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OPERATING MANUAL
WARNING: WARNING:
DEVIATION FROM THESE INSTRUCTIONS MAY LEAD TO DEVIATION FROM THESE INSTRUCTIONS MAY LEAD TO IMPROPER OPIMPROPER OPERATION OF THE ENGINE PERSONAL INJURY ERATION OF THE MACHINE WHICH COULD CAUSEWHICH COULD CAUSE PERSONAL INJURY TO OPERATORS TO OPERATORS OR OTHER NEARBY PERSONNEL. OR OTHER NEARBY PERSONNEL.

EPC-50 AIR-FUEL CONTROLLER

FORM EPC-50 OM 5-09

1.0 SYSTEM DESCRIPTION 1.1 The Altronic EPC-50 is an air/fuel ratio controller designed for use
on low-horsepower, carbureted natural gas-fueled engines. It employs microprocessor technology, allowing for a high level of sophistication in control strategy, ease of programming and diagnostic capability. The EPC-50 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. The EPC-50 is designed to be mounted in the engine/compressor control panel.

1.2 The single control output of the EPC-50 allows for its use

on any engine application incorporating a single fuel gas regulator. An oxygen sensor is used in the exhaust stream to sense O2 content, and a thermocouple input signals when proper exhaust temperature has been reached to allow for accurate sensor operation. The system 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 O2 content in the exhaust. The desired air/fuel ratio can be easily adjusted by changing the control target voltages. the target voltage, sensor voltage, operating temperature, stepper motor position and diagnostic information. can be provided by the Altronic 24 VDC Alternator Power Package. Refer to Altronic Form ALT.

1.3 The EPC-50 has an alphanumeric LCD display showing

1.4 Power requirement is 24 (1030) VDC, 1 amp. In remote areas, power

1.5 The EPC-50 also incorporates a thermocouple input and a dedicated

output for implementation of catalyst over-temperature protection. A second digital output is available for use as an alarm for diagnostics or uncontrolled operation.

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EPC-50 AIR-FUEL CONTROLLER

2.0 SYSTEM COMPONENTS 2.1 One part from each group below is required for each installation:
PART NO. EPC-50 690153-1 690154-1 690154-2 690154-5 690220-1 690225-1 690230-1 693013-1 693006-1 693006-2 610621 ** ** ** DESCRIPTION Air/fuel controller Control Valve, .75" NPT Control Valve, standard 1.5" NPT Control Valve, low HP 1.5" NPT Control Valve, very low HP 1.5" NPT Control Valve, butterfly 2.0" NPT Control Valve, butterfly 2.5" NPT Control Valve, butterfly 3.0" NPT Cable, control valve, 30 ft. Cable, oxygen sensor, 25 ft. Cable, oxygen sensor, 50 ft. Oxygen sensor K Thermocouple Probe (ungrounded w/thermowell) K Thermocouple Ext. Wire 12-16 AWG Hook-up Wire QUANTITY REQUIRED 1 per engine 1 per engine 1 per engine 1 per engine 1 per engine 1 per engine 1 per engine 1 per engine 1 per engine 1 per engine 1 per engine 1 per engine 1 per engine, plus 1 for Catalyst Out 50 ft. per thermocouple 150 ft. per engine

NOTE: If possible, keep the original shipping container. If future transportation or storage of the controller is necessary, this container will provide the optimum protection.

** Not supplied in Altronic kits.

2.2 ACCESSORY KITS

691305-1 ACCESSORY KIT INCLUDES: 610621 693013-1 693006-1 Oxygen Sensor Cable Assembly, Control Valve, 30 ft. Cable Assembly, O2 Sensor, 25 ft.

691305-2 ACCESSORY KIT INCLUDES: 610621 693013-1 693006-2 Oxygen Sensor Cable Assembly, Control Valve, 30 ft. Cable Assembly, O2 Sensor, 50 ft.

2.3 REFER TO FIGS. 1 OR 2 for the general layout of components used in the
EPC-50 control systems.

2 FORM EPC-50 OM 5-09

OPERATING MANUAL
3.0 MOUNTING THE EPC-50

NOTE: A weldment boss may be required for sensor installation in soft or thin wall exhaust systems.

4.2 Drill, tap and spot face a hole in the exhaust pipe at the selected location. A flat smooth sealing surface is required to assure accurate readings since air or exhaust leaks will impact sensor operation. SEE FIG. 5 FOR DETAILS

4.3 New sensors are packaged with an anti-seize compound already ap-

plied to the threads. There is no need to apply additional anti-seize unless reinstalling a used sensor. If required, use high temperature anti-seize very sparingly and apply only to the sensor threads. Sensors should be torqued to 28-34 lb.-ft.

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EPC-50 AIR-FUEL CONTROLLER

5.0 MOUNTING THE K-TYPE THERMOCOUPLES 5.1 ExHAUST TEMPERATURE THERMOCOUPLE is used to monitor the temperature of exhaust gases near the exhaust oxygen sensor and should be mounted as close as possible to the O2 sensor. As with the O2 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. housing. Provision for thermocouple installation is normally provided for in the design and manufacture of the catalyst. Installation of the thermocouple at the outlet of the catalyst provides two modes of protection: High Outlet Temp Shutdown and High Catalyst Temperature Rise Shutdown. Consult catalyst manufacturers recommendations for required overtemp protection.

5.3 CATALYST PROTECTION THERMOCOUPLE should be installed in the catalyst

5.3 ONLY UNGROUNDED THERMOCOUPLE PROBES can be used with the EPC-50.

Grounded type thermocouples will not function correctly. Resistance from either lead of the thermocouple to the probe shell should be 2 megohms or greater.

4 FORM EPC-50 OM 5-09

OPERATING MANUAL
6.0 MOUNTING THE FUEL CONTROL VALVE
NOTE: For detailed instructions covering the gas control valve, see form GCV1 OM (690154 series) or GCV2 OM (6902XX series).

6.1 In order to control the air/fuel ratio, an electronically controlled

valve is connected in series between each regulator and carburetor. The valve should be installed as close to the fuel inlet of the carburetors as possible. The distance from the valve to the carburetor inlet should not exceed 12 pipe diameters in length. The valve should be installed with the control cable connector facing upward to avoid the collection of condensation in the stepper motor. currently in use. The threaded connection to the valve body may require the use of thread adapters. If adapters are used, proper plumbing procedures must be followed.

6.2 If possible connection piping should be of the same diameter as

6.3 The control valve is connected to the EPC-50 using the 693013-1 cable.
The cable wires are color coded and must be connected to the valve output terminal block of the EPC-50 according to color. This cable must not be run in the same conduit as the ignition primary or other O2 Sensor or Thermocouple wires. A distance of 4 to 6 inches should be maintained between EPC-50 wiring and other engine wiring.

