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ALTRONIC EPC-100
AIR-FUEL CONTROLLER
WARNING: DEVIATION FROM THESE INSTALLATION INSTRUCTIONS MAY LEAD TO
IMPROPER OPERATION OF THE ENGINE WHICH COULD CAUSE PERSONAL INJURY TO
OPERATORS OR OTHER NEARBY PERSONNEL.
1.0 SYSTEM DESCRIPTION
1.1 The Altronic EPC-100 is an air/fuel ratio controller for use on carbureted gas engines. The
controller utilizes microprocessor technology, allowing a high level of sophistication in control
strategy, ease of programming and diagnostic capability. The EPC-100 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.
NOTE:
When used in conjunction with a catalyst, a separate means of catalyst over-
temperature detection and protection should be installed. An Altronic DPYH
temperature gauge with alarm/shutdown switch can provide this function. Refer to
Altronic Form DPYH13.
1.2 One model is universal and can be applied to in-line or V-type, naturally-aspirated or
turbocharged engines.
1.3 The EPC-100 provides dual channel operation for application with one or two carburetors.
All 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 O
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 O
ratio can be easily adjusted by changing the control target voltages through the sealed
membrane keypad or through the use of a PC.
1.4 The EPC-100 has an alphanumeric LCD display showing the target voltage, estimated
operating lambda, sensor voltage and operating temperature, stepper motor position and
diagnostic information.
1.5 Power requirement is 24 VDC, 1 amp. In remote areas, power can be provided by the
Altronic 24 VDC Alternator Power Package. Refer to Altronic Form ALT.
content; a thermocouple input signals when
2
content in the exhaust. The desired air/fuel
2
-1-
OPERATING MANUAL
FORM EPC100 OM 12-04
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Summary of Contents for Altronic EPC-100
- Page 1 OPERATORS OR OTHER NEARBY PERSONNEL. 1.0 SYSTEM DESCRIPTION 1.1 The Altronic EPC-100 is an air/fuel ratio controller for use on carbureted gas engines. The controller utilizes microprocessor technology, allowing a high level of sophistication in control strategy, ease of programming and diagnostic capability. The EPC-100 is designed for use on engines operating at or near a stoichiometric air/fuel ratio (lambda .95 - 1.05) and is ideally...
- Page 2 ** Not supplied in Altronic kits. 2.2 See Fig. 1 for illustration of kit components. Fig. 11 lists the accessory kit contents. 2.3 Refer to Fig. 2 for the general layout of components used in the EPC-100 control system. 3.0 MOUNTING THE EPC-100 3.1 The EPC-100 is preferably panel-mounted off the engine in such a manner as to minimize...
- Page 3 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. 5.2 ONLY UNGROUNDED thermocouple probes can be used with the EPC-100. Grounded type thermocouples will not function correctly. Resistance from either lead of the thermocouple...
- Page 4 6.3 The control valves are connected to the EPC-100 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.
- Page 5 Again, care should be taken to identify the left from right bank thermocouple wires. 7.8 The "Dual Bank" or "Single Bank" mode of the EPC-100 is programmed via a jumper wire connection on terminal block TS1. The "Dual Bank" mode is the default mode which results "...
- Page 6 8.0 THEORY OF OPERATION 8.1 The primary task of the EPC-100 is to accurately control the exhaust air fuel ratio (AFR) of an engine. Control should be maintained through reasonable load and fuel BTU variations. 8.2 Three-Way Catalysts are used to oxidize CO and HC and to reduce NOx. These processes require high temperature and correct AFR control.
- Page 7 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-100 adjusts the stepper motor to maintain a specific input voltage from the O Sensor. When the sensor voltage is above the O Target voltage, the system is richer than desired, and the stepper position is increased to further restrict fuel flow to the carburetor.
- Page 8 9.2 With the EPC-100 powered up and the engine not running: Display should follow the power-up sequence described in section 11.2 . Display of O Sensor voltages should go to 0.5 volts. This may require a few minutes. Section 13.0 explains how to view data screens.
- Page 9 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-100 set-up is complete; the unit should be controlling the engine.
- Page 10 Whenever possible, special messages indicate what is happening or why a command is not accepted. 11.3 With the engine not running (cool exhaust), when power is first applied to the EPC-100, the display will show an Altronic product description message.
- Page 11 12.0 SETUP MODE - KEYPAD AND DISPLAY OPERATION 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.
- Page 12 12.7 Press "F1" to rotate to the left default stepper position screen. The default position is used when any of the O 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.
- Page 13 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 O Sensor voltage, and the current left stepper valve position are provided on the automatic display screen.
- Page 14 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-100 is not in automatic control. L MAN! 0.81v1010 R Auto 0.79v 982...
- Page 15 (open) any time that the alarm indicator on the front panel is On solid. 16.3 The system diagnostics included in the EPC-100 are designed to identify conditions which are not considered normal operation. These diagnostic tests are performed continuously while the controller is in automatic mode.
- Page 16 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-100 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..
- Page 17 17.8 EPC-100 will not move stepper valves during "F1" then "Start Pos." command. Check stepper cable connections at EPC-100 and at stepper valve. Inside EPC-100 verify that red LED on control board is ON. If LED is off, or flashing check the fuses on the control board.
- Page 18 EPC-100 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-100 to meet the needs of continuous emissions monitoring should it be required.
- Page 19 10064 = Dual Bank System 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.
- Page 20 Reg(40128) = 06885 Manual move right stepper rich (-100) Reg(40128) = 07140 Manual move right stepper lean (+100) The EPC-100 unit also supports a Modbus function 17 which will return the unit information including the Version, Date and Name. -20-...
- Page 21 WIRE ROUTING DETAIL FIG. 7 TERMINAL LAYOUT FIG. 8 TYPICAL 02 SENSOR RESPONSE FIG. 9 PARTS BREAKDOWN - EPC-100 (separate control and stepper boards) FIG. 9a PARTS IDENTIFICATION - EPC-100 (separate control and stepper boards) FIG. 10 PARTS BREAKDOWN - EPC-100 (single control/stepper board) FIG.
- Page 28 FIG. 8 TYPICAL O2 SENSOR RESPONSE (Estimated Data) 1.00 0.90 0.80 0.70 0.60 0.50 0.40 0.30 0.20 0.10 0.00 0.96 0.98 1.00 1.02 1.04 0.97 0.99 1.01 1.03 LAMBDA...
- Page 30 FIG. 9a - EPC-100 PARTS IDENTIFICATION (separate control and stepper boards) The following replacement parts are available from authorized Altronic distributors. REF. NO. QTY. PART NO. DESCRIPTION 670040 Enclosure/keypad assembly 672124 Display board assembly 681052 Stepper drive board assembly 601653...
- Page 32 FIG. 10a - EPC-100 PARTS IDENTIFICATION (single control/stepper board ass’y.) The following replacement parts are available from authorized Altronic distributors. REF. NO. QTY. PART NO. DESCRIPTION 670040 Enclosure/keypad assembly 672124 Display board assembly 681064-1 Control/stepper board assembly 610583 Cable assembly, display board...
- Page 33 FIG. 11 - EPC-100 ACCESSORY KIT IDENTIFICATION Contents of Accessory Kit 691310-1: REF.NO. QTY. PART NO. DESCRIPTION 693005-1 Cable Assembly, Control Valve, 25 ft. 693006-1 Cable Assembly, Oxygen Sensor, 25 ft. 610621 Oxygen Sensor Contents of Accessory Kit 691310-2: REF.NO.
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