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OPERATING MANUAL
WARNING: WARNING:
DEVIATION FROM THESE INSTRUCTIONS MAY LEAD TO DEVIATION FROM THESE INSTRUCTIONS MAY LEAD TO IMPROPER OPIMPROPER OPERATION OF THE ENGINE PERSONAL INJURY ERATION OF THE MACHINE WHICH COULD CAUSEWHICH COULD CAUSE PERSONAL INJURY TO OPERATORS TO OPERATORS OR OTHER NEARBY PERSONNEL. OR OTHER NEARBY PERSONNEL.

AIR-FUEL CONTROLLER EPC-110/120-1 EPC-110/120-2

FORM EPC-110/120 OM 10-07

1.0 SYSTEM DESCRIPTION 1.1 The Altronic EPC-110 and the EPC-120 are air/fuel ratio
controllers for use on carbureted gas engines. These controllers utilize microprocessor technology, allowing a high level of sophistication in control strategy, ease of programming and diagnostic capability. The EPC-110 is intended for stand-alone, off-engine post- or wall-mounting. The EPC-120 is intended for off-engine, panel mounting. Both controllers are identical in operation. The EPC-110/120 is designed for use on engines operating at or near a stoichiometric air/fuel ratio (lambda .95 - 1.05) and is ideally suited for application with 3-way catalytic converters. applications with one carburetor. The EPC-110/120-2 provides dual channel operation for applications with one or two carburetors. Inputs and outputs are used in duplicate for a V-engine with two carburetors. An oxygen sensor is used in the exhaust stream to sense O2 content; a thermocouple input signals when proper temperatures have been reached to allow for accurate sensor operation. A fuel/control valve installed in the fuel line to the carburetor is precisely adjusted by a stepper-motor under microprocessor control to maintain the correct O2 content in the exhaust. The desired air/fuel ratio can be easily adjusted by changing the control target voltages through the sealed membrane keypad or through the use of a PC. target voltage, sensor voltage, operating temperature, stepper motor position and diagnostic information. areas, power can be provided by the Altronic 24 VDC Alternator Power Package. Refer to Altronic Form ALT. puts and a dedicated output for implimentation of catalyst over-temperature protection.

1.2 The EPC-110/120-1 provides single channel operation for

1.3 The EPC-110/120 has an alphanumeric LCD display showing the

1.4 Power requirement is 24 (1030) VDC, 1 amp. In remote

1.5 The EPC-110/120 also incorporates thermocouple in-

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EPC-110/120 AIR-FUEL CONTROLLER

2.0 SYSTEM COMPONENTS 2.1 One part from each group below is required for each installation:
PART NO. EPC-110-1 EPC-110-2 EPC-120-1 EPC-120-2 690154-1 690154-2 690154-5 690220-1 690225-1 690230-1 693005-1 693005-2 693006-1 693006-2 610621 ** ** ** DESCRIPTION Air/fuel controller, stand-alone Air/fuel controller, stand-alone Air/fuel controller, panel mount Air/fuel controller, panel mount QUANTITY REQUIRED 1 per enginesingle bank 1 per enginedual bank 1 per enginesingle bank 1 per enginedual bank

NOTE: If possible, keep the original shipping container. If future transportation or storage of the controller is necessary, this container will provide the optimum protection.

Control Valve, standard 1.5 NPT 1 per carburetor Control Valve, low HP 1.5 NPT Control Valve, very low HP 1.5 NPT Control Valve, butterfly 2.0 NPT Control Valve, butterfly 2.5 NPT Control Valve, butterfly 3.0 NPT Cable, control valve, 25 ft. Cable, control valve, 50 ft. Cable, oxygen sensor, 25 ft. Cable, oxygen sensor, 50 ft. Oxygen sensor K Thermocouple Probe (ungrounded w/thermowell) K Thermocouple Ext. Wire 12-16 AWG Hook-up Wire 1 per carburetor 1 per carburetor 1 per carburetor 1 per carburetor, plus 2 for Catalyst In/Out 50 ft. per thermocouple 150 ft. per engine

** Not supplied in Altronic kits.

2.2 FIG. 14 lists the accessory kit contents. 2.3 REFER TO FIGS. 1 OR 2 for the general layout of components used in the
EPC-110/120 control systems.

3.0 MOUNTING THE EPC-110/120 3.1 The EPC-110 fiberglass enclosure is designed and intended for offengine, stand-alone post- or wall-mounting. REFER TO FIG. 3 tended for off-engine, panel mounting. REFER TO FIG. 4

3.2 The EPC-120 traditional painted steel enclosure is designed and in3.3 Mounting location for EPC-110/120 should be chosen to minimize
exposure to vibration.

3.3 Operating temperature range is -40 to 158F. / -40 to 70C.

Humidity specification is 0-95%, non-condensing. Housed in a

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EPC-110/120 AIR-FUEL CONTROLLER

NEMA 4X enclosure, the EPC-110 is rain and weather resistant; however the mounting site should provide as much protection from inclement weather as is practical. Avoid mounting the LCD display and keypad in direct sunlight.

4.0 MOUNTING THE OXYGEN SENSORS 4.1 The sensor should be installed in the exhaust system between the
engine and the catalytic converter and/or muffler. The mounting location should be as close to the exhaust manifold of the engine as possible. The tip of the sensor should be exposed to the unobstructed flow of the exhaust gases from all cylinders to be controlled by that sensor. On a V-engine using two control banks, each sensor should be mounted such that it is exposed only to exhaust from the appropriate bank of the engine. This requires that the sensors be positioned at a point before the two banks join together. On engines using only one control bank, exhaust flow from all cylinders must be sensed. This means that the sensor should be mounted near, but still before the exhaust stack. DO NOT locate the sensor in a coupling or in a location where the exhaust gas flow is uneven due to obstructions or sharp bends. The sensor location chosen should allow easy access since sensor replacement may be required as often as every 2000 hours in some applications. The location chosen should not subject the exterior shell of the sensor to an ambient air temperature greater than 350F.

NOTE: A weldment boss may be required for sensor installation in soft or thin wall exhaust systems.

4.2 Drill, tap and spot face a hole in the exhaust pipe at the selected lo-

cation. A flat smooth sealing surface is required to assure accurate readings since air or exhaust leaks will impact sensor operation. SEE FIG. 5 FOR DETAILS

4.3 New sensors are packaged with an anti-seize compound already applied to the threads. There is no need to apply additional anti-seize unless reinstalling a used sensor. If required, use high temperature anti-seize very sparingly and apply only to the sensor threads. Sensors should be torqued to 28-34 lb.-ft.

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EPC-110/120 AIR-FUEL CONTROLLER

5.0 MOUNTING THE K-TYPE THERMOCOUPLES 5.1 ExHAUST TEMPERATURE THERMOCOUPLES are used to monitor the temperature of exhaust gases near the exhaust oxygen sensor and should be mounted as close as possible to the appropriate O2 sensor. As with the O2 sensor, the location should be easily accessible, and the tip of the probe, which should be enclosed by a thermowell, should be surrounded by unobstructed exhaust flow. lyst housing. Provision for thermocouple installation is normally provided for in the design and manufacture of the catalyst. Installation of the thermocouples on the inlet to the catalyst and the outlet of the catalyst provides three modes of protection: High Inlet Temp Shutdown, High Outlet Temp Shutdown and High Catalyst Temperature Rise Shutdown. Consult catalyst manufacturers recommendations for required overtemp protection. 110/120. Grounded type thermocouples will not function correctly. Resistance from either lead of the thermocouple to the probe shell should be 2 megohms or greater.

5.3 CATALYST PROTECTION THERMOCOUPLES should be installed in the cata-

5.3 ONLY UNGROUNDED THERMOCOUPLE PROBES can be used with the EPC-

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EPC-110/120 AIR-FUEL CONTROLLER

6.0 MOUNTING THE FUEL CONTROL VALVES
NOTE: For detailed instructions covering the gas control valve, see form GCV1 OM (690154 series) or GCV2 OM (6902XX series).

6.1 In order to control the air/fuel ratio, an electronically controlled

valve is connected in series between each regulator and carburetor. These valves should be installed as close to the fuel inlet of the carburetors as possible. The distance from the valve to the carburetor inlet should not exceed 12 pipe diameters in length. The valves should be installed with the control cable connector facing upward to avoid the collection of condensation in the stepper motor. Predrilled mounting holes are provided for user supplied brackets. currently in use. The threaded connection to the valve body may require the use of thread adapters. If adapters are used, proper plumbing procedures must be followed.

6.2 If possible connection piping should be of the same diameter as

6.3 The control valves are connected to the EPC-110/120 using the 693005

cables. If it is desired to enclose the cables in conduit this can be accomplished by cutting the 693005 cable in half. The cables are color coded and must be reconnected with each wire color matching. These cables must not be run in the same conduit as the ignition primary or other wires. A distance of 4 to 6 inches should be maintained between EPC-110/120 wiring and other engine wiring. Note that the upper connector on the EPC-110/120 controls the stepper valve for single control channel applications and the left bank valve on V-engines.

