User Manual - Electronic Monitoring Solutionz
Contents
1. EMS834 Genset Controller User Manual This document applies to 9001 0051 Firmware Version 5000 0057 V3 0 3G Version History S No Version No Changes Made Date Modified Modified By Approved By 1 2 www ems gen nz The information contained in this document is copyright and shall not be reproduced without the written authority of EMS 2010 FUTURE ELECTRONICS LIMITED PHONE 6498184726 ADDRESS 5C WESTECH PLACE KELSTON AUCKLAND 0602 NEW ZEALAND EMS 834 GENSET CONTROLLER Contents 1 Introduction tada 4 A tet LN I IUE UN M Cn MU LI E 4 3 Physical FONG S EINE UE 5 A FUNCIONS cp M a as 6 4 1 Li UE TII E UU UI ee ee eee eee ee 6 4 2 3er ida uilenehu m 6 4 3 G ne rator Monitoring casen aia 7 4 4 System LED Indications 3 Eae eor tse rire io 7 4 5 System LED Display ER 7 4 6 Engine LED Displays ccrto re rete Retrieve einen ies ie dev e esas 7 4 7 AD sv ee ae esea a aeee E ERa e aE Neee 8 4 8 AC NPULS eiie E 8 4 9 nrc LE 8 410 Digital Te RR 8 SR 8 AND A EE 9 4 13 EMS930 Connections for Potential Free contacts eene nennen nns 9 S Operational MT 10 5 1 BUON Me PEDE 10 5 2 dp p 11 5 3 initial Power Up2. e An adjustable Start Delay follows the autostart input activation This is usually configured to avoid nuisance starting The Display shows Starting with a countdown value For long start delays the start time units may be set to minutes If the autostart restores for more than the Start Restore time then the start sequence is aborted e The unit cranks the engine for the crank time or until the engine fires If the engine does not fire after the crank time then the unit will repeat the crank procedure after waiting for the crank rest time This cycle is repeated for the Crank Retries and if the engine has not started after the last cycle a Fail to Start alarm is generated e The Start sequence now follows the manual starting sequence until the engine is running e During an Autostart run the LCD displays Auto in the top left of the display The stopping sequence is initiated by deactivation of the autostart input The engine does not stop immediately as there are three additional states in the Auto stopping sequence e Run On follows Running and is a provided as an adjustable delay to reduce nuisance stopping The Contactor A amp B Outputs remain activated and the Display shows Run On with a countdown value If the autostart input is re activated during Run On the unit returns to normal Running until the autostart input is deactivated e Cool Down follows Run On and allows the engine and or generator to cool
3. AutoStart On The unit has detected an Autostart signal when not in auto mode indicating the engine needs to be started in Auto mode Low Oil Pressure The Oil Pressure has dropped below the Oil Pressure Warning set point while the engine is running The Oil Pressure Icon is lit High Engine Temp High Water Temp Engine Coolant temperature has exceeded the high temperature warning set point after the Temperature monitoring delay has expired High Canopy Temp Canopy Temperature was activated after the Temperature monitoring delay has expired High Oil Temp Oil temperature has exceeded the high oil temperature warning set point after the Temperature monitoring delay has expired Low Fuel Level Fuel level is less than the warning set point Fuel Level Fit The unit has detected that the fuel sender is open circuit This is only a warning and will not shut down the engine No Speed Signal A speed signal could not be detected after the engine had started Confidential www ems gen nz Page 40 EMS 834 GENSET CONTROLLER Maintenance pressing the button for 60 seconds will reset the timer The time since the last maintenance has exceeded the maintenance time The alarm output is not activated for this warning The warning is cleared by pressing and holding the button for 30 seconds If the engine maintenance is carried out prior to t
4. Excitation Internal High Impedance input Battery Voltage Internal High Impedance GR Voltage Generator Red Phase Volts Max 350VRMS GY Voltage Generator Yellow Phase Volts Max 350VRMS GB Voltage Generator Blue Phase Volts Max 350VRMS GN Voltage Generator Neutral CTR Amps Red Phase CT Amps S2 5A RMS Max 6A for 1 second CTY Amps Yellow Phase CT Amps S2 5A RMS Max 6A for 1 second CTB Amps Blue Phase CT Amps S2 5A RMS Max 6A for 1 second CTCom Amps Common connection for CT S1 terminals Do not connect to earth SPA Voltage Speed A magnetic pickup input 3V 70V peak at gt 500 to 10KHz Speed A Battery Alternator input 2V 70V peak at 20Hz to 1KHz SPB Voltage Speed B magnetic pickup input 3V 70V peak at gt 500 to OKHz Speed B Battery Alternator input Connect to common SPCom Voltage Speed Common OVDC 15 Outputs Electrical Specification Output Type Comment Charger WL Current 200mA burst mode pulsed current controlled output Used to provide the battery charging alternator with excitation current Stop Fuel Relay Open Drain 300mA Open Drain protected coil drive Max 36VDC This output is used to control the fuel solenoid interposing relay and can be set for either Energise to Run or Energise to Stop functionality It is recommended that the fuel relay is located near to the fuel control solenoid This position removes the need for high current wiring to the control box a
5. Idle Up 0 60 10 Engine Runs at low speed while the Idle Output is sec activated Under speed is not monitored Warm Up 0 60 10 Time for the engine to warm up after cranking sec Under speed is not monitored Stop Time 3 600 15 Time to allow large engines to completely stop rotating sec and oil pressure decline when stopping During this time if Energize to Stop option is chosen the fuel solenoid will activate up to the Fuel Max Time Stop Rest 2 20 6 The time that oil pressure and speed signals are absent sec for before the unit considers the engine to be stopped Test Time 0 720 0 The duration to run the Engine for when started in Test min mode 0 Run until the user stops the engine Sounder Time 0 600 0 O Sounder remains on indefinitely until acknowledged sec Value Sounder maximum time is the value in seconds Maintenance OFF 250 Hours between Maintenance Requests 50 1000 hours 12 4 Contactor a Column ltem Range Defaut Description Unload Imed Delay Imed Contactor A unload mode Run Imed Unloads contactor A at the beginning of the Start Delay Delay Unloads contactor A after a delay see next item or when the genset is ready for load whichever is the sooner Run Unloads contactor A when the genset is ready for load Confidential www ems gen nz Page 28 EMS 834 GENSET CONTROLLER Unload Dly
6. No Excitation Excitation voltage is low when engine is running This indicates a probable charging fault or the alternator belt has broken Low Charge Volts Battery Voltage is below the charging voltage setpoint when the engine is running Indicates that the alternator is not charging the battery Under Voltage Battery Voltage is below the low battery setpoint Over Voltage Battery Voltage is above the high battery volts setpoint This may be due to a faulty regulator or battery charger Oil Lock Out The unit has detected that the oil pressure is above the oil pressure alarm setpoint with the engine not running This warning prevents the engine from attempting to crank with the engine potentially running This may be due to a faulty oil sender or a very tight engine This warning is disabled if Oil Pressure Check before Cranking is set to Off Tacho Lock Out The unit has detected that a speed signal is present with the engine not running This warning prevents the engine from attempting to crank with the engine potentially running This warning can sometimes be caused by ripple generated by mains powered battery chargers Excite Lock Out The unit has detected that Excitation is present with the engine not running This warning prevents the engine from attempting to crank with the engine potentially running This warning can sometimes be caused by ripple generated by mains powered battery chargers
7. changes from Item to Column and Exit setup mode Confidential www ems gen nz Page 23 EMS 834 GENSET CONTROLLER The button ENTER is used to accept Value changes and Start Setup mode Setup mode automatically terminates if no button in pressed for 60 seconds or when you press the O button with the column headers list visible 12 1 System Column a Contrast 0 11 LCD Contrast Disp Update 2 60 3 Display Cycle Time sets frequency of display updates sec For manual scrolling press the button for the next measurement screen Disp Hold 5 60 30 Display hold time Sets the duration of display hold when sec the alarm button is pressed to halt the scrolling PowerUp Manual Manual PowerUp mode restore On power restore places the Last unit in either Manual or the last used mode Wake Delay 0 720 0 The interval when the unit will power up and check min inputs for alarms etc When set to O the unit will never enter sleep mode LCDReverse No Cycle Controls the LCD Pixel Reverse Yes No LCD Always shows information with pixels on Cycle Yes LCD Always shows background with pixels on Cycle LCD alternates showing information with pixels on and showing the background with pixels on Site ID 0 30000 0 Site Identifier May also be used for asset numbering RemoteSetup No No Allows the unit to request remote units to enter setu
