Murphy EMS PRO Installation And Operation Manual
EMS PRO
Engine Monitoring System Controller
Installation and Operations Manual
00-02-0716
2013-06-03
Section 40
systems.
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.
ENOVATION CONTROLS has made efforts to ensure the reliability of the EMS PRO
and to recommend safe use practices in system applications. Please note that in any
application, operation and controller failures can occur. These failures might result in
full control outputs or other outputs that might cause damage to or unsafe conditions
in the equipment or process connected to the EMS PRO.
Good engineering practices, electrical codes, and insurance regulations require that
you use independent external protective devices to prevent potentially dangerous or
unsafe conditions. Assume that the EMS PRO can fail with outputs full ON, outputs
full OFF or that other unexpected conditions can occur.
Please read the following information before installing.
BEFORE BEGINNING INSTALLATION OF THIS MURPHY
PRODUCT:
• This installation information is intended for all EMS PRO Series models. A visual
inspection of this product before installation for any damage during shipping is
recommended.
• Disconnect all electrical power to the machine. Failure to disconnect all electrical
power connections before welding can result in damage to the panel and/or its
components.
• It is your responsibility to have a qualified technician install the unit and make sure
installation confirms with local codes.
• Observe all Warnings and Cautions in each section of these instructions.
• The EMS PRO is designed for use in industrial environments. There might be
potential difficulties in ensuring electromagnetic compatibility in other
environments due to conducted as well as radiated disturbances.
• Please contact ENOVATION CONTROLS immediately if you have any questions.
IMPORTANT! False or improper use and operation of electronic
products could be dangerous. It is required that point-of-operation
guarding devices be installed and maintained. All such devices must
meet OSHA and ANSI Machine safety standards. The manufacturer shall
not accept any responsibility for installation, application or safety of
Table of Contents
Introduction ................................................................................................................................. 1
Product Description ......................................................................................................1
User Interface and Navigation ......................................................................................2
Quick Set Up ............................................................................................................................... 6
Setting the Time/Date Clock .........................................................................................7
Setting for Mechanical Engines ....................................................................................7
Start/Stop Settings .......................................................................................................8
System Throttling Types ..............................................................................................9
Transducer Types ...................................................................................................... 10
Tier 4 Emissions ......................................................................................................... 11
Unit System – Metric or English ................................................................................. 12
Operational Directions ............................................................................................................ 12
AUTO Start/Stop Sequence ....................................................................................... 12
Start Sequence .......................................................................................................... 13
Stop Sequence ........................................................................................................... 15
Manual Start/Stop Sequence ..................................................................................... 16
Special Features ........................................................................................................ 18
Menus ........................................................................................................................ 19
Inputs and Outputs ..................................................................................................... 31
General Information ................................................................................................................. 33
LCD CONTRAST ADJUSTMENT ON STARTUP ...................................................... 33
General Wiring Precautions ....................................................................................... 33
Communications ........................................................................................................ 34
ENTRY CODE SUPPLEMENT ................................................................................................. 38
LOADING PROGRAM ............................................................................................... 38
Installation ................................................................................................................................. 39
EMS PRO Mounting and Dimensions ........................................................................ 39
Specifications ........................................................................................................................... 40
NOTES
Introduction
This document is designed to support a user in getting familiar with the EMS PRO and how to navigate
the interface, modify the settings and install and operate the controller. The Quick Set Up guide assists
with establishing the different functions in the EMS PRO System Controller. Before attempting to set
up the controller, be sure to read and understand this manual in its entirety.
Product Description
The EMS PRO is a flexible, all-in-one customizable unit that meets the needs of engine-driven pumping
equipment applications. The EMS PRO is a dedicated microprocessor-based, single-engine controller.
It offers field-adjustable operating parameters that can be changed without the need for a laptop
computer. It is able to support both mechanical and J1939 electronic engines.
The EMS PRO has a selectable auto start/stop with many auto throttling options. The auto start/stop
options (Single Contact, Floats, Momentary, and Transducer) are available at the touch of a button. In
addition, there are many performance-enhancing features, all of which are available via a back-lit
operator interface that’s easy to learn and use. The display is readable day or night.
