Woodward ECM3 User manual

EC-US-L1
Product Manual 26348
(Revision E, 01/2022)
Original Instructions
ECM3
Electronic Fuel Injection Control
Installation and Operation Manual
Released

EC-US-L1
General
Precautions
Read this entire manual and all other publications pertaining to the work to be
performed before installing, operating, or servicing this equipment.
Practice all plant and safety instructions and precautions.
Failure to follow instructions can cause personal injury and/or property damage.
Revisions
This publication may have been revised or updated since this copy was produced.
To verify that you have the latest revision, check manual 26455, Customer
Publication Cross Reference and Revision Status & Distribution Restrictions, on
the publications page of the Woodward website:
http://www.woodward.com
The latest version of most publications is available on the publications page. If
your publication is not there, please contact your customer service representative
to get the latest copy.
Proper Use
Any unauthorized modifications to or use of this equipment outside its specified
mechanical, electrical, or other operating limits may cause personal injury and/or
property damage, including damage to the equipment. Any such unauthorized
modifications: (i) constitute "misuse" and/or "negligence" within the meaning of
the product warranty thereby excluding warranty coverage for any resulting
damage, and (ii) invalidate product certifications or listings.
Translated
Publications
If the cover of this publication states "Translation of the Original Instructions"
please note:
The original source of this publication may have been updated since this
translation was made. Be sure to check manual 26455, Customer Publication
Cross Reference and Revision Status & Distribution Restrictions, to verify whether
this translation is up to date. Out-of-date translations are marked with . Always
compare with the original for technical specifications and for proper and safe
installation and operation procedures.
Revisions—A bold, black line alongside the text identifies changes in this publication since the
last revision.
Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is
believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly
undertaken.
Manual 26348
Copyright © Woodward, Inc. 2006–2022
All Rights Reserved
Released

Manual 26348 ECM3 Electronic Fuel Injection Control
Woodward 1
EC-US-L1
Contents
WARNINGS AND NOTICES ...............................................................................................................4
ELECTROSTATIC DISCHARGE AWARENESS......................................................................................6
REGULATORY COMPLIANCE............................................................................................................7
CHAPTER 1. GENERAL INFORMATION..............................................................................................9
Introduction ...................................................................................................................................................9
Control Specifications .................................................................................................................................10
CHAPTER 2. INSTALLATION...........................................................................................................13
Introduction .................................................................................................................................................13
General Installation Notes and Warnings ...................................................................................................13
On-Engine Mounting...................................................................................................................................14
Temperature Specifications ........................................................................................................................16
Electrical Connections.................................................................................................................................17
Grounding for Protection against Electrical Shock .....................................................................................18
Grounding for Protection against Electrical Noise......................................................................................18
Harsh EMC Environmental Guidance.........................................................................................................20
ECM3 Wiring Diagrams...............................................................................................................................21
Input Power.................................................................................................................................................24
General Purpose Analog Inputs..................................................................................................................31
Engine Sensor Analog Inputs......................................................................................................................35
Temperature Sensor Analog Inputs............................................................................................................37
Boolean and PWM Inputs ...........................................................................................................................39
Boolean and PWM Outputs.........................................................................................................................43
CHAPTER 3. SERIAL COMMUNICATIONS.........................................................................................61
Modbus Communication .............................................................................................................................61
Port Adjustments.........................................................................................................................................63
CHAPTER 4. PROGRAMMING AND SERVICE TOOLS ........................................................................64
Introduction .................................................................................................................................................64
Connecting the ECM3 to a PC....................................................................................................................65
Loading Woodward Software Tools on the PC...........................................................................................65
Applying Power to the ECM3......................................................................................................................65
Toolkit Software Instructions.......................................................................................................................65
Watch Window Software Instructions .........................................................................................................70
Using Watch Window..................................................................................................................................73
CHAPTER 6PRODUCT SUPPORT AND SERVICE OPTIONS ...............................................................81
Product Support Options.............................................................................................................................81
Product Service Options .............................................................................................................................81
Returning Equipment for Repair .................................................................................................................82
Replacement Parts......................................................................................................................................82
Engineering Services..................................................................................................................................83
Contacting Woodward’s Support Organization...........................................................................................83
Technical Assistance ..................................................................................................................................84
APPENDIX A. CONNECTOR INFORMATION......................................................................................85
Recommended Wire Size and Types .........................................................................................................86
Wire Gauge—AWG to Metric Comparison .................................................................................................87
APPENDIX B. COMMISSIONING PROCEDURE ..................................................................................88
Control I/O Commissioning.........................................................................................................................88
EFI Valve Commissioning...........................................................................................................................88
APPENDIX C. PROXIMITY SENSORS...............................................................................................89
Released

