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CONTENTS
Insuring Performance and Compliance: Altronic Control Systems for Natural Gas-Fueled Engines
Each make and model of natural gas The pages that follow will give you a solid CERTIFIED FOR USE IN
HAZARDOUS LOCATIONS
engine has its own unique set of starting introduction to the range and specific ca- NOTE: Most, but not all, Altronic
digital instruments and controls in
and performance requirements. For well pabilities of each member of the Altronic this catalog are CSA certified and
compliant with the appropriate
over twenty years, Altronic has met these engine control product line. Additional CE/ATEX regulations. Check each
individual needs with high-quality, easily- details, including application, installa- product listing for certification and
hazardous area classification.
installed and understood control systems tion, and operating information associa-
for small and large gas engines alike. ted with each system, can be found on
Constant attention to product develop- the web at www.altronicinc.com. Your
ment and manufacturing quality prompt local authorized Altronic Distributor and
users around the world to turn to Altronic Dealer, Regional Manager, and Altronic
control products to meet their natural gas factory sales and service staff are also
engine air/fuel ratio control, speed gover- available to address your specific applica-
ning, and starting system requirements. tion questions
EPC-50 Air/fuel Ratio Control for ratio and is ideally suited for application sired air/fuel ratio can be easily adjusted
Low-Horsepower Carbureted Natural with 3-way catalytic converters. While it by changing the control target voltages
Gas-Fueled Engines is designed to be mounted in the engine/ through the sealed membrane keypad or
The Altronic EPC-50 is an air/fuel ratio compressor control panel, a NEMA 3R through the use of a PC. The EPC-50 also
controller designed for use on low-horse- housing (720004-1) is also available as incorporates a thermocouple input and a
power, carbu- an alternative mounting option. dedicated output for implementation of
reted natural catalyst over-temperature protection. A
The single control output of the EPC-50
gas-fueled second digital output is available for use
allows for its use on any engine appli-
engines. It em- as an alarm for diagnostics or uncon-
cation incorporating a single fuel gas
ploys micropro- trolled operation.
regulator. An oxygen sensor is used in the
cessor technol-
exhaust stream to sense O2 content, and The EPC-50 has an alphanumeric LCD
ogy, allowing
a thermocouple input signals when proper display showing the target voltage, sensor
for a high level
exhaust temperature has been reached voltage, operating temperature, stepper
of sophistication in control
to allow for accurate sensor operation. motor position and diagnostic information.
strategy, ease of configuration
A system fuel control valve installed in
and diagnostic capability. The CERTIFIED Power requirement is 24 (12–30) VDC,
CLASS 1 the fuel line to the carburetor is pre-
EPC-50 and associated small DIV. 2 1 amp. In remote areas, power can be
GROUPS C & D cisely adjusted by a stepper-motor under
engine-specific control valves provided by the Altronic 24VDC Alternator
microprocessor control to maintain the
are designed for use on engines operat- Power Package. Refer to Altronic Form ALT.
correct O2 content in the exhaust. The de-
ing at or near a stoichiometric air/fuel
Designed specifically for use on low-
horsepower stoichiometric natural
gas-fueled engines
Accurate closed-loop control of
air/fuel ratio for minimum engine
emissions
Precise full authority actuation using
digitally-controlled valves for positive
fuel control
I N T A K E
Modbus-based EPC terminal
E X H A U S T program and expanded I/O available
to implement advanced control
strategies
Fully supports Modbus RTU
communications with included PC
monitoring software
EPC-110/120 Air/Fuel Ratio Control The control approach of the EPC- setpoint. Using a sensor in the exhaust
and Monitoring Systems for 110/120 assures engine operation at stream to sense the O2 content, the unit
Carbureted, Stoichiometric Engines the optimum begins to adjust the flow of fuel to meet
The Altronic EPC-110 and the EPC-120 lambda (exhaust the proper exhaust oxygen setpoint(s) for
are air/fuel ratio controllers for use on oxygen) setpoint minimum emissions. The full-authority
carbureted gas engines. These control- determined to fuel control valve(s), mounted in the fuel
lers utilize microprocessor technology, be the point of line between the carburetor and the final
allowing a high level of sophistication maximum cata- cut regulator, assures precise, repeatable
in control strategy, ease of programming lytic converter control of the air/fuel ratio without resort-
and diagnostic capability. The EPC-110 efficiency and ing to the potentially dangerous strategy
is intended for stand-alone, off-engine, minimum engine of adding fuel to the air intake of the
post- or wall-mounting. The EPC-120 is emissions. Once engine.
