Installation Of 132-5560 Remote Speed Control Kit{1915, 1900} Caterpillar

Introduction

This Special Instruction describes the procedures for installation and troubleshooting of the 132-5560 Remote Speed Control Kit for G3600 Engines with the Engine Supervisory System (ESS) panel.

This Special Instruction contains installation, operations, and basic troubleshooting information. Read, study, and keep this information with the other product literature for your engine.

Whenever a question arises about this product or this Special Instruction, contact your Caterpillar dealer regarding the latest available information.

Reference: G3600 Engine Troubleshooting, SENR6510.

Description

The purpose of the G3600 Engine Supervisory System (ESS) Remote Speed Control (RSC) is to provide a 4 to 20 milliamperes (mA) interface to the desired speed input of the ESS for a customer-supplied engine rpm (speed) input. The RSC monitors the Local Speed (Desired Speed Potentiometer) input and the Remote Speed (4 to 20 mA) input. (Refer to Illustration 2.)

The RSC provides outputs to inform the customer that the engine is running from the Remote Speed or Local Speed input. (Refer to Illustration 2.) The RSC also provides circuitry that will only allow switching between the inputs if the two speed inputs are within 2.5 percent of each other.

General Information

When an RSC is installed the following requirements must be met.

* The mounting, environment, power, and wire specifications must be followed as outlined in this Special Instruction.

* The connection diagrams must be adhered to.

Specifications

* Environmental

The ambient operating temperature range is from -40 to 85° C (-40 to 185° F).

The storage temperature is from -40 to 85° C (-40 to 185° F).

Power

The RSC requires 24 volts DC power (VDC) which is the same requirement as for the ESS system. The RSC can therefore be powered by the ESS system.

Maximum power dissipation is 12 watts at 24 VDC.

The relay driver outputs can drive a relay or lamp that is rated for 200 mA or less. The 130-2707 Indicator Assembly (Green Lamp) and the 130-2708 Indicator Assembly (Amber Lamp) are recommended.

Installation Procedure

Mounting 7C-6854 And 7C-6855 ESS Panels

1. Install the 130-2705 Film (Remote Speed) on the ESS panel door over the current desired speed film. (Refer to Illustration 1.)

2. Cut one 12.2 mm (0.48 in) hole and four 13.2 mm (0.52 in) holes in the ESS panel door for the switch and indicator lamps. Use the 130-2705 Film (Remote Speed) as a guide. Be aware of existing wires on the back side (inside) of the door when cutting the holes.

3. Install one 130-2707 Indicator Assembly (Green Lamp), three 130-2708 Indicator Assemblies (Amber Lamps), and one 130-2704 Switch Assembly in the ESS panel door. (Refer to Illustration 1.)

NOTE: The switch should be mounted so that it points toward the LOCAL active lamp (green) when the circuit is open. The switch should be mounted so that it points toward the REMOTE active lamp (amber) when the circuit is closed.

4. Remove the Desired Speed Buffer from the inside of the ESS panel. The Desired Speed Buffer is the lower control of the two on the left side of the ESS panel. (Refer to Illustration 3.) DO NOT discard the mounting screws. They will be required in Step 6. Disconnect the wires from the Desired Speed Buffer.

5. Remove the Fuel Energy Content (BTU) buffer from the ESS panel. (Refer to Illustration 3.) DO NOT discard the mounting screws. They will be required in Step 8.

6. Install the 125-5486 Control Group on top of the 130-2706 Plate Assembly. Use the two mounting screws from Step 4. (Refer to Illustration 5.)

7. Install the 130-2706 Plate Assembly onto the side of the ESS panel using two 3H-3627 Machine Screws and two 4B-4863 Washers. (Refer to Illustration 5.)

8. Install the Fuel Energy Content (BTU) potentiometer buffer onto the 130-2706 Plate Assembly. Use the two mounting screws from Step 5. (Refer to Illustration 5.)

9. Tighten all fasteners (screws) to 1.7 ± 0.3 N·m (15 ± 2 lb in). Connect the wires according to Illustration 6 and Chart B in this Special Instruction.

10. The 4 to 20 mA input on the RSC may have a different resistance than any module it replaces. The module generating the 4 to 20 mA signal may have to be adjusted to compensate for this difference.

