Enovation Controls Murphy EMS PRO LITE Installation And Operation Manual Download Page 1

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2015-03-23

00-02-0787

Section 40

EMS PRO LITE

Engine Monitoring System Controller

Installation and Operations Manual

Summary of Contents for Murphy EMS PRO LITE

Page 1: ...2015 03 23 00 02 0787 Section 40 EMSPROLITE EngineMonitoringSystemController Installation and Operations Manual ...

Page 2: ...ration and controller failures can occur These failures might result in full control outputs or other outputs that might cause damage to or unsafe conditions in the equipment or process connected to the EMS PRO LITE To follow good engineering practices electrical codes and insurance regulations requires that you use independent external protective devices to prevent potentially dangerous or unsafe...

Page 3: ...conforms to local codes Observe all Warnings and Cautions in each section of these instructions The EMS PRO LITE is designed for use in industrial environments There might be potential difficulties in ensuring electromagnetic compatibility in other environments due to conducted as well as radiated disturbances Please contact Enovation Controls immediately if you have any questions IMPORTANT Improp...

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Page 5: ...rt Stop Settings 8 Transducer Start Stop Types 8 Pressure Start Stop Type 9 Level Start Stop Type 9 2 Float Start Stop Type 10 Throttle Type 10 Throttle to Pressure 10 Throttle to Level 11 Tier 4 Emissions 11 Unit System Metric or English 13 Operating Instructions 15 AUTO Start Stop Sequence 15 Start Sequence 15 Stop Sequence 18 Manual Start Stop Sequence 19 Start Sequence 19 Stop Sequence 20 Spec...

Page 6: ...iring Precautions 42 Diodes 42 Wire power leads directly to battery post 42 Pilot excessive loads 42 Use stranded wire for hookup 43 Separate AC and DC wiring 42 Wire standby battery charger directly to battery 42 Special precautions for spark ignition engines 42 Use shielded cable on magnetic pickup 42 Fuses 42 Communications 43 CAN 43 RS 485 43 RS 232 43 CPU PCB Wiring Interface J2 DB9 Connector...

Page 7: ...P NUMBERS 48 S NUMBERS 48 M Numbers 48 Loading a Program 48 Installation 49 EMS PRO LITE Dimensions 49 EMS PRO LITE Wiring Diagram 50 Specifications 51 ...

Page 8: ...NOTES ...

Page 9: ...to use performance enhancing features The display is readable day or night The EMS PRO LITE is ideal for use with a remote modem or in a SCADA system offering Modbus RTU protocol on either the RS232 or RS485 port NOTE Your EMS PRO LITE must be modified to use these ports changes include additional wiring and enclosure modifications User Interface and Navigation This section defines how to navigate...

Page 10: ...so scroll through and decrease values in the ENTER Scroll to the entry code and press Enter to get into or out of the M S or P numbers group or an individually selected M S or P number to make changes If changes were made press Enter to exit and your changes are saved Key Switch The controller accepts inputs from a 3 position key switch The three positions are AUTO OFF and MAN Input Description AU...

Page 11: ...ntry Code S Number Screen P Number Screen The EMS PRO LITE screens described below may appear in an order that is different from listed Screens Displayed Screen Name Description FW Murphy Murphy Enovation Controls From the 4 Up screen default depending where in the screen scroll you are when you press the down arrow the top line of the text page could be either FW MURPHY MURPHY or ENOVATION CONTRO...

Page 12: ... during operation ST STATE XXXX This text line displays states the controller can execute during operation NOT READY occurs when the key switch is in the OFF position This is seen briefly while the controller is powering ON No sequence occurs in this state PANEL READY occurs when the key switch is in the AUTO position and no shutdowns have occurred The controller is waiting for an auto start condi...

Page 13: ... auto sequence can continue COOLDOWN occurs after the Stop Delay has expired During the Cool down state the controller throttles the engine to an idle SHUTDOWN occurs if a shutdown condition is detected Reasons for shutdown include low oil pressure high engine temperature overspeed etc During this state the engine is signaled to shutdown and all start signals are ignored until the state is reset b...

Page 14: ...MEDIUM or SOOT LEVEL HIGH UREA LEVEL IF SELECTED This shows the urea level percentage from SPN 1761 FIRST FOUR UP SCREEN DEFAULT SCREEN The first four up screen should display Engine Oil Pressure Engine Coolant Temp Battery Voltage Engine RPM This is the default screen when powering up the controller SECOND FOUR UP ELECTRONIC ONLY SCREEN The second four up screen should display Run Hours Fuel Cons...