8. down before stopping The cool time is adjustable At the start of Cool Down the Contactor A amp B Outputs are deactivated transferring the load to the mains The display shows Cool Down with a countdown If the autostart input is re activated during Run On the unit returns to normal Running and Contactor A and B are activated Pressing the Stop button in auto mode stops the engine immediately deactivates the Contactor A amp B Outputs and changes the mode of the unit to Manual 6 Display Operation When the genset is ready When the genset is in standby and waiting for a start signal the following display is shown Confidential www ems gen nz Page 15 EMS 834 GENSET CONTROLLER When the genset is running When the genset is starting and stopping the display shows the state of the sequence together with the time remaining before the next state will commence Once the genset is fully running or if the genset is stopped and in READY the running parameters are displayed This includes generator and engine parameters simultaneously on separate displays The unit sequentially scrolls through screens as shown below Product Identification Only shown at Power up Software Version KOEL Serial Number KOEL Application Code ID Sequence Status Engine Speed in RPMs Oil Pressure Engine Temperature Genset Battery Voltage Status Fuel Status If Enabled The Hour
9. Hz Generator frequency is low 8 Load Transfer and Contactor Operation The unit provides for both Mains and Generator contactor control even though in many applications this function will not be used instead an MCB is used to switch the generator to and from the load Contactor outputs if selected are controlled in both Manual and Auto operating modes The Mains contactor output can be setup to deactivate the Mains contactor in several ways e Immediately when the start button is pressed or the autostart input is activated e A short delay after the start request Confidential WWW ems gen nz Page 19 EMS 834 GENSET CONTROLLER e When the genset is running and able to take load The Generator contactor output will activate only after the Mains contactor has opened and only when the genset able to take load The timing is controlled by the XFR DELAY configuration setting If the genset was started by activating the Autostart input then deactivating the input will move the sequence to the Run On sequence then to the Cool Down sequence During cool down the Generator contactor output is deactivated and after a delay the Mains Contactor output is controlled to re activate the Mains contactor 9 Speed Sensing The unit can obtain speed information from one of four sources e Magnetic pickup unit MPU e Battery charging flywheel magneto e Generator output 50 60Hz if used for gens
10. is aware of the need for battery recharging Set up In the factory environment the unit can be setup by the EMS Cloning Utility or by the EMS Windows setup utility In the field adjustments to the unit can be made using the buttons on the front panel The EMS Windows setup utility and the EMS Cloning options are detailed elsewhere and only the field adjustment method is discussed here To enter set up when the unit is showing READY press and hold the button for 20 seconds When the unit enters set up mode the LCD will show Setup and request a PIN number PIN Entry Column Selection Item Selection Entry to Setup mode can also be done while the unit is RUNNING to allow the Genset Amps and Voltages to be adjusted against the calibration standard This should ONLY be done in the factory Navigating in the setup menu The setup menu comprises a range of columns where each column comprises of a list of items and each item has a range of settable values Column Headings are as follows Syste m AC Manu I O Calibrati Comms Stop Test Engin Timer Start AGF al Config jon Alm IP Con A e S Stop Setu Setup p The 5 button UP is used to select the previous Column Item or to Increment a value The D button DOWN is used to select the next Column Item or to Decrement a value The O button RIGHT changes from Column to Item to Value editor The O button LEFT
11. is not started in that time the unit goes into sleep mode to conserve battery power In this mode the unit wakes periodically to check for any unusual conditions and if it finds none it goes back to sleep otherwise it alarms accordingly Any activity on the buttons immediately wakes the unit and the appropriate action is taken In this state the engine and generator parameters are as expected for a stationary genset If the conditions are not as expected an appropriate warning or alarm is displayed on the LCD 5 4 Mode Selection The unit may be operated in Auto Manual Test or Stop modes The mode is selected by pressing the appropriate mode button The mode is indicated on the LCD and the LED associated with the mode buttons The engine can be stopped with the Stop button in MANUAL AUTO or TEST modes In MANUAL mode the unit responds only to the manual push button and may control A and B contactors if these options have been enabled In the AUTO mode the unit responds to the autostart input or Remote Starts and controls A and B contactors In TEST mode the engine responds only to the manual start button and runs for a preset test time if configured Contactors are not controlled In STOP mode the unit will enter low power mode which turns off all LEDs and sensor checking and will not start the genset To enter STOP mode press the Manual Stop button when the unit is showing READY in the manual mode To exit STOP mode press a
12. phases above which 5 6553 will shut down the engine Amps LoadImbal Tm 5 60 10 Time before the alarm will react to Load Imbalances Sec Transfer No Yes Enables Transfer of the load to the Genset in manual Yes mode 12 9 1 0 Config Column O P1 Cona Selectable Digital Output Function from one of the O P2 ConB following Confidential www ems gen nz Page 30 EMS 834 GENSET CONTROLLER ltem Defaut Description O P3 PreHeat ConA Contactor A Control O P4 Idle Control ConB Contactor B Control PreHeat Control Preheater prior to cranking Start Warn Turn on output to warn of an impending start Fuel Pullin Controls the high current coil on the Starter motor Crit Alarm Turn on output when the is shut down for alarm Idle Control Start and stop engine with Idle Output Start Fail Turns on when the Engine failed to start Stop Fail Turns on when the engine failed to stop Low Oil Stop Turns on when the engine stopped for low oil HiTempStop Turns on when the engine stopped for Hi ETemp Low Fuel Stop Turns on when the engine stopped for low Fuel U O RPM Stop Turn on if engine stops for RPM alarm GenOverload Turn on if engine stops for Overloading Maintenance Turn on if the Maintenance timer has expired Charger Flt Turn on if the charger has failed while running BatteryLow Battery voltage is low BatteryHigh Batte
13. start button press MAN ENE f LED indicates manual mode is active e Auto mode button Used to select auto mode Allows genset to be started only with Auto start input activation AUTO LED indicates auto mode is active Test mode button Menu Control e Used to select Test mode D Allows the genset to be started manually without changing the contactors TEST LED indicates test mode is active Used as system menu DOWN button Manual Start button Menu Control D Used to initiate generator manual start or test sequence START Used as system menu RIGHT button Confidential www ems gen nz Page 10 EMS 834 GENSET CONTROLLER Screen Scroll button Menu Control Used to scroll LCD display to next screen Used to enter the menu system and accept changes Pressing this button will turn on the Alarm LED to indicate that entry to setup mode will occur in 20 seconds Alarm Acknowledge Menu Control Used to silence the sounder when the system is in alarm or has an cu active warning Self resetting if enabled LED indicates warnings and alarms 42 Used as menu system UP button ACK RESET While the Engine is running pressing this button will show any active warnings Used to clear the Maintenance Warning 5 2 LEDs LED Function Description Alarm LED e Indicates warnings and alarm ALARM Warnings are indicated by 1 blink per second
14. 3 999 5 Note Only displayed if Unload is set to Delay sec Delay for Delayed Unload mode see above Xfr Delay 0 10 5 Delay time between break and make operations for A to sec B and B to A contactor transfer control 12 5 Start Stop Column Start Delay 0 600 2 Autostart Delay Time The time between the detection of an Autostart activation and the initiation of starting Start time units are set in the next item Start Units Ses SEC Units for the Autostart delay time Min Sec Seconds Min Minutes StartRestore 1 600 5 Selects the time for which the Autostart has to be sec restored before the start delay timer is reset and starting aborted Start Warn 0 30 2 Prestart warning time If an output has been assigned to sec a Start Warning function then it will turn on for this time period before a start occurs Run On 0 3600 60 Run On Time During run on reactivation of Autostart sec input will return the engine to running state The generator remains on load Cool Down 0 3600 60 Cool Down Time Used to cool the turbo and alternator sec as required The generator is off load Idle Down 0 360 0 Engine is run and low speed prior to stopping The Idle sec output is on during this time 12 6 AC Setup Column VPhases 1 3 3 1 1 Phase Alternator system 2 2 Phase Alternator system 3 3 Phase Alternator system IPhases 1 3 3 Selects the number of CTs used When the load is balanced between phases and cost minimisati