11. Replace the Personality Module with one that has the updated Desired Speed scaling.

Installation Procedure

Mounting 129-1316 And 129-1317 ESS Panels

1. Install the 130-2705 Film (Remote Speed) on the ESS panel door over the current desired speed film. (Refer to Illustration 1.)

2. Cut one 12.2 mm (0.48 in) hole and four 13.2 mm (0.52 in) holes in the ESS panel door for the indicator lamps and switch. Use the 130-2705 Film (Remote Speed) as a guide. Be aware of existing wires on the back side (inside) of the door when cutting the holes.

3. Install one 130-2707 Indicator Assembly (Green Lamp), three 130-2708 Indicator Assemblies (Amber Lamps), and one 130-2704 Switch Assembly in the ESS panel door. (Refer to Illustration 1.)

NOTE: The switch should be mounted so that it points toward the LOCAL active lamp (green) when the circuit is open. The switch should be mounted so that it points toward the REMOTE active lamp (amber) when the circuit is closed.

4. Remove the Desired Speed Buffer from the inside of the ESS panel. The Desired Speed Buffer is the upper control of the two on the left side of the ESS panel. (Refer to Illustration 4.) DO NOT discard the mounting screws. They will be required in Step 5. Disconnect the wires from the Desired Speed Buffer.

5. Install the 125-5486 Control Group where the Desired Speed Buffer was removed. (Refer to Illustration 4.)

6. Tighten all fasteners (screws) to 1.7 ± 0.3 N·m (15 ± 2 lb in). Connect the wires according to Illustration 6 and Chart B in this Special Instruction.

7. The 4 to 20 mA input on the RSC may have a different resistance than any module it replaces. The module generating the 4 to 20 mA signal may have to be adjusted to compensate for this difference.

8. Replace the Personality Module with one that has the updated Desired Speed scaling.

Illustration 1. Film (Decal) On ESS Panel Door: (1) 130-2705 Film (Remote Speed). (2) 130-2708 Indicator Assembly (Amber Lamp). (3) 130-2707 Indicator Assembly (Green Lamp). (4) 130-2704 Switch Assembly.

Illustration 2. Remote Speed Control On Top Of Plate Assembly: (5) 125-5486 Control Group.

Illustration 3. 7C-6854 And 7C-6855 ESS Panels: (6) Fuel Energy Content (BTU) Buffer. (7) Desired Speed Buffer.

Illustration 4. 129-1316 And 129-1317 ESS Panels: (7) Desired Speed Buffer.

Illustration 5. 130-2706 Plate Assembly: (8) 125-5486 Control Group. (9) Existing screws. (10) 3H-3627 Machine Screw and 4B-4863 Washer. (11) 130-2706 Plate Assembly. (12) Existing screws. (13) Fuel energy content (BTU) buffer.

Illustration 6: Connection Diagram.

Wires And Cables

*The wires connected to the Remote Speed Control must be at least 18 AWG.

No terminations or splices are allowed on any of these wires, except as noted in the connection diagrams.

System Operation And Instructions

Switch Positions

When the selector switch is in the LOCAL position, engine rpm (speed) is adjusted with the Desired Speed Potentiometer on the front of the ESS panel. The Local Speed Active output on the RSC is energized to indicate engine rpm is being locally controlled. This mode is primarily used for initial engine starting, shutdown, and maintenance operations.

When the selector switch is in the REMOTE position, engine rpm (speed) is adjusted by an external 4 to 20 mA signal. The Remote Speed Active output is energized to indicate the engine is being controlled from a remote source.

The mode (Local or Remote) is controlled by a selector switch on the front of the ESS panel. Switching modes is only allowed when the engine rpm differential between the Local setting and the Remote setting is less than a preset tolerance (within 2.5 percent). If the selector switch is moved when the rpm differential is less than 2.5 percent, nothing will happen until the differential is less than the tolerance.

Status Lamps

There are two status indicators to help with switching modes. The indicator lamps are Local Speed Low and Local Speed High.

The Local Speed Low output is energized if the local speed is too far below the remote speed to facilitate switching. The Local Speed High output is energized if the local speed is too far above the remote speed to facilitate switching.