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EPC-50 AIR-FUEL CONTROLLER

7.0 ELECTRICAL HOOK-UP 7.1 The power connections to the EPC-50 must be in accordance with the
National Electrical Code. The EPC-50 is suitable for installation in Class I, Division 2, Groups C and D locations. external fuse (5 amp max.) near the power source is recommended.

7.2 Although the input power has an internal protective fuse (3 amp), an 7.3 The EPC-50 can be powered in one of the following ways:
NOTE: Voltage and current supplied must be sufficient to operate all transducers used in the installation. If a heated Oxygen Sensor is required, the heater current must be added to the requirements shown.

24 volt battery with trickle charger (1 amp min. output). DC power supply capable of furnishing 12-30 VDC, 2 amps. Altronic 24 VDC Alternator Power Package see form ALT.
7.4 Power wiring and signal (transducers) wiring must be in separate
conduits and conduit entries into the panel containing the EPC-50 to avoid undesired electrical interaction.

7.5 Input power supply wires (16 AWG minimum) should connect to the 24
volt supply terminals of the main terminal block.

7.6 Oxygen sensor is connected via shielded cable P/N 693006. This

should be run in conduit only with the EPC-50 thermocouple connections. These cables should enter the panel containing the EPC-50 and connect to the main terminal block. The red wire should be connected to the O2 sensor (RED) terminal, and the black wire to the O2 sensor (BLACK) terminal. The shield wire should be cut short and not connected. The cable provided is terminated with weather tight connectors which mate to the O2 sensors provided by Altronic. The shield wire (green wire at connector end) must be connected to the exhaust piping near to the sensor. This shield will assist in rejecting noise from other wiring which could affect the O2 sensor signal. REFER TO FIGS. 4 AND 5

NOTE: Engines using positive ground DC accessories or starter motors will require a separate dedicated ungrounded power supply for the EPC-50.

6 FORM EPC-50 OM 5-09

OPERATING MANUAL
7.7 The thermocouple (24 AWG min. type K extension) wires should be run in a
conduit only with the EPC-50 O2 sensor wires. The yellow wire should be connected to the T/C (YELLOW) terminal and the red wire to the T/C (RED) terminal. Again, care should be taken to identify the two thermocouple wires (TC1 AND TC2). REFER TO FIGURE 5

7.8 The CATALYST TEMP PROTECTION SHUTDOWN OUTPUT is configured as a

normally closed output signal. Any of three protection shutdown diagnostic temperature thresholds can cause this output to open. Connect this output to the safety shutdown system in combination with a relay to result in an engine shutdown for the purpose of catalyst protection. This output is non-latching and is self-resetting upon the clearing of related protection conditions. (SOLID STATE SWITCH RATED 30 VOLTS/0.5 AMPS MAx.) The protection shutdown switch is labeled SW2 and a red LED indicator located below the terminal will turn on when the switch opens to indicate the shutdown condition. Any diagnostic relating to measured temperatures, O2 sensor voltages, or rich or lean limit stepper positions will cause this output to open for identification of possible improper airfuel control system operation. This output is non-latching and is self-resetting upon the clearing of all the alarm conditions. (SOLID STATE SWITCH RATED 30 VOLTS/0.5 AMPS MAx.) The Alarm shutdown output is labeled SW1 and a yellow LED indicator located below the screw terminal will turn on when the switch opens to indicate an alarm or diagnostic condition. installed, a serial port has been included which can be used for MODBUS RTU slave communications using an RS-485 connection. The port configuration is accomplished using the display and keypad as described in SECTIONS 12.12 & 12.13. SEE SECTION 20.0 FOR MODBUS REGISTER DETAILS. SEE FIGURE 6 FOR CONNECTION DETAILS.

7.9 The ALARM OUTPUT is configured as a normally closed output signal.

7.10 Although the EPC-50 does not require a computer to be operated or

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EPC-50 AIR-FUEL CONTROLLER

8.0 THEORY OF OPERATION 8.1 The primary task of the EPC-50 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. Catalysts perform best for all emissions when operated near the stoichiometric AFR.

8.3 The stoichiometric AFR is the AFR at which exactly the required

amount of air (O2) is present to completely burn all of the fuel. Because no engine can perform perfect combustion, typical emission by-products include O2, HC, NO and CO even though the engine is running at stoichiometry. The stoichiometric AFR is determined by the chemical composition of the fuel, thus they are different for each fuel, or BTU rating. (e.g. Methane => 16.09 : 1 and Gasoline => 14.70 : 1)

8.4 Because the fuel type is not always known, it is often easier to specify the AFR target in terms of lambda. Lambda is an indicator of AFR normalized to the appropriate stoichiometric AFR. (Lambda Actual AFR/Stoichiometric AFR) Thus lambda for stoichiometric combustion would be 1.0, no matter what fuel is used. Lambda > 1 = Lean, Lambda < 1 = Rich.

8.5 An O2 sensor (lambda sensor) is used to provide exhaust AFR feedback to the EPC-50. This type of sensor uses a zirconia element which, when combined with a catalyzing outer surface, creates an output voltage used to indicate lambda. Characteristics of the sensor include: an output range of about 0.1 to 0.9 volts when above 650F, a very high output impedance when cool, a very high sensitivity at stoichiometry and a very low sensitivity away from stoichiometry. The output signal provides a very suitable means of controlling just rich of lambda 1.0 which is the AFR range required to obtain best catalyst efficiencies for methane-based fuels. FIG. 8 describes a typical sensor output voltage curve versus lambda.

8.6 A type K thermocouple is used to assure that exhaust tempera-

tures are high enough for correct operation of the sensor before closed loop control is enabled. An additional thermocouple is used to monitor outlet temperature. The EPC-50 was designed for use on small engines where the catalyst is assumed to be close to the engine. The engine out temperature is assumed to be representative of the catalyst in temperature. The three shutdown thresholds are Engine/CatIn temperature too high, CatOut temperature too high, and Catalyst temperature rise too high. Temperature limit setpoints are provided to create a catalyst protection shutdown capability.

8 FORM EPC-50 OM 5-09

OPERATING MANUAL
8.7 An electronic valve is used to create a variable restriction between
the fuel pressure regulator and the carburetor inlet. This restriction is used to adjust the effective inlet pressure seen by the carburetor and results in a mechanical adjustment of the air/fuel mixture delivered by the carburetor. A stepper motor adjusts the restriction by moving a plunger inside the valve. A stepper motor is a brushless motor consisting of a permanent magnet armature and a four-coil multi-pole stator. The armature is moved by sequentially pulsing the four stator coils. Coupled to a worm screw, the rotating armature of the motor provides very accurate linear positioning capability. The motor used provides 1700 steps of travel at .0005 inch/step for a total valve stroke of 0.85 inch. voltage from the O2 sensor. When the sensor voltage is above the O2 target voltage, the system is richer than desired, and the stepper position is increased to further restrict fuel flow to the carburetor. Conversely, when the sensor voltage is below the O2 target voltage, the system is leaner than desired, and the stepper position is decreased to reduce the restriction of fuel flow. would not be practical to adjust the system faster when the error from the set-point is greater. So in order to maximize the control response, the motors are instead adjusted faster as the error persists longer. This method provides rapid response characteristics as well as control stability. Control target voltages must be determined with the use of an exhaust analyzer to locate the operating point of lowest stack emissions. These target values are adjustable in the EPC-50 through the keypad. The resulting system provides accurate and stable control of air/fuel ratio which results in high catalyst efficiencies and reduced stack emissions.

