EMS447 Engine Controller

Description
The EMS Controller is a microprocessor based Engine controller with built-in service reminder features. It will automatically warn you when certain service items need to be performed and will signal your engine to shut down if a fault is detected.

The system is accessed through three push-buttons and a backlit, dot-matrix liquid crystal display. A more detailed description of operator functions can be found in the operating instruction section.

Sensor Inputs
The EMS Controller accepts several different types of sensor inputs. Below is a list of which types are accepted. See the wiring hookup drawing for terminal details.

Electric Gauge Senders. These inputs allow you to use standard electric gauge type senders for oil pressure and water temperature.

Digital alarm inputs. These inputs are negative grounding type inputs. Typically, external shutdown switches are wired to these inputs. They can include vibration, low pressures, high temperatures, and low levels.

Frequency input. This input is an optically isolated speed sensing input. You may get your speed signal from either a magnetic pickup or the tachometer post of your alternator. See the S-number listing section later on in this manual for information on calibrating the speed signal.

Operating the EMS Controller
The EMS Controller is very simple to operate. Once the Setup numbers have been configured for your operation, the unit will automatically perform its duties with very little user interface.

The front plate has three push-buttons for scrolling through information, changing set-points, and acknowledging alarms. See the Operating Instructions section for more information.

Installation Accessories
Hardware, tools, and optional equipment needed to install the EMS Controller.

n Tools as needed for the system mounting, such as saw and phillips head screw driver or allen wrench.

n 18 ga. wire for extension and hook up.

n Set of wire terminating tools.

n Wire termination; such as ring or spade terminals.

Typical Sequence
The EMS Controller senses the charging voltage has reached the start VDC set-point. The vent fan output turns on for the adjustable time delay. Next, the unit cranks the engine until it starts or over-cranks. If the engine starts, the vent fan output turns back on throughout the duration of the run. During run, shutdown conditions are monitored and acted upon if any reaches the set-point. Once the battery voltage reaches the stop vdc set-point and the current reaches the stop amps set-point, the unit initiates an automatic stop. It then waits for another start condition to present itself.

Operating the Interface
By using the three push-buttons and the liquid crystal display, you can make set-point changes, acknowledge alarms, and scroll through the display. The graphic below shows the display and push-buttons. The l s t keys are membrane type push-buttons. The l button is best described as an Enter key. You can confirm a set-point and acknowledge alarms with this button. The s button is used for increasing a set-point or scrolling up the display. The t button is used for decreasing a set-point or scrolling down the display.

MURPHY EMS
PROGRAM A94077

.

The 2 line dot-matrix liquid crystal display shows information pertinent to its current running mode. For example, if the unit receives a remote start signal, it will auto start the engine and display the current operation on the screen. These states include Crank On, Crank Off, Warm-up, Cool-down, etc. When the unit has brought the engine on stream, the display will scroll vertically through the engine vital signs. These include, Oil Pressure, Water Temperature, Engine Speed, Running Hours, etc.

First Time Setup
Before using the unit for the first time, it is necessary to configure all the set-points. To access the S-numbers (Setup numbers), use the following procedure:

WARNING: Make sure all S-numbers have been adjusted to your application before running panel in Automatic Mode.

1. Press the t button until the title page appears.

2. Now, press the l button once. This will bring up the entry code screen.

MURPHY EMS
PROGRAM A94077

3. Next, press the s t buttons until the appropriate entry code is displayed. This code is 64.

4. Finally, press the l button once. You are now able to edit the S-numbers.

To change an S-number, the following procedure should be used. We will change the OVERSPEED set-point for this example.

1. Once you have accessed the S-numbers through the above procedure, the screen will show the following:

RUN HOURS XX.X
S1 LINE 1 SELECT

Note: The top line may be different. Refer to S1 in S-Number Description And Listing section.

2. Now, press the s button three times to see the following screen:

RUN HOURS XX.X
S3 OVERSPEED

3. Next, press the l button once. This will bring up the following screen: (Note: The value in the Overspeed may vary).

RUN HOURS XX.X
2500 RPM

4. Next, press the s t buttons until the appropriate value is displayed. For demonstration purposes, set the unit to 3500 RPM.

