FW Murphy AS705S KD, RD Generator Controller Installation Instructions

Autostart AS705S Generator Controller V1.00 – V1.06(a)

Installation Instructions

Section A: Installation and Wiring

mi5396 revision E, 1 st

June 2010 catalogue section 75

Please read the following information before installing. A visual inspection of this product for damage during shipping is recommended before installation. It is your responsibility to ensure that qualified mechanical and electrical technicians install this product. If in doubt, please contact your local Murphy representative.

GENERAL INFORMATION

WARNING

BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT

Disconnect all electrical power to the machine

Make sure the machine cannot operate during installation

Follow all safety warnings of the machine manufacturer

Read and follow all installation instructions

Description Familiarisation

Unpacking

Each AS705S is supplied complete with:-

The Autostart AS705S is part of the AS7XX family of controls, designed for use in the automatic or manual control of a standby diesel generator, pump or other engine driven equipment. The unit has over 50 programmable features – timers, inputs, outputs, control options and fault protections – allowing it to be used in a wide variety of engine applications.

• 2 terminal blocks (connected into the rear of the unit)

• 2 keys (keyswitch versions only).

• 2 mounting clamps

• 1 custom label sheet

• these instructions

Model numbers

Operator control is by a 3 way keyswitch or rotary switch

(off, auto and manual). Indication of plant status and fault conditions is by 17 front facia LED indicators; 5 of these LEDs may be programmed and labelled to customer requirements.

All units feature a communication port, providing optional monitoring, control and programming from a local PC and

Murphy software.

The model variation is labelled on the top side of each unit

(as shown overleaf), and should be checked before installation to ensure compatibility with each application.

Standard models are:-

The AS705S is designed for front of panel mounting through a DIN standard 92 x 92 mm aperture. Electrical connection is

AS705SKD 76.70.0065 AS705S with keyswitch, 230VAC at the rear, via a pair of two-part type screw terminal blocks. nominal generator voltage.

This document details the panel installation and electrical connection of the AS705S (standard versions as detailed opposite) fitted with firmware versions V1.00 – V1.06(a).

Additional information on the operation, specification and programming of the AS705S and AS7xx family of controls

Doc. Ref. ms5258 mi5265 mi5266

AS705S bulletin and specification

AS7xx installation section B: programming

AS705SRD 76.70.0037 AS705S with rotary (knob) switch,

230VAC nominal voltage

Special build variants have a numbered suffix to the model reference e.g. AS705SKD/001. For full details of special

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GENERAL INFORMATION (cont.)

Familiarisation (cont.)

Front Facia

LED indicators:-

- Preset x 10

- Programmable x 5

- Auto mode x 1

Manual mode x 1

Specifications

Power supply:

Operating voltage: steady state range

crank brown-out

Current consumption

Inputs:

Custom label sheet

Rear Facia

3 position operating mode switch (keyswitch shown):-

Off/reset

Auto

Manual

DC inputs (inputs 1 - 5, remote start) positive input voltage range negative input voltage range

Generator AC input:- operating voltage range frequency measurement range

Magnetic pickup:- operating voltage range frequency measurement range

2 x 15 way, two-part connectors, numbered

1 – 15 and 16 – 30

Outputs:

Start and fuel relays

Top Facia Labelling

Communication port

Mounting clamps x 2

Programmable outputs 1 to 3

Programmable output 4

Programmable output 5

(default setting: Common Alarm)

Programmable output 6

(default setting: Gen. contactor)

Auto & Manual outputs

Off/reset output

5 to 40 V DC continuous to 0V for <= 100 mSec typically 150 mA

80% to 100% of battery +ve

-1V to +2V from battery -ve

90 to 300 V AC rms

0 to 99 Hz.

7 to 80 V AC rms

0 to 10 kHz

(all ratings for resistive load) positive DC (switched relay) rated 16A max. @ 24V DC negative DC (semiconductor) rated 250mA max. @ 33 VDC negative DC (switched relay) rated 5A max. @ 24V DC positive DC (switched relay) rated 5A max. @ 24V DC volt free SPNO relay contacts rated 5A max. @ 240V AC positive DC, 250mA max. negative DC, 250mA max.

