Ajax-Superior — .. CleanBurn’ II Control System egg CSS Cooper Energy Services Mount Vernon Training Centera A AE SSA OL LL Ajax - Superior CleanBurn™ IIT TABLE OF CONTENTS Introduction wl Fuel, Air and Exhaust 2 Fuel System. 2 Main Fuel Flow Measurement 6 Pilot Fuel Flow Measurement Air and Exhaust System. Air Flow Measurement Control System Software... Control Algorithm: Speed Governin; Air/Fuel Ratio (EAR) Control Ignition Timing Control Main Fuel Contro 16 Pilot Fuel Control 16 Start Sequencing... 7 Trips and Shutdown Sequencin 19 Alarms.. 20 User Programmable Constant: Fuel Quality Compensation (Optional Data Display/Control Panel Panel Features . LCD Display Feature: LCD Display Menu: Active Trip List Active Alarm Li Engine Status Engine Hours. Reset Hour Metei RPM Setpoint Tunin; Performance Data .. Cylinder Temperatures Temperatures . Cooper Energy Services ‘Mount Vernon Training CenterAjax - Superior CleanBurn™ III Pressures Control Loop: Fuel Data... Define Fuel Quality Test Digital Trips. PGM Optional Digital Trips PGM Optional Di PGM Timer Functions .. Alarm Limit. Trip Limit PWR Relay Status.. Solenoid Valve Statu: System Status Information. Digital Input Module (Optional)... Stand-Alone Power Supply (Optional) Control System Hardware FT-50 Main Processor.. FT-50 VO Cards Digital Input Card. Digital Output Card Analog Input Card Analog Output Card Thermocouple Scanner Car Pressure Transducer Uni Fuel Module... Interconnect Cable Reference FT-50 Connections .. Analog Inputs... Thermocouple Inputs. Analog Outputs Optional Digital Inputs .. Serial Communications Port Pressure Transducer Box.. Fuel Sensor RPM Ignition Timing Output. Cooper Energy Services Mount Vernon Training Centeraa mmm nn Ajax - Superior CleanBurn™ IL Display and Control Panel. Battery Voltage... Power Supply Module Connectors. Power Supply Interface Alternator Ignition System ‘Appendix - FT-S0 Processor Diagnostics Training Notice Cooper Energy Services Mount Vernon Training Center iiiAjax - Superior CleanBurn™ III Introduction ‘The CleanBurm III control system is a modular, totally integrated system which safely allows the engine to meet the load applied as it controls emissions. Its design is based upon the years of field experience gained with the CleanBurn I and CleanBurn II control system. It utilizes connectors on all control system sensors and actuators, making it a modular system. All control elements are connected to the master control unit with wiring harnesses. This allows easy field change out of all components with minimal engine down time. The below figures show the hardware features of the CleanBurn III contro! system. Fool Seasing ) (Foner Supiy The main computer, a Programmable Logic Controller (PLC) and its programs are contained in the Master Control Unit, Inputs are taken from on-engine field devices such as pressure, temperature and speed transducers and processed into digital information. This information is then utilized by the control programs to safely allow the engine to meet the load while maintaining guaranteed emission levels with the best fuel consumption possible. All safety shutdowns and alarms are measured and monitored by the CleanBum III control system Cooper Energy Services Mount Vernon Training CenterAjax - Superior CleanBurn™ II Every CleanBurn III system comes with a master control panel but final configuration of the system is based on customer requirements. ‘A Data Display and Control panel is the user's interface with the engine. It allows the user to start and stop the engine both manually and automatically with just the push of a button, set the engine speed, look at real - time data and monitor all alarms and trips Available options allow the customer to configure his engine with: ‘© fuel property measurement devices for sites where fuel quality is inconsistent + additional digital inputs for engine or valve control «a stand-alone on-engine power system to maintain 24 volt control panel power «monitoring systems for remote control and graphic engine performance and alarm monitoring ‘The modular design of this system allows simple and straightforward diagnostics and easy change out of faulty components and modules in the field, These components and modules are all stocked in Cooper Aftermarket warehouses and can be at the customer’ site the next day. All of these components and modules are 100% tested and calibrated before being put into inventory, ensuring that every part will work the first time when it gets to the customer. Fuel, Air and Exhaust Systems The fuel, air and exhaust systems for the Superior 2400G series function in a similar manner on all other Superior natural gas engines. The CleanBurn Ill control system therefore can be applied to any of the engines with only minor modifications Fuel System The fuel system controls the flow of fuel to both the pilot and the main fuel header. The amount of fuel sent to each of these headers is determined by specially designed control algorithms programmed specifically for each Superior engine series. The control systema monitors on-engine devices, analyses fuel quality, monitors fuel header pressures and temperatures and then calculates the flow rate required to operate the engine efficiently and at specified emissions levels. Cooper Energy Services Mount Vernon Training CenterCleanBurn™ II Ajax - Superior ‘adVaH 1404 NIVIN lg BAH Hod 1aiul Wea OL, = —t ( Mount Vernon Training Center Cooper Energy ServicesAjax - Superior CleanBurn™ IT The figure on the previous page depicts @ typical CleanBur III fuel control system and consists of a Main and Pilot fuel header. The fuel system consists of the following major components: + Main Pressure Regulator - Used to drop the supply gas to @ workable pressure range. «Fuel Shutoff Valve - Used to isolate the fuel gas from the engine when not in operation. «Pilot Fuel Header - Provides the small initial fuel flow to each cylinder for proper fuel combustion to take place within the prechamber © Main Fuel Header - Provides the fuel required by each cylinder for normal operation of the engine. Customer fuel gas is sent to a pressure regulator set for 45 to 50 PSIG, supplying a safe fuel pressure to the engine fuel system. The fuel then flows through a bubble-tight shutoff valve which is operated via solenoid by the CleanBurn Ill control system, The regulated fuel is then supplied to both Main and Pilot fuel circuits. solenoid Operated hte Vave ‘The main fuel monitoring components that determine proper fuel flow to both the Main and Pilot fuel headers are contained in the Fuel Metering Box. These components are used by the CleanBum III control system to determine Cooper Energy Services Mount Vernon Training CenterPeau UUUIUUUIEESETEESRTIEECEIEESECIEESESELSECIEECEIELSE CIEE SOIRLSEEIESSEIELSORLEASOLELSEELLASEIELSEEIESSEIELSEELEASEIELSEE IESE CIELO IESE CIRLSEELESECIRLSEELLSECIRLSEELESETIRLSEELESESLLASEELLSESLASEELISEELLASEELISESLLSSEELLSEEILE! Ajax - Superior CleanBurn™ III + The fuel quality by measuring the specific gravity of the fuel + The Pilot fuel flow rate for proper ignition of the fuel +The Main fuel flow rate required to operate the engine ‘To measure the specific gravity of the fuel, the Fuel Metering Box contains a Molecular Weight Sensor Tube (this is an optional item, it may not be used if the BTU content does not vary dramatically) that utilizes sound waves passing through a small quantity of gas from the fuel header. As the molecular consistency of the gas changes, the time it takes for sound waves traveling the length of the tube and back varies. From this information, the CleanBurn III control system can determine the fuel quality or Low Heat Value of the fuel gas. | Fuel Metering Main Fue Metering | Box @) orcs Maleclar Weight ‘Sensor Tube The other components of the Fuel Metering Box are used by the CleanBurn III control system to determine the flow rate of the gas in both the Pilot and Main fuel header. A pressure transducer measures the header pressure and is used in conjunction with another pressure transducer that measures the differential across a metering orifice. Given a certain header pressure and the differential pressure ‘Cooper Energy Services Mount Vernon Training CenterAjax - Superior CleanBurn™ TI across the metering orifice, the CleanBum III control alg the fuel flow in each header hms can determine Main Fuel Flow Measurement ‘Main fuel flow is measured using an orifice run. As shown in the figure below, ‘the main gas flows through a precision orifice located between the fuel control valve and the main fuel header. As the fuel flows through the orifice, a pressure drop across this orifice is created. The orifice upstream gas pressure, the pressure drop across the orifice, the gas temperature, the gas specific gravity and the gas specific heat ratio are measured, and the mass flow rate of gas is calculated using | the orifice flow equation. The metering orifice is sized to produce 4 PSI differential pressure across the orifice at 110% load and 1200 RPM with pipeline quality fuel 4-20 mA Regulator Control Signal oe To Each net Port Pilot Fuel Flow Measurement Pilot fuel flow is measured using an orifice run in the same way as show for the main fuel header above. Pilot gas flows through a precision orifice located between the fuel control valve and the pilot fuel header. As the fuel flows through the orifice, a pressure drop across this orifice is created. The orifice upstream gas pressure, the pressure drop across the orifice, the gas temperature, the gas specific gravity and the gas specific heat ratio are measured, and the mass flow rate of gas Cooper Energy Services Mount Vernon Training CenterAjax - Superior CleanBurn™ III produce 4 PSI differential pressure across the orifice at 110% load and 1200 RPM with pipeline quality fuel Cooper Energy Services Mount Vernon Training CenterCleanBurn™ UI Ajax - Superior [pue Ary OPT S}iog jsnvyxy oursuy seq oct ‘up SBI, doyedng - xefy Mount Vernon Training Center Cooper Energy ServicesAjax - Superior CleanBurn™ TI Air and Exhaust System The figure on the previous page shows a schematic of the air and exhaust system for the 2406G/2408G inline engines, Ambient air enters the turbocharger where the radial flow compressor wheel compresses the air. During compression, the air gets hot. At full load, the air is about 370° F, The air then flows through two air- to-water heat exchangers (intercoolers) where the high-pressure air is cooled by the intercooler water to 140° F. The air exits the two intercoolers into a common plenum, Each cylinder head’s air inlet port is connected to this plenum through a rubber bushing, The air then flows into the cylinder through each cylinder head's two inlet valves. The exhaust system functions as follows. The exhaust gas flows out of each cylinder head and collects in a water-cooled constant-pressure exhaust manifold. The hot, high-pressure exhaust gas flows into the turbocharger's radial flow exhaust turbine. This high-pressure hot exhaust causes the turbine to spin, which then spins the air compressor wheel and compresses the inlet ait. The amount of air delivered to the engine is controlled by bypassing some of the hot, high- pressure exhaust gas around the turbine. This bypass slows the turbine's rotation and reduces the air manifold pressure, thus reducing the air flowing to the engine. The exhaust bypass valve (wastegate) is a butterfly valve which is moved by an electric-pneumatic actuator. This wastegate actuator controls the engine's exhaust bypass valve. This wastegate actuator controls the engine’s air/fuel ratio. The bypass exhaust gas and the low-pressure gas coming out of the turbine collect in an exhaust pipe before the exhaust flows out of the stack Air Flow Measurement Engine combustion air flow is measured using what is commonly called a speed- density routine. To understand how air flow is measured this way, visualize the engine as a positive displacement air pump. A fixed volume of air flows through the engine for every two revolutions of the crankshaft. The efficieney of this air pump is defined by the engine's volumetric efficiency. Therefore, the