A900-9025N
Revised 10-99
Section 40
(00-02-0197)
SERIES A900
®
MURPHYMATIC GENERATOR
ENGINE CONTROL SYSTEM
DESIGN, INSTALLATION
AND OPERATING MANUAL
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Table of Contents
Section 1: Introduction
1-1 System
page 1
1
1
1
1
1
1-2 Models
1-3 Purpose
1-4 Definitions
1-5 How To Use This Manual
Section 2: Specifications
2-1 Enclosure Type
1
1
1
1
1
1
1
2-2 Power Requirements
2-3 Input Ratings
2-4 Output Ratings
2-5 Field Wiring Connections
2-6 Operating Temperature
Section 3: Model Identification
1
1
2
3-1 Model Numbers
3-1
3-2
32
5
7
3-5 A902
3-6 A903
3-7 A903-2
8
10
12
Section 4: Installation
4-1 Location
14
14
14
19
19
4-2 Wiring
4-3 Crank Disconnect
4-4 Pre-Operational Check-Out
Section 5: Operation
5-1 Operator Controls
5-2 Operating Modes
21
21
21
Section 6: Routine Maintenance and Operational Tests
6-1 Routine Maintenance
21
6-2 Operational Tests
Section 7: Troubleshooting and Repair
7-1 Tools Required
21
21
21
23
7-2 A900 SELECTRONIC® Control Operation and Shutdown
7-3 A900 SELECTRONIC® Control Alarm Circuit Operation
Section 8: Service Parts
24
24
24
8-1 Table 8-1: Replacement Components of the A900 Series Generator Controls
8-2 Table 8-2: Replacement Components of the A900 Controls for Detroit Diesel
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1-5 How to use this manual.
1-5.1 Section 1, 2, 4, 5, 6 and 7 contain general information that
applies to all A900 models.
1-5.2 Section 3, Model Identification, is broken into seven sub
sections. Section 3-1 allows you to chose the model that best
fits your requirements and Section 3-2 through 3-7 explain each
models features in detail.
Section 1: Introduction
1-1 System.
1-1.1 The MURPHYMATIC® Generator Engine Control System,
Series A900 is designed to meet the requirements of the engine
control, shutdown and alarm section of NFPA-110 “Emergency
And Standby Power Systems” specification. The controller also
meets the minimum requirements of NFPA99 “Health Care
Facilities” and the Canadian standard CAN/CSA-C282-M89
“Emergency Electrical Power Supply for Buildings” for engine
Section 2: Specifications
control, shutdown and alarm systems. By combining one of the 2-1 Enclosure Type.
A900 series controls with generator instruments, a complete engine 2-1.1 The A900 Series enclosure is designed to be mounted in a
generator control panel meeting the above specifications can be standard electrical enclosure for indoor use.
provided.
1-2 Models.
2-2 Power Requirements.
2-2.1 The engine controls, shutdown circuits, alarm and shut-
down indicators are powered from the engine starting battery.
The A900 series is available in either 12 or 24 V, negative ground.
1-2.1 The Series A900 is available in three basic configurations:
1-2.1.1 Model A901 for automatic start and stop generator sets
which includes the minimum shutdowns and alarms per NFPA-
110 Level 1.
1-2.1.2 Model A902 for automatic start and stop generator sets
which incthe minimum shutdowns and alarms per NFPA-
110 Leve
2-2.2 The A900 is fused for 3 A maximum current.
2-3 Input Ratings.
2-3.1 All input switches should be dry contact type, maximum
current is 2 mA, 8 V DC or less.
2-3.2 Frequency signal for the speed sensing circuit requires a
1-2.1.3 90or automatic start and stop generator sets
minimum input of 2 V rms from a magnetic pickup (preferred) or
which includes the inimm stdowns and alarms per NFPA-
from the tachometer terminal of the battery charging alternator.
110 Level 2 and sven unleled rlights for additional
2-3.2.1 Frequency range of the speed sensing circuits is 25 Hz to
10,000 Hz.
customer specified alarms.
1-2.2 All models are available for or 24 V tion.
1-2.3 All models are available for use on eitle our 2-4 Output Ratings.
cycle engines. Models for two cycle enginee arm 2-4.1 The A900 Control / Display Module has outputs for remote
light for “Air Damper Closed” and an “Overspeed ayindon of alarm and shutdowns. These outputs are transistors
operate the air shutoff solenoid for overspeed shutdown.
thalose to e negative supply (sink) and are rated at 1 amp, 30
1-2.4 Each model is made up of two parts, a Control/Display V C maxum.
module and a Relay module.
2-4.2 ThConDlay Module also has an output for an
auxiliary starteonwhis rated 1 A, 30 V DC maximum.
This is a transistor thosethe ptive supply (source).
2-4.3 The Relay Module inudeengcool relays with
contact ratings of 7 A, 30 V DC ice. powered
contacts must be supplied from an 8 fuse obreaker
(customer supplied). The 3 alarm relays have cts, also
rated at 7 A, 30 V DC maximum.
1-3 Purpose.
1-3.1 This manual is directed to the installation, maintenance and
operating personnel who will be in day to day contact with the
A900 system. However the basic knowledge gained with this
material will allow those personnel to easily adjust to special
circumstances.
1-4 Definitions.
1-4.1 Throughout this manual, reference is made to organi- 2-5 Field Wiring Connections.
zations, trade names and trademarks which may not be familiar to 2-5.1 All field wiring connections are barrier terminal blocks, UL
the reader. Some of these are:
rated for 15 A, 300 V.
1-4.1.1 CSA: Canadian Standards Association.
1-4.1.2 CAN/CSA-C282-M89: The standard for Emergency
Electrical Power Supply for Buildings, 1989 Edition.
1-4.1.3 NFPA: National Fire Protection Association.
1-4.1.4 NFPA-70: The National Electrical Code.
1-4.1.5 NFPA-99-1990: The standard for Health Care Facilities,
1990 Edition.
2-6 Operating Temperature.
2-6.1 The operating temperature range of the A900 is -4°F to
158°F (-20°C to 70°C.)
Section 3: Model Identification
3-1 Model Numbers.
3-1.1 A901-12 and A901-24: These models are designed for an
automatic start four cycle engine driven generator, and
include the shutdown and alarm points recommended in NFPA-
110-1988 “Emergency and Standby Generator Systems” for Level
1 installations. These controllers also meet or exceed the
minimum requirements of NFPA99-1990 “Health Care Facilities”
and with the addition of a Low Water Level alarm, the Canadian
standard CAN/CSA-C282-M89 “Emergency Electrical Power
Supply for Buildings”. The suffix numbers -12 and -24 indicate
the engine starting battery voltage.
1-4.1.6 NFPA-110-1988: The standard for Emergency And
Standby Power Systems, 1988 Edition.
1-4.1.7 Several terms used in this manual are registered
trademarks of Frank W. Murphy Mfr.
(a) MURPHYMATIC®: Refers to all Murphy automatic controls.
(b) SELECTRONIC®: A name that is applied to all electronic
controls manufactured by Murphy.
(c) SWICHGAGE®: A combination indicating gauge and switch.
(d) TATTLETALE®: A term that refers to a shutdown indicating
device or circuit in the control panel.
3-1.2 A901-2-12 and A901-2-24: These models are designed for
1
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an automatic-start, two-cycle, engine-driven generator, and
include the shutdown and alarm points recommended in NFPA-
110-1988 “Emergency and Standby Generator Systems” for
Level 1 installations. These controllers also meet or exceed the
minimum requirements of NFPA-99-1990 “Health Care
Facilities” and with the addition of a Low Water Level alarm,
the Canadian standard CAN/CSA-C282-M89 “Emergency
Electrical Power Supply for Buildings”. The suffix numbers -12
and -24 indicate the engine starting battery voltage.
6-1/2 in.
(165 mm)
Low Water
Overcrank
Overspeed
Oil Pressure
Temperature
Loss of Speed
Signal
Lamp Test
3-1.2.1 The A901-2 series control includes an “Air Damper
Closed” light and “Overspeed Relay” to trip the air shut-off
solenoid on overspeed of a two-cycle engine.
Water
Temperature
AUTO
OFF
9-3/4 in.
(248 mm)
TEST
3-1.3 A902-12 and A902-24: These models are designed for an
automatic-start, four-cycle, engine-driven generator, and include
the shutdown and alarm points recommended in NFPA-110-
1988 “Emergency and Standby Generator Systems” for Level 2
installations. The suffix numbers -12 and -24 indicate the
engine starting battery voltage.
3-1.4 A902-2-12 and A902-2-24: These models are designed
for an autoc-start, two-cycle, engine-driven generator, and
include the n and alarm points recommended in NFPA-
110-1988 ncnd Standby Generator Systems” for
Level 2 instaons. he fix umbers -12 and -24 indicate
the engine starting bery volte.
Switch
Low Oil Pressure
PreAlarm
Not In AUTO
Low Fuel
Level
High Water Temp.
PreAlarm
Battery Charger
AC Failure
High Battery
Voltage
Low Battery
Voltage
Alarm Silence
3-1.4.1 The A902-2 sericroncludan “Air Damper
Closed” light and “Overspeed Re” to trip shut-off
solenoid on overspeed of a two-cycle ene.
3-1.5 A903-12 and A903-24: These models are d f
automatic-start, four-cycle, engine-driven generator, and iud
the shutdown and alarm points recommended in NFPA-110
1988 “Emergency and Standby Generator Systems” for Level 2
installations plus seven unlabeled alarms that the user may
specify and an “Alarm Silence Switch”. The suffix numbers -12
and -24 indicate the engine starting battery voltage.
Figure 3-2.1
(c) turns on the engine controls and shutdown circuits.
start nal is applied to the automatic control and the
engine rt snce begins.
3-2.1.2 LaTePhttonTests the lights on the A901
module.
3-2.1.3 Alarm Silence Pshbon: ns y audible alarm
that is connected to the Local ote ible Alam Relays.
The indicating light will remain on as ng as thtion
exists. If the Alarm Silence pushbutton is ot he
audible alarm will turn off when the alarm contact cl
3-2.1.4 The A901 SELECTRONIC® Control Module includes
the following engine control features:
3-1.6 A903-2-12 and A903-2-24: These models are designed for
an automatic-start, two-cycle, engine driven generator, and
include the shutdown and alarm points recommended in NFPA-
110-1988 “Emergency and Standby Generator Systems” for
Level 2 installations plus seven unlabeled alarms that the user
may specify and an “Alarm Silence Switch”. The suffix numbers
-12 and -24 indicate the engine starting battery voltage.
(a) Cycle crank circuit; will crank the engine for 15 seconds
then rest for 15 seconds until the engine starts. The
crank/rest time can be selected for either 10, 15, 20, 25 or
30 seconds. If the engine false starts, goes above crank
disconnect speed then drops below that speed, the control
will rest for a fixed 10 second period before cranking again.
(b) Crank Disconnect Speed Switch; this circuit detects
engine speed and terminates cranking when engine speed
rises above the speed switch setting. The speed switch is
adjustable, 25 Hz to 2000 Hz, and is factory set at 1180
Hz. This would be 600 RPM on an engine with 118 teeth
on the flywheel ring gear.
(c) Auxiliary Crank Disconnect Circuit; this circuit, required by
NFPA-110, is provided as a back up for the Crank
Disconnect Speed Switch. It is operated by an external
switch sensing either speed, generator voltage or some other
variable that could be used to terminate cranking. Either
circuit will disconnect the starter when the engine starts.
3-1.6.1 The A903-2 series control includes an “Air Damper
Closed” light and “Overspeed Relay” to trip the air shut-off
solenoid on overspeed of a two-cycle engine.
3-1.7 Table 3-1.7 illustrates the alarm and shutdown require-
ments of NFPA-110, NFPA99 and CAN/CSA-C282-M89 and
compares the features of the A900 series controls to those
requirements.
3-2 A901.
3-2.1 Control / Display Module. The Control / Display Module,
figure 3-2.1, includes the control and test switches, the solid state
logic elements, shutdown and alarm TATTLETALE® lights that
make up the generator engine control for a four-cycle engine.
3-2.1.1 Mode Selector Switch, OFF-AUTO-TEST:
(a) OFF; turns off the control system and resets any shutdown
circuits.
