diesel engine controller 업체자료

7/29/2019 Diesel Engine Controller

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DIESEL FIRE PUMP CONTROLLERINSTRUCTION MANUAL

SERIAL NO.

MODEL NO.

DEC

FOR ENGINE

CLARKE, CUMMINS, CATERPILLAR & DEUTZ

MASTER CONTROL SYSTEMS, INC.P.O. BOX 276 910 NORTH SHORE DRIVE LAKE BLUFF, ILLINOIS 60044, USA

TELEPHONE: 847-295-1010 FAX: 847-295-0704

www.mastercontrols.com


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- 1 -Master Control Systems, Inc. Lake Bluff, IllinoisDEC Issue 02-v02 2009.08.3

Forward

MASTER DEC Series Diesel Engine Fire Pump Controllers are of the Combined Manual and Automatic type; forthe control of internal combustion engines driving centrifugal pumps. Controller operation is strictly inaccordance with the latest requirements of the National Fire Protection Association Standard NFPA-20 onStationary Fire Pumps.

The fundamental purpose of this controller is to automatically start an engine driven fire pump to provide therequired volume and pressure for proper operation of the sprinkler system in the event of a fire in the propertiesprotected by the system. The Start Signal is usually obtained from the Pressure Control Switch included in thecontroller.

Basic Model DEC controllers are used with listed or approved fire pump engines. When additional options areincluded in the controller, the appropriate option symbol is included in the model number shown on the nameplateof the controller as follows:

GeneralOptions

Included in G1Group Option

Description

RA or DA YES Built-in Dual Battery Charger and AlarmH YES Energize to Stop (Caterpillar, Deutz and others)M Manual, Non-Automatic (removes pressure transducer and adds test relay)1 YES Automatic Stop w/ Minimum Running Period Timer2 Electric Motor Lockout (including Dual Drive)4 YES Remote Start Inputs for Deluge Start and Remote Start Pushbutton5 YES A.C. Power Failure Start (Time Delayed)6 Gas or Gasoline Engines (No Overspeed Signal, Retrofit Only)7 Contacts for Individual Remote Signals8 Timed Energized to Stop (Diesel Engine)9 YES Sequence Start (Time Delayed)

0 YES Pump House Alarm and Signals (Per NFPA 20)X Other Controller Modifications (Modifier Code)DPR YES Digital Pressure RecorderDR Digital Pressure and Alarm RecorderG1 Combines options RA, H, 1, 4, 5, 9, 0, DPR, 17A, 21

Consult Master Control Systems for additional Modifications or Options available.


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Table of Contents

Forward Page 1

Table of Contents. Page 2

DEC Controller Outside View Labeled Diagram Page 3

DEC Controller Inside View Labeled Diagram... Page 4

Installation of Controller.. Page 5

Wiring of Controller. Page 5

Main Engine to Controller Wiring Table. Page 6

A.C. Wiring Table Page 6

Input Alarm Signal Wiring Table Page 7

Controller Input Signal Wiring Table.. Page 7

Remote Alarm Contact Wiring Table.. Page 7

Installation of Main Selector Switch Hinge. Page 8

Factory Default Switch Settings.. Page 9- Weekly Test, Minimum Run Timer, Sequence Start, AC Power

Factory Default J umper Settings..Page 10

Pressure Switch Adjustments... Page 11

Pressure Settings...Page 12

Start-Up Procedures.Page 14

Controller Operating Instructions.... Page 17

Operation of Model MBC3 Dual Battery Charger... Page 23

Option RA Battery Charger Failure Alarm.. Page 25

Weekly Maintenance Procedures. Page 26

Replacement Parts List.Page 28

Model PR4001 Paperless Pressure and Alarm Recorder New Document listed after Replacement Parts List

Drawings:Controller Schematic DiagramBuilt-in Battery Charger Schematic DiagramExternal Wiring DiagramPiping Connection


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DEC Controller-Labeled Diagrams-

Outside View

1) Bulkhead Pressure Connectionsk

2) RESET Pushbuttonk

3) Audible Alarmk

4) TEST Pushbuttonk

5) STOP Pushbutton

Note:The Y-Strainer, exclusiveto Master Control Systems,prevents debris from enteringthe drain valve solenoid.

k

6) START Pushbuttonk

7) Main Selector Switch (behind hinge)a. AUTO Positionb. OFF Positionc. MAN Position

k

8) PR4001 Displaya. Alarm History / Pressure History

b. Scroll Up / Scroll Downc. Check-In / Off

k

9) Battery (BATT) 1 and 2 Selector Switchk

10) Y-Strainerk

11) Drain Valve Solenoid



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Inside View

12) Master Battery Charger (MBC3C)


13) Diesel Control Engine Interface (DC-EIF)

14) Customer Terminal Bar 1 (CTB1)

15) Pressure Switch (PS)-See P. 11 for details.

16) Display Box

Note: CTB3, which is the inputfor the AC power, is coveredwith an insulating materialfor electrical safety purposes.

17) Paperless Recorder xPN-See P. 29 for details.




21) Diesel Control Chassis Unit (DC-CU)

(CTB1-CTB4 MAY BE FOUND ON DRAWING 17100)


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Installation of the Controller

The Controller should be located as close to the engine as is practical, preferably 25 or less. Thesecontrollers are also designed for wall mounting using the hanger bracket supplied. Controllers should be boltedsolidly by means of expansion bolts through holes provided in support brackets. These controllers are alsodesigned for mounting on the common base of the engine and pump when additional mounting legs are used.When so installed, use adequate bracing and suitable vibration dampers to keep vibration to a minimum.

The pressure connection to the controller must be installed as shown in the NFPA Pamphlet No. 20. Seethe piping diagram in the drawing section of this Instruction Manual.

Wiring of the Controller (see the following tables)

Wire terminals 1 through 12, 301 and 302 on CTB1 of the DC-EIF chassis to the corresponding numberson the engine terminal bar in the engine junction box. Always use flexible stranded wire that is not affected bywater, oil, or engine heat and terminate with ring lugs. Terminal 7 should only be connected with engines thatonly use a 20 amp alternator and rely on the controller to provide Control Battery to the engine circuits.

Wire terminals 16 and 17 on CTB3 of the DC-EIF chassis to the A.C. power (mains) branch circuit at thecontroller nameplate voltage and frequency. Chassis grounding is terminated on terminal 15. Do not exceed

ampere limits shown on the External Wiring Diagram.

Wire terminals 18 through 25 on CTB2 of the DC-EIF chassis to the corresponding Input Alarm Signals.These are for dry contacts in the pump room that close terminals 19 through 25 to terminal 18 to activate thealarm. Typically, these alarms are: Low Fuel Level, System Overpressure, Reservoir Level Low, ReservoirEmpty, Flow Meter Open, Pump Room Temp Low, Relief Valve Open.

Wire terminals 31 through 34 on CTB4 of the DC-CU chassis to the corresponding Controller InputSignals. These are for dry contacts that open between 31 and 32 for Deluge Starting, and that open between 31and 33 for Remote Starting. Contacts close between 31 and 34 for lockout.

Wire to terminals 26 through 28 (10 Amp, form C contacts) on CTB2 of the DC-EIF chassis for remote

indication of Engine Running.

Wire to terminals 5 through 7 (1 Amp, form C contacts) on CTB4 of the DC-CU chassis for remoteindication of Engine Running.

Wire to terminals 8 through 10 (1 Amp, form C contacts) on CTB4 of the DC-CU chassis for remoteindication of Engine Failure.

Wire to terminals 11 through 13 (1 Amp, form C contacts) on CTB4 of the DC-CU chassis for remoteindication of Switch Off.

Wire to terminals 14 through 16 (1 Amp, form C contacts) on CTB4 of the DC-CU chassis for remote

indication of Pumphouse Trouble.


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Main Engine to Controller Wiring Table

*When used. ** For 10 amp chargers.

DC-EIF Minimum Wire Size (AWG)Terminal 25 Max. Run Metric (mm2) 50 Max Run Metric (mm2) Max Amps Function

CTB1-1 #14 2.1 #14 2.1 10A Fuel / Water

CBT1-2 #16 1.3 #16 1.3 1A Crank Terminate

CTB1-3 #16 1.3 #16 1.3 1A OVS

CTB1-4 #16 1.3 #16 1.3 1A LOP

CTB1-5 #16 1.3 #16 1.3 1A HWT

CTB1-6** #12 3.3 1 #10 or 2 #12 1x 5.3 or 2x 3.3 20A Bat. #1

CTB1-7* #12 3.3 #12 3.3 20A C.B.

