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Summary of Contents for Controls XE-9501-AS
- Page 1 PRODUCT MANUAL GRAPHICAL PUMP CONTROL PANEL Part Number: XE-9501-AS Revision: 1.0 Engine Type: Electronic J1939 Engines ______________________________________________________________________________________________________________________________________...
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Page 2: Table Of Contents
TABLE OF CONTENTS INSTALLATION …….…………………………………………………………………………………….…………………………………………..…………. CONSIDERATIONS DIMENSIONAL TYPICAL CONNECTIONS QUICK SETUP OPERATION …………………………………………………………………………………………………….…………………..……………………………… POWER UP MANUAL OFF MANUAL STARTING SAFETY BYPASS ENGINE RUNNING SPEED CONTROL ELECTRONIC SPEED CONTROL MECHANICAL STOPPING THE ENGINE SPEED CONTROL OPTIONS …………………………………………………………………………………………………………………………. ELECTRONIC ENGINE SPEED CONTROL REQUESTED VERSUS ACTUAL SPEED TSC VERNIER THROTTLE TSC BUMP... - Page 3 DISPLAY CONFIGURATION ………………………………………………………………………………………………………………………. GRAPHICAL DISPLAY DISPLAY LAYOUT DISPLAY CUSTOMIZATION PROTECTION OPTIONS …………………………………………………………………………………………………………………..…………. EECU SAFETY SHUTDOWNS AND WARNINGS MODULE SAFETY SHUTDOWNS AND WARNINGS LOW POWER MODE OTHER MODULE FUNCTIONALITY …………………………………………………………………………………………..……………. STANDARD FEATURES CUSTOM SPLASH SCREEN SENDER FAILURE AUDIBLE WARNING HORN SHUTDOWN OVERRIDE AUTO START OPERATION ………………………………………………………………………………………………………………..……….
- Page 4 TRANSDUCER INSTALLATION ……………………………………………………………………………………………….….…………. GENERAL INFORMATION LEVEL CONTROL PRESSURE CONTROL MAIN MENU ACCESS ……...………………………………………………...……………………………………………….……………..………. MAIN MENU TOPICS ……...………………………………………………...…………………………………………….……..….………………. ACTIVE ENGINE FAULT CODES SERVICE CODES STORED ENGINE FAULT CODES ENGINE PARAMETERS EMISSION PARAMETERS SENDER PARAMETERS PUMP PARAMETERS OPERATION EVENT LOG ALARM EVENT LOG ENGINE IDENTIFICATION MODULE INFORMATION MODULE PROGRAMMING...
- Page 5 DISPLAY CONFIGURATION CAN CONFIGURATION AUTO OPERATION SETTINGS AUTO START CONFIGURATION BATTERY RECHARGE CONFIGURATION MODBUS CONFIGURATION MAINTENANCE CONFIGURATION EMISSIONS CONFIGURATION CLUTCH CONFIGURATION CLOCK SET UP MODULE INFORMATION MODULE CONNECTORS ………………………………………………………………………………..………………………….……………... MODULE PRIMARY CONNECTOR MODULE SECONDARY CONNECTOR PANEL CONNECTORS ………………………………………………………………………………..………………………….……………..ENGINE HARNESS CONNECTOR ACCESSORY HARNESS CONNECTOR FLOAT &...
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Page 6: Installation
Consider the operator when locating the module. Ease of access to the unit, keys and display are all critical in allowing the operator to successfully and safely operate the module. Extension harnesses are available from Controls, Inc. if the engine harness being used does not allow for proper location selection. - Page 7 MOUNTING LOCATION...