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EPC-110/120 AIR-FUEL CONTROLLER

7.0 ELECTRICAL HOOK-UP 7.1 The power connections to the EPC-110/120 must be in accordance
with the National Electrical Code. The EPC-110/120 is suitable for installation in Class I, Division 2 Group D locations. external fuse (5 amp min.) near the power source is recommended.

7.2 Although the input power has internal protective fuses (3 amp), an 7.3 The EPC-110/120 can be powered in one of the following ways:
NOTE: Voltage and current supplied must be sufficient to operate all transducers used in the installation. If a heated Oxygen Sensor is required, the heater current must be added to the requirements shown.

24 volt battery with trickle charger (1 amp min. output). DC power supply capable of furnishing 10-30 VDC, 2 amps. Altronic 24 VDC Alternator Power Package see form ALT.
7.4 Power wiring and signal (transducers) wiring must be in separate
conduits and conduit entries into the EPC-110/120 to avoid undesired electrical interaction. Separate as follows (SEE FIG. 6):

Left Conduit Entry: Power Wiring and Earth Grounding Center Conduit Entry: Signal Wiring: Oxygen Sensor wiring and Thermocouple inputs. Right Conduit Entry: Alarm Outputs

7.5 Input power supply wires (16 AWG minimum) should enter the left

most conduit entry and connect to the 24 volt supply terminals of terminal block TS2A. An earth ground wire (12 AWG minimum) should enter this same location and connect to the Earth Ground terminal. This connection is in addition to the power negative which may also be grounded. should be run in conduit with, AND ONLY WITH, the EPC-110/120 thermocouple connections. These cables should enter the EPC-110/120 enclosure through the center conduit opening and connect to terminal block TB4. The red wire should be connected to the O2 sensor (red) terminal, and the black wire to the O2 sensor (black) terminal. The shield wire should be cut short and not connected. Care should be taken to identify the left from right bank sensor wires. The cables provided are terminated with weather tight connectors which mate to the O2 sensors provided by Altronic. The shield wire (green wire at connector end) must be connected to the exhaust piping near to the sensor. This shield will assist in rejecting noise from other wiring which could affect the O2 sensor signal. REFER TO FIGS. 5 AND 6

7.6 Oxygen Sensors are connected via shielded cable P/N 693006. These

NOTE: Engines using positive ground DC accessories or starter motors will require a separate dedicated ungrounded power supply for the EPC-110.

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7.7 The thermocouple (24 AWG min. type K extension) wires should
be run in a conduit with and only with the EPC-110/120 O2 sensor wires. These thermocouple wires should enter the enclosure through the center conduit opening and connect to terminal block TB4. The yellow wire should be connected to the T/C (YELLOW) terminal and the red wire to the T/C (RED) terminal. Again, care should be taken to identify the four thermocouple wires (LEFT, RIGHT, CATIN, CATOUT).

Although the EPC-110/120 does not require a computer to be operated or installed, a serial port, located on the control board assembly, has been included which can be used to communicate with a personal computer. Connections to the RS-485 port are made via TS3, a 3-position plug located near the center of the circuit board. A software terminal package which permits communication with the EPC-110/120 is provided on a CD-ROM shipped with each unit. This Modbus based PC program provides operational monitoring and the capability to adjust default parameters and setpoints remotely. On screen directions and help are provided by the Altronic terminal software. Modbus communication register lists may be used to interface to PLC or SCADA systems. SEE SECTION 20.0 FOR DETAILS

7.8 The CATALYST TEMP ALARM OUTPUT is configured as a normally closed

output signal. Any of the protection shut down (PSD) diagnostic thresholds will cause this output to open. Connect this output to the safety shutdown system in combination with a relay to result in an engine shutdown for the purpose of catalyst protection. This output is not latching and self-resetting upon the clearing of related protection conditions. (SOLID STATE SWITCH RATED 30 VOLTS/0.5 AMPS MAX)

Note: this output can be restored to the closed position by pressing the ALARM ACK key to acknowledge the condition.

7.9 The ALARM OUTPUT is configured as a normally closed output signal.

Any diagnostic relating to measured temperatures, O2 sensor voltages, or rich or lean limit stepper positions will cause this output to open for identification of possible improper airfuel control system operation. This output is not latching and is self-resetting upon the clearing of all the alarm conditions. (SOLID STATE SWITCH RATED 30 VOLTS/0.5 AMPS MAX)

7.10 Although the EPC-110/120 does not require a computer to be operated or installed, a serial port, located on the control board assembly, has been included which can be used for MODBUS RTU slave communications. Connections using RS-485 (3 position plug TS3) or RS-232 (DB9 connector) are supported (SEE FIGURE 7). The port configuration is accomplished using the display and keypad as described in SECTION 12.18. SEE SECTION 20.0 FOR MODBUS REGISTER DETAILS.

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EPC-110/120 AIR-FUEL CONTROLLER

8.0 THEORY OF OPERATION 8.1 The primary task of the EPC-110/120 is to accurately control the
exhaust air fuel ratio (AFR) of an engine. Control should be maintained through reasonable load and fuel BTU variations. NOx. These processes require high temperature and correct AFR control. Catalysts perform best for all emissions when operated near the stoichiometric AFR. amount of air (O2) is present to completely burn all of the fuel. Because no engine can perform perfect combustion, typical emission by-products include O2, HC, NO and CO even though the engine is running at stoichiometry. The stoichiometric AFR is determined by the chemical composition of the fuel, thus they are different for each fuel, or BTU rating. (e.g. Methane => 16.09 : 1 and Gasoline => 14.70 : 1)

8.2 Three-way catalysts are used to oxidize CO and HC and to reduce

8.3 The stoichiometric AFR is the AFR at which exactly the required

8.4 Because the fuel type is not always known, it is often easier to specify the AFR target in terms of Lambda. Lambda is an indicator of AFR normalized to the appropriate Stoichiometric AFR. (Lambda Actual AFR/Stoichiometric AFR) Thus Lambda for stoichiometric combustion would be 1.0, no matter what the fuel. Lambda > 1 = Lean, Lambda < 1 = Rich.

8.5 An O2 sensor (lambda sensor) is used to provide exhaust AFR feedback to the EPC-110/120. This type of sensor uses a zirconia element which, when combined with a catalyzing outer surface, creates an output voltage used to indicate lambda. Characteristics of the sensor include: an output range of about 0.1 to 0.9 volts when above 650F, a very high output impedance when cool, a very high sensitivity at stoichiometry and a very low sensitivity away from stoichiometry. The output signal provides a very suitable means of controlling just rich of Lambda 1.0 which is the AFR range required to obtain best catalyst efficiencies for methane-based fuels. FIG. 4 describes a typical sensor output voltage curve versus lambda.

8.6 Type K thermocouples are used to assure that exhaust temperatures are high enough for correct operation of the sensor before closed loop control is enabled. Additional thermocouples are used to monitor catalyst temperatures: In, Out and Rise. Temperature limit setpoints are provided to create a catalyst protection shutdown capability.

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8.7 An electronic valve is used to create a variable restriction between
the fuel pressure regulator and the carburetor inlet. This restriction is used to adjust the effective inlet pressure seen by the carburetor and results in a mechanical adjustment of the air/fuel mixture delivered by the carburetor. A stepper motor adjusts the restriction by moving a plunger inside the valve. A stepper motor is a brushless motor consisting of a permanent magnet armature and a four-coil multi-pole stator. The armature is moved by sequentially pulsing the four stator coils. Coupled to a worm screw, the rotating armature of the motor provides very accurate linear positioning capability. The motor used provides 1700 steps of travel at .0005 inch/step for a total valve stroke of 0.85 inch.

8.8 The EPC-110/120 adjusts the stepper motor to maintain a specific

input voltage from the O2 sensor. When the sensor voltage is above the O2 Target voltage, the system is richer than desired, and the stepper position is increased to further restrict fuel flow to the carburetor. Conversely, when the sensor voltage is below the O2 Target voltage, the system is leaner than desired, and the stepper position is decreased to reduce the restriction of fuel flow.

8.9 Because the sensor voltage output is not linear with lambda, it

would not be practical to adjust the system faster when the error from the set-point is greater. So in order to maximize the control response, the motors are instead adjusted faster as the error persists longer. This method provides rapid response characteristics as well as control stability. Control target voltages must be determined with the use of an exhaust analyzer to locate the operating point of lowest stack emissions. These target values are adjustable in the EPC-110/120 through the keypad. The resulting system provides accurate and stable control of air/fuel ratio which results in high catalyst efficiencies and reduced stack emissions.

