EMS EMS827 User manual

EMS827
AMF Genset Controller
User Manual
This document applies to Product
9001-xxxx
Build Version
3600-xxxx
Firmware Version
5000-xxxx
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
©2010

EMS 827
GENSET CONTROLLER
Confidential www.ems.gen.nz Page 2
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 Monitoring..........................................................................................................8
4.4 Mains AC Monitoring...........................................................................................................8
4.5 System LED Indications ........................................................................................................8
4.6 Transfer Control LED Indications ...........................................................................................9
4.7 System LCD Displays ............................................................................................................9
4.8 AC Inputs..........................................................................................................................10
4.9 Analog Inputs....................................................................................................................10
4.10 Digital Inputs ....................................................................................................................10
4.11 Outputs............................................................................................................................11
5. Operation ................................................................................................................................12
5.1 Buttons ............................................................................................................................12
5.2 LEDs ................................................................................................................................13
5.3 Initial Power Up ................................................................................................................14
5.3.1 Ready...........................................................................................................................14
5.3.2 Mode Selection .............................................................................................................14
5.4 Manual Operation.............................................................................................................15
5.4.1 To start the genset.........................................................................................................15
5.4.2 To stop the genset .........................................................................................................16
5.5 Autostart Engine Control....................................................................................................16
6. Display Operation .....................................................................................................................17
6.1 When the genset is running................................................................................................17
7. Alarms and Warnings ................................................................................................................21
7.1 Inputs Electrical Specification .............................................................................................26
7.2 Outputs Electrical Specification...........................................................................................28
8. Load Transfer and Contactor Operation.......................................................................................29
9. Speed Sensing ..........................................................................................................................29
9.1 MPU ................................................................................................................................29
9.2 Magneto ..........................................................................................................................29
9.3 Generator ........................................................................................................................30
9.4 Battery Charging Alternator................................................................................................30
10. Battery Charging Alternator Excitation ....................................................................................31
11. Battery Voltage Monitoring and Charging Detection .................................................................31
12. Set-up .................................................................................................................................32
12.1 Navigating in the setup menu .............................................................................................32
12.2 System Column .................................................................................................................33
12.3 Engine Column..................................................................................................................33
12.4 Timers Column..................................................................................................................38
12.5 Contactor A Column ..........................................................................................................39
12.6 Start/Stop Column.............................................................................................................39
12.7 AC Setup Column ..............................................................................................................40
12.8 AMF Setup Column............................................................................................................41
12.9 AGF Setup Column ............................................................................................................41
12.10 Testing Column.................................................................................................................42
12.11 Manual Column ................................................................................................................42

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GENSET CONTROLLER
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12.12 Room Temp Column ..........................................................................................................43
12.13 Aviation Light Column (Not protected against prolonged power loss)......................................43
12.14 I/O Config Column.............................................................................................................43
12.15 Comms (Communications) Setup Column.............................................................................45
12.16 Log Viewer Column............................................................................................................45
13. Communications...................................................................................................................46
13.1 Unit General Specifications.................................................................................................46
14. Installation and Wiring ..........................................................................................................49
14.1 Connector Detail ...............................................................................................................49
15. Trouble shooting ..................................................................................................................52
16. Wiring Options .....................................................................................................................55

EMS 827
GENSET CONTROLLER
Confidential www.ems.gen.nz Page 4
EMS827
AMF Controller for
30KVA to 160KVA Gensets
1. Introduction
The unit is a controller for mid-engine Gensets with Automatic Mains Failure (AMF)
functionality sold in the private market segment.
The unit incorporates Manual, Autostart Start and AMF Autostart initiated start and stop
sequencing, monitors engine and alternator operating parameters and provides both engine
and alternator protection, in a single integrated package.
The Mains and Alternator status and operating parameters are shown by scrolling screens on a
backlit Graphics LCD. Alarms and warning are also shown on the LCD and supplemented by
status LEDs and a sounder output.
The unit provides comprehensive monitoring of the engine operating parameters and provides
automatic shutdown of the set in the event of damaging conditions. In addition to standard
engine safety protections the unit monitors battery voltage, battery status, charging
conditions, coolant level and temperature, fuel level, canopy temperature, oil pressure and
temperature, engine speed and operating hours.
On the Alternator side, the unit monitors and displays 1 or 3 phase voltages, for L-N and L-L. It
monitors the operating frequency, 3 individual phase currents, Average PF, KVA, KVAr for each
phase and Alternator total. It maintains 3 phase Power meter functions which comprise, Total
Mains KWH, Total Alternator KWH and Total Alternator KVArH,
The alternator incorporates several protection features which include Over-load, Over-current,
Load imbalance, and IDMT protection.
In the factory environment, the unit is configured by cloning through a Personal Computer (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.
Flexibility, the unit can be customised by PC cloning for individual genset model
characteristics and fitments.
Includes communications port for remote monitoring applications, dual station
operation and companion auxiliary units.
Inbuilt data logs provide operating history in the event of engine or alternator failure.