Manual 26348 ECM3 Electronic Fuel Injection Control
Woodward 2
EC-US-L1
APPENDIX DTECHNICAL SPECIFICATIONS.....................................................................................91
REVISION HISTORY .......................................................................................................................93
DECLARATIONS ............................................................................................................................94
Illustrations and Tables
Figure 1-1. ECM3 Outline Drawing.............................................................................................................12
Figure 2-1. Vibration Isolator Installation ....................................................................................................15
Figure 2-2. Mounting Hole Layout...............................................................................................................16
Figure 2-3. I/O Isolation...............................................................................................................................20
Figure 2-4. Input Power Wiring Diagram.....................................................................................................27
Figure 2-5 Duty Cycle .................................................................................................................................29
Figure 2-6. MPU Wiring Diagram................................................................................................................29
Figure 2-7. MPU Signal Arm and Trigger....................................................................................................30
Figure 2-8. MPU Wired Correctly................................................................................................................30
Figure 2-9. MPU Wired Incorrectly..............................................................................................................30
Figure 2-10. Proximity Sensor Wiring Diagram...........................................................................................31
Figure 2-11. Current Input Wiring Diagram: Loop Powered .......................................................................33
Figure 2-12. Current Input Wiring Diagram: Self-Powered.........................................................................33
Figure 2-13. Voltage Input Wiring Diagram: Self-Powered.........................................................................34
Figure 2-14. Engine Sensor Analog Input Wiring Diagram.........................................................................36
Figure 2-15. Temperature Sensor Analog Input Wiring Diagram...............................................................38
Figure 2-16. Boolean Usage.......................................................................................................................40
Figure 2-17. PWM Usage............................................................................................................................40
Figure 2-18. PWM Input Wiring Diagram....................................................................................................41
Figure 2-19. Boolean Input Wiring Diagram................................................................................................41
Figure 2-20. Sourcing Input Wiring Diagram...............................................................................................42
Figure 2-21. Sinking Input Wiring Diagram.................................................................................................43
Figure 2-22. PWM Output Wiring Diagram for L-Series, FCV, Flo-Tech....................................................45
Figure 2-23. PWM Output Wiring Diagram for ProAct Digital Plus.............................................................45
Figure 2-24. PWM Output Wiring Diagram for General Application...........................................................45
Figure 2-25. PWM Output Wiring Diagram for Linear Actuator ..................................................................46
Figure 2-26. Boolean Output Wiring Diagram.............................................................................................46
Figure 2-27. Fuel Injection Group Design...................................................................................................48
Figure 2-28. Fuel Injection Output Wiring Diagram ....................................................................................50
Figure 2-29. RS-232 Wiring Diagram..........................................................................................................52
Figure 2-30. RS-485 Wiring Diagram..........................................................................................................54
Figure 2-31. CAN Cable Cross-Section......................................................................................................56
Figure 2-32. CAN System Wiring Example.................................................................................................56
Figure 2-33a. CAN-1 Wiring Diagram.........................................................................................................58
Figure 2-33b. CAN-1 Wiring Diagram—On and Off Engine .......................................................................59
Figure 2-34a. CAN-2 and CAN-3 Wiring Diagram......................................................................................59
Figure 2-34b. CAN-2 and CAN-3 On Engine Enhanced Wiring Diagram...................................................60
Figure 3-1. ASCII/RTU Representation of 3 ...............................................................................................61
Figure 4-1. Connecting the ECM3 to a PC .................................................................................................65
Figure 5-1. Sensor Symbol Key..................................................................................................................74
Figure 5-2. Pattern 1...................................................................................................................................75
Figure 5-3. Pattern 4...................................................................................................................................75
Figure 5-4. Pattern 2...................................................................................................................................77
Figure 5-5. Pattern 8...................................................................................................................................77
Figure 5-6. Pattern 3...................................................................................................................................78
Figure 5-7. Pattern 6...................................................................................................................................78
Figure 5-8. Pattern 7...................................................................................................................................79
Figure 5-9. Pattern 9...................................................................................................................................79
Figure 5-10. Pattern 5.................................................................................................................................80
Figure C-1. Prox Sensor Schematic ...........................................................................................................89
Released