The EMS PRO is designed for use with a SCADA system, offering Modbus® RTU protocol on either the
RS232 or RS485 port. See the Modbus portion of this manual for details.
NOTE: Harness kit 40000536 is available to “bring out” the (2) wire RS485 to the
bottom of the enclosure. The RS232 is accessed via a DB9 connector located on
the display/CPU board. Customer modification to the enclosure is required to use
either port.
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User Interface and Navigation
This section defines how to navigate through the EMS PRO user interface. It will assist the user in
understanding the screens and keys used to modify settings and how each works.
Membrane Keypad
The membrane keypad is made up of eight buttons. All of the functions for the EMS PRO can be set
using these eight buttons.
ICON Description
“START” = In the “MAN” (manual) mode this will initiate a start sequence. Can be used for
local auto start if “Local Pushbutton” is selected in start/stop type, S35.
“STOP” = In the “MAN” (manual) mode this will initiate a stop sequence. Can be used for
local auto stop if “Local Pushbutton” is selected in start/stop type, S35.
“THROTTLE INCREASE” = In the “MAN” (manual) mode this will increase engine speed.
“THROTTLE DECREASE” = In the “MAN” (manual) mode this will decrease engine speed.
“MENU” = Toggles between the front display and the password window and allows user to
exit menus.
“UP” arrow = Scrolling on the front display, scrolling through and increasing values in the “S”
& “P” numbers.
“DOWN” arrow = Scrolling on the front display, scrolling through and decreasing values in the
“S” & “P” numbers.
“ENTER” = Getting into the “S” or “P” numbers group after the correct entry code is entered,
getting into an actual “S” or “P” number selected to make changes.
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Input
Description
AUTO
Functions described in the “Auto Start/Stop Sequence” of this document.
OFF
Disconnects control power to prevent the engine from starting or continuing to run through the
control panel. The OFF position provides an immediate shutdown whenever the key switch is
placed in this position while the engine is running in either the automatic or manual modes.
MAN
Functions as described in the “MAN Start/Stop Sequence” in this document.
Screens Displayed
Screen Name
Description
FW MURPHY or
This is the last line of the text page when pressing the down arrow key from
BUILD xxxxxx
Refer to the program and build number when requesting technical assistance.
PROGRAM 50333178
Refer to the program and build number when requesting technical assistance.
Key Switch
The controller accepts inputs from a 3 position key switch. The 3 positions are “AUTO”, “OFF” and
“MAN”:
Screens Displayed
During normal operation, the controller allows you to scroll through a number of informative front screen
displays by using the membrane keys. Below are several example screens.
Example Four-Up Screen Entry Code Screen
Example S-Number Screen Example P-Number Screen
The screens displayed by the EMS PRO are listed and described below:
MURPHY or
ENOVATION
CONTROLS
the default screen.
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Screens Displayed
Screen Name
Description
SELECTOR XXXX
There are three positions displayed on this line: AUTO and MAN. When a start
START”, “CLOCK START”, “SCADA START”
DAY OF THE WEEK
This line shows the present day of the week.
DD MMM YYYY
This line displays the present date.
HH:MM:SS
This line shows the present time.
STATE:
XXXXXXXXXX
The following are the different states the controller will execute during the auto
sequence:
signal is active, the display will change to show the start option being used in
place of Auto or MAN: “SINGLE CONTACT START”, “FLOAT START”,
“MOMENTARY START”, “PRESSURE START”, “LEVEL START”, “TEMP
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Screens Displayed
Screen Name
Description
STATE:
This text line displays any of the following states the controller will execute
OFF position and then back to AUTO or MAN.
FUEL XXX%
This displays the current fuel level as sensed from a sender.
SYS BAT XX.X VDC
This displays the current engine battery voltage.
SYS HRS or ECU HRS
This displays the current total engine run time. The prompt and data shown in
SELECT”. S39 will not appear when S38 is set to “MECHANICAL”.