RUN HOURS XX.X
3500 RPM

5. Finally, press the l button once. You have now changed the OVERSPEED set-point to 3500 RPM. If the unit senses the engine speed reach this point, it will signal the engine to shut down and display an OVERSPEED Fault.

All set-points are adjusted in the same manner as described above. The only difference is which S-number you select before scrolling the set-point change. Once you have adjusted each S-number, with the appropriate values, you must exit the S-number setup mode. To do this, hold the t button until the following screen is displayed and then press the l button once. This will put the unit back into normal operation mode. If you forget to exit the S-numbers, the unit will exit for you after a pre-programmed amount of time.

RUN HOURS XX.X
S0 CIRCLE = EXIT

Scrolling Main Displays
During normal operation, the unit allows you to scroll through a number of informative front displays by using the s t buttons. A listing and explanation of each follows:

1. MURPHY CONTROL

This is the first line of the title page.

2. PROGRAM A94077

This is the second line of the title page. It shows which program and version is installed in your unit. This information is helpful when calling for technical assistance.

3. RUN HOURS XXXX.X

This is your on board hour meter. It digitally displays the number of hours your engine has been running. All the service reminders are based on the elapsed time on the hourmeter.

4. ENGINE XX.X VDC

This displays your engine battery voltage.

5. ENG SPD XXXX RPM

This displays the current engine RPM. Decisions to stop cranking and shutdown on overspeed / underspeed are based on this number. Remember to calibrate this in the S-numbers.

6. OIL PR XXX PSI

This displays the current engine oil pressure as sensed from an electric gauge sender. Shutdowns based on oil pressure reference this number.

7. ENG TEMP XXX �F

This displays the current engine coolant temperature as sensed from an electric gauge sender. The unit will signal the engine to shutdown if this temperature reading exceeds the shutdown point selected in S10.

8. FUEL PRS XXX PSI

This displays the current fuel pressure.

9. BATTERY XX.X VDC

This displays the voltage of the batteries being charged.

10. BATTERY XXX AMPS

This displays the charging current, in amps, to the batteries being charged.

11. SELECTOR - XXXX

There are three positions on the selector switch that are displayed on this line: AUTO, TEST, and OFF.

When this window shows AUTO, your TEST - OFF - AUTO switch is in the AUTO position. When in AUTO, the unit is ready to start the engine or already has started the engine.

When this window shows OFF, your TEST - OFF - AUTO switch is in the OFF position. The unit will not initiate an auto start with the switch in the OFF position. If the switch is moved to the OFF position while the engine is running, the unit will signal the engine to stop.

When this window shows TEST, your TEST - OFF - AUTO switch is in the TEST position. When the switch is flipped to TEST, the unit will start the engine as if a start signal had been received; regardless of the start / stop contacts.

If the remote start / stop input is active, this line will read REMOTE OVERRIDE. This means all control for starting and stopping the engine comes from the remote contact.

12. ST: XXXXXXXXXX

ST stands for STATE. This window shows what state your controller is in. These states include the following: NOT READY, PANEL READY, START DLY, PRELUBE, CRANK ON, CRANK OFF, WARM-UP, AT LOAD, SHUTDOWN, STOP DLY and COOLDOWN.

NOT READY: This state occurs when the selector is in the OFF position. It means that the panel is not ready to run in Automatic mode.

PANEL READY: This state occurs when the selector is in the AUTO position and no shutdowns have occurred. It means that the panel is ready to run in Automatic mode.

START DLY: This state occurs when a start signal is sensed and the start delay is timing. The start signal must be present throughout this delay before the unit goes to the next state.

VENT FAN: This state occurs after the Start Delay expires. During the Vent Fan state, the Vent Fan output is turned on.

CRANK ON: This state occurs after the Prelube Delay expires. During the Crank On state, the unit energizes the starter circuit and attempts to start the engine.

CRANK OFF: This state occurs after the Crank On state if the unit senses that the engine has not started. During the Crank Off state, the unit removes power from the starter circuit to cool off the starter before another cranking attempt is made. The fuel valve output is also turned off.

WARM-UP: This state occurs after the unit senses that the engine has started. The Lockout Delay begins timing when the Warm-up State begins.

AT LOAD: This state occurs after the Warm-up state concludes. It can also occur if a start signal is received during the Cool-down state (see Cool-down below). When the At Load state first begins, the voltage regulator circuit is activated.

