EMS 350 User Manual V28

EMS350
Genset Controller
User Manual
The information contained in this manual is copyright, and is not to be reproduced without the written authority of EMS 2002 EMS 350 User Manual V28.doc
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For Software Version 1.0.6
27/03/03
EMS 350 Genset Controller

1. Introduction
Overview The EMS 350 is a controller suitable for use with Diesel powered Gensets which are used for standby or prime power generation. The unit controls the starting and stopping of the engine and the transferring of electrical load between engine and mains, . Vital engine and genset operating parameters are monitored and displayed. In the event of abnormal operation the unit alarms and protects the equipment by load removal and engine shutdown. The EMS 350 can be configured for both manual and automatic control. Parameters monitored are: Engine Parameters Engine Speed Oil Pressure Coolant Temperature Oil Temperature or Fuel Level Battery Voltage Engine Hours. Fuel Level Fuel Usage Electrical parameters Mains Volts and frequency Generator Volts and frequency Load Current Load KVA Load KW Load KVAR Load KWHr Power factor
Electrical parameters can be either single or three phase. The EMS350 is fitted with a serial RS232 port for local connection to programming and cloning software. An EMS 350 unit comprises two modules which are connected together by a ribbon cable. The controller and user interface. (usually mounted on the front of the control cabinet ) The equipment interface module. (usually mounted on a DIN rail inside the control cabinet) Front Panel Features An EMS 350 front panel is shown below.
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The front panel comprises the following major components: Mode Buttons. Start /Stop/ Auto Transfer button with associated status LEDs LCM display and menu buttons Engine gauge set Alarm indicator and Mute button
The Mode Buttons The Start (I) / Stop (O) / Auto (A) buttons are used to select the operating mode. They allow manual or automatic control during normal operation or system testing. The Transfer Button and Status LEDs The Transfer (<>) button allows manual transfer of the load between mains and generator when the unit is in manual mode. The associated status LEDs display green when the mains/generator voltage and frequency is within specified correct limits, orange when a transfer is underway, and red if the voltage or frequency is not within specification. A flashing LED indicates that the load is not connected to that source. A green flashing LED shows that the power at that point is within specification but that load is connected to the alternative source. A red flashing LED shows that the power is out of specification and a transfer to that source cannot be carried out. The Display The display is a 16 Character by 2 Line display and is used to show operating mode, current status, operating values, alarm messages and setup items. The Menu Buttons The 5 menu buttons are used to select the setup options and control the display of information during normal operation. Engine Gauge Set The engine gauges display from left, oil pressure, temperature and battery volts. They are used to give a rapid overview of correct engine operation. When the engine is not running, the gauges are shut off to conserve battery power. Alarm indicator and Mute Button The Alarm indicator provides an overall view of the system status. It functions as follows: Green Flashing Green (Fast) Flashing Green (Slow) Red Flashing Red Normal Operation Starting Stopping Alarm Warning
The Mute button disables the hooter output. This output can be used to connect the Hooter if required. Back Panel Features The Ribbon Cable The back panel has a 34-way ribbon cable which connects the controller to the interface module. RS232 Connector A 9 Pin Din connector is fitted for the local RS232 and remote communications. The termination is DTE. Interface Module
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The EMS350 has a termination unit which is used to connect the engine wiring, mains voltages, generator voltages and load currents to the unit. The termination unit is DIN rail mounted (76mm) and uses screwless connectors suitable for terminating 0.5mm to 0.75mm wire sizes. Inputs and Outputs The unit has 5 isolated inputs . Four of these are configurable as listed below: Input Autostart Inputs 1 to 4 Function Autostart Emer Stop Trip Belt Broken. Gen Trip Fuel Flow Lo Fuel Alm Lo Fuel Warn Plant 1 Plant 2 Plant 3 Plant 4 Plant 5
The operation of each input mode is described in section 4 below. The unit has 9 relay driver outputs, which are configurable as listed below: Output Fuel Output Crank Output Outputs 1 to 7 Function Fuel Relay Crank Relay OFF Running Preheat Fuel Pump Fuel Pull In Coil Idle Control Charger Flaps Excitation Warn Alarm Crit Alarm Hooter Emer Stop Not in Auto Black Warn Start Warn Start Fail Stop Fail Contactor A Contactor B
The description of each output mode is described in section 4 below. Display Modes
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The top line of the display generally displays the source of the starting signal on the left, and the name of the parameters displayed on the right . The bottom line cycles the Engine and associated parameters including alarms and warnings if they are present.
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Values shown on the top left of the display are as follows: UNCAL AUTO The EMS350 is running in an uncalibrated mode. The EMS350 is running in Auto mode, and is under the control of the Autostart input The EMS350 is running in Auto mode, and is under the control of the AMF system The EMS350 is running in Manual mode. AMF and Autostart inputs are ignored. The EMS350 is running in Manual mode and is being controlled remotely. AMF and Autostart inputs are ignored. The EMS350 is running in Auto mode and is under the control of the scheduler.
