EMS EMS372 User manual

EMS372
GCU/3AS
Genset Controller
User Manual
This document applies to:
9001-0104
Build version
3600-0168
Firmware Version
5000-0046 (V3.G.3D)
Version History:
S. No.
Version No.
Changes Made
Date Modified
Modified By
Approved By
1
2
3
www.ems.gen.nz
The information contained in this document is copyright, and
shall not be reproduced without the written authority of EMS
©2008

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Contents
1. Introduction ...............................................................................................................................4
2. Benefits .....................................................................................................................................4
3. Physical Form .............................................................................................................................5
4. Functions ...................................................................................................................................6
4.1 System...............................................................................................................................6
4.2 Engine Monitoring...............................................................................................................6
4.3 Generator AC Monitoring.....................................................................................................7
4.4 Mains AC Monitoring...........................................................................................................8
4.5 System LED Indications ........................................................................................................8
4.6 System LCD Displays ............................................................................................................8
4.7 Engine LCD Displays.............................................................................................................8
4.8 Genset LCD Displays ............................................................................................................9
4.9 Mains AC LCD Displays.........................................................................................................9
4.10 AC Inputs............................................................................................................................9
4.11 Analog Inputs......................................................................................................................9
4.12 Digital Inputs ....................................................................................................................10
4.13 Special Inputs ...................................................................................................................10
4.14 Digital Outputs..................................................................................................................10
5. Operation ................................................................................................................................11
5.1 Buttons ............................................................................................................................11
5.2 LEDs ................................................................................................................................11
5.3 Password Access ...............................................................................................................12
5.4 Initial Power Up ................................................................................................................12
5.4.1 Ready...........................................................................................................................12
5.4.2 Mode Selection .............................................................................................................12
5.5 Manual Operation.............................................................................................................12
5.5.1 To start the genset.........................................................................................................12
5.5.2 To stop the genset .........................................................................................................13
6. Automatic Operation.................................................................................................................14
7. Display Operation .....................................................................................................................15
7.1 When the genset is ready...................................................................................................15
7.2 When the genset is running................................................................................................15
8. Alarms and Warnings ................................................................................................................17
8.1 Inputs Electrical Specification .............................................................................................20
8.2 Outputs Electrical Specification...........................................................................................22
9. Load Transfer and Contactor Operation.......................................................................................22
9.1 Battery Charging Alternator Excitation.................................................................................23
9.2 Battery Voltage Monitoring and Charging Detection..............................................................23
10. Set-up .................................................................................................................................24
10.1 Navigating in the setup menu .............................................................................................24
10.2 System Column .................................................................................................................25
10.3 Engine Column..................................................................................................................25
10.4 Timers Column..................................................................................................................29
10.5 Contactor A Column ..........................................................................................................30
10.6 Start/Stop Column.............................................................................................................30
10.7 AC Setup Column ..............................................................................................................31
10.8 AMF Setup Column............................................................................................................31
10.9 AGF Setup Column ............................................................................................................32
10.10 I/O Setup Column..............................................................................................................33

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10.11 Comms (Communications) Setup Column.............................................................................33
11. Communications...................................................................................................................34
11.1 Unit General Specifications.................................................................................................34
12. Installation and Wiring ..........................................................................................................36
12.1 Connector Detail ...............................................................................................................37
13. Trouble shooting ..................................................................................................................38
14. Wiring Options .....................................................................................................................41
15. Engine Sensor Tables.............................................................................................................42

