AutoControl Pressure Governor

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1 AutoControl Governor OPERATION and INSTALLATION MANUAL MODEL WSD-100: Cummins Electronics Engines-ISB, ISC, ISL, ISM WSD-200: DDEC electronics engines-series 50 and Series 60 WSD-240: DDEC Series 40 engines WSD-300: Mechanical engines WSD-400: Navistar engines-dt466e, DT530E WSD-500: Caterpillar engines WSD-700: MAC electronic engines W.S. Darley & Company Chippewa Falls Tel (715) Page 1

2 INTRODUCTION : The Auto Control is a pressure governor and engine monitoring system designed for the electronic engines. It regulates the engine RPM to maintain a steady pump pressure (pressure mode) or engine RPM (RPM mode) regardless of the engine load. The Auto Control will automatically compensate for the low and high pressure reliably and accurately. The Auto Control also dispays the discharge and intake pressure. It replaces the two traditional 6 pressure gauges on the pump panel. The engine RPM is displayed in large LED readout. The engine oil pressure, coolant temperature, and the battery voltage are displayed in 3 easy to read bar graphs. Both visual and audible alarm are generated when any of the 3 engine parameters are at faulty level. All displays are sunlight readable with the super bright LEDs. Two choices of operation are available: regulation and RPM regulation. If the pump runs out of water during operation, the engine RPM will decrease to idle. When water is again available, the pump pressure will return to the previous setting. This pressure governor is easy to operate and to install. FEATURES : p Discharge and Intake pressure readings. The positive discharge and intake pressures are shown in 1 psi increment and the suction pressure is in -1 in/hg increment. p Two modes of operation: control or RPM control. p System always default to pressure mode on power up p OK to Pump LED for pump engaged p The PRESET button can be used to raise the pump pressure or engine RPM to a preset level. This is a very useful feature when the operator always operate at a commonly used pump pressure or engine RPM. The preset level is field adjustable. p The IDLE button brings the engine to idle quickly after operations. p Fault codes display for easy system diagnostic p Display instantly shows operator the chosen setting. p Large readout for engine RPM. Bar graph display and color coded scale to show the safe operating region for the engine oil pressure, engine temperature, and battery voltage. p Audio and visual warning for: low engine oil pressure, high engine temperature, low and high battery voltage. Page 2

3 System Specifications: I) Display The following readouts are provided: 1) A 4-digits readout to display the pump discharge pressure ( psi, 1 psi increment) 2) A 4-digits readout to display the pump intake pressure ( Absolute to 600 psi, 1 psi increment. For pressure below 0 psi, the pressure is registered in in/hg) 3) A 20 segments LED bar grarh to display the pressure or RPM setting. governor will operate from 45 to 300 psi. 4) A 4-digits readout to display the engine RPM (10 RPM increments) 5) 3-10 segments bar graph to display the battery voltage level (11.0 to 15.5 volts), engine oil pressure (0 to 90 psi), and engine temperature ( F) 6) Throttle Ready LED (green) to indicate the pump is engaged II) Functional switches 1) IDLE - to bring the engine to idle 2) Mode - to select PSI or RPM control 3) Preset - select the preset PSI or RPM control setting 4) Increase - to increase the pressure or RPM setting 5) Decrease - to lower the pressure or RPM setting 6) Silence - to silence the audio alarm III) Sensors supplied 1) psi pressure transducer 2) 1 - Absolute to 600 psi pressure transducer IV) Input signal from the engine Will utilize the J1587 data bus to pick up the engine data and battery voltage from the engine ECM V) A buzzer will be provided for the audio alarm VI) All necessary extension cables will be provided Page 3

4 Throttle Ready LED Switch inputs: l Idle - engine idle l Preset - engine control l Increase - engine control l Decrease - engine control l Mode - PSI or RPM control selection l Silence - alarm AutoControl Governor Audio alarm Buzzer Discharge psi Intake -30 in/hg to 600 psi Engine Control Monitor engine data: 1) Engine RPM 2) Engine oil pressure psi, low pressure warning at 15 psi 3) Engine temperature F, high temperature F 4) Battery voltage to 15.5 volt, low battery warning at 12.3 volts and high voltage warning at 15.4 volts Page 4

