Diesel Engine Controller 업체자료

DIESEL FIRE PUMP CONTROLLER INSTRUCTION MANUAL
SERIAL NO.
MODEL NO.
DEC
FOR ENGINE
CLARKE, CUMMINS, CATERPILLAR & DEUTZ
MASTER CONTROL SYSTEMS, INC.

P.O. BOX 276 910 NORTH SHORE DRIVE LAKE BLUFF, ILLINOIS 60044, USA TELEPHONE: 847-295-1010 FAX: 847-295-0704 www.mastercontrols.com
Forward
MASTER DEC Series Diesel Engine Fire Pump Controllers are of the Combined Manual and Automatic type; for the control of internal combustion engines driving centrifugal pumps. Controller operation is strictly in accordance with the latest requirements of the National Fire Protection Association Standard NFPA-20 on Stationary Fire Pumps. The fundamental purpose of this controller is to automatically start an engine driven fire pump to provide the required volume and pressure for proper operation of the sprinkler system in the event of a fire in the properties protected by the system. The Start Signal is usually obtained from the Pressure Control Switch included in the controller. Basic Model DEC controllers are used with listed or approved fire pump engines. When additional options are included in the controller, the appropriate option symbol is included in the model number shown on the nameplate of the controller as follows: General Options RA or DA H M 1 2 4 5 6 7 8 9 0 X DPR DR G1 Included in G1 Group Option YES YES YES YES YES Description Built-in Dual Battery Charger and Alarm Energize to Stop (Caterpillar, Deutz and others) Manual, Non-Automatic (removes pressure transducer and adds test relay) Automatic Stop w/ Minimum Running Period Timer Electric Motor Lockout (including Dual Drive) Remote Start Inputs for Deluge Start and Remote Start Pushbutton A.C. Power Failure Start (Time Delayed) Gas or Gasoline Engines (No Overspeed Signal, Retrofit Only) Contacts for Individual Remote Signals Timed Energized to Stop (Diesel Engine) Sequence Start (Time Delayed) Pump House Alarm and Signals (Per NFPA 20) Other Controller Modifications (Modifier Code) Digital Pressure Recorder Digital Pressure and Alarm Recorder Combines options RA, H, 1, 4, 5, 9, 0, DPR, 17A, 21
YES YES YES
Consult Master Control Systems for additional Modifications or Options available.
-1Master Control Systems, Inc.

DEC Issue 02-v02
Lake Bluff, Illinois

2009.08.3
Table of Contents
Forward Page 1 Table of Contents. Page 2 DEC Controller Outside View Labeled Diagram Page 3 DEC Controller Inside View Labeled Diagram... Page 4 Installation of Controller.. Page 5 Wiring of Controller. Page 5 Main Engine to Controller Wiring Table. Page 6 A.C. Wiring Table Page 6 Input Alarm Signal Wiring Table Page 7 Controller Input Signal Wiring Table.. Page 7 Remote Alarm Contact Wiring Table.. Page 7 Installation of Main Selector Switch Hinge. Page 8 Factory Default Switch Settings.. Page 9 - Weekly Test, Minimum Run Timer, Sequence Start, AC Power Factory Default Jumper Settings..Page 10 Pressure Switch Adjustments... Page 11 Pressure Settings...Page 12 Start-Up Procedures.Page 14 Controller Operating Instructions.... Page 17 Operation of Model MBC3 Dual Battery Charger... Page 23 Option RA Battery Charger Failure Alarm.. Page 25 Weekly Maintenance Procedures. Page 26 Replacement Parts List.Page 28 Model PR4001 Paperless Pressure and Alarm Recorder New Document listed after Replacement Parts List Drawings: Controller Schematic Diagram Built-in Battery Charger Schematic Diagram External Wiring Diagram Piping Connection

DEC Issue 02-v02

2009.08.3
DEC Controller -Labeled DiagramsOutside View 1) Bulkhead Pressure Connections

k
2) RESET Pushbutton
k
3) Audible Alarm
k
4) TEST Pushbutton
k
5) STOP Pushbutton
Note: The Y-Strainer, exclusive to Master Control Systems, prevents debris from entering the drain valve solenoid.
6) START Pushbutton
k
7) Main Selector Switch (behind hinge) a. AUTO Position b. OFF Position c. MAN Position
k
8) PR4001 Display a. Alarm History / Pressure History b. Scroll Up / Scroll Down c. Check-In / Off
k
9) Battery (BATT) 1 and 2 Selector Switch

k
10) Y-Strainer
k
11) Drain Valve Solenoid

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Inside View
12) Master Battery Charger (MBC3C) 13) Diesel Control Engine Interface (DC-EIF) 14) Customer Terminal Bar 1 (CTB1) 15) Pressure Switch (PS) -See P. 11 for details. 16) Display Box
Note: CTB3, which is the input for the AC power, is covered with an insulating material for electrical safety purposes.
17) Paperless Recorder xPN -See P. 29 for details. 18) Customer Terminal Bar 2 (CTB2) 19) Customer Terminal Bar 3 (CTB3) 20) Customer Terminal Bar 4 (CTB4) 21) Diesel Control Chassis Unit (DC-CU)
(CTB1-CTB4 MAY BE FOUND ON DRAWING 17100)

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Installation of the Controller

The Controller should be located as close to the engine as is practical, preferably 25 or less. These controllers are also designed for wall mounting using the hanger bracket supplied. Controllers should be bolted solidly by means of expansion bolts through holes provided in support brackets. These controllers are also designed for mounting on the common base of the engine and pump when additional mounting legs are used. When so installed, use adequate bracing and suitable vibration dampers to keep vibration to a minimum. The pressure connection to the controller must be installed as shown in the NFPA Pamphlet No. 20. See the piping diagram in the drawing section of this Instruction Manual.
Wiring of the Controller (see the following tables)

Wire terminals 1 through 12, 301 and 302 on CTB1 of the DC-EIF chassis to the corresponding numbers on the engine terminal bar in the engine junction box. Always use flexible stranded wire that is not affected by water, oil, or engine heat and terminate with ring lugs. Terminal 7 should only be connected with engines that only use a 20 amp alternator and rely on the controller to provide Control Battery to the engine circuits. Wire terminals 16 and 17 on CTB3 of the DC-EIF chassis to the A.C. power (mains) branch circuit at the controller nameplate voltage and frequency. Chassis grounding is terminated on terminal 15. Do not exceed ampere limits shown on the External Wiring Diagram. Wire terminals 18 through 25 on CTB2 of the DC-EIF chassis to the corresponding Input Alarm Signals. These are for dry contacts in the pump room that close terminals 19 through 25 to terminal 18 to activate the alarm. Typically, these alarms are: Low Fuel Level, System Overpressure, Reservoir Level Low, Reservoir Empty, Flow Meter Open, Pump Room Temp Low, Relief Valve Open. Wire terminals 31 through 34 on CTB4 of the DC-CU chassis to the corresponding Controller Input Signals. These are for dry contacts that open between 31 and 32 for Deluge Starting, and that open between 31 and 33 for Remote Starting. Contacts close between 31 and 34 for lockout. Wire to terminals 26 through 28 (10 Amp, form C contacts) on CTB2 of the DC-EIF chassis for remote indication of Engine Running. Wire to terminals 5 through 7 (1 Amp, form C contacts) on CTB4 of the DC-CU chassis for remote indication of Engine Running. Wire to terminals 8 through 10 (1 Amp, form C contacts) on CTB4 of the DC-CU chassis for remote indication of Engine Failure. Wire to terminals 11 through 13 (1 Amp, form C contacts) on CTB4 of the DC-CU chassis for remote indication of Switch Off. Wire to terminals 14 through 16 (1 Amp, form C contacts) on CTB4 of the DC-CU chassis for remote indication of Pumphouse Trouble.

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Main Engine to Controller Wiring Table DC-EIF

Terminal 25 Max. Run
Minimum Wire Size (AWG)

Metric (mm2) 50 Max Run Metric (mm2) Max Amps Function
CTB1-1 CBT1-2 CTB1-3 CTB1-4 CTB1-5 CTB1-6** CTB1-7* CTB1-8** CTB1-9 CTB1-10 CTB1-11A CTB1-11B CTB1-12* CTB1-301* CTB1-302*
#14 #16 #16 #16 #16 #12 #12 #12 #14 #14 #10 or 2 #12 #10 or 2 #12 #14 #16 #16
2.1 1.3 1.3 1.3 1.3 3.3 3.3 3.3 2.1 2.1 1x 5.3 or 2x 3.3 1x 5.3 or 2x 3.3 2.1 1.3 1.3
#14 #16 #16 #16 #16
2.1 1.3 1.3 1.3 1.3
10A 1A 1A 1A 1A 20A 20A 20A 10A 10A 20A 20A 10A 1A 1A
Fuel / Water Crank Terminate OVS LOP HWT Bat. #1 C.B. Bat. #2 Crank #1 Crank #2 Ground Ground SDS Alternate ECM Injector Failure
1 #10 or 2 #12 1x 5.3 or 2x 3.3 #12 3.3
1 #10 or 2 #12 1x 5.3 or 2x 3.3 #14 #14 1 #8 or 2 #10 1 #8 or 2 #10 #14 #16 #16 2.1 2.1 1x 8.4 or 2x 5.3 1x 8.4 or 2x 5.3 2.1 1.3 1.3
*When used. ** For 10 amp chargers.

CAUTION DO NOT CONNECT OR DISCONNECT BATTERY LEADS WITH ANY LOADS CONNECTED IN ORDER TO PREVENT ARCS OR SPARKS AT OR NEAR THE BATTERY.
DC-EIF
Terminal 25 Max Run
A.C. Wiring Connections Minimum Wire Size (AWG)

Metric (mm2) 50 Max Run Metric (mm2) Max Amps Function
CTB3-15 #14 2.1 #14 CTB3-16 #14 2.1 #14 CTB3-17*** #14 2.1 #14 *** Except also Line (hot) for 230/240 Vac @ 60 Hz.
2.1 2.1 2.1
n/a 12A 12A
Cabinet Ground A.C. Line A.C. Neutral
CAUTION ALWAYS DISCONNECT, TURN OFF, OR REMOVE A.C. POWER FROM CHARGER BEFORE CONNECTING OR DISCONNECTING CHARGER OR BATTERY LEADS.

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2009.08.3
DC-EIF
Terminal
Input Alarm Signal Connections Minimum Wire Size

AWG Metric (mm2) Function
CTB2-18 CTB2-19 CTB2-20* CTB2-21* CTB2-22* CTB2-23* CTB2-24* CTB2-25* *When used.
#16 #16 #16 #16 #16 #16 #16 #16
1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3
Alarm Common Low Fuel Level System Overpressure Reservoir Level Low Reservoir Emtpy Flow Meter Open Pump Room Temp Low Relief Valve Open
DC-CU
Terminal
Controller Input Signals Minimum Wire Size

CTB4-31 CTB4-32* CTB4-33* CTB4-34* *When used.
#16 #16 #16 #16
1.3 1.3 1.3 1.3
Signal Common for CTB4-2, CTB4-3, and CTB4-4 Deluge Start Input, Open to Start, Max. Burden 0.2 Adc at Engine Battery Voltage Remote Momentary Start Input, Open to Start, Max. Burden 0.2 Adc Lockout Input, Close to Lockout AC Fail, Deluge, Pressure Start.
DC-CU
Terminal
Remote Alarm Contacts Minimum Wire Size

CTB2-26, 27, 28* CTB4-35,36,37 CTB4-38,39,40
#16 #16 #16
1.3 1.3 1.3
CTB4-41,42,43 CTB4-44,45,46 *When used.
#16 #16
1.3 1.3
Extra 10 Amp. Engine Run Contacts (Mod. 17A, G1 Engine Running Alarm Contacts Remote Engine Failure Alarm Contacts (Bat. 1 failure, Bat. 2 failure, Charger Failure, Low Oil Pressure, High Water Temperature, Overspeed, Failure to Start, Alt. ECM, Injection Failure Remote Switch OFF Alarm Contacts (or not in Auto) Remote Pump House Trouble Alarm Contacts (any Pump House Trouble Alarm)