15. Activate by switching to common Configurable for various functions See Menu Options above J3 6 18 Digital Input 2 Digital Input 2 Activate by switching to common Configurable for various functions See Menu Options above Connector Assignment Pin Wire Name Function J4 Speed J4 Speed J4 1 24 SpeedA Frequency sensing Input for speed sensors Connects to MPU MPU Battery Charging Alternator W or Magneto Note Not suitable for connecting to the Generator Output Instead Use the Generator Voltage Input GR J4 2 25 Speed B Return connection for the MPU Connect to MPU J4 3 26 Shield Common connection for the MPU shield J5 Current Transformers J5 1 31 CTR Connects to the external Red Phase CT terminal S2 The load wire must pass through the CT in the direction of the CT arrow J5 2 34 CT Com Connects to the external CT s commoned S1 terminals J5 3 32 CTY Connects to the external Yellow Phase CT terminal S2 The load wire must pass through the CT in the direction of the CT arrow J5 4 33 CTB Connects to the external Blue Phase CT terminal S2 The load wire must pass through the CT in the direction of the CT arrow J6 Alternator AC Input J6 Generator LAOA J6 1 27 GR Connects to the Generator Red Phase output J6 2 28 GY Connects to the Generator Yel
16. Alarms are indicated by 4 blinks per second Low oil pressure LED LOP e Indicates low oil pressure warnings and alarms E Warnings are indicated by 1 blink per second Alarm is on solid High Engine Temperature LED 9 Indicates warnings and alarm icr Warnings are indicated by 1 blink per second Alarm is on solid Battery Charging LED e Blinking indicates under voltage over voltage and charge failure CLAN On solid indicates no excitation while the engine is running Off indicates battery charging condition is OK Under over speed LED e Indicates warnings and alarm UNDER OVER Warnings are indicated by 1 blink per second SPEED Alarm is on solid Low Fuel Level LED e Indicates warnings and alarm LOW FUEL Warning is indicated by 1 blink per second LEVEL Alarm is on solid o Genset Running LED GENSET Indicates the genset is running RUNNING Blinks to indicate the genset is starting or stopping Confidential www ems gen nz Page 11 EMS 834 GENSET CONTROLLER 5 3 Initial Power Up On power up the unit displays the Kirloskar logo and turns on LEDs for a lamp test The unit then displays the Serial number Application Code and Firmware version After the initialisation process is complete the unit enters the mode selected in the setup menu and changes to READY 5 3 1 Ready When the unit is in READY all measuring systems and display systems are turned on The unit remains on for 1 minute and if the genset
17. CD as follows Alarms are indicated by fast flashing of the ALARM LED and displaying the appropriate message on the LCD Message Function description Oil Pressure Low The oil pressure went below the alarm set point while running Check oil level and replenish Check for blocked oil filter Oil Temperature High The Engine Oil temperature went above the alarm set point while the genset was running Check for over loading Check cooling air flows Check coolant level Engine Temp High Coolant Temp High The Engine Coolant temperature went above the alarm set point while the genset was running Check for over loading Check cooling air flows Check coolant level Canopy Temp High The Canopy Temperature switch input was activated Check cooling air flows Check for overloading Fuel Level Low The Fuel Level is below the alarm set point The engine is stopped to prevent air and dirt infiltration to the engine Replenish the fuel Battery Voltage High The battery voltage went above the set point High battery voltage usually indicates that the battery charging alternator has failed and it is producing a voltage which might damage the battery control relays or the controller Engine shutdown is recommended to minimise the risk of damage and fire Under Speed The engine was running below the under speed set point Check for overloading Check fuel system Over Speed The engine was r
18. ConA Default Contactor A ConB Output 2 PreHeat Default Contactor B Start Warn Output 3 Fuel Pullin Default Preheat Crit Alarm Output 4 Idle Control Default Off Start Fail Stop Fail Low Oil Stop HiTempStop Low Fuel Stop U O RPM Stop Gen Overloaded Maintenance Charger Fault Battery Low Battery High Open drain 300mA overload protected 4 13 EMS930 Connections for Potential Free contacts _ Connector Assignment Funtin OP 1 Failed to Start OP 2 Failed to Stop OP 3 Stopped for Low Oil Pressure OP 4 Stopped for High Engine Temperature OP 5 Stopped for Low Fuel Level OP 6 Stopped for High Engine Speed OP 7 Low Fuel Level OP 8 Critical Alarm present Confidential www ems gen nz Page 9 EMS 834 GENSET CONTROLLER Front Layout ACK RESET LOW OIL HIGH ENGINE BATTERY UNDER OVER LOW FUEL GENSET PRESSURE TEMPERATURE CHARGING SPEED LEVEL RUNNING T muc Q 0 TEST AUTO MAN STOP START 5 1 Buttons Button Function Description Manual Stop button Menu Control e Used to initiate generator manual stop sequence LED blinks during the stopping sequence lodi Used to select Off mode when the engine is in standby Used to clear alarms when the Genset was stopped for an alarm Used as system menu LEFT button Manual mode button e Ey Used to select manual mode Allows genset to be started only with
19. E 8 cc elay MCB Raley Typical Contactor Control Confidential www ems gen nz Page 42
20. Introduction The EMS834 is an integrated Engine and AC controller for small gensets The unit incorporates both manual and autostart initiated start and stop sequencing monitors engine and alternator operating parameters and provides both engine and alternator protection in a single integrated package The genset operating parameters are shown by scrolling screens on a backlit 128 x 64 dots Graphics LCD Alarms and warning are also shown on the LCD and supplemented by an alarm LED and Hooter output The unit provides comprehensive monitoring of the engine and generator operating parameters and provides automatic shutdown of the genset in the event of damaging conditions In addition to the usual engine safety protections the unit monitors coolant level fuel level canopy temperature and generator loading to provide even more comprehensive protection The unit incorporates a Stop Alarm Log 10 events to give the field service engineer the operational alarm history for easier diagnostics The Engine Hours are logged to allow the user to determine when the alarm happened In the factory environment the unit is configured by cloning through a PC system Field specific parameters can be adjusted by using the front panel buttons and an inbuilt menu system The EMS834 can be used in conjunction with an EMS930 to provide 8 potential free relay outputs 2 Benefits e Reduces system cost e Integrates engine gauges and AC metering into one un
21. Protection from analog input only Both Combined protection Oil Check No Yes Checks for oil pressure prior to cranking and raises the Yes warning Oil Present if oil pressure is present Cil Dis No Yes Yes Uses the digital Oil Pressure input to disconnect Yes the crank This may be used as an auxiliary mechanism to disconnect the crank quickly when the speed source is slow to establish No Switch is only used for alarm if enabled Oil Prot Cil Dis Dly Off Off Cil Pressure Disconnect delay Used to delay the effect On of the oil disconnect switch by 1 second for cold climatic conditions Only configurable via the PC configuration Software WLevel VBelt Off On Enables the Radiator Water Level Alarm Must be On disabled if the Water level is not monitored When the ETemp Type Engine this becomes the VBelt input ETemp Delay 1 300 30 Monitoring Delay time from engine starting before sec monitoring for high engine temperature This is to allow the starting of a hot engine ETemp System Water Water Engine Cooling Temperature Source Engine Water Water monitoring Engine Engine Air temperature monitoring ETemp Type COF TS150 Selects Engine temperature sensor type TS120 COF Switch Close on Fault TS150 TS120 VDO Sensor with FSD of 1202C TS200 TS150 VDO Sensor with FSD of 1502C User TS200 VDO Sensor with FSD of 20009C User Curve uploaded by EMS Setup utility ETemp Alarm 70 200 98 High Engine temperature alarm shutdown set poi
