Epc50-50e Om 2-20

Operating Manual
EPC-50/50e AIR-FUEL CONTROLLERS
Form EPC-50/50e OM 2-20
HOERBIGER Engine Division

1.0 SYSTEM DESCRIPTION
1.1 The Altronic EPC-50 is an air/fuel ratio controller designed for use on low-
horsepower, carbureted natural gas-fueled engines. It employs microprocessor WARNING: DEVIATION FROM THESE
technology, allowing for a high level of sophistication in control strategy, ease INSTRUCTIONS MAY LEAD TO IMPROP-
of programming and diagnostic capability. The EPC-50 is designed for use on ER ENGINE OPERATION WHICH COULD
engines operating at or near a stoichiometric air/fuel ratio (lambda .95 - 1.05) CAUSE PERSONAL INJURY TO OPERA-
and is ideally suited for application with 3-way catalytic converters. The EPC-50 TORS OR OTHER NEARBY PERSONNEL.
is designed to be mounted in the engine/compressor control panel.
1.2 The single control output of the EPC-50 allows for its use on any engine ap- EPC-50E OPTION: TO TAKE ADVANTAGE
plication incorporating a single fuel gas regulator. An oxygen sensor is used in OF THE EPC-50E FEATURES, THE FIRM-
the exhaust stream to sense O2 content, and a thermocouple input signals when WARE UPDATER MUST BE INSTALLED TO
proper exhaust temperature has been reached to allow for accurate sensor op- THE LOCAL PC AND LOADED INTO THE
eration. The system fuel control valve installed in the fuel line to the carburetor EPC-50. SEE SECTION 21
is precisely adjusted by a stepper-motor under microprocessor control to main-
tain 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.
1.3 The EPC-50 has an alphanumeric LCD display which shows the target voltage,
sensor voltage, operating temperature, stepper motor position, and diagnostic
information.
1.4 Power requirement is 24 (10–30) Vdc, 1 amp. In remote areas, power can be pro-
vided by the Altronic 24Vdc Alternator Power Package. Refer to Altronic Form ALT.
1.5 The EPC-50 also incorporates a thermocouple input and a dedicated output for
implementation of catalyst over-temperature protection. A second digital output is
available for use as an alarm for diagnostics or uncontrolled operation.
2.0 SYSTEM COMPONENTS
2.1 One part from each group below is required for each installation:
PART NO. DESCRIPTION QUANTITY REQUIRED

EPC-50 Air/fuel controller 1 per engine
690153-1 Control Valve, .75" NPT 1 per engine
690154-1 Control Valve, standard 1.5" NPT 1 per engine
690154-2 Control Valve, low HP 1.5" NPT 1 per engine
690154-5 Control Valve, very low HP 1.5" NPT 1 per engine
690220-1 Control Valve, butterfly 2.0" NPT 1 per engine
693013-1 Cable, control valve, 30 ft. 1 per engine
693006-1 Cable, oxygen sensor, 25 ft. 1 per engine
693006-2 Cable, oxygen sensor, 50 ft. 1 per engine
610621 Oxygen sensor 1 per engine
** “K” Thermocouple Probe 1 per engine, plus 1 for
(ungrounded w/thermowell) Catalyst Out
** “K” Thermocouple Ext. Wire 50 ft. per thermocouple
** 12-16 AWG Hook-up Wire 150 ft. per engine
** Not supplied in Altronic kits.
2.2 Accessory Kits

691305-1 Accessory Kit Includes:
610621 Oxygen Sensor
693013-1 Cable Assembly, Control Valve, 30 ft.
693006-1 Cable Assembly, O2 Sensor, 25 ft.
EPC-50/50e OM 2-20
All rights reserved © ALTRONIC, LLC 2020 2
691305-2 Accessory Kit Includes:
610621 Oxygen Sensor
693013-1 Cable Assembly, Control Valve, 30 ft.
693006-2 Cable Assembly, O2 Sensor, 50 ft.
691306-KT EPC-50e Kit Includes:

691306-1 Enhanced Adaptor
609035-1 CD-ROM
610372 Screw Driver
2.3 See Figure 1 for general layout of EPC-50 components.
3.0 MOUNTING THE EPC-50
3.1 Operating temperature range is -40°F to 158°F / -40°C to 70°C. Humidity spec-
ification is 0-95%, non-condensing. Mount the EPC-50 inside a control panel,
preferably off the engine, in such a manner as to minimize exposure to vibration.
The Control Module should be mounted so that the display is at a convenient
viewing height. See Figure 2 for mounting dimensions. A NEMA 3R housing
(720004-1) is also available as an alternative mounting option, see Figure 3.
Avoid mounting the LCD display and keypad in direct sunlight.
4.0 MOUNTING THE OXYGEN SENSOR
4.1 The sensor should be installed in the exhaust system between the engine and the
NOTE: A WELDMENT BOSS MAY BE catalytic converter and/or muffler. The mounting location should be as close to
REQUIRED FOR SENSOR INSTAL- the exhaust manifold of the engine as possible. The tip of the sensor should be
LATION IN SOFT OR THIN WALL exposed to the unobstructed flow of the exhaust gases from all cylinders of the
EXHAUST SYSTEMS. engine. This means that the sensor should be mounted near, but still before, the
exhaust stack. DO NOT locate the sensor in a coupling or in a location where the
exhaust gas flow is uneven due to obstructions or sharp bends. The sensor loca-
tion should allow easy access since sensor replacement may be required as often
as every 2000 hours in some applications. The location should not subject the
exterior shell of the sensor to an ambient air temperature greater than 350°F.
4.2 Drill, tap, and spot face a hole in the exhaust pipe at the selected location. A
flat, smooth sealing surface is required to assure accurate readings since air or
exhaust leaks will impact sensor operation. See Figure 4 for details
4.3 New sensors are packaged with an anti-seize compound applied to the threads.
There is no need to apply additional anti-seize unless reinstalling a used sensor.
If required, use high temperature anti-seize very sparingly and apply only to the
sensor threads. Sensors should be torqued to 28-34 lb.-ft.
5.0 MOUNTING THE K-TYPE THERMOCOUPLES
5.1 An exhaust temperature thermocouple is used to monitor the temperature of

exhaust gases near the exhaust oxygen sensor. It should be mounted as close
as possible to the O2 sensor. As with the O2 sensor, the location should be easily
accessible, and the tip of the probe, which should be enclosed by a thermowell,
should be surrounded by unobstructed exhaust flow.
5.3 Catalyst protection thermocouple should be installed in the catalyst housing.

Provision for thermocouple installation is normally incorporated in the design
and manufacture of the catalyst. Installation of the thermocouple at the outlet
of the catalyst provides two modes of protection: High Outlet Temp Shutdown
and High Catalyst Temperature Rise Shutdown. Consult the recommendations of
the catalyst manufacturer for required overtemp protection.
5.3 Only ungrounded thermocouple probes can be used with the EPC-50. Grounded
type thermocouples will not function correctly. Resistance from either lead of
the thermocouple to the probe shell should be 2 megohms or greater.
EPC-50/50e OM 2-20
6.0 MOUNTING THE FUEL CONTROL VALVE
6.1 In order to control the air/fuel ratio, an electronically controlled valve is con-
nected in series between each regulator and carburetor. The valve should be NOTE: FOR DETAILED INSTRUC-
installed as close to the fuel inlet of the carburetors as possible. The distance TIONS COVERING THE GAS CONTROL
from the valve to the carburetor inlet should not exceed 12 pipe diameters in VALVE, SEE FORM GCV1 OM (690154
length. The valve should be installed with the control cable connector facing SERIES) OR GCV2 OM (6902XX
upward to avoid the collection of condensation in the stepper motor. SERIES).
6.2 If possible, connection piping should be of the same diameter as currently in
use. The threaded connection to the valve body may require the use of thread
adaptors. If adaptors are used, proper plumbing procedures must be followed.
6.3 The control valve is connected to the EPC-50 using the 693013-1 cable. The
cable wires are color-coded and must be connected to the valve output terminal
block of the EPC-50 according to color. This cable must not be run in the same
conduit as the ignition primary or other O2 sensor or thermocouple wires. A dis-
tance of 4 to 6 inches should be maintained between EPC-50 wiring and other
engine wiring.
7.0 ELECTRICAL HOOK-UP
7.1 The power connections to the EPC-50 must be in accordance with the National
Electrical Code. The EPC-50 is suitable for installation in Class I, Division 2,
Groups C and D locations.
7.2 Although the input power has an internal protective fuse (3 amp), an external
fuse (5 amp max.) near the power source is recommended.
7.3 The EPC-50 can be powered in one of the following ways:

• 24 volt battery with trickle charger (1 amp min. output). NOTE: VOLTAGE AND CURRENT SUP-
• DC power supply capable of furnishing 12-30Vdc, 2 amps. PLIED MUST BE SUFFICIENT TO OPER-
• Altronic 24Vdc Alternator Power Package – see form ALT. ATE ALL TRANSDUCERS USED IN THE
INSTALLATION. IF A HEATED OXYGEN
7.4 Power wiring and signal (transducers) wiring must be in separate conduits and SENSOR IS REQUIRED, THE HEATER
conduit entries into the panel containing the EPC-50 to avoid undesired electri- CURRENT MUST BE ADDED TO THE
cal interaction. REQUIREMENTS SHOWN.
7.5 Input power supply wires (16 AWG minimum) should connect to the 24 volt sup-
ply terminals of the main terminal block.
7.6 The oxygen sensor is connected via shielded cable P/N 693006. This should be
run in conduit only with the EPC-50 thermocouple connections. These cables NOTE: ENGINES USING POSITIVE
should enter the panel containing the EPC-50 and connect to the main terminal GROUND DC ACCESSORIES OR
block. The red wire should be connected to the O2 sensor (red) terminal, and the STARTER MOTORS WILL REQUIRE A
black wire to the O2 sensor (black) terminal. The shield wire should be cut short SEPARATE, DEDICATED, UNGROUND-
and not connected. The cable provided is terminated with weather-tight connec- ED POWER SUPPLY FOR THE EPC-50.
tors which mate to the O2 sensors provided by Altronic. The shield wire (green
wire at connector end) must be connected to the exhaust piping near the sensor.
This shield will assist in rejecting noise from other wiring which could affect the
O2 sensor signal. Refer to Figures 4 and 5.
7.7 The thermocouple (24 AWG min., type K extension) wires should be run in a
conduit only with the EPC-50 O2 sensor wires. The yellow wire should be con-
nected to the T/C (yellow) terminal and the red wire to the T/C (red) terminal.
Care should be taken to identify the two thermocouple wires (TC1 and TC2).
Refer to Figure 5.
7.8 The Catalyst Temp Protection Shutdown Output is configured as a normally-

closed output signal. Any of three protection shutdown diagnostic temperature
thresholds can cause this output to open. Connect this output to the safety shut-
down system in combination with a relay to result in an engine shutdown for the
purpose of catalyst protection. This output is non-latching and is self-resetting
upon the clearing of related protection conditions. (Solid State Switch Rated 30
EPC-50/50e OM 2-20
Volts/0.5 Amps max.) The protection shutdown switch is labeled SW2 and a red
LED indicator located below the terminal will turn on when the switch opens to
indicate the shutdown condition.
7.9 The Alarm Output is configured as a normally-closed output signal. Any diagnos-
tic relating to measured temperatures, O2 sensor voltages, or rich or lean limit
stepper positions will cause this output to open for identification of possible
improper airfuel control system operation. This output is non-latching and is
self-resetting upon the clearing of all the alarm conditions. (Solid State Switch
Rated 30 Volts/0.5 Amps max.) The Alarm Shutdown Output is labeled SW1
and a yellow LED indicator located below the screw terminal will turn on when
the switch opens to indicate an alarm or diagnostic condition.
7.10 Although the EPC-50 does not require a computer to be operated or installed, a
serial port has been included which can be used for MODBUS RTU slave com-
munications using an RS-485 connection. The port configuration is accomplished
using the display and keypad as described in sections 12.12 and 12.13.
8.0 THEORY OF OPERATION

8.1 The primary task of the EPC-50 is to accurately control the exhaust air fuel ratio
(AFR) of an engine. Control should be maintained through reasonable load and
fuel BTU variations.
8.2 Three-way catalysts are used to oxidize CO and HC and to reduce NOx. These
processes require high temperature and correct AFR control. Catalysts perform
best for all emissions when operated near the stoichiometric AFR.
8.3 The stoichiometric AFR is the AFR at which exactly the required amount of air (O2)
is present to completely burn all of the fuel. Because no engine can perform perfect
combustion, typical emission by-products include O2, HC, NO, and CO even though
the engine is running at stoichiometry. The stoichiometric AFR is determined by the
chemical composition of the fuel, thus they are different for each fuel, or BTU rating.
(e.g., Methane => 16.09 : 1 and Gasoline => 14.70 : 1)

8.4 Because the fuel type is not always known, it is often easier to specify the AFR
target in terms of lambda. Lambda is an indicator of AFR normalized to the ap-
propriate stoichiometric AFR.
(Lambda Actual AFR/Stoichiometric AFR)
Thus lambda for stoichiometric combustion would be 1.0, no matter what fuel is used.
Lambda > 1 = Lean, Lambda < 1 = Rich.
8.5 An O2 sensor (lambda sensor) is used to provide exhaust AFR feedback to the
EPC-50. This type of sensor uses a zirconia element which, when combined with
a catalyzing outer surface, creates an output voltage used to indicate lambda.
Characteristics of the sensor include: an output range of about 0.1 to 0.9 volts
when above 650°F, a very high output impedance when cool, a very high sensi-
tivity at stoichiometry, and a very low sensitivity away from stoichiometry. The
output signal provides a very suitable means of controlling just rich of lambda
1.0, which is the AFR range required to obtain best catalyst efficiencies for
methane-based fuels.
8.6 A type K thermocouple is used to assure that exhaust temperatures are high
enough for correct operation of the sensor before closed loop control is enabled.
An additional thermocouple is used to monitor outlet temperature. The EPC-50
was designed for use on small engines where the catalyst is assumed to be close
to the engine. The engine out temperature is assumed to be representative of
the catalyst in temperature. The three shutdown thresholds are Engine/CatIn
temperature too high, CatOut temperature too high, and Catalyst temperature
rise too high. Temperature limit setpoints are provided to create a catalyst pro-
tection shutdown capability.
EPC-50/50e OM 2-20
8.7 An electronic valve is used to create a variable restriction between the fuel
pressure regulator and the carburetor inlet. This restriction is used to adjust
the effective inlet pressure seen by the carburetor and results in a mechanical
adjustment of the air/fuel mixture delivered by the carburetor. A stepper motor
adjusts the restriction by moving a plunger inside the valve. A stepper motor is
a brushless motor consisting of a permanent magnet armature and a four-coil
multi-pole stator. The armature is moved by sequentially pulsing the four stator
coils. Coupled to a worm screw, the rotating armature of the motor provides very
accurate linear positioning capability. The motor used provides 1700 steps of
travel at .0005 inch/step for a total valve stroke of 0.85 inch.
8.8 The EPC-50 adjusts the stepper motor to maintain a specific input voltage from
the O2 sensor. When the sensor voltage is above the O2 target voltage, the sys-
tem is richer than desired, and the stepper position is increased to further re-
strict fuel flow to the carburetor. Conversely, when the sensor voltage is below
the O2 target voltage, the system is leaner than desired, and the stepper position
is decreased to reduce the restriction of fuel flow.
8.9 Because the sensor voltage output is not linear with lambda, it would not be
practical to adjust the system faster when the error from the set-point is greater.
So, in order to maximize the control response, the motors are instead adjusted
faster as the error persists longer. This method provides rapid response charac-
teristics as well as control stability. Control target voltages must be determined
with the use of an exhaust analyzer to locate the operating point of lowest stack
emissions. These target values are adjustable in the EPC-50 through the key-
pad. The resulting system provides accurate and stable control of air/fuel ratio
which results in high catalyst efficiencies and reduced stack emissions.
9.0 PRE-START INSTALLATION CHECKLIST
9.1 Before applying power to the EPC-50:
A. Measure the power supply voltage to assure voltage is within limits (12-30
volts). Leave unit unpowered.
B. With the terminal block disengaged, use an ohm meter to measure resis-
tance between the black O2 sensor wire and the earth ground of the panel.
This should be less than 1 ohm. Also measure the resistance between
earth ground and the common of the 24v power supply terminal to verify
that it is less than 1 ohm.
C. With the main terminal block disengaged, measure voltage between yellow
and red thermocouple wires. The voltage should be 0.80-1.50mV for tem-
peratures 60-100°F. This verifies that thermocouple wires are terminated.
If engine has been running, measurements will be higher, reflecting higher
actual temperatures.
D. With the terminal block still disengaged, measure resistance between the
red wire and the still-connected earth ground terminal. Resistance should
be very high or open circuit. Repeat measurement between yellow wire
and earth ground. This verifies that thermocouples are ungrounded and
that wires are not shorted in conduit.
9.2 With the EPC-50 powered up and the engine not running:
A. Display should follow the power-up sequence described in section 11.0.

NOTE: IF ENGINE WAS RUNNING
B. Display of O2 sensor voltage should go to 0.5 volts. This may require a few RECENTLY, TEMPERATURE WILL BE
minutes. Section 14.0 explains how to view data screens. HIGHER.
C. Data display screen for exhaust temperatures should indicate ambient

temperatures.
D. Control valve operation should be verified during a start position command.

This can easily be done if the valves are not yet fully installed in the fuel
EPC-50/50e OM 2-20
line. Press ALARM ACK if the alarm LED is on. Then press F1 followed by
START POS. During the start position activity, the left valve plunger should NOTE: GROUND LOOPS COULD BE MORE
be fully retracted, then positioned near the middle of its travel. No move- SIGNIFICANT WHEN THE ENGINE IS
ment, erratic movement, or movement in the wrong direction will result from RUNNING. THE ADDITION OF OTHER
incorrect wiring of the stepper cables. ELECTRICAL DEVICES MAY AFFECT EPC
OPERATION WITH REGARD TO SIGNAL
F. Return the setup values to the factory defaults. This can be done by slowly OFFSETS.
pressing the following keys in order: F1, F3, F2, F4. Then, once the screen
indicates that you are in the setup mode, press F2 followed by F2 again
to restore default setup values. Then press F4 to exit the setup mode. The
default values are set as follows:
Gain Value = 0.50

Left O2 Target = 0.80 volts
Left Default Position = 1000 steps

G. Configure catalyst protection thresholds. Reasonable value ranges for pro-
tection thresholds are shown below. These max. temperature limit values NOTE: SETTINGS SHOULD BE ESTAB-
should be configured based on the recommendations of the catalyst manu- LISHED BASED ON THE RECOMMENDA-
facturer. This can be done by slowly pressing the following keys in order: F1, TION OF CATALYST MANUFACTURER.
F3, F2, F4, then F1 to view each successive setup parameter:
Exh Temp Hi = (1000 to 1250°F)