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Page 9: Quick Setup
QUICK SETUP During initial installation, each control panel will need to be configured to work properly with the type of engine it is being installed on. As engine ecu’s have become more complex this set has become critical to ensure proper operation for your engine. The Quick Setup menu is located under the Controller Setup menu and contains…... -
Page 10: Operation
OPERATION POWER UP Turn on the power to the module. The display will illuminate and show the module part number version in the upper left status line and the graphical logo will be centered in the screen. The LED indicators will turn on for one second to verify operation. Warning Lamp Stop Lamp Mode... -
Page 11: Manual Off
MANUAL OFF After the Power Up cycle is complete, the module will be in the Manual Off mode as shown in the upper left status line and the corresponding red LED indicator above the Off key. -
Page 12: Manual Starting
MANUAL STARTING RUN KEY Press the green RUN key. If a preheat cycle is programmed in the display, or requested by the engine’s ECU, the status line will indicate a Wait to Start message or Preheat Countdown. Once completed, the status line will show Ready to Start. Press and Hold the green RUN key. -
Page 13: Safety Bypass
SAFETY BYPASS Immediately after the engine begins to run, the module will enter the “Safety Bypass” period. This time period is typically set to 10 seconds and is programmable. During this period, any engine parameter set to be monitored as RUN will be ignored until the bypass period is passed, at which point the safeties will become active. -
Page 14: Speed Control Electronic
SPEED CONTROL - ELECTRONIC ENGINES The display can control the engine’s speed using J1939 Torque Speed Control (TSC1). When the engine is started manually, the control panel will request the minimum programmed speed. Pressing the Up-arrow key will cause the panel to increase the requested speed. The display will place an up or down arrow to the right of the RPM displayed to indicate that a change in speed is being requested. -
Page 15: Stopping The Engine
STOPPING THE ENGINE When it comes time to stop the engine, simply press the red OFF key. This will de-energize the fuel solenoid on mechanical engines or the engine ECU Run/Stop circuit on electronic engines. In some cases, the module will send an engine STOP command over the J1939 CAN Bus to shut down the engine. -
Page 16: Speed Control Options
SPEED CONTROL OPTIONS ELECTRONIC ENGINE SPEED CONTROL The display can control the engine’s speed using J1939 Torque Speed Control (TSC1). When the engine is started manually, the control panel will request the minimum programmed speed. Pressing the Up-arrow key will cause the panel to increase the requested speed. The display will place an up or down arrow to the right of the RPM displayed to indicate that a change in speed is being requested. -
Page 17: Requested Versus Actual Speed
The control panels TSC address and the engine’s ECU address must match. Most major engine manufacturer’s TSC addresses are loaded into the control panel when that engine manufacturer is selected in the Quick Setup. However, there may be instances where ECU programming may vary. The control does have the ability to change the TSC address manually in the CAN Configuration menu. -
Page 18: Tsc Vernier Throttle
TSC VERNIER THROTTLE TSC Vernier is the most popular throttle selection when operating in the manual start mode. The operator can control the engine speed anywhere between the programmed speed range. This throttle type allows you to set the minimum engine speed, maximum engine speed, ramp rate, curve type and bump speed increments without the use of a computer. -
Page 19: Tsc Bump
TSC BUMP The operator can control the engine speed anywhere between the programmed speed range. However, changes in speed are limited to single presses of the Rabbit and Turtle keys. Each press will change the requested RPM by the programmed Bump speed. TSC MULTISTATE THROTTLE Another widely used throttle type in manual mode allows the operator to increment the engine speed between predetermined speed settings by pressing the Rabbit or Turtle keys. -
Page 20: Tsc Hi-Lo Momentary Throttle
MODBUS THROTTLE Engine speed can be requested through the modules RS485 MODBUS interface. Contact Controls, Inc. for a complete register map. The example for speed control is below. Use of 40004 or 40051 is... -
Page 21: Speed / Torque Limit
The main module must be configured as the Primary, while the remaining modules should be set to remote. TWIST THROTTLE KNOB The TT-100 throttle knob is available to work with Controls, Inc. modules as well. Contact CI for more details. - Page 22 DISPLAY CONFIGURATION GRAPHICAL DISPLAY The XL Series uses a 5.5” wide OLED (Organic Light Emitting Diode) display with a resolution of 256x64 pixels. The OLED technology provides a vibrant display that is highly readable in direct sunlight while also offering a wide temperature range of -40C to +80C for both operating and storage. DISPLAY LAYOUT The display is defined into 10 sections.