Manual 26348 ECM3 Electronic Fuel Injection Control
Woodward 3
EC-US-L1
Figure C-2. Metric Proximity Sensor...........................................................................................................90
Figure C-3. SAE Proximity Sensor..............................................................................................................90
Table 1-1. Input/Output Arrangement...........................................................................................................9
Table 1-2. ECM3 Processor Capabilities....................................................................................................10
Table 2-1. Wiring Types..............................................................................................................................17
Table 2-2. J1 Pinout....................................................................................................................................21
Table 2-3. J2 Pinout....................................................................................................................................22
Table 2-4. J3 Pinout....................................................................................................................................23
Table 2-5. J4 Pinout....................................................................................................................................24
Table 2-6. Power Input Specifications ........................................................................................................25
Table 2-7. Input Power Monitor Specifications ...........................................................................................26
Table 2-8. Speed Input Specification..........................................................................................................28
Table 2-9. Speed Sensor Connections.......................................................................................................30
Table 2-10. Proximity Power Specifications................................................................................................31
Table 2-11. Proximity Probe Power Monitor Specifications........................................................................31
Table 2-12. Current Input Specification ......................................................................................................32
Table 2-13. Current Input Connections.......................................................................................................33
Table 2-14. Voltage Input Specification......................................................................................................34
Table 2-15. Voltage Input Connections.......................................................................................................35
Table 2-16. Engine Sensor Analog Input Specification ..............................................................................35
Table 2-17. Engine Sensor Analog Input Impedance.................................................................................35
Table 2-18. Engine Sensor Analog Input Connections...............................................................................36
Table 2-19. Transducer Power Specifications............................................................................................37
Table 2-20. Transducer Power Monitor Specifications...............................................................................37
Table 2-21. Temperature Input Specification..............................................................................................37
Table 2-22. Temperature Sensor Analog Input Impedance........................................................................38
Table 2-23. Temperature Sensor Analog Input Connections .....................................................................39
Table 2-24. Discrete and PWM Input Specification....................................................................................39
Table 2-25. Discrete and PWM Input Connections.....................................................................................40
Table 2-26. Sourcing Input Specification....................................................................................................42
Table 2-27. Sinking Input Specification.......................................................................................................42
Table 2-28. Discrete Input Connections......................................................................................................43
Table 2-29. Boolean and PWM Outputs Specification................................................................................44
Table 2-30. PWM Outputs...........................................................................................................................44
Table 2-31. PWM Output Connections.......................................................................................................46
Table 2-32. Discrete Output Connections...................................................................................................47
Table 2-33. Fuel Injection Outputs Specification........................................................................................47
Table 2-34. Fuel Injection Connections ......................................................................................................48
Table 2-35. Boost Supply Monitor Specifications.......................................................................................49
Table 2-36. RS-232 Specification...............................................................................................................51
Table 2-37. RS-485 Specification...............................................................................................................52
Table 2-38. Serial Cable Requirements......................................................................................................53
Table 2-39. CAN Specification....................................................................................................................55
Table 2-40. Cable Specification..................................................................................................................55
Table 2-41. CAN-1 Wiring Limitations.........................................................................................................58
Table 2-42. Engine CAN Connections........................................................................................................60
Table 3-1. ASCII vs. RTU Modbus..............................................................................................................61
Table 3-2. Modbus Frame Definition...........................................................................................................62
Table 3-3. Modbus Function Codes............................................................................................................62
Table 3-4. Modbus Error Codes..................................................................................................................63
Table 3-5. Modbus Communication Port Adjustments ...............................................................................63
Table 5-1. 2-Cycle Sensor Application Options..........................................................................................74
Table 5-2. 4-Cycle Sensor Application Options..........................................................................................76
Table A-1. Deutsch Harness Component Part Numbers............................................................................85
Table A-2. Wire Sizes .................................................................................................................................86
Table A-3. Wire Gauge Comparison...........................................................................................................87
Table C-1. Proximity Sensor Specifications................................................................................................89
Table D-1. ECM3 Control Specifications ....................................................................................................91
Released

Manual 26348 ECM3 Electronic Fuel Injection Control
Woodward 4
EC-US-L1
Warnings and Notices
Important Definitions
This is the safety alert symbol used to alert you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid possible injury or death.
•DANGER - Indicates a hazardous situation, which if not avoided, will result in death or serious injury.
•WARNING - Indicates a hazardous situation, which if not avoided, could result in death or serious
injury.
•CAUTION - Indicates a hazardous situation, which if not avoided, could result in minor or moderate
injury.
•NOTICE - Indicates a hazard that could result in property damage only (including damage to the
control).
•IMPORTANT - Designates an operating tip or maintenance suggestion.
Overspeed /
Overtemperature /
Overpressure
The engine, turbine, or other type of prime mover should be
equipped with an overspeed shutdown device to protect against
runaway or damage to the prime mover with possible personal injury,
loss of life, or property damage.
The overspeed shutdown device must be totally independent of the
prime mover control system. An overtemperature or overpressure
shutdown device may also be needed for safety, as appropriate.
Personal Protective
Equipment
The products described in this publication may present risks that
could lead to personal injury, loss of life, or property damage.
Always wear the appropriate personal protective equipment (PPE) for
the job at hand. Equipment that should be considered includes but is
not limited to:
•Eye Protection
•Hearing Protection
•Hard Hat
•Gloves
•Safety Boots
•Respirator
Always read the proper Material Safety Data Sheet (MSDS) for any
working fluid(s) and comply with recommended safety equipment.
Start-up
Be prepared to make an emergency shutdown when starting the
engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
property damage.
Automotive
Applications
On- and off-highway Mobile Applications: Unless Woodward's
control functions as the supervisory control, customer should install
a system totally independent of the prime mover control system that
monitors for supervisory control of engine (and takes appropriate
action if supervisory control is lost) to protect against loss of engine
control with possible personal injury, loss of life, or property
damage.
Released

