Controls EMGRT1 User manual

Product Manual
Programmable Microprocessor-Based Pump Controller
for Mechanical Diesel Engines
Part Number: EMGRT1
Customer: The Gorman Rupp Company
Revision: 2.0
______________________________________________________________________________________________________________________________________
Copyright ©Controls, Inc.
P.O. Box 368 • Sharon Center, OH 44274
Phone [phone] • Fax [phone] • www.controlsinc.com

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Basic Controller Operation
A. Manual Engine Start / Stop
1. For manual start, put key switch in “Run” position and press “Enter” button to crank
engine. When engine is started manually, the controller will operate. To stop the engine,
the key needs to be switched to the “Off” position.
B. Automatic Engine Start / Stop
1. For auto start, place key in the “Auto” position. When the single or dual float circuit is
closed closed, the controller will begin the engine start sequence. When the single or dual
float circuit is opened, the controller will shut the engine off.

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1) Introduction
1.1 The EMGRT1 is a microprocessor-based controller for industrial electronic engines with J1939 CAN Bus. It
is based on the Controls, Inc. 1410-000 series controller platform with Motorola/Freescale processor.
1.2 The product is housed in an 8”W x 8”H x 4”D polycarbonate enclosure that is rated NEMA 4X. The
controller is plug & play with all engine and accessory connectors incorporated into the enclosure.
1.3 The backlit digital display is 1”H x 4”W with two rows of 16 characters. Character height is approximately ½”.
1.4 The controller is manual and auto start capable. Auto start and stop can be via:
1.4.1 Single Float
1.4.2 Dual Float
1.5 Controller specific inputs/alarms are available for E-Stop (Digital), Fuel Level (Analog) with corresponding
engine shutdown, LED illumination and digital display message.
1.6 Controller is independent and does not require connection to a laptop computer to change programmable
settings.

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2) Interface
2.1 Display – The backlit digital display is 1”H x 4”W with two rows of 16 characters. Character height is
approximately ½”.
2.2 Display Parameters – The six full-time display parameter are:
· Water Temperature (Degrees F) · Battery Voltage
· Engine RPM · Fuel Level (if fuel level sender installed)
· Oil Pressure (PSI) · Engine Hours
2.3 Menu & Enter Buttons – To access and scroll menus.
2.4 Up / Down Buttons – For menu navigation.
2.5 Key Switch – Auto / Off / Run
2.6 Fuse – 10 amp fuse
2.7 Amber (Pre Alarm) LED and Red (Alarm) LED located above the digital display.
Digital
Display
10 Amp
Fuse
Auto/Off/Run
Key Switch
Keypad
Buttons

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3) Enclosure
3.1 The product is housed in an 8”W x 8”H x 4”D polycarbonate enclosure that is rated NEMA 4X.
3.2 The enclosure is hinged. Door is held by four screws that are removable for internal access.
3.3 The controller is plug & play with all engine and accessory connectors incorporated into the enclosure.
These connections include:
• Engine Harness Connector – 16 Pin Deutsch Plug
• Float Connector – Pollack Single / Dual Float. Use two normally open contacts
which when both closed will start the engine. When the low contact open, the
engine will stop.
Engine Harness
Connector Dual Float Connector

