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mec 20 microprocessor engine/ generator controller

1. Modem Personal MEC 20 Computer Engine Controller 3 Communication cable wiring must be suitably routed to protect it from sources of electrical To additional MEC 20 controllers interference Refer to installation section for further ES maximum 10 total per network information G ENGINEER PRODUCTS MEC20 MEC20_22 VSD FIGURE 16 NETWORKED MEC 20 INTERCONNECTION DIAGRAM PM047 Rev 11 2002 09 09 37 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 7 EXPANSION OUTPUT MODULE OPTION An optional expansion output module is available for the MEC 20 engine generator controller This module provides 16 individual fault output contacts for remote alarming or control purposes The expansion module is interconnected to the MEC 20 controller via RS 422 communication link utilizing 8 conductor shielded cable with plug in RJ45 connectors Refer to FIGURE 17 for the expansion output module connection diagram TO ADDITIONAL 20 EXPANSION 26 UNIT LI LI lus MI ard C282 NFPA STANDARD FAULTS J17 OFF 12 24VDC B J1 J2 POWER SM meee 1 EMERGENCY STOP INPUT B 2 OVERCRANK 3 OVERSPEED S 4 LOSS OF SPEED SIGNAL GRD 5 WEAK BATTERY 5 17 6 LOW BATTERY VOLTAGE K1 E WY Vol 7 HIGH BATTERY VOLTAGE 8 LOW ENGINE TEMPERATURE 19 9 HIGH ENGINE TEMPERATURE ALARM Ka lol V 10 LOW OIL PRESSURE AL
2. JMP FOR gt RMALLY _ JMP CONTACT 1 10 JMP FOR NORMALLY X CLOSED CONTACT TB1 B B GRD 1 gt 20 Q K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 JMP2 JMP3 JMP4 JMPS JMP7 JMP8 JMP9 JMP10 51919 ICICIC ololol 1915 ololol 1919 JMP11 K11 JMP12 K12 JMP13 K13 l JMP14 O K14 JMP15 15 e JMP16 V16 Y 32 J1 RJ45 IN J2 RJ45 OUT DIAGNOSTIC LED S JMP 17 of O O O m G ENGINEER PRODUCTS MEC20 MEC20_16 VSD FIGURE 18 MEC 20 EXPANSION OUTPUT MODULE PRINTED CIRCUIT BOARD LAYOUT PM047 Rev 11 2002 09 09 39 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER Diagnostic LED s are provided on each expansion module as shown in FIGURE 17 Their functions are described as follows WATCHDOG This LED flashes on and off at a very high rate which indicates that the expansion module microprocessor is functioning normally MESSAGE This LED flashes on and off at irregular intervals which indicates that the expansion module is correctly receiving all data messages from the MEC 20 Two expansion modules may be connected to a single MEC 20 controller to provide a maximum of 32 output contacts Two modules are interconnected together using a single communication cable to the MEC 20 controller Refer to
3. 0 4pf Form A e Analog Oil Pressure Measurement Range 15 PSI 150 PSI maximum Pressure Accuracy Operating range 15 59 PSI 6 PSI Operating range 60 75 PSI 2 PSI Operating range 76 150 PSI 7 PSI e Analog Engine Temperature Measurement Range 0 200 C maximum Temperature Accuracy Operating range 0 30 8 C Operating range 30 100 C 2 Operating range 100 200 C 8 Specifications subject to change without notice PM047 Rev 11 2002 09 09 90 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 13 12 24Vdc s ens GRD CONNECTION DIAGRAM GENERATOR OUTPUT VOLTAGE 120Vac TO 600Vac VB 3 PHASE OR SINGLE PHASE N VC DELETE PHASE VC FOR SINGLE PHASE J SYSTEMS VA W CRANK PILOT RELAY f RUN CIRCUIT MV RUN CIRCUIT FUEL SOL GOV V SPEED SENSING MAGNETIC PICKUP OIL PRESSURE SENDER V ENGINE TEMPERATURE SENDER REMOTE EMERGENCY STOP CLOSE TO INITIATE REMOTE FAULT RESET GENERATOR OUTPUT CURRENT SENSING TRANSFORMERS 5 Aac SECONDARY DELETE PHASE C FOR SINGLE PHASE SYSTEMS COMMON FAIL CONTACT OPERATES ON AN ALARM OR SHUTDOWN CONDITION CLOSE TO INITIATE REMOTE START CONTACT PROGRAMMABLE CONTACT 1 DIGITAL FAULT INPUT CONTACTS 1 TO 12 PROGRAMMABLE CONTACT 2 PROGRAMMABLE CONTACT 3 PROGRAMMABLE
4. CONTACT 4 QOOOODOOOoOOoQ NOTES dd 444 PM047 Rev 11 2002 09 09 CONTACTS RATED MAXIMUM 10A 240Vac 8A 24Vdc RESISTIVE LOGIC IS SOFTWARE PROGRAMMABLE FOR OPEN OR CLOSE ON FAIL GENERATOR SUPPLY MUST UTILIZE A SOLIDLY GROUNDED NEUTRAL SYSTEM REFER TO INSTRUCTION MANUAL FOR ALTERNATE CONNECTIONS ENGINE MOUNTED COMPONENTS GRD CONNECTION TO BE MADE TO COMMON CHASSIS ENCLOSURE GROUND BOND SYSTEM GAENGINEERIPPRODUCTSWMEC20 04 VSD REV 02 02 20 91 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 14 TROUBLE SHOOTING A number of problems can cause the MEC 20 controller not to function properly Refer to the following list of typical problems Consult the factory for any detailed information or for any problems not listed CAUTION Before opening the enclosure to perform any service task it is imperative to isolate the control system from any possible source of power Failure to do so may result in serious personal injury or death due to electrical shock Service procedures must be undertaken by qualified personnel only SYMPTOM CORRECTIVE ACTION Controller does not power up even with correct DC Check that there are no wiring errors short power applied circuits connected to the controller Note The MEC 20 contains an electronic fuse that triggers upon an overload condition and does not reset until the supply voltage is removed and overload condition is corrected LCD Disp
5. Displays engine oil pressure in either pounds per square inch PSI or in Kilopascals KPA as selected 9 2 6 PROGRAM MENU The programming menu is used to access the MEC 20 s programmable functions such as time delays analog fault settings digital fault settings and calibration Access to the programming sub menus may only be obtained with a security password number The sub menus are organized as follows PROGRAMMING MENU NO YES PASSWORD PM047 Rev 11 2002 09 09 49 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER LCD DISPLAY PROGRAM MENU NO Displays two messages that may be toggled between YES and NO by pressing the INCREMENT push button Their functions are described as follows NO Programming sub menus are disabled when NO is displayed YES Programming sub menus are enabled when YES is displayed and a valid password number is entered 9 3 SEQUENCE OF OPERATION 9 3 1 GENERAL The MEC 20 Engine generator controller is designed to start and stop an engine from either a local manual or remote automatic command When this command is issued the controller issues a run and crank output signal The controller then monitors engine speed and when crank disconnect speed is reached the crank signal is terminated While the engine accelerates to normal speed the controller continuously monitors the engines speed signal Should the engine speed exceed the ma
6. PROGRAMMABLE 1 OUTPUT 3 m G AUX b UTILITY MAINS 537 V I WV oi 720V 5 e w 4 s Y MANUAL Lw OVERRIDE SWITCH f OPTIONAL x 220v e gt 9 GRTL 20 PROGRAMMABLE 21 GENERATOR gt 4 gt iiio 09 U AUX b contactor w VAOP 4 d 9 ONS P gt NOTES 220 380V S7 CONTACTS RATED 10A 240VAC RESISTIVE MAINS FAILURE CONTACT CLOSES WHEN VOLTAGE DROPS BELOW SETPOINT PROGRAMMABLE OUTPUT 3 MUST BE PROGRAMMED FOR UTILITY READY TO LOAD PROGRAMMABLE OUTPUT 4 MUST BE PROGRAMMED FOR GENERATOR READY TO LOAD ALL COMPONENTS SHOWN EXTERNAL TO THE MEC 2 MEC 20 ARE OPTIONAL ITEMS 3 POLE CHANGEOVER SWITCH SHOWN FOR OTHER SYSTEM VOLTAGE APPLICATIONS CONSULT TTI FACTORY WW AC COIL SPIKE SUPPRESSION DEVICES ARE REQUIRED lt 1 lt lt 1 lt FIGURE 21 M047 Rev 11 2002 09 09 55 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 9 4 CONTROL PUSH BUTTONS The following control push buttons are located on the front faceplate keypad 9 4 1 RUN OFF AUTO LOAD TEST 9 4 1 1 RUN In this position the engine will start and operate continuously providing no shutdown circuits are active All protective circuits will be operative in this mode There will be no cooldown cycle at the end of a manual run sequence 9 4 1 2 OFF This position immediate
7. ubsidiary of Regal Beloit Corporation aa amp CONTROL MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER WITH REMOTE COMMUNICATION EXPANSION OUTPUT MODULE amp EAP 110 REMOTE ANNUNCIATOR OPTIONS INSTALLATION OPERATING amp SERVICE MANUAL Software Version 1 8 9087 198 Street Langley BC Canada V1M 3B1 Telephone 604 888 0110 Telefax 604 888 3381 E Mail info thomsontechnology com www thomsontechnology com MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER CONTENTS 1 INTRODUCTION 1 1 1 PRODUCT REVISION HISTORY 1 1 2 GENERAL DESCRIPTION 3 2 INSTALLATION 5 21 GENERAL INFORMATION 5 2 2 BATTERY SUPPLY INPUT 5 2 3 SPEED SENSING INPUT 6 2 4 DC VOLTAGE INPUTS 7 2 5 AC VOLTAGE INPUT 7 2 6 AC CURRENT INPUT 8 2 1 OUTPUTS 9 2 8 EXTERNAL PANEL CONTROL WIRING 9 2 9 REMOTE START CONTACT FIELD WIRING 10 2 10 REMOTE COMMUNICATION WIRING 10 2 11 EXPANSION OUTPUT MODULE LOCATION INSTALLATION 11 2 12 MEC MOUNTING LOCATION INSTALLATION 12 2 13 FACEPLATE MOUNTING DIMENSIONS 13 2 14 MEC 20 ASSEMBLY SIDE VIEW 13 2 15 DIELECTRIC TESTING 14 3 DESCRIPTION 15 PM047 Rev 11 2002 09 09 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 3 1 LEXAN FACEPLATE 15 3 2 PRINTED CIRCUIT BOARD 17 4 FAULT CIRCUIT DESCRIPTIONS 19 4 1 MEC 20 FUNCTIONAL BLOCK DIAGRAM 20 4 2 INTERNAL FAULT CIRCUITS 21 4 3 DIGITAL FAULT INPUT CIRCUITS 22 4 4 ANALOG FAULT INPUT CIRCUITS 24
8. 10 5 7 equipment damage ACTION This setting allows fault circuit to be programmed as either an alarm or a shutdown Note All activated alarm and shutdown faults will energize the fail circuit and sound the alarm horn ALARM LATCH If an alarm fault was programmed it may be selected as a latching alarm or non latching When latching is selected it will no unlatch until a reset command clears it Note This programming prompt only appears if alarm faults are programmed Shutdown faults are automatically set as latching POLARITY This setting allows the digital fault circuit to be set for Open to Fail or Close to Fail sensing contacts BYPASS ON START DELAY This allows the alarm or shutdown circuit to be disabled until after the bypass timer has expired Fault circuits that are not delayed will be enabled at all times i e engine running or stopped TRANSIENT DELAY TIMES This allows the selected fault circuit to be inhibited from being activated until the specified time delay period has expired Delay times from 0 0 to 999 9 seconds are available by entering the time required IDLE CONTROL DIGITAL INPUT PROGRAMMING When a digital input is programmed as Idle function the following settings must be programmed to ensure correct operation ACTION Alarm 70 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER ALARM LATCH No POLARITY Close BYPASS ON START No TRANSI
9. CURRENT SENSING CALIBRATION CURRENT A ZERO 99 350A Displays the generators load current phase A B or C to be calibrated 47 Rev 11 2002 09 09 74 Thomson Technology Inc PM047 Rev 11 2002 09 09 MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 10 6 5 Displays the type of calibration function either ZERO or SPAN Displays the calibration correction factor number 0 255 used to obtain the correct current reading Note To correctly calibrate any of the current sensors the ZERO function must be calibrated before the SPAN function Displays the actual current measurement that will be the same value as shown on the MEC 20 display menus for generator supply This current reading may be calibrated higher or lower by changing the correction factor number CURRENT CALIBRATION PROCEDURE NOTE To accurately calibrate the MEC 20 s current sensors an external test AC ammeter and current clamp is required with an accuracy of 0 596 or better Note Zero calibration must be completed before span calibration To calibrate the generator supply current sensors perform the following procedure 10 6 5 1 ZERO CALIBRATION Connect an external AC ammeter with current clamp of adequate current range to the MEC 20 controller terminals associated with the current phases to be calibrated With the generator stopped confirm there is 0 current on the phases to be calibrated In the programming mode sc
10. PM047 Rev 11 2002 09 09 29 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER of nominal level The generators output AC voltage is utilized for back up crank disconnect protection should the speed sensor fail 5 1 3 COMMON FAIL OUTPUT The Common Fail output contact is a Form C dry contact and is typically used to provide a remote alarm signal should the generator set fail The common fail output contact closes when any programmed alarm or shutdown fault condition is activated Note The MEC 20 may be programmed to activate the common fail output for any desired fault input circuits or for abnormal switch position i e switch not in auto Refer to the programming instructions for further information 5 2 PROGRAMMABLE OUTPUT CONTACTS The MEC 20 Controller provides four standard programmable output contacts Each programmable output is a Form C dry contact that is programmable for many different control functions All programmable outputs may be user field programmed for the desired control function The following programmable features are provided ENERGIZE TO STOP GEN READY TO LOAD AIR FLAP UTILITY READY TO LOAD OIL BYPASS TIMER COMPLETE DIGITAL FAULTS 1 12 COMMON FAIL OVERSPEED SWITCH NOT IN AUTO LOSS OF SPEED SIGNAL ENGINE READY LOW BAT VOLTAGE ENGINE RUN FUEL HIGH BAT VOLTAGE PREHEAT WEAK BAT VOLTAGE ENGINE RUNNING LOW OIL PRESS 1 ALARM ATS TEST LOW OIL PRESS 2 SHUTDOWN COMMON ALA
11. SWITCH NOT IN AUTO CRANK ALARM 10A 240Vac 8A 24Vdc RESISTIVE ENGINE TEMPERATURE LOW ENGINE TEMP SENDER ALARM II TEMP HIGH ENGINE TEMP DISPLAY ALARM HIGH ENGINE TEMP COMMON FAIL SHUTDOWN CONTACT 10A 240Vac 8A 24Vdc RESISTIVE ENGINE OIL PRESSURE SENDER LOW OIL PRESSURE i PRESS ALARM DISPLAY LOW OIL PRESSURE SHUTDOWN PROGRAMMABLE CONTACT 1 LOW BATTERY 10A 240Vac 8A 24Vdc BATTERY an VOLTAGE ALARM RESISTIVE VOLTAGE VOLT HIGH BATTERY DISPLAY VOLTAGE ALARM WEAK BATTERY PROGRAMMABLE 3 PHASE AC AG UNDERVOLTAGE CONTACT 2 VOLTAGE VOLT OVERVOLTAGE 1 8A 24Vdc N V FREQ UNDERFREQUENCY DISPLAY OVERFREQUENCY 3 AG PROGRAMMABLE NII CURRENT OVERCURRENT TONOVE DISPLAY 96 RESISTIVE DIGITAL INPUT CONTACTS N O or N C LOW OIL PRESSURE SHUTDOWN HIGH ENGINE TEMP PROGRAMMABLE SHUTDOWN CONTACT 4 LOW COOLANT 10A 240Vac 8A 24Vdc LEVEL SHUTDOWN RESISTIVE LOW FUEL LEVEL DIGITAL FAULT 5 DIGITAL FAULT 6 NOTES DIGITAL FAULT 7 N DIGITAL FAULT LABEL LIST EACH POINT DIGITAL FAULT 8 PROGRAMMABLE PM047 Rev 11 2002 09 09 FIGURE 12 20 DIGITAL FAULT 9 DIGITAL FAULT 10 DIGITAL FAULT 11 DIGITAL FAULT 12 PROGRAMMABLE FUNCTION LIST G ENGINEER PRODUCTS MEC20_10 VSD Rev 3 02 02 20 Thomson Technology Inc 4 2 PM047 Rev 11 2002 09 09 MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER INTERNAL FAULT CIRCUITS The MEC 20 Engine Controller p
12. death Standard safety procedures should be followed and be performed by qualified personnel only Failure to do so may cause personnel injury and or death Use the INCREMENT or DECREMENT push buttons to adjust the correction factor number while observing the displayed current level on the MEC 20 Adjust the correction factor PM047 Rev 11 2002 09 09 76 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER number to obtain an identical current reading as measured with the external AC ammeter With the correct current displayed press the ENTER push button to accept the correction factor number Record the correction factor number on the MEC 20 programming sheet for future reference if required Repeat the above procedures for all remaining generator current phases NOTE Once the span calibration setting has been completed re confirm the zero calibration points If the zero calibration setpoint needs further adjustment the span calibration point must also be re calibrated 10 6 6 BATTERY VOLTAGE CALIBRATION BAT VOLTS SPAN 99 24 6V Displays the type of calibration function SPAN Displays the calibration correction factor number 0 255 used to obtain the correct voltage reading Displays the actual battery voltage measurement that will be the same value as shown on the MEC 20 display menu This voltage reading may be calibrated higher or lower by changing the correction factor number
13. operation 10 3 25 HORN FOR NOT IN AUTO The Horn may be programmed to sound when the controllers operating mode is switched from the Auto position If the Horn is not to sound select program setting no 10 3 26 WARM UP DELAY The WARM UP Delay programming menu appears when the Gen Ready To Load programmable output is selected as is typically used in an AMF application Set to the desired time in seconds which the generator requires to effectively warm up before accepting load This 47 Rev 11 2002 09 09 64 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER is typically set for 3 seconds The warm up Delay is initiated once the generator output rises above programmed voltage and frequency limits per the analog programming menus Refer to Section 9 3 for further details on this timing function 10 3 27 NEUTRAL DELAY The Neutral Delay programming menu appears when the Utility Ready To Load programmable output is selected as is typically used in an AMF application The Neutral Delay timer is initiated when transferring between the available sources When transferring from the utility supply to the generator supply the Neutral Delay timer will start when The Utility Ready To Load output de energizes Once the Neutral Delay time period expires The Generator Ready To Load output will then be energized The similar sequence will occur when transfer in the opposite direction The purpose of the Neutral