Manual 26348 ECM3 Electronic Fuel Injection Control
Woodward 5
EC-US-L1
IOLOCK
IOLOCK: driving I/O into a known state condition. When a control
fails to have all the conditions for normal operation, watchdog logic
drives it into an IOLOCK condition where all output circuits and
signals will default to their de-energized state as described below.
The system MUST be applied such that IOLOCK and power OFF
states will result in a SAFE condition of the controlled device.
•Microprocessor failures will send the module into an IOLOCK
state.
•Discrete outputs / relay drivers will be non-active and de-
energized.
•Analog and actuator outputs will be non-active and de-energized
with zero voltage or zero current.
The IOLOCK state is asserted under various conditions, including:
•Watchdog detected failures
•PowerUp and PowerDown conditions
•System reset and hardware/software initialization
•PC tool initiated
NOTE—Additional watchdog details and any exceptions to these
failure states are specified in the related section of the product
manual.
Battery Charging
Device
To prevent damage to a control system that uses an alternator or
battery-charging device, make sure the charging device is turned off
before disconnecting the battery from the system.
Released

Manual 26348 ECM3 Electronic Fuel Injection Control
Woodward 6
EC-US-L1
Electrostatic Discharge Awareness
Electrostatic
Precautions
Electronic controls contain static-sensitive parts. Observe the
following precautions to prevent damage to these parts:
•Discharge body static before handling the control (with power to
the control turned off, contact a grounded surface and maintain
contact while handling the control).
•Avoid all plastic, vinyl, and Styrofoam (except antistatic
versions) around printed circuit boards.
•Do not touch the components or conductors on a printed circuit
board with your hands or with conductive devices.
To prevent damage to electronic components caused by improper
handling, read and observe the precautions in Woodward manual
82715, Guide for Handling and Protection of Electronic Controls,
Printed Circuit Boards, and Modules.
Follow these precautions when working with or near the control.
1. Avoid the build-up of static electricity on your body by not wearing clothing made of synthetic
materials. Wear cotton or cotton-blend materials as much as possible because these do not store
static electric charges as much as synthetics.
2. Touch your finger to a grounded surface to discharge any potential before touching the control or
installing cabling connectors. Alternatively, ESD mitigation may be used as well: ESD smocks, ankle
or wrist straps and discharging to a reference grounds surface like chassis or earth are examples of
ESD mitigation.
•ESD build up can be substantial in some environments: the unit has been designed for
immunity deemed to be satisfactory for most environments. ESD levels are extremely
variable and, in some situations, may exceed the level of robustness designed into the
control. Follow all ESD precautions when handling the unit.
oI/O pins within connectors have had ESD testing to a significant level of immunity to
ESD, however do not touch these pins if it can be avoided.
▪Discharge yourself after picking up the cable harness before installing it as a
precaution.
oThe unit is capable of not being damaged or improper operation when installed to a
level of ESD immunity for most installation as described in the specifications.
Mitigation is needed beyond these specifications.
Released

Manual 26348 ECM3 Electronic Fuel Injection Control
Woodward 7
EC-US-L1
Regulatory Compliance
European Compliance for CE Marking
These listings are limited only to those units bearing the CE Marking.
EMC Directive: Directive 2014/30/EU of the European Parliament and of the Council of 26
February 2014 on the harmonization of the laws of the Member States relating to
electromagnetic compatibility (EMC)
North American Compliance
These listings are limited only to those units bearing the CSA agency identification.
CSA: CSA Certified for Class I, Division 2, Groups A, B, C & D, T4 with application-
defined temperature limits. For use in Canada and the United States.
Certificate 1801919 (LR 79726)
Marine Compliance
Lloyds Register Lloyd’s Register of Shipping: LR Type Approval Test
of Shipping: Specification No. 1, 2002 for Environmental Categories ENV1, ENV2, ENV3, and
ENV4
Det Norske Veritas: Standard for Certification No. 2.4, 2006: Temperature Class B, Humidity Class B,
Vibration Class B, EMC Class A, and Enclosure Class B.
Nippon Kaiji Kyokai: Rules Ch. 1, Part 7, of Guidance for the approval and type approval of materials
and equipment for marine use and relevant Society’s Rules.
General Compliance:
This product is certified as a component for use in other equipment. The final combination is subject to
acceptance by CSA International or local inspection.
The ECM3 is suitable for use in Class I, Division 2, Groups A, B, C, D per CSA for Canada and US or
non-hazardous locations only.
Wiring must be in accordance with North American Class I, Division 2 wiring methods as applicable, and
in accordance with the authority having jurisdiction.
Field wiring must be suitable for at least 105 °C. Grounding is required to the input PE terminal.
Product listings are limited only to those units bearing the CSA or CE logos.
The 8-pin power connector should be used with a PVC boot (Deutsch part number DT8S-BT) when
exposed to direct sunlight.
Released

