MC-9142N
Revised 12-00
Section 40
(
00-02-0202)
SERIES MC-900 MURPHYMATIC
®
MANUAL GENERATOR
ENGINE CONTROL SYSTEM
DESIGN, INSTALLATION
AND OPERATING MANUAL
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Pr k f or A oduct Discontinued
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Table of Contents
Section 1: Introduction
page 1
1-1 System ...............................................................................................................................................
1
1-2 Models ...............................................................................................................................................
1
1-3 Purpose ..............................................................................................................................................
1
1-4 Definitions .........................................................................................................................................
1
1-5 How To Use This Manual ...............................................................................................................
1
Section 2: Specifications
1
2-1 Enclosure Type .................................................................................................................................
1
2-2 Power Requirements ........................................................................................................................
1
2-3 Input Ratings ....................................................................................................................................
1
2-4 Output Ratings .................................................................................................................................
1
2-5 Field Wiring Connections ................................................................................................................
1
2-6 Operating Temperature ...................................................................................................................
1
Section 3: Model Identification
1
3-1 Model Numbers ................................................................................................................................
1
3-2 MC-900 ..............................................................................................................................................
2
3-3 MC-900-2 ..........................................................................................................................................
3
Section 4: Installation
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3
4-1 Location ............................................................................................................................................
3
4-2 Wiring ...............................................................................................................................................
3
4-3 Overspeed Switch .............................................................................................................................
7
4-4 Pre-Operational Check-Out ............................................................................................................
7
Section 5: Operation
5-1 Operator Controls ............................................................................................................................
8
vaila
8
Section 6: Routine Maintenance and Operational Tests
8
8
6-1 Routine Maintenance .......................................................................................................................
8
6-2 Operational Tests ............................................................................................................................
8
Section 7: Troubleshooting and Repair
......................................................................................
8
7-2 MC-900 SELECTRONIC ®
or A
8
9
Section 8: Replacement Parts
11
8-2 Replacement Parts Detroit Diesel Modules ................................................................................... 11 oduct Discontinued
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Section 1: Introduction Section 2: Specifications
1-1 System.
1-1.1
The MURPHYMATIC
®
Manual Generator Engine
Control System, Series MC-900 is designed to meet the requirements of the engine control and shutdown for manual start generator engines.
By combining one of the MC-900 series controls with generator instruments, a complete engine generator control panel can be provided.
2-1 Enclosure Type.
2-1.1 The MC-900 Series enclosure is designed to be mounted in a standard electrical enclosure for indoor use.
2-1.2 The MC-900 Series shares the same enclosure as the A-
900 automatic start controller so they can be used interchangeably in a generator control panel.
1-2 Models.
1-2.1 The Series MC-900 is available in two basic configurations:
1-2.1.1 Model MC-900 for manual start and stop generator sets with four cycle engines which includes the minimum normal shutdowns.
1-2.1.2 Model MC-900-2 for manual start and stop generator sets with two cycle engines which includes the minimum normal shutdowns and an “Overspeed Relay” to operate the air shutoff solenoid for overspeed shutdown.
1-2.2 Both models are available for 12 or 24 volt operation.
1-2.3 Both models include four unlabeled shutdown circuits for additional customer specified shutdowns.
1-2.4 Each model is made up of two parts, a Control/Display module and a Relay module.
1-3 Purpose.
1-3.1 This manual is directed to the installation, maintenance and operating personnel who will be in day to day contact with the MC-900 system.
1-3.2 No manual can cover all aspects of a product. However the basic knowledge gained with this material will allow those personnel to easily adjust to special circumstances.
2-2 Power Requirements.
2-2.1 The engine controls, shutdown circuits and shut-down indicators are powered from the engine starting battery. The
MC-900 series is available in either 12 or 24 volt, negative ground.
2-2.2 The MC-900 is fused for 3 amp. maximum current.
2-3 Input Ratings.
2-3.1 All input switches should be dry contact type, maximum current is 2 ma, 8 VDC or less.
2-3.2 Frequency signal for the speed sensing circuit requires a minimum input of 2 volts RMS from a magnetic pickup
(preferred) or from the tachometer terminal of the battery charging alternator.
2-3.2.1 Frequency range of the speed sensing circuit is 300 Hz to 10,000 Hz.
2-4 Output Ratings.
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2-4.1 The MC-900 Control / Display Module has outputs for remote indication of shutdowns. These outputs are transistors that close to the negative supply (sink) and are rated at 1 amp,
30 VDC maximum.
2-4.2 The Control / Display Module also has an output for an vaila
(source).
2-4.3 The Relay Module includes 3 engine control relays with contact ratings of 7 amp, 30 VDC inductive. These powered
1-4 Definitions.