STOP DLY: This state occurs when a stop signal is sensed and the stop delay is timing. The stop signal must be present throughout this delay before the unit goes to the next state.

COOL-DOWN: This state occurs after the Stop Delay has expired. The unit also deactivates the voltage regulator circuit. If a start signal is received during the Cool-down state, the unit will switch to the At Load state and ignore the Warm-up state.

SHUTDOWN: This state occurs if a shutdown condition is detected. Reasons for shutdown include low oil pressure, high water temperature, overspeed, etc. During this state, the engine is signaled to shutdown and all start signals are ignored until the state is reset by moving the selector to the OFF position and then back into AUTO or TEST.

13. CHG OIL XXX HRS

This display shows the number of running hours remaining before the oil must be changed in the engine.

14. OIL FLT XXX HRS

This display shows the number of running hours remaining before the oil filter on the engine must be changed.

15. FUEL FLT XXX HRS

This display shows the number of running hours remaining before the fuel filter on the engine must be changed.

16. AIR CLNR XXX HRS

This display shows the number of running hours remaining before the air cleaner on the engine must be serviced or changed.

17. SERV BAT XXXX HRS

This display shows the number of running hours remaining before the engine cranking battery must be serviced or changed.

S-Number Description and Listing
The S-numbers are used for customizing the controller to your specific engine. Included in the S-numbers are variables such as crank / rest times and warm-up / cool-down times. These S-Numbers must be set before trying to use the unit to auto start your engine. Following is a list of available S-Numbers and a short description of the function of each.

1. S0 CIRCLE = EXIT

Used to exit the S-number setup mode.

2. S1 LINE 1 SELECT

Used to change what is displayed on the top line throughout your S-number editing session. Your choices include: Run Hours, Engine Speed, Battery Voltage, Oil Pressure, Engine Temperature, and input / output status. The input / output status information will show an X on an I/O if that particular input is active or output is ON. If there is no input or the output is OFF, the unit will display an O. This can be used for testing wiring before starting the engine. For more information, see the section titled "Double Checking Your Wiring".

3. S2 SPEED CALIB

This setting is used to calibrate the speed signal so that the unit will display engine RPM. This setting must be adjusted for items such as crank stop RPM and OVERSPEED RPM to work. Simply enter the number of Pulses per revolution the magnetic pickup or alternator supplies to the unit . Another way to set this variable is to get the engine running at a known RPM and then change the number until the top line matches your known RPM. The resulting number is the pulses per revolution.

4. S3 OVERSPEED

This setting allows you to enter the highest speed the engine can run before damage is caused. If the unit senses that the engine has exceeded this speed, it will signal the engine to shutdown.

5. S4 UNDERSPEED

If the engine speed dips to the RPM in this set-point, an automatic shutdown will be initiated. If you do not want to use this feature, change this variable to 0.

6. S5 LOCKOUT DELAY

This delay is used to ignore conditions such as low oil pressure when the engine first starts to allow the pressure time to reach its normal operating range.

7. S6 LOP @ LOW SPD

The EMS Controller gives you two oil pressure shutdown points. For engines that develop very little oil pressure at an idle, you put a lower shutdown setting in this set-point. The unit automatically changes the shutdown point between the Low Speed Shutdown point and the High Speed Shutdown point.

8. S7 LOP @ HI SPD

This set-point is the higher oil pressure shutdown point that is referred to in number 7 above. This is the point that you want the engine to shutdown during normal high speed engine operation. By shutting down the engine at a higher oil pressure, you can avert damage that could be caused by waiting to shut down the engine at the lower set-point needed to accommodate an idle.

9. S8 LOP LO SPEED.

Set this to your engine idle speed. If the engine is running at this speed, an idle for example, and the oil pressure reaches the set-point selected in S6, the unit will initiate an automatic shutdown.

10. S9 LOP HI SPEED

Set this to your engine maximum speed. If the engine is running at this speed, and the oil pressure reaches the set-point selected in S7, the unit will initiate an automatic shutdown.

The Graph below shows how the set-point changes between your high speed set-point and low speed set-point. As the engine speed increases, the unit automatically raises the oil pressure shutdown set-point along a straight line between the two set-points you entered. This graph represents the following set-points: S6 is set to 10, S7 is set to 45, S8 is set to 600, and S9 is set to 2150.

