Local Engine Control Panel (LEC Panel)
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| Illustration 1 | g03368235 |
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Front of the control panel (1) Direct control unit panel (DCU panel) (2) "READY TO START" lamp (3) "EMERGENCY STOP" lamp (4) "GENERAL ALARM" lamp (5) "EMERGENCY STOP" switch (6) "TEST" switch for the panel lamps (7) "ENGINE CONTROL" switch | |
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| Illustration 2 | g03367772 |
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Switches on the inside panel of the control panel (8) "LOCAL THROTTLE" switch (9) "CRANK OVERRIDE" switch (10) "MANUAL RUN/STOP" switch (11) "LOW IDLE" switch (12) "ENGINE PRTN OVERRIDE" switch (13) "PRELUBE OVERRIDE" switch (14) "MANUAL PRELUBE" switch | |
The "READY TO START" lamp is illuminated when none of the following conditions exist:
- Faults on the engine control input are present.
- The starting air pressure is outside of operating limits.
- Faults exist on the starter relay.
- The barring device is engaged.
- Level 3 events are active.
- Emergency stops are engaged.
- The air shutoff is active.
The "EMERGENCY STOP" lamp will illuminate when an engine shutdown occurs due to an emergency stop condition.
The "GENERAL ALARM" lamp will illuminate when an alarm is active.
Use the "EMERGENCY STOP" switch ONLY in an emergency situation. DO NOT use the "EMERGENCY STOP" switch for normal engine stopping. After an emergency stop, DO NOT start the engine until the problem that caused the emergency stop has been corrected.
The "TEST" switch is a momentary push switch. Activation of the "TEST" switch activates all of the lamps on the door of the panel. Activation of the "TEST" switch tests the"GENERAL ALARM" relay and the "READY TO START" relay.
OFF/RESET - When the "ENGINE CONTROL" switch is in the OFF/RESET position, all alarms, safety shutdowns, and emergency shutdowns are reset. If the switch remains in this position, all electronics will enter a power-saving mode.
LOCAL - When the "ENGINE CONTROL" switch is in the LOCAL position, the controls are active and are in LOCAL mode. All remote engine controls are disabled. The engine may only be started and stopped locally from the DCU controller. The following switches inside of the door panel are operable: "LOW IDLE", "PRELUBE OVERRIDE", "CRANK OVERRIDE", "ENGINE PROTECTION OVERRIDE" and "MANUAL START/STOP".
REMOTE - When the "ENGINE CONTROL" switch is in the REMOTE position, the controls on the LEC panel are disabled except for the "EMERGENCY STOP" switch. The remote input capabilities of the DCU are activated.
The "LOCAL THROTTLE" switch is only active when the "ENGINE CONTROL" switch is in the LOCAL position and 0-5V is selected in the software.
Note: Do not use the "CRANK OVERRIDE" switch for normal engine operation. The starting motor may turn during engine operation which may damage the starting motor and the engine flywheel teeth.
The "CRANK OVERRIDE" switch is a two position switch and is only operational when the "ENGINE CONTROL" switch is in the LOCAL position. The operator may use the "CRANK OVERRIDE" switch to crank the engine with the engine starting motor when the engine control unit has completed the cycle crank sequence. The "CRANK OVERRIDE" switch is intended for use in system troubleshooting and engine maintenance. The switch can also be used to start the engine in an emergency when the engine control unit fails to crank the engine or when the primary engine control unit has failed and the engine is to be started with the secondary engine control unit.
The "MANUAL RUN/STOP" switch is a three position momentary toggle switch which automatically returns to the center position when not in use. The switch is only operational when the "ENGINE CONTROL" is in the LOCAL position. The "MANUAL RUN/STOP" switch may be used to start or stop the engine if the DCU fails. Do not operate the engine with this switch unless the DCU has failed.
The "LOW IDLE" switch is only operational when the "ENGINE CONTROL" switch is in LOCAL mode. Activating the "LOW IDLE" switch reduces the engine speed to low idle.
