Murphy Autostart AS731 User manual

1. Introduction
The Autostart AS731 and AS732 are full-function,
programmable controllers for automatic or manual
running of a standby generator. The modules include
comprehensive measurement and display of engine
and generator parameters, with automatic plant
protection and operator warning in the event of faults.
All units are fitted with an RS232 communication link
that allows remote configuration, monitoring and
control using Murphy PC software. AS732 units
additionally have RS485 MODBUS facility, allowing
communications with other AS732 units, or PLC,
SCADA and building management systems.
This document details the user operation of the AS731
and AS732. Further information on the specification,
electrical connection and set up may be found in the
following documents:-
Doc. ref. Title
ms6127 AS731 bulletin and technical spec.
ms6343 AS732 sales bulletin and technical spec.
mi6128 AS731/732 installation A: electrical connection
mi6129 AS731/732 installation B: programming
mi6131 AS731/732 and AS7CN PC comms software
2. Front facia and controls
As shown in the diagram right, the front facia contains a
liquid crystal display (LCD), two mode indicating LEDs
and 5 operator control keys.
2.1 Display
The 2 line by 16 character, backlit LCD provides
continuous information about the system status.
Automatically scrolled messages indicate operating
mode, engine status, generator parameters (e.g. VAC,
Hz, Amps), timer progress and fault conditions.
Press the ikey to manually scroll to additional system
information (see 2.3.4 below).
Examples of LCD messages are given in section 3.
2.2 Mode Indicators
Two LEDs at the right of the front facia provide ‘at-a-
glance’ indication of operating mode:-
This green LED lights when the Autostart is in Auto
mode and flashes when RS232 communication is in
progress, e.g. during remote control via a modem link.
This amber LED lights when the Autostart is in manual
mode. When the operator selects manual mode from
the front facia, the RS232 communication link can be
used to monitor, but not control) the Autostart.
Autostart AS731/AS732 Generator Controller
Operating Instructions
mi6130
revision B, 10th Sept 2007
catalogue section 75
Please read the following information before operating. Before using this product, it is your responsibility to
ensure that it has been correctly installed by qualified mechanical and electrical technicians.
Front facia
1. 2 line x 16 character backlit liquid crystal display
2. Operator control keys:
Off/reset
On/Auto mode
Manual mode start
Manual mode stop
i Info (scroll display)
3. Auto/manual mode LED indication
FRANK W. MURPHY LTD.
Church Rd, Laverstock,
Salisbury, SP1 1QZ, United Kingdom
tel: [phone]
fax: [phone]
email: [e-mail]
web: www.fwmurphy.co.uk
FW MURPHY
PO Box 470248
Tulsa, Oklahoma 74147, USA
tel: [phone]
fax: [phone]
email: [e-mail]
web: www.fwmurphy.com
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.
MURPHY, the Murphy logo, are registered and/or common law trademarks of Murphy Industries, Inc. This document, including
textual matter and illustrations, is copyright protected by Frank W Murphy Ltd., with all rights reserved. © 2007 Frank W Murphy Ltd.
Product Discontinued

FWMurphy – AS731/732 operating instructions mi6130 revision B 10th September 2007 p2/4
2.3 Operator Controls
The AS731/732 has five front control keys. The symbols
within and above each key indicate its control function
during normal operation. The arrow symbols below each
key relate to the programming of the unit. For full details
about programming, please refer to document mi6129.
2.3.1Off/reset
Press this key at any time, and hold for around 2
seconds, to power down the Autostart. This will stop the
engine (if running) and reset a latched shutdown fault.
2.3.2On/Auto
Press this key to power up the unit into Auto mode,
or to switch to Auto mode control after manual mode
operation.
In Auto mode, the Autostart automatically starts, runs
and stops the engine in response to the ‘remote start’
contact. Full details are given in section 3.1 below.
2.3.3Manual Start
Manual Stop
Use these keys to manually control the generator. Press
either key momentarily to select manual mode: note that
the top left of the LCD changes from AUTO to MAN and
that the amber LED lights.
If the engine is stationary, selection of manual mode
can be used to start the engine. If the engine is
already running in Auto mode, selection of manual
mode can be used to maintain running indefinitely.
For full details, refer to section 3.2 below.
