Controls XL-500E-AS Product Manual Download

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PRODUCT MANUAL

ENGINE CONTROL MODULE

Part Number: XL-500E-AS
Revision: V1.0
Engine Type: Electronic J1939 and Mechanical Engines

Summary of Contents for XL-500E-AS

Page 1: ...PRODUCT MANUAL ENGINE CONTROL MODULE Part Number XL 500E AS Revision V1 0 Engine Type Electronic J1939 and Mechanical Engines ...

Page 2: ...ER UP MANUAL OFF MANUAL STARTING SAFETY BYPASS ENGINE RUNNING SPEED CONTROL ELECTRONIC SPEED CONTROL MECHANICAL STOPPING THE ENGINE SPEED CONTROL OPTIONS 14 ELECTRONIC ENGINE SPEED CONTROL REQUESTED VERSUS ACTUAL SPEED TSC VERNIER THROTTLE TSC BUMP TSC MULTISTATE THROTTLE TSC HI LO MOMENTARY THROTTLE FLEX ANALOG THROTTLE MODBUS THROTTLE SPEED TORQUE LIMIT COOPERATIVE THROTTLE TWIST THROTTLE KNOB S...

Page 3: ... STANDARD FEATURES CUSTOM SPLASH SCREEN SENDER FAILURE AUDIBLE WARNING HORN SHUTDOWN OVERRIDE AUTO START OPERATION 27 GENERAL INFORMATION AUTO START MODE LEVEL TRANSDUCER AUTO START PRESSURE TRANSDUCER AUTO START SCHEDULER AUTO START GENERAL TRANSDUCER AUTO START AUTOMATIC SPEED CONTROL MODES SINGLE SPEED TARGET SPEED CONTROL LINEAR SPEED CONTROL FLOAT OPERATION 31 SINGLE FLOAT DUAL FLOAT FAILSAFE...

Page 4: ...N EVENT LOG ALARM EVENT LOG ENGINE IDENTIFICATION ETHERNET STATUS MODULE INFORMATION MODULE PROGRAMMING 41 PROGRAMMING OPTIONS PC BASED PROGRAMMING MODULE BASED PROGRAMMING CONTROLLER SETUP 43 PASSWORD ENTERY SETUP MENU QUICK SETUP ENGINE PARAMETER CONFIGURATION PUMP PARAMETER CONFIGURATION SCHEDULER CONFIGURATION INPUT CONFIGURATION OUTPUT CONFIGURATION THROTTLE CONFIGURATION ENGINE SAFETY CONFIG...

Page 5: ... CONFIGURATION BATTERY RECHARGE CONFIGURATION MODBUS CONFIGURATION ETHERNET CONFIGURATION MAINTENANCE CONFIGURATION EMISSIONS CONFIGURATION CLUTCH CONFIGURATION CLOCK SET UP MODULE INFORMATION MODULE CONNECTORS 55 MODULE PRIMARY CONNECTOR MODULE SECONDARY CONNECTOR WARRANTY 56 ...

Page 6: ...splay are all critical in allowing the operator to successfully and safely operate the module Extension harnesses are available from Controls Inc if the engine harness being used does not allow for proper location selection WEATHER AND WASHDOWN The control panel is designed to be weather tight and can be used in open outdoor conditions The enclosure has a Gore vent located on the rear of the enclo...

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Page 9: ...luminate and show the module part number version in the upper left status line and the graphical logo will be centered in the screen The LED indicators will turn on for one second to verify operation Stop Lamp Warning Lamp Low DEF Lamp Regen Active Lamp Mode Indicator Lamps ...

Page 10: ...9 MANUAL OFF After the Power Up cycle is complete the module will be in the Manual Off mode as shown in the upper left status line and the corresponding red LED indicator above the Off key ...

Page 11: ...ll display Starting Engine The module will energize the crank relay or send the J1939 CAN Start Engine command depending on the engine manufacturer selected The green status LED above the RUN key will flash while cranking is occurring Once the engine has started the green LED will become solid and the RUN key can be released KEY SWITCH OPTION An optional key switch with a crank position can be use...

Page 12: ...ed up regardless of the engine s run state This bypass does not apply to the engine s ECU safeties The status line will change to show Engine Safeties ACTIVE briefly when the module begins monitoring the parameters ENGINE RUNNING Once the engine has been running for a time that exceeds the safety bypass period all controller programmed engine safeties that are set to be monitored during engine run...

Page 13: ...ease the requested speed The display will place an up or down arrow to the right of the RPM displayed to indicate that a change in speed is being requested See Speed Control Options for more details SPEED CONTROL MECHANICAL ENGINES For mechanical engines the module supports multiple mechanical actuators Typically two relays are assigned to extend or retract a screw type actuator Other CAN Bus driv...

