-ff. F=*'l DETROIT DIESEL ELECTRONIC FIRE COMMANDER PRESSURE GOVERNOR OPERATION GUIDE EEE]EI. ElFIlE I IDLE I MESSAGES DISPLAYED HERE

Transcription

1 DETROIT DIESEL ELECTRONIC FIRE COMMANDER PRESSURE GOVERNOR OPERATION GUIDE Revised September, 2006 DerRorr trtesels ^Q ENGINE RPM EEMH] OIL PRESSURE EEE]EI VOLTS ElFIlE ENG TEMP EIFI_E -ff ld erucltsx (psr-"r) O metntc (kpa -t) ENGINE DATA I IDLE I Q nen I enrssune I MODE i Il GOVERNOR O puuprnonceo I oxavropurvrp O THRoTTLEREADv MESSAGES DISPLAYED HERE INFORMATION CENTER For Engineers and Certified Operators of Chicago Fire Department Pumpers

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3 INTRODUCTION As with the automotive industry, Federal emission standards have extended to the trucking industry. As a result, today's generation of diesel engines have been redesigned to produce lower emissions. To achieve cleaner operating diesel engines, the blending of diesel fuels has been modified, but more importantly, the fuel control and emissions systems have been computerized. As a result, the fuel control of diesel engines has become an electronic function rather than a mechanical function. The latest deliveries of fire apparatus reflect the new technology with electronically operated accelerator pedals, throttle controls for aerial apparatus, as well as controllers for regulating fire pumps. The Chicago Fire Department has taken delivery of several pumpers as part of a contract to replace the oldest portion of our fleet. These new pumpers are equipped with "Detroit Diesel" engines that are controlled electronically. To regulate the pump, an electronic pressure controller has been installed which combines a throttle control and automatic pressure regulating device in one unit. The "Electronic Fire Commander" is a combination electronic pressure governor and engine data information center designed exclusively for use with pumpers equipped with a Detroit Diesel engine. This device provides rapid and accurate regulation of engine speed to maintain a desired pump discharge pressure while displaying digital readings for vital engine operating parameters. In tests of the Electronic Fire Commander (EFC), performance has been found to be superior to previous electronic pressure controllers installed on earlier Chicago Fire Department pumpers. While engineers and members certified to operate pumpers may be familiar with the operation of the Class I "Captain" pressure governor introduced with recent apparatus purchases, this Operation Guide must be studied and serves as the exclusive reference for the operation of the Electronic Fire Commander. A copy of this Operation Guide should be kept in each apparatus equipped with the Electronic Fire Commander.

4 T'ETROIT DIESELO CLCCTROIIIC FIRC COI'XAIfECR ENGINE RPM VOLTS EEMH EIFIEI OIL PRESSURE ENG TEMP FI-HIE]E] EIFIFI (D erucltsh (psr.?) OMETRtc (kpa-"c) ENGINE DATA I IDLE I Q neu I enessune I MODE I GOVERNOR O put'rperucaoeo O oxnvropump a THRoTTLEREADv MESSAGES DISPLAYED HERE INFORMATION CENTER Control Switches: "MODE" "lnc" ''DEC".'IDLE",,PRESET'' "MENU'' The MODE switch selects the desired operating mode of the governor. The INC switch is used to gradually increase the speed of the ensine. The DEC switch is used to gradually decrease the speed of the engine. The IDLE switch is used to instantly bring the engine to idle rpm. The PRESET switch is used to instantly bring the engine to a pre-programmed rpm in the RPM mode, or to a preprogrammed pump pressure in the PRESSURE mode. The MENU switch is to be used only by qualified service personnel when installing the governor.