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Assembling and Attaching Main Selector Switch Hinge

INSTALLING THE HINGE: 1. Slide the glass rod into the hinge by pushing the ends of the rod together until it fits cleanly, as shown below in Picture A. The hinge should now be ready to be installed (Picture B).
Picture A
Picture B
2. Turn the hinge over and place one end into Hole A first, then push the other end of the rod together allowing the glass rod to contract and fit cleanly in both holes.
Push glass rod together
Hole A
Picture C

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Factory Default Switch Settings

On the DC-CU there are switches that can be set for various timing functions such as Minimum run, AC Power Fail Start, and Sequence Start. -These are fully described on the following pages: Minimum Run (P. 19), AC Power Fail Start (P. 20), and Sequence Start (P. 21).
Minimum Run Timer (factory default Off) 0 = Off 1 = 2 Minutes (2 Min. per Division) AC Power Fail Start (factory default Off) 0 = Off 1 = 20 Seconds (20 Sec. per Division)
Sequence Start (factory default Off) 0 = Off 1 = 5 Seconds (5 Sec. per Division)
Weekly Test Pushbutton

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2009.08.3
Factory Default Jumper Settings

Behind the cover plate on the DC-CU, there are jumpers that can be used to enable or disable various functions such as Lockout, Remote Start, Deluge Start, or Weekly Test. These are fully described under the controller operation section. NOTE: To set the Weekly Test Sequence, first enable the Weekly Test Jumper by moving the Weekly Test Jumper (shown in Picture 1) one pin to the right. Then, simply press the Weekly Test Pushbutton. When pressed, the controller will remember that day and time during the week and initiate the test at the same time indefinitely. If you wish to change the testing time, just push the button at the desired day and time and the new time will be automatically saved. To disable, move the Weekly Test Jumper back to the position shown in Picture 1 below or remove the Weekly Test Jumper.
Lockout Jumper (factory default disable) Remote Start Jumper (factory default disable)
Jumper
Deluge Start Jumper (factory default disable)
Weekly Test Pushbutton
Weekly Test Jumper (factory default disabled)
(Picture 1) (Picture 2)
- 10 Master Control Systems, Inc.

DEC Issue 02-v02

2009.08.3
Pressure Setting Adjustments

To adjust the Trip and Reset points of the pressure switch, hold the toggle switch up towards the Reset potentiometer or down towards the Trip potentiometer and rotate the potentiometer while watching the display on the front of the cabinet. The potentiometers have a full range of 10 turns.
The Trip and Reset settings are changed by turning the 10 turn trip and reset potentiometers either clockwise to increase, or counterclockwise to decrease.

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PRESSURE SETTINGS
NOTE: When adjusting the Reset Setting or Trip Setting, first find out which direction you need to adjust the setting. If you need to adjust the Trip Setting up, you cannot adjust it past the Reset Setting without first adjusting the Reset Setting up. The two functions cannot overlap one another at any time, and will refuse to cross over each other. -In the following example imagine the two points as labeled on the diagram below (Note: the settings will not always be starting at 90 and 70): Example 1 Desired Trip Setting: 100 Desired Trip Setting: 100 Reset Setting: 90 Trip Setting: 70
Your Reset Setting is at 90, and your Trip Setting is at 70. You wish to adjust the Trip Setting up to 100. You must first adjust the Reset Setting above 100, then you can adjust the Trip Setting up to 100. Note: if you attempt to adjust the Trip Setting first it will refuse to set above 90, as this is limited by the Reset Setting which is set at 90. Continuing in the example of how to adjust the Trip Setting to 100: STEP 2 NEW Reset Setting: 110 Old Reset Setting: 90 Trip Setting: 70 As you see in Step 2 we move the Reset Setting above 100 before adjusting the Trip Setting. Notice that the new Reset Setting is now 110. This allows a 10 PSI differential with the Trip Setting goal of 100. The typical differential between the Reset Setting and Trip Setting is 10 PSI, although you may go as low as 3 PSI. STEP 3 Reset Setting: 110 NEW Trip Setting: 100 Old Trip Setting: 70
Lastly, in Step 3 we adjust the Trip Setting up to our goal of 100.

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PRESSURE SETTINGS Continued

Example 2 Desired Reset Setting: 60 Reset Setting: 90 Trip Setting: 70 Desired Reset Setting: 60
Another example Your Reset Setting is at 90, and your Trip Setting is at 70. You wish to adjust the Reset Setting to 60. You must first adjust the Trip Setting down below 60 by the appropriate differential of at least 3 PSI (the typical differential is 10). This then allows you to adjust the Reset Setting to 60. STEP 2
Reset Setting: 90 Old Trip Setting: 70 New Trip Setting: 50
As you can see in Step 2 we first lower the Trip Setting below the desired Reset Setting of 60. STEP 3 Old Reset Setting: 90 New Reset Setting: 60 Trip Setting: 50
We now adjust the Reset Setting down to the desired level of 60.

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START-UP PROCEDURES
The following tests are required on each new installation. It is recommended that they be repeated yearly to prove the reliability of the controller, engine, and battery equipment. NOTE: When tests are completed, be certain to return the control switch to the "AUTO" position. I. Manual Starting
NOTE: Before starting energize to stop engines, verify that battery voltage is present at Terminal 12 when the Main Selector Switch is in the OFF position. If not, contact factory before starting engine. A. B. C. D. E. F. G. Place Main Selector Switch in the MANUAL position. Place the Battery Selector Switch in the BAT1 position. Depress Manual START Pushbutton and release when engine starts. Turn control switch to OFF position to stop engine. Place Battery Selector Switch in the BAT2 position. Depress Manual START Pushbutton and release when engine starts. Turn control switch to OFF position to stop engine. NOTE: Observe battery voltage while cranking. If voltage drops below 75% of nominal, it may be an indication of impending battery failure.
II.
Cranking Cycle Test This test simulates a condition when the engine refuses to start as covered in the preceding "OPERATION OF PANEL" sequence. A. B. Contact the engine manufacture to determine how to disable the engine fuel circuit. Place the Main Selector Switch in the AUTO position. Push the TEST pushbutton. The Drain Valve Solenoid will open to create a Pressure Drop and initiate cranking of the engine. The engine should crank six times after which the audible alarm will sound, the Failure to Start signal light will energize and the Remote Engine Failure Alarm will be energized. Return Main Selector Switch to the OFF position, reconnect Terminal No. 1, and all engine devices, if previously disconnected. Drain Valve Solenoid will continue to dump water until control switch is placed in OFF position.
C. D. III.
Checking Starting Motor Release A. Place Main Selector Switch in the AUTO position and press the TEST pushbutton. Engine should start promptly and the starting motor should release at approximately 1/3 engine speed. Check that the starter releases by watching the LEDs on Terminal 2, 9 or 10. Verify that the Terminal 9 or 10 LED goes Off when the Terminal 2 LED goes On. B. Return switch to OFF position to stop engine. Oil Pressure Failure Test A. Place Main Selector Switch in the AUTO position and press the TEST pushbutton to start the engine. B. Connect temporary jumper between terminal of oil pressure switch (jumper CTB1-4 and CTB1-11A or CTB1-11B) and battery common. Engine Failure Alarm will operate approximately 10 seconds later. C. Turn switch to OFF position to stop engine. D. Remove jumper from oil switch.
IV.
NOTE: Whenever the engine is started, the oil pressure light will come on momentarily and go off when engine builds up oil pressure. This indicates oil pressure switch is operating properly.

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START-UP PROCEDURE - Continued

V. High Water Temperature Test A. Place Main Selector Switch in the AUTO position and press the TEST pushbutton to start the engine. B. Connect temporary jumper between terminal of water temperature switch and battery common (CTB1-5 to CTB1-11A or CTB1-11B). C. Alarm bell should sound and Remote Engine Failure Alarm should operate, and water temperature signal light in controller should come on immediately. D. Turn switch to OFF position to stop engine. E. Remove jumper from water temperature switch. Pump House Alarm Test (Option "O", G1) A. Place Main Selector switch in AUTO position. B. Connect temporary jumper between terminals 18 and 19 on CTB2 of the DC-EIF chassis. The audible alarm will sound, the Remote Pump House Trouble Alarm should operate, and the Low Fuel Level signal will light. Press the RESET pushbutton to silence the audible alarm. The controller audible alarm will silence while the Remote Pump House Alarm and signal light will remain on. Remove the jumper and the remote alarm and signal light should go off. C. Repeat step B. With terminals 20 for "System Overpressure" (if present). D. Repeat step B. With terminals 21 for "Reservoir Level Low" (if present). E. Repeat step B. With terminals 22 for "Reservoir Empty" (if present). F. Repeat step B. With terminals 23 for "Flow Meter Open" (if present). G. Repeat step B. With terminals 24 for "Pump Room Temp Low" (if present). H. Repeat step B. With terminals 25 for "Relief Valve Open" lamp (if present). Overspeed Test (NOT applicable to controllers equipped with Option "6") A. Place Main Selector Switch in the AUTO position and press the TEST pushbutton to start the engine. B. Operate the Overspeed test switch on the engine mounted control panel, if provided. If not, momentarily jumper terminal 3 to terminal 7. Engine should shutdown, alarm should sound, the overspeed signal lamp should light, and the remote engine failure alarm should operate and remain energized without the jumper. C. Turn switch to OFF position to reset signals. Power Failure Alarm Test (Controllers without Option "5", G1) A. Place Main Selector Switch in the AUTO position. B. Open the 115 Vac circuit to the controller at any convenient point. The A.C. Failure Signal Lamp and Remote Engine Failure Alarm should both operate. (Controller audible alarm is NOT energized). C. Reconnect 115 Vac
VI.
VII.
VIII.
IX.
AC Power Failure Starting Test (Only for controllers equipped with Option "5", G1) A. Place Main Selector Switch in the AUTO position. B. Open the 115 Vac circuit to the controller at any convenient point. C. After delay, depending on the time setting, which is usually set at approximately 10 seconds, engine should start and continue to run. Reconnect 115 Vac D. Turn switch to OFF position to stop engine or depress STOP pushbutton to stop engine.
NOTE: On controllers that have AUTOMATIC stop, the engine will run for the time setting on the DC-CU chassis, provided the power has been restored, and then stop automatically.

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START-UP PROCEDURE - Continued

X. Pressure Starting Test A. Place Main Selector Switch in the AUTO position. B. Drain down the pressure in system until a pressure start occurs. C. Engine should start automatically. AFTER engine has started, close the drain. D. Engine should continue to run even after pressure has been restored to normal. E. Turn switch to OFF or depress STOP pushbutton to stop engine.
NOTE: On controllers which have AUTOMATIC STOP, the engine, when started from pressure switch or deluge start contact, will run for the time delay set or until the pressure or deluge demand is reset, whichever takes longer. STOP button will not stop engine, unless demand has cleared. XI. Remote / Deluge Starting Test (For controllers equipped with Option "4", G1) A. Place Main Selector Switch in AUTO position. B. Operate a remote starting contact or disconnect the wire from CTB4, terminal #33 on the DC-CU chassis. Use terminal #32 for Deluge Valve starting. C. Engine should start automatically and continue to run even after the circuit to terminal #32 or #33 has been re-established. Minimum Run shutdown only works with Deluge. D. Place switch in OFF position or depress STOP pushbutton to stop engine. Automatic Weekly Starting Test (Weekly Test Start when enabled See P.10) A. Place Main Control Switch in AUTO position. B. Press the Weekly Test button on the DC-CU chassis. C. Drain Valve Solenoid will energize and dump water to cause a pressure loss start. E. Engine will start and run for 30 minutes. The Drain Valve will close after engine is running. F. After 30 minutes, the engine will stop. G. Weekly test will occur again seven days later at the same time that the weekly test button was last pressed. It can be defeated by removing the jumper in the DC-CU chassis (See P.10). Battery Failure Test A. Place Main Selector Switch in AUTO position. B. Temporarily disconnect the battery charger by opening the 115 Vac circuit to the controller at any convenient point.
XII.
XIII.
NOTE: If controller is equipped with option "5"(G1), Power Failure Start, set the rotary switch on the DC-CU chassis to 0 to disable. C. D. E. F. G. H. XIV. Disconnect main cable from battery #1, or alternatively, disconnect and insulate the wire from terminal #6. After a brief delay, the Battery 1 Failure Signal, audible alarm, and Remote Engine Failure Alarm should all operate. Repeat Pressure Starting Test (Paragraph X). Engine should start normally. Control should be capable of performing all previously described Tests. Reconnect battery cable (or re-connect wire to terminal #6) and depress battery failure RESET pushbutton (Battery 1 fail signal and alarms should de-energize). Repeat steps A through E above except disconnect battery #2. Reconnect Battery Charger and reset Power Failure Start timer, if used.
Sequence Start Test (Option"9", G1) A. Most automatic start signals active in the AUTO positions will be delayed by the Sequence Start rotary switch setting on the DC-CU chassis. Does not delay remote start. B. On Power Fail Start (Option "5", G1), the engine should start after the combined delays of the AC Power Failure Start and Sequence Start delays. - 16 -
Master Control Systems, Inc.