8.8 The EPC-50 adjusts the stepper motor to maintain a specific input

8.9 Because the sensor voltage output is not linear with lambda, it

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EPC-50 AIR-FUEL CONTROLLER

9.0 PRE-START INSTALLATION CHECKLIST 9.1 BEFORE APPLYING POWER TO THE EPC-50:
A. Measure the power supply voltage to assure voltage is within limits (12-30 volts). Leave unit un-powered. B. With the terminal block disengaged, measure resistance with an ohm meter between the black O2 sensor wire and the earth ground of the panel. This should be less than 1 ohm. Also measure the resistance between earth ground and the common of the 24v power supply terminal to verify that it is less than 1 ohm. C. With the main terminal block disengaged, measure voltage between yellow and red thermocouple wires. The voltage should be 0.80-1.50 mV for temperatures 60-100F. This verifies that thermocouple wires are terminated. If engine had been running, measurements will be higher, reflecting higher actual temperatures. D. With the terminal block still disengaged, measure resistance between the red wire and the still-connected earth ground terminal. Resistance should be very high or open circuit. Repeat measurement between yellow wire and earth ground. This verifies that thermocouples are ungrounded and that wires are not shorted in conduit.

9.2 WITH THE EPC-50 POWERED UP AND THE ENGINE NOT RUNNING:
A. B. Display should follow the power-up sequence DESCRIBED IN SECTION 11.2. Display of O2 sensor voltage should go to 0.5 volts. This may require a few minutes. SECTION 14.0 explains how to view data screens. Data display screen for exhaust temperatures should indicate ambient temperatures. Control valve operation should be verified during a start position command. This can easily be done if the valves are not yet fully installed in the fuel line. Press ALARM ACK if the alarm LED is on. Then press F1 followed by START POS. During the start position activity, the left valve plunger should be fully retracted then positioned near the middle of its travel. No movement, erratic movement, or movement in the wrong direction will result from incorrect wiring of the stepper cables.

C. D.

NOTE: If engine was running recently, temperature will be higher.

NOTE: Ground loops could be more significant when the engine is running. The addition of other electrical devices may affect EPC operation with regard to signal offsets.

10 FORM EPC-50 OM 5-09

OPERATING MANUAL
F. RETURN THE SET-UP VALUES TO THE FACTORY DEFAULTS: This can be done by slowly pressing the following keys in order F1, F3, F2, F4. Then, once the screen indicates that you are in the set-up mode, press F2 followed by F2 again to restore default setup values. Then press F4 to exit the setup mode. The default values are set as follows: Gain Value = 0.50 Left O2 Target = 0.80 volts Left Default Position = 1000 steps G. CONFIGURE CATALYST PROTECTION THRESHOLDS: Reasonable value ranges for protection thresholds are shown below. These max temperature limit values should be configured based on catalyst manufacturers recommendations. This can be done by slowly pressing the following keys in order F1, F3, F2, F4, then F1 to view each successive set-up parameter: Exh Temp Hi = (1000 to 1250F) Cat Out Hi = (1100 to 1250F) Cat Rise Hi = (100 to 300F)

NOTE: Settings should be established based on catalyst manufacturers recommendation.

9.3 When all of these checks have been made successfully, move on to
the Start-Up Procedure.

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EPC-50 AIR-FUEL CONTROLLER

10.0 START-UP PROCEDURE 10.1 BEFORE STARTING ENGINE:
A. Check for fuel leaks where the fuel line was modified. B. Verify that catalyst over-temp thermocouples and thresholds are in place and functional according to catalyst provider requirements and recommendations. C. Press F1, then press START POS on the EPC-50 keypad to reset stepper position and enable the warm-up delay. D. Be sure that the power screw adjustments on carburetors are full open or full rich. If these adjustments are not fully open, then the control range of the stepper control valve will be limited. E. If the alarm outputs of the EPC-50 are being used, temporarily disconnect or override these signals so that an alarm indication will not shut down the engine during setup. F. Verify that the catalyst protection output is wired and functional to cause a shutdown in an overtemp condition. G. Place EPC-50 controller in MANUAL mode by pressing LEFT MANUAL key. H. Start and warm-up engine.

10.2 WITH THE ENGINE RUNNING:

A. Load engine to desired operating point. B. Verify that the exhaust temperature data screen is displaying reasonable values, and that the temperatures exceed 650F. REFER TO SECTION 14.0 FOR DISPLAY KEY OPERATION C. Enable automatic control by pressing the AUTO OPER key. The unit should begin adjusting the stepper valves trying to control the engines air/fuel ratio. Use any diagnostic warnings which may occur to trouble-shoot the system. Rich or lean limit errors are a good indication that the pressure regulators need some adjustment. D. Once the unit has gained control of the engine (O2 sensor voltage very near the target voltage), adjust the fuel pressure regulators until the EPC-50 is controlling with the stepper valve positions near 1000 steps. This is approximately the middle of the valves control range.

12 FORM EPC-50 OM 5-09

OPERATING MANUAL
10.3 FINE TUNE THE CONTROL SETPOINTS:
A. Using an exhaust analyzer, determine the set-point voltage which results in the best emission performance. This can be done by incrementally adjusting the O2 target voltage in the Set-Up Mode. Reference SECTION 12.0 for an explanation of the setup mode. Alternatively, manual mode can be used to adjust the control valves to the positions which give the best emissions performance. REFERENCE SECTION 15.0 for an explanation of manual mode operation. Then the O2 target voltages should be adjusted to match the actual sensor voltages using the Set-Up Mode. The control gain rate and default stepper positions can also be adjusted now; however, the default values represent the best typical values for these parameters.

B.

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-50 SET-UP IS COMPLETE; THE UNIT SHOULD BE CONTROLLING THE ENGINE.

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EPC-50 AIR-FUEL CONTROLLER

11.0 GENERAL: KEYPAD AND DISPLAY OPERATION 11.1 The EPC-50 includes a front-mounted keypad and an LCD display
which permits the monitoring and adjustment of various parameters and actions.

