e GE Transportation Systems PowerStar Controller Summary 84A213165BH Rev 0

Author: Melpolder, D & Miller, E Approved: Bailey, K

May 13, 2005 First Made For: GENSET & MARINE EFI CONTROL Page 1/19

PowerStar

Electronic Fuel Injection Controller

Summary
e GE Transportation Systems PowerStar Controller Summary 84A213165BH Rev 0
Author: Melpolder, D & Miller, E Approved: Bailey, K
May 13, 2005 First Made For: GENSET & MARINE EFI CONTROL Page 2/19

1 Introduction

The primary function of the GE PowerStar Electronic Fuel Injection (EFI) control, for Stationary Genset and Marine
applications, is engine speed control under varying loads. Additional functions include engine protection and start-stop
control.

Advantages of an EFI controlled engine are to reduce specific fuel consumption, reduce emissions, and improve engine
reliability while maintaining the same engine horsepower. The EFI controller enforces rate limits on speed, acceleration
and deceleration, limits loading according to lube oil temperature and pressure, limits fueling to prevent smoke
discharge and protects the engine against overspeed, overload, low oil pressure, low water pressure, and positive
crankcase pressure. The EFI controller supports both forward and reverse rotating engines.

PowerStar’s operating requirements and functions are defined in the EFI Controller’s SFS 84A213165AB and Purchase
Specifications 84A213165AC, AD, & AE.

The PowerStar EFI control resides in two controllers, the Speed Reference & Load Control (SRLC) and the Engine
Governor Unit (EGU).

The SRLC manages the speed and load functions as well as start-stop control. The functions are software driven within
the SRLC micro processor (µP).

The EGU is also a µP based controller with imbedded software which determines the amount of fuel injected into each
cylinder by controlling the high-pressure fuel pump solenoid.

Both the SRLC and EGU share engine protection.

1.1 Material List

PART NO. OUTLINE DESCRIPTION

PowerStar Enclosure 84A213165AJG1 84C603254 Enclosure Assembly

SRLC Controller 84A213165ACP1 84C602776 Woodward 723PLUS speed controller
DIN Input Module 84A213165ACP3 84B521896 with one remote input module and
DOUT Output Mod 84A213165ACP4 84B521896 two remote output modules.
Term Mod 84A213165ACP5 ------------- Termination Module
EGU Controller 84A213165Adxx 84C602777 BAE 17FM664H1 Engine Controller
DC–DC Converter 84A213165AEP1 84B521897 Vicor 24vdc to 72vdc DC Converter

Fuel Transfer Pump 41A224285ACP1 84B516340AC Paragon 12 gpm 230VAC/60Hz fuel pump
41A224285ACP2 84B516340AC Paragon 12 gpm 460VAC/60Hz fuel pump
41A224285ACP3 84B516340AC Paragon 12 gpm 380VAC/50Hz fuel pump

Air Starter Valves 41A221118P1 41A221118 24V DC Solenoid

41A221118P2 41A221118 240VAC/60Hz Solenoid
41A221118P3 41A221118 115V DC Solenoid
e GE Transportation Systems PowerStar Controller Summary 84A213165BH Rev 0
Author: Melpolder, D & Miller, E Approved: Bailey, K
May 13, 2005 First Made For: GENSET & MARINE EFI CONTROL Page 3/19

1.2 Acronym Definitions

ABS American Bureau of Shipping

BIT Built In Test
DIN Discrete Input Module
DOUT Discrete Output Module
EFI Electronic Fuel Injection
EGU Engine Governor Unit
FPR Fuel Pump Relay
MCC Motor Control Center
NC Contact Normally Closed
NO Contact Normally Open
SRLC Speed Reference and Load Control
7FDS GE 12 or 16 cylinder diesel engine for Stationary Genset application
7FDM GE 12 or 16 cylinder diesel engine for Marine application

1.3 Controller Strategy

POWERSTAR

EFI CONTROL ENGINE

SRLC EGU Engine SENSOR

Sensors BOX

Pump/injector 12/16
+ Σ Cylinder
Fuel Injection Map Solenoid controls
Desired Speed Fuel Injection 7FDS / 7FDM Engine
– Limit
Solenoid & Pump
Speed Error Demand Data Speed
 e GE Transportation Systems PowerStar Controller Summary 84A213165BH Rev 0
Author: Melpolder, D & Miller, E Approved: Bailey, K
May 13, 2005 First Made For: GENSET & MARINE EFI CONTROL Page 4/19