LEAD SPD XXXX RPM
This displays the internally generated lead/command speed.
during the auto sequence:
• PANEL READY occurs when the key switch is in the AUTO position and
no shutdowns have occurred. The controller is waiting for an auto start
condition to occur.
• START DELAY occurs when a start signal is active and the start delay is
timing. The start signal must remain active throughout this delay before
the auto start sequence can continue.
• PRESTART occurs after the start delay expires. During this state, the
prestart output is turned ON. This output remains on until the engine
actually starts.
• WAIT FOR ECU occurs after the Prestart delay expires, if “ECU” is
selected in the engine type. During this state, the unit allows the ECU to
initialize prior to cranking. A “J1939 COMM FAIL” will occur if the PRO is
not receiving CAN data when this delay expires.
• CRANK ON occurs when cycle cranking begins. During this state, the
crank output is turned ON.
• CRANK OFF occurs when cycle cranking begins. During this state, the
crank output is turned OFF.
• RECRANK DELAY occurs if the engine speed drops below the “crank
stop” set point before the “shutdown lockout delay” expires. Cycle
cranking continues when this delay expires.
• WARMUP occurs after the engine starts. During this state, the engine is
throttled to the warm-up RPM until this delay expires.
• AT LOAD occurs after the Warm-up delay expires. The low discharge
pressure shutdown is armed when this delay expires.
• FILL MODE occurs after the Warm-up delay expires. During this state,
the engine is throttled to minimum rpm and held there until this delay
expires.
• STOP DELAY occurs when a stop signal is active and the stop delay is
timing. The stop signal must remain active throughout this delay before
the auto stop sequence can continue.
• COOLDOWN occurs after the Stop Delay has expired. During this state,
the engine is throttled to the cooldown rpm.
• SHUTDOWN occurs if a shutdown condition is detected. Reasons for
shutdown include low oil pressure, high engine temperature, overspeed,
etc. During this state, the engine is signaled to shutdown and all start
signals are ignored until the state is reset by moving the key switch to the
XXXX.X
this display is dependent on S38 ”ENGINE TYPE” and S39 ”ECU HOUR
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Screens Displayed
Screen Name
Description
ENG XXXX RPM
This displays the current engine RPM sensed from either a magnetic pickup
or as broadcasted from the ECU.
OIL PR XXX PSI
This displays the current engine oil pressure as sensed from an electric
gauge sender, or as broadcasted from the ECU.
ENG TEMP XXX °F
This displays the current engine jacket water temperature as sensed from an
electric gauge sender, or as broadcasted from the ECU.
DISCH PR XXX PSI
(IF SELECTED)
This displays the current discharge pressure as sensed from a transducer.
LEVEL XX.X
(IF SELECTED)
This displays the current system level as sensed from a transducer.
AMB TEMP XXX °F
(IF SELECTED)
This displays the current ambient temperature as sensed from a Murphy
Model 12 transducer.
LOCAL THROT
This is only show if Local Throttle is selected in S36.
SOOT LEVEL
This shows the soot level percentage. There are also 3 alarms associated
“REGEN NEEDED HIGH”.
UREA LEVEL
This shows the urea level percentage as broadcasted over CAN SPN 1761.
FIRST FOUR-UP
(DEFAULT SCREEN)
The first four-up screen should display Engine Oil Pressure, Engine Coolant
powering up the controller.
SECOND FOUR-UP
The second four-up screen should display Run Hours, Fuel Consumption,
icons by temporarily writing over ECU run hours, LOAD%, and FUEL RATE.
SHUTDOWN SCREEN
This screen shows the last five shutdowns that have occurred. This screen can
(IF SELECTED)
(IF SELECTED)
(IF SELECTED)
SCREEN
ECU ONLY SCREEN
Quick Set Up
with this Status sent from the ECU. The Alarms will be displayed on the
Alarm line as “REGEN NEEDED LOW”, “REGEN NEEDED MEDIUM”, or
Temp, Battery Voltage, & Engine RPM. This is the default screen when
Engine Load %, & Engine RPM. This screen can be viewed by pressing the
arrow up key from the default screen. This screen will also display (3) Tier 4
be accessed by pressing the arrow up key past the four-up screen(s).