Cat Out Hi = (1100 to 1250°F)
Cat Rise Hi = (100 to 300°F)
9.3 When all of these checks have been made successfully, move on to the Start-
Up Procedure.
10.0 START-UP PROCEDURE
10.1 Before starting engine:
A. Check for fuel leaks where the fuel line was modified.
B. Verify that catalyst over-temp thermocouples and thresholds are in place and
functional according to catalyst provider requirements and recommendations.
C. Press F1, then press START POS on the EPC-50 keypad to reset stepper
position and enable the warm-up delay.
D. Be sure that the power screw adjustments on carburetors are fully open or
fully rich. If these adjustments are not fully open, the control range of the
stepper control valve will be limited.
E. If the alarm outputs of the EPC-50 are being used, temporarily disconnect
or override these signals so that an alarm indication will not shut down the
engine during setup.
F. Verify that the catalyst protection output is wired and functional to cause a
shutdown in an overtemp condition.
G. Place EPC-50 controller in manual mode by pressing the LEFT MAN key.
H. Start and warm-up engine.
EPC-50/50e OM 2-20
10.2 With the engine running:
A. Load engine to desired operating point.
B. Verify that the exhaust temperature data screen is displaying reasonable

values, and that the temperatures exceed 650°F. Refer to section 14.0 for
display key operation.
C. Enable automatic control by pressing the AUTO OPER key. The unit should
begin adjusting the stepper valves, trying to control the engine air/fuel
ratio. Use any diagnostic warnings which may occur to trouble-shoot the
system. Rich or lean limit errors are a good indication that the pressure
regulators need some adjustment.
D. Once the unit has gained control of the engine (O2 sensor voltage very near
the target voltage), adjust the fuel pressure regulators until the EPC-50 is
controlling with the stepper valve positions near 1000 steps. This is ap-
proximately the middle of the valve’s control range.
10.3 Fine tune the control setpoints:

A. Using an exhaust analyzer, determine the set-point voltage which results
in the best emission performance. This can be done by incrementally ad-
justing the O2 target voltage in the setup mode. Reference section 12.0 for
an explanation of the setup mode. Alternatively, manual mode can be used
to adjust the control valves to the positions which give the best emissions
performance. Reference section 15.0 for an explanation of manual mode
operation. The O2 target voltages should be adjusted to match the actual
sensor voltages using the setup mode.
B. The control gain rate and default stepper positions can also be adjusted,
however, the default values represent the best typical values for these
parameters.
10.4 Once the system is controlling at the best emissions point, the alarm output
can be re-enabled.
10.5 The EPC-50 setup is now complete; the unit should be controlling the engine.
11.0 GENERAL: KEYPAD AND DISPLAY OPERATION
11.1 The EPC-50, or 50e (for enhanced), includes a front-mounted keypad and an LCD
display which permits the monitoring and adjustment of various parameters and actions. Altronic Inc.
11.2 The keypad and display function together as the user interface. Only one key on EPC-50-1
the pad should be pressed at a time. Some commands require a key sequence
(a series of key presses, one followed by the next). Whenever possible, special OR
messages indicate what is happening or why a command is not accepted.
Altronic Inc.
11.3 With the engine not running (cool exhaust), when power is first applied to the
EPC-50, the display will show an Altronic product description message, then
EPC-50e-
perform an F1-Start function.
11.4 After a few seconds, the display will indicate that the controller is in warm-up
mode. This display indicates that the thermocouples are still reading tempera- AutoWarmUp1000
tures too cool for the O2 sensors to function correctly. The number at the end of
the message indicates the current stepper valve position in steps. If the engine
is not started this condition will persist for 10 minutes.
11.5 After 10 minutes with a cool exhaust, the display will begin rotating through the
diagnostic messages for low exhaust temperature. All diagnostic messages in-
clude the ! character for recognition. Diagnostics exist for several functions and
are explained in detail in section 16. When any diagnostic condition is present,
the status containing ! will appear, then all of the appropriate descriptions will
follow in rotation. O2 sensor voltage and stepper valve position are also shown.
EPC-50/50e OM 2-20
11.6 Press ALARM ACK. When a new alarm (ALM) or protection shutdown condition
(PSD) is detected, the user keypad functions will be restricted until the user !Auto!.802v1000
acknowledges the new condition. The message ALARMS MUST BE ACKNOWL-
EDGED! will be triggered by keypad presses until the ALARM ACK key is pressed
to acknowledge the new condition. Pressing ALARM ACK does not affect any
other indicators or outputs of the EPC-50. The display will indicate that the unit AND
is responding to the ALARM ACK key press by showing the message WORKING.
The low temperature alarm has now been acknowledged and the EPC-50 will
!Auto!.802v1000
accept other keypad commands. When the alarm LED is on steady, no keypad ALM! ExhTemp°LO!
commands will be accepted until the ALARM ACK key is pressed. The display will
indicate that the unit is responding to this command with message WORKING.
12.0 SETUP MODE: KEYPAD AND DISPLAY OPERATION
12.1 Once any alarm is acknowledged, press F1, followed by F3, followed by F2,
followed by F4. This is the setup mode entry key sequence. The display will
indicate that the setup mode is now active.
$$$ SETUP $$$

F1=Next F4=EXIT

12.2 Press F2, then press F2 again to restore factory default parameters. This special
command can be used only from this screen when the user wants to restore factory NOTE: THE FACTORY DEFAULT PSD
default values. A message will indicate that the default values have been restored, SETTINGS ARE VERY CONSERVATIVE
then will return to the main setup message. Default control values are in section AND WILL MOST LIKELY RESULT IN THE
9.2. There is a second restore defaults command sequence: F3, then F2, that will SHUTDOWN OF A LOADED ENGINE.
reload all factory defaults with regard to diagnostic and PSD thresholds. These are
kept separate to avoid changing protection settings for the catalyst.
F2 RESTORING
F2
DEFAULT SETUP
THEN
$$$ SETUP $$$

F1=Next F4=EXIT

12.3 Press F1 to increment to the control gain setup screen. The factory default value
for this parameter is 0.50 as shown on the display. This parameter determines the
stepper valve adjustment rate when in automatic mode. The higher the value, the
faster the controller will move the stepper in response to the O2 sensor.
$ F2=Up F3=Dn $
F1
GAIN VALUE=0.50

12.4 Press F2 to increase the value for the gain parameter. The display will indicate
that the value has been changed. The updated value will be used until the value
is changed again.

$ F2=Up F3=Dn $
F2
GAIN VALUE=0.60

EPC-50/50e OM 2-20
12.5 Press F3 to decrease the value. The value is decreased to the default value.
The range for the gain value is limited to 0.1 to 2.0. The value cannot be moved
NOTE: ALL SCREENS IN SETUP MODE
beyond its limits.
INCLUDE THE $ CHARACTER.

$ F2=Up F3=Dn $
F3
GAIN VALUE=0.50

12.6 Press F1 to increment to the left O2 target setup screen. The factory default
value for this parameter is 0.80 volts as shown on the display. Like the gain
value, the target can be increased and decreased with the F2 and F3 keys. The
typical range is near 0.8 volts. The allowable range is 0.01 to 1.05; however, the
output range of most sensors is limited to 0.1 to 0.9 volts.
$ F2=Up F3=Dn $
F1 O2SetPnt=0.800v

12.7 Press F1 to rotate to the left default stepper position screen. The default posi-
tion is used when any of the O2 sensor or thermocouple diagnostics are active.
The number on the right is the current default position. Because the tempera-
ture diagnostic is still active, the actual stepper position on the left is also 1000.
$F2=chng L.dflt$
F1 1000 ---> 1000

12.8 Press F2 to update the default position (on right) with the value of the current posi-
tion (on left). Since both values are the same no change was actually made in this
example. By using the manual mode described in section 15.0, the actual position
can be adjusted to the desired position before entering the setup mode. NOTE: MULTIPLE PRESSES OF THE KEY
ARE REQUIRED TO CONTINUE INCRE-
MENTING THE VALUE. IF THE KEY IS
UPDATING HELD, THE VALUE WILL BE ADJUSTED AT
F2 DEFAULT POSITION A PROGRESSIVELY FASTER RATE.
THEN
$F2=chng L.dflt$
1000 ---> 1000
12.9 Press F1 to rotate to the first temperature protection setup value. The Exhaust
Temperature Hi setpoint represents the maximum permitted engine exhaust tem-
perature as sensed by the left engine out thermocouple mounted near the O2 sen-
sors. High temperatures at this location may indicate engine overload or engine
misfire. The Catalyst Temperature Protection Shutdown output switch will open if
this threshold is exceeded, causing a protection shutdown.

$ F2=Up F3=Dn $
F1 ExhTempHI=1000°F

12.10 Press F1 to display the Catalyst-Out Hi temperature setpoint threshold. If the
outlet temperature of the catalyst should exceed this setting, the Catalyst
Temperature Protection Shutdown output switch, as well as the ALARM out-
put switch, will open, causing a protection shutdown. Conditions of misfire or
overload, or improper engine operation, may be identified by this test. Extreme
temperature at the outlet of the catalyst indicates that the catalyst is being dam-
aged by the operating conditions of the engine. Provision may be provided in the
EPC-50/50e OM 2-20
catalyst to mount a temperature probe at the catalyst element. This location may
serve as an alternative to catalyst outlet temperature. Consult the catalyst manu-
facturer for the recommended outlet-temperature shutdown limits.

$ F2=Up F3=Dn $
F1 CatOutHI =1100°F

12.11 Press F1 to display the Catalyst Temperature Rise Hi setpoint threshold. The
temperature difference outlet–inlet is compared to this setpoint to identify ex-
cessive temperature rise across the catalyst. The catalyst inlet temperature is
assumed to be the same as the engine out exhaust temperature thermocouple.
This condition of temperature rise is an indication that the catalyst is reacting to
unburned air and fuel that may result from a misfire or poor combustion condi-
tion. If the temperature rise across the catalyst should exceed this setting, then
the Catalyst Temperature Protection Shutdown output switch will open, causing
a protection shutdown. Consult the catalyst manufacturer for the recommended
temperature rise shutdown limits.

$ F2=Up F3=Dn $
F1 CatRiseHI= 100°F

12.12 Press F1 to display the ModBus Node ID setup screen. Valid node ID’s are 0 to
255, permitting the communication system to incorporate multidrop communi-
cations to various ModBus slave devices.

$ F2=Up F3=Dn $
F1 ModBus ID=50

12.13 Press F1 to display the ModBus port setup screen. Various baud rates are sup-
ported by the EPC-50. The selections include baud rates of 600, 1200, 2400,
4800, 9600, 19200, 38400, and 57600.