AMF
MAN
REMOTE
SCHED
Default Parameter Display In general, the display shows the engine and generator parameters in a sequential form as follows: Note that only the values which are currently relevant are displayed. AUTO RUNNING
AUTO 999.9 AUTO
HOURS 999999.9 ENGINE 1500 RPM
AUTO ENGINE 123 Kpa 199C AUTO FUEL 99% Full FUEL 9.99l/m FUEL 9999l BATTERY 5.6Vmin
AUTO
AUTO 999.9l AUTO 12.6V
AUTO MAIN VOLT 229 228 228 AUTO MAIN FREQ 50.0 Hz
AUTO GEN VOLT 229 228 228 EMS 350 User Manual V28.doc
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AUTO
GEN FREQ 50.0 Hz
AUTO GEN AMP 523A 540A 560A AUTO GEN KVA 300 340 345 AUTO GEN KVAr 300 340 345 AUTO GEN KW 300 340 345 AUTO GEN KVA 300 340 345 AUTO GEN PF 0 .75
AUTO GEN KWHr 999.9 9999999
When in Ready mode, the display can be made to show any of the current parameters simply by pressing the Stop button. Every time the stop button is pressed the display scrolls to the next value. Releasing the stop button will leave the latest value displayed. This function is useful for commissioning and fault finding purposes. When the engine is running, the display can be scrolled through its current value for 30 seconds by pressing the menu button briefly. The display will continue to update the values. Briefly pressing the menu button again will increment the display to the next value. If the menu button is not pressed for 30 seconds the unit will restore the sequential scrolling.
2. Operation
First Turn On When the EMS350 is first turned on and is not yet calibrated, it exercises the gauge LEDs and displays the product name and software revision. This display is disabled when the Menu ( ) button is pressed. Once the unit has been calibrated, this display is shown for three seconds after power on and then the unit reverts back to the normal display. Modes of Operation. The EMS350 has 3 modes of operation; Auto Manual Uncal The unit responds to the Autostart input The unit responds to the Manual Start and Stop buttons or remote controls over the communication system. The unit is not yet calibrated and is running in a speed-unprotected mode.
When the unit is in Auto mode, it is primarily controlled by the AMF system, or auto start input remote start facility. When in Manual mode it is controlled by the manual push buttons or remote start facility. Calibration mode is described in section 3. 7 27/03/03 EMS 350 User Manual V28.doc For Software Version 1.0.6
Auto/Manual Selection The EMS unit is switched to Auto mode by pressing the Auto (A) pushbutton. If a condition exists which will prevent the engine from starting in this mode, the EMS unit will enter the appropriate lockout state until this condition is cleared If a condition exists which will immediately start the engine, such as an AMF or Autostart input, then the EMS unit will enter the AMF or Auto lockout condition. (see the section on Lockouts later in this manual). If the EMS unit is running in Auto or Manual, pressing the Stop (0) button will immediately stop the engine. If the EMS unit was running in manual mode, then it will remain in manual. If the EMS unit was running in AMF or Auto mode, then it will enter the AMF or Auto Lockout condition. (see the section on Lockouts later in this manual). Automatic starting options The EMS350 can be started automatically by the activation of the Autostart input, the AMF system which operates off the mains input signals (if enabled), or by the scheduler. The source of the start command is displayed while the engine is running. In the descriptions below, it is assumed that the starting source is the auto start input. However the starting and stopping process is the same for each input. Operational States There are five basic states. Power Down Ready Starting Running Stopping Power Down When in Power Down mode the EMS350 turns off all unnecessary items (including the display) to minimize battery usage. Every 5 seconds the alarm LED flashes green to indicate the unit is alive. Pressing the Menu button wakes the unit up and forces it into Ready mode. Activating the Autostart or pressing the manual button will change the state to Starting. The Power Down state can be disabled in the setup menu. Ready While in AUTO MODE all starting inputs off, or in MANUAL MODE and not running, the unit is in Ready Mode. The following status message will be displayed if in AUTO: AUTO READY
In MANUAL MODE the AUTO text will be replaced with MAN. Other messages may be displayed depending on the options which have been configured. If the Amp Source parameter is set to Load, indicating that the measuring CTs are installed between the power source and the load, EMS 350 User Manual V28.doc
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then the AC mains parameters may be shown on the display. These values can be accessed by pressing the button briefly During the ready state, the alarm LED is a steady green. Starting in Auto
menu
When the Autostart input is activated, the starting sequence is initiated. If the input deactivates during the starting sequence, the sequence is truncated and the unit returns to the Ready sequence. If an output has been configured as a start warning output, then it will activate during the period before cranking is initiated. Note that if the warning period is close to or less than the start delay, then the warning time will be truncated to the start delay plus 2 seconds. During the start delay, the alarm LED flashes orange quickly. During the starting state, the alarm LED flashes green quickly. The starting sequence is as follows: Process Starting State Start Delay Preheat Fuel Comment The Autostart input is activated and the engine is preparing to start The preheat output is activated The Fuel output is activated. If an output is configured to act as a fuel pull in output, this output will activate for 1 second at the start of the fuel state. The engine is cranking The engine is pausing between cranks. Fuel is turned off during crank rest periods. The engine has started. During Runup, Engine Oil pressure, Engine Temperature and Underspeed are not monitored. The engine is warming up. During warmup the idle output (if configured) will be activated. Engine Temperature is not monitored until one minute after the warmup period starts. The engine is running. The run output is activated.