14. optional features as follows 3 2 4 1 J6 EXP This port is utilized to interconnect an external expansion module for additional output contacts and or the EAP 110 remote annunciator Refer to Section 7 0 amp 8 0 for additional information 3 2 4 247 COM This port is utilized to interconnect to a remote communication system for remote monitoring and control Refer to Section 6 0 for additional information 4 FAULT CIRCUIT DESCRIPTIONS The MEC 20 engine generator controller utilizes many analog and digital inputs to perform both monitoring and control functions Three types of fault circuits are used to monitor and control the engine generator set The first type is nternal Fault Circuits that are derived from a combination of digital and analog inputs The second type is Digital Input Fault circuits that are initiated from external contact inputs The third type is Analog Input Fault circuits that are initiated from external analog signal inputs The following functional block diagram FIGURE 12 shows how all input output fault circuits are organized PM047 Rev 11 2002 09 09 19 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 4 1 MEC 20 FUNCTIONAL BLOCK DIAGRAM FACTORY PROGRAMMED CUSTOMER CONFIGURED FEATURE STANDARD FAULTS FAULTS OUTPUT CONTACTS MAGNETIC OVERSPEED PICKUP SHUTDOWN LOSS OF SPEED RUN ALARM SHUTDOWN 10A 240Vac 8A 24Vdc RESISTIVE OVERCRANK SHUTDOWN
15. these contacts Contacts indicated on schematic drawings and connection diagrams are shown in a de energized state and will change state upon activation of the specific control function 5 4 RUN CRANK COMMON FAIL OUTPUT CONTACTS The MEC 20 Controller provides three dedicated output contacts for basic control and alarm circuits as described below 5 1 1 RUN OUTPUT The Run output contact is a Form A dry contact and is used to control the engines run circuit This typically includes external control devices such as fuel rack solenoids or electronic governors Note An additional pilot relay will be required to energize high current devices that exceed the 10A resistive rating The run output control logic provides an energize to run signal i e the run contact closes when a run condition is activated Note For energize to stop control logic refer to the programmable output control function 5 1 2 CRANK OUTPUT The Crank output contact is a Form A dry contact and is used to control an external crank pilot relay that directly controls the engine starter motor Note An external crank pilot relay is required to energize the high current starter motor pinion solenoid that exceeds the 10A resistive crank output contact rating The crank output contact closes when a crank condition is activated and the contact will automatically open when crank disconnect speed is obtained and or the generators output AC voltage exceeds 10
16. 10 6 7 BATTERY VOLTAGE CALIBRATION PROCEDURE NOTE To accurately calibrate the MEC 20 s battery voltage sensor an external test DC voltmeter is required with an accuracy of 0 5 or better To calibrate the battery voltage sensor perform the following procedure PM047 Rev 11 2002 09 09 77 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 10 6 7 1 SPAN CALIBRATION Energize the battery supply voltage to the controller and connect the external test DC voltmeter to the battery terminals B and B In the programming mode scroll to the battery span calibration point Use the INCREMENT or DECREMENT push buttons to adjust the correction factor number while observing the displayed battery voltage level on the MEC 20 Adjust the correction factor number to obtain an identical voltage reading as measured with the external DC voltmeter With the correct voltage displayed press the ENTER push button to accept the correction factor number Record the correction factor number on the MEC 20 programming sheet for future reference if required 10 6 8 ENGINE TEMPERATURE amp OIL PRESSURE CALIBRATION ENGINE TEMP 127 95 Displays the type of calibration function Displays the calibration correction factor number 0 255 used to obtain the correct Temperature or Pressure reading Displays the actual temperature or pressure measurement that will be the same value as shown on the MEC 20 display
17. BOARD UNDER PANEL DOOR 49 mm JM 49 mm gt 3 16 DRILL D G ENGINEER PRODUCTS MEC20_07 VSD FIGURE 6 2 14 MEC 20 ASSEMBLY SIDE VIEW FRONT PANEL DOOR REAR x MEC 20 PCB 4 20 REAR COVER STUD 8 32 1 8 32 x 3 8 MACHINE SCREW 8 32 INTERNAL TOOTH LOCK WASHER 1 2 NYLON SPACER 48 32 CLEARANCE UNTHREADED 1 25 ALLUMINUM STANDOFF HEX 88 32 THREAD HIGH VOLTAGE MYLAR BARRIER mounts on bottom right hand corner as viewed from rear 38 32 INTERNAL TOOTH LOCK WASHER GAENGINEERIPRODUCTSWMEC20 09 VSD Rev O 97 06 02 FIGURE 7 PM047 Rev 11 2002 09 09 13 Thomson Technology Inc Notes MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER Ensure that all lockwashers are installed as shown above The high voltage mylar barrier P N TMW 10805 1 must be installed as shown when the MEC 20 is installed onto the door of a control panel When the MEC 20 is installed on a door without 1 PEM studs 1 machine screws must be used 9 HOLES d 1 4 DIAMETER 5 n C n m C4 gt gt _ _ ___ __ __ 2___ _ T 010 I C I 4 STUDS 8 32 414 gt T ML 3 lt 14 FIGURE 8 ADAPTER FACEPLATE lt 5 5 in b ponet le 10 875 in FIGURE 9 DOOR CUTOUT FOR ADAPTER FACEPLATE GAENGINEERIPRODUCT
18. Delay timer is to prevent out of phase transfers which may be caused by a fast transfer and the two sources of supply are out of synchronism The Neutral Delay timer ensures the load voltages decay before the transfer is initiated Set to the desired time in seconds The Neutral Delay timer is typically set for 3 seconds Refer to Section 9 3 for further details on this timing function NOTE The Neutral Delay feature is only effective when an electrically held contactor type transfer switch is connected Contact Thomson Technology for further application information on use with other types of transfer switch mechanisms 10 3 28 RETURN DELAY The Return Delay programming menu appears when the Utility Ready To Load programmable output is selected as is typically used in an AMF application The Return Delay is initiated once the remote start PM047 Rev 11 2002 09 09 65 Thomson Technology Inc PM047 Rev 11 2002 09 09 MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 10 3 29 signal is removed signaling that utility power is now available Once the Return Delay timer expires the Generator Ready To Load output will be removed and the Utility Ready To Load output energizes to signal transfer the load back to the utility supply The purpose of the Return Delay timer is to ensure that the utility power has returned to a steady state for the selected time period before the load is transferred back to the utility
19. GENERATOR CONTROLLER CIM Communication Interface Module To expansion output module optional RD DC Power 8 35Vdc FIGURE 15 MEC 20 WITH CIM MODULE amp REMOTE CONNECTED PC Personal Computer N 8 conductor Shielded Cable c w RJ45 connectors 305M 1000 maximum cable _ length Communication cable wiring must be suitably routed to protect it from sources of electrical interference Refer to installation section for further information MEC 20 Engine Controller G ENGINEER PRODUCTS MEC20 MEC20_21 VSD The MEC 20 RS422 communication port allows multiple MEC 20 controllers to be directly interconnected together to form a single network system Up to 10 MEC 20 controllers may be interconnected to a single CIM module Each MEC 20 controller is remote programmed with an unique communication address number for the communication system to reference The network system may be connected to a local PC or to a remote PC via telephone system and CIM module Refer to FIGURE 15 for a typical MEC 20 network system with CIM module 47 Rev 11 2002 09 09 36 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER CIM Communication Interface Module 8 conductor Shielded Cable c w RJ45 connectors MEC 20 Engine SS I Controller AX L iH DC Power U 8 35Vdc E 305 1000 XS maximum cable Controller length 2
20. Refer to the programming instructions for further information 4 4 4 ENGINE TEMPERATURE ANALOG INPUT The MEC 20 s engine temperature sensor measures a DC analog signal from an engine mounted sender The MEC 20 software provides calibration for engine temperature to coordinate with the engine mounted sender and control logic to detect a wiring or sender failure i e open or shorted signal In case of a sender or wiring failure the MEC 20 will display zero or 9999 and will initiate an alarm signal as programmed by the user The engine temperature analog input provides the following control functions 4 4 4 1 LOW ENGINE TEMPERATURE ALARM The low engine temperature alarm fault circuit is activated when the engine temperature drops below a pre determined setpoint for a specified time delay The low engine temperature alarm fault is programmable for temperature setpoint level transient time delay settings and other functions Refer to the programming instructions for further information 4 4 4 2 HIGH ENGINE TEMPERATURE 7 ALARM The high engine temperature alarm fault circuit is activated when the engine temperature rises above a pre determined setpoint for a specified time delay The high engine temperature alarm fault is programmable for the level of temperature setpoint transient time delay settings and other functions Refer to the programming instructions for further information 4 4 4 3 HIGH ENGINE TEMPERATURE 2 SHUTDOWN T
21. The display menu will automatically revert to a low power sleep mode following the expiry of the 999 second internal timer 10 3 MAIN PROGRAMMING MENU The main programming menu contains general system configuration programming such as system input voltages currents transformer ratios as well as standard operating time delay functions The programming prompts are listed in order as they appear in the MEC 20 software To program the specific MAIN MENU items refer to the following descriptions 10 3 1 NODE ADDRESS Set to unique controller address 1 255 for use with network connected MEC 20 controllers Note This programming feature is only active when the remote communication option is enabled Default setting for single MEC 20 applications is 1 10 3 2 SYSTEM VOLTAGE Set to nominal system voltage as expressed in phase to phase voltage i e 347 600 volt system would be entered as 600 The programmable range of values is 120V 15 000V PM047 Rev 11 2002 09 09 60 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 10 3 3 SYSTEM FREQUENCY Set to nominal system frequency of either 50 HZ or 60 HZ 10 3 4 SYSTEM PHASES Set to match the power distribution system used on the generator set i e either single phase or 3 phase system 10 3 5 NEUTRAL CONNECTED Set to Yes if generator s neutral conductor is connected to the MEC 20 controller terminal TB1 VN and it is desired to display line n
22. The display will automatically scroll through all active faults at a rate of every two seconds FAULT DISPLAY MENU The fault display menu is automatically displayed when either an alarm or shutdown circuit is activated The specific alarm or shutdown fault label will be displayed and if multiple alarm conditions are present the display will automatically scroll through all active faults TIMER COUNTDOWN MENUS Timer countdown menus are automatically displayed when a specific time delay function occurs during a control sequence When a time delay 44 Thomson Technology Inc PM047 Rev 11 2002 09 09 MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 9 2 4 begins the LCD display will indicate the time delay function name i e ENGINE START DELAY and the current time remaining in the countdown sequence When the timing function has expired the LCD display will automatically change to either the next timing sequence countdown display or return to the original system status menu ENGINE START DELAY 45 SEC LCD DISPLAY Displays specific time delay function currently in operation Displays current time in seconds or minutes that are left in the specific timing sequence NOTE During a timer countdown sequence a different display screen may be selected by pressing the ENTER push button The following timer countdown screens are provided ENG START DELAY XX SEC CRANK PERIOD XX SEC REST PERIOD XX SEC S
23. default to one 62 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 10 3 15 BYPASS DELAY This setting is the time period that affected Alarm or Shutdown inputs will be ignored after crank disconnect allowing the engine to settle into its normal operating mode i e proper oil pressure etc This is typically set to 10 seconds 10 3 16 COOLDOWN TIME Set to desired cooldown time in seconds Up to 9999 seconds of cooldown time may be programmed Set to zero if not required Note If the controller is used in an AMF application it is recommended to set the cooldown timer to a minimum of 10 seconds to allow the generator to transfer Off Load before enabling the cooldown time Ensures the load is transferred off of generator prior to stopping the engine 10 3 17 NOMINAL ENGINE RPM Set to the nominal engine speed in revolutions per minute RPM 10 3 18 FLYWHEEL TEETH Set to the number of ring gear teeth on the engine flywheel The magnetic pick up must be installed to sense the same teeth for speed sensing as programmed 10 3 19 CRANK DISCONNECT SPEED Set crank disconnect speed in percentage of nominal speed i e 3096 or 540 RPM on a 1800 RPM engine 10 3 20 OVERSPEED Set overspeed shutdown point in percentage of nominal speed i e 110 or 1980 RPM on a 1800 RPM engine 10 3 21 OVERSPEED TRANSIENT DELAY Select desired overspeed transient delay time in seconds Time setting may
24. delay function Following the BYPASS DELAY time period typically 10 seconds all fault circuits programmed as BYPASS DELAY YES will be activated Note All fault circuits programmed as BYPASS DELAY NO are continuously armed irrespective of any operation sequence When the OFF push button on the front keypad is depressed the controllers RUN output will be immediately terminated which will initiate the engine to stop 9 3 3 AUTOMATIC START STOP SEQUENCE When the controller is selected for automatic operation via the front keypad push button the engine will automatically start upon activation of the remote start contact input Note The remote initiates a start sequence upon contact closure Once the remote start signal is activated the engine will start as per the sequence of operation described for the manual start sequence The automatic stop sequence will be initiated by removal of the remote start signal Once the start signal is removed a cooldown delay function will be initiated Once the cooldown time delay period expires typically programmed for 5 minutes the controllers RUN output will be immediately terminated which will initiate the engine to stop 9 3 4 AUTOMATIC FAULT SHUTDOWN SEQUENCE When a fault circuit is programmed as a SHUTDOWN the engine will immediately stop once the fault circuit is activated Note A specific shutdown fault may be programmed with a definite time transient delay period that must expire b
25. distances up to 100ft 30m 9 are as follows 2 8 1 Battery Control Power 14 AWG 2 5mm 2 8 2 Engine Alarm Shutdown Contacts 16 AWG 1 5mm 2 8 3 Remote Start Contact for Transfer Switch 14 AWG 2 5mm 2 8 4 Crank amp Preheat Output Wiring 14 AWG 2 5 To pilot relays 2 8 5 Speed Sensing Wiring 16 AWG 1 5mm 2 Conductor Shielded Cable 2 8 6 Metering Voltage Inputs 16 AWG 1 5mm PM047 Rev 11 2002 09 09 9 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 2 8 7 Metering Current Inputs from CT s 14 AWG 2 5mm 9 For distances exceeding 100 Ft 30m consult TTI For unit mounted control panels wire sizes may be reduced to the next smallest wire size available 2 9 REMOTE START CONTACT FIELD WIRING Field wiring of a remote start contact from a transfer switch to a control panel should conform to the following guidelines to avoid possible controller malfunction and or damage 2 9 1 Remote start contact wires 2 14 AWG 2 5mm should be run in a separate conduit 2 9 2 Avoid wiring near AC power cables to prevent pick up of induced voltages 2 9 3 interposing relay may be required if field wiring distance is excessively long i e greater than 100 feet 30m and or if a remote contact has a resistance of greater than 5 0 ohms 2 9 4 The remote start contact must be voltage free i e dry contact The use of a powered contact will damage the engine contr
