THOMSON MEC 20 Service Manual Download

Page: 1 / 98

9087A – 198

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

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

MEC 20

MICROPROCESSOR

ENGINE/GENERATOR CONTROLLER

(WITH REMOTE COMMUNICATION, EXPANSION OUTPUT MODULE &

EAP 110 REMOTE ANNUNCIATOR OPTIONS)

INSTALLATION, OPERATING &

SERVICE MANUAL

Software Version 1.82

PM047 Rev 13 05/03/30

Summary of Contents for MEC 20

Page 1: ...8 3381 E Mail info thomsontechnology com www thomsontechnology com MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER WITH REMOTE COMMUNICATION EXPANSION OUTPUT MODULE EAP 110 REMOTE ANNUNCIATOR OPTION...

Page 2: ......

Page 3: ...UT 5 2 3 SPEED SENSING INPUT 6 2 4 DC VOLTAGE INPUTS 6 2 5 AC VOLTAGE INPUT 7 2 6 AC CURRENT INPUT 8 2 7 OUTPUTS 8 2 8 EXTERNAL PANEL CONTROL WIRING 8 2 9 REMOTE START CONTACT FIELD WIRING 9 2 10 REMO...

Page 4: ...2 4 4 ANALOG FAULT INPUT CIRCUITS 23 5 CONTROL OUTPUT CONTACT DESCRIPTIONS 28 5 1 RUN CRANK COMMON FAIL OUTPUT CONTACTS 29 5 2 PROGRAMMABLE OUTPUT CONTACTS 29 6 REMOTE COMMUNICATION OPTION 34 7 EXPANS...

Page 5: ...G FAULT PROGRAMMING MENU 66 10 5 DIGITAL FAULT PROGRAMMING MENU 67 10 6 CALIBRATION MENU 70 11 PROGRAMMING SHEETS 80 11 1 SUMMARY CONFIGURATION DATA SHEET 80 11 2 MAIN CONFIGURATION 81 11 3 ANALOG FAU...

Page 6: ...MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER...

Page 7: ...ssure 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 R9279C Note The...

Page 8: ...ircuit Add new Programmable Output features Engine Ready Engine Run Fuel There were also minor changes that are reflected in the manual 1 6 01 07 18 Added Ready to load programmable output and new Iss...

Page 9: ...3 98 05 08 Corrected minor errors Rev 2 98 02 18 New version with communication features expansion relay module capability and revised password number Rev 1 98 01 22 Corrected minor errors Rev 0 97 0...

Page 10: ...r display and programming Digital 3 phase voltage 3 phase current KVA and frequency metering for generator output Non volatile memory retains logic and set points if control power is lost Direct 3 pha...

Page 11: ...ing installation guidelines are provided for general information only pertaining to typical site installations For specific site installation information consult Thomson Technology as required Note Fa...

Page 12: ...nvironments i e gas engines with high voltage ignitions etc wiring from battery should be a twisted pair of 14 AWG 2 5mm2 wires 2 3 SPEED SENSING INPUT Field wiring of the speed sensing signal wires s...

Page 13: ...ted as shown GRD MEC 20 FIGURE 1 3 4W 208 380 480 600VAC DIRECT SENSING SOLIDLY GROUNDED NEUTRAL SYSTEM VOLTAGE INPUTS 600VAC L L 347VAC L N 380VAC L L 220VAC L N 480VAC L L 277VAC L N 208VAC L L 120V...

Page 14: ...ossible excessive current draw and or damage should an external fault occur Note These outputs will require external overcurrent protection Maximum 10 Amp The use of AC or DC operated solenoids or rel...

Page 15: ...excessively long i e greater than 100 feet 30m and or if a remote contact has a resistance of greater than 5 0 ohms 2 9 4 The remote start contact must be voltage free i e dry contact The use of a po...

Page 16: ...on protection against electrical interference contact Thomson Technology factory 2 11 EXPANSION OUTPUT MODULE LOCATION INSTALLATION The expansion module s are to be mounted inside a control panel usi...

Page 17: ...t exceed the maximum allowable level on the control panel door as per the applicable control panel certification standard The MEC 20 controller can be installed onto a door of a control panel using on...