Manual 26348 ECM3 Electronic Fuel Injection Control
Woodward 8
EC-US-L1
EXPLOSION HAZARD—Do not remove covers or connect/disconnect
electrical connectors unless power has been switched off or the area
is known to be non-hazardous.
Substitution of components may impair suitability for Class I,
Division 2.
Do not use any test points on the power supply or control boards
unless the work area these will be used in is known to be a non-
hazardous location.
RISQUE D’EXPLOSION—Ne pas enlever les couvercles, ni
raccorder / débrancher les prises électriques, sans vous en
assurez auparavant que le système a bien été mis hors
tension; ou que vous vous situez bien dans une zone non
explosive.
Le remplacement de composants peut rendre ce matériel
inacceptable pour des applications de Classe I, Division 2.
Ne pas utiliser aucun points-test de l'alimentation ou des
cartes de controle à moins que l'atmosphere soit non
dangereuse.
HIGH VOLTAGE—Before doing any maintenance, always disconnect
power and any hazardous voltages that may be connected and follow
all appropriate lockout/lockdown procedures.
ELECTRIC SHOCK—To reduce the risk of electric shock, Protective
Earth (PE) must be connected to the termination point on the top of
the unit next to the label with the symbol.
The conductor providing the connection must have a properly sized
ring lug and wire gauge larger than or equal to 4 mm² (12 AWG). The
ring lug should be placed between the nut and star washer.
The calibration and checkout procedure should only be performed by
authorized personnel. To be authorized personnel, personnel must
be knowledgeable of the risks posed by live electrical equipment.
This unit is not qualified for use in residential installations due to
EMC compliance. It is only allowed in non-residential applications.
Released

Manual 26348 ECM3 Electronic Fuel Injection Control
Woodward 9
EC-US-L1
Chapter 1.
General Information
Introduction
A gas engine should be equipped with equipment to detect and
protect against engine detonation (knocking) to prevent damage to
the prime mover with possible personal injury, loss of life, or
property damage.
This manual describes the installation procedures for the Woodward ECM3 Electronic Fuel Injection
Control. The ECM3 provides control of electronic fuel injection systems for gas, diesel, and dual fuel
reciprocating engines.
The ECM3 (depending on GAP program) can perform a number of functions in addition to fuel injection,
but its primary purpose is fuel injection.
Via the use of expanded I/O on the CAN networks, many additional engine monitoring and protection
functions can be provided. Multiple ECM3 units can be used, networked via CAN, for engines with more
than 24 injection outputs to control.
The ECM3 is designed to be installed directly on the engine. On engine mounting minimizes wiring cost
by minimizing wiring length and the number of junctions.
Input/Output Arrangement
Table 1-1 shows standard I/O (input/output) for the ECM3 control.
Table 1-1. Input/Output Arrangement
Type of Input
Quantity
Options/Details
DC Power Input
Low Voltage DC Input
1
18–32 Vdc, protected from reverse
polarity
Analog Inputs
Function Configurable Inputs
3
Current (4–20 mA) or Voltage (0–5 Vdc)
Sensor Inputs
13
51.1 kPull Down resistor
Thermistor Inputs
12
1 kPull Up resistor
MPU / Proximity Speed Sensor
2
10–10000 Hz (general purpose use)
10–6000 Hz (when used as fuel injection
“speed” input)
Proximity Speed Sensor
1
5–2000 Hz (when used as fuel injection
“TDC” or “Phase” input)
Fuel Injection Outputs
EFI outputs
24
Up to 11 A pull-in current
Discrete Inputs
Configurable Switch or PWM Inputs
2
Differential input
Switch or Contact Inputs
14
Switch to return pins to activate
Key Switch Input
1
Switch to B+ to enable operation
Released

Manual 26348 ECM3 Electronic Fuel Injection Control
Woodward 10
EC-US-L1
Table 1-1. Input/Output Arrangement (cont’d.)
Type of Input
Quantity
Options/Details
Discrete Outputs
Configurable Relay Driver or
PWM Outputs
2
Low side drivers, 3 A
Configurable Relay Driver or
PWM Outputs
2
Low side drivers, 500 mA
Relay Driver Outputs
8
Low side drivers, 500 mA
Communication Ports
Serial Ports
2
(1)—RS-232, (1)—RS-485
CAN Ports
3
(1)—Isolated, (2)—On-Engine use
Control Specifications
The ECM3 I/O accuracies and environmental specifications are listed inside the back cover of this
installation manual.
Control CPU
The ECM3 control uses a GAP programmable processing core that provides all the necessary functions
in a single CPU. The below listed specifications give some insight to the processor capability relative to
other Woodward controls.
Table 1-2. ECM3 Processor Capabilities
Processor Type
Motorola MPC565
Clock Frequency
56 MHz
Math Support
Floating point CPU
Real Time Clock
Built into CPU
RTC Accuracy
1 Minute / month
Flash Memory
1 Mbyte
RAM
512 Kbytes
EEPROM
32 Kbytes
The Real Time Clock (RTC) is a part of the CPU. It is not a software clock, but it does not have battery
backup. The RTC clock will function as long as power is applied to the ECM3 power input.
A temperature monitor is also provided inside the control housing on the circuit board. It provides the
internal control temperature to the application with 2 °C accuracy. The GAP application engineer is
encouraged to use this temperature to warn operators of conditions above the control rating. Such
conditions can occur when long injection durations are used for extended periods of time, ambient
temperature is higher than normal, and/or injection currents are higher than normal due to mechanical
reasons in the injector. A temperature limit of 100 °C or lower should be used as the warning
temperature.
Applications and Functions
The ECM3 control is a microprocessor-based, electronic fuel injection control. It is designed for use with
the following fuel systems: Gas Admission Valve, Electronic Unit Injector (EUI), Electronic Unit Pump
(EUP), and Common Rail (CR).
The primary purpose of the ECM3 is to control the timing and duration of up to 24 fuel injection devices
on a “group 3” reciprocating engine. Group 3 engines include all reciprocating gas and diesel engines
producing more than 500 kW per engine but less than 100 kW per cylinder. Typical engine speeds are
greater than 1200 rpm. The speed and angular position of the engine are determined using Magnetic
Released

