9/1/2020 PMG3516 Power Module JKK00001-UP POWERED BY G3516C Engine(SEBP6665 - 28) - Documentation

Previous Screen
Welcome: r460jef
Product: POWER MODULE
Model: PMG3516 POWER MODULE JKK
Configuration: PMG3516 Power Module JKK00001-UP POWERED BY G3516C
Engine

Systems Operation
G3500C and G3500E Generator Set Engines
Media Number -KENR6834-13 Publication Date -01/08/2019 Date Updated -29/08/2019

i06943902

Air/Fuel Ratio Control

SMCS - 1278

The Electronic Control Module (ECM) provides control of the air/fuel mixture for performance and for
efficiency at low emission levels. The system includes the following components: maps in the ECM, output
drivers in the ECM, air inlet pressure sensor, inlet manifold air temperature sensor, engine speed/timing sensor,
generator output power sensor and fuel metering valve. Additionally, the customer input via the Caterpillar
Electronic Technician (Cat ET) is required. Illustrations 1 and 2 are diagrams of the system main components
and of the inputs for the system.

For engines that are equipped with an Auxiliary Sensing Module (ASM), ASM receive inputs from the
following sensors:

Generator output power sensor

Air inlet pressure sensor

Engine speed sensor

The ASM rapidly processes the signals from these sensors and passes the information to the master ECM via the
Cat Data Link.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/mediasearch/mediaheaderinfoframeset.jsp&calledpage=/… 1/6
9/1/2020 PMG3516 Power Module JKK00001-UP POWERED BY G3516C Engine(SEBP6665 - 28) - Documentation

Illustration 1 g01443064
Diagram of the air/fuel ratio control
The engine is not equipped with an ASM.

Illustration 2 g01443066
Diagram of the air/fuel ratio control

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/mediasearch/mediaheaderinfoframeset.jsp&calledpage=/… 2/6
9/1/2020 PMG3516 Power Module JKK00001-UP POWERED BY G3516C Engine(SEBP6665 - 28) - Documentation

The engine is equipped with an ASM.

Cat ET - This software is designed to run on a personal computer. Technicians can use the program to perform
many functions. For the air/fuel ratio control, the technician programs configuration parameters into the ECM.

Generator output power sensor - The engine control system requires an input which indicates the generator
output in kilowatts. This input can be from the EMCP II+, from a programmable logic controller (PLC), or from
a wattmeter. If the EMCP II+ is not used, the equipment that monitors the generator output is provided by the
customer. The PLC or the wattmeter must provide an analog signal with a range of 0 to 5 VDC. The signal must
use as much of this range as possible. The signal must be accurate within 0.5 percent of the generator actual
output. The signal must have a linear relationship with the generator actual output in electrical kilowatts (ekW).
Engines that are equipped with ASM are not compatible with EMCP II+ load signal.

Inlet manifold air temperature sensor - This sensor monitors the temperature of the air/fuel mixture in the
inlet manifold.

Air inlet pressure sensor - This sensor monitors the pressure of the air/fuel mixture in the inlet manifold.

Engine speed/timing sensor - This sensor monitors the rotation of a speed-timing wheel in order to provide
information on the engine timing and on the engine rpm.

Fuel metering valve - The valve is an electronically controlled actuator and a valve that regulates the flow of
fuel. The device monitors the fuel temperature, the fuel pressure, and the valve differential pressure. The ECM
sends a command signal for the fuel flow to the device. The device modulates the valve in order to match the
command signal. The ECM communicates with the fuel metering valve via the CAN data link.

Optional Fuel Quality Sensor - Some applications support an input for remote fuel quality. These engines can
accept an input from a fuel quality sensor that is provided by the customer. The sensor performs continuous
analysis of the fuel in order to determine the fuel LHV. The sensor provides a 4 to 20 mA signal to the ECM
which indicates the fuel LHV. The sensor has a "CONFIG" setting and a "4 to 20 mA" setting. The "CONFIG"
setting is only used if the quality of fuel supply is constant. The "4 to 20 mA" setting is used when the quality of
the fuel supply is variable.

The air/fuel ratio control has two basic modes of operation:

Open loop

Charge density feedback

The modes of operation are explained below.