11.2 The keypad and display function together as the user interface.

Only one key on the pad should be pressed at one time. Some commands require a key sequence (a series of key presses, one followed by the next). Whenever possible, special messages indicate what is happening or why a command is not accepted. plied to the EPC-50, the display will show an Altronic product description message, then perform an F1-Start function.

11.3 With the engine not running (cool exhaust), when power is first ap-

Altronic Inc. EPC-50-1

11.4 After a few seconds the display will indicate that the controller is

in warm-up mode. This display indicates that the thermocouples are still reading temperatures too cool for the O2 sensors to function correctly. The number at the end of the message indicates the current stepper valve position in steps. If the engine is not started this condition will persist for 10 minutes. ing the diagnostic messages for low exhaust temperature. All diagnostic messages include the ! character for recognition. Diagnostics exist for several functions and are ExPLAINED IN DETAIL IN SECTION 16. When any diagnostic condition is present, the status containing ! will appear, then all of the appropriate descriptions will follow in rotation. O2 sensor voltage and stepper valve position are also shown. condition (PSD) is detected, user keypad functions will be restricted until the user acknowledges the new condition. The message ALARMS MUST BE ACKNOWLEDGED! will be triggered by keypad presses until the ALARM ACK key is pressed to acknowledge the new condition. Pressing ALARM ACK does not effect any other indicators or outputs of the EPC-50. The display will indicate that the unit is responding to the ALARM ACK key press by showing the message WORKING. The low temperature alarm has now been acknowledged and the EPC-50 will accept other keypad commands. Any time the alarm LED is on steady, no keypad commands will be accepted until the ALARM ACK key is pressed. The display will indicate that the unit is responding to this command with message WORKING.

AutoWarmUp1000

11.5 After 10 minutes with a cool exhaust, the display will now begin rotat-

!Auto!.802v1000
AND

11.6 Press ALARM ACK When a new alarm (ALM) or protection shutdown

!Auto!.802v1000 ALM! ExhTempLO!

14 FORM EPC-50 OM 5-09

OPERATING MANUAL
12.0 SETUP MODE: KEYPAD AND DISPLAY OPERATION 12.1 Once any alarm is acknowledged, 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.

$$$ SETUP $$$ F1=Next F4=EXIT 12.2 Press F2 then press F2 again to restore factory default parameters.

NOTE: The factory default PSD settings are very conservative and will most likely result in the shutdown of a loaded engine.

This special command can be used only from this screen when the user wants to restore factory default values. A message will indicate that the default values have been restored, then will return to the main setup message. DEFAULT CONTROL VALUES ARE IN SECTION 9.2. There is a second restore defaults command sequence: F3, then F2, that will reload all factory defaults with regard to diagnostic and PSD thresholds. These are kept separate to avoid changing protection settings for the catalyst.

F2

F2

RESTORING DEFAULT SETUP

THEN

$$$ SETUP $$$ F1=Next F4=EXIT

12.3 Press F1 to increment to the control gain setup screen. The factory
default value for this parameter is 0.50 as shown on the display. This parameter determines the stepper valve adjustment rate when in automatic mode. The higher the value the faster the controller will move the stepper in response to the O2 sensor.

F1

$ F2=Up F3=Dn $ GAIN VALUE=0.50

12.4 Press F2 to increase the value for the gain parameter. The display will
indicate that the value has been changed. At this point the value is updated and will be used until the value is changed again.

F2

$ F2=Up F3=Dn $ GAIN VALUE=0.60

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EPC-50 AIR-FUEL CONTROLLER

12.5 Press F3 to decrease the value. Now the value is decreased to the

default value again. The range for the gain value is limited to (0.1 to 2.0). The value cannot be moved beyond its limits.

NOTE: All screens in setup mode include the $ character.

F3

$ F2=Up F3=Dn $ GAIN VALUE=0.50

12.6 Press F1 to increment to the left O2 target setup screen. The factory

default value for this parameter is 0.80 volts as shown on the display. Like the gain value, the target can be increased and decreased with the F2 and F3 keys. The typical range is near 0.8 volts. The allowable range is 0.01 to 1.05; however most sensors output range is limited to 0.1 to 0.9 volts.

F1

$ F2=Up F3=Dn $ O2SetPnt=0.800v

12.7 Press F1 to rotate to the left default stepper position screen. The
default position is used when any of the O2 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.

F1

$F2=chng L.dflt$ 1000 ---> 1000

12.8 Press F2 to update the default position (on right) with the value of
the current position (on left). Since both values are the same no change was actually made in this example. By using the manual mode which is DESCRIBED IN SECTION 15.0, the actual position can be adjusted to the desired position before entering the setup mode.

F2

UPDATING DEFAULT POSITION

THEN

NOTE: Multiple presses of the key are required to continue incrementing the value. If the key is held, the value will be adjusted at a progressively faster rate.

$F2=chng L.dflt$ 1000 ---> 1000

16 FORM EPC-50 OM 5-09

OPERATING MANUAL
12.9 Press F1 to rotate to the first temperature protection setup value.
The ExHAUST TEMPERATURE HI setpoint represents the maximum permitted engine exhaust temperature as sensed by the left engine out thermocouple mounted near the O2 sensors. High temperatures at this location may indicate engine overload or engine misfire. The CATALYST TEMPERATURE PROTECTION SHUTDOWN output switch will open if this threshold is exceeded to cause a protection shutdown.

F1

$ F2=Up F3=Dn $ ExhTempHI=1000F

12.10 Press F1 to display the CATALYST-OUT HI temperature setpoint threshold.

If the outlet temperature of the Catalyst should exceed this setting, then the CATALYST TEMPERATURE PROTECTION SHUTDOWN output switch as well as the ALARM output switch will open to cause a protection shutdown. Conditions of misfire or overload or improper engine operation may be identified by this test. Extreme temperature at the outlet of the catalyst indicates that the catalyst is being damaged by the operation conditions of the engine. Provision may be provided in the catalyst to mount a temperature probe at the catalyst element. This location may serve as an alternative to catalyst outlet temperature. Consult the catalyst manufacturer for the recommended outlet-temperature shutdown limits.

F1

$ F2=Up F3=Dn $ CatOutHI =1100F

12.11 Press F1 to display the CATALYST TEMPERATURE RISE HI setpoint thresh-

old. The temperature difference outletinlet is compared to this setpoint to identify excessive temperature rise across the catalyst. The catalyst inlet temperature is assumed to be the same as the engine out exhaust temperature thermocouple. This condition of temperature rise is an indication that the catalyst is reacting unburned air and fuel that may result from a misfire or poor combustion condition. If the temperature rise across the Catalyst should exceed this setting, then the CATALYST TEMPERATURE PROTECTION SHUTDOWN output switch will open to cause a protection shutdown. Consult the catalyst manufacturer for the recommended temperature rise shutdown limits.

