibration software
Controller
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58
Introduction
Reference: General Information
NOTICE
Do not perform any procedure that is outlined in this
publication until you have read the information and
understand the information.
Illustration 1
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Controller
Speed Sensor
ECG Software
Illustration 2
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Actuator
Illustration 3
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Illustration 4
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Programmable Features
Table 1
Feature
Description
Additional Hardware
No
Autocrank
Yes
Auxiliary output
Yes
Droop governing
No
Yes
No
Yes
Overspeed/Underspeed
Protection
No
Proportional Integral
Derivative Gain adjustment
(PID)
No
Yes
Yes
(1)
Refer to Table 2 for further information on available engine speed selection options.
Table 2
Description
No analog input
Speed trim
Wiring Guidelines
Table 3
Part Number
Description
20198
Connector kit
CH11155
Crimping tool
Wiring Lengths
Table 4
Wiring Specifications
Gauge
20 m (66 ft)
10 m (33 ft)
Length
Controller Wiring
Illustration 6
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Illustration 7
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Illustration 5
Table 5
94 mm (3.70 inch)
75 mm (2.953 inch)
g01300075
Table 6
Function
Remarks
Pin Information
Actuator Output
Analog Input
Auxiliary Output
Auxiliary Output #2
Battery
Switch to ground
ACT Connector
Switched Inputs
Switch to Vbat
g01300420
Illustration 8
(1) J1 connector (gray)
(2) Actuator
(3) Speed sensor
Illustration 9
g01301437
g01302234
(1) Controller
Illustration 12
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(1) Controller
g01301436
(1) Controller
Single-speed
Two-speed
Three-speed
Four-speed
Choose a switch that is designed for low currents
with a range of 5 to 20 mA. Avoid choosing a switch
that is designed to use high current devices that rely
on the current to clean the switch contacts. A dry
circuit switch is recommended.
The speed select switch is typically installed on the
control panel.
Refer to this Special Instruction, Perkins Electronic
Controlled Governor, Switch Wiring for further
information on installing the speed select switch.
On installing the speed select switch, calibrate
the Speed Setup parameters. Refer to this
Special Instruction, Perkins Electronic Controlled
Governor, Operation of the ECG software for further
information.
10
Switch Wiring
Single Switch Mode
g01344532
Illustration 13
Typical example of a wiring diagram for the single switch mode
(1) Controller
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Illustration 14
Typical example of a wiring diagram for the two-speed mode
(1) Controller
11
(3) Speed 2
Three-Speed Mode
g01344536
Illustration 15
Typical example of a wiring diagram for the three-speed mode
(1) Controller
(2) Speed 1 (No connection)
(3) Speed 2
(4) Speed 3
g01344538
Illustration 16
Typical example of a wiring diagram for the Four-position rotary switch
(1) Controller
(2) Speed 1
(3) Speed 2
(4) Speed 3
(5) Speed 4
12
1N4001
1N4002
1N4007
A wiring diagram of the four-position rotary switch
mode is shown in Illustration 16.
g01302721
Illustration 17
Typical example of the wiring for the glow plug control
(1) Controller
(2) Autostart switch input
13
Autocrank Wiring
The ECG offers an autocrank feature for the use on
remote starting or automatic starting. Contact your
Perkins dealer or your Perkins distributor for further
details.
Either of the two auxiliary outputs may be configured
for autocrank operation.
14
g01344645
Illustration 18
Typical example of the wiring for the autocrank wiring
(1) Controller
(2) Autostart switch input
NOTICE
If using the autocrank feature, ensure that the
autocrank feature has been calibrated prior to
connecting to the ECG controller.
If the Electronic Controlled Governor (ECG) controller is not calibrated for the autocrank feature
and the crank motor relay is connected, the engine may start as soon as power is applied to the
controller. This could result in the possible loss of
engine control which could result in personal injury or death. Be sure to calibrate the autocrank
feature before you connect the ECG controller.
15
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Illustration 19
Typical example of a wiring diagram for the lamp
(1) Controller
(2) Lamp
g01344672
Illustration 20
Typical example of a wiring diagram for the relay
(1) Controller
(2) Relay
Flash faults
Autocrank output
Diagnostic shutdown
16
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Illustration 21
Typical example of a wiring diagram for the engine protection
(1) Controller
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Illustration 22
Typical example of a wiring diagram for sensors that are wired in parallel
(1) Controller
Hardware requirements
IBM-COMPATIBLE PC
CD-ROM drive
Serial port with a DB-9 connector that is capable of
18
g01343732
Illustration 23
Typical example of the hardware
(1) Controller
(2) OEM connection
(3) Harness
(4) PC
19
20
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Illustration 24
A typical view of the Progress Display Screen
File Menu
Calibrate Menu
Monitor Menu
Configure Menu
Help Menu
File Menu
Viewing files
Saving files
Converting files
or accept a condition.
