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Electronic Controls
Electronic Control Module
The ECM consists of two main components, the control computer (hardware) and the flash file (software). The control computer consists of a microprocessor and electronic circuitry. The flash file contains the engines operational characteristics. The operating maps influence the engines performance.Engine Governor
The engine ECM governs engine speed. The engine ECM and the flash file work together by controlling the amount of fuel that is delivered by the injectors. Desired engine rpm is determined by the throttle position sensor signal and certain sensor readings. Diagnostic codes may derate the engine. Actual engine rpm is measured by the engine speed/timing signal.Fuel Injection
The engine ECM controls the timing and the duration of the fuel that is injected. The engine ECM varies the signals to the fuel injectors. Fuel is injected only while an injector solenoid is energized by a 105 V signal from the engine ECM. The timing of the injection signal determines the engine timing. The length of the injection signal determines engine speed. By controlling the timing and duration of the 105 V signal, the ECM controls the engine speed.Injection timing depends on the following conditions: desired engine rpm and load. The ECM detects the top center of each cylinder. The ECM sends an injection signal at the desired time.Cold Cylinder Cutout
During a cold start or extended periods at low idle, the engine ECM will automatically turn off one unit injector at a time to determine if the cylinder is firing. If the ECM determines that the cylinder is not firing, the ECM turns off the unit injector. If the ECM determines that the cylinder is firing, the ECM turns on the unit injector. This strategy improves engine starting. This strategy reduces the following: white smoke, the use of ether injection and warmup time.Cold Mode Operation
Cold Mode operation automatically stops fuel injection to cylinders that are not firing. Cold Mode operation has the following benefits: increased startability, reduced warm-up period, and reduced white smoke.FRC Limit
The flash file inside the engine ECM sets certain limits on the amount of fuel that can be injected. The FRC limit is a limit that is based on the boost pressure. The boost pressure is calculated as the difference in pressure between atmospheric pressure and turbocharger outlet pressure. The FRC limit is used to control the air/fuel ratio for control of emissions. When the engine ECM senses a higher boost pressure, the engine ECM increases the FRC limit. A higher boost pressure indicates that there is more air in the cylinder. When the engine ECM increases the FRC limit, the engine ECM allows more fuel into the cylinder.Rated Fuel Position
The rated fuel position is a limit that is based on the power rating of the engine. The rated fuel position is like the rack stops and the torque spring on a mechanically governed engine. The rated fuel position determines maximum power and torque values for a specific engine family and a specific rating. The rated fuel position is programmed into the flash file at the factory.Dynamic Gas Blending (DGB)
The DGB engine kit automatically adjusts to changes in incoming gas fuel quality and pressure allowing diesel engines to run on a wide variety of fuels. The kit has an engine electrical and protection system that protects the engine from any abnormal combustion event such as detonation or knock that may occur as a result of blending natural gas. To maintain detonation protection and engine life, it is necessary to regulate the flow of gaseous fuel. Through continuous engine monitoring, the DGB engine kit achieves maximum substitution of gaseous fuel while maintaining engine life.The key components of the DGB engine electrical and protection systems are:
A5:E4 Engine ECM
A6:E5 Gas ECM
In Cylinder Pressure Sensors (ICPS)
Gas Admission Valve (GAV)
Gas Shut Off Valve (GSOV)Engine Control Module (ECM)
All engine functions are controlled by an integrated A5:E4 ECM. The ECM monitors the status of the various systems and displays the system operating values. The ECM uses these same values to generate alarms and shutdowns to protect the engine.The ECM provides the basic principles for:
Engine speed governing
Monitoring and protection
Diagnostic codesGas ECM
In addition to the A5:E4 ECM the engine employs an A6:E5 gas ECM. The gas ECM controls the following:
In Cylinder Pressure Sensors (ICPS)
Gas Admission Valve (GAV)
Gas Shut Off Valve (GSOV)The gas ECM has responsibility for monitoring the engine In Cylinder Pressure Sensors (ICPS) and to detect any abnormal conditions within the combustion of an individual cylinder.Cylinder pressure levels are always being monitored for abnormal conditions. When abnormal conditions are detected that indicate premature ignition or detonation has occurred, the ICPS ECM will notify the engine ECM via the local CAN B Data Link. The engine ECM will take action to mitigate the abnormal conditions which may include altering the gas substitution ratio, advancing or retarding timing controls, or disabling gas blending.The ICPS ECM receives inputs from the following components:
CAN local data link
ICPS
Camshaft position sensor #1 and crankshaft position sensor #1The ICPS ECM receives and communicates these inputs to the engine ECM via the Local CAN B data link.In Cylinder Pressure Sensor (ICPS)
An ICPS is installed into each cylinder head and replaces the detonation sensors typically seen on engines operating on a gaseous fuel supply. The ICPS will actively measure cylinder pressure and provide a feedback signal to the ICPS ECM to determine cylinder health and efficiency.The ICPS connector style is a press-fit "Hirschmann connector" which is unique from other styles of sensor connectors found on Cat engines and equipment. Due to the type of connection found at the sensor adapter harness at the ICPS, it is not possible to accurately measure resistance or create short circuits. Exchanging the adapter harness with another harness from a known good cylinder may be necessary for troubleshooting purposes.Gas Admission Valve (GAV)
The GAV is a solenoid operated, mechanically actuated fuel valve that is mounted on the outboard side of each cylinder head. The GAV is connected to the engine intake manifold runner via a flexible fuel line which delivers fuel to the intake stream per