CTB1-8** #12 3.3 1 #10 or 2 #12 1x 5.3 or 2x 3.3 20A Bat. #2

CTB1-9 #14 2.1 #14 2.1 10A Crank #1

CTB1-10 #14 2.1 #14 2.1 10A Crank #2

CTB1-11A #10 or 2 #12 1x 5.3 or 2x3.3

1 #8 or 2 #10 1x 8.4 or 2x 5.3 20A Ground

CTB1-11B #10 or 2 #12 1x 5.3 or 2x3.3

1 #8 or 2 #10 1x 8.4 or 2x 5.3 20A Ground

CTB1-12* #14 2.1 #14 2.1 10A SDS

CTB1-301* #16 1.3 #16 1.3 1A Alternate ECM

CTB1-302* #16 1.3 #16 1.3 1A Injector Failure

CAUTIONDO NOT CONNECT OR DISCONNECT BATTERY LEADS WITH ANY LOADS CONNECTED IN ORDER

TO PREVENT ARCS OR SPARKS AT OR NEAR THE BATTERY.

A.C. Wiring ConnectionsDC-EIF Minimum Wire Size (AWG)Terminal 25 Max Run Metric (mm2) 50 Max Run Metric (mm2) Max Amps Function

CTB3-15 #14 2.1 #14 2.1 n/a Cabinet GroundCTB3-16 #14 2.1 #14 2.1 12A A.C. Line

CTB3-17*** #14 2.1 #14 2.1 12A A.C. Neutral*** Except also Line (hot) for 230/240 Vac @ 60 Hz.

CAUTIONALWAYS DISCONNECT, TURN OFF, OR REMOVE A.C. POWER FROM CHARGERBEFORE CONNECTING OR DISCONNECTING CHARGER OR BATTERY LEADS.



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Input Alarm Signal ConnectionsDC-EIF Minimum Wire SizeTerminal AWG Metric (mm2) Function

CTB2-18 #16 1.3 Alarm CommonCTB2-19 #16 1.3 Low Fuel LevelCTB2-20* #16 1.3 System OverpressureCTB2-21* #16 1.3 Reservoir Level Low

CTB2-22* #16 1.3 Reservoir EmtpyCTB2-23* #16 1.3 Flow Meter OpenCTB2-24* #16 1.3 Pump Room Temp LowCTB2-25* #16 1.3 Relief Valve Open*When used.

Controller Input SignalsDC-CU Minimum Wire Size

Terminal AWG Metric (mm2) Function

CTB4-31 #16 1.3 Signal Common for CTB4-2, CTB4-3, and

CTB4-4CTB4-32* #16 1.3 Deluge Start Input, Open to Start, Max.

Burden 0.2 Adc at Engine Battery VoltageCTB4-33* #16 1.3 Remote Momentary Start Input, Open to

Start, Max. Burden 0.2 AdcCTB4-34* #16 1.3 Lockout Input, Close to Lockout AC Fail,

Deluge, Pressure Start.*When used.

Remote Alarm Contacts

*When used.

DC-CU Minimum Wire SizeTerminal AWG Metric (mm2) Function

CTB2-26, 27, 28* #16 1.3 Extra 10 Amp.Engine Run Contacts (Mod. 17A,G1

CTB4-35,36,37 #16 1.3 Engine Running Alarm ContactsCTB4-38,39,40 #16 1.3 Remote Engine Failure Alarm Contacts (Bat. 1

failure, Bat. 2 failure, Charger Failure, Low OilPressure, High Water Temperature, Overspeed,Failure to Start, Alt. ECM, Injection Failure

CTB4-41,42,43 #16 1.3 Remote Switch OFF Alarm Contacts (or not inAuto)

CTB4-44,45,46 #16 1.3 Remote Pump House Trouble Alarm Contacts (anyPump House Trouble Alarm)



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Assembling and Attaching Main Selector Switch Hinge

INSTALLING THE HINGE:

1. Slide the glass rod into the hinge by pushing the ends of the rod together until it fits cleanly, as shownbelow in Picture A. The hinge should now be ready to be installed (Picture B).

Picture A Picture B

2. Turn the hinge over and place one end into Hole A first, then push the other end of the rod togetherallowing the glass rod to contract and fit cleanly in both holes.

Push glass rodtogether

Hole A

Picture C



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Factory Default Switch Settings

On the DC-CU there are switches that can be set for various timing functions such as Minimum run, AC PowerFail Start, and Sequence Start.

-These are fully described on the following pages: Minimum Run (P. 19), AC Power Fail Start (P. 20), andSequence Start (P. 21).

Minimum Run Timer (factory default Off)0 =Off1 =2 Minutes (2 Min. per Division)

Sequence Start (factory default Off)0 =Off1 =5 Seconds (5 Sec. per Division)

AC Power Fail Start (factory default Off)

0 =Off1 =20 Seconds (20 Sec. per Division)

Weekl Test Pushbutton



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Factory Default J umper Settings

Behind the cover plate on the DC-CU, there are jumpers that can be used to enable or disable various functionssuch as Lockout, Remote Start, Deluge Start, or Weekly Test. These are fully described under the controlleroperation section.

NOTE: To set the Weekly Test Sequence, firstenablethe Weekly Test Jumper by moving the Weekly TestJumper (shown in Picture 1) one pin to the right. Then, simply press the Weekly Test Pushbutton. When pressed,the controller will remember that day and time during the week and initiate the test at the same time indefinitely.

If you wish to change the testing time, just push the button at the desired day and time and the new time will beautomatically saved. To disable, move the Weekly Test Jumper back to the position shown in Picture 1 below orremove the Weekly Test Jumper.

Remote Start Jumper(factory default disable)

Lockout Jumper(factory default disable)

Weekly TestPushbutton

.Jumper

Deluge Start Jumper(factory default disable)

Weekly Test Jumper(factory default disabled)

(Picture 1)(Picture 2)



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Pressure Setting Adjustments

To adjust the Trip and Reset points of the pressure switch, hold the toggle switch up towards the Resetpotentiometer or down towards the Trip potentiometer and rotate the potentiometer while watching the display onthe front of the cabinet. The potentiometers have a full range of 10 turns.

The Trip and Reset settings are changed by turning the 10 turn trip and reset potentiometers eitherclockwise to increase, or counterclockwise to decrease.



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PRESSURE SETTINGS

NOTE: When adjusting the Reset Setting or Trip Setting, first find out which direction you need to adjust thesetting. If you need to adjust the Trip Setting up, you cannot adjust it past the Reset Setting without first adjustingthe Reset Setting up.The two functions cannot overlap one another at any time, and will refuse to cross over eachother.

-In the following example imagine the two points as labeled on the diagram below (Note: the settings will notalways be starting at 90 and 70):

Example 1

Desired Trip Setting: 100

Desired Trip Setting: 100

Reset Setting: 90

Trip Setting: 70

Your Reset Setting is at 90, and your Trip Setting is at 70. You wish to adjust the Trip Setting up to 100.You must first adjust the Reset Setting above 100,then you can adjust the Trip Setting up to 100. Note: if youattempt to adjust the Trip Setting first it will refuse to set above 90, as this is limited by the Reset Setting which isset at 90. Continuing in the example of how to adjust the Trip Setting to 100:

STEP 2

NEW Reset Setting: 110

Old Reset Setting: 90

Trip Setting: 70

As you see in Step 2 we move the Reset Setting above 100beforeadjusting the Trip Setting. Notice thatthe new Reset Setting is now 110. This allows a 10 PSI differential with the Trip Setting goal of 100. The typicaldifferential between the Reset Setting and Trip Setting is 10 PSI, although you may go as low as 3 PSI.

STEP 3Reset Setting: 110

NEW Trip Setting: 100

Old Trip Setting: 70

Lastly, in Step 3 we adjust the Trip Setting up to our goal of 100.



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PRESSURE SETTINGS Continued

Example 2

Desired Reset Setting: 60

Reset Setting: 90


Trip Setting: 70

Desired Reset Setting: 60

Another example Your Reset Setting is at 90, and your Trip Setting is at 70. You wish to adjust the ResetSetting to 60. You must first adjust the Trip Setting downbelow60by the appropriate differential of at least 3 PSI(the typical differential is 10).This then allows you to adjust the Reset Setting to 60.