1-4.1 Throughout this manual, reference is made to organizations, trade names and trademarks which may not be familiar to the reader. Some of these are:
1-4.1.1 NFPA: National Fire Protection Association.
1-4.1.2 NFPA-70: The National Electrical Code.
contacts must be suppied from an 8 amp. fuse or circuit breaker
(customer supplied).
or A
1-4.1.3 Several terms used in this manual are registered trademarks of Frank W. Murphy Mfr.
(a) MURPHYMATIC controls.
(b) SELECTRONIC
®
® k f
: A name that is applied to all electronic
2-5.1 All field wiring connections are barrier terminal blocks,
UL rated for 15 amp, 300 volt.
2-6 Operating Temperature.
2-6.1 The operating temperature range of the MC-900 is -4°F to
Section 3: Model Identification
(c) SWICHGAGE
®
: A combination indicating gauge and switch.
Pr
®
: A term that refers to a shutdown
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1-5.1 Section 1, 2, 4, 5, 6 and 7 contain general information that applies to all MC-900 models.
3-1 Model Numbers.
3-1.1 MC-900-12 and MC-900-24: These models are designed for a manual start four cycle engine driven generator, and include the minimum shutdown points normally supplied on such installations. The suffix numbers -12 and -24 indicate the engine starting battery voltage.
3-1.2 MC-900-2-12 and MC-900-2-24: These models are
1-5.2 Section 3, Model Identification, is broken into three sub designed for a manual start two cycle engine driven generator, sections. Section 3-1 allows you to chose the model that best and include the minimum shutdown points normally supplied on fits your requirements and Section 3-2 and 3-3 explain each such installations. The suffix numbers -12 and -24 indicate the models features in detail.
engine starting battery voltage.
3-1.2.1 The MC-900-2 series control includes an “Overspeed
Relay” to trip the air shut-off solenoid on overspeed of a two cycle engine.
1
2
3-2 MC-900.
3-2.1 Control / Display Module. The Control / Display
Module, figure 3-2.1, includes the control and test switches, the solid state logic elements and shutdown TATTLETALE ® lights that make up the generator engine control for a four cycle engine.
9-3/4 in.
(248 mm)
Overcrank
Overspeed
Lamp Test
OFF
RUN
START
6-15/32 in.
(164 mm)
Oil Pressure
Water
Temperature
Figure 3-2.1
position. This same delay can also lock out all other shutdown circuits except Overspeed and Overcrank.
The user may select which circuits are locked out by the time delay bypass.
(c) Overspeed Speed Switch;
1. Provides a signal to the overspeed shutdown circuit if the engine exceeds the preset speed. The factory setting is approximately 3894 Hz, or 1980 RPM on an engine with 118 teeth on the flywheel ring gear.
The adjustment range is 300 Hz to 10,000 Hz.
2. A push to test switch is provided to allow testing of the overspeed circuit without overspeeding the engine. When switch is depressed, the set point of the speed switch is lowered approximately 10%.
3. The push to test switch can also be used to set the overspeed switch at approximately 110% of running speed. Hold the switch depressed while adjusting the setting until the overspeed trips. When switch is released, the set point will be 10% above normal running speed. This is the method used to make the factory setting. With engine speed at 1800 RPM or
3540 Hz.
bility the fuel relay and lockout the MC-900 until reset. Shutdown circuits are activated by the Mode Selector Switch and or
Shutdown Time Delay Bypass. Eight (8) Red Shutdown
Indicating Lights are provided.
(a) Overcrank; tripped by the overcrank timing circuit vaila exceeds a preset speed.
(c) Oil Pressure; tripped by the oil pressure SWICHGAGE ®
3-2.1.1 Mode Selector Switch, OFF-RUN-START:
(a) OFF; turns off the control system and resets any shutdown circuits.
(b) RUN; turns on the engine controls and shutdown if pressure drops below preset point while the engine is running.
(d) Water Temperature; tripped by the water temperature or A
® if engine coolant temperature exceeds
(e) Spare Shutdowns; tripped by an external switch. These circuits. System is on, waiting for the engine to start.
Switch returns to run position from START after starting engine.
k f applied to the auxiliary start solenoid and the engine circuits are provided for additional shutdowns that may be recommended by the engine supplier or required by the user.
3-2.2 Relay Module. The Relay Module, figure 3-2.2, starter engages. Releasing the start switch disconnects cranking.
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3-2.1.2 Lamp Test Pushbutton: Tests the lights on the MC-900 module when the Mode Selector Switch is in the RUN position.
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Control Module
(a) Overcrank circuit; will stop manual cranking and indicate overcrank if start switch remains closed longer than the overcrank time setting. The crank time is selectable for 10, 15, 20, 25 or 30 seconds before shutdown.