DEC Issue 02-v02

2009.08.3
CONTROLLER OPERATION
OFF Position: This is a safety position on the Main Selector switch which prevents the engine from starting during periods of engine maintenance. It is also used to reset the control after a Failure to Start, Overspeed Shutdown, High Water Temperature, or Low Oil Pressure. NOTE: Set the Main Selector switch to the OFF position before making final connections to the batteries and before energizing the A.C. (Mains) Power circuit. BATT Position: Placing the Battery Selector Switch in BATT1 or BATT2 selects which battery is used during cranking in the MAN Position. MAN Position: This position on the Main Selector Switch is for manual starting of the engine through the Manual START Pushbutton. To crank on battery 1, place the Battery Selector Switch to BAT 1 and push the START Pushbutton. To crank on battery 2, place the Battery Selector Switch to BAT 2 and again push the START Pushbutton. Initial testing of the engine is usually accomplished in this manner. It may also be used in case of emergencies to bypasses all automatic circuitry. NOTE: All alarm circuits are active in manual positions. AUTO Position: Placing the Main Selector Switch in the AUTO position energizes the "AUTO ON" signal light. This indicates that the controller is in the standby position, ready to start the engine should an emergency occur. RESET Pushbutton: This pushbutton is located on the upper left front of the control cabinet. Depressing this pushbutton resets the battery failure circuits and silences the audible alarm. If either Battery Failure lights remains lit or re-lights, a defective battery bank is indicated. NOTE: Operate the battery failure RESET pushbutton prior to putting the controller in operation. TEST Pushbutton: With the Main Selector Switch in the AUTO position, pressing the TEST pushbutton opens the drain valve solenoid to initiate the engine starting sequence by a pressure drop. The TEST position should be used for routine starting. This mode of operation brings into use all of the automatic cranking, running, and safety shutdown circuits. When the engine starts, the Remote Engine Running Alarm contacts transfer. STOP Pushbutton: The basic controller is furnished for Manual Stop. When a pump demand occurs, such as low pressure, the engine will start and continue to run until the control switch is placed in the OFF position. Engine may also be stopped by depressing the "STOP" Pushbutton provided that all the starting demands have been satisfied. If they are not, the engine will not stop when the STOP button is pressed. PRESSURE Switch (PS): These controllers are equipped with a pressure transducer Start (Trip) and Stop (Reset) control circuit. If the Start or Stop pressure setting(s) need to be set or the settings changed, follow these instructions: A. Pressurize the system using the Jockey Pump or by Running the Fire Pump. This is to avoid pump starting while setting the Pressure Switch Start and Stop set points. To check the pump Start (Trip) set point (setting), operate the METER toggle switch on the side of the display box (door mounted) to the START PRESSURE position and observe the reading on the digital display. The value displayed is the pump Start (Trip) pressure set point. The pump will start whenever the system pressure is below this value.
B.

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CONTROLLER OPERATION - Continued

C. To check the pump Stop (Reset) set point (setting), METER toggle switch to the STOP PRESSURE position and observe the reading on the digital display. The value displayed is the pump Stop (Reset) pressure set point. On controllers set for Automatic Stop, the controller will stop the pump whenever the system pressure is above this value if the Minimum Run Timer has timed out. To set the pump Start (Trip) set point, rotate the TRIP SETTING knob or shaft on the side of the display box (door mounted) until the display shows the desired Start Pressure setting. Increases clockwise. The Trip and Reset settings are changed by turning the 10 turn trip and reset potentiometers. If the Stop (Reset) potentiometer is set down to the trip setting, the pot will continue to turn but the setting will not drop below the Trip (Start) point. Several Clockwise (increasing) turns of the Reset (Stop) control or Counterclockwise (decreasing) turns of the Trip(Start) control may be needed. The two LEDs on either side of the controls indicate the presence (Pressure Start Demand) or absence of a pump demand. To set the Stop (Reset) set point, rotate the RESET SETTING knob or shaft on the side of the display box (door mounted) until the display shows the desired Stop Pressure setting. Increases clockwise. Close and lock the controller door. Use the test valve to drop pressure to check for pump pressure loss starting. Use the Stop pushbutton to stop the pump to leave it in service (standby mode).
D.
Note:
E.
F. G.
H.
Make sure the pump discharge valve is open and that any other valves are properly set.
Failure to Start: If the engine does not start in approximately 15 seconds, cranking will stop for about 15 seconds and then continue in "crank" and "rest" periods for a total of six (6) cranking attempts (with five rest periods) or a total overall starting cycle of about 2-3/4 minutes. If the engine has not started by this time, all further cranking will discontinue, starting and running circuits will remain energized, the "Failure to Start" light will energize, the Alarm Bell will sound, and the Remote Engine Failure Alarm contacts will transfer. The controller must be reset by placing the control switch in the OFF position. NOTE: If the engine starts and runs but the speed switch or other crank terminate signal does not energize terminal 2, the engine will continue to run with the Failure To Start LED on. Low Oil Pressure: If the lube oil pressure of the engine falls below the setting of the oil pressure switch while the engine is running, the Low Oil Pressure signal light will energize. After approximately 10 seconds the controller alarm bell will sound and the Remote Engine Failure Alarm contacts will transfer. Engine will continue to run. The controller does not shutdown the engine on low oil pressure unless it is running in the Weekly Test or Test mode. The Low Oil Pressure LED remains on until the Main Selector Switch is turned Off. NOTE: Whenever the engine is started, the Low Oil Pressure signal light is energized momentarily until engine builds up oil pressure. This indicates oil pressure switch is operating properly. High Water Temperature: Should the temperature of the engine cooling water system exceed the setting of the engine high water temperature switch, the High Water Temperature light is energized, the controller audible alarm sounds and the Remote Engine Failure Alarm contacts transfer. Engine will continue to run. The controller does not shutdown the engine on high engine jacket water temperature unless it is running in the Weekly Test or Test mode. The High Water Temperature LED remains on until the Main Selector Switch is turned Off. Battery Failure: If the voltage of a battery drops below about 2/3rds of its nominal rating for more than one or two seconds, usually while the engine is cranking, the controller will indicate a battery failure by energizing the corresponding "Battery Failure" signal light. Simultaneously, all control cranking and running circuits are locked - 18 Master Control Systems, Inc.
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to the remaining battery. The controller alarm bell is energized and the Remote Engine Failure Alarm operates. After battery failure has been corrected, depress Battery Failure RESET Pushbutton to return controller to normal operation. Tripping of the overload Circuit Breaker will energize associated Battery Failure signal and operate local and Remote Engine Failure Alarms. Disconnecting a battery lead will also energize associated Battery Failure signal light local and Remote Engine Failure Alarms. Engine Overspeed: If the engine Overspeed Switch trips, usually when the engine speed exceeds approximately 120% of its rated speed, automatic safety shutdown will occur. Simultaneously, the audible alarm will sound, the "Overspeed" signal light will energize, the Remote Engine Running Alarm contacts and Remote Engine Failure Alarm contacts will transfer. Terminal #1 is de-energized to avoid fuel leakage and cooling water drain as well as battery drain. In the AUTO position, the Overspeed light, audible alarm and remote alarms will remain energized by a latch circuit even if the pump demand signal is removed. After an Overspeed, the engine overspeed shutdown device and controller must be reset. To reset the controller, place the control switch in OFF position. NOTE: Always: 1) reset engine devices first before resetting the Selector Switch to Off and (2) start the engine again to be sure the overspeed has been remedied AND the engine shutdown devices has been reset. Failure to follow this procedure may erase the overspeed memory (latch) circuit and can cause immediate overspeed shutdown on next start. Pump House Trouble Alarm(s) - Option "O", G1: Controllers so equipped have signal lights which will indicate when their respective Pump House trouble alarm switches have closed. Closing the trouble switch will also transfer the Remote Pump House Trouble Alarm contacts and energize the audible alarm. The bell can be silenced by pushing the RESET pushbutton. Weekly Test Start: Standard controllers are furnished with automatic Weekly Test Start to provide weekly starting of the engine to insure it will start in the event of an emergency. You must first enable the Weekly Test by moving the Weekly Test Jumper to the enabled position (See P.10 for a diagram of both positions). Now push the Weekly Test pushbutton on the DC-CU chassis and the Drain Valve Solenoid will dump water from the pressure sense line to start the engine in the same manner as if a sprinkler head opens during a fire. The engine will run for 30 minutes and shutdown. It will start again 7 days later at the exact same time. Minimum Run / Automatic Stop - Option "1", G1: When permitted by the local Authority Having Jurisdiction (AHJ), the controllers may be equipped for Automatic Stop with Minimum Running Period Timer (Option "1", G1). Using this arrangement, an automatic start resulting from a pump demand, will cause the engine to run at least for the time setting of the Minimum Run time delay. If the demand still exists after the time delay interval, the engine will continue to run until all pump demands are clear (reset), at which time, the controller will automatically shutdown the pump. This option should not be added or activated, unless prior approval has been obtained from local AHJ (Authority Having Jurisdiction). NFPA-20 requires that it not be used with "sole source pumps" or pumps supplying standpipes or hose cabinets. The Time Delay is part of the DC-OM Option Module Board in the DC-CU chassis. The time range is 2 to 30 minutes in 2 minute intervals. The time delay is set by operating 16 position rotary switch marked "MIN RUN" to the desired position. Position "0" defeats this function and results in Manual Stop operation. Position "1" is 2 minutes, position "9" is 18 minutes and position "F" is 30 minutes. The normal setting is "F", 30 Minutes.
Electric Motor Lockout - Option "2": Controllers so equipped contain an auxiliary chassis to (1) prevent engine from running while associated electric motor driven pump is operating and (2) while engine is running to prevent associated motor driven pump from operating. Electric motor controller must be equipped with a lockout relay and auxiliary contact to indicate motor is operating. The time delay
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allows spin down of the engine before the electric motor is enabled in the case of dual drive installations where a diesel and electric driver are connected to the same pump. This option should not be added or activated, unless prior approval has been obtained from local AHJ (Authority Having Jurisdiction). NFPA-20 does not allow dual drivers for a single pump.
Pressure Recorder Options DPR (G1), DR, PN" or "PNT"(Paperless Recorders): Controllers are equipped with a Paperless Pressure Recorder to continuously record the pressure in the fire protection sprinkler system. Refer to P. 34 for further details. Remote Deluge Valve or Remote Momentary (Pushbutton) Start - Option "4", G1: Controllers so equipped have a Remote Start drop-out loop circuit. Any number of NORMALLY CLOSED contacts may be wired in series with the loop. The total loop (round trip) resistance of circuit between terminals 31 and 32 or 31 and 33 must not exceed 50 ohms on 12 volt system and 250 ohms on 24 volt system. See the wiring resistance table below. In operation, the Remote Deluge Start Contacts and/or the Remote Momentary Start contacts open to cause the pump to start. Controllers equipped with Sequence Start (Options "9", G1) will delay starting the engine after receipt of a Deluge Valve Contact signal (contacts on CTB4-32 open). This delay does not affect a Remote Momentary (Terminal CTB4-33) input. Engine Lockout, Mod. "X21": Closing of contacts wired to Terminal CTB4-34 will cause the controller to stop a running engine or prevent it from starting when the Main Selector Switch is in the AUTO position. This input does not affect running with the Main Selector Switch is in the MAN position. Remote/Deluge Start or Lockout Circuit Wiring Table Wire Resistance Ohm/1,000 Ft. 1.588 2.525 4.016 6.385 10.15 16.14 25.67 40.18 12 vdc (50 Ohms) 15,700 Ft. 9,900 6,200 3,900 2,500 1,500 940 620 24 vdc (250 Ohm) 78,500 Ft. 49,000 31,000 19,500 12,500 7,500 4,700 3,100
Wire Size #12 AWG #14 #16 #18 #20 #22 #24 #26
NOTE: Resistance and number of splices and contacts in circuit must be taken into consideration when calculating size of wire to be used. A single splice may exceed the total resistance of 1,000 Ft. or more of wire. Charger Failure - Option "A": All controls are provided with Charger Failure circuitry to detect a loss of A.C. Power to the controller or a mal-function of either battery charger. Either condition will energize the "Charger Failure" light and transfers the Remote Engine Failure Alarm contacts. This circuitry resets immediately upon restoration of A.C. Power and/or replacement of battery charger input fuse. The Alarm Bell does not actuate on Charger Failure Alarm to avoid additional battery drain. A.C. Power Failure Start - Option "5", G1: Controllers so equipped are furnished with a Power (Mains) Failure Start Time Delay circuit on the DC-OM Options Module board on the DC-CU chassis. This is to prevents the engine from starting on brief power interruptions. The time range is 20 to 300 second, in 20 second intervals. The time delay is set by operating 16 position rotary switch marked "POWER FAIL START" to the desired position. Position "0" defeats this option (no start on power failure). Position "1" is 20 seconds, position "9" is - 20 Master Control Systems, Inc.
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180 seconds and position "F" is 300 seconds. Actual time setting should be determined by authority having jurisdiction. Spark Ignition Engines - Option "6": Spark ignition gasoline or natural gas engines may not be equipped with an Overspeed signal (speed switch). Controllers having Option "6" have no Overspeed light and are not arranged to provide overspeed shutdown or alarm. Terminal #3 is unused. Individual Failure Contacts - Option "7": Controllers so equipped provide independent S.P.D.T. contacts for the connection of remote signals which correspond to the individual signals in the controller. Sequence Starting - Option "9", G1: Controllers so equipped furnish Sequence Start Time Delay as part of the DC-OM Option Module Board on the DC-CU chassis. It is used to provide the mandatory sequential pump starting on installations having multiple pump in parallel. The time range is zero to 75 second, in 5 second intervals. The time delay is set by operating 16 position rotary switch marked "SEQUENCE" to the desired position. Position "0" is no delay, position "1" is 5 seconds, position "9" is 45 seconds and position "F" is 75 seconds. Actual time setting should be determined by authority having jurisdiction. This delay affects pressure loss start, Deluge valve start, when used, and Power Failure start, when used. Typically, the initial setting would be a zero delay for the first (lead) pump, 5 or 10 seconds for the second pump and etc. High Zone Delay - Option "Z": Controllers so equipped furnish High Zone Time Delay start as part of the DCOM Option Module Board on the DC-CU chassis. It is used to provide the mandatory sequential pump starting on installations having multiple pump in series. The time range is zero to 30 second, in 2 second intervals. The time delay is set by operating 16 position rotary switch marked "HI ZONE" to the desired position. Position "0" is no delay, position "1" is 2 seconds, position "9" is 18 seconds and position "F" is 30 seconds. Actual time setting should be determined by authority having jurisdiction. This delay affects all automatic start demands including Pressure Loss, Remote Momentary (pushbutton) start, Deluge valve start, and Power Failure start, when used. Typically, the initial settings would be zero delay for the high zone pump, 5 or 10 seconds for a low zone pump or a mid-zone pump and 10 to 15 seconds for a low zone pump. Dual Battery Charger - Option "RA", or "DA": The built-in Dual Battery Charger is designed to automatically maintain the batteries in a fully charged condition. The battery charger will charge and maintain both batteries simultaneously. The ampere output to each battery will vary depending upon individual battery demand. The Model MBC3 Battery Charger (Option "RA" or "DA") is two separate Float-Equalize automatic mode switching two rate regulated battery chargers. They switch modes automatically between high rate (equalize) and low rate (float) depending on charge state & load on batteries. It is A.C. line compensated, current limiting and requires no adjustment. See MAINTENANCE AND ADJUSTMENTS for further details. Controller Voltmeters V1 (hinge side) and V2 (handle side) monitor battery banks No. 1 and No. 2 respectively. They monitor the battery charger float and equalize voltages. These meters are also used to indicate the condition of battery during cranking. A battery in good condition and state of charge should maintain at least 75% of nominal voltage while cranking (except for breakaway). Controller Ammeters A1 and A2 sense the charge current being supplied to battery #1 and #2, respectively, by the built-in dual battery charger in either the float (maintaining) mode or the equalize (high rate) mode. Note that the signals for the digital voltmeters and ammeters are supplied by the MBC3 battery charger. Stop Pushbutton: The STOP pushbutton is located on the upper right front of the control cabinet. Its primary purpose is to provide means for stopping the engine without unlocking the door on the controller. It will operate only when the control switch is in the AUTO position and then, only after all engine running requirements have been satisfied. - 21 Master Control Systems, Inc.
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Battery Overload Circuit Breakers: These two circuit breakers, CB1 and CB2, are located on the upper left portion of the DC-EIF Chassis. A short circuit in the engine wiring can cause them to trip. Push firmly to reset.