Cranking Crankrest Runup Warmup
Running
Running
During the running state, the Alarm LED shows a steady green if operation is normal. Transferring in Auto Once the engine is warmed up and running, the unit will attempt to transfer the load to the generator. Depending on the options selected to control the A contactor which disconnects the load form the mains, the A contactor may be deactivated immediately at the end of the blackout delay, after a configurable time delay, or when the engine is fully running and ready to take on the load. If the AGF system is enabled, then the EMS350 checks to see if the generator will allow the transfer to occur. The conditions which must be met are: Volts within specification Frequency within specification Generator trip input (if configured) not activated If these conditions are met, then the transfer process will occur. During the transfer process both the Mains and Generator transfer LEDs will flash orange while maintaining the status indication of the mains and generator supplies in the background colour.. Genset Running in Auto Once the load has been transferred, if the AGF option has been enabled, the generator voltages, load currents and frequencies are monitored and displayed. EMS 350 User Manual V28.doc
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If volts or frequency values stray outside the limits set in the AGF system for longer than the times set for each values, then the B contactor will be deactivated to remove the generator load. Once voltage and frequency are within limits after the transfer delay time, the unit will re-activate the B contactor and attempt to restore the load on the generator. If after a preset number of tries the generator has not been able to reconnected, the B contactor is deactivated and the engine is shut down. Note that the A Contactor will not pull in until the AMF module indicates that the mains voltage is within specification. If the system is operating normally, and if the auto start or AMF condition is removed, the reverse transfer will occur. On completion of this transfer the engine is shut down. Stopping in Auto When the Autostart input is deactivated, the run on state will commence. The starting sequence is as follows: Process Stopping State Runon Comment The Autostart or AMF input is deactivated and the engine is preparing to stop. If the Autostart or AMF input is reactivated, the the engine will revert to the running state and continue to run. If the engine has run for less than its minimum run time, the runon time will be extended. The B Contactor output is deactivated. If enabled, the idle output is activated The Fuel output is activated if an energize to stop system in configured. A delay to ensure the engine has completely come to rest before the fuel solenoid is released. The engine is stopped and ready to run again
Cooldown Fuel Stop Ready Ready
The alarm LED flashes green slowly until the engine is stopped. During the stopping sequence the RUN ON and COOLDOWN periods may be prematurely terminated by pressing the stop button during these periods. Running in Manual Running in Manual uses similar starting sequences and display messages as when running in Auto. The AUTO text on the display is changed to MAN. During the stopping sequence the RUN ON and COOLDOWN periods may be prematurely terminated by pressing the stop button during those periods. Transferring in Manual Manual transfer is actioned by pressing the transfer button. If the generator is not ready to accept load (i.e. the generator transfer LED is not green), or the synchronized input is enabled and not activated, then the transfer will not occur. Running in remote mode Remote control may only be carried out in Manual mode. If the unit is started remotely , its operation is the same as a manual start. Transfer will not occur automatically and will require a remote command to activate. EMS 350 User Manual V28.doc
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The Display indicates that the unit is running under remote control.
3. AMF Operation
The EMS350 has a fully functional Automatic Mains Fail detection system. This system detects frequency and voltage excursions and if enabled, will open the A contactor regardless of the Engine status. If the EMS350 is in any mode except Manual, the AMF system will deactivate contactor A (or prevent Contactor A closing) if the mains voltage is lower than the low voltage levels, or higher than the high voltage levels or if the frequency exceeds it upper or lower allowable band. While the Mains is outside its permissible limits, the Mains transfer LED is red. If AMF operation is not required, it may be disabled in the AMF Menu by setting the AMF protect selection to No. If the AMF Start selection is set to Yes, then the engine will attempt to start at completion of the Blackout time.
4. AGF Operation
The EMS350 has a fully functional Automatic Generator Fail detection system. This system detects generator Frequency, Voltages, Currents and Power, and will deactivate the B Contactor (or prevent it from closing) if the generator is not producing power within the specifications. Once the B Contactor is opened, the AGF system will continue to check the Frequency, Voltage , Current and Power, and will attempt to re-close if Voltage, Frequency, Current and Power specifications are met. This attempt will be repeated for the number of tries that have been set up in the configuration system. The retries self reset after the engine has been running normally for a period of time.
5. Scheduled Running
The EMS350 may be configured to run at scheduled times by setting a non zero value in the Sched Time. If a non zero value is set, then the engine will start after the number of hours set has elapsed and will continue to run for the minimum run time. If the generator is to be transferred to the load during this running, then the Sched Trans value should be set to yes.
6. Excessive Run Time

The EMS350 may be configured to limit auto running to a defined time period set by MaxRun Time. If MaxRun Type is set to Warn, then a dial out event will occur if dial out is enabled. If MaxRun is set to Rest, then a Rest time can be configured during which the engine will shut down and ignore any consequent autostart or AMF start inputs. At the end of the rest time the engine will be restarted in the normal way if the Autostart or AMF start is activated.
7. Alarm Dial Out

The EMS350 has the ability to dial out to the POWERLINK remote monitoring software when alarms or specific plant inputs are activated. Up to 4 different phone numbers can be configured using POWERCONFIG configuration software. All alarms, Plant Input 1 and Plant Input 2 can be individually configured to dial out using a one of a list of four phone numbers.
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8. Calibration
Engine speed can be sensed by an MPU, 50 or 60 Hz Generator signal (using a low voltage transformer), or the Tacho signal from the battery-charging alternator. For each of these options the unit needs to be calibrated. In all cases, calibration may be carried out automatically by using the self-calibration facility. This process can be initiated whenever the engine is running in manual or uncalibrated mode. Before calibration is attempted, the calibrating speed set point must be set in the configuration menu to the speed at which calibration will occur in RPM. To calibrate the unit the engine must be started and warmed up. If the unit is uncalibrated, it cannot calculate engine speed, and the operation of the cranking system is carried out manually. To start the engine press and hold the start button (I) for the entire starting sequence until the engine fires. Note that there is no protection against overspeed or underspeed running. When the engine is running, the display shows: UNCAL RUNNING OIL 95Kpa UNCAL RUNNING VOLTS 13.2V UNCAL RUNNING TEMP 90C When the engine has gone through the warmup period and is running at its steady state speed (which should be the same as the calibration set point speed), press the menu button and horn button for 10 seconds. At this point the display shows: CAL VOLTS 13.2V
When the calibration process is completed, the display reverts back to the engine running sequence. Since the engine is not protected against excessive speed excursions it needs to be shut down and restarted. To shut the engine down, press the stop button (0). Once the engine has been calibrated, it will respond to manual and auto start inputs in the normal way. Note that if the EMS350 is reinstalled on a different engine or if its speed signals are derived from a different source, it may be recalibrated when running in manual by using the procedure outlined above. Note als o that after calibration, the engine should always be shut down so that normal speed monitoring can occur. CAUTION: If the menu button and horn button are pressed and held for 10 seconds with the engine running in manual, then the engine will recalibrate itself. If the PC based CONFIG350 software is used to clone identical engines with identical speed connection, then the speed setting can be cloned and a separate calibration process is not required.