Manual 26348 ECM3 Electronic Fuel Injection Control
Woodward 11
EC-US-L1
Pickup (MPU) sensors or active Proximity sensors located on the crankshaft flywheel and/or camshaft
gear wheel.
Using the Controller Area Network (CAN) communication ports, it is possible to increase functionality by
measuring additional sensors and controlling additional actuators, valves, ignition equipment, and system
components. Using the CAN communication links to expand functionality and control creates a networked
engine with less wiring, thereby increasing reliability.
The ECM3 uses a patented automatic calibration procedure for all fuel injectors that it controls. The
automatic calibration procedure runs continuously while the control is operational to compensate for
electrical resistance changes over temperature and valve movement differences caused by pressure and
wear out effects. This feature eliminates the need for detailed injector configuration that would require
using manufacturer proprietary information about the injector electrical and mechanical characteristics. It
also ensures repeatable performance throughout the life of the injectors.
Released

Manual 26348 ECM3 Electronic Fuel Injection Control
Woodward 12
EC-US-L1
Figure 1-1. ECM3 Outline Drawing
(Dimensions are shown in inches)
Released

Manual 26348 ECM3 Electronic Fuel Injection Control
Woodward 13
EC-US-L1
Chapter 2.
Installation
Introduction
This chapter provides the general information for selecting a mounting location, installation, and wiring of the
ECM3 control. Information, on hardware dimensions for mounting, electrical ratings, and application
requirements, is given in this section.
Unpacking the Shipping Carton
Before unpacking the control, refer to the inside front cover and pages 4 through 6 of this manual for
WARNINGS and CAUTIONS, including the Electrostatic Discharge Awareness procedures, before
handling the ECM3 Control.
Be careful when unpacking the control. Check for signs of damage such as bent or dented panels,
scratches, bent connector pins and loose or broken parts. If any damage is found, immediately notify the
shipper.
The ECM3 was shipped from the factory in an anti-static, foam-lined, carton. This carton should always
be used for transport of the ECM3 when it is not installed.
Check for and remove all manuals, connectors, mounting screws, and other items before discarding
(storing) the shipping box.
General Installation Notes and Warnings
Due to typical noise levels in engine environments, hearing
protection should be worn when working on or around the ECM3.
The surface of this product can become hot enough or cold enough
to be a hazard. Use protective gear for product handling in these
circumstances. Temperature ratings are included in the specification
section of this manual.
External fire protection is not provided in the scope of this product. It
is the responsibility of the user to satisfy any applicable
requirements for their system.
Due to the hazardous location listings associated with this product,
proper wire type and wiring practices are critical to operation.
When selecting a location for mounting the ECM3 control, consider the following:
•Protect the unit from direct exposure to exhaust manifolds. Mount low on the engine.
•The operating range of the ECM3 control is –40 to +85 °C or less depending on injector current
output.
•Do not install near high-voltage or high-current devices.
•Allow adequate space around the unit for servicing.
Released

Manual 26348 ECM3 Electronic Fuel Injection Control
Woodward 14
EC-US-L1
•Ground the chassis for proper safety and EMI shielding.
•When installing on the engine, provide vibration isolation.
•Mount the unit to a solid metal mounting plate grounded to the engine structure so the rear
facing side does not have access.
The ECM3 is an integrated control package. All control hardware is contained in one compact enclosure.
All field wiring connects to the ECM3 through sealed connectors located on the top face of the control.
Installation placement of the ECM3 must allow sufficient room for wiring access and harness strain relief.
The ECM3 weighs approximately 5.8 kg (12.8 lb).
On-Engine Mounting
Vibration isolators should be used when mounting the ECM3. For example, when mounting to a plate
directly on a side or end of the engine, the vibration isolators are used between the ECM3 and the
mounting plate.
To install the ECM3 using the vibration isolators, first install the isolators onto the ECM3. Then install the
ECM3 with isolators onto the mounting plate. Attach a ground strap as described in the GROUNDING
sections following.
Vibration isolator components include:
•(12) M6 snubbing washers
•(4) M6 locking nuts
•(4) sleeves
•(4) M6 x 45 mm bolts
•(4) isolation mount pairs
When installing the vibration isolators, use 8.5 Nm (75 lb-in) torque to install the nut onto the bolt.
Vibration isolators should be inspected at 3 years after installation. If any visual damage, drying
(cracking), or wear is observed, replace with a new kit of 4 isolators. If new isolators are not needed,
recheck every year thereafter.
The ECM3 should be mounted vertically with the connectors facing away from the engine to prevent
moisture entry. Horizontal orientations are not recommended due to internal heat flow that causes
temperature increases within the control and to avoid water puddles on the connectors.
A minimum clearance of 15 cm (6 inches) in all directions except to the mounting plate should be left free
around the control to allow a free airflow and heat dissipation.
Released