(b) Shutdown Time Delay Bypass; this delay prevents the oil pressure and water temperature shutdown circuits from operating for 30 seconds after the engine starts as detected by the Mode Selector Switch returning to RUN available for operation on either 12 or 24 volt battery systems.
Two (2) relays are included for:
3-2.2.1 Fuel Relay; this relay provides two outputs, one to energize the engine fuel solenoid and a separate circuit to energize the battery charging alternator field.
3-2.2.2 Shutdown Relay; this relay is operated by the shutdown circuits of the Control / Display Module and provides an output that can be used to trip the generator circuit breaker on an emergency shutdown.
3-2.3 Status Signal; The relay module also includes an output that can be used with external circuits for signaling or control functions.
3-2.3.1 The Run signal at terminal 17 is on (closed to negative) as long as the Mode Selector Switch is in either Run
TB1
Torque
Terminal
12 lbs
14
10
11
12
13
8
9
6
7
1
4
5
J1 J2
WARNING
For continued protection against fire & shock hazard, replace only with same type fuse & rating.
3AMP Fuse
RH2V2
-U
DC12V
RH2V2
-U
DC12V
TB2
17
18
19
20
15
4
16
21
22
23
24
25
Torque
Terminal
12 lbs
6-1/4 in.
(159 mm) shutdown. This relay provides an output to trip an air shut off solenoid to close the air damper on a two cycle engine.
3-2.3 Status Signal; The relay module also includes an output that can be used with external circuits for signaling or control functions.
3-2.3.1 The Run signal at terminal 17 is on (closed to negative) as long as the Mode Selector Switch is in either Run or Start and no shutdown TATTLETALE
® circuit is latched on.
This can be used to signal that the generator engine is ready to start or is running.
4-1/2 in.
(114 mm) or Start and no shutdown TATTLETALE
® circuit is latched on.
This can be used to signal that the generator engine is ready to start or is running.
Figure 3-2.2
3-3 MC-900-2.
3-3.1 Control / Display Module. The Control / Display
Module, figure 3-2.1, is also used as on the Model MC-900-2.
3-3.2 Relay Module. The Relay Module, figure 3-3.2, includes all of the control and shutdown relays that are required to make up the generator engine control. Relays are available for operation on either 12 or 24 volt battery systems.
Section 4: Installation
4-1 Location.
4-1.1 The MC-900 series is designed to mount in a
MURPHYMATIC
®
Generator Control panel with the Control /
Display module on the front panel and the Relay module on the inside bottom surface. Other types of installation is possible as long as the relationship of the two modules are maintained.
4-1.2 Clearance for Installation and Service; The modules must be accessible for wiring to the terminal blocks and adjustment of the user controls on the back of the Control / bility
4-1.3 Wiring Terminals; Terminal blocks are provided on both sides of the Control / Display enclosure and the Relay
Module. Torque all terminal screws to 12 inch pound maximum.
4-2 Wiring.
wiring connections can be made. This work should be done with all electrical power disconnected from the engine. BE
TB1
Torque
Terminal
12 lbs
J1 J2
1
4
5
6
7
8
9
10
11
12
13
14
WARNING
For continued protection against fire & shock hazard, replace only with same type fuse & rating.
3AMP Fuse
RH2V2
-U
DC12V
RH2V2
-U
DC12V
RH2V2
-U
DC12V
15
4
16
17
18
19
20
21
22
23
24
TB2
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4-1/2 in.
(114 mm)
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Three (3) relays are included for:
6-1/4 in.
(159 mm) k f
SURE THAT THE BATTERY IS DISCONNECTED.
4-2.2 All electrical installation work should be done in accordance with the National Electrical Code, NFPA-70, and or A
(a) Battery positive and negative.
(b) Engine run device, such as a fuel shutoff solenoid.
(c) Engine speed sensor, such as a magnetic pickup or the tachometer output of a battery charging alternator.
(d) Engine starter circuit; an auxiliary starter solenoid is
4-2.3.1 The complete wiring of a Model MC-900 control is shown in figure 4-2.3.1. Provision is made in the MC-900 series to operate remote lights for all of the shutdown circuits however these circuits do not have to be wired for the MC-900 to function.
4-2.3.2 Figure 4-2.3.2 is for wiring of the MC-900-2 control.
The same provisions as for the MC-900 are made.