- Page 23 DISPLAY CUSTOMIZATION There are three objects that can be used to create your display. Digital, Analog and Custom structures are available to tailor the screen to display what is important to your piece of equipment. Customization is available in Areas 1 through 8. Digital –...
- Page 24 PROTECTION OPTIONS ECU SAFETY SHUTDOWNS AND WARNINGS Once the engine is started, the engine’s ECU has primary control over the operation of the engine under safe conditions. If the ECU detects that any of its critical parameters are out of tolerance, the ECU can take a variety of actions, including derating of the engine horsepower or complete engine shut down.
- Page 25 MODULE SAFETY SHUTDOWNS AND WARNINGS The control panel also has the ability to monitor the engine vitals if configured. The ability to set pre alarms and alarms in the panel is supported to back up the ECUs safeties in the event the ECU shutdowns were not enabled or a more conservative setting is desired.
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Page 26: Low Power Mode
LOW POWER (SLEEP) MODE A low power mode is available to allow the module to minimize power consumption during times when the panel is on, but the engine is not running. This may occur simply because an operator has left the key on without starting the engine or the engine had been running, but was shut down due to a fault condition such as high engine temperature, low oil pressure, low fuel level, over speed or any other monitored switch input such as a low coolant level switch. - Page 27 OTHER MODULE FUNCTIONALITY STANDARD FEATURES The control panel has many options that can be configured, enabled or selected that will enhance the operation of the equipment. A list of items is below with descriptions on the selection and use of each.
- Page 28 AUDIBLE HORN An alarm horn can be driven from a relay output to annunciate alarm conditions and/or a pre-start warning on auto start applications. When a relay is assigned to any Horn function, the Enter key will be used the silence the horn. SHUTDOWN OVERRIDE The module contains logic that can be enabled to provide a safety shutdown override.
- Page 29 AUTO START OPERATION GENERAL INFORMATION The XL Series modules have a high degree of configurability when it comes to auto start applications. The information herein is designed to be a general guide to the different methods of auto start operation. An auto start signal can come from a digital input, analog input, MOD Bus, CAN Bus or from the real-time clock scheduler.
- Page 30 LEVEL TRANSDUCER AUTO START If an analog channel is configured to start and stop the engine based on a level, the display will rotate through the set point screen displaying the start and stop settings as well as the current measured value.
- Page 31 AUTOMATIC SPEED CONTROL MODES When operating in Auto, the controller will start the engine at the warm up speed and maintain that speed until the warm up time delay expires. After that, the control will ramp the speed up to the Prime Speed setting and maintain that through the time period.
- Page 32 4-20 mA signal from a PLC or other device, you can vary the engine speed in direct relationship to the signal. This also the ability to invert the slope if desired. For more details, contact a Controls, Inc. sales engineer.
- Page 33 FLOAT OPERATION SINGLE FLOAT SYSTEM Basic level control can be accomplished using a float device that contains a contact closure internally. For applications that do not have critical start and stop points and do not involve turbulence, such as a pond or lagoon, a single float can provide adequate control over water levels.
- Page 34 TRANSDUCER WITH DUAL FLOAT BACK UP SYSTEM If operating the auto start system using a transducer, you can install a single or dual set of floats positioned at a critical high level that will start and run the pump at a programmable speed and for a programmable length of time.
- Page 35 The costs can be considerably different, so talk to a specialist. Controls, Inc. does stock transducers and can assist in selection. Contact a sales engineer for more help. When using a transducer for start, stop and possible speed control, you first need to tell the control panel what type of transducer you are connecting.