volume flow rate of air through the engine equals Volumetric Efficiency x Displacement 2 Volume Flow Rate = Cooper Energy Services Mount Vernon Training CenterAjax - Superior CleanBurn™ III To convert the volume flow rate of air to mass flow rate, Mass Air Flow = Volume Flow Rate x Air Desity the volume flow rate is multiplied by the air density at intake manifold conditions, The density of the air is calculated using the air manifold temperature and pressure. Volumetric Efficiency Inputs | Jacket H20 Trap ‘Air Mant. Press. RPM Calculate Volumetic Ef ——_2eu_»| > | __oumeticEf._| calculate LOAD Volumetric ‘ir Mant. Timp Air Flow tot pl Eiciency | Mass “Ar Mant. Tp RPM a Cooper Energy Services Mount Vernon Training Center 10mots ona} ond venqe9 kaa CleanBurn™ III sony [aor |[Serommer— eos a fe sinea meres aR [a |< aaeneara ——— ays6s a sony wa \ wodies oe i noid ea — | sree b 3 a ° a 3 2 song ona 1 er e309 * a < Mount Vernon Training Center Cooper Energy ServicesAjax - Superior CleanBurn™ IL Control System Software This section covers the CleanBurn III control system software. It describes how the system controls the engine, start and stop sequencing, fuel quality compensation, trips and alarms Control Algorithms The control algorithms described below are the fundamental workings of the control system. The text and diagrams describe these workings but do not cover | the many details too intricate to be described here. ‘The figure on the previous page shows a flow chart of the control system. The basic control of the engine is broken down into speed governing, air/fuel ratio control, ignition timing control, main fuel flow control and pilot fuel flow control. These four main control functions are described below. Speed Governing The CleanBur III control system governs speed through a totally electronic, integrated system. There is no separate mechanical governor. Engine speed is sensed via a magnetic pickup positioned over a 180-tooth wheel attached to the engine damper. This signal is processed through a frequeney-to- voltage conditioner ( 5 k Hz = 5 Volts), fed as a voltage to the main. control board where it is digitized (with an analog-to-digital converter), read into the control computer program as a digital number and finally converted to engineering units Cooper Energy Services Mount Vernon Training Center iPAjax - Superior CleanBurn™ IIL cas : Low Heat value Main Fue! Calculate Valve Main | _ Main Fuel Flow Main Df. Press. | Fuel Flow ‘rfice Const (K) Gas Preseure Main Fuel SP , - cr Low Signal Selector Calculate Max. Fuel Flow Intemal to the program, the RPM signal is fed into a control loop which compares the actual speed signal from the engine to the speed setpoint. This control loop then calls for an inerease or decrease in fuel flow rate, depending on whether the actual engine speed is above or below the speed setpoint. This fuel flow signal is then compared to the instantaneous maximum fuel flow limit, and the lower of the two is sent to the fuel flow control loop, assuring the engine will not be over- fueled Air/Fuel Ratio (EAR) Control Actual air flow delivered to the engine is calculated as described in a previous section and again shown in the following figure. The main and pilot fuel flows are measured as described in previous sections. The actual air/fuel ratio is calculated by: Air Flow Air Fuel Ratio = — Main Fuel Flow + Pilot Fuel Flow Cooper Energy Services Mount Vernon Training Center 13Ajax - Superior CleanBurn™ III The air/fuel ratio is converted to EAR (Excess Air Ratio) by: Air/Fuel Ratio EAR ————— Air / Fuel Ratio stoichiometric The stoichiometric air/fuel ratio is defined as the mass ratio of air to fuel where theoretically the exact amount of oxygen for the amount of fuel is provided to the engine, When combustion occurs, all of the fuel is bumed and all of the air are consumed, This is expressed as 100% theoretical air. The stoichiometric air/fuel ratio is @ function of the fuel constituents, so it changes with fuel specific gravity EAR <1 = Unbured Fuel in the Exhaust, mixture rich EAR > 1 = Excess Oxygen in the Exhaust, mixture lean Lean burn engines operate with an EAR of greater than 1, which means there is excess air (or oxygen) in the exhaust. ‘The CleanBurn Ill system controls EAR (not air/fuel ratio) via intake manifold pressure. The turbocharger exhaust wastegate is adjusted by the control system. The measured EAR is compared with the EAR setpoint, and the wastegate position is varied by the wastegate actuator until the actual EAR equals the calculated EAR setpoint. The EAR setpoint is mapped to RPM, load, jacket water temperature, air manifold temperature and fuel quality, The maps are determined by the best tradeoff between emissions and fuel consumption. The EAR is also controlled by the fuel control valve, In a case where a step load is applied, the fuel valve can supply fuel much faster than the turbocharger can speed up and supply more air. In this case, the fuel valve is prevented from ‘opening too much and over-fueling the engine. By controlling the rate of fuel increase and allowing the turbocharger to supply more air as it speeds up, the controls ensure that the engine will always operate within safe EAR limits, Cooper Energy Services Mount Vernon Training CenterAjax - Superior CleanBurn™ JIT, sachet H20 Tmo, REM | Calculate ton | AF Ratio Wastegate ‘Air Mant. Tmo. ary Actuator >| EAR Setpoint Low Heat Value EAR Pit vei figw > | Calculate Mein Fueitiow> | A Ratio RT >| and EAR ee Jasket 120 Tmo ‘AieMact. Press —_—_| =| | Calculate |! Volumetric Ef. Calculate ae ‘Air Mae. Tg zl Air Flow aoe || eS | cateattor Calculations: Ignition Timing Control The Ignition timing is controlled by the ignition system, The ignition timing setpoint is communicated from the main control unit to the ignition system via a 4-20 milliamp (mA) loop. The ignition timing is mapped to EAR, RPM, jacket water temperature, air manifold temperature and fuel quality. These maps are determined by the best tradeoff between emissions, fuel consumption, step load response and engine safety. Calculate ignition Timing Low Heat Value Jacket 20 Tap | Setpoint Ignition System 4-20 mA Cooper Energy Services Mount Vernon Training CenterAjax - Superior CleanBurn™ III Main Fuel Control The main fuel flow rate is controlled via an electric-pneumatic pressure regulator. The actual fuel flow is measured as described in a previous section. The | measured fuel flow is compared to the fuel flow setpoint, and the fuel control valve output pressure is varied until the actual fuel flow equals the fuel flow setpoint. The fuel flow setpoint is determined by the lower of the two: either the fuel flow called for by the governor control loop or the instantaneous maximum fuel flow allowable before an over-fuel condition will exist. To summarize, the main fuel control system controls engine speed (getting its setpoint from the governor control loop) and keeps the EAR within safe limits Gas To Low Heat Value ASS | calculate | sain ret Fiow Ses Pressure) Main > Main Dif Press.) Fuel Flow L— Main Fuel ‘Orica Const. (K) Valve Main FuelSepont] 4-20 mA. Low Signal | ate Selector Flow Pilot Fuel Control The pilot fuel flow rate is also controlled via an electric-pneumatie pressure regulator. The actual fuel flow is measured as described in a previous section. ‘The measured pilot fuel flow is compared to the pilot fuel flow setpoint, and the valve output pressure is varied until the pilot fuel flow equals the pilot fuel flow rate setpoint. This setpoint is the ratio between pilot fuel flow and total fuel flow and is called Pilot Percent. Pilot Percent is defined as Cooper Energy Services Mount Vernon Tr: ing CenterAjax - Superior CleanBurn™ III Pilot % = 100 x 0 Pilot Flow Pilot Flow + Main Fuel Flow) RPM Ting ee Calculate Pilot Flow Setpoint Main Fuel Flow. Low Heat Value ‘Gas Timp Pict Gas Press Plot Dif. Press Pilot Ore Const.) Start Sequencing Calculate Pilot Fuel Flow Pilot Fuel Pilot Fue! SP Wve Pilot Fuel Flow ‘The following flow chart describes the automatic start sequencing of the engine. During the automatic start sequence, the CleanBurm III system controls the prelube pump, starter motor, ignition system and fuel gas supply to safely start the engine, Any trip condition which may occur during the start sequence immediately causes the start to be aborted, ‘The engine may also be started manually by turning on the prelube pump, starter, ignition, and gas with the contro] switches on the control panel. Cooper Energy Services Mount Vernon Training Center 17Ajax - Superior |) Purge Delay | Time Ae iow fing f REM> 13 Foe ‘ON Command ‘TRIP ENGINE START SEQUENCE He Cooper Energy Services 18 Mount Vernon Training CenterAjax - Superior CleanBurn™ II Trips and Shutdown Sequencing ‘The following figure shows a flow chart of the engine trips and the resulting shutdown sequence. OFF Prelube Pump 02 Ignition OFF Posilsbe Prelube Pump ‘Timer ON ‘OFF =F Tine AG. Ma, Fuel PM <300, } f TEMS, ‘The CleanBurn II system handles class A, B and C trip shutdowns as described below. Class A. Trips that are always active and will result in an engine shutdown when they occur. Class B Trips that are blocked by time delay on startup. Once the delay timer has timed out, the trips become active. Jacket water low pressure trips are not active until after the pressure has been established and a time delay assures pressures have stabilized Class C Trips that are blocked until the completion of an action. A low RPM trip is blocked until the engine speed has increased above a certain RPM during startup. Trips are indicated on the contro! pane! by a red lamp and are registered on the data display in the sequence they occur. The user must acknowledge each trip by pressing the acknowledge button. Cooper Energy Services Mount Vernon Training Center 19Ajax - Superior CleanBurn™ III Alarms Alarm points and limits are handled by the CleanBurn III system in a similar manner to the trip points. Alarms are indicated on the control panel by a flashing red lamp and are registered on the data display in the sequence they occur. The user must acknowledge each alarm by pressing the acknowledge button ‘The following listings are typical examples of trips and alarm setpoints. Most setpoints indicated in the listing are valid for a particular engine but may change for other engines. To verify the alarm and trip setpoints for your engine, consult the RDU LCD screens "Alarm Limits" and "Trip Limits" [rr iss Tacket Water Temperature [30 2¢ ‘Main Fuel Gas Temperature 30 130 50. ‘Turbine Inlet Temperature 500) 1000 Oil Temperature 150 220 Intercooler Water Temperature o 150. Cylinder Exhaust Temperature | ACTIVE TRIP LIST ACTIVE ALARM LIST ENGINE STATUS ENGINE HOURS The Menu list consists of a series of menu selections that allow for access to Vall be eonoring or control functions of the system. The first item on the list will be marked with a Right Arrow. The arrow can be moved Up or down with the Prey witches to select any of the other available items from the Menu lise Pressing the Mode switch with the ACTIVE TRIP LIST menu item marked by the ENGINE STATUS js selected will display a listing of the current status of the Engine, Pressing the Mode switch again will return the user back to the Mens list Depending on how long the MODE switch is pressed, may result in a different than desired action when viewing a Menu item. If the switch is pressed less than fone second, the display will return to the Menu listing with the arrow marking the item that was selected the last time. If the MODE switch is held down more than Or the ranch the Menu item marked by the Right Arrow will be the item at the top of the Main Menu listing, the ACTIVE TRIP LIST. ihe Menu selections available consists ofa series of single or multiple screen displays. Below is a listing of the Menu items available Active Trip List Fuel Data Active Alarm List Define Fuel Quality Engine Status Test Digital Trips Engine Hours Program Optional Digital Trips Cooper Energy Services Mount Vernon Training Center 30Ajax - Superior CleanBurn™ DI Reset Hour Timer Program