STEP 2

Reset Setting: 90

Old Trip Setting: 70

New Trip Setting: 50

As you can see in Step 2 we first lower the Trip Settingbelowthe desired Reset Setting of 60.

STEP 3

Old Reset Setting: 90

New Reset Setting: 60

Trip Setting: 50

We now adjust the Reset Setting down to the desired level of 60.


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START-UP PROCEDURES

The following tests are required on each new installation. It is recommended that they be repeated yearly to prove thereliability of the controller, engine, and battery equipment.

NOTE: When tests are completed, be certain to return the control switch to the "AUTO" position.

I. Manual Starting

NOTE: Before starting energize to stop engines, verify that battery voltage is present at Terminal 12 when the MainSelector Switch is in the OFF position. If not, contact factory before starting engine.

A. Place Main Selector Switch in the MANUAL position.B. Place the Battery Selector Switch in the BAT1 position.C. Depress Manual START Pushbutton and release when engine starts.D. Turn control switch to OFF position to stop engine.E. Place Battery Selector Switch in the BAT2 position.F. Depress Manual START Pushbutton and release when engine starts.G. Turn control switch to OFF position to stop engine. NOTE: Observe battery voltage while cranking. If

voltage drops below 75% of nominal, it may be an indication of impending battery failure.

II. Cranking Cycle TestThis test simulates a condition when the engine refuses to start as covered in the preceding "OPERATION OFPANEL" sequence.

A. Contact the engine manufacture to determine how to disable the engine fuel circuit.B. Place the Main Selector Switch in the AUTO position. Push the TEST pushbutton. The Drain Valve

Solenoid will open to create a Pressure Drop and initiate cranking of the engine. The engine shouldcrank six times after which the audible alarm will sound, the Failure to Start signal light will energizeand the Remote Engine Failure Alarm will be energized.

C. Return Main Selector Switch to the OFF position, reconnect Terminal No. 1, and all engine devices, ifpreviously disconnected.

D. Drain Valve Solenoid will continue to dump water until control switch is placed in OFF position.

III. Checking Starting Motor ReleaseA. Place Main Selector Switch in the AUTO position and press the TEST pushbutton. Engine should start

promptly and the starting motor should release at approximately 1/3 engine speed. Check that thestarter releases by watching the LEDs on Terminal 2, 9 or 10. Verify that the Terminal 9 or 10 LEDgoes Off when the Terminal 2 LED goes On.

B. Return switch to OFF position to stop engine.

IV. Oil Pressure Failure TestA. Place Main Selector Switch in the AUTO position and press the TEST pushbutton to start the engine.B. Connect temporary jumper between terminal of oil pressure switch (jumper CTB1-4 and CTB1-11A or

CTB1-11B) and battery common. Engine Failure Alarm will operate approximately 10 seconds later.C. Turn switch to OFF position to stop engine.D. Remove jumper from oil switch.

NOTE: Whenever the engine is started, the oil pressure light will come on momentarily and go off when engine buildsup oil pressure. This indicates oil pressure switch is operating properly.


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START-UP PROCEDURE - Continued

V. High Water Temperature TestA. Place Main Selector Switch in the AUTO position and press the TEST pushbutton to start the engine.B. Connect temporary jumper between terminal of water temperature switch and battery common (CTB1-5

to CTB1-11A or CTB1-11B).C. Alarm bell should sound and Remote Engine Failure Alarm should operate, and water temperature

signal light in controller should come on immediately.D. Turn switch to OFF position to stop engine.

E. Remove jumper from water temperature switch.

VI. Pump House Alarm Test (Option "O", G1)A. Place Main Selector switch in AUTO position.B. Connect temporary jumper between terminals 18 and 19 on CTB2 of the DC-EIF chassis. The audible

alarm will sound, the Remote Pump House Trouble Alarm should operate, and the Low Fuel Levelsignal will light. Press the RESET pushbutton to silence the audible alarm. The controller audiblealarm will silence while the Remote Pump House Alarm and signal light will remain on. Remove the

jumper and the remote alarm and signal light should go off.C. Repeat step B. With terminals 20 for "System Overpressure" (if present).D. Repeat step B. With terminals 21 for "Reservoir Level Low" (if present).E. Repeat step B. With terminals 22 for "Reservoir Empty" (if present).F. Repeat step B. With terminals 23 for "Flow Meter Open" (if present).G. Repeat step B. With terminals 24 for "Pump Room Temp Low" (if present).H. Repeat step B. With terminals 25 for "Relief Valve Open" lamp (if present).

VII. Overspeed Test (NOT applicable to controllers equipped with Option "6")A. Place Main Selector Switch in the AUTO position and press the TEST pushbutton to start the engine.B. Operate the Overspeed test switch on the engine mounted control panel, if provided. If not,

momentarily jumper terminal 3 to terminal 7. Engine should shutdown, alarm should sound, theoverspeed signal lamp should light, and the remote engine failure alarm should operate and remainenergized without the jumper.

C. Turn switch to OFF position to reset signals.

VIII. Power Failure Alarm Test (Controllers without Option "5", G1)A. Place Main Selector Switch in the AUTO position.B. Open the 115 Vac circuit to the controller at any convenient point. The A.C. Failure Signal Lamp and

Remote Engine Failure Alarm should both operate. (Controller audible alarm is NOT energized).C. Reconnect 115 Vac

IX. AC Power Failure Starting Test(Only for controllers equipped with Option "5", G1)A. Place Main Selector Switch in the AUTO position.B. Open the 115 Vac circuit to the controller at any convenient point.C. After delay, depending on the time setting, which is usually set at approximately 10 seconds, engine

should start and continue to run. Reconnect 115 VacD. Turn switch to OFF position to stop engine or depress STOP pushbutton to stop engine.

NOTE: On controllers that have AUTOMATIC stop, the engine will run for the time setting on the DC-CU chassis,provided the power has been restored, and then stop automatically.


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START-UP PROCEDURE - Continued

X. Pressure Starting TestA. Place Main Selector Switch in the AUTO position.B. Drain down the pressure in system until a pressure start occurs.C. Engine should start automatically. AFTER engine has started, close the drain.D. Engine should continue to run even after pressure has been restored to normal.E. Turn switch to OFF or depress STOP pushbutton to stop engine.

NOTE: On controllers which have AUTOMATIC STOP, the engine, when started from pressure switch or deluge startcontact, will run for the time delay set or until the pressure or deluge demand is reset, whichever takes longer. STOPbutton will not stop engine, unless demand has cleared.

XI. Remote / Deluge Starting Test (For controllers equipped with Option "4", G1)A. Place Main Selector Switch in AUTO position.B. Operate a remote starting contact or disconnect the wire from CTB4, terminal #33 on the DC-CU

chassis. Use terminal #32 for Deluge Valve starting.C. Engine should start automatically and continue to run even after the circuit to terminal #32 or #33 has

been re-established. Minimum Run shutdown only works with Deluge.D. Place switch in OFF position or depress STOP pushbutton to stop engine.

XII. Automatic Weekly Starting Test (Weekly Test Start when enabled See P.10)A. Place Main Control Switch in AUTO position.B. Press the Weekly Test button on the DC-CU chassis.C. Drain Valve Solenoid will energize and dump water to cause a pressure loss start.E. Engine will start and run for 30 minutes. The Drain Valve will close after engine is running.F. After 30 minutes, the engine will stop.G. Weekly test will occur again seven days later at the same time that the weekly test button was last

pressed. It can be defeated by removing the jumper in the DC-CU chassis (See P.10).

XIII. Battery Failure TestA. Place Main Selector Switch in AUTO position.B. Temporarily disconnect the battery charger by opening the 115 Vac circuit to the controller at any

convenient point.

NOTE: If controller is equipped with option "5"(G1), Power Failure Start, set the rotary switch on the DC-CU chassisto 0 to disable.

C. Disconnect main cable from battery #1, or alternatively, disconnect and insulate the wire from terminal#6.

D. After a brief delay, the Battery 1 Failure Signal, audible alarm, and Remote Engine Failure Alarmshould all operate.

E. Repeat Pressure Starting Test (Paragraph X). Engine should start normally. Control should be capableof performing all previously described Tests.