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EMS372
Genset Controller
1. Introduction
The EMS372 is a custom designed controller gensets sold in the private market segment.
The unit incorporates both manual ,autostart and AMF(Automatic Mains Failure) initiated start
and stop sequencing, monitors engine and alternator operating parameters and provides both
engine and alternator protection, in a single integrated package.
The genset operating parameters are shown by scrolling screens on a backlit 16 Character by 2
line LCD. Alarms and warning are also shown on the LCD and supplemented by an alarm LED
and Hooter output. The unit has provided Passwords for security purposes.
The unit provides comprehensive monitoring of the engine and generator operating
parameters and provides automatic shutdown of the set in the event of damaging conditions.
In addition to the usual engine safety protections the unit monitors water level, fuel level,
engine temperature, canopy temperature, oil pressure its supports perheat and generator
loading to provide even more comprehensive protection.
The unit incorporates an Event Log (20 events)and a Stop Alarm Log (40 events) to give the
field service engineer the operational history and alarm history for easier diagnostics.
In the factory environment, the unit is configured by cloning through a PC system. Field
specific parameters can be adjusted by using the front panel buttons and an inbuilt menu
system.
2. Benefits
Reduces system cost:
oIntegrates engine gauges and AC metering into one unit.
oMinimises control panel wiring offering reduced material and labour costs.
Reduces warranty costs by providing comprehensive engine and generator protection
and a maintenance due timer.
Flexible, the unit can be customised by PC cloning for individual genset model
characteristics and fitments.
Includes communications port for remote monitoring applications or dual station
operation.

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3. Physical Form
Front View
Back View

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4. Functions
4.1 System
Function
Description
Protection Shutdown
Automatic preventative engine and genset shutdown in the event
of abnormal operating conditions with optional configuration
parameters and clear LCD status messages
Manual Start
In response to the front panel pushbutton performs a fully
sequenced engine start with optional configuration parameters and
clear LCD status messages
Manual Stop
In response to the front panel pushbutton performs a fully
sequenced engine stop with optional configuration parameters and
clear LCD status messages
Auto Start
In response to a digital input performs a fully sequenced engine
start with optional configuration parameters and clear LCD status
messages
Auto Stop
In response to a digital input performs a fully sequenced engine
cool down then stop with optional configuration parameters and
clear LCD status messages
AMF Start
In response to a mains failure event performs a fully sequenced
engine start with optional configuration parameters and clear LCD
status messages
AMF Stop
In response to a mains restored event performs a fully sequenced
engine stop with optional configuration parameters and clear LCD
status messages
Manual Transfer Control
Manually initiated and automatically sequenced A and B contactor
control with optional configuration parameters and clear LCD status
messages
Emergency Stop
In response to a digital input performs a fully sequenced engine
stop with optional configuration parameters and clear LCD status
messages
Automatic Transfer Control
Automatically initiated and sequenced A and B contactor control
with optional configuration parameters and clear LCD status
messages
4.2 Engine Monitoring
Function
Description
Lubrication Oil Pressure
Monitors engine oil pressure with optional configuration
parameters and clear LCD status messages this ensures the oil

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pressure remains within configured limits. Exceeding these limits
will result in automatic engine shutdown to prevent damage.
Oil Temperature
Monitors engine oil temperature with optional configuration
parameters and clear LCD status messages this ensures the engine
temperature remains within configured limits. Exceeding these
limits will result in automatic engine shutdown to prevent damage.
Engine Temperature
Monitors engine temperature with optional configuration
parameters and clear LCD status messages this ensures the engine
temperature remains within configured limits. Exceeding these
limits will result in automatic engine shutdown to prevent damage.
Battery Voltage
Monitors engine battery voltage with optional configuration
parameters and clear LCD status messages this ensures the battery
voltage remains within configured limits.
Battery Charging
Monitors engine battery charging status and clear LCD status
messages this ensures the battery is charged when the engine is
running.
Radiator Water Level
Monitors engine radiator water minimum level with clear LCD
status messages this ensures the radiator water level remains
sufficient. Low water will result in automatic engine shutdown to
prevent damage.
Fuel Level
Monitors engine fuel level with clear LCD status messages. Low
fuel level will result in automatic engine shutdown to prevent
damage.
Canopy Temperature
Monitors engine canopy temperature with optional configuration
parameters and clear LCD status messages this ensures the engine
canopy temperature remains within configured limits. Exceeding
these limits will result in automatic engine shutdown to prevent
damage.
Running Hours
Records engine run hours with clear LCD status messages.
4.3 Generator AC Monitoring
Function
Description
AC Phase Voltage
Monitors 1, 2 or 3 phases of AC voltage with optional configuration
parameters and clear LCD status messages.
AC Phase Current
Monitors 1, 2 or 3 phases of AC current with optional configuration
parameters and clear LCD status messages.
Uses externally uses shunts.
AC Phase Frequency
Monitors 1, 2 or 3 phases of AC Frequency with optional

