Woodward GECO Technical Manual Download Page 4

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GECO



Stoichiometric Manual

03554

Woodward

Contents

HAPTER

GECO™

ISTA

HMI

ISPLAY

................................................ 46

Overview ............................................................................................................... 46

Navigation ............................................................................................................. 46

Main Screen .......................................................................................................... 47

Alarm Screen ........................................................................................................ 48

Trend Screen ........................................................................................................ 48

Diagnostic Screen ................................................................................................ 49

HMI Display Offline Mode ..................................................................................... 49

HMI Screen Brightness Adjustment...................................................................... 51

HAPTER

NSTALLATION

ETUP

............................................................. 52

Installation Tasks .................................................................................................. 52

Included GECO



Stoichiometric Components ....................................................... 52

Optional GECO



Stoichiometric Components ....................................................... 52

Required Installer-Provided Components ............................................................ 53

Optional Installer-Supplied Components .............................................................. 53

Unpacking ............................................................................................................. 53

Power Requirements ............................................................................................ 53

Control Location Considerations .......................................................................... 54

Class I, Division 2, Groups A, B, C, D Hazardous Locations ............................... 55

Wiring Installation ................................................................................................. 55

Making Electrical Connections ............................................................................. 55

Status Indicator LEDs ........................................................................................... 62

Software Installation ............................................................................................. 62

Updating Application Programming (.S19 file) ..................................................... 63

Fuel Metering/Valve Location Considerations ...................................................... 63

Plumbing Considerations ...................................................................................... 63

EGO Installation .................................................................................................... 64

HEGO Installation ................................................................................................. 65

Catalyst Temperature Sensor Installation ............................................................ 65

Supplemental Valve Installation Diagrams ........................................................... 66

Full-flow Valve Installation Diagrams.................................................................... 67

Configuration and Calibration ............................................................................... 68

HAPTER

AINTENANCE AND

AULT

NDICATIONS

................................. 70

Maintenance ......................................................................................................... 70

Safety Checks ....................................................................................................... 70

Replacement Information ..................................................................................... 70

Troubleshooting .................................................................................................... 71

Recommended Spare Parts ................................................................................. 73

HAPTER

10.

ERVICE

PTIONS

................................................................ 74

Product Service Options ....................................................................................... 74

Woodward Factory Servicing Options .................................................................. 75

Returning Equipment for Repair ........................................................................... 75

Replacement Parts ............................................................................................... 76

Engineering Services ............................................................................................ 76

How to Contact Woodward ................................................................................... 77

Technical Assistance ............................................................................................ 77

PPENDIX

ODBUS

EGISTER

DDRESSES

.............................................. 78

Summary of Contents for GECO

Page 1: ...cal Manual 03554 Revision D Original Instructions GECO GECO Vista Stoichiometric Gas Engine Controls Air Fuel Ratio Control for Emissions controlled Stationary Gas Engines Installation and Operation M...

Page 2: ...To verify that you have the latest revision be sure to check the publications page on the Woodward website www woodward com searchpublications aspx The current revision and distribution restriction o...

Page 3: ...Communications 9 Modbus Communication 10 System Diagram Examples 11 CHAPTER 3 SYSTEM COMPONENTS 13 Circuit Board Panel Assembly 13 Hand Held Terminal 14 Enclosure 14 Fuel Control Valve for Supplementa...

Page 4: ...Making Electrical Connections 55 Status Indicator LEDs 62 Software Installation 62 Updating Application Programming S19 file 63 Fuel Metering Valve Location Considerations 63 Plumbing Considerations...

Page 5: ...sions 15 Figure 3 2 Circuit Board Cover wiring legend plate 16 Figure 3 3 Valve Outline Drawing 17 Figure 3 4 HEGO Sensor Connector Pin Arrangement 20 Figure 4 1 Pre Catalyst EGO Closed Loop Control M...

Page 6: ...used within a suitable enclosure The final assembly is subject to acceptance by the authority having jurisdiction Wiring must be in accordance with North American Class I Division 2 wiring methods as...

Page 7: ...ials such as plastic or Styrofoam cups cup holders cigarette packages cellophane wrappers vinyl books or folders plastic bottles and plastic ash trays away from the control the modules and the work ar...