- Page 36 LEVEL CONTROL Highly accurate level control can be obtained by using a level transducer to monitor the depth of fluid at your site. You can use a level transducer to pump a tank down or fill a tank up. These settings are found in the Auto Operation menu.
- Page 37 MAIN MENU ACCESS To access the module menu system, apply power to the module and press the Menu key. ENTER BACK MENU DOWN...
- Page 38 If the engine is running, the throttle keys will remain active for speed control. The menu system is broken into two main sections; the Operator Main Menu and the Controller Setup Menu. The operator menu contains information about the engine and module. The topics will vary based on the engine type and control panel model.
- Page 39 MAIN MENU TOPICS The Main Menu contains many areas that are useful for the routine operation and troubleshooting of an industrial engine. Each feature cannot be covered in this manual; however, a list of main topics is below. ACTIVE ENGINE FAULT CODES If the engine’s ECU is generating trouble codes, they can be viewed from this menu.
- Page 40 ENGINE PARAMETERS Engine’s ECUs collect a large amount of information about the operating conditions of the engine. To view more of these details and gain a better understanding of your engine’s operating conditions, view this menu. EMISSIONS PARAMETERS For engines equipped with emission components, a menu is available to view these details.
- Page 41 SENDER PARAMETERS This menu allows you to view the raw values of the four configurable analog senders if configured. To configure these senders, use the Analog Input Configuration menu under Controller Setup. PUMP PARAMETERS If the four analog senders are configured for pump use, the values can be seen here. Note, you must select either Application Level or Application Pressure when configuring the transducers.
- Page 42 ALARMS EVENT LOG The module will record the last 32 Alarm events and show the most recent first. What is different about this log when compared to the Stored Code list is that the Alarm Log will record both the ECU codes and module monitored events, such as low fuel level or other non-ECU monitored events.
- Page 43 The CI Station allows the user to save configurations and reuse them over and over for production line programming or to configure replacement panels to match the original OEM programming. Contact Controls, Inc. for more details.
- Page 44 MODULE BASED PROGRAMMING The control panel will come with a factory configuration unless otherwise specified. Consult with your sales channel for modifications to the factory configurations. A Quick Setup menu is located under the Controller Setup area that will provide the basic selections you may want to review and/or change to meet your needs.
- Page 45 CONTROLLER SETUP When navigating through the Main Menu you will arrive at the Controller Setup selection. To configure the module to new settings, you can enter into this area by pressing the Enter Key PASSWORD ENTRY The next screen will ask for a password. If no password, or an incorrect password is used, navigation into the menu is still possible and permitted, however, the ability to make changes will be restricted.
- Page 46 SETUP MENU Navigating the Controller Setup menu structure is done in the same manner as the Main Menu system. Up and Down arrows will scroll to the next topic; Enter key will access the topic, etc. To make changes to the settings, you will need to locate the item you are looking to modify under the appropriate topic and then press the Enter key.
- Page 47 QUICK SETUP This menu is designed to allow you to configure the module in a simple manner, asking you to select the most common options used with today’s industrial engines. Based on your selections here, other items will be affected. For example, if you select Engine Type as Mechanical, the module will default the engine oil pressure, coolant temperature and speed sender options to be typical senders rather than J1939.
- Page 48 PUMP PARAMETER CONFIGURATION Individual pump parameters can be changed here. Up to four transducers can be configured for typical pumping applications. This menu is setup as a convenience associated with pump parameters. If you wish to use the along inputs to monitor other types of parameters, use the Analog Input Configuration menu below.
- Page 49 INPUT CONFIGURATION The module has eight on board digital inputs that can be configured in a large variety of ways. All digital inputs are pulled high and must be closed to ground. For alternatives, from simple switch shutdowns to remote engine operation, contact CI application engineers to discuss. The example below shows a normally open, low engine oil switch that is wired into the digital 4 input.