3-3.2.1 Fuel Relay; this relay provides two outputs, one to
4-2.3.3 Wire Termination; the terminal blocks that are energize the engine fuel solenoid and a separate circuit to supplied requires that all wires be terminated with #6 stud size energize the battery charging alternator field.
forked spade solderless wire connectors or stripped and
3-3.2.2 Shutdown Relay; this relay is operated by the inserted under the captive terminal plates. Torque all terminal shutdown circuits of the Control / Display Module and screws to 12 inch pound maximum.
provides an output that can be used to trip the generator circuit
4-2.3.4 All inductive loads (relays-soleniods-coils-etc.) that breaker on an emergency shutdown.
are connected to the MC-900 must have reverse diodes wired
3-3.2.3 Overspeed Relay; operates only on an Overspeed
3
4
Figure 4-1.2: Dimensions
5-5/8 in.
(143 mm)
6 in.
(152 mm)
3 in.
(76 mm)
2-13/16 in.
(71 mm)
1-1/2 in.
(38 mm) clearance
1-1/2 in.
(38 mm) clearance
Mounting
Holes
1/8 in.
(3 mm) diameter
6-3/4 in.
(171 mm)
3-3/8 in.
(86 mm) bility
4-15/32 in.
(114 mm)
9-3/8 in.
(238 mm) vaila
Pr
5 in. (127 mm) maximum
NOTE:
Clearance required for wire run.
(140 mm)
between MC-900 and relay module
k f or A
3/16 in.
(5 mm) dia.
4 places
1-7/8 in.
(48 mm)
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clearance
3-3/4 in.
(95 mm)
1-7/8 in.
(48 mm) clearance
Figure 4-2.3.1: MC-900 wiring
Hourmeter
+ – +
Voltmeter
–
Input
Barrier
Terminal
Blocks
MANUAL START
MODULE
28
4
29
30
15
26
4
27
31
32
33
34
FUSE B+ OUT
B– TO HOURMETER
B GROUND
MAGNETIC PICKUP
OVERCRANK LIGHT OUTPUT
OVERSPEED LIGHT OUTPUT
LOW OIL PRESS. LIGHT OUTPUT
HIGH WATER TEMP. LIGHT O/P
LOW OIL PRESS.
GROUND
HIGH WATER TEMP.
SPARE #1 SHUTDOWN INPUT
SPARE #1 LIGHT OUTPUT
SPARE #2 LIGHT OUTPUT
SPARE #2 SHUTDOWN INPUT
SPARE #3 SHUTDOWN INPUT
SPARE #4 SHUTDOWN INPUT
SPARE #3 LIGHT OUTPUT
SPARE #4 LIGHT OUTPUT
39
40
41
42
35
36
37
38
43
44
45
46
Output
Barrier
Terminal
Blocks bility
B+ vaila
Battery
Pr
Starter
Auxiliary Starter
Solenoid
(FR) Energize to Run solenoid
Fuel relay N.C. dry contact
Fuel relay Com. dry contact
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TB1
5
6
7
8
9
10
11
12 k f
J1 A B
Fuel
Relay or A
A
Over
Speed
Relay
A B C D E
J2
Shut
Down
Relay
J2
C
J2
J2
B
TB2
16
17
18
19
20
21
22
23
Lamp
B+ to aux. starter solenoid
Run signal switched B–
Shutdown relay N.C. dry contact
Shutdown relay COM. dry contact
Shutdown relay N.O. dry contact
Overspeed relay N.C. dry contact
Overspeed relay COM. dry contact
Overspeed relay N.O. dry contact
13
14
24
25
5
6
Figure 4-2.3.2: MC-900-2 wiring
Hourmeter
+ – +
Voltmeter
–
Input
Barrier
Terminal
Blocks
MANUAL START
MODULE
15
26
4
27
28
4
29
30
31
32
33
34
FUSE B+ OUT
B– TO HOURMETER
B GROUND
MAGNETIC PICKUP
LOW OIL PRESS.
GROUND
OVERCRANK LIGHT OUTPUT
OVERSPEED LIGHT OUTPUT
LOW OIL PRESS. LIGHT OUTPUT
HIGH WATER TEMP. LIGHT O/P
SPARE #1 LIGHT OUTPUT
SPARE #2 LIGHT OUTPUT
HIGH WATER TEMP.