Page 15: ...the day of the week Use the following steps to set the Clock 1 Access the S Menu by pressing Menu 2 Use the Up or Down Arrow to increase or decrease the value to reach the correct Entry Code See Entry Code Supplement for Entry Codes 3 When the Entry Code displays press Enter to access the S menu NOTE S1 through S6 are the S Numbers used to set the clock A complete guide to all S Numbers is found i...

Page 16: ... S38 ENGINE TYPE is displayed and press Enter 5 Press the Up Arrow until MECHANICAL is highlighted then press Enter 6 Press the Up Arrow until S40 ENG THR TYPE displays and press Enter 7 Press the Up Arrow until MECHANICAL is highlighted then press Enter 8 Press the Down Arrow until S7 SPEED CALIB displays and press Enter 9 Press the Up or Down Arrow to enter the number of pulses per revolution PU...

Page 17: ...rough S56 for Pressure Start Stop Type To modify press Enter while the setting is highlighted When finished with the modification press Enter again Refer to the S Number table in Menus for a description of the S Numbers settings 8 When finished with the S45 through S56 settings press Menu to exit Level Start Stop Type The Level Start Stop Type allows you to automatically start and stop the engine ...

Page 18: ... for Entry Codes 3 Press the Up or Down Arrow until S35 SRT STP SEL is displayed and press Enter 4 Press the Up Arrow until FLOATS is highlighted then press Enter 5 Exit the S Menu by pressing Menu Clock Start Stop Type Using the internal real time clock the user can select up to 3 different start times per day The clock start stop feature can be used in conjunction with other start stop types Thr...

Page 19: ...press Enter 4 Press the Up or Down Arrow until the desired pressure to maintain is highlighted and press Enter 5 Press the Up or Down Arrow until S60 DEADBAND LEVEL is shown in the menu and press Enter 6 Press the Up or Down Arrow until the desired deadband range is highlighted and press Enter 7 Press Menu to exit Tier 4 Emissions Murphy products are compliant with requirements for U S EPA Emissio...

Page 20: ...tive and no regen occurs To use the controller on a Tier 4 engine follow the steps below 1 Access the S Menu by pressing Menu 2 Press the Up or Down Arrow to scroll to the correct Entry Code See Entry Code Supplement for Entry Codes 3 Press the Up or Down Arrow until S73 Tier Rating is displayed in the menu and press Enter 4 Press the Up or Down Arrow until TIER 4 is highlighted and press Enter 5 ...

Page 21: ...he default units from English units PSI and F to Metric units kPa C Use the following steps to change the units 1 Access the S Menu by pressing Menu 2 Press the Up or Down Arrow and scroll to the correct Entry Code See Entry Code Supplement for Entry Codes 3 Press the Up or Down Arrow until S72 Unit System is displayed in the menu and press Enter 4 Press the Up or Down Arrow until METRIC is highli...

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Page 23: ...the SELECTOR text line shows AUTO and the STATE text line shows PANEL READY Important When the key is in the AUTO position and ECU is selected for engine type the ECU enable output will turn ON for a period of 5 minutes After a 5 minute period of inactivity without a start signal or key press the output will become inactive This has no affect on the start sequence If Mechanical is selected for eng...

Page 24: ...ly if float backup not selected XDUCER OOR Out of Range LOW Only if float backup not selected High System Level Self clearing alarm or shutdown LO System Level Self clearing alarm or shutdown The fuel ECU enable output is turned ON NOTE the following WAIT FOR ECU If ECU is selected in engine type the controller will go through a fixed 10 second delay to allow the ECU to warm up prior to cranking A...

Page 25: ...rding engine run hours The engine is throttled to the WARMUP RPM set point NOTE When you set the Engine Type if you selected Mechanical the throttle actuator will throttle the engine If you set Electronic the ECU throttling is determined by what you selected in the ECU THROTTLE TYPE The shutdown lockout delay begins timing When this delay expires the following shutdowns are armed Low Oil Pressure ...

Page 26: ...he controller initiates an auto stop sequence The STATE text line will display STOP DELAY The stop condition must remain active throughout the stop delay or the delay will reset to zero When the stop delay expires the following occurs The SELECTOR text line will display AUTO and the STATE text line will display COOLDOWN The engine is throttled to the cooldown RPM set point The low discharge pressu...