Manual 26348 ECM3 Electronic Fuel Injection Control
Woodward 15
EC-US-L1
Figure 2-1. Vibration Isolator Installation
Wiring harnesses should have strain relief no further than 30 cm (12 inches) from the control. The ECM3
must be located so that no wire or cable (except those noted later) in the ECM3 harness exceeds 10
meters in total length.
The ECM3 is shipped from Woodward with a clear chromate finish to protect it from corrosion. Further
painting of the control is anticipated. If the control is to be painted (such as during engine painting), take
care to minimize paint thickness and to mask all labels so they are readable after painting. Thick layers of
paint will inhibit the thermal transfer and can cause overheating of the control.
To prevent damage to the ECM3, do not use any electrostatic
painting process.
The ECM3 was designed for on-engine installation. It is suitably protected against water and dust entry,
thermal cycles, and exposure to oils, coolant, and fuels. The mating wiring harnesses must be installed to
complete the moisture seal. Pressure washing of the engine will not harm the ECM3 but take care to
avoid long-term exposure to high pressure water at the connector interface.
Figure 1-1 shows a physical outline drawing with dimensions of the ECM3 for reference during the
construction of mounting panels, etc. The enclosure size is 305 mm high x 400 mm wide x 96 mm deep
(12 inches H x 15.7 inches W x inches 3.8 D).
Released

Manual 26348 ECM3 Electronic Fuel Injection Control
Woodward 16
EC-US-L1
Figure 2-2 below shows the mounting hold pattern and dimensions for use when designing a mounting
plate.
Temperature Specifications
The temperature rating of the ECM3 is generally listed as –40 to +85 °C. However, the actual temperature
rating depends on many factors which influence the amount of heat dissipated inside the enclosure. These
factors include engine rpm (injection frequency), injection duration, use of pre or post injection, the number
of injection outputs used, and the level of current used for each injection event.
Consider the below cases to determine the proper ambient temperature application for the ECM3. If your
application does not fit one of the cases below, contact Woodward for assistance.
Figure 2-2. Mounting Hole Layout
Case 1—Rated for use in ambient temperatures up to 85 °C
A 12-cylinder engine using 24 injection outputs where pairs are operated simultaneously but no pre
or post injection is used. The engine is a 4-cycle diesel with rated speed of 1800 rpm and maximum
injection duration of 50°crank angle at rated speed. The injectors use a pull-in current of 11 A and
hold-in current of 4 A with CPD achieved in 1.2 ms.
Case 2—Rated for use in ambient temperatures up to 85 °C
A 12-cylinder engine using 12 injection outputs and up to one pre-injection event. The engine is a
4-cycle diesel with rated speed of 1800 rpm and maximum injection duration of 50° crank angle at
rated speed plus another 10 degrees for the optional pre-injection event. The injectors use a pull-in
current of 11 A and hold-in current of 4 A with CPD achieved in 1.2 ms.
Released