1.4 Equipment Description/Hardware Interface Diagram

EGU SRLC DOUT1 DOUT2 DIN *OPERATOR

PS1
74VDC FUEL DEMAND CONTROL
FUEL DISCRETE DISCRETE DISCRETE
DC-DC INPUT DEMAND SPEED REF
ES
&
OUTPUT OUTPUT INPUT
CONVERTER VOLTAGE INPUT STOP
LOADING 8 OUT 8 OUT 16 IN
24VDC RUN
to START
74VDC  DISCRETE BLOWDOWN
INPUTS:
IC OVER TEMP OUTPUTS RUN PERMISSIVE PRELUBE
LOW OIL PRESS COP FAULT
LOW H2O PRESS HI TEMP FAULT
CHECK ENGINE RS232 NET NET NET NET NET NET
LOW PRESS FAULT
PS2 OVER SPEED FAULT
EGU DIAGNOSTIC
DC-DC PUMP DIESEL
CONVERTER SOLENOID SENSOR DIESEL SENSOR
24VDC DRIVERS INPUTS INPUTS OUTPUTS OUTPUTS INPUTS
to
74VDC DSS1 & 2 STARTER
CNK1 & 2 24VDC
EPS FIMAP FUEL PUMP CONTROL
COP, LOT PRELUBE VOLTAGE
FIWPS, FIOP1
FIEWT, FIMAT

FUEL
7FDM / 7FDS
PUMP SOLENOIDS TRANSFER
PUMP * MCC
460VAC 3φ 60Hz
ENGINE *LOAD TRANSFER PUMP MOTOR STARTERS
AIR STARTER
OPERATING VOLTAGES
460VAC 3φ 60Hz
SENSORS FUEL PUMP 24VDC
PRELUBE 0.5KVA CPT
AIR STARTER 120VAC
120VAC SOLENOID
* NOTE:
SUPPLIED BY
END USER
e GE Transportation Systems PowerStar Controller Summary
Author: Melpolder, D & Miller, E Approved: Bailey, K
May 13, 2005 First Made For: GENSET & MARINE EFI CONTROL
2 SRLC Controller
The SRLC is a 32 bit microprocessor-based digital
speed controller providing engine speed control and
the interface between the customer speed request and
EGU control. The SRLC develops a 4-20ma Fuel
Demand signal for the EGU. Fuel Demand consists of
the fuelling limits and speed requirements on the
engine. The SRLC develops an additional 4-20ma
proportional load limit signal to limit engine loading for
Genset applications. The SRLC also provides the
control logic to start and stop the diesel, relay contacts
to operate the pump starters in the customer provided
MCC, and relay contacts for the customer alarm
system.
SRLC parameters are monitored with a commercial PC
computer loaded with Woodward Watch Window
software. The SRLC communicates with the PC through
a RS-232 or RS-422 serial interface.
The SRLC controller consists of a single printed circuit
board in a sheet metal chassis to be mounted on an
electrical cabinet’s back panel. Three terminal strips
and three 9-pin D connectors provide hardwire
interface connections to the EGU, engine sensors, Local
Control Panel (LCP) and customer provided Motor
Control Panel (MCC).
The SRLC provides eight discrete inputs and three relay
outputs. Additional I/O is provided with stand alone
remote I/O modules. The modules communicate to the
SRLC over the LON local area network. Discrete Input
Module (DIN) provides sixteen 24 vdc input channels to
the SRLC. Discrete Output Modules (DOUT1 & 2) each
provide additional eight relay contacts rated for 2 amp
to operate 24vdc pilot relays and to interface with the
customer’s engine alarms. The pilot relay contacts are
wired to motor starters in the customer’s MCC.
84A213165BH Rev 0
Page 5/19
3 EGU Control
The EGU is a microprocessor-based controller providing
fuel injection control for 8, 12, and 16 cylinder diesel
engines. The Fuel Demand signal developed from the
SRLC requests the fuel required to satisfy the speed
reference applied to the SRLC. The EGU monitors the
magnitude of the signal to determine the amount of
fuel and monitors the rate of signal change to
determine transient timing conditions.
The EGU controller consists of one primary Printed
Wafer Board (PWB) designed to be mounted by
standoff bolts to the enclosure back panel. Card
mounted plug connectors provide hardwire interface
connections to the SRLC controller, engine sensors, and
fuel pump solenoids. RS232 serial interface cabled
from the card-mounted daughter board communicates
temperature and pressure sensor values and EGU fault
status to the SRLC controller.
The EGU controller protects the engine against
overspeed, overload, low oil pressure, low water
pressure, and crankcase overpressure. A ”POP Test”
feature is also provided for assisting in engine
diagnosis.
Hardwired inputs program the EGU controller for either
a forward or reverse rotating engine.
 e GE Transportation Systems PowerStar Controller Summary 84A213165BH Rev 0
Author: Melpolder, D & Miller, E Approved: Bailey, K
May 13, 2005 First Made For: GENSET & MARINE EFI CONTROL Page 6/19

