Controls CX-2556 User manual

PRODUCT MANUAL
ENGINE CONTROL MODULE
MANUAL START
Part Number: CX-2556
Revision: V1.2
Engine Type: Electronic J1939 and Mechanical Engines

1
TABLE OF CONTENTS
INSTALLATION…….…………………………………………………………………………………….…………………………………………....………….5
CONSIDERATIONS
DIMENSIONAL
WIRING SCHEMATIC
SPECIFIC OPERATION……………………………………………………………………………….…..………………..………………………………..7
POWER UP
STARTING ENGINE
ENGINE OPERATION
RPM MODE
PRESSURE MODE
CLUTCH OPERATION
OPERATION…………………………………………………………………………………………………….…………………..………………………………..10
POWER UP
MANUAL OFF
MANUAL STARTING
SAFETY BYPASS
ENGINE RUNNING
SPEED CONTROL ELECTRONIC
SPEED CONTROL MECHANICAL
STOPPING THE ENGINE
SPEED CONTROL OPTIONS………………………………………………………………………………………………………………………….16
ELECTRONIC ENGINE SPEED CONTROL
REQUESTED VERSUS ACTUAL SPEED
TSC HYDRO THROTTLE
TSC VERNIER THROTTLE
TSC BUMP
TSC MULTISTATE THROTTLE
TSC HI-LO MOMENTARY THROTTLE
FLEX ANALOG THROTTLE
MODBUS THROTTLE
SPEED / TORQUE LIMIT
COOPERATIVE THROTTLE
DISPLAY CONFIGURATION……………………………………………………………………………………………………………………….22

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GRAPHICAL DISPLAY
DISPLAY LAYOUT
DISPLAY CUSTOMIZATION
PROTECTION OPTIONS……………………………………………………………………………………….…………………………..………….24
EECU SAFETY SHUTDOWNS AND WARNINGS
MODULE SAFETY SHUTDOWNS AND WARNINGS
LOW POWER MODE
OTHER MODULE FUNCTIONALITY…………………………………………………………………………………………..…………….26
STANDARD FEATURES
CUSTOM SPLASH SCREEN
SENDER FAILURE
AUDIBLE WARNING HORN
SHUTDOWN OVERRIDE
MAIN MENU ACCESS……...………………………………………………...………………………………………………….……………..……….27
MAIN MENU TOPICS……...………………………………………………...……………………………………………….……..….……………….27
ACTIVE ENGINE FAULT CODES
STORED ENGINE FAULT CODES
ENGINE PARAMETERS
EMISSION PARAMETERS
SENDER PARAMETERS
PUMP PARAMETERS
OPERATION EVENT LOG
ALARM EVENT LOG
ENGINE IDENTIFICATION
MODULE INFORMATION
MODULE PROGRAMMING……...………………………………………………...……………………………………………….……………….33
PROGRAMMING OPTIONS
PC BASED PROGRAMMING
MODULE BASED PROGRAMMING
CONTROLLER SETUP……...………………………………………………...……………………………………………….…………………..……….35

3
PASSWORD ENTERY
SETUP MENU
QUICK SETUP
ENGINE PARAMETER CONFIGURATION
PUMP PARAMETER CONFIGURATION
INPUT CONFIGURATION
OUTPUT CONFIGURATION
THROTTLE CONFIGURATION
ENGINE SAFETY CONFIGURATION
PUMP SAFETY CONFIGURATION
MODULE CONFIGURATION
DISPLAY CONFIGURATION
CAN CONFIGURATION
MODBUS CONFIGURATION
MAINTENANCE CONFIGURATION
EMISSIONS CONFIGURATION
CLUTCH CONFIGURATION
CLOCK SET UP
MODULE INFORMATION
PANEL CONNECTORS…………..………………………………………………………………………........…………………..……………...44
MODULE CONNECTORS………………………………………………………………………………........…………………..……………...46
MODULE PRIMARY CONNECTOR
MODULE SECONDARY CONNECTOR
WARRANTY………………………………………….……………………………………………………………………….…………………………....48