F1

$ F2=Up F3=Dn $ CatRiseHI= 100F

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EPC-50 AIR-FUEL CONTROLLER

12.12 Press F1 to display the MODBUS NODE ID setup screen. Valid node IDs
are 0 to 255 permitting the communication system to incorporate multidrop communications to various ModBus slave devices.

F1

$ F2=Up ModBus

F3=Dn $ ID=50

12.13 Press F1 to display the MODBUS PORT setup screen. Various baud rates

are supported by the EPC-50. The selections include baud rates of 600, 1200, 2400, 4800, 9600, 19200, 38400, 57600.

F1

$ F2=Up F3=Dn $ BaudRate 9600n81

12.14 Press F1 to rotate back to the main screen.

F1

$$$ SETUP $$$ F1=Next F4=EXIT

12.15 Press F4 to exit the setup mode. F4 can be used from any setup

screen. Remember all setup screens have the $ character on them somewhere. This returns the display to the warning message which was caused by low exhaust temperatures.

F4

!Auto! .802v1000

AND

!Auto! .802v1000 ALM! ExhTempLO!

Note: Loading default settings as shown in section 12.2 does not affect settings relating to the Catalyst Temp Alarm Output or ModBus configuration.

18 FORM EPC-50 OM 5-09

OPERATING MANUAL
13.0 ENGINE STARTUP: KEYPAD AND DISPLAY OPERATION 13.1 Press ALARM ACK to acknowledge alarms if alarm LED is ON. 13.2 Press F1 then press START POS to send the steppers to start position
(stepper default position) and disable the alarm warnings due to a cold engine for 10 minutes. The controller will return each stepper to its start position and then display the warm-up screen. This procedure should ALWAYS be used when starting the engine.

F1

Moving Stepper to Zero Pos.

Moving Stepper to START Pos.

AutoWarmUp1000

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 O2 sensor voltage, and the current stepper valve position are provided on the automatic display screen.

AUTO .812v1010

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EPC-50 AIR-FUEL CONTROLLER

14.0 DATA VIEWING: KEYPAD AND DISPLAY OPERATION 14.1 Press DSPL SEL to display the first data view screen. The first data
screen displays the current O2 sensor voltages.

DSPL SEL

AUTO .625v 985 02Sensor=.625v

14.2 Press DSPL SEL again to display current O2 target voltages. DSPL SEL AUTO .625v 985 02Target=.800v

14.3 Press DSPL SEL again to display the engine out exhaust temperature
reading from thermocouple TC1 which is located near the O2 sensor. SINGLE BANK TC1

DSPL SEL

AUTO .625v 985 EXH TMP=1049F

14.4 Press DSPL SEL again to display the Catalyst inlet temperature

is assumed to be the same as engine out exhaust temperature as measured by TC1.

DSPL SEL

Cat Rise=+ 24F In=1098 Out=1125

14.5 Press DSPL SEL again to loop back to the automatic screen. DSPL SEL

AUTO .811v1010

20 FORM EPC-50 OM 5-09

OPERATING MANUAL
15.0 MANUAL MODE: KEYPAD AND DISPLAY OPERATION 15.1 Press MAN to enter the manual mode. The display will indicate
WORKING and then return to manual mode. This mode can be used to help setup the controller, and to diagnose problems. Because no diagnostic alarms are present, it was not necessary to acknowledge alarms. Also, once in manual mode, diagnostic alarms are disabled. In manual mode, the alarm output SW1 will be open and the yellow LED will be on to indicate system is not in automatic control.

NOTE: Both the ALARM LED and the ALARM output return to the normal condition when the system fault is corrected.

LEFT MAN

MAN! .811v1010

15.2 Press LEFT LEAN to increase the stepper position by 25 steps. A descriptive message will be displayed and then the modified position will be returned. Increasing the position causes the valve to close and the mixture to change in the lean direction.

LEFT LEAN

MOVING STEPPER
THEN

MAN! .811v1035

15.3 Press LEFT FAST, then press LEFT LEAN to increase the stepper position by
100 steps.

LEFT LEAN

LEFT FAST

MOVING STEPPER
THEN

MAN! .811v1135

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EPC-50 AIR-FUEL CONTROLLER

15.4 Press LEFT RICH to decrease the stepper position by 25 steps. Decreasing the position causes the valve to open and the mixture to change in the rich direction.

LEFT RICH

MOVING STEPPER
THEN

MAN! .811v1110

NOTE: When F1 then START are pressed before starting the engine, the exhaust temperature diagnostic will be delayed 10 minutes displaying the warm-up screen.

15.5 Press AUTO OPER to return to automatic mode. Any time this key is
pressed, automatic mode will be enabled for both banks.

AUTO OPER

AUTO .811v1110

15.6 POSITION UNCERTAIN

If power to the EPC-50 is interrupted, the display reads *Pos.UnCertain* and may or may not blink. This occured because the position was not saved automatically at the moment of power loss/interruption. Typically this would occur if the EPC-50 were powered up while the engine was running.

AUTO OPER

AUTO .811v1110 *Pos.UnCertain*

It is important to note that this is a temporary and resolvable condition. The EPC-50 is functioning properly and, if it is in AUTOMATIC mode, it will correct itself. If the EPC-50 is in MANUAL mode, the proper display setting can be restored by performing an F1 start.

22 FORM EPC-50 OM 5-09

OPERATING MANUAL
16.0 DIAGNOSTIC DISPLAYS AND OPERATION 16.1 ALARM OUTPUT
The ALARM output is configured as a NORMALLY CLOSED output signal. Any system fault will open the alarm circuit. including loss of power, diagnostic warnings, etc. As described above, the alarm output would be in its fault condition (open) any time that an unacknowledged alarm or shutdown is present. The system diagnostics included in the EPC-50 are designed to identify conditions which are not considered normal operation. These diagnostic tests are performed continuously while the controller is in automatic mode. Each of the diagnostics will display a descriptive message and place the alarm output in the fault condition (OPEN). Active diagnostic warning messages include the ! character and are displayed in rotation, each message being displayed for about 1 second. The home screen uses the ! character to indicate the status and that other diagnostics will follow in rotation.

16.2 SYSTEM DIAGNOSTICS

16.3 DIAGNOSTIC WARNING MESSAGES

!Auto!.765v1000

16.4 ExHAUST TEMPERATURE

The Exhaust Temperature diagnostic monitors the exhaust temperatures near the O2 sensors as measured with the thermocouples. If the temperature is below 650F or above 1400F, then the EPC-50 displays the appropriate low or high message and activates the ALARM LED and ALARM output. Automatic control is also disabled and the stepper valves are positioned at the default stepper position. Thermocouple probe or thermocouple connection failures will also activate this diagnostic.

!Auto! .800v 982 ALM! ExhTempLO!