4 Functional Description Detailed Flow Diagram

DC-DC CONV DSS1 ENGINE SPEED ENGINE

24 to 74 VDC DSS2 SENSORS FIMAP SENSOR BOX
EFI
EGU BOSCH HIGH
24 VDC POWER 74 VDC 24 VDC
DC-DC CONV PRESSURE
SUPPLY CB
24 to 74 VDC PUMP
VOLTAGE TORQUE
LIMIT
SPEED
LIMIT INJECTION -
24 VDC SPEED
FUEL MAPS PUMP
ERROR SOLENOIDS
CUSTOMER DEMAND 1. LINEAR INJECTOR
SPEED REF
PROVIDED REF Σ Y=f(x)
2. ADVANCE
ANGLE
SOLENOID
E-STOP CONTROL
INPUTS 3. RUN INIT WITH CPD
RUN PERMISSIVE 723PLUS 4-20ma
MAX SMOKE CNK1
FUEL FUEL CUSTOMER SPEED& ENGINE
IDLE CNK2
LIMIT LIMIT % LOAD POSITION SPEED
RESET EPS SENSORS
MONITORS
LOP, LOT, OS, COP & EGU RS-232 RS-232 EWT
FROM
BLOW DOWN BIT FAULTS PORT MAT
LOCAL ENGINE
LON LON HI IC TEMP LOT
CONTROL SENSOR BOX
PRE-LUBE START EGU FAULTS VARIABLE BLOCK LOP
PANEL COP FAULT LOW LOP
PRE-LUBE STOP LOAD OS FAULT COP
SRLC
INPUTS

LIMIT FAULTS BIT FAULT LOW WP FAULT EWP

PRE-LUBE BYPASS FUEL
LOT > 225°F LOW LOP DETECTOR
LIMIT
OS FAULT IC TEMP EGU FAULT SELECT AV ROTATION
LUBE OIL BYPASS DETECT (OS, COP, BIT) ROTATION BV JUMPER
FPR
START ENGINE FPR DV
DISABLE
INCREASE SPEED FUEL PUMP RELAY PLR EGU
SHED LOAD PRE LUBE RELAY N
DECREASE SPEED
READY TO RUN LIGHT SR STARTER
ENGINE BOS BARRING OV SW
RELAY
FUEL PUMP INTL
OUTPUTS LOW LOW IC OUTPUTS SRLC EGU EGU LOT LOT>2 LOT>
SPD LOP WP COP
PRE LUBE INTL FUEL PRE RUN AIR TEMP OS OS BIT <14F 20F 240F TRIP
VESSEL LMT FLT FLT FLT FLT FLT FLT
FLT FLT
LON PUMP LUBE LITE START LON
MCC
FUEL PUMP STARTER
FPR
PRE LUBE STARTER
PLR
AIR STARTER
SR
TO ADVISORY PANEL
e GE Transportation Systems PowerStar Controller Summary 84A213165BH Rev 0
Author: Melpolder, D & Miller, E Approved: Bailey, K
May 13, 2005 First Made For: GENSET & MARINE EFI CONTROL Page 7/19