intended for off-engine, panel mounting. determined
Monitoring and protecting the engine and
Both controllers are identical in opera- (through an
catalyst from high temperature-related
tion. The EPC-110/120 is designed for analysis of the
damage or out-of-compliance operation is
use on engines operating at or near a engine exhaust),
a key function of the EPC-110/120 sys-
stoichiometric air/fuel ratio (lambda .95 – it is entered into
tem. Critical temperatures are monitored
1.05) and is ideally suited for application the EPC-110/120
against user-adjustable setpoints using
with 3-way catalytic converters. as the control
type K thermocouples.
EPC-100E Advanced Air/Fuel Ratio or even further reduced exhaust emis- can be dynamically adjusted versus load
Control System for Carbureted, sion levels across a range of operating (typically derived via an input transducer
Stoichiometric Engines conditions. monitoring air manifold pressure).
EPC-150 Lean-Burn Engine Air/Fuel nes the oxygen level at which engine-out governor. This control approach — which
Ratio Controller emissions are at their lowest, and the monitors intake air pressure both before
The EPC-150 is designed for use on all corresponding setpoint is entered into the and after the throttle plate — enables
lean-burn, carbureted, natural gas-fueled EPC-150 as the control setpoint. As load the controller to automatically offset the
engines. Suitable applications include Ca- and other parameters change, the EPC- oxygen setpoint for richer operation and
terpillar 3400 and 3500-series, Waukesha 150 maintains the air/fuel ratio necessary ultimately increased turbo boost pres-
VHP-class, and most Cummins and Supe- to meet the sures. With the engine operating more
rior models. This innovative control offers desired exhaust smoothly and achieving the necessary
reliable, precise, and positive air/fuel oxygen level, as- RPM, automatic control at the desired
ratio control, with simple installation and suring “in-com- oxygen setpoint is then restored. As with
operation. It also incorporates advanced pliance” engine all other EPC-150 operating parameters,
operating features which address engine performance. the point at which such an offset would
conditions specific to lean-burn operation. be made, and its value, is fully adjusta-
A unique control ble from the keypad of the control unit
The EPC-150 adjusts fuel delivery protocol limits “lug” con- or remotely using the integral RS-485
to meet and maintain a user-entered ditions, whereby a lightly ModBus RTU communications system.
CERTIFIED
CONTROL
TYPE "K"
EPC-150 THERMOCOUPLE
“lug” recovery protocol
LEAN BURN AIR/FUEL CONTROLLER
691207-1 MUFFLER
MODBUS RTU
COMMUNICATIONS
(RS-485)
SENSOR Integral, ModBus-RTU-based serial
ADAPTER
LEAN OXYGEN
monitoring and control and
SENSOR
Terminal Software
TURBO
24VDC POWER ALARM OUTPUT
(REQUIRED)
I E
N X
BOOST SENSOR T H
A A
K U
THROTTLE E S CARBURETOR
T
M
MANIFOLD
AIR PRESSURE FUEL GAS
CONTROL VALVE
SENSOR SUPPLY LINE
ASSEMBLY
FUEL PRESSURE
REGULATOR
Actuating Control Valves (690-Series) “ Universal” valve designs are suitable Stepper Motor (Fuel Control Valve)
for use on virtually any carbureted Controller (SMC-Series)
To operate in conjunction with its Air/
natural gas engine
Fuel Ratio Control Systems and other gas The SMC-series Stepper Motor Control-
Sophisticated digital linear actuator
control applications, Altronic offers a com- utilized in all valve models assures ler is designed to give users of control
plete family of actuating control valves. precise, repeatable control systems having a standard analog output
These rugged and reliable actuators Field proven and oilfield-ready an effective and convenient means of inte-
incorporate sophisticated position control grating Altronic Actuating Control Valves.