Page 18: ...Rev 13 05 03 30 12 Thomson Technology 268 mm 126 mm 126 mm 166 mm 49 mm 49 mm 24 mm 24 mm OUTLINE OF PRINTED CIRCUIT BOARD UNDER PANEL DOOR 20 mm 32 mm 80 mm 8 mm 8 mm TOP CUTOUT 9 HOLES 6 mm DIAMETER...

Page 19: ...YLON SPACER 8 32 CLEARANCE UNTHREADED PEM STUD 8 32 1 G ENGINEER PRODUCTS MEC20_09 VSD Rev 0 97 06 02 REAR FRONT HIGH VOLTAGE MYLAR BARRIER mounts on bottom right hand corner as viewed from rear FIGUR...

Page 20: ...dielectric testing on the control panel with the MEC 20 connected in the circuit as serious damage will occur to the controller All AC control fuses connected to the MEC 20 must be removed if high vol...

Page 21: ...XIT function is used to scroll backwards through the status menus or programming prompts to the previous item The EXIT function is used to exit the programming menu by holding this button down for app...

Page 22: ...on is used to initiate automatic operation of the engine generator set Refer to the operating instructions for detailed information LOAD TEST push button and LED light viewing window The LOAD TEST fun...

Page 23: ...t board PCB is shown in FIGURE 11 The PCB contains the following user interface items MEC 20 CIRCUIT BOARD LAYOUT 17 MP1 MP2 1 TB2 TB1 IN IC IB IA VN VC VB VA WATCHDOG REMOTE START CRANK RUN COM FAIL...

Page 24: ...so may cause personal injury and or death TB2 Speed sensing and digital contact input terminal block TB3 Output contacts and engine temperature pressure input signal terminal block TB4 DC power input...

Page 25: ...port is utilized to interconnect an external expansion module for additional output contacts and or the EAP 110 remote annunciator Refer to Section 7 0 8 0 for additional information 3 2 4 2 J7 COM Th...

Page 26: ...LT LOGIC ENGINE TEMPERATURE SENDER ENGINE OIL PRESSURE SENDER OVERSPEED SHUTDOWN SWITCH NOT IN AUTO ALARM LOSS OF SPEED ALARM SHUTDOWN OVERCRANK SHUTDOWN LOW ENGINE TEMP ALARM HIGH ENGINE TEMP ALARM L...

Page 27: ...rammable for the percentage of nominal engine speed i e overspeed setpoint and for the transient time delay period The programming prompts for overspeed are located in the main menu programming loop R...

Page 28: ...BLE IDLE BREAKER TRIPPED LOW COOLANT LEVEL DC FAIL LOW ENGINE TEMP FAILED TO SYNC LOW FUEL PRESS GEN BREAKER OPEN LOW FUEL LEVEL GROUND FAULT LOW OIL LEVEL HIGH BEARING TEMP LOW OIL PRESSURE HIGH COOL...

Page 29: ...ontact to the MEC 20 input terminal as indicated All fault circuits may be user field programmed for different control functions or alternate fault names Note For CSA C282 applications the controller...

Page 30: ...n standard analog fault circuits as follows FAULT NAME FAULT ACTION INPUT SIGNAL Undervoltage Shutdown Generator voltage Overvoltage Shutdown Generator voltage Underfrequency Alarm Generator frequency...

Page 31: ...r to the programming instructions for further information 4 4 2 3 GENERATOR UNDERFREQUENCY The MEC 20 controller provides an underfrequency sensor for the generator supply The underfrequency sensor is...

Page 32: ...VOLTAGE ALARM The low battery voltage alarm fault circuit is activated when the battery voltage drops below a pre determined setpoint for a specified time delay The low battery voltage alarm fault is...

Page 33: ...instructions for further information 4 4 4 3 HIGH ENGINE TEMPERATURE 2 SHUTDOWN The high engine temperature shutdown fault circuit is activated when the engine temperature rises above a pre determine...

Page 34: ...to the programming instructions for further information Note Low Oil Pressure shutdown may alternately be programmed and wired as a digital fault input contact Refer to Section 4 3 for further detail...