2.3.4Information i
In normal operation, the LCD automatically scrolls a
series of predefined status messages. Press the ikey
to manually scroll through additional information
screens such as:-
•DC/Battery voltage
•Engine hours run
•Engine RPM (where a magnetic pickup is fitted)
•Engine oil pressure (where a sender is fitted)
•Engine temperature (where a sender is fitted)
•Generator frequency, in Hz
•Generator 3 phase voltage, V AC
•Generator 3 phase current, A AC
3. Operation
3.1 Operation in Auto mode
In Auto mode, the AS731/732 controls engine starting,
load transfer and engine stopping in response to the
‘remote start’ input.
An automatic start, run and stop (return to standby)
cycle is typically displayed on the LCD as follows:-
LCD message Status
AUTO:standby
Battery 27.0V
The engine is stationary and
the AS731 is on ‘standby’.
LCD displays battery
voltage and any fault
conditions.
AUTO:Remote strt
Start delay 0:03
Remote start input is active.
The Autostart will begin its start
sequence as soon as the start
delay expires.
Start no 1 of 3
Cranking 10 sec
The Autostart is cranking the
engine, and will release the
starter motor as soon as
engine speed is detected.
If engine speed is not
detected, the unit will go
through a crank cool period,
then further attempts to
(preheat and) start engine.
AUTO:eng running
Warmup 05s
With the engine running,
the Autostart waits for the
warmup delay to expire before
loading generator.
AUTO:gen on load
50Hz 230V 150A
The remote start input is still
active, all parameters are in
limits and the ‘gen contactor’
output has activated (running
the generator on load).
AUTO:gen on load
restore: 0:04:59
The remote start input has
de-activated, but the Autostart
keeps the generator on load
until the restore timer has
expired. The restore timer will
reset if the remote start input
re-activates.
AUTO:eng running
Cooling 0:02:59
The Autostart is running the
generator off load, cooling
down. The AS731 returns
the system to standby at the
end of the cool time, but will
reload the generator (and reset
restore and cool times) if the
remote start input re-activates.
3.2 Operation in Manual mode
3.2.1Manual engine start
With the AS731/732 in Auto mode and the engine
stationary (on standby), use the manual mode keys to
give an immediate engine start:-
•Press and immediately release the or
key. The Autostart adopts manual mode, the amber
LED lights, and the top left of the LCD changes
from AUTO to MAN. Note: provided the or
key is immediately released, the Autostart
assumes manual mode but does not crank the
engine – the unit does not then respond to the
(automatic) remote start input.
•To initiate an engine start sequence, press and
hold the key for at least 1 second. If a timed
preheat output option has been set, it will activate.
At the end of the preheat time, or if a preheat
option has not been set, the Autostart will crank
the engine. The key may be released as
soon as the preheat/crank sequence has begun:
the start sequence then continues automatically,
as for auto mode.
Product Discontinued

FWMurphy – AS731/732 operating instructions mi6130 revision B 10th September 2007 p3/4
Once the engine has started, the AS731/732 runs the
generator indefinitely if required. While Autostart is
running the engine in manual mode, activation of the
‘remote start’ or ‘mains fail’ input may or may not cause
an attempt to load the generator: please refer to the
‘load in MAN’ section of ‘programming’ document
mi6129.
3.2.2 Maintaining engine running
If the Autostart is running the engine in Auto mode,
selection of manual mode allows the engine to be run
indefinitely:-
•Press and release the key. The manual mode
LED lights and the top left of the LCD changes from
AUTO to MAN.
Note: the above operation does not affect the generator
load status.
3.2.3Stopping the engine
With the engine running in manual mode, there are
several options for stopping the engine:-
a) Press the key and release after about
1 second. The Autostart immediately stops the
engine and remains in manual mode.
b) Press the (off/reset) key. The Autostart
immediately stops the engine and powers down.
c) Press the key. Engine stopping (and re-
starting) then reverts to automatic, i.e.-
¾If the remote start input is active (e.g. if the mains
supply has failed), the Autostart maintains or
reloads the generator until the remote start input
clears.
¾If the remote start input is inactive (e.g. if mains
is healthy) and the generator is running on load,
the Autostart maintains load and begins a
‘return to standby’ sequence, starting with a
‘restore’ time.
¾If the remote start input is inactive and the
generator is running off load, a return to standby’
sequence begins, starting with an ‘engine cool’
time.