Manual 26348 ECM3 Electronic Fuel Injection Control
Woodward 17
EC-US-L1
Electrical Connections
The ECM3 is not shipped with mating connectors because many applications may have a standard wiring
harness, or it is desirable to have the mating connectors in advance to use when wiring. However, for
service and convenience, Woodward also carries ECM3 connector kits containing all the mating terminal
blocks used on the ECM3. See Appendix A for mating connector usage instructions.
The sealed connectors on the ECM3 are not designed for removal by hand. After input power is
disconnected, the connectors can be removed using a 4 mm Allen head driver. Individual wires can be
removed using an extraction tool (included in connector kit). See Appendix A for instructions. When
replacing the connectors, use 6.0 ±0.1 Nm of force on the jackscrew. Too little force will allow the
connector to leak, and too much force may damage the connector.
A hand crimp tool is necessary for use with the hand crimp sockets included in the connector kit. The tool
can be purchased from Woodward or directly from Deutsch. See Appendix A for part numbers.
Noise interactions can affect the accuracy of the control. To facilitate noise confinement, it is
recommended that:
•All low-current wires should be separated from all high-current wires when routing from the
ECM3 to the engine components.
•Injector cables should be routed away from all other types of cables.
•Communications, analog, and speed signals should be routed separately from the injector
wiring.
•Discrete wiring (such as relay outputs or Boolean inputs) may be routed separately or with the
analog wiring.
Table 2-1 shows the wiring types for each signal type.
Table 2-1. Wiring Types
Signal Type
Wiring Type
Comment
Differential Analog
Input
Shielded, twisted pair
Use 1.0 mm2(18 AWG) or 1.5 mm2(16 AWG)
Sensor Analog Input
No requirement
Use 1.0 mm2(18 AWG) or 1.5 mm2(16 AWG)
PWM Input
Shielded, twisted pair
Use 1.0 mm2(18 AWG) or 1.5 mm2(16 AWG)
PWM Output
Twisted pair
Use 1.0 mm2(18 AWG) or 1.5 mm2(16 AWG)
Discrete Input
No requirement
Use appropriate return pin –do NOT return to B-
Discrete Output
No requirement
Use appropriate return pin –do NOT return to B-
MPU or Proximity
Input
Shielded, twisted pair
Use 1.0 mm2(18 AWG) or 1.5 mm2(16 AWG)
Injector Output
Shielded, twisted pair
Use 1.0 mm2(18 AWG) or 1.5 mm2(16 AWG)
RS-232 or RS-485
Shielded, twisted pair
Must use serial cable
CAN
Shielded, twisted pair
Must use CAN cable (See CAN section for details)
Battery Input
Twisted pairs
Use 2.0 mm2(14 AWG)
Splicing
Individual returns are not provided for each signal. Some signals share a common return pin. In these
cases, harness splicing will be necessary.
Regardless of how the splicing is accomplished, signal routing is still very important. A signal should
always be routed together with its return. Signals using twisted pair must have wires in close proximity
and separations through the splice should be minimized to the greatest extent possible.
Wiring for discrete signals must be done so that the signal wire and the return are always in the same
cable bundle. They should never take different paths between the ECM3 and the sensor. This
requirement is for signal integrity and EMI/EMC purposes.
Released

Manual 26348 ECM3 Electronic Fuel Injection Control
Woodward 18
EC-US-L1
Harness splicing should always be done using hot solder-crimp splices. The solder is necessary for good
signal conductivity at all frequencies. The crimp is necessary for strength and protection in the on-engine
environment. Cold crimp joints alone are not sufficient signal joints and are unreliable in a high vibration
environment.
Splicing of shielded, twisted pair wiring is not recommended. These signals should have a single origin
and destination. Breaking the signal path or shield is not desirable as it provides an opportunity for EMI or
EMC interference and reduced signal integrity.
Grounding for Protection against Electrical Shock
Protective Earth (PE) must be connected to the termination point on the side of the unit next to the label
with the symbol to reduce the risk of electric shock. The conductor providing the connection
must have a properly sized ring lug and wire larger than or equal to 4 mm² (12 AWG). It is acceptable to
use the EMI ground strap for this purpose. See Grounding for Protection Against Electrical Noise
following this paragraph for details.
Recommended Grounding Practices
Providing a proper ground for the ECM3 is important. Improper connection of the ECM3 chassis to the
ground plane may affect accuracy of I/O and immunity to noise. Differences in potential between the
chassis and the ground reference result in an equalizing current flow. The current flow produces
unacceptably high common mode noise voltages.
Common mode voltages may result in improper readings for analog and speed inputs or even damage to
the ECM3 in extreme cases. To minimize this problem, it is necessary to provide a low resistance
(impedance) path between ground and the chassis of the ECM3. Typically a single ground point is
designated for the engine and all related equipment.
Grounding for Protection against Electrical Noise
A proper ground strap must be connected to the chassis termination point to provide a low impedance
path for EMI. The strap providing the connection must have a properly sized ring lug and be constructed
of ½ inch wide, flat, hollow braid no more than 12 inches long or any strap that is equivalent at DC-to-RF
frequencies. (Example braid: International Wire, Continental Cordage Corp. P/N 233/2, Woodward P/N
2008-957) This strap may be used in place of the PE grounding conductor if desired. In such cases, this
strap becomes both the EMI ground strap AND the protective earth connection.
Shields and Grounding
Signals that require shielding include speed inputs, some analog inputs, PWM inputs, communications
links, and injector wiring. Relay outputs, contact inputs, high current PWM outputs, and power supply
wiring does not normally require shielding but can be shielded if desired. All shielded cable must be a
twisted conductor pair. Do not attempt to tin (solder) the braided shield prior to crimping it into the socket
or splice. The solder will affect the crimp strength and create vibration susceptibility.
Shield terminations are provided through the ECM3 connectors for each of the signals requiring shielding.
It is important that only the shield pin designated for a specific type
of signal be used. Do not substitute shield pin connections between
different groups. Not all shields are connected the same way within
the ECM3 control.
Signal lines are shielded to prevent picking up stray signals from adjacent equipment. Injector wiring is
shielded to suppress emissions that can affect other wiring and equipment. Wire exposed beyond the
shield should be as short as possible, not exceeding 50 mm (2 inches). In most cases, one end of the
shields must be left open and insulated from any other conductor. Typically, the shield at the end opposite
Released