26. menus This reading may be calibrated higher or lower by changing the correction factor number 10 6 9 TEMPERATURE CALIBRATION PROCEDURE Before the equipment is put into final operating service the engine temperature analog circuit must be field calibrated to meet the performance accuracy as specified to ensure correct operation The engine temperature analog circuit must be calibrated with the engine PM047 Rev 11 2002 09 09 78 Thomson Technology Inc PM047 Rev 11 2002 09 09 MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER temperature sender supplied with the controller and mounted on the engine WARNING Failure to field calibrate and validate the correct operation of the temperature analog circuit on the equipment may result in severe equipment failure or damage To calibrate the MEC 20 temperature sensor perform the following procedure NOTE To accurately calibrate the MEC 20 s temperature sensor an external temporary engine mounted temperature gauge is required The external temperature gauge should be connected as close as possible to the temperature sender for the MEC 20 The calibration procedure is to be done only at a single point which is the normal operating temperature of the engine Connect a temporary engine mounted temperature gauge of suitable accuracy and start the engine Once the engine reaches normal operating temperature enter the programming mode and scro
27. 02 09 09 85 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 11 3 ANALOG FAULT PROGRAMMING MENU TYPICAL PROGRAM FACTORY DEFAULT SETTINGS ANALOG FAULT PROGRAMMING MENU INPUT ANALOG FAULT SETPOINT SETPOINT ACTION ALARM LATCH BYPASS ON TRANSIENT TYPE E ENABLE LEVEL LEVEL S SHUTDOWN DELAY SEC D DISABLE PICK UP DROP OUT A ALARM AC VOLTAGE AC VOLTAGE AC FREQUENCY FREQUENCY OVER AC FREQUENCY FREQUENCY AC CURRENT DC VOLTAGE DC VOLTAGE DC VOLTAGE TEMP SENDER TEMP SENDER TEMP SENDER PRESS SENDER PRESS SENDER SHUTDOWN Indicates feature is non programmable i e is fixed in software PM047 Rev 11 2002 09 09 86 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 11 4 DIGITAL FAULT PROGRAMMING MENU TYPICAL PROGRAM FACTORY DEFAULT SETTINGS DIGITAL FAULT PROGRAMMING MENU FAULT INPUT ACTION POLARITY BYPASS ON TRANSIENT NAME S SHUTDOWN A ALARM LOW OIL PRESSURE BATT CHGR INPUT FAIL LOW FUEL LEVEL blank blank blank blank blank PM047 Rev 11 2002 09 09 87 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 11 5 CALIBRATION MENU B B VOLTS B C ZERO XXX XXXVAC VOLTS B C A A SPAN XXX XXXVAC VOLTS C N PM047 Rev 11 2002 09 09
28. 09 09 41 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 9 OPERATING INSTRUCTIONS 9 1 MEC 20 POWER UP OPERATION SEQUENCE When the MEC 20 is first energized with DC supply voltage at terminals 8 amp B the controller will power up into a fail safe mode preventing possible engine operation The controller will default to an Emergency Stop failure mode and must be manually reset before the controller is put into normal operation To reset the Emergency Stop condition press the OFF push button first then press both INCREMENT and ENTER push buttons simultaneously The controller will then reset provided a remote emergency stop condition is not activated The Utility Read to Load programmable output will energize if the remote start contact is open 9 2 MEC 20 DISPLAY MENUS The MEC 20 contains a Liquid Crystal Display LCD which is visible through the front lexan faceplate viewing window The LCD has pre programmed display screens and menus that may be selected by pressing the ENTER or EXIT push buttons in succession until the desired screen or menu is displayed The display screen types and order in which they are programmed are as follows PM047 Rev 11 2002 09 09 42 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER OPERATING STATUS TIMER COUNTDOWN f FAULT DISPLAY FAULT DISPLAY Multiple Faults GENERATOR METERING Average GENERATOR PHASE VOLTAGES GEN
29. 1 generator set control requirements RS 422 remote communication port Expansion output module communication port for individual output fault contact capability Backlit LCD display screen with alpha numeric readout for display and programming Digital 3 phase voltage 3 phase current KVA and frequency metering for generator output Non volatile memory retains logic and set points if control power is lost Direct 3 phase voltage sensing inputs on generator supply from 120Vac up to 600Vac nominal Security password protected programming levels Self diagnostic features continuously verify processing I C and memory circuits Superior EMI RFI noise immunity and surge performance features as per IEEE C62 41 requirements Dual microprocessor design provides independent speed sensing circuitry for higher performance CAUTION contents subject to damage by STATIC ELECTRICITY This equipment contains static sensitive parts Please observe the following anti static precautions at all times when handling this equipment Failure to observe these precautions may cause equipment failure and or damage PM047 Rev 11 2002 09 09 4 Thomson Technology Inc e Discharge body static charge before handling the equipment contact a grounded surface and maintain contact while handling the equipment a grounded wrist strap can should also be utilized MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER e Do not touch any components on the pri
30. 3 1 ZERO CALIBRATION Connect an external AC voltmeter of adequate voltage range and accuracy to the MEC 20 controller terminals associated with the voltage phases to be calibrated With the generator stopped confirm there is Zero volts on the phases to be calibrated In the programming mode scroll to each of the desired generator supply voltage phases i e phase to phase or phase to neutral with the ZERO function selected Use the INCREMENT or DECREMENT push buttons to adjust the correction factor number to obtain zero volts on the right hand side of the display as confirmed with the external voltmeter The factory default correction factor is 127 Increasing this will raise the displayed value conversely decreasing this value will decrease the displayed value Note Adjusting the ZERO function with voltage applied will result in non linear voltage readings With the correct voltage displayed press the ENTER push button to accept the correction factor number Record the correction factor number on the MEC 20 programming sheet for future reference Repeat the above procedure for all remaining phases of the generator supply as required 10 6 3 2 SPAN CALIBRATION Energize the generator supply voltage to the controller at nominal level Note It may be necessary to program the optional under and over voltage shutdowns as alarms to ensure the generator will continue to operate during calibration Caution must be taken to ensure the ge
31. 5 CONTROL OUTPUT CONTACT DESCRIPTIONS 29 5 1 RUN CRANK COMMON FAIL OUTPUT CONTACTS 29 5 2 PROGRAMMABLE OUTPUT CONTACTS 30 6 REMOTE COMMUNICATION OPTION 34 T EXPANSION OUTPUT MODULE OPTION 38 8 EAP 110 REMOTE ANNUNCIATOR OPTION 41 9 OPERATING INSTRUCTIONS 42 9 1 MEC 20 POWER UP OPERATION SEQUENCE 42 9 2 MEC 20 DISPLAY MENUS 42 9 3 SEQUENCE OF OPERATION 50 9 4 CONTROL PUSH BUTTONS 56 10 PROGRAMMING INSTRUCTIONS 58 10 1 SECURITY PASSWORDS 58 PM047 Rev 11 2002 09 09 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 10 2 BASIC PROGRAMMING OPERATION 59 10 3 MAIN PROGRAMMING MENU 60 10 4 ANALOG FAULT PROGRAMMING MENU 68 10 5 DIGITAL FAULT PROGRAMMING MENU 69 10 6 CALIBRATION MENU 71 11 PROGRAMMING SHEETS 82 11 1 SUMMARY CONFIGURATION DATA SHEET 82 11 2 MAIN CONFIGURATION 83 11 3 ANALOG FAULT PROGRAMMING MENU 86 11 4 DIGITAL FAULT PROGRAMMING MENU 87 11 5 CALIBRATION MENU 88 12 SPECIFICATIONS 90 13 CONNECTION DIAGRAM 91 14 TROUBLE SHOOTING 92 15 NOTES 95 PM047 Rev 11 2002 09 09 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 1 INTRODUCTION 1 1 PRODUCT REVISION HISTORY The following information provides an historical summary of changes made to this product since the original release 1 1 1 Software Version 1 8 02 09 09 Added Programmable Output Feature EPS Supplying Load a Added Dig
32. 5 2 14 OIL BYPASS TIMER COMPLETE The designated programmable output relay will energize upon the expiry of the controller s oil bypass delay timer function following a normal start sequence 5 2 15 COMMON ALARM The designated programmable output relay will energize when any alarm fault circuit has been activated 5 2 16 COMMON FAIL The designated programmable output relay will energize when any alarm or shutdown fault circuit has been activated 5 2 17 COMMON SHUTDOWN The designated programmable output relay will energize when any shutdown fault circuit has been activated 5 2 18 EPS SUPPLYING LOAD The designated programmable output relay will energize when the engine is running and the generator is supplying current to the load more than or equal to 1096 of nominal CT ratio 6 REMOTE COMMUNICATION OPTION The MEC 20 engine generator controller is available with an optional remote communication feature The remote communication feature allows a MEC 20 controller to be monitored and controlled from a remote location via serial communication link to a personal computer PC PC s may be connected locally via serial communication cable to the MEC 20 or remotely via modem and telephone systems Remote communication can be via customer supplied equipment or an external communication interface module CIM as manufactured by Thomson Technology Inc The CIM module utilizes an internal modem and contains Modbus protocol to inter
33. 88 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER ZERO XXX XXXAAC CURRENT A SPAN XXX XXXAAC CURRENT B ZERO XXX XXXAAC CURRENT B SPAN XXX XXXAAC CURRENT ZERO CURRENT SPAN XXX XXXAAC BATTERY VOLTAGE SPAN XXX XX X VDC ENGINE TEMPERATURE XXX XXX CIF OIL PRESSURE XXX XXXX PSI KPA PM047 Rev 11 2002 09 09 89 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 12 SPECIFICATIONS e Power supply 10 to 30Vdc negative ground Operating temperature 15 C to 50 C Extended temperature ratings are available using the VFD display option Extended ratings are Operating 40 C to 70 C Storage 50 C to 85 C e Environmental Faceplate NEMA 12 e Vibration 4g 5 250Hz e Power consumption 5 watts max e Storage temperature 20 C to 70 e Humidity 5 to 95 non condensing e Dimensions 10 75 W x 6 75 H x 2 0 D AC Metering Accuracy 1 096 25 Volts Amps 296 25 KVA e Inputs Engine Speed Sensing 100 10 000HZz 3 0 20Vac rms AC Voltage 120 600Vac nominal 0 1VA 3 phase 50 60Hz AC Current 0 5Aac nominal 1 5VA 3 phase Engine Parameters Dedicated Senders supplied loose Digital Fault Contacts Open or close to DC Negative e Output contacts Run Crank 10A 240Vac 8A 24Vdc resistive 3A inductive 0 4pf Form A Programmable 10A 240Vac 8A 24Vdc resistive 3A inductive
34. ARM 9 29 11 DIGITAL FAULT 1 2 12 DIGITAL FAULT 2 NS wie 13 DIGITAL FAULT 3 K3 Oo K11 o 22 14 DIGITAL FAULT 4 5 15 SWITCH NOT IN AUTO vw vf 16 PROGRAMMABLE OUTPUT 5 K4 0 12 9 L2 ADDITIONAL FAULTS J17 ON Tl 5 1 UNDER VOLTAGE V Nos KS 2 OVER VOLTAGE 9 3 UNDER FREQUENCY 274 4 OVER FREQUENCY K6 V WX js 5 OVER CURRENT LI 6 HIGH ENGINE TEMPT 2 SHUTDOWN 5 29 7 LOW OIL PRESSURE 2 SHUTDOWN B N NV gas 8 DIGITAL FAULT 5 de 30 9 DIGITAL FAULT 6 31 10 DIGITAL FAULT 7 Lk N RE 11 DIGITAL FAULT 8 V w L826 12 DIGITAL FAULT 9 18 DIGITAL FAULT 10 x 14 DIGITAL FAULT 11 7 15 DIGITAL FAULT 12 16 PROGRAMMABLE OUTPUT 6 NOTES N ALL CONTACTS RATED MAXIMUM 0 5A 120Vac 1 0A 30Vdc RESISTIVE PROGRAMMABLE MODULE ADDRESS REMOVE JUMPER FOR STANDARD C282 NFPA FAULTS ADD JUMPER FOR ADDITIONAL FAULTS CONTACT LOGIC IS INDIVIDUALLY PROGRAMMABLE VIA PIN JUMPERS CONTACT TO OPEN OR CLOSE WHEN FAULT ACTIVATED W PROGRAMMABLE CONTACT USER CONFIGURED FUNCTION VIA MEC 20 SOFTWARE REFER TO MEC 20 LITERATURE GRD CONNECTION BE MADE TO COMMON CHASSIS ENCLOSURE GROUND BOND SYSTEM C282 OR NFPA 110 STANDARD FAULTS EXCLUDE ANALOG FAULTS OVER UNDER VOLTAGE OVER UNDER FREQUENCY OVERCURRENT SPARE DIGITAL FAULT INPUTS 5 12 AND PROGRAMMABLE OUTPUT 6 I E MUST SPECIFY SECOND EXPANSION MODULE TO OBTAIN CONTACTS FOR THESE FAULTS G ENGINEER P
35. C SYSTEM FREQUENCY 50HZ 60HZ SYSTEM PHASES 1 PHASE 3 PHASE NEUTRAL CONNECTED VOLTAGE SENSING RATIO XXX CURRENT SENSING RATIO XXX TEMPERATURE SCALE DEG C DEG F PRESSURE SCALE PSI KPA START DELAY XXX SECONDS CRANK TIME XX SECONDS REST TIME XX SECONDS STARTER RE ENGAGE DELAY XX SECONDS PM047 Rev 11 2002 09 09 EMOTE COM OPTION LINE TO LINE VOLTAGE 120 15000VAC BETWEEN 50 60 HZ BETWEEN 1 amp 3 PHASE rear BETWEEN YES NO ora SENSING PT RATIO ENTER NUMBER 1 208 1 DIRECT current SENSING CT RATIO ENTER NUMBER 1 999 1 DIRECT BETWEEN DEG C DEG F reae BETWEEN PSI KPA SECONDS SECONDS SECONDS SECONDS 0 DISABLED 83 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER MAIN PROGRAMMING MENU 0 99 SECONDS 0 9999 SECONDS 0 4000RPM ENGINE SPEED SENSING VIA MAGNETIC PICK UP 0 999 TEETH 0 100 X BYPASS DELAY XX SECONDS COOLDOWN DELAY XX SECONDS NOMINAL RPM XXXX RPM FLYWHEEL TEETH XX CRANK DISCONNECT XX PERCENT OVERSPEED OVERSPEED TRANSIENT 0 0 9 9 SEC TOGGLE BETWEEN YES NO TOGGLE BETWEEN ALARM SHUTDOWN X X SEC RUN OUTPUT SHUTDOWN ALARM SHUTDOWN TOGGLE BETWEEN YES NO Common Fail Factory default unless otherwise COMMON FAIL FOR NOT IN AUTO YES NO PM047 Rev 11 2002 09 09 84 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER PM047 Rev 11 20
36. ENT TIME 0 1 NOTE A programmable output must also be programmed for IDLE to enable correct operation Refer to Section 5 2 2 for further details 10 5 8 NO LOAD TEST CONTROL DIGITAL INPUT PROGRAMMING When a digital input is programmed as NO LOAD TEST the following settings must be programmed to ensure correct operation ACTION Alarm ALARM LATCH No POLARITY Close or Open dependent on external circuit used BYPASS ON START No TRANSIENT TIME 0 1 The No Load Test digital input feature is typically used in an AMF application where it is required to do an automatic timed No Load Test of the engine generator set A contact from an external exercise clock timer is required to be connected to the digital input circuit which is programmed for No Load Test Refer to Section 9 3 6 for details on sequence of operation 10 6 CALIBRATION MENU 10 6 1 GENERAL AC Voltage AC current and battery voltage analog circuits are factory calibrated before the product is shipped therefore these circuits should not require any field calibration Should field calibration be required refer to the applicable procedure as described further in this section PM047 Rev 11 2002 09 09 71 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER Engine oil pressure and engine temperature analog circuits are not factory calibrated and therefore require field calibration before the equipment is placed into service Refe
37. ERATOR LINE TO NEUTRAL VOLTAGES GENERATOR PHASE CURRENTS GENERATOR KVA GENERATOR FREQUENCY HOURMETER BATTERY VOLTAGE ENGINE SPEED TACH ENGINE TEMPERATURE OIL PRESSURE PROGRAM MENU 9 2 1 OPERATING STATUS MENU The operating status menu provides the operator with detailed information as to the status of the engine generator set NOTE The operating status screen may be momentarily replaced with a time delay countdown screen when a start or stop sequence is initiated The display will automatically return to the previous menu following expiry of the timing sequence 47 Rev 11 2002 09 09 43 Thomson Technology Inc PM047 Rev 11 2002 09 09 MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 9 2 2 9 2 3 The operating status sub menus are organized as follows OPERATING STATUS UNIT READY SWITCH IN OFF UNIT RUNNING UNIT SHUTDOWN UNIT ALARM 9 2 1 1 UNIT READY This indicates that the controller is in Auto position and there are no active shutdowns or alarms 9 2 1 2 SWITCH IN OFF This indicates that the controller has been selected to the off position from the front panel keypad push button 9 2 1 3 UNIT RUNNING This indicates that the engine is running and all conditions are normal 9 2 1 4 UNIT SHUTDOWN This indicates that a shutdown fault is active The specific fault condition will be automatically displayed 9 2 1 5 UNIT ALARM This indicates that one or more alarm fault circuits are active
