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    Cummins Contr. Syst.

    Uploaded by

    Ankit Vyas
    This document provides instructions for operating the diesel engine control system for a Cummins KTA 19 DM1 engine. It describes the control system components, including the programmable logic controllers (PLCs) and electric fuel controller (EFC). It also provides technical specifications for the engine, EFC, and speed and temperature sensors. Startup and shutdown sequences are outlined as well as procedures for communication and cooling system faults. Troubleshooting tips are provided for common alarm and sensor issues.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Cummins Contr. Syst.

    Uploaded by

    Ankit Vyas
    2K views8 pages
    This document provides instructions for operating the diesel engine control system for a Cummins KTA 19 DM1 engine. It describes the control system components, including the programmable logic controllers (PLCs) and electric fuel controller (EFC). It also provides technical specifications for the engine, EFC, and speed and temperature sensors. Startup and shutdown sequences are outlined as well as procedures for communication and cooling system faults. Troubleshooting tips are provided for common alarm and sensor issues.

    Original Description:

    framo

    Original Title

    5. Cummins Contr. Syst.

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    This document provides instructions for operating the diesel engine control system for a Cummins KTA 19 DM1 engine. It describes the control system components, including the programmable logic controllers (PLCs) and electric fuel controller (EFC). It also provides technical specifications for the engine, EFC, and speed and temperature sensors. Startup and shutdown sequences are outlined as well as procedures for communication and cooling system faults. Troubleshooting tips are provided for common alarm and sensor issues.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    2K views8 pages

    Cummins Contr. Syst.

    Uploaded by

    Ankit Vyas
    This document provides instructions for operating the diesel engine control system for a Cummins KTA 19 DM1 engine. It describes the control system components, including the programmable logic controllers (PLCs) and electric fuel controller (EFC). It also provides technical specifications for the engine, EFC, and speed and temperature sensors. Startup and shutdown sequences are outlined as well as procedures for communication and cooling system faults. Troubleshooting tips are provided for common alarm and sensor issues.

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    © All Rights Reserved
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    The key takeaways are that this instruction manual describes the control system for a Cummins KTA 19 DM1 diesel engine, including the programmable logic controllers (PLCs), electric fuel controller (EFC), operating sequences, technical specifications, and troubleshooting information.

    The purpose of this instruction manual is to describe the control system for the diesel engine, including the operator interface, communication between control panels, and the electric fuel controller. It should be read along with dedicated drawings.

    The main components of the diesel engine control system described are the programmable logic controllers (PLCs), electric fuel controller (EFC), hydraulic system control panel, diesel engine control panel, and junction box. It also describes the communication and connections between these components.

    No.

    1400-0256-4

    Framo

    Rev.E Aug 2005

    Instruction for diesel engine


    control system
    Cummins KTA 19 DM1 Engine

    CONTENTS

    GENERAL DESCRIPTION
    1.1
    Control system / PLC
    1.2
    Electric Fuel Controller, EFC

    TECHNICAL DATA
    2.1
    Engine / EFC
    2.2
    Engine / Speed sensor
    2.3
    Engine / Alarm-shutdown limits

    OPERATING INFORMATION
    3.1
    Start / Stop sequence
    3.2
    Communication fault
    3.3
    Engine cooling at High High temperature

    TROUBLE SHOOTING / ADJUSTMENTS


    4.1
    Alarm / Shutdown indications
    4.2
    Speed sensor

    Instruction for Diesel Engine Control System


    CUMMINS KTA 19 DM1 ENGINE
    1.

    No.
    Date/sign.:
    Page:
    Rev. 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, programmable logic controllers (PLCs), communication between
    hydraulic system control panels and local panels in addition to electric fuel control (EFC)
    (see fig.1).
    This manual should be read in conjunction with dedicated drawings.
    Fig. 1 : Interconnection of control system