(b) AUTO; turns on the engine controls and shutdown circuits.
System is on standby waiting for a contact closure to start
engine.
2
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Table 3-1.7
3
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(d) Overcrank circuit; will stop automatic cranking and
indicate overcrank if engine fails to start after 3 attempts.
The number of cranks are selectable for 1, 2, 3, 4 or 5
cycles before shutdown. The overcrank circuit may also
be turned off so no overcrank shutdown occurs.
activated by the frequency input, it prevents the engine
from running without overspeed protection.
(g) Remote Shutdown; this circuit is provided to shutdown
the engine generator from a remote location. No
indicating light is provided.
(e) Shutdown Time Delay Bypass; this delay prevents the oil 3-2.1.6 Nine (9) Alarm Indicating Circuits; provide indication of
pressure, water temperature and loss of speed signal cause of alarm. These circuits activate the alarm relays. Alarm
shutdown circuits from operating for 15 seconds after the circuits are active as long as power is applied to the A901. All are
engine starts as detected by the crank disconnect circuit. active when the engine is running, shutdown or on standby except
This same delay also locks out the Low Oil Pressure Pre- Low Oil Pressure Pre- alarm and High Water Temperature Pre-
alarm and High Water Temperature Pre-alarm circuits alarm. Nine (9) Amber Alarm Indicating Lights are provided.
when the engine is not running.
(f) Overspeed Speed Switch;
(a) Low Water Temperature; operated by low water temp-
erature SWICHGAGE®.
1. Provides a signal to the overspeed shutdown circuit if
the engine exceeds the preset speed. The factory
setting is approximately 3894 Hz, or 1980 RPM on an
engine with 118 teeth on the flywheel ring gear. The
adjustment range is 300 Hz to 10,000 Hz.
(b) Spare Alarm; operated by an external switch. This circuit
is provided for an additional alarm that may be required by
the user.
(c) Switch Not In Automatic; operated by the OFF-AUTO-
TEST mode selector switch.
2. A push-to-test switch is provided to allow testing of the
oveed circuit without overspeeding the engine.
tch is depressed, the set point of the speed
owed approximately 10%.
3. The ush-test witcan also be used to set the
overspeed witch at pproxly 110% of running
speed. Hold the itdessed hile adjusting the
setting until the oversptrips. witch is
released, the set point will be 10% aboung
speed. This is the method used to fa
setting. With engine speed at 1800 RPM or 3540
(d) Low Fuel Level; operated by level switch on fuel tank.
(e) High Battery Voltage; operated by relay contact in
battery charger.
(f) Low Battery Voltage; operated by low voltage sensing
device in battery charger.
(g) Low Oil Pressure Pre-alarm; operated by pre-alarm
switch in oil pressure SWICHGAGE®.
(h) High Water Temperature Pre-alarm; operated by pre
alarm switch in water temperature SWICHGAGE®.
(i) Battery Charger AC Failure: operated by a relay contact in
Battery Charger.
(g) Cooldown circuit; this circuit keeps the engine runnin3-2.2 elay Mdule. The Relay Module, figure 3-2.2, includes
for five minutes after the transfer switch has removed all oe con, aland shutdown relays that are required to
the load from the generator and signaled the A901 to make up the nerene control. Relays are available for
stop the engine. This feature may be selected (turned operation on eith2 volattery systems. Five (5) relays
On, standard setting is Off) with a switch on the back of are included for:
the Control / Display Module.
3-2.2.1 Fuel Relay; this rey prdes wo tputs, one to
3-2.1.5 Seven (7) First-out Shutdown Circuits; provide first-out energize the engine fuel solenod and parate cuit to
indication of cause of shutdown. These circuits deactivate the
fuel relay and lockout the A901 until reset. Shutdown circuits
Figure 3-2.2
are activated by the crank disconnect circuit and are not active
when the engine is stopped. Six (6) Red Shutdown Indicating
Lights are provided. The Remote Shutdown circuit does not
have an indicator light.
3A Fuse
1A
4
(a) Overcrank; tripped by the overcrank sensing circuit which
counts the number of cranking attempts.
RH2V2
RH2V2
5
6
7
8
9
16
17
18
19
20
21
22
-U
-U
(b) Overspeed; tripped by overspeed switch when engine
exceeds a preset speed.
(c) Oil Pressure; tripped by the oil pressure SWICHGAGE®
if pressure drops below preset point while the engine is
running.
DC12V
DC12V
6-1/4 in.
(159 mm)
RH2V2
-U
DC12V
RH2V2
-U
DC12V
(d) Water Temperature; tripped by the water temperature
SWICHGAGE® if engine coolant temperature exceeds the
switch setting.
(e) Spare Shutdown; tripped by an external switch. This
circuit is provided for an additional shutdown that may be
recommended by the engine supplier.
23
24
25
RH2V2
-U
DC12V
(f) Loss of Speed Signal; tripped by an internal sensing
circuit that detects the loss of the Magnetic Pickup
frequency signal for the speed switches while the engine
is still running. Since the Overspeed shutdown circuit is
4-1/2 in.
(114 mm)
4
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energize the battery charging alternator field.
crank/rest time is selectable for either 10, 15, 20, 25 or 30
seconds. If the engine false starts, goes above crank
disconnect speed then drops below that speed, the control
will rest for a fixed 10 second period before cranking again.
(b) Crank Disconnect Speed Switch; this circuit detects
engine speed and terminates cranking when engine speed
rises above the speed switch setting. The speed switch is
adjustable, 25 Hz to 2000 Hz, and is factory set at 1180
Hz. This would be 600 RPM on an engine with 118 teeth
on the flywheel ring gear.
3-2.2.2 Shutdown Relay; this relay is operated by the shutdown
circuits of the Control / Display Module and provides an output
that can be used to trip the generator circuit breaker on an
emergency shutdown.
3-2.2.3 Local Audible Alarm Relay; provides a contact closure
to operate a local audible alarm as required by NFPA-110, Level
1 and Level 2.
3-2.2.4 Remote Audible Alarm Relay; provides a contact
closure to operate a remote audible alarm as required by NFPA-
110, Level 1.
3-2.2.5 Remote Visual Alarm Relay; provides a contact closure
to operate a remote visual alarm as required by NFPA- 110,
Level 1.
6-1/2 in.
(165 mm)
3-2.3 Status Signals. The relay module also includes three
outputs that can be used with external circuits for signaling or
control functions.
3-2.3.1 The Control On function at terminal 12 is on (closed
to negative) as long as the Mode Selector Switch is in either
Auto ost. When the Mode Selector is turned Off, the
Contrnal is open. This can be used to signal switch
posiesn external circuit when the Mode Selector
is turned f.
Low Water
Overcrank
Overspeed
Oil Pressure
Temperature
Loss of Speed
Signal
Lamp Test
Water
Temperature
AUTO
OFF
9-3/4 in.
(248 mm)
TEST
3-2.3.2 The Syem Reasignerminal 13 is on (closed
to negative) as long athMSelor Switch is in either
Auto or Test and no shutdown attletale latched on.
This can be used to signal that the generais dy to
automatically start or is running in Test.
3-2.3.3 The Control On function at terminal 14 is (
to positive) as long as the Mode Selector Switch is in er
Auto or Test. When the Mode Selector is turned Off, the
Control On signal is open. This can be used to signal switch
position or to reset an external circuit when the Mode Selector
is turned Off.
Air Damper
Closed
Switch
Low Oil Pressure
PreAlarm
Not In AUTO
Low Fuel
Level
High Water Temp.
PreAlarm
Battery Charger
AC Failure
High Battery
Voltage
attery
age
Alarm Silence
3-3 A901-2.
3-3.1 Control / Display Module. The Control / Display Module,
figure 3-3.1, includes the control and test switches, the solid state
logic elements, shutdown and alarm TATTLETALE® lights that
make up the generator engine control for a two-cycle engine.
3-3.1.1 Mode Selector Switch, OFF-AUTO-TEST:
(a) OFF; turns off the control system and resets any shutdown
circuits.
(b) AUTO; turns on the engine controls and shutdown
circuits. System is on standby waiting for a contact
closure to start engine.
(c) TEST; turns on the engine controls and shutdown circuits.
A start signal is applied to the automatic control and the
engine start sequence begins.
3-3.1.2 Lamp Test Pushbutton: Tests the lights on the A- 901-2
module.
3-3.1.3 Alarm Silence Pushbutton: Turns off any audible alarm
that is connected to the Local or Remote Audible Alarm Relays.
The indicating light will remain on as long as the condition
exists. If the Alarm Silence pushbutton is not operated, the
audible alarm will turn off when the alarm contact clears.
3-3.1.4 The A901-2 SELECTRONIC® Control Module includes
the following engine control features:
Figure 3-3.1
(c) Auxiliary Crank Disconnect Circuit; this circuit, required by
NFPA-110, is provided as a back up for the Crank Discon-
nect Speed Switch. It is operated by an external switch
sensing either speed, generator voltage or some other
variable that could be used to terminate cranking. Either
circuit will disconnect the starter when the engine starts.
(d) Overcrank circuit; will stop automatic cranking and
indicate overcrank if engine fails to start after 3 attempts.
The number of cranks are selectable for 1, 2, 3, 4 or 5
cycles before shutdown. The overcrank circuit may also
be turned off so no overcrank shutdown occurs.
(e) Shutdown Time Delay Bypass; this delay prevents the oil
pressure, water temperature and loss of speed signal
shutdown circuits from operating for 15 seconds after the
engine starts as detected by the crank disconnect circuit.
This same delay also locks out the Low Oil Pressure Pre-
alarm and High Water Temperature Pre-alarm circuits
when the engine is not running.
(a) Cycle crank circuit; will crank the engine for 15 seconds
then rest for 15 seconds until the engine starts. The
5
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(f) Overspeed Speed Switch;
(b) Air Damper Closed; operated by an external switch or by
the Overspeed Relay circuit. This circuit is provided with
a selector switch to allow the user to determine the source
of the signal.
(c) Switch Not In Automatic; operated by the OFF-AUTO-
TEST mode selector switch.
1. Provides a signal to the overspeed shutdown circuit if
the engine exceeds the preset speed. The factory
setting is approximately 3894 Hz, or 1980 RPM on an
engine with 118 teeth on the flywheel ring gear. The
adjustment range is 300 Hz to 10,000 Hz.
2. A push to test switch is provided to allow testing of the
overspeed circuit without overspeeding the engine.
When switch is depressed, the set point of the speed
switch is lowered approximately 10%.
3. The push to test switch can also be used to set the
overspeed switch at approximately 110% of running
speed. Hold the switch depressed while adjusting the
setting until the overspeed trips. When switch is
released, the set point will be 10% above normal running
speed. This is the method used to make the factory
setting. With engine speed at 1800 RPM or 3540 Hz.
(d) Low Fuel Level; operated by level switch on fuel tank.
(e) High Battery Voltage; operated by relay contact in battery
charger.
(f) Low Battery Voltage; operated by low voltage sensing
device in battery charger.
(g) Low Oil Pressure Pre-alarm; operated by pre-alarm
switch in oil pressure SWICHGAGE®.
(h) High Water Temperature Pre-alarm; operated by pre-
alarm switch in water temperature SWICHGAGE®.
(i) Battery Charger AC Failure; operated by relay contact in
Battery Charger.
(g) Cooldown circuit; this circuit keeps the engine running 3-3.2 Relay Module. The Relay Module, figure 3-3.2, includes
for five minutes after the transfer switch has removed all of the control, alarm and shutdown relays that are required to
the lrom the generator and signaled the A901-2 to make up the generator engine control. Relays are available for
stop ne. This feature may be selected (turned operation on either 12 or 24 volt battery systems. Six (6) relays
Onseg is Off) with a switch on the back of are included for:
the Conol / Dplay ode.
3-3.1.5 Seven (7) Fit-out Shdown its; provide first-out
indication of cause of shuose ciuits deactivate the
fuel relay and lockout the A901-2 ul reset. Scircuits
are activated by the crank disconnect cicuit aace
when the engine is stopped. Six (6) Red Shutdic
3A Fuse
Lights are provided. The Remote Shutdown circuit don
A
have an indicator light.
