Autostart AS731 Generator Controller
Installation Instructions
mi6243
st
revision A, 1 November 2002
catalog section 75
Section C: AS730 to AS731/AS732 retrofitting
TM
GENERAL INFORMATION
WARNING
Front facia
AS730
AS731/732
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
General
The Autostart AS731 and AS732 are full function,
programmable controllers for the automatic or manual
control of a standby generator.
Both units have similar features to the older AS730. This
document gives compatibility details for use when fitting an
AS731/732 in place of an AS730. Full information about the
specification, installation and operation of the units may be
found in the following documents:-
1. 2 line x 16-character backlit liquid crystal display
2. Operator control keys
3. Auto/manual mode LED indication
Rear facia
AS730
AS731/732
Doc. ref. Title
ms6127
ms6343
mi6128
mi6129
mi6130
mi6131
ms5261
mi5264
mi5265
mi5266
AS731 bulletin and specification
AS732 bulletin and specification
AS731/732 installation section A: mounting/wiring
AS731/732 installation section B: programming
AS731/732 operation
AS731/732 comms and AS7CN PC software
AS730 bulletin and specification
AS730 installation section A: mounting/wiring
AS730 installation section B: programming
AS730 communications and AS7CK PC software
4.
5.
6.
7.
Mounting clamps
Screw terminal blocks
RS232 communication port (RJ11 connector)
(AS732 only) RS485 comms ports (2 x RJ45 connectors)
Panel mounting
The AS730 and AS731/AS732 use the same casing and
mounting procedure. Please consult document mi6128 for
full details.
TM
FWMurphy
Murphy
PO Box 470248
Tulsa, Oklahoma 74147, USA
tel: (918) 317 4100
fax: (918) 317 4266
email: [email protected]
web: www.fwmurphy.com
CONTROL SYSTEMS AND SERVICES DIVISION
PO Box 1819, Rosenberg, Texas 77471, USA
tel: (281) 342 0297
fax: (281) 341 6006
email: [email protected]
FRANK W. MURPHY LTD.
Church Rd, Laverstock, Salisbury, SP1 1QZ, UK
tel: +44 1722 410055
fax: +44 1722 410088
email: [email protected]
web: www.fwmurphy.co.uk
MURPHY DE MEXICO S.A. DE C.V.
Blvd. Antonio Rocha Cordero 300, Fracción del Aguaje
San Luis Potosí, S.L.P. México 78384
tel: + 52 444 8206264
fax: + 52 444 8206336
email: [email protected]
web: www.murphymex.com.mx
MURPHY SWITCH OF CALIFORNIA
41343 12th Street West,
Palmdale, CA 93551-1442, USA
tel: (661) 272 4700
fax: (661) 947 7570
email: [email protected]
web: www.murphyswitch.com
MACQUARRIE CORPORATION
1620 Hume Highway,
Campbellfield, Victoria 3061, Australia
tel: +61 3 9358 5555
fax: +61 3 9358 5558
email: [email protected]
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.
ELECTRICAL CONNECTION
DANGER !
HIGH VOLTS
WARNING: DANGER OF INJURY OR DEATH. During normal operation, the
AS730/731/732 is connected to high voltage circuits. Before connection, disconnection
or handling of these units, ensure that all AC and DC power supplies are isolated.
Connection to or disconnection from live wiring can also cause damage to Autostart internal
components.
Electrical Compatibility
Most of the AS730 connections have electrically
compatible counterparts on the AS731/AS732. Note,
however, that the physical connectors and terminal
numbering are NOT compatible. The AS730 has 3
vertically oriented terminals blocks, whereas the
AS731/732 has 2 horizontal (non-compatible) blocks.
Individual wiring connections must be unscrewed from
the AS730 blocks, and re-connected into the appropriate
AS731/732 terminal(s).
AS730 AS731/ Function/Compatibility
pin no. AS732
pin no.
8
(cont)
-
+
The guide below gives terminal number cross references,
and details of compatibility, for use when migrating from
AS730 to AS731/AS732. Typical wiring diagrams for both
units are shown on page 4.
