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Systems Operation
G3500B Engines
Media Number -RENR2268-08 Publication Date -01/04/2007 Date Updated -16/04/2007
i02723855
Certain parameters are unique for each engine application. Table 1 is a list of the parameters that can be
configured for G3500B Engines. The parameters are programmed into the Electronic Control Module
(ECM) via the Caterpillar Electronic Technician (ET). The values of the parameters can be viewed on
the "Configuration" screen of Cat ET.
Most of the parameters are common to engines that use oxygen feedback and to engines that use charge
density. However, some of the parameters are associated only with oxygen feedback or with charge
density.
Table 1
Timing Control
"First Desired Timing" Yes Yes
"Second Desired Timing" Yes Yes
Air/Fuel Ratio Control
"Fuel Quality" Yes Yes
"Gas Specific Gravity" Yes Yes
"Desired Oxygen at Full Load" Yes No
"Oxygen Feedback Enable Status" Yes No
"Fuel Specific Heat Ratio" No Yes
"Desired Emission Gain Adjustment" No Yes
"Air/Fuel Proportional Gain" Yes Yes
"Air/Fuel Integral Gain" Yes Yes
Speed Control
"Low Idle Speed" Yes Yes
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No Yes
Information for the ECM
Yes
"Engine Serial Number" Yes
Yes
"Equipment ID" Yes
Yes
"Customer Password #1" Yes
Yes
"Customer Password #2" Yes
Yes
"Total Tattletale" Yes
Timing Control
The "Desired Timing" parameters allow the customer to electronically program the timing of the
ignition spark of the electronic system in order to meet the needs for specific applications and specific
installations. The desired timing value can be changed while the engine is running or while the engine is
stopped. The value that is entered for the desired timing is the ignition timing when the engine is
operating at rated speed and at full load.
Note: The actual ignition timing at a given instance may vary from the desired timing value. This
variance is due to variations in the engine speed or the detonation.
The range for programming the desired timing is 0 to 40 degrees before the top center (TC) position.
The "First Desired Timing" is determined with the methane number of the primary fuel that is used. Use
the Engine Performance Sheet, "Fuel Usage Guide". The ECM selects the "First Desired Timing" when
terminal J1-20 is not connected to ground.
The "Second Desired Timing" is determined with the methane number of the alternate fuel that is used
and the Engine Performance Sheet, "Fuel Usage Guide". The ECM selects the "Second Desired Timing"
when terminal J1-20 is connected to ground. If an alternate fuel is not used, enter the same timing that
was entered in the "First Desired Timing".
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recommended. Data from the gas analysis must be entered into Caterpillar Software, LEKQ6378,
"Methane Number Program". The results are programmed into the ECM.
Note: It is very important to use the Caterpillar Software, LEKQ6378, "Methane Number
Program". Use of only the data from the gas analysis can result in incorrect settings.
"Fuel Quality"
This is the fuel's Low Heat Value (LHV). The air/fuel ratio control of the ECM will compensate for
some inaccuracy in this setting. The ECM assumes a corrected value that is multiplied by the "Fuel
Correction Factor". This factor can be displayed on the Cat ET screen.
The "Fuel Quality" parameter can be used to change the air/fuel ratio when the engine is operating in the
open loop mode. To richen the air/fuel mixture, reduce the value. The calculation will compensate for
the reduced LHV by increasing the fuel flow. To lean the air/fuel mixture, increase the value. The
calculation will compensate for the increased LHV by reducing the fuel flow.
This is the fuel's specific gravity in relation to the specific gravity of air. The ECM does not use this
information. The ECM provides the information to the fuel metering valve via the CAN data link. Some
fuel metering valves require an input for the "Gas Specific Gravity" in order to precisely meter the fuel
flow.
The ECM contains an oxygen map that is programmed at the factory. The "Desired Oxygen At Full
Load" parameter is used to trim the oxygen map when the engine is in "Oxygen Feedback" mode. If the
measured exhaust oxygen or the NOX emissions are not the required value, increase the "Desired
Oxygen At Full Load" parameter in order to lean the engine or decrease the "Desired Oxygen At Full
Load" parameter in order to richen the fuel mixture.