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9. Configuration
Configuring the EMS350 Many of the EMS350 operating parameters can be varied to suit the specific requirements of the application. This can achieved by the use of the menu buttons on the front panel or PC based POWERCOFIG software. Only the menu button option is described in this document. Configuration using the menu buttons. Note that the unit must be in the ready mode and the engine stationary in order to configure it. To select the manual configuration mode press and hold the menu button for 5 seconds. If a non-zero PIN number has been configured, then the configuration mode is protected and requires the entry of the PIN number to gain access. This requirement may be disabled as a configuration item if required by entering a zero PIN number.. On initial startup, the default pin number is 0000 and security is disabled. If security is enabled and the setup menu is selected, the display shows: ENTER PIN XXXX Press the Value up or Value down buttons to cycle through the 4 digit number sequence until the correct PIN number is displayed. Pressing the Menu button when the correct number is displayed will enable the configuration mode. When a valid PIN number has been entered, the the item to be changed is located. Menu headers are shown below: System Timers Engine AC Setup AMF Setup and AGF Setup I/O Config Comms menu buttons can be used to select the menu header in which
When the required menu header is displayed, the until the required one is reached. Pressing the
buttons can be used to scroll through the list of items
menu buttons increments and decrements the values associated with that item.
Pressing the button returns the display to the Header selection display. Pressing again closes the configuration menu. Configuration Items The following table lists configuration items and the possible values. In the range column, the first two values are minimum and maximum, the bold value is the default. Note that values which are coupled, ie such as a trip and a restore setpoint, the minimum value cannot be set above the maximum value.
Item System Contrast Site ID Coms ID Security PIN
Range 0 - 10, 6 0 - 30, 000, 0 1 - 240, 240 On - Off, Off 0 - 9999, 0
Description LCD Brightness Site Identifier. May be used for asset numbering. Comms Address. Required for remote communications Allow Configuration Values to be changed = Off. When ON, all values are read only Pin # required before access is allowed to configuration values. Disabled when zero.
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Defaults
No - Yes, No
Setting to Yes will load all configuration items to their factory default values. Note that engine calibration will be lost.
Timers Start Delay Start Units Start Warn Preheat Time Crank Time Crank Rest Crank Tries Warm up Accn Time Run Min MaxRun Time MaxRun Type
1 - 500, 5 Sec min, sec 0 30, 2 3 - 60, 5 3 - 30, 5 3 - 30, 5 1 - 10, 3 5 - 255, 10 0 - 60, 5 0 999,0 0 - 999, 0 Warn Rest, Warn
Rest Time Run On Cool Down Stop Time
1 999, 1 1 - 60, 1 1 - 60, 1 2 - 20, 4
Stop Rest ETS Tries ETS Rest Alarm Time
2 20, 4 1 - 5, 3 5 - 30, 5 0 - 999, 30
Trip Delay
0 60, 0
Disp Update Wake Delay Sched Time Sched Trans Alm DialOut Alm DialOut PT1 DialOut
2 - 10, 2 0-240, 0 0 999, 0 Off On, Off Off 1 4, Off Off 1 4, Off Off 1 4, Off
Autostart Delay Time. Units may be minutes or seconds depending on the Start Units (next item) Selects the units for the Start Delay (see above). Prestart warning time. If an output has been assigned to a Start Warning function, then it will turn on for this time period before a start occurs. PreHeat Time Maximum Cranking Time Delay between cranking retries Crank Retries Underspeed is not checked during the warmup time. If configured, the Idle output is on for this period. Time to accelerate from Idle Running The minimum running time for the engine. If the engine is called to run for a shorter time than this, then the Runon time is extended. Maximum time in hours for which the engine is permitted to run. Disabled if set to zero. Action to be taken when MaxRun time expires. If set to Warn, then a warning of excessive run time will be activated which will trigger a dial out event if enabled. If set to Rest, then the engine will be shut down normally and prevented from starting automatically until the rest time expires (See next item) Note this item is only displayed when MaxRun time is non zero. Time from start of cool down to engine restart if MaxRun type is Rest. Run On Time. During runon, reactivation of Autostart input will return the engine to running state. Run output is off. Cool Down Time Time to allow large engines to completely stop rotating when stopping. During this time if Energize to Stop option is chosen, the oil solenoid will activate.. The time that Oil Pressure and Tacho signals are absent for before the unit considers the engine to be stopped. Maximum Stop Retries for ETS Fuel Control. This is only displayed if ETS option for oil solenoid type. Stop Retry Pause time for ETS Fuel Control. This is only displayed if ETS option for oil solenoid type. Maximum Hooter time. 0 disables the timeout, i.e. alarms will continue until the condition restores or the mute button is pressed. This is used to limit the maximum time that the alarm hooter will operate. Delayed trip time. If an input is configured as a trip input, if it is not activated by this time after commencement of the warmup state, the engine will trip. This function may be used for flow detection on pumping applications etc. If trip time is set to 0, this function is disabled. Display Cycle Time, sets frequency of display update The interval in minutes when the EMS350 will power up and check inputs for alarms etc. ) indicated this is turned off. Time in hours between scheduled starts used to exercise the Genset. This function enables or disables the transfer during scheduled runs. Dial out on alarm. 1 to 5 selects the preprogrammed phone number (only configurable with POWERCONFIG). 1 is the first number etc. Dial out on alarm. 1 to 5 selects the preprogrammed phone number (only configurable with POWERCONFIG). 1 is the first number etc. Dial out on Plant 1 input. 1 to 5 selects the preprogrammed phone number (only configurable with POWERCONFIG). 1 is the first number etc.
