THOMSON MEC 2 Service Manual Download Page 1

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9087A – 198

Street, Langley, BC Canada V1M 3B1 Telephone (604) 888-0110

Telefax (604) 888-3381 E-Mail: [email protected] www.thomsontechnology.com

MEC 2

MICROPROCESSOR

ENGINE/GENERATOR CONTROLLER

(WITH EAP 110 REMOTE ANNUNCIATOR OPTIONS)

INSTALLATION, OPERATING &

SERVICE MANUAL

Software Version 1.4

PM056 Rev 6 05/10/15

Summary of Contents for MEC 2

Page 1: ...888 0110 Telefax 604 888 3381 E Mail info thomsontechnology com www thomsontechnology com MEC 2 MICROPROCESSOR ENGINE GENERATOR CONTROLLER WITH EAP 110 REMOTE ANNUNCIATOR OPTIONS INSTALLATION OPERATI...

Page 2: ......

Page 3: ...2 BATTERY SUPPLY INPUT 4 2 3 SPEED SENSING INPUT 5 2 4 DC VOLTAGE INPUTS 6 2 5 AC VOLTAGE INPUT 6 2 6 AC CURRENT INPUT 8 2 7 OUTPUTS 8 2 8 EXTERNAL PANEL CONTROL WIRING 8 2 9 REMOTE START CONTACT FIEL...

Page 4: ...ONS 26 5 1 RUN CRANK OUTPUT CONTACTS 26 5 2 PROGRAMMABLE OUTPUT CONTACT 27 6 EXPANSION OUTPUT MODULE OPTION 30 7 EAP 110 REMOTE ANNUNCIATOR OPTION 34 8 OPERATING INSTRUCTIONS 35 8 1 MEC 2 POWER UP OPE...

Page 5: ...CALIBRATION MENU 62 10 PROGRAMMING SHEETS 73 10 1 SUMMARY CONFIGURATION DATA SHEET 73 11 MAIN CONFIGURATION 74 11 1 ANALOG FAULT PROGRAMMING MENU 76 11 2 DIGITAL FAULT PROGRAMMING MENU 77 11 3 CALIBR...

Page 6: ...g revised pressure resistance calibration data New Oil Pressure Sender Thomson p n 003654 Manufacturer Datcon p n 102227 Discontinued Oil Pressure Sender Thomson p n 000772 Manufacturer Isspro p n R92...

Page 7: ...xpansion Port Enabled for optional relay expansion board There were also minor changes that are reflected in the manual 1 1 01 07 24 Add Ready to Load changes in temperature and pressure calibrations...

Page 8: ...r design provides high accuracy for all voltage monitoring current monitoring and timing functions as well as providing many standard features which were previously only available as expensive add on...

Page 9: ...t on grounded surfaces and only use an anti static bag for transporting the equipment 2 INSTALLATION 2 1 GENERAL INFORMATION NOTE Installations should be done according to all applicable electrical re...

Page 10: ...to do so may subject the control panel to an over voltage condition in which damage may result 2 2 2 Wiring from battery to engine control panel should be two 14 AWG 2 5mm2 wires i e do not use the e...

Page 11: ...ed and one side must be connected to the common DC negative conductor 2 5 AC VOLTAGE INPUT The MEC 2 can accept direct AC voltage input from 120 600VAC nominal Note Direct input voltage sensing can on...

Page 12: ...EUTRAL SYSTEM VOLTAGE INPUTS 240VAC L L 120VAC L N Note L1 and L2 phase voltages must be 120Vac when referenced to common neutral Delta connected generators required PTs as per figure 3 no phase C PT...

Page 13: ...vent internal damage due to possible excessive current draw and or damage should an external fault occur Note These outputs will require external over current protection Maximum 10 Amp The use of AC o...

Page 14: ...ower cables to prevent pick up of induced voltages 2 9 3 An interposing relay may be required if field wiring distance is excessively long i e greater than 100 feet 30m and or if a remote contact has...

Page 15: ...to mount on the door then re assembled Refer to FIGURE 7 for correct assembly location of all parts The second method of controller mounting requires a factory supplied adapter faceplate as shown in...

Page 16: ...HER 1 2 NYLON SPACER 8 32 CLEARANCE UNTHREADED PEM STUD 8 32 1 G ENGINEER PRODUCTS MEC2 MEC2_09 VSD Rev 0 00 12 11 REAR FRONT HIGH VOLTAGE MYLAR BARRIER mounts on bottom right hand corner as viewed fr...