22. Speed CJ commana sz ose os oos rs so Confidential www ems gen nz Page 5 4 Functions 4 1 System EMS 834 GENSET CONTROLLER Function Description Protection Shutdown Automatic preventative engine and genset shutdown in the event of abnormal operating conditions with optional configuration parameters and clear LCD status messages Manual Start In response to the front panel pushbutton performs a fully sequenced engine start with optional configuration parameters and clear LCD status messages Manual Stop In response to the front panel pushbutton performs a fully sequenced engine stop with optional configuration parameters and clear LCD status messages Auto Start Stop In response to a digital input activation the unit performs a fully sequenced engine start Deactivating the input performs a fully sequenced engine cool down then stops Contactors if used are also fully sequenced for changing the load between Mains and DG Emergency Stop In response to a digital input performs a fully sequenced engine stop with optional configuration parameters and clear LCD status messages 4 2 Engine Monitoring Function Description Over Under Speed Monitors engine speed with optional configuration parameters and clear LCD status messages this ensures the engine speed remains within configured limits Exceeding these limits will result in aut
23. cnir 12 BeBe READY nia 12 54 Mode SelectiON siora R a A A ERR 12 5 5 Manual MOde Op eration izeccscccececsdesdescsecacee toto eie ti eret ie ier tes o ue eaae us 13 5 5 1 To Start the genset aca teria deca Oe cR cR e Rz DOES 13 5 5 2 To stop the genset cett iio 14 5 6 NS RSS enne enne nenne eren nenne a iea nennen eren ener ense ener enne eene nennen 15 COMME PIEISIEVESICI fo EET SO TDI DS D Tm 15 di Alarms and Warnings unida 17 8 Load Transfer and Contactor Operation esses eene eene enne thnn nnns ases en nna n nass nnne 19 9 SpesdiSensing O 20 9 1 Vp 20 9 2 MER ML 20 9 3 Glue I 20 9 4 Battery Charging Alternator ccccccccccccsssssessececececeesesesaeseceeecsseeseuseaeeeescesseseuaeseeeeeseseesenaeaeseeseneees 21 10 Battery Charging Alternator Excitation ccccccccccccssssssssecesecessessseeaeceseceseeseaesecesecsseeseasaeeeseessseseaaeas 22 11 Battery Voltage Monitoring and Charging DetectiON cccccononocoononcnnnnnnanonannnnnnnonanannonnnnnnnncnnanonannos 22 12 fuor CER 23 LE ES IESU A A 24 12 2 Engine Col NO ai FF ERN ea EORR 24 123 Timers Col ED 28 124 Contactor a CoN iere reri iii ANA ERO 28 12 5 Start Stop Colui eera IA 29 12 6 ACSOtUP Col iarsin eE o Ee E EaR EAR Er REEE 29 12 7 AGE Setup COLUM
24. con turns on Either message may also be shown depending on temperature system setup High Canopy Temp Canopy temperature switch was activated Low Water Level Water Level has gone below the water sensor Under speed Engine speed has dropped below the under speed set point Over speed Engine speed has exceeded over speed set point High Rev Engine has exceeded safe operating speed No Speed Signal Engine has lost speed signals while running Start Failure The engine has failed to start Stop Failure The engine has failed to stop E S Lock out The emergency stop input has stopped the engine Oil Pressure Flt The unit has detected that the Oil Pressure sender has become open circuit Normally this indicates a faulty sender or broken wiring This will only shut down when the Oil System is set to Sender Engine Temp Flt The unit has detected engine temperature has not risen above 50 degrees after 5 minutes of running or the temperature This indicates a faulty temperature sender or damaged Oil Temp Fit The sensor connected to Oil Temperature input is faulty or open circuit Confidential www ems gen nz Page 39 EMS 834 GENSET CONTROLLER The following warning messages indicate potential problems When a warning occurs the message associated with the warning is displayed Warnings clear automatically when the warning condition is cleared 17 2 Warning Messages i Message Cause
25. d Detected Speed signal is unexpectedly present Check the associated speed sensor wiring and external influences such as poorly operating battery chargers and poorly filtered UPS systems connected to the load Check electrical safety earthing systems Check associated communications networks are isolated and not part of an unexpected earth loop Oil Detected Oil Pressure is unexpectedly present Check the Oil Pressure Sensors and associated wiring Check the Oil filter system is not blocked Check the engine is not running with a failed speed sensing system E S Lock out The emergency stop input has been activated Deactivate the emergency stop input and then press the stop button to clear this alarm AGF Phase Reversal The generator has a phase reversal or the wiring is incorrect AGF Loss GR Volts Voltage on Generator Red Phase was lost AGF Loss GY Volts Voltage on Generator Yellow Phase was lost AGF Loss GB Volts Voltage on Generator Blue Phase was lost AGF Low GR Volts Voltage on Generator Red Phase is Low AGF Low GY Volts Voltage on Generator Yellow Phase is Low AGF Low GB Volts Voltage on Generator Blue Phase is Low AGF High GR Volts Voltage on Generator Red Phase is High AGF High GY Volts Voltage on Generator Yellow Phase is High AGF High GB Volts Voltage on Generator Blue Phase is High AGF High Hz Generator frequency is high AGF Low
26. et control internally connected from GR e Battery charging alternator 9 1 MPU The magnetic pickup unit counts teeth on the flywheel and is mounted in the bell housing It is important to ensure the gap between the MPU face and the teeth is 1mm to 2mm as this distance greatly affects the output of the MPU The unit requires a minimum of 3VRMS at low speed to ensure proper crank disconnect Setup requires calculating the number pulses per 10 revolutions and the calculated number is then entered into the menu system Cal Value Calculate Number of Teeth x 10 Speed Pulses Per 10 Revolutions Eg 125 teeth x 10 1250 Enter the number 1250 9 2 Magneto Battery charging flywheel magneto is similar to the MPU in that there is a fixed relationship between the engine speed and the number of pulses per revolution The number of pulses per 10 revolutions must be calculated and entered into the menu system Cal Value Calculate Measure frequency at some standard RPM and Calculate as follows Cal Value Freq x 600 RPM Eg 100Hz x 600 1500 40 Enter the number 40 9 3 Generator If the unit is used in a genset application the speed source can be the generator 50 60 Hz output and is connected internally within the unit from the AC input connectors AC should NOT be connected directly to the speed MPU Magneto Confidential www ems gen nz Page 20 EMS 834 GENSET CONTROLLER input For co
27. f unit wiring is low current for which 0 75mm wire is sufficient This excludes the CT wires CTR CTY CTB CTCom for which 1 5mm wire should be used 16 1 Connector Details J1 DC Power Supply J1 1 01 DC Battery Supply OV Common ie This connection must be made E directly to the engine crankcase for lowest electrical noise This connection must not have currents other than the controller currents flowing and must be used exclusively for the controller J1 2 02 DC Battery Supply This connection must be made directly to the positive terminal of the battery for best Confidential www ems gen nz Page 36 EMS 834 GENSET CONTROLLER Connector Assignment Pin Wire Name Function performance Do not make this connection to the positive terminal on the Starting Motor Connector Assignment Pin Wire Name Function J2 Engine J2 1 05 Charger WL Battery Charging Alternator J2 Engine Excitation WL point AAAA J2 2 06 Stop Fuel Coil Drive for the Fuel Control Relay Relay Switches to common 5 J2 3 03 Crank Relay Coil Drive for the Crank Relay Switches to common J2 4 19 Fault Relay Coil Drive for the Fault Relay Switches to common J2 5 15 HCT Switch High Canopy Temperature Switch Input Activate by switching to common J2 6 08 Cil Switch Low Oil Pressure Switch Input Ac
28. he timer expiring 18 Wiring Options Pressure Input Digital Oil Pressure Input Analog Oil C9 3 Crankcase Crankcase Crankcase Crankcase Oil Pressure Sensing Options mperature Input Temperature Input Temperature Input ao S Crankcase Crankcase Crankcase Temperature Sensing Options Top Mounting Side Mounting Water Level Probe ww Water Level Radiator Probe Top a ae sa Radiator 7 Sde SSeS Note The radiator must be electrically bonded to the crankcase common Waier Level Wiring Options V V V Sngle Sage Two Sage Crankcase Crankcase Fuel Solenoid Wiring Options Speed A MPU Orar Shield D Battery Excitation WL W Speed A Charging MUST Alternator be used oV Speed Detection Options Confidential www ems gen nz Page 41 EMS 834 GENSET CONTROLLER Load F L2 L3 N E Main Switchboard oe Earth oboo FEED s ils GCB MCB a GN olo OTS MEN saasaa L GLI HS MALI e i J E olo OTS M L2 GS les sts MdL er 9 O OT Mechanical interlock SA 7 toG NO NC 3 5 Omo c o Oo NIC e 3324V IP
29. it e Minimises control panel wiring offering reduced material and labour costs e Reduces warranty costs by providing comprehensive engine and generator protection and a maintenance due timer e Flexible the unit can be customised by PC cloning with application codes for individual genset model characteristics Serial Numbers and fitments Confidential www ems gen nz Page 4 EMS 834 GENSET CONTROLLER 3 Physical Form Front View ENGINE PARAMETERS LOW OIL HIGH ENGINE BATTERY UNDER OVER LOW FUEL GENSET PRESSURE TEMPERATURE CHARGING SPEED LEVEL RUNNING TEST AUTO STOP START ACK RESET Back View 27 28 29 30 EMS834 Generator Controller J6 Generator 34 4 pc 01 32 11 Auto Start Switch 14 J4 2 Speed B 25 J1 2 DC 02 J2 5 HCT Switch 15 4 3 Shield 26 42 3 Crank Relay 03 213 Analog Input 1 16 J6 1 GR 27 32 14 Charger WL 05 43 5 Digital Input 1 17 J6 2 GY 28 Danger J2 2Stop Fuel Relay 06 J3 6 Digital Input 2 18 J6 3 GB 29 High J2 6 Oil Switch 08 324 Fault Relay 19 J6 4 GN 30 Voltage J2 8 Engine Temp Sensor 09 J3 1 Output 1 20 J5 1 CTR 31 32 7 LOP Sensor 10 43 2 Output 2 21 J5 3 CTY 32 32 40 Wat Lev Sw V Belt 11 J3 3 Output 3 22 454 CTB 33 32 9 Fuel Lev Sensor 12 33 4 Output 4 23 5 2 CT Com 34 32 12 Emerency Stop Sw 13 J4 1 Speed A 24 32 14 No Connection NC J7 Test Port J1DC J2 Engine J3 VO J4
