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No.

1400-0256-4

Framo

Rev.E Aug 2005

Instruction for diesel engine


control system
Cummins KTA 19 DM1 Engine

CONTENTS

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

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

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

TROUBLE SHOOTING / ADJUSTMENTS


4.1
Alarm / Shutdown indications
4.2
Speed sensor

Instruction for Diesel Engine Control System


CUMMINS KTA 19 DM1 ENGINE
1.

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

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

GENERAL DESCRIPTION
This instruction manual describes the control system for the diesel engine including
operator interface, programmable logic controllers (PLCs), communication between
hydraulic system control panels and local panels in addition to electric fuel control (EFC)
(see fig.1).
This manual should be read in conjunction with dedicated drawings.
Fig. 1 : Interconnection of control system

HYDRAULIC SYSTEM
CONTROL PANEL
CARGO PUMPING SYSTEM
OPERATION

MISCELLANEOUS

AUX. UNIT

HYDR. OIL TEMPERATURE

FEED PRESSURE

SYSTEM PRESSURE

MAIN PRESSURE SET

EM. STOP HYDR. SYSTEM

OIL HEATING ON/OFF

POWER ON

CARGO
PRESSURE
HIGH

THRUSTER ON

INERT GAS
PRESSURE
LOW

bar/MPa

100

bar/MPa

16

400

1,6
50

MANUAL OVERRIDE

40

200
0,8

20

FP1

SHUTDOWN
EM. STOP HYDR. SYSTEM

RETURN LINE CLOSED

EM. STOP CARGO PUMPS

START

STOP

OIL LEVEL LOW LOW

PLC FAILURE

FEED PRESSURE LOW


PP1

OIL TEMPERATURE HIGH

OIL LEVEL LOW

POWER FAILURE

MAIN FILTER DIRTY

COMMUNICATION FAILURE

SYSTEM PRESSURE LOW

FUEL OIL HIGH LEVEL

PROTECTION PRESSURE LOW

FUEL OIL LOW LEVEL

PP3

MOTOR CURRENT

1.0

OIL LEVEL HIGH

PP2

MOTOR CURRENT

FP2

ALARMS

PP4

COOLING WATER

1.0

0.5

150

0.5

LUBE OIL PRESSURE

COOLING WATER

10

b ar/MPa

75

150

1,0

10
1,0

5
0,5

STOP
0

FP3

HPU OIL LEAKAGE

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

LUBE OIL PRESSURE


ba r/MPa

75
0,5

START

WEAR INDICATION

WEAR INDICATION

WEAR INDICATION

SUCTION LINE

SUCTION LINE

SUCTION LINE

DIESEL RPM

WEAR INDICATION

2500

RPM

DIESEL RPM
2500

RPM

SUCTION LINE

1250

1250

COOLING SYSTEM FAILURE


0

TEST

HORN SILENCE

ACKNOWLEDGE

RESET

START

STOP

START

STOP

START

STOP

START

ALARM

STOP

START

ALARM

TRIP

TRIP

REMOTE
CONTROL

REMOTE
CONTROL

STOP

( MAIN PLC )
CARGO CONTROL ROOM
ENGINE ROOM
DIESEL ENGINE
CONTROL PANEL
+P31

DE NO 1

JUNCTION BOX
WITH EFC

DIESEL ENGINE CONTROL


ALARM

DIESEL RPM

RPM

2500

LUBE OIL
PRESSURE LOW
LUBE OIL
TEMPERATURE HIGH
COOLING WATER
LEVEL LOW
COOLING WATER
TEMPERATURE HIGH
HYDRAULIC PUMP
WEAR INDICATION

1250

SHUTDOWN

LUBE OIL PRESSURE

BAR/MPa

10

OVERSPEED

1,0

DIESEL ENGINE

LUBE OIL
PRESSURE LOW LOW
COOLING WATER
TEMPERATURE HIGH HIGH

5
0,5

HYDRAULIC SYSTEM
SUCTION LINE CLOSED

OPERATION

COOLING WATER TEMPERATURE

150

START

STOP

LOCAL REMOTE

75

TEST

ACKNOWLEDGE

RESET

POW ER O N

MANUAL
O VERRIDE

( LOCAL PLC )

- Start/stop signals
- Analogue feedback
signals
- Digital feedback signals

+P32

DE NO 2

DIESEL ENGINE CONTROL


ALARM

DIESEL RPM

RPM

2500

LUBE OIL
PRESSURE LOW
LUBE OIL
TEMPERATURE HIGH
COOLING WATER
LEVEL LOW
COOLING WATER
TEMPERATURE HIGH
HYDRAULIC PUMP
WEAR INDICATION