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OPERATION OF MODEL MBC3 DUAL BATTERY CHARGER

GENERAL DESCRIPTION: The Model MBC3 Dual Battery Chargers are constant voltage, Automatic Mode switching, two rate (Float & Equalize) current limited and regulated (line compensated). These chargers meet the requirements of NFPA 20 which requires that the battery charger must be capable of restoring two fully discharged batteries, 100% of their ampere hour rating within 24 hours. These Models provide fast recharge in the high rate Equalize mode; with low water consumption in the low rate Float mode. These chargers have very high line regulation, load regulation, and very low temperature coefficient. They also have extremely wide A.C. voltage operating range, since they have both outstanding low A.C. line margin and very high A.C. line voltage tolerance. These chargers also have short circuit and reverse battery protection by way of the "Low Voltage ShutDown" feature. The Model MBC3 Dual Charger is two separate 10 Amp (Option "RA") or two separate 20 Amp (Option "DA") battery chargers on a single baseplate. The 12 volt, 10 Amp model utilizes two different secondaries of a single transformer for both chargers. These two chargers are separately controlled and capable of charging both batteries independently. Each charger has a separate plug-in Regulator P.C. Board Assembly, separate replaceable power rectifier and SCR Heatsink Assembly and separate D.C. fuses. This completely eliminates the undesirable interaction between battery outputs that occurs with chargers using a single regulator and diode isolated (divided) outputs. Note: The Model MBC3 Battery Charger (Option "RA" or "DA") must be connected to batteries and placed in operation at least 24 hours prior to testing. OUTPUT CAPACITY: These chargers are capable of supplying 100% of their rated D.C. output current without allowing the batteries to be depleted. The full rated output current (10 Amps for Option "RA" 20 Amps for Option "DA") are always available for each battery bank (battery units). BATTERY SIZE (CAPACITY): The Battery capacity of the charger (each output) is marked on the charger chassis. Batteries larger than the maximum rated capacity may not be completely charged within the 24 hours and can also cause charger to "high rate mode lock-up" which will result in very high water consumption, battery heating and subsequent battery damage. WATER CONSUMPTION: The Model MBC3 Chargers provide the fastest charge time for a given rating consistent with the lowest water consumption. Under normal conditions the Charger will be in the "float" mode with low water consumption. The battery water level should be checked once a month until a water consumption pattern is established. The water level should be checked at least every 3 months due to climatic changes. Longest battery life will be obtained when distilled water is used to fill batteries. LINE REGULATION: The Model MBC3 are regulated (line compensated) and require no tap setting. The line voltage regulation (output change) is 0.2% or better for a 10% line voltage change. The Chargers will operate with line changes up to 15% of nominal. MODE SWITCHING: The Charger will switch modes between Float mode and Equalize mode depending on the state of charge in the batteries and upon external loads. The mode switching decision is based on the Charger output current. When the batteries and/or other loads require much over 50% or rated current the Charger automatically switches to the high rate mode and remains there until the battery or batteries is/are charged and the output current drops down toward 50% of rated current. At that point the Charger will switch back to the float mode, with a corresponding reduction in output current and remain in "float" until the next demand occurs.
- 23 Master Control Systems, Inc._____________________________________________________________Lake Bluff, Illinois

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OPERATION OF MODEL MBC3 DUAL BATTERY CHARGER - Continued

Engine cranking, will cause the charger to switch to the high rate again. In the float mode the Charger will supply only to the batteries a current equal to battery leakage plus any external loads. Power interruption will also cause the Charger to switch to the high rate upon power restoration. The Charger will return the charge lost during the power interruption and then return to the float mode. The Charger will not discharge the batteries during periods of power failure. BATTERY CONDITION: A fully charged battery will be indicated by a low Charger output current and, for lead acid batteries, a full charge specific gravity hydrometer reading in all cells. A battery which has approached end of life will have a reduced ampere hour capacity (something less than the battery's rated capacity). An adequate check of a battery for capacity in engine starting applications is to monitor the battery voltage while it is cranking the engine during an expected worst case cranking attempt. The cranking voltage of a fully charged battery of adequate capacity should be at least 75% of nominal (9 volts minimum on a 12 volt lead acid battery). Batteries with sufficient capacity which are not fully charged may not pass the test. CAUTION: AS SOON AS ELECTROLYTE IS ADDED TO BATTERIES, CONNECT AND ENERGIZE BATTERY CHARGER THE SAME DAY TO PREVENT DAMAGE TO BATTERIES.
NORMAL OPERATION: When power is first applied, the Charger will normally supply its full rated current in the high rate mode, as indicated by the Charger ammeter(s). The current will remain at the current limit value until the battery approaches full charge. It will then taper down toward 75% of rated current and then drop to zero indicating the battery is charged and the Charger has switched to float mode. The Charger will then begin to supply whatever is required by battery leakage and external loads. NOTE: The Charger should remain in high rate mode for no more that 24 hours when used with a fully discharged good battery of proper size and type and with no external loads. Adding electrolyte to a "dry charge" battery results in the battery being approximately 2/3 charged. Thus, for an MBC3, while cranking, the cranking battery will cause that charger to switch to the high rate (momentary full scale on the ammeter) then to current limiting (10 Amps or 20 amps) until the battery is charged. When the engine is running the engine generator or alternator will normally cause the control battery charger output to be reduced. CHARGER MAINTENANCE: There are no field adjustments to be made on these chargers. The only adjustable device is the float voltage adjustment trim pot on the regulator P.C. board which is factory set using precision equipment. The same is true of the two charger failure trim pots on the DFA dual charger failure alarm board (PC3).

