A91 Series MURPHYMATIC Engine Microcontroller Installation and Operation Manual Models A91, A91-S, A91-WC, and A91-S-WC Option -LC (less case)

Transcription

1 A Series MUPHYMATI Engine Microcontroller Installation and Operation Manual Models A, A-S, A-W, and A-S-W Option -L (less case) AN-N Effective - Section (--) Please read the following information before installing. A visual inspection for any damage which may have occur during shipping is recommended. It is your responsibility to have a qualified person install the unit and make sure it conforms with applicable codes. GENEAL INFOMATION WANING BEFOE BEGINNING INSTALLATION OF THIS MUPHY PODUT Disconnect all electrical power to the machine. Make sure the machine cannot operate during installation. Follow all safety warnings of the machine manufacturer. ead and follow all installation instructions. Description The A Series is a state-of-the-art, automatic engine controller. It is used to automatically start and stop internal combustion engine driven equipment. It includes features like, crank and rest cycles, sensing circuit for crank disconnect and overspeed, lockouts, first-out shutdown indication LED's for overcrank, overspeed, high temperature and low lube oil. (Murphy SWIHGAGE instruments are ideal end devices to monitor these functions.) The A can operate from either or VD. With all the A models the customer MUST provide a magnetic pick-up switch. Vrms minimum, such as Murphy s MP magnetic sensor. The A-W model, can operate automation devices such as our: AT throttle actuator, or the O clutch operator. A Series Designation MODELS A A-S A-W A-S-W All of the above DESIPTION For less than amp. up to V electric run output*. For amp. up to V electric run output**. Same A with warmup/cooldown. Same A-S with warmup/cooldown. Less weatherproof (NEMA ) enclosure *un output is the voltage and current required for an ignition system, fuel valve, or actuator that allows the engine to run. **For grounding ignitions. Specifications Power Input: or VD nominal (specify). Input: equires V rms minimum. Input Polarity: Negative (-). Sensor Outputs: Six () open collector transistor ma sink; Two () VD normally open contacts. everse Polarity Protection: volt peak reverse voltage. On-board Memory: k POM (programmable, read only memory). Operating ange: - to F (- to ). Operating Humidity ange: -% Non-ondensing User Trip point Adjustments: Five () on-board potentiometers ( turn). Test-Off-Automatic Toggle Switch: Three position switch for: Test: Starts engine in automatic mode and runs until switched off or emergency shutdown occurs. Off: Disconnects all power to control circuits, Stop/disables engine from starting and resets shutdown indicators. Auto: Automatic start/stop sequencing is initiated by external switches and signals. ycle rank Timer: crank attempts seconds each; rest periods seconds each, before overcrank. Overspeed Trip Point Setting: From - Hz. rank Disconnect Speed Setting: From - Hz. Shutdown Time Delay: seconds after engine start; locks out low lube oil and high temperature. Engine un LED: Turns on when crank disconnect occurs. Shutdown Output: emoves D.. output operates dry contacts for engine shutdown. Start/Stop: SPDT or SPST switches. Warmup Time Delay: Field adjustable from - seconds to load the engine after warmup (model -W only). ooldown Time Delay: Field adjustable from - seconds (model -W only). Enclosure: Weatherproof NEMA. Enclosure oating: ed enamel. Subpanel oating: White enamel. AN-N page of

2 MOUNTING AUTION: THE A SHOULD BE MOUNTED OFF ENGINE (ON A WALL O PEDESTAL). USE A JUNTION BOX TO WIE THE ENGINE SENSOS/ONTOLS (SUH AS FUEL VALVE, MAGNETI PIK-UP, SWIHGAGE AND THOTTLING DEVIE). Mounting the A Panel Select a suitable mounting location for the A that provides easy access to the panel. The A should be mounted away from the engine to avoid shock and vibration. Never mount the A on top of the engine. Enclosure Dimensions A wall or a pedestal are recommended mounting location for the A. To secure the A in place, mounting screws are required (not included). Mounting screws size should be /- (recommended) or larger. efer to the Dimensions schematic, below. Front View Side View Mounting Holes -/ in. in. ( mm) ( mm) -/ in. ( mm) / x / in. ( x mm ) places -/ in. ( mm) onduit hole ( places) / in. ( mm) dia. Front View Side View Mounting Holes in. -/ in. ( mm) ( mm) LOW LUBE OIL HIGH TEMP OVEANK OVESPEED ENG. UNNING TEST OFF Subpanel (Option -L) Dimensions Engine Status Indicating LED s Three position Toggle Switch -/ in. ( mm) in. ( mm) in. ( mm) in. ( mm) in. ( mm) / in. ( mm) / in. ( mm Dia.) places -/ in. ( mm) A INTENAL SHEMATI Sub Panel Assembly (less enclosure) LOW LUBE OIL HIGH TEMP OVEANK OVESPEED ENG. UNNING TEST OFF Enclosure Shown Less Door Description. Enclosure, NEMA. Sub Panel, internal (panel only). Micro-controller ( or V). TEST-OFF-MATI Toggle Switch. Fuse Blocks. or A Fuse(s). Terminal Block -point (marker not shown). elay(s) ( or V). Diode(s). elay(s) Socket(s). Label Faceplate. LED Indication Lights (dress rings). aptive Fastener. IV-Nut. Potentiometers AN-N page of

