MURPHY Cascade Auto-Start Controller Installation and Operations Manual
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Cascade Auto-Start Controller 00-02-0587 Revised 03-11-05 Section 40 Installation and Operations Manual Version: 1.01 nt bi in lit u y ed Please read the following information before installing. A visual inspection of this product for damage during shipping is recommended before mounting. It is your responsibility to have a qualified person install this unit and make sure it conforms to NEC and local codes. GENERAL INFORMATION Mounting the Cascade Cut a 5.63 x 4.06 in. (143 x 103mm) mounting hole, and drill four 0.169 in.(4.3 mm) diameter holes for the mounting screws. See Schematic below: WARNING Cut Out Dimensions 5.63 x 4.06 in. (143 x 103 mm). Specifications A va To Install, You Will Need: #2 Phillips (cross head) head screwdriver Nut driver to fit #6-32x1/2” machine nuts Wire for hook-up (rising cage clamp suitable for 14-24 gage wire). MURPHY, the Murphy logo, Cascade, and SWICHGAGE(r) are registered and/or common law trademarks of Murphy Industries, Inc. This document, including textual matter and illustrations, is copyright protected by Murphy Industries, Inc., with all rights reserved. (c) 2004 Murphy Industries, Inc. Not used 15 Aux. 4 out 14 Aux. 3 out 13 Remote call to run 12 Aux. 2 in 11 Aux. 1 in 10 Hi engine temp. 9 Lo oil press. 8 Alt. Excite. 7 Aux. 2 out 6 Aux. 1 out 5 Crank 4 Mag. Pickup + Mag. Pickup – OPEN 24 25 26 27 Fuel/ECU 3 -V Batt. 2 +V Batt. 1 5.63 in. (143 mm) 6.06 in. (154 mm) 6.57 in. (167 mm) fo r C ro he ck du ct D Power input: 9-35VDC continuous - operates during total blackout for 2 sec. min. Power consumption: Sleep Mode (Manual): 1mA typical;(Automatic) 4mA typical. Running Mode (Manual): 20mA typical; (Automatic): 24mA typical. Operating/Storage temperature: -40 to 85°C; (-40 to 185°F). Humidity: 0-100%, non-condensing. Housing: UV stabilized black polycarbonate and epoxy encapsulation. Weather tight and includes sealing gasket to keep moisture and debris out of enclosure. Properly mounted controller will maintain NEMA4 / IP65 rating of enclosure. Vibration: Rated to 6G. Impact: Rated to 10G. Inputs: Dedicated digital inputs for low oil pressure, high engine temperature, remote start, DC charge fail/Alternator fail. Two aux inputs are configurable for multiple functions. Outputs: 7 – 4 auxiliary, configurable (2A DC protected). 3 dedicated outputs for Crank, Fuel/ECU, Alternator excitation. Crank attempts: 3, 5, 10, Continuous. Crank Rest: 5-60 seconds, adjustable. Shutdown lockout time delay: 5, 10, 15, 20, 25, 30 seconds. Crank disconnect speed setting: Field settable 0-9999 RPM (16-60Hz AC freq input). Overspeed/underspeed trip point setting: ±5 to 50% of nominal. Speed sensing inputs: Magnetic pickup (5-120VAC RMS / 0-10 kHz) & AC frequency (30-600VAC RMS / 16-80 Hz). CANbus interface: Directly reads engine speed, & engine status data* from SAEJ1939 enabled engines. MODbus interface: In J1939 applications drives PVA series analog gages *Engine status data limited to low oil pressure, high engine temperature, “Wait to start” status, Warning & Fault lamp information, and communication error. 1 2 3 4 AC Neutral is The Cascade controller offers automatic start/stop control with easy configuration for a broad number of engine driven applications. 0.169 in. (4.3 mm) diameter 4 places ila Description P Gasket co 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. 4.06 in. (103 mm) 4.49 in. (114 mm) 5.00 in. (127 mm) ✔ ✔ ✔ ✔ AC Line BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT Recommended Wiring Practices Warning: The CASCADE is designed for pilot-duty use and its outputs are for control only. Wire the CASCADE controller with 18 gage stranded wire. Important: For applications involving automatic start equipment, we strongly recommend the installation of an appropriate Emergency Stop device. 