30. its terminal voltage is above 13 1Volts Typically a fully charged battery has a terminal voltage of 13 6V above this and the battery is being overcharged During cranking the large discharge current will reduce the battery terminal voltage below 12 5V and the battery cannot increase the terminal voltage again without the assistance of a charger This sequence provides a useful mechanism to determine if a battery is being actively charged Many applications have a current meter to show charging current Such meters provide very limited value as a good battery will recover its terminal voltage very quickly and then be maintained with a very low level of trickle current This trickle current is usually too small a percentage of the current meters range to provide any useful information The unit constantly measures the battery terminal voltage and can detect proper charging and discharging performance Voltage readings are taken and compared against an inbuilt voltage profile If the battery terminal voltage falls outside the critical voltages for each action then a battery warning is indicated Confidential www ems gen nz Page 22 12 EMS 834 GENSET CONTROLLER During standby and particularly where an on line charger is not available monitoring the health of the battery is vital The unit regularly wakes and measures the battery voltage if it falls below the set point a warning is issued to ensure the operator
31. l consumption Used to calculate the Off number of runtime hours remaining for current fuel Litre level When set to Off the Hrs is removed from the Fuel Screen Fuel Total 50 1000 Total fuel tank volume Used to calculate the litres of 30000 fuel remaining in fuel tank for current fuel level Litre 4 Fuel Type 10 180 Fuel level sensor type User Curve uploaded by EMS Setup utility Fuel Alarm Off 50 Fuel level alarm set point 1 50 Alarm output activates and engine is shutdown 96 When low fuel alarm is active engine start is inhibited Off 55 5 55 Fuel Warn Fuel level warning set point Note This must be set above the Alarm set point Oil Type 10 180 10 180 Selects type of oil sensor being used User Dual station sensors can be used on same analog input User Curve uploaded by EMS Setup utility Oil Range 10 10 Used to select the oil sensor full scale in Bar Bar 1 0 Oil Alarm 0 2 3 0 Low oil pressure alarm shutdown set point Bar Alarm output activates and engine is shutdown Confidential www ems gen nz Page 25 EMS 834 GENSET CONTROLLER Item Range Default Description Oil Warn 0 2 3 1 1 5 Low oil pressure warning set point and engine Bar continues to run NOTE This value must be set above the alarm set point Cil Prot Switch Switch Oil protection sensor mode Sender Switch Protection from switch input only Both Sender
32. low Phase output J6 3 29 GB Connects to the Generator Blue Phase output J6 4 30 GN Connects to the Generator Neutral Confidential www ems gen nz Page 38 EMS 834 GENSET CONTROLLER Connector Assignment Pin Wire Name Function output where available J7 Test Port J7 Test Port Programming Validation Test Port cono NB Connect ONLY EMS expansion ju modules to this port NB The unit is a complex electronic device and caution should be taken to ensure correct wiring before power is applied 17 Trouble shooting The unit displays the following messages when an alarm occurs Alarms shut down the engine set the alarm output and flash the alarm indicator The alarm indications can be cleared after the genset has stopped by pressing the stop button The hooter can be silenced with the Hooter Button 17 1 Alarm Messages Message Mas O Low Oil Pressure Cil pressure has not reached the Oil Alarm set point Oil Alarm at the end of the run up time or has dropped below this value when the engine is running High Oil Temperature Oil temperature has exceeded the high oil temperature set point Low Fuel Level Fuel level is less than the minimum value set point High Engine Temp Engine temperature has exceeded the high temperature set point High Water Temp The temperature i
33. nd thus leads to lower cost Crank Relay Open Drain 300mA Open Drain protected coil drive Max 36VDC This output is used to control the interposing crank relay coil The crank relay should be sized for the crank contactor current It is recommended that the crank relay is located near to the starter motor This position removes the need for high current wiring to the control box and thus leads to lower cost Output 1 to Output 4 Open Drain 300mA Open Drain protected coil drive Max 36VDC These outputs can be configured for various functions The are intended to drive interposing relays and not the particular loads directly Confidential www ems gen nz Page 35 EMS 834 GENSET CONTROLLER J5 J6 C 32 12 Emerency Stop Sw 13 J4 1 Speed A 24 32 14 No Connection NC J7 Test Port J1DC J2 Engine J3 VO J4 Speed tspspspe o pape Gades ee fo soe os sod oss J7 S J1 J2 J3 J4 NB The unit is a complex electronic device and caution should be taken to ensure correct wiring before power is applied The unit is fitted with 2 3 6 and 14 way Molex Minifit or equivalent socket connectors for which mating plugs can be selected from the Molex Tyco Amp PE or TPK 5566 range The unit is also fitted with 4 way Mate N Lok or equivalent socket connectors for which mating plugs supplied by Tyco Electronics or equivalent can be used The majority o
34. nt ETemp Warn Alarm output activates Engine is shutdown High Engine temperature warning set point Engine continues to run NOTE This value must be set below the alarm set point OTemp Type Off TS150 Selects Oil temperature sensor type via Analog input 1 COF COF Switch Close on Fault TS150 TS150 VDO Sensor with FSD of 1509C User User Curve uploaded by EMS Setup utility Confidential www ems gen nz Page 26 EMS 834 GENSET CONTROLLER 98 95 Engine continues to run NOTE This value must be set below the alarm set point OTemp Delay 1 300 30 sec the starting of a hot engine Lo Bat VIt OFF 10 0 Low Battery voltage level warning 9 5 24 Volts Hi Bat VIt 12 32 15 0 High Battery voltage level warning OFF Volts 13 1 Yes Maximum Battery Voltage If the Battery voltage exceeds this level then the engine is shut down This is used to protect the battery from a failed alternator Range Default Description 70 200 High Oil temperature alarm shutdown set point Alarm output activates Engine is shutdown Monitoring Delay time from engine starting before MaxBat VIt ec OTemp Warn 70 200 High Oil temperature warning set point 2C monitoring for high Oil temperature This is to allow Charge Min V OFF The minimum battery voltage below which a Low 10 28 Charge Volts warning is activated when the engine is Volts running This generally indicates an exci
35. ny button on the Front Panel Confidential www ems gen nz Page 12 EMS 834 GENSET CONTROLLER 5 5 Manual Mode Operation 5 5 1 To start the genset When the display is showing READY press the start button momentarily to start the genset Any warning or alarm conditions must be cleared before the genset can be started The unit will perform the starting sequence as follows e PREHEAT o The PREHEAT Output if configured will activate for the time specified e FUEL ON o If ETR Energise to Run fuel control is configured the unit will control the fuel output and display FUEL ON and the proceeds to the CRANK state If the Fuel Pull in is configured it will be on for the first second of this sequence o For ETS Energise to Stop the sequence does not activate the output and proceeds to the Crank sequence after a short delay e CRANK o The Crank output is activated and the display shows Cranking with a countdown time o The Crank output is deactivated when the unit has detected a speed signal above the crank disconnect speed specified in the settings If selected the crank will also terminate on achieving oil pressure or Battery charging alternator excitation has been achieved This provides a secondary crank disconnect function to avoid over cranking o If the genset does not start the LCD will show STOPPING control the Fuel and Crank outputs accordingly and return to READY There are no ret
36. olant temperature sensor Air or Water Current limited excitation for resistance sensing Fuel Level Engine fuel level sensor Current limited excitation for resistance sensing 4 10 Digital Inputs Function Description O Auto Start Stop Input Auto start switch Close to Common to activate Emergency Stop Input Emergency stop switch Close to Common to activate Cil Switch Input Cil pressure switches LLOP Close to Common to activate Canopy Temperature Canopy temperature switches HCT Close to Common to activate Digital Input 1 User defined Default Not Used Close to Common to activate Digital Input 2 User defined Default Not Used Close to Common to activate 4 11 Special Inputs X Furton Description Battery Voltage Internal measurement of incoming DC supply Excitation Voltage Internal measurement of battery charging alternator excitation voltage Low Water Level Vbelt Oscillating AC coupled Zero net current flow Selectable between Low Water detection and V Belt broken Confidential www ems gen nz Page 8 EMS 834 GENSET CONTROLLER 4 12 Outputs Excitation Output Battery charging alternator excitation control WL Current controlled pulse Fuel Output Fuel relay coil control Open drain 300mA overload protected Crank Output Crank relay coil control Open drain 300 mA overload protected Output 1