Model reference

Electrical connection details

Physical:

Overall dimensions (W x H x D)

Panel cut-out size

Weight

Operating ambient temperature

Case sealing

96 x 96 x 162 mm

DIN standard 92 x 92 mm approx. 650 g

-10 to +55 o

C

IP22

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FWMurphy – AS705S V1.00 – V1.06(a) installation instructions mi5396 revision E 1 st

June 2010 p2/6

INSTALLATION INFORMATION

Panel Mounting

The software is used to create and edit program ‘profiles’, which can be downloaded to the Autostart over the communication link, quickly and error free.

92

The AS705 is mounted in the front of a control panel through a

DIN standard aperture, 92 mm

(3 5/8 ”) square.

92

Full information about communication links and PC software may be found in document mi5266. Detailed information about the AS705 program options can be found in document mi5265 (AS7xx programming reference).

With the mounting clamps removed, insert the unit through the front of the panel cut-out (A).

Electrical Connection

General

A

B

(mm)

150

D

30

(typ)

C

The case extends to 150mm (6”) behind the panel front; a extra

30mm (1.25”) minimum should typically be allowed for the connection of the wiring harness.

Electrical connection is through a pair of terminal blocks at the rear of the unit: the two-part, screw terminals blocks are labelled 1 – 15 and 16 – 30. Use a 3mm (1/8”) flat head screwdriver to loosen and tighten each screw terminal.

Working behind the panel front, fit both mounting clamps to pairs of studs on each side of the case. Locate the clamp on to the front stud (B), compress the clamp by pushing on the screw

(C) and push the clamp upwards to locate on to the rear stud (D).

Before connection or disconnection, ensure that the unit is switched to O (off) and that all DC and AC power supplies are isolated.

WARNING: connection to or disconnection from live wiring can cause damage to internal

components.

General wiring recommendations

With both clamps fitted, tighten the screwed pins (E) so that they move forward and secure the unit to the rear of the panel facia (F). The case design allows for a panel thickness of up to 8mm.

Programming

The AS705 has over 50 programmable features, including settings for timers, trip levels, alarms and control options.

These MUST be programmed correctly before the Autostart can be tested or used to control an engine.

Murphy make the following recommendations:-

Terminal blocks

• Ensure that no more than 2 wires are inserted into each screw terminal

• Ensure that terminal blocks are fully pushed home into

Autostart rear facia receptacles.

External Slave Relays are a recommended connection on all outputs (as shown right), either to achieve the required load switching capability, or to reduce wear and tear on internal relay contacts.

Positive outputs

+

+

Autostart RL1

WARNING: Failure to correctly program each unit can result in damage to Autostart, engine

Slave relay and solenoid

coils will naturally emit voltage spikes when de-energising. and other equipment.

Negative outputs:-

+

Suppress this interference at source using the relay

The AS705 is programmed by connection to a PC running

1

2

3

4

5

12

13

14

15

6

7

8

9

10

11

16

17

18

19

20

27

28

29

30

21

22

23

24

25

26

Autostart

Murphy software model AS7CK. The communication link is made through the D-connector at the AS705 rear, and requires an RS232 interface unit and lead (supplied separately):- manufacturer’s recommended suppression network. DC coiled relays can also be

Product Phase Out RL1

Interface

AS7CC

705 AS7CK Check Availability

AS7CA (9 way F - 9 way F)

PC

COM shown right.

Battery chargers

Some battery chargers feature significant ripple and switching noise on the DC output. This electrical interference can be imposed on the panel power supply and control lines, with the potential to cause faulty operation of (and in extreme

Control panel

Autostart charger

+ or AS7CB (9 way F - 25 way F) cases damage to) electronic battery control equipment.

FWMurphy – AS705S V1.00 – V1.06(a) installation instructions mi5396 revision E 1 st

June 2010 p3/6

INSTALLATION INFORMATION (cont.)

Minimise the effects of charger output noise by using separate wiring 1) between charger output and battery terminals and

2) between battery terminals and panel DC supply rail.