1. To help prevent electrical noise and voltage drop to the controller during cranking and preheat, wire the controller DC power connections directly to the cranking battery. This will also help improve “Low battery” starting capability. 2. When using a battery charger, it should be connected directly to the battery to help prevent electrical noise which could cause an engine ECU or associated equipment to operate erratically. 3. Never route low voltage DC wiring in the same conduit as high voltage AC wiring. Noise from electrical loads such as motors and variable frequency drives can be coupled into the engine ECU, governor, or associated equipment and may cause erratic operation. 4. Always use twisted shielded pair wires for the magnetic pickup wiring. Ground one end of the shield only. 5. In spark ignited engine applications, always use resistive spark plugs and spark plug wires, as these greatly reduce the amount of radiated noise. 6. Always place a snubbing diode (sometimes also called an anti-flyback, anti-kickback or reverse bias diode) directly across any inductive load. This helps eliminate a common source of electrical noise, as well as increases the operating lifetime of any solid state output. 7. Always use twisted shielded pair communications wiring for RS-485, and SAE standard wire for J1939. Make sure that terminating resistors (if required) have the correct rating and are installed properly. 00-02-0587 page 1 of 8 LED Status Lights Setting Up the Cascade Eleven LEDs separated into two banks (see “Fig. 1”) are provided on the faceplate. The LEDs Bank 1 includes 6 LEDs and Bank 2 includes 5. In Setup mode, these banks form a binary code to indicate either the controller setup configuration or error status, which is indicated by the last 8 (red) LEDs. Refer to Tables 1, 2, 3 and 4 for configuration and status listings. One LED is located next to the “AUTO” button to indicate that the controller is waiting for the remote start input to become active. The LED status light are (from top to bottom) see “Fig. 1”: ● ● On the back of the controller are four DIP switches, set switch #1 to ON (see schematic at right) OPEN then restore DC power. The AUTO mode LED NOTE: Switch settings are will blink to indicate that the Cascade is in the read at Power Up only. SETUP MODE. Engine running - If the green LED is ON, then the unit is receiving a speed signal, indicating that the engine is above the crank cut speed. ● When in the “SETUP” mode, pressing the “MAN” (Manual) button steps up thru the entire list of parameters. The pattern of the top six LEDs, LEDs Bank 1 (see “Fig. 1”), is used to indicate which parameter is selected. The pattern will change once each time the “MAN” button is pressed. ● Pressing the “OFF” button steps up thru all the available values for each parameter. The pattern of the bottom five LEDs, LEDs Bank 2 (see “Fig. 1”), is used to indicate which value is selected. The pattern will change once each time the OFF button is pushed. ● Pressing the “AUTO” button stores the displayed value. ● If any value is changed, it will blink until stored, except a value of zero. If any value is changed but not stored, and then the parameter is changed, the value will still be what was shown originally. nt bi in lit u y ed A C ECU STATUS LEDs Bank 1 LOW OIL PRESSURE Parameter # P ENGINE RUNNING HIGH ENGINE TEMPERATURE ● 3 Operating the Cascade When power is first applied, all LEDs will flash indicating a Lamp Test function. ● To manually start the engine, press the “MAN” (Manual) button. The controller will initiate a normal start sequence. ● To manually stop the engine (or turn off the controller) press the “OFF” button. ● To place the controller in automatic mode, press the