Page 14: ...This will de energize the fuel solenoid on mechanical engines or the engine ECU Run Stop circuit on electronic engines In some cases the module will send an engine STOP command over the J1939 CAN Bus to shut down the engine Once the engine has stopped the status line will display Manual Off ...

Page 15: ...el to increase the requested speed The display will place an up or down arrow to the right of the RPM displayed to indicate that a change in speed is being requested Please note that if the low idle speed on the engine s ECU is higher than the minimum speed programmed in the controller the actual engine RPM will be the low ECU setting until the controller s speed request command TSC1 exceeds the E...

Page 16: ... s ECU does have J1939 throttling enabled REQUESTED SPEED VERSUS ACTUAL SPEED The requested speed by the control panel cannot exceed the maximum programmed speed of the engine ECU Once the speed is being controlled by the module the acceleration will be based on the ramp rate in the controller If precise speed control is desired be sure to have the ECU governing mode set to Isochronous or Zero Dro...

Page 17: ...grammed rate until the Rabbit key is released The display will indicate an up arrow to the right of the RPM If the maximum speed is reached the up arrow on the display will be replaced by an X indicating the maximum speed has been reached This same operation applies to slowing the engine speed down using the down arrow key A single press of the Rabbit or Turtle key will cause the RPM of the engine...

Page 18: ...ator starts the engine the controller will run the engine at Speed 1 setting the lowest speed Pressing the Rabbit key momentarily will ramp the engine speed up to the Speed 2 setting Another press would accelerate to speed three and so on Pressing the down key will increment the speed to the next lower speed You cannot operate the engine between the speed settings Leave all unused speeds below the...

Page 19: ...te switch to be installed elsewhere on the equipment FLEX ANALOG THROTTLE If an analog signal is available from a PLC output or other device it can be used to control the engine speed A Flex Analog channel must be configured to accept the 4 20mA or 0 5 VDC signal and the throttle type assigned to Flex Analog A linear relationship will be created between the minimum and maximum programmed speeds an...

Page 20: ...t found under the Throttle Configuration menu COOPERATIVE THROTTLE Controls Inc modules can be installed together on the same engine to provide additional display and speed control from multiple locations The main module must be configured as the Primary while the remaining modules should be set to remote TWIST THROTTLE KNOB The TT 100 throttle knob is available to work with Controls Inc modules a...

Page 21: ... a wide temperature range of 40C to 80C for both operating and storage DISPLAY LAYOUT The display is defined into 10 sections Sections 1 through 8 are defined as the rectangles that contain various engine and system parameters They are numbered from the upper left as Area 1 with Area 2 directly below and continuing as shown below Area 9 is the Status annunciation and Area 10 is the Clock Area 1 Ar...

Page 22: ...an indicating needle against the dial the value s unit of measure and an indication of the acceptable range Each analog display will occupy two areas on the display and must be set at any of the odd numbered areas Each analog gauge option will occupy the area set plus 1 area For example if you set the Engine RPM AG to Area 1 Area 2 will be over written with the lower half of the gauge automaticall...

Page 23: ...f actions including derating of the engine horsepower or complete engine shut down The display will illuminate the red or yellow LED as instructed by the ECU and display any trouble code as presented from the ECU Some engine manufacturers have unique codes that the control panel will show in lieu of the J1939 DM1 messaging Otherwise codes will be displayed as J1939 SPN Suspect Parameter Number and...

Page 24: ...ve setting is desired If the parameter falls outside of the normal operating range the control panel will stop the engine by removing power to the fuel solenoid or ignition circuit The display will indicate the reason for the shutdown and a red alarm lamp will be illuminated in the upper left corner of the module Mechanical engines should use the module for all desired engine protection Example of...

Page 25: ...out the engine starting or after a protection shutdown occurs While in sleep mode the display goes blank and the red lamp blinks once every ten seconds The engine s ECU circuit is de energized as to not allow a continuous power drain The module will wake up and resume normal operation if any key is pressed or the power is cycled off and then back on If any of the keys are pressed the display will ...

Page 26: ...grammed to customize the initial display screen when powered up OEMs can provide a graphic file of their artwork to CI for loading into the firmware application SENDER FAILURE The control panel can detect when a local sender for a parameter such as oil pressure coolant temperature or fuel level is not present The display will indicate that a valid signal is not present by placing dashes in the are...

Page 27: ...ains logic that can be enabled to provide a safety shutdown override The override applies to any module monitored and activated alarm It does not apply to engine ECU safety shutdowns For ECU overrides consult with your engine supplier To use this feature an available digital input must be assigned to the Shutdown Override action and have a switch connected to it When the override is active the yel...

Page 28: ...ted The control panel will monitor all parameters as it would do in manual operation Once the auto start signal is no longer present the control panel will initiate the cooldown programmed configuration This may include a warm up sequence normal operating method and a cooldown sequence prior to shutting down the engine The panel will then resume the previous auto armed condition awaiting a new aut...

