No.1400-0256-4 Framo Rev.E Aug 2005 Instruction for diesel engine control system Cummins KTA 19 DM1 Engine CONTENTS 1 GENERAL DESCRIPTION 1.1 Control system / PLC 1.2 Electric Fuel Controller, EFC 2 TECHNICAL DATA 2.1 Engine / EFC 2.2 Engine / Speed sensor 2.3 Engine / Alarm-shutdown limits 3 OPERATING INFORMATION 3.1 Start / Stop sequence 3.2 Communication fault 3.3 Engine cooling at High High temperature 4 TROUBLE SHOOTING / ADJUSTMENTS 4.1 Alarm / Shutdown indications 4.2 Speed sensor 8 20 FP1 SHUTDOWN EM. STOP CARGO PUMPS START STOP 0 0 0 OIL LEVEL LOW LOW PLC FAILURE FEED PRESSURE LOW PP1 OIL TEMPERATURE HIGH OIL LEVEL LOW POWER FAILURE MAIN FILTER DIRTY COMMUNICATION FAILURE SYSTEM PRESSURE LOW FUEL OIL HIGH LEVEL PROTECTION PRESSURE LOW FUEL OIL LOW LEVEL PP3 MOTOR CURRENT 1. This manual should be read in conjunction with dedicated drawings. serial communication .Em. Date/sign. SYSTEM RETURN LINE CLOSED EM.Instruction for Diesel Engine Control System CUMMINS KTA 19 DM1 ENGINE 1.0 LUBE OIL PRESSURE LOW LOW COOLING WATER TEMPERATURE HIGH HIGH 5 0. programmable logic controllers (PLC’s).remote start/ stop .common alarm / trip .5 HYDRAULIC SYSTEM SUCTION LINE CLOSED 0 OPERATION COOLING WATER TEMPERATURE °C 150 START STOP LOCAL REMOTE 75 0 TEST ACKNOWLEDGE RESET POW ER O N MANUAL O VERRIDE ( LOCAL PLC ) RS485. stop.0 DIESEL ENGINE LUBE OIL PRESSURE LOW LOW COOLING WATER TEMPERATURE HIGH HIGH 5 0.5 HYDRAULIC SYSTEM SUCTION LINE CLOSED 0 OPERATION COOLING WATER TEMPERATURE °C 150 START STOP LOCAL REMOTE 75 0 TEST ACKNOWLEDGE RESET POW ER O N MANUAL O VERRIDE ( LOCAL PLC ) .manual override Mode 1/2 .indication signals. . SYSTEM OIL HEATING ON/OFF POWER ON CARGO PRESSURE HIGH THRUSTER ON INERT GAS PRESSURE LOW °C bar/MPa 100 bar/MPa 16 400 1.1).Start/stop signals .remote/ local control . No.5 LUBE OIL PRESSURE COOLING WATER 10 b ar/MPa 75 150 °C 1. UNIT HYDR. system inhibit/ acceptancefor each engine . E: 1400-0256-4 10Jul98/JaEi 2 of 8 25Aug05/JaEi GENERAL DESCRIPTION This instruction manual describes the control system for the diesel engine including operator interface.5 150 °C 0.: Page: Rev.0 5 10 1. LUBE OIL PRESSURE ba r/MPa 75 0. Fig.0 A 0.0 5 0. OIL TEMPERATURE FEED PRESSURE SYSTEM PRESSURE MAIN PRESSURE SET EM. 1 : Interconnection of control system HYDRAULIC SYSTEM CONTROL PANEL CARGO PUMPING SYSTEM OPERATION MISCELLANEOUS AUX.Digital feedback signals +P32 DE NO 2 DIESEL ENGINE CONTROL ALARM DIESEL RPM RPM 2500 LUBE OIL PRESSURE LOW LUBE OIL TEMPERATURE HIGH COOLING WATER LEVEL LOW COOLING WATER TEMPERATURE HIGH HYDRAULIC PUMP WEAR INDICATION 1250 0 SHUTDOWN LUBE OIL PRESSURE BAR/MPa 10 OVERSPEED 1.hydr.run/ load indication signal . STOP HYDR.0 A OIL LEVEL HIGH PP2 MOTOR CURRENT FP2 ALARMS PP4 COOLING WATER 1.6 50 MANUAL OVERRIDE 40 8 200 0.Analogue feedback signals . STOP HYDR.5 START 0 0 0 WEAR INDICATION WEAR INDICATION WEAR INDICATION SUCTION LINE SUCTION LINE SUCTION LINE 0 0 DIESEL RPM WEAR INDICATION 2500 RPM DIESEL RPM 2500 RPM SUCTION LINE 1250 1250 COOLING SYSTEM FAILURE 0 TEST HORN SILENCE ACKNOWLEDGE RESET START STOP START STOP START STOP START ALARM 0 STOP START ALARM TRIP TRIP REMOTE CONTROL REMOTE CONTROL STOP ( MAIN PLC ) CARGO CONTROL ROOM ENGINE ROOM DIESEL ENGINE CONTROL PANEL +P31 DE NO 1 JUNCTION BOX WITH EFC DIESEL ENGINE CONTROL ALARM DIESEL RPM RPM 2500 LUBE OIL PRESSURE LOW LUBE OIL TEMPERATURE HIGH COOLING WATER LEVEL LOW COOLING WATER TEMPERATURE HIGH HYDRAULIC PUMP WEAR