5 FUNCTION OF SWITCHES ) The "IDLE" switch brings engine to idle imme diately after operations 2) The "INCREASE" switch will increase the pressure or RPM setting 3) The "DECREASE" switch will decrease the pressure or RPM setting ) The "PRESET" switch ramps engine to the preset pressure or RPM quickly ) The "MODE" switch changes the mode of operation between pressure and RPM LED to indicate operation in pressure mode 7 - LED to indicate operation in RPM mode 8) The THROTTLE READY LED indicates the governor is active 9) Discharge pressure display 10) and RPM setting display 11) Intake pressure display. It also displays the new PSI/RPM setting for 6 seconds when a new PSI/RPM setting is selected 12) Engine RPM display 13) Engine oil pressure display 14) Battery voltage display 15) Coolant temperature display 16) Audio warning silence button Page 5

6 I) PRESSURE GOVERNOR Display... The Discharge pressure is displayed from psi in increments of 1 psi. Upon power up, the AutoControl will perform self calibration to offset any drift in pressure readings due to temperature or voltage variations. In this way, the pressure reading will always be set to 0 at startup. The Intake pressure is displayed from -30 inhg. to 600 psi. During a drafting situation where the pump pressure drops below 0 psig, the AutoControl will display the pressure in -inhg. Above atmospheric pressure, the pump intake pressure will be displayed in psi. The Intake pressure is displayed in 1 psi increments with presure above 0 psi or in -1inHg. increment when in suction. Operations... When the AutoControl is energized, it will automatically select the control mode. The pump has to be engaged in order for the governor to be active. This is indicated by the green THROTTLE READY LED. NOTE: The Buzzer will beep 5 times when the throttle is ready. Always operate the AutoControl in control mode. If RPM control is prefered, use the MODE switch to do so. The operator can use the + button to raise the pressure setting or use the PRESET button to select a preprogrammed setting. How to operate : PSI Mode When the AutoControl is on, the red LED next to the "IDLE" switch will be on to indicate that the engine is at idle. The mode of operation is always default to PRESSURE after power up (indicated by the amber LED above the "MODE" switch). The governor requires a discharge pressure of at least 15 psi in order for it to operate. This is a safety feature to prevent the engine from turning a dry pump. A good example for this scenario is when operating the pump without the tank to pump valve open. There are 5 pushbuttons on the control module : Page 6

7 1) The 2 yellow "+" and "-" switches allow easy selection of the desired pressure from 45 to 300 psi. Depress "+" to bring the pressure up, and depress "-" to lower the pressure. The LED bar graph in the middle of the display shows the pressure setting. When pressing the "+" or "-" switch, the lower display window will show the desired pressure setting instead of the intake pressure reading. This reading will flash to indicate that it is displaying the pressure setting. This is done to allow the operator to set the pressure setting more precisely. The pressure will ramp up or down at 1 psi increments when pressed momentarily. When the pushbutton is held down for more than 2 seconds, it will ramp up or down at a rate of 5psi and then 10 psi increments. Release the pushbuttons when the desired pressure is reached. Once the button is released, the pressure setting reading will continue to flash for an additional 6 seconds before it goes back to display the intake pressure reading. 2) The "IDLE" switch will bring engine to idle quickly after operations. After the end of the operations, simply push the "IDLE" switch and the AutoControl will bring the engine to idle. The word "idle" will flash for 6 seconds on the intake pressure window and goes away. The "IDLE" switch is ideal to drive the engine to idle in emergency situation. 3) The "PRESET" switch brings pressure to the preset pressure quickly and conveniently with the touch of a button. After pressing the "PRESET" switch, the intake pressure window display will show the flashing pressure setting and the AutoControl will raise the engine RPM to reach the desired pressure. After the "PRESET" switch is used, the "+" and "-" switches can still be used to easily change the selected pressure. The "IDLE" switch can bring the engine to idle. How to change the preset PSI? The preset pressure setting can be easily changed. To change the setting, simply follow steps (a) through (d): a) Make sure the engine is at idle when changing the setting. If the engine RPM is not at idle, press "IDLE" switch to bring the engine to idle. b) If you are not in pressure mode, select the pressure mode by pressing the "MODE " switch. c) Press "PRESET" button and hold it for a few seconds. The intake pressure display window will flash to show the current preset pressure. Use the "+" or "-" switch to program the new preset pressure. d) When the new desired preset pressure is programmed, release the "PRESET" button and the new preset pressure will be stored in the memory. Page 7

