Transcript
Installation and Operation Manual for Generator Control System® MGC2000
MGC-02030N Effective 04-03 Section 75 00-02-0505
Please read the following information before installing. A visual inspection of this product for damage during shipping is recommended before mounting. It is your responsibility to have a qualified person install this unit and make sure it conforms to NEC and local codes. GENERAL INFORMATION
WARNING BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT
✔ ✔ ✔ ✔
Disconnect all electrical power to the machine. Make sure the machine cannot operate during installation. Follow all safety warnings of the machine manufacturer. Read and follow all installation instructions.
Description The compact and powerful MGC2000 generator control system features a unique, simple-to-install and setup design and enhanced operation. The control method for the MGC2000 may be specified for using either the AS3000 Autostart automatic controller or the 518APH electrically tripped annunciator method. The system is available in 2 basic configurations: 1. MGC2000 features mechanical gages: - MGC2000-A Automatic Control: with AS3000 Generator Controller. - MGC2000-M Manual Control: with 518APH annunciator control. Both configurations include standard AC voltmeter, AC ammeter, and frequency meter. Available for single phase, standard three phase, and three phase re-configutable generators. 2. MGC2000E features electric gages: - MGC2000E-A Automatic Control: with AS3000 Generator Controller. - MGC2000E-M Manual Control: with 518APH annunciator control. Both configurations include standard AC voltmeter, AC ammeter, and frequency meter. Available for single phase, standard three phase, and three phase re-configutable generators.
System Specifications Pressure gage: 100°psi (680 kPa) [7 bar] Mechanical gage pressure connection: 1/8" NPT. Electric gage pressure connection: 2-wire. Temperature gage: 0-250°F (121°C) Mechanical gage temperature connection: 12ft. (3.67 m) capillary tubing and sensing bulb. Electric gage temperature connection: 2-wire. Enclosure: 16 Ga CRS powder coated.
WARNING: Do not bundle AC and DC wiring together. It is required to use separate conduit runs and keep apart by at least 2 inches. Optional NEMA 4X Type Enclosure: Water and dust tight indoor/outdoor enclosure intended to protect enclosed equipment against splashing, seepage, falling or hose-directed water and severe external condensation. AC Meters: AC ammeter and an AC voltmeter and a frequency meter are standard features. Ranges must be specified. Single or Three phase: Specify. Control Method: may be specified: - AS3000 Autostart automatic controller or - 518APH Annunciator control method. NOTE: Autostart method is highly recommended. DC Voltage: 12 or 24 volt DC voltage must be specified. Power supply: • Continuous voltage range: 8-35 VDC • Brown out voltage < 5 VDC for 2 secs (recovery to 8V) • Blackout voltage: 0V for 50mS (from 10V, recovery to 5V) • Overvoltage withstand: 50 VDC for 5 seconds (to SAEJ1810 load dump immunity • Reverse voltage withstand: 100 VDC continuous Current consumption (standby): 50mA Current consumption (max): 500mA (plus output loads) DC Inputs: • Pressure, coolant temperature • Closed to negative DC (±3V) on fault auxiliary and charger faults • Remote start positive open from positive DC to start • Remote start negative close to negative DC (±3V) to start DC (±3V) to activate DC input protection ±50 VDC max.
MGC-02030N page 1 of 8
continued on next page
GENERAL INFORMATION continued AC Inputs: • Magnetic pickup:3 – 60 VAC, 50Hz – 10 kHz. • Generator AC: 600 VAC max (L-L or L-N), 50/60 Hz.
Physical: • Dimensions: See pages 3 and 4. • Operating temperature: -10 to +65 oC • Relative humidity: 95% @ 60 oC • Environmental protection: - AS3000U front: IP65, NEMA4 - Vibration: ISO 88528 pt.9, & 3 axis 3g
Outputs: • Fuel: positive DC (relay switched), 5A max. • Crank, preheat: positive DC (relay switched), 2A max. • Common alarm, fault lockout negative DC (semiconductor), 300mA max. • Generator Hz. meter: 0 – 5VDC (@ 45–65Hz), 10mA max
Note: Standard terminal blocks inside the MGC2000 enclosure. Booted type grommets for a tight seal are available.