The "Oxygen Feedback Enable Status" can be set to "Enable" or to "Disable". The engine will not
operate in the "Oxygen Feedback" mode when the "Oxygen Feedback Enable Status" parameter is
disabled. This feature allows the feedback mode to be disabled in order to troubleshoot. For example,
the disabling of this feature can help determine whether the air/fuel ratio control is the cause of
instability.
If the signal from the oxygen sensor is not available, the engine control system does not have the
feedback that is necessary for maintaining consistent exhaust emissions.
If there is a problem with the oxygen sensor, this parameter can be set to "Disable" in order to allow the
engine to run in the open loop mode until a new sensor is obtained. During operation in this mode, an
emissions analyzer must be used to verify the emissions level. The "Fuel Quality" parameter is adjusted
in order to adjust the air/fuel mixture.
When the "Oxygen Feedback Enable Status" is enabled, adjustment of the "Fuel Quality" parameter
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does not affect the air/fuel ratio. Do not adjust the "Fuel Quality" parameter when the "Oxygen
Feedback Enable Status" is enabled.
Note: Do not operate an engine that is unattended in the open loop mode if the fuel has an LHV that is
changing. The engine risks a shutdown due to lean misfire or to detonation.
This is a ratio of the fuel's specific heat at a constant pressure and at a constant volume. The ratio is also
known as "k". The ratio is related to the expansion of the gas across the fuel metering valve. The ECM
does not use this information. The ECM provides the information to the fuel metering valve via the
CAN data link. Some fuel metering valves require an input for the "Fuel Specific Heat Ratio" in order to
precisely meter the fuel flow.
This is an adjustment for the level of the engine's exhaust emissions for engine operation at full load.
The adjustable range is 85 to 115.
The "Air/Fuel Proportional Gain" determines the speed of the fuel metering valve's response in adjusting
for the difference between the actual air/fuel ratio and the desired air/fuel ratio.
The factory default setting is 0. This value should not require adjustment. If problems occur, this is one
of the last parameters that should be adjusted. The adjustable range is −50 to +50. Negative values
reduce the speed of the fuel metering valve's response and positive values increase the speed of the fuel
metering valve's response.
The "Air/Fuel Integral Gain" determines the response of the fuel metering valve to the error that is
accumulated over time for the air/fuel ratio.
The factory default setting is 0. This value should not require adjustment. If problems occur, this is one
of the last parameters that should be adjusted. The adjustable range is −50 to +50. Negative values
reduce the response of the valve and positive values increase the response of the valve.
Speed Control
"Low Idle Speed"
Program this parameter to the desired low idle rpm. The low idle rpm can be programmed within the
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Program this parameter to the desired minimum high idle rpm. The actual high idle speed is regulated by
the desired speed input. The regulation is linear in proportion to the input. An input of 0 percent results
in the minimum high idle rpm and an input of 100 percent results in the maximum high idle rpm.
For the 50 Hz arrangement, the minimum high idle speed can be programmed between 900 rpm and
1500 rpm. The default value is 1400 rpm.
For the 60 Hz arrangement, the minimum high idle speed can be programmed between 900 rpm and
1800 rpm. The default value is 1600 rpm.
For an industrial arrangement, the minimum high idle speed can be programmed between 650 rpm and
1350 rpm. The default value is 1350 rpm.
The "Minimum High Idle Speed" and the "Maximum High Idle Speed" determine the slope of the
desired speed input.
Program this parameter to the desired maximum high idle rpm. The actual high idle speed is regulated
by the desired speed input. The regulation is linear in proportion to the input. An input of 0 percent
results in the minimum high idle rpm and an input of 100 percent results in the maximum high idle rpm.
For the 50 Hz arrangement, the maximum high idle speed can be programmed between 1500 rpm and
1900 rpm. The default value is 1600 rpm.
For the 60 Hz arrangement, the maximum high idle speed can be programmed between 1800 rpm and
2200 rpm. The default value is 2000 rpm.