"ENGINE PRTN OVERRIDE" Switch (12)
When the "ENGINE PRTN OVERRIDE" switch is activated, the engine protection that is provided by the engine monitoring system is ignored. If a diagnostic condition that requires an engine shutdown is detected monitoring system, the engine ECM will ignore the shutdown request. The use of the "ENGINE PRTN OVERRIDE" switch to operate an engine with an active fault code may cause the engine to be seriously damaged or destroyed.
"PRELUBE OVERRIDE" Switch (13)
The "PRELUBE OVERRIDE" switch is a two position switch and is only operational when the "ENGINE CONTROL" switch is in the LOCAL position. The "PRELUBE OVERRIDE" switch allows the operator to override the prelube pump sequence at the beginning of the engine crank sequence during engine start-up. Use the "PRELUBE OVERRIDE" switch for troubleshooting and to provide for immediate engine starting during emergency situations.
The switch "MANUAL PRELUBE" is used to initiate a manual prelubrication. The "MANUAL PRELUBE" switch is only operational when the "ENGINE CONTROL SWITCH" is in the LOCAL position.
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| Illustration 3 | g03368709 |
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(15) LCD screen
(16) "POWER" indicator lamp (17) "ALARM" list (18) "START" switch (19) "STOP" switch (20) Context-sensitive menu switches (soft switches) (21) "SCROLL DOWN" switch (22) "SCROLL UP" switch (23) "MENU" switch | |
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| Illustration 4 | g02459816 |
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Typical example of the DCU 410 control panel | |
The status bar is the top line of the DCU screen.
- The "M" symbol indicates that the control unit is in manual mode. The "Automatic Start/Stop" function is not permitted when the control unit is in manual mode.
- The "SO" symbol indicates that the control unit is in shutdown override mode.
- The green"OK" symbol indicates that the following events are not present on the alarms list: warning, alarm and shutdown. The green"OK" symbol indicates that no yellow diagnostic messages and no red diagnostic message are present on the alarms list.
- The wrench symbol indicates that a maintenance interval which has been programmed into the control unit is overdue.
The screen is divided into three main sections:
All instruments and menu items are displayed on the main screen. The screen for the control unit may have multiple instrument screens. Press the "UP ARROW" button and press the "DOWN ARROW" button in order to navigate between the instrument screens. If there is only one instrument screen, pressing the buttons does not change the screen. Pressing the same button repeatedly will eventually scroll back to the first screen.
The following symbols and icons may be displayed on the instrument screen:
The "YELLOW TRIANGLE" is the warning symbol. When the "YELLOW TRIANGLE" flashes above an instrument, a new warning exists for that channel. The "YELLOW TRIANGLE" stops flashing when the operator acknowledges the warning.
The "RED TRIANGLE" is the alarm symbol or the shutdown symbol. When the "RED TRIANGLE" flashes above an instrument, a new alarm exists for that channel or the channel is responsible for an engine shutdown. The "RED TRIANGLE" stops flashing when the operator acknowledges the alarm.
The bottom most line on the screen is reserved for the description of the current function of the context-sensitive switches (soft switches). The soft switches have varying functionality depending on the selected screen. The function of the soft switch is listed above the soft switch.
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| Illustration 5 | g02459818 |
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Arrow switches | |
The DCU can have multiple screens that show instrumentation. Press the arrow switches to navigate from one instrument screen to another. If there is only one instrument screen, pressing the switches will not change the screen. Pressing the same switch repeatedly will eventually scroll around to the same screens.
- Alarm and shutdown (automatic stop) entries are displayed in red. A warning is displayed in yellow.
- New alarms (unacknowledged) are displayed in bold text, and acknowledged alarms are displayed in normal text.
- An alarm that is not acknowledged, then goes inactive, is displayed in normal text on a gray background.