button labeled “AUTO”. The LED next to the “AUTO” button should come on to indicate that the controller is waiting for the remote start input to become active to initiate a start sequence. ● To reset the controller, press the “OFF” button. Then correct the cause of the shutdown. This will clear all faults except when the aux inputs are programmed for either shutdown immediate or warning immediate, or if the engine ECU is broadcasting a shutdown fault. In the event of a fault that causes the engine to shutdown, the cause of the event will be indicated on one of the 11 status lights on the right hand side of the controller. When the cause of shutdown is corrected,the controller can resume normal operation. Modes of Operation Setup Mode (See “Setting Up The Cascade” section, above and “Table 1”). Error Mode OVERCRANK/START FAIL LEDs Bank 2 Value AUXILIARY2 The parameter/value list and correspondFig. ing LED indication are shown on Table 1. When you are finished with setup, set switch #1 to in the Normal Operating Position (OPEN), remove DC power for 10 seconds, then restore DC power. The DIP switch #1 must be in the open position in order to enter this mode upon power up. The “Table 2” shows the meaning of each LED state for this mode. UNDERSPEED AUXILIARY1 AUTO Normal Operating Mode (Engine Control Mode) OVERSPEED CHARGE FAIL OFF A va D LED’s REMOTE START/CRANK REST MAN fo r ct he ck du ro Fig. 1 ● AUTO Mode LED If you accidentally go past a desired parameter or value, you can step back by pressing the down arrow button. is ● 1 2 3 4 ila O Move Switch toward the numbers to Turn On Fig. 2 co ECU status - If the green LED is on solid, it indicates that in a J1939 application the ECU and the unit are communicating properly. If the LED is blinking slowly the ECU is broadcasting a “wait to start” message. If the LED is blinking fast, the ECU is NOT communicating properly. Remote Start/ Crank Rest - If the green LED is on, then the remote start input is active and if the system is in AUTO mode, it will try to start. If the LED is blinking, the crank cycle has ended and is now in crank rest cycle. Low oil pressure - If the red LED is on, the controller has caused the engine to shutdown and lockout. If the LED is blinking, the engine ECU has transmitted a SPN for an oil pressure related condition. High Engine Temperature - If the red LED is on, the controller has caused the engine to shutdown and lockout. If the LED is blinking, the engine ECU has transmitted a SPN for an engine temperature related condition. M Overspeed - If the red LED is on, the controller has caused the engine to shutdown and lock out due to engine speed exceeding the setpoint. Underspeed - If the red LED is on, the controller has caused the engine to shutdown and lock out due to engine speed falling below the minimum needed for proper operation. Overcrank - If the red LED is on, the controller has exceeded the set number of start attempts without receiving a valid speed signal indicating that engine speed is above crank disconnect. This causes the engine to shutdown and lockout. Charge Fail - If the red LED is on it indicates that the battery charging alternator is not charging the cranking batteries, or that the battery charger fail output is on. Aux 1 - If the red LED is on it indicates that this custom-configured input is active. On an ECU (ECM) equipped engine, if this LED is blinking slowly, it indicates that one or more engine parameters are near exceeding engine manufacturer’s setpoints. If the LED is blinking fast, it indicates that one or more engine parameters have exceeded setpoints, the ECU has issued a fault - and most likely the engine has shut down. Aux 2 - If the red LED is on it indicates that this custom-configured input is active. Overspeed & Underspeed - If these two LED’s are both blinking, the