F. Reconnect battery cable (or re-connect wire to terminal #6) and depress battery failure RESETpushbutton (Battery 1 fail signal and alarms should de-energize).

G. Repeat steps A through E above except disconnect battery #2.H. Reconnect Battery Charger and reset Power Failure Start timer, if used.

XIV. Sequence Start Test (Option"9", G1)A. Most automatic start signals active in the AUTO positions will be delayed by the Sequence Start rotary

switch setting on the DC-CU chassis. Does not delay remote start.B. On Power Fail Start (Option "5", G1), the engine should start after the combined delays of the AC

Power Failure Start and Sequence Start delays.


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CONTROLL ER OPERATION

OFF Position: This is a safety position on the Main Selector switch which prevents the engine from startingduring periods of engine maintenance. It is also used to reset the control after a Failure to Start, OverspeedShutdown, High Water Temperature, or Low Oil Pressure.

NOTE: Set the Main Selector switch to the OFF position before making final connections to the batteries andbefore energizing the A.C. (Mains) Power circuit.

BATT Position: Placing the Battery Selector Switch in BATT1 or BATT2 selects which battery is used duringcranking in the MAN Position.

MAN Position: This position on the Main Selector Switch is for manual starting of the engine through theManual START Pushbutton. To crank on battery 1, place the Battery Selector Switch to BAT 1 and push theSTART Pushbutton. To crank on battery 2, place the Battery Selector Switch to BAT 2 and again push theSTART Pushbutton. Initial testing of the engine is usually accomplished in this manner. It may also be used incase of emergencies to bypasses all automatic circuitry.

NOTE: All alarm circuits are active in manual positions.

AUTO Position: Placing the Main Selector Switch in the AUTO position energizes the "AUTO ON" signal light.This indicates that the controller is in the standby position, ready to start the engine should an emergency occur.

RESET Pushbutton: This pushbutton is located on the upper left front of the control cabinet. Depressing thispushbutton resets the battery failure circuits and silences the audible alarm. If either Battery Failure lightsremains lit or re-lights, a defective battery bank is indicated.

NOTE: Operate the battery failure RESET pushbutton prior to putting the controller in operation.

TEST Pushbutton: With the Main Selector Switch in the AUTO position, pressing the TEST pushbutton opensthe drain valve solenoid to initiate the engine starting sequence by a pressure drop. The TEST position should beused for routine starting. This mode of operation brings into use all of the automatic cranking, running, and safetyshutdown circuits. When the engine starts, the Remote Engine Running Alarm contacts transfer.

STOP Pushbutton: The basic controller is furnished for Manual Stop. When a pump demand occurs, such as lowpressure, the engine will start and continue to run until the control switch is placed in the OFF position. Enginemay also be stopped by depressing the "STOP" Pushbutton provided that all the starting demands have beensatisfied. If they are not, the engine will not stop when the STOP button is pressed.

PRESSURE Switch (PS): These controllers are equipped with a pressure transducer Start (Trip) and Stop (Reset)control circuit. If the Start or Stop pressure setting(s) need to be set or the settings changed, follow theseinstructions:

A. Pressurize the system using the Jockey Pump or by Running the Fire Pump. This is to avoid pumpstarting while setting the Pressure Switch Start and Stop set points.

B. To check the pump Start (Trip) set point (setting), operate theMETER toggle switch on the side of thedisplay box (door mounted) to theSTART PRESSURE position and observe the reading on the digitaldisplay. The value displayed is the pump Start (Trip) pressure set point. The pump will start wheneverthe system pressure is below this value.


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CONTROLLER OPERATION - Continued

C. To check the pump Stop (Reset) set point (setting), METER toggle switch to theSTOP PRESSURE positionand observe the reading on the digital display. The value displayed is the pump Stop (Reset) pressure setpoint. On controllers set for Automatic Stop, the controller will stop the pump whenever the systempressure is above this value if the Minimum Run Timer has timed out.

D. To set the pump Start (Trip) set point, rotate theTRIP SETTING knob or shaft on the side of the display box(door mounted) until the display shows the desired Start Pressure setting. Increases clockwise.

Note: The Trip and Reset settings are changed by turning the 10 turn trip and reset potentiometers. If the Stop(Reset) potentiometer is set down to the trip setting, the pot will continue to turn but the setting will notdrop below the Trip (Start) point. Several Clockwise (increasing) turns of the Reset (Stop) control orCounterclockwise (decreasing) turns of the Trip(Start) control may be needed. The two LEDs on eitherside of the controls indicate the presence (Pressure Start Demand) or absence of a pump demand.

E. To set the Stop (Reset) set point, rotate theRESET SETTING knob or shaft on the side of the display box(door mounted) until the display shows the desired StopPressure setting. Increases clockwise.

F. Close and lock the controller door.

G. Use the test valve to drop pressure to check for pump pressure loss starting. Use the Stop pushbutton tostop the pump to leave it in service (standby mode).

H. Make sure the pump discharge valve is open and that any other valves are properly set.

Failure to Start: If the engine does not start in approximately 15 seconds, cranking will stop for about 15 secondsand then continue in "crank" and "rest" periods for a total of six (6) cranking attempts (with five rest periods) or atotal overall starting cycle of about 2-3/4 minutes. If the engine has not started by this time, all further crankingwill discontinue, starting and running circuits will remain energized, the "Failure to Start" light will energize, theAlarm Bell will sound, and the Remote Engine Failure Alarm contacts will transfer. The controller must be resetby placing the control switch in the OFF position.

NOTE: If the engine starts and runs but the speed switch or other crank terminate signal does not energizeterminal 2, the engine will continue to run with the Failure To Start LED on.

Low Oil Pressure: If the lube oil pressure of the engine falls below the setting of the oil pressure switch while theengine is running, the Low Oil Pressure signal light will energize. After approximately 10 seconds the controlleralarm bell will sound and the Remote Engine Failure Alarm contacts will transfer. Engine will continue to run.

The controller does not shutdown the engine on low oil pressure unless it is running in the Weekly Test or Testmode. The Low Oil Pressure LED remains on until the Main Selector Switch is turned Off.

NOTE: Whenever the engine is started, the Low Oil Pressure signal light is energized momentarily until enginebuilds up oil pressure. This indicates oil pressure switch is operating properly.

High Water Temperature: Should the temperature of the engine cooling water system exceed the setting of theengine high water temperature switch, the High Water Temperature light is energized, the controller audible alarmsounds and the Remote Engine Failure Alarm contacts transfer. Engine will continue to run. The controller doesnot shutdown the engine on high engine jacket water temperature unless it is running in the Weekly Test or Testmode. The High Water Temperature LED remains on until the Main Selector Switch is turned Off.

Battery Failure: If the voltage of a battery drops below about 2/3rds of its nominal rating for more than one ortwo seconds, usually while the engine is cranking, the controller will indicate a battery failure by energizing thecorresponding "Battery Failure" signal light. Simultaneously, all control cranking and running circuits are locked


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to the remaining battery. The controller alarm bell is energized and the Remote Engine Failure Alarm operates.After battery failure has been corrected, depress Battery Failure RESET Pushbutton to return controller to normal

operation. Tripping of the overload Circuit Breaker will energize associated Battery Failure signal and operatelocal and Remote Engine Failure Alarms. Disconnecting a battery lead will also energize associated BatteryFailure signal light local and Remote Engine Failure Alarms.

Engine Overspeed: If the engine Overspeed Switch trips, usually when the engine speed exceeds approximately120% of its rated speed, automatic safety shutdown will occur. Simultaneously, the audible alarm will sound, the"Overspeed" signal light will energize, the Remote Engine Running Alarm contacts and Remote Engine FailureAlarm contacts will transfer. Terminal #1 is de-energized to avoid fuel leakage and cooling water drain as well asbattery drain.

In the AUTO position, the Overspeed light, audible alarm and remote alarms will remain energized by a latchcircuit even if the pump demand signal is removed. After an Overspeed, the engine overspeed shutdown deviceand controller must be reset. To reset the controller, place the control switch in OFF position.

NOTE: Always: 1) reset engine devices first before resetting the Selector Switch to Off and (2) start the engineagain to be sure the overspeed has been remedied AND the engine shutdown devices has been reset. Failure to

follow this procedure may erase the overspeed memory (latch) circuit and can cause immediate overspeedshutdown on next start.

