3512B Generator Set Oil Field Land Rig PTF00001-UP(SEBP3451 - 67) - Systems ...

Página 1 de 5

Shutdown SIS

Previous Screen

Product:  GENERATOR SET

Model:  3512B GENERATOR SET PTF
Configuration: 3512B Generator Set Oil Field Land Rig PTF00001-UP

Special Instruction
Operation of the Direct Fuel Control (Direct Rack){1265, 1276, 1926}
Media Number -REHS7491-00 Publication Date -27/06/2012 Date Updated -27/06/2012

  
i04935122

Operation of the Direct Fuel Control (Direct Rack){1265,

1276, 1926}
SMCS - 1265; 1276; 1926

Engine:
3508 (S/N: 95Y1-UP; 68Z1-UP)
3508B (S/N: S2A1-UP; CBB1-UP; S2B1-UP; PTN1-UP)
3512 (S/N: PTG1-UP; 49Y1-UP; 65Z1-UP; 67Z1-UP)
3512B (S/N: PTF1-UP; 2AF1-UP; S2G1-UP; S2H1-UP; PTM1-UP; 4AW1-UP)
3512C (S/N: LLK1-UP; RMS1-UP; LLT1-UP; R1T1-UP)
3516 (S/N: RKT1-UP; 71Z1-UP; 73Z1-UP)
3516B (S/N: S2P1-UP; S2R1-UP; 1NW1-UP; S2Z1-UP)
3606 (S/N: 8RB1-UP)
3608 (S/N: 6MC1-UP)
3612 (S/N: 9RC1-UP)
3616 (S/N: 1PD1-UP)
C175-16 (S/N: P6L1-UP)
Generator Set:
C18 (S/N: PEJ1-UP)
C27 (S/N: EGG1-UP)
Marine Engine:
C280-12 (S/N: TSJ1-UP; RDW1-UP)
C280-16 (S/N: NKB1-UP; TDX1-UP)
Petroleum Engine:
3508C (S/N: LLC1-UP)
3512C (S/N: LLA1-UP; R1A1-UP; LLB1-UP; LLF1-UP; R1S1-UP)
3516C (S/N: PES1-UP)
Petroleum Power Train Package:
C32 (S/N: PEF1-UP)

Introduction
The Direct Fuel Control (DFC) enables the customer switchgear or silicon controlled regulator to
control desired fuel for the engine. The DFC is used to maintain constant engine speed under
varying loads.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/s... 17/08/2012
3512B Generator Set Oil Field Land Rig PTF00001-UP(SEBP3451 - 67) - Systems ... Página 2 de 5

The Electronic Control Module (ECM) controls fuel to the injectors based on the DFC input. The
customer control of the fuel value needs to be accurate, controlled, and properly damped in order
to maintain stability of the engine rpm.

Stability is necessary during steady state and transient electrical loading for the following reasons:

• Provide clean power to the switchgear and to the electrical loads

• Ensure smooth synchronization when additional generator sets are brought on line

• Prevent cyclic oscillations in the engine rpm (hunting)

The DFC option removes governing from the engine software. The governing relies on the analog
signal (0 to 200 mA) from the controller and a Pulse Width Modulation (PWM) converter. The
signal converter converts the standard 0 to 200 mA signal from the switchgear to a pulse width
modulated (PWM) analog signal. The PWM signal is the required input for the ECM.

Note: Use of the 175-4998 Signal Converter is recommended.

The ECM provides a 4 to 20 mA load feedback signal for use by the customer. The analog output
from the ECM provides the customer a signal that is proportional to the load on the engine. The 4
mA signal is equal to 0 percent load and the 20 mA signal is equal to 100 percent load.

Use of the load feedback into the customer feedback loop can prevent unexpected response in rack
adjustment when the engine is loaded 100 percent. The feedback signal can also be used to trigger
additional generator sets on-line in order to support the application load requirements.

Recommendations for Using Direct Fuel Control

Table 1
PWM Duty Current for PWM Duty Current for
ECM
Cycle for Maximum Throttle Cycle for Minimum Throttle
Sample
Maximum ( 175-4998 Signal Minimum ( 175-4998 Signal
Rate    
Throttle     Converter )     Throttle     Converter )    
15 to 20
75 %     175 mA     13 %     20 mA    
ms    

PWM Duty Cycle for Maximum Throttle - The ECM uses an analog PWM input signal to
determine the desired fuel position. This 500 Hz / 5 V signal varies the on-time (5 V) to the off-
time (0 V). The variation establishes the duty cycle and the desired fuel position.

Refer to Illustration 1 for an example of the waveforms for a 50 percent and 25 percent duty
PWM.