$ F2=Up F3=Dn $
F1 BaudRate 9600n81

12.14 Press F1 to rotate to the main screen.

$$$ SETUP $$$
F1 F1=Next F4=EXIT

12.15 Press F4 to exit the setup mode. F4 can be used from any setup screen. All setup
screens include the $ character. Pressing F4 returns the display to the warning mes-
sage which was caused by low exhaust temperatures.
!Auto! .802v1000 NOTE: LOADING DEFAULT SETTINGS AS

F4 DESCRIBED IN SECTION 12.2 DOES NOT
AFFECT SETTINGS RELATING TO THE
CATALYST TEMP ALARM OUTPUT OR
AND MODBUS CONFIGURATION.
!Auto! .802v1000

ALM! ExhTemp°LO!
EPC-50/50e OM 2-20
13.0 ENGINE STARTUP: KEYPAD AND DISPLAY OPERATION
13.1 Press ALARM ACK to acknowledge alarms if alarm LED is ON.
13.2 Press F1, then press START POS to send the steppers to start position (stepper
default position) and disable the alarm warnings due to a cold engine for 10 min-
utes. The controller will return each stepper to its start position and then display the
warm-up screen. This procedure should ALWAYS be used when starting the engine.
Moving Stepper
F1 to Zero Pos.
Moving Stepper
to START Pos.
AutoWarmUp1000

13.3 Now the engine should be started, warmed up and loaded. Temperature require-
ments will be met before the 10 minute delay expires, and the controller will
go into automatic control. Both the current O2 sensor voltage, and the current
stepper valve position are provided on the automatic display screen.

AUTO .812v1010

4.0 DATA VIEWING: KEYPAD AND DISPLAY OPERATION
14.1 Press DSPL SEL to display the first data view screen. The first data screen dis-
plays the current O2 sensor voltages.
DSPL AUTO .625v 985

SEL 02Sensor=.625v

14.2 Press DSPL SEL again to display current O2 target voltages.
DSPL AUTO .625v 985

SEL 02Target=.800v

14.3 Press DSPL SEL again to display the engine out exhaust temperature reading
from thermocouple TC1 which is located near the O2 sensor.
SINGLE BANK TC1
DSPL AUTO .625v 985

SEL EXH TMP=1049°F
EPC-50/50e OM 2-20
14.4 Press DSPL SEL again to display the catalyst inlet temperature which is as-
sumed to be the same as engine out exhaust temperature as measured by TC1.
DSPL Cat Rise=+ 24°F

SEL In=1098 Out=1125

14.5 Press DSPL SEL again to display TableA and TableB, Reg Val, X input and Y output
(EPC-50e version only).
DSPL TblA= 503=+.000

SEL TblB= 4773=+.000

14.6 Press DSPL SEL to display TableC, X input and Y output, Aux Input voltage and
Max-units (EPC-50e version only).
DSPL TblC= 4773=0.000

SEL AUX1=4.773= 5
OR
TblC= 2122=0.200
NOTE: WHEN 40063=0, AUX INPUT
AUX1 O2SNS=.532v IS ASSUMED TO BE AN O2 SENSOR
WITHOUT THE ADAPTOR. SEE SECTION
23.0.
14.7 Press DSPL SEL again to return to the automatic screen.
DSPL AUTO .811v1010

SEL

15.0 MANUAL MODE: KEYPAD AND DISPLAY OPERATION

15.1 Press MAN to enter the manual mode. The display will indicate WORKING and
then return to manual mode. This mode can be used to help setup the controller, NOTE: BOTH THE ALARM LED AND
and to diagnose problems. Because no diagnostic alarms are present, it was not THE ALARM OUTPUT RETURN TO THE
necessary to acknowledge alarms. Also, once in manual mode, diagnostic alarms NORMAL CONDITION WHEN THE SYSTEM
are disabled. In manual mode, the alarm output SW1 will be open and the yellow FAULT IS CORRECTED.
LED will be on to indicate system is not in automatic control.
LEFT MAN! .811v1010

MAN

EPC-50/50e OM 2-20
15.2 Press LEFT LEAN to increase the stepper position by 25 steps. A descriptive
message will be displayed and then the modified position will be returned. In-
creasing the position causes the valve to close and the mixture to change in the
lean direction.
LEFT MOVING
LEAN STEPPER
THEN
MAN! .811v1035

15.3 Press LEFT FAST, then LEFT LEAN to increase the stepper position by 100 steps.
LEFT LEFT MOVING

FAST LEAN
STEPPER
THEN
MAN! .811v1135

15.4 Press LEFT RICH to decrease the stepper position by 25 steps. Decreasing the
position causes the valve to open and the mixture to change in the rich direction.
LEFT MOVING
RICH NOTE: WHEN F1, THEN START, ARE
STEPPER PRESSED BEFORE STARTING THE
ENGINE, THE EXHAUST TEMPERATURE
THEN DIAGNOSTIC WILL BE DELAYED 10
MINUTES, DISPLAYING THE WARM-UP
SCREEN.
MAN! .811v1110

15.5 Press AUTO OPER to return to automatic mode. Whenever this key is pressed,
automatic mode will be enabled for both banks.

AUTO AUTO .811v1110

OPER

15.6 POSITION UNCERTAIN — If power to the EPC-50 is interrupted, the display reads
*Pos.UnCertain* and may or may not blink. This occured because the position was
not saved automatically at the moment of power loss/interruption. Typically this
would occur if the EPC-50 were powered up while the engine was running.
AUTO AUTO .811v1110

OPER *Pos.UnCertain*

EPC-50/50e OM 2-20
It is important to note that this is a temporary and resolvable condition. The
EPC-50 is functioning properly and, if it is in AUTOMATIC mode, it will correct
itself. If the EPC-50 is in MANUAL mode, the proper display setting can be
restored by performing an F1 start.
16.0 DIAGNOSTIC DISPLAYS AND OPERATION
16.1 ALARM OUTPUT — The ALARM output is configured as a normally-closed out-

put signal. Any system fault will open the alarm circuit, including loss of power,
diagnostic warnings, etc. As described above, the alarm output will be in the fault
condition (open) whenever an unacknowledged alarm or shutdown is present.
16.2 SYSTEM DIAGNOSTICS — The system diagnostics included in the EPC-50

are designed to identify conditions which are not considered normal operation.
These diagnostic tests are performed continuously while the controller is in
automatic mode. Each of the diagnostics will display a descriptive message and
place the alarm output in the fault condition (open).
16.3 DIAGNOSTIC WARNING MESSAGES — Active diagnostic warning messages

include the ! character and are displayed in rotation, each message being dis-
played for about 1 second. The home screen uses the ! character to indicate the
status and that other diagnostics will follow in rotation.

!Auto!.765v1000

16.4 EXHAUST TEMPERATURE — The Exhaust Temperature diagnostic monitors the

exhaust temperatures near the O2 sensors, as measured with the thermocou-
ples. If the temperature is below 650°F or above 1400°F, the EPC-50 displays
the appropriate low or high message and activates the Alarm LED and Alarm
output. Automatic control is also disabled and the stepper valves are positioned
at the default stepper position. Thermocouple probe or thermocouple connec-
tion failures will also activate this diagnostic.
!Auto! .800v 982

ALM! ExhTemp°LO!
OR
!Auto! .800v 982

ALM! ExhTemp°HI!
16.5 SENSOR NOT READY — The Sensor Not Ready diagnostic is designed to iden-
tify problems with the O2 sensor. The controller has a very high impedance pull
up resistor to 0.5 volts in parallel with each exhaust sensor input. When the
sensor is too cool or disconnected this will force the input to read 0.5 volts. If
the controller sees that the sensor output is 0.5 volts for 10 or more seconds the
EPC-50 will display the sensor not ready message and activate the Alarm LED
and Alarm output. Automatic control is also disabled and the stepper valves are
moved to the default stepper position. The sensor ready test is only performed if
the exhaust temperature requirements of 16.4 are satisfied. Failure of this test
indicates a cold, disconnected or failed sensor.
!Auto! .800v 1000

ALM! O2 NotRdy !

EPC-50/50e OM 2-20
16.6 SENSOR INPUT VOLTAGE — The Sensor Input Voltage diagnostic is also de-
signed to identify problems with the O2 sensor. Normal input voltages should be
between 0.1 and 0.9 volts. If the sensor input voltage is less than 0.1 volts, or
more than 1.1 volts, the EPC-50 will display the appropriate low or high mes-
sage and activate the Alarm LED and Alarm output. Automatic control is also
disabled, and the stepper valves are moved to the default stepper position.
Failure of this diagnostic test indicates shorted wiring or a failed sensor.

!Auto! .800v 1000
ALM! Exh O2v LO!
OR
!Auto! .800v 1000

ALM! Exh O2v HI!

16.7 LEAN AND RICH LIMIT — The Lean and Rich Limit diagnostic monitors the
stepper positions. If the position of a stepper valve is at the minimum (0) or
maximum (1700) travel limit, the EPC-50 displays the appropriate message
and activates the Alarm LED and Alarm output. The rich limit warning indicates
that the engine is too lean and the controller cannot open the valve any farther
to enrich the mixture. The lean limit warning indicates that the engine is too rich
and the controller cannot close the valve any farther.

!Auto! .800v 0
ALM! Rich Limit!
OR
!Auto! .800v 1700

ALM! Lean Limit!

16.8 ENGINE OUT EXHAUST OVER-TEMPERATURE — When the left or right bank
exhaust temperature exceeds the setup threshold, the alarm output will open,
the alarm LED will turn on, the Catalyst Protection Alarm output (PSD) will
open, and the message below may be displayed.
AUTO!WARN!1000
PSD! ExhTemp°HI!

16.9 CATALYST OUTLET OVER-TEMPERATURE — When the outlet temperature of
the catalyst exceeds the setup threshold, the alarm output will open, the alarm
LED will turn on, the Catalyst Protection Alarm output (PSD) will open and the
message below is displayed.
Auto!WARN!1000
PSD! CatTemp°HI!