38. FIGURE 19 for interconnection details The first expansion module addresses standard C282 NFPA110 MEC 20 fault circuits and the second expansion module addresses all additional fault circuits To select which faults are addressed by each expansion module jumper pins and clips are provided on the circuit boards location and configuration settings Expansion Expansion Module 2 Module 1 C282 NFPA Standard Fault Circuits Additional Fault Circuits Refer to FIGURE 18 for jumper pin 8 conductor Shielded Cable c w RJ45 connectors MEC 20 ate Engine Controller J7 To remote 300M 1000 gt communication system optional maximum cable length 1 C282 110 standard faults exclude analog faults Over Under voltage Over Under Frequency Overcurrent spare digital inputs 5 12 and programmable output 6 i e must specify second expansion module to obtain contacts for these faults G ENGINEER PRODUCTS MEC20 MEC20_17 VSD FIGURE 19 MEC 20 EXPANSION MODULE INTERCONNECTION DIAGRAM PM047 Rev 11 2002 09 09 40 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 8 EAP 110 REMOTE ANNUNCIATOR OPTION An optional EAP 110 remote annunciator is available for the MEC 20 engine generator controller The standard features of the EAP 110 meet and exceed all requirements of NFPA 110 NFPA 99 amp CSA 282 00 bu
39. IN AUTO The Switch Not In Auto fault circuit is initiated when the controller s operating mode switch is changed from the auto position to any other position via the front mounted keypad This fault is internally programmed 21 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER as a non latching alarm In the main programming loop this alarm may be user programmed to initiate the common fail output relay 4 3 DIGITAL FAULT INPUT CIRCUITS The MEC 20 Engine Controller provides up twelve digital fault input circuits that are user programmable Each digital fault input circuit is activated via a remote sensing contact that is external to the controller Each digital fault input circuit may be programmed with a unique fault label description as stored in the controller s non volatile memory The following digital fault labels are provided in each MEC 20 engine controller AIR DAMPER TRIPPED HIGH OIL TEMP BAT CHARGER INPUT FAIL HIGH WINDING TEMP BAT CHRG TROUBLE IDLE BREAKER TRIPPED LOW COOLANT LEVEL DC FAIL LOW ENGINE TEMP FAILED TO SYNC LOW FUEL PRESS GEN BREAKER OPEN LOW FUEL LEVEL GROUND FAULT LOW OIL LEVEL HIGH BEARING TEMP REMOTE EMERG STOP HIGH COOLER VIBRATION REVERSE POWER HIGH ENGINE TEMP BASIN RUPTURE HIGH ENGINE VIBRATION ATS IN BYPASS HIGH FUEL LEVEL FUEL LEAK HIGH OIL LEVEL LOW FUEL PRESS NO LOAD TEST BAT CHARGER FAIL HIGHINTKMANFTEMP VENT DAMPER FAIL HIGH FUEL LEVEL FAIL TO S
40. LT MENU LOOP CALIBRATION MENU LOOP 7 The MAIN MENU message will be displayed immediately upon entering the programming mode To select the desired programming menu press the INCREMENT push button to scroll through the available menu types and once displayed press the ENTER push button to select the specific program menu When the programming mode is accessed the programming parameters will be displayed in the same order as the Programming Sheets To skip over parameters that do not require changes push and hold the ENTER push button until the desired function is displayed The EXIT push button may be used to scroll backwards through the programming parameter loops To change a programmed parameter use the INCREMENT or DECREMENT push buttons to scroll through the available options or to adjust a value up or PM047 Rev 11 2002 09 09 59 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER down to the desired number When the desired option or number is displayed press the ENTER push button to accept the new value NOTE If the programming mode is terminated before the last change had been entered the programming parameter will remain unchanged To exit the programming mode press the EXIT push button and hold for two seconds The controller will automatically exit the Program Mode when an internal timer set for 999 seconds expires from when a key press was last received by the controller Note
41. OR ENGINE GENERATOR CONTROLLER 11 PROGRAMMING SHEETS 11 1 SUMMARY CONFIGURATION DATA SHEET MEC 20 SS MICROPROCESSOR ENGINE GENERATOR CONTROLLER SUMMARY CONFIGURATION DATA SHEET WORK ORDER REV REV DATE INITIATED BY CUSTOMER DEFAULT PROGRAM DATE PROJECT NAME TPS VER NOTES ENGINE GEN SYSTEM INPUTS SYSTEM AC VOLTS PHASES FREQUENCY DC VOLTAGE DIGITAL DISPLAY FEATURES AC VOLTAGE AC CURRENT BATTERY VOLTAGE ENGINE TEMPERATURE KVA TACHOMETER OIL PRESSURE FREQUENCY HOURMETER DIGITAL FAULT CIRCUITS 15 ANALOG FAULT CIRCUITS FAULT NAME INPUT NAME FAULT NAME INPUT NAME Overcrank Shutdown Internal Overspeed Shutdown Mag Pickup Switch Not in Auto Alarm Internal Loss of Speed Sig Shtdn Mag Pickup Emergency Stop Internal ext Undervoltage Shutdown AC Voltage Low Oil Press Shtdn Std Default or Ext Dig Input 1 Overvoltage Shutdown AC Voltage Custom a High Eng Temp Shtdn Std Default or Ext Dig Input 2 Under Frequency Alarm AC Freq Custom Low Coolant Lvl Shtdn CSA Std Default or Ext Dig Input 3 Querhreauency AC Freq Bat Chgr AC Fail NFPA Std Default or Custom Low Fuel Level Alarm Std Default or Ext Dig Input 4 Overcurrent Alarm AC Curre
42. RM HIGH ENG TEMP 1 ALARM COMMON SHUTDOWN HIGH ENG TEMP 2 SHUTDOWN EPS SUPPLYING LOAD 5 2 1 ENERGIZE TO STOP The designated programmable output relay will energize when a stop signal has been activated The output will remain energized for 10 PM047 Rev 11 2002 09 09 30 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER seconds once the engine has come to a complete stop then de energizes 5 2 2 IDLE CONTROL The designated programmable output relay will energize when an idle signal has been issued to the engine controller The output contact would typically be connected to the idle run input control of an electronic governor Note The controller receives an idle signal from a digital input contact that must additionally be programmed for an idle function During an idle condition the engine controller automatically bypasses all alarm or shutdown circuits except oil pressure and overspeed which are programmed for bypass on start 5 2 3 PRE POST CYCLIC LUBE CONTROL The designated programmable output relay will energize when a lube signal has been initiated Note The Lube function will be automatically terminated once an engine start signal is issued Refer to the programming instructions for further information 5 2 4 SWITCH NOT IN AUTO The designated programmable output relay will energize when the controller s operation mode switch is not in the auto position 5 2 5 OVERCURRENT
43. RODUCTS MEC 20 MEC20_15 VSD FIGURE 17 EXPANSION OUTPUT MODULE CONNECTION DIAGRAM PM047 Rev 11 2002 09 09 38 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER The expansion module outputs are relay contacts which may be individually configured for normally open or normally closed contact position Contact configuration is via circuit board mounted jumper pins and clips Refer to FIGURE 18 for jumper pin location and configuration settings Each output contact is rated maximum 0 5A 120Vac 1 0A 30Vdc resistive Each expansion module also provides one programmable contact for desired control function The programmable contact on the first expansion module in the system is referenced as Programmable Output 5 On the second expansion module the programmable contact is referenced as Programmable Output 6 Refer to Section 9 0 of this manual for programming functions and procedures for the programmable contact feature Note The communication cable between the MEC 20 and the expansion module must be ordered separately
44. SMEC20 11 VSD Rev 1 00 07 13 2 15 DIELECTRIC TESTING PM047 Rev 11 2002 09 09 Do not perform any high voltage dielectric testing on the control panel with the MEC 20 connected in the circuit as serious damage will occur to the controller All AC control fuses connected to the MEC 20 must be removed if high voltage dielectric testing is performed on the control panel 14 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 3 DESCRIPTION The MEC 20 controller consists of three parts a Lexan faceplate which is mounted externally on the enclosure door a printed circuit board PCB which is mounted inside the enclosure door and a rear cover for the PCB 3 1 LEXANFACEPLATE The Lexan faceplate is shown as in FIGURE 10 The Lexan push buttons are connected to the main PCB via plug in ribbon cable The main features of the Lexan faceplate are described as follows with reference to FIGURE 10 13 1 MICRQPROCESSOR ENGINE CONTROLLER OEP PA 11 MEC 20 Ec ALARM READY SHUTD O O SPEED SIGNAL 5 te o Loe1 o D i THOMSO CHNOLOGY 9g TA POWER amp CONTROL MEC20 O3 VSD Rev2 01 07 09 FIGURE 10 LCD viewing window The LCD display is mounted on the main that is visible through the lexan faceplate viewing window EXIT push button The EXIT function is used to scroll ba
45. TARTER RE ENGAGE DELAY XX SEC BYPASS DELAY XX SEC COOLDOWN DELAY XXXX SEC WARMUP DELAY XX SEC RETURN DELAY XXX SEC NEUTRAL DELAY XX SEC Countdown screens only appear if Utility Gen Ready to Load outputs are programmed GENERATOR AC METERING Four generator AC metering screens are provided as described below 45 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 9 2 4 1 AVERAGE VOLTAGE CURRENT amp FREQUENCY DISPLAY The generator average voltage current amp frequency metering screen allows the operator to simultaneously view all the listed parameters LCD DISPLAY Vavg Aavg Freq 600 432 60 1 Displays the average generator voltage as follows 3 phase system AVERAGE LINE TO LINE VOLTAGE Phases AB BC CA 1 phase system LINE TO LINE VOLTAGE Phases A to B Displays the average generator current as follows 3 phase system AVERAGE LINE CURRENT Phases 1 phase system AVERAGE LINE CURRENT Phases A B Displays generator frequency in hertz HZ The frequency is displayed with a resolution of 1 10 of a hertz 9 2 4 2 GENERATOR KVA DISPLAY The generator s total power output in kilo voltamperes KVA is displayed LCD DISPLAY 532 31 PM047 Rev 11 2002 09 09 46 Thomson Technology Inc PM047 Rev 11 2002 09 09 MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 9 2 4 3 GENERATOR PHASE VOLTAGE DISPLAY LINE TO LINE The generator phase voltage screen
46. The ALARM LED illuminates flashes when any pre programmed alarm fault has been activated SHUTDOWN LED light viewing window The SHUTDOWN LED illuminates flashes when any pre programmed shutdown fault has been activated 3 2 PRINTED CIRCUIT BOARD The printed circuit board PCB is shown in FIGURE 11 The PCB contains the following user interface items MEC 20 CIRCUIT BOARD LAYOUT 6 e s orp 154 6 MP1 2 1 gt R115 TB1 RJ45 IN CONTRAST Ic 1 RJ45 VN C WATCHDOG vc C REMOTE START CRANK VB C RUN C COM FAIL TB3 18 38 GAENGINEERIPRODUCTSWMEC20 02 VSD Rev 2 01 07 09 DRAWING SCALE mm 6 1 FIGURE 11 PM047 Rev 11 2002 09 09 17 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 3 2 1 TERMINAL BLOCKS Four terminal blocks are located on the PCB as follows TB1 AC Voltage and Current sensing terminal block 120 600VAC amp 0 5AAC WARNING Voltage sensing circuits are capable of lethal voltages while energized Current transformer CT secondary circuits are capable of generating lethal voltages when open circuited with their primary circuit energized Standard safety procedures should be followed and be performed by qualified personnel only Failure to do so may cause personal injury and or death TB2 Speed sensing and digital contact input terminal block TB3 Output contac
47. The designated programmable output relay will energize when the overcurrent fault circuit is activated The output will remain energized until the fault condition has been manually reset if programmed as a latching type fault or until the overcurrent level drops below the setpoint 5 2 6 ENGINE READY The designated programmable output relay will energize when the engine controller s mode switch is in the auto mode and no shutdown or alarm conditions are present 5 2 7 PREHEAT The designated programmable output relay will energize during the start delay timer period and cranking period until the engine starts and reaches PM047 Rev 11 2002 09 09 31 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER crank disconnect speed The preheat output is typically used for an engine starting aid such as glow plugs Note An external pilot relay is required to switch the high current glow plug load 5 2 8 GEN READY TO LOAD The designated programmable output relay will energize when the generators voltage and frequency exceeds predetermined setpoints e g voltage 9096 nominal frequency 95 nominal as user programmed and a warm up time delay period expires Once the output has energized it will remain latched on irrespective of voltage frequency levels until the controller either has a stop shutdown signal or the engine s speed drops below crank disconnect level The voltage frequency and time delay levels programm
48. UN function is used to initiate a manual start signal to the engine generator set Refer to the operating instructions for detailed information OFF push button and LED light viewing window The OFF function is used to initiate a stop signal to the engine generator set Refer to the operating instructions for detailed information AUTO push button and LED light viewing window The AUTO function is used to initiate automatic operation of the engine generator set Refer to the operating instructions for detailed information LOAD TEST push button and LED light viewing window The LOAD TEST function is used to initiate load test of the engine generator set when connected to an associated transfer switch Refer to the operating instructions for detailed information EMERGENCY STOP push button and LED light viewing window The EMERGENCY STOP function is used to initiate an emergency stop signal to the engine generator set Refer to the operating instructions for detailed information READY LED light viewing window The READY LED illuminates when the engine generator set is set for automatic operation and no shutdown or alarm faults have been activated SPEED SIGNAL LED light viewing window The SPEED SIGNAL LED PM047 Rev 11 2002 09 09 16 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER illuminates when the engines speed signal is detected i e the engine is turning over ALARM LED light viewing window
49. User can view the programmable parameters only and cannot change any values The factory default number for the read only level is one 1 10 1 2 READ WRITE MODE User can view and modify any programming parameter as required The Factory default number for the read write level is two 2 10 1 3 MASTER READ WRITE MODE User can view modify any programming parameter as well as view modify the security password level numbers Contact III factory for master password if required To enter the programming mode follow the procedure as shown PROGRAM MENU YES Select the Program Menu by scrolling through the display menus using the ENTER push button When displayed use the INCREMENT push button to select the YES prompt and push the ENTER button PASSWORD 0 Use the INCREMENT or DECREMENT push buttons to ramp the displayed number up or down to the desired password access number Press the ENTER push button when the correct number is displayed 58 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER NOTE If an invalid number is entered programming access will be denied To exit the programming mode press the EXIT push button for more two seconds until the display changes 10 2 BASIC PROGRAMMING OPERATION Once the correct password number is entered the user may choose one of four separate programming menus as shown below MAIN MENU LOOP ANALOG FAULT MENU LOOP DIGITAL FAU
50. YNC Blank i e no text for unused inputs Note Up to six custom user defined fault label names may be specified for the MEC 20 controller at time of purchase The six custom fault label names cannot be changed once shipped from the factory PM047 Rev 11 2002 09 09 22 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 4 3 1 FACTORY PROGRAMMED DIGITAL FAULT CIRCUITS The MEC 20 is supplied from the factory programmed with twelve standard digital fault circuits as follows FAULT FAULT INPUT NAME ACTION TERMINAL Low Oil Pressure Shutdown 1 High Engine Temperature Shutdown 2 Battery Charger Input Fail Alarm 3 Low Fuel Level Alarm 4 Digital Input 5 Alarm 5 Digital Input 6 Alarm 6 Digital Input 7 Alarm 7 Digital Input 8 Alarm 8 Digital Input 9 Alarm 9 Digital Input 10 Alarm 10 Remote Emergency Stop Shutdown 11 Idle N A 12 Refer to Section 11 4 Digital Fault Programming Menu for the factory default settings Note Fault Input 5 10 must be customer configured unless specified at time of order All faults require a customer connected contact to the MEC 20 input terminal as indicated All fault circuits may be user field programmed for different control functions or alternate fault names Note For CSA C282 applications the controller will be factory supplied with Low coolant level shutdown in place of Battery charger input fail alarm Refer to the programming instructions for furthe