SPARE #1 SHUTDOWN INPUT
SPARE #2 SHUTDOWN INPUT
SPARE #3 SHUTDOWN INPUT
SPARE #4 SHUTDOWN INPUT
SPARE #3 LIGHT OUTPUT
SPARE #4 LIGHT OUTPUT
38
39
40
41
35
36
37
42
43
44
45
46
Output
Barrier
Terminal
Blocks
B+ bility vaila
Battery
Starter
Pr
Fuel
Pressure
Auxiliary Starter
Solenoid
B+
B– Ground
(FR) Energize to Stop solenoid
(FR) Energize to Run solenoid
TB1
1
4
5 k f
J1 A B or A
A B C D E
3A Fuse
J2
Fuel relay N.C. dry contact
Fuel relay Com. dry contact
Fuel relay N.O. dry contact
(SDR) Circuit breaker shunt trip
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11
12
13
14
7
8
9
10
Fuel
Relay
J2
A
Shut
Over
Speed
Relay
J2
C
J2
B
20
21
22
23
24
25
TB2
15
4
16
17
18
19
Lamp
B+ to aux. starter solenoid
Run signal switched B–
Shutdown relay N.C. dry contact
Shutdown relay COM. dry contact
Shutdown relay N.O. dry contact
Overspeed relay N.C. dry contact
Overspeed relay COM. dry contact
Overspeed relay N.O. dry contact
across the coil to suppress reverse voltage that is generated whenever the inductive load is de-energized. This will protect the electronic components in the MC-900 and should prevent operating malfunction due to noise. The “rule of thumb” for sizing the reverse diode is to use one with a PIV (Peak Inverse
Voltage) rating equal to the operating voltage or at least 100 volts and a current rating that is equal to or greater than the forward current that the coil draws to operate. For example, a relay less than 1 A, use a 1 A diode since they are readily available. The wiring shown in figures 4-2.3.1 and 4-2.3.2 have examples of the places that a reverse diode is required.
4-4.1.2 All of the adjustments and controls shown in Table 4-
4.1 are located on the rear of the control/display module. See
Figure 4-4.1.2. Each light and switch is labeled for ease of identification. The LED’s are supplied as an aid in installation and troubleshooting of the MC-900.
Torque
Scews to
12 In./lb.
Figure 4-4.1.2
Fuel Relay
Torque
Scews to
12 In./lb.
4-3 Overspeed Switch.
4-3.1 A magnetic pickup is recommended to supply the speed signal for the MC-900 series overspeed switch. This pickup will be mounted in the flywheel housing in line with the ring gear on the flywheel and wired to the MC-900 using either a twisted pair or a shielded cable to reduce the possibility of electrical noise pickup in the wiring.
4-3.2 The tachometer terminal, of the battery charging alternator, may be used for the speed signal but a broken drive belt will disable this source and some alternators have electrical noise which will cause the speed switches to operate at speeds well below the desired RPM.
15
26
04
27
28
04
SW1 = 10 s.
SW2 = 15 s.
SW3 = 20 s.
SW4 = 25 s.
SW5 = 30 s.
Crank
Time
1
0
2
N
3 4 5
Close Only One
Crank Relay
CLOSE
PUSH
OPEN
Lockout for start T.D.
1
0
2
N
3 4 5 6 7
SW1 = Oil Pr
SW2 = Wt Tem
SW3 = Spare #1
SW4 = Spare #2
SW5 = Spare #3
SW6 = Spare #4
35
36
37
38
39
4-4 Pre-operational Check-out.
4-4.1 After installation is complete, it is necessary to make some adjustments to the MC-900 SELECTRONIC ® Control before the system is operational. All shutdown circuits also should be tested. Table 4-4.1 lists the standard factory setting of the adjustable functions on the MC-900 series control. To determine if the frequency of the speed switch must be changed, calculate the required setting using the following formulas:
29
30
31
32
33
Overspeed Overspeed
Test
Pickup
Present bility
40
41
42
Overspeed
Set
Overspeed
Relay
43
Relay
44
45
46 either end.
Set point
No. of Gear Teeth x RPM set points
Set point frequency in HZ
=
=
34 frequency in HZ
OR
60
60
Pulley ratio x No. of Alternator Poles x RPM set points or A
Refer to Table 4-4.1 to determine if the speed switch setting is k f proceeding. Turn the Overspeed Set pot clockwise to increase oduct Discontinued
Table 4-4.1
Function
Crank Time
Pr
Standard
Setting
15 seconds
Adjustment
Chec and 30 Seconds
Adjustment
Type
Switch
Pot. 500 Hz per turn CW to increase
Overspeed
3894 Hz 300 to 10 KHz
Lockout for Start
– Switch
4-4.1.1 Be sure to have a fully charged battery to do these tests. Low battery voltage can cause improper results during the tests.
SW1, SW2
Closed
SW3, 4, 5, 6
Open
4-4.2 Start and Stop Engine; to test the start and stop function, proceed as follows:
(a) Double check all wiring to be sure it is connected.
(b) Turn Mode Selector switch to the START position.
(c) Engine should crank and start. Return switch to RUN position.
(d) When engine has come up to speed and governor has
7
8
been adjusted for proper running speed, turn Mode
Selector switch OFF.
(e) All lights on the back of the MC-900 should go off and the engine stop. If engine does not stop, check run solenoid to be sure it has returned to the stop position.
4-4.3 Overspeed Switch Setting; To set the speed switch, proceed as follows:
(a) Turn Mode Selector switch to the START position.