4
(a) Overcrank; tripped by the overcrank sensing circuit which
7
8
9
16
17
18
19
2
12V
DC12V
DC12V
DC12V
DC12V
counts the number of cranking attempts.
(b) Overspeed; tripped by overspeed switch when engine
exceeds a preset speed.
(c) Oil Pressure; tripped by the oil pressure SWICHGAGE® if
pressure drops below preset point while the engine is running.
(d) Water Temperature; tripped by the water temperature
SWICHGAGE® if engine coolant temperature exceeds the
switch setting.
6-1/4 in.
(159 mm)
23
24
25
(e) Spare Shutdown; tripped by an external switch. This
circuit is provided for an additional shutdown that may be
recommended by the engine supplier.
(f) Loss of Speed Signal; tripped by an internal sensing
circuit that detects the loss of the Magnetic Pickup
frequency signal for the speed switches while the engine
is still running. Since the Overspeed shutdown circuit is
activated by the frequency input, it prevents the engine
from running without overspeed protection.
4-1/2 in.
(114 mm)
Figure 3-3.2
(g) Remote Shutdown; this circuit is provided to shutdown
the engine generator from a remote location. No
indicating light is provided.
3-3.1.6 Nine (9) Alarm Indicating Circuits; provide indication
of cause of alarm. These circuits activate the alarm relays.
Alarm circuits are active as long as power is applied to the
A901-2. All are active when the engine is running, shutdown or
on standby except Low Oil Pressure Pre- alarm and High Water
Temperature Pre-alarm. Nine (9) Amber Alarm Indicating
Lights are provided.
3-3.2.1 Fuel Relay; this relay provides two outputs, one to
energize the engine fuel solenoid and a separate circuit to
energize the battery charging alternator field.
3-3.2.2 Shutdown Relay; this relay is operated by the shutdown
circuits of the Control / Display Module and provides an output
that can be used to trip the generator circuit breaker on an
emergency shutdown.
3-3.2.3 Overspeed Relay; operates only on an Overspeed
shutdown. This relay provides an output to trip an air shut off
solenoid to close the air damper on a two-cycle engine.
3-3.2.4 Local Audible Alarm Relay; provides a contact closure
(a) Low Water Temperature; operated by low water temp-
erature SWICHGAGE®.
6
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to operate a local audible alarm as required by NFPA- 110,
Level 1 and Level 2.
3-3.2.5 Remote Audible Alarm Relay; provides a contact
closure to operate a remote audible alarm as required by NFPA-
110, Level 1.
3-3.2.6 Remote Visual Alarm Relay; provides a contact closure
to operate a remote visual alarm as required by NFPA- 110,
Level 1.
on the flywheel ring gear.
(c) Auxiliary Crank Disconnect Circuit; this circuit, required
by NFPA-110, is provided as a back up for the Crank
Disconnect Speed Switch. It is operated by an external
switch sensing either speed, generator voltage or some
other variable that could be used to terminate cranking.
Either circuit will disconnect the starter when the engine
starts.
3-3.3 Status Signals. The relay module also includes three
outputs that can be used with external circuits for signaling or
control functions.
3-3.3.1 The Control On function at terminal 12 is on (closed
to negative) as long as the Mode Selector Switch is in either
Auto or Test. When the Mode Selector is turned Off, the
Control On signal is open. This can be used to signal switch
position or to reset an external circuit when the Mode Selector
is turned Off.
(d) Overcrank circuit; will stop automatic cranking and
indicate overcrank if engine fails to start after 3 attempts.
The number of cranks are selectable for 1, 2, 3, 4 or 5
cycles before shutdown. The overcrank circuit may also
be turned off so no overcrank shutdown occurs.
6-1/2 in.
(165 mm)
3-3.3.2 The System Ready signal at terminal 13 is on (closed
to negative) as long as the Mode Selector Switch is in either
Auto ost and no shutdown Tattletale circuit is latched on.
This ced to signal that the generator engine is ready to
autotarr is running in Test.
Low Water
Overcrank
Temperature
Loss of Speed
Overspeed
Signal
Lamp Test
Oil Pressure
3-3.3.3 Cool fution at terminal 14 is on (closed
to positive) as ng as tModector Switch is in either
Auto or Test. WhehMoSeleor is turned Off, the
Control On signal is open. Tcan be uignal switch
position or to reset an external circt whde ector
is turned Off.
Water
Temperature
AUTO
OFF
9-3/4 in.
(248 mm)
TEST
3-4 A902.
3-4.1 Control / Display Module. The Control / Diay
Module, figure 3-4.1, includes the control and test switches, the
solid state logic elements, shutdown and alarm TATTLETALE®
lights that make up the generator engine control for a four-cycle
engine.
3-4.1.1 Mode Selector Switch, OFF-AUTO-TEST:
(a) OFF; turns off the control system and resets any shutdown
circuits.
(b) AUTO; turns on the engine controls and shutdown
circuits. System is on standby waiting for a contact
closure to start engine.
(c) TEST; turns on the engine controls and shutdown circuits.
A start signal is applied to the automatic control and the
engine start sequence begins.
3-4.1.2 Lamp Test Pushbutton: Tests the lights on the A902
module.
3-4.1.3 The A902 SELECTRONIC® Control Module includes
the following engine control features:
Figure 3-4.1
(e) Shutdown Time Delay Bypass; this delay prevents the oil
pressure, water temperature and loss of speed signal
shutdown circuits from operating for 15 seconds after the
engine starts as detected by the crank disconnect circuit.
(f) Overspeed Speed Switch;
(a) Cycle crank circuit; will crank the engine for 15 seconds
then rest for 15 seconds until the engine starts. The
crank/rest time is selectable for either 10, 15, 20, 25 or 30
seconds. If the engine false starts, goes above crank
disconnect speed then drops below that speed, the control
will rest for a fixed 10 second period before cranking
again.
(b) Crank Disconnect Speed Switch; this circuit detects
engine speed and terminates cranking when engine speed
rises above the speed switch setting. The speed switch is
adjustable, 25 Hz to 2000 Hz, and is factory set at 1180
Hz. This would be 600 RPM on an engine with 118 teeth
1. Provides a signal to the overspeed shutdown circuit if
the engine exceeds the preset speed. The factory
setting is approximately 3894 Hz, or 1980 RPM on an
engine with 118 teeth on the flywheel ring gear. The
adjustment range is 300 Hz to 10,000 Hz.
2. A push to test switch is provided to allow testing of the
overspeed circuit without overspeeding the engine.
When switch is depressed, the set point of the speed
switch is lowered approximately 10%.
3. The push to test switch can also be used to set the
overspeed switch at approximately 110% of running
speed. Hold the switch depressed while adjusting the
7
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setting until the overspeed trips. When switch is that can be used to trip the generator circuit breaker on an
released, the set point will be 10% above normal emergency shutdown.
running speed. This is the method used to make the
factory setting. With engine speed at 1800 RPM or
3540 Hz.
(g) Cooldown circuit; this circuit keeps the engine running
for five minutes after the transfer switch has removed the
load from the generator and signaled the A902 to stop
the engine. This feature may be selected (turned On,
standard setting is Off) with a switch on the back of the
3A Fuse
1A
4
5
6
7
8
9
16
17
18
19
20
21
22
DC12V
DC12V
DC12V
Control / Display Module.
3-4.1.4 Seven (7) First-out Shutdown Circuits; provide first-out
indication of cause of shutdown. These circuits deactivate the
fuel relay and lockout the A902 until reset. Shutdown circuits
are activated by the crank disconnect circuit and are not active
when the engine is stopped. Six (6) Red Shutdown Indicating
Lights are provided. The Remote Shutdown circuit does not
have an indicator light.
6-1/4 in.
(159 mm)
23
24
25
(a) Overcrank; tripped by the overcrank sensing circuit which
countnumber of cranking attempts.
(b) Ovetripped by overspeed switch when engine
exset eed.
(c) Oil Pressure; tped thil pressure SWICHGAGE® if
pressure dropbelow set while the engine is
running.
4-1/2 in.
(114 mm)
(d) Water Temperature; tripped y the waerature
SWICHGAGE® if engine coolant tempeeds e
switch setting.
(e) Spare Shutdown; tripped by an external switch. h
circuit is provided for an additional shutdown that may b
recommended by the engine supplier.
(f) Loss of Speed Signal; tripped by an internal sensing
circuit that detects the loss of the Magnetic Pickup
frequency signal for the speed switches while the engine
is still running. Since the Overspeed shutdown circuit is
activated by the frequency input, it prevents the engine
from running without overspeed protection.
(g) Remote Shutdown; this circuit is provided to shutdown
the engine generator from a remote location. No
indicating light is provided.
3-4.1.5 Two (2) Alarm Indicating Circuits; provide indication
of cause of alarm. These circuits activate the alarm relay. Alarm
circuits are active as long as power is applied to the A902. All
are active when the engine is running, shutdown or on standby.
Two (2) Amber Alarm Indicating Lights are provided.
(a) Low Water Temperature; operated by low water
temperature SWICHGAGE®.
(b) Spare Alarm; operated by an external switch. This circuit
is provided for an additional alarm that may be required
by the user.
3-4.2 Relay Module. The Relay Module, figure 3-4.2, includes
all of the control, alarm and shutdown relays that are required to
make up the generator engine control. Relays are available for
operation on either 12 or 24 volt battery systems. Three (3)
relays are included for:
3-4.2.1 Fuel Relay; this relay provides two outputs, one to
energize the engine fuel solenoid and a separate circuit to
energize the battery charging alternator field.
Figure 3-4.2
4.2.3 Local Audible Alarm Relay; provides a contact closure
o opelocal audible alarm as required by NFPA- 110, Level
1 and vel 2.
3-4.Status gnThe relay module also includes three
outputs that n bd h external circuits for signaling or
control functions
3-4.3.1 The Control Ouncn at tmin12 is on (closed to
negative) as long as the Modeler Sh is n either Auto
or Test. When the Mode Selector is turnOthe ol On
signal is open. This can be used to signal witch r to
reset an external circuit when the Mode Selector iff.
3-4.3.2 The System Ready signal at terminal 13 is on (closed
to negative) as long as the Mode Selector Switch is in either
Auto or Test and no shutdown TATTLETALE® circuit is
latched on. This can be used to signal that the generator engine
is ready to automatically start or is running in Test.
3-4.3.3 The Control On function at terminal 14 is on (closed to
positive) as long as the Mode Selector Switch is in either Auto
or Test. When the Mode Selector is turned Off, the Control On
signal is open. This can be used to signal switch position or to
reset an external circuit when the Mode Selector is turned Off.
3-5 A902-2.
3-5.1 Control / Display Module. The Control / Display Module,
figure 3-5.1, includes the control and test switches, the solid state
logic elements, shutdown and alarm TATTLETALE® lights that
make up the generator engine control for a two-cycle engine.
3-5.1.1 Mode Selector Switch, OFF-AUTO-TEST:
(a) OFF; turns off the control system and resets any shutdown
circuits.
(b) AUTO; turns on the engine controls and shutdown circuits.
System is on standby waiting for a contact closure to start
engine.
3-4.2.2 Shutdown Relay; this relay is operated by the shutdown
circuits of the Control / Display Module and provides an output
8
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6-1/2 in.
(165 mm)
be turned off so no overcrank shutdown occurs.
(e) Shutdown Time Delay Bypass; this delay prevents the oil
pressure, water temperature and loss of speed signal
shutdown circuits from operating for 15 seconds after the
engine starts as detected by the crank disconnect circuit.
(f) Overspeed Speed Switch;
Low Water
Temperature
Overcrank
Overspeed
Oil Pressure
Loss of Speed
Signal
1. Provides a signal to the overspeed shutdown circuit if
the engine exceeds the preset speed. The factory
setting is approximately 3894 Hz, or 1980 RPM on an
engine with 118 teeth on the flywheel ring gear. The
adjustment range is 300 Hz to 10,000 Hz.
Lamp Test
Water
Temperature
AUTO
OFF
9-3/4 in.
(248 mm)
TEST
2. A push to test switch is provided to allow testing of the
overspeed circuit without overspeeding the engine.
When switch is depressed, the set point of the speed
switch is lowered approximately 10%.
