M2500 Engine Controller Configuration Manual

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1 M2500 Engine Controller Configuration Manual Revision: Page 1

2 Contents 1 Preface Configuration from front panel Engine Controller Configuration RPM settings Stop Settings Run/ Stop Solenoid Settings Pre-lubrication Starter engagement protection Service indication Service interval Analogue input configuration Text Unit Cable monitoring enabled Scale, min Scale, max Show decimal Digital Input configuration Text Cable monitoring J1939 input configuration Alarm configuration Text Enabled Alarm type Auto reset Monitoring Delay Input Output Functions Siren Reset Alarm Reset Dashboard configuration Device name Oil Inp. Src (Engine oil pressure gauge) Water inp. Src (Engine coolant water temperature gauge) Modbus configuration Display and LED configuration Time and date Password configuration Firmware update from SD card Revision: Page 2

3 2.13 Save configuration to SD card Load configuration from SD card Reset all settings to default values About (SW Revision) Language configuration Automatic configuration update from SD Configuration via PC (USB) Connecting to a PC Description of the configuration tool Saving of changes in the configuration Save all Reset Page Revert Page Engine Controller Tab Digital Inputs Tab Analogue Inputs Tab Alarms Tab Output Functions Tab General Parameters Tab Communication Tab Service Indication Tab Revision: Page 3

4 1 Preface The M Engine Controller is designed for control and monitoring of marine engines. Together with the optional M Shutdown Unit the M Engine Controller forms a complete alarm, control and protective safety system for marine engines. Typical applications are marine generator engines such as auxiliary generators, emergency generators, harbour generators and propulsion engines. The unit is designed for assembly in the main switchboard or at the engine. This manual describes the configuration of M2500. Revision: Page 4

5 2 Configuration from front panel Enter the configuration mode by pressing button. Now the user is prompted for a configuration pin code. Once a valid pin code has been entered, configuration of the M2500 is allowed: Note: The factory default configuration pin code is The pin code can be changed from within the configuration area. Note: The changes made to the configuration, are only applied when the configuration area is exited. Revision: Page 5

6 2.1 Engine Controller Configuration The Engine Controller Configuration menu includes following settings: RPM settings Choice and shift between settings by use of cursor keys. Move cursor to Save & Exit and press ENTER in order to accept a change. Press ESC in order to discard a change. Revision: Page 6

7 RPM Source With this parameter the source for the speed detection is selected. It can be either a pick-up (magnetic, PNP or NPN, to be selected on DIP switches on the rear of the unit as described in the installation manual), from the J1939 bus or from an external tacho relay (connected as normally open contacts on terminal 11 for crank disconnect speed) Flywheel teeth count Here the number of teeth on the flywheel is configured. This setting is only relevant when the RPM source is set to Pick Up Nominal RPM When using a pick up or the J1939 bus for the speed detection the nominal speed of the engine must be configured. The crank disconnect and overspeed limits refer to the nominal speed setting Crank Disconnect RPM The crank disconnect rpm is the ignition speed of the engine, at which the starter is disengaged. This setting is only relevant if the speed is detected by pick up or J1939 bus. The crank disconnect speed is expressed as a percentage of the nominal speed Overspeed RPM If the overspeed limit is exceeded the M2500 will issue a shutdown command instantaneously. This shutdown is always monitored regardless if engine is running or not and cannot be overridden. This setting is only relevant if the speed is detected by pick up or J1939 bus. The over speed limit is expressed as a percentage of the nominal speed Tacho failure output If the M2500 loses the speed signal during operation, a tacho fail alarm will be issued. This alarm can be configured to trigger any of the programmable outputs Start sequence settings Start delay The start delay is the delay between activation of the remote start input and start of cranking. During the start delay the Start Warning output (terminal 37) is activated. This output can be used for connection of a horn for start warning, the pre-glow function for the engine or for energizing the engine ECU. The start delay is expressed in seconds. Revision: Page 7

