EPC-50 Air/Fuel Ratio Control for Low-horsepower, Carbureted Natural Gas Engines

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 configuration and diagnostic capability. The EPC-50 and associated small engine-specific control valves are designed for use on engines operating at or near a stoichiometric air/fuel ratio and is ideally suited for application with 3-way catalytic converters. While it is designed to be mounted in the engine/compressor control panel, a NEMA 3R housing (720004-1) is also available as an alternative mounting option.

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. A 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 through the sealed membrane keypad or through the use of a PC. The EPC-50 also incorporates a thermocouple input and a dedicated output for implementation of catalyst overtemperature protection. A second digital output is available for use as an alarm for diagnostics or uncontrolled operation.

The EPC-50 has an alphanumeric LCD display showing the target voltage, sensor voltage, operating temperature, stepper motor position and diagnostic information.
Power requirement is 24 (12–30) VDC, 1 amp. In remote areas, power can be provided by the Altronic 24VDC Alternator Power Package. Refer to Altronic Form ALT.

Concurrent with the release of this new and exciting system is also the introduction of a totally new line of air/fuel ratio control valves specifically engineered and manufactured for use on smaller natural-gas fueled engines. Evolving state and federal air quality regulations are expanding the base of engines subject to emissions control to more fully include engines at the lower end of the horsepower range (50-250 hp). The single-channel EPC-50 and companion fuel control valves provide a capable, cost-effective means of assuring precise and consistent control of air/fuel ratio for those applications required to operate with catalytic converters.

The smaller, lower-cost control valves also make the EPC-50 more financially attractive. These all-aluminum construction valves are lightweight and designed for the smaller fuel intake piping typically seen on lower-horsepower applications. Models are available in both piston- and butterfly-style configurations.

For details, click here for the EPC-50 Brochure or here for the EPC-50 Operating Manual.

 

CPU-95 Digital Ignition is Available with a Backward-Compatible Enhanced Display.

The Altronic CPU-95 is a 24 Vdc-powered, microprocessor-based digital ignition system designed for application to medium-range industrial gas engines. Advantages include a full-featured user display and interface, spark characteristic control, advanced timing adjustment options, serial communications, and state-of-the-art diagnostics.

Full access to all CPU-95 operating data and control functionality is available through an advanced, user-friendly Display Module as well as via a PC operating the provided CPU-95 Terminal Program. Both options display essential engine and ignition data such as RPM, timing angle, spark energy level, and diagnostic messages, along with global and individual cylinder timing adjustments, spark energy level control, overspeed setpoint and double strike/extended spark (VariSparkTM variant) selectability. Additionally, the Enhanced Display Module features extensive spark reference number graphing and trending.

Patented CPU-95 diagnostics and prognostics (predictive diagnostics) supervise all ignition system-related functions. The secondary analysis capabilities detect shorted spark plugs and leads, as well as spark plugs that exhibit high voltage demand or are not firing at all. A display of the relative voltage demand of each spark plug is provided, allowing spark plug changes to be predicted and scheduled. Module and pickup operation, timing input, and primary output functions are also monitored for operation within preset limits.

The CPU-95 system is shop or field configurable. Using the standard Terminal Program and the Enhanced CPU-95 Display Module, the user has the added flexibility and convenience associated with a USB-based connection to the system for programming. Operation of the Enhanced Display Module also enables the user to download and retain the ignition operating parameters (firing code, number of monitored gear teeth, 4-20mA or RPM control loop, etc.) from the connected Ignition Module. Should the ignition module ever require replacement, the Enhanced Display Module can then simply upload the correct ignition operating parameters into the new unit without need for a laptop, the Terminal Program, or the services of an instrumentation technician.

For details, click here for the CPU-95 Brochure or here for the CPU-95 Operating Instructions or Operating Instructions for Enhanced Display.

 

VSM - Vibration Sensing Monitor Safeguards Engine
from Excessive Vibration

The Altronic Vibration Sensing Monitor (VSM) is a 32-bit microprocessor-based electronic instrument designed to protect industrial engines, compressors, and associated equipment from damage caused by excessive vibration. The monitor accepts up to four (VSM-400) or eight (VSM-800) industry-standard low-cost, broadband, piezoelectric vibration sensors that are used to transform mechanical vibrations into electrical signals which are then evaluated by the VSM. The resulting vibration levels are displayed on a LCD display and are compared to user adjustable setpoint levels (2 per channel). If a high vibration level surpasses a user-configured setpoint value, an indication is shown on the LCD and an output switch - one for alarm and one for shutdown - is activated.

