HD2021 HGS Amy RT 0008

HGS DISCOVER
Trouble Shooting for Automatic Control System

Of HiMSEN Diesel Engine
• KOMECO
• YECS
HGS DISCOVER
No. HD2021-HGS-HSM-TS-0008
Date May 14, 2021
Centum Science Park, 79, Centum Jungang-Ro3, Haeundae-Gu, Busan 48058, Republic of Korea
Tel + 82 52 204 7820 | Fax + 82 52 204 7700 | [email protected] | www.hyundai-gs.com/eng
HGS DISCOVER
T/S for HiMSEN Automatic Control System
Introduction • The purpose of this document is to

provide the troubleshooting guidance
and sharing service experiences for
the troubles which are occurring
occasionally on HiMSEN Diesel
Engine’s Control System.
Service Exp. 1) Reverse Comm. Error

2) Communication Fail
3) TACHO fail during stand-by
4) Start fail
5) Stop fail
6) Can Error (1), (2)
7) Jet System fail
8) Monitoring Sensor Fail
9) L.O pressure trip during stand-by
10) Non- Activation of Alarm blocking
Appendix. • Module Replacement procedure

(KOMECO)
• Module Replacement procedure

(YECS)
HGS DISCOVER
1. REVERSE COMM. ERROR
Description Reverse communication error
Problem indication Communication failure
Troubleshooting/
Causes of problem
Corrective Action
1. Improper cable connection Normally, the communication between ECS and

AMS consists of RS485/422 communication and it is
connected as parallel each other.
• To Check if there is contact or connection failure
• To connect the cable after disconnection by

referring to the order
• To check the address no. for MCU or ACU if it is

matched properly
※ In case the situation is persisting, please contact

with nearest HGS service station.
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2. COMMUNICATION FAIL
Description Communication fail
Problem indication Communication fail
Troubleshooting/
Causes of problem
Corrective Action
1. Malfunction of communication module
* KOMECO (SMU/MCU) • To do the swapping test of comm. module with the
other engine’s one.
(exchanging the address is necessary)
＃ The relevant procedure will be provided by nearest HGS

service station.
* YECS-1000 (ACU)
2. Improper matching of address no. • To check the address no. for each module if it is
The communication module of terminal box such as matched with engine. No.
SMU/MCU or ACU has a specific address no. for (ex. : add. No. 1 = eng. No. 1)
communication with AMS
• To check the CNC cables if there is connection
3. Improper connection of CNC cable
failure.
The cables for CAN communication should be
checked.

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3. TACHO FAIL DURING STAND-BY

Description Tacho fail during stand-by
Problem indication Tacho failure
Troubleshooting/
Causes of problem
Corrective Action
1. Excessive lub. oil press. at engine inlet
Engine control system recognizes the running • To check the L.O pressure at engine inlet and,
signal when RPM exceeds rated or lub. oil pressure adjust it to lower value by controlling the relief
is higher than specific value regardless of engine valve mounted on L.O priming pump in case the
status. L.O pressure is higher than 3.0bar.
 The engine could be ready to start on condition of 0.08bar of lub. oil
press. at engine inlet
2. Malfunction of L.O press. Switch PSL62

• To check the cable connection of PSL62
• To do swapping test of PSL62 with the other

engine’s one.
3. Malfunction of rpm pick-up sensor
• To dismantle the pick up sensor and clean it away

from any dust or particle.
• To adjust the clearance between sensor and

flywheel gear teeth.

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4. TRIP CIRCUIT FAIL

Description Trip circuit failure
Problem indication Trip circuit failure
Troubleshooting/
Causes of problem
Corrective Action
1. Cable dislocation or break off

The Trip circuit failure is happened in case one of
following LEDs is off.
• To check which LED is off firstly on SCCS module
• To check the relevant cables according to the LED

status
<Cable Supervision>
Cable #1 : Detection for L.O low press. S/W
Cable #2 : Detection for HT water high temp S/W
Cable #3 : Detection for Oil mist high density S/W
Cable #4 : Detection for Spare
Cable #5 : Detection for Em’cy stop S/W (Eng. RM)
Cable #6 : Detection for Em’cy stop S/W (MSBD)
Cable #7 : Detection for Em’cy stop sol. valve

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5. START FAIL
Description Start failure
Problem indication Engine start failure
Troubleshooting/
Causes of problem
Corrective Action
1. Air-running failure
Starting Non • If air running failed , please check
return valve starting air supply system whether main
starting air valve or pilot air valve is stuck.
※ Note : Poor cleanliness of air causes rust and stuck
of valves.
2. Malfunction of starting motor or sol. v/v
• There is abnormal function on Air starting motor or
sol. v/v, the start failure may be happened.
1) Check the starting motor if it is working properly.