5 LED Indicators: ''RPM'' LED.'PRESSURE" LED ''PUMP ENGAGED'' LED ''OKAY TO PUMP" LED ''THROTTLE READY'' LED,.ENGLISH/METRIC'' LED'S ''ENGINE DATA'' DIGITAL DISPLAY ''IN FORMATION CENTER'' DIGITAL DISPLAY WINDOW When illuminated, the RPM LED indicates that the RPM mode is active. When illuminated, the PRESSIIRE LED indicates that the PRESSURE mode is active. When illuminated, the PUMP ENGAGED LED indicates that the road-to-pump shift has been completed. When illuminated, the OKAY TO PLMP LED indicates that the road transmission has been placed in pump gear and the pump is in operation. When illuminated, the THROTTLE READY LED indicates that the throttle control interlock is active. Selects the units of measure indicated in the INFORMATION CENTER ANd ENGINE DATA displays. This selection is programmed by the technician installing the EFC. Engine RPM, Battery Voltage, Engine Oil Pressure, and Engine Coolant Temperature are displayed digitally in the ENGINE DATA portion of the EFC control panel. Messages are displayed in this window regarding the operating status of the EFC as well as displaying any problems with the apparatus such as low voltage, low oil pressure, overheated engine, etc. In addition, when a problem occurs with the mechanical or electrical systems of the apparatus which require immediate attention, the EFC will sound a loud audible waming to alert the pump operator.

6 OPERATING the DETROIT DIESEL ELEGTRONIC FIRE COMMANDER (EFC): Understanding the EFG Functions: Mode Selection The first decision to be considered by the pump operator should be which mode of operation to select for controlling the pump. This requires that the capabilities and limitations offered in each mode be thoroughly understood before operating the EFC. The EFC offers two modes of operation: the RPM Mode and the Pressure Mode. It must be remembered that the Pressure Mode has no relationship to the "Pressure" position of the Transfer Valve. When initially activated the EFC defaults to the RPM Mode which offers control of the pump in a fashion similar to the use of the vernier hand throttle used on our older apparatus. In the RPM Mode, the engine speed can be varied by the pump operator to establish the desired pump discharge pressure. The EFC will maintain the last RPM set by the operator regardless of variations in the flow of water from the pump and the resulting changes in pump discharge pressure. As a result, there is no automatic pressure regulation available to prevent unwanted pressure surges when operating in the RPM Mode. Can the EFC be used in the RPM Mode when only a single hose line is to be supplied? Yes, under certain circumstances. With our older apparatus, there are many pumping situations where the use of a relief valve is not required and the hand throttle is used exclusively to adjust the pump discharge pressure. Rubbish fires, grass fires, auto fires, or any situation where the pumper will be used exclusively from the water tank supply does not require automatic pressure reguiation. Where it is anticipated that a transition from tank supply to hydrant supply will be encountered, or where it is likely that more than one line will be supplied, the Pressure Mode should be selected. Are there situations where the RPM Mode must be used? The answer is yes. The RPM Mode must be initially used when the pump is empty and must be primed before r,\'ater can be discharged. In cold weather where the pump may have been drained, when drafting from a static source of supply, when intake screens have been cleaned and water allowed to drain from the pump, are some examples where the pump will not have sufficient water to develop pressure untilit has been primed. The EFC will not function in the Pressure Mode unless it can detect a pressure in the pump when the Pressure Mode is selected. After pnming the pump with the EFC set to the RpM Mode, the Mode switch can be pressed to switch to the Pressure Mode either before or after a hose line is charged and the desired pressure has been established' Another situation where the RPM should be used is when receiving water in a relay or in-line operation. The safest operation requires that the pump operator maintain direct control over engine RPM to avoid a loss of control of the pump discharge pressure where coordination between the supply engine and the receiving engine/s may not be easily maintained' It is strongly...o**.nded that the pump discharge pressure of the receiving engine/s be regulated