Note: Red text color indicates an alarm or shutdown. Yellow text color indicates a warning.
| Alarm Color Chart | ||
|---|---|---|
| Alarm or Shutdown | New active alarm | Red background |
| Acknowledged active alarm | Red background | |
| Unacknowledged inactive alarm | Red text, gray background | |
| Warning | New active warning | Yellow background |
| Acknowledged active warning | Yellow background | |
| Unacknowledged inactive warning | Yellow text, gray background | |
| Diagnostic | New White Diagnostic | White background |
| Acknowledged white diagnostic | White background | |
| Unacknowledged inactive diagnostic | Black text, gray background | |
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| Illustration 6 | g02459820 |
To view the alarm list, press the "Alarm List" soft key.
Press the switch again to exit the alarm list, or press the Exit switch.
New alarms are displayed in bold text. Once the alarm is acknowledged, the alarm text is no longer bold.
The alarm list can filter alarms in three groups:
All Alarms - all alarms and diagnostics
Panel Alarms - all alarms, no diagnostics
Diagnostics - diagnostics only
To switch between the different views, press the corresponding soft key 2 and/or soft key 3.
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| Illustration 7 | g02517259 |
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Alarm List switch | |
If the buzzer sounds, press the alarm list switch to silence the buzzer.
If the display does not already show the alarm list, the alarm will cause the display to open the alarm list automatically.
If the alarm list is open when the buzzer sounds, pressing the alarm list switch to silence the buzzer will not exit the alarm list. Pressing the alarm list switch will only silence the buzzer.
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| Illustration 8 | g02459822 |
Use the following procedure to acknowledge a single alarm.
- With the alarm list open, select the desired alarm that is to be acknowledged by using the arrow switches.
The selected alarm line will expand to reveal additional information, if there is any.
- Press the "Acknowledge" switch to acknowledge the selected alarm.
Open the alarm list. Press and hold the "Acknowledge" switch for 1 second. All alarms will be acknowledged.
Note: Alarms that are still active will still be displayed in the screen. The active alarms will remain displayed until the alarm is inactive.
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| Illustration 9 | g02459817 |
The "START" switch can be configured to act as a latched or maintained switch. That is, once the switch is pressed and released, the switch will act as if the switch is still being pressed.
The "START" switch can also be configured as a "hold" or momentary switch. If the "START" switch is configured as a "hold", the "START" switch will always need to be pressed and held to provide an input. That is, if the switch is released, the switch will act as a momentary push switch.
If the switch is configured as latched (maintained) switch, press the s"START" switch. Observe the confirmation dialog. Press "Yes" to start the engine. The DCU will complete the start sequence.
If the "START" switch is configured as a "hold" switch (momentary push switch), press and hold the "START" switch until the engine has started.
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| Illustration 10 | g02459819 |
The "STOP" switch can be configured to act as a latched or maintained switch. That is, once the switch is pressed and released, the switch will act as if the switch is still being pressed.
The "STOP" switch can also be configured as a "hold" or momentary switch. If the "STOP" switch is configured as a "hold", the "STOP" switch will always need to be pressed and held to provide an input. That is, if the switch is released, the switch will act as a momentary push switch.
If the switch is configured as "latched" (maintained) switch, press the "STOP" switch. Observe the confirmation dialog. Press "Yes" to stop the engine. The DCU will complete the stop sequence.
If the "STOP" switch is configured as a "hold" (momentary) switch, press and hold the "STOP" switch until the engine has stopped.
Context-Sensitive Menu Switches (Soft Switches) (20)
The DCU has four soft switches. A soft switch is similar to a push switch except that the function of the switch can change. Software may be used to change the function of a soft switch. The current function of the soft switch is displayed above the switch.
The following four functions are assigned to the soft switches in the instrument view:
Soft switch # 1 - Language
Soft switch # 2 - Back light
Soft switch # 3 - Units displayed as metric or U.S.
Soft switch # 4 - "LOCAL/REMOTE"
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| Illustration 11 | g02459825 |
The following information explains each menu item.
