Sel M2500 User manual

SELCO A/S M2500 Installation Manual
Revision: 23-04-2012 Page 1
M2500 Engine Controller
Installation Manual

SELCO A/S M2500 Installation Manual
Revision: 23-04-2012 Page 2
Contents
1Preface .........................................................................................................................................4
2Installation ...................................................................................................................................5
3Terminal Connections..................................................................................................................6
4Inputs ...........................................................................................................................................7
4.1 Power Supply...........................................................................................................................7
4.2 Mode/ Control Inputs...............................................................................................................7
4.2.1 Connection of Mode Selector Switch ..................................................................................8
4.2.2 Remote Start (terminal 8).....................................................................................................9
4.2.3 Remote Stop (terminal 9).....................................................................................................9
4.2.4 Override (terminal 10) .......................................................................................................10
4.2.5 Crank Disconnect (terminal 11).........................................................................................10
4.2.6 Reset (terminal 12).............................................................................................................10
4.2.7 COM (terminal 13) ............................................................................................................11
4.3 Speed detection......................................................................................................................11
4.3.1 Connection of magnetic pick-up........................................................................................11
4.3.2 Connection of PNP pick-up...............................................................................................12
4.3.3 Connection of NPN pick-up...............................................................................................12
4.4 Digital sensor inputs ..............................................................................................................13
4.4.1 Connection of a normally open sensor without cable monitoring.....................................13
4.4.2 Connection of a normally closed sensor without cable monitoring...................................14
4.4.3 Connection of a normally open sensor with cable monitoring ..........................................14
4.4.4 Connection of a normally closed sensor with cable monitoring........................................15
4.4.5 COM (terminal 13) ............................................................................................................15
4.5 Analogue sensor inputs..........................................................................................................15
4.5.1 Analogue inputs (terminals 27 to 34).................................................................................16
4.5.2 COM (terminal 13) ............................................................................................................16
5Outputs.......................................................................................................................................17
5.1 Engine Status Outputs............................................................................................................17
5.1.1 Connection of Engine Status Outputs................................................................................17
5.1.2 Ready (terminal 36) ...........................................................................................................18
5.1.3 Start warning (terminal 37)................................................................................................18
5.1.4 Engine running (terminal 38).............................................................................................18
5.1.5 Cool Down (terminal 39)...................................................................................................18
5.1.6 REF 1 (terminal 40)...........................................................................................................18
5.2 Engine Control Outputs .........................................................................................................19
5.2.1 Connection of Engine Control Outputs..............................................................................19
5.2.2 Auxiliary Lubrication Pump (terminal 41)........................................................................19
5.2.3 Crank (terminal 42)............................................................................................................20
5.2.4 C/B trip (terminal 43).........................................................................................................20
5.2.5 Air Intake Valve (terminal 44)...........................................................................................20
5.2.6 REF 2 (terminal 45)...........................................................................................................20

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5.3 Alarm Outputs........................................................................................................................20
5.3.1 Connection of alarm outputs..............................................................................................21
5.3.2 Common Alarm (terminal 46) ...........................................................................................21
5.3.3 Shutdown (terminal 47) .....................................................................................................21
5.3.4 Cable break (terminal 48) ..................................................................................................21
5.3.5 CAN (terminal 49).............................................................................................................21
5.3.6 REF3 (terminal 50)............................................................................................................21
5.4 Digital Outputs.......................................................................................................................22
5.4.1 Connection of digital outputs.............................................................................................22
5.4.2 Digital Outputs Out 1 to Out 12 (terminals 51 to 62)........................................................23
5.4.3 REF 4 (terminal 50)...........................................................................................................23
5.5 Control Relays .......................................................................................................................23
5.5.1 Engine Stop Output (terminal 64 and 65)..........................................................................23
5.5.2 Run/ Stop Solenoid (terminal 66 and 67) ..........................................................................24
5.6 Siren Relay.............................................................................................................................26
5.6.1 Connection of the Siren Relay...........................................................................................26
6Communication..........................................................................................................................27
6.1 CAN J1939 Bus .....................................................................................................................27
6.1.1 CAN J1939 Connector:......................................................................................................27
6.1.2 CAN cable..........................................................................................................................27
6.1.3 RS485 MODBUS...............................................................................................................28
6.1.4 RS485 cable.......................................................................................................................28
7Functional Description...............................................................................................................29
7.1 Remote Mode.........................................................................................................................29
7.2 Alarm Monitoring..................................................................................................................31
7.2.1 Alarm flowchart:................................................................................................................32
7.3 Shutdown Monitoring............................................................................................................33
7.3.1 Shutdown flowchart:..........................................................................................................34
7.4 Specification ..........................................................................................................................35

SELCO A/S M2500 Installation Manual
Revision: 23-04-2012 Page 4
1Preface
The M2500 - Engine Controller is designed for control and monitoring of marine engines.
Together with the optional M2600 - Shutdown Unit the M2500 - Engine Controller forms a
complete alarm, control and protective safety system for marine engines.
Typical applications are marine generator engines such as auxiliary generators, emergency
generators, harbour generators and propulsion engines.
The M2500 is designed for assembly in the main switchboard or at the engine.
This manual describes the installation of the M2500 - Engine Controller.