7 with the EFC operating in the RPM Mode and a blow-off line be used to maintain the desired pressure as required. This does not differ from in-line operations with older apparatus where the relief valve has little or no ability to maintain the desired pressure. For the engine located at the source of supply, the EFC can be safely operated in the Pressure Mode, but only after the supply line is charged at idle pressure and water is flowing from the receiving engine/s. In addition, when testing fire hose, the EFC must be operated in the RPM mode. Should a hose line burst during the testing process, the EFC would attempt to maintain the set pump pressure. When operated in the Pressure Mode, the EFC utilizes a Pressure Sensing Govemor (PSG) to sample the existing pump discharge pressure. Any changes to the flow into or from the pump, which cause a change to the last set pump discharge pressure, will be compensated for by the EFC by automatically increasing or decreasing the speed of the motor as necessary to maintain that pressure. When a pumping operation begins with a tank water supply followed by a changeover to a hydrant supply, and/or when more than one line is to be supplied from the pumper, the Pressure Mode must be used to maintain the desired pump discharge pressure. By automatically adjusting the speed of the motor, the EFC will maintain the set pump pressure as the changeover from tank to hydrant supply is made or as additional hose lines are charged or shut down. This greatly simplifies these tasks for the pump operator. ING/DEC Switches Following the selection of the operating mode of the EFC and opening the appropriate discharge port, the desired discharge pressure must be adjusted by using the INC switch to increase the speed of the motor. In the Pressure Mode, each time the ING switch is briefly pressed, the pump pressure will increase about 4 PSL If the INC switch is pressed and held, the pump pressure will increase at a rate of 8 PSI per second. Conversely, if the DEG switch is briefly pressed, the pump pressure will decrease about 4 PSI. If the DEC switch is pressed and held, the pump pressure will decrease at a rate of 8 PSI per second. When operating in the RPM Mode, pressing the ING switch briefly will increase the engine speed in 25 RPM increments. When the INC switch is pressed and held, the engine speed will increase by about 2 increments (50 RPM) per second. Conversely, if the DEG switch is briefly pressed, the engine speed will decrease in 25 RPM increments. If the DEG switch is pressed and held, the Engine speed will decrease by about 2 increments (50 RPM) per second. From this we can see that the engine speed can be slowly and accurately adjusted with the INC and DEC switches whether operating in the RPM or Pressure Modes. ldle Switch Unlike the red Emergency Shut-down Button on a conventional vernier hand throttle, the IDLE switch can be used to bring the engine to idle speed in emergency or non-emergency situations. ln fact, the IDLE switch must be pressed to shut down operations when the Pressure Mode is being used. When operating in the Pressure Mode, the EFC will return to the RPM

8 Mode whenever the IDLE switch is pressed. This will be discussed later in this Operation Guide. Preset Switch The PRESET switch is used to activate a preset RPM in the RPM Mode or a preset pressure in the Pressure Mode. These presets are programmed when the EFC is installed and are not to be changed by field personnel. The preset feature was developed primarily for fire departments where the initial attack lines are standardized and the pump operator may have limited experience in calculating discharge pressures for varied hose lays. In Chicago, there is a wide variety to the size, length, and number of initial attack lines that may be used by the first arriving engine. As a result, a single preset pressure is not appropriate for our varied hose lays. The decision was made to program the PRESET switch to provide the appropriate pressure for the one situation that is constant: the deck gun. With the EFC in the Pressure Mode, pressing the PRESET switch will cause the engine speed to be automatically adjusted to create a pump discharge pressure of 100 PSI. In all other situations, it is recommended that the use of the PRESET switch be avoided and the pump discharge pressure be adjusted with the ING or DEC switches. When operating the EFC in the RPM Mode, the PRESET feature is also available. When the PRESET switch is pressed, the EFC will automatically adjust the engine speed to 1000 RPM. Since the RPM Mode must be used when the pump has been drained and has no water, using ttre PRESET switch will increase the engine speed sufficiently for priming the pump. After the pump has been primed, a check should be made of the pump discharge pressure before charging hose lines. If the indicated pressure appears to be excessive, the DEG switch can be used to reduce the pump pressure as required before opening any discharge port. After the pump operator becomes familiar with the operation of the EFC, it should become apparent that the PRESET switch has limited applications and that using the INC and DEC switches to control pump discharge pressures is the most desirable method of operation in most situations. Getting Started: Engage the pump as with any other apparatus following all in-cab procedures. After exiting the apparatus, a quick check of the three LED's on the EFC's Information Center should find the "PUMP ENGAGED", "OKAY TO PLMP", and "THROTTLE READY" LED's illuminated. This verifies that all interlocks have been activated and the EFC is ready for operation. A check of the Mode LED's should indicate that the EFC is operating in the ttrpm'' mode. The choice of the appropriate mode of operation will depend on the nature of the incident. While the Pressure Mode is generally reconmended, as stated earlier, minor incidents