Pump House Trouble Alarm(s) - Option "O", G1: Controllers so equipped have signal lights which willindicate when their respective Pump House trouble alarm switches have closed. Closing the trouble switch willalso transfer the Remote Pump House Trouble Alarm contacts and energize the audible alarm. The bell can besilenced by pushing the RESET pushbutton.

Weekly Test Start: Standard controllers are furnished with automatic Weekly Test Start to provide weeklystarting of the engine to insure it will start in the event of an emergency. Y ou must first enable the Weekly Test bymoving the Weekly Test Jumper to the enabled position (See P.10 for a diagram of both positions). Now pushthe Weekly Test pushbutton on the DC-CU chassis and the Drain Valve Solenoid will dump water from thepressure sense line to start the engine in the same manner as if a sprinkler head opens during a fire. The enginewill run for 30 minutes and shutdown. It will start again 7 days later at the exact same time.

Minimum Run / Automatic Stop - Option "1", G1: When permitted by the local Authority Having Jurisdiction(AHJ ), the controllers may be equipped for Automatic Stop with Minimum Running Period Timer (Option "1",G1). Using this arrangement, an automatic start resulting from a pump demand, will cause the engine to run atleast for the time setting of the Minimum Run time delay. If the demand still exists after the time delay interval,the engine will continue to run until all pump demands are clear (reset), at which time, the controller willautomatically shutdown the pump. This option should not be added or activated, unless prior approval has beenobtained from local AHJ (Authority Having Jurisdiction). NFPA-20 requires that it not be used with "sole sourcepumps" or pumps supplying standpipes or hose cabinets. The Time Delay is part of the DC-OM Option ModuleBoard in the DC-CU chassis. The time range is 2 to 30 minutes in 2 minute intervals. The time delay is set byoperating 16 position rotary switch marked "MIN RUN" to the desired position. Position "0" defeats this functionand results in Manual Stop operation. Position "1" is 2 minutes, position "9" is 18 minutes and position "F" is 30minutes. The normal setting is "F", 30 Minutes.

Electric Motor Lockout - Option "2": Controllers so equipped contain an auxiliary chassis to (1) preventengine from running while associated electric motor driven pump is operating and (2) while engine isrunning to prevent associated motor driven pump from operating. Electric motor controller must beequipped with a lockout relay and auxiliary contact to indicate motor is operating. The time delay


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allows spin down of the engine before the electric motor is enabled in the case of dual drive installationswhere a diesel and electric driver are connected to the same pump. This option should not be added oractivated, unless prior approval has been obtained from local AHJ (Authority Having Jurisdiction).NFPA-20 does not allow dual drivers for a single pump.

Pressure Recorder Options DPR (G1), DR, PN" or "PNT"(Paperless Recorders): Controllers are equippedwith a Paperless Pressure Recorder to continuously record the pressure in the fire protection sprinkler system.

Refer to P. 34 for further details.

Remote Deluge Valve or Remote Momentary (Pushbutton) Start - Option "4", G1: Controllers so equippedhave a Remote Start drop-out loop circuit. Any number of NORMALLY CLOSED contacts may be wired inseries with the loop. The total loop (round trip) resistance of circuit between terminals 31 and 32 or 31 and 33must not exceed 50 ohms on 12 volt system and 250 ohms on 24 volt system. See the wiring resistance tablebelow.

In operation, the Remote Deluge Start Contacts and/or the Remote Momentary Start contacts open to cause thepump to start. Controllers equipped with Sequence Start (Options "9", G1) will delay starting the engine afterreceipt of a Deluge Valve Contact signal (contacts on CTB4-32 open). This delay does not affect a RemoteMomentary (Terminal CTB4-33) input.

Engine Lockout, Mod. "X21": Closing of contacts wired to Terminal CTB4-34 will cause the controller to stop arunning engine or prevent it from starting when the Main Selector Switch is in the AUTO position. This inputdoes not affect running with the Main Selector Switch is in the MAN position.

Remote/Deluge Start or Lockout Circuit Wiring Table

Wire Resistance 12 vdc 24 vdcWire Size Ohm/1,000 Ft. (50 Ohms) (250 Ohm)#12 AWG 1.588 15,700 Ft. 78,500 Ft.#14 2.525 9,900 49,000#16 4.016 6,200 31,000

#18 6.385 3,900 19,500#20 10.15 2,500 12,500#22 16.14 1,500 7,500#24 25.67 940 4,700#26 40.18 620 3,100

NOTE: Resistance and number of splices and contacts in circuit must be taken into consideration whencalculating size of wire to be used. A single splice may exceed the total resistance of 1,000 Ft. or more of wire.

Charger Failure - Option "A": All controls are provided with Charger Failure circuitry to detect a loss of A.C.Power to the controller or a mal-function of either battery charger. Either condition will energize the "ChargerFailure" light and transfers the Remote Engine Failure Alarm contacts. This circuitry resets immediately upon

restoration of A.C. Power and/or replacement of battery charger input fuse. The Alarm Bell does not actuate onCharger Failure Alarm to avoid additional battery drain.

A.C. Power Failure Start - Option "5", G1: Controllers so equipped are furnished with a Power (Mains) FailureStart Time Delay circuit on the DC-OM Options Module board on the DC-CU chassis. This is to prevents theengine from starting on brief power interruptions. The time range is 20 to 300 second, in 20 second intervals.

The time delay is set by operating 16 position rotary switch marked "POWER FAIL START" to the desiredposition. Position "0" defeats this option (no start on power failure). Position "1" is 20 seconds, position "9" is


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180 seconds and position "F" is 300 seconds. Actual time setting should be determined by authority havingjurisdiction.

Spark Ignition Engines - Option "6": Spark ignition gasoline or natural gas engines may not be equipped with anOverspeed signal (speed switch). Controllers having Option "6" have no Overspeed light and are not arranged toprovide overspeed shutdown or alarm. Terminal #3 is unused.

Individual Failure Contacts - Option "7": Controllers so equipped provide independent S.P.D.T. contacts for theconnection of remote signals which correspond to the individual signals in the controller.

Sequence Starting - Option "9", G1: Controllers so equipped furnish Sequence Start Time Delay as part of theDC-OM Option Module Board on the DC-CU chassis. It is used to provide the mandatory sequential pumpstarting on installations having multiple pump in parallel. The time range is zero to 75 second, in 5 secondintervals. The time delay is set by operating 16 position rotary switch marked "SEQUENCE" to the desiredposition. Position "0" is no delay, position "1" is 5 seconds, position "9" is 45 seconds and position "F" is 75seconds. Actual time setting should be determined by authority having jurisdiction. This delay affects pressureloss start, Deluge valve start, when used, and Power Failure start, when used. Typically, the initial setting wouldbe a zero delay for the first (lead) pump, 5 or 10 seconds for the second pump and etc.

High Zone Delay - Option "Z": Controllers so equipped furnish High Zone Time Delay start as part of the DC-OM Option Module Board on the DC-CU chassis. It is used to provide the mandatory sequential pumpstarting on installations having multiple pump in series. The time range is zero to 30 second, in 2 secondintervals. The time delay is set by operating 16 position rotary switch marked "HI ZONE" to the desired position.Position "0" is no delay, position "1" is 2 seconds, position "9" is 18 seconds and position "F" is 30 seconds.Actual time setting should be determined by authority having jurisdiction. This delay affects all automatic startdemands including Pressure Loss, Remote Momentary (pushbutton) start, Deluge valve start, and Power Failurestart, when used. Typically, the initial settings would be zero delay for the high zone pump, 5 or 10 seconds for alow zone pump or a mid-zone pump and 10 to 15 seconds for a low zone pump.

Dual Battery Charger - Option "RA", or "DA": The built-in Dual Battery Charger is designed to automaticallymaintain the batteries in a fully charged condition. The battery charger will charge and maintain both batteriessimultaneously. The ampere output to each battery will vary depending upon individual battery demand.

The Model MBC3 Battery Charger (Option "RA" or "DA") is two separate Float-Equalize automatic modeswitching two rate regulated battery chargers. They switch modes automatically between high rate (equalize) andlow rate (float) depending on charge state & load on batteries. It is A.C. line compensated, current limiting andrequires no adjustment. See MAINTENANCE AND ADJUSTMENTS for further details.