With each input channel operating independently of the other, the VSM can be used as the monitoring device for all of the vibration points of interest on an application. For example, individual sensors mounted on a gas compressor cooler, on each bank of the engine, and on the compressor cross-heads are individually configured for the appropriate vibration characteristics and monitored by a single VSM device. RS-485 Modbus RTU communications is resident in the device allowing the vibration data from each channel to be communicated to a control PC/PLC or remotely as a means of determining the overhaul health and well-being of the equipment. Configuration of the device can be accomplished simply and conveniently directly from the front of the device using the system keypad.

The VSM is housed in a 6.50” x 6.50” powder-coated aluminum case for maximum durability in difficult applications. Rugged, pluggable Phoenix-type connectors are used for all input/output connections to assure long-term, reliable system service. Each VSM is also certified as safe for use in Class I, Division 2, Group C and D hazardous operating areas by the Canadian Standards Association (CSA).

For details, click here for the VSM Brochure or here for the VSM Installation and Operating Instructions.

 

DET-1600 Detonation Sensing Monitor Helps
Avoid Engine Damage

This 24VDC-powered, 32-bit microprocessor-based electronic instrument is designed for use on natural gas-fueled engines to detect detonation and misfire and avoid consequential engine damage. Industry-standard, low-cost, piezoelectric vibration sensors are mounted directly on the engine and are used to transform the vibrations caused by combustion into electrical signals which are then evaluated by the DET-1600. These values – generated for every cylinder on a cycle-by-cycle basis – are then measured against misfire and detonation setpoints configured by the user for the monitored engine. The monitor accepts up to 16 detonation sensors that are wired to pluggable Phoenix-type connectors; the recommended configuration is one sensor per cylinder.

The DET system can be configured to take a number of control actions to protect the monitored engine upon indication of detonation (or misfire). In many applications, the DET will utilize one of two solid-state output switches to activate an external unloader to reduce engine load. Should that remedial action be unsuccessful addressing the detonation issue, the DET can be configured (when used in conjunction with a digital ignition system) to automatically retard the ignition timing. In the event that an ignition timing adjustment also proves to be ineffective in eliminating engine detonation, the second output switch – typically tied to a digital annunciator or other monitoring device – acts as a final safety measure to shut down the engine.

The DET system is housed in a rugged, powder-coated, aluminum enclosure and features an integral 2x16 backlit LCD to display the detonation and misfire reference level numbers, engine cylinder labels, control and output switch status, the cause of shutdown log, and all diagnostic messages. System configuration is accomplished using an on-board RS485 serial port and a powerful, yet easy to use, system configuration and monitoring program.

For details, click here for the DET-1600 Brochure or here for the DET-1600 Installation and Operating Instructions.

 

EZRail Modular Ignition Wiring and Coil-Mounting
Rail System Simplifies Engine Wiring

EZRail systems are complete wiring/mounting system from the ignition unit to the ignition coils. They're factory-built and thoroughly tested in Altronic’s Ohio facility.

EZRail eliminates hours of wire and conduit cutting in the field and guarantees against skinned insulation due to long conduit pulls.

The universal design takes advantage of standard cables, wiring rails and integral/flange or off-mounted coils (shielded or unshielded). EZRail systems can be cost-effectively configured for service in any hazardous or non-hazardous area. Optional bolt-on coil mounting rails give users a robust and reliable means of mounting ignition coils without compromising the integrity of the wiring rail or the ability of the rail to be serviced if necessary.

These systems are flexible and upgradable. If coil types are changed, e.g., from unshielded to shielded or integral, the same wiring rail can be used without modification. The same is true if the coil mounting rail is added later. Competing systems require a completely new, entirely different rail assembly.

Altronic uses only premium construction materials. No “pop rivets” or foam here — only high-quality aluminum extrusions, sealed junction boxes, and military-style connectors and harnesses are used. To insure long-term service, all connector back shells are potted and strain-relieved.

An ignition wiring rail is too critical to be a “disposable” item, so all EZRail systems are fully serviceable. Incorporating standard Altronic ignition components into the design, including the primary and secondary cables and leads, allows for quick, cost-effective repair and service in the field. In the unlikely event that the rail itself requires service (or if on-engine mechanical work is required), the EZRail system can be easily disconnected, removed, and re-installed.

Service makes the difference. EZRail is backed by the most capable and experienced gas engine accessory product distribution system in the world. At the end of the day, good product performance relies upon solid field service. Altronic Distributors and Dealers are unparalleled in their ability to deliver timely, high-quality technical services for all products, including the EZRail system.