9 using tank water exclusively, can be handled with the EFC in the RPM Mode. Any adjustments to pump discharge pressure can be accomplished with the ING and DEC switches. For all fires of consequence, where a quick water attack or a reverse lay is used, the Pressure Mode should be selected by pressing the MODE switch once. With the EFC operating in the Pressure Mode, automatic pressure regulation will be applied continuously to assist the pump operator in coping with the many variables that may be encountered during the operation. As a rule, engineers initially charge hose lines using tank water followed by a change over to a positive supply from a hydrant. After selecting the water tank for supply, the discharge port is opened to allow water to flow through the hose line. The desired discharge pressure is adjusted by pressing the ING switch. After the hook-up to the hydrant is complete and water is sent through the supply line to the pump, the engineer can open the intake. The EFC will automatically adjust the motor speed downward to account for the added incoming pressure from the hydrant. ln situations where a reverse lay to the hydrant is used, the EFC can remain in the RPM Mode while the first hose line is charged and the discharge pressure adjusted using the INC switch. The use of the Pressure Mode is optional unless additional hose lines are to be supplied, in which case the EFC should be switched to the Pressure Mode before charsins the new hose line. If an additional line is to be supplied, no additional adjustments to the discharge pressure need be made if the new line will operate at or below the pressure of the highest pressured line already in operation. If the new hose line is to operate at a higher pressure, it may be slowly charged and the discharge pressure increased using the ING switch while gating back the previous hose lines to maintain their proper pressure. With all hose lines set at their proper pressure, the EFC will automatically compensate for any changes which could effect the set pump discharge pressure such as the closing of nozzleq fluctuations in residual pressure, refilling of the water tank, vehicles driving over hose lines, etc. Shutting Down Hose Lines: Where multiple lines are being supplied, and an order is given to shut down a particular line, that discharge port can be slowly closed without any re-adjusting of the EFC. If, after closing the discharge, it is determined that the remaining line/s are operatingat a lesser pressure than the line which was shut down, the DEC switch should be used to lower the pump pressure until the next highest pressure line is fully opened and all remaining lines are properly adjusted. Remember, for proper operating efficiency, the discharge port for the highest pressure hose line must be fully opened. When ordered to shut down the last remaining hose line, the IDLE switch should be pressed, bringing the engine to idle speed. The MODE switch should now be depressed to retum the EFC to the RPM mode. This is important due to the fact that if the transmission is placed in neutral to disengage the pump, and the EFC is in the pressure mode, the engine will rev up in an