5 Engine Sensors/Switches Function

PLUG
NAME FUNCTION CONTROL or SCALE Acc’y SENSOR TYPE
PIN
Mechanically closed switch to
BOS Detect Open
BOS Bar Over Switch open when barring-over
1&2 Barring-Over Cover
engine
FIS Momentary normally open
FIPTS POP Test Switch Close to initiate POP test
L&M toggle switch
FIS
DSS1 Diesel speed sensor 1
U,V,W
52 pulses / engine rev
FIS
DSS2 Diesel speed sensor 2
X,Y,Z
Magnetic sensor producing a
Freq = Engine rpm ±0.1°
ECA sinusoidal waveform with
CNK1 Crankshaft speed 1 (58 pulses / engine rev plus crank
A,B,C amplitude and frequency
two missing teeth)
proportional to crankshaft
0.8vpp = 35Hz = 35 rpm
ECA rotational speed.
CNK2 Crankshaft speed 2 45vpp = 1200Hz = 1200 rpm
D,E,F
Max = 1320 rpm
EPS ±0.4°
EPS Cam shaft position 1 pulse / 2 engine rev
A&B cam
Transmitter producing a
Crankcase over FIS 4ma = -1 psig
COP ±2% current proportional to
pressure S&T 20ma = +1 psig
crankcase air pressure
Transmitter producing a
FIS 4ma = 0 psig
FIOP1 Lube oil pressure ±2% current proportional to engine
E&F 20ma = 150 psig
oil pressure
Transmitter producing a
Engine water FIS 4ma = 0 psig
FIWPS ±2% current proportional to engine
pressure G&H 20ma = 50 psig
water pressure
Transmitter producing a
FIS 4ma = 0 psia
FIMAP Manifold air pressure ±2% current proportional to
J&K 20ma = 75 psia
manifold air pressure
Thermistor characterized by a
Manifold air FIS 1380 Ω = + 125° C
FIMAT ±2% resistance which varies with
temperature A&B 1.21MΩ = - 40° C
manifold air temperature
Thermistor characterized by a
Engine water FIS 1380 Ω = + 125° C
FIEWT ±2% resistance which varies with
temperature C&D 1.21MΩ = - 40° C
engine water temperature
Thermistor characterized by a
FIS 1380 Ω = + 125° C
LOT Lube oil temperature ±2% resistance which varies with
N&P 1.21MΩ = - 40° C
engine lube oil temperature
High pressure fuel FIS Normally closed dry contact
HPFLD Presence of fuel leak
leak detector Q&R for alarm
e GE Transportation Systems PowerStar Controller Summary 84A213165BH Rev 0
Author: Melpolder, D & Miller, E Approved: Bailey, K
May 13, 2005 First Made For: GENSET & MARINE EFI CONTROL Page 8/19

6 PowerStar Wiring Diagrams: Black – Supplied By Customer Gray – Supplied By GE

6.1 PowerStar Enclosure Arrangement (Dimensions in inches)

6.1.1 Outside View

e GE Transportation Systems PowerStar Controller Summary 84A213165BH Rev 0
Author: Melpolder, D & Miller, E Approved: Bailey, K
May 13, 2005 First Made For: GENSET & MARINE EFI CONTROL Page 9/19

6.1.2 Inside View

e GE Transportation Systems PowerStar Controller Summary 84A213165BH Rev 0
Author: Melpolder, D & Miller, E Approved: Bailey, K
May 13, 2005 First Made For: GENSET & MARINE EFI CONTROL Page 10/19

6.2 PowerStar Schematic

FIP
PLUG
ENGINE HIGH PRESSURE PUMP SOLENOIDS

MCC
POWERSTAR
FUEL TRANSFER PUMP STARTER
TB2
PRE LUBE STARTER

AIR STARTER CONTACTOR

TBB EGU BOX
THIRD PARTY MODBUS COMM PORT

EGU IDS TOOL BOX

SRLC WATCH WINDOW

ECA
PLUG
CRANK 1 & 2 SENSORS
EPS
PLUG
ENGINE POSITION SENSOR
BOS
PLUG
BAR OVER SWITCH

FOT
DIN DOUT 1 DOUT 2 PLUG
FUEL OIL TEMPERATURE

ENGINE SENSOR BOX

TB1

SRLC FIS
LUBE OIL TEMPERATURE
PLUG

LUBE OIL PRESSURE

ENGINE WATER TEMPERATURE

ENGINE WATER PRESSURE

FUI&2
CRANKCASE PRESSURE

MANIFOLD AIR TEMPERATURE

FIS
PLUG MANIFOLD AIR PRESSURE

DIESEL SPEED SENSORS 1 & 2

CONTROL STATION

DISCONNECT SWITCH
ENUNCIATOR PANEL
24vdc (+)
SUPPLY
(–)

E-STOP READY TO RUN LIGHT

RESET LOAD LIMIT

ENGINE STOP SPEED LIMIT

IDLE / RATED SPEED LOW LUBE OIL PRESSURE

ADJUST SPEED LOW WATER PRESSURE

IC OVER TEMPERATURE

OVERSPEED (SRLC & EGU)

