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Engine Interface Module: Functional Description
Engine Interface Module: Functional Description
The Engine Interface Module is a sealed, engine mounted module that provides
switching relays for the Starter Motor Solenoid, Glow Plug and Fuel Solenoid.
Each of these circuits is protected with individual automotive fuses mounted in the
module. Individual LED’s illuminate when each circuit is energized in addition
these LED’s greatly aid when fault finding.
This module is mounted on the engine with anti-vibration mounts and is easily
connected to the engine via loom plugs. Use of the EIM means that heavy
currents such as Fuel Solenoid power are isolated from the control panel thus
enabling individual protection of each of the circuits.
Functional Description
There are four versions of the Engine Interface Module available - the 12/24 volt
EIM SR and the 12/24 volt EIM Plus.
The EIM SR is the basic level module that provides all the switching functionality;
the EIM Plus provides the same functionality as the EIM SR plus the additional
feature of Overspeed Sensing and an Overspeed Trip Adjuster. A magnetic pick-
up on the engine flywheel housing provides the speed signal to the EIM Plus.
When an overspeed situation is sensed, the EIM Plus signals the 2001, 4001 or
4001E generator set control panel to stop the engine. The Overspeed Trip Point
can be easily set-up for 10% above the normal operating speed.
The overspeed feature on the EIM Plus, including the magnetic pickup is
mandatory for all the Autostart control panels except the Access 4000 (2001,
4001 and 4001E).
Schematic Representation
System Operation
The generating set is started by turning the key on the front of the panel fully
clockwise. This will connect a positive supply to Run, Thermostart and Start
wires. The thermostart and start signal wires go directly to the EIM via wires
10 & 4, this will energise the glow plug (if applicable) and the starter motor.
The fuel signal will connect onto wire 3A as soon as relay 1CR energises, this
will occur due to contact 1CR/1 closing to link wire 7 to wire 3 via pin 22 on
the PCB.
The starter will be disengaged by the operator releasing the key which will
spring back to keep a supply on the run wire only. This means we lose the
supply for the glow plug and starter motor.
The 2001 control panel offers autostart capabilities along with 5 engine
protection channels, 4 of which are configured as shutdowns and are
allocated as Fail to Start, High Engine Temperature, Low Oil Pressure and
Emergency Stop/Overspeed. The last channel of the five is a spare channel
which may be configured at the factory when additional protections are
requested by the customer. Otherwise this channel may be configured by the
customer as an alarm or a shutdown, the protection can also be FPT (Fault
Protection Timer) enabled.
Fail to Start: This protection activates when the engine has been given a start
signal and the engine has failed to start. This is factory set to allow 3 attempts
to start, each attempt is made up of a 5 second crank cycle followed by a 5
second rest period.
Low Oil Pressure: The protection is activated externally by the VDO oil
pressure sender. The sender typically switches at 0.8 bar/ 11.75 psi on the 0-
5 bar model and 1.25 bar/18.5 psi on the 0-10 bar model. This protection is
also FTP protected.
Basic Operation
(i) Once the thermostart button on the front of the panel is pushed the
positive will be connected to wire 10 through the n/o contact and then
to the EIM to energise the glow plug.
(ii) The positive supply to the PCB through pin 24 will supply a +ve to the
fault LED’s, once the lamp test button is pushed a –ve will also be
connected to the LED’s and they will illuminate.
(iii) When the three position switch is turned to the RUN position we will get
+ve on wires 50 & 8. Wire 50 allows a + supply to the 5 faults relays
F1, F2…F5 through pin 4 on the PCB. The relays will not switch as no
dc -ve signal is connected to the coil of the relays.
Wire 8 will effectively become the RUN signal, it firstly goes through a
n/c contact on the emergency stop button, so if the button is locked in,
the Run signal will not progress. Providing the button is not locked then
the Run signal progresses along wire 11a through the remote stop link
and onto wire 11. Wire 11 will supply a signal to the battery volt meter
and also enter the PCB through pin 17. The run signal now enters the
fault array, the section of the schematic made up of F1/1, F2/1, F3/1,
F4/1 and F5/1; these are contacts on the fault relays ie F2/1 is contact
1 on fault relay 2.