DIMENSIONS FOR ALL MODELS CAUTION: To mount the MGC2000 drill and tap the mounting suface, see Mounting Drill Pattern, below. Use the four
mounting inserts, one on each corner of the bottom of the enclosure, to secure the unit to the mounting surface by tightening the clamps with a blade type screwdriver. Do not bundle AC and DC wiring together. It is required to use separate conduit runs and keep apart by at least 2 inches. Front View
Side View 9.25 in. (235 mm)
16-80 in. (427 mm)
25 A-C VOLTS
A-C AMPERES
6.81 in. (173 mm) 3
OVERCRANK
ENGINE RUNNING
LOW OIL PRESSURE
BATTERY CHARGER FAIL
HIGH ENGINE TEMPERATURE
PLANT FAIL/ AUXILIARY INPUT
OVERSPEED
OFF/ STOP
OFF 1
50
75 100
0 REMOTE START DEMAND
MANUAL START
PSI 0 kPa
HOURS
350 700
QUARTZ
7.94 in.
AUTO START
25
50
75
25 100
0
PSI 0 kPa
HERTZ
350 700
50
75 100
0
PSI 0 kPa
350 700
(202 mm)
Hinges for front-opening door option shown in shaded areas.
Bottom View Mounting Pattern 6.36 in.
16-80 in. (427 mm)
9.25 in. (235 mm)
(162 mm)
MGC-02030N page 2 of 8
NEMA 4X ENCLOSURE DIMENSIONS CAUTION: To mount the MGC2000 drill and tap the mounting suface, see Mounting hole Pattern, below. Use the four mounting holes (see mounting details), one on each corner of the bottom of the enclosure, to secure the unit to the mounting surface by tightening the clamps with a blade type screwdriver. Do not bundle AC and DC wiring together. It is required to use separate conduit runs and keep apart by at least 2 inches
13-31/32 in.
10-5/8 in.
(355 mm)
(270 mm)
A-C VOLTS
HERTZ
A-C AMPERES
MOUNTING DETAIL MGC Panel
Wall or Pedestal
Screw Washer
Nut Lock Washer Washer
18-63/64 in. (480 mm)
OFF 1
REMOTE START DEMAND
OVERCRANK
ENGINE RUNNING
LOW OIL PRESSURE
BATTERY CHARGER FAIL
HIGH ENGINE TEMPERATURE
PLANT FAIL/ AUXILIARY INPUT
OFF/ STOP
OVERSPEED
MANUAL START
AUTO START
18-1/2 in. 25
50
25
75
350
PSI 0 kPa
HOURS
50
75
25 100
0
100
0
PSI 0 kPa
700
50
75
PSI 0 kPa
700
(470 mm)
100
0
350
350 700
QUARTZ
Wall or Pedestal
MGC Panel
5/16 x 1/2 in. (8 x 13 mm) Mounting Holes, 4-Places
Subpanel Dimensions 15 in. (xxx mm)
15 in. (xxx mm)
A-C VOLTS
15 in. (xxx mm)
HERTZ
A-C AMPERES
OFF 1
OVERCRANK
ENGINE RUNNING
LOW OIL PRESSURE
BATTERY CHARGER FAIL
HIGH ENGINE TEMPERATURE
OFF/ STOP
25
50
100 350 700
OVERSPEED
MANUAL START
15 in. (xxx mm)
AUTO START
25
75
0
PSI 0 kPa
HOURS
15 in. (xxx mm)
REMOTE START DEMAND
PLANT FAIL/ AUXILIARY INPUT
50
75
25 100
0
PSI 0 kPa
15 in. (xxx mm)
350 700
50
15 in. (xxx mm)
75 100
0
PSI 0 kPa
350 700
QUARTZ
MGC2000 SCHEMATIC 2
3
Description
1
9
8
25 A-C VOLTS
REMOTE START DEMAND
OVERCRANK
ENGINE RUNNING
LOW OIL PRESSURE
BATTERY CHARGER FAIL
HIGH ENGINE TEMPERATURE
PLANT FAIL/ AUXILIARY INPUT
OVERSPEED
OFF/ STOP
OFF 3
4
75 100
MANUAL START
5
PSI 0 kPa
HOURS
350 700
QUARTZ
10 AUTO START
25
50
75
6
25 100
0
PSI 0 kPa
HERTZ
1
50
0
A-C AMPERES
50
75 100
0
350
PSI 0 kPa
700
7
350 700
11
MGC-02030N page 3 of 8
1. AS3000= Automatic Controller 2. AC Ampmeter= AC Amps 3. AC Voltmeter= AC Volts 4. Phase Switch= 1-3 Phase Selector Switch 5. Frequency Meter= 45-65 Hertz 6. Pressure Gage= 0-100 psi 7. Temperature Gage= 0-250 °F 8. DC Hourmeter= DC hourmeter 9. DC Voltmeter= DC Volts 10. Enclosure= Fixed or Hinged door. 11. Vibration Shocks= Help excesive vibration.