10 attempt to maintain pump pressure. Therefore, the EFC must be in RPM mode before attempting to disengage the pump. Drafting with EFC: Drafting operations are rcrely necessary throughout the city as a whole. When a situation arises which requires pumpers to be supplied from a static source of water, members are required to be familiar with the unique procedures for a successful drafting operation. Therefore engineers must be familiar with drafting procedures as they relate to the use of the Electronic Fire Commander. After following all established procedures to prepare the pumper for drafting, the engineer will engage the pump. As stated earlier, with any situation where the pump must be primed, the EFC must be placed in the RPM Mode. The PRESET switch can be pressed which will increase the engine speed to 1000 RPM, which is adequate to engage the priming pump. The priming pump is activated until a steady pressure is indicated on the pump discharge pressure gauge and water is being discharged from the priming pump. Afler releasing the primer control switch, the pump pressure should be adjusted to approximately 50 PSI with the DEG switch. The appropriate discharge port can now be slowly opened while manually maintaining at least a 50 PSI pump discharge pressure with the ING switch. With water flowing from the nozzle, the transfer valve can be set to the proper position (PRESSTIRE or VOLUME) and the correct discharge pressure adjusted with the ING switch. The choice of which mode to operate with the EFC (RPM or Pressure) will now be subject to the same guidelines as when operating from a hydrant. Operating ln'line with the EFC: In-line operations are probably the most challenging situations that the engineer must encounter. While not as rare as drafting operations, most engineers seldom perform this task. Due to the fact that more than one pumper is involved in delivering water to the fire from the source of supply, increased skill and cooperation between engineers is an absolute necessity for a safe and effective operation. Engineers can find themselves assuming one of three roles when involved with an in-line operation: 1. Supply Engine 2. Relay Engine Operating at the source of supply and delivering water to another pumper. (Transfer Valve in "VOLUME" position) Midway in a relay operation, being supplied with water from one engine and delivering it to another engine. (Transfer Valve in "VOLUME" position)

11 3. Attack Ensine Positioned near the incident, being supplied from another engine and supplying hand lines or appliances. (Transfer Valve in "VOLUME" or "PRESSURE" position as required). When all pumpers involved in the rclay are in position, with hose lines stretched, the engineer of the attack pumper will indicate to the other engineers to send water at idle pressure. No adjustments are to be made to discharge pressures until water is flowing steadily from at least one discharge line of the attack pumper. At this time, the engineer of the attack pumper will indicate to the other engineers the total gallons per minute required to supply the attack line/s. Each engineer will slowly increase his/her discharge pressures until the proper flow has been established on each attack line. The Electronic Fire Commander pressure governor is designed for operation in the Pressure Mode when engaged in relay or in-line pumping operations. We have, however, encountered incidents where discharge pressures have surged out of control when the pump operators involved in the relay failed to follorv a coordinated process when initiating a relay operation and a Pressure governor was controlling one of the pumpers in the Pressure Mode. In an effort to avert dangerous situations involving the use of the EFC with an in-line operation, the follorving policy should be strictly adhered to. The Electronic Fire Commander pressure governor shall be kept in the RPM Mode as the operation is initiated. This will give each engineer total control of engine RPM while all hose lines are charged and the proper pressures are adjusted at each pumper. When the desired flow and discharge pressures have been established at each pumper, only the engineer of the pumper at the source of supply may switch the EFC to the Pressure Mode. Doing so will greatly assist the engineer/s of the receiving engine/s in maintaining their proper discharge pressures. The EFC on a relay or attack engine must be kept in the RPM Mode throughout the duration of the operation. To maintain a steady pump discharge pressure as nozzles are opened or closed, a blow-off line shall be used as with our older type pumpers. Gavitation Protection Feature: The Electronic Fire Commander has a feature that is designed to detect a loss of water sr.rpply to the pump and to bring the engine to idle speed. Since the EFC monitors water pressure only in the Pressure Mode, the cavitation protection feature is available only in that mode. When the EFC is set in the Pressure Mode, the purnp discharge pressure is generally in excess of 50 PSL Additionally, when the pump discharge pressure has been set, any required adjustments to engine speed by the EFC are relatively small. In fact, many adjustments are slight enough to be unnoticed by the pump operator. If any situation arises which causes the pump discharge pressure to drop below 30 PSI for more than 5 seconds or results in an increase in engine speed of more than 400 RPM, the EFC assumes that cavitation is occurring. if the pump