Page 29: ...d stop settings as well as the current measured value SCHEDULER AUTO START If the Scheduler is set up to provide starting and stopping based on the time of day and day of week the lower line will rotate to show the next start event Once running under the scheduler the Stop time will be displayed The scheduler can accommodate up to thirty two 32 start and stop events GENERAL TRANSDUCER AUTO START I...

Page 30: ...up prime or cool down speeds are not desired you can set the time period for that parameter to zero and the control will skip that routine SINGLE SPEED Single speed control refers to a single operating speed This is the speed at which the engine will run at for the duration of the automatic engine operation with the exception of warm up speed prime speed and cool down speed During the operating sp...

Page 31: ...while at the minimum analog signal and the maximum engine speed will be obtained when reaching the maximum analog signal level For example if you were using a 4 20 mA signal from a PLC or other device you can vary the engine speed in direct relationship to the signal This also the ability to invert the slope if desired For more details contact a Controls Inc sales engineer ...

Page 32: ... SYSTEM A more precise level control can be accomplished using two floats One float is installed at the low level limit and the other float is installed at the high level limit This dual float system is desirable when there are more stringent requirements on level control particularly in narrow tanks or turbulent fluids Assign one digital input to High Float and another the Low Float functions and...

Page 33: ...e This is an available option for backing up a level transducer installation A digital input must be assigned to the Float functions When the engine is running under the failsafe mode the yellow LED will be illuminated and the display will indicate the mode If the high float closes before the level as measured by the transducer reaches the On setpoint the transducer will be considered failed and t...

Page 34: ...propriate Range Use a transducer that matches your needs For example if you need to start and stop the pump between 10 and 40 inches use a 0 to 10 transducer The closer the working range is to the actual range the better performance and control you will achieve Material Know the type of liquid you will be subjecting your transducer to Typical materials range from stainless steel to titanium The co...

Page 35: ...dard Single Speed option Target and Linear See the Automatic Speed Control Modes section in the Auto Start Operation section of this manual PRESSURE CONTROL Highly accurate pressure control can be obtained by using a pressure transducer to monitor the pressure of fluid in the system You would typically use this option to monitor a system pressure and start the pump if it drops below a certain sett...

Page 36: ...35 MAIN MENU ACCESS To access the module menu system apply power to the module and press the Menu key MENU ENTER UP DOWN BACK ...

Page 37: ...nu contains information about the engine and module The topics will vary based on the engine type and control panel model Pressing the Up and Down key will move the highlighted selection up or down in the list Indicator Arrows show if there are additional subjects above or below the current screen view Pressing the Enter key will select the highlighted sub menu Menu Topic Sub Menus Indicator Arrow...

Page 38: ...cannot be covered in this manual however a list of main topics is below ACTIVE ENGINE FAULT CODES If the engine s ECU is generating trouble codes they can be viewed from this menu Typically a yellow warning lamp will be illuminated as well STORED ENGINE FAULT CODES The engine s ECU will store its fault codes The module can be used to view and clear them ...

Page 39: ...on about the operating conditions of the engine To view more of these details and gain a better understanding of your engine s operating conditions view this menu EMISSIONS PARAMETERS For engines equipped with emission components a menu is available to view these details ...

Page 40: ... Setup PUMP PARAMETERS If the four analog senders are configured for pump use the values can be seen here Note you must select either Application Level or Application Pressure when configuring the transducers OPERATION EVENT LOG The module will record the last 32 operational events and show the most recent first The event log can be cleared in the Module Configuration menu of the Controller Setup ...

Page 41: ...des and module monitored events such as low fuel level or other non ECU monitored events This paints a more complete picture of what is occurring at the engine while troubleshooting This log can also be cleared under the Module Configuration menu ENGINE IDENTIFICATION Use this menu to view the engine s Model and Serial number MODULE INFORMATION Use this menu to view the detailed information about ...

Page 42: ...lled CI Station PC BASED PROGRAMMING The CI Station is available in a kit form that includes the PC application USB programming adapter power supply and interconnect harnessing The CI Station allows the user to save configurations and reuse them over and over for production line programming or to configure replacement panels to match the original OEM programming Contact Controls Inc for more detai...

Page 43: ...l engines you would select the flywheel tooth count and preheat time is required For electronic engines you would be able to select the engine manufacturer minimum engine speed and maximum engine speed For further in depth programming you can access up to twenty other menu topics that will vary based on your model The ability to change the controller behavior though these menu systems is equivalen...

Page 44: ...he menu is still possible and permitted however the ability to make changes will be restricted To enter the password press the Enter key and brackets will appear Use the Up and Down arrow keys to set each digit individually pressing the Enter key to index to the next digit from left to right Once the last digit is entered the Setup Menu will be displayed and the selected sub topic will be the Quic...