CYT is a cyclic timer with two states On & Off, these are usually set for 5
seconds each at the factory. When CYT is On contact CYT/1 closes allowing
a supply to SMR (Starter Motor Relay). When CYT is in the Off state CYT/1
will open and prevent SMR from energising. When SMR does energise during
the On state of CYT, contact SMR/1 switches to allow a positive supply onto
wire 4 this is the signal input to the EIM to engage the starter motor and crank
the engine.
SMR
DT
0 5 10 15 20 25
If the engine does fire during one of the crank cycles then we need to end the
starting sequence and disengage the starter motor, this is achieved with the
use of AR or ER. ER is the engine relay, it energises when it receives a
negative supply to its coil from the EIM via wire 54. The EIM will output the
required –ve signal when the magnetic pickup fitted to the engine senses a
signal of 1090Hz. Due to ER energising contacts ER/1 and ER/2 will switch,
ER/1 removes any supply from reaching SMR and ER/2 enables the FPT
(Fault Protection Timer) to start timing out. The FPT has a default value of 15
seconds. If for some reason ER did not energise then AR will disengage the
starter. AR is the alternator relay and is energised by an ac supply to its coil
via wires 108 and 115. If AR gets an AC supply of 180 volts or more, then its
associated contacts will switch. AR/2 removes any +ve signal from reaching
CYT, DT & SMR. AR/3 enables the FTP timer and AR/4 opens to remove a
–ve supply reaching F1 when the FPT relay energises and its contacts switch.
Autostart Mode
Protection Activication
To activate any of the five protection channels we require a –ve to reach the
corresponding relay. The relay will energise and at the same time the LED
illuminates. Due to the relay energising contact Fx/1 in the fault array will
switch and cause CR1 to de-energise hence cutting of the fuel supply to the
engine.
Timer Adjustments
4 1
The 4001 and 4001E series control systems provide for automatic
starting and stopping of the generator set from a remote signal as well
as manual starting and stopping. This makes it appropriate for standby
generating systems.
On the 4001 and 4001E systems we have the same basic protections
as that on the 2001 control system with the addition of an alarm
protection for Low Battery Voltage. On 4001E series control systems
there are additional alarms for Approaching Low Oil Pressure,
Approaching High Engine Temperature, Battery Charger Failure and
Not in Auto Mode. Both systems have spare additional protection
channels as detailed below.
.
Since these control systems are designed for automatic starting, they
are fitted with connections for remote control. Included are terminals
for Remote Emergency Stop and an interface to an Intelligent Load
Transfer Panel (MTi) or Automatic Transfer Switch (ATS). Additionally,
the 4001 and 4001E Series Control Systems are fitted with an interface
to Remote Annunciators
When the main control panel fuse is fitted the panel is powered by the
battery. The battery positive is branched of to four areas (i) to the glow
plug , if applicable (ii) to terminals to be connected to the ATS (iii) to the
PCB via pin 24 (iv) 3 position switch.
(ii) The supply to terminals is for the ATS, when the ATS wants to start the
generator it will close a n/o contact and link 7 to 24.
(iii) The supply to the PCB via pin 24 will enable the Low Battery Voltage
monitoring circuit and also provide a supply for the LED’s for the Lamp
Test.
(iv) The supply to the three-position switch plays no role until run or auto is
selected.
RUN Mode
When the switch is turned to the run position wire 7 will be connected
onto wire 8; this then goes through a n/c contact on the emergency
stop button. If the button is locked in we do not progress. Provided the
emergency stop is not locked in the run signal will transfer onto wire 9.
Wire 9 is linked to wire 11 by the remote stop link. Wire 11 will supply a
voltage to the battery volts gauge for display and also enters the PCB
via pin 16.
On drawing D20449 we can see that the signal entering the PCB via
pin 16 sends a supply to the oil and coolant gauges via pins 8 and 12.
The signal also energises CR1 and CR2 via the fault array (F1R/1 to
F5R/1).