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Table 7
Main Menu
Commands
Save ECG Cal to File
View Cal File Comments
View Text File
File Menu
g01305276
Illustration 25
Typical view of the Select/Create File Name to save to window
22
g01308630
Illustration 26
Illustration 27
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23
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Illustration 28
Engine data
Application data
Environmental data
Use the following process in order to view the
calibration Cal File Comments.
Illustration 29
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Convert Commands
The Save ECG Cal to File command stores the
calibration data as a software file. Printing and
viewing must be done from a converted text file.
The following commands are available with the ECG
software:
Illustration 30
g01316575
25
g01327519
Illustration 31
26
Illustration 32
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Calibrate Menu
The Calibrate Menu allows the operator to perform
operations that are related to the calibration of the
ECG. The following commands are available:
Illustration 33
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Illustration 34
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Illustration 35
Illustration 37
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Illustration 38
g01318066
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Calibration Wizard
The Calibration Wizard command allows the
operator to use an interactive guide in order to
calibrate the ECG for specific engine requirements.
Use the following process in order to calibrate the
ECG by using the Calibration Wizard.
1. Select the Calibrate option. Select the
Calibration Wizard option.
Illustration 39
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Illustration 41
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Illustration 40
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29
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Illustration 42
Illustration 43
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30
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Illustration 44
Illustration 45
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Monitor Menu
The Monitor Menu allows the operator to observe
the engine and operation of the ECG in real time.
The following commands are available:
Parameter View
Parameter Plot
Display Faults
Control Strategy
Parameter List
Parameter View
The Parameter View command allows the operator
to view certain operating variables in real time.
Use the following process in order to view operating
variables by using the Parameter View.
1. Select the Monitor option. Select the Parameter
View option.
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Illustration 46
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Illustration 47
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Table 8
Description
Code
P
Proportional gain
Integral gain
Derivative gain
Plot
Description
Plot1/Plot 2
Axis Min/Max
Display Faults
35
g01320632
Illustration 48
Control Strategy
The Control Strategy option allows the operator
to check the version of the control strategy that is
being used. This information may be required for
identification of the strategy and for future use.
Parameter List
36
g01320735
Illustration 49
Illustration 50
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Configure Menu
The Configure Menu option allows the operator to
designate the correct communication port for the
PC in order to enable communications between the
actuator and the controller. The Configure Menu
option allows the operator to start a Demonstration
Mode for various supported controllers.
Configure the Serial Port
Use the following process in order to configure the
serial port.
1. Select the Configure option. Select Com 1 or
Com 2 in order to attempt to open the serial port
and establish communication with the controller.
Configure the Demonstration Mode
Use the following process in order to configure the
Demonstration Mode.
1. Select the Configure option. Select ECG 4500
DEMO option. The application will simulate
communications with the controller.
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g01320819
Illustration 51
Help Menu
The Help Menu option provides the operator with
on-line access to the user manual and other helpful
information. The following commands are available
from the Help Menu option.
Help Topics
About ACT
User Manuals
Help Topics
The Help Topics option allows the operator to
search for specific information by displaying menu
items or by searching using words or by using a
phrase.
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g01321201
Illustration 52
Compact disc
About ACT
The About ACT option displays the version of the
calibration tool that is being used. This information
is important for tool identification and for servicing
support.
User Manual
The user manual contains comprehensive information
on the controller, wiring diagrams, menus and
calibration parameters. The user manual can be
accessed through the following:
On-line facility
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NOTICE
It is possible to enter values in the ECG controller
that are in excess of what the engine is capable of
performing and outside the engine operating range.
It is the users responsibility to be accurate when
entering data into the ECG or the software. Entering
values outside the safe operating range can result in
damage to the equipment or application.
Calibration Category
Features
Governor Gain
Engine start
Diagnostics
Overspeed/underspeed protection
Actuator output
Auxiliary output
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NOTICE
The range is fairly wide and it is possible to enter
values in excess of the capability of the application.
The range is limited for engine protection and human
safety. The limits do not reflect the capability of
any application that may be driven. It is possible
to command engine speeds up to 2500rpm with
the ECG software. The engine may not be able to
operate at this speed due to mechanical limitations.