EPC-50/50e OM 2-20
16.10 CATALYST TEMPERATURE RISE — When the temperature from the inlet to the
outlet of the catalyst exceeds the setup threshold, the alarm output will open,
the alarm LED will turn on, the Catalyst Protection Alarm output (PSD) will open
and the message below is displayed.
Auto!WARN!1000
PSD! CatTmpRise!

17.0 AUTOLOG FEATURE
17.1 Press F3 to display the first out AutoLog screen which provides the most recent-
ly detected cause for leaving normal automatic operation. The cause is logged to
a modbus register and also presented as below on the screen using a text string.
The example below indicates that, while the engine was running in automatic
mode, the measured catalyst output temperature exceeded the PSD shutdown,
triggering the snapshot of the AutoLog values as the engine was shutdown. The
AutoLog values are updated on every transition out of fully-automatic control
without alarms. The table of AutoLog causes is shown below.
AutoLOG Code 69
PSD! CatTemp°HI!

ALM! Exhtemp°LO!
ALM! ExhTemp°HI!
ALM! Exh O2v LO!
ALM! Exh O2v HI!
ALM! O2 NotRdy !
ALM! Lean Limit!
ALM! Rich Limit!
PSD! ExhTemp°HI!
PSD! CatTemp°HI!
PSD! CatTmpRise!
USER Left MANUAL
EPC-50/50e OM 2-20
17.2 The following screens are viewed in rotation, each press of F3 displays the
next screen.
AutoLOG EXHtemps
Eng1066°Cat1360°
Identifies the temperature at AutoLog event.
AutoLOG
AuxO2Sensr=.531v
Identifies O2 voltage measurement at AutoLog event trigger.
AutoLOG Steppers
ValvePos = 835
Identifies stepper position at AutoLog event trigger.
AutoLOG Supply V
CJT 25.7°C 24.8v
Identifies internal and supply voltage at AutoLog event trigger
(EPC-50e version only).
AutoLOG Aux 0-5v

1.198v= 771cnts
OR
NOTE: WHEN 40063=0, AUX INPUT
AutoLOG IS ASSUMED TO BE AN O2 SENSOR
AuxO2Sensr=.531v WITHOUT THE ADAPTOR. SEE SECTION
23.0.
Identifies Aux input voltage value and register counts at AutoLog
event trigger (EPC-50e version only).
EPC-50/50e OM 2-20
18.0 ADDITIONAL DISPLAY SCREENS
18.1 Three additional screens exist which can be helpful in obtaining information
about the version and supply voltage and temperature of the EPC-50. They can
be viewed as follows.
Press F1 then DISP-SEL, to view the product description screen.
Altronic Inc.
EPC-50-1
OR
Altronic Inc.
EPC-50e-

Press F2 then DISP-SEL, to view the version and date information.
Version 1: 0
Date 02/14/09
OR
Version 2: 1
Date 07/25/12

Press F1 then F2 then DISP-SEL to view the supply voltage and temperature.
PWR Supply 24.8V

CJT Temp 26.0°C

19.0 TROUBLE-SHOOTING THE EPC-50 SYSTEM
19.1 Green PWR LED and LCD display backlight are dark; power is interrupted.
A. Check power supply voltage at EPC terminal block (10-30 volts), while still
connected.
B. Replace EPC-50 unit.
19.2 LCD Display backlight is lit, but blank or not functioning properly.
A. Power-down unit for 1 minute. Re-power and check status of LCD display
and green PWR LED.
B. LCD backlight is on with blinking PWR LED, indicates: Internal problem

with terminal program. Replace EPC-50 unit.
19.3 Key pad entries do not generate a display response.

A. Verify connection of keypad ribbon connector at bottom of board inside unit.
B. Replace enclosure and keypad assembly.
19.4 EPC-50 will not move stepper valves during F1, then Start Pos. command.
A. Check stepper cable connections at EPC-50 and at stepper valve.
B. Test EPC-50 with a spare stepper valve assembly.
EPC-50/50e OM 2-20
C. Test EPC-50 and stepper valve assembly, with a spare stepper cable.
(Verify cable connections pin-to-pin.)
D. Replace EPC-50 unit.
19.5 High or low exhaust temp warnings persist.

A. Observe thermocouple readings for reasonable values using display select
screens in section 14.0.
B. Compare observed readings to—and verify feasibility of—catalyst protec-
tion setpoints as described in section 9.2 (G).
C. If engine is not running, start and warm up engine.
D. Test the disconnected thermocouple reading at EPC-50 with an alternate

thermocouple reading device.
E. Replace thermocouple or correct wiring if temperatures are incorrect. The

life of thermocouple probes is highly dependent on the use of a thermowell
and on corrosives in exhaust.
F. If low temperature is a problem during first installation, an alternate sen-

sor and probe location may be required. Please contact the factory before
pursuing any other action to raise sensor temperatures.
G. Replace EPC-50 unit.
19.6 Rich or lean limit warnings persist.

A. A misfiring engine can cause the system to shift in the rich direction.
Check the engine for misfiring cylinders using a timing light or exhaust
pyrometer.
B. Use an exhaust analyzer and the EPC-50 manual mode to adjust the %O2
before the converter to around 1.0%. If the %O2 cannot be manipulated
in the manual mode, test to make sure the stepper valve is functioning as
was done during installation.
C. If manual mode moves the %O2 but cannot attain 1.0%, the fuel system
may need to be readjusted. First, verify that the load screw adjustments
on the carburetors are fully rich or fully open. If they are not fully open, the
control range of the stepper valves will be limited. Second, adjust the fuel
pressure regulators so that, when in automatic mode, the stepper valves
are controlling near 1000 steps.
D. If the fuel system appears to be adjusting correctly, use an exhaust ana-

lyzer and the EPC-50 manual mode to sweep the %O2 from around 3%
down to 0.2% while watching the O2 sensor voltage on the display. The
voltage should move from around 0.2 volts toward 0.8 volts as the %O2 is
changed. If this is not the case, a new sensor should be tested.
E. If the EPC-50 O2 sensor voltage display does not match the actual sensor
voltage, test for ground loop problems.
F. Replace EPC-50 unit.

19.7 Setup values are lost at power-down; EEPROM memory has failed.
A. Replace EPC-50 unit.
EPC-50/50e OM 2-20
20.0 EPC-50e ADVANCED CONTROL OPTIONS

20.1 In addition to the basic closed loop Lambda sensor control, it may be useful to
apply additional automatic air/fuel ratio control trimming strategies. This might
be done in an effort to secure more consistent exhaust emission levels across a
wider range of operating conditions. The EPC-50e offers a number of advanced,
user-customizable control options. For example, a dynamic adjustment of the pre-
catalyst O2 target setpoint based upon another measured engine operating param-
eter can be made. Some of the parameters which could be used are post catalyst
O2, engine load, or differential temperature across the catalyst. It is also possible
to automatically adjust controller gain at various load levels or other measured
operating conditions to maintain the best possible control stability. Under certain
other conditions, a means of inhibiting automatic control on the basis of satisfying
an external parameter such as load or temperature can be implemented. Selection
of options is accomplished via a proprietary, high-level Windows™-based Mod-
bus RTU Terminal Program included with each Altronic EPC-50e. Operation and
configuration is essentially hidden from the casual user and therefore completely
resistant to tampering or unauthorized adjustment.
20.2 The user can configure the EPC-50e system to automatically adjust the target
O2 setpoint or the controller gain (responsiveness) versus a variety of measured
engine operating parameters. It is also possible to inhibit automatic control
based upon a specified measured operating parameter, if necessary.
20.3 Enhanced control inputs and outputs include:

• Standard EPC-50 I/O
• AUX Input
These inputs and outputs, combined with the Terminal Program, offer the flex-
ibility to meet specific control requirements for exhaust gas emissions levels.
Specific control strategies that can be implemented by the user are almost limit-
less, with various control functions used simultaneously or in combination.
Examples include:
• Dynamic adjustment of the O2 setpoint versus post-catalyst O2, or load,
catalyst differential temperature, post-catalyst NOx, ambient temperature,
engine RPM, fuel flow, or other parameters.
• Adjustment of the controller gain (responsiveness) versus post-catalyst O2,

load, catalyst differential temperature, fuel BTU, post-catalyst NOx, ambi-
ent temperature, engine RPM, fuel flow, or other parameters.
• Inhibiting automatic control based on post-catalyst O2, load, catalyst dif-

ferential temperature, fuel BTU, post-catalyst NOx, ambient temperature,
engine RPM, or other parameters.
• Shutting down the engine or alarming based on post-catalyst O2, fuel flow,
catalyst temperature, NOx emissions, catalyst differential temperature,
catalyst differential pressure, or other parameters.
EPC-50/50e OM 2-20
21.0 SETTING UP THE FIRMWARE UPGRADE AND TERMINAL PROGRAM
21.1 The standard EPC-50 has the ability to become the EPC-50e with the instal-
lation of the firmware updater to the EPC followed by the installation, and use
of the terminal program on a PC. A CD-ROM has been provided in the kit that
contains all of the necessary equipment. If the CD-ROM is not available, the
software is available via the internet. See Figure 1 for the proper wiring to con-
nect the EPC-50E system to a Personal Computer. The computer must have
an operating system of Windows™ 95 or above.
21.2 The CD-ROM has an auto-install feature that will prompt the contents of the
CD to be installed immediately after loading the disk into the PC.
EPC-50/50e OM 2-20
When using the default settings during the installation, the contents of the CD
will install to a default directory on the All Programs Start Menu of the PC. It
will be located under the new Altronic tab. First, select the UPDATER_EPC-
50e_v2.1_7-25-2012.
EPC-50/50e OM 2-20
Follow the instructions that load directly within the updater window for comm.
port setup and procedure.
21.3 Open the Terminal Program Version 2.1 or greater, which is located under the
All Programs Start Menu. The communications link to the EPC-50e must be
set up, and differs from the communication setup for the updater file. Click
on the word Connection on the top toolbar to open the connection dialog box
shown below. Select an available comm. port on your computer and configure
the Modbus port settings. The default communication settings for the RS-485
EPC-50e are 9600, N, 8, 1. The default NODE address is 50.
EPC-50/50e OM 2-20
22.0 IMPLEMENTING THE ADVANCED CONTROL OPTIONS
22.1 With version 2.1, or later, of the Terminal Program installed on a PC connected
to an EPC-50e unit which has been updated to 2.1, or later, the user will see the
main, or legacy, screen which shows the current operating conditions.
The current dynamic operating conditions are displayed on cockpit-style gauges

