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Related Manuals for Controls MX Series
Summary of Contents for Controls MX Series
- Page 1 PRODUCT MANUAL ENGINE CONTROL MODULE MX SERIES Part Number: MX-500-AS through MX-505-AS Revision: V1.0 Engine Type: Electronic and Mechanical Engines ______________________________________________________________________________________________________________________________________...
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Page 2: Table Of Contents
TABLE OF CONTENTS INSTALLATION …….…………………………………………………………………………………….…………………………………………..…………. CONSIDERATIONS DIMENSIONAL WIRING SCHEMATIC MANUAL OPERATION ……………………………………………………………………………………..…………..……………………………… POWER UP MANUAL OFF MANUAL STARTING SAFETY BYPASS ENGINE RUNNING SPEED CONTROL ELECTRONIC SPEED CONTROL MECHANICAL STOPPING THE ENGINE SPEED CONTROL OPTIONS …………………………………………………………………………………………………………………………. ELECTRONIC ENGINE SPEED CONTROL REQUESTED VERSUS ACTUAL SPEED TSC VERNIER THROTTLE TSC BUMP TSC MULTISTATE THROTTLE... - Page 3 PROTECTION OPTIONS …………………………………………………………………………………………………………………..…………. ECU SAFETY SHUTDOWNS AND WARNINGS MODULE SAFETY SHUTDOWNS AND WARNINGS LOW POWER MODE OTHER MODULE FUNCTIONALITY …………………………………………………………………………………………..……………. STANDARD FEATURES CUSTOM SPLASH SCREEN SENDER FAILURE AUDIBLE HORN SHUTDOWN OVERRIDE AUTO START OPERATION ………………………………………………………………………………………………………………..………. GENERAL INFORMATION AUTO START MODE SCHEDULER AUTO START AUTOMATIC SINGLE SPEED OPERATION FLOAT OPERATION...
- Page 4 OPERATION EVENT LOG ALARM EVENT LOG ENGINE IDENTIFICATION MODULE INFORMATION MODULE PROGRAMMING ……...………………………………………………...……………………………………………….………………. PROGRAMMING OPTIONS PC BASED PROGRAMMING MODULE BASED PROGRAMMING CONTROLLER SETUP ……...………………………………………………...……………………………………………….…………………..………. PASSWORD ENTERY SETUP MENU QUICK SETUP ENGINE PARAMETER CONFIGURATION PUMP PARAMETER CONFIGURATION TRANSMISSION PARAMETER CONFIGURATION SCHEDULER CONFIGURATION INPUT CONFIGURATION OUTPUT CONFIGURATION THROTTLE CONFIGURATION...
- Page 5 WARRANTY ………………………………………….……………………………………………………………………….……………………………..
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Page 6: Installation
• ENCLOSURE MOUNT: If your installation is better suited for a full control panel rather than a module, contact Controls, Inc. for available options or assistance in designing an enclosure for your application. -
Page 9: Manual Operation
MANUAL OPERATION POWER UP Turn on the power to the module. The display will illuminate and show the module part number version in the upper left status line and the graphical logo will be centered in the screen. The LED indicators will turn on for one second to verify operation. -
Page 10: Manual Off
CONTROLLER MODES MANUAL OFF After the Power Up cycle is complete, the module will be in the Manual Off mode as shown in the upper left status line and the corresponding red LED indicator above the Off button. -
Page 11: Manual Starting
MANUAL STARTING RUN BUTTON Press the green RUN button. If a preheat cycle is programmed in the display, or requested by the engine’s ECU, the status line will indicate a Wait to Start message or Preheat Countdown. Once completed, the status line will show Ready to Start. Press and Hold the green RUN button. -
Page 12: Safety Bypass
SAFETY BYPASS Immediately after the engine begins to run, the module will enter the “Safety Bypass” period. This time period is typically set to 10 seconds and is programmable. During this period, any engine parameter set to be monitored as RUN will be ignored until the bypass period is passed, at which point the safeties will become active. -
Page 13: Speed Control Electronic
SPEED CONTROL - ELECTRONIC ENGINES The display can control the engine’s speed using J1939 Torque Speed Control (TSC1). When the engine is started manually, the control panel will request the minimum programmed speed. Pressing the Up-arrow button will cause the panel to increase the requested speed. The display will place an up or down arrow to the right of the RPM displayed to indicate that a change in speed is being requested. -
Page 14: Stopping The Engine
STOPPING THE ENGINE When it comes time to stop the engine, simply press the red OFF button. This will de-energize the fuel solenoid on mechanical engines or the engine ECU Run/Stop circuit on electronic engines. In some cases, the module will send an engine STOP command over the J1939 CAN Bus to shut down the engine. -
Page 15: Speed Control Options
SPEED CONTROL OPTIONS ELECTRONIC ENGINE SPEED CONTROL The display can control the engine’s speed using J1939 Torque Speed Control (TSC1). When the engine is started manually, the control panel will request the minimum programmed speed. Pressing the Up-arrow button will cause the panel to increase the requested speed. The display will place an up or down arrow to the right of the RPM displayed to indicate that a change in speed is being requested. -
Page 16: Requested Versus Actual Speed
The control panels TSC address and the engine’s ECU address must match. Most major engine manufacturer’s TSC addresses are loaded into the control panel when that engine manufacturer is selected in the Quick Setup. However, there may be instances where ECU programming may vary. The control does have the ability to change the TSC address manually in the CAN Configuration menu. -
Page 17: Tsc Vernier Throttle