Air Damper
Closed
3. The push to test switch can also be used to set the
overspeed switch at approximately 110% of running
speed. Hold the switch depressed while adjusting the
setting until the overspeed trips. When switch is
released, the set point will be 10% above normal
running speed. This is the method used to make the
factory setting. With engine speed at 1800 RPM or
3540 Hz.
(g) Cooldown circuit; this circuit keeps the engine running
for five minutes after the transfer switch has removed
the load from the generator and signaled the A902-2 to
stop the engine. This feature may be selected (turned
On, standard setting is Off) with a switch on the back of
the Control / Display Module.
3-.4 Seen (7) First-out Shutdown Circuits; provide first-out
ication caof shutdown. These circuits deactivate the
fuel reland ut A902-2 until reset. Shutdown circuits
are activated tnk connect circuit and are not active
when the engine ippSix ) Red Shutdown Indicating
Lights are provided. ThReme Sdocircuit does not
have an indicator light.
Figure 3-5.1
(c) TEST; turns on the engine controls and shutdown cir.
A start signal is applied to the automatic control and the
engine start sequence begins.
3-5.1.2 Lamp Test Pushbutton: Tests the lights on the A- 902-2
module.
3-5.1.3 The A902-2 SELECTRONIC® Control Module includes
the following engine control features:
(a) Cycle crank circuit; will crank the engine for 15 seconds
then rest for 15 seconds until the engine starts. The
crank/rest time is selectable for either 10, 15, 20, 25 or 30
seconds. If the engine false starts, goes above crank
disconnect speed then drops below that speed, the control
will rest for a fixed 10 second period before cranking
again.
(a) Overcrank; tripped by the overnk senst which
counts the number of cranking attempts.
(b) Overspeed; tripped by overspeed switch en engine
exceeds a preset speed.
(c) Oil Pressure; tripped by the oil pressure SWICHGAGE®
if pressure drops below preset point while the engine is
running.
(b) Crank Disconnect Speed Switch; this circuit detects
engine speed and terminates cranking when engine speed
rise above the speed switch setting. The speed switch is
adjustable, 25 Hz to 2000 Hz, and is factory set at 1180
Hz. This would be 600 RPM on an engine with 118 teeth
on the flywheel ring gear.
(d) Water Temperature; tripped by the water temperature
SWICHGAGE® if engine coolant temperature exceeds the
switch setting.
(e) Spare Shutdown; tripped by an external switch. This
circuit is provided for an additional shutdown that may be
recommended by the engine supplier.
(c) Auxiliary Crank Disconnect Circuit; this circuit, required
by NFPA-110, is provided as a back up for the Crank
Disconnect Speed Switch. It is operated by an external
switch sensing either speed, generator voltage or some
other variable that could be used to terminate cranking.
Either circuit will disconnect the starter when the engine
starts.
(d) Overcrank circuit; will stop automatic cranking and
indicate overcrank if engine fails to start after 3 attempts.
The number of cranks are selectable for 1, 2, 3, 4 or 5
cycles before shutdown. The overcrank circuit may also
(f) Loss of Speed Signal; tripped by an internal sensing
circuit that detects the loss of the Magnetic Pickup
frequency signal for the speed switches while the engine
is still running. Since the Overspeed shutdown circuit is
activated by the frequency input, it prevents the engine
from running without overspeed protection.
(g) Remote Shutdown; this circuit is provided to shutdown
the engine generator from a remote location. No
indicating light is provided.
3-5.1.5 Two (2) Alarm Indicating Circuits; provide indication
9
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of cause of alarm. These circuits activate the alarm relay. reset an external circuit when the Mode Selector is turned Off.
Alarm circuits are active as long as power is applied to the 3-5.3.2 The System Ready signal at terminal 13 is on (closed
A902-2. All are active when the engine is running, shutdown or to negative) as long as the Mode Selector Switch is in either
on standby. Two (2) Amber Alarm Indicating Lights are Auto or Test and no shutdown TATTLETALE® circuit is
provided.
(a) Low Water Temperature; operated by low water engine is ready to automatically start or is running in Test.
temperature SWICHGAGE®.
3-5.3.3 The Control On function at terminal 14 is on (closed to
latched on. This can be used to signal that the generator
(b) Air Damper Closed; operated by an external switch or by positive) as long as the Mode Selector Switch is in either Auto
the Overspeed Relay circuit. This circuit is provided with or Test. When the Mode Selector is turned Off, the Control On
a selector switch to allow the user to determine the source signal is open. This can be used to signal switch position or to
of the signal.
reset an external circuit when the Mode Selector is turned Off.
3-5.2 Relay Module. The Relay Module, figure 3-5.2, includes
all of the control, alarm and shutdown relays that are required to
make up the generator engine control. Relays are available for
operation on either 12 or 24 volt battery systems. Four (4)
relays are included for:
3-6 A903.
3-6.1 Control / Display Module. The Control / Display Module,
figure 3-6.1, includes the control and test switches, the solid
state logic elements, shutdown and alarm TATTLETALE® lights
that make up the generator engine control for a four cycle
engine. This module is the same as Model A- 901 except 7 of
the alarm circuits are un-labeled. This allows the customer to
specify labels other than those recommended in NFPA-110.
This model has shutdown and alarm circuits labeled to meet the
requirements of NFPA-110, Level 2.
3A Fuse
4
5
6
7
8
9
17
18
19
20
21
22
DC1
DC12V
DC12V
C12
4 in.
m
23
24
25
4-1/2 in.
(114 mm)
Figure 3-5.2
3-5.2.1 Fuel Relay; this relay provides two outputs, one to
energize the engine fuel solenoid and a separate circuit to
energize the battery charging alternator field.
3-5.2.2 Shutdown Relay; this relay is operated by the shutdown
circuits of the Control / Display Module and provides an output
that can be used to trip the generator circuit breaker on an
emergency shutdown.
3-5.2.3 Overspeed Relay; operates only on an Overspeed
shutdown. This relay provides an output to trip an air shut off
solenoid to close the air damper on a two-cycle engine.
3-5.2.4 Local Audible Alarm Relay; provides a contact closure
to operate a local audible alarm as required by NFPA- 110, Level
1 and Level 2.
3-5.3 Status Signals. The relay module also includes three
outputs that can be used with external circuits for signaling or
control functions.
3-5.3.1 The Control On function at terminal 12 is on (closed to
negative) as long as the Mode Selector Switch is in either Auto
or Test. When the Mode Selector is turned Off, the Control On
signal is open. This can be used to signal switch position or to
Figure 3-6.1
3-6.1.1 Mode Selector Switch, OFF-AUTO-TEST:
(a) OFF; turns off the control system and resets any shutdown
circuits.
(b) AUTO; turns on the engine controls and shutdown circuits.
System is on standby waiting for a contact closure to start
engine.
(c) TEST; turns on the engine controls and shutdown circuits.
A start signal is applied to the automatic control and the
engine start sequence begins.
10
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3-6.1.2 Lamp Test Pushbutton: Tests the lights on the A903
module.
3-6.1.3 Alarm Silence Pushbutton: Turns off any audible alarm
that is connected to the Local or Remote Audible Alarm Relays.
the load from the generator and signaled the A903 to
stop the engine. This feature may be selected (turned
On, standard setting is Off) with a switch on the back of
the Control / Display Module.
The indicating light will remain on as long as the condition 3-6.1.5 Seven (7) First-out Shutdown Circuits; provide first-
exists. If the Alarm Silence pushbutton is not operated, the out indication of cause of shutdown. These circuits deactivate
audible alarm will turn off when the alarm contact clears.
3-6.1.4 The A903 SELECTRONIC® Control Module includes circuits are activated by the crank disconnect circuit and are not
the following engine control features: active when the engine is stopped. Six (6) Red Shutdown
the fuel relay and lockout the A903 until reset. Shutdown
(a) Cycle crank circuit; will crank the engine for 15 seconds Indicating Lights are provided. The Remote Shutdown circuit
then rest for 15 seconds until the engine starts. The does not have an indicator light.
crank/rest time is selectable for either 10, 15, 20, 25 or 30
seconds. If the engine false starts, goes above crank
disconnect speed then drops below that speed, the control
will rest for a fixed 10 second period before cranking
again.
(a) Overcrank; tripped by the overcrank sensing circuit
which counts the number of cranking attempts.
(b) Overspeed; tripped by overspeed switch when engine
exceeds a preset speed.
(c) Oil Pressure; tripped by the oil pressure SWICHGAGE®
if pressure drops below preset point while the engine is
running.
(b) Crank Disconnect Speed Switch; this circuit detects
engine speed and terminates cranking when engine speed
rises above the speed switch setting. The speed switch is
atable, 25 Hz to 2000 Hz, and is factory set at 1180
would be 600 RPM on an engine with 118 teeth
whring gear.
(c) Aury nk coect Circuit; this circuit, required
by NFPA10, is pvided back up for the Crank
Disconnect SpeSchIt is erated by an external
switch sensing either spe, generatge or some
other variable that could be d to cring.
Either circuit will disconnect the starthine
starts.
(d) Water Temperature; tripped by the water temperature
SWICHGAGE® if engine coolant temperature exceeds
the switch setting.
(e) Spare Shutdown; tripped by an external switch. This
circuit is provided for an additional shutdown that may
be recommended by the engine supplier.
(f) Loss of Speed Signal; tripped by an internal sensing
circuit that detects the loss of the Magnetic Pickup
frequency signal for the speed switches while the engine
is still running. Since the Overspeed shutdown circuit is
activated by the frequency input, it prevents the engine
from unning without overspeed protection.
RemShdown; this circuit is provided to shutdown
the ngienator from a remote location. No
indicatiigrovd.
(d) Overcrank circuit; will stop automatic cranking
indicate overcrank if engine fails to start after 3 attempts.
The number of cranks are selectable for 1, 2, 3, 4 or 5
cycles before shutdown. The overcrank circuit may also
be turned off so no overcrank shutdown occurs.
3-6.1.6 Nine (9) AInating ircuits; provide indication
(e) Shutdown Time Delay Bypass; this delay prevents the oil of cause of alarm. Thesircuacte e alarm relays.
pressure, water temperature and loss of speed signal Alarm circuits are active as g as er is aed to the
shutdown circuits from operating for 15 seconds after the A903. All are active when the enginrunninwn or
engine starts as detected by the crank disconnect circuit. on standby except alarm circuit #7 and #8 whiced out
This same delay also locks out alarm circuit #7 and #8 until the engine is running. Nine (9) Amber Alardicating
when the engine is not running.
(f) Overspeed Speed Switch;
Lights are provided however only two circuits are labeled. The
other 7 are for customer specified alarms.
1. Provides a signal to the overspeed shutdown circuit if
the engine exceeds the preset speed. The factory
setting is approximately 3894 Hz, or 1980 RPM on an
engine with 118 teeth on the flywheel ring gear. The
adjustment range is 300 Hz to 10,000 Hz.
(a) Low Water Temperature; operated by low water
temperature SWICHGAGE®.
(b) #2 Spare Alarm; operated by an external switch. This
circuit is provided for an additional alarm that may be
required by the user.
2. A push to test switch is provided to allow testing of
the overspeed circuit without overspeeding the
engine. When switch is depressed, the set point of the
speed switch is lowered approximately 10%.
3. The push to test switch can also be used to set the
overspeed switch at approximately 110% of running
speed. Hold the switch depressed while adjusting the
setting until the overspeed trips. When switch is
released, the set point will be 10% above normal
running speed. This is the method used to make the
factory setting. With engine speed at 1800 RPM or
3540 Hz.
(c) Switch Not In Automatic; operated by the OFF-AUTO-
TEST mode selector switch.
(d) #4 Spare Alarm; operated by an external switch. This
circuit is provided for an additional alarm that may be
required by the user.
(e) #5 Spare Alarm; operated by an external switch. This
circuit is provided for an additional alarm that may be
required by the user.
(f) #6 Spare Alarm; operated by an external switch. This
circuit is provided for an additional alarm that may be
required by the user.
(g) #7 Spare Alarm; operated by an external switch. This
circuit is provided for an additional alarm that may be
required by the user.