The settings menu has four related menu items:
- Automatic/Manual
- Local/Remote
- Start disabled
- Switch beep
When the control is set to automatic, the DCU will perform automatic start and stop from a remote signal. An example of a remote signal is a power management system.
If the control is in manual, the DCU will not perform automatic start and stop functions.
The symbol "M" is visible in the status bar if the control is in manual.
Note: The DCU automatic mode will override a manual setting in the menu. The input for DCU automatic mode is terminal 88.
The mode will change to automatic if there is input from the menu or via a remote signal.
Select "Start Disabled" to disable all starts, local, and remote, on an engine.
Note: Caterpillar recommends removing the start battery connection before any maintenance work on the engine.
The switch beep selection allows the user to determine whether a switch press shall activate the buzzer.
The counters dialog displays engine-related hours.
The "Total" dialog shows the total accumulated engine hours. Depending on the configuration, the value is calculated in the DCU or read from the ECM.
The counter value cannot be reset by the operator.
The "Since Start" counter starts at zero every time the engine is started, and counts until the engine is stopped.
The since start counter value cannot be reset by the operator.
The "Since Reset" counter accumulates every time the engine is running. Press the "Reset" switch to zero the values since last reset.
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| Illustration 12 | g02508217 |
The DCU keeps a log of all events. The log retains approximately 500 events. After the limit is reached for the number of logged events that can be retained, the oldest event is deleted.
An event is any diagnostic, warning alarm, or engine shutdown situation. The list of events that are retained do not include switches pressed.
The events can be sorted as follows:
- Oldest first
- Most severe first
- Least severe first
- Count
Use the up and down arrow to navigate in the event log.
Use the timestamp function to expand a selected event to view the running hours and when the event happened.
For alarms, the second line will also display the running hours for an acknowledged and inactive situation.
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| Illustration 13 | g02527640 |
The DCU can be configured to indicate service from as many as four different service counters.
All counters have a predefined hour counter interval and count engine running hours.
"Service Due" is indicated with a wrench key icon (10). "Service Due" is not indicated in the alarm list. Refer to Illustration 13.
When service work is completed, select the desired menu item and press the "Service Done" switch to restart the counter for a new service interval.
The "Screen Backlight" function is used to select different screen backlight settings. The backlight settings are as follows:
- 10% backlight is as dark as can be
- 50% backlight is half full
- 100% backlight is fully lit
- Automatic varies between 10 % and 100% using an ambient light detector.
Select "units" to choose whether metric or U.S. measurement system is to be used.
- Metric (for example: Celsius, bar)
- U.S. (for example: Fahrenheit, psi)
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| Illustration 14 | g02508316 |
Use the "Language" function to select from any of the available panel languages. The list of available languages is as follows:
- English
- French
- Spanish
- Italian
- German
- Dutch
- Russian
- Norwegian
- Chinese
Note: Texts for configured instruments must be translated manually during installation.
If a language is selected for which there is no such manual translation, the default language will be used.
In the engine overspeed test mode, the engine can be tested for overspeed by lowering the overspeed set point to nominal speed.
- Ensure that the engine is not running. The over speed test mode cannot be entered while the engine is running.
- Confirm that the over speed set point has been lowered by observing the red arrow on the rpm meter.
- Start the engine and adjust the rpm until the rpm crosses the red labeled set point.
- Observe engine shutdown.
The over speed test times out after 5 minutes or when an actual over speed condition occurs.
The test can be turned off also by pressing the over speed icon again.
If the PC cannot connect to the DCU, there may be an IP address conflict.
Often, the IP address in a laptop PC cannot be changed by the user, since access is blocked due to company policy. If so, the PC IP address can only be set changed by a DHCP server when connected in a network where a DHCP server exists.
The DCU has a DHCP server that is built in in order to allow the process. The DHCP may be activated in order to issue a new IP address to the laptop.
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| Illustration 15 | g02508336 |
The current IP number (15), is in the DCU, is listed near the top of the display. The next lines of the display show a "Start" and "End" IP address. The display shows the range that the DHCP server will scan. A free address in the range will be given to the connected PC.