OR

!Auto! .800v 982 ALM! ExhTempHI!

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EPC-50 AIR-FUEL CONTROLLER

16.5 SENSOR NOT READY
The Sensor Not Ready diagnostic is designed to identify problems with the O2 sensor. The controller has a very high impedance pull up resistor to 0.5 volts in parallel with each exhaust sensor input. When the sensor is too cool or disconnected this will force the input to read 0.5 volts. If the controller sees that the sensor output is 0.5 volts for 10 or more seconds the EPC-50 will display the sensor not ready 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. The sensor ready test is only performed if the exhaust temperature requirements of 16.5 are satisfied. Failure of this test indicates a cold, disconnected or failed sensor.

!Auto! .800v 1000 ALM! O2 NotRdy !

16.6 SENSOR INPUT VOLTAGE

The Sensor Input Voltage diagnostic is also designed to identify problems with the O2 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-50 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. Failure of this diagnostic test indicates shorted wiring or a failed sensor.

!Auto! .800v 1000 ALM! Exh O2v LO!

OR

!Auto! .800v 1000 ALM! Exh O2v HI!

24 FORM EPC-50 OM 5-09

OPERATING MANUAL
16.7 LEAN AND RICH LIMIT
The Lean and Rich Limit diagnostic monitors the stepper positions. If the position of a stepper valve is at the minimum (0) or maximum (1700) travel limit, the EPC-50 displays the appropriate message and activates the ALARM LED and ALARM output. The rich limit warning indicates that the engine is too lean and the controller cannot open the valve any farther to enrich the mixture. The lean limit warning indicates that the engine is too rich and the controller cannot close the valve any farther.

!Auto! .800v 0 ALM! Rich Limit!

OR

!Auto! .800v 1700 ALM! Lean Limit! 16.8 ENGINE OUT ExHAUST OVER-TEMPERATURE

When the left or right bank exhaust temperature exceeds the setup threshold, the alarm output will open, the alarm LED will turn on, the Catalyst Protection Alarm output (PSD) will open, and the messages below may be displayed.

AUTO!WARN!1000 PSD! ExhTempHI! 16.9 CATALYST OUTLET OVER-TEMPERATURE

When the outlet temperature of the catalyst exceeds the setup threshold, the alarm output will open, the alarm LED will turn on, the Catalyst Protection Alarm output (PSD) will open and the message below is displayed.

Auto!WARN!1000 PSD! CatTempHI! 16.10 CATALYST TEMPERATURE RISE

When the temperature from the inlet to the outlet of the catalyst exceeds the setup threshold, the alarm output will open, the alarm LED will turn on, the Catalyst Protection Alarm output (PSD) will open and the message below is displayed.

Auto!WARN!1000 PSD! CatTmpRise!

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EPC-50 AIR-FUEL CONTROLLER

17.0 AUTOLOG FEATURE 17.1 Press F3 to display the first out Autolog screen which provides the first
most recent detected cause for leaving normal automatic operation. The cause is logged to a modbus register and also presented as below on the screen using a text string. The example below indicates that, while the engine was running in automatic mode, the measured catalyst output temperature exceeded the PSD shutdown triggering the snapshot of the auto log values as the engine was shutdown. The auto log values are updated on every transition out of fully automatic control without alarms. The table of auto log causes is shown below.

AutoLOG Code 69 PSD! CatTempHI! ALM! ExhtempLO! ALM! ExhTempHI! ALM! Exh O2v LO! ALM! Exh O2v HI! ALM! O2 NotRdy ! ALM! Lean Limit! ALM! Rich Limit! PSD! ExhTempHI! PSD! CatTempHI! PSD! CatTmpRise! USER Left MANUAL

26 FORM EPC-50 OM 5-09

OPERATING MANUAL
17.2 The following screens are viewed in rotation, displaying the next screen on each press of F3. AutoLOG EXHtemps Eng1066Cat1360
Identifies the temperature at auto log event.

AutoLOG EXH O2V EXH O2 = .813v

Identifies O2 voltage measurement at auto log event trigger.

AutoLOG Steppers ValvePos = 835

Identifies stepper position at auto log event trigger.

AutoLOG Supply V CJT 25.7C 24.8v

Identifies internal and supply voltage at auto log event trigger.

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EPC-50 AIR-FUEL CONTROLLER

18.0 ADDITIONAL DISPLAY SCREENS 18.1 Three additional screens exist which can be helpful in obtaining information about the version and supply voltage and temperature of the EPC-50. They can be viewed as follows.

Press F1 then DISP-SEL, to view the product description screen.

Altronic Inc. EPC-50-1

Press F2 then DISP-SEL, to view the version and date information.

Version Date

1: 0 02/14/09

Press F1 then F2 then DISP-SEL to view the supply voltage and temperature.

PWR Supply 24.8V CJT Temp 26.0C

28 FORM EPC-50 OM 5-09

OPERATING MANUAL
19.0 TROUBLE-SHOOTING THE EPC-50 SYSTEM 19.1 GREEN PWR LED AND LCD DISPLAY BACKLIGHT ARE DARK;
POWER IS INTERRUPTED. A. B. Check power supply voltage at EPC terminal block (10-30 volts), while still connected. Replace EPC-50 unit.

19.2 LCD DISPLAY BACKLIGHT IS LIT, BUT BLANK OR NOT FUNCTIONING PROPERLY.
A. B. Power-down unit for 1 minute. Re-power and check status of LCD display and green PWR LED. LCD BACKLIGHT ON, WITH BLINKING PWR LED, INDICATES: Internal problem with terminal program. Replace EPC-50 unit.

19.3 KEY PAD ENTRIES CAUSE NO DISPLAY RESPONSE.

A. B. MAND. A. B. C. D. Verify connection of keypad ribbon connector at bottom of board inside unit. Replace enclosure and keypad assembly.

19.4 EPC-50 WILL NOT MOVE STEPPER VALVES DURING F1 THEN START POS. COMCheck stepper cable connections at EPC-50 and at stepper valve. Test EPC-50 with a spare stepper valve assembly. Test EPC-50 and stepper valve assembly, with a spare stepper cable. (Verify cable connections pin-to-pin.) Replace EPC-50 unit.

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EPC-50 AIR-FUEL CONTROLLER

19.5 HIGH OR LOW ExHAUST TEMP WARNINGS PERSIST.
A. B. C. D. E. Observe thermocouple readings for reasonable values using display select screens in SECTION 14. Compare observed readings toand verify feasibility ofcatalyst protection setpoints as described in SECTION 9.2 (G). If engine is not running, start and warm up engine. Test the disconnected thermocouple reading at EPC-50 with an alternate thermocouple reading device. Replace thermocouple or correct wiring if temperatures are incorrect. The life of thermocouple probes is highly dependent on the use of a thermowell and on corrosives in exhaust. If low temperature is a problem during first installation, an alternate sensor and probe location may be required. Please contact the factory before pursuing any other action to raise sensor temperatures.