8 Crank time Configuration of the crank time during each start attempt. The crank time is expressed in seconds Rest time Configuration of the rest time between start attempts. The rest time is expressed in seconds Monitoring delay Condition for the start of monitoring is detection of crank disconnect speed (ignition speed) and expiration of the monitoring delay time after detection of crank disconnect speed. The monitoring delay is expressed in seconds Auto start attempts In remote mode the number of start attempts can be configured. Usually in marine application 3 start attempts are used Start failure output If all start attempts have expired but the engine did not start, a start fail alarm will be issued. If required this alarm can be configured to trigger any of the programmable outputs Disable pulse start In default configuration pulse start is enabled. Pushing the start button briefly in local mode will start the engine according to the start configuration (with regard to crank- and rest time). If disabled the start attempt will only proceed as long as the start button is pressed. The same applies to the stop procedure. Note that in local mode only 1 start attempt is available Stop Settings Cool down time The cool down time is the time delay between activation of the stop command and the start of the stop procedure. After receiving the stop command M2500 will immediately trip the circuit breaker but allow the engine to run for the duration of the cool down time in order to cool down the engine. The cool down time is expressed in seconds and applies only in remote mode. Shutdowns will be executed immediately. Revision: Page 8

9 Stop time The stop time defines the time the stop solenoid will be activated during an engine stop procedure. If the engine continues running after expiration of the stop time, a stop failure alarm will be issued. The stop command can be interrupted if the engine is still in cool down and stop signal is removed from the stop input (terminal 9) and a start command is given at the start input (terminal 8). However cranking will be blocked until both engine speed detection is low and the oil pressure is low Stop failure output If the stop time has expired but the engine is still running (detection of crank disconnect speed) a stop fail alarm will be issued. If required this alarm can be configured to trigger any of the programmable outputs Run/ Stop Solenoid Settings Enable cable monitoring M2500 includes the possibility of cable monitoring between the stop/ run solenoid output of M2500 (terminals 66/ 67) and the stop or run solenoid Run/Stop relay as The Run/ Stop output of M2500 (terminals 66/ 67) can be configured to operate with a run solenoid (energized to run) or a stop solenoid (energized to stop). Usually the application defines which should be used: - Auxiliary generators use run solenoids. - Emergency generators use stop solenoids. Revision: Page 9

10 2.1.4 Pre-lubrication Enable lubrication When enabled, this function will lubricate the engine when the engine is stopped Mode Continuous and periodic mode are available. Continuous mode means that the will be active continuously with engine not running (between expiration of stop procedure until next cranking. Periodic means that the pre-lubrication works in intervals with engine not running. Interval time and lubrication time can be configured Interval Interval between each lubrication period. It is expressed in minutes Duration Duration of each lubrication period. It is expressed in minutes Starter engagement protection The starter engagement protection is used in order to prevent the starter from engaging to the flywheel in case the speed signal is lost and a start command is being given. Thus it protects the starter from damage. The function will check for oil pressure before each start attempt. In case oil pressure is present the start attempt will be suppressed and an alarm will be issued. Naturally the starter engagement protection cannot run together with the pre lubrication function, as pre lubrication would then prevent the engine from starting, as oil pressure would be present in spite of a not running engine. Revision: Page 10

11 Enabled This command enables or disables the starter engagement protection Oil pressure source The starter engagement protection needs to read the oil pressure in order to decide whether the engine is running or not. This command assigns the oil pressure sensor to the starter engagement protection function. The source can be any of the digital inputs, any of the analogue inputs or the J1939 bus Service indication Note: When the operator attempts to access the service indication page, he is prompted for the configuration pin code Service interval Adjustment of the running hours between each service interval. 2.2 Analogue input configuration Configuration of the analogue sensor inputs.. All analogue inputs use 4-20mA signals. The analogue inputs screen gives an overview over all analogue inputs: Revision: Page 11