Terminal Functions

Control panel

Autostart other controls charger

+ battery

6

7

9

10

Programmable output 1

Programmable output 2

Programmable output 3

Programmable output 4

These outputs may be programmed to give a range of signalling and control ‘actions’, e.g. ‘preheat’, ‘engine running’, ‘overspeed’, etc. Please refer to programming literature mi5265 for full details.

Electrically, all 4 terminals give a negative DC output when active. Outputs 1 to 3 are open collector transistor types, rated to a maximum current of 300mA. Output 4 is relay based, giving a switched negative output of up to 5 Amps.

The connection of slave relays is recommended, as detailed above in ‘general wiring recommendations’.

The functions of each connection are as follows:-

Terminal block 1 – 15

Pin Function

1

3

Negative DC power supply

Positive DC power supply

Autostart will operate with any clean, noise-free supply in the range 5 to 40 V DC (normally the engine’s 12V or

24V battery). Connect a 5 Amp anti-surge fuse in the positive DC line (pin 3). See also ‘general wiring recommendations’ above regarding battery chargers.

In normal operation, the AS705 measures the DC supply, and will flash the charge fail LED if the supply voltage falls out of programmed high and low limits.

8 A800 enable output

Pin 8 may be used to give a ‘seam free’ operation with the Murphy A800 alarm/annunciator unit. The output may be connected directly to the A800 enable input: the A800 fault/warning inputs are only then enabled once the

Autostart detects that the engine is running.

No attempt should be made to connect pin 8 to anything other than an A800 enable circuit.

11 Remote start/mains fail input

Use this input to initiate an automatic engine start in

AUTO mode. Pin 11 must be switched to positive DC when the engine is required to be on standby, and made open circuit to initiate an automatic start.

2 Charge fail input

A ‘charge fail’ warning may occur if pin 2 is switched to negative DC. The following program options are available:- a) Charge ‘alternator’. Connect pin 2 to the charge alternator warning lamp (WL) terminal – note that

Autostart provides the necessary charge excitation current. The ‘WL crank cut’ program settings allows the option of an automatic crank release above a pre-set charge alternator voltage.

Gives a negative DC output (250mA max.) when the unit is switched to (off/reset).

14

15

Manual mode output

Auto mode output

Each of these terminals gives a positive DC output

(250mA max) when Autostart is respectively switched to manual or auto modes. b) ‘Mains charger’. Connect pin 2 to the ‘charge fail’ output of a Murphy BC700 series charger, or direct to negative DC via relay contacts which close on fault. c) ‘Not used’ (or - -). Use this option if a charge fail alarm is not required, and leave pin 2 open circuit.

Terminal block 16 – 30

16

17

Input 1: (low) oil pressure (LOP)

Input 2: (high) engine temperature (HET)

4 Positive DC (feed for relays)/Emergency stop

This positive DC connection provides a feed for the Fuel and Start outputs (pins 22 and 23). If required, emergency stop switches (push to break, mechanically

‘emergency stop’ if pin 4 is made open circuit.

Allows the optional use of a magnetic pickup for sensing

Input pins 16 and 17 are dedicated for use with low oil pressure and high engine temperature fault switches.

The inputs may be programmed for use with either

‘open on fault’ or ‘closed on fault’ contacts, and for

Product Phase Out

Before use, the AS705 must be programmed with the correct number of flywheel teeth, and with correct trip levels (in engine RPM) for crank release, underspeed

The oil pressure input is also checked by Autostart before cranking the engine, and MUST therefore be connected to ensure correct operation. If a high oil pressure is detected, Autostart inhibits cranking and lights the ‘plant fail’ LED. and overspeed.

FWMurphy – AS705S V1.00 – V1.06(a) installation instructions mi5396 revision E 1 st

June 2010 p4/6

INSTALLATION INFORMATION (cont.)

18

19

20

Input 3 (programmable)

Input 4 (programmable)

Input 5 (programmable)

These inputs may be used with switch contacts to trigger a range of programmable ‘actions’, e.g. shutdown fault, warning fault, lamp test, manual restore

(of mains), etc. Full details of program ‘actions’ can be found in document mi5265.

