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Installation and Operating Instructions

Engine Performance Controller

Form EPC-250 IOI 6-18

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Summary of Contents for EPC-250

Page 1: ...Installation and Operating Instructions Engine Performance Controller Form EPC 250 IOI 6 18 ...

Page 2: ...Memory card to increase memory capacity collect trending and data logging information and store larger con figuration files 1 4 EPC 250 TYPICAL CONTROL FUNCTIONS A IGNITION TIMING RETARD Ignition Timing Retard vs Engine Speed Ignition Timing Retard vs Fuel Manifold Pressure Ignition Timing Retard vs Air Manifold Pressure Ignition Timing Retard vs Air Manifold Temperature Ignition Timing Retard vs ...

Page 3: ... range 4 140 F 20 60 C Storage temperature range 20 70 C Storage humidity 80 maximum relative humidity non condensing from 0 to 50 C The EPC 250 is not rain and weather resistant The mounting site should provide as much protection from inclement weather as possible Waste Gate Control or Other Air Fuel Ratio Control 4 20mA To Altronic CPU Ignition or Other Ignition Timing Control Six Output Switche...

Page 4: ...vice The area should be tested as non hazardous before such testing commences 3 3 Analog Sensor Wiring For each analog monitored point select a transducer either an Altronic pres sure or temperature transducer listed above or one that outputs a signal in the range of 0 to 5Vdc or 0 to 25mA Mount as described above Use cable as sembly 693008 x or similar to wire transducer to the Modbus terminal bo...

Page 5: ...s terminal board NODE 1 BAUD RATE 38 4K DATA BITS 8 PARITY No STOP BITS 1 Baud Rate Data Bits Parity and Stop Bits are fixed and cannot be changed The node number indicated by the mechanical switch on the Modbus Terminal Board must be set to position 1 3 6 HMI Ethernet Communications The IP network configuration of the EPC 250 is edited via the network icon in the navigation pane The pane has been...

Page 6: ...including K or J type thermocouples These are listed as channels 01 30 They accept industry standard transducer signals in the range of 0 5Vdc 4 2 The Modbus Terminal Board is designed to operate with industry standard voltage or current amplified output transducers in the range of 0 5Vdc or 0 25mA Four series of transducers are available from Altronic pressure trans ducers 691201 x 691204 x and t...

Page 7: ... 2 for proper wiring of these types of inputs 4 7 4 20mA Inputs The terminal board can accept 4 20mA inputs by selecting the internally con nected 200 ohm resistors creating a termination voltage of 8 to 4 0 volts The jumper wires between the and terminals for that channel must be connected for proper operation 4 8 For each input the corresponding CHANNEL SWITCH must be set according to the input ...

Page 8: ...utton displays the MAIN MENU screen 6 3 Press LEGACY CONFIG to view the configuration screen for the legacy EPC 200 inputs When replacing an existing EPC 200 the end devices require configuration within this screen as described below prior to calibrating any channel 6 4 Section 1 Input Scaled Nine different device types can each be scaled to the desired units Each pressure signal can be displayed ...

Page 9: ...n value If a precise value is desired click the input box for that signal and enter the value 6 7 Decimal Point DP Used to set the number of decimal places to display 6 8 Section 3 Type Legacy configuration will only allow for a 1 5V transmitter range imitating the limitations of the EPC 200 A Sensor Volt Range span is available for custom voltage devices 6 9 Section 4 Engine Speed Displays the ac...

Page 10: ... channel which can be enabled for any application as needed When using any of the inputs it must be Enabled and calibrated thru its group page as shown below 7 1 CH Channel Denotes the channel number to be configured 1 31 7 2 Enable Each input channel can be enabled disabled by pressing the Off On button on each calibration page When the input channel is enabled all alarms and shutdown setpoints f...

Page 11: ...alue for the low the difference between this value and 12 5 is 6 25 12 5 6 25 The overall value of the sensor is 62 5 12 5 75 0 To calculate the value use the following expression 6 25 75 0 65535 5461 The slightly greater value for Modbus regis ter 40114 of 5464 was due to some slight errors due to internal protection circuits With this offset value 0V in would yield a displayed value of 6 2 for t...

Page 12: ...ned integer TRANSDUCER SLOPE X OFFSET B ZERO SPAN D P CONFIG COMMENTS 0 50 213 5464 125 625 1 0 100 213 5464 250 1250 1 0 300 213 5464 750 375 1 0 500 213 5464 1250 6250 0 0 1000 213 5464 250 1250 0 0 2000 213 5464 500 2500 0 0 5000 213 5464 1250 6250 0 VOLTMETER 255 0 0 500 2 0 100 0 4 20mA 267 76 250 1250 1 dEG1 432 0 0 300 0 dEG2 300 0 143 675 256 J TC 271 500 76 1382 512 K TC 271 500 76 1472 7...

Page 13: ...to be configured 1 31 8 2 Enable Displays if the input s shutdown alarm capabilities have been enable disable by pressing the Off On button on each calibration page A check mark denotes enabled while an X represents disabled 8 3 Sensor Displays the status of the sensor A fault status will be displayed if the sensor connection goes open or in a the case of a failed device 8 4 Current Displays the a...