Optional Digital Alarms RPM Setpoint Tuning _—-Program Timer Functions Performance Data Alarm Limit Cylinder Temperatures Trip Limits ‘Temperatures Power Relay Status Pressures Solenoid Valve Status Control Loops System Status Information ‘The following sections will summarize each of the above listed Menu items and their associated displays. Active Trip List This Menu item allows for viewing and acknowledging of active digital trip channels. The channels are viewing in the order of occurrence, beginning with the "First Out" followed by any additional "Non-First Out" trip. If no trips are present, the first line of the screen will display the message "NO ACTIVE TRIPS" ‘Although this Menu item can be viewed at any time, when a trip occurs, the listing as shown below will automatically be displayed no matter what other ‘Menu item has been selected for viewing. %® TRIP 1OF 1 FIRST OUT SUPPLY VOLTS LOW Should multiple "First Out" occur, a maximum of two first out channels can be displayed on the screen. In the case of "Non-First Out" trips, a maximum of three can be displayed on the screen The first line of the screen will list the number of trips present. The up and down arrows can select any of the trips in the listing, changing the first line to indicate which of the trips was selected. [fan "*" is the leading character on the first line, it indicates there is an unacknowledged trip in the list. With an unacknowledged trip present the RDU Alarm LED will continue to flash. Any trip in the list will remain in the list until it has been returned to normal and the acknowledge switch ‘has been pressed to clear it from the list, An "N" in front of a trip indicates the device has returned to normal but the trip has not been acknowledged. When all trips have been cleared the screen will read, NO ACTIVE TRIPS, at which time the RDU Alarm LED will go out. Cooper Energy Services Mount Vernon Training Center 3Ajax - Superior CleanBurn™ HI Active Alarm List This Menu item allows for the viewing and acknowledging of active alarms. Like the trips, the alarms are displayed in the order of occurrence. If no alarms are present, the first line of the screen will display the message “NO ACTIVE ALARMS" 3 ALARM 1 OF 1 20.62 SUP VOLTAGE Should multiple alarms occur a maximum of three alarms can be displayed on the screen. ‘The first line of the display will list the number of alarms present. The up and down arrows can select any of the alarms in the listing, changing the first line to indicate which of the alarms was selected. If an we" is the leading character on the first line, it indicates there is an unacknowledged alarm in the list. With an unacknowledged alarm present the RDU Alarm LED will continue to flash. Any ‘alarm in the list will remain in the list until it has been returned to normal and the acknowledge switch has been pressed to clear it from the list. When all alarms have been cleared the screen will read, NO ACTIVE ALARMS, at which time the RDU Alarm LED will go out. Engine Status “The Engine Status display provides information of the running condition of the engine. As conditions of the engine change, the information displayed will also change. The following display is an example of an engine that is not in operation ‘As the condition of the engine changes, the display screen will be updated. ENGINE STATUS ENGINE NOT RUNNING NOT STEADY STATE START SEQUENCE OFF Engine Hours The following Engine Hours display lists information on the number of hours the engine has been running. A Reset Timer displayed on line three allows the Cooper Energy Services ‘Mount Vernon Training Center 32eee Ajax - Superior CleanBurn™ IIT customer to monitor any other particular function he desires. Should he want to track the number of hours before an oil change, he can monitor this time and when the oi] change has been performed, the timer can be reset to 0.0. HOUR METER PG 4 OF 4 232.6 ENG. hours 120.0 RESET TIME END OF LIST. Reset Hour Meter When this function is displayed the screen will change to display the below message | RESET TIMER PG 1 OF 4 | TIMER RUNNING PUSH MODIFY & ENTER The screen indicates that the hour meter Reset Timer is currently running and continues to increment its time base. When the Modify switch is pressed the display changes to: RESET TIMER PG 1 OF 1 TIMER RUNNING RESET HOUR TIMER PUSH MODIFY & ENTER ‘The Reset Timer will reset to 0.0 if the Enter switch is pressed. If the Mode switch is pressed before the Enter switch is pressed, the display will return to the ‘Menu list and the timer will not be reset RPM Setpoint Tuning This is a set of three screens. The first allows for a manual setpoint change from the RDU, the last two are used to determine the origin of the speed setpoint. The setpoint can originate from the RDU or from a remote signal to the RDU Cooper Energy Services Mount Vernon Training Center 33Superior CleanBurn™ II PROGRAM RPM PG 1/3 700 RPMSP MAN. RANGE 650 TO 1220 If the setpoint originates from the RDU, a new setpoint can be selected from a range of 650 RPM to 1220 RPM. To change the setpoint press the Modify switch to display the following screen. PROGRAM RPM PG 1/3 700 RPMSP MAN. 400700 <--new value RANGE 650 TO 4220 ‘A-cursor will flash on the least significant digit of the number on the third line Pressing modify again will move the cursor one digit to the left. While pressing and holding the Modify switch, the t or & arrows can be used to increase or decrease the value of the digit the cursor is on. When the setpoint change is complete, press the Enter switch to send the new setpoint to the processor. Ifa Value not within the specified limits is sent to the processor a message will appear ‘on the fourth line to indicate the value is too high or too low. PROGRAM RPM PG 2/3 4 RPMSP FLAG USE RDU RPM INPUT This screen must be re-configured to change the origin of the speed setpoint. On the second line, the 1 next to RPMSP FLAG indicates that the speed setpoint comes from the RDU. For the control system to accept a remote speed signal from a location other than the RDU, press the Modify switch to display the following screen. Cooper Energy Services Mount Vernon Training Center 34Ajax - Superior CleanBurn™ III PROGRAM RPM PG 2/3 4 RPMSP FLAG #00001 <--new value USE RDU RPM INPUT With a flashing cursor on the 1 in the third line, press and hold the Modify switch and press the { to display a value 00000 and press the Enter switch. The control system will now accept one of two types of remote speed setpoint signals. The Jast screen will] be used to configure the origin of that signal. PROGRAM RPM PG 3/3 0 RPMSP REMOTE 4=USE EXT. 4-20ma ‘The RDU is capable of accepting a remote speed signal either from a 4 - 20 mA loop or from a pneumatic 0 - 12 PSI signal. If the value of number next to RPMSP REMOTE is 0, the setpoint originates from a0 - 12 PSI pneumatic signal. If the value is 1, the external speed setpoint originates from a 4 - 20 mA signal into the back of the RDU. PROGRAM RPM PG 3/3 0 RPMSP REMOTE #00001 <--new value 4=USE EXT. 4-20ma Press and hold the Modify switch while using the arrow. switches when the cursor is on the first digit will allow for the reconfiguration of the remote signal. Press Enter when complete. Performance Data “The Performance display screens allow for viewing of engine performance data The information available is displayed on the four display screens and are shown below Cooper Energy Services ‘Mount Vernon Training CenterCleanBurn™ IIT | PERFORMANCE PG 1/4 0 RPM 0 TORQUE (%) 110.0 MAX TORQUE The above screen displays the following: RPM - The actual engine RPM Torque - The actual torque in percentage control program Max. Torque - The maximum allowable torque, a constant value contained in the contro! program, as calculated by the PERFORMANCE PG 2/4 4.80 IGN TIMING 0.00 EAR 0.00__ PILOT % The second screen contains the following information: Ignition Timing - The ignition timing signal in degrees being sent to the ignition system, EAR - The Excess Air Ratio as calculated by the processor Pilot Percentage - A calculated value that determines the Pilot Fuel pressure and is a percentage of Main Fuel flow. PERFORMANCE PG 3/4 0.00 FUEL LB/MIN 0.00 AIR LB/SEC 0.000 PILOT #/MIN ‘The third screen displays the following information: Fuel Ib/min - The actual Main fuel flow to the engine. Air Ib/sec - The actual air flow to the engine. Pilot Ib/min - The actual Pilot fuel flow to the engine Cooper Energy Services Mount Vernon Training Center 36 ieian*_,aaAjax - Superior CleanBurn™ TIT PERFORMANCE PG 4/4 0.00 = A/F RATIO 29.56 | SUP VOLTAGE The last screen displays the following information + Air Fuel Ratio- The calculated air to fuel ratio of the engine based on current input values. + Supply Voltage - The battery voltage to the control system Cylinder Temperatures All cylinder exhaust port temperatures can be viewed using in six screens, Each screen displays three cylinders at a time starting with the right bank cylinders and continuing on to all left bank cylinders. The below screens represent the first and last screens available. TEMPS R BANK PG 1/6 69.1 EXH PORT R1 70.0 EXH PORT R2 70.5 __EXH PORT R3 TEMPS L BANK PG 6/6 69.9 EXH PORTL6 70.3. EXHPORTL7 70.6 EXHPORTL8 Temperatures The three temperature screens display those temperatures not associated with the cylinders and are all shown below. TEMPS DEGF PG 1/3 66.2 MANIFOLD T 65.6 9 J. W. TEMP 61.9 OIL TEMP Cooper Energy Services Mount Vernon Training Center esAjax - Superior CleanBurn™ III TEMPS DEG F PG 2/3 66.7 TURBOTRB 66.5 TURBOTLB 57.9 __1.C. TEMP TEMPS DEGF PG 3/3 64.2 FUEL GAST 65.6 AIRINLETT END OF LIST-- Pressures The following readings are available on the pressure display screens. PRESS. PSI PG 1/3 0 Ol 7 J. W. PRES 40 1. C. PRES TEMPS DEG F PG 2/3 0.4 MANIFOLD P 0.0 MAIN GAS PR 0.0 PILOT GAS PR TEMPS DEGF PG 3/3 0.4 MAIN GAS DP 0.0 PILOT DP 14.12 BAROMETER Control Loops Each of the Control Loop screens represents an output from the controller to the engine, Within the control program there are four PID controllers, each providing, an output to control: Cooper Energy Services Mount Vernon Training Center 38Ajax - Superior CleanBurn™ I + RPM-T + AF Ra he speed of the engine ~ The Air to Fuel Ratio that controls the wastegate, Fuel Flow - The PID that maintains a specific fuel flow in the Main Fuel header. header, Pilot - the PID that maintains e specific fuel flow in the Pilot Fuel The main purpose of a PID controller is to maintain a stable output to the controlling device. A stable output is achieved when the setpoint matches the actual signal into the PID. Should the setpoint increase or decrease, the output out of the controller inci setpoint. Fuel Data RPM PG 1/4 700 RPM DESIRED 0 RPM 0.0 M. FUEL SP. AIF RATIO PG 2/4 0.83 EAR DESIRED 0.00 EAR 400.00 WASTE OUT FUEL FLOW PG 3/4 0.0 M. FUEL SP 0.0 FUEL 0 - 100% 0.00 __M, FUEL OUT PILOT 0.0 0.0 0.00 PG 4i4 PILOT SP % PILOT % PILOT FUEL OUT eases or decreases until the actual signal again matches the “These two Fuel Date screens display the fuel quality values required by the control program in making the proper fuel flow calculations. Those vs aalues that Cooper Energy Services Mount Vernon Training Center 39Ajax - Superior CleanBurn™ III are configurable by the customer can be changed in “Define Fuel Quality" and is discussed in the following section. FUELDATA PG 1/2 0.595 FUELS.G. 939 FUEL LHV (v) 17.23 FUEL M.W. FUEL DATA PG 2/2 46.58 © STOICH AIF 4.00 INERTS VOL % 33.34 INERTS M. W. Define Fuel Quality The following display screens are used to re-define the fuel quality based on customer's fuel gas analysis. These values are used by the fuel programs to determine the proper Main and Pilot fuel pressures, wastegate position in controlling EAR and ignition timing. Al! values are determined by chemical analysis of the customer's fuel gas and should not be arbitrarily changed. PROGRAM FUEL INPUT INERTS VOL % PG 1/4 4.80 INERTS VOL % PROGRAM FUEL, INPUT INERTS M. W. PG 2/4 33.34 INERTS M. W. bee —“———C“‘e Cooper Energy Services 40 Mount Vernon Training Centera Ajax - Superior CleanBurn™ II PROGRAM FUEL PG 3/4 0.595 FUEL SG HI