51. able Refer to Section 10 3 for Programming The Generator Ready To Load output is typically used in an Auto Mains Failure AMF application Refer to Section 9 3 5 for further details on sequence of operation 5 2 9 UTILITY READY TO LOAD The designated programmable output relay will energize when the remote start input has not been activated i e contact on terminals 16 amp 17 is not closed and the Return Delay amp Neutral Delays have expired if programmed The output will de energize when the remote start input has been activated and the Engine Start Delay amp warm up Delays have expired if programmed This output is typically used for Auto Mains Failure AMF applications Refer to Section 9 3 5 for further details on the sequence of operation 5 2 10 ENGINE RUNNING The designated programmable output relay will energize when the engine has started and has reached crank disconnect speed 5 2 11 ENGINE RUN FUEL The designated programmable output relay will energize when the engine RUN i e FUEL energizes prior to the engine starting The output will remain on until the engine has reached a stop or shutdown command PM047 Rev 11 2002 09 09 32 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 5 2 12 AIRFLAP The designated programmable output relay will energize when the engine s speed exceeds the overspeed setpoint level The output will remain energized until the engine s speed d
52. allows the operator to view the generator AC voltage on all 3 phases or single phase system as selected LCD DISPLAY Vab Vbc Vca 600 600 600 Displays generator voltage as follows 3 phase system LINE TO LINE VOLTAGE Phases A to B 1 phase system LINE TO LINE VOLTAGE Phases A to B Displays generator voltage as follows 3 phase system LINE TO LINE VOLTAGE Phases B to C 1 phase system LINE TO NEUTRAL VOLTAGE Phases A N Displays generator voltage as follows 3 phase system LINE TO LINE VOLTAGE Phases C A 1 phase system LINE TO NEUTRAL VOLTAGE Phases B N 9 2 4 4 GENERATOR PHASE NEUTRAL VOLTAGE DISPLAY LINE TO NEUTRAL The generator phase neutral display allows the operator to view the generator line to neutral voltage for all 3 phases of the system Note The generators neutral must be connected to MEC 20 terminal TB1 VN and the neutral connected prompt in the main program menu must be selected as Yes LCD DISPLAY Displays generator voltage Phase A to Neutral Displays generator voltage Phase B to Neutral Displays generator voltage Phase C to Neutral 47 Thomson Technology Inc PM047 Rev 11 2002 09 09 MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 9 2 4 5 GENERATOR PHASE CURRENT DISPLAY The generator phase current screen allows the operator to view the generator load current on all 3 phases or single phase system as selected LCD DISPLAY Displays generator load
53. alues for the voltage sensing PT ratio and or current sensing CT ratio Verify that the battery supply DC negative conductor is properly grounded to the engine block i e to a common ground point Verify that the controllers analog input has been properly calibrated as per manual instructions Verify the voltage sensing wiring connection to the MEC 20 matches power distribution type Note standard direct voltage connection requires that the generators neutral is solidly grounded Engine temperature or oil pressure display is Verify that the controllers analog input has been reading incorrectly properly calibrated as per manual instructions Verify engine sensor wiring is correct Note engine sensors must be factory supplied units only Verify that the battery supply DC negative conductor is properly grounded to the engine block i e to a common ground point PM047 Rev 11 2002 09 09 93 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER SYMPTOM CONT D CORRECTIVE ACTION CONT D Engine temperature or oil pressure displays Check the wiring from the MEC 20 terminal 37 amp 9999 38 to the engine mounted sender are correct i e wiring is not open or shorted Verify the engine mounted senders have correct resistance reading for corresponding input temperature or pressure refer to the Analog Temperature and Pressure Calibration table for values Verify calibration Engine alar
54. as shown PM047 Rev 11 2002 09 09 7 Thomson Technology Inc 2 6 PM047 Rev 11 2002 09 09 MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER VOLTAGE INPUTS 600VAC L L 347VAC L N 380VAC L L 220VAC L N 480VAC L L 277VAC L N 208VAC L L 120VAC L N FIGURE 1 4W 208 380 480 600VAC DIRECT SENSING SOLIDLY GROUNDED NEUTRAL SYSTEM 08 up GRD GRD 2 OL GRD SECONDARY PT VOLTAGE 208VAC L L 120VAC L N 120VAC L L 69VAC L N FIGURE 3 30 4W WYE PT s AC CURRENT INPUT MEC 20 L1 L2 N VOLTAGE INPUTS 240VAC L L 120VAC L N Note L1 and L2 phase voltages must be 120Vac when referenced to common neutral Delta connected generators required PTs as figure 3 amp no phase C PT FIGURE 2 19 3W 120 240VAC DIRECT SENSING SOLIDLY GROUNDED NEUTRAL SYSTEM MEC 20 8 e vB 120 120 C SECONDARY PT VOLTAGE 120VAC L L NO NEUTRAL FIGURE 4 39 3W DELTA PT s G ENGINEER PRODUCTS MEC20 MEC20_08 VSD REV 2 02 02 22 Current transformers CT s must be used to supply the MEC 20 current inputs CT polarity is not critical for correct circuit operation Note The CT secondary common conductors must be externally grounded for correct operation CT s must be rated for a minimum of 1 5VA output at the specified accuracy Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER CAUTION Whe
55. ator voltage Underfrequency Alarm Generator frequency Overfrequency Alarm Generator frequency Overcurrent Alarm Generator current Weak battery Alarm Battery voltage Low battery voltage Alarm Battery voltage High battery voltage Alarm Battery voltage Low engine temperature Alarm Engine temperature High engine temperature 1 Alarm Engine temperature High engine temperature 2 Shutdown Engine temperature Low oil pressure 1 Alarm Oil pressure Low oil pressure 2 Shutdown Oil pressure Overspeed Shutdown Engine speed Loss of speed signal Shutdown Engine speed MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER All fault circuits may be user field programmed for different control functions however their designated fault function is not programmable Refer to the programming instructions for further information 4 4 2 GENERATOR AC VOLTAGE FREQUENCY CURRENT 4 4 2 1 GENERATOR UNDERVOLTAGE The MEC 20 controller provides a 3 phase undervoltage sensor for the generator supply The undervoltage sensor is programmable for type of fault action i e alarm or shutdown pickup dropout voltage setpoints i e adjustable hysteresis and transient time delay settings Refer to the programming instructions for further information 4 4 2 2 GENERATOR OVERVOLTAGE The MEC 20 controller provides a 3 phase overvoltage sensor for the generator supply The overvoltage sensor is programmable for type of fault action i e alarm or shutdown pickup a
56. be entered in tenths of seconds 10 3 22 RUN OUTPUT FAIL SAFE When enabled this feature will inhibit the run output until the controller receives a speed sensing signal thus preventing possible damage from PM047 Rev 11 2002 09 09 63 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER starting the engine with no speed sensing for crank disconnect and overspeed II selected ensure that the speed signal is not less than 3 0Vac from the magnetic pick up while the engine is cranking Note If this feature is disabled no overspeed protection or crank disconnect will be provided if the speed signal fails Should the user elect to disable this feature Thomson Techology strongly recommends that backup crank disconnect protection and additional overspeed protection is utilized NOTE The run output Fail safe feature will be factory programmed as enabled The user of this equipment may elect to change this feature dependent upon site conditions and does so at their discretion 10 3 23 LOSS OF SPEED SIGNAL Select the desired action i e alarm or shutdown when a loss of speed signal is detected during operation Note A loss of speed signal must be detected for longer than 2 seconds to initiate the desired action 10 3 24 COMMON FAIL FOR NOT IN AUTO FUNCTION Use this function to select if a common fail alarm condition is to be activated when the engine controller is not selected for automatic
57. board for control wiring e Verify that the intended AC voltage input to the controller does not exceed the maximum allowable level on the control panel door as per the applicable control panel certification standard The MEC 20 controller can be installed onto a door of a control panel using one of the following methods e first method requires a special door cutout for the LCD display and LED s as shown in FIGURE 6 This mounting method requires the lexan faceplate to be mounted directly onto the door of the control panel The controller must be disassembled to mount on the door then re assembled Refer to FIGURE 7 for correct assembly location of all parts lt lt The second method of controller mounting requires a factory supplied adapter faceplate as shown in FIGURE 8 This method only requires a single large rectangular hole to be cut out of the door as shown in FIGURE 9 12 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 2 13 FACEPLATE MOUNTING DIMENSIONS gt 1 8 3 3 v 8 3 3 mY 9 HOLES 80 mm 6 mm DIAMETER 1 4 DRILL CUTOUT ra 32 mm 166 mm I lo mm AIA Sora oot tue eh al 3 6 33 mm e mm 3 75 mm fS _ gt __ Tee eene sinere lt mm 3424 4 HOLES OUTLINE OF PRINTED CIRCUIT _ 4 mm DIAMETER
58. ce the warm up timer expires the Utility Ready to Load output de energizes and the NEUTRAL Delay timer is initiated e Once the NEUTRAL DELAY timer expires the Gen Ready to Load output energizes to signal the transfer switch to transfer to the generator supply Note The neutral delay PM047 Rev 11 2002 09 09 52 Thomson Technology Inc PM047 Rev 11 2002 09 09 MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER function is only operative with an electrically held type transfer switch mechanism i e electrical contactor type 9 3 5 8 UTILITY POWER RETURN Remote Start input signal is removed and the Return Delay timer is initiated i e Utility Voltage returns to normal and the Utility voltage sensor contact opens Once the Return Delay timer expires the Generator Ready to Load output de energizes and the Neutral Delay timer is initiated Once the Neutral Delay timer expires the Utility Ready to Load output energizes to signal the transfer switch to transfer to the utility supply Note If the generator has a shutdown during the Return or Neutral Delay periods the timers are bypassed and the Utility Ready to Load output immediately energizes The generator Cooldown Timer starts timing following expiry of the Return Delay timer The generator stops following expiry of the Cooldown Timer 9 3 5 4 MEC LOAD TEST PUSH BUTTON OPERATION NOTE The following sequence as described is applicable only if both Util
59. ckwards through the status menus or programming prompts to the previous item The EXIT function is used to exit the programming menu by holding this button down for approximately 2 seconds while in the programming mode DECREMENT push button The DECREMENT function is used to change a programming value while in the programming mode When this push PMO47 Rev11 20020909 CThomsonTechnologyinc _ 15 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER button is held down the displayed value will be decremented to a lower value as desired Note The longer the push button is held down the faster the value will be decremented INCREMENT push button The INCREMENT function is used to change a programming value while in the programming mode or to select a desired programming menu loop When this push button is held down the displayed value will be incremented to a higher value as desired Note The longer the push button is held down the faster the value will be incremented ENTER push button The ENTER function is used to scroll forwards through the status menus or programming prompts to the next item The ENTER function is used to enter a programming mode as well as accepting changed programming values Note In the programming mode the longer the ENTER push button is held down the faster the next menu prompts will appear RUN push button and LED light viewing window The R
60. controller malfunction and or damage PM047 Rev 11 2002 09 09 5 Thomson Technology Inc 2 3 PM047 Rev 11 2002 09 09 MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 2 2 1 Avoid wiring from the engine starter terminals wiring should go directly from the battery terminals to the engine control panel to avoid voltage drop in the starter cables and starter motor commutator noise Note Unit mounted control panels with short wiring runs may utilize connections from the starter terminals provided that the specific application is tested satisfactorily CAUTION The battery charger must be turned off before battery cables are removed from the battery i e for servicing Failure to do so may subject the control panel to an overvoltage condition in which damage may result 2 2 2 Wiring from battery to engine control panel should be two 14 AWG 2 5mm wires i e do not use the engine block as one of the common conductors 2 2 3 Under noisy environments i e gas engines with high voltage ignitions etc wiring from battery should be a twisted pair of 14 AWG 2 5mm wires SPEED SENSING INPUT Field wiring of the speed sensing signal wires should conform to the following guidelines to avoid possible controller malfunction and or damage 2 3 1 Wiring from magnetic pickup must utilize a 2 conductor shielded twisted cable The drain shield wire must be connected at the control panel end only 2 3 2 Magnet
61. current as follows 3 phase system PHASE A CURRENT 1 phase system PHASE A CURRENT Displays generator load current as follows 3 phase system PHASE B CURRENT 1 phase system PHASE B CURRENT Displays generator load current as follows 3 phase system PHASE C CURRENT 1 phase system not applicable 9 2 4 6 GENERATOR FREQUENCY HOURMETER DISPLAY The generator frequency and operating hours are displayed simultaneously on this screen LCD DISPLAY FREQ 60 1 Hz HOURS 56783 Hrs Displays generator frequency in hertz HZ The frequency is displayed with a resolution of 1 10 of a hertz Displays unit operating hours 9 2 5 ENGINE PARAMETER DISPLAY Two engine operating parameter screens are provided as described below 9 2 5 1 BATTERY VOLTAGE ENGINE SPEED tachometer 48 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER The battery voltage and engine speed are displayed simultaneously on this screen LCD DISPLAY BATTERY 27 0Vdc SPEED 1800rpm Displays battery voltage in DC volts The voltage is displayed with a resolution of 1 10 of a volt Displays engine speed in revolutions per minute RPM 9 2 5 2 ENGINE TEMPERATURE OIL PRESSURE The engines operating temperature and oil pressure are displayed simultaneously on this screen LCD DISPLAY ENG TEMP 57 Deg C OIL PRESS 200 KPA Displays engine temperature in either degrees Celsius or Fahrenheit as selected
62. efore the shutdown is activated The stop PM047 Rev 11 2002 09 09 51 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER sequence will cause the controlers RUN output to be immediately terminated which will cause the engine to stop 9 3 5 AUTO MAINS FAILURE AMF SEQUENCE When the controller is applied in an Auto Mains Failure AMF application with a transfer switch it must be wired as per FIGURE 21 shown at the end of this section Programmable output 3 must be selected for Utility Ready To Load and programmable output 4 must be selected for Gen Ready To Load Once the controller is programmed and wired as per FIGURE 21 the AMF sequence of operation will be as follows 9 3 5 1 UTILITY NORMAL CONDITION e Remote Start input signal MEC terminals 16 amp 17 is not activated i e Utility power is Normal e Utility Ready To Load output is energized i e signal to transfer switch to transfer to utility power e Generator Ready To Load output is de energized 9 3 5 2 UTILITY POWER FAILURE CONDITIONS e Remote Start input signal is activated i e remote start contact closes when utility power fails as sensed by utility voltage sensor e Engine starts following expiry of the Engine Start Delay timer Utility Ready To Load output stays energized e Once the engine has started and the generator output rises above the programmed voltage and frequency limits a warm up timer is initiated e On