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EPC-110/120 AIR-FUEL CONTROLLER

9.0 PRE-START INSTALLATION CHECKLIST 9.1 BEFORE APPLYING POWER TO THE EPC-110/120:
A. Measure the power supply voltage to assure voltage is within limits (10-30 volts). Leave unit un-powered. B. Inside the EPC-110/120, disengage terminal block TB4 and measure resistance between the red and black O2 sensor wires. Resistance should be higher than 2 megohms if sensors are cool. This verifies that wires are not shorted in conduit. C. Inside the EPC-110/120, disengage terminal block TB4 and measure voltage between yellow and red thermocouple wires. The voltage should be 0.80-1.50 mV for temperatures 60-100F. This verifies that thermocouple wires are terminated. If engine had been running, measurements will be higher, reflecting higher actual temperatures. D. With the terminal block still disengaged, measure resistance between the red wire and the still connected earth ground terminal. Resistance should be very high or open circuit. Repeat measurement between yellow wire and earth ground. This verifies that thermocouples are ungrounded and that wires are not shorted in conduit.

9.2 WITH THE EPC-110/120 POWERED UP AND THE ENGINE NOT RUNNING:
A. Display should follow the power-up sequence DESCRIBED IN SECT. 11.2.

B. Display of O2 sensor voltages should go to 0.5 volts. This may require a few minutes. SECTION 14.0 explains how to view data screens. C. Data display screen for exhaust temperatures should indicate ambient temperatures. D. Disengage terminal block TB4 and measure voltage between black O2 sensor wire and still connected earth ground terminal. The voltage should be 0 volts 50 mV. This is to test for potential ground loop problems. E. Control valve operation should be verified during a start position command. This can easily be done if the valves are not yet fully installed in the fuel line. Press ALARM ACK if the alarm LED is on. Then press F1 followed by START POS. During the start position activity, the left valve plunger should be fully retracted then positioned near the middle of its travel, followed by the right valve. No movement, erratic movement, or movement in the wrong direction will result from incorrect wiring of the stepper cables.

NOTE: If engine was running recently, temperature will be higher.

NOTE: Ground loops could be more significant when the engine is running. The addition of other electrical devices may affect EPC operation with regard to signal offsets.

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F. RETURN THE SET-UP VALUES TO THE FACTORY DEFAULTS: This can be done by slowly pressing the following keys in order F1, F3, F2, F4. Then, once the screen indicates that you are in the set-up mode, press F2 followed by F2 again to restore default setup values. Then press F4 to exit the setup mode. The default values are set as follows: Gain Value = 0.50 Left O2 Target = 0.80 volts Left Default Position = 1000 steps Right O2 Target = 0.80 volts Right Default Position = 1000 steps G. CONFIGURE CATALYST PROTECTION THRESHOLDS: This can be done by slowly pressing the following keys in order F1, F3, F2, F4, Then, F1 to view each successive set-up parameter: Exh Temp Hi = 1000F Exh Diff Hi = 200F Cat In Hi = 1000F Cat Out Hi = 1100F Cat Rise Hi = 100F

NOTE: Settings should be established based on catalyst manufacturers recommendation.

9.3 When all of these checks have been made successfully, move on to
the Start-Up Procedure.

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10.0 START-UP PROCEDURE 10.1 BEFORE STARTING ENGINE:
A. Check for fuel leaks where the fuel line was modified. B. Verify that a catalyst over-temp thermocouples and thresholds are in place and functional according to catalyst provider requirements and recommendations. C. Press F1, then press START POS on the EPC-110/120 keypad to reset stepper position and enable the warm-up delay. D. Be sure that the power screw adjustments on carburetors are full open or full rich. If these adjustments are not fully open, then the control range of the stepper control valve will be limited. E. If the alarm outputs of the EPC-110/120 are being used, temporarily disconnect or override these signals so that an alarm indication will not shut down the engine during setup. F. Verify that the catalyst protection output is wired and functional to cause a shutdown in an overtemp condition. G. Place EPC-110/120 controller in MANUAL mode by pressing LEFT MANUAL, then RIGHT MANUAL keys. H. Start and warm-up engine.

10.2 WITH THE ENGINE RUNNING:

A. Load engine to desired operating point. B. Verify that the exhaust temperature data screen is displaying reasonable values, and that the temperatures exceed 650F. REFER TO SECTION 14.0 FOR DISPLAY KEY OPERATION C. Enable automatic control by pressing the AUTO OPER key. The unit should begin adjusting the stepper valves trying to control the engines air/fuel ratio. Use any diagnostic warnings which may occur to trouble-shoot the system. Rich or lean limit errors are a good indication that the pressure regulators need some adjustment. D. Once the unit has gained control of the engine (O2 sensor voltage very near the target voltage), adjust the fuel pressure regulators until the EPC-110/120 is controlling with the stepper valve positions near 1000 steps. This is approximately the middle of the valves control range.

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10.3 FINE TUNE THE CONTROL SETPOINTS:
A. Using an exhaust analyzer, determine the set-point voltage which results in the best emission performance. This can be done by incrementally adjusting the O2 Target voltage in the Set-Up Mode. Reference section 12.0 for an explanation of the setup mode. Alternatively, manual mode can be used to adjust the control valves to the positions which give the best emissions performance. REFERENCE SECTION 15.0 for an explanation of manual mode operation. Then the O2 Target voltages should be adjusted to match the actual sensor voltages using the SET-UP mode.

B. The control gain rate and default stepper positions can also be adjusted now; however, the default values represent the best typical values for these parameters.

10.4 ONCE THE SYSTEM IS CONTROLLING AT THE BEST EMISSIONS POINT, THE ALARM
OUTPUT CAN BE RE-ENABLED.

10.5 AT THIS POINT, THE EPC-110/120 SET-UP IS COMPLETE; THE UNIT SHOULD BE CONTROLLING THE ENGINE.

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EPC-110/120 AIR-FUEL CONTROLLER

11.0 GENERAL: KEYPAD AND DISPLAY OPERATION 11.1 The EPC-110/120 includes a front-mounted keypad and an LCD display which permits the monitoring and adjustment of various parameters and actions. Two LED indicators are also included. The power LED (GREEN) is illuminated any time there is power to the unit. The alarm LED (YELLOW) will come on momentarily on power up then go out as soon as the unit is running. The alarm LED is used to indicate when a diagnostic test is violated. REFERENCE SECTION 16.0 for more detail regarding diagnostics and the alarm indicator. one key on the pad should be pressed at one time. Some commands require a key sequence (a series of key presses, one followed by the next). Whenever possible, special messages indicate what is happening or why a command is not accepted.

11.2 The keypad and display function together as the user interface. Only

11.3 With the engine not running (cool exhaust), when power is first applied
to the EPC-110/120, the display will show an Altronic product description message.

Altronic Inc. EPC110/120 Stoic

11.4 After a few seconds the display will indicate that the controller is in

warm-up mode. This display indicates that the thermocouples are still reading temperatures too cool for the O2 sensors to function correctly. The number at the end of the message indicates the current stepper valve position in steps. If the engine is not started this condition will persist for 10 minutes.

L AutoWarmUp1000 R AutoWarmUp1000

11.5 After 10 minutes with a cool exhaust, the display will now begin ro-

tating the diagnostic messages for low exhaust temperature. All diagnostic messages include the ! character for recognition. Diagnostics exist for several functions and are ExPLAINED IN DETAIL IN SECTION 16. When any diagnostic condition is present, the status containing ! will appear, then all of the appropriate descriptions will follow in rotation. The number in the warning message represents the present stepper valve position.

L!Auto!.802v1000 R!Auto!.802v1000
AND

L! EXH TEMP LO ! R! EXH TEMP LO !

11.6 Press ALARM ACK and the alarm LED which was turned on by the

above warning will begin to flash. The low temperature alarm has now been acknowledged and the EPC-110/120 will accept other keypad commands. Any time the alarm LED is on steady, no keypad commands will be accepted until the ALARM ACK key is pressed. The display will indicate that the unit is responding to this command with message WORKING.

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12.0 SETUP MODE: KEYPAD AND DISPLAY OPERATION
NOTE: all screens in setup mode include the $ character.

12.1 Once the alarm LED is no longer on steadily, press F1 followed by F3

followed by F2 followed by F4. This is the setup mode entry key sequence. The display will indicate that the setup mode is now active.

$$$ SETUP $$$ F1=Next F4=EXIT 12.2 Press F2 then press F2 again to restore factory default parameters.
This special command can be used only from this screen when the user wants to restore factory default values. A message will indicate that the default values have been restored, then will return to the main setup message. NOTE DEFAULT VALUES LISTED IN SECTION 9.2

F2

RESTORING DEFAULT SETUP

THEN

F2

$$$ SETUP $$$ F1=Next F4=EXIT

12.3 Press F1 to increment to the control gain setup screen. The factory

default value for this parameter is 0.50 as shown on the display. This parameter determines the stepper valve adjustment rate when in automatic mode. The higher the value the faster the controller will move the stepper in response to the O2 sensor.

F1
NOTE: Multiple presses of the key are required to continue incrementing the value. If the key is held, the value will be adjusted at a progressively faster rate.

$ F2=Up F3=Dn $ GAIN VALUE=0.60

12.4 Press F2 to increase the value for the gain parameter. The display will
indicate that the value has been changed. At this point the value is updated and will be used until the value is changed again.