Page 27: ...uel level factory default on aux 1 input NOTE A NO SPEED SIGNAL shutdown will occur when enabled if the controller does not read a frequency within 3 seconds after cranking begins To achieve a start condition press the green start key This will initiate the prestart delay after the start key is pressed the following will occur The STATE text line will display PRESTART DELAY The prestart delay begi...

Page 28: ...he engine fails to start after the number of cranking attempts is exceeded OVERCRANK will be indicated on the display The auto start sequence will be stopped requiring manual reset of the controller The controller is reset by moving the panel key switch to the OFF position After the crank cycle has finished the following will occur The STATE text line displays AT LOAD The shutdown lockout delay be...

Page 29: ...The Shutdown history screen also displays the last 5 shutdowns without date and time stamping Float Backup If the level transducer fails high or low a shutdown occurs If the float backup feature is enabled a shutdown will not occur and the controller will start and stop on floats If the engine is already running it will remain running until a float stop occurs During backup float operation the eng...

Page 30: ...p mode Press menu to exit S1 Set Time Minutes To adjust the minute portion of the Real Time Clock S2 Set Time Hours To adjust the hour portion of the Real Time Clock S3 Set Date Day To adjust the day portion of the date display S4 Set Date Month To adjust the month S5 Set Date Year To adjust the year S6 Set Day of Week Adjusts day of week Sunday through Saturday Day advances with date S7 SPEED CAL...

Page 31: ...you put a lower shutdown setting in this set point The controller automatically changes the shutdown point between the Low Speed Shutdown point and the High Speed Shutdown point Factory set to 15 S11 LOP HI SPD This set point is the higher oil pressure shutdown point that is referred to in LOP LOW SPD S10 above This is the point at which you want the engine to shutdown during normal high speed eng...

Page 32: ...his set point it will initiate an automatic shutdown Factory set to 220 S15 LOW FUEL LEVEL Enter in the fuel level that will cause a self clearing alarm to occur This alarm is disabled when set to 0 Factory set to 0 see S76 and S77 for aux 1 input configuration S16 LOW FUEL SHUTDOWN Enter the fuel level that will cause a shutdown to occur This alarm is disabled when set to 0 Factory set to 0 see S...

Page 33: ...red adjustable from 1 to 30 seconds Factory set to 10 S23 CRANK STOP RPM This RPM set point is used to adjust where the controller releases the starter during cranking Set this to the RPM the engine attains just as it starts Set this way the starter is not unnecessarily engaged after the engine starts This is how the controller senses whether the engine is running or not Factory set to 300 S24 CRA...

Page 34: ...ngine is hunting then lower the value If the engine never reaches the set point then increase the value Used with MECHANICAL engine throttle type S40 Factory set to 8400 S32 THR FDBK DLY This set point is used to adjust the amount of time the controller waits to sample the change made by the previous throttle pulse If the system pressure for example takes a long time to change based on engine spee...

Page 35: ...e if S35 Transducer Enter the transducer type used NONE PRESSURE CONTROL LEVEL CONTROL Factory set to NONE S38 ENGINE TYPE Enter ECU J1939 for diesels with ECU J1939 communications Enter MECHANICAL for engines that do not have an ECU J1939 When ECU J1939 is selected engine parameters are read from the ECU J1939 Factory set to ECU S39 ECU HOUR SELECT When set to ECU J1939 the hourmeter display will...

Page 36: ... Factory set to 1 S45 START PSI S45 is only visible if S35 Transducer S37 Pressure When pressure is selected in the start stop type an auto start will occur when the discharge pressure drops to this set point adjustable from 0 to 1000 PSI Factory set to 40 S46 STOP PSI S46 is only visible if S35 Transducer S37 Pressure When pressure is selected in the start stop type an auto stop will occur when t...

Page 37: ...he warm up delay expires The Low Discharge Pressure shutdown is armed when this delay expires adjustable from 1 to 9 999 seconds Factory set to 180 S52 FILL MODE DLY S45 is only visible if S35 Transducer S37 Pressure This delay begins timing after the warm up delay expires The engine is held at the minimum RPM set point until this delay expires adjustable from 1 to 9 999 seconds Factory set to 0 S...