37. olts Power Nominal 12VDC or 24VDC or Station Battery Supply Range 6 36VDC Must be connected at the Battery Positive terminal OV Common Power OVDC Common Must be connected at the Crank motor for OVDC Fuel Level Sensor Analog Digital Suitable for either resistive or switch C O F senders Coolant Analog Digital Suitable for either resistive or switch C O F senders Temperature Sensor Oil Temperature Analog Digital Suitable for either resistive or switch C O F senders Sensor Canopy Digital Suitable for switch input Connect to OV Active Temperature Oil Pressure Sensor Analog Suitable for either resistive or switch senders Optionally for protection or display only Low Water Level Special Suitable for probe or switch input Open Circuit No water present Requires radiator connected to OVDC for common system Requires dual probes for galvanically isolated systems Autostart Digital Suitable for switch input Connect to OV Active Emergency Stop Digital Suitable for switch input Connect to OV Active Oil Pressure Switch Digital Used for backup Oil Pressure protection Confidential www ems gen nz Page 34 EMS 834 GENSET CONTROLLER Input Type Comment Digital Input 1 Digital Suitable for switch input Connect to OV Active Digital Input 2 Digital Suitable for switch input Connect to OV Active
38. omatic engine shutdown to prevent damage Lubrication Oil Pressure Monitors engine oil pressure with optional configuration parameters and clear LCD status messages this ensures the oil pressure remains within configured limits Exceeding these limits will result in automatic engine shutdown to prevent damage Engine Temperature Monitors engine temperature with optional configuration parameters and clear LCD status messages this ensures the engine temperature remains within configured limits Exceeding these limits will result in automatic engine shutdown to prevent damage Battery Voltage Monitors engine battery voltage with optional configuration parameters and clear LCD status messages this ensures the battery voltage remains within configured limits Battery Charging Monitors engine battery charging status and clear LCD status messages this ensures the battery is charged while the engine is running Radiator Water Level Monitors engine radiator water minimum level with clear LCD status messages this ensures the radiator water level remains sufficient Low water will result in automatic engine shutdown to prevent damage Fuel Level Monitors engine fuel level with clear LCD status messages Low fuel Confidential www ems gen nz Page 6 EMS 834 GENSET CONTROLLER level will result in automatic engine shutdown to prevent damage Oil Temperature Monitor
39. on is important a single CT for phase 1 may be used CT Ratio 1 2000 12 Selects the CT ratio PhaseRev Off Off Enables genset phase reversal to generate an alarm and On shut down the engine 12 7 AGF Setup Column Confidential www ems gen nz Page 29 EMS 834 GENSET CONTROLLER Lo Volt Trip 60 240 180 The minimum voltage below which the Genset is shut Volts down Lo Volt Dly 0 30 3 Time before the alarm will react to Low voltage Sec Hi Volt Trip 110 300 275 The maximum voltage above which the Genset is shut Volts down Hi Volt Dly 0 30 3 Time before the alarm will react to high voltage Sec Lo Hz Trip Off 44 The minimum frequency below which the Genset is shut 30 60 down This is only checked while the engine is Running Hz on load Lo Hz Dly 0 30 3 Time before the alarm will react to low frequency sec Hi Hz Trip 50 70 56 The maximum frequency above which the Genset is shut Hz down Hi Hz Dly 0 30 3 Time before the alarm will react to high frequency Secs O Load KW Off 30 Maximum KW above which the Genset will shut down 5 6553 KW O Load KW Tm 5 60 10 Time before the alarm will react to KW Overloading Sec O Load Amp Off 50 Maximum KW above which the Genset will shut down 5 6553 Amps O Load Amp Tm 5 60 10 Time before the alarm will react to Amps Overloading Sec LoadImbal Off 10 Maximum difference between Amp
40. out resetting 95 non condensing Supply Current Standby 10mA CT current range 0 5A 20 Overload Measured values below 5 FSD are suppressed to O Amps Overall Accuracy Digital Output Rating Open Drain Relay Coil Driver 300mA 32VDC max Short Circuit protected Digital Input Rating Whetting current 10mA at 12 V DC DC input protection for 30V DC Transient Protected Analog Input Rating Current limited outputs approx 15mA or less as required by sensors Short circuit and reverse voltage protected Confidential www ems gen nz Page 33 EMS 834 GENSET CONTROLLER Feature Specification Cil Pressure Sensor Type Switch Close on fault Engine Temperature Sensor Type Switch Close on fault re me e o Oil Temperature Sensor Type Switch Close on fault MM FC NN Engine Temperature Ranges VDO 1509C User Curve Cil Pressure Ranges 5 0 7 5 10 Bar Canopy Temperature Sensor SuitehePlassantault Type Fuel Level Sensor Type Switch Close on fault Resistive 10 to 180 Ohms User Curve Battery Volts Measurement 8 to 36 Volts Set up and Adjustment All features may be adjusted using set up buttons and LCD menu or via a PC Windows based utility Amp DUAC Molex Mini Fit JNR Testing Environmental Tests IEC68 Part2 EMC Compliance EN50081 1 EN50081 2 IEC6100 4 3 Electrical Safety AS 3100 and AS 3260 14 Inputs Electrical Specification Input Type Comment Battery V
41. p Yes mode Defaults No No Setting to Yes will load all configuration items to their Yes factory default values Note Engine RPM Cal Value calibration will be lost 12 2 Engine Column Item Range Default Description Crank Rel 100 1000 300 Crank Disconnect RPMs RPM Cal Value 1 2500 20 RPM Calibration Value Refer to Speed Sensing section U Spd Wrn OFF OFF Warning threshold for slow engine speed 400 3600 RPM U Spd Alm OFF OFF Alarm threshold for slow engine speed 400 3600 RPM O Spd Wrn OFF 1600 Warning threshold for high engine speed 400 4000 RPM Confidential www ems gen nz Page 24 EMS 834 GENSET CONTROLLER Item Range Default Description O Spd Alm OFF 1650 Alarm threshold for high engine speed 400 4000 RPM Fuel Select ETR ETR Fuel Solenoid Type ETS ETR Energize To Run ETS Energize To Stop ETS Tries 1 2 2 Note This item is only displayed when Fuel Select ETS See Above Maximum Stop Retries for ETS Fuel Control ETS Rest 5 60 5 Note This item is only displayed when Fuel Select ETS sec See Above Stop Retry Pause time for ETS Fuel Control During this time the Fuel output is Off FuelMaxTm 5 600 15 Maximum fuel solenoid activation time before a Failed sec to stop alarm is raised Fuel Show 96 No Yes Yes No Do not show the Fuel value Only Yes Show the Fuel value Only Hide the Fuel Litres amp Fuel Hours FuelLitreHr 1 600 Genset fue
42. ries with a Manual Start o If the unit loses power due to battery voltage droop during cranking and the engine fires then on regaining adequate battery voltage the unit will continue to allow the engine to run e RUN UP o When the engine starts the display shows RUN UP with a countdown in seconds This allows the engine measurement system to stabilise Over speed and loss of speed signal are the only parameters checked during RUN UP e WARM UP o The display shows WARM UP with a countdown time This allows the engine to stabilise at full speed before going on load Oil pressure and Over speed are monitored e RUNNING Confidential www ems gen nz Page 13 EMS 834 GENSET CONTROLLER o The display shows RUNNING Operating parameters are scrolled onto the display o Engine temperature alarms have a hold off period and will not prematurely cause engine shutdown if the engine has been previously run and has a high temperature o Contactors if configured are controlled 5 5 2 To stop the genset Push the stop button briefly The unit will perform a stopping sequence as follows e COOLDOWN o The display will show COOLDOWN with a countdown time o The Bcontactor if configured is opened immediately and after a short delay contactor A if selected is closed o On expiry of the cool down timer the sequence continues to stop the engine o The cool down timer can be set to zero in the menu s