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2Installation
The M2500 is designed for flush mounting to the front panel of the switchboard. It is secured by 6
mounting brackets which are supplied with the M2500.
The panel cut out dimension is 138mm x 210mm

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3Terminal Connections
Primary and
back-up
power supply
Inputs for
activation of
operation
modes,
Inputs for
remote start and
stop
Input for
magnetic, NPN
or PNP pick-
up for speed
detection
Digital sensor
inputs for
alarms and
shutdowns
Analogue
sensor inputs
for alarms and
shutdowns
Outputs for
indication of
engine state
(e.g. to PMS)
Control
outputs
Common
alarm outputs
Programmable
outputs for
indication of
alarms and
shutdowns
Engine stop
relay
Programmable
output for stop
or run
solenoid with
cable
monitoring
Siren relay
RS485 Modbus
Adjustment of
display contrast
Interface for
CANJ1939
Slot for SD card for read out
of log and configuration
USB interface for
configuration and
read out of alarm log
Future use

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4Inputs
4.1 Power Supply
Redundant Power Supply (2x 24V DC, -30 % / +30 %)
Alarm in case any power supply fails (common alarm + display text).
Primary supply will not be monitored during cranking, as the battery voltage will drop during this
process.
Nr.
Description
01
Primary Supply +
02
Primary Supply -
03
Primary Supply +
04
Primary Supply -
4.2 Mode/ Control Inputs
Nr.
Description
Logic (NO/NC)
05
Remote Mode
NO
06
Local Mode
NO
07
Off Mode
NO
08
Remote Start
NO
09
Remote Stop
NO
10
Override
NO
11
Crank disconnect
NO
12
Reset
NO
13
COM
Common
reference for
control inputs

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4.2.1 Connection of Mode Selector Switch
The external mode selector switch is used for switching the M2500 into OFF, REMOTE or LOCAL
mode.
4.2.1.1 Local Mode (terminal 5)
The local mode input is considered active when connected to COM, inactive when open.
When active the M2500 will be in local mode. This means start and stop are only available from the
push buttons on the front panel. The remote start and stop terminals are disabled. The LOCAL LED
on the front panel will be lit. Not ready LED on the front panel will be lit and READY output
terminal 36 will be deactivated indication that the engine is not available for remote start.
4.2.1.2 Remote Mode (terminal 6)
The remote mode input is considered active when connected to COM, inactive when open.
When active the M2500 will be in remote mode. This means start and stop are only available from
the REMOTE START and REMOTE STOP terminals. The Local start and stop push buttons are
disabled.
Provided no alarm, shutdown or Off command is active, the green REMOTE LED on the front
panel will be lit and the engine is ready for remote start.
4.2.1.3 Off (terminal 7)
The off input is considered active when connected to COM, inactive when open.
When activated, the M2500 will initiate a stop procedure. Engine start will be blocked as long as
this input is active.
Not ready LED on the front panel will be lit indicating that the engine is not available for remote
start.

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4.2.2 Remote Start (terminal 8)
The Remote Start input is considered active when connected to COM, inactive when open. It can be
a pulse or continuous signal.
The input is only enabled in remote
mode.
When activated, the M2500 will
generate a start signal to the engine.
The pre-configured number of start
attempts is available. During the start
attempt the green Engine Running
LED on the front panel will be fast
flashing. During the rest periods
between start attempts this LED will
be slow flashing. When the engine is
running, the LED will be lit continuously.
If the engine does not start the M2500 will initiate a stop procedure and a Start Fail Alarm. The red
ALARM LED on the front panel will be lit. The alarm text “START FAILURE” will be shown on
the display.
4.2.3 Remote Stop (terminal 9)
The Remote Stop input is considered active when connected to COM, inactive when open. It can be
a pulse or a continuous signal.
The input is only enabled in remote
mode.
When activated, the M2500 will
initiate a stop procedure. During the
stop procedure the green Running
LED will be slow flashing. The
Stopping LED will be lit. If the
engine does not stop the M2500 will
generate a Stop Fail Alarm. The red
ALARM LED on the front panel will
be lit. The alarm text “STOP
FAILURE” will be shown on the
display.
The engine will be blocked for start as long as the stop input is active. When activated
simultaneously, Stop overrides Start.