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4) Engine Start & Stop
4.1 The controller is manual and auto start capable.
4.1.1 Manual Start – With the key in the manual start position, a display message of “Press Enter to Start”
will appear. Pressing the Enter button will crank the engine. The engine is shut down by turning the
key to the Off position.
4.1.2 Auto Start - Single or Dual Float - USE TWO NORMALLY OPEN CONTACTS WHICH WHEN BOTH
ARECLOSED, THE CONTROLLER WILL START THE ENGINE. WHENTHE LOW FLOAT OPENS,
THE ENGINE WILL BE STOPPED.
5) Engine Speed Control (Throttle Control)
5.1 None
6) Engine Faults
6.1 Engine Faults - In the case of an engine parameter is measured outside of the normal operating range, the
control panel will shut the engine down by opening the run circuit. A red LED will illuminate above the LCD
display and the LCD will display a text message describing which shutdown occurred.
6.1.1 Low Oil Pressure - Engine shutdown if below 15 PSI for 5 seconds.
6.1.2 High Engine Temperature – Engine shutdown if above 235 degrees F for 5 seconds.
6.1.3 Over Speed – Engine RPM is above 2550 for 1 second.
6.1.4 Low Fuel Level – Fuel Level is measured below 1% for 5 seconds.
7) Controller Specific Alarms
7.1 The controller monitors additional “system” inputs directly including:
7.1.1 Emergency Stop (Digital) - An Emergency Stop button can be attached to Term 12 on the control
board. Use a normally open button, which closes to ground. A shut down will occur when active.
7.1.2 Fuel Level Sender (Analog) - A Fuel Level Sender can be attached to Term 7 on the control board.
Use a 240 to 33 ohm scale for a 0 to 100% display. Attaching a fuel sender will automatically change
the LCD to display Fuel Level. A pre alarm is programmed at 20%. A shutdown is programmed at
1%.
7.1.3 Low Water Level Switch (Digital) - A Low Water Level switch can be attached to Term 5 on the control
board. Use a normally open switch, which closes to ground. A shut down will occur when active.
7.1.4 Low Oil Level Switch - A Low Oil Level switch can be attached to Term 6 on the control board. Use a
normally open switch, which closes to ground. A shut down will occur when active.
7.2 In the case of a fault, the engine will be shut down, the red LED will illuminate and a message will appear on
the digital display defining the specific shutdown condition.
7.3 To clear alarms, it is necessary to eliminate the cause of the alarm and cycle power to the controller (turn off
and back on).

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8) External Connectors
8.1 Engine Connection - The controller is connected to the engine via a 16-pin Deutsch plug. The pin out for the
engine harness is shown below.
Pin S Battery + to Controller Pin H Temperature
Pin D Battery + to Start Slave Relay Pin C Oil Pressure
Pin F Battery - Pin G Battery + to Alt. Excite
Pin R Battery + to Fuel Solenoid Pin J Battery + to Pre Heat Relay
Pin P MPU + Pin A MPU -
8.2 Float Connection - The controller is connected to the float system via a four pin, Pollack plug. The pin out for the
engine harness is shown below. All float contacts are assumed Normally Open.
8.2.1 Single Float Connection – Connect Float between terminals 1 and 3.
8.2.2 Dual Float Connection – Connect Low Float between 1 and 4. Connect High Float between 2 and 3.
1
3
2
4

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9) Controller Menus
9.1 The control panel has menus to view engine and controller parameters. These menus are accessible via a
four-button pad located on the face of the control panel.
9.2 Available Menus
Sender Configuration: Speed signal and overspeed settings.
Control Functions: Glow plug and auto start settings.
Discrete Input Configurations (View only)
9.3 Menu Access & Navigation
9.3.1 Entering Menus
1. Press and hold the MENU key & simultaneously press the ENTER key.
9.3.2 Navigation
1. Press MENU to select the next menu category.
2. Press UP to view or edit the specific screen(s) in the category.
3. Use the UP and DOWN keys to move among the screens in the category.
4. Press MENU at any time within a category to jump back to the inner ring
9.3.3 Password Entry
The password screen is provided to restrict the edit of sensitive values to authorized personnel.
Not entering a password permits viewing, but no editing of restricted values. Upon encountering
the password screen, a series of dashes will be displayed. To enter the password:
1. Press ENTER to begin editing. The password zeroes will be bracketed.
2. Use the UP and DOWN keys to set the first (leftmost) digit, as you would for a cylinder
combination lock.
3. Press ENTER to freeze that digit and move to the next one on the right.
4. Repeat steps 2 and 3 until all digits have been set. After the final digit is set, the brackets
automatically disappear.
5. Press the UP key to proceed to the next screens.
If the correct password was entered earlier, navigating back over the password entry screen will
show the password as a row of stars. The password approval state is retained as long as the
panel is powered up.
9.3.4 Editing
Some screens permit parameter changes.
1. Press ENTER to start editing. The value on the screen will be surrounded by brackets. On
password-protected screens, brackets appear only when the correct password was entered
earlier.
2. Use the UP and DOWN keys to adjust the value. In the case of a selection list, the various
possible selections will be shown in a ring. In the case of a variable number, press the
appropriate key to step up/down. For larger changes, press and hold the UP or DOWN key.
(The value will step faster as the key is held down. Stepping will stop when preset value limits
are reached or the key is released.)
3. Press ENTER to save the new value. The brackets will disappear.
4. To skip the edit and retain the old value, press MENU instead of ENTER.
9.3.5 Exiting
1. Press and hold the MENU key & simultaneously press the ENTER key.
Leaving during editing will abandon the edit and the old value will be retained. Exiting has no effect
on the password approval. To clear the approved password state, power cycle the panel.