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PT2 DialOut Engine Cal Speed Crank Rel Lo Spd Alarm Lo Spd Warn Hi Spd Alarm Hi Spd Warn Oil Type Oil Units Oil Range Oil Alarm Oil Warn ETemp Type
Off 1 4, Off
Dial out on Plant 2 input. 1 to 5 selects the preprogrammed phone number (only configurable with POWERCONFIG). 1 is the first number etc. Calibration Speed. Setting to 0 will uncalibrate the Engine. / Crank Disconnect Speed Under Speed Alarm Under Speed warning Over Speed Alarm Over Speed warning Oil Pressure Sensor Type. COF is a closed on fault switch.
0 - 5000, 0 100 - 5000, 350 0 - 5000, 0 0 - 5000, 0 0 - 5000, 0 0 - 5000, 0 0 - 90, 10 - 180, or COF, 0 - 90 Kpa Bar, KPa
ETemp Alarm ETemp Warn Lo Bat Vlt Hi Bat Vlt Charge Min
User Sensor OTemp Type
OTemp Alarm OTemp Warn Fuel Type
Fuel Warn Fuel Flow RST Fuel Flo PPL Fuel Select Fpump On Fpump Off
Sets display of Oil Pressure to Kpa or Bar. Note that setpoints and range values are always shown in Kpa. 500, 750 or 1000, Oil Pressure Sensor Full scale range 1000 100 - 500, 200 Oil Pressure Alarm Level 100 - 500, 250 Oil Pressure Pre-Alarm Level TS120, TS150, Engine Temperature Sensor Type. COF is a closed on fault switch. Note TS200, or COF, that if Engine Temperature is below 60C the display will show Lo C. TS120 75 - 200, 95 Engine Temperature Alarm Level 70 - 200, 90 Engine Temperature Pre-Alarm Level 7.5 - 28, 10 Low Battery voltage level 7.5 - 32, 15 High Battery voltage level Off, 10.0 28.0, The minimum battery voltage below which a Low charge volts alarm is 13.1 activated when the engine is running. This generally indicates an excitation failure or broken alternator belt. Off,Fuel,OilT, Selects the functionality of the Fuel/Oil Temperature input. Off TS120, TS150, Oil Temperature Sensor Type. COF is a closed on fault switch. TS200 or COF, Only displayed if Oil Temperature Option is selected (User Sensor). . Note TS120 that if Oil Temperature is below 60C the display will show Lo C. 75 - 200, 95 Oil Temperature Alarm Level. Only displayed if Oil Temperature Option is selected (User Sensor) 70 - 200, 90 Oil Temperature Pre-Alarm Level. Only displayed if Oil Temperature Option is selected (User Sensor) 0 - 90, 10 - 110, Fuel Level Sensor Type. COF is a closed on fault switch Only displayed 0 - 90 or COF, 0 if Fuel Level Option is selected (User Sensor) - 90 5 - 90, 25 Low Fuel Pre-Alarm Level. Only displayed if Fuel Level Option is selected (User Sensor) Yes No, No Setting this to yes resets the fuel total flow to zero. 1 - 999 Fuel Flow input pulses per litre. This assigns a value to each fuel flow input pulse if configured. ETR - ETS, ETR Fuel Solenoid Type ETR is energized to run, ETS energized to stop. 0 - 50, 0 Fuel Pump Start Level. Fpump = 0 turns this function off. 50 - 90, 90 Fuel Pump Stop Level. Only displayed if Fuel Pump Start Level Option is greater than 0 (Fpump On) 1 - 99, 5 Max Fuel Pump run time (Minutes). This is used to check for correct fuel pump operation. If the pump runs for longer than this period, then there will be a problem with the pump or fuel system. Only displayed if Fuel Pump Start Level Option is greater than 0 (Fpump On). Note that the fule pump control system requireds a fuel level sensor to be configured. Oil Pressure or Oil Level Sensing. Used for Petrol engines fitted with oil slingers.