Page 35: ...external crank pilot relay is required to energize the high current starter motor pinion solenoid that exceeds the 10A resistive crank output contact rating The crank output contact closes when a cra...

Page 36: ...y will energize when a stop signal has been activated The output will remain energized for 10 seconds once the engine has come to a complete stop then de energizes 5 2 2 IDLE CONTROL The designated pr...

Page 37: ...auto mode and no shutdown or alarm conditions are present 5 2 7 PREHEAT The designated programmable output relay will energize during the start delay timer period and cranking period until the engine...

Page 38: ...for further details on the sequence of operation 5 2 10 ENGINE RUNNING The designated programmable output relay will energize when the engine has started and has reached crank disconnect speed 5 2 11...

Page 39: ...to Load outputs are programmed the Load Test programmable output is not required as the engine starting logic is internally initiated 2 When both Utility Ready to Load and Generator Ready to Load prog...

Page 40: ...telephone systems Remote communication can be via customer supplied equipment or an external communication interface module CIM as manufactured by Thomson Technology The CIM module utilizes an intern...

Page 41: ...be suitably routed to protect it from sources of electrical interference Refer to installation section for further information FIGURE 14 MEC 20 WITH CIM MODULE DIRECT CONNECTED PC GRD GRD G ENGINEER P...

Page 42: ...ne system and CIM module Refer to FIGURE 15 for a typical MEC 20 network system with CIM module G ENGINEER PRODUCTS MEC20 MEC20_22 VSD 8 conductor Shielded Cable c w RJ45 connectors CIM Communication...

Page 43: ...ULT 3 14 DIGITAL FAULT 4 15 SWITCH NOT IN AUTO 16 PROGRAMMABLE OUTPUT 5 1 UNDER VOLTAGE 2 OVER VOLTAGE 3 UNDER FREQUENCY 4 OVER FREQUENCY 5 OVER CURRENT 6 HIGH ENGINE TEMPT 2 SHUTDOWN 7 LOW OIL PRESSU...

Page 44: ...ystem is referenced as Programmable Output 5 On the second expansion module the programmable contact is referenced as Programmable Output 6 Refer to Section 9 0 of this manual for programming function...

Page 45: ...details The first expansion module addresses standard C282 NFPA110 MEC 20 fault circuits1 and the second expansion module addresses all additional fault circuits To select which faults are addressed b...

Page 46: ...attery as the engine controller is connected to Two EAP 110 annunciators can be interconnected together via the communication link to allow up to 40 remote annunciator points from a single engine cont...

Page 47: ...condition press the OFF push button first then press both INCREMENT and ENTER push buttons simultaneously The controller will then reset provided a remote emergency stop condition is not activated Th...

Page 48: ...A GENERATOR FREQUENCY HOURMETER BATTERY VOLTAGE ENGINE SPEED TACH ENGINE TEMPERATURE OIL PRESSURE PROGRAM MENU 9 2 1 OPERATING STATUS MENU The operating status menu provides the operator with detailed...

Page 49: ...a shutdown fault is active The specific fault condition will be automatically displayed 9 2 1 5 UNIT ALARM This indicates that one or more alarm fault circuits are active The display will automaticall...

Page 50: ...During a timer countdown sequence a different display screen may be selected by pressing the ENTER push button The following timer countdown screens are provided ENG START DELAY XX SEC CRANK PERIOD X...

Page 51: ...se 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 9 2...

Page 52: ...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 53: ...equency and operating hours are displayed simultaneously on this screen LCD DISPLAY FREQ 60 1 Hz HOURS 56783 Hrs Displays generator frequency in hertz HZ The frequency is displayed with a resolution o...

Page 54: ...ENU The programming menu is used to access the MEC 20 s programmable functions such as time delays analog fault settings digital fault settings and calibration Access to the programming sub menus may...

Page 55: ...perating conditions such as start delays cooldown and cranking periods 9 3 2 MANUAL START STOP SEQUENCE When the RUN push button on the front faceplate keypad is pressed an ENGINE START DELAY timer wi...

Page 56: ...a 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 p...