INPUT FUEL SG HI PROGRAM FUEL PG 4/4 0.595 FUEL SGLL INPUT FUEL SG HI When changes to these values are required, press the Modify switch PROGRAM FUEL PG 4/4 0.595 FUEL SGLL 400.595 <-- new value INPUT FUEL SG HI A blinking cursor over the least significant digit allows the user to change the value. Pressing the Modify switch will move the cursor one digit to the left. Hold the Modify switch while pressing the up or down arrow switch changes the value of that digit, Press the Enter switch to accept the new value, or press the Cancel, switch to exit and not save the new value. If Enter is pressed to change the old value, the information is sent to the processor ‘where a check is made of the new value. Should the new value exceed a predetermined upper or lower limit the bottom line will display a message indicating the new value is t00 high or too low. Otherwise, the processor will | accept the new value and the Fuel Data display screens will now display the new value. Test Digital Trips Currently forty optional digital inputs are available to the customer. Twenty of these are for trips. If this option is available, the customer has the ability to check the operation of these trips without causing an engine trip. This display screen allows the customer to bypass all twenty trips for a pre-programmed period of time. Should a trip condition still exist when the timer times out, the engine will t come to a stop Cooper Energy Services Mount Vernon Training Center 41Ajax - Superior CleanBurn™ II ‘The initial screen indicates that all trips are armed. The bottom line instructs the user to push the Modify switch and press Enter. TEST DIG. TRIPS DIG TRIPS ARMED PUSH MODIFY & ENTER Pressing the Modify switch places a message on line three asking the user if he would like to test the inputs. TEST DIG. TRIPS DIG TRIPS ARMED TEST DIGITAL INPUTS PUSH MODIFY & ENTER Pressing Cancel will delete the message and continue to display the same screen. Pressing the Mode switch will return the user to the Main Menu. Below is the display after the Enter switch has been pressed. TEST DIG. TRIPS TEST DIG TRIPS PUSH MODIFY & ENTER The second line now indicates that the digital inputs are being tested. When the timer times out, the second line will again display DIG TRIPS ARMED, Caution should be used when using this function since no count down time is displayed. PGM Optional Digital Trips Currently forty optional digital inputs are available to the customer. Twenty of these are for trips, Although this function is available in the program, additional hardware will be required. Once this hardware is installed, the additional digital trips must be configured for the processor to recognize them. Below is the first of Cooper Energy Services Mount Vernon Training Center 42Ajax - Superior CleanBurn™ JIT twenty display screens that must be configured for each added channel. There is one screen for each of twenty optional digital trips. ‘The customer determines if each of the optional channels is to be a Class A, B or C trip, and if the channel is not used, configure the channel with the 1 option, PGMINPUTS PG 1/20 0 DIGIN1 FLAG 4=NONE 2=A 3=B 4=C Pressing the Modify switch will cause line three to be displayed with a flashing cursor on the I up or down arr ‘ow switch allows for the selection of num! least significant zero. While holding the Modify switch, pressing the bers of 1, 2, 3 or 4. PGM Optional Similar to the configured in PGMINPUTS PG 1/20 0 DIGIN1 FLAG +00000 <-- new value 4=NONE 2=A 3=B 4=C Digital Alarms optional trips, the twenty Optional Digital the same way as the trips above. Alarms must be PGMINPUTS PG 1/20 0 DIGIN21 FLAG PGM Timer Functions Within the starting sequence, several functions are controlled by timers. These functions include: Cooper Energy Services Mount Vernon Training Center 43Ajax - Superior CleanBurn™ IIL + Prelube © Crank + Purge + Postlube + ClassB Depending on the application or location the engine is used in there may be a need to extend or shorten the times for these timers. These screens allow for the reconfiguration of those times. Each of the soreens lists the current setting of the timer and on the bottom line lists the minimum and maximum time that the timer can be set for. PGMTIMERS PG 1/6 0.0 CRANK sec. 40 - 120 seconds PGMTIMERS PG 2/6 30.0 = PWR OFF min. 410 - 120 minutes This is the only timer that is not associated with the starting sequence. It is used to configure the amount of time before power is removed from the FT-50 once the engine has come to a stop. For this function to operated properly, the key switch on the RDU must be in the RUN position. When the engine comes to a stop, the timer will start to count down. When thirty minutes has expired, power will be removed from the FT-50. Caution, if the key switch is left in the POWER position, power will be maintained to the FT-50 and could result in the complete discharge of the batteries. In this case an alarm and trip condition will annunciate on the RDU panel Cooper Energy Services Mount Vernon Training Center 44Ajax - Superior CleanBurn™ HI PGMTIMERS PG 3/6 0.0 PRELUBE min. 4-60 minutes PGMTIMERS PG 4/6 0.0 POSTLUBE min. 4-60 minutes PGMTIMERS PG 5/6 5.0 PURGE sec. 5 - 20 seconds PGMTIMERS PG 6/6 45.0 CLASS B sec. 410 - 240 seconds Class B alarms and Trips are those functions that are bypassed in the starting sequence until a specific time. In the above case, 45 seconds after a start has been issued, all class B alarms and trips will be armed. Inall cases, timer functions can be changed to suit the need of the customer as long as they are within the specified limits for each of the timers. To change a timer, display the desired timer screen and press the Modify switch. The screen will now display line three as shown below. PGMTIMERS PG 6/6 45.0 CLASS B sec. +0045.0 <- new value 40 - 240 seconds Cooper Energy Services Mount Vernon Training Center 45Ajax - Superior CleanBurn™ II A flashing cursor will appear on the least significant digit of the number in the third line. Pressing Modify again will move the cursor on digit to the left. While holding the Modify switch, pressing the up and down arrow switches will increase or decrease the value of the digit the cursor is currently on. When changes have been completed, press the Enter switch. Once the processor has verified that the new value is between the specified limits, the value of the timer has been changed. Alarm Limit The alarm limit display provides a listing of the engine alarms and their setpoint. Below are two sample screens from that listing. On this engine the listing consists of a 13 screens. Following the two sample screens is a complete listing of the contents of all screens. [ALARM LIMIT PG 1/13 15.0 A PBARHL 1.0 A PBARLL 29.5 A PSVOLTS HL [ALARM LIMIT PG 1/13 23.0 A PSVOLTSLL 1300 =A RPMHL 400 A__RPMLL ALARMLIMITS PG 1 through 13 15.0 | PBAR HL. [| BAROMETRIC PRESSURE. 1.0 | PBAR LL, 39.5 | PSVOLTS HL_| POWER SUPPLY VOLTAGE, 23.0 | PSVOLTS LL 1300.0 | RPM HL ENGINE SPEED 400.0 | RPM LL. 140.0 | OI PRAL | OTL PRESSURE 40.0 | OILPRLL | 45.0 | JWPRHL | JACKET WATER PRESSURE 7.0| SW PRLL 50.0 [IC PR AL. INTERCOOLER PRESSURE m AIR INTAKE MANIF, TEMP. =30.0 | TINT LL = 200.0 | TSW AL JACKET WATER TEMP Cooper Energy Services Mount Vernon Training Center 46 beAjax - Superior CleanBurn™ III [300 [Two [_ 2 130.0 | TGAS HL ‘GAS TEMPERATURE, — =30.0 | TGAS LL 220.0 | TOIL HL. LUBE O11. TEMP 150.0 | TOM LL 150.0 | TICH20 HIL__| INTERCOOLER WATER TEMP =30.0 | TICH20 LL 18 [EARSPLL | EXCESS AIR RATIO. 1.6 | EARAC LL. 15.0 | TIMING AL__| IGNITION TIMING 720.0 [TMB HL [AMBIENT TEMP [0.0 Tame 1000.0. TIT BL TURBINE INLET TEMP 00 | TILL oan.“ TCYL Bi __| C¥EINDER TEMP 61,7 [TCYLLL, ~ Set [PINT Hi. | INTERCOOLER PRESSURE 51.0 PGAS HL | MAIN GAS PRESSURE 31.0 | PPILOT HL___| PILOT GAS PRESSURE. 5.0 | MAINDP HL __| MAIN GAS DIFF. PRESSURE ‘5.0. | PILOTDP HL__| PILOT GAS DIFF. PRESSURE Trip Limit Similar to the Alarm Limits the Trip Limits are nine screens listing the trips and the setpoints associated with those trips. The following are two sample screens followed by a complete listing of the trips for the engine. TRIP LIMIT PG 1/9 30.0 T PSVOLTHL 21.0 T PSVOLTLL 450.0 T OPRHL TRIP LIMIT PG 2/9 35.0 T OILPRLL 4325. T RPMHL 350 T__RPMLL Cooper Energy Services Mount Vernon Trai a7Ajax - Superior CleanBurn™ III TRIPLIMITS PG 1 through 9 PSVOLTHL | POWER SUPPLY VOLTAGE PSVOLT LL 7 OIL PRHL | Off, PRESSURE (OWL PR LL. RPM HL ENGINE SPEED RPMLL JWPRHL | JACKET WATER PRESSURE IWPRLL ICPRAL, INTERCOOLER PRESSURE ICPRLL TINT HL, INLET TEMP TINT LL TIWLL | JACKET WATER TEMP : TGAS AL, ‘GAS TEMPERATURE TGAS LL. TOM. HL. “OIL TEMPERATURE EARACLL | EXCESS AIR RATIO TIT HL ‘TURBO INLET TEMP TIMING AL | IGNITION TIMING INT HI INLET PRESSURE PGAS HL MAIN GAS PRESSURE PPILOT HL | PLLOT GAS PRESSURE _ 5:1 | MAINDP HL | MAIN GAS DIFF. PRESSURE __| 7.1 | PILOTDP HL _| PILOT GAS DIFF. PRESSURE 1020.0 | TCYL HL | CYLINDER TEMPERATURE, PWR Relay Status The following screen monitors the condition of the power sources. PWR RELAY STATUS ALTERNATOR OFF SPARE POWER OFF CONTROL UNIT OFF Solenoid Valve Status The following screen monitors the desired state of the solenoid valves. The desired state indicates that the solenoid has been commanded on by the FT-50, which does not imply that the solenoid has actually energized. Cooper Energy Services Mount Vernon Training Center 48 EE —“——"Ajax - Superior CleanBurn™ III SOL. VALVE STATUS PRELUBE PUMP OFF STARTER OFF GAS VALVE OFF System Status Information This screen is used by the FT-50 to supply fault condition information should a problem occur within the FT-50, For more information on any fault that might appear on this screen, consult the FT-50 manuals or the COS 100 Operating System Software manual NO ACTIVE FAULTS Digital Input Module (Optional) The digital input module is a junction box with a 30 foot cable connected to the master control unit, where the user can connect up to 20 alarm and 20 shutdown switches for the CleanBum III control system to annunciate, This unit will replace an Altronic type annunciator. The user can program any of the 40 contact points as class A, B or C via the data display/control panel, The user can also program the class B time-out via the data display/control panel. The status of these 40 contact shutdowns are available on the LCD data display. These shutdowns are also acknowledged from the control panel Stand-Alone Power Supply (Optional) ‘The CleanBum Ill is a 24 volt system. The stand-alone power supply system includes a totally enclosed, brushless 30-amp, gear driven alternator, a power supply module and cables. The power supply module contains two, totally sealed 12-volt, 30 amp-hour batteries, fuses, solid state relays for power switching and battery charger regulator. The batteries are designed to last between five and ten years. There is a connector port on the power supply module for charging the batteries with an external battery charger, or supplying power to a 24-volt device such as a light, radio, etc. This port can also be configured for the CleanBurn TIT system to turn off and on a 24-volt device such as a siren Cooper Energy Services Mount Vernon Training Center 49 fee eee eee cee enerAjax - Superior CleanBurn™ HI Control System Hardware ‘The hardware section of this manual briefly describes the controller hardware utilized by Superior in control of the CleanBurn Ill engine. Additional publications are available through Cooper Energy Services EnTronics or the Mount Vernon Training Center. These include: - 50 Introduction FT - 50 Service Manual FT - 50 CBOS Software Operating System Superior CleanBurn III Service Manual FT-50 Main Processor “The main processor is a PLC manufactured by Cooper Energy Services EnTronics and is located in the master controller assembly box mounted to the side of the engine. The box contains the FT-50 main processor, the inpuVoutput (1/0) cards, the speed tachometer and a 24 VDC power supply. A set of drawings is supplied at the end of this manual that will detail the contents of the controller assembly box. ‘The FT-50 is a dual 80¢186 16 MHz based processor