For more information, click here for the EZRail Brochure or here for the EZRail Application List or Installation Instructions.

 

DE-3000 Configurable Safety Shutdown and
Control System with Analog Input Capabilities

Using state-of-the-art microcontrollers and surface-mount PCB assembly technology, the DE-3000 provides users of compressors and other critical rotating equipment with a sophisticated, yet reliable, means of protecting and controlling both the prime mover and the load machine (compressor, pump, etc.). Incorporating an “intelligent” add-on board system, the DE-3000 system is fully scalable, allowing users to incorporate a single control system technology across a wide range of applications.

The base DE-3000 configuration offers a number of both digital and analog outputs, as well as thirty (30) inputs that can be individually configured for use with switch contacts, thermocouples, or analog transducers. Using one of two different add-on terminal boards, medium and high-spec applications can be accommodated with up to sixty (60) configurable inputs, twenty (20) digital outputs, and four (4) user-adjustable, analog PID outputs. This approach also allows for a single control system to be used across a fleet of units, thus simplifying maintenance and part stocking requirements, along with system training requirements for operating personnel.

Ease of system setup and configuration sets the DE-3000 apart from other PLC-style or competitive controllers. USB-based connectivity to the device and an intuitive, Windows(TM)-based terminal program for system configuration eliminates the need for any knowledge of ladder-logic or other functional programming languages. ModBus-RTU communications are fully supported for remote monitoring and/or control applications.

For further information, click here for the DE-3000 Brochure or here for the DE-3000 Installation and Operating Instructions.

 

DSG-1611DUPS, DSG-1692DUS, and DSG-1682DUPS Devices Take Critical Temperature and Process Monitoring to New Levels

The Altronic DSG-1611DUPS, DSG-1692DUS, and DSG- 1682DUPS are advanced digital/bar-graph setpoint gauges for monitoring, displaying and protecting either one or two process variables. The DSG-1611 is a universal one-point model which replaces the former DSG-1301/1601 series. The DSG- 1682DUPS and DSG-1692DUS are two-point versions.

These universal models can be connected to either type J or K thermocouples, 0–5 volts or 0–25mA (scalable) input signals. In the DSG-1692, this choice is made independently for each of the two monitored points. In addition, all versions have a RS-485 serial port with ModBus communications protocol with 5 selectable baud rates: 9,600, 19,200, 38,400, 57,600, and 115,200. This versatility makes the DSG gauges universal panel products, thus reducing spare parts requirements to a
minimum. Power requirement is 12–36Vdc, 0.25A maximum.

A unique feature of the DSG gauges is the high resolution 16 character
x 8 line digital readout/bar-graph display which givesthe operator an immediate indication of the reading as a percent of (user-selectable) transducer span or span between high/low setpoints, as well as a reference to direction and amplitude of a rapid change in reading. The display also indicates the units and annunciates an alarm by number (1st or 2nd setpoint) and type (high or low).

The front panel of the microprocessor-based gauge has a sealed membrane keypad for easy selection and adjustment of the units, transducer range and setpoints. There are two (one on the DSG- 1682DUPS) solid-state, form C (N.O. and N.C.) output switches. Each output can be assigned both high and low setpoint values which are retained indefinitely. The precision nature of the output switch allows these gauges to be used as control devices.

DSG-1611DUPS: The single-point model has both 4–20mA proportional output and RS-485 serial communications. It replaces all prior models of the DSG-1301 and 1601 and can be programmed for both a low and high output for each of the two
output switches.

DSG-1682DUPS: The dual-channel DSG-1682DUPS is a singleloop PID controller that accepts up to two (2) type J or K thermocouples or 0-5 volt/0-25mA transducer input signals. This sophisticated instrument/controller is designed to offer the following modes of operation: 4-20mA output loop vs. the channel 1 input OR channel 2 -channel 1 (differential) and Direct or inverse PID output based on the input of channel 1 or in a “mapping” mode that allows the channel 1 PID setpoint to be modified by the monitored input of channel 2.

DSG-1692DUS: In the standard dual-point model, each channel is independently assigned for type J or K thermocouple, 0–5 volts or 0–25mA input signals. This allows the device to be used for one temperature and one pressure or two of either type. In addition, the device can be set up with a differential setpoint between the two monitored points.

For further information, click here for the DSG 16 Brochure or here for the DSG-1611DUPS Installation Instructions or DSG-1692DUS Installation Instructions or DSG-1682DUPS Installation Instructions.

Altronic EPC-110/120 Offer Moderately-priced Air/Fuel Ratio Control for Carbureted Natural Gas-Fueled Engines