Page 17: ...0_11 VSD Rev 1 00 07 13 5 5 in 3 5 in C C FIGURE 9 DOOR CUTOUT FOR ADAPTER FACEPLATE 10 875 in 6 875 in 2 13 DIELECTRIC TESTING Do not perform any high voltage dielectric testing on the control panel...

Page 18: ...03 VSD Rev 0 00 12 11 DECREMENT INCREMENT SILENCE RESET SHUTDOWN ALARM READY SPEED SIGNAL EMERGENCY STOP RUN OFF AUTO LOAD TEST EXIT ENTER 14 3 2 13 1 6 7 4 11 12 5 8 9 10 LAMP TEST MICROPROCESSOR ENG...

Page 19: ...efer to the operating instructions for detailed information OFF pushbutton and LED light viewing window The OFF function is used to initiate a stop signal to the engine generator set Refer to the oper...

Page 20: ...pre programmed shutdown fault has been activated 3 2 PRINTED CIRCUIT BOARD The printed circuit board PCB is shown in FIGURE 11 The PCB contains the following user interface items MEC 2 CIRCUIT BOARD...

Page 21: ...and engine temperature pressure input signal terminal block TB4 DC power input and ground connection terminal block 3 2 2 DIAGNOSTIC LED S The MEC 2 controller provides five diagnostics LED lights th...

Page 22: ...ESCRIPTIONS The MEC 2 engine generator controller utilizes many analog and digital inputs to perform both monitoring and control functions Three types of fault circuits are used to monitor and control...

Page 23: ...VERCRANK SHUTDOWN LOW ENGINE TEMP ALARM HIGH ENGINE TEMP ALARM LOW OIL PRESSURE ALARM LOW OIL PRESSURE SHUTDOWN HIGH ENGINE TEMP SHUTDOWN LOW COOLANT LEVEL SHUTDOWN LOW FUEL LEVEL ALARM CRANK 10A 240V...

Page 24: ...programmable for the percentage of nominal engine speed i e over speed setpoint and for the transient time delay period The programming prompts for over speed are located in the main menu programming...

Page 25: ...C 2 Engine Controller AIR DAMPER TRIPPED HIGH OIL LEVEL BAT CHARGER INPUT FAIL HIGH OIL TEMP BAT CHRG TROUBLE HIGH WINDING TEMP BREAKER TRIPPED LOW COOLANT LEVEL DC FAIL LOW ENGINE TEMP FAILED TO SYNC...

Page 26: ...mperature sender inputs if programmed accordingly in the analog fault programming menu Refer to Section 9 4 for further information 4 4 ANALOG FAULT INPUT CIRCUITS The MEC 2 Engine Controller provides...

Page 27: ...Engine speed Loss of speed signal Shutdown Engine speed All fault circuits may be user field programmed for different control functions however their designated fault function is not programmable Ref...

Page 28: ...ERATOR OVER CURRENT The MEC 2 controller provides a 3 phase current sensor for the generator supply The current sensor is programmable for type of fault action i e alarm or shutdown pickup current set...

Page 29: ...LOG INPUT The MEC 2 engine temperature sensor measures a DC analog signal from an engine mounted sender The MEC 2 software provides calibration for engine temperature to coordinate with the engine mou...

Page 30: ...2 software provides calibration for oil pressure to coordinate with the engine mounted sender and control logic to detect a wiring or sender failure i e open or shorted signal In case of a sender or w...

Page 31: ...ive 0 4pf Output contacts are not fused therefore external over current protection maximum 10A is required for all control circuits using these contacts Contacts indicated on schematic drawings and co...

Page 32: ...Controller provides four 4 standard programmable output contacts Each programmable output is a Form C dry contact that is programmable for many different control functions The programmable output may...

Page 33: ...e when the generators voltage and frequency exceeds predetermined setpoints e g voltage 90 nominal frequency 95 nominal as user programmed and a warmup time delay period expires Once the output has en...

Page 34: ...tpoint typically 5 of rated speed Note An external pilot relay will be required if the main air flap solenoid current rating exceeds the MEC 2 contact rating Refer to Section 2 7 5 2 10 ATS TEST NOTE...