For an industrial arrangement, the maximum high idle speed can be programmed between 1200 rpm and
1900 rpm. The default value is 1350 rpm.
This parameter controls the rate for engine response to a change in the desired engine speed. For
example, the engine can be programmed to accelerate at a rate of 50 rpm per second when the
"Idle/Rated" switch is turned to the "Rated" position.
This parameter determines the signal input to the ECM for control of the desired speed. The signal can
be either 0 to 5 VDC or 4 to 20 mA.
Note: The ECM is not configured to accept a pulse width modulated signal for input of the desired
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engine speed. If you try to select a Pulse Width Modulated input (PWM), the ECM will reject the
selection. An error will be generated.
The "Governor Type Setting" parameter can be set to "Droop Operation" or to "Isochronous Mode".
This setting is dependent upon the application of the engine.
This programmable parameter allows precise control of the speed droop. The "Governor Type Setting"
parameter must be set to "Droop". The droop can be programmed to a value between 0 and 10 percent.
Refer to Testing and Adjusting, "Engine Governing - Adjust" for the adjustment procedure for the
governor.
This parameter is based on a proportional multiplier. The "Governor Proportional Gain" determines the
speed of the throttle actuator's response in adjusting for the difference between the actual speed and the
desired speed. Increasing this value provides a faster response to the difference between the actual speed
and the desired speed.
This parameter changes the reaction of the throttle actuator when the "Grid Status" parameter is "Off". If
changing this value causes no effect, check the "Grid Status" in order to make sure that the status is
"Off".
This parameter is based on an integral multiplier. The "Governor Integral Gain" controls the speed for
elimination of the error in the difference between the actual speed and the desired speed. Increasing this
value provides less damping.
This parameter changes the reaction of the throttle actuator when the "Grid Status" parameter is "Off". If
changing this value causes no effect, check the "Grid Status" in order to make sure that the status is
"Off".
This parameter is based on a derivative multiplier. The "Governor Derivative Gain" is used to adjust for
the time delay between the control signal and the movement of the throttle actuator. If this value is too
low, the engine speed will slowly hunt. If this value is too high, the engine speed will rapidly fluctuate.
This parameter changes the reaction of the throttle actuator when the "Grid Status" parameter is "Off". If
changing this value causes no effect, check the "Grid Status" in order to make sure that the status is
"Off".
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This parameter is based on a proportional multiplier. The "Auxiliary Proportional Governor Gain 1"
determines the speed of the throttle actuator's response in adjusting for the difference between the actual
speed and the desired speed. Increasing this value provides a faster response to the difference between
the actual speed and the desired speed.
This parameter changes the reaction of the throttle actuator when the "Grid Status" parameter is "On". If
this value is changed and the "Grid Status" is "Off", the stability of the engine will not change. If
changing this value causes no effect, check the "Grid Status" in order to make sure that the status is
"On".
This parameter is based on an integral multiplier. The "Auxiliary Integral Governor Gain 1" controls the
speed for elimination of the error in the difference between the actual speed and the desired speed.
Increasing this value provides less damping.
This parameter changes the reaction of the throttle actuator when the "Grid Status" parameter is "On". If
this value is changed and the "Grid Status" is "Off", the stability of the engine will not change. If
changing this value causes no effect, check the "Grid Status" in order to make sure that the status is
"On".
This parameter is based on a derivative multiplier. The "Auxiliary Derivative Governor Gain 1" is used
to adjust for the time delay between the control signal and the movement of the throttle actuator. If this
value is too low, the engine speed will slowly hunt. If this value is too high, the engine speed will
rapidly fluctuate.
This parameter changes the reaction of the throttle actuator when the "Grid Status" parameter is "On". If
this value is changed and the "Grid Status" is "Off", the stability of the engine will not change. If
changing this value causes no effect, check the "Grid Status" in order to make sure that the status is
"On".
The ECM accepts an input from the driven equipment that indicates when the equipment is ready for
operation. When the input is grounded, the driven equipment is ready. The ECM will not start the engine
until this input is grounded.
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The ECM can be programmed to wait for a certain period of time after receiving a start command before
starting the engine. This allows the driven equipment to get ready for operation.