2) Check the staring sol. if it is working properly.
3. Improper set for fuel common linkage

• Improper setting can causes to start failure due to
not enough fuel oil index
• Please refer to the service letter “HGS-HSM-SL-

18-001”
4. Abnormal function of Governor

• Check the fuel rack position during starting and
measure the values for each position
1) To check fuel rack position of cylinder near
governor at < 180rpm
2) To check fuel rack position of cylinder near
governor at > 180rpm
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HGS DISCOVER
6. STOP FAIL
Description Stop fail
Problem indication Engine Stop failure
Troubleshooting/
Causes of problem
Corrective Action
1. Malfunction of rpm pick-up sensor

• To dismantle the pick up sensor and clean it away

2. Improper connection of cables between • To check the flat cable between P1 board and
Governor and terminal box, MSBD Main Control Unit
• To check the cable connection between governor

and X1 terminal 1, 7
• To check the connection TB9 of P1 board

Tel + 82 52 204 7820 | Fax + 82 52 204 7700 | [email protected] | www.hyundai-gs.com/eng 8
HGS DISCOVER
7. CAN ERROR (1)

Description CAN COMMUNICATION ERROR
Problem indication CAN error of Local monitoring box
Troubleshooting/
Causes of problem
Corrective Action
<LOCAL MONITORING BOX / KOMECO> Local monitoring box consists with 3kinds of
module, and each module indicates the engine
OPERATION UNIT status such as rpm, temp. press. etc.
1. CAN ERROR ON OPU :
• To do the swap test of MCU with the others

• To check the cable connection of flat cable
MONITORING TEMP. 2. CAN ERROR ON MTP :
/ PRESS. UNIT • To do the swap test of ADU with the others

3. CAN ERROR ON ETM :
• To check the control course

• To check the CAN-Communication cable
EXH. GAS TEMP.

MONITOR UNIT

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HGS DISCOVER
8. CAN ERROR (2)

Description CAN COMMUNICATION ERROR
Problem indication CAN error of Local monitoring box
Troubleshooting/
Causes of problem
Corrective Action
<LOCAL MONITORING BOX / YECS-1000> Local monitoring box consists with 3kinds of
module, and each module indicates the engine
YECS-1000D status such as rpm, temp. press. etc.
1. CAN ERROR ON YECS-1000D :
• To do the swap test of MCU with the others

2. CAN ERROR ON YECS-1000T :

YECS-1000T • To do the swap test of ADU with the others
3. CAN ERROR ON YECS-1000E :
• To check the control course

• To check the CAN-Communication cable
YECS-1000E

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HGS DISCOVER
9. JET SYSTEM FAIL

Description Jet Assist system fail
Problem indication Jet Assist system fail
Troubleshooting/
Causes of problem
Corrective Action
1. Malfunction of Jet pick up sensor (ZT88) • To do swap test of the sensor with the other
engine’s one
• To replace the sensor with new one
2. Abnormal contact of Jet pick up sensor • To check and clean the area between plate and
pick up sensor.
• To adjust the plate to be 1mm at least.
Bend this plate !
1mm at least

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HGS DISCOVER
10. MONITORING SENSOR FAIL

Description Monitoring sensor failure
Problem indication Monitoring sensor failure
Troubleshooting/
Cause of problem
Corrective Action
<Possible causes>
1. Improper connection or break of the monitoring Case 1. lighting LED on Dev. Alarm or Thermocouple
sensors such as Thermocouple, PT100 temp. sensor fail
sensor, Press. Transmitter
2. Sensor failure • To check the cables related with thermocouple
3. Disconnection of the sensor temp. connected with the TB3,4 of P1 board if
there is abnormality
<Check points>
 Analog/Communication Unit (YECS-1000) • To replace the sensor which have problem.
 To check if there is LED on on analog
communication unit.
Case 2. lighting LED on PT100 or PT100 sensor fail
• To check the cables related with PT100 temp.

sensors connected with the TB1 of P1 board if
• To replace the sensor which have problem.
Case 3. lighting LED on Currunt Open or Pressure

sensor fail
 Analog/Digital Unit (KOMECO)
 To check if there is LED on on analog • To check the cables related with pressure
communication unit. transmitter connected with the TB2 of P1 board if
• To replace the sensor which have problem

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HGS DISCOVER
11. L.O LOW PRESS. TRIP DURING STAND-BY

Description Low L.O pressure trip
Problem indication Low L.O pressure trip during stand-by
Troubleshooting/
Cause of problem
Corrective Action
<Possible causes>
High pressure of PI62 (L.O pressure engine inlet) • To prevent the above phenomenon during engine
during stand-by stop condition, we recommend to adjust the relief
valve to reduce the lube oil pressure as described
The phenomenon can happens when engine starts below
during winter season or pre lube oil pump starts
under cold condition. Under these condition,
viscosity of lube oil is too low because of low
temperature of oil, therefore, lube oil pressure gets
higher than normal and the pressure will go down
when engine is getting warm by engine running.
Engine control system detects engine running by

rpm, and in addition, system recognize the engine
running condition when lube oil pressure is higher
than 3.0 bar as redundancy for the case of rpm pick Fig.1 Pressure relief valve
up sensor fail.
1. Remove cap nut item 4
When L.O. pressure drops down belw 3.0 bar from 2. Loosen hexagon nut item 6
above 3.0 bar, pressure switch sends trip signal. 3. Make pressure setting by adjusting the spindle
(slot).
4. Replace CU sealing ring (2each) Item 9 (DIN
7603-A21x26-Cu)
5. Tighten hexagon nut Item 6 according to Fig.1,
hold spindle at slot with screw driver
6. Mount cap nut Item 4 according to Fig.1