(b) Engine should crank and start. Return switch to RUN position.
(c) With engine running, adjust governor to bring engine speed to normal RPM.
(d) Depress and hold the Overspeed Test pushbutton.
(e) Slowly turn the Overspeed Set adjustment counterclockwise until the “Overspeed” and “Overspeed Relay” lights on the MC-900 come on and the engine shuts the engine by turning the Mode Selector switch to RUN position.
(c) To test other shutdowns, a jumper wire can be used to short the input terminal for that circuit, to ground, terminal 4.
Section 5: Operation
5-1 Operator Controls.
5-1.1 Mode Selector Switch; allows the operator to start the engine (START), run the engine (RUN), or stop the engine
(OFF).
5-1.2 The OFF position on the mode selector also provides a reset function for the shutdown circuits. If the engine is shut down by the automatic control, the operator must turn selector off and back on to reactivate the system.
5-1.3 Push to Test Lamps; this pushbutton tests the shutdown indicator lights.
down.
(f) Release pushbutton; check “Overspeed” light on front panel to be sure it is on.
(g) Turn Mode Selector switch OFF to reset shutdown circuits.
(h) Restart engine, when engine starts, increase governor speed setting slowly until engine shuts down on overspeed. This should occur about 10% above governor speed.
shutdown circuit:
5-2.2 Manual electric start is provided for operation of the generator set.
bility the engine starter.
(i) Turn Mode Selector switch OFF.
4-4.4 Overcrank setting; to test the time before system shuts down on overcrank;
(a) Disconnect the run solenoid wire from terminal 6 of the
Relay Module.
(b) Check time set on the “Crank Time” switch on MC-900 back panel. It is factory set at 15.
(c) Turn Mode Selector switch to START.
engine, turn selector switch OFF.
vaila
Section 6: Routine Maintenance
1. Engine will crank for 15 seconds.
2. After 15 seconds the “Overcrank” light on the MC-
900 will come on and engine will stop cranking.
(d) Turn Mode Selector switch OFF.
or A
and Operational Tests
6-1 Routine Maintenance.
little maintenance is required to the MC-900 Control.
Relay Module.
4-4.5 Oil Pressure; to test oil pressure shutdown circuit: starts, wait 30 seconds then, k f
(b) Use a jumper wire and short from terminal 28 to 4.
6-1.2 Visual inspection of the internal wiring of the control panel, along with checking wire connections for tightness, should be done on a semiannual schedule for stand- by systems or quarterly for prime power. Check wire bundles for chafing and wear to the insulation of the wires where they contact the panel or engine.
(c) ”Oil Pressure” light will come on and engine will stop.
5-2.3 OFF or Not Operating; to prevent operation of the
6-1.4 Shutdown Circuits should be tested on a monthly basis
(d) Turn Mode Selector switch OFF.
This removes start signal and the engine will run.
for prime power and quarterly for stand-by sets. The same
4-4.6 Water Temperature; to test the water temperature
5-2.2.2 When engine starts, return selector switch to RUN.
tests run during pre-operation check out, Section 4-4, should
Pr
5-2 Operating Modes.
5-2.1 The MC-900 Generator Engine Control has only one operating mode: manual start and automatic shutdown on a sensed failure of one of the monitored inputs.
oduct Discontinued
(b) Use a jumper wire and short from terminal 29 to 4.
(c) “Water Temperature” light will come on and engine will be included.
6-2 Operational Tests.
6-2.1 No special operational tests are required. The routine operational tests for the generator set will exercise the control.
stop.
(d) Turn Mode Selector switch OFF.
4-4.7 All other Shutdowns; all other shutdowns would be tested in the same manner.
(a) For shutdown circuits which are locked out by the
Shutdown Time Delay Bypass, you must wait 30 seconds before running the test.
(b) Circuits that are not locked out may be tested as soon as the engine is running or may be tested without starting
Section 7: Troubleshooting and Repair
7-1 Tools Required.
7-1.1 Some of the tools necessary for troubleshooting are built into the MC-900 Series controls.
7-1.1.1 By observing the lights on the front and rear of the control panel, clues to a problem and the possible source can be seen.
7-1.2 Other tools which may be required are:
7-1.2.l AC/DC Voltmeter for taking voltage readings and an
Ohmmeter for testing resistance of wires and connections.
7-1.2.2 Jumper wires with alligator clips to bypass or simulate circuit closures.
DO NOT USE THESE JUMPER WIRES TO CHECK IF
VOLTAGE IS PRESENT AT A TERMINAL BY DRAWING
AN ARC TO GROUND. THIS WILL DAMAGE OR
DESTROY EQUIPMENT IN THE MC-900 CONTROL
PANEL.