Connect the switch contact between each input and battery positive or negative, and program each input to activate as required (open/closed/positive/negative). circuit. The output will activate (contacts close) when:- a) generator voltage is above 66% of nominal (nonprogrammable) b) generator frequency/speed is above the programmed trip level c) oil pressure is OK, and d) after the ‘warm-up’ delay time has expired.

21 Index pin (no connection)

22

23

Fuel output

Starter output

These are positive DC outputs, rated to 16 Amps, for the control of engine fuel and starter motor circuits.

Connection of slave relays is recommended, as detailed above in ‘general wiring recommendations’.

27

28

–ve DC

Manual Start Manual Stop

These terminals may be wired as above to panel pushbuttons, allowing operator control of engine starting and stopping when the unit is switched to ‘manual’ mode.

Alternatively, hard-wire pins 27 and 28 to battery negative to give an immediate engine start on switching to manual mode.

24 Programmable output 5

(default setting: ‘common alarm’)

Pin 24 is a positive DC relay output, rated to 5 Amps.

With its default ‘common alarm’ setting, the output activates during any fault (warning or shutdown). The output can, however, be programmed to give other

‘actions’, as for inputs 1 to 4.

25

26

Programmable output 6 (Normally Open contact)

Programmable output 6 (Change-over contact)

(default setting: ‘gen. contactor’)

Output 6 is a volt-free set of normally open relay contacts, which can be programmed with the same range of ‘actions’ as outputs 1 to 5.

With its default ‘gen. contactor’ action, the output is typically used to control a generator contactor coil

29

30

Generator Live

Generator Neutral

For generator applications, connect these terminals to generator AC (50/60Hz). Line to neutral or line to line connections may be used, so long as the voltage does not exceed 300VAC. Connect a 1 Amp anti-surge fuse in series with the generator live terminal (pin 29).

Autostart uses these terminals to sense the generator voltage, and also its frequency when a magnetic pickup is not used. Correct voltage and frequency is needed to ensure the operation of a ‘generator contactor’ output.

Frequency alone may be used to trigger the automatic crank release and overspeed trip.

For non-generator applications (e.g. a diesel pump), leave these terminals open circuit and ensure that the

‘AC sense’ setting is programmed to ‘no’. Speed sensing must then be made using a magnetic pickup (see pin 5).

TYPICAL CONNECTION (mains fail generator application)

M

A

I

N

S

L1

L2

L3

N mains contactor

L O A D

L1L2 L3 N gen.

contactor

MCCB

L1 L2 L3 N

UVR500

MCR

MCR1

1 2 3 4 5 6

GCR1

+ve DC

+

–

Fuse

GCR

Reset RPO1

Emerg.

stop 5A

16

WL

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Magnetic

RPO4 RPO2

2

3

4

5

6

8

9

10

11

13

14

15

AUTOSTART

705

17

18

19

20

22

23

24

25

26

28

29

30

1A

RST

RFL inputs

Fuel

Starter

Pickup

1

Manual Auto RAL Alarm

L1

L2

L3

N R

A

T

O

R

G

E

N

E

–ve DC

FWMurphy – AS705S V1.00 – V1.06(a) installation instructions mi5396 revision E 1 st

June 2010 p5/6

Custom labelling

INSTALLATION INFORMATION (cont.)

The top right of the front facia features 5 LEDs (2 amber,

3 red), each of which may be programmed to customer requirements. Approximately 40 functions are available, e.g. fuel on, generator on load, etc. - for a full lists of functions, please refer to programming reference mi5265.

Warranty and Maintenance

This unit is supplied with a 2 year warranty on parts and workmanship. Details are available on request and are supplied with each unit.

Next to these LEDs, the front label contains a pocket with clear windows, into which an appropriate custom message label can be inserted. Custom labelling is carried out as follows:-

Front

Bezel

Front

Label

The AS705 contains no user-serviceable parts. Maintenance is therefore limited to the following preventative checks:-

•

Check that the rear terminal blocks are pushed home fully, and that the wiring to screw terminals is secure.