(g) Cooldown circuit; this circuit keeps the engine running
for five minutes after the transfer switch has removed
11
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(h) #8 Spare Alarm; operated by an external switch. This positive) as long as the Mode Selector Switch is in either Auto
circuit is provided for an additional alarm that may be or Test. When the Mode Selector is turned Off, the Control On
required by the user.
signal is open. This can be used to signal switch position or to
(i) #9 Spare Alarm; operated by an external switch. This reset an external circuit when the Mode Selector is turned Off.
circuit is provided for an additional alarm that may be
required by the user.
3-6.2 Relay Module. The Relay Module, figure 3-6.2, includes
3-7 A903-2.
3-7.1 Control / Display Module. The Control / Display Module,
figure 3-7.1, includes the control and test switches, the solid
all of the control, alarm and shutdown relays that are required to
state logic elements, shutdown and alarm TATTLETALE® lights
make up the generator engine control. Relays are available for
that make up the generator engine control for a two-cycle
operation on either 12 or 24 volt battery systems. Three (3)
engine. This module is the same as Model A901-2 except 6 of
the alarm circuits are un-labeled. This allows the customer to
relays are included for:
specify labels other than those recommended in NFPA-110.
This model has shutdown and alarm circuits labeled to meet the
requirements of NFPA-110, Level 2.
3A Fuse
1A
4
9
16
17
18
19
20
22
DC24V
24V
DC24V
6-1/4 in.
(159 mm)
23
25
4-1/2 in.
(114 mm)
Figure 3-6.2
3-6.2.1 Fuel Relay; this relay provides two outputs, one to
energize the engine fuel solenoid and a separate circuit to
energize the battery charging alternator field.
3-6.2.2 Shutdown Relay; this relay is operated by the shutdown
circuits of the Control / Display Module and provides an output
that can be used to trip the generator circuit breaker on an
emergency shutdown.
3-6.2.3 Local Audible Alarm Relay; provides a contact closure
to operate a local audible alarm as required by NFPA- 110, Level
1 and Level 2.
3-6.3 Status Signals. The relay module also includes three
outputs that can be used with external circuits for signaling or
control functions.
3-6.3.1 The Control On function at terminal 12 is on (closed to
negative) as long as the Mode Selector Switch is in either Auto
or Test. When the Mode Selector is turned Off, the Control On
signal is open. This can be used to signal switch position or to
reset an external circuit when the Mode Selector is turned Off.
3-6.3.2 The System Ready signal at terminal 13 is on (closed
to negative) as long as the Mode Selector Switch is in either
Auto or Test and no shutdown TATTLETALE® circuit is
latched on. This can be used to signal that the generator
engine is ready to automatically start or is running in Test.
3-6.3.3 The Control On function at terminal 14 is on (closed to
Figure 3-7.1
3-7.1.1 Mode Selector Switch, OFF-AUTO-TEST:
(a) OFF; turns off the control system and resets any shutdown
circuits.
(b) AUTO; turns on the engine controls and shutdown
circuits. System is on standby waiting for a contact
closure to start engine.
(c) TEST; turns on the engine controls and shutdown circuits.
A start signal is applied to the automatic control and the
engine start sequence begins.
3-7.1.2 Lamp Test Pushbutton: Tests the lights on the A- 903-2
module.
3-7.1.3 Alarm Silence Pushbutton: Turns off any audible alarm
that is connected to the Local or Remote Audible Alarm Relays.
The indicating light will remain on as long as the condition
exists. If the Alarm Silence pushbutton is not operated, the
12
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audible alarm will turn off when the alarm contact clears.
are provided. The Remote Shutdown circuit does not have an
3-7.1.4 The A903-2 SELECTRONIC® Control Module includes indicator light.
the following engine control features:
(a) Overcrank; tripped by the overcrank sensing circuit which
(a) Cycle crank circuit; will crank the engine for 15 seconds
then rest for 15 seconds until the engine starts. The
crank/rest time is selectable for either 10, 15, 20, 25 or 30
seconds. If the engine false starts, goes above crank
disconnect speed then drops below that speed, the control
will rest for a fixed 10 second period before cranking again.
(b) Crank Disconnect Speed Switch; this circuit detects
engine speed and terminates cranking when engine speed
rises above the speed switch setting. The speed switch is
adjustable, 25 Hz to 2000 Hz, and is factory set at 1180
Hz. This would be 600 RPM on an engine with 118 teeth
on the flywheel ring gear.
counts the number of cranking attempts.
(b) Overspeed; tripped by overspeed switch when engine
exceeds a preset speed.
(c) Oil Pressure; tripped by the oil pressure SWICHGAGE® if
pressure drops below preset point while the engine is
running.
(d) Water Temperature; tripped by the water temperature
SWICHGAGE® if engine coolant temperature exceeds the
switch setting.
(e) Spare Shutdown; tripped by an external switch. This
circuit is provided for an additional shutdown that may be
recommended by the engine supplier.
(c) Auxiliary Crank Disconnect Circuit; this circuit, required by
NFPA-110, is provided as a back up for the Crank
Disconnect Speed Switch. It is operated by an external
switch sensing either speed, generator voltage or some other
vable that could be used to terminate cranking. Either
cl disconnect the starter when the engine starts.
(d) k cuit; will stop automatic cranking and
inovranf eine fails to start after 3 attempts.
The numof cras are stable for 1, 2, 3, 4 or 5
(f) Loss of Speed Signal; tripped by an internal sensing
circuit that detects the loss of the Magnetic Pickup
frequency signal for the speed switches while the engine is
still running. Since the Overspeed shutdown circuit is
activated by the frequency input, it prevents the engine
from running without overspeed protection.
(g) Remote Shutdown; this circuit is provided to shutdown
the engine generator from a remote location. No
indicating light is provided.
cycles before shdo. e ovrank circuit may also 3-7.1.6 Nine (9) Alarm Indicating Circuits; provide indication
be turned off so no overcrk shutdows. of cause of alarm. These circuits activate the alarm relays.
(e) Shutdown Time Delay Bypashis ents he oil Alarm circuits are active as long as power is applied to the
pressure, water temperature and leegnaA903-2. All are active when the engine is running, shutdown or
shutdown circuits from operating for 15 secondfttoandby except alarm circuit #7 and #8 which are locked out
engine starts as detected by the crank disconnect ci. unthe engine is running. Nine (9) Amber Alarm Indicating
This same delay also locks out alarm circuit #7 and #8 Lhts are ovid however only three circuits is labeled. The
when the engine is not running.
other 6 aor mepecified alarms.
(f) Overspeed Speed Switch;
(a) Low teTmpture; operated by low water
1. Provides a signal to the overspeed shutdown circuit if
the engine exceeds the preset speed. The factory
setting is approximately 3894 Hz, or 1980 RPM on an
engine with 118 teeth on the flywheel ring gear. The
adjustment range is 300 Hz to 10,000 Hz.
temperature CHAGE
(b) Air Damper Closedoperd bn ternal switch or by
the Overspeed Relay ct. Tircuit iovided with
a selector switch to allow the r to detesource
of the signal.
2. A push to test switch is provided to allow testing of the
overspeed circuit without overspeeding the engine.
When switch is depressed, the set point of the speed
switch is lowered approximately 10%.
(c) Switch Not In Automatic; operated by thF-AUTO-
TEST mode selector switch.
(d) #4 Spare Alarm; operated by an external switch. This
circuit is provided for an additional alarm that may be
required by the user.
(e) #5 Spare Alarm; operated by an external switch. This
circuit is provided for an additional alarm that may be
required by the user.
(f) #6 Spare Alarm; operated by an external switch. This
circuit is provided for an additional alarm that may be
required by the user.
(g) #7 Spare Alarm; operated by an external switch. This
circuit is provided for an additional alarm that may be
required by the user.
(h) #8 Spare Alarm; operated by an external switch. This
circuit is provided for an additional alarm that may be
required by the user.
3. The push to test switch can also be used to set the
overspeed switch at approximately 110% of running
speed. Hold the switch depressed while adjusting the
setting until the overspeed trips. When switch is
released, the set point will be 10% above normal running
speed. This is the method used to make the factory
setting. With engine speed at 1800 RPM or 3540 Hz.
(g) Cooldown circuit; this circuit keeps the engine running
for five minutes after the transfer switch has removed the
load from the generator and signaled the A903-2 to stop
the engine. This feature may be selected (turned On,
standard setting is Off) with a switch on the back of the
Control / Display Module.
3-7.1.5 Seven (7) First-out Shutdown Circuits; provide first-out
indication of cause of shutdown. These circuits deactivate the
fuel relay and lockout the A903 until reset. Shutdown circuits are
(i) #9 Spare Alarm; operated by an external switch. This
circuit is provided for an additional alarm that may be
required by the user.
activated by the crank disconnect circuit and are not active when 3-7.2 Relay Module. The Relay Module, figure 3-7.2, includes
the engine is stopped. Six (6) Red Shutdown Indicating Lights all of the control, alarm and shutdown relays that are required to
13
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make up the generator engine control. Relays are available for
operation on either 12 or 24 volt battery systems. Four (4)
relays are included for:
Section 4: Installation
4-1 Location.
4-1.1 The A900 series is designed to mount in a
MURPHYMATIC® Generator Control panel with the Control /
Display module on the front panel and the Relay module on the
inside bottom surface. Other types of installation is possible as
long as the relationship of the two modules are maintained.
4-1.2 Clearance for Installation and Service; The modules must
be accessible for wiring to the terminal blocks and adjustment of
the user controls on the back of the Control / Display module.
Figure 4-1.2 shows the mounting dimensions and the minimum
clearances recommended for installation.
3A Fuse
1A
4
5
6
7
8
9
16
17
18
19
20
21
22
DC12V
DC12V
DC12V
DC12V
4-1.3 Wiring Terminals; Terminal blocks are provided on both
sides of the Control / Display enclosure and the Relay Module.
Torque all terminal screws to 12 inch pound maximum.
6-1/4 in.
(159 mm)
4-2 Wiring.
4-2.1 After the A900 has been located and installed, the wiring
connections can be made. This work should be done with all
electrical power disconnected from the engine. BE SURE THAT
THE BATTERY IS DISCONNECTED.
23
24
25
4-2.2 All electrical installation work should be done in
accordance with the National Electrical Code, NFPA-70, and all
applicable local codes.
4-2.3 In general, the following connections will be made:
(a) Battery positive and negative. An 8 A fuse or circuit
breaker must be provided to protect powered relay contact
circuits.
42 in
(114
Figure 3-7.2
3-7.2.1 Fuel Relay; this relay provides two outs, o
energize the engine fuel solenoid and a separate circt t
energize the battery charging alternator field.
(b) ngine run device, such as a fuel shutoff solenoid.
(c) ispeed sensor, such as a magnetic pickup or the
chomeoutput of a battery charging alternator.
3-7.2.2 Shutdown Relay; this relay is operated by the shutdown
circuits of the Control / Display Module and provides an output
that can be used to trip the generator circuit breaker on an
emergency shutdown.
3-7.2.3 Overspeed Relay; operates only on an Overspeed
shutdown. This relay provides an output to trip an air shut off
solenoid to close the air damper on a two-cycle engine.
3-7.2.4 Local Audible Alarm Relay; provides a contact closure
to operate a local audible alarm as required by NFPA- 110, Level
1 and Level 2.
(dAuxilicrdisconnect device, such as a voltage
sensinelaoacireo the generator output.
(e) Engine staer it; auxary starter solenoid is
required to handle mosarter enoquirements.
(f) Remote start contact. This rmafrom the automatic
transfer switch but other sources aossible.
(g) Alarm and shutdown sensing switches req
4-2.3.1 The complete wiring of a Model A901 contown
in figure 4-2.3.1. Provision is made in the A900 series to
operate remote lights for all of the alarm and shutdown circuits
however these circuits do not have to be wired for the A900 to
function. Alarm input switches are not required but the alarm
circuits will not work without them.
3-7.3 Status Signals. The relay module also includes three
outputs that can be used with external circuits for signaling or
control functions.
3-7.3.1 The Control On function at terminal 12 is on (closed to
negative) as long as the Mode Selector Switch is in either Auto
or Test. When the Mode Selector is turned Off, the Control On
signal is open. This can be used to signal switch position or to
reset an external circuit when the Mode Selector is turned Off.