Page 35: ...2 13 COMMON FAIL The designated programmable output relay will energize when any alarm or shutdown fault circuit has been activated 5 2 14 COMMON SHUTDOWN The designated programmable output relay will...

Page 36: ...R CURRENT 6 HIGH ENGINE TEMP 2 SHUTDOW N 7 LOW OIL PRESSURE 2 SHUTDOW N 8 9 10 11 12 13 14 15 16 PROGRAMMABLE OUTPUT 6 ADDITIONAL FAULTS J17 ON 1 2 3 4 5 6 G ENGINEER PRODUCTS MEC 2 MEC2_14 VSD NOTES...

Page 37: ...rogrammable contact for desired control function Refer to Section 9 2 of this manual for programming functions and procedures for the programmable contact feature Note The communication cable between...

Page 38: ...ils The first expansion module addresses standard C282 NFPA110 MEC 2 fault circuits1 and the second expansion module addresses all additional fault circuits To select which faults are addressed by eac...

Page 39: ...both visual LED lights audible alarm annunciation The EAP 110 is DC powered from the same 12 or 24V engine starting battery as the engine controller is connected to Two EAP 110 annunciators can be in...

Page 40: ...condition press the OFF pushbutton first then press both INCREMENT and ENTER pushbuttons simultaneously The controller will then reset provided a remote emergency stop condition is not activated The...

Page 41: ...GENERATOR FREQUENCY HOURMETER BATTERY VOLTAGE ENGINE SPEED TACH ENGINE TEMPERATURE OIL PRESSURE PROGRAM MENU 8 2 1 OPERATING STATUS MENU The operating status menu provides the operator with detailed...

Page 42: ...down fault circuit is active The specific fault condition will be automatically displayed 8 2 1 5 UNIT ALARM This indicates that one or more alarm fault circuits are active The display will automatica...

Page 43: ...During a timer countdown sequence a different display screen may be selected by pressing the ENTER pushbutton The following timer countdown screens are provided ENG START DELAY XX SEC CRANK PERIOD XX...

Page 44: ...e system AVERAGE LINE CURRENT Phases A B C 1 phase system AVERAGE LINE CURRENT Phases A B Displays generator frequency in hertz HZ The frequency is displayed with a resolution of 1 10 of a hertz 8 2 4...

Page 45: ...PHASE NEUTRAL VOLTAGE DISPLAY LINE TO NEUTRAL The generator phase neutral display allows the operator to view the generator line to neutral voltage for all 3 phases of the system Note The generators n...

Page 46: ...applicable 8 2 4 6 GENERATOR FREQUENCY HOURMETER DISPLAY The generator frequency and operating hours are displayed simultaneously on this screen LCD DISPLAY FREQ 60 1Hz HOURS 56783 Hrs Displays gener...

Page 47: ...re in either pounds per square inch PSI or in Kilopascals KPA as selected 8 2 6 PROGRAM MENU The programming menu is used to access the MEC 2 programmable functions such as time delays analog fault se...

Page 48: ...s for normal operating conditions such as start delays cooldown and cranking periods 8 3 2 MANUAL START STOP SEQUENCE When the RUN pushbutton on the front faceplate keypad is pressed an ENGINE START D...

Page 49: ...fault circuit is programmed as a SHUTDOWN the engine will immediately stop once the fault circuit is activated Note A specific shutdown fault may be programmed with a definite time transient delay per...

Page 50: ...transfer to the generator supply Note The neutral delay function is only operative with an electrically held type transfer switch mechanism ie electrical contactor type 8 3 5 3 UTILITY POWER RETURN R...

Page 51: ...expires the Utility Ready to Load output de energizes and the Neutral Delay timer is initiated Once the Neutral Timer expires the Gen Ready To Load output energizes to signal the transfer switch to tr...

Page 52: ...ted by closing an external exercise timer contact to the programmed digital input for No Load Test Once the external exercise timer contact closes the engine will start and come up to normal operating...

Page 53: ...F 16 17 35 36 20 21 VA VB VC PROGRAMMABLE OUTPUT 3 PROGRAMMABLE OUTPUT 4 3 URTL GRTL 1 4 5 G 5 5 5 5 5 7 6 7 220V U 220V G 8 8 2 G ENGINEER PRODUCTS MEC2 MEC2_10 VSD REV 0 01 11 20 CONTACTS RATED 10A...