•

Check that the Autostart is securely clamped in the front of panel aperture, and kept free from ingress of water or build up of excessive dust/dirt. The front facia label and casing may be wiped with a clean, damp cloth. Do not use cleaning solvents.

B

Main

Message

Label

E

C

A

D

Individual

Message

Labels

1 Remove the front facia bezel (A) by unsnapping each of the four corners in turn.

The keys of all AS705 units are generally interchangeable, but note that the key type changed in Jan. 2001. The keys, fixing clamps, terminal blocks are available as spare components, as are the range of communication accessories:-

Stock code Model ref

76.70.0096 AS3/KEYB

76.70.0304 AS7/KEYC

Description

1 pair of keys (L&F93201), for units Dec 2000 or earlier

(‘V’ serial number or earlier)

1 pair of keys (L&F85000), for units Jan 2001 or later

(‘W’ serial number or later)

76.70.0124 KEY/CLAMPS 1 pair of mounting clamps

2 Remove any existing label (B) by pulling on the label tab (C).

76.70.0121 AS7TBA

76.70.0122 AS7TBB

Terminal block 1-15

Terminal block 16-30

3 Prepare a new custom label. A sheet provided with each unit includes individual messages for common status and fault conditions. Cut out the text messages 76.70.0018 AS7CA Comms lead (null modem), as appropriate, remove the adhesive backing, and fix 9 way (interface) to 9 way (PC) the messages in the spaces provided on the ‘main

76.70.0019 AS7CB Comms lead (null modem), message label’ (also supplied on each sheet).

9 way (interface) to 25 way (PC)

Alternatively, custom labels may be designed and

76.70.0020 AS7CC Interface, Autostart to RS232 printed using Microsoft Excel spreadsheet file AS705 local communication

custom label.xls, which is supplied with programming

76.70.0203 AS7CK PC software for AS7xx software AS7CK. communication and

4 Insert the completed label into the AS705 front label programming (also available pocket. Ensure the label is correctly aligned, then snap free of charge from the on the front bezel.

‘Downloads’ section of

Note: the 10 LEDs on the left of the front facia are also www.fwmurphy.co.uk) programmable (LEDs A – J in the programming software), but are preset in terms of the standard front facia label.

Labels to custom design are however available in bulk quantities – please contact your Murphy representative

FW MURPHY

P.O. Box 470248, Tuls a, Oklahoma 74147 USA

In the event of a fault or technical query, please contact your

Murphy representative for technical support. Technical documents are also available from the Products sections of our web-site www.fwmurphy.co.uk

Product Phase Out

INDUSTRIAL PANEL DIVISION

Fax: +1 918 317 4124

FRANK W. MURPHY LTD.

Church Road, Laverstock,

Salisbury, SP1 1QZ, United Kingdom

Tel: +44 1722 410055

Fax: +44 1722 410088

E-mail: [email protected]

FW MURPHY INSTRUMENTS (HANGZHOU) CO., LTD.

77 23 r d Street, Hangzhou Economic & Technological Development Area

Hangzhou, Z hejiang, 310018, China

Phone: +86 571 8788 6060 Fax: +86 571 8684 8878

E-mail: [email protected]

Phone: +1 281 633 4500 Fax: +1 281 633 4588

E-mail: css -solutions @fwmurphy.com

+1 918 317 4100 Fax: +1 918 317 4266

E-mail: s [email protected]

E-mail: ipds [email protected]

MURPHY POWER IGNITION

Website: www.murphy-pi.com

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CONTROL SYSTEMS AND SERVICES DIVISION

P.O. Box 1819, Rosenberg, Texas 77471 USA

41 – 46 Railway Terrace, Nechells,

Birmingham, B7 5N G, United Kingdom

Tel: +44 121 327 8500

Fax: +44 121 327 8501

E-mail: [email protected]

Web: www.computroniccontrols.com

FWMurphy – AS705S V1.00 – V1.06(a) installation instructions mi5396 revision E 1 st

June 2010 p6/6