Controller Voltmeters V1 (hinge side) and V2 (handle side) monitor battery banks No. 1 and No. 2 respectively.They monitor the battery charger float and equalize voltages. These meters are also used to indicate the conditionof battery during cranking. A battery in good condition and state of charge should maintain at least 75% ofnominal voltage while cranking (except for breakaway).

Controller Ammeters A1 and A2 sense the charge current being supplied to battery #1 and #2, respectively, by thebuilt-in dual battery charger in either the float (maintaining) mode or the equalize (high rate) mode.

Note that the signals for the digital voltmeters and ammeters are supplied by the MBC3 battery charger.

Stop Pushbutton: The STOP pushbutton is located on the upper right front of the control cabinet. Its primarypurpose is to provide means for stopping the engine without unlocking the door on the controller. It will operateonly when the control switch is in the AUTO position and then, only after all engine running requirements havebeen satisfied.


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Battery Overload Circuit Breakers: These two circuit breakers, CB1 and CB2, are located on the upper leftportion of the DC-EIF Chassis. A short circuit in the engine wiring can cause them to trip. Push firmly to reset.


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- 23 -Master Control Systems, Inc._____________________________________________________________Lake Bluff, Illinois

DEC Issue 02-v02 2009.08.3

OPERATION OF MODEL MBC3 DUAL BATTERY CHARGER

GENERAL DESCRIPTION: The Model MBC3 Dual Battery Chargers are constant voltage, Automatic Modeswitching, two rate (Float & Equalize) current limited and regulated (line compensated). These chargers meetthe requirements of NFPA 20 which requires that the battery charger must be capable of restoring two fullydischarged batteries, 100% of their ampere hour rating within 24 hours. These Models provide fast recharge inthe high rate Equalize mode; with low water consumption in the low rate Float mode. These chargers have veryhigh line regulation, load regulation, and very low temperature coefficient. They also have extremely wideA.C. voltage operating range, since they have both outstanding low A.C. line margin and very high A.C. line

voltage tolerance. These chargers also have short circuit and reverse battery protection by way of the "LowVoltage ShutDown" feature.

The Model MBC3 Dual Charger is two separate 10 Amp (Option "RA") or two separate 20 Amp (Option "DA")battery chargers on a single baseplate. The 12 volt, 10 Amp model utilizes two different secondaries of a singletransformer for both chargers. These two chargers are separately controlled and capable of charging bothbatteries independently. Each charger has a separate plug-in Regulator P.C. Board Assembly, separatereplaceable power rectifier and SCR Heatsink Assembly and separate D.C. fuses. This completely eliminatesthe undesirable interaction between battery outputs that occurs with chargers using a single regulator and diodeisolated (divided) outputs.

Note: The Model MBC3 Battery Charger (Option "RA" or "DA") must be connected to batteries and placed in

operation at least 24 hours prior to testing.

OUTPUT CAPACITY: These chargers are capable of supplying 100% of their rated D.C. output currentwithout allowing the batteries to be depleted. The full rated output current (10 Amps for Option "RA" 20 Ampsfor Option "DA") are always available for each battery bank (battery units).

BATTERY SIZE (CAPACITY): The Battery capacity of the charger (each output) is marked on the chargerchassis. Batteries larger than the maximum rated capacity may not be completely charged within the 24 hoursand can also cause charger to "high rate mode lock-up" which will result in very high water consumption,battery heating and subsequent battery damage.

WATER CONSUMPTION: The Model MBC3 Chargers provide the fastest charge time for a given rating

consistent with the lowest water consumption. Under normal conditions the Charger will be in the "float" modewith low water consumption. The battery water level should be checked once a month until a waterconsumption pattern is established. The water level should be checked at least every 3 months due to climaticchanges. Longest battery life will be obtained when distilled water is used to fill batteries.

LINE REGULATION: The Model MBC3 are regulated (line compensated) and require no tap setting. The linevoltage regulation (output change) is 0.2% or better for a 10% line voltage change. The Chargers will operatewith line changes up to 15% of nominal.

MODE SWITCHING: The Charger will switch modes between Float mode and Equalize mode depending onthe state of charge in the batteries and upon external loads. The mode switching decision is based on theCharger output current. When the batteries and/or other loads require much over 50% or rated current the

Charger automatically switches to the high rate mode and remains there until the battery or batteries is/arecharged and the output current drops down toward 50% of rated current. At that point the Charger will switchback to the float mode, with a corresponding reduction in output current and remain in "float" until the nextdemand occurs.


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DEC Issue 02-v02 2009.08.3

OPERATION OF MODEL MBC3 DUAL BATTERY CHARGER - Continued

Engine cranking, will cause the charger to switch to the high rate again. In the float mode the Charger willsupply only to the batteries a current equal to battery leakage plus any external loads.

Power interruption will also cause the Charger to switch to the high rate upon power restoration. The Chargerwill return the charge lost during the power interruption and then return to the float mode. The Charger will notdischarge the batteries during periods of power failure.

BATTERY CONDITION: A fully charged battery will be indicated by a low Charger output current and, forlead acid batteries, a full charge specific gravity hydrometer reading in all cells. A battery which hasapproached end of life will have a reduced ampere hour capacity (something less than the battery's ratedcapacity). An adequate check of a battery for capacity in engine starting applications is to monitor the batteryvoltage while it is cranking the engine during an expected worst case cranking attempt. The cranking voltage ofa fully charged battery of adequate capacity should be at least 75% of nominal (9 volts minimum on a 12 voltlead acid battery). Batteries with sufficient capacity which are not fully charged may not pass the test.

CAUTION:AS SOON AS ELECTROLY TE IS ADDED TO BATTERIES, CONNECT AND ENERGIZE BATTERY

CHARGER THE SAME DAY TO PREVENT DAMAGE TO BATTERIES.

NORMAL OPERATION: When power is first applied, the Charger will normally supply its full rated currentin the high rate mode, as indicated by the Charger ammeter(s). The current will remain at the current limitvalue until the battery approaches full charge. It will then taper down toward 75% of rated current and thendrop to zero indicating the battery is charged and the Charger has switched to float mode. The Charger willthen begin to supply whatever is required by battery leakage and external loads.

NOTE: The Charger should remain in high rate mode for no more that 24 hours when used with a fullydischarged good battery of proper size and type and with no external loads. Adding electrolyte to a "drycharge" battery results in the battery being approximately 2/3 charged. Thus, for an MBC3, while cranking, thecranking battery will cause that charger to switch to the high rate (momentary full scale on the ammeter) thento current limiting (10 Amps or 20 amps) until the battery is charged. When the engine is running the engine

generator or alternator will normally cause the control battery charger output to be reduced.

CHARGER MAINTENANCE: There are no field adjustments to be made on these chargers. The onlyadjustable device is the float voltage adjustment trim pot on the regulator P.C. board which is factory set usingprecision equipment. The same is true of the two charger failure trim pots on the DFA dual charger failurealarm board (PC3).


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DEC Issue 02-v02 2009.08.3

OPTION "RA" or "DA" BATTERY CHARGER FAILURE ALARM

DESCRIPTION OF EQUIPMENT: The center plug-in printed circuit board is the DC-DFA Dual ChargerFailure Alarm assembly (module). The "A.C. Power & Charger Failure" relay K9 is controlled by the reedrelay(s) on the DFA board.

OPERATION PROCEDURES: The DFA assembly is adjusted at the factory, using precision equipment, tooperate with the specific voltage and battery type for which the Charger was built and adjusted. There are nofield adjustments to be made.

Both of the DFA Charger Failure Alarm circuits will usually reset automatically after power restoration. If not:1) Momentarily remove A.C. power from the controller (branch circuit breaker may be used if convenient

to turn off controller A.C. power). Reapply power after approximately 10 seconds. Both ChargerFailure Alarm circuits will usually reset upon power restoration.

2) Place Main Selector Switch in the MAN position and the Battery Selector Switch in the BAT1 position.Crank the engine by using the START pushbutton until BATTERY 1 AMMETER (left hand, hinge sideammeter) has jumped up to full scale and settled down to current limit value which takes 2 to 5 seconds.

This will reset the DFA Battery No. 1 Charger Failure Alarm. Repeat this procedure with the BatterySelector switch in the BAT2 position observing BATTERY 2 AMMETER (right hand, handle side,ammeter). This will reset the DFA Battery No. 2 Charger Failure Alarm.