11. S10 HI H20 TEMP

Adjust this setting to the coolant temperature you do not want to exceed. If the unit senses a coolant temperature higher than this set-point, it will initiate an automatic shutdown.

12. S11 WARM-UP DLY

You can adjust this variable to the number of seconds you want your engine to warm-up before it turns on the voltage regulator enable output.

13. S12 COOLDOWN DLY

You can adjust this variable to the number of seconds you wish to cooldown your engine before it shuts off after a stop signal is received.

14. S13 VENT FAN DLY

This delay adjusts the amount of time the Vent Fan output will be energized before the cranking sequence begins.

15. S14 ENG STRT DLY

Set this delay on engine start to the number of seconds that the start signal must be present before the unit accepts it and initiates an auto start sequence.

16. S15 ENG STOP DLY

Set this delay on engine stop to the number of seconds that the stop signal must be present before the unit accepts it and initiates a stop sequence.

17. S16 CRANK TIME

Set this delay to the desired amount of time you want each engine cranking attempt to last. Consult your engine manual for recommended cranking and resting times.

18. S17 REST TIME

Set this delay to the desired amount of time you want each rest period between cranking attempts to last. Consult your engine manual for recommended resting and cranking times.

19. S18 RECRANK DLY

This delay is used to adjust the amount of time the unit will wait for the engine to spool down before attempting another crank if a false start occurs. A false start is when the engine starts but then dies before the LOCKOUT DELAY has expired.

20. S19 CRK STOP RPM

This RPM set-point is used to adjust where the unit releases the starter during cranking. Set this to the RPM the engine attains just as it starts. This way, the starter is not engaged unnecessarily after the engine starts.

21. S20 CRK ATTEMPTS

Set the number of attempts you would like the controller to try an engine start. If the engine fails to start after the number of attempts you have selected, it will fail the engine and display OVERCRANK on the front display. This shutdown requires a manual reset.

22. S21 SPARE 1 TYPE

This set-point lets you pick the way you want the controller to handle an input on the spare 1 terminal. Your choices include: Immediate alarm only, Immediate alarm & Shutdown, Immediate alarm before shutdown, Delay alarm only, Delay alarm & shutdown, and Delay alarm before shutdown. These types of shutdowns are self explanatory. An immediate type alarm, shutdown or both will be processed whenever the input is active. A delay type alarm, shutdown or both will be processed after the Lockout Delay has expired (S5).

23. S22 CHANGE OIL

Set the interval in engine running hours you wish to be prompted to change your engine oil.

24. S23 CHG OIL FLTR

Set the interval in engine running hours you wish to be prompted to change your engine oil filter.

25. S24 CHG FUEL FLT

Set the interval in engine running hours you wish to be prompted to change your engine fuel filter.

26. S25 SERV AIR CLN

Set the interval in engine running hours you wish to be prompted to service your engine air cleaner.

27. S26 SERV BATTERY

Set the interval in engine running hours you wish to be prompted to service your cranking battery.

28. S27 START VDC

Set this to the voltage the batteries being charged must drop to for the unit to initiate an auto start.

29. S28 STOP VDC

Set this to the voltage the batteries being charged must rise to for the unit to initiate an auto stop.

30. S29 MIN VDC

This set-point allows you to configure the voltage divider analog input. The value you put in this set-point is what 0 VDC from the sensor represents.

31. S30 MAX VDC

This set-point is also used to configure the voltage divider analog input. The value you put in this set-point is what 5 VDC from the sensor represents.

32. S31 BT VLT SLOPE

With the minimum amount of voltage present on your voltage sender, make this set point match the number on the top line.

33. S32 MAX AMPS

Set this to the value the Current sender represents at 5 VDC. For example, if the current sender works from 0 to 100 AMPS, place 100 in this set-point.

34. S33 STOP AMPS

Set this to the value the current must fall below before an auto stop may be initiated.

35. S34 AMPS SLOPE

With no current present on your current sender, make this set-point match the number on the top line.

36. S35 FUEL PRS MAX

Set this to the value the Fuel Pressure sender represents at 5 VDC. For example, if the Fuel Pressure sender works from 0 to 200PSI, place 200 in this set-point.

37. S36 FUEL PRS SLP

With no pressure on your Fuel Pressure sender, make this setpoint match the number on the top line.

