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Genset Controller EMC-01
Introduction
EMC-01 is a diesel generator controller designed for small Gensets (3.5KVA-12.5KVA)
sold in the private market segment. The unit incorporates Manual and Auto-Start input initiated
start and stop sequencing, monitors engine and alternator operating parameters
and provides both engine and alternator protection in a single integrated package.
The Genset's operating parameters are shown in sequence on a four character seven segment
LED display.
Separate LEDs indicate which parameter is currently being shown. Alarms and Warnings are
indicated on the seven segment display using Error Codes which are printed on the front label.
The unit provides monitoring of the engine and generator operating parameters and provides
automatic shutdown of the set in the event of damaging conditions. In regards to engine
protection the unit monitors oil pressure, fuel level and engine temperature to provide
protection. For alternator protection, it monitors AC voltage, frequency and load and if any
parameter goes beyond the safe operating limits the unit shuts down the Genset.
Benefits
• Reduces system cost.
• Integrates engine gauges and AC metering into one unit.
• No need of external Current Transformer, as it has on-board CT (0-64A).
• Minimizes control panel wiring offering reduced material and labour costs.
• Reduces warranty costs by providing comprehensive engine and generator protection.
EMC - Operation and Maintenance Manual
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Summary of Contents for Procom EMC-01
- Page 1 Genset Controller EMC-01 Introduction EMC-01 is a diesel generator controller designed for small Gensets (3.5KVA-12.5KVA) sold in the private market segment. The unit incorporates Manual and Auto-Start input initiated start and stop sequencing, monitors engine and alternator operating parameters and provides both engine and alternator protection in a single integrated package.
- Page 2 Physical Form Figure 1: EMC-01- Front View Figure 2: EMC-01 Rear View EMC - Operation and Maintenance Manual...
- Page 3 System Diagram Figure 4 and 5 shows the field view and system level diagram of EMC-01 & EMC-02. Engine Monitoring System Level Diagram EMC - Operation and Maintenance Manual...
- Page 4 Functions System Functions Description Engine Monitoring Functions Description Alternator AC Monitoring Functions Description EMC - Operation and Maintenance Manual...
- Page 5 System LED Indications Functions Description Engine 7-Segment LED Displays Functions Description Alternator 7-Segment LED Displays Functions Description EMC - Operation and Maintenance Manual...
- Page 6 AC Inputs Functions Description Analog Inputs Functions Description Digital Inputs Functions Description Digital Inputs Functions Description EMC - Operation and Maintenance Manual...
- Page 7 Digital Outputs Functions Description Operations Start The unit supports three types of Starts , i.e., External / Key Switch Start : When the Key Switch is turned to ON position, the unit powers up, shows ”Strt” on its LED Display and activates the Pre-Heat output for the configured time (only available in EMS733).
- Page 8 it sees Oil Pressure and/or AC Frequency otherwise it jumps to Ready state at the end of 30 seconds. Manual Start : In response to the front panel push button the unit performs a fully sequenced engine start. Auto Start : In response to a digital input the unit performs a fully sequenced engine start. Run Up Once the engine starts the unit goes in Run Up state and LED display shows ”runP”.
- Page 9 FIGURE : RMP DISPLAY FIGURE : RMP DISPLAY FIGURE : OVER FREQUENCY FIGURE : OVER CURRENT If any of the alternator or engine measurements move outside operational limits the unit deactivates the Fuel Control Output to shut down the engine, if required and display the respective Error Code on the LED display. EMC - Operation and Maintenance Manual...
- Page 10 Speed Sensing The unit obtains the speed information from the Generator AC output and shows the AC frequency and the Engine RPM on its 4-Digit LED display. AC Current Measurement The unit measures AC current with the help of an on-board CT. Since the controller is designed to be used with 3.5KVA to 12.5KVA sets so a 64A/25mA CT is used to cover the whole range.
- Page 11 Shut Down To shut down the engine, simply turn off the key switch or Press the the Manual Stop Button. The unit will deactivate the Fuel Control Output causing the engine to shut down. If the unit still sees Oil pressure and/or AC Frequency, 30 seconds after deactivating the fuel output, it will raise a Failed to Stop Alarm.
- Page 12 If AC current goes above set limit for more than E 24 Over Current Alarm the configured time If one minute after pressing Manual Start button or activating Auto Start input the unit E 25 Failed To Start Alarm doesn’t see oil pressure and AC frequency If the unit sees oil pressure or AC frequency, 30 E 26 Failed To Stop Alarm...
- Page 13 Battery Voltage Internal High Impedance Generator Phase 1 Volts. Max AC Voltage 300VRMS AC Voltage Generator Neutral. Max 300VRMS AC Amperes Phase 1 Amps. Max 64A Outputs Electrical Specifications Output Type Comment 300mA Open Drain protected coil drive. Max 18VDC Fuel Solenoid Open Drain This output is used to maintain the fuel...
- Page 14 Unit General Specifications Feature Specifications Overall Dimensions 96 x 96 mm (Bezel) x 28 mm behin d bezel IP Rating IP51 front, IP20 rear Supply Voltage 8 V to 18V DC Operating -20 to +70C Temperature Storage Temperatur -20 to +70C Relative Humidity 95% non condensing Supply Current...
- Page 15 Connect the wires as per the labelling done in back sticker: • The unit is a complex electronic device and caution should be taken to ensure correctwiring before power is applied. • The unit is fitted with a 10 way Molex Minifit or equivalent socket connector for which mating plugs can be selected from Amp PE or TPK range.
- Page 16 Fuel Output (Low Side Relay Driver) Crank Output (Low Side Relay Driver) Contactor A (Low Side Relay Driver) - For EMS324 Pre-Heat - For EMS733 Contactor B (Low Side Relay Driver) Low Fuel Level Switch (Close on Fault) High Engine Temperature Switch (Close on Fault) Low Oil Pressure (Close on Fault) Auto Start Input (Close to 0V to activate) Not Connected...
- Page 17 5KVA at PF = 5KVA at PF = 0. 7.5KVA at PF = 0. 10KVA at PF = 0. 12.5KVA at PF = 0. Required Loops around CT and Position of DIP Switches EMC - Operation and Maintenance Manual...
- Page 18 Recommended Wiring Diagram EMC - Operation and Maintenance Manual...
- Page 19 EMC - Operation and Maintenance Manual...
- Page 20 Notes • All outputs are rated at 300mA maximum. • All relays must be used and installed in the DG panel. • Fuse (F1) must be used and installed near the power source, i.e., DG battery. • Keep DG battery voltage (12V) in mind and use appropriate relay (coil voltage needs to be looked at). •...
- Page 21 Turn the Key Switch at ON position and check whether the Fuel Fuel Output Output is properly driving the external relay or no Connect the Fuel relay coil directly across battery to verify that External Fuel Relay it is still operational. Low Fuel Check the Fuel tank and fill it up if fuel level is very low.
- Page 22 Low Genset Voltage Alarm. Genset voltage has gone below E 22 207V for more than 3 seconds. Over Current Alarm. Current has exceeded the limit. E 24 Failed To Stop Alarm. It means even 30 seconds after deactivating Fuel Solenoid output the unit is still seeing Oil Pressure or AC frequency.
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