SYSTEM BASIC INFORMATION
CAUTION: Do not bundle AC and DC wiring together. It is required to use
separate conduit runs and keep apart by at least 2 inches This section provides basic information for the MGC2000 Generator Control System and the AS3000 controller. For instructions on using the AS3000 controller and software, see the AS3000 controller instruction manual (AS3-02075N), included with this package, and the controller electrical print. The prints show how to physically/electrically connect the MGC200. There are some points to consider about the MGC2000.
Inputs All the control inputs of the AS3000 are activated by connecting them to ground, except the "remote start positive" input. It must be connected to +V battery to make a "stop" condition, and left floating (unconnected) to initiate an automatic start. In all standard MGC2000’s, this connection is made by default, and the user connects the automatic start contacts to the "ground to activate" position on the terminal block
Outputs If the controller is equipped with the relay option, you will need to provide DC power to the relays, as they are supplied from the factory as dry contact only.
Without Relay Option If the controller is supplied without the relay option, please install an inductive kick-back suppression diode as show in the AS3000 instruction manual. Failure to properly suppress the inductive kickback can potentially destroy the solid state outputs of the controller and is not a warrantable failure.
The LED’s The LED’s on the front display will either be off, on 100%, blinking at a rate of 1/second (slow blink) or 4 times/sec (fast blink) This allows the 8 LED’s to indicate 24 potential fault, alarm, or information states. There is a display map, as well as textual indication on the controller face, in the AS3000 instruction manual.
Other Connections The AS3000 has inputs for AC frequency (20-21) magnetic pickup (17,18,19) along with power and ground (+V battery & -V battery respectively)
AC Voltage AC Voltage is measured via a standard AC meter movements scaled 0300VAC, 0-600VAC, or as a dual scale meter movement with both 0600 & 0-300 scales indicated. In the case of a dual scale meter, the actual meter movement is 0-300VAC.
AC Current
There are many available ammeter scales (See the how to order section of the MGC2000 cut sheet). The MGC2000 uses current transformers that are in a ratio back to 5A AC. Any commonly made CT that is of acceptable accuracy and labeled "xxx:5" will work in the MGC2000. Please be aware that under no circumstances should the CT of a generator under load be disconnected. An unconnected CT will generate highly hazardous voltages and in the right conditions is capable of causing a catastrophic failure of the CT.
AC Frequency The standard MGC2000 uses the AS3000 to measure the AC frequency and drive a 0-1mA meter movement to indicate AC frequency over the 45-65Hz range.
Circuit Breakers The MGC2000 is equipped with "push to reset" type circuit breakers. There are two different ratings, a 250VAC/32VDC rated one for the DC panel voltages and single phase AC applications whose normal operating voltage never rises above 250VAC, and 600VAC rated circuit breakers for applications with operating voltages over 250VAC.
Speed Sensing If the application specifies that a magnetic pickup must be used then the AC frequency meter will be a standard 240/277VAC frequency meter, at a slightly higher cost.
Phase Selector Switch The models with a phase selector switch are wired as follows, unless the customer specifies otherwise. On three phase control sets, the metering shows the AC voltage L1-L2, L2-L3, L3-L1, with the corresponding amps reading L1, L2, & L3. In single phase with phase select option, the voltage is displayed as: L1-N, L2, N, L1-L2, and the current is displayed as L1, L2, and none.
Crank Disconnect/Overspeed The AS3000 can be used to automatically start and stop (based on a contact closure) the generator set. Crank disconnect and overspeed protection are provided by either the AC frequency input, the magnetic pickup input or the two ground to activate inputs labeled "crank disconnect" and "overspeed".