and is capable of handling the following inputs and outputs: 64 Digital Inputs 64 Digital Outputs 32 Analog Inputs 8 Analog Outputs, 64 Thermocouples and / or RTDs All /O is resident in the master controller assembly box and is connected to the processor through ribbon eable connections to each card. Connections from each Of the cards to the field devices is accomplished by cable connections from the bottom of the master controller assembly box to on-engine connectors. Charts at the end of this manual deseribe the connection of each cable from the Master Controtler Box to the appropriate on-engine connector. The Superior Service Manual contains additional drawings that provide detailed information on each cable and its connection from the controller assembly box to the engine. The following sections briefly describes the purpose of each of the /O cards. Cooper Energy Services Mount Vernon Training CenterAjax - Superior CleanBurn™ J FT-50 0 Cards “The VO cards are the engine device interface to the FT-50 processor. Each card is specifically designed to process information from a specific type of input, These include: Digital Inputs Digital Outputs Analog Inputs Analog Outputs Temperature Inputs A switching device whose information can be translated into either ON or OFF such as a pressure switch or relay contact. When the contact is OPEN, the processor places a "0" into a mem« channel location. If the contact is CLOSED, is placed in memory. y or Based on a logical decision within the processor, a is placed in a memory location. A'"]" in memory will result in turning ON an output relay to start a pump, or turn on a light, A "1" in memory returning to "0" de-energizes the output relay. ‘These inputs are normally derived from transmitters that convert process information (gas PSI, or TEMP.) to.a 4 - 20 mA signal. This signal is then interpreted by the processor and placed into ‘memory as real numbers for use by the programs contained in the FT-50. Based on a logic decision within the processor, a value is placed into memory. The information is sent from this memory location to an output card and converted into a 4 - 20 mA signal to be used to control a remote device ‘Temperature input cards use either Thermocouples or RTDs for their input. The temperature information is converted to digital data and sent to the FT-50 main processor where itis stored in ‘memory for used by the programs. Cooper Energy Services Mount Vernon Training CenterAjax - Superior CleanBurn™ III Digital Input Card The FT-50 is capable of accommodating two digital input cards, each capable of 32 digital inputs. Features of the card include + 32_Digital inputs + Transient Filtering + Reverse Polarity Protection + 24 VDC Built-in power distribution + Designed for 24 V dry contact operation E Overcurrent protection on the 24 VDC supply ‘The FT-50 software provides a method of reading into memory the state of the digital inputs. The inputs in the field are open/closed type of devices such as push buttons, switches or contacts. Each of the 32 inputs is read in tum and its information is placed in memory of the FT-S0, For an OPEN contact, the processor interprets this as a "0", and for a CLOSED contact the processor places aI” into an assigned memory location. Connection to the FT-50 is accomplished through a prefabricated cable supplied by Superior. The cable listing is supplied in section "Interconnect Cable Reference" of this manual. Digital Output Card ‘The FT-50 is capable of accommodating four digital output cards, each capable of 16 digital outputs, The cards provide 16, 3 Amp Normally Open (N/O) and Normally Closed (N/C) contacts and are designed with dry contacts that utilize an external power supply. The relays that operate the contacts are optically isolated from the FT-50 main processor. The FT-50 software provides a method of reading the state of various memory locations designated as output channels and changes the state of the digital output relay based on the information contained in that channel. A "0" state in that channe! will keep the relay de-energized, and a "I" state will energize the output relay. Energizing the relay on the digital output card will change the state of the relay contacts, the Normally Open contact closes, the Normally Closed contact opens, Connection to the FT-50 is accomplished through a prefabricated cable supplied by Superior. The cable listing is supplied in section "Interconnect Cable Reference” of this manual Cooper Energy Services Mount Vernon Training Centerrc Ajax - Superior CleanBurn™ HT Analog Input Card The FT-50 is capable of 32 analog inputs using two Analog Input cards but for the Superior CleanBur III master controller, only one card is required. This is, accomplished by connecting a ribbon cable from the analog input card to a connector on the FT-50 processor card, The analog input card provides 16 analog inputs to the FT-50 processor. The input card features include + Conditioning + Current protection + Overvoltage protection The analog input card provides connections for analog devices to the FT-50. Each input has a selector switch on the card which allows for two different input selections. the input selections include; a voltage input, 0 10 4 VDC; and a current input of 4 to 20 mA. Each input selector switch must be set properly for the type of input device being used. The external input device can be powered by the analog input card by connecting the card's 24 VDC power to the device. “The FT-50 software provides a method for reading the measured process by analyzing the magnitude of the signal being sent from the field device to the analog input card. These signals represent the analog input device's interpretation of the process being measured. The analog input card accepts these signals, sends them to the main processor, where the signal is converted from an analog signal to the digital information the processor can understand, Internally, the processor scales that information according to the engineering units specified by the software. ‘The following table lists the field device specifications for the analog inputs Cooper Energy Services Mount Vernon T aai | ' Ajax - Superior CleanBurn™ II Analog Input Specifications T Description |___Specification Tain Gas Supply Pressure 0-50 PSIG 2 | Main Gas Orifice Dif Presse 0-5 PSD. 3 [ Pilot gas Supply Pressure 0-0 PSIG “4_| Pilot Gas Orifice Dif Pressure 0-5 PSD Snake Ar Manifold Pressure 0-80 PSIG 6} Barometric Pressure 0-15 PSIA, —7—TRPM Seipoint fom Pressure TPSI= 100 RPM | Battery Volase : 0-32 Vols 9 _ | RPM from Converter 3 Kis Ful Sede 10 [Open {5:20 ma or 05 Vols 11 Ol Presse 0 200 PSIG. 12 | Jackes Water Pressure 0-200 PSIG 13 | Intercooler Water Presure 0-200 PSIG 14 [Open = {4-20 mA or 03 Valls 15_[ RPM Sepoin 4:20 mA oF 0.5 Vals Connection to the FT-50 is accomplished through a prefabricated cable supplied by Superior. The cable listing is supplied in section "Interconnect Cable. Reference" of this manual. Analog Output Card The FT-50 analog output card provides six 4 to 20 mA analog outputs from the FT-50 main processor to peripheral devices. Features of the card include: + 6 Analog output channels + LED Indications for Loop Integrity + Prevents Reverse Voltage or Overvoltage Input Voltage ‘The analog output card contains all the driver components and connections for all six outputs. Connections to the card include 24 volt DC power connections and shield connections for the ribbon cable shield. The analog output card accepts & voltage signal from the FT-50, which is then converted to the required 4 - 20 mA current output. The range of the output is between 4 mA and 20 mA ‘The FT-50 provides a method of reading the state of various analog memory channels designated as analog output channels. When this information is read from the memory channels, itis sent as voltage levels to the analog output card The voltage level is then converted to a current signal for use by the peripheral device attached to the output Cooper Energy Services Mount Vernon Training CenterAjax - Superior CleanBurn™ HI Connection to the FT-50 is accomplished through a prefabricated cable supplied by Superior. The cable listing is supplied in section "Interconnect Cable Reference” of this manual Thermocouple Scanner Card ‘The thermocouple scanner card connects a maximum of eight thermocouples to the ET-50 main processor from one scanner card, The thermocouple scanner card isolates, conditions, adds Cold Junction Temperature Compensation, and digitizes the thermocouple input voltage. The scanner card can handle either "J" or type °K" thermocouples operating in temperature ranges between -100° F to 1300° F. The features of the card include: + Thermocouple Isolation + Jor K Type Thermocouple Selection + Card Active Indication + Up/Down Scale Open Probe Selection «OnBoard A/D (Analog to Digital) Conversion ‘The FT-50 can control a maximum of eight thermocouple scanner cards, for a maximum of 64 temperature points. The scanner cards are connected together in series and use a shielded ribbon cable connected to the main processor. The processor considers these cards to be in a multiplexed configuration, with each card having its own address. The FT-50 scans each of the cards in sequence and places its information into memory. t ‘Each thermocouple scanner card has its own: serial Analog to Digital (A/D) converter on the card. Its purpose is to read the voltage from the thermocouple and convert that voltage into a digital signal that the FT-50 processor can understand. The digital information is then sent to the FT-50 VO processor where it is linearized for the type of thermocouple that is being used. The UO processor then places the information into the processor memory channels that were configured for temperature information. Connection to the FT-50 is accomplished through a prefabricated cable supplied by Superior, The cable listing is supplied in section "Interconnect Cable Reference" of this manual. Cooper Energy Services Mount Vernon Training CenterAjax - Superior CleanBurn™ IIT Pressure Transducer Unit ‘The Pressure Transducer Unit is a box mounted on the engine and contains the ‘components required for seven pressure inputs, Pressure transducers in the box translate the pressure signal into a voltage, the voltage is amplified and then converted to a current signal that is sent to the FT-50 as an analog input. Connection to the FT-50 is accomplished through a prefabricated cable supplied by Superior. The cable listing is supplied in section "Interconnect Cable Reference” of this manual, Fuel Module The Fuel Module mounted on the engine contains the control module for the ultrasonic sensor which measures the fuel density. The Ultrasonic sensor mounted in the Fuel Module Box receives a small quantity of gas for sampling. The signal from the sensor tube is conditioned and amplified before being sent to the FT-50 as an analog input Cooper Energy Services Mount Vernon Training Center 56 a ____Ajax - Superior CleanBurn™ III Interconnect Cable Reference The following listing of cable connections are intended for training purposes only and do not represent a standard engine configuration. They are example listing of information supplied by Superior. Please verify the accuracy of these listing with the manuals supplied for your specific Superior engine. FT-50 Connections Analog Inputs The remaining six channels of analog input will be available to an analog expansion unit through a connector containing both clean and dirty power as well as six analog input terminations. FT-50 Connector: 37 Pin Female (AMP P/N 206203-1) FTB-4 Analog Expansion Unit Connector: 37 Pin Male (AMP P/N 206151-1) TB-4 FTS0 | CBOS FS) | Analog Exp: Pin#_| Chan. Signal Name Terminal_| Module Pin # 1 Tv NO 1 ee A TT A z 3 Analog Ga BE fl + Seale wF z st av pee ——Ts 6 ieee Weer Pree Bre 16 7 aan Goad err = esl Sele ra = a =v ND. 5 1] Herter Pasar GE 0 0 ‘aay Gis G3 i wT Sil ace sy =v BLD a i eee Fr 068 his—t Analg Grand ——fer is cas @——fe 7 oe ‘Ni20 7 on HA i is rn i 30 Tass ——T20 31 te Sr a es = Thermocouple Inputs The thermocouples are organized into three groups requiring three connectors. The connectors are FT-S0 Connector: Quantity 3, 24 Pin Male (AMP P/N 206838-1) Cooper Energy Services Mount Vernon Training CenterAjax - Superior CleanBurn™ II ‘These connectors are grouped as follows: Board 37A Thermocouple Inputs Connector FTB - 5, CBOs Desrption TERT ios Coun # | Tem. 3 Rates Toop TE i EARL 3 z HVA $ mwas] Be Banal Maat Temp TE = WAS | —_[ewAs = Teg Wee Temp TE Tf aar 35 re HRA ‘SHIELD 5 aA 3 Tas Maine Ger Sip Top TE 1a 36 Taas- Ti Pras SHIELD isa TT Tem Te Para cor ig aac SHED 15 [ror Dire Te 1S 310m tir SELS [eps ici" | erste Waser Teme BC 19 [20D 39 rick. x SHIELD 2 Wo SPARETES | Sore 2 a0 SPARETC? 