controller has lost its speed signal. To enter the SETUP MODE first remove DC power to the Cascade controller for approximately 10 seconds. Upon power up, when the DIP switch #1 is in the Normal Operating Position (open position) and an error is detected in the user configuration, the Error mode will be accessed. The LEDs will Blink Fast indicating the error. To correct the errors before the unit can operate in Engine Control mode, the user will need to go back to Setup mode. “Tables 3 and 4” show the meaning of each LED state and configuration for the Error mode. 00-02-0587 page 2 of 8 Table 1. Parameter Values and Corresponding LED Indication LEDs shown here form a binary code indicating the configuration value. Shown from Top to bottom the LEDs read from Left to Right (see Fig.1). A filled dot means LED is ON. Crank Attempts ❍❍❍❍●❍ Crank Timer ❍❍❍❍●● Crank Rest Timer ❍❍❍●❍❍ ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍●❍❍ ❍❍●❍● ❍❍●●❍ ❍❍●●● ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍●❍❍ ❍❍●❍● ❍❍●●❍ ❍❍●●● ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍●❍❍ ❍❍●❍● ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍●❍❍ ❍❍●❍● ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍●❍❍ ❍❍●❍● ❍❍●●❍ ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍●❍❍ ❍❍●❍● ❍❍●●❍ ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍●❍❍ ❍❍●❍● ❍❍●●❍ ❍❍❍❍❍ ❍❍❍❍● ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍●❍❍ Stop Delay Timer (auto mode only) ❍❍❍●●❍ ❍❍❍●●● Extended Preheat ❍❍●❍❍❍ ro Cooldown Timer ❍❍●❍●❍ Bypass Timer C ❍❍●❍❍● P Warmup Timer ❍❍●❍●● Energize to Stop Timer ❍❍●●❍❍ Aux Input Bypass Timer ❍❍●●❍● Remote Start Signal Type ❍❍●●●● Digital Input 1 ❍●❍❍❍❍ Digital Input 2 ❍●❍❍❍● Digital Input 3 (Auxiliary Input 1) ❍●❍❍●❍ Digital Input 4 (Auxiliary Input 1) ❍●❍❍●● fo r he ck du ct Preheat Timer LED Bank 1 A va ❍❍❍●❍● D Start Delay Timer (auto mode only) Parameter Value (*= default) LED Bank 2 5 Min 6 Min 7 Min 8 Min 9 Min 10 Min 15 Min 20 Min 25 Min 30 Min 35 Min 40 Min 45 Min 50 Min 55 Min 1 Hr Maintained* Momentary Lo Oil Press (Open/Fault) Lo Oil Press (Close/Fault)* Hi Eng Temp (Open/Fault) Hi Eng Temp (Close/Fault)* Not Used* Winter/Summer Momentary Stop Immediate Warning Delayed Warning Immediate Shutdown Delayed Shutdown Delayed Aux Input Shtdwn Run/Idle (Line Fill) Auxiliary Crank Disconnect Remote Reset (Clear Faults) Not Used* Winter/Summer Momentary Stop Immediate Warning Delayed Warning Immediate Shutdown Delayed Shutdown Delayed Aux Input Shtdwn Run/Idle (Line Fill) Auxiliary Crank Disconnect Remote Reset (Clear Faults) Energized to Run* Energized to Stop Not Used* Warmup Cooldown Warmup/Cooldown Preheat Engine Running At Load Lo Oil Press Shutdown Hi Eng Temp. Shutdown Overspeed Shutdown Overcrank Shutdown Alternator Fail Engine Speed Up Engine Speed Down Common Alarm Not Used* Warmup Cooldown Warmup/Cooldown Preheat Engine Running At Load Lo Oil Press Shutdown Hi Eng Temp. Shutdown Overspeed Shutdown ❍❍●❍● ❍❍●●❍ ❍❍●●● ❍●❍❍❍ ❍●❍❍● ❍●❍●❍ ❍●❍●● ❍●●❍❍ ❍●●❍● ❍●●●❍ ❍●●●● ●❍❍❍❍ ●❍❍❍● ●❍❍●❍ ●❍❍●● ●❍●❍❍ ❍❍❍❍❍ ❍❍❍❍● ❍❍❍❍❍ ❍❍❍❍● ❍❍❍❍❍ ❍❍❍❍● ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍●❍❍ ❍❍●❍● ❍❍●●❍ ❍❍●●● ❍●❍❍❍ ❍●❍❍● ❍●❍●❍ ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍●❍❍ ❍❍●❍● ❍❍●●❍ ❍❍●●● ❍●❍❍❍ ❍●❍❍● ❍●❍●❍ ❍❍❍❍❍ ❍❍❍❍● ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍●❍❍ ❍❍●❍● ❍❍●●❍ ❍❍●●● ❍●❍❍❍ ❍●❍❍● ❍●❍●❍ ❍●❍●● ❍●●❍❍ ❍●●❍● ❍●●●❍ ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍●❍❍ ❍❍●❍● ❍❍●●❍ ❍❍●●● ❍●❍❍❍ ❍●❍❍● nt bi in lit u y ed LED Bank 2 Magnetic Pickup* Generator AC J1939 3* 5 10 Continuous 5 Sec 10 Sec 15 Sec* 20 Sec 25 Sec 30 Sec 45 Sec 60 Sec 5 Sec 10 Sec 15 Sec* 20 Sec 25 Sec 30 Sec 45 Sec 60 Sec 0 Sec* 5 Sec 10 Sec 15 Sec 30 Sec 60 Sec 0 Sec* 5 Sec 10 Sec 15 Sec 30 Sec 60 Sec 0 Sec* 5 Sec 10 Sec 15 Sec 20 Sec 25 Sec 30 Sec 0 Sec* 5 Sec 10 Sec 15 Sec 20 Sec 25 Sec 30 Sec 0 min.