TSC VERNIER THROTTLE TSC Vernier is the most popular throttle selection when operating in the manual start mode. The operator can control the engine speed anywhere between the programmed speed range. This throttle type allows you to set the minimum engine speed, maximum engine speed, ramp rate, curve type and bump speed increments without the use of a computer. -
Page 18: Tsc Multistate Throttle
TSC MULTISTATE THROTTLE Another widely used throttle type in manual mode allows the operator to increment the engine speed between predetermined speed settings by pressing the Rabbit or Turtle buttons. The number of discreet speeds set is up to four ascending speeds. After the operator starts the engine, the controller will run the engine at Speed 1 setting, the lowest speed. -
Page 19: Flex Analog Throttle
MODBUS THROTTLE Engine speed can be requested through the modules RS485 MODBUS interface. Contact Controls, Inc. for a complete register map. The example for speed control is below. Use of 40004 or 40051 is acceptable. -
Page 20: Cooperative Throttle
The main module must be configured as the Primary, while the remaining modules should be set to remote. TWIST THROTTLE KNOB The TT-100 throttle knob is available to work with Controls, Inc. modules as well. Contact CI for more details. -
Page 21: Display Configuration
DISPLAY CONFIGURATION GRAPHICAL DISPLAY The MX Series uses a 3.2” diagonally measured, OLED (Organic Light Emitting Diode) display with a resolution of 256x64 pixels. The OLED technology provides a vibrant display that is highly readable in direct sunlight while also offering a wide temperature range of -40C to +80C for both operating and storage. -
Page 22: Display Customization
DISPLAY CUSTOMIZATION There are three objects that can be used to create your display. Digital, Analog and Custom structures are available to tailor the screen to display what is important to your piece of equipment. Customization is available in Areas 1 through 8. Digital –... -
Page 23: Protection Options
PROTECTION OPTIONS ECU SAFETY SHUTDOWNS AND WARNINGS Once the engine is started, the engine’s ECU has primary control over the operation of the engine under safe conditions. If the ECU detects that any of its critical parameters are out of tolerance, the ECU can take a variety of actions, including derating of the engine horsepower or complete engine shut down. -
Page 24: Module Safety Shutdowns And Warnings
MODULE SAFETY SHUTDOWNS AND WARNINGS The control panel also has the ability to monitor the engine vitals if configured. The ability to set pre alarms and alarms in the panel is supported to back up the ECUs safeties in the event the ECU shutdowns were not enabled or a more conservative setting is desired. -
Page 25: Low Power Mode
LOW POWER (SLEEP) MODE A low power mode is available to allow the module to minimize power consumption during times when the panel is on, but the engine is not running. Examples include auto start mode, manual start mode, but the engine did not start, or a shutdown condition. To minimize current draw, the module goes into a sleep mode after a programmable time period (two-minute default) after being powered on without the engine starting or after a protection shutdown occurs. -
Page 26: Other Module Functionality
OTHER MODULE FUNCTIONALITY STANDARD FEATURES The control panel has many options that can be configured, enabled or selected that will enhance the operation of the equipment. A list of items is below with descriptions on the selection and use of each. -
Page 27: Audible Horn
AUDIBLE HORN An alarm horn can be driven from an output to annunciate alarm conditions and/or a pre-start warning on auto start applications. When an output is assigned to any Horn function, the Enter button will be used the silence the horn. -
Page 28: Shutdown Override
SHUTDOWN OVERRIDE The module contains logic that can be enabled to provide a safety shutdown override. The override applies to any module monitored and activated alarm. It does not apply to engine ECU safety shutdowns. For ECU overrides, consult with your engine supplier. To use this feature, an available digital input must be assigned to the Shutdown Override action and have a switch connected to it. -
Page 29: Auto Start Operation
AUTO START OPERATION GENERAL INFORMATION The MX Series modules have a high degree of configurability when it comes to auto start applications. The information herein is designed to be a general guide to the different methods of auto start operation. An auto start signal can come from a digital input(s), Modbus, CANbus or from the real- time clock scheduler. -
Page 30: Auto Start Mode
AUTO START MODE With power on to the module, press the white AUTO button to place the unit in the Auto Start mode. The display will indicate that the module is now in the Auto mode. The status line will display Auto Off. While in the Auto Off mode, the controller will await an auto start signal. -
Page 31: Scheduler Auto Start
SCHEDULER AUTO START If the Scheduler is set up to provide starting and stopping based on the time of day and day of week, the status/mode line will rotate to show the next start event. Once running under the scheduler, the Stop time will be displayed. - Page 32 AUTOMATIC SINGLE SPEED CONTROL MODE When operating in Auto, the controller will start the engine at the warm up speed and maintain that speed until the warm up time delay expires. After that, the control will ramp the speed up to the Prime Speed setting and maintain that through the time period.