8 How to operate in RPM mode... There are 5 pushbuttons on the control module : 1) Use the "MODE" button to select the RPM operation. Once the RPM mode is selected the red LED below the "MODE" switch will be turned on. 2) The 2 yellow "+" and "-" switches allow easy selection of the desired engine RPM from 700 to 2400 RPM. Depress "+" to bring the RPM up, and depress "-" to lower the engine RPM. When pressing the "+" or "-" button, the intake pressure display window will show the desired RPM setting instead of the intake pressure reading. This reading will flash to indicate that it is displaying the engine RPM setting. This is done so that the operator is able to set the RPM easier. The LED bar graph in the middle of the display also shows the RPM setting. The engine RPM setting will ramp up or down at 10 RPM increments when the button is pressed momentarily. When the pushbutton is held down for more than 2 seconds, it will ramp up or down at a rate of 50 RPM and then 100 RPM increments. Release the pushbuttons when the desired RPM setting is reached. Once the button is released, the RPM setting reading will continue to flash for an additional 6 seconds before it goes back to display the intake pressure reading. 3) The "IDLE" switch will bring engine to idle quickly after operations. After the end of the operations, simply push the "IDLE" switch and the AutoControl will bring the engine to idle. The word "idle" will flash for 6 seconds on the lower window and goes away. The "IDLE" switch is ideal to drive the engine to idle in emergency situation. 4) The "PRESET" button ramps engine to the preset RPM quickly and conveniently with the touch of a button. After the "PRESET" switch is used, the "+" and "-" switches can still be used to change the selected RPM easily. "IDLE" switch can bring the engine to idle How to change the preset RPM? The preset RPM setting can be easily changed. To change the setting, simply follow steps (a) through (d): a) Make sure the engine is at idle when changing the setting. If the engine RPM is not at idle, press "IDLE" switch to bring engine to idle. b) If you are not in RPM mode, select the RPM mode by pressing the "MODE " switch. c) Press "PRESET" switch and hold it for a few seconds. The intake pressure display window will flash to show the preset RPM. Use the "+" or "-" switch to program the new preset RPM. d) When the new desired preset RPM is programmed, release the "PRESET" switch and the new preset RPM will be stored in the memory. Page 8

9 How to change the Operation Mode... The "MODE" button will toggle the operation between pressure control and RPM control. To change the control mode, simply push the "MODE" button and release it. The LED above and below the "MODE" switch will change to indicate the control mode selected. The operator can change the control mode during operations without having to bring the engine down to idle. To change the control mode while in operation, the MODE button has to be held down longer until the LED switches to the desired mode of operation. (This is to avoid the control mode being accidentally changed because the operator inadvertently press the MODE button) For example: when you are in pressure mode, press the "MODE" switch until the lower red LED is on. The intake pressure display window will show the flashing pressure setting. After 3 seconds this window will display the actual RPM reading to indicate that the you are now in RPM control. Release the "MODE" button at this point. Vice versa you can change the control from RPM to pressure. Open and Close Valves... The AutoControl will maintain the selected pressure setting regardless of the number of discharges that are opened as long as the water supply is good. As more lines are opened the discharge pressure will drop and the AutoControl will raise the engine RPM up to maintain the required pressure. The AutoControl will reduce the engine RPM to maintain the required pressure when one or more of the discharges are closed. It acts like a ' cruise control ' for the pump. The operator dials in the required pressure and the AutoControl will quickly and accurately adjust the engine RPM to maintain the pressure. Out of Water... There are situations during pump operation when the system runs out of water due to an empty water tank or there is a problem on the intake line. When this situation occurs, the AutoControl will increase the engine RPM to maintain the selected pressure. The engine RPM will stay high until the AutoControl detects a pressure that is below 45 psi. If the pressure is between 45 and 15 psi, the engine RPM will go to a preprogrammed set prime RPM at 1100 RPM for 7 seconds. The engine will go to idle if the pressure drops below 15 psi during the prime cycle. The engine RPM will also drop to idle if the water supply does not return after 7 seconds during the prime cycle. The engine RPM will stay idle as long as the discharge pressure is below 15 psi. At any time if the discharge pressure is greater than 15 psi and the pressure setting is unchanged, the AutoControl will resume normal operation. Page 9

