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post #1 of 22 (permalink) Old 02-24-2019, 03:50 PM Thread Starter
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Cheap DIY EGT based shutdowns + anit-theft

Greetings everybody! I’m new to the forum so bare with me. So far my research hasn’t found anything similar to what I’m doing, so I figured I would share “the journey” with all of you. -if you want?

As the title implies, I’m building (not buying) an automatic “turbo timer” or EGT based shut down. This system can easily integrate a form of Antitheft system, high EGT alarms and arm EGT mitigation systems. I will be installing these systems in both of my old 12 valve service trucks and all of this will be built out of surplus industrial controls and inexpensive items off amazon.

This is an exercise in relay/ladder logic. I know it would be “easier” to buy a turbo timer and a security system and just install them, but where’s the fun in that?
The obvious bonus with this type of system is the fact that you can easily build, troubleshoot and integrate other controls and components into the system as you see fit.

With that being said, anyone interested in learning and or watching this post? Otherwise I won’t waste my breath/key strokes.

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post #2 of 22 (permalink) Old 02-24-2019, 04:10 PM
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Would be interesting seeing some kind of egt defueling option that attaches to the afc housing. I though of the idea when I was using my truck for my company so I donít have to worry about employees melting down the truck.

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99 Ram 3500 SLT 4x4, 19.5's, P24v, ZF6-750, s362/475, 7x0.014, supporting mods.
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post #3 of 22 (permalink) Old 02-24-2019, 05:42 PM Thread Starter
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Defueling is possible a number of ways, it depends on how harsh and or complicated you want it to be.
I should mention that I am currently dealing with the bosh p-pump on my trucks so what applies to me and my build will not apply to the VE guys.

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post #4 of 22 (permalink) Old 02-27-2019, 10:12 PM Thread Starter
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EGT/Turbo Cool Down and high temp alarm.
(a description of how and why it works)
The reason I’m using this specific EGT gauge (Aside from being very inexpensive) is because it has 2 programmable alarms with normally open and normally closed contacts. This allows 2 completely separate temperature thresholds.
The truck can keep running until EGTs drop to a safe limit with the key out of the ignition, and alarm when temperatures rise to an unacceptable limit. This is the heart of the system.
To keep the truck running in spite of the key being removed from the ignition, the fuel shut off solenoid is bypassed. To do this, an isolated power source is applied to the “maintain” coil as the ignition is turned off. This is activated by Alarm 1 seeing “higher than set point” temperatures on the EGT gauge and through control relay 1. As the truck runs with the key on, Alarm 1’s N.O. contacts close due to EGTs therefore supplying power from the “maintain” coil circuit to control relay 1. Energizing control relay 1 closes its N.O. contacts which in turn supplies power to itself, the other controls and the fuel shut off solenoid. To prevent electrical back feed in a key off situation, a diode is placed between the solenoid and the main wiring harness. The bypass voltage is then applied between the diode and the solenoid to keep it isolated. To help preserve the life of the EGT gauge’s alarm contacts, the outputs are run through control relays capable of handling the higher amperage draws. Power to the fuel shut off solenoid is supplied by a constant power source and as mentioned, through one of the N.O. sets of contacts on control relay 1. In the event that EGTs hover just above the alarm set point, a timer is integrated on the same line as the relay to prevent excessive run time. The timer would be set to the maximum desired idle time. However, to ensure the timer only begins counting only when the ignition is turned off, a second control relay is necessary. Control relay 2 is energized by an ignition based switched circuit in the vehicle. Therefore timer and control relay 1 are fed through the N.O. contacts of control relay 1, Alarm 1’s N.O. contacts, control relay 2’s N.C. contacts and the timer’s own N.C. contacts. This allows the timer to shut itself and the rest of the circuit off after cycling. Again, one of the N.O. sets of contacts on relay 1 maintains auxiliary power to the EGT gauge once the ignition is shut off to keep it active. This way, the entire control system automatically powers down once Alarm 1 is satisfied or the system times out. At the same time, an “emergency stop” button with N.C. contacts is put in place ahead of control relay 1 to stop the sequence therefore killing the engine if required. An indicator light identifying the unit is in cool down sequence is tied into the same circuit as the timer.

The high EGT alarm circuit is very simple. Power is taken from a constant power source and directed to a set of N.O. contacts on control relay 2. It is then linked to Alarm 2’s N.O. contacts which are then fed to a simple strobe/buzzer indicator. The moment alarm 2 is triggered, the strobe flashes and the buzzer rings indicating high EGTs.
A high EGT mitigation system could then be incorporated into the system using a 3rd control relay wired parallel to the strobe/buzzer. This could then be linked to AFC controls, governors, ect.

A simple form of anti theft system could also be integrated in with the E-stop switch. Simply incorporate a N.O. set of contacts in the switch and make your starter solenoid run in series with it. -or your clutch pedal switch in series with it. The truck will only start with the E-stop and whatever else pushed. Most thieves won’t have the time to figure it out...