Page 8: ...GECO Stoichiometric Manual 03554 vi Woodward...

Page 9: ...n feedback cascade control allowing adaptation to changing catalyst performance Post catalyst exhaust oxygen control set point variable with engine load Adjustable fuel valve dithering algorithm for b...

Page 10: ...mbda 1 phi Degree Fahrenheit Gas Engine Control Ignition pulse output signal high voltage used for engine speed measurement Heated Exhaust Gas Oxygen Sensor kilopascal pressure kilowatt power A transd...

Page 11: ...solute p n 6910 314 1 Differential Pressure Sensor 1 5 Vdc 0 15 H2O 1 Magnetic Pickup p n 5430 929 or equivalent 0 20 100 Vrms 8 10 000 Hz 1 G lead pulse from ignition system 250 V max Outputs 2 PWM F...

Page 12: ...I Division 2 Groups A B C D T5 at 70 C Ambient For use in Canada and the United States CSA Certificate 1214651 GECO Vista CSA Certified for Class I Division 2 Groups A B C D T4A at 40 C Ambient For u...

Page 13: ...e adjusted slightly rich During operation the GECO stoichiometric control restricts flow using a full flow trim valve located inline upstream of the carburetor to bring the air fuel mixture to the req...

Page 14: ...atalyst EGO Control Post Catalyst Exhaust Oxygen Control In order to assure optimal catalyst performance over time as conditions vary and the catalyst element ages the GECO Stoichiometric control has...

Page 15: ...erent loads The GECO control keeps track of engine load by monitoring the intake manifold pressure MAP and engine speed MPU The intake manifold pressure and engine speed are used to calculate an appro...

Page 16: ...Loop Control The open loop control mode can be used as the primary control mode but it mainly serves as a backup to the pre catalyst closed loop control mode If the EGO1 or 2 sensor fails the control...

Page 17: ...drift more without reducing the efficiency of the catalyst Diagnostics and Monitoring For system reliability the GECO control monitors sensor inputs and control outputs for high and low failure condit...

Page 18: ...PC So Modbu l is also capab The commu rmation distrib ning many helpful data monitorin l allows only v p and calibrati 2 9 PC Com ontrol Moni s High eam OK eam OK Misc er OK ontrol ate HOLDIN Relay O...

Page 19: ...Manual 03554 GECO Stoichiometric Woodward 11 System Diagram Examples Figure 2 11 GECO System for Single Carburetor Engine...

Page 20: ...GECO Stoichiometric Manual 03554 12 Woodward Figure 2 12 GECO System for Dual Carburetor Engine...

Page 21: ...rd See the section in this chapter titled Hand Held Terminal The 6 pin Molex connector next to the RJ12 connector provides a connection to a panel or remotely mounted LED display of power alarm and sh...

Page 22: ...it is live not be opera when a haza ure P N 1627 101 enclosed in a steel box The x 127 mm 12 quick release access The environm enclosure mee 3 UL 50 IEC standard EGP otection from d Vdc supplied b 470...

Page 23: ...obstruction and available for conduit entry We recommend locating knockouts in the bottom of the box It is highly recommended that the circuit board be removed from the enclosure before conduit openi...

Page 24: ...to the engine The GECO system adjusts this supplemental fuel with a proportional solenoid valve command and powered from the GECO circuit board The valve position is proportional to the command signal...

Page 25: ...gh holes in a square 41 1 mm 1 62 inch pattern for mounting Figure 3 3 Valve Outline Drawing The gas inlet is a 0 25 inch 6 4 mm NPT threaded fitting and the outlet is 3 8 inch 9 5 mm NPT Environmenta...

Page 26: ...retor fuel inlet Connector The following Deutsch connector components are recommended for harness designs Recommended Optional Mating Connector DT06 12SA P012 DT06 12SA Secondary Lock W12S P012 N A So...

Page 27: ...ard part number for the mating connector is 8928 399 Connector Wiring Terminal Wire Color Function GECO Terminal 1 gray signal 75 77 2 black signal ground 76 78 Heated Exhaust Gas Oxygen HEGO Sensor P...

Page 28: ...used by the control to measure the intake manifold pressure It is an absolute pressure sensor with a 300 kPa 43 5 psia range and a 0 5 Vdc output signal Like the EGO and HEGO sensors it was developed...