For proper operation of the air/fuel ratio control, inputs from the customer are necessary.

Inputs from the Customer

To control the air/fuel ratio, the control system depends on these inputs from the customer:

Fuel Quality

Engine Load

Fuel Quality

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/mediasearch/mediaheaderinfoframeset.jsp&calledpage=/… 3/6
9/1/2020 PMG3516 Power Module JKK00001-UP POWERED BY G3516C Engine(SEBP6665 - 28) - Documentation

Before the initial start-up, a current gas analysis is required. Data from the gas analysis must be entered into
Caterpillar Software, LERW4485, "Gas Engine Rating Pro (GERP)". The results are programmed into the ECM.

Note: Use the Caterpillar Software, LERW4485, "Gas Engine Rating Pro (GERP)". Use of only the data
from the gas analysis can result in incorrect settings.

The ECM must have values for the following parameters. The values are entered via the "Configuration" screen
of Cat ET:

"Fuel Quality Input Type Configuration"

"Fuel Quality Sensor LHV Lower Setpoint"

"Fuel Quality Sensor LHV Upper Setpoint"

"Fuel Quality"

"Gas Specific Gravity"

"Fuel Specific Heat Ratio"

Note: The "Fuel Quality Sensor LHV Lower Setpoint" and the "Fuel Quality Sensor LHV Upper Setpoint" are
needed only when using the 4-20 mA signal from a fuel quality sensor.

Note: For more details on these parameters, refer to Systems Operation/Testing and Adjusting, "Electronic
Control System Parameters".

"Fuel Quality Input Type Configuration" - Program this parameter to either "CONFIG" or "4 to 20 mA". The
"CONFIG" setting is only used if the quality of fuel supply is constant. If the "CONFIG" setting is used, enter a
value under the "Fuel Quality" setting. The "4 to 20 mA" setting is used when the quality of the fuel supply is
variable. If the "4 to 20 mA" is used, enter the values for the "Fuel Quality Sensor LHV Lower Setpoint" and for
the "Fuel Quality Sensor LHV Upper Setpoint".

"Fuel Quality Sensor LHV Lower Setpoint" - The ECM uses the value of this parameter to determine the
lower limit of the range of the fuel LHV.

"Fuel Quality Sensor LHV Upper Setpoint" - The ECM uses the value of this parameter to help determine the
upper limit of the range of the fuel LHV.

"Fuel Quality" - This parameter is the fuel Low Heating Value (LHV). The value is obtained from a fuel
analysis which is entered into Caterpillar Software, LERW4485, "Gas Engine Rating Pro (GERP)". Only use
this value when the fuel quality sensor is in the "CONFIG" setting.

During operation, the ECM uses the LHV to help determine the command signal for the fuel flow.

"Gas Specific Gravity" - This parameter is the fuel-specific gravity in relation to the specific gravity of air. The
value is obtained from a fuel analysis which is entered into Caterpillar Software, LERW4485, "Gas Engine
Rating Pro (GERP)".

"Fuel Specific Heat Ratio" - This parameter is a ratio of the fuel-specific heat at a constant pressure and at a
constant volume.

The ECM provides the fuel-specific gravity and heat ratio to the fuel metering valve via the CAN data link. The
fuel metering valve uses this information to help regulate the fuel flow.

In addition to the information on the fuel, the ECM requires information on the engine load.
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/mediasearch/mediaheaderinfoframeset.jsp&calledpage=/… 4/6
9/1/2020 PMG3516 Power Module JKK00001-UP POWERED BY G3516C Engine(SEBP6665 - 28) - Documentation

Engine Load

The ECM must have values for the following parameters. The parameters are entered into the ECM via Cat ET.

"Engine Output Power"

"Engine Driven Accessory Load Configuration"

"Generator Output Power Sensor Scale Factor"

"Generator Output Power Sensor Offset"

"Engine Output Power" - This parameter is the engine full load rating in ekW. The rating is stamped on the
engine Information Plate. During engine operation, the ECM uses this value to determine the engine load as a
percentage of the maximum load.

"Engine Driven Accessory Load Configuration" - This parameter is the load of the auxiliary equipment such
as a radiator fan that is directly driven by the engine. The value is in units of ekW. The ECM adds this load to
the estimate of the generator actual output in order to determine the total load on the engine.