INDICATION 1250 0 SHUTDOWN LUBE OIL PRESSURE BAR/MPa 10 OVERSPEED 1.5 STOP 0 FP3 HPU OIL LEAKAGE Hardwired signals : . communication between hydraulic system control panels and local panels in addition to electric fuel control (EFC) (see fig. Detection of communication failure will release an alarm on main hydraulic system control panel. lamptest. . There are two circuits for rpm control. the engines can be operated in local mode. All circuits including EFC are FAIL SAFE. acknowledge and reset buttons in addition to remote/local selector switch. The local PLC communicates with the main PLC via RS 485 interface. shutdowns and running signals. which means that loss of electric power supply or loose wires during operation will stop the diesel engine. Indicating LED’s are provided for all alarms. Alarm/shutdown and monitoring of the engine lubrication pressure and cooling water temperature are based on analogue signals. E: 1400-0256-4 10Jul98/JaEi 3 of 8 25Aug05/JaEi Control system / PLC (Programmable Logic Controller) The local panels contains individual PLC’s for increased availability. the engine must be operated from local panel. In case of failure to the link. and one speed pickup for monitoring and overspeed trip is connected to the PLC.Instruction for Diesel Engine Control System CUMMINS KTA 19 DM1 ENGINE 1. In this case.and stop as described later in this manual. Date/sign. One speed pickup for rpm control is connected to the EFC located in the diesel engine juncton box.and cooling sequences are implemented during start.1. as the vital signals are hardwired to/from hydraulic system control panel. shutdowns and alarms. The local PLC controls functions such as start / stop. Engine heating. No. The front panel contains start/stop. Loop detection is provided and the engine will trip when open or shorted current loop is detected.: Page: Rev. No. . a change in current from the EFC to the actuator will regulate the magnetic force in the actuator.2 FLY WHEEL SPEED SENSOR NO. Shaft movement is proportional to the amount of actuator current and is counter balanced by the internal spring in actuator.1 CYLINDERS / PISTONS FUEL INJECTORS FUEL RETURN RAIL FUEL SUPPLY RAIL CHECK VALVE CHECK VALVE FUEL INLET MAGNETIC FILTER FUEL STOP VALVE FUEL TANK ACTUATOR CENTRIFUGAL GOVERNOR FUEL PUMP FUEL FILTER The unit compare the feedback signal to a preset engine speed setting. 2 ENGINE DIESEL CONTROL PANEL PLC EFC SPEED SENSOR NO. 2 Fig.The movement of the actuator shaft will then adjust the fuel flow to the engine and cause the engine speed to be equal to the preset value. 1400-0256-4 10Jul98/JaEi 4 of 8 25Aug05/JaEi Electric fuel control system.: Page: Rev. This system is designed for regulation of engine acceleration and steady state fuel flow dependent on engine start-up and load requirements.2. When deviaton is detected. The magnetic pickup senses the engine speed at the flywheel ring gear and gives an input signal to the EFC unit ref. Date/sign. E: Instruction for Diesel Engine Control System CUMMINS KTA 19 DM1 ENGINE 1. EFC The electric fuel control system consist of a magnetic pickup. Fig. an electric fuel control governor (EFC) and actuator. +/.3 °C Alarm Shutdown 1.10 bar/ 4-20mA 0 -150 °C/ 4-20 mA 60 -150 °C/ switch Sensor tolerance +/.9 Amps at 24VDC : 15 milliseconds Speed sensors connected to EFC and engine monitoring system (PLC) Type : magnetic pick up Threads : 5/8-18 UNF-2A Signal at normal speed 1770 +5 / -10 rpm : 4201 / 4165 Hz Signal at low speed 1500 +50 / -0 rpm : 3550 / 3669 Hz Number of gear teeth at ‘flywheel‘ : : 142 pcs. E: 1400-0256-4 10Jul98/JaEi 5 of 8 25Aug05/JaEi Technical data : 2.8 +-*** 96 °C 120 °C NA 1.2 2. (°C) Lube.3+-*** 100 °C NA 1860 rpm 4402 Hz 1890 rpm 4473 Hz .15 % : 1. Date/sign. Function Sensor range Lube.2 °C +/.Instruction for Diesel Engine Control System CUMMINS KTA 19 DM1 ENGINE 2. Alarm and shutdown data. (°C) Overspeed with 1 sec delay Overspeed without delay 0 .3 : analogue : 24 VDC.: Page: Rev.Oil pressure (bar) Cool water Temp.3 Amps at 24VDC : 3.04 bar +/.1 Electric fuel control unit ( EFC ) Signals Supply voltage Nominal Operating Current Maxium Operating Current Response time of actuator 2.0.0 No.Oil temp. Date/sign.1 Start/ Stop sequence Following start/ stop sequences are implemented in the local PLC.: Page: Rev. 1400-0256-4 10Jul98/JaEi 6 of 8 25Aug05/JaEi . E: OPERATING INFORMATION 3.Instruction for Diesel Engine Control System CUMMINS KTA 19 DM1 ENGINE No. The engine will run in low speed for 1 minute and then stop.3 Engine cooling at cooling water temp. remote control indication lamp is flashing Fasten loose wire/ connections with reference to actual drawings. Measure sensor output signal with reference to technical data.2 No. .lube oil low press . 3. it is possible to start the diesel engine in local mode to avoid overheating of engine.1 Alarm/ Shutdown indications. High High In case of stop caused by cooling water temp. E: 1400-0256-4 10Jul98/JaEi 7 of 8 25Aug05/JaEi Communication fault In case of failure at RS485 communication system. indicator = zero / temp. indicator = max.cool Water temp HI HI Cooling Water temperature sensor/cable loop failure. indicator = zero/max. it is possible to run the diesel engine as follow : . 4. LED activated at local panel Hydraulic System not ready.Oil pressure sensor/cable loop failure.lube oil low-low press Lube. high high. Both alarm activated : . Both alarm activated : . Check alarm status on hydraulic system control panel Communication fault No red LEDs flickering at indicated at main cargo actual diesel control PLC control panel.0 TROUBLE SHOOTING For detailed trouble shooting and maintance at engine refer to separate instruction from engine manufacturer. Date/sign. Temp. Check alarm status on hydraulic system control panel Manual Override. Actual diesel communication port. Press.cool Water temp HI .select local mode and start engine locally Communication fault is indicated by flashing diesel engine power unit remote and PLC/ communication failure lamp at hydraulic system control panel. Symptom/ failure: Possible reason: Remedy Hydraulic System.: Page: Rev. 4. LED activated at local panel Manual override mode is activated.Instruction for Diesel Engine Control System CUMMINS KTA 19 DM1 ENGINE 3. when required.Instruction for Diesel Engine Control System CUMMINS KTA 19 DM1 ENGINE 4. Date/sign. do not use excessive pressure to install the pickup Back the pickup out ½ to ¾ of a turn Adjust the pickup so the output signal level from pickup is approx. .: Page: Rev. Plug the electrical connection into the pickup. E: 1400-0256-4 10Jul98/JaEi 8 of 8 25Aug05/JaEi Speed sensor/ pickup adjustment Re installation of speed sensor : Screw the magnetic pickup all of the way down until it contacts a flywheel gir tooth. the piuckup will screw in very easy.2 No. 20 VAC at 1770 rpm Tighten the locknut down on the flywheel housing.