3 WIING INFOMATION WANING: STOP THE MAHINE AND DISONNET ALL ELETIAL POWE BEFOE BEGINNING INSTALLATION. DISONNET BATTEY S GOUND ABLE DUING WIING. Wiring diagram on pages / show typical engine installations, and the following is by explanation of that wiring. Terminal must be connected to the ungrounded side of the battery (). Terminal must be connected to a good engine ground (-). Terminals and are to be connected to the magnetic pick-up. It is good practice to use a shielded two conductor cable for these connections. Ground the shield to a good engine ground, or connect to. Terminal is an optional connection to the low lube oil shutdown SWIHGAGE or other device. (Pressure, level, etc.) Terminal is an optional connection to the high engine temperature shutdown SWIHGAGE or other device. (, level, etc.) Terminal is an optional connection for battery charging alternator excitation. Terminals - must be connected to the start and stop inputs. These s can be connected for two different type of circuits. (See drawings, p-/.) Single Pole Single Throw (close to run, open to stop) a. onnect to a good engine ground. b. onnect to the start contact. Start contact should be grounded. Single Pole Double Throw (on-off-on, or on-off) a. onnect to the normally closed (stop). b. onnect to the normally open (start). c. onnect common to a good engine ground. Terminal - - are reserved for the A-S option, and are used to power up, or ground out higher voltage or current ignition systems, or higher current operators. See supplement drawing on pages and. Terminal must be connected to an energized-to-run device, not to exceed amps in current. This device can be: a. An ignition coil, or ignition module. b. A fuel valve. c. A operator. d. A pilot for any of the above. Terminal,, and are reserved for the A-W option, and are used to operate throttle, or clutch engagement devices. See supplement drawing, p- and. Terminal must be connected to starter pilot. TO SELET THE TYPIAL WIING DIAGAM FO YOU APPLIATION, SEE TYPIAL WIING DAW- INGS ON PAGES AND. AUTION: BEFOE PEFOMING THE SEQUENE OF OPEATION, MAKE SUE THE OMPLETE A IS POPELY MOUNTED AND INSTALLED. HEK ALL ELETIAL WIING ONNETIONS. EPLAE ALL OVES, LIDS AND ENLOSUES BEFOE APPLYING POWE TO THE A. STAND LEA OF MAHINE AT ALL TIMES WHEN IT IS OPEATING. Toggle Switch Functions TEST: When in the TEST position, the automatic start and run sequences initiate. The A will perform its operations as though an automatic start signal was received. The engine will remain in operation until the selector is moved to the OFF position and will shut down immediately. OFF: Disconnects control power to prevent the engine from starting/running. Provides an immediate shutdown when the selector is placed to OFF. (matic): As described in the sequence of operations. TO ESET: Turn the selector switch to OFF, and wait for seconds. eturn to the or TEST position. To Start the Engine NOTE: The A features a field adjustable time delay (from to sec.) that delays both, the start and stop periods equally.. Move the toggle switch to the position.. When a momentary start signal is applied to the A start input (. sec. approx.), an automatic start sequence will occur. a. () is supplied to for alternation excitation. b. Ignition or fuel valve power is supplied to, ready for engine start, for magneto/ignition, is ungrounded (-S models only). c. The overspeed shutdown circuit is armed immediately. d. ycle cranking begins: battery () is alternately supplied to to crank the engine for seconds and rest for seconds until engine starts or the overcrank circuit operates. NOTE: If engine refuses to start after cranking attempts, the Overcrank LED will light, and the A will shut down and lock out. The LED and lockout circuits must be manually reset by turning toggle switch to OFF, then back to or TEST, before the A resumes normal operation.. When the engine speed rises above the adjustable crank disconnect speed setting, the automatic run sequence begins. a. ycle cranking is discontinued immediately and is indicated by the Engine running green LED. b. Two timer periods begin.. The oil pressure and engine temperature shutdown lockout time delay begins. If the engine dies before the second time delay expires, the A will wait seconds before attempting to restart. SEQUENE OF OPEATIONS AN-N page of. The warm up time delay begins (field adjustable from to sec. on -W models only.) c. When the time delay expires, the oil pressure and engine temperature shutdowns are armed. If engine dies after the sec. time delay expires, the A will shut down/lock out turning ON both the overcrank and overspeed LED's indicating loss of speed/speed signal, requiring manual reset. Shutdown and Lockout When a SWIHGAGE senses low oil pressure or high temperature, it signals the A to shut down immediately. An LED will indicate the shutdown. Manual reset is required before resuming normal operation. Overspeed A overspeed sensing circuit will trip the overspeed LED and shutdown the engine. Manual reset is required before resuming normal operation. d. When the warm up time delay expires: (model -W only).. An SPDT contact, connected to s, and operates the loading device (throttle control, clutch actuator, etc).. When a stop signal is received at the A (for approx.. sec.), an automatic stop sequence begins: a. The SPDT contact connected to s,, and resets to actuate loading devices to unload the engine and reduce the speed to a cooldown condition. (Model -W only.) b. ooldown time delay begins: (field adjustable - sec. Model -W). After the cooldown time delay expires (Model-W only.) c. All shutdown circuits are locked out. d. Ignition or fuel valve power is removed from to stop the engine. For magneto ignitions the is grounded (Model -S). e. ontrol circuits automatically reset for next start sequence. LED's: Light Emitting Diodes indicate the cause of shutdown and lockout for: LOW LUBE OIL HIGH TEMPEATUE OVEANK OVESPEED NOTE: When both the overspeed and the overcrank LED's are lit, the engine died for some unknown reason, or the engine reference speed signal (magnetic pick-up) was lost.