This section is to help in setting portions of the program in which cover the primary uses of this
controller. The steps below will only cover how to change certain portions of the program to better suit
your application. There are other parameters to be setup in the menus before the unit is placed in
service.
NOTE: This section is used as a reference guide and this entire document
should be completely read and understood before ever placing the controller into
service.
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Setting the Time/Date Clock
Setting up the clock is critical to many of the other functions of the EMS PRO. Use the following steps
to set the EMS PRO Clock. The clock includes the time (displayed in 24hr format), the date and the day
of the week.
1. Access the S numbers menu by pressing [Menu].
2. Use the [Up Arrow] and [Down Arrow] to scroll to the correct Entry Code (See Entry Code
Supplement for Entry Codes).
3. When the correct Entry Code is displayed, press [Enter] to access the S numbers menu.
NOTE: If the incorrect code is entered, “PASSWORD FAILURE” will appear on
the display. Press [Enter] and try again.
NOTE: (S1 - S6) are the S-Numbers used to set the clock. See the S number
section of this manual for details.
4. Press [Up Arrow] and [Down Arrow] to scroll through the S-Numbers.
5. Press [Enter] when displaying the correct S number to highlight the current setting.
6. Use the [Up Arrow] and [Down Arrow] to enter the correct setting in the S number.
7. Press [Enter] to un-highlight the value and to move to another S number.
8. Repeat steps 4 through 7 for each clock and date setting.
9. When setup is complete, exit the S Menu by pressing [Menu].
NOTE: The user must be out of the S or P number (un-highlighted) to exit the
menu.
NOTE: Accessing the S or P numbers to change any set point is done in the
same manner as above.
10. Verify the clock is set to the current time, date and day of the week.
Setting for Mechanical Engines
The EMS PRO Controller factory defaults are set to run on an ECU equipped engine. In order to set
the controller to work on a mechanical engine, follow the steps below:
1. Access the S numbers menu by pressing [Menu].
2. Use the [Up Arrow] and [Down Arrow] to scroll to the correct Entry Code (See Entry Code
Supplement for Entry Codes).
3. When the correct Entry Code is displayed, press [Enter] to access the S numbers menu.
NOTE: If the incorrect code is entered, “PASSWORD FAILURE” will appear on
the display. Press [Enter] and try again.
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NOTE: (S7, 38 & 40) are the S-Numbers used to set the controller for a
mechanical engine. See the S number section of this manual for details.
4. Press the [Up Arrow] and [Down Arrow] until (S38) ENGINE TYPE is displayed, press [Enter]
to highlight the current setting.
5. Press the [Up Arrow] and [Down Arrow] until MECHANICAL is displayed, press [Enter] to un-
highlight the new setting.
6. Press the [Up Arrow] and [Down Arrow] until (S40) ENG THR TYPE is displayed, press
[Enter] to highlight the current setting.
7. Press the [Up Arrow] and [Down Arrow] until MECHANICAL is highlighted then press [Enter]
to un-highlight the new setting.
8. Press the [Up Arrow] and [Down Arrow] until (S7) SPEED CALIB is displayed, press [Enter]
to highlight the current setting.
9. Press the [Up Arrow] and [Down Arrow] to enter the number of teeth on the engine’s flywheel
ring gear and press [Enter] to un-highlight the new setting.
10. Exit the S Menu by pressing [Menu].
NOTE: For mechanical engine throttling, see the PCBA SHUNTS section of this
manual for details.
Start/Stop Settings
There are five start/stop types in S35: SINGLE CONTACT, FLOATS, MOMENTARY, TRANSDUCER,
LOCAL PB (GREEN AND RED PUSHBUTTONS).
Single Contact Start/Stop:
The Single Contact Start/Stop is when a remote contact closes and remains closed for auto start, and
re-opens for auto stop.