    HYDRAULIC SYSTEM
    CONTROL PANEL
    CARGO PUMPING SYSTEM
    OPERATION

    MISCELLANEOUS

    AUX. UNIT

    HYDR. OIL TEMPERATURE

    FEED PRESSURE

    SYSTEM PRESSURE

    MAIN PRESSURE SET

    EM. STOP HYDR. SYSTEM

    OIL HEATING ON/OFF

    POWER ON

    CARGO
    PRESSURE
    HIGH

    THRUSTER ON

    INERT GAS
    PRESSURE
    LOW

    bar/MPa

    100

    bar/MPa

    16

    400

    1,6
    50

    MANUAL OVERRIDE

    40

    200
    0,8

    20

    FP1

    SHUTDOWN
    EM. STOP HYDR. SYSTEM

    RETURN LINE CLOSED

    EM. STOP CARGO PUMPS

    START

    STOP

    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

    1.0

    OIL LEVEL HIGH

    PP2

    MOTOR CURRENT

    FP2

    ALARMS

    PP4

    COOLING WATER

    1.0

    0.5

    150

    0.5

    LUBE OIL PRESSURE

    COOLING WATER

    10

    b ar/MPa

    75

    150

    1,0

    10
    1,0

    5
    0,5

    STOP
    0

    FP3

    HPU OIL LEAKAGE

    Hardwired signals :
    - Em. stop.
    - manual override Mode 1/2
    - indication signals.

    LUBE OIL PRESSURE


    ba r/MPa

    75
    0,5

    START

    WEAR INDICATION

    WEAR INDICATION

    WEAR INDICATION

    SUCTION LINE

    SUCTION LINE

    SUCTION LINE

    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

    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

    SHUTDOWN

    LUBE OIL PRESSURE

    BAR/MPa

    10

    OVERSPEED

    1,0

    DIESEL ENGINE

    LUBE OIL
    PRESSURE LOW LOW
    COOLING WATER
    TEMPERATURE HIGH HIGH

    5
    0,5

    HYDRAULIC SYSTEM
    SUCTION LINE CLOSED

    OPERATION

    COOLING WATER TEMPERATURE

    150

    START

    STOP

    LOCAL REMOTE

    75

    TEST

    ACKNOWLEDGE

    RESET

    POW ER O N

    MANUAL
    O VERRIDE

    ( LOCAL PLC )

    - Start/stop signals
    - Analogue feedback
    signals
    - 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

    SHUTDOWN

    LUBE OIL PRESSURE

    BAR/MPa

    10

    OVERSPEED

    1,0

    LUBE OIL
    PRESSURE LOW LOW
    COOLING WATER
    TEMPERATURE HIGH HIGH

    5
    0,5

    HYDRAULIC SYSTEM
    SUCTION LINE CLOSED

    OPERATION

    COOLING WATER TEMPERATURE

    150

    START

    STOP

    LOCAL REMOTE

    75

    TEST

    ACKNOWLEDGE

    RESET

    POW ER O N

    MANUAL
    O VERRIDE

    ( LOCAL PLC )

    RS485, serial communication


    - remote/ local control
    - remote start/ stop
    - common alarm / trip
    - hydr. system inhibit/
    acceptancefor each engine
    - run/ load indication signal

    Instruction for Diesel Engine Control System


    CUMMINS KTA 19 DM1 ENGINE
    1.1.

    No.
    Date/sign.:
    Page:
    Rev. E:

    1400-0256-4
    10Jul98/JaEi
    3 of 8
    25Aug05/JaEi

    Control system / PLC (Programmable Logic Controller)


    The local panels contains individual PLCs for increased availability. The local PLC
    communicates with the main PLC via RS 485 interface. In case of failure to the link,
    the engines can be operated in local mode, as the vital signals are hardwired
    to/from hydraulic system control panel.
    There are two circuits for rpm control. One speed pickup for rpm control is
    connected to the EFC located in the diesel engine juncton box, and one speed
    pickup for monitoring and overspeed trip is connected to the PLC.
    Engine heating- and cooling sequences are implemented during start- and stop as
    described later in this manual.
    The local PLC controls functions such as start / stop, shutdowns and alarms.
    The front panel contains start/stop, lamptest, acknowledge and reset buttons in
    addition to remote/local selector switch.
    Indicating LEDs are provided for all alarms, shutdowns and running signals.
    All circuits including EFC are FAIL SAFE, which means that loss of electric power
    supply or loose wires during operation will stop the diesel engine.
    Alarm/shutdown and monitoring of the engine lubrication pressure and cooling
    water temperature are based on analogue signals. Loop detection is provided and
    the engine will trip when open or shorted current loop is detected.
    Detection of communication failure will release an alarm on main hydraulic system
    control panel. In this case, the engine must be operated from local panel.

    No.
    Date/sign.:
    Page:
    Rev. E:

    Instruction for Diesel Engine Control System


    CUMMINS KTA 19 DM1 ENGINE
    1.2.

