Control Panel (Status-Timing) Location Of Components

Control Panel (Status-Timing) Location Of Components
(1) Junction box. (2) Timing control module. (3) Emergency stop push button. (4) Engine status control module. (5) Engine control switch.

Inside Of Junction Box Door Location Of Components
(2) Timing control module. (3) Emergency stop push button. (4) Engine status control module. (5) Engine control switch. (6) Junction box door.

The Control Panel (Status-Timing) contains the Timing Control Module (TCM), Engine Status Control Module (SCM), an Emergency Stop Push Button (ESPB) and an Engine Control Switch (ECS).

The Engine Status Control Module (SCM) is used to monitor engine parameters (oil pressure, coolant temperature, engine overspeed and over cranking of the starter motor), provides an engine protection system (two stage shutdown) and controls normal start/stop functions.

The Timing Control Module (TCM) monitors the engine for detonation through the two detonation sensors. If detonation is detected the timing is retarded. If the engine stays in detonation after the timing has been retarded, the TCM will shut down the engine. The TCM also controls timing based upon engine speed.

An Emergency Stop Push Button (ESPB) is located on the control panel.

When this button is pressed, the fuel is shut off and the engine ignition is turned off.

The Engine Control Switch (ECS) has four positions - "Off/Reset, Auto, Manual and Stop".

NOTE: For location and specifications on components located on the engine, make reference to the respective Engine Service Manual.

Components On The Back Of SCM (4)
(7) Fuses (F1 through F8). (8) Switch (overspeed verify).

NOTE: For point to point wiring diagrams and schematics, make reference to the Electrical Schematic, System D.C. Schematic.

Function Of Controls

The Emergency Stop Push Button (ESPB) (3). When this button is pressed, the gas shutoff valve is de-energized which stops the fuel supply to the engine. At the same time a relay is energized to turn the ignition off (The magneto is not grounded, but the ground to the interface box from the timing control is opened).

To restart the engine, the emergency stop push button (ESPB) must be turned until it pops out. Below the emergencey stop is the Engine Control Switch (ECS) (5).

The ECS determines the status of the control panel. In the automatic position (3 o'clock), the engine will start automatically whenever the remote initiating contact (IC) (line 47) (optional) is closed. The engine will also shut down after the initiate contacts open. An adjustable cooldown time can be programmed to give a 0 to 30 minute cooldown period before the engine shuts down. In the manual (run) position (6 o'clock), the engine will start and run as long as the ECS is in this position. In the stop position (9 o'clock), the fuel solenoid shuts the engine down after cooldown. In the off/reset position (12 o'clock), the fault lights are reset and engine shuts down immediately. The power will be removed from the SCM and TCM as soon as the engine is shutdown.

Engine Status Control Module

The bottom of the control panel contains the Status Control Module. This displays fault conditions and key engine parameters.

The Engine Status Control Module (SCM) accepts information from the operator, magnetic speed pickup (MPU) (line 21), oil pressure (OP) and water temperature (WT) transducer (line 49), and the timing control (line 18). This information is used to determine the "on/off" state of the engine's fuel and ignition system.

Engine Status Control Module (SCM)
(1) Display LCD. (2) Switch (display hold switch). (3) Overcrank LED. (4) Low oil pressure LED. (5) Overspeed LED. (6) Emergency stop LED. (7) High coolant temperature LED. (8) Auxiliary shutdown.

In the very basic operating conditions, the SCM receives a signal to run the engine. The SCM then turns on the engine's fuel and starter. When the engine speed reaches the crank termination speed, the starter is disengaged. When the SCM receives a signal to stop the engine, it shuts the fuel off.

The SCM has the following features:

Cycle Crank - The SCM can be programmed to crank-rest-crank etc. for adjustable time periods (see Service Procedure A for adjusting).

2301 Control - When the engine oil pressure increases past the low oil pressure setpoint, the SCM will indicate to a 2301 Woodward Governor that it should increase the engine speed from idle to rated.

Cool Down - Upon receiving a signal to perform a normal shutdown, the SCM will wait a preprogrammed amount of time before shutting the engine off by means of the gas shutoff valve.

Automatic Operation - While in the automatic mode, the SCM can be started by a remote initiate signal [when initiate contact (IC) (line 47) closes]. Upon loss of the signal, the SCM will perform a normal shutdown.