BLOWDOWN EGU BIT FAULT

PRE LUBE (START, STOP, BYPASS) CRANKCASE OVERPRESSURE

ENGINE START LOT < 140 °F

LOCAL / REMOTE LOT > 220 °F

SPEED (INCREASE & DECREASE) LOT > 240 °F

COLD ENGINE BYPASS SYSTEM OK

e GE Transportation Systems PowerStar Controller Summary 84A213165BH Rev 0
Author: Melpolder, D & Miller, E Approved: Bailey, K
May 13, 2005 First Made For: GENSET & MARINE EFI CONTROL Page 11/19

6.3 Terminal Board 1 (TB1)

TB1
FIS
SPEED SENSOR 1
}
V
INPUT #1 (Cam gear speed Sensor 1 input)
(DSS1) W 2
U 3
4
}
Y
SPEED SENSOR (Cam gear speed Sensor 2 input)
INPUT #2 Z 5
(DSS2)
ES ES X 6
7 (Emergency Stop – Trip Fault with Alarm Shutdown)
RESET
8 (Resets all Alarm Shutdowns and Warning Alarms)
STOP
9 (Run Permissive – Close to run – Open for normal control stop)
IDLE RUN SPEED
10 (Open for idle speed – Close for rated speed)
SPEED
11

FIS 12
} (4 – 20 ma speed reference from pilothouse)

13
}
J
MANIFOLD AIR (Manifold Air Pressure Sensor input)
PRESSURE SENSOR K 14
(FIMAP)
+24VDC 15
16 ENGINE CAPACITY
(Percent of available engine capacity before limits)
{ 17
4-20MA ANALOG
OUTPUT
(–24vdc) 18
READY TO RUN
(Pre Lube cycle complete & Run Permissive applied) +24vdc 19 G
LOAD LIMIT
(On to signal that Engine in static or smoke limit) +24vdc 20 R
SPEED LIMIT
(On to signal Engine speed > 1070 rpm limit) +24vdc 21 A
LOW LOP
(Off to signal Low Lube Oil Pressure per engine speed) +24vdc 22 R
LOW EWP
(Off for Low Engine Water Pressure per engine speed) +24vdc 23 A
IC OVER TEMP
(Off for High Water or Manifold Air Temperatures) +24vdc 24 R
SRLC OVERSPEED
(Off to signal Overspeed detected by the SRLC) +24vdc 25 R

(+24vdc)
26
EGU OVERSPEED
(Off to signal Overspeed detected by the EGU) +24vdc 27 R
EGU BIT FAULT
(Off to signal EGU Built In Test Diagnostic fault) +24vdc 28 R
COP FAULT
(Off to signal Crankcase Overpressure fault) +24vdc 29 R
LOT < 140°F
(Off to signal Lube Oil Temperature less than 140 °F) +24vdc 30 A
LOT > 220°F
(Off to signal Lube Oil Temperature greater than 220 °F warning) +24vdc 31 A
LOT > 240°F
(Off to signal Lube Oil Temperature greater than 240 °F fault) +24vdc 32 R
SYSTEM OK
(Steady on for a working system, on-+24vdc 33 G
off for a warning and
off for a trip fault alarm)
 e GE Transportation Systems PowerStar Controller Summary 84A213165BH Rev 0
Author: Melpolder, D & Miller, E Approved: Bailey, K
May 13, 2005 First Made For: GENSET & MARINE EFI CONTROL Page 12/19

6.4 Terminal Board 2 (TB2)

TB2

+24VDC
1 (+24vdc – Terminals 1 to 4)

2 MARINE
+24VDC JUMPER
3
+24VDC
4
BLOWDOWN
5 (Close to rotate engine without fuel to blow out moisture in cylinders)
PRE LUBE START
6 (Close to start Pre Lube Pump)
PRE LUBE STOP
7 (Open to stop Pre Lube Pump)
PRE LUBE BYPASS
8 (Close to bypass Pre Lube start cycle)
COLD ENGINE STRATEGY BYPASS
9 (Close to bypass cold engine strategy warm up cycle)
ENGINE START
10 (Close to engauge starter to start engine – Ready to Run light must be on)
SPEED >
11 (Close to increase running speed locally)
SPEED <
12 (Close to decrease running speed locally)
LOCAL / REMOTE