3-7.3.2 The System Ready signal at terminal 13 is on (closed
to negative) as long as the Mode Selector Switch is in either
Auto or Test and no shutdown TATTLETALE® circuit is
latched on. This can be used to signal that the generator
engine is ready to automatically start or is running in Test.
3-7.3.3 The Control On function at terminal 14 is on (closed to
positive) as long as the Mode Selector Switch is in either Auto
or Test. When the Mode Selector is turned Off, the Control On
signal is open. This can be used to signal switch position or to
reset an external circuit when the Mode Selector is turned Off.
4-2.3.2 Figure 4-2.3.2 is for wiring of the A902 control. The
same provisions as for the A901 are made.
4-2.3.3 The A903 wiring is shown in figure 4-2.3.3.
4-2.3.4 Wire Termination; the terminal blocks that are supplied
requires that all wires be terminated with #6 stud size forked
spade solderless wire connectors or stripped and inserted under
the captive terminal plates. Torque all terminal screws to 12
inch pound maximum.
4-2.3.5 All inductive loads (relays-soleniods-coils-etc.) that are
connected to the A900 must have reverse diodes wired across
the coil to supress reverse voltage that is generated whenever the
inductive load is de-energized. This will protect the electronic
components in the A900 and should prevent operating
malfunction due to noise. The “rule of thumb” for sizing the
reverse diode is to use one with a PIV (Peak Inverse Voltage)
rating equal to the operating voltage, or at least 100 volts and a
14
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Figure 4-1.2.5: Mounting Dimensions
6 in.
(152 mm)
3 in.
(76 mm)
2-13/16 in.
(71 mm)
A900 Series
Module
5-5/8 in.
(143 mm)
1-1/2 in.
(38 mm)
clearance
Mounting
Holes
1/8 in.
(3 mm)
diameter
6-3/4 in.
(171 mm)
9-3/8 in.
(238 mm)
3-3/8 in.
(86 mm)
4-in.
(114 mm)
5 in. (mmaximm
between A-900 eries m
& relay module whn mg
Relay Module
3/16 in.
(5 mm) dia.
4 places
5-1/2 in.
(140 mm)
3-3/4 in.
(95 mm)
1-7/8 in. (48 mm)
clearance
1-7/8 in. (48 mm)
clearance
15
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Figure 4-2.3.1: A901 wiring
Hourmeter
Voltmeter
B+
Input
Output
Barrier
Terminal
Blocks
Barrier
Terminal
Blocks
AUTO START
MODULE
15 B+ OUT
ALARM SILENCE 35
AUDIBLE ALARM
HOURMETER
B-
26
4
36
OVERCRANK 37
38
Remove jumper from
4 and 27 to use
manual start switch
27
MANUAL START
OVERSPEED
28 START
PICKUP
OIL PRESSURE 39
HI WATER TEMP. 40
REMOTE SHUTDOWN 41
SPARE SHUTDOWN 42
LOSS OF SPEED 43
4
29 PICKUP
30 OIL PRESSURE
31 LO WATER TEMP.
32 HI WATER TEMP.
33 REMOTE S.D.
34 SPARE ALARM
LO WATER TEMP. 44
SPARE ALARM 45
*
SWITCH NOT IN AUTO 46
47
LOW FUEL LEVEL
HIGH BATTERY VOLTAGE
53
54
55
56
57
58
49
50
51
52
LOW BATTERY VOLTAGE
OW OIL PRESSURE PREALARM
HI ER TEMP. PREALARM
ATCHGER AC FAILURE
LL 1 ARM
Optional
Aiper osed
oycngine
*
Battery
NOTE 2
Auxiliary Starter
Solenoid
Red
Blk
Starter
+ -
J1 A B C D E F G H I J K L M N J2
8A
D9
Circuit
Breaker
NOTE 2
100K
MDQ3
B+
B-
3A Fuse
1A
4
15
Auxiliary crank
disconnect
relay
4
Energize to Stop solenoid
Energize to Run solenoid
NOTE 2
NOTE 2
5
16
17
18
19
20
21
22
23
24
25
Local
Fuel
Relay
Audible
6
Crank relay
Alarm
Alternator Excitor
I
D
C
B
7
Optional Run relay and Remote signal
Local audible alarm
J1G
8
Alternator
Breaker Shunt trip coil
Fuel Pressure Switch
Shut
Down
Relay
Remote
Audible
Alarm
9
NOTE 1
NOTE 2
Power supply
10
11
12
13
14
H
G
Spare shutdown
Remote audible alarm
Control on sink 200 mA MAX
System ready sink 200 mA MAX
Çontrol on source 200 mA MAX
Power supply
Over
Speed
Relay
Remote
Visual
Alarm
To Battery +
To Battery +
Remote visual alarm
Q2
D8
Air Damper
Solenoid
Power supply
Q3
Q1
NOTE 1: Fuel Pressure Switch and Air Damper Solenoid
are used on a 2-cycle engine
NOTE 2: Place Reverse Bias Diodes across inductive loads.
Drawing Revision C
16
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Figure 4-2.3.2: A902 wiring
Hourmeter
Voltmeter
B+
Input
Output
Barrier
Terminal
Blocks
Barrier
Terminal
Blocks
AUTO START
MODULE
15 B+ OUT
ALARM SILENCE 35
AUDIBLE ALARM
HOURMETER
26
4
36
OVERCRANK 37
38
B-
Remove jumper from
4 and 27 to use
manual start switch
27
MANUAL START
OVERSPEED
28 START
PICKUP
OIL PRESSURE 39
HI WATER TEMP. 40
REMOTE SHUTDOWN 41
SPARE SHUTDOWN 42
LOSS OF SPEED 43
4
29 PICKUP
30 OIL PRESSURE
31 LO WATER TEMP.
32 HI WATER TEMP.
33 REMOTE S.D.
34 SPARE ALARM
LO WATER TEMP. 44
SPARE ALARM 45
*
46
Optional
EL 2 M
Air mper closed
ocycengine
*
Battery
NOTE 2
Auxiliary Starter
Solenoid
Red
Blk
Starter
+ -
J1 A B C D E F G H I J K L M N J2
8A
Circuit
Breaker
D9
NOTE 2
100K
MDQ3
B+
B-
3A Fuse
1A
4
15
Auxiliary crank
disconnect
relay
4
Energize to Stop solenoid
Energize to Run solenoid
NOTE 2
NOTE 2
5
16
17
18
19
20
21
22
23
24
25
Local
Fuel
Relay
Audible
6
Crank relay
Alarm
Alternator Excitor
I
D
C
B
7
Optional Run relay and Remote signal
Local audible alarm
J1G
8
Alternator
Breaker Shunt trip coil
Fuel Pressure Switch
Shut
Down
Relay
Remote
Audible
Alarm
9
NOTE 1
NOTE 2
Power supply
10
11
12
13
14
H
G
Spare shutdown
Remote audible alarm
Control on sink 200 mA MAX
System ready sink 200 mA MAX
Çontrol on source 200 mA MAX
Power supply
Over
Speed
Relay
Remote
Visual
Alarm
To Battery +
To Battery +
Remote visual alarm
Q2
D8
Air Damper
Solenoid
Power supply
Q3
Q1
NOTE 1: Fuel Pressure Switch and Air Damper Solenoid
are used on a 2-cycle engine
NOTE 2: Place Reverse Bias Diodes across inductive loads.
Drawing Revision C
17
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Figure 4-2.3.3: A903 wiring
Hourmeter
Voltmeter
B+
Input
Output
Barrier
Terminal
Blocks
Barrier
Terminal
Blocks
AUTO START
MODULE
15 B+ OUT
ALARM SILENCE 35
AUDIBLE ALARM
HOURMETER
B-
26
4
36
OVERCRANK 37
38
Remove jumper from
4 and 27 to use
manual start switch
27
MANUAL START
OVERSPEED
28 START
PICKUP
OIL PRESSURE 39
HI WATER TEMP. 40
REMOTE SHUTDOWN 41
SPARE SHUTDOWN 42
LOSS OF SPEED 43
4
29 PICKUP
30 OIL PRESSURE
31 LO WATER TEMP.
32 HI WATER TEMP.
33 REMOTE S.D.
34 SPARE ALARM
LO WATER TEMP. 44
SPARE ALARM 45
*
SWITCH NOT IN AUTO 46
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
47
49
50
52
53
54
55
56
57
58
EVALA
Optional
amclosed
a 2-engine
*
NOTE 2
Battery
Auxiliary Starter
Solenoid
Red
Blk
Starter
+ -
J1 A B C D E F G H I J K L M N J2
8A
D9
Circuit
Breaker
NOTE 2
NOTE 2
100K
MDQ3
B+
B-
3A Fuse
1A
4
15
Auxiliary crank
disconnect
relay
4
Energize to Stop solenoid
Energize to Run solenoid
5
16
17
18
19
20
21
22
23
24
25
Local
Fuel
Relay
Audible
6
Crank relay
Alarm
Alternator Excitor
I
D
C
B
7
Optional Run relay and Remote signal
Local audible alarm
J1G
NOTE 2
8
Alternator
Breaker Shunt trip coil
Fuel Pressure Switch
Shut
Down
Relay
Remote
Audible
Alarm
9
NOTE 1
NOTE 2
Power supply
10
11
12
13
14
H
G
Spare shutdown
Remote audible alarm
Control on sink 200 mA MAX
System ready sink 200 mA MAX
Çontrol on source 200 mA MAX
Power supply
Over
Speed
Relay
Remote
Visual
Alarm
To Battery +
To Battery +
Remote visual alarm
Q2
D8
Air Damper
Solenoid
Power supply
Q3
NOTE 1: Fuel Pressure Switch and Air Damper Solenoid
Q1
are used on a 2-cycle engine
NOTE 2: Place Reverse Bias Diodes across inductive loads.
Drawing Revision C
18
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current rating that is equal to or greater than the forward current determine if the frequency of the speed switches must be
that the coil draws to operate. For example, a relay less than 1 A, changed, calculate the required setting using the following
use a 1 A diode since they are readily available. The wiring formulas:
shown in Figures 4-2.3.1, 4-2.3.2 and 4-2.3.3 have examples of
the places that a reverse diode is required.
No. of Gear Teeth x RPM set points
60
Set point
frequency in HZ
=
4-3 Crank Disconnect.
OR
4-3.1 A magnetic pickup is recommended to supply the speed
signal for the A900 series primary crank termination circuit and
for the overspeed switch. This pickup will be mounted in the
flywheel housing in line with the ring gear on the flywheel and
wired to the A900 using either a twisted pair or a shielded cable
to reduce the possibility of electrical noise pickup in the wiring.
4-3.1.1 The tachometer terminal, of the battery charging
alternator, may be used for the speed signal but a broken drive
belt will disable this source and some alternators have electrical
noise which will cause the speed switches to operate at speeds
well below the desired RPM.
4-3.2 An auxiliary crank disconnect circuit, required by
NFPA-110, is provided in the A900. Any signal that detects
when tine is running and provides a contact closure
betwin4 and 16 can be used. This circuit
termikievethe speed signal fails. The “Loss
Of Speed” shutwn / rm on the A900 will indicate if the
speed signal is lost whilhe giis running by either
shutdown of the enginr oration of thalarm circuit.
“Loss Of Speed” alarm will onlopeate liary crank
disconnect circuit is used. Provision is alr a ond
N.C. contact between Terminals 17 and 1inteth
output to the auxiliary starter solenoid. This would co
cranking even if both crank disconnect circuits in the A0
should fail. If this contact is not provided, you must jumper
Terminals 17 and 18 for the start signal to reach the auxiliary
starter solenoid. A voltage sensing relay wired to one output
phase of the generator is one way to provide both of these
contacts.
Pulley ratio x No. of Alternator Poles x RPM set points
60
Set point
frequency in HZ
=
Refer to Table 4-4.1 to determine if the speed switch settings are
below the factory settings listed. If required frequency will be
higher than the standard, increase the setting before proceeding.
Turn The Crank Disconnect Set and Overspeed Set pots
clockwise to increase setting. The adjustments are 20 turn
controls without stops at either end.