Page 54: ...opping of the engine will be controlled by a remote contact When the remote start signal is removed the engine will continue to run for the cooldown period if selected then stop Re selecting the Off p...

Page 55: ...h must be placed in the Off position 8 4 4 HORN SILENCE FUNCTION To initiate a horn silence function both EXIT DECREMENT pushbuttons must be simultaneously pressed This function will silence the audib...

Page 56: ...numbers Contact THOMSON TECHNOLOGY factory for master password if required To enter the programming mode follow the procedure as shown PROGRAM MENU YES Select the Program Menu by scrolling through th...

Page 57: ...programming mode is accessed the programming parameters will be displayed in the same order as the Programming Sheets To skip over parameters that do not require changes push and hold the ENTER pushb...

Page 58: ...as expressed in phase to phase voltage i e a 347 600 volt system would be entered as 600 The programmable range of values is 120V 15 000V 9 3 2 SYSTEM FREQUENCY Set to nominal system frequency of eith...

Page 59: ...re utilized the engine start delay time should be set as required for these functions 9 3 10 CRANK TIME Select desired cranking time in seconds If cycle cranking is selected this time will be the cran...

Page 60: ...c This is typically set to 10 seconds 9 3 15 COOLDOWN TIME Set to desired cooldown time in seconds Up to 9999 seconds of cooldown time may be programmed Set to zero if not required Note If the control...

Page 61: ...this feature Thomson Technology strongly recommends that backup crank disconnect protection and additional over speed protection is utilized NOTE The run output Fail safe feature will be factory prog...

Page 62: ...y timer will start when The Utility Ready To Load output de energizes Once the Neutral Delay time period expires The Generator Ready To Load output will then be energized The similar sequence will occ...

Page 63: ...or 120 seconds Refer to Section 11 for further details on this timing function 9 3 28 PROGRAMMABLE OUTPUT CONTACTS Select the desired function that will activate the programmable relay output contact...

Page 64: ...tion 11 1 for a table indicating programmable features provided 9 4 1 LEVEL This setting determines the actual analog signal setpoint at which the selected fault type will be activated Note For AC vol...

Page 65: ...the available labels The digital fault labels are stored in non volatile memory and are as follows AIR DAMPER TRIPPED HIGH OIL TEMP BAT CHARGER INPUT FAIL HIGH WINDING TEMP BAT CHRG TROUBLE LOW COOLAN...

Page 66: ...amming prompt only appears if alarm faults are programmed Shutdown faults are automatically set as latching 9 5 4 POLARITY This setting allows the digital fault circuit to be set for Open to Fail or C...

Page 67: ...rnal circuit used BYPASS ON START No TRANSIENT TIME 0 1 The No Load Test digital input feature is typically used in an AMF application where it is required to do an automatic timed No Load Test of the...

Page 68: ...RATION PHASE TO PHASE OR PHASE TO NEUTRAL VOLTS AB ZERO 99 600V Displays the generator phase voltages to be calibrated Displays the type of calibration function either ZERO or SPAN Displays the calibr...

Page 69: ...sing this will raise the displayed value conversely decreasing this value will decrease the displayed value Note Adjusting the ZERO function with voltage applied will result in non linear voltage read...

Page 70: ...to accept the correction factor number Record the correction factor number on the MEC 2 programming sheet for future reference if required Repeat the above procedures for all remaining phases of the g...

Page 71: ...ntroller terminals associated with the current phases to be calibrated With the generator stopped confirm there is 0 current on the phases to be calibrated In the programming mode scroll to each of th...

Page 72: ...safety procedures should be followed and be performed by qualified personnel only Failure to do so may cause personnel injury and or death Use the INCREMENT or DECREMENT pushbuttons to adjust the corr...

Page 73: ...st DC voltmeter is required with an accuracy of 0 5 or better To calibrate the battery voltage sensor perform the following procedure 9 6 7 1 SPAN CALIBRATION Energize the battery supply voltage to th...

Page 74: ...into final operating service the engine temperature analog circuit must be field calibrated to meet the performance accuracy as specified to ensure correct operation The engine temperature analog circ...

Page 75: ...on to accept the correction factor number Record the correction factor number on the MEC 2 programming sheet for future reference if required 9 6 10 PRESSURE CALIBRATION PROCEDURE Before the equipment...