* 1 min. 5 min. 10 min. 0 min.* 1 min. 5 min. 10 min. 0 Sec 5 Sec 10 Sec* 15 Sec 20 Sec 25 Sec 30 Sec 15 Sec* 30 Sec 30 Sec* 1 Min 2 Min 3 Min 4 Min ila Value (*= default) ❍❍❍❍❍● co LED Bank 1 Engine Speed Source is Parameter Fuel Relay Control (non ECU Engines) Auxiliary Output 1 ❍●❍●●❍ Auxiliary Output 2 ❍●●❍❍❍ 00-02-0587 page 3 of 8 ❍●❍●●● Table 1. Parameter Values and Corresponding LED Indication (continued) LEDs shown here form a binary code indicating the configuration value. Shown from Top to bottom the LEDs read from Left to Right (see Fig.1). A filled dot means LED is ON. ❍●●●●❍ Crank Disconnect RPM (ECU or MPU speed source only) (100’s digit) ●❍❍❍❍● C P Crank Disconnect RPM (ECU or MPU speed source only) (1000’s digit) ●❍❍❍●❍ Value (*= default) 0 1 2 3 4* 5 6 7 8 9 0* 1 2 3 4 5 6 7 8 9 5% 10%* 15% 20% 25% 30% 35% 40% 45% 50% 5% 10% 15% 20%* 25% 30% 35% 40% 45% 50% none Warning* Shutdown Disabled (no shutdown) 0 PSI 5 PSI 10 PSI 15 PSI 20 PSI 25 PSI 30 PSI* 35 PSI 40 PSI 45 PSI 50 PSI 55 PSI 60 PSI Disabled (no shutdown) 190 deg F 195 deg F 200 deg F 205 deg F 210 deg F 215 deg F 220 deg F 225 deg F 230 deg F* 235 deg F 240 deg F 245 deg F 250 deg F Warning Disabled 8.5V 9.0V LED Bank 2 ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍●❍❍ ❍❍●❍● ❍❍●●❍ ❍❍●●● ❍●❍❍❍ ❍●❍❍● ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍●❍❍ ❍❍●❍● ❍❍●●❍ ❍❍●●● ❍●❍❍❍ ❍●❍❍● ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍●❍❍ ❍❍●❍● ❍❍●●❍ ❍❍●●● ❍●❍❍❍ ❍●❍❍● ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍●❍❍ ❍❍●❍● ❍❍●●❍ ❍❍●●● ❍●❍❍❍ ❍●❍❍● ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍●❍❍ ❍❍●❍● ❍❍●●❍ ❍❍●●● ❍●❍❍❍ ❍●❍❍● ❍●❍●❍ ❍●❍●● ❍●●❍❍ ❍●●❍● ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍●❍❍ ❍❍●❍● ❍❍●●❍ ❍❍●●● ❍●❍❍❍ ❍●❍❍● ❍●❍●❍ ❍●❍●● ❍●●❍❍ ❍●●❍● ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ nt bi in lit u y ed Crank Disconnect RPM (ECU or MPU speed source only) (1’s digit) ●❍❍●❍❍ Overspeed Setpoint (% above run speed ●❍❍●❍● ila co ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍●❍❍ ❍❍●❍● ❍❍●●❍ ❍❍●●● ❍●❍❍❍ ❍●❍❍● ❍●❍●❍ ❍●❍●● ❍●●❍❍ ❍●●❍● ❍●●●❍ ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍●❍❍ ❍❍●❍● ❍❍●●❍ ❍❍●●● ❍●❍❍❍ ❍●❍❍● ❍●❍●❍ ❍●❍●● ❍●●❍❍ ❍●●❍● ❍●●●❍ ❍❍❍❍❍ ❍❍❍❍● ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍●❍❍ ❍❍●❍● ❍❍●●❍ ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍●❍❍ ❍❍●❍● ❍❍●●❍ ❍❍●●● ❍●❍❍❍ ❍●❍❍● ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍●❍❍ ❍❍●❍● ❍❍●●❍ ❍❍●●● ❍●❍❍❍ ❍●❍❍● ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍●❍❍ ❍❍●❍● ❍❍●●❍ ❍❍●●● ❍●❍❍❍ ❍●❍❍● he ck ●❍❍❍❍❍ LED Bank 1 ●❍❍❍●● ❍●●●❍ ct ❍●●●●● ro Crank Disconnect Freq. (Generator AC speed source only) (1’s digit) Crank Disconnect RPM (ECU or MPU speed source only) (10’s digit) du Nominal Generator Frequency (genset only) Crank Disconnect Freq (Generator AC speed source only) (10’s digit) Lower Limit=16 Hz Parameter ❍●❍●❍ ❍●❍●● ❍●●❍❍ ❍●●❍● D ❍●●❍●❍ Auxiliary Output 4 LED Bank 2 Overcrank Shutdown Alternator Fail Engine Speed Up Engine Speed Down Common Alarm Not Used* Warmup Cooldown Warmup/Cooldown Preheat Engine Running At Load Lo Oil Press Shutdown Hi Eng Temp. Shutdown Overspeed Shutdown Overcrank Shutdown Alternator Fail Engine Speed Up Engine Speed Down Common Alarm Not Used* Warmup Cooldown Warmup/Cooldown Preheat Engine Running At Load Lo Oil Press Shutdown Hi Eng Temp. Shutdown Overspeed Shutdown Overcrank Shutdown Alternator Fail Engine Speed Up Engine Speed Down Common Alarm 50 Hz 60 Hz* 0 1 2* 3 4 5 6 0* 1 2 3 4 5 6 7 8 9 0* 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5* 6 7 8 9 Underspeed Setpoint (% below run speed ●❍❍●●❍ A va ❍●●❍❍● Auxiliary Output 3 Value (*= default) is LED Bank 1 Underspeed Response fo r Parameter ●❍❍●●● Lo Oil Press Shutdown