technology (digital linear actuator-based), Butterfly Style (6902XX-Series) The unit is DIN-rail mounted and easily
and have become the fuel control standard installed in the back of a control panel or
in the oil, gas, other suitable enclosure.
and power gen-
eration indus- A standard 4-20mA input control signal
tries for the is used as the primary input to the SMC
precision control Controller. That input signal is converted
that they offer such that, across the 4-20mA range of
and the minimal the input, the user achieves a fully linear
maintenance and calibration 1700-step span to dynamically adjust
CERTIFIED
that they require. CLASS 1 the position of the control valve piston or
DIV. 2
GROUPS C & D butterfly. The SMC board drives a single
Altronic actuating control valves are availa- Actuating Control Valve.
Piston Style (690154-Series)
ble in both the piston style (silver body),
Offers simple integration of the
and butterfly plate Altronic actuating valves into control
(black body) configu- systems with analog output
rations. “Universal” Assures precise valve control
in their design, they
are suitable for use
with all Altronic
controllers on both
in-line and V-type
engines, and on both naturally-aspirated
and turbocharged models. 1.5" NPT, 2.0"
NPT., 2.5" NPT, and 3.0" NPT fuel line
diameters can be directly accommodated
without the need for additional adaptor
fittings in the line.
EPC-200C Fuel-Admitted Engine manifold pressure, air manifold pressure, Available power options include 12 or
Performance Controller and air manifold temperature are config- 24VDC, as well as 110VAC input. Serial
Complete air/fuel ratio and ignition tim- ured as the primary control inputs. The communications capabilities are standard
ing control for fuel-admitted gas engines fourth (unspecified) input is often con- in all EPC-200 system models. EPC-200
is provided by the Altronic EPC-200 nected to a variety of devices including Engine Performance Controllers are often
Engine Perfor- exhaust oxygen sensors, KW sensors, and integrated with other Altronic instruments
mance Control- calorimeters. Using operating data taken in an Altronic Controls-manufactured
ler. Replacing from the existing controls and determined panel, providing complete engine/com-
obsolete OEM during the commissioning process, these pressor protection and control.
and/or pneu- monitored values are used as inputs to “Universal” controller suitable for use
matic controls, optimize both the engine air/fuel ratio on turbocharged, fuel-admitted gas
this flexible and and the desired ignition timing across the engines
fully-configurable range of ambient conditions, speeds, and Improves engine performance and
efficiency
system is an ef- engine loads. Control of these functions
Fail-safe design features and fault
fective upgrade solution for op- is accomplished by two independent
annunciation
erators of turbocharged integral 4-20mA signals: one for use with an Al-
CERTIFIED Seven discrete outputs for sequence
compressor engines, as well as CLASS 1 tronic CPU-series digital ignition system control
DIV. 2
AGV5 Smart Gas Control Valve Control is derived from industry-standard manifold to a desired setpoint for startup,
Designed for service as an actuation 4-20mA output signals generated by the and then to switch to standard governing
device for a supervisory speed govern- associated controller. For speed control logic when the engine comes up to rated
ing or air/fuel applications, this would require that speed. The result of this unique approach
ratio control all governing logic, RPM and pressure is that the engine starts more consistently
system, the setpoints, and timers be defined and resi- and reliably, and runs in a more stable
Altronic AGV5 is dent within the controller itself, driving fashion. Pairing the AGV5 with such a
a single-stage, the AGV for fuel actuation. supervisory speed control also eliminates
electronically- the need for maintenance-intensive and
(Note: If a full-authority, turnkey speed
actuated, bal- costly mechanical or bladder-style fuel
control capability is required, please see
anced poppet, valves and actuators, hydraulic governors,
the description of the GOV10/50 Gas
fuel control and all linkages associated with them.