Page 38: ...ur when the system level reaches this set point adjustable from 0 to 100 0 FT Factory set to 5 0 FT S59 MAINTAIN LEVEL S59 is only visible if S35 Transducer and S37 Level When level is selected in the throttle type the engine will be throttled between the minimum and maximum rpm set points to maintain this level adjustable from 0 to 100 0 FT Factory set to 10 0 FT S60 DEADBAND LEVEL S60 is only vi...

Page 39: ...evel reaches this set point A shutdown occurs with fill in S62 Factory set to 20 0 FT S64 LOW LEVEL S64 is only visible if S35 Transducer and S37 Level When fill is selected in S62 a self clearing alarm will occur if the level reaches this set point A shutdown occurs with fill in S62 Factory set to 1 0 FT S65 LEVEL MAX S65 is only visible if S35 Transducer and S37 Level Set this to the maximum val...

Page 40: ...e float backup enable S71 a shutdown will occur if the transducer s raw count reaches this set point Factory set to 100 This feature is not available if the transducer is 0 5 VDC S71 ENBL FLT BCKP Enable Float Backup S71 is only visible if S35 Transducer and S37 Level The choices are YES or NO YES will cause the float switches to take control of the system if the transducer fails on OOR high or lo...

Page 41: ...her FUEL LEVEL or AUX 1 Shutdown Factory set to FUEL LEVEL P Number Description and Listing The EMS PRO LITE Controller has P numbers in addition to the S numbers previously configured These are accessed in the same manner but using a different access code See the Entry Code Supplement for this code number P Number Name Description P0 MENU Press to exit P1 SUN SEL Set this to YES if you want to st...

Page 42: ...nd C Factory set to 0 0 P9 CLK A HR This set point lets you set the clock hour you would like to start in 24hr format For example if you want to start in the 3 o clock in the afternoon hour set it to 15 Factory set to 00 P10 CLK A MIN This set point lets you set the clock minute you would like to start For example if you want to start at 8 30 in the morning you would adjust this until it read 30 i...

Page 43: ...If Level Start Stop is selected this shows what the system level was when the controller initiated the last failure shutdown P19 OIL PSI SHDN Shows what the engine oil pressure was when the controller Initiated the last failure shutdown P20 ENG TEMP SHDN Shows what the engine jacket water temperature was when the controller initiated the last failure shutdown P21 FUEL LVL SHDN Shows what the engin...

Page 44: ...one set point for both ports 232 and 485 but they each have their own timers The delay starts timing on power up of the unit The delay is restarted anytime a MODBUS packet is received on the associated port If the delay times out an alarm only message is displayed SCADA FAILURE This warning message ends as soon as MODBUS packets resume on the port M10 SYS V MAX This number calibrates the controlle...

Page 45: ... an auto scan feature for the controller to find the source address The engine is set for TSC1 throttling M23 DROOP VALUE This display shows the state of the droop factor The state is calculated at load and has the following values NO this means that droop is not used on the ECU YES This means that droop is used on the ECU UNKNOWN This means the program was not able to determine the use of droop T...

Page 46: ...L1 2 00 M35 Analog in 0 This displays the raw count value of analog 0 Range 0 1023 M36 Analog in 1 This displays the raw count value of analog 1 Range 0 1023 M37 Analog in 2 This displays the raw count value of analog 2 Range 0 1023 M38 Analog in 5 This displays the raw count value of analog 5 Range 0 1023 M39 Analog in 6 This displays the raw count value of analog 6 Range 0 1023 M40 Analog in 7 T...

Page 47: ...nsducer Pin 4 9 Pos Conn supplies transducer power can be fused Pin A 9 Pos Conn is transducer input 7 Reserved 8 Reserved 9 System Level Transducer 4 20mA Sending Transducer Pin D 9 Pos Conn supplies transducer power Pin H 9 Pos Conn is the transducer input for level 10 Reserved 11 Reserved 12 Reserved Digital Outputs All Outputs are Pilot Duty The first three outputs DO 1 3 are B FET s rated 8 3...

Page 48: ...umpers on the PCBA s RS485 Terminating Resistor LK3 Shunt This shunt allows a terminating resistor to be used on the RS485 port Default ON ON Jumper Installed allows the terminating resistor to be present OFF Jumper Removed removes terminating resistor from the RS485 Sender Shunt LK5 Shunt This shunt controls sender power Default ON This shunt must be installed to use senders It can be removed whe...