12 Specific inputs can be selected by the up and down cursor keys. The configuration of the specific input can be entered by the curser right key: Text Sensor name editor.. Choose Text and press cursor right: The name of the sensor can be chosen via the up/down cursor (each letter individually). Move cursor to Save & Exit and press ENTER in order to accept the change. Press ESC in order to discard the change. Note: Text editing The following applies for the alarm text editor as well as any other text being edited. The following characters are available in the editor Please note they are presented in 5 groups: 1) a-z Lower case letters 2) A_Z Upper case letters 3) 0-9 Numbers 4) Special characters including, % 5) Empty character/ space In order to facilitate easier text editing, long pressing the up button will fast forward to the first character in the next character group. E.g., if the current character in the editor is k, then long pressing the up button, will change the character to A since that is the first character in the next character group. Similarly, long pressing the down button will change the character to the last character of the previous character group. Revision: Page 12

13 2.2.2 Unit The unit of the measurement can be chosen (as text) with help of the up/down cursor keys Cable monitoring enabled Cable monitoring can be enabled or disabled for the specific input. If enabled a cable fail alarm will be issued in case the measurement signal on the input drops below 4mA Scale, min. Adjustment of minimum measurement at input signal of 4mA Scale, max. Maximum measurement at input signal of 20mA Show decimal Indication of measurement with none or one decimal (e.g. 1 bar or 1,0 bar). 2.3 Digital Input configuration Configuration of the digital sensor inputs. All digital inputs use voltage free contacts. The digital inputs screen gives an overview over all digital inputs: Specific inputs can be selected by the up and down cursor keys. The configuration of the specific input can be entered by the curser right key: Revision: Page 13

14 2.3.1 Text Sensor name editor. Choose Text and press cursor right: The name of the sensor can be chosen via the up/down cursor (each letter individually). Move cursor to Save & Exit and press ENTER in order to accept the change. Press ESC in order to discard the change Cable monitoring Cable monitoring can be enabled or disabled for the specific input. For cable monitoring of digital inputs resistors have to be mounted close to the sensor (see installation manual). 2.4 J1939 input configuration The measurements can be taken from the J1939 bus. For this the J1939 bus must be enabled. Note: When the J1939 communication is enabled, the M2500 expects communication on the CAN-J1939 interface More specifically it expects the J1939 messages carrying the expected SPN signals. If it does not detect any communication (Not connected to bus, or remote ECU not active), a communication error alarm will be activated. It should be noted that to suppress the communications error alarm, all expected SPN signals must be present on the bus. Revision: Page 14

15 2.5 Alarm configuration The alarms screen shows a list of all programmable alarms: Each line, presents a summary of the alarm; First column indicates if the alarm gives Shutdown signal or not (alarm or shutdown). A shutdown is indicated by an exclamation mark. The checkbox in the Second column indicates if the alarm is enabled or not. The third column shows the text label assigned to the alarm. The status line at the bottom shows a summary of the trigger (Input and setpoint) for the selected alarm. Note: Navigating lists -Long-pressing the up and down buttons, takes you to the top/bottom of the list. - Pressing the up button, whilst the top most item is selected, takes you to the bottom of the list. - Pressing the down button, whilst the bottom most item is selected, takes you to the top of the list. To edit an alarm, move the cursor to the alarm and press the enter button. The alarm editor is presented: Revision: Page 15

16 2.5.1 Text Alarm text editor. Place the cursor over the Text entry and press the enter button: The name of the sensor can be chosen via the up/down cursor (each letter individually). Move cursor to Save & Exit and press ENTER in order to accept the change. Press ESC in order to discard the change Enabled Alarms can be enabled and disabled Alarm type Here the type of alarm is selected: Alarms are indicated on the Common output (terminal 46) and the Alarm LED. Alarms will not give shut down. The engine will continue running. Shutdowns are indicated on the Shutdown output and the corresponding LED, while initiating the shutdown procedure. Shutdown with override: This type of alarm is handled differently depending on the Override input (Terminal 10). - Override not activated: Treated as a Shutdown - Override activated: Treated as a normal alarm (i.e. engine will not be stopped) Auto reset Each alarm can be configured for manual or auto rest. In auto reset, the alarm disappears automatically when the alarm condition disappears. If auto reset is not selected, the alarm must be manually reset before it disappears from the LED and current alarm list. Alarms set to manual reset will block the engine from starting Monitoring Alarms can be configured to continuous monitoring or monitoring with engine running only. Continuous monitoring means that the alarm condition is monitored regardless if the engine is running or not. Revision: Page 16