Alarm Module Communication - The SCM can transmit fault and alarm conditions to an alarm module.

Power Down - The Control Panel (Status-Timing) system is designed to remove power from the SCM and TCM when in the off/reset mode. The SCM will not allow the power down until the Crank Termination Relay and the Fuel Control Relay are both "off" (both relays turn off 2 seconds after zero RPM).

Fuel Solenoid Type - The SCM can be programmed to work with either an Energize To Run (ETR) fuel system or an Energize To Shutdown (ETS) fuel system.

LED Display - Six LEDs are located on front of the SCM to annunciate overcrank shutdown, overspeed shutdown, low oil pressure shutdown, high coolant temperature shutdown, emergency stop and auxiliary shutdown.

Emergency Stop - If the SCM detects an emergency stop, the engine will shut down by means of ignition and fuel control. LED (6) will flash.

Transducer Module Malfunction - If the signal from the engine mounted oil pressure/temperature transducer module is lost or unreadable, the engine will be shut down by means of the fuel control and a diagnostic code will be displayed. The SCM can be programmed to ignore the transducer module malfunction.

Speed Pickup Malfunction - If the SCM loses its magnetic pickup signal, the engine will be shut down by means of the ignition system and fuel control and a diagnostic code will be displayed.

Overcrank Protection - If the engine fails to start in a preprogrammed amount of time, the SCM will halt the starting sequence and flash an LED (3). Another attempt at starting the engine cannot be made without first going into the off/reset position on the ECS.

Liquid Crystal Display (1) - Service hours, engine speed, system battery voltage, engine oil pressure and engine coolant temperature are sequentially displayed in either English or metric units. Pressing switch (2) on the front of the SCM will cause the display to lock (stop) on one of the engine parameters. Pressing the switch again will resume the display to normal sequencing. When a fault signal is detected, the display is also used to indicate diagnostic codes, to aid in troubleshooting. See Troubleshooting, Using Diagnostic Code Interpretation.

NOTE: All diagnostic lights should turn on briefly when the panel is powered up. This is a lamp test.

Overspeed Protection - If the engine speed exceeds the overspeed setpoint, it will be shut down by means of ignition and fuel control. LED (5) will flash. The overspeed setpoint is lowered to 75% of its original value while the overspeed verify switch is depressed. This will allow the overspeed circuit to be tested while the engine is operating at rated speed. See illustration in Location of Components showing location of this switch on back of SCM.

Low Oil Pressure Protection - If the engine oil pressure drops below the low oil pressure setpoint, it will be shut down by means of the fuel control. LED (4) will flash. There are two low oil pressure setpoints, one for when the engine speed is below the oil step speed and another for when the engine speed is above the oil step speed.

High Coolant Temperature Protection - If the engine coolant temperature exceeds the high coolant temperature setpoint, the engine will shut down by means of the fuel control. Led (7) will flash.

NOTE: For all fault conditions, if the fuel control fails to shutdown the engine, the ignition system is shut off five seconds after the fault occurs.

Sequence Of Operation

The Engine Control Switch (ECS) of the control panel has four positions - "AUTO, RUN (MANUAL), STOP, OFF/RESET". If the ECS is in the "AUTO" position and a signal to run is received from a remote initiate contact (IC), or the ECS is placed in the "RUN" position, the engine will crank, terminate cranking and run. The engine may cycle crank if the cycle crank feature is utilized. Engines equipped with electronic governors will run at low idle speed until lube oil pressure has exceeded the idle low oil pressure setpoint, then the 2301 relay contact of the SCM will close and the engine will accelerate to rated speed. Engines with hydra-mechanical governors will accelerate to their speed setting immediately after crank termination. The engine will run until the signal to run is removed by either turning the Engine Control Switch (ECS) to "STOP", "OFF", or the remote initiate contact opens. Once the ECS is moved to the "OFF" position, the engine will shut down immediately. However, if the control switch is placed in the "STOP" position, or if in the "AUTO" position and the remote initiate contact opens, the engine will run for a short time in the cooldown mode, if the cooldown feature was utilized. Otherwise, the engine will shutdown immediately. The engine shall then be capable of immediate restart.

