Engineering Concepts Unlimited (ECU) recently launched a new engine control unit for engine generator set and pump set control. While targeted primarily toward the smaller end of market, the new 9960 Series control has enough flexibility and capability to be suitable for application in ECU'S more traditional larger engine installations, according to Adam Suchko, president of the Fishers, Ind., manufacturer.

"These units can be configured for everything from ultra-simple to reasonably complicated applications," said Suchko. "It is really targeted at small sets and pumps, but it has just enough capability to eke onto a regular set. It's probably one of the most flexible controls we've ever offered."

The new 9960 Series control is a fully potted unit housed in an ECU standard (2.9 in. x 3.1 in. x 1 in.) zinc case. It can accommodate as many as three 40 amp relays and a total of 12 connections to monitor and control a range of engine conditions and functions. Faston connectors are used to provide high power and density and facilitate quick installation, Suchko noted.

* Battery monitoring with auto start at low voltage, low voltage timer and automatic stop at high voltage.

* Glow plug, starter and fuel.

* Frequency and ac voltage of the speed input.

* A range of optional capabilities such as pressure and temperature sensing, run-time monitoring, etc.

"It can be custom ordered in many different versions that allow even the small packager to have his own OEM-style control," noted Suchko. "There is a lot of capability packed into this."

The control can be set up to run on generator output voltage or magnetic pickup and incorporates a proprietary processing algorithm for ac to avoid problems with load noise. On-board high current relays are designed to eliminate the need for pilot relays on most small gen-sets.

"Loads are orchestrated to allow one inline fuse to pretty, much handle it, since we make sure the starter and glow plugs aren't on at the same time," Suchko said.

Depending on the version, information can be displayed on LEDs and can also be sent to an external readout, such as a laptop or an optional screen display. The system can be used with any other ECU engine control product and Suchko said the system configuration can be altered by the use of an external programming device. The customer may choose whether he wants to have field programmable or factory programmable adjustment capability.

"One version allows for multiple station operation of the gen-set anywhere in the vehicle or building," Suchko said. "A simple external on/off push button controls it and a single wire for an external light or LED allows monitoring from anywhere using simple flash codes. A push rocker switch with built-in LED makes them great for truck dashes."

Suchko added that ECU was planning to incorporate software into the 9960 Series control, essentially "turning the unit into a small PLC for doing speed and timing.

"We can't thank our customers enough for their continued support and we continue to listen to their needs for simple, robust engine controls that deliver years of solid reliability," Suchko added, also noting ECU's ability to respond quickly. He cited one case where the company "delivered a replacement part to Juneau, Alaska, for the FAA on a VOR system on an island. Our staff arranged for airline transit to have it there as quickly as possible per the customer's request."

The 9960 Series control is the latest in a growing range of products from ECU that includes CAN-bus engine controls, speed switches, voltage detectors and other components and modules, primarily for stationary engine systems.

The new 9960 Series modules have undergone more than six months of testing with customers, with 50 units in field trials. "They're running in the Florida hurricane outage as we speak" Suchko noted. It is built at ECU's advanced manufacturing facility in Fishers, Ind. The 10,000 sq.ft. site encompasses a highly automated manufacturing system based on high-speed Sanyo equipment, including cassette loading and unloading sections and vision-aligned chip pasters and shooters. ECU-built process machines include an automatic module tester for full testing of each product.

The new manufacturing system, which went online in late 1992, allows ECU to place more than 50,000 parts per hour and has increased the production capacity of the Fishers plant by more than 500% over the previous levels, Suchko said. Because of that efficiency, Suchko said the 9960 Series control, when ordered in volume, could actually break the $100 price plateau, making it much more applicable to small equipment where pricing is even more paramount.