63. eutral AC voltages for a 3 phase 4 wire system 10 3 6 VOLTAGE SENSING RATIO For direct voltage sensing wiring connections from 208 to 600 volts enter 1 i e a ratio of 1 1 When potential transformers are utilized for voltage sensing enter the calculated transformer ratio e g when using 600 120 transformers enter a number of 5 10 3 7 CURRENT SENSING RATIO For current sensing wiring connections from current transformers CT s enter the calculated CT ratio e g when using a 600 5 CT enter a number of 120 10 3 8 TEMPERATURE SCALE Select the desired type of engineering units for the engine temperature display and analog setpoints as provided Degrees Fahrenheit or Degrees Celsius Note Alarm setpoints do not automatically re configure when changing between Fahrenheit or Celsius 10 3 9 PRESSURE SCALE Select the desired type of engineering units for the engine pressure display and analog setpoints as provided Pounds per square inch PSI or Kilopascals KPA Note Alarm setpoints do not automatically re configure when changing between PSI and KPA PM047 Rev 11 2002 09 09 61 Thomson Technology Inc PM047 Rev 11 2002 09 09 MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 10 3 10 START DELAY Select desired engine start delay time in seconds If engine start delay is not required set to zero Note If preheat and or prelube functions are utilized the engine start delay time sho
64. face with different remote monitoring software programs Refer to separate literature for detailed information on the CIM module The MEC 20 remote communication option must be ordered and be factory enabled prior to shipment The communication feature cannot be user enabled once shipped from the factory PM047 Rev 11 2002 09 09 34 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER The MEC 20 communication port utilizes a RS422 data transmission signal which is directly interconnected to the CIM module via 8 conductor shielded cable with plug in RJ45 connectors Refer to FIGURE 14 8 15 for detailed information on direct connected or remote connected PC applications with CIM module TV Trademarks belong to their respective parties CIM Communication Interface Module To expansion MEC 20 output module lt J6 optional 9 Engine gt Controller 8 conductor RS 232 Signal Shielded Cable c w 15M 50 RJ45 connectors maximum cable length 305M 1000 maximum cable length null modem connector Personal Communication cable wiring must be suitably routed Computer to protect it from sources of electrical interference Refer to installation section for further information G ENGINEER PRODUCTS MEC20 MEC20_20 VSD FIGURE 14 MEC 20 WITH CIM MODULE amp DIRECT CONNECTED PC PM047 Rev 11 2002 09 09 35 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE
65. has expired Delay times from 0 0 to 999 9 seconds are available by entering the time required 10 5 DIGITAL FAULT PROGRAMMING MENU To program the controller s digital fault circuits refer to the following descriptions 10 5 1 DIGITAL FAULT LABEL To select the desired fault label description use the increment key to scroll through the available labels The digital fault labels are stored in non volatile memory and are as follows AIR DAMPER TRIPPED HIGH OIL TEMP BAT CHARGER INPUT FAIL HIGH WINDING TEMP BAT CHRG TROUBLE IDLE BREAKER TRIPPED LOW COOLANT LEVEL DC FAIL LOW ENGINE TEMP FAILED TO SYNC LOW FUEL PRESS GEN BREAKER OPEN LOW FUEL LEVEL GROUND FAULT LOW OIL LEVEL HIGH BEARING TEMP REMOTE EMERG STOP HIGH COOLER VIBRATION REVERSE POWER HIGH ENGINE TEMP BASIN RUPTURE HIGH ENGINE VIBRATION ATS IN BYPASS HIGH FUEL LEVEL FUEL LEAK HIGH OIL LEVEL LOW FUEL PRESS NO LOAD TEST BAT CHARGER FAIL HIGHINTKMANFTEMP VENT DAMPER FAIL HIGH FUEL LEVEL FAIL TO SYNC Blank i e no text for unused inputs Once the desired fault label is selected press the enter key to accept the selection PM047 Rev 11 2002 09 09 69 Thomson Technology Inc PM047 Rev 11 2002 09 09 MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER WARNING The digital fault label programming must match with the external control wiring to the controller Failure to do so may cause severe 10 5 2 10 5 3 10 5 4 10 5 5 10 5 6
66. he high engine temperature shutdown fault circuit is activated when the engine temperature rises above a pre determined setpoint for a specified time delay The high engine temperature shutdown fault is programmable for the level of temperature setpoint transient time delay settings and other functions Refer to the programming instructions for further information PM047 Rev 11 2002 09 09 27 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER Note High Engine Temperature shutdown may alternately be programmed and wired as a digital fault input contact Refer to Section 4 3 for further details 4 4 5 ENGINE OIL PRESSURE ANALOG INPUT The MEC 20 s engine oil pressure sensor measures a DC analog signal from an engine mounted sender The MEC 20 software provides calibration for oil pressure to coordinate with the engine mounted sender and control logic to detect a wiring or sender failure i e open or shorted signal In case of a sender or wiring failure the MEC 20 will display zero or 9999 PSI and will initiate an alarm and or shutdown signal as programmed by the user The engine oil pressure analog input provides the following control function 4 4 5 1 LOW OIL PRESSURE 1 ALARM The low oil pressure alarm fault circuit is activated when the oil pressure drops below a pre determined setpoint for a specified time delay The low oil pressure alarm fault is programmable for pressure setpoint level transient time dela
67. ic pickup voltage at cranking speed must be greater than 3 0VAC At nominal speed magnetic pickup voltage should be between 3 0 and 5VAC 2 3 3 Asingle dedicated magnetic pickup is recommended for connection to the speed sensing input terminals Note One common magnetic pickup may be utilized for the system provided specific test measurements are done with the equipment installed i e mag pickup voltage levels meet the required levels 6 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 2 4 DC VOLTAGE INPUTS All DC voltage inputs to the MEC 20 are optically isolated and filtered for protection from noise spikes and transients Input wiring must be routed so that it is not near electrically noisy wiring such as ignition starter wires or main AC power conductors All contacts must be dry i e non powered and one side must be connected to the common DC negative conductor 2 5 AC VOLTAGE INPUT The MEC 20 can accept direct AC voltage input from 120 600Vac nominal Note Direct input voltage sensing can only be used when the generator utilizes a single phase 3 wire or 3 phase 4 wire distribution system with a solidly grounded neutral conductor For 3 phase 3 wire systems i e no neutral or high voltage systems potential transformers must be used Refer to FIGURES 1 4 for voltage sensing connections To display generator line to neutral voltage in a 3 phase 4 wire system the neutral must be connected
68. ilding code standards for Emergency Standby Generator systems The design uses a 8 conductor RS 422 communication data link to provide the control amp monitoring signals between the engine controller and remote annunciator Up to 20 individual fault conditions are remotely monitored utilizing both visual LED lights amp audible alarm annunciation The EAP 110 is DC powered from the same 12 or 24V engine starting battery as the engine controller is connected to Two EAP 110 annunciators can be interconnected together via the communication link to allow up to 40 remote annunciator points from a single engine controller For complete information on the EAP 110 contact Thomson Technology to obtain the specific product documentation available Refer to FIGURE 20 for the EAP 110 remote annunciator connection diagram EAP 110 MEC 240 iat 1 EH 1 9 Engine nnunciator n t Controller Communication Cable N ES J J7 oo ui ui B 1000 maximum cable Pot 8 8 length External Alarm Sensing contacts optional useas T required M In 12 24V Engine 8 conductor Shielded Twisted Cable c w RJ45 connectors Communication cable wiring must be Cranking Battery suitably routed to protect it from sources of electrical interference Refer to instruction manual for further information FIGURE 20 EAP 110 REMOTE ANNUNCIATOR CONNECTION DIAGRAM PM047 Rev 11 2002
69. ital Input Feature No Load Test a Added New Digital Fault Names Basin Rupture ATS in Bypass Fuel Leak Vent Damper Fail High Fuel Level Low Fuel Press Bat Charger Fail Fail to Sync HighIntkManfTemp Added Independent Programming features for AMF Outputs Added references for EAP 110 Remote Annunciator a Misc Display amp Menu changes PM047 Rev 11 2002 09 09 1 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 1 7 02 02 15 Key changes implemented as follows e Auto Mains Failure AMF logic with new timers control outputs and display features e Line to Neutral AC Voltage Display on Phase 4 Wire Systems neutral connection required e Analog Shutdown Capability from Pressure Temperature Senders e Expanded oil pressure operation up to 150 PSI was 100 PSI e Single Point Calibration for Oil Pressure engine temperature sender inputs simplified calibration field calibration is now mandatory e Programmable Output features now expanded to map to every available fault circuit Add new Programmable Output features Engine Ready amp Engine Run Fuel There were also minor changes that are reflected in the manual 1 6 01 07 18 Added Ready to load programmable output and new Isspro Oil Pressure sender curves increased standard digital amp analog fault features 1 5 00 09 20 Added kVA metering 1 4 99 12 09 Added new digi
70. ith the conductors For additional information on protection against electrical interference contact TTI factory EXPANSION OUTPUT MODULE LOCATION INSTALLATION The expansion module s are to be mounted inside a control panel using four screws with stand offs provided The expansion module must be mounted within 300 metres 1000 feet wiring distance from the MEC 20 using an 8 conductor shielded cable provided with the module The communication cable must not be bundled together with other control wiring inside the panel Mounting dimensions for the expansion output module are shown in FIGURE 5 0 00 mm le 152 4 mm i 0 7 62 mm 137 16 mm 4 HOLES 4 75 MM DIAMETER O PL 0 00 nm EIGURE 5 MEC 20 EXPANSION MODULE MOUNTING DIMENSIONS 152 4 mm G ENGINEER PRODUCTS MEC20 MEC20_14 VSD DRAWING SCALE 75 1 11 Thomson Technology Inc 2 12 PM047 Rev 11 2002 09 09 MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER MEC MOUNTING LOCATION INSTALLATION The MEC 20 Engine generator controller is designed for mounting directly onto a control panel door Considerations should be given for the following e The controller should be installed in a dirt free dry location away from extreme heat sources e The LCD window should be installed at an optimum height for operator viewing e Adequate space should be provided around the rear of the MEC 20 circuit
71. ity Ready to Load and Gen Ready to Load outputs are programmed and used When the MEC Load Test pushbutton is pressed the controller s logic will internally simulate receiving a remote start input Engine starts following expiry of the Engine Start delay timer 53 Thomson Technology Inc PM047 Rev 11 2002 09 09 MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 9 3 5 5 e Once the engine has started and the generator output rises above the programmed voltage and frequency limits a warm up timer is initiated e Once the warm up timer expires the Utility Ready to Load output de energizes and the Neutral Delay timer is initiated e Once the Neutral Timer expires the Gen Ready To Load output energizes to signal the transfer switch to transfer to the generator supply Note if a generator shutdown occurs during a Load Test Operation the Load Test mode will be de activated When the MEC mode is re selected to Auto Mode the following sequence occurs e Simulated Remote Start input signal is removed e Gen Ready To Load output de energizes and Neutral Delay timer is initiated e Once the Neutral Delay timer expires The Utility Ready To Load output energizes to signal the transfer switch to transfer to the utility supply e The generator Cooldown timer starts timing following the transfer to the utility supply e The generator stops following expiry of the Cooldown timer NO LOAD TEST To all
72. lay is not operational Check that the controllers microprocessor is running by observing a red flashing watchdog LED on the rear of the PCB Check that there is sufficient DC supply voltage to input terminals B amp B 10 30VDC Verify that the LCD contrast potentiometer R115 on rear of PCB is adjusted for good pixel resolution for the operating temperature of the unit Controller cannot be Reset Check that the controller is set to the OFF mode before trying to reset Check that the engine has come to a complete stop before trying to reset PM047 Rev 11 2002 09 09 92 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER SYMPTOM CONT D CORRECTIVE ACTION CONT D No RUN output signal Check that all shutdown circuits are reset red shutdown LED must be off Engine speed signal must be detected speed signal green LED on during cranking if the run output fail safe feature is enabled Verify correct magnetic pick up signal at cranking 2 0VAC min Check that the RUN output LED on the rear of the PCB is on If yes verify relay contact operation on terminals 18 amp 19 Overspeed shutdown occurs at normal speed Verify that the controller has been programmed with the correct values for the number of flywheel teeth nominal RPM and overspeed setpoint percentage Voltage current metering is reading Verify that the controller has been programmed with incorrectly the correct v
73. le while using the Master programming security password ANALOG FAULT PROGRAMMING MENU To program the controllers analog fault circuits refer to the following descriptions Note certain programming functions listed below may not be provided for a specific fault Refer to Section 11 3 for a table indicating programmable features provided 10 4 1 LEVEL This setting determines the actual analog signal setpoint at which the selected fault type will be activated Note For AC voltage fault circuits two levels i e pick up amp drop out must be programmed 10 4 2 ACTION This setting allows a fault circuit to be programmed as either an alarm or a shutdown 10 4 3 ALARM LATCH If an alarm fault was programmed it may be selected as a latching alarm or non latching When latching is selected it will not un latch until a reset command clears it Note This programming prompt only appears if alarm faults are programmed Shutdown faults are automatically set as latching 10 4 4 BYPASS ON START DELAY This allows the alarm or shutdown circuit to be disabled until after the bypass timer has expired Fault circuits that are not delayed will be enabled at all times i e engine running or stopped 68 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 10 4 5 TRANSIENT DELAY TIMES This allows the selected fault circuit to be inhibited from being activated until the specified time delay period
74. ll to the Engine Temperature Offset calibration point Use the INCREMENT or DECREMENT push buttons to adjust the correction factor number while observing the displayed temperature on the MEC 20 Adjust the correction factor number to obtain the identical temperature reading as measured with the external temperature gauge With the correct temperature displayed press the enter push button to accept the correction factor number Record the correction factor number on the MEC 20 programming sheet for future reference if required 79 Thomson Technology Inc PM047 Rev 11 2002 09 09 MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 10 6 10 PRESSURE CALIBRATION PROCEDURE Before the equipment is put into final operating service the engine pressure analog circuit must be field calibrated to meet the performance accuracy as specified to ensure correct operation The engine pressure analog circuit must be calibrated with the engine pressure sender supplied with the controller and mounted on the engine WARNING Failure to field calibrate and validate the correct operation of the pressure analog circuit on the equipment may result in severe equipment failure or damage To calibrate the MEC 20 pressure sensor perform the following procedure NOTE To accurately calibrate the MEC 20 s pressure sensor an external temporary engine mounted pressure gauge is required The external pressure gauge should be connec