F.

G. Replace EPC-50 unit.

19.6 RICH OR LEAN LIMIT WARNINGS PERSIST.

A. A misfiring engine can cause the system to shift in the rich direction. Check the engine for misfiring cylinders using a timing light or exhaust pyrometer. Use an exhaust analyzer and the EPC-50 manual mode to adjust the %O2 before the converter to around 1.0%. If the %O2 cannot be manipulated in the manual mode, then test to make sure the stepper valve is functioning as was done during installation. If manual mode moves the %O2 but cannot attain 1.0%, then the fuel system may need to be readjusted. First verify that the load screw adjustments on the carburetors are full rich or full open. If they are not full open, the control range of the stepper valves will be limited. Second, adjust the fuel pressure regulators so that when in automatic mode, the stepper valves are controlling near 1000 steps. If the fuel system appears to be adjusting correctly, use an exhaust analyzer and the EPC-50 manual mode to sweep the %O2 from around 3% down to 0.2% while watching the O2 sensor voltage on the display. The voltage should move from around 0.2 volts toward 0.8 volts as the %O2 is changed. If this is not the case, a new sensor should be tested. If EPC-50 O2 sensor voltage display does not match actual sensor voltage, test for ground loop problems. DESCRIBED IN SECTION 9.1B. Replace EPC-50 unit.

B.

C.

D.

E.

F.

19.7 SETUP VALUES ARE LOST AT POWER-DOWN; EEPROM MEMORY HAS FAILED.
A. Replace EPC-50 unit.

30 FORM EPC-50 OM 5-09

OPERATING MANUAL
20.0 EPC-50 MODBUS REGISTER LIST
The EPC-50 incorporates a half-duplex RS-485 port which is Modbus RTU slave compliant. The protocol used follows the Modicon Modbus RTU standard. The default configuration for the port is BaudRate 9600n81 with a node ID of 50. The Modbus communications could allow the EPC-50 to meet the needs of continuous emissions monitoring should it be required. The 10xxx registers are read-only binary, and support Modbus standard function 1. These registers are read in multiples of 8 (1 byte) addressed at each 8 bit boundary (10001-10008, etc.). A single Boolean read from registers 10001 to 10064 can be made which will return all 64 values as a group of 8 bytes. These registers also support an Altronic custom function 101 which will return a descriptive label for each specific register. The custom label function can be used to reduce the need for the Modbus master to maintain a current listing of all of the register labels for each unit. REGISTER 00017 00018 00019 00020 00021 00022 00023 00024 10001 10002 10003 10004 10005 10006 10007 10008 10009 10010 10011 10012 10013 10014 10015 10016 16-BIT BINARY REGISTER VALUE L-Manual Reserved Coil Reserved Coil Reserved Coil Reserved Coil Reserved Coil Reserved Coil Reserved Coil Reserved Status Reserved Status Warmup Mode Reserved Status Stepper Resetting Now Reserved Status Reserved Status Unacknowledged Alarm Preset Exh Temp Low Exh Temp High O2 Signal Low O2 Signal High Reserved Status O2 Sensor Not Ready Stepper Lean Limit Stepper Rich Limit

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EPC-50 AIR-FUEL CONTROLLER

REGISTER 10025 10026 10027 10028 10029 10030 10031 10032 10033 10034 10035 10036 10037 10038 10039 10040 10049 10050 10051 10052 10053 10054 10055 10056 10057 10058 10059 10060 10061 10062 10063 10064 16-BIT BINARY REGISTER VALUE Reserved Status Reserved Status Reserved Status Reserved Status Left Bank Step Coil Open A Left Bank Step Coil Open B Left Bank Step Coil Open C Left Bank Step Coil Open F Auto Control is Active Getting Richer Very Rich Rich ----ONTARGET---Lean Very Lean Getting Leaner Reserved Status Reserved Status Reserved Status Reserved Status Step Coil Drive A Step Coil Drive B Step Coil Drive C Step Coil Drive F Left Valve Position Uncertain Reserved Status Reserved Status Reserved Status Reserved Status Reserved Status Reserved Status Reserved Status

>512mv +/-5mv >512mv

32 FORM EPC-50 OM 5-09

OPERATING MANUAL
REGISTER 10065 10066 10067 10068 10069 10070 10071 10072 10089 10090 10091 10092 10093 10094 10095 10096 16-BIT BINARY REGISTER VALUE TC ENG LEFT HiTemp PSD Reserved Status Reserved Status Reserved Status TC CAT OUT HiTemp PSD TC CAT DELTA HiDelta PSD Reserved Status Reserved Status Reserved Status Reserved Status DIGOUT1 0=NORM 1=ALM=YELLOW DIGOUT2 0=NORM 1=SHUTDOWN=RED Reserved Status Reserved Status Reserved Status Reserved Status

The 30xxx registers are read-only, 16 bit, analog values. The Modbus standard function 4 is supported. Multiple register reads are supported up to 32 registers per request. These registers also support an Altronic custom function 104 which will return a descriptive label for each specific register. REGISTER 30001 30002 30003 30004 30005 30006 30007 30008 30009 30010 30011 30012 30013 30014 30015 30016 30017 16-BIT BINARY REGISTER VALUE Input Bit Mirror 10016-10001 Input Bit Mirror 10032-10017 Input Bit Mirror 10048-10033 Input Bit Mirror 10064-10049 Input Bit Mirror 10080-10065 Input Bit Mirror 10096-10081 Input Bit Mirror 10112-10097 Input Bit Mirror 10128-10113 SUPPLY INPUT VOLTAGE CJT DEG C ExH TEMP ENG-OUT reserved ExH TEMP CAT-IN ExH TEMP CAT-OUT ExH O2 VOLTAGE-1 reserved SMP1C Stepper Position .1v/cnt signed 0.01degc/cnt 1degf/cnt 1degf/cnt 1degf/cnt 1mv/cnt