Page 29: ...e 9 pin DB9 male to 9 pin DB9 female Minimum PC requirements are Pentium processor 32 MB of RAM memory Windows NT Windows 2000 XP Windows Vista This software will NOT run on DOS or Windows 9x P N 202...

Page 30: ...g Diagram The LEDs can be connected as in the wiring diagram above Also you can check with your GECO distributor for availability of pre wired panel mounted LED modules that include a DB9 connector fo...

Page 31: ...atio signal in the vicinity of stoichiometry for precise fuel control feedback Figure 4 1 Pre Catalyst EGO Closed Loop Control Mode Diagram The GECO PC Tool will display the EGO feedback value in the...

Page 32: ...rating conditions Figure 4 2 Adaptive EGO Closed Loop Control Mode Diagram The most common upstream EGO target value is entered as the EGO1 Base and the EGO2 Base values These values automatically bec...

Page 33: ...y at the time of installation and setup They can also be learned through an internal Valve Learn function during normal closed loop operation While the engine and control are operating in one of the c...

Page 34: ...p operation Modbus Communication The GECO Stoichiometric control can serve as a Modbus slave unit and will respond to requests for information from a properly programmed master The table below gives s...

Page 35: ...control value bank 1 15 Battery voltage low alarm 31 Closed loop control value bank 2 35 TC2 lower than expected alarm 34 Fuel valve command bank 1 36 TC1 lower than expected alarm 35 Fuel valve comma...

Page 36: ...the p o move the bl er 5 nal Ope nal Opera erminal is des monitoring func oichiometric co rrent operating faults When rminal can be store normal osed loop con both alarm a control and fa access code...

Page 37: ...on and revision date will be displayed 2 If fault codes need to be cleared quickly to resume normal operation all alarm and shutdown codes can be cleared from this screen However for maintenance and d...

Page 38: ...voltage from the power supply The miscellaneous faults on this screen are for internal ECU operation and problems with the engine speed signal 6 In addition to the shutdown screen which indicates exc...

Page 39: ...anges Hand Held Terminal Configuration Screens Password required for these screens Contact your distributor for more information 10 The closed loop and adaptive gain values control system response and...

Page 40: ...be activated by a switch signal through the digital input D1 Hand Held Programmer Configuration A hand held set up mode is activated by holding down any key when power is applied Although it should n...

Page 41: ...addition the PC interface allows configuration changes To install the GECO PC interface software 1 Insert the CD or diskette in the appropriate disk drive 2 Run the file named GECOPC_Setup exe and fo...

Page 42: ...modes can be toggled with the arrow keys then selected with the ENTER key The current text information from any screen can be saved to a file with the F2 function key The ESC escape key will exit fro...

Page 43: ...Manual 03554 GECO Stoichiometric Woodward 35 Screen 2 GECO Stoichiometric Air Fuel Control Configuration password protected Screen 3 GECO Stoichiometric Air Fuel Control Calibration password protected...

Page 44: ...e input in degrees F TC Downstream Post catalyst thermocouple input in degrees F Control1 OPEN LOOP CLOSED LOOP CL ADAPTIVE These are the air fuel ratio control modes Control2 Same as Control1 except...

Page 45: ...tch OFF ON The position of the closed loop switches on the circuit board Manual Mode OFF ON This mode can be activated only while in the OPEN LOOP control mode It allows for manual positioning of the...

Page 46: ...ue EGO2 See above EGO3 See above Screen 2 Inputs EGO1 ON OFF EGO2 ON OFF EGO3 ON OFF TC_upstream Catalyst inlet temperature ON OFF TC_downstream Catalyst outlet temperature ON OFF MAP Inlet manifold t...

Page 47: ...ed to the inH2O voltage input and is the low end calibration variable Span The multiplier applied to the DP voltage input and is the high end calibration variable Default The value that the DP scaled...

Page 48: ...seen by the magnetic pickup RPM Auto Mode ENABLED or DISABLED When DISABLED the start sequence switches from CRANKING to RUNNING at 450 rpm When ENABLED this switch takes place at a speed calculated f...