Page 57: ...o transfer to the generator supply Note The neutral delay function is only operative with an electrically held type transfer switch mechanism i e electrical contactor type 9 3 5 3 UTILITY POWER RETURN...

Page 58: ...er 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...

Page 59: ...iated 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 operati...

Page 60: ...MF 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 61: ...gine 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 position will sto...

Page 62: ...tiate a reset command the engine must come to a complete stop and the controller s switch must be placed in the Off position 9 4 4 HORN SILENCE FUNCTION To initiate a horn silence function both EXIT D...

Page 63: ...as required The Factory default number for the read write level is two 2 10 1 3 MASTER READ WRITE MODE User can view modify any programming parameter as well as view modify the security password level...

Page 64: ...mediately upon entering the programming mode To select the desired programming menu press the INCREMENT push button to scroll through the available menu types and once displayed press the ENTER push b...

Page 65: ...al timer 10 3 MAIN PROGRAMMING MENU The main programming menu contains general system configuration programming such as system input voltages currents transformer ratios as well as standard operating...

Page 66: ...20 transformers enter a number of 5 10 3 7 CURRENT SENSING RATIO For current sensing wiring connections from current transformers CT s enter the calculated CT ratio e g when using a 600 5 CT enter a n...

Page 67: ...e engages it again This process will repeat until a speed signal is sensed or cranking time expires whichever occurs first If a speed signal is sensed the cranking output will be maintained until the...

Page 68: ...et crank disconnect speed in percentage of nominal speed i e 30 or 540 RPM on a 1800 RPM engine 10 3 20 OVERSPEED Set overspeed shutdown point in percentage of nominal speed i e 110 or 1980 RPM on a 1...

Page 69: ...und when the controllers operating mode is switched from the Auto position If the Horn is not to sound select program setting no 10 3 26 WARM UP DELAY The WARM UP Delay programming menu appears when t...

Page 70: ...t Thomson Technology for further application information on use with other types of transfer switch mechanisms 10 3 28 RETURN DELAY The Return Delay programming menu appears when the Utility Ready To...

Page 71: ...E PREHEAT WEAK BAT VOLTAGE ENGINE RUNNING LOW OIL PRESS 1 ALARM ATS TEST LOW OIL PRESS 2 SHUTDOWN COMMON ALARM HIGH ENG TEMP 1 ALARM COMMON SHUTDOWN HIGH ENG TEMP 1 SHUTDOWN CAUTION The programming fu...

Page 72: ...zed during the engine start delay and crank cycles and de energized when the engine reaches crank disconnect speed Select the desired cycle lube duration i e on time in minutes 0 999 10 3 34 RESET RUN...

Page 73: ...ed from being activated until the specified time delay period has expired Delay times from 0 0 to 999 9 seconds are available by entering the time required 10 5 DIGITAL FAULT PROGRAMMING MENU To progr...

Page 74: ...an alarm or a shutdown Note All activated alarm and shutdown faults will energize the common fail circuit and sound the alarm horn 10 5 3 ALARM LATCH If an alarm fault was programmed it may be selecte...

Page 75: ...o TRANSIENT TIME 0 1 NOTE A programmable output must also be programmed for IDLE to enable correct operation Refer to Section 5 2 2 for further details 10 5 8 NO LOAD TEST CONTROL DIGITAL INPUT PROGRA...

Page 76: ...ation on field calibration procedures required WARNING Failure to field calibrate and validate the correct operation of the engine oil pressure and engine temperature analog circuits on the equipment...

Page 77: ...e to neutral with the ZERO function selected Use the INCREMENT or DECREMENT push buttons to adjust the correction factor number to obtain zero volts on the right hand side of the display as confirmed...

Page 78: ...d personnel only Failure to do so may cause personnel injury and or death Use the INCREMENT or DECREMENT push buttons to adjust the correction factor number while observing the displayed voltage level...

Page 79: ...r 10 6 5 CURRENT CALIBRATION PROCEDURE NOTE To accurately calibrate the MEC 20 s current sensors an external test AC ammeter and current clamp is required with an accuracy of 0 5 or better Note Zero c...

Page 80: ...ary current exceeds 5 amps and will similarly effect the MEC 20 displayed values In the programming mode scroll to the desired generator supply current phases with the SPAN function selected Connect a...