2 SHOELD a Board #828 Thermocouple Inputs Connector FTB - 6 Taos] TAC FIR] Board Chan _| Name | Term. Sev | Cid East Tap TE 1 WAAL [reve s ~ z TATA SHOELD i BDAAS ET reve | Cider Ean Tp TE © zWar | a Prev. 3 HAAS SHIELD ef asiwas Pa revise | Caine Ein Tap TE Z 7B Trews. 5 [BB SHIELD. 5 20) a reve | eer Eaton Tae TE ig ars apres Tip ras | SHIELD. TP asons revise | Conder Sion Te 1 Th [28 Ses i pac SHIELD. 1 PHBICs Tevise | Cinder Eimast Ting 1 isa Lrews: 17 Paepics SHIELD — a Cooper Energy Services Mount Vernon Training Center a aTL Ajax - Superior CleanBurn™ II 5a i a en Hist Hens cia TE [as Prevee . San Board HRC Thermocouple Tapas Connector FIB-7 Geos | Tae [Bastion TAR Boat Chan _| None ee tem Ge sy Sin aa TTS Ha Brey 7 acs Sar Facas Geren Gis Eas TE i isear 3 ete Hea Sao fice 5 ahs eine ae FE $—iscar Sie Teens SED Stee | Sie DE Ta TE Ties He | SD Here 5 rei Sis BET TE Eo hinerr Khe Pace: ‘SHIELD [ 1s | #a2CCS 3 Sao i a TE epee Tere hase EE - Hee [e—Trenis cot 3 Ter ae | SH an Sani Sie ean TE ce Hens HECDS HELD BEDE Analog Outputs The analog output connector interfaces with the control element module. This module contains the control element's (valve, actuators etc. .) electronics. Five of the six available analog output channels as well as three digital output channels drives the devices in the control element module. FT-50 Connector: 37 Pin Female (AMP P/N 206306-1) FTB - 8 Control Element Module Connector: 37 Pin Male (AMP P/N 206151-1) TB - 8 F I-50 | CBOS | Signal FI-30 | Control Pin | Chan. | Name Terminal | Element Mol. Pin # 7 To Wan Fos Vane mar} z a Ma Fe ale ara 7 Shell mat a ria vae= BAG z Cooper Energy Services Mount Vernon Training Centera Ajax - Superior CleanBurn™ IIT = 32] Pir Valve Tat z 3 Shall Tae $— as iene Tse 7 ee tise ae — tie —t tise ae T BE a5 Ba 0s He ris, ‘Shield no Hepat ret Sema ae [Bir Can Sad ate eat Bast [Ful Send Vale i = ‘Isolated +24 Tan far = ‘Analog Gro oF, 15 Sarva —_ Dart 3 7 Note: #2 Terminals A2, AS and B2 are wired to the Dirty +24 VDC supply (N18) so they can supply dirty +24 VDC to the solenoid valves. Optional Digital Inputs ‘The remaining unused digital input channels will be available through a 37 Pin connector. This connects to a junction box (Digital Input Module) which is an i optional feature FT-50 Connector: 37 Pin Male (AMP P/N 206151-1) FTB - 12 Digital Input Connector: 37 Pin Female (AMP P/N 206306-1) FTB - 12 FF-0 | CBOS | Signal FT-50 | Dig. Input Pin# | Chan. | Name Terminal | Module Pini z | bien mar 7 « 5 Ppignais rE s ix__Pbignvts #36 3 & a EY ust 16 % z 5 DIGS DIG Dianne DIGS DIGINDD DIGIT DIGRE DIGINDS DIGNE IGN IGN z DIGI 19 [3s ——T picnes 20[29__ [rene a 20 [piainso, Cooper Energy Services Mount Vernon Training Center 60ae Ajax - Superior CleanBurn™ II oe mor [Dis +3800 Nis Tae [Day Gross Los Las Serial Communications Port The serial communications port is accessed through a connector mounted on the FT-50, FT-50 Circuit Board Connector: Molex FCC-68 FT-50 Connector: 9 Pin Male (AMP P/N 206705-1) FTB - 13 ‘Annunciator Connector: 9 Pin Male (AMP P/N 206705-1) TB - 13 FT-S0 | Signal FT-50 | Computer Pint | Name Molex _ | RS-232 DBO Terminal | Pin# T Be 3 7 z TK 1 2 t DIE ts + 5 [a 3 s é ‘GND, CLEAN oF 6 3 [ 2s Voe CLEAN ait 3 7 [GROUND z z Pressure Transducer Box FT-50 Connector: 37 Pin Female (AMP P/N 206306-1) FTB-1 Pressure Box Connector: 24 Pin Male (AMP P/N 206838-1) FT-S0 | CBOS | FI-s0 Description FI-s0 Pin# | Chan. | Name Chan. Connector 717 Tan Gos Sep 2d Sis [ 2 Maia Gat Once Desh = es Pilot Gas Suepiy 15.33 4 Pio Once Desc 15.867 Ti ‘Ar Manos Pressure #503 Bi 16 [ Bsromevis Pressure ¥5.C517 38 7 Speed Seto cee as. 10 [lean 34 VDC A io ‘Giesn 34 VDC aS. 7 ‘len 28 VDC wc Fl #48 = 7 Be 3 = ce Cooper Energy Services Mount Vernon Training Center 61Ajax - Superior CleanBurn™ HI Fuel Sensor The fuel sensor option will be housed in one box and contain the electronics to drive an ultrasonic molecular weight sensor. This circuit are powered by +12 Volts DC. The total current for this circuit is 0.058 amps. 24 Volt DC power is, provided to digital input channel 11 which allows the FT-SO to turn the sensor power ON and OFF, FT-S0 Connector: 14 Pin Female (AMP P/N 206043-1)FTB-3 Fuel Sensor Connector: 9 Pin Male (AMP P/N 206705-1) TB-3 FT-50 | Signal FT-50) CBOS | Fuel Pin# | Name Terminal | Chan. | Sensor Pin i Tv Mi T 2 =v eae 3 RVG Bi 3 3 5 ‘ Shad ae 6 7 Mi Pale aS Es = Shield FDS — z = 1g ra Note: FT-50 Terminal #: wired to isolated +12 Volts. RPM The RPM signal from a magnetic pickup will terminate at the FT-50. This mag pickup signal goes to an Electro Corporation model TA24-05000, 5 kHz F.S. frequency to voltage converter. The output of this then goes to the FT-50 as Analog Channel 9, FT-50 Connector: 4 pin female (AMP P/N 206430-1) FTB-2 Mag Pickup Cable Connector: MIL Spec 3106A-10SL-4S TB-2 FT-30 | Mag | Signal [F-v FTO Pin# | Pickup | Name Converter. | Terminal Ping 7 1 Varker | a Mag Pap) [Tern 2 3 Tore —f ses _ Toe Tops cj Tes [ni [een 6-102 [tem ib Cooper Energy Services Mount Vernon Training Center 62Ajax - Superior CleanBurn™ TIT Ignition Timing Output ‘An ignition timing signal driven by analog output Channel 6 goes to the ignition system through a four pin connector. FT-50 Connector: 4 Pin Male (AMP P/N 206061-1) FTB - 9 Ignition System Connector: 4 Pin Female (AMP P/N 206430-1) TB- 9 FT-50 | CBOS ] Signal Pin#t_| Chan. | Name [FF50__] Igniton ‘Terminal_| Pin# i é Tgaiuon Timing 1IORA THs.c6 T 2 6 gnton Timing $20mA 2 — Shield is tT Esyre i Display and Control Panel FF-50 | CBOS | Signal Frs0 Pin # | Chan. | Name Terminal T VDE Teed 5A 2} Ri Spe Sto Sh BAD ‘Aalog Grd BAL Suid AS Dane VBC era) NI BE VDC Grd a $1.50 ONOEF Ganicbe Ma FISOONOFF (oS) Dr [RUNSTOP cont Toss) HAL STOP sees Smasoo) HAP START dfonenn Suit AAS Autor Fee HAL Frise ONOFF [ias Aussie Con BAe {Mn Crank — Har ‘Alo BA Vahe Cat fae BEV Vale ONO #1 Enste Persie Lam DIDS alam Cao Sat Sequence LR Engine Ck Lap Furl Gas ON La GLE? ignios ON Lam 2.04.05 Auto gts Coase is? —| Maral aoe —hnst ibe amp 0 oT Battery Voltage Measurement Measures the battery voltage feeding the FT-50 using a 32.0 volt to 4.0 volt divider network. Cooper Energy Services 63 Mount Vernon Training CentereS Ajax - Superior CleanBurn™ HT TuOS | CHOS | Signal [Fro Chan, | Name__| Name Terminal Chan, Natt Then age evo BEY Power Supply Module Connectors “The power supply module has three connectors on it, They connect 0 the FT-50, the ignition system and the alternator. Power Supply Interface “The power supply interface connector includes connections to power the FT-50 \with 24 VDC as well as provides digital output signals to tum on the FT-50 ower, turn on the ignition system, energize the alternator and provide an optional switched power supply. FT-50 Connector: 9 Pin Male (AMP P/N 206705-1) FTB - 10 Power Unit Connector: 14 Pin Female (AMP P/N 206043-1) TB - 10 FF-0 | CBOS | Signal FF0 | Igniton Pin #_| Chan. | Name Terminal | Pin # ial Day $9 VDE Vasa Bas 1 z Day #28 VDE Swiebel z x Tepition > [sts Spare z « @ F150-ONOF s 7 7 cot Gea = z Clean 924 VDE Grea i Note: £2 terminals BS, C2 and CS are tied to the dirty, switched, +24 VDC. Alternator PSM Connector: 3 Pin Female (AMP P/N 206425-1) TBI4a ‘Attemator Connector: MIL STD MS3102R20-14P TB14b FSM] jena Alternator | Harness #_| Name Pin Wire Gage [8s a TGs ee iz 2 Lisa Cooper Energy Services ‘Mount Vernon Training Center 64Ajax - Superior CleanBurn™ TIT Ignition System P.S.M Connecotor: 4 Pin Female (AMP P/N 206430-1) TB15a_ Altemator Connector: (AMP P/N 206061-1) TBISb PSM. | Signal Tgnition | Harness Pin #_| Name Pin# | Wire Gage TPB OE TA “ii Gage z Engi Grund 1s ope x Clean 235 VOC tb {Tis Cen Grind Cooper Energy Services Mount Vernon Training Center 65Ajax - Superior CleanBurn™ IIT APPENDIX FT-50 PROCESSOR DIAGNOSTICS Cooper Energy Services Mount Vernon Training CenterAjax - Superior CleanBurn™ III FT-50 PROCESSOR DIAGNOSTICS The FT-50 Main Board is provided with a series of LEDs that are visible through the cover of the processor. These LEDs flash in a specific pattern when the processor is operating normally, and when the processor faults, these LEDs will provide useful information to the technician in diagnosing why the processor fails to function properly. The following figure shows the FT-50 Main Board, the three main groupings of diagnostic LEDs and the configuration switch packs, NODE ID SWITCHES CoumaucmTons) | CONTROLLER O OGOOSIOO 2g Cooper Energy Services Mount Vernon Training CenterAjax - Superior CleanBurn™ Til This section will provide information on the diagnostic LEDs, their meaning when the processor faults and how they would appear under normal operating conditions. Many of the LEDs are associated with a specific operating condition of the processor. Listings, explain the functions associated with each LED. A built in Error Log in the form of an LED pattern provides useful information when the processor fails. A listing of these Error messages is provided to aid the technician in troubleshooting Main Board problems. In addition, the Main Board contains three switch packs that must be configured for proper communications to remote devices. This section will describe the purpose of these switches, how they should be configured and if communications problems arise, which LEDs will aid in solving the problem Hardware Controlled LEDs The Hardware Controlled LEDs that are related to the hardware functions are listed following the below figure, Each LED has a specific meaning and alerts the user toa potential problem or activity. The LEDs are located on the bottom left edge of the Main Board but are not in the order of the listing. The purpose of each LED is marked on the cover of the FT-50, on the Main Board each LED is identified by a CR# Main Processor Reset Main Procaaot Bus Tinecut FLEXNET Tranemit Atty FLEXNET Communication Uo Processor Reset VO Processor Bus Timeout +6 Vor OK Benery Sats FT-50 Hardware Controlled LEDs Cooper Energy Services ‘Mount Vernon Training Center Sener ee er ee re ee ee ere eee ee eeAjax - Superior CleanBurn™ TI CRI CR2 CRS cR20 cR21 Hardware Controlled LEDs Battery Status - Green indicates that the battery is operating correctly. Red indicates that the battery is not, connected or the voltage is low. Solution - Check jumper JP1. Pins ] and 2 should be jumpered. Furthermore, check the battery voltage with a meter. The battery voltage should be greater than 2.5 VDC, if not, replace the battery. Main Processor Bus Timeout - This LED should always be off. Solution - Press the Reset button. If the problem still exists, return the equipment to En-Tronic Controls for repair, Main Processor Reset - This LED should be briefly on during power-up. It will blink at approximately one second intervals indicating that the processor is not running Solution - Verify that the EPROM Versions match. If the EPROMS do not match or the problem still exists, return the Main Board to En-Tronic Controls for repair. FLEXNET Transmit Activity - Indicates that the FT-50 is transmitting data on the FLEXNET high speed communications network FLEXNET Communication - If on solid, processor has established link with a remote device on the LAN (Local Area Network) If flashing, processor is attempting to establish ‘communications link with a remote device on the LAN but can not get a response. Cooper Energy Services Mount Vernon TraiEY = =—~— Ajax - Superior CleanBurn™ IIT R23 R24 CR25 Solution - If FT-210 is used and LED flashes, check the