17 Running only alarms are monitored after M2500 has detected that the engine is running (crank disconnect condition) and expiration of the monitoring delay. In default configuration this is 8 s after detection of the crank disconnect signal. Note: Typical alarms and shutdowns for continuous monitoring are over speed, emergency stop and high water temperature. Typical alarm and shutdown for running only is oil pressure Delay Each alarm can be configured with an individual alarm delay. This delay is expressed in seconds. Only if the alarm condition remains active for the entire alarm delay the alarm is issued Input This line shows a summary of the input criteria for the alarm being edited. To edit the input criteria, press the ENTER button to bring up the alarm input editor Input source Selection of the input source of the input alarm signal. Options are: Analogue RPM (Pick up) Digital J Input channel The specific channel is selected. The channel may correspond to a physical input or a bus-signal (J1939). The number of channels depends on the input source: Analogue: 1-8 (SENSOR 1 - SENSOR 8 inputs) RPM: 1 (Pick-up input) Digital: 1-9 (INPUT 1 INPUT 9 inputs) J1939: SPN 100, SPN 110, SPN 190 Revision: Page 17

18 J1939 channels For J1939 inputs, the channel indicates the J1939 signal / SPN number: Oil Pressure SPN 100 Coolant Temperature SPN 110 Engine Speed SPN Set point Configuration of the actual set point differs depending on the input source Analogue, RPM and J1939 For alarms monitoring an analogue type value (including RPM and J1939) the input trigger level is expressed in terms of a trigger level and an >= or <= operator, as shown below: The range which the trigger level can be set, depends on the selected input source and channel. The valid range is indicated in the brackets immediately under the set point value. Note: When the input source is analogue, the valid range for the trigger level depends on the configuration of the targeted analogue input channel. Revision: Page 18

19 Digital Input The digital input works with reference to COM. It can be configured to trigger an alarm in open or closed position. 2.6 Output Functions Some special output functions can be configured on the Output Functions tab Siren Reset The Siren Reset button can be configured to activate any of the programmable outputs. Purpose of this function is to reset an external alarm system with the siren reset button on M2500. Revision: Page 19

20 2.6.2 Alarm Reset The Alarm Reset button can be configured to activate any of the programmable outputs. Purpose of this function is to reset an external alarm system with the alarm reset button on M Dashboard configuration Device name Configuration of the device name. Revision: Page 20

21 2.7.2 Oil Inp. Src (Engine oil pressure gauge) Selection of the Engine Oil pressure gauge input. Options are: Analogue SENSOR 1 input J1939, SPN 100 Note: When input source is set to J1939, the J1939 communication must be enabled Water inp. Src (Engine coolant water temperature gauge) Selection of the Engine Coolant water temperature gauge input. Options are: Analogue SENSOR 2 J1939, SPN 110 Note: When input source is set to J1939, the J1939 communication must be enabled 2.8 Modbus configuration The RS485 communication interface can be configured with regard to MODBUS slave address, baud rate and parity. Note: MODBUS slave address The MODBUS slave address must be unique on the MODBUS network Note: RS-485 network termination Make sure the underlying RS-485 network is properly terminated. If the M2500 is the last node on your network, the switch DIP1 on the back of the device can be used to enable an internal termination resistor. Revision: Page 21

22 2.9 Display and LED configuration This section is for dimming of the LED and the Backlit display. The LED intensity and LCD backlight intensity changes as you alter the value in the dialogue. LED test can be performed by choosing LED test in the dialogue or long pressing gauges button Time and date Adjustment of date and time to be shown by the controller and used by the Log Revision: Page 22

23 2.11 Password configuration In this menu the service and configuration password can be set. The service password must be entered in order to get access to these settings. After the password has been entered the settings are accessible: Note: The passwords are NOT reset when the configuration parameters are reset or by upgrading the firmware. Make sure to keep safe copies of your passwords, if changed! Revision: Page 23