F2

$ F2=Up F3=Dn $ GAIN VALUE=0.60

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EPC-110/120 AIR-FUEL CONTROLLER

12.5 Press F3 to decrease the value. Now the value is decreased to the
default value again. The range for the gain value is limited to (0.1 to 2.0). The value cannot be moved beyond its limits.

F3

$ F2=Up F3=Dn $ GAIN VALUE=0.50

12.6 Press F1 to increment to the left O2 Target setup screen. The factory
default value for this parameter is 0.80 volts as shown on the display. Like the gain value, the target can be increased and decreased with the F2 and F3 keys. The typical range is near 0.8 volts. The allowable range is 0.01 to 1.05; however most sensors output range is limited to 0.1 to 0.9 volts.

F1

$ F2=Up F3=Dn $ LO2SetPnt=0.800v

12.7 Press F1 to move to the right O2 Target setup screen. This screen
functions just like the one described in section 12.6 for the left bank. In a single bank application, this set-up screen would be skipped.

F1

$ F2=Up F3=Dn $ RO2SetPnt=0.800v

12.8 Press F1 to rotate to the left default stepper position screen. The

default position is used when any of the O2 sensor or thermocouple diagnostics are active. The number on the right is the current default position. Because the temperature diagnostic is still active, the actual stepper position on the left is also 1000.

F1

$F2=chng L.dflt$ 1000 ---> 1000

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12.9 Press F2 to update the default position (on right) with the value of
the current position (on left). Since both values are the same no change was actually made in this example. By using the manual mode which is DESCRIBED IN SECTION 15.0, the actual position can be adjusted to the desired position before entering the setup mode.

F2

UPDATING LEFT DEFAULT POSITION

THEN

$F2=chng L.dflt$ 1000 ---> 1000 12.10 Press F1 to move to the right default stepper position screen. This

screen functions just like the one described in section 12.7 for the left bank. In a single bank application, this set-up screen would be skipped.

F1

$F2=chng R.dflt$ 1000 ---> 1000

12.11 Press F1 to rotate to the first temperature protection setup value.

The ExHAUST TEMPERATURE HI setpoint represents the maximum permitted engine exhaust temperature as sensed by the left and right (dual bank) thermocouples mounted near the O2 sensors. High temperatures at these locations may indicate engine overload or engine misfire. The CATALYST TEMP ALARM output as well as the ALARM output switch will open if this threshold is exceeded to cause a protection shutdown. The same value is used to test both left and right bank temperatures.

F1

$ F2=Up F3=Dn $ ExhTempHi=1000F

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EPC-110/120 AIR-FUEL CONTROLLER

12.12 Press F1 to rotate to L VS R ExHAUST TEMPERATURE DIFFERENCE HI setting.
For dual bank applications, the absolute difference between the left and right bank thermocouples will be compared to this threshold. If the temperature difference exceeds the setpoint, then the CATALYST TEMP ALARM output as well as the ALARM output switch will open to cause a protection shutdown. A condition of misfire or improper bank to bank engine balance are potential conditions identified by this test.

F1

$ F2=Up F3=Dn $ ExhDiffHi= 200F

12.13 Press F1 to display the CATALYST-IN HI temperature setpoint threshold.

If the inlet temperature to the Catalyst should exceed this setting, then the CATALYST TEMP ALARM output as well as the ALARM output switch will open to cause a protection shutdown. Conditions of misfire or overload or improper engine operation may be identified by this test. Extreme temperature at the inlet to the catalyst will lead to premature failure of the catalyst element and its support structure. Consult the catalyst manufacturer for the recommended inlet temperature shutdown limits.

F1

$ F2=Up F3=Dn $ CatInHi =1000F

12.14 Press F1 to display the CATALYST-OUT HI temperature setpoint threshold.

If the outlet temperature of the Catalyst should exceed this setting, then the CATALYST TEMP ALARM output as well as the ALARM output switch will open to cause a protection shutdown. Conditions of misfire or overload or improper engine operation may be identified by this test. Extreme temperature at the outlet of the catalyst indicates that the catalyst is being damaged by the operation conditions of the engine. Provision may be provided in the catalyst to mount a temperature probe at the catalyst element. This location may serve as an alternative to catalyst outlet temperature. Consult the catalyst manufacturer for the recommended outlet-temperature shutdown limits.

F1

$ F2=Up F3=Dn $ CatOutHi =1100F

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12.15 Press F1 to display the CATALYST TEMPERATURE RISE HI setpoint threshold. The temperature difference Outlet Inlet is compared to this setpoint to identify excessive temperature rise across the catalyst. This condition of temperature rise is an indication that the catalyst is reacting unburned air and fuel that may result from a misfire or condition. If the temperature rise across the Catalyst should exceed this setting, then the CATALYST TEMP ALARM output as well as the ALARM output switch will open to cause a protection shutdown. Consult the catalyst manufacturer for the recommended temperature rise shutdown limits.

F1

$ F2=Up F3=Dn $ CatRiseHi= 100F

12.16 Press F1 to display the NUMBER OF BANKS setting screen. Should a dual

bank EPC-110/120 be applied to a single bank application, this screen provides the opportunity to select the single bank operation mode. This setup value is not presented on the single bank EPC-110/120 model.

F1

$ F2=Up F3=Dn $ Number Banks = 2

12.17 Press F1 to display the MODBUS NODE ID setup screen. Valid node IDs
are 1 to 250 permitting the communication system to incorporate multidrop communications to various ModBus slave devices.

F1

$ F2=Up ModBus

F3=Dn $ ID=100

12.18 Press F1 to display the MODBUS PORT setup screen. Various baud rates

and parity modes are supported by the EPC-110/120. The selections include baud rates of (300, 600, 1200, 4800, 9600, 19200, 38400, 57600). The selection of parity includes (Even, Odd and None). The selection of port types includes (RS485 and RS232, both support half-duplex ModBus RTU).

F1

$ F2=Up F3=Dn $ 485ModBus9600n81

12.19 Press F1 to rotate back to the main screen.

F1

$$$ SETUP $$$ F1=Next F4=EXIT

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EPC-110/120 AIR-FUEL CONTROLLER

12.20 Press F4 to exit the setup mode. F4 can be used from any setup

screen. Remember all setup screens have the $ character on them somewhere. This returns the display to the warning message which was caused by low exhaust temperatures.

F4

L !WARNING! 1000 R !WARNING! 1000

AND

L EXH TEMP LO ! R EXH TEMP LO !

Note: Loading default settings as shown in section 12.2 does not affect settings relating to the Catalyst Temp Alarm Output or ModBus configuration.

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EPC-110/120 AIR-FUEL CONTROLLER

13.0 ENGINE STARTUP: KEYPAD AND DISPLAY OPERATION 13.1 Press ALARM ACK to acknowledge alarms if alarm LED is ON. 13.2 Press F1 then press START POS to send the steppers to start position (stepper default position) and disable the alarm warnings for 10 minutes. The controller will return each stepper to its start position and then display the warm-up screen. This procedure should ALWAYS be used when starting the engine.

F1

Moving L Stepper to Zero Pos.

Moving L Stepper to START Pos.

Moving R Stepper to Zero Pos.

Moving R Stepper to START Pos.

L AutoWarmUp1000 R AutoWarmUp1000

13.3 Now the engine should be started, warmed up and loaded. Temperature requirements would be met before the 10 minute delay expires and the controller would go into automatic control. Both the current left O2 sensor voltage, and the current left stepper valve position are provided on the automatic display screen.

L AUTO .812v1010 R AUTO .796v 982

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EPC-110/120 AIR-FUEL CONTROLLER

14.0 DATA VIEWING: KEYPAD AND DISPLAY OPERATION 14.1 Press DSPL SEL to display the first data view screen. The first data
screen displays the current O2 sensor voltages. DUAL BANK

DSPL SEL

L O2Sensor=.812v R O2Sensor=.796v
SINGLE BANK

AUTO .625v 985 02Sensor=.625v 14.2 Press DSPL SEL again to display current O2 target voltages.
DUAL BANK

DSPL SEL

L O2Target=.800v R O2Target=.800v
SINGLE BANK

AUTO .625v 985 02Target=.800v 14.3 Press DSPL SEL again to display the exhaust temperature readings
from the thermocouples near the O2 sensors. DUAL BANK

DSPL SEL

L EXH TMP=1024F R EXH TMP=1049F

SINGLE BANK

AUTO .625v 985 EXH TMP=1049F

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EPC-110/120 AIR-FUEL CONTROLLER

14.4 Press DSPL SEL again to display the Catalyst temperatures.
DUAL OR SINGLE BANK

DSPL SEL

Cat Rise=+ 24F In=1098 Out=1125

14.5 Press DSPL SEL again to loop back to the automatic screen.
DUAL BANK

DSPL SEL
SINGLE BANK

L AUTO .811v1010 R AUTO .796v 982

DSPL SEL

AUTO .811v1010

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EPC-110/120 AIR-FUEL CONTROLLER

15.0 MANUAL MODE: KEYPAD AND DISPLAY OPERATION
play will indicate WORKING and then return with the left bank in manual mode. This mode can be used to help setup the controller, and to diagnose problems. Because no diagnostic alarms are present, it was not necessary to acknowledge alarms. Also, once in manual mode, diagnostic alarms for that bank are disabled. The alarm LED will flash while in manual mode to serve as a reminder that the EPC-110/120 is not in automatic control.