Setpoint (ECU eng. only) ●❍●❍❍❍ Hi Eng Temp. Shutdown Setpoint (ECU engines only) ●❍●❍❍● Lo Batt Voltage Setpoint. ●❍●❍●❍ 00-02-0587 page 4 of 8 Table 1. Parameter Values and Corresponding LED Indication (continued) LEDs shown here form a binary code indicating the configuration value. Shown from Top to bottom the LEDs read from Left to Right (see Fig.1). A filled dot means LED is ON. ●●❍❍❍❍ Flywheel Tooth Count (MPU speed source only) (10’s digit) ●●❍❍❍● Value (*= default) LED Bank 2 ●●❍❍●❍ 0 1 2 3 4 5 6 7 8* 9 0 1* 2 3 4 0 1 2 3 4 5 6 7 8* 9 0* 1 2 3 4 5 6 7 8 9 0* 1 2 3 4 5 6 7 8 9 Version 1 & 4 * Version 2 & 4 Version 3 & 4 ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍●❍❍ ❍❍●❍● ❍❍●●❍ ❍❍●●● ❍●❍❍❍ ❍●❍❍● ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍●❍❍ ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍●❍❍ ❍❍●❍● ❍❍●●❍ ❍❍●●● ❍●❍❍❍ ❍●❍❍● ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍●❍❍ ❍❍●❍● ❍❍●●❍ ❍❍●●● ❍●❍❍❍ ❍●❍❍● ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍●❍❍ ❍❍●❍● ❍❍●●❍ ❍❍●●● ❍●❍❍❍ ❍●❍❍● ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ Run Speed (ECU or MPU speed source only) (1000’s digit) ●●❍❍●● Run Speed (ECU or MPU speed source only) (100’s digit) ●●❍●❍❍ ❍❍●❍● Run Speed (ECU or MPU speed source only) (10’s digit) ●●❍●❍● ila ❍❍●●❍ ❍❍●●● ❍●❍❍❍ ❍●❍❍● ❍●❍●❍ ❍●❍●● ❍●●❍❍ ❍●●❍● ❍●●●❍ ❍●●●● ●❍❍❍❍ ●❍❍❍● ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍●❍❍ ❍❍●❍● ❍❍●●❍ ❍❍●●● ❍●❍❍❍ ❍●❍❍● ●●❍●●❍ fo r Run Speed (ECU or MPU speed source only) (10’s digit) Fault Code SPN Conversion ●●●❍●● Method (ECU Eng. only) he ck du nt bi in lit u y ed LED Bank 1 Flywheel Tooth Count (MPU speed source only) (1’s digit) ct Flywheel Tooth Count (MPU speed source only) (100’s digit) Parameter ❍❍❍●● ❍❍●❍❍ ❍❍●❍● ❍❍●●❍ ❍❍●●● ❍●❍❍❍ ❍●❍❍● ❍●❍●❍ ❍●❍●● ❍●●❍❍ ❍●●❍● ❍●●●❍ ❍●●●● ❍❍❍❍❍ ❍❍❍❍● ❍❍❍●❍ ❍❍❍●● ❍❍●❍❍ co ●❍●❍●● LED Bank 2 9.5V 10.0V 10.5V* 11.0V 11.5V 18.0V 19.0V 20.0V 21.0V 22.0V 22.5V 23.0V 23.5V Warning Disabled 12.5V 13.0V 13.5V 14.0V 14.5V* 15.0V 16.0V 24.5V 25.0V 25.5V 26.0V 26.5V 27.0V 28.0V 29.0V 30.0V 31.0V 0 1* 2 3 0 1 2 3 4 5 6* 7 8 9 A va Hi Batt Voltage Setpoint. Value (*= default) is LED Bank 1 D Parameter ro Table 2. LED States for Normal Operating Mode LED OFF ON Slow Blink Fast Blink Manual Start Mode Engine is not Running Auto Start Mode Engine is Running ECU Status Non-ECU configuration Valid CAN Activity (no errors, Error Active state) Remote Start active Wait-to-Start Pressure is below setpoint or low oil pressure input active Fault code SPN 100 received AND ECU warning/shutdown active No pressure data (ECU only) Fault code SPN 110 received AND ECU warning/shutdown active No temperature data (ECU only) Remote Start/Crank Rest Low Oil Pressure Remote start input is inactive and manual start has not been initiated C P AUTO Engine Running Pressure is above setpoint or low oil pressure input is inactive High Engine Temperature Temperature is below setpoint or high Temperature is above setpoint or high engine temperature input is inactive engine temperature input is active Overspeed Engine speed below overspeed setpoint Engine speed above overspeed setpoint Underspeed Engine speed above underspeed setpoint Engine speed below underspeed setpoint Overcrank/Start Fail Failure to start has not occurred Overcrank start failure (crank attempts exceeded) Charge Fail Alternator warning lamp terminal voltage is above threshold or charge fail input is inactive Alternator warning lamp terminal voltage is below threshold or charge fail input is active Auxiliary 1 Auxiliary input 1 is inactive Auxiliary input 1 is active Auxiliary 2 Auxiliary input 2 is inactive Auxiliary input 2 is active Bus Off/Error Passive/Failed Address Claim In Crank Rest or one of the prestart states (startdelay, preheat, waitecu, wait rpm) Start Condition Failure (RPM not