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9.4 Reset to Factory Settings – The factory default settings can be reset in two ways:
9.4.1 Reset Procedure (See picture below)
1. Turn the key to the Auto position.
2. Open the enclosure to access the circuit board.
3. Make connection between two pins labeled “JP10” with screwdriver.
4. Push micro button down and release.
Reset Button
JP10 Pins
Speed Cal
Button

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9.5 Factory Settings
Engine Settings
Sender Type LLPA LLA HLPA HLA
Speed MPU Na Na Na 2550
Oil Press SW to PSI 20 15 Na Na
Engine Temp SW to F Na Na 230 235
Fuel Level SW to % 20 1 Na Na
Battery Analog 12/24 15/30
LLPA = Low Level Pre Alarm HLPA = High Level Pre Alarm
LLA = Low Level Alarm HLA = High Level Alarm Na = Not Activated
Control Settings
Parameter Setting PA A AWRO
Number of Cranks 5
Crank Duration 10 Sec
Crank Rest
Duration 10 Sec
Optional Digital
Inputs
Digital Input 1 Low Water Level Na Yes
Digital Input 2 Low Oil Level Na Yes
PA = Pre Alarm A = Alarm AWRO = Alarm While Running Only
RPM Calibration (Speed Set Procedure)
Your control system may need to be calibrated to display the correct RPM on the LCD.
1) After installing control system, start the engine and set the speed to 1500 RPM using an external
tachometer. (The EMGRT1 is shipped from factory with 30 teeth flywheel setting.)
2) Press the circuit board mounted button labeled SW3. It is located next in the upper right corner of the pcb.
3) The controller will calculate the correct number of pulses per revolution to obtain an accurate RPM display.
The crank disconnect and over speed settings are also calculated from this calibration.

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10) Terminal Strip Connections
10.1 Below is a list of connection definitions for circuit board mounted terminal connectors
10.1.1 PCB Version 1410-000 V1.4.
1 Battery Positive 16
2 Battery Negative 17 Power to Fuel System (10A DC Max)
3 MPU+ 18 Battery Positive Relay Common
4 MPU- 19
5 Fuel Level Sender 240-33 ohm 20 Alternator Excite (D+)
6 Low Water Level Switch 21 Power Crank Solenoid (10A DC Max)
7 Low Oil Level Switch 22 Fault Common
8 Remote Start Input 23 Fault Normally Open
9 Engine Temp Sender 24 Fault Normally Closed (5A DC max)
10 25 Pre Alarm Common
11 Oil Pressure Sender 240-33 ohm 26 Pre Alarm Normally Open (5A DC max)
12 Emergency Stop 27
28 Glow Plug Normally Open (5A DC max)
Engine / System Inputs Engine Operation Outputs