Page 81: ...Displays the type of calibration function SPAN Displays the calibration correction factor number 0 255 used to obtain the correct voltage reading Displays the actual battery voltage measurement that w...

Page 82: ...factor number 0 255 used to obtain the correct Temperature or Pressure reading Displays the actual temperature or pressure measurement that will be the same value as shown on the MEC 20 display menus...

Page 83: ...fset calibration point Use the INCREMENT or DECREMENT push buttons to adjust the correction factor number while observing the displayed temperature on the MEC 20 Adjust the correction factor number to...

Page 84: ...e is to be done only at a single point which is the normal operating pressure of the engine Connect a temporary engine mounted pressure gauge of suitable accuracy and start the engine Once the engine...

Page 85: ...0 302 150 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 14...

Page 86: ...Custom ________________________ Ext Dig Input 4 Overcurrent Alarm AC Current Ext Dig Input 5 Weak Battery Alarm DC Volts Ext Dig Input 6 Low Battery Voltage Alarm DC Volts Ext Dig Input 7 High Battery...

Page 87: ...PHASE 3 PHASE TOGGLE BETWEEN 1 3 PHASE NEUTRAL 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...

Page 88: ...000RPM FLYWHEEL TEETH ENGINE SPEED SENSING VIA MAGNETIC PICK UP XXX 0 999 TEETH CRANK DISCONNECT XX PERCENT 0 100 OVERSPEED XX PERCENT 100 150 OVERSPEED TRANSIENT X X SEC 0 0 9 9 SEC RUN OUTPUT FAIL S...

Page 89: ...47 Rev 13 05 03 30 83 Thomson Technology MAIN PROGRAMMING MENU PROG OUTPUT 4 PROG OUTPUT 5 PROG OUTPUT 6 WARMUP DELAY 0 99 SECONDS NEUTRAL DELAY 0 99 SECONDS RETURN DELAY 0 999 SECONDS RESET RUN HOURS...

Page 90: ...AC VOLTAGE E S Y N 2 0 UNDER FREQUENCY AC FREQUENCY E S Y Y 5 0 OVER FREQUENCY AC FREQUENCY E A Y N 2 0 OVER CURRENT AC CURRENT E 500 4990 A Y N 20 0 WEAK BATTERY DC VOLTAGE E 18 0 N A A Y N 3 0 LOW B...

Page 91: ...ACTION S SHUTDOWN A ALARM ALARM LATCH Y YES N NO POLARITY O OPEN C CLOSE BYPASS ON START Y YES N NO TRANSIENT DELAY SEC LOW OIL PRESSURE 1 S __ O Y 0 5 HIGH ENG TEMP 2 S __ O Y 1 0 BATT CHGR INPUT FAI...

Page 92: ...ZERO XXX XXXVAC VOLTS C A SPAN XXX XXXVAC VOLTS A N ZERO XXX XXXVAC VOLTS A N SPAN XXX XXXVAC VOLTS B N ZERO XXX XXXVAC VOLTS B N SPAN XXX XXXVAC VOLTS C N ZERO XXX XXXVAC VOLTS C N SPAN XXX XXXVAC CU...

Page 93: ...Speed 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 C...

Page 94: ...T 4 PROGRAMMABLE CONTACT 3 PROGRAMMABLE CONTACT 2 PROGRAMMABLE CONTACT 1 COMMON FAIL CONTACT OPERATES ON AN ALARM OR SHUTDOWN CONDITION IN IC IB IA VN VC VB VA VC VB VA 1A 1A 1A N GRD GENERATOR OUTPUT...

Page 95: ...does 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 20 contains an electronic fuse that triggers upon an...

Page 96: ...is reading incorrectly Verify that the controller has been programmed with the correct values for the voltage sensing PT ratio and or current sensing CT ratio Verify that the battery supply DC negati...

Page 97: ...and Pressure Calibration table for values Verify calibration Engine alarms on high engine temperature or low oil pressure when engine is operating within normal limits Check the wiring from the MEC 20...

Page 98: ...MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER PM047 Rev 13 05 03 30 92 Thomson Technology 15 NOTES...

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