The PWM Duty Cycle for Maximum Throttle is the maximum duty cycle that will request the
maximum fuel command in DFC. The fuel limit will likely be achieved at some point below
maximum throttle.

The load feedback signal can be used to determine if maximum fuel command has been achieved.
Higher duty cycles of the PWM signal will not increase fuel any further. Increasing the duty cycle
further may cause delays in recovering and reducing fuel, based, upon the signal received from the
controller. The delays are due to the time required for the controller to reduce the command below
the PWM signal that established the maximum fuel command.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/s... 17/08/2012
3512B Generator Set Oil Field Land Rig PTF00001-UP(SEBP3451 - 67) - Systems ... Página 3 de 5

Illustration 1 g03114178

(A) 50 % duty cycle

(B) 25 % duty cycle

Current for Maximum Throttle - The current required from the controller (0 to 200 mA) to
achieve the maximum throttle, which will translate to the maximum allowable fuel request. The
request is based from the transfer function of the 175-4998 Signal Converter .

The purpose of the converter is to convert the analog signal of the controller to the analog PWM
signal for the ECM. The transfer function of the 175-4998 Signal Converter is graphed in
illustration 2.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/s... 17/08/2012
3512B Generator Set Oil Field Land Rig PTF00001-UP(SEBP3451 - 67) - Systems ... Página 4 de 5

Illustration 2

(C) PWM output signal from the converter

(D) mA input signal to the converter

PWM Duty Cycle for Minimum Throttle - The duty cycle of the analog input signal to the ECM
to command minimum fuel. Minimum fuel is referred to as 0 fuel on all DFC engines. This 0 fuel
command will shut down the engine if the minimum fuel setting is maintained for sufficient time.

Any duty cycle signal less than the minimum fuel indicated in Table 1 will not reduce fuel any
further. A lower signal may cause an unexpected delay in recovery of the engine speed due to the
delay in increasing the fuel command. The delay is due to the time for the controller to raise the
command above the PWM signal that established the minimum fuel command.

Current for Minimum Throttle - The current from the controller using the 175-4998 Signal
Converter to achieve the minimum throttle, which translates to the minimum fuel request
command. Any current below this value will have no effect on the rack. A lower value may cause
a delay in recovery of the engine speed.

ECM Sample Rate - The rate at which the ECM monitors the duty cycle of the input signal. The
ECM then adjusts the fuel delivery, based on the DFC input to the ECM.

Instability may occur if the controller makes aggressive adjustment to the fuel because the
controller expects changes in the engine speed quicker or slower than the sample rate and
increases or decreases the mA signal. The instability is due to the ECM not continuously
monitoring the input signal and only making fuel adjustments based on the discrete samples.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/s... 17/08/2012
3512B Generator Set Oil Field Land Rig PTF00001-UP(SEBP3451 - 67) - Systems ... Página 5 de 5

Setting the Range of the Signal Converter

In order to provide a properly damped feedback from the controller, account for the current range
and the sample rate of the ECM.

Set the range of the 0 to 200 mA signal between the minimum and maximum fuel setpoints in
Table 1. Current outside those values will have no additional effect on the fuel. Current outside
those values may cause delays in engine speed recovery.

The sample rate of the ECM and subsequent fuel adjustments are based on the value requested by
the controller, regardless of the engine speed. Set the feedback signal and expected affect on
engine speed based on the sample rate.

Signal Quality and Calibration

Most direct fuel controllers utilize analog circuits and signal systems. The systems allow only for
resistor and capacitor changes to adjust the signal for stable engine control (feedback). The
changes are referred to as calibration of the controller. The changes are performed by a technician
from the controller manufacturer.

Calibration adjusts the output signal in variations and amplitude in order to meet the responses and
stability of the engine. Use the following guidelines for systems that use the 0 to 200 mA to PWM
converter:

• Maintain the steady state variations in the controller current signal, characterized as noise,
within ±5 mA of the desired output.

• Operating outside of the recommended values could lead to speed instability or engine
surging that could adversely affect engine performance and synchronization of generators.

• Calibration of the controller by the controller technician may be needed to ensure that the
controller current is within the acceptable values.

The capacitor and resistor values of the controller rarely need changes once the controller has been
properly calibrated. However, sometimes drift in resistor and capacitor values over time may
occur.

If engine instability is observed, recalibration is recommended in order to ensure that the

controller signal remains within the 5 mA signal value.

Copyright 1993 - 2012 Caterpillar Inc.   Fri Aug 17 14:20:33 EST 2012
All Rights Reserved.
Private Network For SIS Licensees.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/s... 17/08/2012