SOP for 500kVA DG / Engine fuel pump actuators & ECU

operating conditions checking / failure analysis

 Fuel pump actuators and ECU operating conditions

➢ Insert wire link (See red wire link) in to wiring ferrule no-28D & 28E, when DG / Engine not in operation

➢ Remove wire link from wiring

ferrule no-28D & 28E before
starting DG / Engine after
checking of all below given
parameters.
Check battery voltage conditions on ECU terminals

➢ Check battery supply on battery terminals U & V

(wiring ferrule no- 21 & 28I should be >24V)
( Voltage specifications 19V to 26V)
➢ Battery Voltage should be as per given
specifications
 Check ECU operating conditions

➢ Check actuator 1 voltage on terminals S & T (wiring ferrule no- 8A & ➢ Check actuator 2 voltage on terminals W & X (wiring ferrule no-
8B should be 12.91V (Voltage specifications 10V to 26V) 9A & 9B should be 10.54V (Voltage specifications 10V to 26V)
➢ If <10V check current limit setting, if current limit setting is ok, then ➢ If <10V check current limit setting, if current limit setting is ok,
remove the wires & check on ECU terminals S & T. If still not getting then remove the wires & check on ECU terminals W & X. If still
required voltage in this ECU can be failed. not getting required voltage in this ECU can be failed.
Check ECU operating conditions…

➢ Check voltage on terminals B & D (wiring ferrule no-

8D/9D & 8E/9E should be 5.05V (Voltage specifications
4.90V to 5.10V

➢ If voltage out of this range, remove the D terminal wiring

& check the voltage again as above, if still not getting
required voltage then ECU can be failed.
 Check fuel pumps wirings, connectors & actuators operating conditions…

Note: Check voltage on terminals B & C (wiring ferrule no- 8D/9D &
Note: Check voltage on terminals A & B (wiring ferrule no- 8C &
9C should be 2.966V (Voltage specifications 0.5V to 4.5V)
8D/9D should be 2.939V (Voltage specifications 0.50V to 4.50V)
➢ If voltage observed <0.5V error will be P02L – Reasons can be
➢ If voltage <0.5V error will be P01L – Reasons can be Loose
Loose wiring, loose wiring connectors, fuel pump actuator
wiring, loose wiring connectors, fuel pump actuator failures.
failures etc.
➢ If voltage >4.5V error will be P01H – Wiring short circuit to any
➢ If voltage >4.5V error will be P02H – Reasons are wiring short
other connectors or terminals , fuel pump actuator failures etc.
circuit to any other connectors, terminals & fuel pump actuator
failures etc.
 Remove wire link

➢ Remove wire link from wiring ferrule no- ➢ Check again battery supply on battery
28D & 28E before starting of DG terminals U & V (wiring ferrule no- 21 &
28I should be >24V) during cranking of DG
for to check fuse blown-off conditions
Connect Laptop
 Check fuel pump actuators positions

➢ Click on Adjust actuator output - Check Master & Salve actuator position, both fuel pump actuators should be same readings approximately

Step 1
Step 2
 Check both fuel pumps Actuators failures identifications v/s Ok identifications

Master pump actuator failure identification Salve pump actuator failure Both Master & Salve pump actuators Ok
identification identification
Position Error due to loose wiring errors, lose connectors & Actuator failures etc.

© Greaves Cotton Limited 2018-19 11

 P01L, P01H, P02L,P02H Position Error due to loose wiring errors, loose
connectors & Actuator failures etc. resetting process

Note: If error Po 1L observed on Note: If error Po 2L observed on

ECU display window ECU display window

Note: Reset ECU by pressing both buttons

simultaneously (- & +) through fingers
How To troubleshoot Alarms
Engine parameter to be set when fuel pumps changed
at site
 Set these parameters before starting the engines

S/N Parameters List Set Points S/N Parameters List Set Points
1 Speed 1 1500 RPM 21 Master PID2 Int % 9.70%
2 Speed 2 1400 RPM
22 Master PID2 Der % 14.20%
3 Speed 3 1300 RPM
4 Speed trim DS 750 RPM 23 Slave PID1 Gain % 50.00%
5 Speed trim FS 1500 RPM 24 Slave PID1 Int % 63.00%
6 Idle speed 700 RPM 25 Slave PID1 Der % 0.00%
7 PID loop time 10 msec 26 Slave PID2 Gain % 10.00%
8 Gear Teeth 118
27 Slave PID2 Int % 8.00%
9 Fuel Ramp 1 sec
10 Speed Ramp 3 Sec 28 Slave PID2 Der % 6.00%
11 Crank Termination 250 RPM
12 Overspeed 1650 RPM
13 Start Position 68%
14 Current Limit 63 % for 500KVA
15 Override time 3 Sec
16 Override Position 2%
17 Master PID1 Gain % 34.70%
18 Master PID1 Int % 9.70%
19 Master PID1 Der % 14.20%
20 Master PID2 Gain % 33.70%
 Set these parameters before starting the engines

S/N Parameters List Set Points See actual photos

If Master actuator
position showing
greater than “0”
when master
Master
actuator rack at
29 Actuator
zero position then
Offset
put same value in
minus for showing
actuator rack zero
position

If Slave actuator
position showing
greater than “0”
when Slave
Slave Actuator actuator rack at
30
Offset zero position then
put same value in
minus for showing
actuator rack zero
position
Set these parameters before starting the engines
Remove clicked on Adjust actuator output
 Set these parameters before starting the engines
Both Master & Salve fuel pumps actuator position should be ‘’0’’
 Set these parameters before starting the engines
▪ Gain should be at maximum level % up to engine / DG stability level may be
vary from 35%
 Set these parameters before starting the engines

S/N Parameters List Set Points

31 EGT master offset 0 °C

32 EGT Slave offset 0 °C

33 EGT tolerance max 15 °C

34 EGT tolerance min 0 °C

35 EGT control start 200 °C

36 Max EGT diff 70 °C

37 Max EGT diff time 60 Sec

38 Cold Junction Temp By default. Not editable

39 Max Period Diff 7 Sec

40 Max Position Diff 7%

41 Position Following Select

42 Adjust Actuator Output Don’t Select

43 Actuator Current frequency 70 Hz

Gensets started conditions with out loading
Thanks