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Instructions for Testing

ECP/ECPG/EFC on Testing Rig


1. Ensure that DC supply switch on the rig is in OFF position.
2. Connect 24 V Dc power supply to the ECP/ECPG/EFC Rig with correct polarity.
3. Connect the appropriate harness from the controller to the rig.
4. Put ECP / ECPG toggle switch in correct position. Note that the controls marked with
RED outline are for ECPG, BLUE for ECP & GREEN for EFC.
5. Ensure that pots for Coolant Temperature & Auxiliary Temperature are fully
anticlockwise.
6. Keep the Speed Bias & LLOP at Mid Position & Load Pot at zero position i.e. fully
anticlockwise.
7. Put on the DC supply switch. ‘Power ON DC’ indication on rig will glow green indicating
that the supply is correct.

• FSO (fuel shut off valve or shut down coil) will get the supply & see the indication ‘FSO
ON’ on rig.

FOR E C P
• Observe the self-test followed by scanning is done by the ECP. Check the display goes
from 0000 – 9999. Then all LEDs will glow except charge LED. Ensure that there is No
fault indication on rig or Panel.
• Temperature/Pressure 5 step Selector Switch:-
¾ Temperature range – 70 to 1000C
¾ Pressure range – 1 to 7kg/cm2
• RPM selector switch which has 6 options
¾ Option 1-5 – To select 5 different RPM
¾ Option 6 – To check over speed fault

• Procedure for Checking CT (Coolant Temperature)

Put ‘CT’ selector switch on various positions & check the following:

PAREMETER RANGE/STEPS OBSERVATION & CONCLUSION


CT display 84 84 ± 2 ˚C
92 92 ± 2 ˚C
‘O’ will be displayed on ECP panel. Sensor fault
O/P (open)
LED = ON on ECP display.
‘S’ will be displayed on ECP panel. Sensor fault
S/C (Short)
LED = ON on ECP display.

WT ≥97°C HCT fault LED will glow RED on ECP display.


CT pre alarm HCT alarm LED will glow RED on the rig. ECP
OK.

WT<97°C No fault LED will glow. ECP OK.


HCT fault LED will glow RED on ECP display.
CT fault Set WT≥100°C(right HCT alarm LED will glow RED on the rig. No
hand side) supply to FSO. ECP OK.

NOTE: If the CT LED glows below 97°C then the ECP is Not OK.

Page 1 of 4
Instructions for Testing
ECP/ECPG/EFC on Testing Rig

• Procedure for Checking LOP (Lube Oil Pressure)

Put ‘LOP’ selector switch on various positions & check the following:

PARAMETER RANGE/STEPS OBSERVATION & CONCLUSION


Lube Oil Press. 5.5kg/cm2 5.560.1kg/cm2
Display Open ‘O’ will be displayed on ECP panel. Sensor fault
Short LED = ON on ECP display.
‘S’ will be displayed on ECP panel. Sensor fault
LED = ON on ECP display.

LOP<1.5kg/cm″ LLOP fault LED will glow RED on ECP display.


LLOP alarm LED will glow RED on the rig. ECP
LOP pre alarm
OK.

LOP≥1.5kg/cm″ No fault LED will glow. ECP OK.


LLOP fault LLOP fault LED will glow RED on ECP display.
Set LOP=1kg/cm2 LLOP alarm LED will glow RED on the rig. No
(left hand side) supply to FSO. ECP OK.

NOTE: If the LOP LED glows above 1kg/cm2 then the ECP is Not OK.

• Procedure for checking RPM


¾ 1-5 set of different RPM – The table of RPM display for engines with various ring
gear teeth is given in the manual of the simulator. ECP OK.

¾ Over speed fault – Select position 6 & vary the over speed pot completely clockwise.
The over speed LED glows RED ON the ECP Panel. ECP OK.
NOTE: If the over speed LED does not glow then ECP is Not OK.

RPM switch Ring gear teeth *Overspeed


position 142 118 108 103 168 indication
1 640 771 843 884 541 ON
2 915 1101 1204 1262 773
3 1190 1432 1565 1641 1006 RPM
4 1373 *1652 *1806 *1893 1160 tolerance
5 1533 *1845 *2016 *2114 1296 +/- 3 RPM
6 (OS test) 1650 1650 1650 1650 1650

• Procedure for checking other faults:

PARAMETER STEPS OBSERVATION & CONCLUSION


LCWL fault Press LCWL button ‘LCWL” LED will glow RED on the rig & ECP +
on rig No supply to FSO. ECP OK.
CHARGE fault Press CHARGE ‘CHARGE’ LED will glow RED on rig & ECP.
button on rig ECP OK.
LOP Sensor fault Push LOP Sensor ‘Sensor Fault’ LED will glow RED on ECP. ECP
Fault button OK.

• Procedure for checking other functions:

PARAMETER STEPS OBSERVATION & CONCLUSION


Remote start Push Remote start RPM display will come. ‘FSO ON’ Led will glow.

Page 2 of 4
Instructions for Testing
ECP/ECPG/EFC on Testing Rig

button Magnetic switch ON. ECP Ok.


Remote stop Push remote stop Engine stops. ECP OK.
button

FOR E C P G

• Check that 5V LED is glowing. If not then ECPG not OK.


• Give start command from key switch or from remote start. ‘Magnetic switch On’ LED will
glow. RPM reading is observed as per the IDLE/RATED (as per the droop setting) switch
position on the ECPG display panel & actuator current reading (0.75 to 1.5A) on the rig.
• Vary the load pot & the current varies goes up to 1.5A.