} (Open for local speed control – Control speed from Speed Inc & Dec
Close for remote speed control – Speed reference from 4-20ma speed signal)
BAR OVER SWITCH A BOS B
CUSTOMER 13 (Open to detect Bar Over Door open – Prevent engine from running)
PROVIDED MCC
14
M
FTP STARTER
15 CONTROL
M
PLP STARTER VOLTAGE
16
17 FTP
FPR OL
FTP STARTER
18 M

19 PLP
PLR OL
PLP STARTER
20 M

21 ASC
SR
AIR CONTACTOR
22 M

LUBE OIL FIS 23

TEMPERATURE 24
}
N
SENSOR (Lube Oil Temperature Sensor input)
ECA
(LOT) P 25
C 26
CRANK 1
27
}
B
(CNK1) (Crank speed Sensor 1 input)
A 28
EPS
29
}
A
ENGINE POSITION
SENSOR (Cam gear pin Engine Position Sensor input)
(EPS)
B 30

ECA
31
F 32
CRANK 2
33
}
E
(CNK2) (Crank speed Sensor 2 input)
D 34

CONTINUED
NEXT PAGE
e GE Transportation Systems PowerStar Controller Summary 84A213165BH Rev 0
Author: Melpolder, D & Miller, E Approved: Bailey, K
May 13, 2005 First Made For: GENSET & MARINE EFI CONTROL Page 13/19

TB2
(CONTINUED)

FIS
CRANKCASE 35
}
S
OVERPRESSURE SENSOR (Crankcase Pressure Sensor input)
(COP) T 36
37
FIS
LUBE OIL 38
}
E
PRESSURE (Lube Oil Pressure Sensor input)
SENSOR F 39
(LOP)
40
ENGINE WATER FIS
41
}
G
PRESSURE
(Engine jacket water Pressure Sensor input)
SENSOR
FUEL OIL FFOT (EWP)
H 42
TEMPERATURE 43
}
A
SENSOR (Fuel Oil Temperature Sensor input)
(FOT) B 44
XTM 45
EGU
RS232
LAPTOP
REC 46 } (EGU IDS Tool Box Com Port)

COM PORT COM 47

FIS SHD 48
MANIFOLD AIR 49
}
A
TEMPERATURE (Manifold Air Temperature Sensor input)
(MAT) B 50
51
}
ENGINE WATER C

TEMPERATURE (Engine jacket water Temperature Sensor input)

(EWT)
D 52
53 MARINE
POP JUMPER
FIS FIS 54
M
TEST L
55 (POP Test switch located on Engine Sensor Box – Close to start test)

56
CCW
ROTATION
57 SELECT
CW
58
59

SRLC
GND (5) 60
RS485 RT- (9) 61
CUSTOMER
62
}
USE RT+ (6)
MODBUS (Third Party Com Port interface with Modbus protocol)
TR- (7) 63
TR+ (3) 64
XMIT- (2) 65

SRLC
XMIT+ (4) 66
RS422
WATCH
REC- (3) 67 } (SRLC Watch Window Com Port)

WINDOW REC+ (5) 68

COM PORT
GND (7) 69
+12V (9) 70
e GE Transportation Systems PowerStar Controller Summary 84A213165BH Rev 0
Author: Melpolder, D & Miller, E Approved: Bailey, K
May 13, 2005 First Made For: GENSET & MARINE EFI CONTROL Page 14/19

6.5 Fuel Pump Cabling

TBB
FIP 16 CYL 12 CYL 8 CYL
1 J
2 T
+24vdc
3 W
4 V
5 K R3 R5 R1
6 M R7 R6 -
7 R R4 - R2
8 N R8 R1 -
9 S R6 - R4
10 Q R2 R2 -
11 L R5 R4 R3
12 P R1 R3 -
13 A L3 L2 L1
14 C L7 L1 -
15 G L4 - L2
16 D L8 L6 -
17 H L6 - L4
18 F L2 L5 -
19 B L5 L3 L3
20 E L1 L4 -

U
X
e GE Transportation Systems PowerStar Controller Summary 84A213165BH Rev 0
Author: Melpolder, D & Miller, E Approved: Bailey, K
May 13, 2005 First Made For: GENSET & MARINE EFI CONTROL Page 15/19

6.6 PowerStar Harness Details

6.6.1 Engine Orientation

ENGINE’S
FREE END
FUEL OIL LUBE OIL
WATER LUBE TEMPERATURE
TEMPERATURE PUMP PUMP
SENSOR SENSOR
(FOT) TURBO (LOT)
L1 R1
FOT
PLUG LEFT RIGHT
SIDE SIDE
L2 R2