15.1 Press LEFT MAN to enter the manual mode for the left bank. The dis-

LEFT MAN

L MAN! .811v1010 R Auto .796v 982

NOTE: Both the ALARM LED and the ALARM output return to the normal condition when the system fault is corrected.

15.2 Press RIGHT MAN to enter the right bank manual mode. RIGHT MAN L MAN! .811v1010 R MAN! .796v 982

15.3 Press LEFT LEAN to increase the stepper position by 25 steps. A de-

scriptive message will be displayed and then the modified position will be returned. Increasing the position causes the valve to close and the mixture to change in the lean direction.

LEFT LEAN

MOVING STEPPER
THEN

L MAN! .811v1035 R MAN! .796v 982 15.4 Press LEFT FAST, then press LEFT LEAN to increase the stepper position
by 100 steps.

LEFT FAST

MOVING STEPPER
THEN

LEFT LEAN

L MAN! .811v1135 R MAN! .796v 982

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EPC-110/120 AIR-FUEL CONTROLLER

15.5 Press LEFT RICH to decrease the stepper position by 25 steps. DecreasNOTE: When F1 then START are pressed before starting the engine, the exhaust temperature diagnostic will be delayed 10 minutes displaying the warm-up screen.
ing the position causes the valve to open and the mixture to change in the rich direction. These same commands are used to operate the right bank using the RIGHT LEAN, RIGHT RICH and RIGHT FAST keys.

LEFT RICH

MOVING STEPPER
THEN

LEFT MAN

L MAN! .811v1110 R MAN! .796v 982

15.6 Press AUTO OPER to return to automatic mode. Any time this key is
pressed, automatic mode will be enabled for both banks.

AUTO OPER

L AUTO .811v1110 R AUTO .796v 982

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EPC-110/120 AIR-FUEL CONTROLLER

16.0 DIAGNOSTIC DISPLAYS AND OPERATION 16.1 ALARM LED AND ALARM OUTPUT
The ALARM LED and ALARM output operate in conjunction with the diagnostic features of the EPC-110/120. The three operation modes of these alarm features are described below: A. Alarm LED OFF Indicates that the unit is operating correctly in automatic mode, or in warm-up mode waiting for the exhaust temperatures to increase.

B. Alarm LED ON Steady Indicates that the unit is attempting automatic control; however one of the diagnostic criteria has not been satisfied. The alarm indicator will stay on solid until the alarm acknowledge key is pressed at which time the LED will flash. A solid on yellow LED also indicates that the alarm output terminal is in its alarm state. C. Alarm LED Flashing Indicates one of two things; either an acknowledged alarm condition still exists, or the unit is in manual operation mode. The flashing LED should simply signify to the operator that the unit is not in normal automatic control. The alarm output terminal is in its normal state if the LED is flashing.

16.2 ALARM OUTPUT

The ALARM output is configured as a NORMALLY CLOSED output signal. Any system fault will open the alarm circuit including loss of power, diagnostic warnings, etc. As described above, the alarm output would be in its fault condition (open) any time that the alarm indicator on the front panel is ON solid. The system diagnostics included in the EPC-110/120 are designed to identify conditions which are not considered normal operation. These diagnostic tests are performed continuously while the controller is in automatic mode. Each of the diagnostics will display a descriptive message, turn on the ALARM LED (YELLOW) and place the alarm output in the fault condition (OPEN). Active diagnostic warning messages include the ! character and are displayed in rotation, each message being displayed for about 1 second. The home screen uses the ! character to indicate the status and that other diagnostics will follow in rotation.

16.3 SYSTEM DIAGNOSTICS

16.4 DIAGNOSTIC WARNING MESSAGES

L!Auto!.765v1000 R AUTO .801v 982

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16.5 ExHAUST TEMPERATURE
The Exhaust Temperature diagnostic monitors the exhaust temperatures near the O2 sensors as measured with the thermocouples. If the temperature is below 650F or above 1400F, then the EPC110/120 displays the appropriate low or high message and activates the ALARM LED and ALARM output. Automatic control is also disabled and the stepper valves are positioned at the default stepper position. Thermocouple probe or thermocouple connection failures will also activate this diagnostic.

L EXH TEMP LO ! R Auto .800v 982

OR

L EXH TEMP HI ! R Auto .800v 982 16.6 SENSOR NOT READY

The Sensor Not Ready diagnostic is designed to identify problems with the O2 sensor. The controller has a very high impedance pull up resistor to 0.5 volts in parallel with each exhaust sensor input. When the sensor is too cool or disconnected this will force the input to read 0.5 volts. If the controller sees that the sensor output is 0.5 volts for 10 or more seconds the EPC-110/120 will display the sensor not ready message and activate the ALARM LED and ALARM output. Automatic control is also disabled and the stepper valves are moved to the default stepper position. The sensor ready test is only performed if the exhaust temperature requirements of 16.5 are satisfied. Failure of this test indicates a cold, disconnected or failed sensor.

L O2 NOT READY ! R Auto .800v 982

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16.7 SENSOR INPUT VOLTAGE
The Sensor Input Voltage diagnostic is also designed to identify problems with the O2 sensor. Normal input voltages should be between 0.1 and 0.9 volts. If the sensor input voltage is less than 0.1 volts or more than 1.1 volts, the EPC-110/120 will display the appropriate low or high message and activate the ALARM LED and ALARM output. Automatic control is also disabled, and the stepper valves are moved to the default stepper position. Failure of this diagnostic test indicates shorted wiring or a failed sensor.

L O2 SIGNAL LO! R Auto .800v 982

OR

L O2 SIGNAL HI! R Auto .800v 982

16.8 LEAN AND RICH LIMIT

The Lean and Rich Limit diagnostic monitors the stepper positions. If the position of a stepper valve is at the minimum (0) or maximum (1700) travel limit, the EPC-110/120 displays the appropriate message and activates the ALARM LED and ALARM output. The rich limit warning indicates that the engine is too lean and the controller cannot open the valve any further to enrich the mixture. The lean limit warning indicates that the engine is too rich and the controller cannot close the valve any further.

L RICH LIMIT ! R Auto .800v 982

OR

L LEAN LIMIT ! R Auto .800v 982

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16.9 ENGINE OUT ExHAUST OVER-TEMPERATURE
When the left or right bank exhaust temperature exceeds the setup threshold, the alarm output will open, the alarm LED will turn on, the Catalyst Protection Alarm output (PSD) will open, and the messages below may be displayed. DUAL BANK

!L ExhTempHiPSD! R AUTO!WARN! 875

OR

L AUTO!WARN! 905 !R ExhTempHiPSD!

SINGLE BANK

AUTO!WARN! 905 !L ExhTempHiPSD!

16.10 ENGINE OUT ExHAUST DIFFERENTIAL

On a dual bank application, when the engine exhaust temperature differential between the banks exceeds the setup threshold, the alarm output will open, the alarm LED will turn on, the Catalyst Protection Alarm output (PSD) will open and the message below is displayed.

1LvsR Delta PSD! !LvsR Delta PSD!

16.11 CATALYST INLET OVERTEMP OVER-TEMPERATURE

When the inlet temperature of the catalyst exceeds the setup threshold, the alarm output will open, the alarm LED will turn on, the Catalyst Protection Alarm output (PSD) will open and the message below is displayed.

L AUTO!WARN! 905 !CatInTempHiPSD!

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16.12 CATALYST OUTLET OVER-TEMPERATURE
When the outlet temperature of the catalyst exceeds the setup threshold, the alarm output will open, the alarm LED will turn on, the Catalyst Protection Alarm output (PSD) will open and the message below is displayed.

L Auto!WARN!1000 !CatOutTmpHiPSD! 16.13 CATALYST TEMPERATURE RISE

When the temperature from the inlet to the outlet of the catalyst exceeds the setup threshold, the alarm output will open, the alarm LED will turn on, the Catalyst Protection Alarm output (PSD) will open and the message below is displayed.

L Auto!WARN!1000 !CatTmpRise PSD!

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17.0 AUTOLOG FEATURE 17.1 Press F3 to display the first out Autolog screen which provides the
first most recent detected cause for leaving normal automatic operation. The cause is logged to a modbus register and also presented as below on the screen using a text string. The example below indicates that a difference in the left to right bank temperatures exceeded the setpoint which resulted in a catalyst protection alarm which triggered the snapshot of auto log values. The auto log values are updated on every transition out of fully automatic control without alarms. The table of auto log causes is shown below.