4 FIELD ADJUSTMENTS WANING: EMOVE POWE BEFOE OPENING THE ENLOSUE AESS DOO AND THE SUB PANEL HINGED. DO NOT ATTEMPT TO ADJUST THE POTENTIOMETES WHILE THE MAHINE IS UNNING. IT IS YOU ESPONSIBILITY TO HAVE A QUALIFIED PESON ADJUST THE UNIT, AND MAKE SUE IT ONFOMS WITH NE AND LOAL ODES AND ODINANES. The Potentiometers ADJUSTMENT DETAIL The () potentiometers are mounted on the ASM- Increase printed circuit board, behind the hinged internal subpanel, at the bottom of the PB. See the A Internal Schematic (page ). Potentiometers are assigned as follows: Warm up delay: Adjustable from sec. Decrease ooldown delay: Adjustable from sec. rank disconnect: Adjustable from, hertz. Turn the potentiometer fully clockwise, loosen the crank wire at (causes the engine to start and immediately disconnects the crank wire to prevent further cranking). Slowly turn potentiometer counterclockwise until the green LED (UN) turns on. This adjustment must be completed within seconds, or the engine will shut down and indicate OVEANK. Simply enable starter circuit, manually reset the A, and try again. Overspeed: Adjustable from, -, hertz. Start and Stop delays: Adjustable from sec., (both delays). Adjusting the Potentiometers To make adjustments, turn the potentiometer clockwise to increase the value and counterclockwise to decrease it. See the Adjustment Detail (left) and the Factory Setting schematic (below). To Obtain Frequency (Hertz) Value To obtain the frequency (Hertz) value, multiply the number of teeth on the starter, times the PM value, and divide the result by seconds. Example: If the starter is to disconnect at PM, and the has teeth, use the formula: x = Hertz NOTE: Follow the same formula for the overspeed settings. Factory settings for A- and A--S models S S S S S S S S S S S S S S S S S S S S S S * S S * S ** ** S ** S Factory settings for A--W and A--S-W models S S S S S S S S S S S S S S S S S S S S S S * S S * S ** ** S ** S *The dial calibrations are in seconds and are approximate **The dial calibrations are in hertz and are approximate TESTING THE A WITHOUT UNNING THE ENGINE Tools Needed: small lights with wire leads and bulbs rated the same voltage as the starting battery. screwdriver (medium). A signal generator or a plug-in transformer with a maximum secondary voltage of VA (such as a ADIO SHAK -,or -). jumper wire inches ( mm) long. onnections. Turn the A toggle switch to OFF.. Set potentiometer to its lowest setting (fully counterclockwise).. Disconnect wires from s and and connect the signal generator/plug-in transformer instead.. Disconnect the wire from and connect one wire from one of the lights instead. Ground the other lead and label crank.. Disconnect the wire to and connect one wire from the other light instead. Ground the other lead and label ignition.. Disconnect shutdown switches from s and.. Ground one end of your inch ( mm) jumper. Testing. Turn toggle switch to TEST. Ignition light should turn ON.. rank light should turn ON for seconds, and OFF for seconds and repeat this sequence for tries. The OVEANK LED should turn ON, and turn OFF the ignition light.. eset OVEANK lockout. Move toggle switch to TEST.. Sequence will begin. After one or two crank cycles adjust your signal generator to hertz, or plug-in the transformer. The crank light should turn OFF, and ignition light should turn ON.. Wait for seconds, then with your jumper ground-out, the ignition LED should turn OFF, and the low lube oil LED should stay ON.. eset and repeat. This time ground out to test the high engine temperature lockout.. epeat and. Move the selector to OFF. The ignition light should turn OFF.. All other devices should operate as if the engine was running.. e-connect your original wiring. AN-N page of