If both outputs are not energized, the two speeds are within switching tolerance and the engine can be controlled from the selected engine rpm (speed) input.

The typical Engine Mode Switching is described below.

Engine Start Up - The selector switch is in the LOCAL position. The engine is started and site conditions are stabilized. The local speed is adjusted so that it is within tolerance of the remote speed setting. The selector switch is moved to the REMOTE position. Engine speed now follows the remote signal.

Maintenance/Shutdown - The local speed setting is adjusted to within tolerance of the remote setting. The selector switch is moved to the LOCAL position. Engine rpm is adjusted as necessary for maintenance or the engine is shut down. The selector switch is then placed in the REMOTE position to allow remote speed control as described in the Engine Start Up topic.

Operation With Selector Switch In LOCAL Position

* The desired speed output signal follows the local engine rpm (speed) input.

* The Local Mode Active output is energized.

* The Remote Mode Active output is not energized.

* The Local Speed Low output is energized if the local engine rpm (speed) setting is too far below the remote engine rpm (speed) setting.

* The Local Speed High output is energized if the local engine rpm (speed) setting is too far above the remote engine rpm (speed) setting.

Operation With Selector Switch In REMOTE Position

* The Desired Speed Output signal follows the remote engine rpm (speed) input.

* The Local Mode Active output is not energized.

* The Remote Mode Active output is energized.

* The Local Speed Low output is energized if the local engine rpm (speed) setting is too far below the remote engine rpm (speed) setting.

* The Local Speed High output is energized if the local engine rpm (speed) setting is too far above the remote engine rpm (speed) setting.

Switching From LOCAL Position To REMOTE Position

All output settings are initially as described in the Operation With Selector Switch In Local Position topic. The selector switch is then moved from LOCAL position to REMOTE position. The action that occurs next depends on how far the local and remote engine rpm (speed) input settings are set apart.

Example 1 - The remote engine rpm (speed) setting is close (within tolerance) to the local engine rpm (speed) setting. Therefore, the control of engine rpm immediately transfers to the remote input setting.

Example 2 - The remote engine rpm (speed) setting is not close (out of tolerance) to the local engine rpm (speed) setting. Therefore, the control of engine rpm continues to follow the local engine rpm setting until the local and/or remote setting is moved to within the preset switching tolerance. The local and/or remote setting may be performed manually or by the Customer Programmable Logic Controller (PLC). It is only then that the control of engine rpm will transfer to the remote engine rpm setting.

Switching From REMOTE Position To LOCAL Position

All output settings are initially as described in the Operation In Remote Mode topic. The selector switch is then moved from REMOTE position to LOCAL position. The action that occurs next depends on how far apart the local and remote engine rpm (speed) settings are from one another.

Example 1 - The remote engine rpm (speed) setting is close (within tolerance) to the local engine rpm (speed) setting. Therefore, the control of engine rpm immediately transfers to the local engine rpm setting.

Example 2 - The remote engine rpm (speed) setting is not close (out of tolerance) to the local engine rpm (speed) setting. Therefore, the control of engine rpm continues to follow the remote engine rpm setting until the local and/or remote engine rpm setting is moved to within the preset switching tolerance. The local and/or remote setting may be performed manually or by the Customer PLC. It is only then that the control of the engine rpm will transfer to the local engine rpm setting.

Signal Descriptions

+ BAT

is power to the ESS panel or desired speed potentiometer. It should maintain 24 VDC.

- BAT

is ground (GND) to the ESS panel or desired speed potentiometer. It should maintain - Battery potential.

LOCAL -

is ground (GND) to the desired speed potentiometer. It should maintain - Battery potential.

LOCAL +

is the power to the desired speed potentiometer. It should read 8 VDC when the RSC is powered up.

LOCAL/REMOTE

is a switch input. If the switch is in the "LOCAL" position, the voltage on this terminal should be between 10 VDC and 14 VDC. If the switch is in the "REMOTE" position, the voltage on the terminal should be 0 VDC.

OUT

is a 500 Hz PWM output signal. The voltage lead should be less than 1.5 VDC when low and greater than 100 VDC when high.

LOCAL SIG

is the signal from the desired speed potentiometer. It will be a value between 8 VDC and 0 VDC depending on the position of the potentiometer.