Page 49: ...g Precautions There are steps that can be taken during initial installation that can increase the life of the unit These steps may take a few extra minutes to do at the time of installation but they can save time and expense in the future Enovation Controls strongly recommends taking these precautionary actions Diodes Place suppression diodes across all inductive loads These loads typically includ...

Page 50: ... Sender and shutdown wiring must be routed away from the magneto and spark coil wiring Resistor spark plugs and spark plug wires reduce electrical interference and may be required in especially noisy environments An external relay piloted by the ECU Fuel internal relay will be required if the ignition is to be controlled Use shielded cable on magnetic pickup Shielded cable is recommended for conne...

Page 51: ...d enclosure modifications CPU PCB WIRING INTERFACE LIST JP5 MOLEX 4 PIN CONNECTOR EMS PRO LITE Pin Assignment Hardware Assignment Program Function Assignment 1 RS 485 SCADA 3 RS 485 SCADA 2 Ground 4 Battery RS 232 RS 232 port designated for Modbus RTU slave for SCADA and to upload the actual operating program NOTE Modification to controller enclosure is required to use these ports CPU PCB Wiring I...

Page 52: ...reset Single Register Presets a value into a single holding register MODBUS function code 16 Preset Multiple Registers Presets values in a sequence of holding registers Registers Registers are adjustable or varying data locations within the controller whose value is an integer value not just ON or OFF They can represent the system analog input for flow or pressure The registers could be an adjusta...

Page 53: ...y Engine Temperature 40007 Read Only System Status Bits description follows Bit 0 LSB Auto Ready 1 yes 0 no Bit 1 Prestart Timing 1 yes 0 no Bit 2 Start Delay Timing 1 yes 0 no Bit 3 Warm up Delay Timing 1 yes 0 no Bit 4 Fill Mode 1 yes 0 no Bit 5 At Load 1 yes 0 no Bit 6 Stop Delay Timing 1 yes 0 no Bit 7 Cooldown Delay Timing 1 yes 0 no Bit 8 Common Failure 1 yes 0 no Bit 9 Spare Bit 10 Spare Bi...

Page 54: ...s 0 no Bit 6 Overspeed 1 yes 0 no Bit 7 Overcrank 1 yes 0 no Bit 8 High Discharge Pressure 1 yes 0 no Bit 9 Low Discharge Pressure 1 yes 0 no Bit 10 High System Level 1 yes 0 no Bit 11 Low System Level 1 yes 0 no Bit 12 Loss of Pressure Sender 1 yes 0 no Bit 13 Spare Bit 14 Spare Bit 15 Spare 40009 Read Only Shutdown Status Bits description follows Bit 0 Reserved Bit 1 Low Fuel Level Alarm 1 yes 0...

Page 55: ...9 Spare Bit 10 Spare Bit 11 Spare Bit 12 Spare Bit 13 Spare Bit 14 Spare Bit 15 MSB Spare 40010 Read Only Discharge Pressure Current discharge pressure 40011 Read Only System Level Current system level 40012 Read Write Engine Start Stop 1 yes 0 no 40013 Read Write Maximum RPM Set Point 40014 through 40037 Read Only Reserved ...

Page 56: ... to customization features P NUMBERS The P numbers contain clock functions and the shutdown history The code number is 61 S NUMBERS The S numbers contain critical information and control functions Be sure that only qualified personnel have access to this entry code The code number is 64 M Numbers Please call Enovation Controls Technical Support to access this entry code Loading a Program If a new ...

Page 57: ...LITE Dimensions This section contains the EMS PRO LITE dimensions and connection schematics Mount the EMS PRO LITE in a location that is accessible to the operator Use connection harnesses to connect to the I O and the engine Enclosure Front Enclosure Bottom ...

Page 58: ...15 03 23 50 EMS PRO LITE Wiring Diagram Drawing Notes for the Wiring Diagram 00 02 0814 that is at the center of this manual In addition the wiring diagram can be found on the Enovation Controls Web site http www fwmurphy com ...

Page 59: ...digital 4 20mA 0 5 VDC Digital Inputs 4 Digital Inputs high low Both Battery and ground are detected as active inputs An inactive input floats at approximately 1 2 B Frequency 1 optically isolated input for speed reference magnetic pick up 2VAC 50VAC RMS 30 10kHz Fuel Sender Input 33 Ohm full 240 Ohm empty Analog Output 4 20mA or 4 to 4 2VDC used for 4 4 2V throttling Digital Outputs 6 Digital Out...

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