5 A INTENAL WIING DIAGAMS F- K F- K K F- A-W ASM- Micro-controller A-S-W ASM- Micro-controller D- F- OFF S S G G TEST G S- F- D- F- OFF S S G G TEST G S- NOTES: F- (fuse )= A F- (fuse )= A F- (fuse )= A D-(diode )= A = rimp S = Solder (all other connections are tinned) = ga. red G = ga. green (all other wiring is ga. orange) NOTES: NOTES: F- (fuse )= A F- (fuse )= A F- (fuse )= A D-(diode )= A = rimp S = Solder (all other connections are tinned) = ga. red G = ga. green (all other wiring is ga. orange) NOTES: F- (fuse )= A F- (fuse )= A F- (fuse )= A D-(diode )= A = rimp S = Solder (all other connections are tinned) = ga. red G = ga. green (all other wiring is ga. orange) F- F- K F- A D- ASM- F- OFF Micro-controller S S G TEST G G S- A-S F- D- ASM- Micro-controller F- OFF S S G G TEST G S- AN-N page of F- (fuse )= A F- (fuse )= A F- (fuse )= A D-(diode )= A = rimp S = Solder (all other connections are tinned) = ga. red G = ga. green (all other wiring is ga. orange)

6 TYPIAL WIING DIAGAMS WANING: STOP THE Engine AND DISONNET ALL ELETIAL POWE BEFOE BEGINNING the wiring installation. DISONNET BATTEY S GOUND ABLE DUING WIING. Do not bundle sensor inputs wiring with any other wiring. A Terminal For Spark Ignition Engines with high current, battery powered distributor, less than A. For Spark Ignition Engines with low current electronic module and battery powered distributor, less than A. A Terminal egulator (see note ) High egulator (see note ) High charger (see note ) Distributor ignition resistor (see note ) charger (see note ) Distributor ignition resistor (see note ) Spark plug Ignition coil Spark plug Ignition coil. pressure and water temperature SWIHGAGE instruments are shown for simplicity.. A Delco brand alternator is shown for illustrative purposes. All alternators will operate with the A series microcontroller. The A provides excitation current for ALL alternators.. Leave ignition resistor or resistor wire in place, and only wire to these resistive devices. For Spark Ignition Engines with Magneto Ignition, break point type, high or low tension.. pressure and water temperature SWIHGAGE instruments are shown for simplicity.. A Delco brand alternator is shown for illustrative purposes. All alternators will operate with the A series microcontroller. The A provides excitation current for ALL alternators.. Leave ignition resistor or resistor wire in place, and only wire to these resistive devices. For Spark Ignition Engines with apacitor Discharge (D) type breakerless ignitions. A Terminal A Terminal Ignition resistor (see note ) egulator charger (see note ) High (see note ) egulator charger (see note ) High (see note ) Spark plugs Fuel gas valve (see note ). pressure and water temperature SWIHGAGE instruments are shown for simplicity.. A Delco brand alternator is shown for illustrative purposes. All alternators will operate with the A series microcontroller. The A provides excitation current for ALL alternators.. A fuel gas valve can be installed in the fuel gas line for all gas fire spark ignition engines. AN-N page of apacitor discharge ignition (see note ). pressure and water temperature SWIHGAGE instruments are shown for simplicity.. A Delco brand alternator is shown for illustrative purposes. All alternators will operate with the A series microcontroller. The A provides excitation current for ALL alternators.. A high and low tension magnetos can be killed by grounding directly as shown. apacitor discharge ignition systems also called solid-state and breakerless, can be killed by grounding through a ohm, watt resistor as shown.