RMTE SP +

is the 4 to 20 mA input from the remote PLC. The voltage on this terminal should range between -200 VDC and +200 VDC. The current should range between 4 and 20 mA into the terminal.

RMTE SP -

is the return from the PLC. The voltage on this terminal should range between -200 VDC and +200 VDC. The current through this terminal should be the same as on the RMTE SP + terminal. When the module is attached to the current loop, the voltage at this terminal should be 5.0 to 7.5 VDC lower than the voltage on the RMTE SP + terminal.

NOTE: Connect to - BAT if Customer PLC has no return.

REMOTE ACTIVE +

is the terminal whose voltage should be the same as the + BAT voltage.

NOTE: This terminal has no internal connection to the module. It is wired to the + BAT through an external harness.

REMOTE ACTIVE -

is the terminal whose voltage should be the same as the + BAT voltage when the Remote Active lamp is OFF. The voltage should be 0.5 to 2.0 VDC when the lamp is ON.

LOCAL HI +

is the terminal whose voltage should be the same as the + BAT voltage.

NOTE: This terminal has no internal connection to the module. It is wired to the + BAT through an external harness.

LOCAL HI -

is the terminal whose voltage should be the same as the + BAT voltage when the LOCAL HI lamp is OFF. The voltage should be 0.5 to 2.0 VDC when the lamp is ON.

LOCAL ACTIVE +

is the terminal whose voltage should be the same as the + BAT voltage.

NOTE: This terminal has no internal connection to the module. It is wired to the + BAT through an external harness.

LOCAL ACTIVE -

is the terminal whose voltage should be the same as the + BAT voltage when the Local Active lamp is OFF. The voltage should be 0.5 to 2.0 VDC when the lamp is ON.

LOCAL LOW +

is the terminal whose voltage should be the same as the + BAT voltage.

NOTE: This terminal has no internal connection to the module. It is wired to the + BAT through an external harness.

LOCAL LOW -

is the terminal whose voltage should be the same as the + BAT voltage when the Local Low lamp is OFF. The voltage should be 0.5 to 2.0 VDC when the lamp is ON.

Troubleshooting

System Operation

The Electronic Control Module (ECM) monitors the desired speed input to determine the speed at which to govern the engine.

The desired speed signal may be provided by the Desired Speed Potentiometer and Remote Speed Control located on the ESS panel. It also may be provided by one of several remote-mounted modules that can be connected through the Remote Speed Control. (It is also possible that it is provided by components other than Caterpillar components.)

In Generator Set applications, the control system does not require the desired speed input to the present except when the engine is generating power. (This is determined from measured load and/or parallel indication.)

It is normal for some external desired speed sources (particularly the loadshare module) to not provide a desired speed signal until the generator is producing power (voltage). Under these conditions, the ECM uses a Default Desired Speed.

The desired speed input (DRPM) can be read from the ECM Display Status screen.

Sensor (Potentiometer) Signals

Sensor Supply - The desired speed input is a linear pulse width modulated (PWM) voltage signal corresponding to the user input of present desired speed. The desired speed signal is generated from the Remote Speed Control which is powered from a battery source.

Output Signal - The Remote Speed Control outputs a PWM signal to the ECM. The signal level varies with the desired speed. Minimum expected input from the buffer is approximately 6 percent PWM and maximum expected PWM is approximately 94 percent. The failure (diagnostic) is detected on complete loss of the PWM signal. The valid signal range is approximately 5 to 95 percent duty cycle.

Illustration 7. Film (Decal) On ESS Panel Door: (1) 130-2705 Film (Remote Speed). (2) 130-2708 Indicator Assembly (Amber Lamp). (3) 130-2707 Indicator Assembly (Green Lamp). (4) 130-2704 Switch Assembly.

Control Diagnostics

524-12 Desired Speed Input Alarm indicates that the engine does not have a valid desired speed and is running at the default rated speed or default desired speed. This condition may be normal under some circumstances (such as a loadshare interface and manually energized generator exciter). This condition is permitted provided that the load on the engine has not exceeded 50 percent. This alarm will only occur on generator set application engines.

524-12 Desired Speed Input Shutdown indicates that the engine does not have a valid desired speed and is not an acceptable duty cycle or frequency or there is no desired speed signal. This condition may be caused by a faulty Desired Speed Potentiometer or intermittent problem.