Page 49: ...N LOOP CLOSED LOOP CL ADAPTIVE These are the air fuel ratio control modes Control2 same RunMode STOPPED CRANKING RUNNING These are the start sequence modes Once the engine reaches idle speed it should...

Page 50: ...Base Phi EGO2 Base Voltage corresponding to Base Phi EGO 1 2 Filter Tau EGO sensors 1 2 filter time constant EGO 3 4 Filter Tau EGO sensors 3 4 filter time constant Valve1 Excursion Valve excursion i...

Page 51: ...proportion gain value of the adaptive control loop K_Valve Learn The gain value of the valve position learning function that determines how quickly the recorded valve position value moves toward the...

Page 52: ...s per hour per liter of engine displacement Mdot_air The current calculated air mass flow value in pounds per hour per liter of engine displacement Mdot_air breakpoint The value of air mass flow above...

Page 53: ...s 10 00 variables to d ing interval in t file name da cord FIRST 10 ogging ubleshooting i chiometric int and the T Ta ope type form logging inform 0 second sca key at these e pause the ESC escape e pr...

Page 54: ...FR control The screen firmware can be modified to meet your specific needs such as activating the V bank Main screen Figure 7 4 and is capable of Ethernet connection to a PC server for system data gat...

Page 55: ...oodward 47 Main Screen The Main screen allows access to the key operating information such as engine speed manifold pressure catalyst health and control status Figure 7 3 GECO Vista Main Screen Figure...

Page 56: ...ion of the fault The Alarms and Shutdowns may be cleared by pressing the respective reset button The faults are not permanently logged and will drop out when the reset button is pressed Figure 7 5 GEC...

Page 57: ...vice Tool Figure 7 7 GECO Vista Diagnostic Screen HMI Display Offline Mode The HMI display can be placed in OFFLINE mode to set the current time and date Entering Offline Mode There are two ways of en...

Page 58: ...ight corners within 40 pixels of the edges of the panel screen in this order within 0 5 seconds OR The System Menu will be displayed touch the Offline button To set the current time and date touch the...

Page 59: ...ard 51 HMI Screen Brightness Adjustment This mode must be entered during Run mode only Touch either the upper right and upper left corners or the upper left and upper right corners within 40 pixels of...

Page 60: ...m Cut and weld tubing and flanges Fabricate strong stiff mounting brackets with consideration for vibration and fatigue Provide a power source for the control Provide a 5 A slow blow fuse installed in...

Page 61: ...rm relay circuit Shutdown relay circuit Unpacking Before handling the control read Electrostatic Discharge Awareness at the beginning of this manual Be careful when unpacking the electronic control Ch...

Page 62: ...era and clearanc r conduit on b servicing and from direct ex prone environ from high vo vices which p of vibration kid shock iso ECO distribu of a location t perature rang r GECO Stoic 2 to 104 F e en...

Page 63: ...g for the operator control panel such as switches lights horn or gages should also be installed at this time The GECO enclosure should be properly connected to earth ground Making Electrical Connectio...

Page 64: ...arate conduit from GECO sensors and valves Avoid conduit or wire proximity to hot surfaces specially exhaust components Grommets must be installed in holes conduit ends or boxes to protect wire insula...

Page 65: ...Manual 03554 GECO Stoichiometric Woodward 57...

Page 66: ...GECO Stoichiometric Manual 03554 58 Woodward Figure 8 2 Wiring for Single Bank...

Page 67: ...Manual 03554 GECO Stoichiometric Woodward 59...

Page 68: ...GECO Stoichiometric Manual 03554 60 Woodward Figure 8 3 Wiring for Dual Bank...

Page 69: ...Manual 03554 GECO Stoichiometric Woodward 61 Figure 8 4 Legend Plate...

Page 70: ...e GECO system this program has the extension s19 These two programs work together when changes are made to the configuration or calibration of the system parameters Changes made on the user interface...

Page 71: ...surface or bracket the valve should not be suspended on plumbing or conduit connections Avoidance of vibration Selection of a location that will provide an operating temperature within the specificati...

Page 72: ...e used to facilitate exhaust oxygen and temperature sensor replacement Temperatures at the sensor threads can be as high as 1200 F 650 C so the anti seize compound should be designed for this heat ran...