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Page 33: Float Operation
FLOAT OPERATION SINGLE FLOAT SYSTEM Basic level control can be accomplished using a float device that contains a contact closure internally. For applications that do not have critical start and stop points and do not involve turbulence, such as a pond or lagoon, a single float can provide adequate control over water levels. -
Page 34: Transducer Installation
• Material – Know the type of liquid you will be subjecting your transducer to. Typical materials range from stainless steel to titanium. The costs can be considerably different, so talk to a specialist. Controls, Inc. does stock transducers and can assist in selection. Contact a sales engineer for more help. -
Page 35: Main Menu Access
MAIN MENU ACCESS To access the module menu system, apply power to the module and press the Menu button. ENTER BACK MENU DOWN If the engine is running, the throttle buttons will remain active for speed control. The menu system is broken into two main sections;... - Page 36 operator menu contains information about the engine and module. The topics will vary based on the engine type and control panel model. Pressing the Up and Down button will move the highlighted selection up or down in the list. Indicator Arrows show if there are additional subjects above or below the current screen view.
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Page 37: Main Menu Topics
MAIN MENU TOPICS The Main Menu contains many areas that are useful for the routine operation and troubleshooting of an industrial engine. Each feature cannot be covered in this manual; however, a list of main topics is below. ACTIVE ENGINE FAULT CODES If the engine’s ECU is generating trouble codes, they can be viewed from this menu. - Page 38 ENGINE PARAMETERS Engine’s ECUs collect a large amount of information about the operating conditions of the engine. To view more of these details and gain a better understanding of your engine’s operating conditions, view this menu. EMISSIONS PARAMETERS For engines equipped with emission components, a menu is available to view these details.
- Page 39 PUMP PARAMETERS If the four analog senders are configured for pump use, the values can be seen here. Note, you must select either Application Level or Application Pressure when configuring the transducers. OPERATION EVENT LOG The module will record the last 32 operational events and show the most recent first. The event log can be cleared in the Module Configuration menu of the Controller Setup area.
- Page 40 ENGINE IDENTIFICATION Use this menu to view the engine’s Model and Serial number. MODULE INFORMATION Use this menu to view the detailed information about your MX Series module.
- Page 41 The CI Station allows the user to save configurations and reuse them over and over for production line programming or to configure replacement panels to match the original OEM programming. Contact Controls, Inc. for more details.
- Page 42 MODULE BASED PROGRAMMING The control panel will come with a factory configuration unless otherwise specified. Consult with your sales channel for modifications to the factory configurations. A Quick Setup menu is located under the Controller Setup area that will provide the basic selections you may want to review and/or change to meet your needs.
- Page 43 CONTROLLER SETUP When navigating through the Main Menu you will arrive at the Controller Setup selection. To configure the module to new settings, you can enter into this area by pressing the Enter Button PASSWORD ENTRY The next screen will ask for a password. If no password, or an incorrect password is used, navigation into the menu is still possible and permitted, however, the ability to make changes will be restricted.
- Page 44 SETUP MENU Navigating the Controller Setup menu structure is done in the same manner as the Main Menu system. Up and Down arrows will scroll to the next topic; Enter button will access the topic, etc. To make changes to the settings, you will need to locate the item you are looking to modify under the appropriate topic and then press the Enter button.
- Page 45 QUICK SETUP This menu is designed to allow you to configure the module in a simple manner, asking you to select the most common options used with today’s industrial engines. Based on your selections here, other items will be affected. For example, if you select Engine Type as Mechanical, the module will default the engine oil pressure, coolant temperature and speed sender options to be typical senders rather than J1939.
- Page 46 PUMP PARAMETER CONFIGURATION Individual pump parameters can be changed here. Two transducers can be configured for Inlet and Discharge pressures. Note: These two inputs are also associate with analog oil pressure and coolant temp. They must be assigned to one or the other, not both. SCHEDULER CONFIGURATION The module can be set to start and stop the engine based on the time of day and day of the week.