FLEXNET cabling and the connection to J9C or power (0 remote PC. If LED is off Node ID switches may be configured for "0" 45V OK - The LED is on to indicate the voltage supply is within the specified tolerance Solution - Adjust R54 until 5 V is read between the pins (C223, the capacitor above 1C99, the I/O Processor EPROM near the center of the board. VO Processor Reset - This LED should be briefly on during power-up. It will blink at approximately one second snterval indicating that the I/O processor is not running. Solution - Verify that the EPROM Versions match. Ifthe EPROMS do not match or the problem still exists, rerurn the Main Board to En-Tronic Controls for repair. VO Processor Bus Timeout - This LED should always be off, Solution - Press the Reset button. Ifthe problem stil veists, return the equipment (0 En-Tronic Controls for repair. Cooper Energy Services Mount Vernon Training CenterAjax - Superior CleanBurn™ II Switch Pack 2 - Communications Configuration Switches Switch Pack 2 is primarily used to configure the communications baud rate of Serial Port connector J9A. This connector is located below the FLEXNET BNC connector on bottom right of the Main Board as shown in the following figure. UUUUUUUU SWa Parity sw2 | SW3 | BandRate ‘Asive | Odd Active | Active Baud Detautt | None Default | Default | 2400 Baud ‘ave | Defals | 9600 Baud JOA - Serial Port [ Detaut | Active | 19200 Baud Configuration ‘Two additional switches on Switch Pack 2 are used to determine the clock speed of the processor and the other is used to tell the processor that FLEXNET is available for use by a remote device As noted in the previous figure, the active and default positions are determined by the switches relative position to the word OFF marked on the switch pack. If the switch is toward the word OFF, this is referred to as the ACTIVE, OPEN or ‘ OFF position, away from the word OFF, is referred to as the DEFAULT, CLOSE or ON position. All these references may be used interchangeably depending on the documentation being used Cooper Energy Services Mount Vernon Training Center nAjax - Superior CleanBurn™ MIT Switch #1 of the switch pack should be left in the ACTIVE position for a ZE544- 050-002 Main Board to select the 16 MHz processor contained on that Main Board version. With the older ZE544-050-001 Main Board, two types of processors could have been installed. When a 10 MHz processor is installed, the ACTIVE position selects the 16 MHz processor, the DEFAULT position selects the 10 MHz processor. These selections are summarized in the following chart Switch #1 Description Default | 10 MHz Processor ZE544-050-001_ Active 16 MHz Processor ZE544-050- Active 16 MHz Processor_ZE544-050-002 RS-232 Communications Configuration Switch 2, 3 and 4 of Switch Pack 2 are used to configure the communications baud rate of the RS-232 communications connector located on the right bottom side of the Main Board under the FLEXNET BNC connector. The connector is marked J9A and may be used for RS-232 communications to an RDU, PC or any other device capable of serial communications. The following chart summarizes the baud rate setting for switches 2 and 3 Switch #2 Switch#3 | __ Description Active Active [1200 baud. Default ___ Default 2400 baud ‘Active Default 9600 baud Default Active 19200 baud Switch #4 sets communications parity. The switch positions are summarized in the following table. Switch# 4] Description Default No Parity | Active (Odd Parity (for use with FT-210 & 19200 baud) ‘Communications can be set for any combination of baud rate and parity shown in the above tables, Once the FT-50 has been configured for communications, the device the FT-50 will communicate with must also be set for the same baud and parity settings. In the case of the RDU, a similar set of switches set the baud rate. ‘A summary chart of the RDU baud rate configuration are shown below. Cooper Energy Services Mount Vernon Training CenterAjax - Superior CleanBurn™ HI RDU Baud Rate Configuration Switch #2 Switch#3 | Description OPEN, OPEN 1200 baud CLOSE CLOSE 2400 baud OPEN. CLOSE 9600 baud CLOSE __OPEN 19200 baud Parity can not be configured in the RDU, by default it will always be ODD Parity. Therefore, if an RDU us used, the FT-50 must have Switch 4 set for ODD Parity and the baud rate is normally set for 19200 baud rate. The connector below J9A is serial connector JOB. Like the port above it, it can communicate to any device capable of serial communications. This port thought has no hardware configuration switches and must be configured by the software programmer through the operating system sofiware. Unless the CBOS operating software is available to the user, baud rate and parity can not be set. FLEXNET Communications Configuration When a high speed FLEXNET communications Local Area Network (LAN) is used, Switch 8 of Switch Pack 2 must be set in the ACTIVE position to tell the processor that FLEXNET is available. FLEXNET activity can be monitored by two LEDs on the Main Board and are located on the bottom left side. LED CR20 flashes whenever data is passed between the FT-50 and a remote device over the network, LED CR21 should always on when the FT-5O has established communications on the FLEXNET LAN with a remote device (FT-210). When CR21 flashes, communications has been lost to the remote device and may indicate that the device is powered down or cable problems exist between connector J9C on the ‘Main Board to the remote device. FLEXNET Available Switch #3 | Description Default | FLEXNET not available Active FLEXNET available Cooper Energy Services Mount Vernon Training Center ’ leAjax - Superior CleanBurn™ IIT FLEXNET Node ID A remote device such as an FT-210 is capable of communicating to multiple FT- 50s over the FLEXNET LAN (Local Area Network). Since all FT-50s are identical, the FT-210 must have a way of identifying one FT-50 from another. This can be done by providing each FT-50 with a unique identification number, configured by Switch Pack 4 128 64 32 46 Nf Switch Pack 4 | Node ID Configuration Each of the eight switches of the Switch Pack represent a numeric value, A combination of these switch values when added together make up a specific identification number for this FT-50. The following chart describes the switches and the values they represent in a given position. If the switch is in the UP, or towards the OFF, position, that value will be include in the total. Cooper Energy Services Mount Vernon Training CenterAjax - Superior CleanBurn™ IT ‘Switch Pack 4 ‘Switch Value Switch # when UP 1 2 - 8 16 32 64 128 o2|aforfurfa|es)ro)— In the above example, switch #1 and switch #4 are both in the up position. From the chart above, switch #1 has a value of "1" and switch #4 has a value of "4" Added together the value is 5, and makes this FT-SO on the network Node ID 5 For those users with multiple engines reporting to one FT-210, each unit's FT-50 must have a unique Node ID. None can have a Node ID of "0" (zero) and no two can have the same Node ID. Switch Pack 4 is located to the right of the upper group of diagnostic LEDs and above IC24. The switch configuration number entered is determined by the software programmer. When replacing an F-50 Main Board, configure the Node ID the same as the Main Board being removed, Molecular Weight Sensor Activation ‘Switch Pack 3 is located below Switch Pack 2. Switch 8 of this switch pack is used to activate the Molecular Weight Sensor. If the sensor is not in use leave the switch in the DEFAULT position. If the sensor is used, place the switch in the ACTIVE position. The following chart summarizes the setting of this switch. ‘Switch Pack 3 - Molecular Weight Sensor Switeh #8 Description ‘Default ‘Mol. Weight Sensor NOT used Active Mol, Weight Sensor in use Cooper Energy Services Mount Vernon Training CenterAjax - Superior CleanBurn™ I Diagnostic LEDs Two groups of eight LEDs visible through the cover of the FT-50 are used to determine if a controller is operating normally, or are used to diagnose a problem when the controller fails, The upper group of eight LEDs are referred to as the Communications LEDs and are used to determine; normal operation, communication activity to FT-200 devices, communications to other FT-50s and problem diagnostics, ‘The lower group of eight LEDs are the Controller LEDs and display the ‘operation of the main controller. The LEDs indicate when a program is executing properly and if the system has been properly configured ‘The following figure shows all sixteen LEDs and in the following sections we will detail how the LEDs function under normal operation and how they are used for problem diagnostics. LED Patterns for Normal Operation The following figure shows several of the LEDs in a lighted condition. These are the LEDs that are always active during normal operation Heemae es Toggles at FT-50 aps, Se LED Pattern Time Class 1| 10 1 ‘gles aN 2 13, Time Class 2) 44 “Toggles each ‘Seaton 18 JO} 17 (Gong OK Time Ciass 3 on solid “Toggles each ‘One of the Communications LEDs, CR4, is the Heartbeat LED and will flash at a constant rate. It indicates that the Communications processor is operating Cooper Energy Services Mount Vernon Training Center 10Ajax - Superior CleanBurn™ IIT Controller normally, Should the LED stop flashing, a problem exists within the controller and further diagnostics will be required Other LEDs in the Communications LED group flash only to indicate controller activity to other devices, Should the system communicate with an FT-210, an FT- 100 or another FT-50, they will flash when communications takes place between the FT-S0 and the remote processor. ‘Three LEDs included in the Controller LED group indicate control program activity. The Time Class LED flashes whenever Time Class 1 is executed. The Time Class 2 LED flashes whenever Time Class 2 is executed, And, the Time Class 3 LED flashes whenever no activity is taking place in either Time Class 1 or 2, The flashing rate of these LEDs can vary from one controller to another. The rate is determined by the size of the program and the execution time of each Time Class. In addition to the flashing LEDs in the Controller LED group, LED CR19 must always stay on to indicate there are no hardware configuration errors in the system, The hardware configuration verifies that the /O cards specified in the operating program are properly configured and addressed during normal processor operation, The above description describes a light pattern for normal FT-50 operation. In addition, many of the LEDs have a dual function. These functions will be described in the following sections. gnostic LEDs The Controller Diagnostic LEDs provide status information on a normally operating FT-50 and provide feedback to a technician when the FT-50 is not operating properly. The controller is the processor that performs all the tasks defined by the engine control program. It determines how the engine will start, stop and operate under various ambient conditions. In the program, certain tasks have a higher priority than others. For example, it is much more important to make the proper calculations for a fuel valve opening than it is to update the RDU display information for an operator. Therefore, these functions or tasks, can be placed in any of three possible Time Classes. Time Class 1 has the highest execution priority (50 ms) and may well perform the fuel valve opening calculations, Time Class 2 has the next highest priority (100 ms) where Time Class 3 is a background task that has no time base and is used to update the RDU display screen values. Cooper Energy Services Mount Vernon Training Center coyAjax - Superior CleanBurn™ IT When the processor first starts, all tasks in Time Class 1 are executed first, followed by all the tasks in Time Class 2, When completed, the processor moves to Time Class 3 and performs those tasks. ‘With the times specified above, the processor will now re-execute all tasks in Time Class 1 every 50 ms, and all tasks in Time Class 2 every 100 ms. W hen not executing tasks in either of these time classes, the processor executes the tasks in Time Class 3. CONTROLLER DIAGNOSTIC