1250

SHUTDOWN

LUBE OIL PRESSURE

BAR/MPa

10

OVERSPEED

1,0

LUBE OIL
PRESSURE LOW LOW
COOLING WATER
TEMPERATURE HIGH HIGH

5
0,5

HYDRAULIC SYSTEM
SUCTION LINE CLOSED

OPERATION

COOLING WATER TEMPERATURE

150

START

STOP

LOCAL REMOTE

75

TEST

ACKNOWLEDGE

RESET

POW ER O N

MANUAL
O VERRIDE

( LOCAL PLC )

RS485, serial communication


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

Instruction for Diesel Engine Control System


CUMMINS KTA 19 DM1 ENGINE
1.1.

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

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

Control system / PLC (Programmable Logic Controller)


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

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

Instruction for Diesel Engine Control System


CUMMINS KTA 19 DM1 ENGINE
1.2.

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

Electric fuel control system, EFC


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

Fig. 2
ENGINE

DIESEL CONTROL
PANEL
PLC

EFC

SPEED SENSOR
NO.2

FLY WHEEL

SPEED SENSOR
NO.1

CYLINDERS /
PISTONS
FUEL
INJECTORS

FUEL RETURN
RAIL

FUEL SUPPLY
RAIL
CHECK VALVE

CHECK VALVE

FUEL INLET

MAGNETIC
FILTER
FUEL STOP
VALVE
FUEL TANK

ACTUATOR
CENTRIFUGAL
GOVERNOR
FUEL PUMP

FUEL FILTER

The unit compare the feedback signal to a preset engine speed setting. When
deviaton is detected, a change in current from the EFC to the actuator will regulate
the magnetic force in the actuator.The movement of the actuator shaft will then
adjust the fuel flow to the engine and cause the engine speed to be equal to the
preset value. Shaft movement is proportional to the amount of actuator current and
is counter balanced by the internal spring in actuator.

Instruction for Diesel Engine Control System


CUMMINS KTA 19 DM1 ENGINE

2.0

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

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

Technical data :

2.1

Electric fuel control unit ( EFC )


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

2.2

2.3

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

Speed sensors connected to EFC and engine monitoring system (PLC)


Type
: magnetic pick up
Threads
: 5/8-18 UNF-2A
Signal at normal speed 1770 +5 / -10 rpm
: 4201 / 4165 Hz
Signal at low speed
1500 +50 / -0 rpm
: 3550 / 3669 Hz
Number of gear teeth at flywheel :
: 142 pcs.

Alarm and shutdown data.

Function

Sensor range

Lube.Oil pressure (bar)


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

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

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

Alarm

Shutdown

1.8 +-***
96 C
120 C
NA

1.3+-***
100 C

NA

1860 rpm
4402 Hz
1890 rpm
4473 Hz

Instruction for Diesel Engine Control System


CUMMINS KTA 19 DM1 ENGINE

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

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

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

Instruction for Diesel Engine Control System


CUMMINS KTA 19 DM1 ENGINE

3.2

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

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

Communication fault

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


engine as follow :
- select local mode and start engine locally
Communication fault is indicated by flashing diesel engine power unit remote and
PLC/ communication failure lamp at hydraulic system control panel.

3.3

Engine cooling at cooling water temp. High High


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

4.0

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

4.1 Alarm/ Shutdown indications.


Symptom/ failure:

Possible reason:

Remedy

Hydraulic System, LED


activated at local panel

Hydraulic System not


ready.

Check alarm status on hydraulic


system control panel

Manual Override, LED


activated at local panel

Manual override mode is


activated.

Check alarm status on hydraulic


system control panel

Communication fault
No red LEDs flickering at
indicated at main cargo
actual diesel control PLC
control panel. Actual diesel communication port.
remote control indication
lamp is flashing

Fasten loose wire/ connections


with reference to actual drawings.

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

Lube.Oil pressure
sensor/cable loop failure.

Measure sensor output signal with


reference to technical data.

Temp. indicator = zero /


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

Cooling Water temperature


sensor/cable loop failure.

Instruction for Diesel Engine Control System


CUMMINS KTA 19 DM1 ENGINE

4.2

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

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

Speed sensor/ pickup adjustment

Re installation of speed sensor :


Screw the magnetic pickup all of the way down until it
contacts a flywheel gir tooth. the piuckup will screw in
very easy, do not use excessive pressure to install the
pickup

Back the pickup out to of a turn


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

Tighten the locknut down on the flywheel housing.


Plug the electrical connection into the pickup, when
required.