Page 14: ...urve If this information is not available use the engine performance data supplied by the engine manufacturer This data can be supplemented with actual measurements taken on the engine Air Manifold Pressure vs Fuel Manifold pressure Air Manifold Pressure vs Exhaust Temperature Air Manifold Pressure vs Air Manifold Temperature Air Manifold Pressure vs Speed Air Manifold Pressure vs Pilot Manifold P...

Page 15: ...n All the performance curves are entered into the EPC 250 Controller simply by entering the x y coordinates of each point of the seven line segments In the legacy configuration Channels 67 and 68 correspond to the first point x fuel y air Channels 69 and 70 automatically become the fourth line seg ment and Channels 71 and 72 determine the end point of the curve Pressing the Calculate button automa...

Page 16: ...or know which segment the EPC 250 is using to calculate the air fuel ratio in that instant The calculated value desired air manifold pressure of the 4 point line segment is compared to the actual air manifold pressure The difference between the two values is the input to the PID calculations 9 3 Air plot These values are obtained from the engine manufacturer or from the EPC 200 for the specific en...

Page 17: ...formance This can typically be accomplished using the Rich or Lean arrow buttons to make small advances in ignition timing or slight adjustments to the air fuel ratio 9 7 Lean Rich Arrows The EPC 250 allows the operator to easily change the air fuel ratio if needed The controller will determine which segment will be affected when pressing the Lean or Rich arrow Typically pressing the Lean arrow wi...

Page 18: ...sts The larger the error and the longer the error exists the larger the integral component will be in an attempt to make the process variable equal to the control setpoint The integral control component is used to eliminate all remaining error Derivative Control The derivative control component is proportional to the rate of the change of the error The faster the process variable moves away from t...

Page 19: ...ressure signal 10 11 PID Forward Action Enabled This is used to control the mode of the PID signal from forward acting to re verse acting In forward acting mode 0 4mA 100 20mA In reverse acting mode 0 20mA and 100 4mA 10 12 WG Auto Enabled This button toggles the waste gate control from auto to manual Pushing the Sync button makes the manual waste gate setpoint equal to the auto waste gate output ...

Page 20: ...g values for the functions above are calculated separately accord ing to user entered curves and the Offset is implemented by the EPC 250 Controller Under certain conditions there can be interaction between the Air Fuel Ratio and the Timing Retard function If sufficient air manifold pressure cannot be achieved even with the bypass valve fully closed the ignition timing can be retarded to increase ...

Page 21: ...ariety of ways but the most logical use is during loading of a compressor Closing digital input 29 or pressing the Load Offset ON button adds a predetermined amount of air thus raising the air pressure just before or during loading This feature reduces the need to load an engine slowly or detune the governor while it is waiting for air The above feature works similarly on the Timing Offset When ac...

Page 22: ...m ing at which the engine is designed to run under normal conditions 12 3 Reset Rate Determines the rate at which the program reacts to the output 12 4 RETOutput Calculated value of the actual output as the program cycles through the sequence 12 5 DESOutput This value represents a total sum of all the active retard offsets 12 6 Ret Auto Enable The retard feature can be controlled manually via the ...

Page 23: ...tput 2 0 2 Can be used for various speed switch functions such as crank disconnect 0 2 is tripped when the entered RPM is reached after start up 13 3 Engine Rpm to Trip Output 3 0 3 A second speed switch similar to O 2 except that 0 3 is tripped when the entered RPM is reached after start up 13 4 Time Interval After End of Start Override Signal to Trip Output 4 0 4 0 4 will trip after the entered ...

Page 24: ...he shutdown setpoint or device limits have been exceeded 14 0 TIMERS A second function of the EPC 250 controller is to perform shutdown and alarms The EPC 250 uses a standard class B timer in seconds for every input that adds a delay to the shutdown and alarm to debounce and eliminate nuisance shutdowns ...

Page 25: ...ed and loaded to a new application or back to the original EPC 250 in case of data loss 15 3 CREATE CONFIG REPORT A report of the configuration saved in the SD Memory card can be generated by using this function 15 4 OPEN CONFIG FILE VIEWER Allows the user to view the configured file in a readable format TXT 15 5 PRINT EPC CONFIG A hard copy can be printed if the EPC 250 is connected to a printer ...

Page 26: ...30005 CHANNEL 3 SWAPPED FP 30006 30007 CHANNEL 4 SWAPPED FP 30008 30009 CHANNEL 5 SWAPPED FP 30010 30011 CHANNEL 6 SWAPPED FP 30012 30013 CHANNEL 7 SWAPPED FP 30014 30015 CHANNEL 8 SWAPPED FP 30016 30017 CHANNEL 9 SWAPPED FP 30018 30019 CHANNEL 10 SWAPPED FP 30020 30021 CHANNEL 11 SWAPPED FP 30022 30023 CHANNEL 12 SWAPPED FP 30024 30025 CHANNEL 13 SWAPPED FP 30026 30027 CHANNEL 14 SWAPPED FP 30028...