"Generator Output Power Sensor Scale Factor" - This parameter is a scale for the wattmeter output.

If the generator is equipped with the EMCP II+, information on the generator electrical power output is provided
to the ECM via the Cat Data Link. The value for the "Generator Output Power Sensor Scale Factor" parameter is
correctly programmed at the factory. This parameter has no effect when the EMCP II+ provides the information
on the generator power output.

If the generator is equipped with a wattmeter, the signal from the power sensor increases as the generator output
increases to the maximum output. Select a wattmeter that provides a full scale output (4.8 VDC) for the
generator maximum power output.

The ECM requires a scale factor in order to estimate the generator output. For further information, refer to
Systems Operation, "Electronic Control System Parameters".

"Generator Output Power Sensor Offset" - The offset is used to make the scale accurate for the generator
output power sensor.

If the generator is equipped with the EMCP II+, information on the generator output is provided to the ECM via
the Cat Data Link. The value for the "Generator Output Power Sensor Offset" parameter is correctly
programmed at the factory.

If the generator is equipped with a power sensor, the power sensor output may not be zero when the generator
output is zero. When the discrepancy occurs, the power sensor has an offset voltage. The offset voltage may be
positive or negative. In most cases, the offset voltage is low.

All of the above parameters are programmed into the ECM via the "Configuration" screen of Cat ET. For more
details, refer to Systems Operation, "Electronic Control System Parameters".

Open Loop Mode

Open loop - During operation in this mode, the ECM controls the air/fuel ratio with maps and with calculations
for the desired air/fuel ratio. This mode of operation uses no feedback. The air/fuel ratio is controlled in the open
loop mode from start-up until the engine load becomes greater than approximately 45 percent.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/mediasearch/mediaheaderinfoframeset.jsp&calledpage=/… 5/6
9/1/2020 PMG3516 Power Module JKK00001-UP POWERED BY G3516C Engine(SEBP6665 - 28) - Documentation

The ECM uses a Fuel Correction Factor (FCF) to help determine the fuel flow. During operation in the open
loop mode, the FCF is always 100 percent. The FCF enables the customer programmable "Fuel Quality" or LHV
to affect the air/fuel ratio.

To richen the air/fuel mixture, reduce the LHV. The ECM will compensate for the reduced LHV by increasing
the fuel flow.

To lean the air/fuel mixture, increase the LHV. The ECM will compensate for the increased LHV by reducing
the fuel flow.

Charge Density Feedback

Charge density - This parameter is the density of the air/fuel mixture in the air inlet manifold. The ECM
calculates the charge density from the values of inlet manifold air temperature and air inlet pressure.

Charge density feedback - The ECM calculates the actual charge density. The actual charge density is
compared to the desired charge density. To achieve the desired charge density, the ECM sends a command signal
to the fuel metering valve. The signaling is a continuous process during closed loop operation. The closed loop
operation is activated after a load of approximately 45 percent has been achieved. The closed loop operation is
deactivated when the load is reduced to approximately 25 percent.

The same customer inputs that are required for operation in the open loop are used for the feedback mode. The
following additional configuration parameter must be programmed into the ECM via the "Configuration" screen
of Cat ET:

"Desired Emissions Gain Adjustment Percentage" - This parameter is an adjustment for the charge density.
To richen the air/fuel mixture, increase the gain adjustment. To lean the air/fuel mixture, decrease the gain
adjustment. The adjustment increases the charge density and lowers NOX.

The ECM uses the gain adjustment to help determine the FCF. The FCF varies during operation in the feedback
mode.

Note: A small change in the "Desired Emissions Gain Adjustment Percentage" causes a large change in the
actual exhaust emissions. For example, an adjustment of 1 percent in the parameter value will result in a change
of 20 to 40 ppm in the actual level of NOx. This parameter should only be adjusted only if the engine is above 50
percent load.

Copyright 1993 - 2020 Caterpillar Inc. Thu Jan 09 2020 03:28:41 GMT-0500 (hora estándar de Colombia)
All Rights Reserved.
r460jef
Private Network For SIS Licensees.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/mediasearch/mediaheaderinfoframeset.jsp&calledpage=/… 6/6