7 TYPIAL WIING DIAGAMS WANING: STOP THE Engine AND DISONNET ALL ELETIAL POWE BEFOE BEGINNING the wiring installation. DISONNET BATTEY S GOUND ABLE DUING WIING. Do not bundle sensor inputs wiring with any other wiring. For Diesel Engines with Fuel Solenoid Valve, low current below A, external or built-in injection pump A Terminal A Terminal For Diesel Engines with energized to run work, () wire. egulator charger (see note ) elay (see note ) High Pilot elay Hold (red) Ground (black) Fuel shutoff vlve (see note ). pressure and water temperature SWIHGAGE instruments are shown for simplicity.. A Delco brand alternator is shown for illustrative purposes. All alternators will operate with the A series microcontroller. The A provides excitation current for ALL alternators.. Fuel shutoff can be separate valve installed in fuel line or energized to run built into injection egulator charger (see note ) High (see note ) stop to lever run Energized (white) Hold (red) Ground (black) Energized to run work (see note ). pressure and water temperature SWIHGAGE instruments are shown for simplicity.. A Delco brand alternator is shown for illustrative purposes. All alternators will operate with the A series microcontroller. The A provides excitation current for ALL alternators.. Work can be installed on diesel engines to work-to-run lever for automatic control. TYPIAL WIINGS FO ALL -W (WAMUP /OOLDOWN) MODELS WANING: STOP THE Engine AND DISONNET ALL ELETIAL POWE BEFOE BEGINNING the wiring installation. DISONNET BATTEY S GOUND ABLE DUING WIING. Do not bundle sensor inputs wiring with any other wiring. A Terminal Block Murphy's AT- Throttle actuator To battery positive NOTE: The throttle actuator increases the engine speed at the end of the warmup period, and decreases the speed at the start of the cooldown period. If the throttle controller moves in the opposite direction than desired, reverse wires at # and # on the A, or s # and # at the throttle actuator. The dotted line represents the (typical) basic wiring shown on the installation drawings, pages /. Only one device is required. ontact Murphy for details A Terminal Block To battery positive Murphy's O- lutch operator NOTE: The clutch operator engages the clutch at the end of the warmup period, and dis-engages at the start of the cooldown period. The dotted line represents the (typical) basic wiring shown on the installation drawings, pages /. AN-N page of

8 TYPIAL WIINGS FO EMOTE STAT AND STOP IUITS WANING: STOP THE Engine AND DISONNET ALL ELETIAL POWE BEFOE BEGINNING the wiring installation. DISONNET BATTEY S GOUND ABLE DUING WIING. Do not bundle sensor inputs wiring with any other wiring. A Terminal Block Single Start and Stop contact ontact closes to start and run. ontact opens to stop. Dotted wiring is the wiring shown on the typical wiring diagrams (p-/) A Terminal Block Dual Start and Stop contact (SPDT) Stop Start ommon Momentary close one contact to start and run. Momentary close other contact to stop. Dotted wiring is the wiring shown on the typical wiring diagrams (p/) A SEVIE PATS A, A-S, A-W, and A-S-W PAT NO. DESIPTION PAT NO. DESIPTION -- Enclosure, NEMA -- Terminal -point -- Sub panel, internal (panel only) -- Marker, -- Micro-controller ASM--P-A- ( V) -- V -- Micro-controller ASM--P-A- ( V) -- V -- TEST - OFF - (matic) toggle switch -- Diode -- Fuse s -- elay socket -- A fuse -- Label faceplate -- A fuse -- LED dress ring -- aptive fastener -- IV nut Warranty A limited warranty on materials and workmanship is given with this FW Murphy product. A copy of the warranty may be viewed or printed by going to FW Murphy P.O. Box Tulsa, Oklahoma USA fax sales@fwmurphy.com ONTOL SYSTEMS & SEVIES DIVISION P.O. Box ; osenberg, Texas ; USA fax sales@fwmurphy.com MUPHY DE MEXIO, S.A. DE.V. Blvd. Antonio ocha ordero, Fracción del Aguaje San Luis Potosí, S.L.P.; México fax Villahermosa Office ventas@murphymex.com.mx AN-N page of FANK W. MUPHY, LTD. hurch d.; Laverstock, Salisbury SP QZ; U.K. fax sales@fwmurphy.co.uk MUPHY SWITH OF ALIFONIA th Street West Palmdale, alifornia -; USA fax sales@murphyswitch.com MAQUAIE OPOATION Hume Highway ampbellfield, Vic ; Australia fax murphy@macquarrie.com.au In order to consistently bring you the highest quality, full featured products, we reserve the right to change our specifications and designs at any time. E GISTE ED USA ISO : FM UK ISO : FM Printed in U.S.A.