Sequence Of Operation (Normal Start-Stop)

Upon receipt of a signal to start, the SCM will check to assure that:

a. An emergency stop signal is not present.

b. All faults have been reset.

c. All sensors are connected and operating properly.

d. No abnormal engine control switch signals are present.

e. The engine is not already running.

f. The SCM microprocessor is functioning properly.

g. The SCM is not in the programming mode.

The SCM will not allow the start sequence to begin and will display the proper diagnostic code when applicable, if an above fault condition exists. However, once the SCM is satisfied that conditions are normal, it will energize the Starting Motor Relay (SMR) and Run Relay (RR). The SCM will also signal for fuel (or the 2301 Governor) to be turned on by energizing the Fuel Control Relay (FCR) and Run Relay (RR). If the cycle crank feature is enabled, the SCM will automatically crank-rest-crank the engine for adjustable time periods. If the engine fails to start within the selected total crank time, the SCM will execute an overcrank fault. If a fault condition occurs while the engine is cranking, the SCM will terminate and lock out cranking and display the applicable diagnostic code, or light the appropriate LED.

After the engine starts and has achieved the proper crank termination speed, the SCM will de-energize the starting motor by de-energizing SMR and will energize the Crank Termination Relay (CTR). Once the correct low idle oil pressure is achieved, the SCM will signal for the optional 2301 Governor to accelerate the generator set to rated speed, by energizing the 2301 relay.

The engine will run as long as operating conditions remain normal and a signal to run is being received by the SCM. The SCM will sequentially display (each for a two second period) the engine oil pressure, coolant temperature, RPM, service hours, and system DC volts; by means of the digital display prior to or while the engine is operating; as well as monitor for any fault or abnormal conditions that may occur.

Upon loss of the run signal, the engine will continue to run for an adjustable cooldown period if the cooldown feature is utilized. However, if the cooldown feature is not used or if the SCM receives an off/reset signal, it will immediately de-energize the Run Relay. The fuel circuitry will be de-energized for energized to run (ETR) type (or 2301) systems. If the signal to run returns before the engine stops, the SCM will immediately go back to the running state, i.e., fuel will be turned back on, but the starting motor will not energize. However, if restart does not occur and RPM continues to drop, the SCM will initiate cranking upon reaching zero RPM. Assuming that the run signal does not return and the engine speed continues to diminish until zero RPM is reached, the Crank Termination Relay (CTR) will be de-energized and the SCM will be ready for an instant restart. The Fuel Control Relay will be ready for an instant restart. The Fuel Control Relay (FCR) of the SCM will de-energize 2 seconds after zero RPM.

Sequence Of Operation (Fault Conditions)

If a fault condition occurs prior to starting the engine, the SCM will:

a. De-energize and lock out the starting motor circuit.

b. Assure that fuel is shut off.

c. De-energize the Run Relay Circuit.

d. Energize the fault shutdown circuitry, Engine Failure Relay (ENFR).

If a fault condition occurs while the generator set is running, the SCM will respond as follows:

e. Fuel control circuitry will be:

-De-energized for energized to run engines.

-Energized for energized to shutdown engines, and the de-energized 2 seconds after the engine reaches zero RPM.

f. Magneto Ground Relay (MGR) will be de-energized, for an overspeed, emergency stop, or diagnostic codes 01, 04, 06 or if all six LED's are on. The MGR will also de-energize if the engine has not shutdown within 5 seconds after the FCR commanded it to do so as a result of a fault condition. The MGR circuitry shall be re-energized 10 to 15 seconds after the engine reaches zero rpm. The MGR shuts of the ignition system.

g. The Starter Motor Relay (SMR) circuitry shall be locked in the de-energized state.

h. The Run Relay (RR) circuitry shall be de-energized.

i. The Fault Shutdown Circuitry shall be energized, Engine Failure Relay (ENFR).

If a fault occurs before or after the engine starts, the appropriate fault indicating LED shall flash at 2 Hz or a diagnostic code shall be displayed to indicate the nature of the problem. The indicators shall remain on and the SCM shall remain in the faul mode until it receives a reset signal.

Optional Modules

Alarm Modules

The purpose of the alarm modules (ALM) is to give a warning of conditions that can become a problem before they are bad enough to shut down the engine or keep it from starting.

Alarm Module (NFPA 110 ALM)
(1) Amber LED's. (2) Red LED's. (3) Horn. (4) Acknowledge/silence switch.