75. ly stops the engine and locks it out from operation The OFF position also allows any shutdowns to be reset 9 4 1 3 AUTO In this position starting and stopping of the engine will be controlled by a remote contact When the remote start signal is removed the engine will continue to run for the cooldown period if selected then stop Re selecting the Off position will stop the engine immediately even if the cooldown period is not complete 9 4 1 4 LOADTEST NOTE The control feature is only operative if used in the AMF application or if one of the programmable output contacts is configured for ATS Test and a remote transfer switch is interconnected with remote testing circuitry In this position a signal will be issued to a remote transfer switch to permit an automatic engine start and load transfer Once initiated the engine will receive a start signal from the PM047 Rev 11 2002 09 09 56 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER transfer switch and upon the generator reaching nominal voltage and frequency levels a load transfer will be initiated The generator set will remain running on load until a different operating mode is selected or the generator set develops an alarm or shutdown condition 9 4 2 EMERGENCY STOP PUSH BUTTON This push button will cause the engine to immediately stop and be locked out from operation The engine cannot be restarted in this mode until the co
76. mmunication features expansion relay module Rev 1 98 01 22 Corrected minor errors Rev 0 97 06 04 Original release Contact Thomson Technology Inc to obtain applicable instruction manuals Soft copy of most current version is available at www thomsontechnology com 1 2 GENERAL DESCRIPTION The Thomson Technology MEC 20 Microprocessor based Engine Generator Controller utilizes the latest advancements in microprocessor design technology for the control and monitoring of engine generator sets The MEC 20 provides a comprehensive array of operational protection and display features for automatically controlling an engine generator set All standard and optional features of the MEC 20 are configurable from the front panel LCD display and are security password protected The LCD display screen prompts are in plain English providing a user friendly operator interface with many display options available The microprocessor design provides high accuracy for all voltage monitoring current monitoring and timing functions as well as providing many standard features which were previously only available as expensive add on optional features PM047 Rev 11 2002 09 09 3 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER The MEC 20 provides the following advanced features Up to 28 alarm shutdown fault circuits utilizing analog and digital inputs Standard model meets or exceeds CSA C282 NFPA 110 Level
77. ms on high engine temperature or Check the wiring from the MEC 20 terminals 37 amp low oil pressure when engine is operating 38 to the engine mounted senders is correct i e within normal limits wiring is not open or shorted Verify the engine mounted senders have correct resistance reading for corresponding input temperature or pressure refer to the Analog Temperature and Pressure Calibration table for values Key presses on the lexan faceplate do not Verify the interconnecting ribbon cable between the operate lexan faceplate and main printed circuit board is correctly connected PM047 Rev 11 2002 09 09 94 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 15 NOTES PM047 Rev 11 2002 09 09 95 Thomson Technology Inc
78. n installing or performing any service work on CT circuits always de energize the system before proceeding with any work Never open circuit an energized CT as extreme high voltages may result which may cause serious injury or death 2 7 OUTPUTS All outputs from the MEC 20 are relay driven contacts Relay contacts have a 10A 240Vac resistive 8A 24Vdc 3 Amp inductive 0 4pf rating and are isolated Form A amp Form C types Interposing relays are recommended between the MEC 20 outputs and end devices to prevent internal damage due to possible excessive current draw and or damage should an external fault occur Note These outputs will require external overcurrent protection Maximum 10 Amp The use of AC or DC operated solenoids or relays in control systems can sometimes cause high voltage spikes on the DC power supply which may cause electronic devices to fail Transient suppression devices are recommended for all inductive devices sharing wiring or if physically located near engine generator control panels For DC operated relays or solenoids use a suitably rated counter EMF Diode or commonly known as freewheeling diode For AC operated relays or solenoids use a suitably rated metal oxide varistor MOV or capacitor resistor suppressor 2 8 EXTERNAL PANEL CONTROL WIRING As a minimum all control wiring shall conform to the local regulatory authority on electrical installations Specific wire sizes for typical circuits of
79. nd dropout voltage setpoints i e adjustable hysteresis and transient time delay settings Refer to the programming instructions for further information 4 4 2 3 GENERATOR UNDERFREQUENCY The MEC 20 controller provides a underfrequency sensor for the generator supply The underfrequency sensor is programmable for type of fault action i e alarm or shutdown frequency setpoint and transient time delay settings Refer to the programming instructions for further information 4 4 2 4 GENERATOR OVERFREQUENCY The MEC 20 controller provides an overfrequency sensor for the generator supply The overfrequency sensor is programmable for type of fault action i e alarm or shutdown frequency setpoint and transient time delay settings Refer to the programming instructions for further information PM047 Rev 11 2002 09 09 25 Thomson Technology Inc PM047 Rev 11 2002 09 09 MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 4 4 2 5 GENERATOR OVERCURRENT The MEC 20 controller provides a 3 phase current sensor for the generator supply The current sensor is programmable for type of fault action i e alarm or shutdown pickup current setpoint and transient time delay settings Refer to the programming instructions for further information 4 4 3 BATTERY VOLTAGE ANALOG INPUT The MEC 20 s battery voltage sensor measures DC voltage on terminals B and B that are connected to the engines cranking battery The battery voltage
80. nerator output voltage is set within nominal limits In the programming mode scroll to the desired generator supply voltage phases with the SPAN function selected PM047 Rev 11 2002 09 09 73 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER Connect an external AC voltmeter of adequate voltage range and accuracy to the MEC 20 controller terminals associated with the voltage phases to be calibrated WARNING Voltage sensing circuits are capable of lethal voltages while energized Standard safety procedures should be followed and be performed by qualified personnel only Failure to do so may cause personnel injury and or death Use the INCREMENT or DECREMENT push buttons to adjust the correction factor number while observing the displayed voltage level on the MEC 20 Adjust the correction factor number to obtain an identical voltage reading as measured with the external AC voltmeter With the correct voltage displayed press the ENTER push button to accept the correction factor number Record the correction factor number on the MEC 20 programming sheet for future reference if required Repeat the above procedures for all remaining phases of the generator supply as required NOTE Once the span calibration setting has been completed re confirm the zero calibration points If the zero calibration setpoint needs further adjustment the span calibration point must also be re calibrated 10 6 4
81. nt Custom Ext Dig Input 5 Weak Battery Alarm DC Volts Ext Dig Input 6 Low Battery Voltage Alarm DC Volts Ext Dig Input 7 High Battery Voltage Alarm DC Volts Ext Dig Input 8 Low Engine Temp Alarm Temp Sender Ext Dig Input 9 High Engine Temp 1 Alm Temp Sender Ext Dig Inpt 10 High Engine Temp 2 Shdn Temp Sender Remote Emerg Stop Std Default or Ext Dig Inpt 11 Low Oil Pressure 1 Alarm Press Sender Custom Control or Ext Dig Inpt 12 Low Oil Pressure 2 Shutdown Press Sender Custom STANDARD OUTPUT CONTACTS OUTPUT NAME OUTPUT TYPE Run Fuel Form A Crank Form A Common Fail Form C PROGRAMMABLE CONTACTS OUTPUT NAME OUTPUT TYPE ATS Test Std Default Custom Programmable 1 Form C Common Alarm Std Default or Custom Programmable 2 Form C Shutdown Std Default or Custom Programmable 3 Form C Engine Running Std Default or Custom Programmable 4 Form C EPS Supplying Load Engine Running Std Default or Custom Programmable 5 Form A B 110 MEC 20 Exp Group 1 Only Disabled Std Default or Custom Programmable 6 Form A B 110 MEC 20 Exp Group 2 Only OTHER OPTIONAL FEATURES Remote Communication Port Enabled VFD Display PM047 Rev 11 2002 09 09 82 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 11 2 MAIN CONFIGURATION MAIN PROGRAMMING MENU NODE ADDRESS XX SYSTEM VOLTAGE XXXXX VA
82. nted circuit board with your hands or any other conductive equipment e Do not place the equipment on or near materials such as Styrofoam plastic and vinyl Place the equipment on grounded surfaces and only use an anti static bag for transporting the equipment 2 INSTALLATION 2 1 GENERAL INFORMATION NOTE Installations should be done according to all applicable electrical regulation codes as required The following installation guidelines are provided for general information only pertaining to typical site installations For specific site installation information consult Thomson Technology Inc as required Note Factory installations of I II supplied control panels that have been tested and proven may deviate from these recommendations CAUTION All installation and or service work performed must be done by qualified personnel only Failure to do so may cause personal injury or death 2 2 BATTERY SUPPLY INPUT The MEC 20 can operate on any battery supply from 10 to 30 volts DC The battery DC negative or common conductor must be grounded to the main generator set frame ground The MEC 20 is internally protected by a solid state type fuse that protects it from inadvertent shorts on the output terminals The solid state fuse will automatically reset when the overcurrent condition is removed Wiring from the engine cranking battery to the control panel should conform to the following guidelines to avoid possible
83. ntroller has been reset 9 4 3 FAULT RESET FUNCTION To initiate a fault reset function both INCREMENT and ENTER push buttons must be simultaneously pressed This function resets the controller when in a shutdown mode NOTE To initiate a reset command the engine must come to a complete stop and the controller s switch must be placed in the Off position 9 4 4 HORN SILENCE FUNCTION To initiate a horn silence function both EXIT amp DECREMENT push buttons must be simultaneously pressed This function will silence the audible alarm horn without resetting the fail condition 9 4 5 LAMP TEST A lamp test feature is provided to test all software controlled LED lights as well as the LCD display To activate the lamp test feature simultaneously push the INCREMENT and DECREMENT push buttons The LED s and LCD display will illuminate for approximately 2 seconds then return to their original status Note The emergency stop LED will not be activated by a software initiated test as it is controlled via independent hardware circuitry only PM047 Rev 11 2002 09 09 57 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 10 PROGRAMMING INSTRUCTIONS 10 1 PM047 Rev 11 2002 09 09 SECURITY PASSWORDS Access to the programmable parameters of the MEC 20 Controller is via a security password number Three security password levels are provided as described below 10 1 1 READ ONLY MODE
84. oller 2 10 REMOTE COMMUNICATION WIRING interconnecting wiring to from the MEC 20 engine generator controller communication port shall utilize 22 AWG min 8 conductor twisted shielded cable with RJ45 connectors The drain shield wire must be connected at the MEC 20 controller end only Refer to Section 6 for further information Communication cable from the controllers com port must be suitably routed to protect it from sources of electrical interference Guidelines for protection against possible electrical interference are as follows e Use high quality 8 conductor shielded cable only with drain wire grounded at the controller end only e Route the communication cable at least 3 M 10 away from sources of electrical noise such as variable speed motor drives high voltage power conductors UPS systems transformers rectifiers etc e Use separate dedicated conduit runs for all communication cables Do not tightly bundle communication cables together in the conduit Conduit PM047 Rev 11 2002 09 09 10 Thomson Technology Inc 2 11 47 Rev 11 2002 09 09 MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER should be ferromagnetic type near sources of possible electrical interference The entire length of conduit should be grounded to building earth ground e When communication cables must cross over low or high voltage AC power conductors the communication cables must cross at right angles and not in parallel w
85. ommon fault i e common shutdown common fail or common alarm which will initiate an automatic call out to a remote communication device 10 3 31 POST LUBE DURATION Program the desired post lube duration in minutes 0 999 for postlube duration function Note Lube functions are disabled in Off and whenever the engine is above crank disconnect speed 10 3 32 CYCLE LUBE INTERVAL A cyclic lube function can be set up to circulate oil through the engine several times per day while the engine is not running A non zero post lube duration must be entered to enable the lube output Select the desired cycle lube interval i e time on time off in minutes 1 9999 10 3 33 CYCLE LUBE DURATION Once the lube interval timer has expired it resets itself and starts the lube pump for this time duration If the cycle lube duration is longer than the ube interval the pump will run continuously when the engine is not running The pre lube output is also energized during the engine start delay and crank cycles and de energized when the engine reaches crank disconnect speed Select the desired cycle lube duration i e on time in minutes 0 999 PM047 Rev 11 2002 09 09 67 Thomson Technology Inc 10 4 PM047 Rev 11 2002 09 09 MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 10 3 34 RESET RUN HOURS The controller s engine hourmeter may be reset to zero hours when yes is programmed Note This programming prompt is only accessib
86. ow a timed No Load Test of the engine generator set while using the AMF control application a digital input contact from an external timer must be programmed for NO LOAD Test Refer to Section 10 5 8 for programming details The sequence of operation for a No Load Test condition is as follows 54 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER e With the utility supply normal and the generator stopped a no load test sequence may be initiated by closing an external exercise timer contact to the programmed digital input for No Load Test e Once the external exercise timer contact closes the engine will start and come up to normal operating speed and voltage The MEC will issue an alarm of a No Load Test condition The connected transfer switch will remain on the utility and the generator will not transfer on load Note should the utility supply fail the generator will automatically transfer on load e The engine will continue to run as long as the external exercise timer contact remains closed e Once the external exercise timer contact opens the engine will continue to run for its cooldown time as programmed then it will automatically stop TYPICAL MEC 2 MEC 20 AUTO MAINS FAILURE AMF APPLICATION UTILITY MAINS lt 7 220 380V y 16 _ 2 20 FALURE FUSES GA V C W AME rb ces START PA 9 R U eon C 35 Vu
87. r information on digital fault circuits Note Shutdown functions for Low Oil Pressure and High Engine Temperature may alternatively be provided via analog pressure and PM047 Rev 11 2002 09 09 23 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 4 4 PM047 Rev 11 2002 09 09 24 Thomson Technology Inc temperature sender inputs if programmed accordingly in the analog fault programming menu Refer to Section 11 3 for further information ANALOG FAULT INPUT CIRCUITS The MEC 20 Engine Controller provides up to fifteen analog fault input circuits that are user programmable The controller is supplied from the factory with fifteen standard analog fault circuits Each analog fault input circuit is activated via specific analog signal type Refer to Section 11 3 Analog Fault Programming Menu for the factory default program settings for each analog fault provided WARNING The analog protection circuits for voltage frequency current engine oil pressure engine temperature and engine speed will be set at factory default settings only Final settings will be required to be set by the commissioning authority Failure to do so may result in severe equipment failure or damage 4 4 1 ANALOG FAULT CIRCUITS The MEC 20 is supplied from the factory with fifteen standard analog fault circuits as follows FAULT FAULT INPUT NAME ACTION SIGNAL Undervoltage Shutdown Generator voltage Overvoltage Shutdown Gener