AutoLOG Code 67 !LvsR Delta PSD!

L! EXH TEMP LO ! R! EXH TEMP LO ! L! EXH TEMP HI ! R! EXH TEMP HI ! L! O2 SIGNAL LO! R! O2 SIGNAL LO! L! O2 SIGNAL HI! R! O2 SIGNAL HI! L! O2 NOT READY! R! O2 NOT READY! L! LEAN LIMIT ! R! LEAN LIMIT ! L! RICH LIMIT ! R! RICH LIMIT ! !L EXHTEMPHIPSD! !R EXHTEMPHIPSD! !LVSR DELTA PSD! !CATINTEMPHIPSD! !CATOUTTMPHIPSD! !CATTMPRISE PSD! !L USER MANUAL ! !R USER MANUAL !

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17.2 The following screens are viewed in rotation, displaying the next screen on each press of F3. AutoLOG EXHtemps L 817 R 1021
Identifies the left and right bank temperatures at auto log event.

AutoLOG CATtemps In 985 Out1057

Identifies catalyst temperatures at auto log event trigger

AutoLOG EXH O2V L 804v R .799v

Identifies O2 voltage measurements at auto log event trigger

AutoLOG Steppers L 1191 R 990

Identifies stepper positions at auto log event trigger

AutoLOG Supply V 5.04vdd 2402v

Identifies internal and supply voltage at auto log event trigger

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18.0 ADDITIONAL DISPLAY SCREENS 18.1 Three additional screens exist which can be helpful in obtaining information about the version and supply voltage and temperature of the EPC-110/120. They can be viewed as follows.

Press F1 then DISP-SEL, to view the version number of EPC-110/120 firmware.

LOGIC VER 1.1 DISPLAY VER 1.1

Press F2 then DISP-SEL, to view the version date of EPC-110/120 firmware.

LOGIC 09/19/07 DISPLAY 09/19/07

Press F1 then F2 then DISP-SEL to view the supply voltage and temperature.

Supply 24.3volts Vdd=5.0 23.3C

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19.0 TROUBLE-SHOOTING THE EPC-110/120 SYSTEM 19.1 GREEN LED AND LCD DISPLAY ARE BLANK; POWER IS INTERRUPTED.
A. Check power supply voltage at EPC terminal block TS2A (1830 volts), while still connected.

B. Power down unit, then remove and check resistance of onboard fuses (F1) (< 2 ohms). SEE FIG. 9 C. Verify tight cable connections between control and display boards.

19.2 DISPLAY READS (EPC Bottom Board !NOT Running!); CONTROL BOARD IS NOT
RUNNING. A. Power-down unit for 1 minute. Re-power, check display and status of LED1C on logic board.

B. LED LIT AND NOT BLINKING INDICATES: Firmware mismatch of versions OR Cable between logic and display loose or broken OR Display board damaged OR Logic board damaged C. BLINKING LED INDICATES: Logic board not running properly. Verify IC in blue socket installed properly. Replace logic board assembly. D. LED NOT LIT INDICATES: Replace logic board assembly SEE FIG. 10 OR 12

19.3 DISPLAY TOP ROW IS DARK, BOTTOM ROW IS LIGHT; DISPLAY BOARD IS NOT RUNNING.
A. Power-down unit for 1 minute. Then re-power and check display. B. On back of display board, examine both blue socketed ICs for tight engagement. C. Check cable connection between control and display boards. D. Replace display board assembly. SEE FIG. 10 OR 12

19.4 DISPLAY IS BLANK, BUT GREEN LED IS ON. CONTRAST ADJUSTMENT REQUIRED.
A. On back of display board adjust contrast potentiometer. Clockwise = Lighter; Counterclockwise = Darker. SEE FIG. 10/11 OR 12/13 FOR LOCATION. B. Replace display board assembly. SEE FIG. 10 OR 12

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19.5 KEY PAD ENTRIES CAUSE NO DISPLAY RESPONSE.
A. At bottom of display board, verify connection of keypad ribbon connector.

B. Replace enclosure and keypad assembly. SEE FIG. 10 OR 12

19.6 ALARM LED IS ON SOLID.

A. Read the warning message on the display, and reference the diagnostic section for an explanation of the warning.

B. Press ALARM ACK to permit normal keypad operation and to disable the alarm output terminal.

19.7 EPC-110/120 WILL NOT MOVE STEPPER VALVES DURING F1 THEN START
POS. COMMAND. A. Check stepper cable connections at EPC-110/120 and at stepper valve.

B. Inside EPC-110/120 verify that red LED on control board is ON. If LED is off, or flashing check the fuses on the control board. C. Examine blue socketed I.C. for tight engagement. D. Test EPC-110/120 with a spare stepper valve assembly. E. F. Test EPC-110/120 and stepper valve assembly, with a spare stepper cable. Replace entire control board assembly. SEE FIG. 10 OR 12

19.8 HIGH OR LOW ExHAUST TEMP WARNINGS PERSIST.

A. Observe thermocouple readings for reasonable values using display select screens in SECTION 14.

B. Compare observed readings to, and verify feasibility of catalyst protection setpoints as described in SECTION 9.2 (G). C. If engine is not running, start and warm up engine. D. Test the disconnected thermocouple reading at EPC-110/120 with an alternate thermocouple reading device. E. Replace thermocouple or correct wiring if temperatures are incorrect. The life of thermocouple probes is highly dependent on the use of a thermowell and on corrosives in exhaust.

F. If low temperature is a problem during first installation, an alternate sensor and probe location may be required. Please contact the factory before pursuing any other action to raise sensor temps. G. Replace entire control board assembly. SEE FIG. 10 OR 12

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19.9 RICH OR LEAN LIMIT WARNINGS PERSIST.
A. A misfiring engine can cause the system to shift in the rich direction. Check the engine for misfiring cylinders using a timing light or exhaust pyrometer. B. Use an exhaust analyzer and the EPC-110/120 manual mode to adjust the %O2 before the converter to around 1.0%. If the %O2 cannot be manipulated in the manual mode, then test to make sure the stepper valve is functioning as was done during installation. C. If manual mode moves the %O2 but cannot attain 1.0%, then the fuel system may need to be readjusted. First verify that the load screw adjustments on the carburetors are full rich or full open. If they are not full open, the control range of the stepper valves will be limited. Second, adjust the fuel pressure regulators so that when in automatic mode, the stepper valves are controlling near 1000 steps. D. If the fuel system appears to be adjusting correctly, use an exhaust analyzer and the EPC-110/120 manual mode to sweep the %O2 from around 3% down to 0.2% while watching the O2 sensor voltage on the display. The voltage should move from around 0.2 volts toward 0.8 volts as the %O2 is changed. If this is not the case, a new sensor should be tested. E. If EPC-110/120 O2 sensor voltage display does not match actual sensor voltage, test for ground loop problems. DESCRIBED IN SECTION 9.2D. Replace entire control board assembly. SEE FIG. 10 OR 12

F.

19.10 SETUP VALUES ARE LOST AT POWER-DOWN; BATTERY FOR BBRAM IS FAILED.
A. Replace entire control board assembly. SEE FIG. 10 OR 12

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20.0 EPC-110/120 MODBUS REGISTER LIST
The EPC-110/120 incorporates a half-duplex RS-485 or RS232 port which is Modbus RTU slave compliant. The protocol used follows the Modicon Modbus RTU standard. A complete listing of the Modbus registers is included on the EPC-110/120 Terminal program CD along with a PC-based Modbus-compatible monitoring program. The default configuration for the port is 9600 baud N81 with a node ID of 100. The Modbus communications will allow the EPC-110/120 to meet the needs of continuous emissions monitoring should it be required. The 10xxx registers are read-only binary and support Modbus standard function 1. These registers are read in multiples of 8 (1 byte) addressed at each 8 bit boundary (10001-10008, etc.). A single Boolean read from registers 10001 to 10064 can be made which will return all 64 values as a group of 8 bytes. These registers also support an Altronic custom function 101 which will return a descriptive label for each specific register. The custom label function can be used to reduce the need for the Modbus master to maintain a current listing of all of the register labels for each unit. REGISTER 10001 10002 10003 10004 10005 10006 10007 10008 10009 10010 10011 10012 10013 10014 10015 10016 10017 10018 10019 10020 10021 10022 10023 10024 16-BIT BINARY REGISTER VALUE Left Bank Manual Override Right Bank Manual Override Left Bank Warm-up Right Bank Warm-up Left Bank Stepper Resetting Right Bank Stepper Resetting Reserved Unacknowledged Alarm Preset Left Bank Exh Temp Low Left Bank Exh Temp High Left Bank O2 Signal Low Left Bank O2 Signal High Reserved Left Bank O2 sensor Not Ready Left Bank Stepper Lean Limit Left Bank Stepper Rich Limit Right Bank Exh Temp Low Right Bank Exh Temp High Right Bank O2 Signal Low Right Bank O2 Signal High Reserved Right Bank O2 sensor Not Ready Right Bank Stepper Lean Limit Right Bank Stepper Rich Limit