24 2.12 Firmware update from SD card The firmware upgrade runs automatically once initiated. It is not necessary to export the configuration or log files before the firmware upgrade. The M2500 will automatically save backups of both configuration and log and will restore the configuration automatically as part of the upgrade procedure. The M2500 firmware consists of two files: M2500.bin M2500.md5 In order to upgrade the firmware, these two files must be present in the root directory of the SD card: Insert the SD card containing the firmware into the SD card slot of M2500, enter the configuration mode (password required) and choose Firmware update from SD card. Following screen will appear: Revision: Page 24

25 After pressing ENTER the firmware upgrade will run automatically through following steps: Step Description Validating firmware Backing up firmware The M2500 checks if the new firmware is valid (e.g. if it has access to both M2500 firmware files) The M2500 creates a backup of the firmware that is currently installed on the M2500 in the backup folder on the SD card Backing up configuration The M2500 creates a back up file of the configuration currently installed on the M2500 Backing up log Copying firmware Programming flash Rebooting Restoring configuration The M2500 creates a back up file of the log currently installed on the M2500 The M2500 copies the new firmware from the SD card to the internal memory Firmware upgrade running Restart of M2500 (the screen will briefly become black) The configuration is restored to the condition before the upgrade After the firmware upgrade has finished the unit will show following screen: Press Enter or ESC to return to the configuration menu. Note: SD card up to 4GB can be used with M2500. Bigger cards are incompatible. Revision: Page 25

26 2.13 Save configuration to SD card This menu is used in order to save a copy of the configuration of the M2500 to the SD card. - Enter the configuration mode by pressing - Type pin code and press - Choose Save configuration to SD card by pressing - - Press - The configuration is now copied to the SD card Note: This process will overwrite any existing configurations stored on the SD card. Note: SD cards up to 4GB can be used with M2500. Bigger cards are incompatible. Now a copy of the configuration (config.cfg) is saved in the root directory of the SD card: Revision: Page 26

27 2.14 Load configuration from SD card This menu is used in order to install a configuration from the SD card to the M2500. Note: SD card up to 4GB can be used with M2500. Bigger cards are incompatible. In order to import a configuration (config.cfg) from the SD card to the M2500 the configuration file must be saved in the root directory of the M2500 SD card: For loading of a configuration file from the SD card insert the card into the M Enter the configuration mode by pressing - Type pin code and press - Choose Load configuration from SD card card by pressing - Press - Confirm load of configuration by choosing YES (press ) and press Now the configuration will be uploaded from the SD card and saved on the M2500. Revision: Page 27

28 2.15 Reset all settings to default values This command will reset the configuration to factory default values. While resetting, the M2500 will prompt with the following screen: After resetting the File system busy window will close About (SW Revision) This dialogue indicates the Software revision date and the serial number of the M2500: 2.17 Language configuration The display language can be switched between English and Russian. Revision: Page 28

29 3 Automatic configuration update from SD It is possible to update the configuration from the SD card in an automated fashion This is useful if you have to apply a given configuration to multiple devices. The steps are: 1. Place a configuration file in the root of the SD card and name it auto.cmd. 2. Insert the SD card into M M2500 now detects the presence of the auto.cmd file and prompts the user for the configuration pin code. If the operator enters a valid configuration pin code, M2500 proceeds to read in the configuration. Note: The auto.cmd file is not deleted after it has been parsed. This allows the operator to move the SD card on to a new device. Note: SD card up to 4GB can be used with M2500. Bigger cards are incompatible. Revision: Page 29

30 4 Configuration via PC (USB) The PC application needed to configure the M2500 is built into the M2500 firmware and is preinstalled on the internal drives of the M2500. When connected to a compatible PC via a USB cable, the internal drives of the M2500 are presented in the Windows file manager, similar to accessing a USB key or a USB hard disc. Note: HTA support The configuration and log-viewer applications are implemented using HTA technology. This is a Microsoft-only technology and is only supported by the MS Windows operating system with internet explorer 5.0 or later. Note: USB Mass Storage The USB Mass Storage technology is widely supported. The internal drives of M2500 containing the configuration and log files can be accessed by virtually any computer Even if it is not running a Microsoft operation system. 4.1 Connecting to a PC When M2500 detects a USB cable, M2500 begins a process that ensures all drives contain up-todate configuration and log data: The progress is illustrated on the user interface. When the drives are up to date, the user interface is locked, preventing the operator from making local configuration changes whilst connected to the PC: Note: Locking the user interface does not affect the functionality. The M2500 will continue running and it will be possible to start and stop engines locally or remotely. Revision: Page 30