MGC-02030N page 4 of 8
MGC2000 Typical Wiring WARNING: Turn the power source off before attempting to perform the wiring operation. Do not bundle AC
20P-100
20T-250
VM-12 or VM-24
and DC wiring together. It is required to use separate conduit runs and keep apart by at least 2 inches
MGC-02030N page 5 of 8
MGC2000E Typical Wiring WARNING: Turn the power source off before attempting to perform the wiring operation. Do not bundle AC and DC wiring together. It is required to use separate conduit runs and keep apart by at least 2 inches
MGC-02030N page 6 of 8
Controller Troubleshooting
AS3000 Controller Troubleshooting
6. If AS3000 is consistently shutting down on overspeed when
When enabling the controller presents a problem, make sure that the following conditions are present: DC voltage above 8VDC all the time Good solid ground (-V battery) connected at the terminals in the MGC2000 enclosure. A "daisy chained" ground that is looped from battery to frame to starter to Ac alternator to ground rod to MGC2000 is not a reliable installation. When dealing with a potential for high current, it is imperative that the ground for the controller and the battery be as close and resistance free as possible.
there is: a. No ground signal applied to terminal 14 AND b. No overspeed condition is truly present, then either the crank disconnect/overspeed settings were captured wrong, (See page "Speed calibration" on page 6) OR c. There is a noise source on the speed input: i. For AC Speed driven units, this can take the form of ‘dirty’ loads on AC – like variable frequency drives, large inductive loads etc – typically indicating a poorly grounded AC side. ii. If the system is using a magnetic pickup, the shield is improperly grounded (usually at both ends instead of just one!) iii. If the system is spark ignited, the ignition system should use resistive spark plugs and plug wires, and the magnetic pickup wiring should be routed as far away from the plugs and plug wires as possible. 7. If the preheat, fuel, or crank outputs do not seem to be working (not providing voltage out): Disconnect the load from the suspect terminal(s), and while measuring the voltage on the terminal, initiate a start. If the voltage is there during this test, you have exceeded the current rating of the FET output and must add a slave relay to get the total current draw back under 2 (or 5) Amps per output. 8. If the system tries to immediately crank, without a proper start signal: Verify with a voltmeter that terminal 16 is at +V battery, and that terminal 9 is not grounded. 9. If the engine consistently dies shortly after startup: Make sure that the oil pressure and engine temperature fault switches are operating properly.
When the controller can’t be enabled If the controller won’t run or if the starter is being re-engaged after the controller is running, then one of two states exists: the speed signal source - magnet pickup, AC voltage, or crank disconnect switch supplying the AS3000 is misconnected/not operating properly, or the AS3000 has not been properly programmed. Verify that the speed signal source is functional, and then if the problem persists, reset/recapture the speed signal settings (See the AS3000 section on "controller programming").
1. If the controller is totally unresponsive check the following: a. Ground is applied to terminal 1. b. +V battery is applied to terminal 2 c. The operation jumper is present between terminals 23 and 33 or if a key switch is in the system make sure that it is in the run/on position d. +V battery is at least 8 volts.
2. If the controller attempts to initiate start but either just "bumps" the crank or resets without actually cranking: Verify that the +V battery remains above 8 volts DC as measured across terminals 1 and 2 when the crank cycle is initiated. 3. Verifying the LED’s actually work: a. Ground the LAMP TEST input (terminal 35 on the rear of the User interface) to terminal 1 4. If the starter will not disengage properly, or continues to cycle crank even after the engine starts: a. If the application is using AC frequency for crank disconnect and overspeed, then check the AC connections to terminals 20 & 21. AC voltage MUST be present when the engine is past crank disconnect speed. b. If the application is using magnetic pickup crank disconnect/overspeed, make sure that the wiring is correct and that the output is at least 3Vrms as measured at terminals 17 & 19 (18 is the shield/screen wire) c. If the run signals are present when the genset is running and it still cycle cranks, then the crank disconnect/overspeed settings were captured wrong. See page "Speed calibration" on page 6. 5. If the system tries to immediately crank, without a proper start signal: Verify with a voltmeter that terminal 16 is connected to +V battery, and that terminal 9 is not grounded.