The DCU will preselect a range that is outside the current IP address of the DCU. The DCU IP address cannot be within the start and end IP address. Refer to Illustration 15.
Press the "Save" switch. The DHCP server will issue a new IP address to any PC already connected to the DCU. The DHCP server will issue a new IP address to any new PC connected within the "Timeout" period as shown in Illustration 15 as 10 minutes.
Note: The PC keeps the issued IP address even after the time-out.
If the DCU is connected to a local area network (LAN), the DCU cannot be installed to run several DHCP servers in the same LAN. Also, for LAN applications, the IP address of the DCU must be set within the address range of the LAN.
The configuration functionality is used to configure parameters for sensors that are related to the DCU.
Access to the parameters is password protected. Information to access the parameters is not provided for in this manual.
Up to Eight DCU 410 controllers can be displayed on one RP410.
Note: Ensure that you know what to do before attempting to change the design or layout of the display that is discussed in this section.
Note: Typically, changing the layout or the screens would only be accomplished by the engine supplier by using the web interface programming tool.
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| Illustration 16 | g02508356 |
The screen is made up of templates, slots, and widgets as shown in Illustration 16.
Widget - The widget is the instrument. A widget can be a circular dial or a horizontal bar.
Slot - The slot is the place holder for the widget. Not all widgets fit in all slots.
Template - The template defines where the slots are on the screen.
- Press "Insert" new. Use the up/down arrow switches to select a suitable template. Press "OK", and then "Save".
- Press "Slot Design".
- Press "Edit View".
Show/hide table
Illustration 17 g02508387 - Use the arrow switches to select a slot, then press "Pick Channel".
The slot is indicated by an area that has a bold boarder.
Show/hide table
Illustration 18 g02508390 - Using the arrow switches to select any signal from the list. Press "Select".
- Repeat Steps 3 through 5 until all slots are populated.
- Press "Exit".
Show/hide table
Illustration 19 g02508392 - Review the revised screens. Use the arrow switches to view the screens.
- Use the arrow switches to select the desired user screen.
- Press "Delete" to delete a screen.
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| Illustration 20 | g02508466 |
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Typical troubleshooting screen with power supply information | |
The DCU has a comprehensive set of troubleshooting screens for the DCU. The DCU has a comprehensive set of troubleshooting screens for each of the optional RIO expansion units. The following information relates only to the DCU.
The two power supplies are listed with information about voltage status and supply selection.
The switch screen indicates if the switch is open (0V) or closed (24V input) for each of the eight switch channels.
If the troubleshooting screen indicates open, and there is a 24V signal at the input channel, then the channel is faulty.
For each of the four 4-20mA channels, there is an indication of:
- The 2-25mA current is shown in mA
- Broken wire (<2mA)
- Short circuit (>25mA)
- Channel in use or not used
Each of the four PT100 channels can indicate:
- Value, in Celsius or Fahrenheit
- Faulty circuit
- Channel in use or not used
The "COM" screen lists communication status for communication ports COM 1, 2, 3, 4, 5 and 6.
The output screen lists the output status of DCU terminals 63 to 84.
As an example, if terminal 83 indicates Active (24V) and there is no 24V measured on terminal 83, then that output is faulty.
The "Input" choice lists the input status on DCU terminal 86 to 97.
As an example, if DCU terminal 89 is measured to 24V, but the troubleshooting screen for that channel indicates inactive, then that input is faulty.
A number of different sources can be configured to indicate, for the DCU, that the engine is running.
The "Run Indication Sources" page will reveal which source is providing the DCU with a running engine indication.
Use the "Switch Test" to confirm that all DCU switches are working.
To exit the test, press and hold soft switch 2, then press soft switch 4.
Use the "Version Information" choice to see information about the following:
- Hardware Version
- Software Version
- Connected ECM Version (if any)
- Own IP number