4-4.1.1 Be sure to have a fully charged battery to do these tests.
Low battery voltage can cause improper results during the tests.
4-4.1.2 The “Air Damper Closed” alarm on A900 series for 2
cycle engines can be actuated by either an internal circuit that
senses the output to the overspeed relay, from the “Overspeed”
shutdown circuit or by an external switch wired to terminal 34
of the Control / Display Module. The “Air Damper Closed”
switch, Table 4-4.1 must be turned On for internal sensing and
Off for external switch. This circuit is a Spare alarm on A900
for 4 cycle engines and the switch must be turned Off to
prevent this circuit from operating with the “Overspeed”
shutdown.
4.1.3 All of the adjustments and controls shown in Table 4-4.1
arced on the rear of the control/display module. See Figure
41.3. ch light and switch is labeled for ease of
intifican. LED's are supplied as an aid in installation
and troushonoe A0.
4-4.2 Crank Dscot Sd Seg; to set this speed switch,
proceed as follows:
(a) Disconnect the run swrom terinal 6 on the
Relay Module.
4-4 Pre-operational Check-out.
(b) Check engine to be sure it is safe to ank
4-4.1 After installation is complete, it is necessary to make
some adjustments to the A900 SELECTRONIC® Control before
the system is operational. All shutdown and alarm circuits also
should be tested. Table 4-4.1 lists the standard factory setting of
the adjustable functions on the A900 series control. To
(c) Be sure Mode Selector switch is in OFF po
(d) Connect battery cables to a fully charged cranking battery.
(e) Turn Mode Selector switch to TEST position and watch
the lights on the A900 control module back panel.
1. The engine should start cranking and the “Fuel Relay”,
“Crank Relay”, and “Pickup Present” lights turn on.
2. If engine does not crank, check the lights. If green
light next to Mode Selector Switch on front panel is
not on, check the DC power input wiring and fuse.
3. If green light, “Fuel Relay” and “Crank Relay” lights
are on, check wiring from A900 Terminal 18 to
auxiliary start solenoid and than on to the starter on
engine.
Table 4-4.1
Standard
Setting
Adjustment
Range
Adjustment
Type
Function
Crank/Rest
Time
15
seconds
10, 15, 20, 25
and 30 Seconds
Switch
Switch
1, 2, 3, 4, 5, 6 and
No overcrank
Overcrank
3 cranks
1180 Hz
Crank
Disconnect
Turn CW
to increase
25 to 2 KHz
300 to 10 KHz
Fixed 5 minute
4. With engine cranking, check “Pickup Present” light. It
must be on. If off, check the wiring to magnetic
pickup and check gap between pickup face and ring
gear.
5. If “Crank Disconnect Speed” light comes on and
cranking stops, setting of Crank Disconnect Switch is
still to low. Turn Mode Selector switch OFF and turn
crank disconnect adjustment clockwise 1 or 2 turns
and repeat test.
Turn CW
to increase
3894 Hz
Overspeed
Cooldown
ON-OFF switch
Switch
OFF
Loss of speed
Signal
Shutdown or
Alarm
Shutdown
ON with
Overspeed
shutdown
Internal switch ON
External switch OFF
Air Damper Closed
Alarm on 2 Cycle
Engines only
Switch
19
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adjusted for proper running speed, turn Mode Selector
switch OFF. This gives the A900 Controller a stop signal.
(e) All lights on the back of the A900 should go off and the
engine stop. If engine does not stop, check run solenoid
to be sure it has returned to the stop position.
4-4.4 Automatic Start and Stop; to test the automatic-start and
stop function, proceed as follows:
(a) Turn Mode Selector switch to the AUTO position. Short
terminal 28 to 4 on the Control / Display module. This
gives the A900 Controller a start signal.
(b) Engine will crank, start and come up to governor speed.
(c) When engine has come up to speed, open the circuit
between terminal 28 and 4. This gives the A900
Controller a stop signal.
(d) All lights on the back of the A900 should go off and the
engine stop.
4-4.5 Overspeed Switch Setting; To set the speed switch,
proceed as follows:
(a) Turn Mode Selector switch to the TEST position.
(b) Engine will crank, start and come up to governor speed.
(c) With engine running, adjust governor to bring engine speed
to normal RPM.
(d) Depress and hold the Overspeed Test pushbutton.
(e) Slowly turn the Overspeed Set adjustment counter-
clockwise until the “Overspeed” and “Overspeed Relay”
lights on the A900 come on and the engine shuts down.
(f) Release pushbutton; check “Overspeed” light on front
panel to be sure it is on.
Figure 4-4.1.3
Fuel Relay
Torque
Torque
Scews to
12 In./lb.
Scews to
12 In./lb.
15
35
Crank Relay
SW1 = 1
SW2 = 2
SW3 = 3
SW4 = 4
SW5 = 5
SW6
26
04
27
28
04
29
30
31
32
33
34
36
37
38
39
40
41
42
43
44
45
46
Crank/Rest
Time
Number
of Cranks
SW1 = 10 s.
SW2 = 15 s.
SW3 = 20 s.
SW4 = 25 s.
SW5 = 30 s.
SW7 = None
1
2
3
4
5
1
2
3
4
5
6
7
Unused
Switch
SW6
Close Only One Switch
Close Only One Switch
Crank
Crank
Pickup
Present
Disconnect Disconnect
Set
Speed
Overspeed Overspeed Overspeed Overspeed
Test Set Relay
Shutdown
lay
LAuA
y
Remote Visual Alarm
Relay
(g) n Mode Selector switch OFF to reset shutdown circuits;
n back to TEST.
(h) hen ene sts, increase governor speed setting slowly
until eine don on overspeed. This should occur
about 10% ovgernpeed.
(i) Turn Mode SelecswiOFF
4-4.6 Overcrank setting; to tenumr of anbefore system
shuts down on overcrank;
(a) Disconnect the run solenoid wire m termthe
Relay Module.
(b) Check number set on the “Number Of Cranks” tch on
A900 back panel. It is factory set at 3.
47
48
49
50
51
52
53
54
55
56
57
58
Remote Audible Alarm
Relay
Miscellaneous Program Switches
5 min. Cooldown
SW1 = Open
Unused Switches
Air Damper Closed
Light ON With
1
2
3
4
5
6
7
Overspeed Shutdown
SW7= Closed
SW2
Alarm
Shutdown
SW3 = Closed
SW4 = Open
SW5 = Open
SW6 = Closed
SW3 = Open
SW4 = Closed
SW5 = Closed
SW6 = Open
Loss of Speed Circuit
6. While engine is cranking, turn crank disconnect
adjustment counter clockwise slowly until “Crank
Disconnect Speed” light turns on and cranking stops.
7. Turn crank disconnect adjustment clockwise 1/4 turn.
This sets crank disconnect speed at approximately 125
RPM above cranking speed.
(c) Turn Mode Selector switch to TEST.
1. Engine will crank for 15 seconds.
2. Then rest for 15 seconds
3. This should repeat 3 times and then the “Overcrank”
light on the A900 will come on and engine will not
crank again.
8. Turn Mode Selector switch OFF.
(d) Turn Mode Selector switch OFF.
(e) Reconnect the run solenoid wire at terminal 6 of the Relay
Module.
4-4.7 Oil Pressure; to test oil pressure shutdown circuit:
(a) Turn Mode Selector switch to TEST. When engine starts,
wait 30 seconds then,
(b) Use a jumper wire and short from terminal 30 to 4.
(c) “Oil Pressure” light will come on and engine will stop.
(d) Turn Mode Selector switch OFF.
4-4.8 Water Temperature; to test the water temperature
shutdown circuit:
(a) Turn Mode Selector switch to TEST. When engine starts,
wait 30 seconds then,
(f) Reconnect the run solenoid wire at terminal 6 on Relay
Module.
4-4.3 Start and Stop Engine; to test the start and stop function,
proceed as follows:
(a) Double check all wiring to be sure it is connected.
(b) Turn Mode Selector switch to the TEST position. This
gives the A900 Controller a start signal.
(c) Engine should crank, start and come up to governor speed.
1. Check “Crank Disconnect Speed” light; it should be on
and “Crank Relay” light should be off.
2. If lights are not correct, turn Mode Selector switch
OFF and review paragraph 4-4.2.
(d) When engine has come up to speed and governor has been
(b) Use a jumper wire and short from terminal 32 to 4.
20
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(c) “Water Temperature” light will come on and engine will received, the engine will start.
stop.
5-2.3.2 When the start signal is removed, the engine will stop.
It is now ready to restart.
(d) Turn Mode Selector switch OFF.
4-4.9 Low Water Temperature; to test the low water temperature 5-2.4 OFF or Not Operating; to prevent operation of the engine,
alarm circuit:
turn selector switch OFF.
(a) Engine does not have to be running.
(b) Use a jumper wire and short from terminal 31 to 4.
(c) “Low Water Temperature” alarm light will come on as long
as the jumper maintains the circuit.
4-4.10 Other Alarm and/or Shutdowns; all other alarms and
shutdowns would be tested in the same manner.
(a) For shutdown circuits, the engine must be running for test.
(b) Most alarm only circuits can be tested without starting the
engine. Low Oil Pressure Pre-alarm and High Water
Temperature Pre-alarm are exceptions.
(c) To test other shutdowns or alarms, a jumper wire can be
used to short out the switch contacts at the switch or if this
is not possible, the test can be run by shorting the input
terminal for that circuit, to ground, terminal 4.
(d) Tt Low Oil Pressure Pre-alarm;
Section 6: Routine Maintenance
and Operational Tests
6-1 Routine Maintenance.
6-1.1 Due to the design and types of components used, very
little maintenance is required to the A900 Control.
6-1.2 Visual inspection of the internal wiring of the control
panel, along with checking wire connections for tightness,
should be done on a semiannual schedule for stand-by systems
or quarterly for prime power. Check wire bundles for chafing
and wear to the insulation of the wires where they contact the
panel or engine.
6-1.4 Shutdown and Alarm Circuits should be tested on a
monthly basis for prime power and quarterly for stand-by sets.
The same tests run during pre-operation check out, Section 4-4,
should be included.
Mode Selector switch to TEST. When engine
w30 seconds then,
2. se a mpewirand short from terminal 50 to 4;
“Low il Presse Pre” light will come on as
long as the jupmaains tcircuit.
6-2 Operational Tests.
6-2.1 No special operational tests are required. The routine
operational tests for the generator set will exercise the control.
(e) To test High Water Tempeture Pre-a
1. Turn Mode Selector swith to hen ngine
starts, wait 30 seconds then,
Section 7: Troubleshooting and Repair
7-1 Tools Required.
7-Some of the tools necessary for troubleshooting are built
inthe A90 Series controls.
2. Use a jumper wire and short from termin51 o
“High Water Temperature Pre-alarm” light will e
on as long as the jumper maintains the circuit.
.1.1 Bbseng the lights on the front and rear of the control
panel, clto bleand the possible source can be seen.
7-1.1.2 Operonblewith the automatic engine control
will show up by log ae inand output lights on the rear
of the A900 SELECTROC® CtroDisay Module.
7-1.2 Other tools which may reque:
7-1.2.l AC/DC Voltmeter for takinvoltage and an
Ohmmeter for testing resistance of wires and c.
7-1.2.2 Jumper wires with alligator clips to bypasor simulate
circuit closures.
Section 5: Operation
5-1 Operator Controls.
5-1.1 Mode Selector Switch; allows the operator to select either
manual (TEST), automatic operation (AUTO), or no operation
(OFF).
5-1.2 The OFF position on the mode selector also provides a
reset function for the shutdown circuits. If the engine is shut
down by the automatic control, the operator must turn selector
off and back on to reactivate the system.
5-1.3 Push to Test Lamps; this pushbutton tests the alarm and
shutdown indicator lights.
5-1.4 Alarm Silence Pushbutton; if so equipped, silences the
local and remote audible alarm. Visual indicator remains on
until reset or sensor switch contacts clear.
DO NOT USE THESE JUMPER WIRES TO CHECK IF
VOLTAGE IS PRESENT AT A TERMINAL BY DRAWING
AN ARC TO GROUND. THIS WILL DAMAGE OR
DESTROY EQUIPMENT IN THE A900 CONTROL PANEL.