Page 76: ...and temperature enter the programming mode and scroll to the Engine Pressure Offset calibration point Use the INCREMENT or DECREMENT pushbuttons to adjust the correction factor number while observing...

Page 77: ...302 150 46 621 90 79 284 140 55 552 80 89 266 130 65 483 70 101 248 120 76 414 60 114 230 110 90 345 50 127 212 100 106 276 40 142 194 90 147 207 30 160 176 80 197 138 20 183 150 70 290 69 10 206 140...

Page 78: ...ltage AC Voltage Internal Under Frequency AC Frequency Internal Over Frequency AC Frequency Internal Over Current AC Current Ext Dig Input 3 Low Battery Voltage Alarm DC Volts Ext Dig Input 4 High Bat...

Page 79: ...TRAL CONNECTED TOGGLE BETWEEN YES NO VOLTAGE SENSING VOLTAGE SENSING PT RATIO RATIO XXX ENTER NUMBER 1 208 1 DIRECT CURRENT SENSING CURRENT SENSING CT RATIO RATIO XXX ENTER NUMBER 1 999 1 DIRECT TEMPE...

Page 80: ...K UP XXX 0 999 TEETH CRANK DISCONNECT XX PERCENT 0 100 OVER SPEED XX PERCENT 100 150 OVER SPEED TRANSIENT X X SEC 0 0 9 9 SEC RUN OUTPUT FAIL SAFE YES NO TOGGLE BETWEEN YES NO LOSS OF SPEED SIGNAL SHU...

Page 81: ...VEL PICK UP SETPOINT LEVEL DROP OUT ACTION S SHUTDOWN A ALARM ALARM LATCH Y YES N NO BYPASS ON START Y YES N NO TRANSIENT DELAY SEC UNDER VOLTAGE AC VOLTAGE E S Y Y 5 0 OVER VOLTAGE AC VOLTAGE E S Y N...

Page 82: ...HUTDOWN PRESS SENDER E 20PSI N A S Y Y 2 0 Indicates feature is non programmable i e is fixed in software 11 2 DIGITAL FAULT PROGRAMMING MENU TYPICAL PROGRAM FACTORY DEFAULT SETTINGS DIGITAL FAULT PRO...

Page 83: ...XXXVAC VOLTS C A ZERO XXX XXXVAC VOLTS C A SPAN XXX XXXVAC VOLTS A N ZERO XXX XXXVAC VOLTS A N ZERO XXX XXXVAC VOLTS B N ZERO XXX XXXVAC VOLTS B N ZERO XXX XXXVAC VOLTS C N ZERO XXX XXXVAC VOLTS C N Z...

Page 84: ...GINE GENERATOR CONTROLLER PM056 Rev 6 05 10 15 Thomson Technology 79 CALIBRATION MENU ZERO XXX XXXAAC CURRENT C SPAN XXX XXXAAC BATTERY VOLTAGE SPAN XXX XX X VDC ENGINE TEMPERATURE XXX XXX C F OIL PRE...

Page 85: ...peed Sensing 100 10 000Hz 3 0 20VAC rms AC Voltage 120 600VAC nominal 0 1VA 3 phase 50 60Hz AC Current 0 5Aac nominal 1 5VA 3 phase Engine Parameters Dedicated Senders supplied loose Digital Fault Con...

Page 86: ...TE PHASE C FOR SINGLE PHASE SYSTEMS A B C 10A GENERATOR OUTPUT VOLTAGE 120Vac TO 600Vac 3 PHASE OR SINGLE PHASE DELETE PHASE VC FOR SINGLE PHASE SYSTEMS 5 MEC 2 RUN CIRCUIT FUEL SOL GOV 6 6 6 6 6 3 6...

Page 87: ...oes not power up even with correct DC power applied Check that there are no wiring errors short circuits connected to the controller Note The MEC 2 contains an electronic fuse that triggers upon an ov...

Page 88: ...el teeth nominal RPM and over speed setpoint percentage Voltage or current metering is reading incorrectly Verify that the controller has been programmed with the correct values for the voltage sensin...

Page 89: ...g for corresponding input temperature or pressure refer to the Analog Temperature and Pressure Calibration table for values Verify calibration Engine alarms on high engine temperature or low oil press...

Page 90: ...MEC 2 MICROPROCESSOR ENGINE GENERATOR CONTROLLER PM056 Rev 6 05 10 15 Thomson Technology 85 15 NOTES...

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