Page 73: ...re very thin sensors and very strong exhaust pulses can fatigue and break the sensor tip On the top 180 of the exhaust pipe to avoid corrosion in the fitting due to condensation Drill holes in suitabl...

Page 74: ...e contaminants that will eventually poison the exhaust catalyst In other words a sensor failure may give warning that maintenance is needed before the catalyst is also damaged Supplemental Valve Insta...

Page 75: ...Manual 03554 GECO Stoichiometric Woodward 67 Full flow Valve Installation Diagrams Figure 8 6 L Series ITB Outline Drawings...

Page 76: ...power rated MAP rated rpm rpm source rpm pulse rev 4 Move to the Monitor screen Screen 1 Check that the cursor is highlighting the ClearAll label and press the Enter key Check to see that all faults...

Page 77: ...ons in all Bank1 and Bank2 points of the Valve Learn table 18 Enter 0 00 V for EGO3 Offset into the Valve_Learn at 100 load 19 Set the circuit board toggle switch to Closed Loop Verify that the contro...

Page 78: ...the exhaust gas oxygen sensors intake manifold pressure sensors have a limited life and will require regular replacement A regular program for engine maintenance should continue after the GECO Stoichi...

Page 79: ...CJC Sensor open 4 95 V 300 F CJC Sensor lower than expected 0 05 V 45 F Alarm and Shutdown Configuration Fault Conditions Disable Enable Enable Shutdown UEGO max voltage 1 1 V EGO health 35 TC open 4...

Page 80: ...r supply Short to other voltage source Computer ECU Trigger Other high voltage or high current wires near G lead wiring Unshielded G lead wiring Ignition system problem magnetic pickup EGO Signal High...

Page 81: ...ardous atmosphere is present RPM Signal Issues The control will follow several different control strategies depending on the engine speed signal If the control is not receiving proper speed signals or...

Page 82: ...mentation for details Woodward Business Partner Support Woodward works with and supports a global network of independent business partners whose mission is to serve the users of Woodward controls as d...

Page 83: ...istributor Charges for the Replacement Exchange service are based on a flat rate plus shipping expenses You are invoiced the flat rate replacement exchange charge plus a core charge at the time the re...

Page 84: ...cal Support Product Training Field Service Technical Support is available from your equipment system supplier your local Full Service Distributor or from many of Woodward s worldwide locations dependi...

Page 85: ...2191 Korea 82 51 636 7080 The Netherlands 31 23 5661111 Poland 48 12 295 13 00 United States 1 970 482 5811 You can also locate your nearest Woodward distributor or service facility on our website at...

Page 86: ...6 0 volts 25 EGO2_BASE EGO2 base desired voltage 1 0 8 1 2V 0 004684096 0 volts 26 EGO1_HEALTH EGO1 health 1 0 8 fraction 0 390625 0 27 EGO2_HEALTH EGO2 health 1 0 8 fraction 0 390625 0 28 EGO3_HEALTH...

Page 87: ...82 MAP1_VOLTS MAP raw unfiltered and scaled voltage 1 0 8 5V 0 019607843 0 volts 85 CJC_VOLTS CJC raw unfiltered and scaled voltage 1 0 8 5V 0 019607843 0 volts 86 DP1_VOLTS DP raw unfiltered and scal...

Page 88: ...ULT 0 1 48 7 ISR_AL Unscheduled or improper interrupt alarm OK FAULT 0 1 50 6 1 EGO3_OPEN_AL Open EGO3 connection or lazy EGO3 sensor alarm OK FAULT 0 1 51 2 EGO2_OPEN_AL Open EGO2 connection or lazy...

Page 89: ...erature high alarm OK FAULT 0 1 129 16 0 TC1_L_SD TC1 low temperature shutdown OK SHUTDOWN 0 1 130 1 TC2_L_SD TC2 low temperature shutdown OK SHUTDOWN 0 1 137 17 0 TC1_H_SD TC1 high temperature shutdo...

Page 90: ...st Drake Road Fort Collins CO 80525 USA Phone 1 970 482 5811 Fax 1 970 498 3058 Email and Website www woodward com Woodward has company owned plants subsidiaries and branches as well as authorized dis...

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Woodward GECO, Technical Manual, Page: 4 / 90

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Summary of Contents for GECO

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