38. S37 LO FUEL PRS

When the fuel pressure reaches the value in this set-point, the unit will display a Low Fuel Pressure alarm and will turn on the Common Fail output.

39. S38 HEATER START

When the engine block temperature is sensed to reach this value, the block heater circuit is activated.

40. S39 HEATER DELTA

When the engine block temperature is sensed to have raised the amount in this set-point, the block heater circuit is de-activated.

Accessing the P-Numbers
The EMS Controller has P-numbers in addition to the S-numbers you configured in the previous step. These are accessed in the same manner but using a different access code. The factory default code number for accessing the P-numbers is 61.

P-Number Description and Listing
The P-numbers are used for acknowledging service reminders and for accessing the shutdown history list. Following is a list of available P-number information and acknowledgments.

1. P0 CIRCLE = EXIT

Used to exit the P-number setup mode.

2. P1 LINE 1 SELECT

Used to change what is displayed on the top line throughout your P-number editing session. Your choices include: Run Hours, Engine Speed, Battery Voltage, Oil Pressure, and Water Temperature.

3. P2 VDC @ SHDWN

This displays the charging battery voltage at the time the last failure shutdown occurred. To view the information, press the l button.

4. P3 AMPS @ SHDWN

This displays the charging battery amps at the time the last failure shutdown occurred. To view the information, press the l button.

5. P4 OIL PR @ SHDW

Shows what the engine oil pressure was when the unit initiated the last failure shutdown. To view the information, press the l button.

6. P5 TEMP @ SHDWN

Shows what the engine water temperature was when the unit initiated the last failure shutdown. To view the information, press the l button.

7. P6 TACH @ SHDWN

Shows what the engine speed was when the unit initiated the last failure shutdown. To view the information, press the l button.

8. P7 FUEL PRS @ SD

Shows what the Fuel pressure was when the unit initiated the last failure shutdown. To view the information, press the l button.

9. P8 LAST SHUTDOWN

Shows what caused the last failure shutdown and the time in running hours that it occurred. To view the information, press the l button.

10. P9 THRU P17 ##th SHUTDWN

These P-numbers store the 2nd through the 10th cause of failure shutdown and the running hours they occurred. To view the information, press the l button.

11. P18 ACK CHG OIL

This setting allows the user to acknowledge that he/she has changed the oil in the engine as prompted by the unit. When this setting is toggled from NO to YES, the unit resets the counter and will not prompt the user again until the selected number of running hours has elapsed.

12. P19 ACK OIL FLTR

This setting allows the user to acknowledge that he/she has changed the oil filter as prompted by the unit. When this setting is toggled from NO to YES, the unit resets the counter and will not prompt the user again until the selected number of running hours has elapsed.

13. P20 ACK FUEL FLT

This setting allows the user to acknowledge that he/she has changed the fuel filter as prompted by the unit. When this setting is toggled from NO to YES, the unit resets the counter and will not prompt the user again until the selected number of running hours has elapsed.

14. P21 ACK AIR CLNR

This setting allows the user to acknowledge that he/she has changed or serviced the air cleaner as prompted by the unit. When this setting is toggled from NO to YES, the unit resets the counter and will not prompt the user again until the selected number of running hours has elapsed.

15. P22 ACK BATTERY

This setting allows the user to acknowledge that he/she has serviced / changed the battery as prompted by the unit. When this setting is toggled from NO to YES, the unit resets the counter and will not prompt the user again until the selected number of running hours has elapsed.

General Wiring Precautions
There are several precautions you can take on initial installation to reduce chances of failure over time. Many of these steps may take a few extra minutes to do at the time of installation; however, they can also save many headaches in the future. We strongly recommend that you follow these precautionary steps.

1. Suppression Diodes

Place suppression diodes across all inductive loads. These loads typically include pilot relays, solenoid valves, starter solenoids, etc. This helps increase contact life and eliminate a source of electrical interference.

2. Wire power leads directly to battery Post.

When hooking your power supply to your Test- Off - Auto switch, run your wiring directly to the battery post. This helps minimize noise generated from battery chargers and alternators.

3. Pilot excessive loads.

Many of the outputs on the EMS Controller are rated for low current, control type loads. Do not run high current loads directly to the unit.