10 II) ENGINE MONITORING In the engine monitoring section the AutoControl has a 4 digit LED display for the engine RPM, and 3 LED bar graphs to display the engine oil pressure, engine temperature, and battery voltage. It also generates visual and audible warning. The following are the standard features: 1. Engine RPM readout 2. Oil pressure with low oil pressure warnings 3. Engine temperature with high coolant temperature warnings 4. Battery voltage with low and over voltage warnings The AutoControl utilizes the data broadcasted on the J1587 public data link (from the engine ECM) to display the engine information. The battery voltage is also monitored directly through the J1587 data link. Engine Display... Engine RPM Engine Oil Coolant Temperature Battery Voltage RPM in 10 RPM increments 0-90 psi in 10 psi increments deg.f in 10 deg.f increments volts in 0.5 volt increments Audible and visual warning... The Auto Control will provide an audible and visual warning when: 1) The engine oil pressure is too low: lower than 15 psi 2) The engine temperature is too high; above 230 F 3) Low battery voltage warning; voltage below 12.3 volts 4) Over battery voltage warning; voltage above 15.4 volts How to Silence the audible warning? The audible warning can be silenced by pressing the SILENCE switch. However this will not cancel the visual alarm. The visual alarm will reset itself once the conditions return to normal again. Page 10

11 Interface Harness Connector... Connector A Connector B Pin No. Assignment Pin No. Assignment DC12V GND Pump interlock (+12V) J J DC5V (discharge pressure) GND (discharge pressure) Discharge Signal DC5V (intake pressure) GND (intake pressure) Intake Signal Oil sensor input (optional) Connector A = Deutsch DT15-12P Mating Plug = Deutsch DT06-12S Socket Contact = Part No Hand Crimp Tool = Deutsch HDT VDC reference GND Engine Control Signal High Idle N. C. N. C. Buzzer (-) Buzzer (+) Connector B = Deutsch DT15-4P Mating Plug = Deutsch DT06-4S Socket Contact = Part No Hand Crimp Tool = Deutsch HDT A B Figure 6 Page 11

12 12 PIN DEUTSCH PLUG(GRAY) #DT04-12P RED,BLK & WHITE WIRES 18 AWG 24 WIRES 10 2 COND ALPHA CABLE #2241C 18 AWG 10 3 COND BELDEN CABLE # AWG TERMINATION 1-RED WIRE +12V DC BUTT CONN. 2-BLACK WIRE GROUND BUTT CONN. 3-WHITE WIRE INTERLOCK BUTT CONN. 4-RED J1587 DATALINK+ OPEN LEADS 5-BLACK J1587 DATALINK- OPEN LEADS 6-RED +5V REF. PACKARD PLUG-1, PIN-B 7-BLACK GROUND PACKARD PLUG-1, PIN-A 8-WHITE DISC.PRESSURE SIGNAL PACKARD PLUG-1, PIN-C 9-RED +5V REF. PACKARD PLUG-2, PIN-B 10-BLACK GROUND PACKARD PLUG-2, PIN-A 11-WHITE INTAKE PRESSURE SIG. PACKARD PLUG-2, PIN-C 12-N\C OPTIONAL OIL SENSOR N\C 3 OPEN LEADS PACKARD PLUG-1 PACKARD PLUG-2 -RED HEAT SHRINK FOR THE DISCHARGE SENSOR CONN(PLUG-1). - BLACK HEATSHRINK FOR THE INTAKE SENSOR CONN(PLUG-2). 8 PIN DEUTSCH PLUG(GRAY) #DT04-8P RED & BLK 18 AWG 24 WIRES FOR THE BUZZER 12 3 COND BELDEN CABLE # AWG TERMINATION 1-RED WIRE +5V ECM REFERENCE OPEN LEADS 2-BLACK WIRE ECM GROUND REF. OPEN LEADS 3-WHITE WIRE ECM CONTROL SIGNAL OPEN LEADS 4-N\C N\C 5-BLACK SERVO MOTOR(-) 2 PIN PACKARD PLUG(B) 6-RED SERVO MOTOR(+) 2 PIN PACKARD PLUG(A) 7-BLACK BUZZER (-) FEMALE QUICK CONNECT 8-RED BUZZER (+) FEMALE QUICK CONNECT Page 12 OPEN LEADS NOTE: 2 or 3 leads depends on the engine type For Mechanical engine only