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4.2.4 Override (terminal 10)
The Override input is considered active
when connected to COM, inactive
when open.
When activated all shutdowns that are
marked override will be disabled,
meaning the engine will continue
running despite of a shutdown. If the
override is deactivated while a
shutdown is present, shutdown will be
executed immediately.
4.2.5 Crank Disconnect (terminal 11)
The Cranck Disconnect input is
considered active when connected
to COM, inactive when open.
This input is only used in case
there is no pick-up for speed
detection. The input is a contact
from a tacho-relay that signals
that the speed of the engine is
above ignition speed. When
receiving the Crank Disconnect
signal the M2500 will deactivate
the crank output after a start
attempt. If the M2500 looses this
signal without a stop procedure, the ALARM LED will be lit and a Tacho Fail Alarm will be
displayed.
4.2.6 Reset (terminal 12)
This Reset is considered active when
connected to COM, inactive when open.
When activated, this input will reset the siren
and the alarm/ shutdown.

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4.2.7 COM (terminal 13)
The COM is the common reference for all digital inputs.COM and power supply minus are
internally connected.
4.3 Speed detection
Speed detection
Remark
14
Pick-up
Supply voltage for PNP or NPN pick-up
15
Pick-Up signal input
16
Reference for pick-up signal
4.3.1 Connection of magnetic pick-up
The magnetic pick-up is connected as follows:
For use of magnetic pick-up the DIP switches 3 and 4 on the rear side of M2500 must be in OFF
position. The DIP switches are placed between the RS485 and CAN connectors on the rear side of
M2500.
DIP Switch Position
1 OFF
2 OFF

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4.3.2 Connection of PNP pick-up
The NPN pick-up is connected as follows:
For use of PNP pick-up the DIP switch 3 on the rear side of M2500 must be in ON position, DIP
switch 4 must be in OFF position. The DIP switches are placed between the RS485 and CAN
connectors on the rear side of M2500.
DIP Switch Position
1 ON
2 OFF
4.3.3 Connection of NPN pick-up
The NPN pick-up is connected as follows:
For use of NPN pick-up the DIP switch 3 on the rear side of M2500 must be in OFF position, DIP
switch 4 must be in ON position. The DIP switches are placed between the RS485 and CAN
connectors on the rear side of M2500.
DIP Switch Position
1 OFF
2 ON

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4.4 Digital sensor inputs
Nr.
Description
Remark
17
Digital input 1
Sensor input for digital sensor 1
18
Digital input 2
Sensor input for digital sensor 2
19
Digital input 3
Sensor input for digital sensor 3
20
Digital input 4
Sensor input for digital sensor 4
21
Digital input 5
Sensor input for digital sensor 5
22
Digital input 6
Sensor input for digital sensor 6
23
Digital input 7
Sensor input for digital sensor 7
24
Digital input 8
Sensor input for digital sensor 8
25
Digital input 9
Sensor input for digital sensor 9
26
COM
Common reference for digital
sensor inputs
The Digital sensor inputs are used for the connection of the digital sensors. Digital sensors can be
Normally Open (NO) or Normally Closed (NC) logic. Cable break and short circuit monitoring is
available.
4.4.1 Connection of a normally open sensor without cable monitoring
The following example shows the Connection of a normally open sensor without cable monitoring.
The sensor is considered active when
connected to COM, inactive when open.
When activated, the input generates an
alarm or shutdowns or a control signal,
depending on the configuration.

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4.4.2 Connection of a normally closed sensor without cable monitoring
The following example shows the Connection of a normally closed sensor without cable
monitoring.
The sensor is considered active when open,
inactive when connected to COM.
When activated, the input generates an
alarm or shutdowns or a control signal,
depending on the configuration.
4.4.3 Connection of a normally open sensor with cable monitoring
The following example shows the Connection of a normally open sensor with cable monitoring.
The sensor is considered
active when connected to
COM, inactive when open.
Resistor R1 is used for
cable break monitoring.
Resistor R2 is used for short
circuit monitoring.
It is very important that
both resistors are mounted
close to the sensor.

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4.4.4 Connection of a normally closed sensor with cable monitoring
The following example shows the connection of a normally closed sensor with cable monitoring.
The sensor is considered
active when open, inactive
when connected to COM.
Resistor R1 is used for short
circuit monitoring.
Resistor R2 is used for cable
break monitoring.
It is very important that both
resistors are mounted close
to the sensor.
4.4.5 COM (terminal 13)
The COM is the common reference for all digital inputs.COM and power supply minus are
internally connected.
4.5 Analogue sensor inputs
Analogue sensor inputs are used for temperature and pressure measurements.
All analogue sensors use 4-20mA signals.
Analogue Sensor Inputs
Remark
27
4mA -20mA
Analogue input 1
28
4mA -20mA
Analogue input 2
29
4mA -20mA
Analogue input 3
30
4mA -20mA
Analogue input 4
31
4mA -20mA
Analogue input 5
32
4mA -20mA
Analogue input 6
33
4mA -20mA
Analogue input 7
34
4mA -20mA
Analogue input 8
35
COM
Common reference for
analogue sensor inputs

