Related Manuals for Controls CX-2556
Summary of Contents for Controls CX-2556
- Page 1 PRODUCT MANUAL ENGINE CONTROL MODULE MANUAL START Part Number: CX-2556 Revision: V1.2 Engine Type: Electronic J1939 and Mechanical Engines...
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Page 2: Table Of Contents
TABLE OF CONTENTS INSTALLATION …….…………………………………………………………………………………….…………………………………………..…………. CONSIDERATIONS DIMENSIONAL WIRING SCHEMATIC SPECIFIC OPERATION ……………………………………………………………………………….…..………………..……………………………… POWER UP STARTING ENGINE ENGINE OPERATION RPM MODE PRESSURE MODE CLUTCH OPERATION OPERATION ..10 …………………………………………………………………………………………………….…………………..……………………………… POWER UP MANUAL OFF MANUAL STARTING SAFETY BYPASS ENGINE RUNNING SPEED CONTROL ELECTRONIC SPEED CONTROL MECHANICAL STOPPING THE ENGINE SPEED CONTROL OPTIONS... - Page 3 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 MAIN MENU ACCESS ……...………………………………………………...………………………………………………….……………..……….
- Page 4 PASSWORD ENTERY SETUP MENU QUICK SETUP ENGINE PARAMETER CONFIGURATION PUMP PARAMETER CONFIGURATION INPUT CONFIGURATION OUTPUT CONFIGURATION THROTTLE CONFIGURATION ENGINE SAFETY CONFIGURATION PUMP SAFETY CONFIGURATION MODULE CONFIGURATION DISPLAY CONFIGURATION CAN CONFIGURATION MODBUS CONFIGURATION MAINTENANCE CONFIGURATION EMISSIONS CONFIGURATION CLUTCH CONFIGURATION CLOCK SET UP MODULE INFORMATION PANEL CONNECTORS …………..………………………………………………………………………..…………………..……………...
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Page 5: Installation
ENCLOSURE MOUNT: If your installation is better suited for a full control panel rather than a module, contact Controls, Inc. for available options or assistance in designing an enclosure for your application. -
Page 8: Specific Operation
CX-2556 SPECIFIC OPERATION OPERATING MODE SELECTION At power up, the Operating Mode selection screen will appear. The operator has a choice between two modes RPM Pressure Once an operating mode has been selected the following criteria will be maintained: ... -
Page 9: Engine Operation
Engine Operation Idle After the operator starts the engine: the Controller will set the TSC1 request to TSC Min throttle keys will be locked out until the operate digital input is asserted Idle mode is entered in one of two ways: ... -
Page 10: Pressure Mode
Pressure Operating Mode The Pressure Operating Mode begins after the engine has reached the High Pressure On Setting. The Controller will: using the maintain targeting logic to appropriately adjust the TSC1 requested speed to achieve the target pressure minimum allowed speed is 1200 RPM ... -
Page 11: 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 Regen Active Lamp... -
Page 12: 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. -
Page 13: 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 14: 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 15: 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 16: 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 17: 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 18: 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 19: Tsc Vernier Throttle
HYDRO-THROTTLE Opening and closing the Hydro-Throttle Input can change engine speed between the programmed Minimum Speed and the Last Operating Speed for each run. Last Operating Speed is defined as the engine speed was last when the Hydro Throttle input was opened. TSC VERNIER THROTTLE TSC Vernier is the most popular throttle selection when operating in the manual start mode. -
Page 20: Tsc Bump
TSC BUMP The operator can control the engine speed anywhere between the programmed speed ranges. 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 21: Flex Analog 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 22: Speed / Torque Limit
Torque Derate Limit found under the Throttle Configuration menu. COOPERATIVE THROTTLE Controls, Inc. modules can be installed together on the same engine to provide additional display and speed control from multiple locations. The main module must be configured as the Primary, while the... -
Page 23: Display Configuration
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 24 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 –...
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Page 25: Protection Options
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 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
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: Main Menu Access
MAIN MENU ACCESS To access the module menu system, apply power to the module and press the Menu key. ENTER BACK MENU DOWN... - Page 29 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.
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Page 30: Active Engine Fault Codes
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 31: Engine Parameters
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 32: Sender Parameters
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 33: Alarm Event Log
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 34: Module Programming
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 35: Module Based Programming
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 36: Controller Setup
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 37 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 38 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 39 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 40 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 41 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 42 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 43 CAN CONFIGURATION This menu is used to define how and what messages are transmitted on the J1939 CAN Bus. Destination and broad cast addresses are defined here. Most CAN addresses will be programmed based on the engine manufacturer selection automatically. However, you can overwrite the defaults if desired.
- Page 44 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 as an MODBUS RTU. 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.
- Page 45 PANEL CONNECTORS The control panel has three bulkhead mounted connectors. The engine harness connector is a 21 pin, Deutsch HDP series. This connector includes all of the required circuits to start and run the engine. The second connector is a 31 pin Deutsch HDP Series connector and includes the auxiliary inputs and outputs of each model.
- Page 46 31 Pin Engine Harness Connector Function Relay 5 Output (PTO Engage) Pressure Transducer Input Flex Analog 3 Input Digital Input 8 (Pump Inlet Pressure) – Close to VBATT+ Digital Input 9 – (E-Stop) Close to VBATT+ Relay Output 7 Relay 5 & 6 Common Flex Analog 2 Input Flex Analog 4 Input Modbus A...
- Page 47 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 48 MODULE PRIMARY CONNECTOR Function Function Relay #2 Fuel/ECU J1939 Low Relay Output 1 Relay 3 Common Relay Output 3 Crank Detect Battery Positive Battery Positive Relay #4 Crank Battery Negative Relay 1 Common Fuel Level Sender J1939 High DI #1 CAUTION: Max Load for Relays 1 and 3 is 5 amps each Max Load for Fuel and Crank circuits is 10 amps each...
- Page 49 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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