Page 45: ...opic etc To make changes to the settings you will need to locate the item you are looking to modify under the appropriate topic and then press the Enter key The editing brackets will appear allowing you to make changes to the value or change the selection Once you have made your selection or changed the value simply press Enter again to accept it and the editing brackets will be removed ...

Page 46: ...eed sender options to be typical senders rather than J1939 Additionally the menu selections will change based on how you select certain options If you need to make changes after Quick Setup is complete navigate to the area of interest and set your parameters up as needed ENGINE PARAMETER CONFIGURATION Individual engine parameters can be changed here For example if you had an engine that provided a...

Page 47: ...ATION Up to four channels can be configured to take in 4 20mA 0 5 VDC or Ratiometric transducer In this menu you can configure the name of the parameter the units to be displayed minimum and maximum readings and which Channel it is located on Both Local and Remote Channels can be configured here SCHEDULER CONFIGURATION The module can be set to start and stop the engine based on the time of day and...

Page 48: ...4 input The module will monitor this input while the engine is running and will shut down the engine after five seconds if the modules detects the switch is closed to ground OUTPUT CONFIGURATION The module has eight on board relays that can be configured for engine operation and other requirements Two relays are rated at 10 amps and six are rated at 5 amps Typically relays 1 through 4 are reserved...

Page 49: ... details ENGINE SAFETY CONFIGURATION The module can provide warnings shutdowns deceleration and other behaviors based for the critical engine parameters of oil pressure coolant temperature engine speed fuel level and battery voltage Simply select the parameter in questions and set the thresholds and actions desired In the example below a warning will be annunciated when the fuel level drops below ...

Page 50: ...decelerated to minimum speed if it exceeds 250 psi ANALOG SAFETY CONFIGURATION If you have configured the analog channels for use you can use the settings here to set up warnings and shutdowns based on those values Select the channel of interest first and then program the thresholds as needed MODULE CONFIGURATION This menu allows you to configure the behavior of the module itself and to clear even...

Page 51: ...NFIGURATION This menu is used to define how and what messages are transmitted on the J1939 CAN Bus Destination and broad cast addresses are defined here Most CAN addresses will be programmed based on the engine manufacturer selection automatically However you can overwrite the defaults if desired If you are connecting to a CAN based telematics radio you may want to enable the transmission of param...

Page 52: ... define the time delays and speeds that will be used during an auto start routine Warm Up Seed Prime Speed Cooldown Speeds are programmed here BATTERY RECHARGE CONFIGURATION The module can be used to monitor the engine starting battery voltage and start the engine if the voltage drops below a programmed setting While the engine is running the engine driven alternator will recharge the battery Ther...

Page 53: ...FIGURATION If your engine is equipped with emission components you may use this menu to setup additional warnings enable and disable regen options and other CAN based messaging Consult with a CI application engineer if there are questions on its use MODBUS CONFIGURATION When connecting to a MODBUS devise such as PLCs telematics or other controls this menu will define the communication protocol for...

Page 54: ...has a unique MAC Address from the factory and operates as a MODBUS TCP client DHCP can be turned ON or OFF as well CLUTCH CONFIGURATION Two channels of interlocking relay behavior can be configured using relays 5 8 in the module Relays can be assigned to open and close based on a large number of factors including engine speed state load temperature etc Time delays can also be added as needed ...

Page 55: ...n US Time zone The real time clock on the module is backed up by a large capacitor that will keep the time correct for 2 to 3 months while it sits in the box If reprogramming is needed you can access this menu or use the CI Station setup too The module will automatically grab the date and time from your PCs memory ...

Page 56: ...odule has two Ampseal keyed connectors located on the back of the display The connectors provide access through the weather tight display enclosure which houses the electronics Primary Connector 14 Pin Secondary Connector 23 Pin ...

Page 57: ...Output 5 9 Relay Common 5 6 16 Relay 6 Contact 2 Oil Pressure Sender 10 Temperature Sender 17 Digital Input 2 3 Flex Analog 1 11 Flex Analog 2 18 Digital Input 3 4 Flex Analog 3 12 Flex Analog 4 19 Digital Input 4 5 Speed MPU Input 13 MODBUS A 20 Digital Input 5 6 Digital Input 8 14 MODBUS B 21 Digital Input 6 7 Digital Input 9 15 Relay Common 7 8 22 Digital Input 7 8 Relay Output 7 23 Relay Outpu...

Page 58: ...ns must be met if warranty is valid Seller will not be liable for any damage done by unauthorized repair work or unauthorized misapplication in non suitable environments In no event shall the Seller be liable for loss damage or expense directly or indirectly arising from the use of the units or from any other cause except as expressly stated in the warranty Seller makes no warranties expressed or ...

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