4
INSTALLATION
MOUNTING LOCATION
To ensure a long life from your module, please review the following installation guidelines.
HEAT: Be sure to take into account excessive heat areas when mounting your control panel.
Stay away from turbo chargers, exhaust manifolds, diesel particulate filters or any other location
that would put the control panel in the vicinity of excessive heat
ENCLOSURE MOUNT: If your installation is better suited for a full control panel rather than a
module, contact Controls, Inc. for available options or assistance in designing an enclosure for
your application.
CONVIENCE OF USE: Study the final assembly of the piece of equipment and how it will be
used. Take into account the operator when locating the module. Ease of access to the unit,
keys and display are all critical in allowing the operator to successfully and safely operate the
module. Extension harnesses are available from Controls, Inc. if the engine harness being used
does not allow for proper location selection.
WEATHER AND WASHDOWN: The control panel is designed to be weather tight and can be
used in open outdoor conditions. The enclosure has a Gore vent, located on the rear of the
enclosure, which will allow for breathing between the interior of the control enclosure and the
outside environment. Be sure to not apply undue water pressure during wash down and do
not directly spray the Gore vent area.
HARNESS ROUTING: The use of common sense with respect to harness routing and drip
loops can go a long way in the prevention of unintended water intrusion. Also take into
account the stresses put on the harnessing and the proximity to heat sources as well. For spark
ignited engines, be sure to keep the panel wiring at least 12 inches from the ignition wires.

5

6

7
CX-2556 SPECIFIC OPERATION
OPERATING MODE SELECTION
At power up, the Operating Mode selection screen will appear. The operator has a choice between
two modes
RPM
Pressure
Once an operating mode has been selected the following criteria will be maintained:
it may not be changed until the next power cycle
the selection will be saved as the default for the next power cycle
one of the following selection screens will appear:

Available Pressures
minimum is 5k psi
selection increment size is 5k psi
maximum is the selected Pump Nominal Pressure
Available Speeds
minimum is 1200 RPM
selection increment size is 50 RPM
maximum is 2150 RPM
After the operator selects the desired target (RPM or PRESSURE):
the selection will be saved as the default for the next power cycle
Display Screen A will appear
Starting Engine
The Controller is allowed to start the engine only when all of the following criteria have been met:
the operating mode has been selected
the target (speed or pressure) has been selected
the idle digital input is asserted
After Display Screen A appears:
if the digital input is in the operate position when the operator tries to start the engine:
turn on the Amber Warning Lamp
display “Put In Idle” / “To Start”

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Engine Operation
Idle
After the operator starts the engine:
the Controller will set the TSC1 request to TSC Min
throttle keys will be locked out until the operate digital input is asserted
Idle mode is entered in one of two ways:
manually –the operator asserts the Idle digital input
automatically –the engine generates a red-lamp fault
General Operating Mode
After the operator switches the Operate digital input:
the Controller will immediately set the TSC1 request to the High Pressure On Setting
no ramping
after the engine reaches the High Pressure On Setting (within ± 50 RPM tolerance), the
Controller will:
energize the clutch output
begin targeting (speed or pressure)
enable the throttle keys
When the operator switches to the Idle digital input the Controller will:
disable the throttle keys
de-energize the clutch output
drop the engine speed back to TSC minimum (no ramping)
RPM Operating Mode
The RPM Operating Mode begins after the engine has reached the High Pressure On Setting.
The Controller will:
set the TSC1 requested speed to the target speed
it is the responsibility of the engine electronic governor to maintain the requested speed
increase the target speed by 50 RPM in response to each Throttle Up button press
maximum of 2150 RPM
TSC1 requested speed will immediately follow this change
decrease the target speed by 50 RPM in response to each Throttle Down button press
minimum of 1200 RPM
TSC1 requested speed will immediately follow this change