88. r to Section 10 6 9 amp 10 6 10 for detailed information on field calibration procedures required WARNING Failure to field calibrate and validate the correct operation of the engine oil pressure and engine temperature analog circuits on the equipment may result in severe equipment failure or damage 10 6 2 VOLTAGE SENSING CALIBRATION PHASE TO PHASE OR PHASE TO NEUTRAL VOLTS ZERO 99 600V Displays the generator s phase voltages to be calibrated Displays the type of calibration function either ZERO or SPAN Displays the calibration correction factor number 0 255 used to obtain the correct voltage reading Note To correctly calibrate any of the voltage sensors the ZERO function must be calibrated before the SPAN function Displays the actual voltage measurement that will be the same value as shown on the MEC 20 display menus for generator supply This voltage reading may be calibrated higher or lower by changing the correction factor number 10 6 3 VOLTAGE CALIBRATION PROCEDURE NOTE To accurately calibrate the MEC 20 s voltage sensors an external test voltage meter is required with an accuracy of 0 596 or better Note Zero Calibration must be completed before Span Calibration PM047 Rev 11 2002 09 09 72 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER To calibrate the generator supply voltage sensors perform the following procedure 10 6
89. roll to each of the desired generator supply current phases with the ZERO function selected Use the INCREMENT or DECREMENT push buttons to adjust the correction factor number while observing the displayed current level Adjust the correction factor number just until 0 amps is obtained With the correct current displayed press the ENTER push button to accept the correction factor number Record the 75 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER correction factor number on the MEC 20 programming sheet for future reference Repeat the above procedure for all remaining generator current phases 10 6 5 2 SPAN CALIBRATION Apply 50 100 load to the generator set Note It is recommended to load the generator set to 10096 rated load for calibration purposes to obtain good accuracy throughout the full span of operation NOTE Do not exceed the current rating of the CT Non linear output of the CT will result when the secondary current exceeds 5 amps and will similarly effect the MEC 20 displayed values In the programming mode scroll to the desired generator supply current phases with the SPAN function selected Connect an external AC ammeter and current clamp of adequate current range to the MEC 20 controller terminals associated with the current phases to be calibrated WARNING Never open circuit an energized CT as extreme high voltages may result which may cause serious injury or
90. rops below the low speed setpoint typically 596 of rated speed Note An external pilot relay will be required if the main air flap solenoid current rating exceeds the MEC 20 contact rating 5 2 13 ATS TEST NOTE This control feature is only operative if a remote transfer switch is interconnected with remote testing capability The designated programmable output relay will energize when a load test operating mode is selected via the front keypad push button Once initiated the engine will receive a start signal from the transfer switch and upon the generator reaching nominal voltage and frequency levels a load transfer will be initiated The generator set will remain running on load until a different operating mode is selected or the generator set develops an alarm or shutdown condition Notes 1 The MEC 20 s standard programmable output contact is factory supplied with the ATS LOADTEST function programmed When the Utility Ready to Load and Generator Ready to Load outputs are programmed the Load Test programmable output is not required as the engine starting logic is internally initiated 2 When both Utility Ready to Load and Generator Ready to Load programmable outputs are programmed and utilized in a AMF control configuration the ATS Output is not utilized i e engine start signal is internally generated PM047 Rev 11 2002 09 09 33 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER
91. rovides four internally activated fault circuits as described below All internal fault circuits are provided as standard with every MEC 20 controller 4 2 1 OVERCRANK The overcrank fault circuit is initiated when the engine fails to start after the selected crank time or number of crank cycles The overcrank fault circuit is internally programmed as a latching shutdown fault and is not user programmable Refer to the programming instructions for further information 4 2 2 OVERSPEED The overspeed fault circuit is initiated when the engine s speed has increased above the overspeed setpoint The overspeed fault circuit is internally programmed as a latching shutdown fault The overspeed shutdown fault circuit is programmable for the percentage of nominal engine speed i e overspeed setpoint and for the transient time delay period The programming prompts for overspeed are located in the main menu programming loop Refer to the programming instructions for further information 4 2 3 LOSS OF SPEED The loss of speed fault circuit is initiated when the engine s speed sensing circuit does not detect a speed signal for a period more than 2 seconds following a run signal The loss of speed fault circuit may be user programmed as a latching shutdown fault or alarm only The programming prompts for loss of speed are located in the main menu programming loop Refer to the programming instructions for further information 4 2 4 SWITCH NOT
92. sensor provides information to perform the following control functions 4 4 8 1 WEAK BATTERY ALARM The weak battery alarm fault circuit is activated when the battery voltage drops below a pre determined setpoint for a specified time delay The weak battery alarm will detect a low capacity i e weak battery condition during the cranking cycle The weak battery alarm is programmed for a lower battery voltage setpoint and shorter time delay than the low battery alarm function The weak battery alarm fault is programmable for voltage setpoint level transient time delay settings and other functions Refer to the programming instructions for further information 4 4 3 2 LOW BATTERY VOLTAGE ALARM The low battery voltage alarm fault circuit is activated when the battery voltage drops below a pre determined setpoint for a specified time delay The low battery voltage alarm fault is programmable for the voltage setpoint level transient time delay settings and other functions Refer to the programming instructions for further information 4 4 3 3 HIGH BATTERY VOLTAGE ALARM The high battery voltage alarm fault circuit is activated when the battery voltage rises above a pre determined setpoint for a specified time delay The high battery voltage alarm fault is 26 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER programmable for voltage setpoint level transient time delay settings and other functions
93. supply The Return Delay timer is typically set for 120 seconds Refer to Section 9 3 for further details on this timing function PROGRAMMABLE OUTPUT CONTACTS Select the desired function programmable relay output contact may be selected that will One of the following functions activate the designated Note Programmable output contacts 5 and 6 are located on external expansion output module as optionally available Refer to Section 7 0 for additional information PRE POST CYCLIC LUBE CONTROL OVERCURRENT ENERGIZE TO STOP AIR FLAP OIL BYPASS TIMER COMPLETE COMMON FAIL SWITCH NOT IN AUTO ENGINE READY ENGINE RUN FUEL PREHEAT ENGINE RUNNING ATS TEST COMMON ALARM COMMON SHUTDOWN 66 IDLE CONTROL EPS SUPPLYING LOAD GEN READY TO LOAD UTILITY READY TO LOAD DIGITAL FAULTS 1 12 OVERSPEED LOSS OF SPEED SIGNAL LOW BAT VOLTAGE HIGH BAT VOLTAGE WEAK BAT VOLTAGE LOW OIL PRESS 1 ALARM LOW OIL PRESS Z2 SHUTDOWN HIGH ENG TEMP 1 ALARM HIGH ENG TEMP 1 SHUTDOWN Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER CAUTION The programming function selected must co ordinate with external control wiring prior to energizing the control system Failure to do so may cause severe equipment damage 10 3 30 AUTO CALLOUT When the remote communication option is enabled this programming prompt will appear The controller can be programmed for the desired type of c
94. tal faults labels and blank selections 1 3 98 02 09 New version with communication features expansion relay module capability deletion of horn programming deletion of cooldown shutdown programmability deletion of fail programmability and revised password number 1 2 97 06 04 Original version 1 1 2 Operating amp Service Manual Version Rev 11 02 09 09 Added descriptive information for new software version 1 8 Rev 10 02 02 15 Added descriptive information for new software version 1 7 Rev 9 01 10 17 Clarification of faults required for C282 or NFPA 110 PM047 Rev 11 2002 09 09 2 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER Rev 8 01 07 18 Addition of Static Precaution deletion of calibration jumpers to requiring external calibration resistors potentiometers standard fault circuits increase from 12 to 28 Ready status changes to Ready to Load changes in temperature and pressure calibrations extended temperature ratings Rev 7 00 12 01 Minor text changes Rev 6 00 10 06 Added KVA metering feature Rev 5 00 04 06 Changes made to digital fault labels can be connected changes from 5 to 10 Rev 4 99 02 01 Remote communication wiring changes multiple controllers that Rev 3 98 05 08 Corrected minor errors capability and revised password number Rev 2 98 02 18 New version with co
95. ted as close as possible to the pressure sender for the MEC 20 The calibration procedure is to be done only at a single point which is the normal operating pressure of the engine Connect a temporary engine mounted pressure gauge of suitable accuracy and start the engine Once the engine reaches normal operating pressure and temperature enter the programming mode and scroll to the Engine Pressure Offset calibration point Use the INCREMENT or DECREMENT push buttons to adjust the correction factor number while observing the displayed pressure on the MEC 20 Adjust the correction factor number to obtain the identical pressure reading as measured with the external pressure gauge 80 Thomson Technology Inc PM047 Rev 11 2002 09 09 MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER With the correct pressure displayed press the enter push button to accept the correction factor number Record the correction factor number on the MEC 20 programming sheet for future reference Engine Pressure PA 1034 call 517 EINEN 207 30 155 23 103 15 2162 Sender Resistance 25 25 38 41 47 59 52 35 56 71 62 34 68 37 74 31 81 44 88 76 96 87 107 95 122 22 134 85 140 52 158 16 179 75 197 59 216 2 81 Figure 22 Engine Tem m re 194 176 150 140 122 Sensor Resistance 147 1486 2322 3644 6284 Thomson Technology Inc MEC 20 MICROPROCESS
96. ts and engine temperature pressure input signal terminal block TB4 DC power input and ground connection terminal block 3 2 2 DIAGNOSTIC LED S The MEC 20 controller provides five diagnostics LED lights that are mounted on the rear of the printed circuit board as per FIGURE 11 Their functions are described as follows 3 2 2 1 WATCHDOG This LED flashes on and off at irregular intervals which indicates that the microprocessor is functioning normally 3 2 2 2 REMOTE START This LED is illuminated whenever the MEC 20 has received a remote start signal 3 2 2 3 CRANK This LED is illuminated whenever the MEC 20 is initiating an engine cranking signal PM047 Rev 11 2002 09 09 18 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER 3 2 2 4 RUN This LED is illuminated whenever the MEC 20 has called the engine to run 3 2 2 5 COMMON FAIL This LED is illuminated whenever the MEC 20 has initiated a common fail signal i e whenever an alarm or shutdown fault has been activated Note All LED s will be illuminated whenever a lamp test function is performed 3 2 3 CONTRAST ADJUSTMENT R115 A contrast adjustment potentiometer is located on the rear of the PCB and is factory set for ambient temperatures of 15 to 30 Celsius For different ambient temperatures consult the factory for adjustment procedures 3 2 4 COMMUNICATION PORTS Two RJ45 communication ports are provided on the circuit board for
97. uld be set as required for these functions 10 3 11 CRANK TIME Select desired cranking time in seconds If cycle cranking is selected this time will be the crank time period on each attempt 10 3 12 REST TIME Select desired rest time between cranking attempts Only valid if multiple crank attempts are selected Note This value will be ignored if only one attempt has been programmed 10 3 13 STARTER RE ENGAGE DURATION This feature will check for a speed signal while cranking If no speed signal is sensed the controller assumes that the engine starter is not turning the engine over for whatever reason and disengages it after the programmed time delay and re engages it again This process will repeat until a speed signal is sensed or cranking time expires whichever occurs first If a speed signal is sensed the cranking output will be maintained until the unit starts or an overcrank condition occurs Set time in seconds for desired sampling period i e a setting of 5 seconds will attempt cranking for 5 seconds after which time if no speed signal is detected the crank output will be removed for a preset 1 second delay before re engaging Note This action is more than a cycle cranking function and is independent of the number of attempts selected therefore the crank time should be considered To disable this feature set to zero 10 3 14 NUMBER OF CRANK CYCLES Set to the number of cranking cycles required Zero will
98. ximum predetermined setpoint the overspeed shutdown fault circuit will activate terminating the run signal In addition to overspeed shutdown the engine controller also monitors many other engine protection circuits and should they be activated the engine will be stopped and or alarm initiated The engine will automatically stop for any shutdown condition or when the remote and or local start signal is removed The engine controller operation includes time delay circuits for normal operating conditions such as start delays cooldown and cranking periods 9 3 2 MANUAL START STOP SEQUENCE When the RUN push button on the front faceplate keypad is pressed an ENGINE START DELAY timer will be initiated Note The start sequence will not be initiated if any shutdown fault condition is present Once the engine start delay time expires an engine RUN and CRANK output signal PM047 Rev 11 2002 09 09 50 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER will be initiated Note The RUN output may be programmed to only energize when a start signal is initiated and an engine speed signal is detected Once the engine starts to turn over and begins to accelerate to nominal speed the controllers speed sensor will terminate the CRANK output when engine speed reaches approximately 2096 speed i e CRANK DISCONNECT speed setpoint Immediately upon reaching crank disconnect speed the controller will initiate the BYPASS DELAY time
99. y settings and other functions Refer to the programming instructions for further information 4 4 5 2 LOW OIL PRESSURE 2 SHUTDOWN The low oil pressure shutdown fault circuit is activated when the oil pressure drops below a pre determined setpoint for a specified time delay The low oil pressure shutdown fault is programmable for pressure setpoint level transient time delay settings and other functions Refer to the programming instructions for further information Note Low Oil Pressure shutdown may alternately be programmed and wired as a digital fault input contact Refer to Section 4 3 for further details 4 4 6 ENGINE SPEED ANALOG INPUT The MEC 20 s engine speed sensor measures AC voltage and frequency from an engine mounted magnetic pick up The engine speed sensor provides information to perform the following control functions PM047 Rev 11 2002 09 09 28 Thomson Technology Inc MEC 20 MICROPROCESSOR ENGINE GENERATOR CONTROLLER Overspeed shutdown Crank Disconnect control Loss of speed signal detection Starter Re engage control RPM display Refer to the programming instructions for further information 5 CONTROL OUTPUT CONTACT DESCRIPTIONS All output contacts from the MEC 20 Engine Controller are non powered i e dry contacts and are rated 10A 240Vac 8A 24Vdc resistive 3A inductive 0 4pf Output contacts are not fused therefore external overcurrent protection maximum 104 is required for all control circuits using

mec 20 microprocessor engine/ generator controller

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