When CR1and CR2 energise contacts CR1/1 switches a positive
supply to wire 3 via pin 3 and CR2/1 switches to enable a supply to
CYT, DT and SMR. SMR will energise when contact CYT/2 closes i.e.
during the CYTON cycle, this allows SMR/1 to close and send a starter
motor signal to the EIM through pin 23 onto wire 4.
DT will limit the number of cranks as discussed in the system operation
of the 2001-control system and either ER or AR once again disengages
the starter motor.
Autostart Mode
When the three-position switch is turned to the auto position wire 8 will
connect to wire 13 and the system will wait on the ATS to close the
contact between wire 7 and 24 before anything further happens. When
the ATS closes the contact onto wire 24 a positive supply enters the
PCB via pin 15 which will energise MSRA (mains sensing relay
auxiliary). Contact MSRA/1 closes and allows a positive supply onto
wire 13 via pin 17, wire 8 is connected to wire 13, as stated above and
we are now operating as if the 3 position switch is in the run position.
Protection Activation
Timer Adjustment
Fault Protection Timer (FPT), On cyclic timer (CYTON), Off cyclic timer
(CYTOFF), duration timer (DT), and the run on timer (ROT). The range and
default settings are shown:
5 6 7
Four additional Alarm circuits are provided on the 4001E Series Control
System. The Approaching Low Oil Pressure and Approaching High Engine
Temperature alarms work off the sensors fitted for the gauges. The
temperature alarm is factory set to go off at 95°C ± 1°C but may be adjusted
using the pot on 4001E PCB. The Not in Auto Mode Alarm senses the
position of the Control Switch via P2. The Battery Charger Failure Alarm
detects low voltage from the charger. This level (BCV) is factory set at 13
volts for 12-volt systems and 26 volts for 24-volt systems. This alarm can be
operated in one of 3 modes depending on the position of Link 6 on the 4001E
Expansion PCB (see diagrams below):
Mode 1: Link in Position 1
For generator sets with trickle charger and engine driven charging
alternators. In this position the charger failure circuit monitors the
engine mounted charger when the engine is running and the trickle
charger when the engine is off.
Mode 2: Link in Position 2
For generator sets with no battery charger fitted. In this position the
charger failure circuit is disabled.
1
6
3 2
Item Description
There are two remote analogue annunciator panels to operate with the 4001
and 4001E series control panels. These are the Pan 4 and Pan 5 Remote
Annunciators.
The signals from the interface are then hardwired to the remote annunciator
ensuring that the correct signal is connected to the corresponding channel on
the remote annunciator. The remote annunciator will have an engraved fascia
detailing the faults as listed on the generator control panel fascia.
On the PCB’s inside the remote annunciator the customer has the ability to
change the colour of the fault LED’s from the following choices: red, yellow or
green. Also each channel can be programmed to sound a siren when
activated.
The supply for the remote annunciator panel is taken from the interface board.
The positive supply is taken from pin 11 on the interface and connected to
terminal 9 (Pos) on the annunciator PCB, the negative supply is obtained by
taking a wire 5 from the control panel to terminal 10 on the annunciator PCB.
The operating voltage of the remote annunciator panel is not indicated on the
panel but the voltage can be determined by checking the rating of the relays
The remote annunciator panels may have optional remote start switches or
emergency stops fitted. If the remote start switch is fitted then it is necessary
to connect this switch to wires 7 & 24 in the control panel. If the emergency
stop is fitted then the remote stop link should be removed in the control panel
and wires 9 & 11 connected across to the remote annunciator panel.
The distance that the remote annunciator can be mounted from the genset
depends on the voltage of the system and also the type of wire that is used to
connect both parts of the system. To calculate the maximum length we first
determine the operating voltage and how many channels we are using either
8 or 16. The maximum voltage drop for 12v systems is 2v and for 24v
systems the maximum drop is 4v. We also have to allow 100mA per channel.
We then apply Ohms law to get the overall resistance of the connecting cable.
Resistance = 2v / 800mA
We need to now refer to the cable manufactures handbook for the selected
cable or an IEE/IEEE data table to determine the resistance per yard or metre
for the selected cable. The resistance that we calculated is then divided by the
manufacturers figure to obtain the theoretical maximum length that the
annunciator can be from the generator.