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4.5.1 Analogue inputs (terminals 27 to 34)
The analogue sensor inputs are for
generating alarms and shutdowns. In
case the input signal is below 3mA or
above 25mA the M2500 will generate a
sensor fail alarm. Cable Error LED will
be lit.
Delay times can be programmed for
alarms and shutdowns.
4.5.2 COM (terminal 13)
The COM is the common reference for all digital inputs.COM and power supply minus are
internally connected.

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5Outputs
All outputs are relay contacts.
5.1 Engine Status Outputs
Nr.
Description
Type
Rating
36
Ready/ Not Ready
NO Relay
1A
37
Start warning
NO Relay
1A
38
Engine Running
NO Relay
1A
39
Cool down
NO Relay
1A
40
REF1
Common reference for engine status outputs
5.1.1 Connection of Engine Status Outputs
Following example shows the connection of an external relay for the engine running signal:

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5.1.2 Ready (terminal 36)
Normally Open Relay output. The Ready output indicates the availability of the engine for remote
start e.g. for a power management system. The output can be configured as “Engine Ready” or
“Engine Not Ready”. The output is activated when closed to COM (terminal) 40.
Note: Configuration as Ready Output:
The output is activated when the engine is available for remote start. The output is de-activated in all
other conditions (e.g. M2500 in Local mode shutdown error or start blocking) (normally de-energized
output).
Note: Configuration as Not Ready output:
The output is activated when the engine is not available for remote start (e.g. M2500 in Local mode
shutdown error or start blocking).
The output is de-activated when the output is ready for remote start (normally energized output).
5.1.3 Start warning (terminal 37)
Normally Open Relay output. This output is activated for a preconfigured time before each start
attempt. The output is activated when closed to COM (terminal) 40. The relay is normally de-
energized.
5.1.4 Engine running (terminal 38)
Normally Open Relay output. This output indicates that the engine is running. The output is
activated when closed to COM (terminal) 40. The relay is normally de-energized.
5.1.5 Cool Down (terminal 39)
Normally Open Relay output. This output indicates that the engine is in cool down mode. After
receiving the engine stop command, the M2500 will trip the C/B. The engine will continue running
for the duration of the cool down time. After expiration of the cool down time the M2500 will stop
the engine. The cool down time can be configured. Cool Down only applies to remote mode and
only for normal stops. Shutdowns will be executed immediately.
Note:
Purpose of this output is to give a signal to a synchronizer in order to avoid re-synchronization.
The output is activated when closed to COM (terminal) 40. The relay is normally de-energized.
5.1.6 REF 1 (terminal 40)
Common reference for all output relays terminals 36 to 39.

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5.2 Engine Control Outputs
Nr.
Description
Type
Rating
41
Auxiliary lubrication pump
NO Relay
1A
42
Crank
NO Relay
1A
43
Circuit breaker trip
NO Relay
1A
44
Air intake valve
NO Relay
1A
45
REF 2
Common reference for the control
outputs
5.2.1 Connection of Engine Control Outputs
Following example shows the connection of an external relay for the C/B trip signal:
5.2.2 Auxiliary Lubrication Pump (terminal 41)
Normally Open Relay output. When the engine is stopped the output becomes active every 30 min
for 2 min. Immediately after stop the first lubrication period is after 20 min. The interval and
duration times can be configured.
The relay is normally de-energized.

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5.2.3 Crank (terminal 42)
Normally Open Relay output. This is the start output of the M2500. It activates for each start
attempt and remains active until either the engine has fired or the crank time has expired or a stop
command has been activated at the M2500.
The relay is normally de-energized.
5.2.4 C/B trip (terminal 43)
Normally Open Relay output. This output trips the circuit breaker before the engine stops. It is
always activated after a stop command has been received or a shutdown has been activated.
The relay is normally de-energized.
5.2.5 Air Intake Valve (terminal 44)
Normally Open Relay output. This is an alternative stop output. The output is activated immediately
when a stop procedure is activated, regardless if this is a normal stop or a shutdown.
The relay is normally de-energized.
5.2.6 REF 2 (terminal 45)
Common reference for all output relays terminals 41 to 44.
5.3 Alarm Outputs
Nr.
Description
Type
Rating
46
Common Alarm
NO Relay
1A
47
Shutdown
NO Relay
1A
48
Cable Break
NO Relay
1A
49
Communication Error
NO Relay
1A
50
REF 3
Common reference for the alarm outputs