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Table 11
Parameter
Category
Diagnostic calibration
Description
Proportional gain
Transient response
Integral gain
Derivative gain
Speed stability
Ramp up rate
Set speed 1
Set speed 2
Set speed 3
Set speed 4
Warm_up_time
Speed_type
Magnetic pickup
Overspeed_rpm
Underspeed_rpm
Aux_Output_rpm
Aux_Output_2 rpm
Droop_Percent
Percentage Droop
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Table 12
Configuration Mode
Description
= 1: Single speed
= 2: Two speed
= 3: Three-speed
= 4: Four speed
A switch with two diodes is used. The switch will select four
set speeds.
The engine is started. The engine moves from cranking
mode to run mode. The engine speed will increase from
SET_SPEED_MIN to SET_SPEED_WARMUP at the
RAMP_UP RATE.
Engine speed remains at the warm up speed for
WARM_UP_TIME seconds. The user may select a new
speed by using the switches. The switch will increase the
engine. The switch will decrease the engine speed.
A brief pressing of the switch will change engine speed
by one rpm. Closing the switch for a longer period will
ramp the engine speed. The engine speed will first be
ramped at a slow rate. The engine speed will then increase
at the RAMP_UP_RATE. The engine will decrease
at the RAMP_DOWN_RATE. This depends on the
switch position. The engine speed will never ramp above
SET_SPEED_MAX or below SET_SPEED_MIN.
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Parameter
Description
AUXILIARY_OUTPUT_MODE
AUXILIARY_OUTPUT_2_MODE
GLOWPLUG_TIME
(1)
(1)
(2)
Refer to this Special Instruction, Perkins Electronic Controlled Governor, Auxiliary outputs for further information.
Refer to this Special Instruction, Perkins Electronic Controlled Governor, Auxiliary outputs for further information.
Refer to the appropriate Operation and Maintenance Manual, Starting the Engine for further information.
45
Table 14
Parameter
Description
AUTOCRANK_CRANK_TIME
This value determines the amount of time that cranking will occur. If
the engine starts during the cranking period, engine cranking will
be terminated.
The range is between 0-31.9 seconds. (2)
AUTOCRANK_MAX_TRIES
The maximum number of crank cycles or the rest cycles before the
autocrank logic stops trying to start the engine. This will then flag
a fault.
The range is between 0-255 seconds. (2)
AUTOCRANK_REST_TIME
If the engine does not start during the cranking interval, cranking will
be disabled for AUTOCRANK_REST_TIME seconds in order to
permit the starting motor to cool.
The range is between 0-31.9 seconds. (2)
(2)
(2)
(2)
Refer to the appropriate Operation and Maintenance Manual, Starting the Engine for further information.
Refer to the appropriate Operation and Maintenance Manual, Starting the Engine for further information.
Refer to the appropriate Operation and Maintenance Manual, Starting the Engine for further information.
46
Table 15
Parameter
Description
OVERSPEED_RPM
UNDERSPEED_RPM
47
Table 16
Parameter
Description
AUX_OUTPUT_RPM
AUX_OUTPUT_2_RPM
AUX_OUTPUT_MODE
AUX_OUTPUT_2_MODE
No auxiliary output
Output on when the rpm is more than
AUX_OUTPUT_RPM
Illustration 53
Typical example of the PID gains too low
(Desired rpm) 1
(Actual rpm) 2
(Time) X
(rpm) Y
Troubleshooting
The following section may be used in order to
troubleshoot the ECG.
48
g01345541
Illustration 54
g01345551
(Desired rpm) 1
(Actual rpm) 2
(Time) X
(rpm) Y
Illustration 55
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Illustration 57
(Desired rpm) 1
(Actual rpm) 2
(Time) X
(rpm) Y
g01345556
g01324068
Illustration 58
(Desired rpm) 1
(Actual rpm) 2
(Time) X
(rpm) Y
Required Tools
Illustration 56
Tool
Part Number
Part Description
Digital Multimeter
Qty
1
g01345569
49
Flash Code
Fault
Engine Shutdown
Corrective Action
Yes
Yes
YES
Yes
Yes
Yes
50
No
10
No
11
No
12
No
13
No
14
No
51
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Illustration 59
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Illustration 60
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Illustration 61
54
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Illustration 62
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Illustration 63
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Illustration 64
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Glossary of Terms
A glossary of terms is shown in Table 19.
Table 19
Term
Description
ACT
Actuator
Autocrank
Cal File
The version of the software for the calibration tool that is used
Calibration
Calibration Wizard
Control Strategy
Duty cycle
Glow plugs
Parameter
PTO
Power take-off
The feature of the ECG that allows selection between pedal input
and speed switches
PWM
Speed sensor
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59
Printed i n U K