Illustration 8: Schematic.

Diagnostic Codes

Functional Test

1: Check For Connector Damage

1. Remove power from the control system. Turn the Mode Control Switch (MCS) to the OFF/RESET position. Open the fuse breaker in the ESS Panel.

2. Check the Electronic Control Module (ECM) Connector, Terminal Strip Connections in the ESS Panel, the desired speed signal, and the Desired Speed Potentiometer for corrosion or mechanical failure. (Refer to Section 2: P-002: Inspecting Electrical Connectors Of The G3600 Engine Troubleshooting manual for details.)

3. Install the fuse in the ESS Panel.

4. Check the harness and wiring for abrasion and pinch points from the sensor back to the ECM.

NOTE: All connectors/pins/sockets should be completely mated/inserted and the harness/wiring should be free of corrosion, abrasion, or pinch points.

* If OK and the connectors are in good condition, proceed to Step 2.

* If not OK, repair or replace the faulty connector. STOP.

2: Check For Power To The Remote Speed Control

1. Apply power to the ESS system. Turn the Mode Control Switch (MCS) to the STOP position.

2. Measure the voltage between + BAT and - BAT terminals on the Remote Speed Control.

NOTE: The voltage should be 24 ± 4 VDC.

* If OK and all voltages are within tolerance, proceed to Step 3.

* If NOT OK and if the voltage is 0 VDC, the problem is in the power wiring. Repair the wiring. STOP.

* If NOT OK and if the voltage is outside the indicated range or is unstable, there is a problem with the power supply to the ESS panel. Repair the power supply. STOP.

3: Check For Proper Supply Voltage

1. Adjust the Desired Speed Potentiometer to mid-range position.

2. Apply power to the ESS system. Turn the Mode Control Switch (MCS) to the STOP position.

3. Place the Remote Speed Control Switch in the LOCAL mode position.

4. Measure the voltage between LOCAL + and LOCAL - on the Remote Speed Control.

NOTE: The voltage measurements should be 8.0 ± 0.5 VDC.

* If OK and the voltage is within the tolerance, proceed to Step 4.

* IF NOT OK and the voltage is less than 7.5 VDC or more than 8.5 VDC, the problem is either in the wiring or a faulty Remote Speed Control. Check the wiring. If OK, replace the Remote Speed Control. STOP.

4: Check For Power To The Potentiometer

1. Apply power to the ESS system. Turn the Mode Control Switch (MCS) to the STOP position.

2. Place the Remote Speed Control Switch in the LOCAL mode position.

3. Measure the voltage between LOCAL SIG and LOCAL - (GND) on the Remote Speed Control Switch.

4. Adjust the Desired Speed Potentiometer from lowest position to highest position, then back to lowest position.

NOTE: The voltage should follow the potentiometer reading from 0 volts to 8 volts and back to 0 volts.

* If OK and the voltage follows the potentiometer position, proceed to Step 5.

* If NOT OK and the voltage does not move (parallel) with potentiometer position, check the wiring and the potentiometer. Repair as required. STOP.

5: Check The Desired Speed PWM Signal

1. Apply power to the ESS system. Turn the Mode Control Switch (MCS) to the STOP position.

2. Place the Remote Speed Control Switch in the LOCAL mode position.

3. Use an oscilloscope, multimeter, or voltmeter (with PWM function) to measure the PWM Signal at the Remote Speed Control Switch from OUT to - BAT.

4. Adjust the Desired Speed Potentiometer from lowest position to highest position, then back to lowest position.

NOTE: The voltage should follow the potentiometer reading from 6 to 94 percent, then back to 6 percent with a frequency of 300 to 900 Hz.

* If OK, proceed to Step 8.

* If NOT OK and the PWM signal does not move (parallel) with the potentiometer position or the values exceed the valid ranges, check the wiring and/or replace the Remote Speed Control Module. STOP.

6: Check The Signal (Remote Mode)

1. Reset all diagnostic codes. Turn the Mode Control Switch (MCS) to the OFF/RESET position and then back to the STOP position.

2. Turn the Mode Control Switch (MCS) to the START position. Start the engine and set to rated speed. Activate generator (if equipped) but do not apply load or parallel with utility.