and the numeric values of temperature, stepper position, and oxygen sensor
voltage are shown in the bottom center of the gauge face. The numeric value of
each of the parameters is color matched to the appropriate gauge needle. For
example, the LEFT exhaust temperature is the BLUE 1068 on the left-hand
gauge display shown below. On the right hand gauge display, the BLUE 0.789
is the left bank O2 sensor voltage which matches the setpoint voltage of 0.789
shown on the outside of the gauge scale by a LIGHT BLUE ARROW point.
In addition to these operating values, the status of the standard EPC-50e alarms
for exhaust temperature, O2 sensor voltage, rich or lean limit, and so on are also
displayed. The status flag for each of these turns RED, whenever that particular
alarm is activated. On status flags which are user selected or which are normally
changing during operation a GREEN status flag is used to show that a particular
condition is active and in the normal range of operation.
Throughout the EPC-50e terminal program Windows Tool Tips have been pro-
vided to help guide the user. By placing the mouse indicator over a particular
item any hidden tool tips will be revealed. Typical tips would include the Modbus
register address attached to a flag and its description. On user-adjustable values
a suggested range would also be included.
EPC-50/50e OM 2-20
22.2 The Terminal Program on the PC is the Graphical User Interface (GUI) of the
system and uses the Modbus RTU address structure to simplify the process of
configuration. In general, the user creates custom control functions by entering
the Modbus register number (address) assigned to a particular engine parameter
into a pre-configured control function block. First, the selection of a specific
input parameter to be used as a control variable (engine manifold pressure, ex-
haust temperature, post-catalyst O2, or other) is made. Next, the controller can
be configured to bias the O2 setpoint to make a gain adjustment. Multiple means
of control versus various monitored parameters can be used simultaneously or
under different operating or ambient conditions. Specific examples of the ad-
vanced capability of this control system will follow, but these are examples only.
The specific relationships and values required for best emissions performance
must be developed for each application.
22.3 Offsetting the pre-catalyst Lambda sensor setpoint being used by the controller
for closed loop control can be accomplished with the EPC-50e. This control ap-
proach is often used when a post-catalyst O2 sensor, or an engine load sensor, is
added for feedback trim. Selecting the TableA TableB tab displays the following
PC screen.
Tables A and B are designed to dynamically change the O2 target offset. Each
table creates a five-point schedule, by which the O2 target level would be offset
relative to the input of another parameter. The schedules can be utilized inde-
pendently or collaboratively, whereby the bias (offset) generated by each of the
tables would be summed to determine the offset value. Each table has an input
and an output, labeled X and Y respectively. The input is determined by a user-
selected Modbus register that can be used to control the output. The selected
parameter is placed in the Reg # position of the table. The output Reg # is
predetermined and non-adjustable. In order to see real-time feedback from the
registers in the Reg # position, a Reg Val position is available. Points 1 through
5 in the X value are based on the independent variable, and must be entered
in ascending order, and the Y value of points 1 through 5 are the dependent
variable for the O2 offset (stored in Modbus register 30024). Once the table is
populated, the value in the Reg Val Y position will contain the value to be added
to, or subtracted from, the original O2 target. The Y value can be negative or
positive in sign. As values are entered into the table they appear in RED. When
the values are accepted by pressing the ENTER key on the computer, they turn
BLACK and the resultant graph on the programmed function will appear below
the table. Remember to use the Tool Tips by placing the cursor on the item of
interest. There is also additional help available by clicking the ?.
EPC-50/50e OM 2-20
EXAMPLE 1: The following explanation refers to Table A (page 25). Using an
exhaust gas analyzer, the user has determined that he can minimize engine emis-
sions by incorporating an automatic adjustment of the normally fixed pre-catalyst NOTE: IN THIS EXAMPLE, THE BEST
O2 setpoint as a function of the signal from a post-catalyst O2 sensor. From the RELATIONSHIP WAS NOT LINEAR, SO A
Modbus register address list included with these instructions (section 25.0), the BREAKPOINT AT X EQUALS 2000 WHEN
register which contains the post-catalyst sensor voltage is 30016, this number is Y EQUALS 30 MILLIVOLTS WAS USED.
entered for the X input REG#. The user has determined that the optimum catalyst
performance on a given engine occurs when the post-catalyst O2 sensor is read-
ing about 500mV. On initial setup of the engine, the best emissions were found
to occur with the pre-catalyst sensor setpoint at 720mV, this also corresponded NOTE: THE PERMANENTLY-CONFIGURED
to a post-catalyst sensor voltage of 500mV. In order to maintain this operating ENGINEERING UNIT VALUES FOR EACH
relationship over time, the post-catalyst O2 sensor will be allowed to influence the OF THE PREDEFINED MODBUS REGIS-
pre-catalyst sensor setpoint by a maximum of ±100mV. If the post-catalyst sensor TERS IS INCLUDED IN THE MODBUS
voltage is outside its normal operating range of 100 to 900mV, it has no effect. REGISTER LISTING. THE AUX. ANALOG
The current values of the X and Y variables are shown directly below the Modbus INPUTS HAVE SEPARATE MODBUS REG-
register address number. The actual offset value coming from the programmed ISTER LOCATIONS FOR THE MEASURED
function is also displayed as the small black bar on the graph. VOLTAGE AND FOR USER-DEFINED
EXAMPLE 2: In reference to Table B (page 25), using an exhaust gas analyzer, ENGINEERING UNITS. EITHER OF THESE
the user has determined that he can minimize engine emissions by incorporating REGISTER LOCATIONS MAY BE USED TO
an automatic adjustment of the target O2 setpoint as a function of engine load. ADD AN OFFSET, BUT THE DATA NEEDS
Using a transducer monitoring engine intake manifold pressure (as a represen- TO BE ENTERED ACCORDINGLY. IT IS
tation of engine load), the user has determined that the optimum O2 sensor RECOMMENDED THAT THE ACTUAL
setpoint should range between 750mV and 700mV from zero to full load. Thus, INPUT VOLTAGE BEING MEASURED BE
the baseline O2 sensor setpoint could be established at 700mV with an offset USED WHENEVER POSSIBLE IN ORDER
adjustment of +50mV being made for light engine load conditions. TO SIMPLIFY BASIC TROUBLESHOOTING.
This example would be implemented by adding a 0-50psi transducer (Altronic

P/N 691204-50) to the engine intake manifold and wiring it to EPC adaptor.
The user would then enter the Modbus RTU value for that transducer (in this
case, 30021 for AuxIn 1, 0-5 ratiometric, 1mv/cnt) into Table B under Reg# for
the X input. This configures the system to accept the input of that transducer as
the biasing input for the O2 target value offset. To provide the EPC-50e with the
schedule for when, and by what value, to offset the target value, the user enters
the X value in transducer mV (0 to 5000mV for 0 to 5 volts) and the offset volt-
age in O2 sensor mV (in this case, 0 to 50mV).
These examples are intended only to illustrate the optional capabilities of the
EPC-50e. Among the concepts with the potential to improve long-term emis-
sions may also be using the relative activity of the on-engine catalyst as indi-
cated by the current temperature rise across the converter, or the use of a wide
band oxygen or Nox sensor post-catalyst. Likewise the use of the engine intake
manifold pressure is an example of a means to sense the current engine load
and offset the O2 setpoint, but this could also be done using a KW sensor, a
throttle position sensor or fuel flow signal.
In as much as the generated offset values for Tables A and B are additive, utiliz-
ing both tables simultaneously permits the user to allow for the complex interac-
tion of operating parameters.
EPC-50/50e OM 2-20
22.4 Selecting the TableC Auxcal tab displays the following PC screen.
Table C is designed to dynamically change the gain setting (degree of response)

of the EPC-50e controller. This table functions in the same manner as Tables A
and B, but the value in Reg Val is added or subtracted from the original control
gain. This can be viewed as shown below in the Main EPC-50 tab.