- Page 47 INPUT CONFIGURATION The module has two on board digital inputs that can be configured in a large variety of ways. All digital inputs are pulled high and must be closed to ground. Additional REMOTE I/O can be configured when used with an XCAN-IO-664 from simple switch shutdowns to remote engine operation, contact CI application engineers to discuss.
- Page 48 THROTTLE CONFIGURATION The speed control behavior of the engine can be changed under the Throttle Configuration menu. Selection of throttle type, minimum operating and maximum operating speeds and other details as well can be set here. See Speed Control Options for more details. ENGINE SAFETY CONFIGURATION The module can provide warnings, shutdowns, deceleration, and other behaviors based for the critical engine parameters of oil pressure, coolant temperature, engine speed, fuel level and battery voltage.
- Page 49 PUMP SAFETY CONFIGURATION The module can provide warnings, shutdowns, deceleration, and other behaviors for the critical pump parameters of suction pressure and discharge pressure. Simply set the thresholds and actions desired. In the example below, a warning will be annunciated if the discharge pressure rises above 200 psi and the engine will be decelerated to minimum speed if it exceeds 250 psi.
- Page 50 DISPLAY CONFIGURATION Use this area to set up the display with the parameters you desire to see on the full-time display. For details on configuration, see DISPLAY OPTIONS in this manual. In the example below, Area 3 would display engine Oil Pressure in digital format. The AG suffix stands for Analog Gauge presentation. CAN CONFIGURATION This menu is used to define how and what messages are transmitted on the J1939 CAN Bus.
- Page 51 AUTO START CONFIGURATION These settings define the time delays and speeds that will be used during an auto start routine. Warm Up Seed, Prime Speed, Cooldown Speeds are programmed here. BATTERY RECHARGE CONFIGURATION The module can be used to monitor the engine starting battery voltage and start the engine if the voltage drops below a programmed setting.
- Page 52 MAINTENANCE CONFIGURATION If you would like to set up service intervals for your equipment, use this menu to establish up to three unique service schedules. You can set the time between, name of service, and when to being warning of impending service requirements. EMISSION CONFIGURATION If your engine is equipped with emission components, you may use this menu to setup additional warnings, enable and disable regen options and other CAN based messaging.
- Page 53 MODBUS CONFIGURATION (OPTIONAL) When connecting to a MODBUS devise such as PLCs, telematics or other controls, this menu will define the communication protocol for successful integration. The modules are designed to operate as a MODBUS RTU. CLUTCH CONFIGURATION Two channels of interlocking output behavior can be configured using outputs 5-8 in the module.
- Page 54 CLOCK SETUP When you receive your module, it should be programmed with the correct date and time for the Eastern US Time zone. The real-time clock on the module is backed up by a large capacitor that will keep the time correct for 2 to 3 months while it sits in the box. If reprogramming is needed, you can access this menu or use the CI Station setup too.
- Page 55 MODULE CONNECTORS The module has one Ampseal, keyed connector, located on the back of the display. The connector provide access through the weather tight display enclosure which houses the electronics. Display Connector 14 Pin 776273-5 Sockets 770854-1 (Tin) 770854-3 (Gold)
- Page 56 DISPLAY CONNECTOR (STANDARD) MX-500-AS Function Function DO1; 5A, Fuel CAN Low; J1939- DO2; 5A, Crank DI2; Close to Ground Speed Signal AI2; Oil Pressure DO3; 5A Battery Positive; 12 or 24VDC DO4; 5A Battery Negative AI3; Coolant Temp AI1; Fuel Level CAN High;...
- Page 57 DISPLAY CONNECTOR (KUBOTA Analog Pedal Sensor OPTION) MX-502-AS Function Function DO1; 5A, Fuel CAN Low; J1939- DO2; 5A, Crank DI2; Close to Ground 5.2 VDC Supply for APS *AI2; APS 1 (Required) DO3; 5A Battery Positive; 12 or 24VDC DO4; 5A Battery Negative *AI3;...
- Page 58 DO= Digital Output (Switched Vbatt, 5 Amp max each, 10 Amp Total Load) DI= Digital Input (Normally Open* or Normally Closed) AI = Analog Input (Resistive Sender*, 4-20ma or 0-5VDC) ‘* = Default OTHER CONFIGURATIONS AVAILABLE. CONTACT CONTROLS INC FOR ASSITANCE.
- Page 59 WARRANTY CONTROLS, INC. is herein called “Seller”. The person, firm or corporation to whom or which the sale is made is herein called “Buyer”. Seller warrants to the Buyer that all products furnished under this order will conform to Seller’s specification, drawings as described in its current catalog or quotation and will be free from defects in materials and workmanship.
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