• Procedure for Checking CT (Coolant Temperature)

Coolant Temperature selector switch is a 6 step selector switch


¾ Options 1-5 – for temperature range 70 to 100°C
¾ Option 6 – Variable pot

Put the CT switch in various positions & check the following:-

PARAMETER RANGE/STEPS OBSERVATION & CONCLUSION


CT display 84 84±2 ˚C
92 92±2 ˚C
‘O O’ will be displayed on ECPG panel. Fault
O/P (open)
code = 144 displayed on ECPG.
‘S S’ will be displayed on ECPG panel. Fault
S/C (Short)
code = 144 displayed on ECPG.
CT ≥97°C HCT alarm Led will glow on rig & ECPG display.
CT pre alarm Fault code = 146 displayed on ECPG. ECPG
OK.
CT<97°C No fault LED will glow. ECPG OK.
Set CT≥100 °C HCT alarm LED will glow on rig & display. No
CT fault supply to FSO. Fault code = 146 & 151
displayed on ECPG. ECPG OK.

NOTE: If the WT/CT LED glows below 97°C then the ECPG is Not OK.

• Procedure for Checking LOP (Lube Oil Pressure)

Lube Oil Pressure switch has 6 options


¾ Options 1-5 – Pressure range from 1 to 7 1kg/cm2
¾ Option 6 – Variable pot

Put ‘LOP’ selector switch on various positions & check the following:-

PARAMETER RANGE/STEPS OBSERVATION & CONCLUSION


Lube Oil Pressure 3 bar 3.160.1bar
Display o/p O O … Fault code = 135 displayed on ECPG.
Page 3 of 4
Instructions for Testing
ECP/ECPG/EFC on Testing Rig

short S S…. Fault code = 141 displayed on ECPG.


LOP<1.5kg/cm″ LLOP alarm LED will glow on rig & ECPG
display. Fault code = 143 displayed on ECPG.
LOP pre alarm
ECPG OK.
LOP≥1.5kg/cm″ No fault LED will glow. ECPG OK
LLOP fault Set LOP=1kg/cm″ ‘LLOP’ alarm LED will glow on rig & ECPG. No
supply to FSO. Fault code = 143 & 415
displayed on ECPG. ECPG OK.

NOTE: If the LOP LED glows above 1kg/cm2 then the ECPG is Not OK.

• Procedure for Checking IMT (Intake manifold Temperature or Auxiliary Temperature)

Auxiliary Temperature switch has 6 options


¾ Options 1-5 – Temperature range from 50 to 90˚C
¾ Option 6 – Variable pot

Put ‘IMT’ selector switch on various positions & check the following:

PROCEDURE RANGE/STEPS OBSERVATION & CONCLUSION


IMT display 84 84±2 ˚C
61 61±2 ˚C
‘O O’ will be displayed on ECPG panel. Fault
O/P (open)
code = 153 displayed on ECPG.
‘S S’ will be displayed on ECPG panel. Fault
S/C (Short)
code = 154 displayed on ECPG.
With ‘VARI’ pot ‘High Int. Air/OS’ LED will glow on the rig &
IMT fault Set IMT≥75°C ECPG display. Fault code = 155 displayed on
ECPG. ECPG OK.

NOTE: If the IMT LED glows below 75°C then the ECPG is Not OK.

• Procedure for checking other functions:

PARAMETER STEPS OBSERVATION & CONCLUSION


Remote start Put the key switch in ‘FSO ON’ Led will glow. ‘MAG SW ON’ LED =
run position & press ON. RPM reading is observed on the ECPG
the ‘Remote Start’ panel. ECPG OK.
button
Remote stop Press the ‘Remote No supply to FSO. ‘FSO ON ‘ led = PFF. ECPG
Stop’ button OK.
RPM Raise Press the ‘RPM RPM rises from its current value by 1. ECPG
Raise’ button OK.
RPM Lower Press the ‘RPM RPM drops from its current value by 1. ECPG
Lower’ button OK.
Fail to Crank Toggle switch is on Crank the engine. It will not start. ECPG OK.
‘Fail to crank’ position

NOTE: “speed Bias’ parameter is checked only when ECPG is set to operate in ‘Speed
bias’ mode. For setting speed bias mode in ECPG, refer the ECPG field adjustments
Rev 1 .

FOR EFC

Page 4 of 4
Instructions for Testing
ECP/ECPG/EFC on Testing Rig

• Connect RPM indicator (tachometer) & Actuator


• Keep the Run pot in mid position & idle pot in mid position.
• Keep the droop pot at zero position i.e. fully anticlockwise.
• Keep the gain pot in mid position.
• On giving the supply, the ‘Power OK’, ‘MPU OK’ & ‘Actuator Ok’ LEDs should glow
GREEN. EFC OK.
• Keep the Idle/Rated toggle switch at Idle, check the RPM at the digital rpm meter & adjust it
by the idle pot to 1100 rpm.
• Go to Run Mode.
• Adjust the rpm to 1500. Current on the meter should be 0.7 to 0.8A. EFC OK.
• Vary the load pot and the current on the rig goes up to 1.5A. EFC OK.

PARAMETER STEPS OBSERVATION & CONCLUSION


Governor test Idle 1100rpm
Rated 1500rpm

Page 5 of 4

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