3. Place the Remote Speed Control Switch in the REMOTE mode position.

4. Measure the PWM signal (using multimeter or voltmeter with PWM or oscilloscope) in the ESS panel at the terminals nearest to the ECM.

NOTE: The expected PWM signal is between 5 and 95 percent.

* If OK and the PWM signal is steady, the PWM signal is in range (greater than 5 percent and less than 95 percent) and the frequency steady and in range (between 500 and 1000 Hz), proceed to Step 8.

* If NOT OK and the PWM signal is not steady, the PWM signal is out of range (less than 5 percent or greater than 95 percent), and the frequency is unsteady or out of range (less than 500 Hz or greater than 1000 Hz), proceed to Step 7.

* If NOT OK and the Remote Speed Control Switch will not switch to REMOTE mode, proceed to Step 9.

7: Check For Erratic Or Missing Speed Signal

1. With engine running at rated speed, measure the current into RMTE SP + of the Remote Speed Signal.

NOTE: Current should range between 4 and 20 mA and remain steady.

* If OK and the 4 to 20 mA signal is in range and steady, proceed to Step 8.

* If NOT OK and the 4 to 20 mA signal is erratic, troubleshoot the cause of the erratic signal in the remote signal source. STOP.

* If NOT OK and the 4 to 20 mA signal is missing or out of range (greater than 20 mA or less than 4 mA), troubleshoot the source of the missing or out of range signal. STOP.

8: Verify That The Diagnostic Code Is Present

1. Reset all diagnostic codes. Turn the Mode Control Switch (MCS) to the OFF/RESET position and then back to the STOP position.

NOTE: The engine should be started to verify if diagnostic codes reoccur.

2. Restart the engine to verify if the 524 Diagnostic Code reoccurs.

3. Check the wiring from the remote equipment to the ECM on wire M103 (Signal). Look for shorts to any other wiring (PWM specifically). The PWM signal is provided to the ECM from the Desired Speed input on the user interface terminal (lower right side of the ESS panel), and wire M103 (Signal) to the ECM connector J3 pin-17. The signal must be referenced to ground [-BAT] terminal.

* If OK and the diagnostic code does not return, STOP.

* If NOT OK and the diagnostic code returns, the problem is intermittent or may be caused from a noisy signal. STOP.

9: Check The Power Up Sequence

1. Remove power from the ESS system. Turn the Mode Control Switch (MCS) to the OFF/RESET position.

2. Place the Local/Remote Switch in the LOCAL mode position.

3. Apply power to the ESS system. Turn the Mode Control Switch (MCS) to the STOP position.

* If OK and the RSC powers up with the Local Active Lamp ON and the Remote Active Lamp OFF, proceed to Step 10.

* If NOT OK and the RSC powers up with the Remote Active Lamp ON and the Local Active Lamp OFF, troubleshoot the wiring to the Local/Remote Switch. The switch may have to be reoriented. STOP.

* If NOT OK and the RSC powers up with both Local Active and Remote Active Lamps OFF or ON, troubleshoot the wiring to the lamps. Troubleshoot the power wiring to the RSC. STOP.

10: Check The REMOTE Mode Switching Function

1. Adjust the Desired Speed Potentiometer until the Local Low Lamp and Local High Lamp are OFF.

2. Place the Local/Remote Switch to REMOTE mode position.

* If OK and both lamps turn OFF and the module switches modes to REMOTE, proceed to Step 11.

* If NOT OK and the lamps will not turn OFF, troubleshoot the lamp wiring. Repair as required. STOP.

* If NOT OK and the lamps are intermittently turning ON and OFF, troubleshoot the desired speed signal. Refer to the G3600 Engine Troubleshooting, SENR6510. STOP.

* If NOT OK and the lamps go out but the module will not switch to remote mode, check the lamp wiring, check the switch wiring, and check the switch operation. Repair as needed. STOP.

11: Check The LOCAL Mode Switching Function

1. Switch the Local/Remote Switch back to LOCAL mode

* If OK and the module switches back to LOCAL mode and all the lamps function correctly, then the module is working. STOP.

* If NOT OK and the diagnostic code returns, the problem is intermittent or may be caused from a noisy signal. STOP.