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EPC-50 AIR-FUEL CONTROLLER

REGISTER 30031 30038 16-BIT BINARY REGISTER VALUE CATALYST TEMP RISE (CATOUT-IN) CONTROL GAIN VALUE

The 40xxx registers are read/write, 16-bit, analog values and they support the Modbus standard functions 3, 6 and 16. Multiple register reads and writes are supported up to 32 registers per request. These registers may have new values written to them in order to make setpoint adjustments from a remote location. They also support a custom function 103 which will return a label describing each specific register. REGISTER 40001 40002 40003 40004 40005 40006 40007 40008 40009 40010 40011 40012 40013 40014 40015 40016 40017 40018 40019 40020 40021 40022 40023 40024 40025 16-BIT BINARY REGISTER VALUE REG40001=CoilBits 00016-00001 REG40002=CoilBits 00032-00017 REG40003=CoilBits 00048-00033 REG40004=CoilBits 00064-00049 REG40005=CoilBits 00080-00065 REG40006=CoilBits 00096-00081 REG40007=CoilBits 00112-00097 REG40008=CoilBits 00128-00113 mV O2 SENSOR BASE TARGET reserved DEFAULT VALVE START POS reserved CONTROL GAIN RATE ExH TEMP HI ALARM SETTING ExH TEMP LO ALARM SETTING ExH O2 HI ALARM SETTING ExH O2 LO ALARM SETTING ExH O2 READY HI SETTING ExH O2 READY LO SETTING TC ENGOUT HI PSD TC CAT OUT HI PSD TC CAT DELTA HI PSD reserved reserved reserved

value/40 degF degF mV mV mV mV degF degF degF

34 FORM EPC-50 OM 5-09

OPERATING MANUAL
40082-40089 are Autolog values a snapshot of parameters upon Alarm Event REGISTER 40082 40083 40084 40085 40086 40087 40088 40089 40090 40091 40092 40120 40121 40122 40128 16-BIT BINARY REGISTER VALUE ENUMERATED CAUSE OF NOT AUTO SUPPLY INPUT VOLTAGE .1v/cnt CJT DEG C signed 0.01degc/cnt ExH TEMP ENGINE OUT 1degf/cnt reserved ExH TEMP CAT IN ExH TEMP CAT OUT ExH O2 VOLTAGE-L reserved STEPPER POSITION-L reserved 1degf/cnt 1degf/cnt 1mv/cnt

REG40126 MSB=BAUD LSB=NODEID Warm Boot (reset) Count Cold Boot (powerup) Count MODBUS KEY COMMAND REGISTER

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EPC-50 AIR-FUEL CONTROLLER

Detailed below are the command values which can be written to the Modbus Key Command Register (40128). 1. 2. 3. 5. 6. 7. 10. 11. 12. 13. 20. 21. 22. 23. Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) 00510 00765 01275 01530 01785 02040 02805 03060 03315 03570 05355 05610 05865 06120 Select auto mode for both banks Select manual mode for left bank F1-Start stepper reset Alarm acknowledge Decrement left O2 target Increment left O2 target Decrement control gain rate Increment control gain rate Reload calibration defaults Update left start position with current pos Manual move left stepper rich (- 25) Manual move left stepper lean (+ 25) Manual move left stepper rich (-100) Manual move left stepper lean (+100)

The EPC-50 units also support a Modbus function 17 which will return the unit information including the Version, Date and Name. 30. 31. 32. 33. 34. 35. 199. Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) Reg(40128) 07905 08160 09435 09690 09945 10200 51118 decrement Hi Exhaust Temp Threshold increment Hi Exhaust Temp Threshold decrement Hi Catalyst Temp Out Threshold increment Hi Catalyst Temp Out Threshold decrement Hi Catalyst Rise Temp Threshold increment Hi Catalyst Rise Temp Threshold autolog reset

36 FORM EPC-50 OM 5-09

OPERATING MANUAL
FIGURES SECTION: FIG. 1 EPC-50, GENERAL INSTALLATION LAYOUT: SINGLE BANK FIG. 2 EPC-50, MOUNTING DETAIL FIG. 3 NEMA 3R ENCLOSURE MOUNTING DIMENSIONS FIG. 4 OxYGEN SENSOR DETAIL FIG. 5 EPC-50, WIRE ROUTING DETAIL FIG. 6 EPC-50, MODBUS COMMUNICATION CONNECTIONS FIG. 7 EPC-50, TERMINAL LAYOUT FIG. 8 TYPICAL O2 SENSOR RESPONSE (ESTIMATED DATA)

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EPC-50 AIR-FUEL CONTROLLER

FIG. 1 EPC-50, GENERAL INSTALLATION LAYOUT: SINGLE BANK

38 FORM EPC-50 OM 5-09

OPERATING MANUAL
FIG. 2 EPC-50, MOUNTING DETAIL
6.50

6.50

6.00

1.25 2.19

6.00

5.50

5.50

.203 DIA. (TYP 4)

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EPC-50 AIR-FUEL CONTROLLER

FIG. 3 NEMA 3R ENCLOSURE MOUNTING DIMENSIONS

40 FORM EPC-50 OM 5-09

OPERATING MANUAL
FIG. 4 OXYGEN SENSOR DETAIL
CONNECTOR PIN A B WIRE COLOR TAN BLACK PIN AND WIRE CONNECTION SENSOR (GROUND) OUTPUT

MATING CONNECTOR: PACKARD ELECTRIC DIV. PART NO. 12010501

12.50

1.25 MIN. FLAT REQUIRED FOR SEATING DRILL A 41/64 (16.5) HOLE 90 CSINK TO .732 DIA (18.6) TAP M18 X 1.5 7G THREAD .35 1.10

2.22

RECOMMENDED INSTALLATION DIMENSIONS INSTALLATION INSTRUCTIONS:

1. INSTALL IN THE APPROPRIATE MOUNTING HOLE TO A TORQUE OF 28-34 LB. FT. 2. USE A 7/8 WRENCH SIZE.

1.17

3. SENSORS ARE TO BE SUPPLIED WITH THREADS COATED WITH MS-0572 ANTISEIZE COMPOUND. CAUTION: DO NOT APPLY ANTISEIZE COMPOUND TO AREAS OTHER THAN THE MOUNTING THREADS. 4. FOR OPTIMUM RESISTANCE TO WATER INTRUSION, AC RECOMMENDS MOUNTING SENSORS SUCH THAT THE EXPOSED END (WIRE END) OF THE SENSOR IS ORIENTED AT OR ABOVE HORIZONTAL. 5. THIS SENSOR IS DESIGNED FOR WATER SPLASH RESISTANCE.
.875

.602 .008

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EPC-50 AIR-FUEL CONTROLLER

FIG. 5 EPC-50, WIRE ROUTING DETAIL

42 FORM EPC-50 OM 5-09

OPERATING MANUAL
FIG. 6 EPC-50, MODBUS COMMUNICATION CONNECTIONS

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EPC-50 AIR-FUEL CONTROLLER

FIG. 7 EPC-50, TERMINAL LAYOUT

44 FORM EPC-50 OM 5-09

OPERATING MANUAL
FIG. 8 TYPICAL O2 SENSOR RESPONSE (ESTIMATED DATA)

1.00 0.90

O2 SENSOR VOLTAGE (VOLTS)

0.80 0.70 0.60 0.50 0.40 0.30 0.20 0.10 0.00 0.96 0.97 0.98 0.99 1.00 1.01 1.02 1.03 1.04

LAMBDA

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