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Fpump Time
Oil Sense
Press - Level, Press
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Run 2 Dest
Yes or No, No
Run to Destruction. The engine can only be shut down by manual intervention, ie by pressing the stop button or by activating the emergency stop input if configured. This option is only to be enabled in highly critical applications when the engine must run under all circumstances. AC Parameter Setup Sets single or three phase mode Current Transformer Ratio, CT Input current required to provide 1 amp of CT Output current
AC Setup Phase CT Ratio Power Unit Amp Source
1 or 3, 3 1 - 999, 12
KW MW, KW Gen Load, Gen If CTs are connected in the load circuit rather than the Generator circuit, then the load parametric values can be displayed irrespective of whether the generator is .running or not. Setting this option to Gen disables the display of the load parametrics when the generator is stopped. Auto Mains Fail Setup AMF engine starting control enabled AMF Black-out Delay. (see next item for units) AMF Blackout delay units AMF A contactor control enabled AMF Contactor A Unload mode, Delay unloads after a defined time (see next item) after completion of the blackout delay or when the engine is running, Imedt unloads immediately on completion of the Blackout delay, Run unloads when the engine is running. Delay for Delayed Unload mode (see above) Engine start mains low voltage set point Engine stop mains low voltage set point Engine start mains high voltage set point Engine stop mains high voltage set point Engine start mains low frequency set point Engine stop mains low frequency set point Engine start mains high frequency set point Engine stop mains high frequency set point Delay for A to B and B to A contactor operation Auto Generator Fail Setup AGF Enable Generator Reload tries Generator Reload minimum frequency Generator Reload minimum volts Generator Low volts trip Generator Low volts trip delay Generator High volts trip (Immediate) Generator Low frequency trip Generator Low frequency trip delay Generator High frequency trip (immediate) Generator High Amp trip Generator High Amp trip delay Generator High KW (Actual Power) trip Generator High KW (Actual Power) trip delay If the Generator trip input is active for longer than this time the engine will shut down.
AMF Setup AMF Start Blkout Time Blkout Units AMF Protect Unload
Yes or No, No 1 - 500, 5 Sec min, min Yes or No, Yes Imedt, Delay or Run, Imedt
Unload Dly Lo Volt Trp Lo Volt Rtn Hi Volt Trp Hi Volt Rtn Lo Frq Trp Lo Frq Rtn Hi Frq Trp Hi Frq Rtn Xfr Delay AGF Setup AGF Enabled Load Tries Load Frq Min Load Volt Min Lo Volt Trip Lo Volt Dly Hi Volt Trip Lo Frq Trip Lo Frq Dly Hi Frq Trp Hi Amp Trip Hi Amp Dly Hi KW Trip Hi KW Dly Gen Trip Time
3 - 999, 5 60 - 240, 204 60 - 240, 216 110 - 350, 276 110 - 350, 216 38 - 60, 42 38 - 60, 45 50 - 72, 58 50 - 72, 55 1 - 10, 5
Yes or No, Yes 2 - 10, 3 40 - 80, 45 60 - 250, 216 60 - 250, 204 0 300, 10 110 - 300, 276 38 - 60, 42 1 - 10, 3 50 - 72, 58 10 9999, 60 1 - 600, 60 10 9999, 50 1 - 600, 60 2 30, 5
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I / O Cfg Output 1 Output 2 Output 3 Output 4 Output 5 Output 6 Output 7 Output 8 Input 1 Input 2 Input 3 Input 4 Comms Baud Rate Data Bits Parity Stop Bits Modem Ping Connect time Modem Time No Data Time Rings Dial Mode Modem Term Alm Dial out
Input and output options configuration. (See below for description)
2400 19200, 9600 7 - 9, 8 Even, Odd or None, None 1 - 2, 1 Off - On, Off 10 - 60, 60 1 - 20, 3 1 - 60, 5 0 - 20, 3 Tone or Pulse, Tone CR, LF or CR/LF, CR/LF 0 - 4, 0
Baud Rate for RS232 Coms Number of Data Bits Parity Select Number of Stop Bits This option sends AT commands to the modem every 60 seconds to allow it to set auto baud rate. Max time allowed to establish connection. Max time for modem to respond Max time a connected will remain open with no data before it is shut down Number of rings before answering. 0 inhibits autoanswer Dial mode Modem Command termination setup 0 disables alarm dial out, otherwise the number of dial out attempts.
Output Functions Running The running out is activated once the end of the warm up time is reached. It may used to activate the load on the engine. It is deactivated at the beginning of the cool down period. Preheater The preheat output is activated at the preheat time before the engine is due to be started. It remains on until the engine fires. If retries are required, the preheat will turn off if the preheat time is shorter than the crank rest time, but will remain on if longer than the crank rest time. Fuel Pump The fuel pump output is activated when the fuel level is below the fuel pump start level, and will remain on until the fuel pump off level is reached. If the fuel pump runs longer than the maximum run time, then a Fuel pump fail warning will be displayed. This output may be used for controlling a fuel pump which maintains a day tank from a bulk storage facility. Fuel Pull In The fuel pull in output is used as a pull in booster for dual coil fuel solenoids. It is actuated together with the fuel solenoid, and remains activated for 1 second . Idle Control The idle output is activated during the warm up and cool down periods. It can be used to allow a low speed to be used during the warm up period. EMS 350 User Manual V28.doc
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Charger Disable Charger disable is used to disable or disconnect battery chargers which interfere with the speed sensing systems. This output turns on at start of cranking and remains on until the engine stops. Flap Control The flap control output is activated during the stopping sequence. It is used to control air flaps which restrict inlet airflow to assist in stopping the engine if required. Excitation The excitation output is used in conjunction with a lamp or an appropriate resister to control the excitation of the charging alternator. It turns on just prior to cranking the engine and remains on until the engine shuts down. Warning Alarm The warning alarm output is activated whenever there is a warning present. It remains on while the condition is active or until the mute button is pressed. Critical Alarm The critical alarm output is activated whenever a Critical alarm occurs. It remains on while the condition is active or until the mute button is pressed Hooter The Hooter turns on for 1 second every 2 seconds for a warning and turns on continuously for a Critical alarm. Note that if both critical and warning alarms are active, the Hooter output is on continuously. The Hooter is disabled by the mute button until a new alarm occurs. Emergency Stop Alarm The emergency stop output turns on while the emergency stop input is activated. Not in Auto Alarm The not in auto alarm output turns on whenever the unit is not in automatic mode or in calibrate mode. Fail to Start The Fail to start output is activated when the engine fails to start. Fail to Stop The fail to stop output is activated when the engine fails to stop. Contactor A The contactor A output is activated to disconnect the load from the mains. Depending on configuration it activates either immediately after the blackout delay, a programmable time after this or when the engine is in a fully running state. Contactor B Contactor B output is used to connect the load to the generator. OFF If an output is configured as off, then it will not be activated by any activity. Input functions Autostart The Autostart input is used to automatically start the engine after the start delay. This input is not configurable Emergency Stop The emergency stop input shuts down the engine and triggers a critical alarm. The display will show the alarm condition as follows: EMS 350 User Manual V28.doc
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AUTO ALARM EMERGENCY STOP
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Trip The trip input is used to shut down the engine if the input is not activated within the trip delay time after the start of the warmup period. If the trip delay time is set to zero then this function is disabled. A typical application for this input is flow detection for pumping applications. When the trip condition is activated the display shows the condition as follows: AUTO TRIPPED ALARM
Broken belt The broken belt triggers a critical alarm. The display will show the alarm condition as follows: AUTO ALARM BELT BROKEN Generator Trip The generator trip input is used to allow an external fault condition disconnect the load. The display will show the alarm condition as follows: AUTO WARNING GEN EXT TRIP If this signal remains active for more than the Gen Trp Time, the engine will automatically shut down.