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OPTION "RA" or "DA" BATTERY CHARGER FAILURE ALARM

DESCRIPTION OF EQUIPMENT: The center plug-in printed circuit board is the DC-DFA Dual Charger Failure Alarm assembly (module). The "A.C. Power & Charger Failure" relay K9 is controlled by the reed relay(s) on the DFA board. OPERATION PROCEDURES: The DFA assembly is adjusted at the factory, using precision equipment, to operate with the specific voltage and battery type for which the Charger was built and adjusted. There are no field adjustments to be made. Both of the DFA Charger Failure Alarm circuits will usually reset automatically after power restoration. If not: 1) Momentarily remove A.C. power from the controller (branch circuit breaker may be used if convenient to turn off controller A.C. power). Reapply power after approximately 10 seconds. Both Charger Failure Alarm circuits will usually reset upon power restoration. 2) Place Main Selector Switch in the MAN position and the Battery Selector Switch in the BAT1 position. Crank the engine by using the START pushbutton until BATTERY 1 AMMETER (left hand, hinge side ammeter) has jumped up to full scale and settled down to current limit value which takes 2 to 5 seconds. This will reset the DFA Battery No. 1 Charger Failure Alarm. Repeat this procedure with the Battery Selector switch in the BAT2 position observing BATTERY 2 AMMETER (right hand, handle side, ammeter). This will reset the DFA Battery No. 2 Charger Failure Alarm. The DFA circuits will also reset when battery float voltages return to normal. The DFA Dual Charger Failure Alarm Board will detect any of the following charger malfunctions for either of the two battery chargers: A) Immediate detection of charger A.C. (Mains) power loss, either loss of A.C. Power to the controller or open charger A.C. Fuse(s). B) Detection of loss of output current from either charger, including open charger D.C. output fuses, regardless of the cause. Detection time will vary from instantaneous to an hour depending on size of loads, size of battery, and the state of charge and condition of the battery. C) Detection of failure of either charger to produce high rate current if the battery is not fully charged or if large loads are put on the battery. D) By virtue of the above, detection of blown A.C. or D.C. fuses, broken or open input or output wires, low line voltage, removed charger components. E) Failure of charger circuitry that prevents it from bringing and holding the battery at its full charge voltage level. In general, the DFA module will cause an alarm unless either 1) the battery is fully charged and is receiving a charge maintaining current from the charger, or 2) the charger is producing high rate currents to charge the battery. If either DFA failure circuit detects a failure, the "Charger Failure" LED will Light and the REMOTE ENGINE FAILURE Contacts will transfer. If the control is equipped with Option "5(G1) "Power Failure Start", the engine will start after a time delay period. See the sections titled "A.C. Power Failure Alarm" and "A.C. Powered Failure Start (Option 5, G1) for more details." THEORY OF OPERATION: (GENERAL) If a battery is fully charged and is receiving a charge current sufficient to maintain that charge level, then the battery terminal voltage will be at its normal FLOAT

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OPTION "RA" or "DA" BATTERY CHARGER FAILURE ALARM Continued

VOLTAGE. If the battery fails to receive this current, which the charger produces when it is in the FLOAT mode, then the battery voltage will drop to its FULL CHARGE OPEN CIRCUIT value. If the battery is not fully charged, the voltage will be still lower, particularly if the battery is not receiving high rate charge currents. Part of the Charger Failure Alarm Module is a voltage monitor circuit which will cause the relay to remain in the NORMAL (not-alarm) state if the battery voltage is above its FULL CHARGE OPEN CIRCUIT value. This voltage monitor set point is between the battery full charge open circuit and the nominal Float voltage. If the MBC3 battery charger is producing high rate currents (at least 50% of rated output) the charger will generate an "EAL" signal and light the Yellow (amber) LED to indicate the charger is in the Equalize mode. Thus, any time either charger is producing high rate currents (Yellow LED), or if the battery voltage is high enough to satisfy the voltage monitor, that alarm circuit will enable the failure relay to remain energized (in its normal state). If the battery voltage drops below the voltage monitor set point, the relay will drop-out and cause an alarm unless the charger is producing high rate currents (Yellow LED). The voltage monitor has a time delay to allow time for the charger to switch to high rate currents before causing an alarm. (SPECIFICALLY): The DFA relay coil is connected to the charger "EAL" terminals and is energized any time the charger is producing currents above the CROSSOVER CURRENT value. This will be the case anytime the charger is in the EQUALIZE mode. If and when the battery voltage rises above the DFA alarm set point voltage the voltage monitor energizes the relay to keep the alarm relay energized. If neither condition is true (battery voltage low and not charging at the high rate, the module will de-energize the controller Charger Failure relay to cause a charger failure alarm. Both DFA alarm circuits must be satisfied to prevent the alarm relay from dropping out (to the alarm state). The voltage monitor alarm set point is approximately 12.7 Vdc or 25.5 Vdc for 12 Vdc or 24 Vdc lead acid automotive chargers, respectively.
MAINTENANCE PROCEDURES
WEEKLY TESTING: To insure reliable automatic starting in event of an emergency, the engine and controller must be operated once a week for a minimum of 30 minutes. To do this, first enable the Weekly Test Jumper (See P.10 for a diagram). If not enabled, the controller will not start every week automatically. Once enabled, to initiate the weekly start press the Weekly Test button on the DC-CU chassis. The controller will start immediately and then subsequently at the same time every week. Even when Weekly Test Starting is accomplished automatically, someone should be present at the pump house to make sure all systems are operating properly. The following is a suggested list of items which should be covered at this time: (1) (2) (3) (4) (5) Check specific gravity (before cranking) and height of electrolyte in battery. If necessary, replace water lost through evaporation. Make sure neither "Battery Failure" light is on. Energized battery failure lights indicate the possibility of battery failure. Check crank case oil level. Check water level in heat exchanger. Observe voltmeters on controller while engine is cranking. EXCESSIVE (25% or more) voltage drop will usually be the first indication of battery trouble and should be investigated immediately.

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MAINTENANCE PROCEDURES - Continued

(6) (7) (8) (9) (10) Observe low oil pressure signal light and make sure it comes on momentarily while the engine is cranking. Make sure cooling water solenoid valve opens. Make sure engine is running at rated speed and observe oil pressure, water temperature, and charging generator or alternator output. Make sure pump discharge pressure is normal. Make sure "AUTO ON" light is on before, during, and after weekly test run.
The Authority(s) having Local Jurisdiction (AHJ) may wish to add further items to the above. Also, refer to NFPA-25 Standard on Maintenance and Testing for further information and guidance. BATTERIES: (Lead Acid) The engine starting batteries are the heart of the entire system and although the battery charger incorporated in this control is fully automatic and incorporates the most modern techniques in charge control, there is no substitute for proper and periodic maintenance. CAUTION: AS SOON AS ELECTROLYTE IS ADDED TO BATTERIES, CONNECT AND ENERGIZE BATTERY CHARGER TO PREVENT DAMAGE TO BATTERIES. Inspect batteries once each month to make certain all connections are tight. Remove dust or dirt accumulations from top of batteries. Neutralize acid on covers and terminals by cleaning with ammonia or soda solution (1 pound baking soda per gallon of water). Be sure to keep terminals and metal parts free of corrosion. Never allow water level to drop below top of battery plates. NOTE: Take care to follow all instructions, cautions and warnings provided with the batteries by the battery manufacturer. If the batteries do not come up to full charge (1.240 to 1.285 specific gravity reading), check the charger float voltage.

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REPLACEMENT PARTS LIST: DEC Fire Pump Controllers

Designation Description DC Engine Interface Chassis (DC-EIF) DC-EIF DC-EIF Engine Interface Chassis, 12N w/ H Include 649255 Relay Engine Interface Chassis, 24N w/ H Include 649256 Relay DC Power Supplies Power Supply Board, 12N, 649290 Power Supply and Battery Monitor Power Supply Board, 24N, 649291 Power Supply and Battery Monitor DC Demand Control Boards Demand Control Board, 12V, 649300 Plug-In Board Assy for DEC/DEC. Demand Control Board, 24V, 649301 Plug-In Board Assy for DEC/DEC. Clock Module Clock Module w/ Wkly Tst Plug-In Board A 649311 for DEC. DC Options Modules Options Module Assy, 12V 649325 Plug-In Board Assy for DEC. Options Module Assy, 24V 649326 Plug-In Board Assy for DEC. Module Board Assemblies Display, STD 0, 12V 649352 Module Board Assy, w/ Hardware. Display, STD 0, 24V 649354 Module Board Assy, w/ Hardware. Glass Hinge DEC/DEC Control Switch Lockbox Assemb 649360 (Glass Hinge Assy). Analog Pressure Switches Analog PS, 300 PSI, 12VDC 649413 1-6 VDC, Daughter Board, INT PWR. Analog PS, 500 PSI, 12VDC 649414 1-6 VDC, Daughter Board, INT PWR. Analog PS, 300 PSI, 24VDC 649417 1-6 VDC, Daughter Board, INT PWR. Analog PS, 500 PSI, 24VDC 649418 1-6 VDC, Daughter Board, INT PWR. MCS Part Number
DC-PS DC-PS
DC-DC DC-DC
DEC-CM
DEC-OM DEC-OM
DEC-DP DEC-DP
Glass Hinge Assy
DC-APS DC-APS DC-APS DC-APS

DEC Issue 02-v02 2009.08.3
REPLACEMENT PARTS LIST Continued

Designation DC-APSS Description Analog Pressure Switch - Continued Analog PS Setting Brd Trimpot, LED, Switch Assy. Charger Regulator Board Assembies Regulator E, MBC3C-12-10-LA, Charger Regulator Board Assy. Regulator E, MBC3C-24-10-LA, Charger Regulator Board Assy. Charger Failure Alarms Alarm Module, DFA-12-LA, MBC3C Plug-In Charger Failure Alarm. Alarm Module, DFA-24-LA, MBC3C Plug-In Charger Failure Alarm. Diodes Energize to Stop Diode Bridge Assembly MCS Part Number 649419
REG E REG E
649502 649512
DFA DFA
649522 649532
Diode Bridge Assy
649540

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Model PR4001N
Paperless Pressure and Alarm Recorder
- with Alarm and Status Recording - and Built-In Phone Modem Modification "XPN" in Fire Pump Controllers
Installation and Instruction Manual Table of Contents
Page 31: Page 32: Page 32: Page 33: Page 34: Page 38: Page 40: Page 42:
General Installation Start-up Procedure Normal Operation Getting Data Locally System Commands & Error Codes Customizing Sequence of Operation

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GENERAL
Overview: The Master Control Systems, Inc. Model PR4001N, Paperless Recorder, is a microprocessor based recorder specifically designed to communicate through an RS-232 serial port directly to a lap-top computer or a network server. The built-in modem may also be used to access the system. The PR4001N constantly monitors the system pressure, at a rate of three times per second, and records it into permanent non-volatile solid state memory (NVSRAM or EEPROM) every hour or when the pressure changes by more the 5 psi (default setting) from the last saved value. The recorder also monitors and records all alarm and status change events into memory. All recorded alarm and pressure data are time stamped with the date and time of the event recorded. The recorder is independent of the controller and vice versa. Failure of one does not impede the function of the other. The unit will also record in the absence of A.C. line (mains) power. The unit can also be provided as a free standing unit with battery back-up and battery charger. Fire Pump Controller Option Designations: The basic recorder model number is the above PR4001N which includes both pressure and alarm recording and also contains a built-in modem. As such it replaces previous units designated PR4001A (pressure and alarm recording). When provided as part of a fire pump controller, the controller model designations are as follows: Modification (Mod. Code) XPN includes a Model PR4001N Paperless Pressure and Alarm Recorder with built in dial-up modem. Modification XPS adds Digital pressure switch contacts and a pair of three digit set point switches for both start (low) and stop (reset) pressure set points. Modification XPN in EC** Series Electric Motor Drive Fire Pump Controllers also includes built-in battery back-up using non-rechargeable batteries. Mod. XPBnn provides longer back-up times and rechargeable batteries and battery charger. Note: Mod. XPN in DCF Series Diesel Engine Drive Fire Pump Controllers uses the two engine batteries for battery back-up. Equipment Provided: When installed in a fire pump controller, the system consists of: 1) a through-the-door 4 line by 40 character (160 total characters) LCD display with back-lighting for dim environments, 2) three exterior sealed operator toggle switches for control of the alarm and pressure display and history display and for watch check-in, 3) Solid State Pressure transducer which is in addition to the controller's pressure switch, 4) Interior switches to control unit reset (three types of reset are provided), system security (pass word control) and status send function, 5) Built in Hayse compatible dial-up and auto-answer, unless option XPNT (network enabled) is provided, and 6) RS-232 customer serial port for data access and control.