EXAMPLE (illustrated above): The basic fixed gain adjustment of the EPC-50e
should always be optimized for the typical operating conditions of the engine.
When the engine is operated at “off design” conditions, the normal gain setting
may not be responsive enough to minimize variations in the emissions. In this
example, the register address selected for the X Input (30021) is for the analog
value connected to AuxIn 1 with an adaptor board. A pressure sensor measuring
intake manifold pressure senses engine load. The values entered into the table
EPC-50/50e OM 2-20
result in a higher gain at lighter loads, which is often desirable because as fuel
flow drops at lighter loads, the “leverage” of the flow control valve over the flow
is reduced requiring a greater response to maintain control.
23.0 AUX INPUT ENG UNITS CONVERSION
23.1 The Aux Input section is independent of the TableC function, and offers a means
of calibrating an input voltage to an engineering unit range. LoCal and HiCal
volts are the low and high input voltage range of the sensor respectively, while
the LoCal Units and HiCal Units are the low and high values associated with
what the sensor detects.
For example (shown below) a 0-5psi pressure transducer, “0” being the LoCal-
units and “5” being the HiCal-units. If the input voltage is higher than, or lower
than, the specified range, the Minunits and Maxunits are provided as a means to
bound the engineering unit values. Because only integer math is used here, the
engineering values converted, as the voltage input varies, will be discrete values
of 1, 2, 3, 4, and 5. By placing two zeros after the value of “5” (becoming 500),
there is now a theoretical decimal point after the five that gives two places worth
of resolution. The engineering values converted as the input voltage varies would
be 1–500, representing .01 to 5.00psi. The fixed values shown directly below the
stated labels are the associated Modbus registers that store the associated values.
23.2 Note: REG40063 (Max-Units) is used to select how to handle the AUX input
features.
When Zero (0): the input will be treated as an O2 sensor input having a range of
0 to 1.25v. In this mode, there is no need to create an AuxENG Value.
When NOT Zero(0): the input will be treated as a 0-5vdc input and REQUIRES
the use of the Sensor Adapter Board to scale the input signal appropriately. With
this adapter, 0-5v pressure sensors or other similar inputs signals can be used.
EPC-50/50e OM 2-20
24.0 SENSOR ADAPTOR
A hardware sensor adaptor, P/N 691306-1, has been provided to allow the EPC-
50e to accept sensors that use 5Vdc references. When using the adaptor and
the functions of the additional firmware incorporated into the enhanced version
of the EPC-50e, advanced configurations of the control gain and target O2 offset
are possible. This is accomplished by utilizing the parameters of the TableA Tab-
leB and TableC AuxCal tabs with the Modbus registers associated with the AuxIn
input. There are three terminals on the back that are normally not connected,
terminals 10, 11, and 12. Plugging the adaptor in with adaptor terminal strip
face up, tighten the EPC-50 terminal strips. If the sensor adaptor is not used,
the secondary O2 sensor can be applied to terminals 11 and 12.
25.0 EPC-50E MODBUS REGISTER LIST
The EPC-50e incorporates a half-duplex RS-485 or RS232 port which is Mod-

bus RTU slave compliant. The protocol used follows the Modicon Modbus RTU
standard. A complete listing of the Modbus registers is included on the EPC-50e
Terminal program CD along with a PC-based Modbus-compatible monitoring
program. The default configuration for the port is 9600 baud N81 with a NODE
ID of 50. The Modbus communications will allow the EPC-50e to meet the
needs of continuous emissions monitoring should it be required.

REGISTER BINARY REGISTER VALUES
00001 F1-START
00002 ALARM ACKNOWLEDGE
00003–08 Spare
00009 MOVE LEFT LEAN FAST +100
00010 MOVE LEFT LEAN SLOW +25
00011 MOVE LEFT RICH SLOW -25
00012 MOVE LEFT RICH FAST -100
00013–16 Spare
00017 L-Manual
00018 Spare
00019 DUAL-BANK
00020 Display Temps 0F 1C
00021–128 Spare
The 10xxx registers are read-only binary and support Modbus standard func-
tion 1. These registers are read in multiples of 8 (1 byte) addressed at each
8 bit boundary (10001-10008, etc.). A single Boolean read from registers
10001 to 10064 can be made which will return all 64 values as a group of 8
bytes. These registers also support an Altronic custom function 101 which will
return a descriptive label for each specific register. The custom label function
can be used to reduce the need for the Modbus master to maintain a current
listing of all of the register labels for each unit.
EPC-50/50e OM 2-20
REGISTER BINARY REGISTER VALUES
10001 Save Position
10002 Low Supply Voltage
10003 Warmup Mode
10004 Spare Status
10005 Stepper Resetting Now
10006 Spare Status
10007 Spare Status
10008 Unacknowledged Alarm Preset
10009 Exh Temp Low
10010 Exh Temp High
10011 O2 Signal Low
10012 O2 Signal High
10013 aux auto inhibit
10014 O2 Sensor Not Ready
10015 Stepper Lean Limit
10016 Stepper Rich Limit
10017–28 Spare Status
10029 Step Coil Open Pin A
10030 Step Coil Open Pin B
10031 Step Coil Open Pin C
10032 Step Coil Open Pin F
10033 Auto Control is Active
10034 Getting Richer
10035 Very Rich >512mv
10036 Rich
10037 ----ONTARGET---- +/-5mv
10038 Lean
10039 Very Lean >512mv
10040 Getting Leaner
10053 Step Coil Drive A
10054 Step Coil Drive B
10055 Step Coil Drive C
10056 Step Coil Drive F
10057 Left Valve Position Uncertain
10065 TC ENG LEFT HiTemp PSD
10069 TC CAT OUT HiTemp PSD
10073–74 Spare
EPC-50/50e OM 2-20
The 30xxx registers are read-only, 16 bit, analog values. The Modbus standard
function 4 is supported. These registers also support an Altronic custom func-
tion 104 which will return a descriptive label for each specific register.
REGISTER 16-BIT INPUT REGISTER VALUES

30001 Input Bit Mirror 10016-10001
30009 SUPPLY INPUT VOLTAGE .1v/cnt
30010 CJT DEG C signed 0.01degc/cnt
30011 EXH TEMP ENG-OUT 1degf/cnt
30012–13 Reserved
30014 EXH TEMP CAT-OUT 1degf/cnt
30015 EXH O2 VOLTAGE-1 1mv/cnt
30016 EXH O2 VOLTAGE-2 1mv/cnt
30017 SMP1C
30018 Reserved
30019 SMP1M
30020 Reserved
30021 AUX1 0-5000
30022 AUX1_ENG
30023 Reserved
30024 LOOKUP TABLE A RESULT
30025 LOOKUP TABLE B RESULT
30026 LOOKUP TABLE C RESULT
30027 Reserved
30028 LEFT BANK O2 DYNAMIC TARGETmV
30029–30 Reserved
30031 CATALYST TEMP RISE (CATOUT-IN)
30032–37 Reserved
30038 CONTROL GAIN VALUE
The 40xxx registers are read/write, 16-bit, analog values and they support the Mod-
bus standard functions 3, 6 and 16. These registers may have new values written to
them in order to make setpoint adjustments from a remote location. They also support
a custom function 103 which will return a label describing each specific register.
REGISTER 16-BIT READ/WRITE REGISTER VALUES

40001 CoilBits 00016-00001
40002 CoilBits 00032-00017
40003 CoilBits 00048-00033
40004 CoilBits 00064-00049
40005 CoilBits 00080-00063
EPC-50/50e OM 2-20
40006 CoilBits 00096-00081
40007 CoilBits 00112-00097
40008 CoilBits 00128-00113
40009 LEFT BANK O2 BASE TARGET mV
40010 Reserved
40011 LEFT BANK START POS steps
40012 Reserved
40013 CONTROL GAIN RATE value/40
40014 EXH TEMP HI ALARM SETTING degF
40015 EXH TEMP LO ALARM SETTING degF
40016 EXH O2 HI ALARM SETTING mV
40017 EXH O2 LO ALARM SETTING mV
40018 EXH O2 READY HI SETTING mV
40019 EXH O2 READY LO SETTING mV
40020 TC ENGOUT HI PSD degF
40021 TC CAT OUT HI PSD degF
40022 TC CAT DELTA HI PSD degF
40023–57 Reserved
40058 AUX1 ENG. UNITS CAL POINT 1.X
40059 AUX1 ENG. UNITS CAL POINT 1.Y
40060 AUX1 ENG. UNITS CAL POINT 2.X
40061 AUX1 ENG. UNITS CAL POINT 2.Y
40062 AUX1 ENG. UNITS MINIMUM
40063 AUX1 ENG. UNITS MAXIMUM
40064 TABLE C INPUT REGNUMBER 30XXX
40065 TABLE C POINT 1.X
40066 TABLE C POINT 1.Y
40075–81 Reserved
40082 ENUMERATED CAUSE OF NOT AUTO
40083 SUPPLY INPUT VOLTAGE .1v/cnt
40084 CJT DEG C signed 0.01degc/cnt
40085 EXH ENGINE OUT 1degf/cnt
40086 Reserved
40087 EXH TEMP CAT IN 1degf/cnt
40088 EXH TEMP CAT OUT 1degf/cnt
EPC-50/50e OM 2-20
40089 EXH O2 VOLTAGE 1mv/cnt
40090 AUX INPUT VALUE 1mv/cnt
40091 STEPPER POSITION
40092 AUX ENG VALUE counts
40093 TABLE A INPUT REGNUMBER 30XXX
40094 TABLE A POINT 1.X
40095 TABLE A POINT 1.Y targ O2 ofst
40104 TABLE B INPUT REGNUMBER 30XXX
40105 TABLE B POINT 1.X
40106 TABLE B POINT 1.Y
40115–119 Reserved
40120 REG40126 MSB=BAUD LSB=NODEID
40121 Warm Boot ( reset ) Count
40122 Cold Boot (powerup) Count
40123 Spare-volatile
40126 REMOTE MAN MOVE SIGNED STEPS
40127 Reserved-volatile
40128 MODBUS KEY COMMAND

EPC-50/50e OM 2-20
Detailed below are the command values which can be written to the Modbus Key
Command Register (40128).
1. Reg(40128) 00510 Select auto mode for both banks

2. Reg(40128) 00765 Select manual mode for left bank
3. Reg(40128) 01275 F1-Start stepper reset
4. Reg(40128) 01530 Alarm acknowledge
5. Reg(40128) 01785 Decrement left O2 target
6. Reg(40128) 02040 Increment left O2 target
7. Reg(40128) 02295 Decrement right O2 target
8. Reg(40128) 02550 Increment right O2 target
9. Reg(40128) 02805 Decrement control gain rate
10. Reg(40128) 03060 Increment control gain rate
11. Reg(40128) 03315 Reload calibration defaults
12. Reg(40128) 03570 Update left start position with current pos
13. Reg(40128) 03825 Update right start position with current pos
14. Reg(40128) 05355 Manual move left stepper rich (-25)
15. Reg(40128) 05610 Manual move left stepper lean (+25)
16. Reg(40128) 05865 Manual move left stepper rich (-100)
17. Reg(40128) 06120 Manual move left stepper lean (+100)