3.3 Responding to faults
In Auto and manual modes, the Autostart continuously
monitors for a range of engine and plant faults. The unit
is typically set up to operate an external, audible alarm
during a fault conditions; the LCD backlight will also
flash on and off.
The operator, once alerted, can check the system
and fault status by use of the LCD messages, and/or
panel indicators driven from programmable outputs.
The AS731/732 has three main fault response types -
shutdown, warning and load release.
3.3.1 Shutdown faults
A shutdown response is given to those faults which
require an automatic and immediate engine shutdown
and lock-out. These are serious faults that might
otherwise cause personal injury, or damage to the
generator and other equipment, e.g. ‘emergency stop’,
engine ‘low oil pressure’, ‘high engine temperature’,
‘overspeed’, AC ‘overvolts’, ‘no speed signal’ and
‘failed to start’ (overcrank). A shutdown response may
also be set for other inputs or parameters, e.g. AC over
current, AC undervolts, earth fault, coolant leak, etc.
After a shutdown fault, the front facia LCD flashes and
displays a relevant fault message, e.g.:-
ENGINE SHUTDOWN
LOW OIL PRESSURE
If the Autostart has been set up for use with a ‘klaxon
mute’ panel button, press this button to silence the
audible alarm and leave the fault message displayed.
To clear the fault condition, press and hold the key
for 1 second, or isolate the DC supply (either of which
causes a power down and ‘hard’ reset).
Once reset, the Autostart should only be powered up
again once the reason for the shutdown has been
investigated and corrected.
3.3.2 Warning faults
These faults are less serious in nature, requiring
operator warning or intervention but not an automatic
engine shutdown. Warning faults include ‘charge fail’,
‘low/high battery volts’, ‘low fuel’, etc.
Faults are indicated on the LCD with a flashing backlight.
Typically, the LCD top line continues to display operating
mode and system status, while the bottom line displays
a fault message, e.g.
AUTO:gen on load
CHARGE FAIL
The operator response depends on the nature of the
fault. Some faults can be rectified while the engine is
running, others may require that the engine is stopped
before further investigation. Warning faults are self-
resetting: the displayed fault message and any alarm
outputs will clear as soon as the problem is rectified.
3.3.3 Load release faults
This type of fault is similar to the warning fault above,
but the Autostart will also ‘release’ the generator load,
allow the engine to run on (off load). The Autostart may
be set to give a ‘load release’ response to faults such as
‘generator under voltage’ or ‘generator over current’.
Fault indication is similar to warning faults: the LCD
flashes, the top line displays operating mode and system
status, while the bottom line displays a fault message, e.g.
AUTO:eng running
GEN UNDERVOLTS
Once alerted, the operator should investigate the
cause of the fault.
If a ‘load release’ fault clears, the response depends
on the generator manufacturer’s programming.
If one of the inputs has been configured for ‘load
reset’, the Autostart only attempts to reload the
generator if both the fault has cleared and the input
is activated (typically by the user pressing a panel
push button). Without a ‘load reset’ input, Autostart
automatically reloads the generator and clears its
fault message immediately that the fault clears.
Product Discontinued

FWMurphy – AS731/732 operating instructions mi6130 revision B 10th September 2007 p4/4
3.4 RS485 communication (AS732 only)
AS732 units feature an RS485 MODBUS
communication network through which AS732s can
communicate with each other or other equipment such
as PLC, SCADA or building management systems.
Active communication over the RS485 network is
indicated by a symbol in the LCD, e.g.
AUTO:standby
Battery 27.0V
This symbol remains displayed for 30 seconds after
the last RS485 communication activity.
FRANK W. MURPHY LTD.
Church Rd, Laverstock,
Salisbury, SP1 1QZ, United Kingdom
tel: [phone]
fax: [phone]
email: [e-mail]
web: www.fwmurphy.co.uk
FW MURPHY
PO Box 470248
Tulsa, Oklahoma 74147, USA
tel: [phone]
fax: [phone]
email: [e-mail]
web: www.fwmurphy.com
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.
MURPHY, the Murphy logo, are registered and/or common law trademarks of Murphy Industries, Inc. This document, including
textual matter and illustrations, is copyright protected by Frank W Murphy Ltd., with all rights reserved. © 2007 Frank W Murphy Ltd.
Product Discontinued