The MTi Load Transfer Panel is a microprocessor based control system that is designed to
work with Autostart Control Systems (2001, 4001, 4001E, 6101, 6201 and Access 4000
Series) to form an automatic mains failure system. Only a two wire interconnection is
necessary between the generator set control panel and the MTi panel making the installation
very simple. The two wires are identified for all Autostart Control Systems as:-
MTi C/O System 2001 series panel 4001 Series panel 4001E series panel
Panel
7 & 24 8 & 24 7 & 24 7 & 24
MTi C/O System Access 2000 and 4000 6101 Series panel 6201 series panel
Panel series panel
7 & 24 5 & 24 13 & 93 7M & 90
General Operation
When the micro controller is operating correctly the green heartbeat LED will flash. The MTi
changeover system monitors the mains voltage, if the control system detects that the mains
supply voltage has fallen below a predetermined setpoint a timer is enabled, 2MT (mains fail
timer). Also the corresponding red LED will illuminate to indicate the phase on which the
undervoltage was sensed. If the mains is still below the setpoint when 2MT has timed out
then the MTi will open the mains contactor to disconnect the mains from load. Then the N/O
contact will close to link the two wires of the generator control system autostart (as shown
above). The generator will start and once up to rated speed and voltage a timer will be
enabled, AT. AT is the alternator timer which will time out and then allow the generator
contactor to close, the load will now be supplied by the genset.
The MTi will still monitor the mains for when it returns. As soon as the mains returns and is
above a healthy level setpoint, 1MT (mains return timer) will be enabled. If the mains is still
Timer Settings
There are 5 main timers used on the MTi PCB. These are:
The timers are changed using on board DIP switches SW1 and SW2 and are defined
according to the diagram below.
If fitted, this option allows a remote indication of the status LED’s that are mounted on the MTi
panel. A 10 way ribbon cable connected to connector EC11 on the MTi PCB sends the
appropriate signals to a matching status display PCB
The MTi allows the mains and generator fail/return points to be set on site without the use of
variable AC supplies. This is done with use of a calibrated multimeter and applying the
measured DC values to an equation to calculate the exact AC setpoint.
There are six potentiometers on the PCB called MA, MB, MC, GA, GB and GC. These pots
are for adjusting the setpoint for each phase sensed from the mains and generator. The fail
setpoint is set typically 10% lower than the rated line to neutral voltage. The return setpoint is
then automatically set for 4.5% above the fail point. To give an example:
If the voltage system was 415/240v the fail point would be 240 x 0.9 = 216v. The healthy
return point would then be 216 x 1.045 = 226v.
1. Connect a calibrated DC meter test points PHA and GND. (see diagram over)
2. Adjust pot MA to bias measured DC voltage to desired level based on the formula
To carry on the example we were required to set the fail point for 216v, this would equate to a
dc voltage of 5.687v.
3. Repeat for phase B & C using test point PHB and pot MB for phase B, use PHC and MC
for phase C.
Generator
2. Adjust pot GA to bias measured DC voltage to desired level based on the formula
3. Repeat for phase B & C using test point GENB and pot GB for phase B, use GENC and
GC for phase C.
Control Switches
The main control switch on the front of the panel has three positions:-
TEST WITHOUT TRANSFER – For testing the generator set without connecting the load.
This switch will start the generator immediately.
TEST WITH TRANSFER – For testing the generator set with the load connected. This switch
simulates a mains failure by disconnecting a phase from the PCB and the MTi will operate as
for a mains failure.
In addition to the main control switch there is a “Control Bypass” key switch for use by service
personnel only. In the “normal” position the MTi operates normally. The other two positions
allow for the service personnel to manually connect the load to the operating generator set or
Status LED’s
The front of the door has the status LED’s, maintenance switch and main control switch.
There are four status LED’s as shown.
Pressing the Lamp Test Button, located on the front of the door, will illuminate them for
testing.
Item Description
1
6 2 3
5
4
7
8
1 Link 4 – Timer reprogramming 5 Gen test points GENA, GENB & GENC
2 MA, MB & MC 6 GND Test Point
3 GA, GB & GC 7 Voltage selector link 2
4 Mains test points PHA, PHB &PHC 8 Voltage selector link 3