The EPC-50e unit also supports a Modbus function 17 which will return the unit
information including the Version, Date and Name.
18. Reg(40128) 07905 decrement Hi Exhaust Temp Threshold

19. Reg(40128) 08160 increment Hi Exhaust Temp Threshold
20. Reg(40128) 09435 decrement Hi Catalyst Temp Out Threshold
21. Reg(40128) 09690 increment Hi Catalyst Temp Out Threshold
22. Reg(40128) 09945 decrement Hi Catalyst Rise Temp Threshold
23. Reg(40128) 10200 increment Hi Catalyst Rise Temp Threshold
24. Reg(40128) 51118 autolog reset
EPC-50/50e OM 2-20
26.0 CHARTING THE VALUES OF THE MEASURED VARIABLES
26.1 The EPC-50e Terminal Program allows the user the option of displaying the
measured variables in a strip chart form as shown below. This type of display
can be very useful to analyze large amounts of data quickly or to detect operat-
ing trends over time. To turn this display on, click on the word CHART on the top
toolbar. Scales can be expanded or compressed using the mouse to “drag” the
small white boxes on each axis.
27.0 ROI – THE REMOTE OPERATING INTERFACE
27.1 ROI (Remote Operating Interface) provides the user of the terminal with a direct
interface to the EPC-50e keypad and display, just as if they were at the location.
When using the ROI option, any function normally available at the keypad will NOTE: DO NOT ATTEMPT TO MODIFY
execute and display in same manner as if the local keys were actually pressed. COMMUNICATIONS SETUP VALUES US-
At the site where the EPC-50e unit is operating, the ROI function will appear to ING ROI OR COMMUNICATIONS WILL BE
be keypad operation by an invisible operator. LOST UNTIL THE COMPUTER IS RESET
TO THE NEW VALUES.
EPC-50/50e OM 2-20
28.0 OTHER TOOLBAR OPTIONS
28.1 There are some additional toolbar functions not covered elsewhere in this docu-
ment, the operation of each of these is explained below.
• ResetComStats: Clears the Modbus communications error counter to zero.

This can be very useful when troubleshooting communication problems.
• Connect/Disconnect: Connects/disconnects the computer from the EPC-50e.
• Snapshot: Creates a snapshot of the current screen display on the com-

puter to be saved in a *.jpg file. This captures the gauge or the chart
display, whichever one is active.
• LogFile: Allows for the selection of automatic data logging on the com-
puter connected to the EPC-50e. Datalogs are Excel compatible, CSV
type (Comma Separated Values).
• HotKeys: Gives access from any screen to turn Chart display on, or to en-
able remote control via Modbus.
• Help: Displays software version and dates.
• Exit: Disconnects EPC-50e from computer and exits this program.
EPC-50/50e OM 2-20
FIGURES SECTION:
FIGURE 1 EPC-50, GENERAL INSTALLATION LAYOUT: SINGLE BANK
FIGURE 2 EPC-50, MOUNTING DETAIL
FIGURE 3 NEMA 3R ENCLOSURE MOUNTING DIMENSIONS
FIGURE 4 OXYGEN SENSOR DETAIL
FIGURE 5 EPC-50, WIRE ROUTING DETAIL
FIGURE 6 EPC-50e, WIRE ROUTING DETAIL
FIGURE 7 EPC-50, MODBUS COMMUNICATION CONNECTIONS
FIGURE 8 EPC-50/50e, TERMINAL LAYOUT
EPC-50/50e OM 2-20
FIGURE 1 EPC-50, GENERAL INSTALLATION LAYOUT: SINGLE BANK
EPC-50/50e OM 2-20
FIGURE 2 EPC-50, MOUNTING DETAIL
6.50
6.50
6.00
1.25
2.19
6.00 5.50
.203 DIA.
(TYP 4)
5.50
EPC-50/50e OM 2-20
FIGURE 3 NEMA 3R ENCLOSURE MOUNTING DIMENSIONS
EPC-50/50e OM 2-20
FIGURE 4 OXYGEN SENSOR DETAIL
CONNECTOR WIRE PIN AND WIRE

PIN COLOR CONNECTION
A TAN SENSOR (GROUND)
B BLACK OUTPUT
MATING CONNECTOR:
PACKARD ELECTRIC DIV. PART NO. 12010501
1.25 MIN.
FLAT REQUIRED
12.50 FOR SEATING
DRILL A 41/64 (16.5) HOLE
90º C’SINK TO .732 DIA (18.6)
TAP M18 X 1.5 7G THREAD
.35
1.10
2.22 RECOMMENDED INSTALLATION DIMENSIONS
INSTALLATION INSTRUCTIONS:
1. INSTALL IN THE APPROPRIATE MOUNTING HOLE TO A
TORQUE OF 28-34 LB. FT.
2. USE A 7/8” WRENCH SIZE.
1.17 3. SENSORS ARE TO BE SUPPLIED WITH THREADS COATED

WITH MS-0572 ANTISEIZE COMPOUND.
CAUTION: DO NOT APPLY ANTISEIZE COMPOUND TO
AREAS OTHER THAN THE MOUNTING THREADS.
4. FOR OPTIMUM RESISTANCE TO WATER INTRUSION,

AC RECOMMENDS MOUNTING SENSORS SUCH THAT
THE EXPOSED END (WIRE END) OF THE SENSOR IS
.602
±.008 ORIENTED AT OR ABOVE HORIZONTAL.
5. THIS SENSOR IS DESIGNED FOR WATER SPLASH

RESISTANCE.
.875
EPC-50/50e OM 2-20
FIGURE 5 EPC-50, WIRE ROUTING DETAIL
EPC-50/50e OM 2-20
FIGURE 6 EPC-50e, WIRE ROUTING DETAIL
PWR RS485 SWITCH AUX IN O2 TC-1 TC-2

B A
+RED
+YEL
+YEL
-RED
-RED
COM
-BLK
COM
SW1
SW2
DC+
+5V
N/C
N/C
N/C
N/C
VIN
DC-
(+) (-)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
VALVE OUTPUT
A B C D E F
BLU
RED
WHT
ORG
BLK
GRN
PRESSURE
SENSOR
CONTROL VALVE SENSOR CABLE

CABLE P/N 693006
P/N 693013-1 TO O2 SENSOR
P/N 610621
+ -
24 VDC SUPPLY
OPTIONAL ENG OUT CAT OUT
16 AWG MIN.
ALARM AND SHUTDOWN N/C /CAT IN
SOLID STATE SWITCH OUTPUTS
THERMO COUPLES
RATED 30 VOLTS/0.5 AMPS MAX.
"K" EXTENSION
24 AWG MIN.
EPC-50/50e OM 2-20
FIGURE 7 EPC-50, MODBUS COMMUNICATION CONNECTIONS
EPC-50/50e OM 2-20
FIGURE 8 EPC-50/50E, TERMINAL LAYOUT
EPC-50/50e OM 2-20

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Operating Manual

EPC-50/50e AIR-FUEL CONTROLLERS

Form EPC-50/50e OM 2-20

HOERBIGER Engine Division

2.0 SYSTEM COMPONENTS

PART NO. DESCRIPTION QUANTITY REQUIRED

2.2 Accessory Kits

691306-KT EPC-50e Kit Includes:

2.3 See Figure 1 for general layout of EPC-50 components.

3.0 MOUNTING THE EPC-50

4.0 MOUNTING THE OXYGEN SENSOR

5.0 MOUNTING THE K-TYPE THERMOCOUPLES

5.1 An exhaust temperature thermocouple is used to monitor the temperature of

5.3 Catalyst protection thermocouple should be installed in the catalyst housing.

7.0 ELECTRICAL HOOK-UP

7.3 The EPC-50 can be powered in one of the following ways:

7.8 The Catalyst Temp Protection Shutdown Output is configured as a normally-

8.0 THEORY OF OPERATION

(e.g., Methane => 16.09 : 1 and Gasoline => 14.70 : 1)

(Lambda Actual AFR/Stoichiometric AFR)

Lambda > 1 = Lean, Lambda < 1 = Rich.

9.0 PRE-START INSTALLATION CHECKLIST

9.1 Before applying power to the EPC-50:

A. Display should follow the power-up sequence described in section 11.0.

C. Data display screen for exhaust temperatures should indicate ambient

D. Control valve operation should be verified during a start position command.

Gain Value = 0.50

Exh Temp Hi = (1000 to 1250°F)

10.0 START-UP PROCEDURE

10.1 Before starting engine:

H. Start and warm-up engine.

A. Load engine to desired operating point.

B. Verify that the exhaust temperature data screen is displaying reasonable

10.3 Fine tune the control setpoints:

11.0 GENERAL: KEYPAD AND DISPLAY OPERATION

12.0 SETUP MODE: KEYPAD AND DISPLAY OPERATION

$$$ SETUP $$$

$$$ SETUP $$$

12.14 Press F1 to rotate to the main screen.

!Auto! .802v1000 NOTE: LOADING DEFAULT SETTINGS AS

13.1 Press ALARM ACK to acknowledge alarms if alarm LED is ON.

4.0 DATA VIEWING: KEYPAD AND DISPLAY OPERATION

DSPL AUTO .625v 985

DSPL AUTO .625v 985

SINGLE BANK TC1

DSPL AUTO .625v 985

DSPL Cat Rise=+ 24°F

DSPL TblA= 503=+.000

DSPL TblC= 4773=0.000

DSPL AUTO .811v1010

15.0 MANUAL MODE: KEYPAD AND DISPLAY OPERATION

LEFT MAN! .811v1010

LEFT LEFT MOVING

AUTO AUTO .811v1110

AUTO AUTO .811v1110

16.0 DIAGNOSTIC DISPLAYS AND OPERATION

16.1 ALARM OUTPUT — The ALARM output is configured as a normally-closed out-

16.2 SYSTEM DIAGNOSTICS — The system diagnostics included in the EPC-50

16.3 DIAGNOSTIC WARNING MESSAGES — Active diagnostic warning messages