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REGISTER 10025 10026 10027 10028 10029 10030 10031 10032 10033 10034 10035 10036 10037 10038 10039 10040 10041 10042 10043 10044 10045 10046 10047 10048 10049 10050 10051 10052 10053 10054 10055 10056 10057 10058 10059 10060 10061 10062 10063 10064 16-BIT BINARY REGISTER VALUE Right Bank Step Coil Open Pin C Right Bank Step Coil Open Pin B Right Bank Step Coil Open Pin A Right Bank Step Coil Open Pin F Left Bank Step Coil Open Pin C Left Bank Step Coil Open Pin B Left Bank Step Coil Open Pin A Left Bank Step Coil Open Pin F Left Auto Control is Active Left Getting Richer Left Very Rich Offset >512 mv Left Rich Left On Target +/-5 mv Left Lean Left Very Lean Offset >512 mv Left Getting Leaner Right Auto Control is Active Right Getting Richer Right Very Rich Offset >512 mv Right Rich Right On Target +/-5 mv Right Lean Right Very Lean Offset >512 mv Right Getting Leaner Right Bank Step Coil 1 On Right Bank Step Coil 2 On Right Bank Step Coil 3 On Right Bank Step Coil 4 On Left Bank Step Coil 1 On Left Bank Step Coil 2 On Left Bank Step Coil 3 On Left Bank Step Coil 4 On Reserved Reserved Reserved Reserved Reserved Reserved Reserved Dual Bank System

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REGISTER 10065 10066 10067 10068 10069 10070 10071 10072 10089 10090 10091 10092 10093 10094 10095 10096 16-BIT BINARY REGISTER VALUE TC ENG LEFT HiTemp PSD TC ENG RGHT HiTemp PSD TC ENG LvsR HiDelta PSD TC CAT IN HiTemp PSD TC CAT OUT HiTemp PSD TC CAT Delta HiDelta PSD no function PSD no function PSD no function no function no function OUTPUT ALARM legacy ALM +PSD no function OUTPUT A CATALYST ALARM no function OUTPUT B Auto Operation Active

The 30xxx registers are read-only, 16 bit, analog values. The Modbus standard function 4 is supported. These registers also support an Altronic custom function 104 which will return a descriptive label for each specific register. REGISTER 30001 30002 30003 30004 30005 30006 30007 30008 30009 30010 30011 30012 30013 30030 30031 30101 30102 30103 30104 30105 16-BIT BINARY REGISTER VALUE Left Exh TC Temp 1 deg F/cnt Right Exh TC Temp 1 deg F/cnt Left Exh O2 Volt 1 mv/cnt Right Exh O2 Volt 1 mv/cnt Left Stepper Position Right Stepper Position CJT Deg C +/- 0.01 deg C/cnt Supply Voltage 0.1 v/cnt Logic Voltage 1 mv/cnt Left Est. LAMBDA .01/cnt Right Est. LAMBDA .01/cnt CATALYST IN TC 1 deg F/cnt CATALYST OUT TC 1 deg F/cnt ExHAUST TEMP DELTA |LEFT-RGHT| CATALYST TEMP RISE (OUT-IN) CJT Comp 1 uv/cnt A/D 0 Filt 2.5 v reference A/D 1 Filt supply voltage A/D 2 Filt vss A/D 3 CJT

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EPC-110/120 AIR-FUEL CONTROLLER

REGISTER 30106 30107 30108 30109 30110 30111 30127 30128 16-BIT BINARY REGISTER VALUE A/D 4 O2 Right Legacy A/D 5 O2 Left Legacy A/D 6 TC Right Legacy A/D 7 TC Left Legacy A/D 8 TC Right Aux A/D 9 TC Left Aux Warm-Boot Counter Cold-Boot Counter

The 40xxx registers are read/write, 16-bit, analog values and they support the Modbus standard functions 3, 6 and 16. These registers may have new values written to them in order to make setpoint adjustments from a remote location. They also support a custom function 103 which will return a label describing each specific register. REGISTER 40001 40002 40003 40004 40005 40006 40007 40008 40009 40010 40011 40012 40013 40014 40015 40016 40125 40126 40127 40128 16-BIT BINARY REGISTER VALUE Left Bank O2 Target mV Right Bank O2 Target mV Left Bank Start Position steps Right Bank Start Position steps Control Gain Rate value/40 Exh Temp HI Alarm deg F Exh Temp LO Alarm deg F Exh O2 HI Alarm Setpoint mV Exh O2 LO Alarm Setpoint mV Exh O2 Ready HI Setpoint mV Exh O2 Ready LO Setpoint mV TC ENGOUT HI PSD degF TC ENG LvsR HI PSD degF TC CAT IN HI PSD degF TC CAT OUT HI PSD degF TC CAT DELTA HI PSD degF EPC 110/120 SELECT BITS Modbus Port Config Code Modbus Node ID / Slave ID Modbus Key Command Register

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EPC-110/120 AIR-FUEL CONTROLLER

Detailed below are the command values which can be written to the Modbus Key Command Register (40128). 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 20. 21. 22. 23. 24. 25. 26. 27. Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) 00510 00765 01020 01275 01530 01785 02040 02295 02550 02805 03060 03315 03570 03825 05355 05610 05865 06120 06375 06630 06885 07140 Select auto mode for both banks Select manual mode for left bank Select manual mode for right bank F1-Start stepper reset Alarm acknowledge Decrement left O2 target Increment left O2 target Decrement right O2 target Increment right O2 target Decrement control gain rate Increment control gain rate Reload calibration defaults Update left start position with current pos Update right start position with current pos Manual move left stepper rich (- 25) Manual move left stepper lean (+ 25) Manual move left stepper rich (-100) Manual move left stepper lean (+100) Manual move right stepper rich (- 25) Manual move right stepper lean (+ 25) Manual move right stepper rich (-100) Manual move right stepper lean (+100)

The EPC-110/120 units also support a Modbus function 17 which will return the unit information including the Version, Date and Name. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 199. 200. 201. 202. 203. Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) 07905 08160 08415 08670 08925 09180 09435 09690 09945 10200 51118 51256 51511 51766 52021 decrement Hi Exhaust Temp Threshold increment Hi Exhaust Temp Threshold decrement Hi Exhaust Temp Delta Threshold increment Hi Exhaust Temp Delta Threshold decrement Hi Catalyst Temp In Threshold increment Hi Catalyst Temp In Threshold decrement Hi Catalyst Temp Out Threshold increment Hi Catalyst Temp Out Threshold decrement Hi Catalyst Rise Temp Threshold increment Hi Catalyst Rise Temp Threshold autolog reset increase modportcfg decrease modportcfg increase modidcode decrease modidcode

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EPC-110/120 AIR-FUEL CONTROLLER

FIGURES SECTION: FIG. 1 EPC-110/120 GENERAL INSTALLATION LAYOUT: SINGLE BANK FIG. 2 EPC-110/120, GENERAL INSTALLATION LAYOUT: DUAL BANK FIG. 3 MOUNTING DETAIL, EPC-110 FIG. 4 MOUNTING DETAIL, EPC-120 FIG. 5 OxYGEN SENSOR DETAIL FIG. 6 EPC-110/120, WIRE ROUTING DETAIL FIG. 7 EPC-110/120, MODBUS COMMUNICATION CONNECTIONS FIG. 8 EPC-110/120, TERMINAL LAYOUT FIG. 9 TYPICAL O2 SENSOR RESPONSE (ESTIMATED DATA) FIG. 10 EPC-110 PARTS BREAKDOWN FIG. 11 EPC-110 PARTS IDENTIFICATION FIG. 12 EPC-120 PARTS BREAKDOWN FIG. 13 EPC-120 PARTS IDENTIFICATION FIG. 14 EPC-110/120 ACCESSORY KIT IDENTIFICATION

42 FORM EPC-110/120 OM 10-07

EPC-110/120 AIR-FUEL CONTROLLER

FIG. 1 EPC-110/120 GENERAL INSTALLATION LAYOUT: SINGLE BANK
(SHOWN FOR SINGLE-BANK ENGINE APPLICATION) CONTROL VALVE CABLE PART NUMBER 693005

POWER GROUND

24VDC POWER

ALARM OUTPUT (OPTIONAL) CAT TEMP ALARM OUTPUT

TYPE K THERMOCOUPLE CATALYTIC IN/OUT UNGROUNDED MUFFLER

SENSOR CABLE P/N 693006

TYPE K THERMOCOUPLE (LEFT BANK) (UNGROUNDED)

CATALYTIC CONVERTER

OXYGEN SENSOR P/N 610621 CARBURETOR (LEFT BANK) CONTROL VALVE ASSEMBLY P/N 690154 (LEFT BANK) M FUEL GAS SUPPLY LINE FUEL PRESSURE REGULATOR E X H A U S T

I N T A K E

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EPC-110/120 AIR-FUEL CONTROLLER