L3 R3
FUEL TRANSFER
PUMP
CONNECTION L4 R4

SENSOR BOX L5 R5
BOS
EWT EWP
PLUG
MAT MAP
LOP CCP L6 R6
ECA & EPS BAR
PLUGS OVER
AIR SWITCH
FLYWHEEL
STARTER ( ALTERNATOR )
FIS & FIP
PLUGS DRIVE END
e GE Transportation Systems PowerStar Controller Summary 84A213165BH Rev 0
Author: Melpolder, D & Miller, E Approved: Bailey, K
May 13, 2005 First Made For: GENSET & MARINE EFI CONTROL Page 16/19

6.6.2 Plug FIS (Located on Right Side of Engine Sensor Box)

From To To
Plug Plug Part Numbers
(soc) (Terminal Blk) (pin or tb)
A TB2-49 EGU A34
B TB2-50 EGU A35
C TB2-51 EGU A36
D TB2-52 EGU A37
E TB2-38 EGU A19
F TB2-39 EGU A20
SHIELD TB2-40 EGU A21
G TB2-41 EGU A23
H TB2-42 EGU A24
84B104674ASP27 SHIELD TB2-40 EGU A25
24 Soc (Red, White, Green) J TB1-13 SRLC 39
or (Clear) K TB1-14 SRLC 51
or (Blue) SHIELD TB1-15 SRLC GND
Shell Size 18 L TB2-55 EGU C19
FIS
1 1/4” Conduit EGU C14
JF-9816A24-28S-193-125 M TB2-53 EGU B32
DC: J-TECH 0236 EGU B37
or J-TECH 0230 N TB2-24 EGU A1
or SPACECRAFT 0215 P TB2-25 EGU A2
S TB2-35 EGU A16
T TB2-36 EGU A17
SHIELD TB2-37 EGU A18
V TB1-1 SRLC 11
W TB1-2 SRLC 12
U TB1-3 SRLC GND
Y TB1-4 SRLC 13
Z TB1-5 SRLC 14
X TB1-6 SRLC GND

Test: Unplug the FIS and EGU-A, B & C plugs to validate the correct wiring between the plugs. Passing criterion shall be
measuring the continuity between the plug’s pin and the correct terminating connection within 0 to 0.5 ohms. Each test
shall also check for shorts by cross checking all pins within the plug to the tested terminating connection and to test the
terminating connection to ground. Each cross check tests shall measure infinite resistance.
e GE Transportation Systems PowerStar Controller Summary 84A213165BH Rev 0
Author: Melpolder, D & Miller, E Approved: Bailey, K
May 13, 2005 First Made For: GENSET & MARINE EFI CONTROL Page 17/19

6.6.3 Plug FIP (Located behind Engine Sensor Box)

From To To
Plug Plug Part Numbers
(soc) (Terminal Blk) (plug-soc)
A TBB-13 EGU B15
B TBB-19 EGU B21
C TBB-14 EGU B16
D TBB-16 EGU B18
E TBB-20 EGU B22
F TBB-18 EGU B20
G TBB-15 EGU B17
84B104674ASP34 H TBB-17 EGU B19
24 Soc (Red, White, Green) J TBB-1 EGU B1
or (Clear)
K TBB-5 EGU B5
Shell Size 24
L TBB-11 EGU B11
FIP 1 ” Conduit
M TBB-6 EGU B6
JF-9816A24-28S-193-100
DC: J-TECH 0402 N TBB-8 EGU B8
or SPACECRAFT 0312 P TBB-12 EGU B12
SCPL06UN24-28S-GE1 Q TBB-10 EGU B10
R TBB-7 EGU B7
S TBB-9 EGU B9
T TBB-2 EGU B2
U GND BAR GND BAR
V TBB-4 EGU B4
W TBB-3 EGU B3
X GND BAR GND BAR

Note: Length of FIP cable is critical for the proper control of the high pressure fuel pump solenoids. Engine fuel values
will not be accurate if following reference table is violated. The table provides the required wire gauge for the maximum
distance. Wire resistance shall not exceed 0.1 Ω.