below 10 or crank disconnect input is on before attempting crank) Battery Voltage is below low voltage warning setpoint ECU Warning (malfunction or Amber lamps on) 00-02-0587 page 5 of 8 No speed data (ECU) or loss of speed (non-ECU) No speed data (ECU) or loss of speed (non-ECU) Start Condition Failure (ECU-related) CAN Hw Bus Error preventing start Battery Voltage is above high voltage warning setpoint ECU Shutdown (Red Stop or Protect lamps on) Table 3. Error Codes LED States OFF (not used) (not used) (not used) (not used) (not used) (not used) (not used) (not used) (not used) (not used) (not used) (not used) ON (not used) (not used) (not used) (not used) (not used) (not used) (not used) (not used) (not used) (not used) (not used) (not used) Slow Blink (not used) (not used) (not used) (not used) (not used) (not used) (not used) (not used) (not used) (not used) (not used) (not used) Fast Blink (not used) (not used) (not used) (not used) ERROR CODE (MSB) ERROR CODE ERROR CODE ERROR CODE ERROR CODE ERROR CODE ERROR CODE ERROR CODE (LSB) nt bi in lit u y ed LED Auto Engine Running ECU Status Remote Start /Crank test Low Oil Pressure High Engine Temperature Overspeed Underspeed Overcrank/Start Fail Charge Fail Auxilliary 1 Auxilliary 2 Table 4. Configuration Error Codes ila A va fo r C P ro he ck du ct D is co The eight LEDs shown in the table below form an 8-bit binary error code to indicate the type of configuration error detected The following error codes are currently defined: Error Code(s) LED Indication Error 1 – 63 (varies) Individual configuration parameter number is out of range. The number flashed indicates the configuration parameter number that is in error (see Table 1.) 128 ●❍❍❍❍❍❍❍ Configuration memory CRC error. The user will need to go back to configuration mode and resave at least one configuration parameter. 129 ●❍❍❍❍❍❍● All three digits of flywheel tooth count are zero. This is not allowed. 130 ●❍❍❍❍❍●❍ Remote Start Signal Type is set to MOMENTARY but no auxiliary input is configured for MOMENTARY STOP. 131 ●❍❍❍❍❍●● One of the Aux outputs is configured for “SPEED UP” or “SPEED DOWN” but none of the other Aux outputs is configured for the opposite setting 132 ●❍❍❍❍●❍❍ Speed source is set to AC Frequency and Crank Disconnect Frequency is set to less than 10 Hz. Crank disconnect frequency must be greater than 10 Hz. 133 ●❍❍❍❍●❍● Speed source set to Mag Pickup and Crank Disconnect RPM < 10 RPM. Crank disconnect RPM must be greater than 10 RPM. 134 ●❍❍❍❍●●❍ Run speed is less than or equal to crank disconnect RPM (non-genset engines) FW Murphy P.O. Box 470248 Tulsa, Oklahoma 74147 USA +1 918 317 4100 fax +1 918 317 4266 e-mail [email protected] www.fwmurphy.com INDUSTRIAL PANEL DIVISION FRANK W. MURPHY, LTD. P.O. Box 470248 Tulsa, Oklahoma 74147 USA +1 918 317 4100 fax +1 918 317 4266 e-mail [email protected] Church Rd.; Laverstock, Salisbury SP1 1QZ; U.K. +44 1722 410055 fax +44 1722 410088 e-mail [email protected] 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 +52 444 8206264 fax +52 444 8206336 Villahermosa Office +52 993 3162117 e-mail [email protected] www.murphymex.com.mx Printed in U.S.A. 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. 00-02-0587 page 6 of 8 Typical Wiring Diagrams Basic Mechanical Engine or Engine ECU or Engine AC Speed Sensing Twisted Pair wiring 1 2 3 4 OPEN Mag. Pickup + Mag. Pickup – 24 25 26 27 Aux. 2 out 6 Aux. 1 out 5 Crank 4 Fuel/ECU 3 -V Batt. 2 +V Batt. 1 ESD 20P-F Pressure Swichgage ® B- co Magnetic Pickup 85 87a 87 86 Generator Alternator B- 85 87 87a is B+ A va Solenoid Starter D or 86 B+ Ring Gear D B+ + – Battery L-3 20T Temperature Swichgage ® W Shielded Cable L-1 Neutral Low Coolant Level ECU Hold To J1939 Speed Sensing Only AC Neutral CAN Hi CAN Lo for use with ECU Engines Only AC Line 120 Ohm Low Lube Oil Level Energize 7 8 9 10 Transfer Switch Inc/Dec Throttle nt bi in lit u y ed 6 CAN Sh PVA gages 5 CAN Hi RS485A 1 2 3 4 Not used 15 Aux. 4 out 14 Aux. 3 out 13 Remote call to run 12 Aux. 2 in 11 Aux. 1 in 10 Hi engine temp. 9 Lo oil press. 