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GENERAL - Continued
Connectivity: Controllers equipped with option XPNT are network enabled. The internal modem is replaced by a network server device. This allows direct connection to an Ethernet hub or server for connection to a Local Area Network (LAN) or a Wide Area Network (WAN) or Internet Access. The device has separate password protection. It uses TCP/IP protocol and is assigned an IP address which can be changed in the field. A work sheet is supplied with the appropriate network parameters. A customer supplied IP address and sub-net mask can be pre-programmed by the factory upon notification.
INSTALLATION
Installation consists of a telephone line connection to the phone line terminal block screws. For wall mounted units, a pressure sense line, 115 VAC power, and alarm contact inputs must be brought to the unit in addition to the phone line. The alarm contacts must be "dry" contacts ("volt free").
START-UP PROCEDURES
1) Power up the controller. The unit will begin its self-tests and initialization. After initialization, the Process LED should be flashing. 2) Hold down the "Send Status" pushbutton and momentarily press the Reset pushbutton. Continue holding the Send Status push button down until the "Init" LED goes out, release the "Send Status" pushbutton. This is known as a "default reset". It returns all system settings to their factory values. To clear the permanent memory, repeat this procedure while holding the "Scroll Down" switch. Whenever the batteries have been replaced, the "Replace Battery" message and the internal battery failure needs to be reset. This is accomplished by holding the "Scroll Up" switch while initializing. Note that the internal batteries should be replaced annually to maintain maximum capacity. 3) Set the Security switch to off. 4) Set the "pressure/alarm" toggle on the outside of the controller to the desired position. Push down on the "scroll" toggle to see the history. After a large amount of data is gathered, holding down the scroll toggle will scroll through 20 points at a time. Push up on the "watch check" toggle to check in. This also returns the display back to the main screen in 3-4 seconds. 5) Check the Time & Date. If the time or date is not correct, adjust as indicated below: 5a) Make sure the "Security" is not in the "ON" position. 5b) While holding the "Check-In" switch, press and release the "Reset" pushbutton. 5c) When the ** TIME/DATE ENTRY ** screen appears, release the "Check-In" switch and follow the instructions as stated. 5d) Adjust the value with the "Scroll Up/Down" switch as necessary and use the "Check-In" switch to enter the new value and advance to the next field. Note that the Daylight Savings flag, 'Daylight=', may also be set from this screen.
DEC Issue 02-v02 2009.08.3
START-UP PROCEDURES Continued

Notes: - The field to be changed will be indicated by a blinking block cursor and an underline cursor directly below the right-hand character position in each field. - The clock will not start running until the last field is exited. - The cursor will advance to the next position after approximately 30 seconds if there is no activity. - On units with Version 1.3 or earlier software(shipped prior to 11/12/98), the Time & Date must be changed from a lap-top computer. For these units, see "Getting Data Locally". Once connected, type 'H3' and follow the instructions.
NORMAL OPERATION (default constants)

Switches and LEDs - The back of the display box provides a Security switch, a Send Status push button, and a Reset push button along with system and diagnostic LEDs. The Security switch provided tells the system if password verification is required when answering a call. If verification is required and the password does not verify, the PR4001N terminates the call. It also prevents the system parameters, phone number, password, or memory contents from being altered even if a valid password is used. The Send Status push button sends the present alarm status to the connected lap-top or modem. The Reset push button resets all the hardware and software to their initial states. If non-volatile memory needs to be reset to the factory defaults, hold the Send Status push button down and momentarily press the Reset push button. Continue holding the Send Status push button until the initialize LED goes out. This is known as a "default reset". It returns all operational defaults to their factory values. To clear the data memory, use the Scroll Down switch instead of the Status button as described above. When the internal batteries have been replaced, the Battery Failure may be reset by using the Scroll Up switch as described above. The password and dial-out phone number are not erased using any reset method. The following status LEDs are provided on the display back box: INIT - Indicates that the unit is going through initialize operations. PROC - Indicates that the unit is running in the general program. It should always be flashing. TRBL - Indicates a power supply problem or data overrun. ERROR - Indicates when a received message is not accepted. The error LED glows when parity, framing, and overrun errors are detected by the serial port. It also glows when heading, type, data, or check sum errors are detected by the software. The Error LED is automatically reset on the next valid message or when the call is terminated. CONN - Indicates that the unit is properly connected and ready to communicate. This connection may be made by a lap top computer, network server or the internal modem.
DEC Issue 02-v02 2009.08.3
NORMAL OPERATION (default constants)

+5V - Indicates that +5 VDC power is available. +10R - Indicates that the +10VDC transducer reference source is nominal. FAULT - Indicates when the transducer current is too low (open) or too high (shorted). Getting Data Locally (With the Custom Software Package) 1) Install the Software from provided CD: The Custom Software Package is a Windows based (Win95/98 & Win2000) software suite of programs supplied with each PR4001 data recorder. It consists of a Download module, a Pressure Plot module and an Alarm Display module. It is supplied on CDRom and is self extracting. Install the package by inserting the CDRom into the CDRom drive. If the installation program does not start automatically after a few seconds, start the installation program by selecting or double clicking on the "setup.exe" file which is in the root main) directory on the CDRom disk. Then follow the installation prompts.
2) Connecting the Controller to the Computer: Connect the black custom cable to controller as shown above, then connect the RS232 the black custom cable to the adapter. Now connect the adapter to the laptop.

DEC Issue 02-v02 2009.08.3
Getting Data Locally - Continued

3) Getting Data on the Computer: When the computer is connected to the controller, open the Download program (installed in step 1). You should see the following:
4) Setting Up Connection: Use the Options connection.
Direct Connect
AutoSelected to properly set up the

DEC Issue 02-v02 2009.08.3

5) Connecting: Click the Connect button as shown below. Press OK when asked to try connecting to a Port.
6) Obtaining Data: After the program is done scanning the Port and connecting, you should see the screen below. Click on the Pressure Data button and save the data to your desired folder. Next, click the Alarm Data button, and save the data to your desired folder. After you complete this step you can terminate the Download program.

DEC Issue 02-v02 2009.08.3

7) Reading the Data: To see the data, open two separate programs: Pressure and Alarm. Open the files you saved from the Download program in the respective program (Pressure data in the Pressure program, Alarm data in the Alarm program).
8) Visualizing the Data: You will now see the data graphed out side by side. The programs interact with each other, so when you mouse over a certain point in the Fire Pump Pressure Chart (shown below right) it is reflected in the Fire Pump Alarm Panel (shown below left).
NOTE: Getting data remotely - To get data from the PR4001N over the dial-up phone lines (with option M), call up the PR4001N over the telephone line using a "Hayes" compatible smart modem. (Set the serial port for 9600 baud, 8-bit, no parity one stop bit and XON/XOFF on.) Once connected, follow the directions from the custom software package.

DEC Issue 02-v02 2009.08.3
SYSTEM COMMANDS AND ERROR CODES PR4001 HELP MENU INDEX (H0) Section No. DESCRIPTION H0 MAIN INDEX H1 CONTROL CODES H2 ERROR CODES H3 TIME & DATE ENTRY H4 ALARM NAME ENTRY H5 PASSWORD ENTRY (used with modem) (H1) C0 C1 C6 CONTROL CODES USED Hardware reset (same as power up reset) Software reset Send alarm data buffer Add ",MM/DD/YY" for starting date C7 Send pressure data buffer Add ",MM/DD/YY" for starting date C8 Send current pressure C51 Request current alarm status (H2) E1 E2 E3 E10 E11 E12 E25 E26 ERROR CODES USED Undefined message header Undefined message type Undefined message data Security breech attempted Data buffer empty (see C6/C7) Start date not found (see C6/C7) REMOTE "DIGSTK" overflow REMOTE "DATSTK" overflow
(H3) TIME & DATE ENTRY Type "T=" followed by the day number followed by month/date/year hour:min:sec in 2-digit numeric form then <RETURN>. Set time in 24-hr format. To check type "T" then <RETURN>. EXAMPLE: Type "T=07 10/19/96 16:04:00" <RETURN>. This enters Sunday, October 19, 1996 at 4:04:00 in the afternoon.

DEC Issue 02-v02 2009.08.3
SYSTEM COMMANDS AND ERROR CODES -- continued (H4) ALARM NAME ENTRY To change alarm names, determine the address from the table below and type "M" followed by the 4-digit address, followed by "T", followed by 18 ASCII characters or numbers. Exeample: To change No. 1 to "Pump Running", type "M1012=TPUMP RUNNING ", followed by return>. To read back, type "M1012,18T", <RETURN>. ALM ADDR ALM ADDR ALM ADDR ALM ADDR 1 1012 9 10A2 17 1132 25 11C2 2 1024 10 10B4 18 1144 26 11D4 3 1036 11 10C6 19 1156 27 11E6 4 1048 12 10D8 20 1168 28 11F8 5 105A 13 10EA 21 117A 29 120A 6 106C 14 10FC 22 118C 30 121C 7 107E 15 110E 23 119E 31 122E 8 1090 16 1120 24 11B0 32 1240 (H5) PASSWORD ENTRY Type "P=" followed by 4 to 16 ASCII characters followed by <return>. To check , type "P" <return>. EXAMPLE: Type "P=MASTER" <return>to enter the password "MASTER".
- 39 Master Control Systems, Inc._______________________________________________________________Lake Bluff, Illinois

DEC Issue 02-v02 2009.08.3
CUSTOMIZING THE RECORDER

The operating system allows the user to read all memory addresses and to write to both volatile and nonvolatile memory. This capability allows the user to change many factory defaults. To customize your system, refer to the above help sections H3 thru H5. In addition to these changes, the following system constants can be modified. Constant Location Almpts 1400 Description (all $values are hexidecimal) Number of active alarms (hexadecimal). The default reset does not change this value. Calibration value for the real time clock. Maximum value is 5 bits wide with the sixth bit indicating positive or negative calibration. A value of $00 indicates no calibration. A value of $01 indicates one count negative and a value of $21 indicates one count positive. The maximum positive count is $3F and maximum negative count is $1F. Each count adds or subtracts 0.176 seconds per day. The default reset does not change this value. Daylight saving time change flag. Set to 1 for active. When set, automatically changes the time ahead one hour at 2:00 on the first Sunday in April and back one hour at 2:00 on the last Sunday in October. The default reset does not change this value. Note that this may be set from the front panel, see "Start-up Procedure" item 5. Tells the ACIA what the baud rate of the system will be. The new speed takes effect upon initialization. $16 equals 300 baud, $18 equals 1200 baud, $1A equals 2400 baud and $1E equals 9600. The default reset value is $1E. When this flag is set to a '01' and a valid phone number is entered, the system will automatically place a phone call anytime an alarm input changes state. This is used with the DataMaster option supplied by MCS. Contact The factory for more information. Defines the threshold in PSI when data is stored into permanent memory. The default reset value is 5. In this case, when the last measured pressure is either 5 PSI greater or less than the last saved value, a new value is saved. Data transmit time delay. Adds a delay to each line of Alarm/Pressure data that is sent. Factory default reset setting is $03 (20-30 ms). This is used with the Pagflg above to set the daily phone line test time. Setting this to '24' will disable the daily test.
-40Master Control Systems, Inc._____________________________________________________________Lake Bluff, Illinois
DEC Issue 02-v02 2009.08.3
Clkcal
1403
Daylit
1404
Ctl
1409
Pagflg
140A
Thresh
140D
Prdy
1412
Hrck
1426
CUSTOMIZING THE RECORDER Continued

Constant Location Minck 1427 Secck Nonc 1428 1462-1469 Description (all $values are hexidecimal) Same as Hrck. Same as Hrck. If Swpflg is a 0, then the bits in the 4 odd bytes (even bytes not used) determines if the input contacts alarm on NO (close to alarm) or NC (open to alarm) contacts. A 1 in the appropriate bit indicates NC and a 0 indicates NO. The default reset does not change this value. Swaps input data byte end to end (Factory Set). The default reset does not change this value. Activates Run, Fail, Trbl and Aux output relays. A 1 indicates that the relay drivers are active and follow the appropriate relay masks. The default reset does not change this value. Run relay mask. Uses only even addresses. The Alarm byte turns on the run relay if bits from the Alarm byte match those of the relay mask. For example, if the Run relay mask for address $146A = $01, the Run relay will operate when bit 0 of Alarm byte 61 is set to a 1. $146C corresponds with Alarm byte 62, $146E corresponds with Alarm byte 63 and $1470 corresponds with Alarm byte 64. The default reset does not change this value. Failure relay mask. Operates like the Run relay mask. Trouble relay mask. Operates like the Run relay mask. Auxiliary relay mask. Operates like the Run relay mask.
Swpflg
146A
Rlyset
146B
Run
146D-1473
Fail Trbl Aux
1474-147B 147C-1483 1484-148B