FIP Cable Size vs Length

Length (ft) Gauge (AWG) Ω/KFt)

Resistance (Ω Ω)
Resistance (Ft/Ω
7 22 14.42 69.3
11 20 9.07 110.3
17 18 5.70 175.4
22 16 4.53 220.8
33 14 3.05 327.9
52 12 1.92 520.8
95 10 1.05 953.4

Test: Unplug the FIP and EGU-B plugs to validate the correct wiring between the plugs. Passing criterion shall be
measuring the continuity between the plug’s pin and the correct terminating connection within 0 to 0.5 ohms. Each test
shall also check for shorts by cross checking all pins within the plug to the tested terminating connection and to test the
terminating connection to ground. Each cross check test shall measure infinite resistance.
e GE Transportation Systems PowerStar Controller Summary 84A213165BH Rev 0
Author: Melpolder, D & Miller, E Approved: Bailey, K
May 13, 2005 First Made For: GENSET & MARINE EFI CONTROL Page 18/19

6.6.4 Plug ECA (Located on Left Side Cam Cover, below Engine Sensor Box)

From To To
Plug Plug Part Numbers
(pin) (Terminal Blk) (plug-pin)
84B104674ADP11 A TB2-28 EGU A9
10 Pin (Red, Brown, Red) B TB2-27 EGU A8
Shell Size 18 C TB2-26 EGU A7
ECA
JR-9442A18-1P (BJA) D TB2-34 EGU A15
C-9442A 28-15P (AMP) E TB2-33 EGU A14
DC: J-TECH 0404 F TB2-32 EGU A13

Test: Unplug the ECA and EGU-A plugs to validate the correct wiring between the plugs. Passing criterion shall be
measuring the continuity between the plug’s pin and the correct terminating connection within 0 to 0.5 ohms. Each test
shall also check for shorts by cross checking all pins within the plug to the tested terminating connection and to test the
terminating connection to ground. Each cross check test shall measure infinite resistance.

6.6.5 Plug EPS (Located on Left Side Cam Cover, below Engine Sensor Box)

From To To
Plug Plug Part Numbers
(soc) (Terminal Blk) (plug-pin)
84B104674ASP18 A TB2-29 EGU A10
2 Soc (Red, White, Green) B TB2-30 EGU A11
or (Clear)
Shell Size 10 SL
EPS
3/8” Conduit
SHIELD EGU A12
JF-9816A10SL-4S-193-038 TB2-31
DC: J-TECH 0404
or J-TECH 0330

Test: Unplug the EPS and EGU-A plugs to validate the correct wiring between the plugs. Passing criterion shall be
measuring the continuity between the plug’s pin and the correct terminating connection within 0 to 0.5 ohms. Each test
shall also check for shorts by cross checking all pins within the plug to the tested terminating connection and to test the
terminating connection to ground. Each cross check test shall measure infinite resistance.
e GE Transportation Systems PowerStar Controller Summary 84A213165BH Rev 0
Author: Melpolder, D & Miller, E Approved: Bailey, K
May 13, 2005 First Made For: GENSET & MARINE EFI CONTROL Page 19/19

6.6.6 Plug BOS (Located on Right Side Cam Cover)

From To To
Plug Plug Part Numbers
(soc) (Terminal Blk) (term)
A DIN 2
TB2-3
84A203759P1, P2 & P3
2 Soc (Red, Yellow, Violet) B DIN 18
BOS TB2-13
1 Filler (Blue)
KPSE-6AST03-12-3S (Cannon)
C Blue Filler Blue Filler

Test: Unplug the BOS plug to validate the correct wiring between the plugs. Passing criterion shall be measuring the
continuity between the plug’s pin and the correct terminating connection within 0 to 0.5 ohms. Each test shall also
check for shorts by cross checking all pins within the plug to the tested terminating connection and to test the
terminating connection to ground. Each cross check test shall measure infinite resistance.

6.6.7 Plug FOT (Located on Left Side Fuel Header T near Engine Free End)

From To To
Plug Plug Part Numbers
(soc) (Terminal Blk) (plug-pin)
84B104674ASP18
2 Soc (Red, White, Green) A EGU A5
or (Clear) TB2-43
Shell Size 10 SL
FOT
3/8” Conduit
JF-9816A10SL-4S-193-038 TB2-44
B EGU A6
DC: J-TECH 0404
or J-TECH 0330

Test: Unplug the FOT plug to validate the correct wiring between the plugs. Passing criterion shall be measuring the
continuity between the plug’s pin and the correct terminating connection within 0 to 0.5 ohms. Each test shall also
check for shorts by cross checking all pins within the plug to the tested terminating connection and to test the
terminating connection to ground. Each cross check test shall measure infinite resistance.