Attached I have the basic logic diagram for the system excluding any High EGT mitigation systems or anti theft. Sorry it’s so crude.

Acronyms/symbol meanings:
N.O.= Normally Open
N.C.= Normally Closed
CR1= Control relay 1
CR2= Control relay 2
EGT= EGT gauge
AL1= Alarm 1
AL2= Alarm 2
FSD= Fuel shut off solenoid
TR1= Timer relay
ESD= Emergency stop button
S114 Splice= Fuel shut off splice in wiring harness
B= Blue indicator lamp
>| = Diode
Cheap DIY EGT based shutdowns + anit-theft-a37486d2-e06b-413b-bea7-f0959f8e0a53_1551319894134.jpgCheap DIY EGT based shutdowns + anit-theft-d4ec9104-e3b1-44e2-b12d-26468599b17d_1551576953560.jpgCheap DIY EGT based shutdowns + anit-theft-ec30e97a-5350-43d4-ac27-e705787eae50_1551319842484.jpgCheap DIY EGT based shutdowns + anit-theft-88c5ae5d-ceb6-4374-963c-21b1e288925b_1551319856824.jpgCheap DIY EGT based shutdowns + anit-theft-f1da9574-fed7-4dc0-a812-5900f720bccd_1551577001528.jpg
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post #5 of 22 (permalink) Old 03-02-2019, 09:27 PM Thread Starter
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Attached is a photo of what the circuit looks like wired up.Cheap DIY EGT based shutdowns + anit-theft-59aa9d08-4594-45e3-be11-5a05fc71e723_1551576432575.jpgCheap DIY EGT based shutdowns + anit-theft-6a9eedce-4767-4c53-88fd-9d905086a3da_1551576411783.jpg
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post #6 of 22 (permalink) Old 03-03-2019, 07:29 AM
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Quote:
Originally Posted by marco610 View Post
Would be interesting seeing some kind of egt defueling option that attaches to the afc housing. I though of the idea when I was using my truck for my company so I donít have to worry about employees melting down the truck.
You could just install a valet switch with an adjustable regulator. Set the regulator to the max boost psi that you want the AFC to see. Switch off, the AFC sees full boost psi. Switch on, it will only allow the AFC to see up to the regulated pressure. Full hp when you drive. Reduced hp to your desired level for your employees.

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post #7 of 22 (permalink) Old 03-04-2019, 11:30 PM
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Following...this is cool stuff!!
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post #8 of 22 (permalink) Old 03-05-2019, 02:12 AM Thread Starter
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I have been looking into using a secondary solenoid to use in conjunction with the fuel shut down solenoid to employ a “wipple tree” effect. This way you can limit rack travel in conjunction with modifying the pressure signal seen by the afc to control fueling. You could then have more than one versions of “limp mode” or vary degrees of performance to i operate in. In fact, this method is so effective that even supersedes the governor at low idle. Not that this extreme is desirable,
but it is noteworthy.
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post #9 of 22 (permalink) Old 03-06-2019, 01:34 AM Thread Starter
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Perhaps some clarification on the last post is needed. Movement of the fuel shut off lever towards shutdown actually prevents the rack from advancing, therefore limiting the maximum amount of fuel. This is independent of afc pressure modulation and even the reaction of the governor is impeded by this. Simply limit the rack and you’ll limit the pump’s deliverable capacity.
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post #10 of 22 (permalink) Old 03-09-2019, 04:17 PM
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Subscribed. I love digital logic. Rc circuits and 555 timers are very useful. I de computerised my 99 to get away from all that. By the time I shut the truck off, the egt is very safe well under 600 deg f. I drive by the gauges. I have yet to put egt over temp alarms in. I might just let them trigger water injection at the same time as an led and / or a buzzer. I love what you are building though.
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post #11 of 22 (permalink) Old 03-12-2019, 10:55 PM Thread Starter
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https://youtu.be/47qLRb-FHuY
A link showing proof of concept.
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post #12 of 22 (permalink) Old 03-13-2019, 11:01 PM Thread Starter
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Mounted the terminal block, cleaned up more of the block wiring and now prepping for installation. I’ll be building another insert to fit into the cup holder location to mount the indicators, Digital read out and e-stop. Should be a clean install once it’s finished.Cheap DIY EGT based shutdowns + anit-theft-7720d984-d131-410c-bf15-21012390b15f_1552528886115.jpgCheap DIY EGT based shutdowns + anit-theft-4b049856-2b65-47d0-958e-e037c067e928_1552528840656.jpgCheap DIY EGT based shutdowns + anit-theft-0fbf9d51-0ede-475f-81bc-92fcd76e1104_1552528818829.jpegCheap DIY EGT based shutdowns + anit-theft-c8f1a094-20cf-46bb-a382-d2ccecefbf9b_1552528783045.jpgCheap DIY EGT based shutdowns + anit-theft-a6fc7eb8-2b38-4d38-9685-e9e14cbe2398_1552528729832.jpg
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