When the ECM receives a start command, the ECM will wait for the amount of time that is programmed
into the "Driven Equipment Delay Time". If the "Driven Equipment Delay Time" elapses and the input
is not grounded, an event code is activated. The engine will not start.
If the "Driven Equipment Delay Time" is programmed to "0" the delay is disabled. If the ECM receives
a start command and the driven equipment is not ready, an event code is activated. The engine will not
start.
The ECM disengages the starting motor when the engine speed exceeds the programmed "Crank
Terminate Speed". The default value of 250 rpm should be sufficient for all applications.
The "Engine Purge Cycle Time" is the duration of time for the engine to crank without fuel before the
crank cycle. The "Engine Purge Cycle Time" allows any unburned fuel to exit through the exhaust
before the fuel and the ignition are enabled.
When the ECM receives a "Stop" request, the engine will continue to run in the "Cooldown Mode" for
the programmed cooldown period. The "Cooldown Mode" is exited early if a request for an emergency
stop is received by the ECM. If the "Engine Cooldown Duration" is programmed to zero, the engine will
immediately shut down when the ECM receives a "Stop" request.
The "Cycle Crank Time" is the amount of time for activation of the starting motor and of the gas shutoff
valve for start-up. If the engine does not start within the specified time, the attempt to start is suspended
for a "Rest Cycle" that is equal to the "Cycle Crank Time".
The "Engine Overcrank Time" determines the length of time for the ECM to attempt to start the engine.
An event is generated if the engine does not start within this period of time.
Example Setting
Table 2
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The following sequence will occur if the parameters are programmed according to the example in Table
2:
1. The fuel and the ignition are OFF. The engine will crank for 10 seconds in order to purge gas from
the engine via the exhaust system.
2. The fuel and the ignition are enabled. The engine will continue to crank for a maximum of 30
seconds.
3. If the engine does not start, the ignition, the fuel, and the starting motor are disabled for a 30
second "Rest Cycle".
With this example, a complete cycle is 70 seconds: a purge cycle of 10 seconds, a cycle crank of 30
seconds and a rest cycle of 30 seconds. The "Overcrank Time" of 280 seconds allows a maximum of
four crank cycles.
This parameter is activated when the ECM receives the signal for stopping the engine. This input
ensures the shutdown in case the Gas Shutoff Valve (GSOV) does not close.
After the cooldown period has elapsed, the ECM removes power from the electrical circuit for the
GSOV. The fuel is shut off from the engine. The ignition continues until the engine speed drops below
40 rpm. If the engine rpm does not drop at least 100 rpm within the programmed drop time, the ECM
terminates the ignition and the ECM issues an emergency stop.
The programmable setpoint is a value that separates low engine load from high engine load for events
that are activated by high inlet air temperature. An "Engine Load Factor" can be displayed on a Cat ET
status screen. If the load factor is less than the setpoint and the inlet air temperature reaches the trip
point, a "High Inlet Air Temperature at Low Engine Load" event is activated. If the load factor is greater
than the setpoint and the inlet air temperature reaches the trip point, a "High Inlet Air Temperature at
High Engine Load" event is activated.
Power Monitoring
The ECM monitors the generator's output power in order to accurately control the air/fuel ratio. The
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ECM uses an output from one of the following sources in order to monitor the generator's output power:
Wattmeter
The PLC and the wattmeter are also called power sensors.
The ECM uses the values of the "Power Monitoring" parameters to estimate the generator's actual power
output. The electronic control module's estimate of the generator's actual power output is displayed on
Cat ET as the "Generator Real kW" parameter in Status Group 1. If the value of this parameter is within
one percent of the generator's actual power output, the ECM will accurately control the air/fuel ratio.
If the generator is equipped with the EMCP II+, information on the generator's output is provided to the
ECM via the CAT data link. The value for the "Generator Output Power Sensor Scale Factor" parameter
is correctly programmed at the factory. No further adjustment is necessary for this parameter.