DEC Issue 02-v02 2009.08.3
SEQUENCE OF OPERATION
General: The PR4001N Paperless Pressure Recorder reads pressure signals from a pressure transducer and stores significant values in non-volatile computer memory for later down-loading to either a lap-top computer or to a phone modem. It reads the transducer frequently but only stores data which has changed significantly from the last stored data. It consists of two main elements. Namely: 1) PR4001N Display Back Box. Door mounted, this unit contains the RS-232 serial port connector, serial port & system monitor LED's, pressure transducer connector, Pressure display, and miscellaneous cable connectors. It also contains a PR-PWR Switch, LED and Power supply board, PR-CPU Main Computer board and the PR-AIF Alarm Interface board. 3) Pressure transducer. This is a solid state strain gage type transducer which is powered by the PRPWR board. PR4001N systems having option "P" (power supply for use outside of a Fire Pump Controller) are supplied in separate enclosures and also contain: a) Model MBC6M Dual Rate Automatic Mode Switching battery charger. b) 24 Vdc Battery bank. c) Optional Alarm Output relay modules, typically for: Pump Running Pump Failure System Trouble -or- Pumproom Trouble Local Power Supplies: Units installed into controllers derive power from the controller. The system may be powered from 12Vdc or 24Vdc power or may be powered from various AC power sources (with auxiliary stepdown transformer). The PR-PWR board converts the various input power to +5 Vdc logic power, +15 and -15 Vdc analog and +CP control power supplies. Units with option "P" (PR4001NP) are supplied in a separate enclosure which also contains batteries and a dual rate automatic mode switching battery charger. PR-PWR Switch LED Power Supply Board: In addition to power conversion, this board produces the power needed by the pressure transducer and monitors this power for transducer shorted or transducer open circuit conditions. It conditions, scales and offsets the pressure signal from the transducer. It supplies the conditioned, scaled and offset signal to the A/D convertor on the PR-CPU board for the local pressure display on the PR4001N door display. PR-CPU Memory & Ports board: This board contains the processor, memory, and other peripheral and data bus circuitry including the on board modem. It contains a real time clock for time/date stamping of the data readings and non-volatile memory (EEPROM or NVSRAM) for storing the data readings. PR-AIF Alarm Interface board: This board contains opto-isolators (Alarm Inputs) systems for both the dry contact and/or voltage input alarm signals.
DEC Issue 02-v02 2009.08.3
SEQUENCE OF OPERATION - Continued

PR4001N Display Back Box: The display box contains the above boards and connects to the pressure transducer and both supplies power to it and conditions and scales the pressure signal from it. It also contains power supply circuitry to condition and reduce or convert the supplied input power.
Trademark Notice:
Paperless Recorder and Paperless Pressure Recorder are Trademarks of Master Control Systems, Inc.

DEC Issue 02-v02 2009.08.3
DIESEL FIRE PUMP CONTROLLER:

Optional Equipment Drawings
17500 EFA Module for Engine Failure Contacts: Wiring and Schematic Drawings 17501 ACF Module for AC Power Failure Contacts: Wiring and Schematic Drawings 17624 DMC Mod. A Strip Heater with Humidistat 17730 Option 7 Externals: Individual Alarm Contacts 17731 Option 7 Schematics: Individual Alarm Contacts 4817 Low Fuel Switch 4817L Long Rod, Low Fuel Switch 6288 High Fuel Switch Operating Instructions for Model 4817 and 4817L Low Fuel Switches and 6288 High Fuel Switch Long and Short Rod Fuel Switches (US Measurements) Long and Short Rod Fuel Switches (Metric Measurements) Long and Short Rod Fuel Switches for Oval Tank Float Settings (US and Metric)
Operating Instructions
Models 4817 -and- 4817L Low Fuel Switches - and 6288 High Fuel Switch Installation: The switch is to be installed in a 2" nominal thread tank opening. The switch is to be tightened by the flats located between the threads and the switch body. Do not wrench or torque the switch body. The wiring is terminated in 3/8" seal-tight flexible conduit which is terminated with a 1/2" nominal male threaded conduit fitting. The maximum current rating of the switch is 1/2 Amp. at 28 V.A.C. See drawing for float setting and installation details. Low Fuel Switch Sequence: The Model 4817 and 4817L N.C. Low Fuel Switch consists of a "Form A" reed capsule, an actuating magnet and, a ferrous magnet shunt. When the float is down (low fuel) the magnet shunt is lowered out of the magnet field which causes the reed switch to close. This represents the alarm condition. When the float is up the magnet shunt bypasses the magnet field away from the reed switch causing it to be open. This is the "normal" non-alarm state. High Fuel Switch Sequence: The Model 6288 N.O. Low Fuel Switch consists of a "Form A" reed capsule, an actuating magnet and, a ferrous magnet shunt. When the float is up (high fuel) the magnet shunt is raised out of the magnet field which causes the reed switch to close. This represents the alarm condition. When the float is down the magnet shunt bypasses the magnet field away from the reed switch causing it to open. This is the "normal" non-alarm state. Adjustment: Drawing 4817, 4817L & 6288 shows float adjustment data for various sizes of tanks. Low Fuel Alarm is normally considered to be at levels below 80% full. Replacement Parts List Model and Drawing No. 4817 4817L 6288 M.C.S. Part No. B800372 B801111 B800018 Description Complete Normally Closed Low Fuel Switch - Short Rod Complete Normally Closed Low Fuel Switch - Long Rod Complete Normally Open High Fuel Switch - Short Rod
Master Control Systems, Inc. 910 North Shore Drive P.O. Box 276 Lake Bluff, IL 60044 U.S.A. Phone: 847/295-1010 Fax: 847/295-0704
File: [.IM]Model_4817-6288.wpl Rev. 98.08.10;jsn
Long -and- Short Rod Fuel Switches Float Settings (Inches) for Cylindrical Tanks (U.S. Units)
60% Fuel Height Float Setting Fuel Height Float Setting Fuel Height Float Setting Fuel Height Float Setting Fuel Height Float Setting 75% 80% 85% 90% Fuel Height 95% Float Setting
Round Tank Dia.
50%
Fuel Height
Float Setting
4.750 5.250 5.750 6.250 6.750 7.250 7.750 8.250 8.750 9.250 9.750
9.500 10.000 10.500 11.000 11.500 12.000 12.500 13.000 13.500 14.000 14.500 15.000 15.500 16.000 16.500 17.000 17.500 18.000 18.500 19.000 9.375 9.625 10.000 10.250 10.500 10.875 11.125 11.500 11.750 12.000 12.375 12.625 12.875
3.375 3.750 4.125 4.625 5.000 5.375 5.875 6.250 6.750 7.125 7.500 8.000 8.375 8.750 9.250 9.625
1.125 1.375 1.750 2.000 2.250 2.625 2.875 3.250 3.500 3.750 4.125 4.375 4.750 5.000 5.250 5.625 5.875 6.125 6.500 6.750 7.125 7.375 7.625 8.000 8.250 8.625 8.875 9.125 9.500 9.750
---1.125 1.375 1.625 1.875 2.125 2.375 2.625 2.875 3.125 3.375 3.625 3.875 4.125 4.375 4.625 4.875 5.125 5.375 5.625 5.875 6.125 6.375 6.625 6.875 7.125 7.375 7.750 8.000 8.250 8.500 8.750 9.000 9.250 9.500 9.750 10.000
9.500 9.750 10.000 10.250
18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
9.375 9.750 10.250 10.625 11.000 11.500 11.875 12.375 12.750 13.125 13.625 14.000 14.375 14.875 15.250 15.625 16.125 16.500 17.000 17.375 17.750 18.250 18.625 19.000 ----
9.000 9.500 10.000 10.500 11.000 11.500 12.000 12.500 13.000 13.500 14.000 14.500 15.000 15.500 16.000 16.500 17.000 17.500 18.000 18.500 19.000 19.500 20.000 20.500 21.000 21.500 22.000 22.500 23.000 23.500 24.000 24.500 25.000 25.500 26.000 26.500 27.000 27.500 280.02 8.500 29.000 29.500 30.000
-------------
10.420 10.998 11.577 12.156 12.735 13.314 13.893 14.472 15.051 15.629 16.208 16.787 17.366 17.945 18.524 19.103 19.682 20.260 20.839 21.418 21.997 22.576 23.155 23.734 24.312 24.891 25.470 26.049 26.628 27.207 27.786 28.365 28.943 29.522 30.101 30.680 31.259 31.838 32.417 32.995 33.574 34.153 34.732
12.636 13.338 14.040 14.742 15.444 16.146 16.848 17.550 18.252 18.954 19.656 20.358 21.060 21.762 22.464 23.166 23.868 24.570 25.272 25.974 26.676 27.378 28.080 28.782 29.484 30.185 30.887 31.589 32.291 32.993 33.695 34.397 35.099 35.801 36.503 37.205 37.907 38.609 39.311 40.013 40.715 41.417 42.119
13.427 14.173 14.919 15.664 16.410 17.156 17.902 18.648 19.394 20.140 20.886 21.632 22.378 23.124 23.870 24.616 25.362 26.107 26.853 27.599 28.345 29.091 29.837 30.583 31.329 32.075 32.821 33.567 34.313 35.059 35.804 36.550 37.296 38.042 38.788 39.534 40.280 41.026 41.772 42.518 43.264 44.010 44.756
14.266 15.059 15.851 16.644 17.436 18.229 19.022 19.814 20.607 21.399 22.192 22.984 23.777 24.570 25.362 26.155 26.947 27.740 28.532 29.325 30.118 30.910 31.703 32.495 33.288 34.080 34.873 35.666 36.458 37.251 38.043 38.836 39.628 40.421 41.213 42.006 42.799 43.591 44.384 45.176 45.969 46.761 47.554
--------1.125 1.375 1.500 1.750 2.000 2.125 2.375 2.625 2.750 3.000 3.250 3.375 3.625 3.875 4.000 4.250 4.500 4.625 4.875 5.125 5.250 5.500 5.750 5.875 6.125 6.375 6.500 6.750 7.000 7.125 7.375 7.625 7.750 8.000 8.250
15.183 16.027 16.870 17.714 18.557 19.401 20.245 21.088 21.932 22.775 23.619 24.462 25.306 26.149 26.993 27.836 28.680 29.523 30.367 31.210 32.054 32.897 33.741 34.584 35.428 36.271 37.115 37.958 38.802 39.646 40.489 41.333 42.176 43.020 43.863 44.707 45.550 46.394 47.237 48.081 48.924 49.768 50.611
----------------1.125 1.250 1.375 1.500 1.750 1.875 2.000 2.125 2.375 2.500 2.625 2.750 3.000 3.125 3.250 3.375 3.625 3.750 3.875 4.000 4.250 4.375 4.500 4.625 4.875 5.000 5.125
16.248 17.151 18.054 18.957 19.859 20.762 21.665 22.567 23.470 24.373 25.275 26.178 27.081 27.983 28.886 29.789 30.692 31.594 32.497 33.400 34.302 35.205 36.108 37.010 37.913 38.816 39.718 40.621 41.524 42.427 43.329 44.232 45.135 46.037 46.940 47.843 48.745 49.648 50.551 51.453 52.356 53.259 54.162
------------------------------------1.000 1.125 1.250 1.250 1.375 1.500 1.62
NOTE: 4) Use LONG ROD (two float) Model 4817L or Model 6288L for all Settings shown in bold italics. Sheet 1 of 3 Rev.: 2004.11.14; jsn
File: 4817-6288_Fuel-Switch_Settings.wb
Long -and- Short Rod Fuel Switches Float Settings (Centimeters) for Cylindrical Tanks (Metric Units)
60% Fuel Height Float Setting Fuel Height Float Setting Fuel Height Float Setting Fuel Height Float Setting Fuel Height Float Setting 75% 80% 85% 90% Fuel Height 95% Float Setting
Round Tank Dia.
50%
Fuel Height
Float Setting
12.1 13.3 14.6 15.9 17.1 18.4 19.7 21.0 22.2 23.5 24.8
8.6 9.5 10.5 11.7 12.7 13.7 14.9 15.9 17.1 18.1 19.1 20.3 21.3 22.2 23.5 24.4
23.8 24.8 26.0 27.0 27.9 29.2 30.2 31.4 32.4 33.3 34.6 35.6 36.5 37.8 38.7 39.7 41.0 41.9 43.2 44.1 45.1 46.4 47.3 48.3
45.7 48.3 50.8 53.3 55.9 58.4 61.0 63.5 66.0 68.6 71.1 73.7 76.2 78.7 81.3 83.8 86.4 88.9 91.4 94.0 96.5 99.1 101.6 104.1 106.7 109.2 111.8 114.3 116.8 119.4 121.9 124.5 127.0 129.5 132.1 134.6 137.2 139.7 142.2 144.8 147.3 149.9 152.4 ---25.4 26.0 26.7 27.6 28.3 29.2 29.8 30.5 31.4 32.1 32.7 24.1 24.8 25.4 26.0
22.9 24.1 25.4 26.7 27.9 29.2 30.5 31.8 33.0 34.3 35.6 36.8 38.1 39.4 40.6 41.9 43.2 44.5 45.7 47.0 48.3 49.5 50.8 52.1 53.3 54.6 55.9 57.2 58.4 59.7 61.0 62.2 63.5 64.8 66.0 67.3 68.6 69.9 71.1 72.4 73.7 74.9 76.2
24.1 25.4 26.7 27.9 29.2 30.5 31.8 33.0 34.3 35.6 36.8 38.1 39.4 40.6 41.9 43.2 44.5 45.7 47.0 48.3 -------------
26.5 27.9 29.4 30.9 32.3 33.8 35.3 36.8 38.2 39.7 41.2 42.6 44.1 45.6 47.1 48.5 50.0 51.5 52.9 54.4 55.9 57.3 58.8 60.3 61.8 63.2 64.7 66.2 67.6 69.1 70.6 72.0 73.5 75.0 76.5 77.9 79.4 80.9 82.3 83.8 85.3 86.7 88.2
32.1 33.9 35.7 37.4 39.2 41.0 42.8 44.6 46.4 48.1 49.9 51.7 53.5 55.36 57.1 58.8 60.6 62.4 64.2 66.0 67.8 69.5 71.3 73.1 74.9 76.7 78.5 80.2 82.0 83.8 85.6 87.4 89.2 90.9 92.7 94.5 96.3 98.1 99.9 101.6 103.4 105.2 107.0
2.9 3.5 4.4 5.1 5.7 6.7 7.3 8.3 8.9 9.5 10.5 11.1 12.1 12.7 13.3 14.3 14.9 15.6 16.5 17.1 18.1 18.7 19.4 20.3 21.0 21.9 22.5 23.2 24.1 24.8 23.8 24.4
34.1 36.0 37.9 39.8 41.7 43.6 45.5 47.4 49.3 51.2 53.1 54.9 56.8 58.7 60.6 62.5 64.4 66.3 68.2 70.1 72.0 73.8 75.8 77.7 79.6 81.5 83.4 85.3 87.2 89.0 90.9 92.8 94.7 96.6 98.5 100.4 102.3 104.2 106.1 108.0 109.9 111.8 113.7
---2.9 3.5 4.1 4.8 5.4 6.0 6.7 7.3 7.9 8.6 9.2 9.8 10.5 11.1 11.7 12.4 13.0 13.7 14.3 14.9 15.6 16.2 16.8 17.5 18.1 18.7 19.7 20.3 21.0 21.6 22.2 22.9 23.5 24.1 24.8 25.4
36.2 38.2 40.3 42.3 44.3 46.3 48.3 50.3 52.3 54.4 56.4 58.4 60.4 62.4 64.4 66.4 68.4 70.5 72.5 74.5 76.5 78.5 80.5 82.5 84.6 86.6 88.6 90.6 92.6 94.6 96.6 98.6 100.7 102.7 104.7 106.7 108.7 110.7 112.7 114.7 116.8 118.8 120.8
--------2.9 3.5 3.8 4.4 5.1 5.4 6.0 6.7 7.0 7.6 8.3 8.6 9.2 9.8 10.2 10.8 11.4 11.7 12.4 13.0 13.3 14.0 14.6 14.9 15.6 16.2 16.5 17.1 17.8 18.1 18.7 19.4 19.7 20.3 21.0
38.6 40.7 42.9 45.0 47.1 49.3 51.4 53.6 55.7 57.8 60.0 62.1 64.3 66.4 68.6 70.7 72.8 75.0 77.1 79.3 81.4 83.6 85.7 87.8 90.0 92.1 94.3 96.4 98.6 100.7 102.8 105.0 107.1 109.3 111.4 113.6 115.7 117.8 120.0 122.1 124.3 126.4 128.6
----------------2.9 3.2 3.5 3.8 4.4 4.8 5.1 5.4 6.0 6.4 6.7 7.0 7.6 7.9 8.3 8.6 9.2 9.5 9.8 10.2 10.8 11.1 11.4 11.7 12.4 12.7 13.0
41.3 43.6 45.9 8.1 50.4 52.7 55.0 57.3 59.6 61.9 64.2 66.5 68.8 71.1 73.4 75.7 78.0 80.2 82.5 84.8 87.1 89.4 91.7 94.0 96.3 98.6 100.9 103.2 105.5 107.8 110.1 112.3 114.6 116.9 119.2 121.5 123.8 126.1 128.4 130.7 133.0 135.3 137.6
------------------------------------2.5 2.9 3.2 3.2 3.5 3.8 4.1
NOTE: 4) Use LONG ROD (two float) Model 4817L or Model 6288L for all Settings shown in bold italics.
Sheet 2 of 3
Rev.: 2004.11.14; jsn
Long -and- Short Rod Fuel Switches Oval Tank Settings Float Settings (Inches)
Float Seting Fuel Height 60% Air Height Float Setting Fuel Height Float Setting Fuel Height Float Setting Fuel Height 75% Air Height 80% Air Height 90% Air Height Float Setting
Height
Width
Fuel Height
50% Air Height
36.000 42.000 44.250 45.000 50.000