7-2 A900 SELECTRONIC Control Operation And
Shutdown.
7-2.1 The first step in troubleshooting any equipment is to
understand its normal operation. Table 7-2.1 contains normal
voltage readings taken at the terminals of the A901 with all
equipment shown on the standard drawing, connected.
(a) All voltage readings are DC, except at terminal 29, and
were taken with the negative lead of the meter connected
to ground at terminal 4. Voltage reading at terminal 29
was taken with negative lead grounded and the meter on
AC scale.
(b) The battery voltage, at the time readings were recorded,
was 13.8 V and 27.6 V. All readings will vary depending
on battery voltage, equipment supplied in the panel and
external devices connected to the A900 control. See notes
5-2 Operating Modes.
5-2.1 The A900 Generator Engine Control has two operating
modes: manual and automatic.
5-2.2 Manual Operation is provided for testing of the generator
set.
5-2.2.1 To initiate Manual Control, place the Mode Selector
switch in the TEST position. This provides the automatic
control a start signal.
5-2.2.2 To stop, turn selector switch to OFF. This removes start
signal and the engine will stop.
5-2.3 Automatic operation is the normal mode.
5-2.3.1 To initiate Automatic Control, place the Mode Selector
switch in the AUTOMATIC position. When a start signal is
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Table 7-2.1
22
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to the table for examples.
(b) Shutdown relay K-2 is energized, closing its contacts at
terminal 9. These contacts can be wired to a shunt trip
solenoid in the generator circuit breaker if required.
(c) The fuel relay drops out, removing battery voltage from
the run solenoid, terminal 6, and from the alternator
exciter, terminal 8. The circuits at terminal 5 and 7 will
close to reconnect the battery positive to these terminals.
(d) The run signal, terminal 19 turns off.
(c) Voltages less than battery also may vary due to tolerances
of the electronic components in the A900. Minor
variations, 1 or 2 volts, normally will have no effect on the
A900 operation.
(d) The AC voltage at terminal 29 must be a minimum of 2
VAC to drive the speed sensing circuits of the A900.
7-2.2 With power applied and the Mode Selector switch in
AUTO, the following occurs when a switch is closed from
terminal 28 to ground.
(e) If the shutdown is due to overspeed, the overspeed relay
operates and applies battery positive to terminal 10 to
close an air shutoff solenoid if the engine is so equipped.
7-2.2.1 The fuel relay is energized, which opens the circuits at
terminal 5 and 7, and closes the circuits at terminal 6 and 8. This 7-2.3.5 If the engine is shutdown by the remote stop circuit, no
applies battery power to the run solenoid and to the exciter TATTLETALE® light is provided. Otherwise a TATTLETALE®
terminal of the alternator.
light will show the cause of shutdown.
7-2.2.2 At the same time, the crank relay driver provides battery 7-2.3.6 In the A900, the Loss of Speed signal TATTLETALE®
voltage at terminal 17, thru the auxiliary crank disconnect relay can be either a shutdown or an alarm. It is connected to a circuit
contact to the auxiliary starter solenoid. This output is controlled that monitors the magnetic pickup input at terminal 29. If the
by the crank and rest timer but it can be overridden by the crank input from the pickup fails, drops below the minimum voltage,
disconnect speed switch and / or the auxiliary crank disconnect or is disconnected while the engine is running, the Loss of Speed
circuit. e output will remain on until the crank time expires or Signal TATTLETALE® circuit will activate and shutdown the
the crannect circuits detect that the engine has started.
engine or operate the alarm circuit. It is recommended that the
7-2.2ene does not start during the crank time, the shutdown circuit is used since this prevents the generator set
rest timell pent nkg until it has timed out. After the from running without overspeed protection. If this circuit is
rest time, the ene will egin cng again. This sequence used as an alarm, the auxiliary crank disconnect input MUST be
will repeat until the gistor overcrank shutdown supplied to prevent malfunction of the shutdown circuits.
circuit trips.
7-2.3.7 To reset the circuits, the Mode Selector switch must be
7-2.2.4 Engine speed is detecteby anal om a turned OFF and back on to either the AUTO or TEST position.
magnetic pickup wired to terminal 29. s fenc7-2.4 Normally, the engine will run until the start signal is
exceeds the setting of the crank disconnect speed swit
(a) Cranking is terminated.
reved from terminal 28.
7.1 When the signal is removed, the following occurs to
(b) A time delay starts timing during which the oil pressure p the ene;
and water temperature shutdown circuits are locked out.
(c) The overcrank counter is reset to zero.
(a) Tfuey ps out, removing battery voltage from
the ruo, tinal 6, and from the alternator
exciter, term8. he cits at terminal 5 and 7 will
close to reconnect battpove these terminals.
(b) The run signal, terminaturn
(c) The four engine function TTLETAuits are
locked out as soon as the fuel relay t. This
prevents any TATTLETALE® from trippwhile the
engine coasts to a stop.
(d) The overspeed shutdown circuit is activated.
7-2.2.5 An engine run signal closes to ground at terminal 19
when the engine starts.
7-2.3 With the engine running, the six shutdown TATTLETALE®
circuits are activated and will operate anytime a switch closes
from ground to their inputs.
Circuit
Input
Output
(a) Remote Stop
(b) Oil Pressure
(c) Water Temp
(d) Overspeed
(e) Loss of Speed Signal
(f) Spare Shutdown
Terminal 33
Terminal 30
Terminal 32
Int. Speed Switch
Int. Circuit
Terminal 41
Terminal 39
Terminal 40
Terminal 38
Terminal 43
Terminal 42
7-3 A900 SELECTRONIC® Control Alarm Circuit
Operation.
7-3.1 The A900 alarm circuits perform the following functions;
(a) Turns on individual alarm lights based on input switch
closures.
Terminal 11
(b) Provides lamp test function for all alarm and shutdown lights.
(c) Activates either the local audible alarm relay, K-4, and
remote visual alarm relay, K-6, or the local audible alarm
relay, K-4, the remote audible alarm relay, K-5, and the
remote visual alarm relay, K-6, depending on the
requirements of NFPA-110 1988 paragraph 3-5.5.1 (d).
(d) Provides the audible alarm silence circuit.
7-3.2 A contact closure to ground, at the alarm circuit
input terminal, will cause the associated TATTLETALE® light to
turn on and an output transistor to close to ground and turn on a
remote indicating light.
7-2.3.1 Each circuit has a indicating light and a transistor output that
closes to ground to operate an individual remote indicating light.
7-2.3.2 When any of the six shutdown functions trip, the
shutdown relay K-2, pulls in and applies battery power to
terminal 9. At the same time, the fuel relay, K-1 drops out and if
the shutdown was due to overspeed, the overspeed relay, K-3
pulls in to signal an air shut off solenoid, terminal 10 to close.
7-2.3.3 The six shutdown circuits, paragraph 7-2.3, are first out
latching type TATTLETALE®. That is, only one of the six may
trip at one time and it must be reset before the A900 will operate
again.
7-3.2.1 The alarm circuits also operate the three relays for local
audible alarm, remote audible alarm and remote visual alarm as
required by NFPA-110. The normally open dry relay contacts,
7-2.3.4 If one of the TATTLETALE® circuits trip, the following
occurs to shutdown the engine and generator.
(a) The TATTLETALE® light for that function turns on.
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local audible (K-4) terminal 20 and 21, remote audible (K-5) Module, a Relay Module and a number of Relays.
terminal 22 and 23 and remote visual (K- 6) terminal 24 and 25 8-1.2 There are no field replacement parts in the Control/Display
close to operate the alarm devices wired to them.
Module. The complete module must be replaced if it fails. All
7-3.3 An alarm silence pushbutton is wired between terminal 35 relays are individually replaceable in the Relay Module but the
and ground. This switch is provided on the A901 and can be module must be replaced if a failure of the circuit board occurs.
externally connected on the A902 series. When this switch is 8-2 Table 8-2 displays replaceable components for the A900 series
closed, the audible alarm relays K-4 and K-5 will drop out if they controls manufactured for Detroit Diesel Corporation.
are closed. This turns off the audible alarms but does not affect the These components have Murphy part numbers. In addition, they
individual alarm lights on the panel. The lights will remain on are OEM parts and are available only to Detroit Diesel and their
until the input switches open. If no alarm silence switch is distributors.
provided, the alarm relays will reset when the alarm and / or 8-2.1 The A900-DDC parts are the same as the Murphy A900
shutdown lights reset.
series that has been covered throughout the A900 manual except
the “Spare Shutdown” circuit is labeled “Low Water Level” and
the DDC logo is printed on the face plate.
Section 8: Service Parts
8-1 Table 8-1 covers all of the replaceable components of the
A900 Series Generator Engine Controls. The part numbers that are
shown are Frank W. Murphy Mfr. numbers, and may not appear on
the individual parts.
8-1.1 Each complete control is made up of a Control/Display
Table 8acement Components for A900 Series Generator Engine Controls
Model Nu
art mer
40-02-32
40-0237
40-02-0134
40-02-0140
40-02-0133
40-02-0145
40-02-0135
40-02-0148
40-02-0151
40-02-0152
40-02-0155
40-02-0156
Control/Display Module
40-00-0077
400-0077
078
007
40-00-09
40-00-0079
40-00-0080
40-00-0080
40-00-0081
40-00-0081
40-00-0082
40-00-0082
Relay Module
40-00-0064
40-00-0064
40-00-0064
40-00-0064
-00-0064
40-0064
40--00
40-00-04
40-00-0064
40-00-0064
40-00-0064
40-00-0064
Relay Part Number
00-00-2952
00-00-2953
00-00-2952
00-00-2953
00-00-2952
00-00-2953
00-00-2952
0-00-2953
00-095
0-29
00-00-29
00-00-2953
Relay Qty
A901-12
5
5
6
6
3
3
4
4
3
3
4
4
A901-24
A901-2-12
A901-2-24
A902-12
A902-24
A902-2-12
A902-2-24
A903-12
A903-24
A903-2-12
A903-2-24
Table 8-2: Replacement Components for A900 Series Controls for Detroit Diesel Corporation
Model Number
Part Number
Control/Display Module
Relay Module
Relay Part Number
Relay Qty
A901-12-DDC
A901-2-24-DDC
A902-12-DDC
A902-2-24-DDC
A903-12-DDC
40-35-0020
40-35-0029
40-35-0022
40-35-0037
40-35-0024
40-00-0083
40-00-0084
40-00-0085
40-00-0086
40-00-0087
40-00-0064
40-00-0064
40-00-0064
40-00-0064
40-00-0064
00-00-2952
00-00-2953
00-00-2952
00-00-2953
00-00-2952
5
6
3
4
3
A903-2-24-DDC
40-35-0043
40-00-0088
40-00-0064
00-00-2953
4
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In order to consistently bring you the highest quality, full featured products, we reserve the right to change our specifications and designs at any time.
CONTROL SYSTEMS & SERVICES DIVISION
P.O. Box 1819; Rosenberg, Texas 77471; USA
(281) 342-0297 fax (281) 341-6006
e-mail [email protected]
FRANK W. MURPHY, LTD.
MURPHY SWITCH OF CALIFORNIA
41343 12th Street West
Palmdale, California 93551-1442; USA
(661) 272-4700 fax (661) 947-7570
e-mail [email protected]
Church Rd.; Laverstock, Salisbury SP1 1QZ; U.K.
+44 1722 410055 fax +44 1722 410088
e-mail [email protected]
FWMurphy
P.O. Box 470248
Tulsa, Oklahoma 74147 USA
(918) 627-3550
fax (918) 664-6146
e-mail [email protected]
MURPHY DE MEXICO, S.A. DE C.V.
Blvd. Antonio Rocha Cordero 300, Fracción del Aguaje
San Luis Potosí, S.L.P.; México 78384
+52-48-206264 fax +52-48-206336
e-mail [email protected]
For Service in French:
Pour service en francais:
+44 1722 410697 fax +44 1722 410088
e-mail [email protected]
MACQUARRIE CORPORATION
1620 Hume Highway;
Campbellfield, Vic 3061; Australia
+61 3 9358-5555 fax +61 3 9358-5558
e-mail [email protected]
Printed in U.S.A.
0690040
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