The alarm module (ALM) is an attachment and is remotely mounted. Visual indication is by means of amber LED's (1) and red LED's (2). Audible indication is by means of a horn (3).

If, with the ECS in the "STOP" or "AUTO" positions, an alarm condition develops prior to or while the generator set is running, that condition will be annunciated by means of the optional alarm module and/or the remote annunciator.

One basic alarm module is used to satisfy the requirements of standby NFPA 99 alarm module, standby NFPA 110 alarm, NFPA 99 remote annunciator, and prime power alarm. The only differences between these modules is in the graphics film on the front of the panel and the jumper wires on the rear (see the DC Schematic). The NFPA 99 remote annunciator has a lamp test switch. The following description of operation refers to the alarm/remote annunciator module as the annunciator module.

Description Of Operation

The annunciator module receives data from three sources: switch inputs, internal circuitry, and a serial data link from the Engine Status Control Module (SCM).

Switch Inputs:

Up to four inputs are available to connect switches (i.e., Low Fuel Level) to. (See TABLE 1)

Internal Circuitry:

Internal circuitry is used to determine and annunciate if the supply voltage is below a setpoint.

Data Link:

The annunciator module receives data from the Engine Status Control Module (SCM) by means of a serial data link. The information included in this data stream includes:

1. Coolant temperature has exceeded the high temperature alarm setpoint programmed into the SCM.

2. Oil pressure is below the low oil pressure alarm setpoint programmed into the SCM.

3. Coolant temperature is below the low temperature alarm setpoint programmed into the SCM.

4. The engine control switch is not in the "AUTO" or "RUN" position.

5. Oil pressure is below the low pressure shutdown setpoint programmed into the SCM.

6. Coolant temperature has exceeded the high coolant temperature shutdown setpoint programmed into the SCM.

7. The engine failed to start (overcrank).

8. The engine speed exceeded the overspeed setpoint programmed into the SCM.

9. The engine shut down due to a remote fault condition.

10. The engine shut down due to a spare fault condition.

11. The engine shut down due to an emergency stop condition.

12. The engine shut down due to a diagnostic fault condition.

Data items 1 through 8 control the operation of the LED's and the horn as indicated in TABLE 1. Data items 9 through 12 control the operation of the horn only.

LED And Horn Operation:

When an alarm condition occurs, the LED corresponding to that condition will flash at 2 hertz and the horn will sound. If the alarm condition is "NOT LATCHED", the LED and horn will turn off as soon as the alarm condition ceases. If the alarm condition is "LATCHED", the LED will continue to flash until the acknowledge/silence input is activated. See TABLE 1 for "LATCHED" alarm conditions, LED and horn functions for each operating mode.

Acknowledge/Silence:

Activating the acknowledge/silence switch (4) causes the horn to cease and the LED to stay on continuously.

Data Link Malfunction:

If the data link malfunctions, the LED's controlled by the data link will flash at .5 hertz. The switch controlled LED's will function normally.

Lamp Test:

All diagnostic lights should turn on briefly when the engine is powered up. This is a lamp test.

Mode Selection:

The annunciator module operates in one of the four modes described in TABLE 1. The modes are selected by means of connections made to the mode select inputs (terminals 5 and 6) and switch 2 input (terminal 9) as shown in TABLE 2.

Remote Annunciator Panel Operation (NFPA 110)

This remote panel functions in conjunction with the NFPA 110 alarm module. The alarm module is mounted in the left side of the control panel. When an alarm occurs on the alarm module or a fault occurs on the SCM horns (3) and (6) will sound in both the alarm module and the remote annunciator and trouble light (5) will light in the remote annunciator panel. The appropriate alarm LED will also light in the alarm module or the appropriate fault LED will light in the Engine Status Control Module (SCM) portion of the Control Panel (Status-Timing).

NFPA 110 Remote Annunciator Panel
(5) Trouble light. (6) Horn. (7) Acknowledge/silence switch.

When the alarm acknowledge/silence switch (4) or (7) is pressed on either the remote panel or the alarm module, the horns on both will cease sounding. Trouble light (5) on the remote panel will also go out. The LED on the alarm module or SCM will remain on. Another fault or alarm condition will reactivate the horns, LED and light as before.

Trouble light (5) also acts as a test switch on the remote panel. When light (5) is pushed, horn (6) and light (5) will come on. The alarm module is not affected by the test switch.