43. rrect crank disconnect the generator must be providing a detectable output at low speed and therefore the voltage at 300 RPM must be greater than 40VRMS This can be affected by the AVR and must be confirmed to provide suitable signals and timing for proper crank disconnect For setup the number of pulses per 10 revolutions must be calculated and entered into the menu system Cal Value The generator output frequency and standard RPM must be known Calculate Speed Calibration value as follows Cal Value Freq x 600 RPM Eg 50Hz x 600 1500 20 Enter the number 20 9 4 Battery Charging Alternator A low cost speed source can be derived from the battery charging alternator if fitted It unfortunately is also the most troublesome and not recommended for reliable and repeatable long term service The difficulties arise from the in exact relationship of alternator output frequency and engine RPM As a result of slippage and variable mechanical coupling both calibration and long term stability are compromised The ratio of crank pulley to alternator pulley is indeterminate as it depends very significantly on where the coupling belt rides in the V grove Belt tension plays a very significant role as does belt wear and instantaneous belt loading Immediately after starting an engine the alternator is required to re charge the partially discharged battery The loading on the alternator is very high and belt slippage is common as is bel
44. ry voltage is high 1 P1 Off Selectable Digital Input Function from one of the 1 P2 Off following Trip Stop the engine when sensor is activated Fire Alarm Stop the engine if fire alarm input is activated Bypass prevent engine form starting while activated Door Raise a warning while input is activated LoFuelAlarm Shut the engine down and report low fuel Fuel Heater Pause at the beginning of the Fuel On state until fuel is heated to correct temperature 12 10 Calibration Setup Column Item Range Default Description Clear Cal No No Setthis to Yes to reset unit to EMS default calibration Yes Mains VR Adj 10Vrms OVrms Allows KOEL factory to adjust the Main Red phase offset Mains VY Adj 10Vrms OVrms Allows KOEL factory to adjust the Main Yellow phase offset Mains VB Adj 10Vrms OVrms Allows KOEL factory to adjust the Main Blue phase offset Genset VR Adj 10Vrms OVrms Allows KOEL factory to adjust the Genset Red phase offset Note The engine needs to be running to adjust this Confidential www ems gen nz Page 31 EMS 834 GENSET CONTROLLER Genset VY Adj 10Vrms OVrms Allows KOEL factory to adjust the Genset Yellow phase offset Note The engine needs to be running to adjust this Genset VB Adj 10Vrms OVrms Allows KOEL factory to adjust the Genset Blue phase offset Amps IR Adj 10Vrms OVrms Allow
45. s Engine Oil temperature with clear LCD status messages This function will result in automatic engine shutdown to prevent damage Canopy Temperature Monitors Canopy temperature via a COF style switch This function will result in automatic engine shutdown to prevent damage Running Hours Records engine run hours with clear LCD status messages 4 3 Generator Monitoring AC Phase Voltage Monitors Genset 1 2 or 3 phases of AC voltage with optional configuration parameters and clear LCD status messages AC Phase Current Monitors Genset 1 2 or 3 phases of AC current with optional configuration parameters and clear LCD status messages Uses externally fitted 5A CTs AC Phase Frequency Monitors Genset phase 1 of AC Frequency with optional configuration parameters and clear LCD status messages AC Phase Reversal Monitors Genset AC for Phase reversal with optional configuration parameters and clear LCD status messages AC Loading Monitors AC load in KW and AMPs with optional configuration parameters and clear LCD status messages AC Power Metering Monitors AC power output KW KVA KVAR PF and KWH with optional configuration parameters and clear LCD status messages 4 4 System LED Indications Alarm Red LED indication of system alarm 4 5 System LCD Display Function Description Setup menu System configuration men
46. s KOEL factory to adjust the Amps Red phase offset Amps IY Adj 10Vrms OVrms Allows KOEL factory to adjust the Amps Yellow phase offset Amps IB Adj 10Vrms OVrms Allows KOEL factory to adjust the Amps Blue phase offset Notes 1 These items are intended to allow KOEL factory to make adjustments for variations in CTs and external voltage measuring points 2 The engine needs to be running to adjust Genset related values 12 11 Comms Setup Column Item Range Default Description Comms ID 1 240 134 Comms Address Required for remote communications Baud Rate 1200 9600 Comms Port Baud Rate 57600 1200 2400 4800 9600 19200 38400 57600 Data Bits 7 9 8 Number of Data Bits Parity Even None Parity Select Odd None Stop Bits 10r2 1 Number of Stop Bits UART Mode None None hRS232 Handshaking Mode Modem None No RTS CTS control 3 wire connection LAN Modem Uses RTS CTS flow control 5 wire connection LAN Allows connection to an RS485 adapter EG EMS18 Notes 1 Unit has basic communications to allow factory testing and validation 2 Allows the unit to be connected to external EMS modules for enhanced communication functions 12 12 Test I P Column Item Range Description Auto Start Off Act Displays the status of the Auto start input for testing Emer Stop Off Act Displays the status of the Emergency Stop input for testing Oil Switch Off Act Display
47. s remaining can optionally hidden Oil Temperature If enabled Confidential www ems gen nz Page 16 EMS 834 GENSET CONTROLLER Engine Running Hours Total Engine Starts Genset Voltages Line to Neutral Line to Line Genset Amps and Hz Genset KW and KVA Genset KVAR and Power Factor Genset Power Totals Genset Average Genset KWHours Contactor Status This screen only appears if contactor out control has been configured Any active warnings are shown here This is an example warning screen The sequence returns to the Sequence Status screen 7 Alarms and Warnings In the event of abnormal operating conditions the unit will issue a warning of an impending alarm then an alarm if a failure is detected The genset is then shut down The LCD shows an appropriate message indicating the nature of the condition To draw operator attention to the condition the flashing general alarm LED is used Confidential www ems gen nz Page 17 EMS 834 GENSET CONTROLLER In most cases Warnings do not stop the genset and are self resetting Alarms will normally stop the genset and require the operator to clear the alarm by pressing the Stop or Hooter button The genset cannot be started if an alarm exists Warnings are indicated by slow flashing of the alarm LED and displaying the appropriate message on the L
48. s the status of the Oil Switch input for testing Fire Off Act Displays the status of the Fire Alarm input for testing Door Off Act Displays the status of the Door input for testing By Pass Off Act Displays the status of the By Pass input for testing Trip Off Act Displays the status of the Trip input for testing HCT Off Act Displays the status of the HCT input for testing Stop Alarm Log Viewer Column Confidential www ems gen nz Page 32 EMS 834 GENSET CONTROLLER e This log contains the last 10 reasons that the Engine was stopped along with the value of EHours when they occurred e Stop Alarm log history items cannot be deleted or changed except by using the EMS Windows setup utility program 13 Unit General Specifications Specification Overall Dimensions 180 x 126 x51mm Mounting Hole Rectangular Cutout 155 x 117mm Rivet Mounting Holes 4mm qty 4 Located 85mm from X centre and 43mm fromY centre Panel thickness gt 2mm gt 1 6mm 1mm IP rating Front IP54 when sealed to the enclosure Rear IP20 rear Supply Voltage 8 V to 36V DC Nominal Automotive Survives transients to 190V for 8us 20ms Load Dump Survives voltage surges to 43V DC for upto 1 sec Voltage surges above 43V DC for more than 1 sec may be destructive Cranking Conditions Power Can drop to OV for 50mS with recovery to 8V DC without Supply resetting Can drop to 4V for 100mS with recovery to 8V DC with
49. ss ie aran Ear EREE EE reU a ENE E E REEE LE ERRETES 29 128 Manual Coler aoe EAN AE OAOE EEO AN EO 30 12 9 AAN 30 12 10 Calibration Setup COlUMN ccccccnnononoonnnnononononenononononncnnononnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnaninnos 31 12 11 COMMS Setup Column ccccccccceeesssssseceeecessesesaeseceeecssscseeaeseeeeecessesaeaesesecsseseeaeaeeeeseusseseaeaeeeessesees 32 12 12 Test es ceceeececessecscceccceceesssncececececsesenaeseceeeceseeneaeceeseccuecenenaeceeeseceeseneaeceeeseesenenteeeeseseeeess 32 Confidential www ems gen nz Page 2 EMS 834 GENSET CONTROLLER 13 Unit General Specifications ccccccccccecessessnsececccecessesesaececececssseseeaeeeeeceeessesaeaeeeeeceseesesaaaeeeeecesenseaaeas 33 14 Inputs Electrical Specification eee feet etes ears cepe n xe rere nega een eva ege ee ET ti 34 15 Outputs Electrical Specification eene enne nennen nennen 35 16 Installatiomand WINE atada ideada 36 16 1 Connector Detail Suicidio il ore a En RE Pv Era e RR 36 17 MPOUBIESHOOEIN xe diana 39 1441 Alarm IMGSSABES 2 5 cer rt onn rS VY NER OTTEITA ENOO LE PERF OA VY ERR ERE RNE AERE 39 17 2 Warning Messages recicu egeo e epe aa ERAT EN UXEEE PEU pa a RUNE eR pas ea SURE 40 18 Wiring ODpELIOTS eec oer rrr base it ea en ep y eun re UE 41 Confidential www ems gen nz Page 3 EMS 834 GENSET CONTROLLER EMS834 Genset Controller 1