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Pressure Operating Mode
The Pressure Operating Mode begins after the engine has reached the High Pressure On Setting.
The Controller will:
using the maintain targeting logic to appropriately adjust the TSC1 requested speed to achieve
the target pressure
minimum allowed speed is 1200 RPM
maximum allowed speed is 2150 RPM
increase the target pressure by 5,000 psi in response to each Throttle Up button press
maximum of 40,000 psi
decrease the target pressure by 5,000 psi in response to each Throttle Down button press
minimum of 15,000 psi
Clutch Operation
The Clutch automatically turns on when:
the engine reaches the High Pressure On Setting
The Clutch automatically turns off when:
the engine operation mode goes to idle OR
the engine stops running OR
the Controller enters a Controlled Shutdown phase

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OPERATION
POWER UP
Turn on the power to the module. The display will illuminate and show the module part number
version in the upper left status line and the graphical logo will be centered in the screen. The LED
indicators will turn on for one second to verify operation.
Stop Lamp
Low DEF Lamp
Warning Lamp
Regen Active Lamp

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MANUAL OFF
After the Power Up cycle is complete, the module will be in the Manual Off mode as shown in the
upper left status line.

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MANUAL STARTING
RUN KEY
Press the green RUN key. If a preheat cycle is programmed in the display, or requested by the
engine’s ECU, the status line will indicate a Wait to Start message or Preheat Countdown.Once
completed, the status line will show Ready to Start.
Press and Hold the green RUN key. The status line will display Starting Engine. The module will
energize the crank relay or send the J1939 CAN Start Engine command depending on the engine
manufacturer selected.
KEY SWITCH OPTION
An optional key switch with a crank position can be used if desired to start the engine. CI panel
options typically use the Key Switch option. Contact CI for further details.

13
SAFETY BYPASS
Immediately after the engine begins to run, the module will enter the “Safety Bypass” period. This
time period is typically set to 10 seconds and is programmable. During this period, any engine
parameter set to be monitored as RUN will be ignored until the bypass period is passed, at which
point the safeties will become active. If any engine or system safeties are set to be monitored as
ALWAYS, they will be active as soon as the control panel is powered up regardless of the engine’s run
state. This bypass does not apply to the engine’s ECU safeties. The status line will change to show
Engine Safeties ACTIVE briefly when the module begins monitoring the parameters.
ENGINE RUNNING
Once the engine has been running for a time that exceeds the safety bypass period, all controller
programmed engine safeties that are set to be monitored during engine run will become active. The
control will display engine oil pressure, engine coolant temperature, engine speed, battery voltage,
engine hours and fuel level if a fuel level sender is installed. Up to eight parameters can be shown at
one time. The selections are configurable.

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SPEED CONTROL - ELECTRONIC ENGINES
The display can control the engine’s speed using J1939 Torque Speed Control (TSC1). When the
engine is started manually, the control panel will request the minimum programmed speed. Pressing
the Up-arrow key will cause the panel to increase the requested speed. The display will place an up or
down arrow to the right of the RPM displayed to indicate that a change in speed is being requested.
See Speed Control Options for more details.
SPEED CONTROL - MECHANICAL ENGINES
For mechanical engines, the module supports multiple mechanical actuators. Typically, two relays are
assigned to extend or retract a screw type actuator. Other CAN Bus driven devices are also supported.
Please contact CI for more information.

15
STOPPING THE ENGINE
When it comes time to stop the engine, simply press the red OFF key. This will de-energize the fuel
solenoid on mechanical engines or the engine ECU Run/Stop circuit on electronic engines. In some
cases, the module will send an engine STOP command over the J1939 CAN Bus to shut down the
engine. Once the engine has stopped, the status line will display Manual Off.

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SPEED CONTROL OPTIONS
ELECTRONIC ENGINE SPEED CONTROL
The display can control the engine’s speed using J1939 Torque Speed Control (TSC1). When the
engine is started manually, the control panel will request the minimum programmed speed. Pressing
the up-arrow key will cause the panel to increase the requested speed. The display will place an up or
down arrow to the right of the RPM displayed to indicate that a change in speed is being requested.
Please note that if the low idle speed on the engine’s ECU is higher than the minimum speed
programmed in the controller, the actual engine RPM will be the low ECU setting until the controller’s
speed request command (TSC1) exceeds the ECU low idle speed. This holds true for the high idle
speed set in the ECU as well.