13 SYSTEM WIRING BLOCK DIAGRAM... ISB and ISC Engines A NOTE: 1) Remote Throttle ON/OFF input (Pin B45 on ECM B connector) has to be grounded when the pump is engaged. 2) 'Selected Throttle Control Switch' (Pin B6 on ECM B connector) has to be grounded when the pump is engaged. B Buzzer 12 vdc from OK to pump Ignition switch - 12V + Battery TO ECM Discharge Intake ECM B Conn V reference Signal to ECM Signal return Remote Throttle ON/ OFF switch J1587 Datalink Positive = pin B49 Negative = pin B50 Selected Throttle Control Switch Supply ground when the pump is engaged Page 13 Figure 1

14 SYSTEM WIRING BLOCK DIAGRAM... Detroit DDECII* & DDECIII* elecrtonic Engines A NOTE: THE DDEC ECM DOSE NOT REQUIRE ADDITIONAL SIGNAL TO ACTIVATE THE GOVERNOR CONTROLLER (REMOTE THROTTLE). B Buzzer 12 vdc from OK to pump Ignition switch - 12V + Battery ECM VEHICLE INTERFACE HARNESS CONNEC- TOR. A-3 D-1 C-3 WIRE NO. 5V DC reference #916 Control Signal #510 Signal return #952 Discharge Intake J1587 Datalink DATALINK(+) RED 900 C-2 DATALINK(-) BLACK 901 C1 Page 14

15 SYSTEM WIRING BLOCK DIAGRAM... Mechanical Engines A B Buzzer 12 vdc from OK to pump Ignition switch - 12V + Battery Discharge Intake coolant sensor servo motor oil pressure sensor alternator ac signal Page 15

16 SYSTEM WIRING BLOCK DIAGRAM... INTERNATIONAL NEVISTAR Engines A NOTE: 1) Remote Throttle ON/OFF input (Pin B45 on ECM B connector) has to be grounded when the pump is engaged. 2) 'Selected Throttle Control Switch' (Pin B6 on ECM B connector) has to be grounded when the pump is engaged. B Buzzer 12 vdc from OK to pump Ignition switch - 12V + Battery TO ECM Discharge Intake ECM Conn. 97DD 99F 97HM 97CC 5V reference(red) Signal to ECM(WHITE) Signal return(black) Remote Throttle ON/OFF switch Supply +12V when the pump is engaged J1587 Datalink RED = ATA+ BLACK = ATA- Page 16

17 SYSTEM WIRING BLOCK DIAGRAM... Caterpillar Engines WSD500-DM A NOTE: 1) Remote Throttle ON/OFF input (Pin 56 on ECM connector) has to be grounded when the pump is engaged. 2) Interlock input (Pin3 of conn A on controller) has to be connected to the +12vdc when the pump is engaged. B Ignition switch 12 vdc from OK to pump - 12V + Battery RED Buzzer red black Discharge Intake #FP3100PT-2 #IO3100PT-2 Remote Throttle ON/ OFF switch Supply ground when the pump is engaged black white Signal to ECM Signal return K999-GN G845-PU 993-BR Wire# RED BLK 70 pin OEM connector Pin# ATA Data Link (+) ATA Data Link (-) PTO ON/OFF Switch Input #8 Throttle position Input Sensor Common #2 Engine ECM Page 17

18 SYSTEM WIRING BLOCK DIAGRAM... VMAC Engines A B Buzzer 12 vdc from OK to pump Ignition switch - 12V + Battery Discharge Intake J1587 Datalink Engine control signal ( 0.75v-3.875v) To Engine ECM To Cab Foot Throttle l Orange Green Black Pin 3 Pin 2 A B C OR GR BK A B C DPDT 5 Amp 12Vdc Relay NC NO C NC NO C J1B-L2-0.8 J1B-L1-0.8 J1B-L3-0.8 IN4006 Diode OK to Pump Page 18

19 Fault Codes... Fault Codes PROBLEMS PROBABLE CAUSE F1 No Data is detected on the data bus. Make sure J1587 data link is properly connected F2 The engine is not responding to the command from the governor Make sure all engine control wires are properly connected For the Cummins engines, make sure the remote throttle is selected both in hardware and software Page 19 F3 F5 No RPM data is detected. No discharge pressure transducer is detected. Data bus related problem Bad connections or contacts Defective pressure transducer F6 No intake pressure transducer is detected Bad connections or contacts Defective pressure transducer F7 Engine is responding but the pressure is not changing Pump cavitated Tank to pump valve is not opened Defective pressure transducer F9 F10 No oil pressure data is detected on the data bus No coolant temperature data is detected on the data bus Data bus related problem Data bus related problem