7-2.3 With the Mode Selector switch in the RUN position, six of the eight shutdown TATTLETALE
® circuits are activated and will operate anytime a switch closes from ground to their inputs.
Circuit
(a) Oil Pressure
(b) Water Temp
(c) Overspeed*
(d) Overcrank**
(e) Spare Shutdown #1
(f) Spare Shutdown #2
(g) Spare Shutdown #3
(h) Spare Shutdown #4
Input
Terminal 28
Terminal 29
Int. Speed Switch
Int. Circuit
Terminal 30
Terminal 31
Terminal 32
Terminal 30
Output
Terminal 37
Terminal 38
Terminal 36
Terminal 35
Terminal 39
Terminal 40
Terminal 43
Terminal 44
7-2 MC-900 SELECTRONIC
®
Control Operation and
Shutdown.
7-2.1 The first step in troubleshooting any equipment is to understand its normal operation. Table 7-2.1 contains normal
*Engine must be running to operate speed switch
**Circuit operates only while cranking voltage readings taken at the terminals of the MC-900 with all
7-2.3.1 Each circuit has a indicating light and a transistor equipment shown on the standard drawing, connected.
output that closes to ground to operate an individual remote
(a) All voltage readings are DC, except at terminal 27, and indicating light.
were taken with the negative lead of the meter connected
7-2.3.2 When any of the eight shutdown functions trip, the to ground at terminal 4. Voltage reading at terminal 27 shutdown relay K-2, pulls in and applies battery power to was taken with negative lead grounded and the meter on terminal 10. At the same time, the fuel relay, K-1 drops out
AC scale.
(b) The battery voltage, at the time readings were recorded, was 13.8V and 27.6V. All readings will vary depending on battery voltage, equipment supplied in the panel and external devices connected to the MC-900 control. See and if the shutdown was due to overspeed, the overspeed relay, close.
bility
7-2.3.3 The eight shutdown circuits, paragraph 7-2.3, are first out latching type TATTLETALES ® . That is, only one of the notes to the table for examples.
eight may trip at one time and it must be reset before the MC-
(c) Voltages less than battery also may vary due to
900 will operate again.
tolerances of the electronic components in the MC-900.
Minor variations, 1 or 2 volts, normally will have no effect on the MC-900 operation.
(d) The AC voltage at terminal 27 must be a minimum of 2
VAC to drive the speed sensing circuits of the MC-900.
7-2.3.4 If one of the TATTLETALE vaila
® circuits trip, the following occurs to shutdown the engine and generator.
(b) Shutdown relay K-2 is energized, closing its contacts at terminal 10. These contacts can be wired to a shunt trip
7-2.2 With power applied and the Mode Selector switch in solenoid in the generator circuit breaker if required.
OFF, the following occurs when the switch is moved to the
START position.
7-2.2.1 The fuel relay is energized, which opens the circuits at terminal 5 and 7, and closes the circuits at terminal 6 and 9.
This applies battery power to the run solenoid and to the
(c) The fuel relay drops out, removing battery voltage from the run solenoid, terminal 6. The circuit at terminal 5 or A exciter terminal of the alternator (if used).
terminal.
(d) The run signal, terminal 17 turns off.
(e) If the shutdown is due to overspeed, the overspeed relay battery voltage at terminal 16 to the auxiliary starter solenoid.
This output is controlled by the Mode Selector switch and the operates and applies battery positive to terminal 11 to close an air shutoff solenoid if the engine is so equipped.
oduct Discontinued expires.
7-2.2.3 If the engine does not start during the Overcrank time,
Pr
Chec
7-2.2.4 When the engine starts and the Mode Selector switch is returned to the RUN position,
7-2.3.6 To reset the circuits, the Mode Selector switch must be turned OFF.
7-2.4 Normally, the engine will run until the Mode Selector switch is turned OFF.
7-2.4.1 When this happens, the following occurs to stop the engine;
(a) The fuel relay drops out, removing battery voltage from
(a) Cranking is terminated.
the run solenoid. The circuit at terminal 5 will close to
(b) A time delay starts timing during which the oil pressure reconnect the battery positive to this terminal.
and water temperature shutdown circuits are locked out.
(b) The run signal, terminal 17 turns off.
(c) The overcrank timer is reset to zero.
(c) The TATTLETALE ® circuits are locked out as soon as
(d) The overspeed shutdown circuit is activated.
the switch is turned OFF. This prevents any
7-2.2.5 An engine run signal closes to ground at terminal 17
TATTLETALE ® from tripping while the engine coasts to when the Mode Selector switch is in the RUN position and the a stop.
engine is not shutdown by the MC-900 shutdown circuits.