4. Use stranded wire for hookup.

Solid wire transmits vibration and is more likely to crystallize and break when it is subjected to movement.

5. Wire standby battery charger directly to battery.

Standby chargers must be wired directly to the battery. Failing to do this may result in erratic operation due to electronic "noise" coupled into the microprocessor.

6. Separate AC and DC wiring.

Never run AC and DC handling wiring together. AC signals may get coupled into the control circuits leading to erratic behavior.

7. Special precautions for spark ignition engines.

Magnetos and ignition coils produce high voltage and cause high frequency interference. The EMS Controller is designed to filter out much of this interference; however, precautions must be taken to protect the unit. Sender and shutdown wiring must be routed away from the magneto and spark coil wiring. Noise suppression spark plug wiring may also be required in especially "noisy" environments.

8. Use shielded cable on magnetic pickup.

Shielded cable is recommended for connecting the magnetic pickup to the EMS Controller. This helps prevent signal loss and the possible coupling of electrical interference into the relatively sensitive speed sensing circuit. The shield should only be grounded on one end.

Remember, proper care during installation will help your EMS Controller live a long and trouble-free operating life. If for any reason you have questions during installation, feel free to give us a call.

Double Checking Your Wiring
The EMS Controller has built in diagnostic information for confirming your wiring before you attempt to auto start your engine. The diagnostic information is found in the S-numbers under S1 LINE 1 SELECT. The factory default line 1 display shows the engine RPM. By scrolling through the displays, you will see the following:

O1-7 OOOX OOO
ENTER SELECTION

This represents the 4 standard digital only inputs. An O means that the input is not active. An X means that the input is active. Following is what each input represents.

1. AUTO POSITION ON TOGGLE SWITCH

2. TEST POSITION ON TOGGLE SWITCH

3. EXTERNAL SPARE 1 SHUTDOWN INPUT

4. NOT USED FOR THIS APPLICATION

The next screen shows the rest of your inputs:

I1-4 OOOO
ENTER SELECTION

5. BATTERY VOLTAGE INPUT (IGNORE)

6. TEMPERATURE SENDER (For test purposes, you can ground this input to make sure you have run your wire properly.)

7. OIL PRESSURE SENDER For test purposes, you can ground this input to make sure you have run your wire properly.)

8. LOW COOLANT LEVEL INPUT

9. REMOTE START / STOP

10. CHARGING BATTERY AMPS

11. CHARGING BATTERY VDC

12. FUEL PRESSURE

The next screen shows your outputs:

I5-12 OOOO OOOO
ENTER SELECTION

1. FUEL VALVE OUTPUT

2. STARTER CIRCUIT OUTPUT

3. COMMON FAIL OUTPUT

4. BLOCK HEATER CONTROL

5. NOT USED

6. VENT FAN OUTPUT

7. VOLTAGE REG. ENABLE OUTPUT

WARNING: Do not run alternator or magneto wiring in the same bundle with any control wires. Make sure voltage and current requirements are within the EMS Controller system ratings.

SYMPTOM	SYMPTOM
When Toggle Switch is flipped to the TEST position, nothing happens.	Check all Fuses. If good, check that battery voltage is present on pin number 8 and 9 on your cable.
Starter does not hold in long enough for engine to start.	Unit could be experiencing a voltage drop. Ensure that the battery is hooked directly to the unit, 14 AWG wire is used, and no short circuits are present. Also, make sure that the CRANK STOP RPM is set high enough (S19).
Odd, erratic behavior is noticed.	Check to ensure that all alternator wiring is routed in a separate wiring loom from the rest of the control wiring. Also, confirm the use of shielded cable for the magnetic pickup wiring.
Unit will not disconnect cranking after engine has started.	Adjust CRANK STOP RPM (S19) to a lower setting. Confirm at least 2 Vrms is present from the magnetic pickup.
Unit shuts down on oil pressure soon after start.	Check Oil Level. Increase the LOCKOUT DELAY (S5) time.
Unit will not start when a start signal is received.	Make sure the toggle switch is in the AUTO position. Also, make sure the unit STATE is AUTO READY.
Engine cranks but never starts.	Make sure Fuel Valve circuit is properly wired. See wiring diagram for details.

Warranty
A two year limited warranty on materials and workmanship is provided with this Murphy product. Details are available on request and are packed with each unit.