If the generator is equipped with a power sensor, the signal from the power sensor increases from 0 to
4.8 VDC as the generator's output increases to the maximum output. The maximum output is 110
percent of the generator's rated output. For example, if the generator has a rated output of 1700 ekW, the
maximum output is 1870 ekW. When the generator's output is 1870 ekW, the power sensor will provide
a signal of approximately 4.8 VDC.
The ECM requires a scale factor in order to estimate the generator's output. The equation that is used to
determine the scale factor is provided in Table 3.
Table 3
Computing the Value for the "Generator Output Power Sensor Scale Factor"
(R x 1.1) ÷ 4.8
R is the generator's rated output in kilowatts.
For example, if the generator's rated output is 1700 ekW, the correct value for the "Generator Output
Power Sensor Scale Factor" parameter is 390. In this example, the relationship between the voltage level
of the signal and the generator's output is shown in Illustration 1.
View Image
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Illustration 1 g01062926
In this example, the value of the "Generator Output Power Sensor Scale Factor" parameter is 390.
The ECM multiplies the signal voltage by the scale factor in order to estimate the generator's output. In
this example, a signal level of 3.5 VDC indicates that the generator output is approximately 1365 ekW.
After the ECM estimates the generator's output, the ECM adds the value of the "Generator Output
Power Sensor Offset" parameter to the estimate. This refines the electronic control module's estimate of
the generator's actual output.
If the generator is equipped with the EMCP II+, information on the generator's output is provided to the
ECM via the CAT data link. The value for the "Generator Output Power Sensor Offset" parameter is
correctly programmed at the factory. No further adjustment is necessary for this parameter.
If the generator is equipped with a power sensor, the power sensor's output may not be zero when the
generator's output is zero. When this occurs, the power sensor has an offset voltage. The offset voltage
may be positive or negative. In most cases, the offset voltage is very low. Therefore, the value of the
"Generator Output Power Sensor Offset" parameter must be set to zero.
The offset voltage must be measured before you change this parameter from zero. To measure the offset
voltage, refer to Troubleshooting, "Generator Output Power Readings Do Not Match". If the offset
voltage is less than 0.01 VDC, the value of the "Generator Output Power Sensor Offset" must be set to
zero.
The value of this parameter is in units of ekW. The minimum programmable value for this parameter is
−327 ekW. The maximum programmable value for this parameter is 200 ekW.
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The ECM adds the value of the "Generator Output Power Sensor Offset" parameter to the value that is
determined by the "Generator Output Power Sensor Scale Factor" parameter. This refines the electronic
control module's estimate of the generator's actual output.
The electronic control module's final estimate of the generator's actual output is displayed on Cat ET as
the "Generator Real kW" parameter in Status Group 1. If the value of this parameter is within one
percent of the generator's actual power output, the ECM will accurately control the air/fuel ratio.
The value of the "Engine Output Power Configuration" parameter is the engine's full load rating in ekW.
The rating is stamped on the engine's Information Plate. During operation, the ECM uses this value to
determine the engine's load as a percentage of the maximum load.
The value of this parameter is the rated load of the auxiliary equipment such as a radiator fan that is
directly driven by the engine. The value is in units of ekW. The ECM adds this load to the estimate of
the generator's actual output in order to determine the total load on the engine.
Override Parameters
"Oxygen Sensor Override"
This parameter enables the oxygen sensor and the oxygen buffer to be energized when the engine is not
running. This facilitates troubleshooting of the sensor's electrical circuit. This parameter also allows
verification of the calibration of the oxygen sensor.
The engine serial number is programmed into the ECM at the factory. The number is stamped on the
engine Information Plate.
"Equipment ID"
The customer can assign an "Equipment ID" for the purpose of identification.
Customer Passwords
Two customer passwords can be entered. The passwords are used to protect certain configuration
parameters from unauthorized changes.
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Note: Factory level security passwords are required for clearing certain logged events and for changing
certain programmable parameters. Because of the passwords, only authorized personnel can make
changes to some of the programmable items in the ECM. When the correct passwords are entered, the
changes are programmed into the ECM.
"Total Tattletale"
This item displays the number of changes that have been made to the configuration parameters.
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