The DFA circuits will also reset when battery float voltages return to normal.

The DFA Dual Charger Failure Alarm Board will detect any of the following charger malfunctions for either ofthe two battery chargers:A) Immediate detection of charger A.C. (Mains) power loss, either loss of A.C. Power to the controller or

open charger A.C. Fuse(s).B) Detection of loss of output current from eithercharger, including open charger D.C. output fuses,

regardless of the cause. Detection time will vary from instantaneous to an hour depending on size ofloads, size of battery, and the state of charge and condition of the battery.

C) Detection of failure of either charger to produce high rate current if the battery is not fully charged or iflarge loads are put on the battery.

D) By virtue of the above, detection of blown A.C. or D.C. fuses, broken or open input or output wires,

low line voltage, removed charger components.E) Failure of charger circuitry that prevents it from bringing and holding the battery at its full chargevoltage level.

In general, the DFA module will cause an alarm unless either 1) the battery is fully charged and is receiving acharge maintaining current from the charger, or 2) the charger is producing high rate currents to charge thebattery.

If either DFA failure circuit detects a failure, the "Charger Failure" LED will Light and the REMOTE ENGINEFAILURE Contacts will transfer. If the control is equipped with Option "5(G1) "Power Failure Start", theengine will start after a time delay period. See the sections titled "A.C. Power Failure Alarm" and "A.C.Powered Failure Start (Option 5, G1) for more details."

THEORY OF OPERATION: (GENERAL) If a battery is fully charged and is receiving a charge currentsufficient to maintain that charge level, then the battery terminal voltage will be at its normal FLOAT


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DEC Issue 02-v02 2009.08.3

OPTION "RA" or "DA" BATTERY CHARGER FAIL URE ALARM -Continued

VOLTAGE. If the battery fails to receive this current, which the charger produces when it is in the FLOATmode, then the battery voltage will drop to its FULL CHARGE OPEN CIRCUIT value. If the battery is notfully charged, the voltage will be still lower, particularly if the battery is not receiving high rate charge currents.Part of the Charger Failure Alarm Module is a voltage monitor circuit which will cause the relay to remain inthe NORMAL (not-alarm) state if the battery voltage is above its FULL CHARGE OPEN CIRCUIT value.

This voltage monitor set point is between the battery full charge open circuit and the nominal Float voltage.

If the MBC3 battery charger is producing high rate currents (at least 50% of rated output) the charger willgenerate an "EAL" signal and light the Yellow (amber) LED to indicate the charger is in the Equalize mode.

Thus, any time either charger is producing high rate currents (Yellow LED), or if the battery voltage is highenough to satisfy the voltage monitor, that alarm circuit will enable the failure relay to remain energized (in itsnormal state).

If the battery voltage drops below the voltage monitor set point, the relay will drop-out and cause an alarmunless the charger is producing high rate currents (Yellow LED). The voltage monitor has a time delay to allowtime for the charger to switch to high rate currents before causing an alarm.

(SPECIFICALLY): The DFA relay coil is connected to the charger "EAL" terminals and is energized any timethe charger is producing currents above the CROSSOVER CURRENT value. This will be the case anytime thecharger is in the EQUALIZE mode. If and when the battery voltage rises above the DFA alarm set pointvoltage the voltage monitor energizes the relay to keep the alarm relay energized. If neither condition is true(battery voltage low and not charging at the high rate, the module will de-energize the controller ChargerFailure relay to cause a charger failure alarm. Both DFA alarm circuits must be satisfied to prevent the alarmrelay from dropping out (to the alarm state).

The voltage monitor alarm set point is approximately 12.7 Vdc or 25.5 Vdc for 12 Vdc or 24 Vdc lead acidautomotive chargers, respectively.

MAINTENANCE PROCEDURES

WEEKLY TESTING: To insure reliable automatic starting in event of an emergency, the engine and controllermust be operated once a week for a minimum of 30 minutes. To do this, first enable the Weekly Test Jumper(See P.10 for a diagram). If not enabled, the controller will not start every week automatically. Once enabled,to initiate the weekly start press the Weekly Test button on the DC-CU chassis. The controller will startimmediately and then subsequently at the same time every week.

Even when Weekly Test Starting is accomplished automatically, someone should be present at the pump houseto make sure all systems are operating properly. The following is a suggested list of items which should becovered at this time:

(1) Check specific gravity (before cranking) and height of electrolyte in battery. If necessary, replace water

lost through evaporation.(2) Make sure neither "Battery Failure" light is on. Energized battery failure lights indicate the possibility

of battery failure.(3) Check crank case oil level.(4) Check water level in heat exchanger.(5) Observe voltmeters on controller while engine is cranking. EXCESSIVE (25% or more) voltage drop

will usually be the first indication of battery trouble and should be investigated immediately.


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DEC Issue 02-v02 2009.08.3

MAINTENANCE PROCEDURES - Continued

(6) Observe low oil pressure signal light and make sure it comes on momentarily while the engine iscranking.

(7) Make sure cooling water solenoid valve opens.(8) Make sure engine is running at rated speed and observe oil pressure, water temperature, and charging

generator or alternator output.(9) Make sure pump discharge pressure is normal.(10) Make sure "AUTO ON" light is on before, during, and after weekly test run.

The Authority(s) having Local Jurisdiction (AHJ) may wish to add further items to the above. Also, refer toNFPA-25 Standard on Maintenance and Testing for further information and guidance.

BATTERIES: (Lead Acid) The engine starting batteries are the heart of the entire system and although thebattery charger incorporated in this control is fully automatic and incorporates the most modern techniques incharge control, there is no substitute for proper and periodic maintenance.

CAUTION: AS SOON AS ELECTROLYTE IS ADDED TO BATTERIES, CONNECT AND ENERGIZEBATTERY CHARGER TO PREVENT DAMAGE TO BATTERIES.

Inspect batteries once each month to make certain all connections are tight. Remove dust or dirt accumulations

from top of batteries. Neutralize acid on covers and terminals by cleaning with ammonia or soda solution (1pound baking soda per gallon of water). Be sure to keep terminals and metal parts free of corrosion. Neverallow water level to drop below top of battery plates.

NOTE: Take care to follow all instructions, cautions and warnings provided with the batteries by the batterymanufacturer.

If the batteries do not come up to full charge (1.240 to 1.285 specific gravity reading), check the charger floatvoltage.


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REPLACEMENT PARTS LIST:

DEC Fire Pump Controllers

Designation Description MCS Part Number

DC Engine Interface Chassis (DC-EIF)

DC-EIF Engine Interface Chassis, 12N w/ H Includ

Relay649255

DC-EIF Engine Interface Chassis, 24N w/ H IncludRelay

649256

DC Power SuppliesDC-PS Power Supply Board, 12N,

Power Supply and Battery Monitor649290

DC-PS Power Supply Board, 24N,Power Supply and Battery Monitor

649291

DC Demand Control BoardsDC-DC Demand Control Board, 12V,

Plug-In Board Assy for DEC/DEC.649300

DC-DC Demand Control Board, 24V,Plug-In Board Assy for DEC/DEC.

649301

Clock ModuleDEC-CM Clock Module w/ Wkly Tst Plug-In Board

for DEC.649311

DC Options ModulesDEC-OM Options Module Assy, 12V

Plug-In Board Assy for DEC.649325

DEC-OM Options Module Assy, 24VPlug-In Board Assy for DEC.

649326

Module Board AssembliesDEC-DP Display, STD 0, 12V

Module Board Assy, w/ Hardware.

649352

DEC-DP Display, STD 0, 24VModule Board Assy, w/ Hardware.

649354

Glass HingeGlass Hinge Assy DEC/DEC Control Switch Lockbox Assem

(Glass Hinge Assy).649360

Analog Pressure SwitchesDC-APS Analog PS, 300 PSI, 12VDC

1-6 VDC, Daughter Board, INT PWR.649413

DC-APS Analog PS, 500 PSI, 12VDC1-6 VDC, Daughter Board, INT PWR.

649414

DC-APS Analog PS, 300 PSI, 24VDC

1-6 VDC, Daughter Board, INT PWR.

649417

DC-APS Analog PS, 500 PSI, 24VDC1-6 VDC, Daughter Board, INT PWR.