    1400-0256-4
    10Jul98/JaEi
    4 of 8
    25Aug05/JaEi

    Electric fuel control system, EFC


    The electric fuel control system consist of a magnetic pickup, an electric fuel control
    governor (EFC) and actuator. This system is designed for regulation of engine
    acceleration and steady state fuel flow dependent on engine start-up and load
    requirements. The magnetic pickup senses the engine speed at the flywheel ring
    gear and gives an input signal to the EFC unit
    ref. Fig. 2

    Fig. 2
    ENGINE

    DIESEL CONTROL
    PANEL
    PLC

    EFC

    SPEED SENSOR
    NO.2

    FLY WHEEL

    SPEED SENSOR
    NO.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. When
    deviaton is detected, a change in current from the EFC to the actuator will regulate
    the magnetic force in the actuator.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. Shaft movement is proportional to the amount of actuator current and
    is counter balanced by the internal spring in actuator.

    Instruction for Diesel Engine Control System


    CUMMINS KTA 19 DM1 ENGINE

    2.0

    No.
    Date/sign.:
    Page:
    Rev. E:

    1400-0256-4
    10Jul98/JaEi
    5 of 8
    25Aug05/JaEi

    Technical data :

    2.1

    Electric fuel control unit ( EFC )


    Signals
    Supply voltage
    Nominal Operating Current
    Maxium Operating Current
    Response time of actuator

    2.2

    2.3

    : analogue
    : 24 VDC, +/- 15 %
    : 1.3 Amps at 24VDC
    : 3.9 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.

    Alarm and shutdown data.

    Function

    Sensor range

    Lube.Oil pressure (bar)


    Cool water Temp. (C)
    Lube.Oil temp.
    (C)
    Overspeed with 1 sec
    delay
    Overspeed without delay

    0 - 10 bar/ 4-20mA
    0 -150 C/ 4-20 mA
    60 -150 C/ switch

    Sensor
    tolerance
    +/- 0.04 bar
    +/- 2 C
    +/- 3 C

    Alarm

    Shutdown

    1.8 +-***
    96 C
    120 C
    NA

    1.3+-***
    100 C

    NA

    1860 rpm
    4402 Hz
    1890 rpm
    4473 Hz

    Instruction for Diesel Engine Control System


    CUMMINS KTA 19 DM1 ENGINE

    No.
    Date/sign.:
    Page:
    Rev. E:

    OPERATING INFORMATION
    3.1
    Start/ Stop sequence
    Following start/ stop sequences are implemented in the local PLC.

    1400-0256-4
    10Jul98/JaEi
    6 of 8
    25Aug05/JaEi

    Instruction for Diesel Engine Control System


    CUMMINS KTA 19 DM1 ENGINE

    3.2

    No.
    Date/sign.:
    Page:
    Rev. E:

    1400-0256-4
    10Jul98/JaEi
    7 of 8
    25Aug05/JaEi

    Communication fault

    In case of failure at RS485 communication system, it is possible to run the diesel


    engine as follow :
    - 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.

    3.3

    Engine cooling at cooling water temp. High High


    In case of stop caused by cooling water temp. high high, it is possible to start
    the diesel engine in local mode to avoid overheating of engine,
    The engine will run in low speed for 1 minute and then stop.

    4.0

    TROUBLE SHOOTING
    For detailed trouble shooting and maintance at engine refer to separate instruction
    from engine manufacturer.

    4.1 Alarm/ Shutdown indications.


    Symptom/ failure:

    Possible reason:

    Remedy

    Hydraulic System, LED


    activated at local panel

    Hydraulic System not


    ready.

    Check alarm status on hydraulic


    system control panel

    Manual Override, LED


    activated at local panel

    Manual override mode is


    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. Actual diesel communication port.
    remote control indication
    lamp is flashing

    Fasten loose wire/ connections


    with reference to actual drawings.

    Press. indicator =
    zero/max.
    Both alarm activated :
    - lube oil low press
    - lube oil low-low press

    Lube.Oil pressure
    sensor/cable loop failure.

    Measure sensor output signal with


    reference to technical data.

    Temp. indicator = zero /


    temp. indicator = max.
    Both alarm activated :
    - cool Water temp HI
    - cool Water temp HI HI

    Cooling Water temperature


    sensor/cable loop failure.

    Instruction for Diesel Engine Control System


    CUMMINS KTA 19 DM1 ENGINE

    4.2

    No.
    Date/sign.:
    Page:
    Rev. 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, do not use excessive pressure to install the
    pickup

    Back the pickup out to of a turn


    Adjust the pickup so the output signal level
    from pickup is approx. 20 VAC at 1770 rpm

    Tighten the locknut down on the flywheel housing.


    Plug the electrical connection into the pickup, when
    required.

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