8 Alt. Excite. 7 ila CAN Lo RS485B Cascade Back View RP Series Solenoid Grd Inc/Dec Throttle, Line Fill Delay, Low Oil/Coolant Level, Preheat, Common Alarm Twisted Pair wiring 6 7 8 9 10 CAN Hi RS485A du PVA gages 5 CAN Sh 1 2 3 4 1 2 3 4 OPEN AC Neutral Mag. Pickup + Mag. Pickup – CAN Hi CAN Lo 24 25 26 27 Remote Start Switch Inc/Dec Throttle 20P Pressure Swichgage® Aux. Input 2 set to “Delay Aux. Input Shutdown” Aux. Input Bypass timer set to allow irrigation pump output line 10 minutes to fill the line and build pressure before system shutdown. Timer should be set just above normal line fill and pressurizing time. Aux. 2 out 6 Aux. 1 out 5 Crank 4 Fuel/ECU 3 -V Batt. 2 +V Batt. 1 Low Lube Oil Level Low Coolant Level ESD C ro P AC Line he ck 120 Ohm for use with ECU Engines Only To J1939 Speed Sensing Only Not used 15 Aux. 4 out 14 Aux. 3 out 13 Remote call to run 12 Aux. 2 in 11 Aux. 1 in 10 Hi engine temp. 9 Lo oil press. 8 Alt. Excite. 7 fo r CAN Lo RS485B ct Cascade Back View W + – Battery B85 87 85 B87a 87 Aux. Output 1 Set to Preheat Timer Set to 15 sec. 85 B87a 87 86 86 B+ B+ 85 87a 86 B+ Aux. Output 2 Set to Common Alarm D Alternator B87a 86 B+ B+ Solenoid Starter 00-02-0587 page 7 of 8 87 ECU Since there are many different methods to enable the ECU for running, refer to your manual before making any electrical connections. Typical Wiring Diagrams (continued) Mechanical Engine MPU Source Throttling to Pressure, Low Liquid Level Shutdowns Warmup-Cooldown Output 6 7 8 9 10 CAN Sh 5 CAN Hi RS485A 1 2 3 4 1 2 3 4 AC Line AC Neutral Mag. Pickup + Mag. Pickup – OPEN 24 25 26 27 Not used 15 Aux. 4 out 14 Aux. 3 out 13 Remote call to run 12 Aux. 2 in 11 Aux. 1 in 10 Hi engine temp. 9 Lo oil press. 8 Alt. Excite. 7 Aux. 2 out 6 Aux. 1 out 5 Crank 4 Fuel/ECU 3 -V Batt. 2 +V Batt. 1 20P Pressure Swichgage® 20T Temperature Swichgage® Low Lube Oil Level Low Coolant Level ESD 20P-F Pressure Swichgage ® nt bi in lit u y ed CAN Lo RS485B Cascade Back View Running between two pressure setpoints set Start Contact type Momentary. Aux. Input 1 set to “Momentary Stop”. Aux. Input 2 set to “Immediate Shutdown” for Low Oil and Coolant Level. W + – Battery co B- 87a 85 87 86 86 B- 87a 87 85 86 B+ A va Ring Gear 87 B+ is B+ 87a Solenoid D Aux. Output 2 Set to Warmup/Cooldown Starter Hold B85 Alternator Energize Magnetic Pickup D B+ ila Shielded Cable RP Series Solenoid Grd ct Mechanical Engine Winter/Summer Switch, Preheat Output & Timer Run & Idle Switch Output 7 8 9 10 du 6 CAN Sh 5 CAN Hi RS485A 1 2 3 4 1 2 3 4 AC Line AC Neutral Mag. Pickup + Mag. Pickup – 24 25 26 27 C Fuel/ECU 3 -V Batt. 2 +V Batt. 1 Run / Idle Switch ESD B87a 87 86 B+ Aux. Output 1 Set to Preheat. Timer set to 20 sec. 85 B87a 87 86 B+ 87a 87 86 B+ Aux. Output 2 Set to Run/Idle 85 B+ Solenoid Starter 00-02-0587 page 8 of 8 D Alternator Hold 85 Grd RP Series Solenoid 20P-F Pressure Swichgage ® Aux. Input 2 set to “Winter/Summer” (disables Preheat action in Summer setting). Aux. Input 1 set to “Run/Idle” (disables Underspeed Shutdown & Warnings. On return to “Run a Timer” equals to 2 times the oil pressure bypass) allows system to come up to rated speed. W B+ B87 Winter / Summer Switch + – Battery B- 86 Aux. 2 out 6 Aux. 1 out 5 Crank 4 Magnetic Pickup Ring Gear 87a 20T Temperature Swichgage® Energize P ro he ck OPEN Shielded Cable 85 Remote Start Switch Not used 15 Aux. 4 out 14 Aux. 3 out 13 Remote call to run 12 Aux. 2 in 11 Aux. 1 in 10 Hi engine temp. 9 Lo oil press. 8 Alt. Excite. 7 fo r CAN Lo RS485B Cascade Back View ">
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