17
The control panels TSC address and the engine’s ECU address must match. Most major engine
manufacturer’s TSC addresses are loaded into the control panel when that engine manufacturer is
selected in the Quick Setup. However, there may be instances where ECU programming may vary. The
control does have the ability to change the TSC address manually in the CAN Configuration menu. If
speed control continues to be elusive, verify that the engine’s ECU does have J1939 throttling enabled.
REQUESTED SPEED VERSUS ACTUAL SPEED
The requested speed by the control panel cannot exceed the maximum programmed speed of the
engine ECU. Once the speed is being controlled by the module, the acceleration will be based on the
ramp rate in the controller. If precise speed control is desired, be sure to have the ECU governing
mode set to Isochronous or Zero Droop; otherwise the actual engine speed will be somewhat below
the requested TSC. To verify the speed being requested by the control module, access the Engine
Parameters menu. From here, you can see the Requested TSC and compare it to the Actual RPM.

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HYDRO-THROTTLE
Opening and closing the Hydro-Throttle Input can change engine speed between the programmed
Minimum Speed and the Last Operating Speed for each run. Last Operating Speed is defined as the
engine speed was last when the Hydro Throttle input was opened.
TSC VERNIER THROTTLE
TSC Vernier is the most popular throttle selection when operating in the manual start mode. The
operator can control the engine speed anywhere between the programmed speed ranges. This
throttle type allows you to set the minimum engine speed, maximum engine speed, ramp rate, curve
type and bump speed increments without the use of a computer. At engine start, the display will
request the minimum engine speed. When the operator presses the Rabbit key, the engine speed will
ramp up at the programmed rate until the Rabbit key is released. The display will indicate an up arrow
to the right of the RPM. If the maximum speed is reached, the up arrow on the display will be
replaced by an X indicating the maximum speed has been reached. This same operation applies to
slowing the engine speed down using the down arrow key. A single press of the Rabbit or Turtle key
will cause the RPM of the engine to change in that direction by the bump increment, typically set to 20
RPM.
In the example below, the engine would start at 800 RPM and could be operated up to 2400 RPM.
Pressing a throttle key momentarily would change the RPM by increments of 20 RPM. Holding a
throttle key down would change it by 100 RPM/Second.

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TSC BUMP
The operator can control the engine speed anywhere between the programmed speed ranges.
However, changes in speed are limited to single presses of the Rabbit and Turtle keys. Each press will
change the requested RPM by the programmed Bump speed.
TSC MULTISTATE THROTTLE
Another widely used throttle type in manual mode allows the operator to increment the engine speed
between predetermined speed settings by pressing the Rabbit or Turtle keys. The number of discreet
speeds set is up to four ascending speeds. After the operator starts the engine, the controller will run
the engine at Speed 1 setting, the lowest speed. Pressing the Rabbit key momentarily will ramp the
engine speed up to the Speed 2 setting. Another press would accelerate to speed three and so on.
Pressing the down key will increment the speed to the next lower speed. You cannot operate the
engine between the speed settings. Leave all unused speeds below the previous speed and the
module will ignore them. In the example below, the engine will start at 800 RPM. Pressing the Rabbit
key will ramp the engine to 1100 RPM. Press it again and it will accelerate to 2000 RPM. Pressing the
Rabbit again will have no effect on the engine speed since Multistate Speed 4 is set below the Speed 3
setting.
TSC HIGH-LOW MOMENTARY THROTTLE
This throttle option can be used if only two speeds are desired, a low idle and a high operating speed.
The engine starts at the programmed minimum speed and only accelerates when the Rabbit key is
pressed and held. Once the Rabbit key is released, the speed automatically drops back to the low idle
speed. With this option, it is fairly typical to assign a digital input to the Throttle Up function to allow a
remote switch to be installed elsewhere on the equipment.