MGC-02030N page 7 of 8
HOW TO ORDER THE MGC2000
MGC2000 1 – A – 12 – 300 – 600D – AMVMRLKS4XMP Base Model MGC2000 = Mechanical Gages MGC2000E = Electric Gages
Options AM = DC Ammeter(1) VM = DC Voltmeter(1) HM = Hourmeter RL = Relays KS = Keyswitch PS = Phase Select Switch (single phase only) ES = Emergency Stop Switch 4X = NEMA 4X Enclosure QD = Quick Disconnect Connectors HF = Hinged Front MP = Magnetic Pickup Sensor(2) CT = Provide CT’s(2)
Phases 1 = Single Phase 3 = Three Phase
Controller A = Autostart M = Manual
NOTE: Enter Options prefix in the listed order, example: AMVMRLKS4XMP
DC Voltage 12 = 12 VDC 24 = 24 VDC
AC Ammeter 50, 75, 100, 150, 200, 300, 400, 500, 600, 800, 1000, 1200, 1500, 2000
AC Voltmeter 150, 300, 600 300D = 300/150 Dual Scale 600D = 600/300 Dual Scale
Accessories and Replacement Parts Off-Equipment Mounting Kit This kit allows off-equipment mounting of the ESPM, ES2PM and ESDPM pressure senders. Recommended for protection from damaging vibration. Customer supplies hose and fittings. Specify part number 30-00-0213 when ordering.
Sender ESP ES2P ESDP ESPM ES2PM EST ES2T ESDT
Description 1-wire to ground sender† 2-wire ungrounded sender† 2-wire ungrounded sender, drives two (2) gages† 1-wire to ground sender††** 2-wire ungrounded sender††** 1-wire to ground sender* 2-wire ungrounded sender* 2-wire ungrounded sender, drives two (2) gages*
100D= 50/100 Dual Scale 300D= 150/300 Dual Scale 400D= 200/400 Dual Scale 600D= 300/600 Dual Scale 800D= 400/800 Dual Scale 1000D= 500/1000 Dual Scale 1200D= 600/1200 Dual Scale 1600D= 800/1600 Dual Scale 2000D= 1000/2000 Dual Scale 3000D= 1500/3000 Dual Scale 4000D= 2000/4000 Dual Scale 5000D= 250/5000 Dual Scale
Warranty A limited warranty on materials and workmanship is given with this FW Murphy product. A copy of the warranty may be viewed or printed by going to www.fwmurphy.com/support/warranty.htm
† Thru 100 psi (689 kPa) [6.89 bar]. †† Ranges above 100 psi (689 kPa) [6.89 bar]. ** Mounting off-equipment recommended.
GI
D
MURPHY SWITCH OF CALIFORNIA 41343 12th Street West Palmdale, California 93551-1442; USA +1 661 272 4700 fax +1 661 947 7570 e-mail
[email protected] www.murphyswitch.com
MACQUARRIE CORPORATION 1620 Hume Highway Campbellfield, Vic 3061; Australia +61 3 9358 5555 fax +61 3 9358 5558 e-mail
[email protected]
E
MURPHY DE MEXICO, S.A. DE C.V. Blvd. Antonio Rocha Cordero 300, Fracción del Aguaje San Luis Potosí, S.L.P.; México 78384 +52 444 8206264 fax +52 444 8206336 Villahermosa Office +52 993 3162117 e-mail
[email protected] www.murphymex.com.mx
FRANK W. MURPHY, LTD. Church Rd.; Laverstock, Salisbury SP1 1QZ; U.K. +44 1722 410055 fax +44 1722 410088 e-mail
[email protected] www.fwmurphy.co.uk
RE
FW Murphy P.O. Box 470248 Tulsa, Oklahoma 74147 USA +1 918 317 4100 fax +1 918 317 4266 e-mail
[email protected] www.fwmurphy.com
CONTROL SYSTEMS & SERVICES DIVISION P.O. Box 1819; Rosenberg, Texas 77471; USA +1 281 633 4500 fax +1 281 633 4588 e-mail
[email protected]
STER
USA–ISO 9001:2000 FM 28221 UK–ISO 9001:2000 FM 29422
In order to consistently bring you the highest quality, full featured products, we reserve the right to change our specifications and designs at any time. Printed in U.S.A.
MGC-02030N page 8 of 8