Page 27: ... 30063 AMBIENT TEMPERATURE UNSIGNED INT Displayed in tenths of Kelvins 2954 295 4K 22 4C 30064 CHANNEL 31 0 or 1 digital input only 30065 CHANNEL 32 0 or 1 digital input only 30066 firmware month ASCII 30067 firmware date ASCII 30068 firmware year ASCII 40067 Special analog out 1 occurs when ch32 is tripped See section 6 4 40068 Special analog out 2 occurs when ch32 is tripped See section 6 4 4006...

Page 28: ...SIGNED INT 7 40096 MAXIMUM DISPLAYED NUMBER SIGNED INT 7 40097 SLOPE X SIGNED INT 8 40098 OFFSET B SIGNED INT 8 40099 MINIMUM DISPLAYED NUMBER SIGNED INT 8 40100 MAXIMUM DISPLAYED NUMBER SIGNED INT 8 40101 SLOPE X SIGNED INT 9 40102 OFFSET B SIGNED INT 9 40103 MINIMUM DISPLAYED NUMBER SIGNED INT 9 40104 MAXIMUM DISPLAYED NUMBER SIGNED INT 9 40105 SLOPE X SIGNED INT 10 40106 OFFSET B SIGNED INT 10 ...

Page 29: ...D INT 18 40139 MINIMUM DISPLAYED NUMBER SIGNED INT 18 40140 MAXIMUM DISPLAYED NUMBER SIGNED INT 18 40141 SLOPE X SIGNED INT 19 40142 OFFSET B SIGNED INT 19 40143 MINIMUM DISPLAYED NUMBER SIGNED INT 19 40144 MAXIMUM DISPLAYED NUMBER SIGNED INT 19 40145 SLOPE X SIGNED INT 20 40146 OFFSET B SIGNED INT 20 40147 MINIMUM DISPLAYED NUMBER SIGNED INT 20 40148 MAXIMUM DISPLAYED NUMBER SIGNED INT 20 40149 S...

Page 30: ...YED NUMBER SIGNED INT 29 40185 SLOPE X SIGNED INT 30 40186 OFFSET B SIGNED INT 30 40187 MINIMUM DISPLAYED NUMBER SIGNED INT 30 40188 MAXIMUM DISPLAYED NUMBER SIGNED INT 30 40209 PULSES PER REVOLUTION 2 UNSIGNED INT 40257 DECIMAL POINT SENSOR CONFIG UNSIGNED INT 1 40258 DECIMAL POINT SENSOR CONFIG UNSIGNED INT 2 40259 DECIMAL POINT SENSOR CONFIG UNSIGNED INT 3 40260 DECIMAL POINT SENSOR CONFIG UNSI...

Page 31: ...NT SENSOR CONFIG UNSIGNED INT 27 40284 DECIMAL POINT SENSOR CONFIG UNSIGNED INT 28 40285 DECIMAL POINT SENSOR CONFIG UNSIGNED INT 29 40286 DECIMAL POINT SENSOR CONFIG UNSIGNED INT 30 40769 DIGITAL OUTPUTS UNSIGNED INT LSB 40770 ANALOG OUTPUT 1 UNSIGNED INT 0 4095 40771 ANALOG OUTPUT 2 UNSIGNED INT 0 4095 40772 MODBUS WRITE PROTECT UNSIGNED IT 5300H WRITE ENABLE NOTE Modbus write commands will NOT ...

Page 32: ...ll rights reserved ALTRONIC LLC 2018 32 DRAWINGS SECTION FIGURE 1 MODBUS TERMINAL BOARD FIGURE 2 WIRING DIAGRAM SENSOR AND TRANSDUCER INPUTS POWER FIGURE 3 EPC 250 MOUNTING DIMENSIONS FIGURE 4 EPC 200 250 WIRING DIAGRAM ...

Page 33: ...EPC 250 IOI 6 18 All rights reserved ALTRONIC LLC 2018 33 FIGURE 1 MODBUS TERMINAL BOARD ...

Page 34: ...EPC 250 IOI 6 18 All rights reserved ALTRONIC LLC 2018 34 FIGURE 2 WIRING DIAGRAM SENSOR AND TRANSDUCER INPUTS POWER ...

Page 35: ...EPC 250 IOI 6 18 All rights reserved ALTRONIC LLC 2018 35 FIGURE 3 EPC 250 MOUNTING DIMENSIONS 11 56 293 62 13 53 343 66 12 78 324 61 4 0 2 6 6 5 2 8 5 53 140 50 5 28 134 154 8 00 203 20 ...

Page 36: ... 18 19 20 09 08 07 06 05 04 03 02 01 11 10 12 13 14 15 16 17 18 19 20 09 08 07 06 05 04 03 02 01 30 1 2 3 4 T R S 29 28 27 26 25 24 23 22 21 30 5 6 7 8 R S 29 28 27 26 25 24 23 22 21 A B S 3 2 1 31 30 32 33 34 35 36 37 38 39 40 29 28 27 26 25 24 23 22 21 11 10 12 13 14 15 16 17 18 19 20 09 08 07 06 05 04 03 02 01 B A ...

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