- Page 50 THROTTLE CONFIGURATION The speed control behavior of the engine can be changed under the Throttle Configuration menu. Selection of throttle type, minimum operating and maximum operating speeds and other details as well can be set here. See Speed Control Options for more details. ENGINE SAFETY CONFIGURATION The module can provide warnings, shutdowns, deceleration, and other behaviors based for the critical engine parameters of oil pressure, coolant temperature, engine speed, fuel level and battery voltage.
- Page 51 PUMP SAFETY CONFIGURATION The module can provide warnings, shutdowns, deceleration, and other behaviors for the critical pump parameters of suction pressure and discharge pressure. Simply set the thresholds and actions desired. In the example below, a warning will be annunciated if the discharge pressure rises above 200 psi and the engine will be decelerated to minimum speed if it exceeds 250 psi.
- Page 52 DISPLAY CONFIGURATION Use this area to set up the display with the parameters you desire to see on the full-time display. For details on configuration, see DISPLAY OPTIONS in this manual. In the example below, Area 3 would display engine Oil Pressure in digital format. The AG suffix stands for Analog Gauge presentation. CAN CONFIGURATION This menu is used to define how and what messages are transmitted on the J1939 CAN Bus.
- Page 53 AUTO OPERATION SETTINGS This menu will define the devices used for starting and stopping your engine as well as the default operate mode and speed. Please note, if you are going to use a control transducer, you must have one defined.
- Page 54 MODBUS CONFIGURATION When connecting to a MODBUS devise such as PLCs, telematics or other controls, this menu will define the communication protocol for successful integration. The modules are designed to operate...
- Page 55 CLUTCH CONFIGURATION Two channels of interlocking relay behavior can be configured using relays 5-8 in the module. Relays can be assigned to open and close based on a large number of factors including engine speed, state, load, temperature, etc. Time delays can also be added as needed. CLOCK SETUP When you receive your module, it should be programmed with the correct date and time for the Eastern US Time zone.
- Page 56 MODULE CONNECTORS The module has two Ampseal keyed connectors located on the back of the display. The connectors provide access through the weather tight display enclosure which houses the electronics. Primary Connector 14 Pin Secondary Connector 23 Pin...
- Page 57 MODULE PRIMARY CONNECTOR Function Function Relay Output 2 J1939 Low Relay Output 1 Relay 3 Common Relay Output 3 Crank Detect Battery Positive Battery Positive Relay Output 4 Battery Negative Relay 1 Common Fuel Level Sender J1939 High Digital 1 Input CAUTION: Max Load for Relays 1 and 3 is 5 amps each Max Load for Fuel and Crank circuits is 10 amps each...
- Page 58 PANEL CONNECTORS 1. ENGINE Harness Connector –Deutsch 21 pin (HDP24-24-21PE) 2. ACCESSORY Connector – Deutsch 31 pin (HDP24-24-31PE) 3. REMOTE START Connector – Deutsch 4 pin (DT06-4S) REMOTE START Connector (4 Pin) ENGINE Connector ACCESSORY (21 Pin) Connector (31 Pin)
- Page 59 CONNECTOR PINOUT REMOTE START ACCESSORY Function Function High Float Input (Normally Open) Relay 5 Output (5 amp) Low Float Input (Normally Open) Flex Analog In 1 (4-20mA) High Float Common Flex Analog In 3 (4-20mA) Low Float Common Digital 8 Input (Low) Digital 9 Input (Low) Relay 7 Output (5 amp) Relay Common 5 &...
- Page 60 INTERNAL WIRING DIAGRAM...
- Page 61 TELEMETRY OPTION Each panel can be outfitted with a GSM/GPS equipped telemetry radio. The system can provide remote use, operation and control of your pump. Contact Controls Inc for more details.
- Page 62 WARRANTY CONTROLS, INC. is herein called “Seller”. The person, firm or corporation to whom or which the sale is made is herein called “Buyer”. Seller warrants to the Buyer that all products furnished under this order will conform to Seller’s specification, drawings as described in its current catalog or quotation and will be free from defects in materials and workmanship.
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