AS731
1
3
Negative DC power supply
Positive DC power supply
Fully compatible.
2
2
Charge fail input
Fully compatible. Program the AS731/732
as for the AS730.
4
4
Positive DC / Emergency stop
Fully compatible.
5
-
19
20
Magnetic pickup input
Magnetic pickup input return
On the AS730, one terminal of the
(optional) magnetic is connected to pin 5;
the other pickup terminal is connected to
battery negative.
On the AS731/732, a separate terminal
(pin 20) is provided for the pickup return.
6
7
9
10
9
10
11
-
Output 1 (AS730) / output 2 (AS731/732)
Output 2 (AS730) / output 3 (AS731/732)
Output 3 (AS730) / output 4 (AS731/732)
Output 4 (AS730 only)
AS730 programmable outputs 1 to 3 (pins 6,
7 and 9) are fully compatible with AS731/732
outputs 2 to 4 (pins 9, 10 and 11).
AS730 output 4 is a relay based, negative
DC output rated to 5 Amps max, with no
direct equivalent on the AS731.
8
-
A800 enable (AS730 only)
Pin 8 of the AS730 allows for direct
connection to (and seam free operation of)
the ‘enable’ terminal of a Murphy A800
annunciator.
The AS731/732 does not have a directly
compatible terminal. If an A800 ‘enable’
connection is required, the same result
can be achieved using a spare output:
RL1
A800
enable
11
AS730 AS731/ Function/Compatibility
pin no. As732
pin no.
1
3
connect the slave relay as shown below
(AS731/732 output 4 shown), and program
the output to ‘engine running’.
The relay provides the A800 with the
required positive DC input as soon as the
AS731/732 detects an engine running state.
11
18
12
13
14
15
-
16
17
-
12
13
14
Input 1: (low) oil pressure
Input 2: (high) engine temperature
Input 1 and 2 return (AS731/732 only)
These inputs allow connection to engine
mounted fault switches or resistive senders.
On the AS730, the ‘return’ side of the switch
or sender is connected to battery negative
DC. On the AS731/732, a separate
connection (pin 14) is used for the return
wiring, providing better immunity to signal
noise. Program the AS731/732 as for the
AS730.
18
19
20
15
16
17
Input 3
Input 4
Input 5
These programmable inputs are fully
compatible. Programming of the AS731/732
is similar to the AS730, but each AS731/732
input can be individually set activate on
open/closed/positive/negative signal.
21
-
Index pin (AS730 only)
22
23
5
6
Fuel output
Starter (crank) output
Fully compatible.
FWMurphy – AS731/732 installation section C: AS730 to AS731/AS732 retrofitting
Remote start / mains fail
Fully compatible. Program the AS731/732 as
for the AS730 (open from / closed to positive
DC to activate).
No connection (AS730)
No connection (AS730)
No connection (AS730)
No connection (AS730)
st
mi6243 revision A 1 November 2002 p2/4
ELECTRICAL CONNECTION (cont.)
AS730 AS731/ Function/Compatibility
pin no. AS732
pin no.
Output 5 (AS730 only)
24
AS730 pin 24 is a positive DC relay
output, rated to 5 Amps. There is no
equivalent connection on the AS731/732.
25
26
7
8
Output 6 (AS730) / output 1 (AS731/732)
Output 6 (AS730) / output 1 (AS731/732)
AS730 output 6 (pins 25 and 26) is a pair of
volt free, normally open contacts, rated to 5
Amp max.
AS731/732 pins 7 and 8 are fully compatible
with the above, but are designated output 1.
Program AS731/732 output 1 as for AS730
output 6. The factory default programming
for both is ‘gen contactor’.
27
28
29
30
-
-
AS730 AS731 Function/Compatibility
pin no. AS732
pin no.
74
75
76
77
78
79
25
26
27
28
29
30
CT L1
CT L1 return
CT L2
CT L3 return
CT L3
CT L3 return
These connections are electrically
compatible. Program the AS731/732 as
for the AS730.