(2) Float Start/Stop:
The (2) Float Start/Stop is when both float contacts are closed for auto start, and both float contacts are
open for auto stop.
Momentary Start/Stop:
The Momentary Start/Stop is when a contact closes momentarily for auto start, and a second contact
closes momentarily for auto stop.
Transducer Start/Stop:
A transducer is used for auto throttling. There are set points, allowing the operator to enter the
appropriate values.
Local Pushbutton Start/Stop:
The Local Pushbutton Start/Stop is when the local panel mounted green and red pushbuttons are used
for auto start/stop.
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Use the following steps to select the correct start/stop:
1. Access the S numbers menu by pressing [Menu].
2. Use the [Up Arrow] and [Down Arrow] to scroll to the correct Entry Code (See Entry Code
Supplement for Entry Codes).
3. When the correct Entry Code is displayed, press [Enter] to access the S numbers menu.
NOTE: If the incorrect code is entered, “PASSWORD FAILURE” will appear on
the display. Press [Enter] and try again.
NOTE: S35 is the S-Number used for the start/stop type. See the S number
section of this manual for details.
4. Press the [Up Arrow] and [Down Arrow] until (S35) START/STOP SELECT is displayed,
press [Enter] to highlight the current setting.
5. Press the [Up Arrow] and [Down Arrow] until the desired selection is displayed, press
[Enter] to un-highlight the new setting.
6. Exit the S Menu by pressing [Menu].
System Throttling Types
There are (3) throttling types in S37: MAX. RPM, TRANSDUCER, LOCAL THROTTLE.
Max. RPM:
The Engine is throttled to the max. rpm set point.
Transducer:
A transducer is used for auto throttling. There are set points, allowing the operator to enter the
appropriate values.
Local Throttle:
An external 0-5 vdc potentiometer is used for auto throttling. There are set points, allowing the operator
to enter the appropriate values.
Use the following steps to select the correct transducer type:
1. Access the S numbers menu by pressing [Menu].
2. Use the [Up Arrow] and [Down Arrow] to scroll to the correct Entry Code (See Entry Code
Supplement for Entry Codes).
3. When the correct Entry Code is displayed, press [Enter] to access the S numbers menu.
NOTE: If the incorrect code is entered, “PASSWORD FAILURE” will appear on
the display. Press [Enter] and try again.
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NOTE: S36 is the S-Number used for the transducer type. See the S number
section of this manual for details.
4. Press the [Up Arrow] and [Down Arrow] until (S36) SYSTEM THROTTLE TYPE is
displayed, press [Enter] to highlight the current setting.
5. Press the [Up Arrow] and [Down Arrow] until the desired selection is displayed, press
[Enter] to un-highlight the new setting.
6. Exit the S Menu by pressing [Menu].
Transducer Types
There are (10) transducer types in S37: NONE -- PRESSURE CONTROL -- LEVEL CONTROL -TEMPERATURE CONTROL -- PRESSURE CONTROL / LEVEL DISPLAY -- LEVEL CONTROL /
PRESSURE DISPLAY -- PRESSURE DISPLAY -- LEVEL DISPLAY --PRESSURE CONTROL / FLOW
STOP -- PRESSURE CONTROL / FLOW STOP & THROTTLE. Below are the step-by-step instructions
to set up these options.
None:
There is no transducer wired to the controller.
Pressure Control:
Pressure start/stop and throttling.
Level Control:
Level start/stop and throttling.
Temperature Control:
Temperature start/stop. Throttling to the maximum rpm set point will occur.
Pressure Control / Level Display:
Pressure start/stop, throttling, and level displayed with high and low alarms.
Level Control / Pressure Display:
Level start/stop, throttling, and pressure displayed with high and low shutdowns.
Pressure Display:
Pressure is displayed with high and low shutdowns.
Level Display:
Level is displayed with high and low alarm.
Pressure Control / Flow Stop:
Pressure start, throttling, and flow stop.
Pressure Control / Flow Stop & Throttle:
Pressure start, flow stop, and flow throttling.
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