31 M2500 stays in this mode until the USB cable is detached. When connected to a PC the M2500 implements a USB key -like feature (USB Mass storage). When the M2500 is connected to a PC, three drives will appear in your file manager. These drives behave like standard USB mass storage device and the content can be dragged and dropped to the drive. The drives SELCO Log (the log drive) and SELCO Configuration (the configuration drive) are internal memory of M2500. The log drive is a read only drive. It is not possible to erase the event log from the system. Note: Circular log When the log drive becomes full, the log-file will automatically remove the oldest log-entries to in order to make room for new events. The log will always contain the most recent events. The drive SELCO SD is the SD card M2500 effectively operates like a standard card reader. Note: The changes made through the configuration tool must be saved to the configuration drive The configuration will be saved when the USB cable is disconnected. Revision: Page 31

32 4.2 Description of the configuration tool The configuration tool is saved on the configuration drive of the M2500. The configuration tool will open in the web browser. It is not necessary to install any programming software on the PC. Double click on the config.hta file in the root of the configuration drive and the configuration tool will open in your web browser (the configuration itself is saved in the config.cfg file. The configuration parameters are organized in tabs similarly to the way the configuration menu is organized. Revision: Page 32

33 4.3 Saving of changes in the configuration Save all After changes have been made, the configuration must be saved to the config.cfg file on the configuration disc. This can be done by clicking on the Save all button on the bottom of the configuration spread sheet: The Save all button will save all changes on all spread sheets Note: After pressing the save all button, the changes will only be saved on the Configuration Drive. They will not be loaded to the internal memory of the M2500 and will not influence the operation of M2500. The changes will be saved on the M2500 when the USB cable is disconnected. When the cable is removed, M2500 reads the configuration drive to see if the configuration tool left a config.cmd file i.e. if the operator saved a configuration If so, the user is presented with a pin code prompt. If the user rejects the dialogue with the esc button, the configuration is rejected (Deleted). If a valid password is entered, the configuration is parsed and M2500 is updated accordingly. Revision: Page 33

34 4.3.2 Reset Page The reset page button will reset all settings on the current page to the factory default settings: Revert Page Revert page will re-establish the original configuration for all parameters on the selected screen. Revision: Page 34

35 4.4 Engine Controller Tab The first tab includes the engine controller settings such as rpm settings, start and stop parameters, and the configuration of the starter engagement protection as described in chapter Revision: Page 35

36 4.5 Digital Inputs Tab This tab includes the configuration of the digital inputs. Click on Edit in order to start configuration of the digital input. Revert resets the input to the last saved setting. Click Reset in order to reset the input to the factory default configuration. Copy will copy all settings of the specific input. They can then be pasted to any of the other digital inputs. Paste will paste the copied settings to the specific digital input ( Paste will only appear after settings have been copied ) Click on Edit in order to start configuration of the digital input: On this screen the name of the digital input can be configured and the cable monitoring function for this particular input can be enabled or disabled. Revision: Page 36

37 4.6 Analogue Inputs Tab This tab includes the configuration of the analogue inputs. Click on Edit in order to start configuration of the analogue input: Show decimal point If activated, following scale means 1 to 10 bar. If deactivated it would mean 10 to 100 bar. Revision: Page 37

38 4.7 Alarms Tab This tab includes the configuration of the alarms. Click on Edit in order to configure an alarm: Revision: Page 38

39 4.8 Output Functions Tab Special output functions can be configured on the output functions tab:... Revision: Page 39

40 4.9 General Parameters Tab The LED and display back light intensity (dimming), the dashboard and the display language can be configured on the General Parameters Tab Communication Tab This tab includes the configuration of the J1939 and RS485 communication. Revision: Page 40

41 4.11 Service Indication Tab This tab includes the configuration of the Service indication. Revision: Page 41

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