9
10
Pr
Table 7-2.1
Mode
Selector
OFF
Mode Selector
START
Cranking
Mode Selector
RUN
Running
Mode Selector
RUN
Shutdown
Input
13.8
Voltage
27.6
Input
13.8
Voltage
27.6
Input
13.8
Voltage
27.6
Input
13.8
Voltage
27.6
13.8
0
0
0
0
0
0
0
0
0
0
0
0
0
0
13.8
0
13.8
0
0
0
0
15
16
17
18
19
10
11
12
13
14
20
21
22
23
24
Terminal
Number
7
8
5
6
9
1
4
27.6
0
0
0
0
0
0
0
0
0
0
0
0
0
0
27.6
0
27.6
0
0
0
0
0
0
0
0
0
13.8
27.6
0 0
0 0
13.8
27.6
0
0
0
0
0
0
0
0
0
0
0
13.8
27.6
13.8
27.6
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
13.8
0
0
0
0
0
0
0
0
0
0
0
0
0
0
13.8
0
0
13.8
0
0
0
27.6
0
0
0
0
0
0
0
0
0
0
0
0
0
0
27.6
0
0
27.6
0
0
0
45
46
30
31
32
33
34
25
26
27 (1)
28 (2)
29
0
13.8
0
0
0
0
0
0
0
0
35
36
13.8
13.8
37 (2) 13.8
0
27.6
0
0
0
0
0
0
0
0
27.6
27.6
27.6
4
0
0
0
7.5
4
0
0
0
7.5
7.5
7.5
7.5
7.5
7.5
7.5
7.5
7.5
7.5
7.5
7.5
7.5
0 0
13.8
27.6
13.8
27.6
13.8
27.6
0
13.8
13.8
0
0
4
7.5
7.5
0
0
4
7.5
7.5
7.5
7.5
7.5
7.5
0
27.6
27.6
27.6
0
13.8
0
0 vaila
7.5
7.5
7.5
0
13.8
13.8
0
38
39
40
41
42
43
44
13.8
13.8
13.8
0
0
13.8
13.8
0
27.6
27.6
27.6
27.6
27.6
0
13.8
27.6
13.8
27.6
k f
0
27.6
0
13.8
27.6
13.8
0
0
27.6
13.8
13.8
13.8
0
0
13.8
13.8
27.6
27.6
27.6
0
0
27.6
27.6
13.8
13.8
13.8
0
0
13.8
13.8
27.6
27.6
0
0
27.6
27.6
27.6
0
27.6
0
0
7.5
7.5
7.5
7.5
7.5
0
27.6
27.6
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
13.8
0
0
0
0
13.8
0
0
0
0
0
0
0
0
0
13.8
0
13.8
0
0
0
0
27.6
0
0
0
0
27.6
0
0
0
0
0
0
0
0
0
27.6
0
27.6
0
0
0
0 bility
Note 1: AC voltage measured on AC scale of volt-ohmmeter.
Note 2: Low Oil Pressure shutdown circuit.
Oil pressure was the cause of shutdown on column 4.
Section 8: Replacement Parts
8-1 Replacement Parts
8-1.1 Table 8-1 covers all of the replaceable components of the MC-900 Series Generator Engine Controls. The part numbers shown are Frank W. Murphy Mfr. part numbers and may not appear on the individual parts.
8-1.2 Each complete control is made up of a Control / Display
Module, a Relay Module and a number of Relays.
8-1.3 There are no field replaceable parts in the Control /
Display Module, the complete module must be replaced if it fails. All relays are individually replaceable in the Relay
Module but the module must be replaced if a failure of the circuit board occurs.
8-2 Replacement Parts Waukesha Modules
8-2.1 Table 8-2 part numbers are Murphy part numbers for
MC-900 controls manufactured for Waukesha Corporation.
These OEM parts are available only to Waukesha and their distributors.
8-2.2 The MC-900 parts are the same as the Murphy MC-900 series that has been covered through out this manual.
Model Number
MC-900-12
MC-900-24
MC-900-2-24
Part Number
40-70-0130
40-70-0177
40-70-0173
Table 8-1
Control / Display
40-00-0023
40-00-0023
40-00-0023
Relay Module
40-00-0091
40-00-0091
40-00-0091
Relay Part
00-00-2952
00-00-2953
00-00-2953
Relay Qty. Module
2
2
3
Model Number
MC-900-2-24
Waukesha
Part Number
40-35-0047
Table 8-2
Control / Display
40-00-0223
Relay Module
40-00-0224
Relay Part
00-00-2953 bility vaila
Pr k f or A oduct Discontinued
Chec
CONTROL SYSTEMS & SERVICES DIVISION
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e-mail [email protected]
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+52 444 8206264 fax +52 444 8206336
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