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configuration parameters and clear LCD status messages.
AC Phase Reversal
Monitors Genset AC for Phase reversal with optional configuration
parameters and clear LCD status messages.
AC Loading
Monitors AC load as a percentage of full load with optional
configuration parameters and clear LCD status messages.
AC Power Metering
Monitors AC power output (KW, KVA, KVAR, KWH) with optional
configuration parameters and clear LCD status messages.
4.4 Mains AC Monitoring
Function
Description
AC Phase Voltage
Monitors 1, 2 or 3 phases of AC voltage with optional configuration
parameters and clear LCD status messages
AC Phase Frequency
Monitors 1, 2 or 3 phases of AC frequency with optional
configuration parameters and clear LCD status messages
AC Phase Reversal
Monitors Mains AC for Phase reversal with optional configuration
parameters and clear LCD status messages
Automatic Mains Failure
(AMF)
Monitors AC failure with optional configuration parameters and
clear LCD status messages
4.5 System LED Indications
Function
Description
Alarm
Red LED indication of system alarm.
4.6 System LCD Displays
Function
Description
Setup menu
System configuration menus
Start Up
Clear step-by-step start up sequencing messages
Shutdown
Clear step-by-step shutdown sequencing messages
Transfer
Clear step-by-step load transfer messages
4.7 Engine LCD Displays
Function
Description
Low oil pressure
Engine oil pressure low

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High oil temperature
Engine oil temperature high
High engine temperature
Engine temperature high
Low coolant level
Radiator water level low
Low fuel level
Engine fuel level low
High canopy temperature
Engine canopy temperature high
Engine Hours
Total Engine Hours Total Engine Starts
4.8 Genset LCD Displays
Function
Description
Phase Voltages
Phase 1, 2 and 3 Voltages
Phase Currents
Phase 1,2 and 3 Currents
Phase Frequencies
Phase 1,2 and 3 Frequencies
Phase Reversal
Phase 1,2 or 3 Reversed
AC Power Metering
Monitors AC power output (KW, KVA, KVAR, PF. KWH) with optional
configuration parameters and clear LCD status messages.
Overload
Genset overloaded
4.9 Mains AC LCD Displays
Function
Description
Phase Voltages
Phase 1, 2 and 3 Voltages and L1-L2, L2-L3, L3-L1
Phase Frequencies
Phase 1, 2 and 3 Frequencies
4.10 AC Inputs
Function
Description
3 Phase Genset AC Voltage
Genset AC voltages.
3 Phase Genset Current
Genset AC currents via external shunts.
3 Phase Mains AC Voltage
Mains AC voltages.
4.11 Analog Inputs
Function
Description

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Lubrication Oil Pressure
Engine oil pressure.
Engine Temperature
Engine coolant temperature (Air or Water).
Radiator Water Level
Engine radiator water level.
Fuel Level
Engine fuel level.
Oil Temperature
Engine oil Temperature
Canopy Temperature
Engine canopy temperature.
4.12 Digital Inputs
Function
Description
Auto Start / Stop Input
Auto start.
Emergency Stop Input
Emergency engine stop.
Oil Switch Input
Oil Pressure Switch sensor.
User Input
User Defined Input.
4.13 Special Inputs
Function
Description
Battery Voltage
Internal measurement of incoming DC supply.
Excitation Voltage
Internal measurement of battery charging alternator excitation
voltage.
Low Water Level
Oscillating, AC coupled, Zero net current flow.
4.14 Digital Outputs
Function
Description
Excitation Output
Alternator excitation control and feedback.
Fuel Output
Open drain fuel solenoid control.
Crank Output
Open drain engine crank control.
Configurable OP2
Configurable from the menu item
Refer to section of Setup items for available options
Configurable OP3
Configurable OP1