L cR cR Time Class 1] 12 19 {Time Class 7 ‘(Time Class 2] 14 a5 {Time Class 2 a eae) Download in progress 18 19 (Config. OK ‘The above figure shown the LEDs and the following listing provides more detailed information on the function of each of the Controller Diagnostics LEDs. Controller Diagnostic LEDs LED# Funetion Description CRI2 Time Class 1 Flashes under normal operating conditions Executing when the tasks in Time Class 1 are executed. The flash rate is configured by the programmer. Cooper Energy Services Mount Vernon Training Center 12Ajax - Superior CleanBurn™ TIT R13 Time Class 1 Overfill CRI4 Time Class 2 Executing CRIS Time Class 2 Overfill CRI6 Time Class 3 Executing CRIT Not Used CRI8 Program Download CRIS. Hardware Configuration Normally off. The light comes on when the processor can not execute all the tasks within the program specified time. If on, indicates a programming error, not a hardware error. Flashes under normal operating conditions when the tasks in Time Class 2 are executed, The flash rate is configured by the programmer. ‘Normally off. The light comes on when the processor can not execute all the tasks within the program specified time. If on, indicates a programming error, not a hardware error. Flashes when the tasks in Time Class 3 are executed, If on, indicates a program is in process of being downloaded to the FT-50 In norma! operation this LED is on solid. If abnormal hardware conditions exist this LED will go off and the processor will shutdown. With this LED off, the Heartbeat LED in the Communications LED group will also be off. Cooper Energy Services 13 Mount Vernon TiAjax - Superior CleanBurn™ II Communications Diagnostic LEDs The LED pattern for the operation of the Communications Processor has more options or conditions that it monitors when compare to the Controller LEDs. These LEDs are the top group of 8 LEDs depicted in the following figure. In addition to showing normal operating activity, some of the LEDs are an aid in determining why an FT-50 is not functioning. The first five LEDs in this section make up what is termed the LED Shutdown Log. Each LED is associated witha numeric value, which when added together refers to an error message listing. This function will be described in the following section, COMMUNICATIONS| DIAGNOSTIC LEDs cR oR (Ciearteat} 4 | 5 (Pee Ber FLEXNET ] Peer to Peer) ‘(interrupt Service} © | Response _) (FTZI0 Message) 4. +4 {Peer to Peer Processing Request Timeout ‘The most important LED in this group is CR4, the top left LED, which is called the Heartbeat of the communications processor. Under normal operation, this LED will always flash once every 250 ms, If a fault condition occurs in the system this LED will no longer flash. If the FT-50 has faulted, this LED may or may not be on since it is also an LED associated with the LED Shutdown Log. ‘The function for each LED in the Communications LED group is described in the following listing Cooper Energy Services Mount Vernon Training Center 14Ajax - Superior CleanBurn™ IIT Communications Diagnostic LEDs LED# Function Description CR4 Comm. Heartbeat Flashes ata rate of once every 250 ms to indicated normal operation. If system has faulted, it may be on as part of the Shutdown Log CRS Peer to Peer ‘The LED will be on when this FT-50 is Request asking another FT-50/100 for data. It sends out a request for communication over FLEXNET to the other FT-50/100, The LED will go off when the last packet of information is received from the other FT- 50/100. CR6 FLEXNET Indicates FLEXNET communications is Interrupt Service taking place with another device. The LED will come on only briefly for a FLEXNET request or response for communications. The LED will be off when actual data is being passed over FLEXNET, CR7 Peer to Peer ‘The LED will tum on when another FT- Response 50/100 is asking for data, The LED will go off when the last packet of information has been sent to the other FT-50/100 over the FLEXNET network RS Not Used CRO Not Used CRIO FT-210 Message This LED will be on when this FT-50 is Processing communicating with an FT-210. ‘Communications can take place with the FT- 210 over FLEXNET or over serial communications lines. This should not be | confused with Peer to Peer communications bb) | Cooper Energy Services Mount Vernon Training CenterAjax - Superior CleanBurn™ III which can only take place over a FLEXNET network to another FT-50 or FT-100. The LED will only flash briefly when the FT-50 sends out a message request or responds to a message request from an FT-210, It will not be on during the actual data transmission, CRIL_ Peer to Peer This LED is on to indicate that this FT-50 has Request Timeout requested information from another FT- 50/100 and has not received a response from that device. It should be noted again, the patter of flashing lights of the Communications Diagnostics LEDs during normal operation are dependent on the type of devices the FT-S0 communicates with and may change from one customer to another. Communications Processor LED Shutdown Log Should the FT-50 not function, a shutdown log has been built into the FT-50 Communications Processor to aid the user in determining a possible cause. The shutdown log uses CR4 through CR8 and is shown in the following figure. COMMUNICATIONS PROCESSOR LED SHUTDOWN LOG oR cR (eacena)rS 5 (ee2) e |f 7 (vane = : ; 10 Each LED has a specific value associated with it. When a fault occurs, add the values of the ON LEDs. The total can be used to look up the error fault in the Cooper Energy Services Mount Vernon Training CenterAjax - Superior CleanBurn™ TL listing at the end of this section. The values associated with each of the LEDs is summarized below ‘Communications Processor Shutdown Log cEDEee| Value | cR4 1 crs | 2 “| cré__| a [_CR7 8 CRE 16 ‘Asan example, the figure on the previous page shows that LEDs CR4, CRS and CR7 are on. From the summary table, we can determine the error value as shown below. value= 1 value= 2 8 1 value TOTAL 1 From the following listing, an error code of 11 indicates that the processor has been shutdown for a Download of a program, The solution to this problem would be, "Restart the FT-50 from the Download Menu of CBOS100 or press the Reset button on the Main Board.” Many of the faults listed below do not have a field repairable solution, but the information gained by the LED Shutdown Log provides important information ‘when notifying a service representative in your area. Those solutions that mention the use of CBOS are referring to the Cooper Bessemer Operating Software. In Some instances this operating software may not be available to every customer, especially ifyour engine operating software is programmed into an EPROM in which case, some of the listed faults may never appear. Cooper Energy Services ‘Mount Vernon Training CenterAjax - Superior CleanBurn™ III Communications Processor Shutdown Log Error Messages LED Total Error Meaning 1 Controller Tasks Not Running - Internal Error This error occurs when there is not a software handshake between the Controller TC#1 and the Communications subsystem Solution - Verify that the EPROM Versions match. If the EPROMS do not match or the problem still exists, return the EPROMS to En-Tronic Controls for repair. 2 W/O Address Fault ‘The Error Address Channel must be read to determine the bad /O address. Solution - Verify the (0 addresses and download the CBOS software once again. 3 Ready Line Failure on Main Processor ‘There is a hardware failure on the Main Processor. Solution - Press the Reset button and download the CBOS software once again, If the problem still exists, return the equipment to En-Tronic Controls for repair. 4 VO Handshake Failure There is a lack of communication between the I/O Processor and the Main Processor. Solution - Verify that the EPROM Versions match. If the EPROMS do not match or the problem still exists, return the EPROMS to En-Tronic Controls for repair. 5 1/O Shutdown ‘The /O Processor has detected a problem that requires a shutdown, Cooper Energy Services Mount Vernon Training Center 18Ajax - Superior CleanBurn™ III 10 Solution - The reason for the shutdown may be a mixture of old and new °C or RTD input cards. Therefore, verify that these cards match. Furthermore, the Dump utility found in CBOS, may also be used to determine the shutdown, Watchdog Trip The watchdog on the Main Processor has tripped causing a shutdown. Solution - Press the Reset button and download the CBOS software once again. If the problem still exists, return the equipment to En-Tronic Controls for repair. Unexpected Interrupt ‘An invalid Interrupt vector has been executed causing a shutdown. This is usually a result ofa hardware problem. Solution - Press the Reset button and download the CBOS software once again. If the problem still exists, return the equipment to En-Tronic Controls for repair. Communications Configuration Error The Communications Configuration Checksum does not match the downloaded checksum Solution - The Communications Configuration must be downloaded once again from CBOS. Controller Configuration Error ‘The Controller Configuration does not match the downloaded checksum. Solution - Press the Reset button and download the CBOS software once again. If the problem still exists, return the ‘equipment to En-Tronic Controls for repair. V/O Processor Watchdog Trip ‘The VO Processor watchdog has tripped and it has been detected on the Main Processor. ‘Cooper Energy Services Mount Vernon Training Center 19Ajax - Superior CleanBurn™ II] ry 2 13 14 15 Solution - Press the Reset button and download the CBOS software once again. Ifthe problem still exists, return the equipment to En-Tronic Controls for repair. Downloading This error code is displayed, when a running system is stopped by a Download command. Solution - This error code will disappear once the system is up and running. Wrong 1/0 EPROMs The VO and Main Processor EPROMs are not compatible. Solution - A set of compatible Main Processor or I/O Processor EMPROMSs are needed. Time Class Exceeded One of the three Time Classes exceeded the five second time limit for execution. This is normally caused by Time Class 3 Solution - Time Classes 1 and 2 can be slowed down, thus giving Time Class 3 more time to execute. Time Class 1 and 2 Exceeded Time Classes | and/or 2 have exceeded their programmed time limit for execution, This is normally caused by overloading the Time Classes. Solution - Increase the length of the time period for that Time Class or move some of the tasks to another Time Class. Online Communications Configuration Fault The configuration test has detected that the communications configuration has been changed. Solution - Press the Reset button and download the CBOS software once again. If the problem still exists, return the equipment to En-Tronic Controls for repair. Cooper Energy Services Mount Vernon Training CenterAjax - Superior CleanBurn™ IIT 16 7 18 Online Controller Configuration Fault The controller configuration test has detected that the controller task configuration has been changed. Solution - Press the Reset button and download the CBOS software once again. If the problem still exists, return the equipment to En-Tronic Controls for repair. Online Tuning Constant Fault ‘The configuration test has detected that the tuning constants have been changed. This is normally caused by the application program written into the Tuning area. Solution - Use the Tuning Compare Utility to compare the disk values to the FT-50 values to determine which channel has been changed. The XREF utility can also be used to determine the source of the write function so it can be eliminated. Power Up Tuning Constant Fault ‘The FT-50 detected that there are no Tuning Constants present, Solution - Download the Communications and Controller Configuration and Tuning Constants information once again. If the Configuration information is lost on power-up, check the Battery Back-up Enable Jumper. Should the problem continue after checking the jumper and the battery voltage, the Main Board may need to be replaced. Cooper Energy Services Mount Vernon Training Center 21