Lo Fuel Alm This input can be used as a low fuel engine shut down alarm if the fuel sensor is not enabled. Lo Fuel Warn This input can be used as a warning of a low fuel condition. Plant 1 Plant 1 input acts as a silent dial out activation. When this option is configured, its activation will cause a dial out to be initiated. No other indication of activity is given. This input may be used for security monitoring purposes. Plant 2 Plant 2 input acts in a similar manner to Plant input 1 except that the hooter is sounded during its activation. Plant 3 Plant 3 input locks out the engine and prevents it from running or if the engine is running will shut it down. The alarm condition is displayed as follows: AUTO ALARM PLANT ALARM Plant 4 Plant 4 input acts as a local warning only. Its activation will bring up a warning and activate the hooter if configured. The warning condition is displayed as follows: AUTO WARNING PLANT WARN Plant 5 Plant 5 activation disables all methods of starting the engine and causes a plant lockout condition. This condition is displayed as follows: AUTO WARNING PLANT LOCKOUT EMS 350 User Manual V28.doc
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LOCKOUT CONDITIONS Lockout conditions occur when the engine cannot start when required by the automatic starting signals due to another condition which is preventing it from starting. Lockouts are cleared by removing the condition which prevent the start from occurring. At this point the EMS unit will return to the previous mode (ie the mode before the stop condition occurred,) in the ready state. The Typical lockouts which may occur are shown below: Stop Lockout This occurs when the engine running in auto is stopped with the manual stop button. This condition is cleared by pushing the stop button again. If the previous start signal has deactivated, then the EMS unit will return to the Ready state in the Auto (or Manual) mode. If an another input is calling for the engine to start in the Auto mode, then the EMS unit will go to the appropriate lockout condition described below. These occur if the Emergency Stop or Plant Alarm 3 input is activated and the engine is not running. It is cleared by deactivating the active disabling condition and pressing the stop (0) button. If an another input is calling for the engine to start in the Auto mode, then the EMS unit will go to the appropriate lockout condition described below This occurs when the engine is stopped while the autostart input is active. The engine may be restarted by pressing the Start (1) button. The EMS unit will continue in its Auto mode of operation. This occurs if the engine is manually stopped while the AMF system is active. The engine may be restarted by pressing the Start (1) button. The EMS unit will continue in its AMF mode of operation. Plant lockout is caused by the activation of a Plant 5 input. The lockout is cleared by deactivating the input.
EM Stop Lockout Plant Lockout
Autostart Lockout
AMF Lockout
Plant Lockout
ALARMS There are two categories of Alarms. Warnings. These are non-critical alarms which do not interfere with the normal operation of the engine or generator and only provide a warning of a current or pending abnormal condition. Warnings are nonlatching and do not stop the engine. Generally Warnings are self-resetting. When a warning occurs, the alarm indicator on the front of the EMS350 flashes red, the warning alarm output (if configured) will activate, and the hooter output (if configured) will turn on and off every second. Pressing the Mute button can reset the hooter output. Alarms are critical which normally cause the engine to stop. If the Run to Destruction option has been selected engine shutdown will not occur if the alarm causes are speed related or due to low oil pressure or high temperature.. When an alarm occurs, the alarm indicator indicates red. The Alarm output (if configured) will activate until the alarm is cleared. The Hooter output (if configured) will activate until the alarm is cleared or if the Mute button is pressed. Alarms are latched and can only be reset by pressing the Stop button (0) once the condition causing the alarm is cleared.
Warning alarms are typically displayed as follows: AUTO WARNING LOW FUEL LEVEL Critical alarms are displayed as follows: AUTO ALARM LOW OIL PRESSURE 21 For Software Version 1.0.6
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Typical warnings Charge Failure The EMS350 has not detected the voltage rise that accompanies the charging process. This is probably because charging has not occurred due to broken belt or alternator failure Battery volts are below the low battery set point Battery Volts are above the high battery voltage set point Fuel Level is below the Fuel Warning set point Oil pressure is below the prelim value after the run up period Engine temperature has exceeded the engine temperature prelim level Oil temperature has exceeded the oil temperature prelim set point The warning input has activated The Fuel pump has operated for longer than its maximum time. This warning is cleared by raising the fuel level to greater than the fuel pump start level.