FIG. 2 EPC-110/120, GENERAL INSTALLATION LAYOUT: DUAL BANK

44 FORM EPC-110/120 OM 10-07

EPC-110/120 AIR-FUEL CONTROLLER

FIG. 3 MOUNTING DETAIL, EPC-110

12.50 11.12

12.94

#10-32 THREAD MOUNTING HOLES ON BOTTOM OF ENCLOSURE 1" DIA. CONDUIT ENTRY (TYP. 3) 8.00 10.50 .31 X .50 SLOT (TYP 4)

.16 6.25

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EPC-110/120 AIR-FUEL CONTROLLER

FIG. 4 MOUNTING DETAIL, EPC-120

46 FORM EPC-110/120 OM 10-07

EPC-110/120 AIR-FUEL CONTROLLER

FIG. 5 OXYGEN SENSOR DETAIL
CONNECTOR PIN A B WIRE COLOR TAN BLACK PIN AND WIRE CONNECTION SENSOR (GROUND) OUTPUT

MATING CONNECTOR: PACKARD ELECTRIC DIV. PART NO. 12010501

12.50

1.25 MIN. FLAT REQUIRED FOR SEATING

DRILL A 41/64 (16.5) HOLE 90 CSINK TO .732 DIA (18.6) TAP M18 X 1.5 7G THREAD

.35 1.10

2.22

RECOMMENDED INSTALLATION DIMENSIONS INSTALLATION INSTRUCTIONS:

1. INSTALL IN THE APPROPRIATE MOUNTING HOLE TO A TORQUE OF 28-34 LB. FT. 2. USE A 7/8 WRENCH SIZE.

1.17

3. SENSORS ARE TO BE SUPPLIED WITH THREADS COATED WITH MS-0572 ANTISEIZE COMPOUND. CAUTION: DO NOT APPLY ANTISEIZE COMPOUND TO AREAS OTHER THAN THE MOUNTING THREADS. 4. FOR OPTIMUM RESISTANCE TO WATER INTRUSION, AC RECOMMENDS MOUNTING SENSORS SUCH THAT THE EXPOSED END (WIRE END) OF THE SENSOR IS ORIENTED AT OR ABOVE HORIZONTAL. 5. THIS SENSOR IS DESIGNED FOR WATER SPLASH RESISTANCE.
.875

.602 .008

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EPC-110/120 AIR-FUEL CONTROLLER

FIG. 6 EPC-110/120, WIRE ROUTING DETAIL

1 2 3

9 10 11 12 13 14 15 16 17 18 19 20

ERROR ALARM OUTPUT

CATALYST TEMP ALARM OUTPUT

OXYGEN SENSOR (RED)

OXYGEN SENSOR (BLK)

OXYGEN SENSOR (RED)

OXYGEN SENSOR (BLK)

BANK TC SENSOR (YEL)

BANK TC SENSOR (RED)

BANK TC SENSOR (YEL)

BANK TC SENSOR (RED)

4 NEGATIVE (-) COMMON (GROUND)

INPUT TC SENSOR (RED) 18 CAT

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

INPUT TC SENSOR (YEL)

OUTPUT TC SENSOR (YEL) 19 CAT

9 RIGHT

10 RIGHT

15 RIGHT

16 RIGHT

7 LEFT

8 LEFT

13 LEFT

14 LEFT

17 CAT

LEFT CONDUIT ENTRY

CENTER CONDUIT ENTRY

RIGHT CONDUIT ENTRY

24 VDC SUPPLY 16 AWG MIN. O2 SENSORS P/N 693005 THERMOCOUPLES K EXTENSION 24 AWG MIN. THERMOCOUPLES CAT INPUT CAT OUPUT OPTIONAL REMOTE ALARMS N/C SOLID STATE SWITCH RATED 30 VOLTS / 0.5 AMPS MAX.

EARTH AND ENGINE GROUND 12 AWG MIN.

NOTE: DO NOT ROUTE WIRES INTO UNIT IN ANY OTHER MANNER. MAINTAIN SEPARATION AFTER LEAVING ENCLOSURE. IF CONDUIT IS USED, THREE SEPARATE CONDUITS ARE REQUIRED.

48 FORM EPC-110/120 OM 10-07

20 CAT

12

11

OUTPUT TC SENSOR (RED)

+24V DC IN

-24V DC IN

NO CONNECT

EARTH GND

EPC-110/120 AIR-FUEL CONTROLLER

FIG. 7 EPC-110/120, MODBUS COMMUNICATION CONNECTIONS

SAB RS485

RS-232

LOGIC ASSEMBLY 681072-2

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EPC-110/120 AIR-FUEL CONTROLLER

FIG. 8 EPC-110/120, TERMINAL LAYOUT

LOGIC ASSEMBLY 681072-2

PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10 PIN 11 PIN 12 PIN 13 PIN 14 PIN 15 PIN 16 PIN 17 PIN 18 PIN 19 PIN 20

EPC-110/120 ERROR ALARM OUTPUT CATALYST TEMP ALARM OUTPUT NOT USED NEGATIVE(-) COMMON (GROUND) NOT USED NOT USED LEFT OXYGEN SENSOR (RED) LEFT OXYGEN SENSOR (BLK) RIGHT OXYGEN SENSOR (RED) RIGHT OXYGEN SENSOR (BLK) NOT USED NOT USED LEFT BANK TC SENSOR (YEL) LEFT BANK TC SENSOR (RED) RIGHT BANK TC SENSOR (YEL) RIGHT BANK TC SENSOR (RED) CAT INPUT TC SENSOR (YEL) CAT INPUT TC SENSOR (RED) CAT OUTPUT TC SENSOR (YEL) CAT OUTPUT TC SENSOR (RED)

50 FORM EPC-110/120 OM 10-07

EPC-110/120 AIR-FUEL CONTROLLER

FIG. 9 TYPICAL O2 SENSOR RESPONSE (ESTIMATED DATA)

1.00 0.90

O2 SENSOR VOLTAGE (VOLTS)

0.80 0.70 0.60 0.50 0.40 0.30 0.20 0.10 0.00 0.96 0.97 0.98 0.99 1.00 1.01 1.02 1.03 1.04

LAMBDA

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EPC-110/120 AIR-FUEL CONTROLLER

FIG. 10 EPC-110 PARTS BREAKDOWN

10

5f

52 FORM EPC-110/120 OM 10-07

5a

5b

5d

5e

EPC-110/120 AIR-FUEL CONTROLLER

FIG. 11 EPC-110 PARTS IDENTIFICATION
Replacement parts are available from authorized Altronic distributors. REF. NO. 1 1 2 5 5 5a 5b 5d 5e 5f 6 7 8 10 QTY. 1 1 1 1 1 1 1 3 1 1 4 4 8 2 PART NO. 670053-1 670053-2 672124-4 681072-1 681072-2 610583 604137 601653 610243 610241 902439 901682 902648 501335 DESCRIPTION Enclosure/keypad assembly (-1) Enclosure/keypad assembly (-2) Display board assembly Control/stepper board assembly (-1) Control/stepper board assembly (-2) Cable assembly, display board Terminal block - 4 position Fuse, control board Terminal block - 20 position Terminal block - 3 position Screw 10-32 x 3/8 Nut 10-32 Screw 6-32, seal Gasket, connector

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EPC-110/120 AIR-FUEL CONTROLLER

FIG. 12 EPC-120 PARTS BREAKDOWN

54 FORM EPC-110/120 OM 10-07

EPC-110/120 AIR-FUEL CONTROLLER

FIG. 13 EPC-120 PARTS IDENTIFICATION
Replacement parts are available from authorized Altronic distributors. REF. NO. 1 2 5 5 5a 5b 5d 5e 5f 6 7 8 9 10 QTY. 1 1 1 1 1 1 3 1 1 13 8 8 2 1 PART NO. 670040-3 672124-4 681072-1 681072-2 610583 604137 601653 610243 610241 902439 902064 901000 501335 615119 DESCRIPTION Enclosure/keypad assembly Display board assembly Control/stepper board assembly (-1) Control/stepper board assembly (-2) Cable assembly, display board Terminal block - 4 position Fuse, control board Terminal block - 20 position Terminal block - 3 position Screw 10-32 x 3/8 Screw 6-32 Lockwasher, #6 Gasket, connector Blanking plug, 6-pin (-1 only)

FIG. 14 EPC-110/120 ACCESSORY KIT IDENTIFICATION

Contents of Accessory Kit 691310-1: REF.NO. 1 2 3 QTY. 1 1 1 PART NO. 693005-1 693006-1 610621 DESCRIPTION Cable Assembly, Control Valve, 25 ft. Cable Assembly, Oxygen Sensor, 25 ft. Oxygen Sensor

Contents of Accessory Kit 691310-2: REF.NO. 1 2 3 QTY. 1 1 1 PART NO. 693005-2 693006-2 610621 DESCRIPTION Cable Assembly, Control Valve, 50 ft. Cable Assembly, Oxygen Sensor, 50 ft. Oxygen Sensor

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