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10.2 TTL Outputs
10.2.1 When active the outputs sink to 0 VDC.
10.2.2 When not active, the outputs stay at +5 VDC
39 Low Oil Pressure Shutdown
40 High Temp Shutdown
41 Low Fuel Level Shutdown
42 Over Speed Shutdown
43 Over Crank Shutdown
44 Engine Run Indicator

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11) Dipswitches
11.1 Dipswitch Definitions
Dipswitch 1 Not Used
Dipswitch 2 Not Used
Dipswitch 3 Not Used
Dipswitch 4 Not Used
Dipswitch 5 Turn ON to enable the Self Charging Battery System (SCBS)
Dipswitch 6 Not Used
Dipswitch 7 Not Used
Dipswitch 8 Not Used
NOTE: Glow plug and auto start time delays are enabled via the “Sender Configuration” menu.
11.2 Changing Dipswitch Settings - When making a dipswitch setting change, it is necessary to cycle the power
to the controller before the new setting becomes active. (except dip switch 2)
12) Self Charging Battery System
The Self Charging Battery System (SCBS) included with this control is designed to maintain a high level of battery
capacity during extended periods of standby operation. However, care must be taken when using this system due
to the ability of the control to start and run the engine while in the “Auto” mode.
Conditions
1) Control must be in “Auto”.
2) Dipswitch 5 must be in the ON position.
3) Displayed DC Voltage must be at or below 12.2 VDC for 1 minute.
Results
1) Control will begin the 8-second countdown to starting.
2) Control will start and run the engine at the programmed Warm Up speed for 15 minutes. During this run the
display will flash a message of “Engine Start Low Battery Charge”.
3) Control will stop the engine and wait a minimum of 60 minutes before the SCBS will initiate another run.

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13) Warranty
CONTROLS, INC. is herein called “Seller”. The person, firm or corporation to whom or which the sale is
made is herein called “Buyer”. Seller warrants to the Buyer that all products furnished under this order
will conform to Seller’s specification, drawings as described in its current catalog or quotation and will be
free from defects in materials and workmanship. Seller must approve other special requirements asked
for by the Buyer in its purchase order in writing. Parts replaced or repaired in the warranty period shall
carry the unexpired portion of the original warranty. The foregoing is subject to the provisions that in no
case will the total warranty period extend beyond twelve (12) months from date seller ships equipment
from point of sale.
The Liability of Seller hereunder is limited to replacing or repairing at Seller’s factory any part or parts
which have been returned to the Seller and which are proved by buyer as defective or not conforming to
Seller’s specifications, drawings or other written descriptions, accepted by Seller, provided that such part
or parts are returned by the buyer within thirty (30) days after such defect is discovered. All items
returned to Seller for repair or replacement must be sent freight prepaid to its factory. Buyer must obtain
Seller’s Return Goods Authorization prior to returning items. The above conditions must be met if
warranty is valid. Seller will not be liable for any damage done by unauthorized repair work, unauthorized
misapplication in non-suitable environment.
In no event shall the Seller be liable for loss, damage, or expense directly or indirectly arising from the
use of the units, or from any other cause, except as expressly stated in the warranty. Seller makes no
warranties, express or implied, including any warranty as to merchantability of fitness for a particular
purpose or use. Seller is not liable for and buyer waives any right or action it has or may have against
seller for any consequential or special damages arising out of any breach of warranty, and for any
damages buyer may claim for damage to any property or injury or death to any person arising out of its
purchase or the use, operation or maintenance of the product. Seller will not be liable for any labor
subcontracted or performed by buyer for preparation of warranted item for return to Seller’s factory or for
preparation work for field repair or replacement. The Seller will not consider invoicing of Seller for labor
either performed or subcontracted by buyer as a liability. This warranty shall be exclusive of any and all
other warranties express or implied and may be modified only by a writing signed by an officer of the
Seller. With respect to accessories supplied by Seller, but manufactured by others, there is no warranty
of any kind, express or implied, and specifically there is no warranty of merchantability or fitness, except
as may be set forth in any warranty the manufactures have made to Seller and which can be passed to
the Buyer.