Under Voltage Over Voltage Low Fuel Level Low Oil Pressure High Engine Temp High Oil Temp Warning Fuel Pump Failure
Typical Critical alarms Low Oil Pressure High Engine Temp Broken Belt Emergency Stop Under Speed Over Speed High Speed Speed Failure Start Failure Stop Failure Plant Warning Oil pressure is below the alarm value after the run up period Engine temperature has exceeded the engine temperature alarm level The broken belt input is activated The emergency stop input has been activated Engine speed has not reached its minimum value Engine has exceeded its maximum speed Engine has exceeded top speed limits immediately after turn on. The Tachometer has failed The engine has not started The engine has not stopped A Plant Alarm 4 condition has occurred.
ALARM DIAL OUT The EMS350 can be configured to dial out to a PowerLink or PowerConfig application when alarms and warnings as well as other selected events occur. Before the dial out can function, the EMS350 must be setup by a PowerLink or PowerConfig system. This system in a special mode will communicate through the serial port either locally or via a connected modem and allow the user to set the phone number and other parameters which the unit requires. These values cannot be edited locally via the menu. Dial out can be triggered by a number of events. These are as follows: Alarms Warnings (if active for more than a preset time) Plant 1 or 2 input activation Excessive Run Time
SERIAL PORT CONNECTIONS The EMS350 may be connected to a computer or modem utilizing the DB9 connector on the rear of the controller. Connections are as follows: Use a null modem cable to connect to a PC Use a normal (straight through) cable to connect to a modem. Handshaking used is CTS/RTS.
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EMS350 TERMINATION UNIT The EMS350 termination unit has fitted all the terminations required to connect the engine, generator, mains and other ancillary items. The connections are described below Name +12V 0V Battery +ve Oil Sense Temp Sense Fuel Sense Tacho AutoStart Input 1 Input 2 Input 3 Fuel Crank Output 1 Output 2 Output 3 Output 4 Output 5 Output 6 N Mains L1Mains L2 Mains L3 Mains N Gen L1 Gen L2 Gen L3 Gen Com CT L1 CT L2 CT L3 CT Input 4 Analog 1 Analog 2 Output 7 Function Power Supply Common, connect to engine block Battery Volts Monitor Oil Sensor Temperature Sensor Fuel / Oil Temp Sensor Speed Sense ALT/MPU Auto Start Configurable Configurable Configurable Fuel Control Relay Coil Crank Control Relay Coil Various as configured Various as configured Various as configured Various as configured Various as configured Various as configured Mains Neutral Connection Mains Phase 1 Connection Mains Phase 2 Connection Mains Phase 2 Connection Generator Neutral Connection Generator Phase 1 Connection Generator Phase 2 Connection Generator Phase 3 Connection CT Common Generator Phase 1 CT Connection Generator Phase 2 CT Connection Generator Phase 3 CT Connection Configurable Analog output TBA Analog output TBA Various as configured Value 8V to 16V DC 0V DC 8VDC to 32VDC Resistive. 15mA max. (see notes) Resistive. 10mA max. (see notes) Resistive. 15mA max. (see notes) 0.5V to 70V / 10Hz to 16KHz Switch to 0V DC Switch to 0V DC Switch to 0V DC Switch to 0V DC 32 VDC max / 250mA max 32 VDC max / 250mA max 32 VDC max / 250mA max 32 VDC max / 250mA max 32 VDC max / 250mA max 32 VDC max / 250mA max 32 VDC max / 250mA max 32 VDC max / 250mA max Bonded to Mains Neutral 0 400 V AC 0 400 V AC 0 400V AC Bonded to Generator Manual 0 400V AC 0 400V AC 0 400V AC Bonded to earth 0 5 Amps 0 5 Amps 0 5 Amps Switch to 0V DC 0 10 volts 0 10 volts 32 VDC max / 250mA max
GENERAL SPECIFICATIONS
Feature Controller Overall dimensions Controller Cutout Controller Mounting Controller IP rating Overall dimensions Interface Module Interface Module Mounting Interface IP rating Supply voltage Supply current EMS 350 User Manual V28.doc
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Specification W 180mm x H 126mm x D 28mm W 156mm x H 117mm M4 Plastic Rivets or Screws. 4 Points IP65 from the front, IP20 from rear W 120mm x H76mm x D 40mm Standard Din rail IP20 Nominal 12V DC automotive, 16 volts maximum. TBA For Software Version 1.0.6
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AC Voltage inputs AC Current inputs AC measurement AC accuracy DC accuracy Maximum output current Maximum output voltage Output protection General protection Design Manufacture EMC
50 350 RMS 0 5 Amps RMS. 6X overload 6 seconds True RMS TBA (better than 2%) 1% 300ma 35 Volts DC Short circuit, reverse voltage, load dump, relay inductive currents Reverse voltage, load dump. ISO 9001 ISO 9002 TBA
Note that this unit is not designed for 24-volt operation. For 24-volt operation a din rail mounted power converter (EMS15) is available. Note also that double battery starting may irreparably damage this equipment.
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WIRING DIAGRAMS
EMS15 Power Interface Module
Mechanically
Alternative CT Connection
Tacho Options: MPU Battery Alternator 230/12 Volt Transformer 50/60HZ
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