Communications
RS232 communication
Manual stop input (AS730 only)
Manual start input (AS730 only)
On the AS730, these pins allow optional
connection of panel mounted manual mode
start and stop push buttons.
Both AS730 and AS731/732 have RS232 serial ports on the
rear facia, allowing local or remote (modem) communication
with a PC running Murphy software. AS730 communication
is via a 9 way D-type connector, which also requires an
external RS232 interface unit (models AS7CC or AS7CD).
The AS731/732 uses an RJ11 (telephone type) connector
and does not require a separate interface.
The AS731/732 has no equivalent,
dedicated connection, since manual mode
starting and stop can be carried out from
the front facia.
The communication leads used with the AS730 cannot
be used or easily modified for operation with an AS731/732.
Replacement leads and adaptors are available from your
Murphy representative.
If remote panel controls are required,
AS731/732 inputs 3 to 5 (if spare) can be
programmed to ‘manual start’ and ‘manual
stop’. To ensure compatibility with the
AS730 wiring, the ‘manual start’ input must
be set to activate on ‘closed to negative’,
and the ‘manual stop’ input must be set to
activate on ‘open from negative’.
RS485 communication
Generator AC (AS730 only)
Generator AC (AS730 only)
AS732 units feature RS485 MODBUS communications,
accessed via 2 x RJ45 connectors on the rear facia.
The AS730 and AS731 do not have an RS485 facility.
For full details about AS731/732 communications, PC
software and accessories, please refer to document mi6131.
WARNING: HIGH VOLTAGE - DANGER
OF INJURY OR DEATH.
On the AS730, these (frequency sensing)
connections are required in addition to the
multi-phase connections on pins 70 – 73.
On the AS731/732, frequency sensing is
done through pins 21 – 24 (see below).
70
71
72
73
21
22
23
24
Generator AC phase L1
Generator AC phase L2
Generator AC phase L3
Generator AC neutral
WARNING: HIGH VOLTAGE - DANGER
OF INJURY OR DEATH.
These connections are electrically
compatible. Program the AS731/732 as for
the AS730.
FWMurphy – AS731/732 installation section C: AS730 to AS731/AS732 retrofitting
st
mi6243 revision A 1 November 2002 p3/4
ELECTRICAL CONNECTION (cont.)
AS730 typical wiring diagram (automatic mains fail generator)
mains
contactor
generator
contactor
LOAD
L1 L2 L3 N
L1
L2
L3
N
L1 G
L2 E
L3 N
N E
R
A
T
O
R
MCCB
MCR1
MCR
1 2 3 4 5 6
Autostart
730
+ve DC
Emergency
RPO1 Stop
fuse
RPO2
RPO3
RPO4
+
WL
A
–
5A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
70
71
72
73
74
75
76
77
78
79
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
GCR
GCR1
1A
1A
1A
inputs
RFL
magnetic
pickup
RST
RAL
IP5
IP4
IP3
HET
LOP
L1 L2 L3 N
UVR500
manual manual
start
stop
M
A
I
N
S
fuel
starter
alarm
–ve DC
AS731 typical wiring diagram (automatic mains fail generator)
mains
contactor
M L1
A L2
I L3
N N
S
generator
contactor
LOAD
L1 L2 L3 N
L1 G
L2 E
L3 N
N E
R
A
T
O
R
MCCB
L1L2 L3 N
MCR1
UVR500
MCR
GCR
GCR1
123456
+ve DC
RPO2
RPO3
+
Emerg.
Stop
RPO4
A
Autostart
731 21
5A
fuse
WL
–
magnetic
pickup
IP5
IP3
RST
IP4
starter
RFL
HET
fuel
LOP
inputs
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
22
23
24
1A
1A
1A
25
26
27
28
29
30
–ve DC
FWMurphy – AS731/732 installation section C: AS730 to AS731/AS732 retrofitting
st
mi6243 revision A 1 November 2002 p4/4
">