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HGS DISCOVER
12. NON ACTIVATION OF ALARM BLOCKING
Description Alarm Blocking
Problem indication Alarm blocking is not activated during stopping.
Troubleshooting/
Causes of problem
Corrective Action
1. Malfunction of rpm pick up sensor • To dismantle the pick up sensor and clean it away

 Set value for 900 rpm

• Running on : 880 rpm
2. Improper set value on SMU and MCU • Running off : 700 rpm
 Set value for 720 rpm

• Running on : 710 rpm
• Running off : 600 rpm
＃ For the procedure, it is recommended to see the
Instruction manual (vol.2) of automatic control system vol.2
• To do swap test of SCCS or SCU with the others.
3. Malfunction of SCCS (Safety Control & Cable

Supervision)or, SCU (Safety Control Unit) • To do swap test of Relay output unit with the
others.
4. Malfunction of Relay Output Unit

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HGS DISCOVER
Module Replacement procedure (KOMECO)

[ANALOG/DIGITAL UNIT(U1)-1/2]
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[ANALOG/DIGITAL UNIT(U1)-2/2]
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HGS DISCOVER

[SAFETY CONTROL &
CABLE SUPERVISION UNIT(U4)-1/2]
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[RELAY OUTPUT UNIT(P4)-1/2]
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HGS DISCOVER

[RELAY OUTPUT UNIT(P4)-2/2]
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[MAIN TERMINAL BOARD (P1)-1/2]
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HGS DISCOVER

[MAIN TERMINAL BOARD (P1)-2/2]
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HGS DISCOVER
Module Replacement procedure (YECS)

[ANALOG/COMM UNIT]
No Procedure Descriptions
Open the Terminal Box and Find the location

1
of the ANALOG/COMM. UNIT
To separate the flat cable, Pull on both sides

2
of the fixing lever.
3 Separate the cable.
Find the location of the screw bolt and

4 separate the screw bolt by using ‘+’ screw
driver.
5 Install new module vice versa
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HGS DISCOVER

[MAIN CONTROL UNIT]

1
of the MAIN CONTROL UNIT
To separate the flat cable, Pull on both sides

2
of the fixing lever.

driver.
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HGS DISCOVER

[SAFETY CONTROL UNIT]

1
of the SAFETY CONTROL UNIT

driver
Find the location of the terminal block and

4 separate the screw bolt by using ‘-’ screw
driver.
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HGS DISCOVER

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HGS DISCOVER

Trouble Shooting for Automatic Control System

Date May 14, 2021

T/S for HiMSEN Automatic Control System

Introduction • The purpose of this document is to

Service Exp. 1) Reverse Comm. Error

Appendix. • Module Replacement procedure

• Module Replacement procedure

1. REVERSE COMM. ERROR

Description Reverse communication error

Problem indication Communication failure

1. Improper cable connection Normally, the communication between ECS and

• To Check if there is contact or connection failure

• To connect the cable after disconnection by

• To check the address no. for MCU or ACU if it is

※ In case the situation is persisting, please contact

Problem indication Communication fail

＃ The relevant procedure will be provided by nearest HGS

※ In case the situation is persisting, please contact

3. TACHO FAIL DURING STAND-BY

Problem indication Tacho failure

2. Malfunction of L.O press. Switch PSL62

• To do swapping test of PSL62 with the other

3. Malfunction of rpm pick-up sensor

• To dismantle the pick up sensor and clean it away

• To adjust the clearance between sensor and

※ In case the situation is persisting, please contact

4. TRIP CIRCUIT FAIL

Problem indication Trip circuit failure

1. Cable dislocation or break off

• To check which LED is off firstly on SCCS module

• To check the relevant cables according to the LED

※ In case the situation is persisting, please contact

Problem indication Engine start failure

1) Check the starting motor if it is working properly.

3. Improper set for fuel common linkage

• Please refer to the service letter “HGS-HSM-SL-

4. Abnormal function of Governor

Problem indication Engine Stop failure

1. Malfunction of rpm pick-up sensor

• To adjust the clearance between sensor and

• To check the cable connection between governor

• To check the connection TB9 of P1 board

※ In case the situation is persisting, please contact

7. CAN ERROR (1)

Problem indication CAN error of Local monitoring box

1. CAN ERROR ON OPU :

• To do the swap test of MCU with the others

MONITORING TEMP. 2. CAN ERROR ON MTP :

/ PRESS. UNIT • To do the swap test of ADU with the others

3. CAN ERROR ON ETM :

• To check the control course

EXH. GAS TEMP.

※ In case the situation is persisting, please contact

8. CAN ERROR (2)

Problem indication CAN error of Local monitoring box

1. CAN ERROR ON YECS-1000D :

• To do the swap test of MCU with the others