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GENSET CONTROLLER
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3. Physical Form
Front View
Rear 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, the unit performs a fully
sequenced engine start with optional configuration parameters and
clear LCD status messages
Manual Stop
In response to the front panel pushbutton, the unit performs a fully
sequenced engine stop with optional configuration parameters and
clear LCD status messages
Auto Start / Auto Stop
In response to a digital input, the unit performs a fully sequenced
engine start or stop with optional configuration parameters and
clear LCD status messages.
AMF Start
In response to a mains failure event, the unit performs a fully
sequenced engine start with optional configuration parameters and
clear LCD status messages
AMF Stop
In response to a mains restored event, the unit performs a fully
sequenced engine stop with optional configuration parameters and
clear LCD status messages
Emergency Stop
In response to a digital input, the unit 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
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
Over / Under Speed
Monitors engine speed with optional configuration parameters and
clear LCD status messages. This ensures the engine speed remains
within configured limits. Exceeding these limits will result in
automatic engine shutdown to prevent damage.

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GENSET CONTROLLER
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Function
Description
Lubrication Oil Pressure
Monitors engine oil pressure with optional configuration
parameters and clear LCD status messages this ensures the oil
pressure remains within configured limits. Exceeding these limits
will result in automatic engine shutdown to prevent damage. Oil
pressure monitoring can be from an oil pressure switch, or a
resistive oil pressure sensor, or both.
Lubrication Oil
Temperature
Monitors engine oil temperature with optional configuration
parameters and clear LCD status messages this ensures the oil
temperature remains within configured limits. Exceeding these
limits will result in automatic engine shutdown to prevent damage.
Coolant Temperature
Monitors coolant temperature with optional configuration
parameters and clear LCD status messages this ensures the coolant
temperature remains within configured limits. Exceeding these
limits will result in automatic engine shutdown to prevent damage.
Coolant Level
Monitors radiator water level and provides clear LCD status
messages. Automatic engine shutdown if radiator water is low.
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 during standby and operation
and shows the status with clear LCD status messages. Warnings are
given if charging is under or over charging.
Fuel Level
Monitors engine fuel level with clear LCD status messages. Low
fuel level will result in automatic engine shutdown to prevent
damage. A fuel loss warning and event log are included.
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.
Service Timer
A service timer is incorporated to ensure proper service schedules
are maintained. The service message is displayed on the LCD at the
pre-programmed times. An event log is maintained for service due
and service taken.

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GENSET CONTROLLER
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4.3 Generator Monitoring
Function
Description
AC Phase Voltage
Monitors 1, 2 or 3 phases of AC voltage with optional configuration
parameters and clear LCD status messages. Measurements include
L-N and L-L.
AC Phase Current
Monitors 1 or 3 Delta phases of AC current with optional
configuration parameters and clear LCD status messages.
Uses externally fitted 5A CTs.
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 Alternator 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, KVArH and Avg
PF) 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. Measurements include
L-N and L-L.
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.
Mains Failure
Monitors AC failure with optional configuration parameters and
clear LCD status messages. Includes Under and Over Voltage, Under
and Over Frequency,
4.5 System LED Indications
Function
Description
Alarm
Red LED indication of system alarm.
Manual Mode
Green LED indication that the unit is in Manual Start Mode.

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GENSET CONTROLLER
Confidential www.ems.gen.nz Page 9
Function
Description
Auto Mode
Green LED indication that the unit is in Automatic Start Mode
Test Mode
Green LED indication that the unit is in Test Mode
4.6 Transfer Control LED Indications
Function
Description
Alternator Phase 1
Available
Red LED indication that the Alternator phase 1 voltage is available.
Alternator Phase 2
Available
Yellow LED indication that the Alternator phase 2 voltage is
available.
Alternator Phase 3
Available
Blue LED indication that the Alternator phase 3 voltage is available.
Alternator Available
Green LED indication that the Alternator is available for the load.
Alternator on Load
Green LED indication that the Alternator is on load.
Mains AC Phase 1
Available
Red LED indication that the mains phase 1 voltage is available.
Mains AC Phase 2
Available
Yellow LED indication that the mains phase 2 voltage is available.
Mains AC Phase 3
Available
Blue LED indication that the mains phase 3 voltage is available.
Mains AC Available
Green LED indication that the mains is available for load.
Mains AC on Load
Green LED indication that the mains is on load.
4.7 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

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GENSET CONTROLLER
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4.8 AC Inputs
Function
Description
3 Phase Mains AC Voltage
Mains AC voltages.
3 Phase Alternator AC
Voltage
Alternator AC voltages.
3 Phase Alternator Current
Alternator AC currents via external 5A CTs.
4.9 Analog Inputs
Function
Description
Speed
Engine speed from MPU or battery charging alternator.
Lubrication Oil Pressure
Engine oil pressure. Exciting current approx 13mA
Lubrication Oil
Temperature
Engine oil temperature. Exciting Current approx 5mA
Coolant Temperature
Engine coolant temperature (Air or Water). Exciting current approx
5mA
Fuel Level
Engine fuel level. Exciting current approx 13mA
Canopy Temperature
Engine canopy temperature. Exciting Current approx 5mA
Coolant Level
Engine Radiator level. Exciting frequency 500Hz
Battery Voltage (Internal)
Battery Voltage is measured internally from DC supply point.
4.10 Digital Inputs
Function
Description
Auto Start / Stop Input
Auto start.
Close to common. Current limited 10mA at 10V
Emergency Stop Input
Emergency engine stop.
Selectable Open or Close to common. Current limited 10mA at 10V
Oil Switch Input
Oil Pressure Switch sensor.
Close to common. Current limited 10mA at 10V
Digital Input 1
Configurable. Default = Bypass. No logic control but full
instrumentation available.
Digital Input 2
Configurable. Default = Canopy door open.