13.000 16.000 17.125 17.500 20.000 12.375 13.250 13.500 15.625
16.000 26.000 27.000 23.000 26.000
18.000 21.000 22.130 22.500 25.000
18.000 21.000 22.130 22.500 25.000
21.260 24.640 25.970 26.510 29.440
14.740 17.360 18.280 18.490 20.560
9.750
26.140 29.443 31.146 32.520 36.110
9.860 12.557 13.104 12.480 13.890
5.625 8.250 8.875 8.250 9.625
20.770 30.181 31.919 33.901 37.453
8.230 11.819 12.331 11.099 12.547
4.000 7.625 8.125 6.875 8.250
29.243 31.763 33.590 35.584 39.395
6.757 10.237 10.660 9.416 10.605
2.500 6.000 6.375 5.125 6.375
Oval Tank -- Float Settings (Centimeters)

Float Setting Fuel Height 60% Air Height Float Setting Fuel Height Float Setting Fuel Height 75% Air Height 80% Air Height Float Setting Fuel Height 90% Air Height Float Setting
Height
Width
Fuel Height
50% Air Height
91.4 106.7 111.8 114.3 127.0

33.0 40.6 43.5 44.5 50.8 31.4 34.0 34.3 39.7
40.6 60.0 68.6 58.4 66.0
45.7 53.3 53.7 57.2 63.5
45.7 53.3 53.7 57.2 63.5
54.0 62.3 66.0 67.3 74.8
37.4 44.1 46.4 47.0 52.2
24.8
66.4 74.8 79.1 82.6 91.7
25.0 31.9 33.3 31.7 35.3
14.3 21.0 22.5 21.0 24.4
52.8 76.7 81.1 86.1 95.1
20.9 30.0 31.3 28.2 31.9
10.2 19.4 20.6 17.6 21.0
74.3 80.7 85.3 90.4 100.1
17.2 26.0 20.1 23.9 26.9
6.4 15.2 16.2 13.0 16.2
Notes:
1) 2) 3) 4) 5)
Reference N.F.P.A. Standard NFPA-20 A-2-18. Typical Low Fuel Level Switch (4817) Settings are 50% thru 80%. Typical High Fuel Level Switch (6288) Settings are 80% thru 95%. Use LONG ROD (two float) Model 4817L or Model 6288L for all Settings shown in bold italics. Fuel Height values are Height of Fuel above Tank Bottom (for reference only). Air Height values are the distance from the Fuel Level to the top of the Tank (for reference only). 6) Float Setting is the distance from the top of the Float (or Top Float on Long Rod Fuel Switches) to the bottom of the Float Rod Guide Tube, with the Float (Rod) Extended (Down). 7) Float Setting values are calculated for Diesel Fuel. 8) Refer to Drawing 4817 for Short Rod (Single Float) Low Fuel Switch Dimensions. 9) Refer to Drawing 4817L for Long Rod (Two Float) Low Fuel Switch Dimensions. 10) Refer to Drawing 6288 for High Fuel Switch Dimensions.
NOTE: 4) Use LONG ROD (two float) Model 4817L or Model 6288L for all Settings shown in bold italics. Sheet 3 of 3 Rev.: 2004.11.14; jsn

Diesel Engine Controller 업체자료

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DIESEL FIRE PUMP CONTROLLER INSTRUCTION MANUAL

CLARKE, CUMMINS, CATERPILLAR & DEUTZ

MASTER CONTROL SYSTEMS, INC.

YES YES YES

Consult Master Control Systems for additional Modifications or Options available.

-1Master Control Systems, Inc.

Lake Bluff, Illinois

-2Master Control Systems, Inc.

Lake Bluff, Illinois

DEC Controller -Labeled DiagramsOutside View 1) Bulkhead Pressure Connections

9) Battery (BATT) 1 and 2 Selector Switch

11) Drain Valve Solenoid

Lake Bluff, Illinois

(CTB1-CTB4 MAY BE FOUND ON DRAWING 17100)

-4Master Control Systems, Inc.

Lake Bluff, Illinois

Installation of the Controller

Wiring of the Controller (see the following tables)

-5Master Control Systems, Inc.

Lake Bluff, Illinois

Main Engine to Controller Wiring Table DC-EIF

Minimum Wire Size (AWG)

#14 #16 #16 #16 #16

2.1 1.3 1.3 1.3 1.3

10A 1A 1A 1A 1A 20A 20A 20A 10A 10A 20A 20A 10A 1A 1A

1 #10 or 2 #12 1x 5.3 or 2x 3.3 #12 3.3

*When used. ** For 10 amp chargers.

A.C. Wiring Connections Minimum Wire Size (AWG)

2.1 2.1 2.1

n/a 12A 12A

Cabinet Ground A.C. Line A.C. Neutral

-6Master Control Systems, Inc.

Lake Bluff, Illinois

Input Alarm Signal Connections Minimum Wire Size

#16 #16 #16 #16 #16 #16 #16 #16

1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3

Controller Input Signals Minimum Wire Size

CTB4-31 CTB4-32* CTB4-33* CTB4-34* *When used.

#16 #16 #16 #16

1.3 1.3 1.3 1.3

Remote Alarm Contacts Minimum Wire Size

CTB2-26, 27, 28* CTB4-35,36,37 CTB4-38,39,40

#16 #16 #16

1.3 1.3 1.3

CTB4-41,42,43 CTB4-44,45,46 *When used.

-7Master Control Systems, Inc.

Lake Bluff, Illinois

Assembling and Attaching Main Selector Switch Hinge

Push glass rod together

-8Master Control Systems, Inc.

Lake Bluff, Illinois

Factory Default Switch Settings

Weekly Test Pushbutton

-9Master Control Systems, Inc.

Lake Bluff, Illinois

Factory Default Jumper Settings

Weekly Test Pushbutton

Weekly Test Jumper (factory default disabled)

- 10 Master Control Systems, Inc.

Lake Bluff, Illinois

Pressure Setting Adjustments

- 11 Master Control Systems, Inc.

Lake Bluff, Illinois