12 operator fails to take action rvithin 5 secondso the engine will be automatically slowed to idle RPM. Additionally, the operating mode of the EFC will be returned to the RPM Mode. While this feature is designed to protect the pump from the damage caused by cavitation, it creates some issues that must be understood by the pump operator. Recently reported incidents of dangerous pressure surges involving Electronic Pressure Govemors have been found to center around situations where a loss of adequate water supply to the pump created a sudden and radical increase in engine speed. When the EFC is operating in the Pressure Mode, the pressure sensing governor automatically increases or decreases the motor speed to maintain the last pressure set by the pump operator. Therefore, if the water supply to the pump is lost or reduced to the point where set discharge pressure is reduced, the EFC will increase motor RPM in an attempt to maintain the set pressure. Situations which can cause a radical increase in engine speed are running the booster tank out of water, exceeding the flow capability of the tank-to-pump valve, debris being drawn into the intake screen of the pump, exceeding the supply to the pump from a hydrant, a broken hose line, etc. In some circumstances, the pump discharge pressure will drop to below 30 PSI and/or the engine speed will increase by more than 400 RPM alerting the pump operator that something out of the ordinary is occurring. The real danger to personnel is that a brief, but severe pressure surge r,vill occur if the pump operator attempts to correct the cause of the pressure drop before the EFC senses cavitation and brings the engine to idle speed. For example, if the booster tank is running out of water and the pump pressure has dropped, the motor will most likely increase speed radically. If the pump operator recognizes the problem and opens the intake from the hydrant, the pump pressure will surge to dangerous levels before the pressure governor reacts and readjusts the motor speed. If any situation occurs which causes a loss of adequate water supply to the pump, and there is a sudden and radical increase in engine speed, PRESS THE IDLE SWITCH! Even if the cause can be quickly determined, the engine must be reduced to idle speed before the correction can be safely accomplished. Engine Parameter Display and Information Center: In addition to the switches used to control the fire puffip, there are four digital windows that replace the analog gauges found on earlier apparatus for monitoring vital systems of the apparatus. These include engine RPM, battery voltage, motor oil pressure, and coolant temperature. There are two LED's below these display windows to indicate the type of units of being displayed. The EFC is designed to accommodate both the U.S. market as well as -.aiure foreign markets where metric units are used. The EFC's on our apparatus are programmed to display English units of measure.

13 The lnformation Center display window at the bottom of the EFC panel will display the current operating mode and indicate what control actions are being performed by the controller. Also shown is the correct time of day. An additional feature is a system monitoring and warning system to warn the pump operator both visually and audibly of any serious problem with the apparatus that could require shutting down operations. Low voltage, low oil pressure, and overheating of the motor will activate a loud audible alarm and the nature of the problem will be displayed in the Information Center windorv. System Failure: While the Electronic Fire Commander has proven to be a reliable device, it is dependent on electronics and the potential for a total failure does exist. This is true of other components of the apparatus as well, such as the motor or transmission. Fortunately, if the EFC totally fails to operate upon arrival at an incident, the engine company will still be capabie of a limited, but effective operation. With the engine-to-pump speed ratio of the new pumpers, the pump discharge pressure available at engine idle is greater than on previous apparatus. While some personnel have expressed concern that the idle pressure is too high, it actually prevents the company from being totally out of service should the EFC fail to function. If, upon arrival at an incident, the EFC fails to operate, the pump operator should make certain that the Transfer Valve is placed in the "PRESSURE" position. If the pumper is operating from the booster tank, the pump discharge pressure will be approximately 60 PSI at engine idle. This is adequate to supply a l-314" hose line for auto, rubbish, grass ftres, etc. For more significant fires a higher pressure will be needed. When the connection to a hydrant is completed, the added pressure from the hydrant will provide a pump discharge pressure of approximately 100 PSI at engine idle. This will allow for an adequate pressure to supply a l-3l4"hose line or relatively short lead outof 2-112" hose. Of course, if it is known that there is a failure of the EFC prior to response to an incident, the apparatus should be placed out of service until repairs can be made. Summary: After reviewing the information contained in this manual, it can be seen that the Electronic Fire Commander combines several controls and gauges in a single compact unit. While the use of this device differs from previous pump pressure controls, it is not complex and in many ways, it simplifies some phases of pump operation. If, after studying the information in this manual, engineers or members certified to operate pumpers have any questions regarding the use of the EFC, they should contact the Engineer Training Section at the Fire Academy.

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