Engine Governing Systems on page 10).
valve. Due to Eliminates mechanical fuel valve,
Two models of the AGV5 are available
its precision control, rugged actuator, and linkages
(standard and high-flow) to accommodate
design, and tolerance to fuel Allows for improved starting and
CERTIFIED
the fuel flow control needs of engines up speed stability
contaminants and corrosives, CLASS 1
DIV. 2
to 10,000 horsepower. Regulates gas flow in response to an
the AGV5 is used extensively GROUPS C & D
GOV10/50 Gas Engine Governors The GOV systems are mounted directly in Two GOV models are available—the
Taking an innovative, unique approach to the engine fuel line, and very precisely GOV10 is used on engines up to approxi-
fuel-admitted gas engine speed control, control gas flow to the engine by changing mately 3,500 hp, and the GOV50 applies
the Altronic GOV10/50 Systems bring the position of an internal poppet valve. to engines ranging from 3,500 to 10,000
Using fuel gas pressure as the “muscle” hp. Configuration of the GOV can be ac-
for the actuation force, this poppet valve complished through the system Display
is moved in the open or closed direction Module or via the ModBus-RTU-based
to meter the delivery of the fuel and to GOV10 Terminal Software included with
regulate and govern the speed of the en- each unit. That same RS-485 serial link
gine under all loads. On-board pressure, can also be used for direct interaction be-
differential pressure, and temperature tween the GOV and a supervisory device
both the fuel control valve monitoring sensors, along with engine for remote system monitoring and control.
and a sophisticated elec- RPM and an optional fuel flow mea- I ntegrates governing electronics and a
tronic governor together into CERTIFIED surement capability allow for accurate state-of-the-art fuel control valve
CLASS 1
a single, integrated unit. DIV. 2 control of engine speed. A sophisticated, Eliminates separate actuators and
GROUPS C & D
Designed for use on both user-tunable speed governing algorithim linkages
integral compressors such as Cooper- is resident within the GOV enabling the Improves engine starting and speed
stability
Bessemer, Clark, Ingersoll-Rand, and system to properly meet the individual
Fail-safe design inhibits the flow
Worthington, as well as high-speed startup, loading, and run requirements
of fuel to the engine on the loss of
separables such as Superior and MEP, of each engine. Since many engines are power
these robust, precision-control devices ef- highly sensitive to flooding at startup, the Display Module and Terminal Soft-
fectively eliminate troublesome hydraulic GOV10 can easily be configured to control ware assure convenient access to the
governors, actuators, and linkages. The to a specified pressure curve during the current run data and configuration
values of the GOV system
result is significantly improved starting start and warm-up cycles, and then to
performance and speed stability across switch to an RPM setpoint-based control
the engine load range. strategy for run conditions.
SaveAir™ Electronic Air Start System The heart of the SaveAir™ system is spots” — and to drastically reduce the
Built to replace troublesome, mainte- an innovative, engine-mounted position amount of starting air required. More reli-
nance-intensive OEM or pneumatic air sensing device used to determine the pre- able remote starting, improved operator
start distribution systems, the Exline- cise angular location of the crankshaft, safety (no mechanical barring), reduced
even while the engine is at rest. With air consumption, and more efficient com-
accurate radial position data in hand, the pressor station operation are just a few of
SAVEAir
CONTROL
air start components with solid-state
SAVEAir
SOLENOID
electronics
DISPLAY MODULE
SAVEAir
LOGIC MODULE
IN HEAD
AIR START VALVE
Less costly and complex than ring
gear-based starting conversion systems
SAVEAir
OUTPUT ENGINE
MODULE
AIR
SUPPLY
DIGITAL IN
(DISCRETE START SIGNAL)
24 VOLT
POWER
TERMINAL PROGRAM
PURGE CONFIRM
DIGITAL OUTPUT PC-based Terminal Program
ALTRONIC INC ALTRONIC CONTROLS INC ALTRONIC EUROPE BV Form AEC-C 9-09
712 Trumbull Avenue 1410 North First Street De Tienden 50A
Girard, Ohio 44420 USA Garland, Texas 75040 5674 TB Nuenen
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