50. t set low in the V groove The output frequency may be lower than expected If speed calibration is performed at this time the speed representation will be too low and subsequently as the load reduces on the alternator the engine speed will appear to erroneously increase The battery charging alternator output frequency and current RPM must be known This is achieved by independently running the engine and measuring the battery charging alternator frequency on the W sometimes D terminal Excitation must also be provided to ensure self excitation and an adequate output signal Some small variation in reported speed may result but this can be calibrated out later during engine commissioning For setup the number of pulses per 10 revolutions must be calculated and entered into the menu system Cal Value Calculate Speed Calibration value as follows Cal Value Freq x 600 RPM Eg 257Hz x 600 1500 102 8 Enter the number 103 Confidential www ems gen nz Page 21 EMS 834 GENSET CONTROLLER 10 Battery Charging Alternator Excitation The battery charging alternator excitation system is implemented using a burst mode pulse system This ensures reliable self excitation while managing current consumption during standby heat dissipation during fault conditions and pulsing the battery charging alternator prior to cranking for improved speed signal output During standby and Ready the alternator e
51. tation failure or broken alternator belt Excite Warn No Yes charging alternator excitation failure warning Yes enabled No charging alternator excitation failure warning disabled Excite Dis No Yes Wes uses successful charging alternator excitation as a Yes secondary crank disconnect signal to prevent over cranking No Excitation Disconnect function disabled Stop on Alarm Off On On Engine protection functions are enabled Normal On setting Off All protection shutdown mechanisms for the engine are disabled Warnings and Alarms continue to be indicated Off should only be chosen for mission critical applications when shutdown is not permitted and the engine can run to destruction This option is only settable using the EMS Windows setup utility Confidential www ems gen nz Page 27 12 3 Timers Column e EMS 834 GENSET CONTROLLER PreHeat Time 0 60 Time to turn on the PreHeating output prior to cranking sec 0 Skip Preheat delay Crank Time 1 30 10 Maximum cranking time sec Crank Rest 3 50 10 Delay between cranking retries sec Crank Tries 1 10 3 Crank retries Manual and Test start sequencing will not retry Run Up 2 60 3 Oil pressure Temperature Under speed and Over sec speed checking is disabled to allow these to stabilize during the starting process Hirev is active to protect against a jammed governor
52. tivate by switching to common J2 7 10 LOP Sensor Lube Oil Pressure measuring input Measures Resistance J2 8 09 Engine Temp Engine Temperature measuring Input Sensor Measures Resistance J2 9 12 Fuel Lev Fuel Level sensor Input Measures Sensor Resistance J2 10 11 Wat Lev Sw Water Level or V Belt sensing Input V Belt Oscillating Output Input system Connects to water level probe water level switch or V Belt broken switch J2 11 14 Auto Start Auto Start Input Activate by switching Switch to common Starts the DG J2 12 13 Emergency Emergency Stop Switch Activate by Stop Sw switching to common Stops the DG J2 13 16 Cil Temp Oil temperature measuring input Sensor Measures Resistance J2 14 NC No Not Used Connection J3 Input Output J3 1 20 Output 1 Coil Drive for an external control dati Relay Switches to common Maa Configurable for various functions Ang J3 2 21 Output 2 Coil Drive for an external control Relay Switches to common Configurable for various functions J3 3 22 Output 3 Coil Drive for an external control Confidential www ems gen nz Page 37 EMS 834 GENSET CONTROLLER Connector Assignment Pin Wire Name Function Relay Switches to common Configurable for various functions J3 4 23 Output 4 Coil Drive for an external control Relay Switches to common Configurable for various functions J3 5 17 Digital Input 1 Digital Input 1
53. unning above the set point Check governor system Check power take off couplings Hirev Alarm The speed signal indicates the engine is grossly over speed Check Governor system Coolant Level Low The radiator water level is below the required level The water level needs topping up Start Fail The engine has failed to start Check Fuel supply check battery condition and check air filters Stop Fail The engine has failed to stop Check stop solenoid check rack operation Belt Broken If the belt break detector has been activated Check the belts Oil P Fault The Oil Pressure sensor system is not functioning as expected Check oil pressure sensor and associated wiring Confidential www ems gen nz Page 18 EMS 834 GENSET CONTROLLER Message Function description Oil T Fault The Oil Temperature Sensor is not functioning as expected Check Oil temperature sensor and associated wiring Eng T Fault The Engine Temperature Sensor is not functioning as expected Check engine temperature sensor and associated wiring Fuel L Fault The Fuel Level Sensor is not functioning as expected Check the Fuel Level Sensor and associated wiring Speed Fault The Speed Sensing system is not working as expected Check the associated speed sensor wiring and external influences such as poorly operating battery chargers and poorly filtered UPS systems connect to the load Spee
54. us Start Up Clear step by step start up sequencing messages Shutdown Clear step by step shutdown sequencing messages Transfer Clear step by step load transfer icons 4 6 Engine LCD Displays Low oil pressure Engine oil pressure low High Oil Temperature Engine Oil Temperature High engine temperature Engine temperature high Low coolant level Radiator water level low Low fuel level Engine fuel level low Battery Voltage Engine Battery Voltage and Droop voltage at last cranking cycle Confidential www ems gen nz Page 7 EMS 834 GENSET CONTROLLER 4 7 Genset LCD Displays Phase Voltages Phase 1 2 and 3 Voltages Line to Neutral and Line to Line Phase Currents Phase 1 2 and 3 Currents Phase Frequencies Measured on Phase 1 AC Power Metering Monitors AC power output KW KVA KVAR PF and KWH with optional configuration parameters and clear LCD status messages 4 8 AC Inputs 3 Phase Genset AC Voltage Genset AC voltages 0 300V AC RMS 3 Phase Genset Current Genset AC currents via external 5A CTs 0 5 Amp input 4 9 Analog Inputs Function Description Lubrication Oil Pressure Engine oil pressure sensor LOP Current limited excitation for resistance sensing Engine Oil Temperature Engine oil Temperature sensor LOP Current limited excitation for resistance sensing Engine Temperature Engine co
55. xcitation is pulsed once per minute to maintain some level of residual magnetism in the alternator but still maintaining minimum power consumption On receiving a start signal the unit pulses the alternator excitation input with a burst of 200mA pulses The pulse width is dependent on the battery voltage This pulse burst establishes a definite magnetic field in the battery charging alternator prior to cranking This ensures a significant speed sensing signal is generated for crank disconnect sensing The alternator excitation is turned off and the engine is cranked without the usual alternator burden loading the cranking process This aids easier starting When the engine has fired and is running more 200mA pulse bursts are applied Given the alternator is rotating at more than the 3000RPM the alternator will achieve self excitation If self excitation is not achieved this process will repeat for a few seconds before the excitation failed warning is given Alternator excitation may also be used as a secondary crank disconnect signal for the case where the speed signal has failed immediately the engine starts to run This feature can be disabled if not required by setting Excite Dis to NO For systems where a battery charging alternator is not fitted turning off the excitation warning will disable the excitation system 11 Battery Voltage Monitoring and Charging Detection A battery is considered charged if assuming a 12V system X2 for 24V
56. ystem to skip this sequence step o Totruncate the cool down timer press the stop button again o The set can be returned to the running sequence by pressing the start button The contactors return to place the genset on load again e STOPPING o The display will show STOPPING with a countdown time o If ETR fuel control has been selected the Fuel output will be deactivated o If ETS fuel control has been selected then the Fuel output will be activated for the Max Fuel Time or until the engine stops The stopping process will retry if the engine fails to stop the first time Between stopping retries the Fuel output is deactivated for a short time to help overcome any jamming o The fuel output is controlled until the engine stops rotating and oil pressure decays If the Oil Pressure has not decayed by the end of the Max Fuel Time the fuel output is deactivated and the controller raises the alarm FAILED TO STOP The speed must remain at zero and the oil pressure must be below the alarm set point for the Stop Time before the engine is considered stopped e READY Confidential www ems gen nz Page 14 EMS 834 GENSET CONTROLLER o The engine has stopped and is ready to start again as required 5 6 Automatic Operation If the autostart input is activated the unit will initiate an autostart sequence The sequence is similar to the manual start and stop sequences above with the following additions
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