649418


DEC Issue 02-v02 2009.08.3


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REPLACEMENT PARTS LIST Continued

Designation Description MCS Part NumberAnalog Pressure Switch - Continued

DC-APSS Analog PS Setting BrdTrimpot, LED, Switch Assy.

649419

Charger Regulator Board AssembiesREG E Regulator E, MBC3C-12-10-LA,

Charger Regulator Board Assy.

649502

REG E Regulator E, MBC3C-24-10-LA,Charger Regulator Board Assy.

649512

Charger Failure AlarmsDFA Alarm Module, DFA-12-LA, MBC3C

Plug-In Charger Failure Alarm.649522

DFA Alarm Module, DFA-24-LA, MBC3CPlug-In Charger Failure Alarm.

649532

DiodesDiode Bridge Assy Energize to Stop Diode Bridge

Assembly649540


DEC Issue 02-v02 2009.08.3


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- 30 -Master Control Systems, Inc._____________________________________________________________Lake Bluff, IllinoisDEC Issue 02-v02 2009.08.3

Model PR4001N

Paperless Pressure and Alarm Recorder

- with -

Alarm and Status Recording

- and -

Built-In Phone Modem

Modification "XPN" in Fire Pump Controllers

Installation and Instruction Manual

Table of Contents

Page 31: General

Page 32: Installation

Page 32: Start-up Procedure

Page 33: Normal Operation

Page 34: Getting Data Locally

Page 38: System Commands & Error Codes

Page 40: Customizing

Page 42: Sequence of Operation


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GENERAL

Overview: The Master Control Systems, Inc. Model PR4001N, Paperless Recorder, is a microprocessorbased recorder specifically designed to communicate through an RS-232 serial port directly to a lap-topcomputer or a network server. The built-in modem may also be used to access the system. The PR4001Nconstantly monitors the system pressure, at a rate of three times per second, and records it into permanent

non-volatile solid state memory (NVSRAM or EEPROM) every hour or when the pressure changes bymore the 5 psi (default setting) from the last saved value. The recorder also monitors and records allalarm and status change events into memory. All recorded alarm and pressure data are time stamped withthe date and time of the event recorded. The recorder is independent of the controller and vice versa.Failure of one does not impede the function of the other. The unit will also record in the absence of A.C.line (mains) power. The unit can also be provided as a free standing unit with battery back-up and batterycharger.

Fire Pump Controller Option Designations: The basic recorder model number is the above PR4001Nwhich includes both pressure and alarm recording and also contains a built-in modem. As such it replacesprevious units designated PR4001A (pressure and alarm recording).

W

hen provided as part of a fire pump controller, the controller model designations are as follows:

Modification (Mod. Code) XPN includes a Model PR4001N Paperless Pressure and Alarm Recorderith built in dial-up modem.w

Modification XPS adds Digital pressure switch contacts and a pair of three digit set point switches foroth start (low) and stop (reset) pressure set points.b

Modification XPN in EC** Series Electric Motor Drive Fire Pump Controllers also includes built-inbattery back-up using non-rechargeable batteries. Mod. XPBnn provides longer back-up times and re-hargeable batteries and battery charger.c

Note: Mod. XPN in DCF Series Diesel Engine Drive Fire Pump Controllers uses the two engine batteriesfor battery back-up.

Equipment Provided: When installed in a fire pump controller, the system consists of:1) a through-the-door 4 line by 40 character (160 total characters) LCD display with back-lighting for

dim environments,2) three exterior sealed operator toggle switches for control of the alarm and pressure display and history

display and for watch check-in,3) Solid State Pressure transducer which is in addition to the controller's pressure switch,4) Interior switches to control unit reset (three types of reset are provided), system security (pass word

control) and status send function,

5) Built in Hayse compatible dial-up and auto-answer, unless option XPNT (network enabled) isprovided, and6) RS-232 customer serial port for data access and control.


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GENERAL - Continued

Connectivity: Controllers equipped with option XPNT are network enabled. The internal modem isreplaced by a network server device. This allows direct connection to an Ethernet hub or server forconnection to a Local Area Network (LAN) or a Wide Area Network (WAN) or Internet Access. Thedevice has separate password protection. It uses TCP/IP protocol and is assigned an IP address which canbe changed in the field. A work sheet is supplied with the appropriate network parameters. A customer

supplied IP address and sub-net mask can be pre-programmed by the factory upon notification.

INSTALLATION

Installation consists of a telephone line connection to the phone line terminal block screws.

For wall mounted units, a pressure sense line, 115 VAC power, and alarm contact inputs must be broughtto the unit in addition to the phone line. The alarm contacts must be "dry" contacts ("volt free").

START-UP PROCEDURES

1) Power up the controller. The unit will begin its self-tests and initialization. After initialization,the Process LED should be flashing.

2) Hold down the "Send Status" pushbutton and momentarily press the Reset pushbutton.Continue holding the Send Status push button down until the "Init" LED goes out, release the"Send Status" pushbutton. This is known as a "default reset". It returns all system settings totheir factory values. To clear the permanent memory, repeat this procedure while holding the"Scroll Down" switch. Whenever the batteries have been replaced, the "Replace Battery"message and the internal battery failure needs to be reset. This is accomplished by holding the"Scroll Up" switch while initializing. Note that the internal batteries should be replaced

annually to maintain maximum capacity.

3) Set the Security switch to off.

4) Set the "pressure/alarm" toggle on the outside of the controller to the desired position. Pushdown on the "scroll" toggle to see the history. After a large amount of data is gathered, holdingdown the scroll toggle will scroll through 20 points at a time. Push up on the "watch check"toggle to check in. This also returns the display back to the main screen in 3-4 seconds.

5) Check the Time & Date. If the time or date is not correct, adjust as indicated below:5a) Make sure the "Security" is not in the "ON" position.5b) While holding the "Check-In" switch, press and release the "Reset" pushbutton.5c) When the ** TIME/DATE ENTRY ** screen appears, release the "Check-In"

switch and follow the instructions as stated.5d) Adjust the value with the "Scroll Up/Down" switch as necessary and use the

"Check-In" switch to enter the new value and advance to the next field. Note thatthe Daylight Savings flag, 'Daylight=', may also be set from this screen.


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START-UP PROCEDURES Continued

Notes:- The field to be changed will be indicated by a blinking block cursor and an underline cursor directly

below the right-hand character position in each field.

- The clock will not start running until the last field is exited.

- The cursor will advance to the next position after approximately 30 seconds if there is no activity.

- On units with Version 1.3 or earlier software(shipped prior to 11/12/98), the Time & Date must bechanged from a lap-top computer. For these units, see "Getting Data Locally". Once connected, type'H3' and follow the instructions.

NORMAL OPERATION (default constants)

Switches and LEDs - The back of the display box provides a Security switch, a Send Status push button,and a Reset push button along with system and diagnostic LEDs.

The Security switch provided tells the system if password verification is required when answering a call.If verification is required and the password does not verify, the PR4001N terminates the call. It alsoprevents the system parameters, phone number, password, or memory contents from being altered even ifa valid password is used.

The Send Status push button sends the present alarm status to the connected lap-top or modem.

The Reset push button resets all the hardware and software to their initial states. If non-volatile memoryneeds to be reset to the factory defaults, hold the Send Status push button down and momentarily press theReset push button. Continue holding the Send Status push button until the initialize LED goes out. Thisis known as a "default reset". It returns all operational defaults to their factory values. To clear the data

memory, use the Scroll Down switch instead of the Status button as described above. When the internalbatteries have been replaced, the Battery Failure may be reset by using the Scroll Up switch as describedabove. The password and dial-out phone number are not erased using any reset method.

The following status LEDs are provided on the display back box:

INIT - Indicates that the unit is going through initialize operations.

PROC - Indicates that the unit is running in the general program. It should always be flashing.

TRBL - Indicates a power supply problem or data overrun.

ERROR - Indicates when a received message is not accepted. The error LED glows when parity,

framing, and overrun errors are detected by the serial port. It also glows when heading, type, data, orcheck sum errors are detected by the software. The Error LED is automatically reset on the next validmessage or when the call is terminated.

CONN - Indicates that the unit is properly connected and ready to communicate. This connection maybe made by a lap top computer, network server or the internal modem.


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NORMAL OPERATION (default constants)

+5V - Indicates that +5 VDC power is available.

+10R - Indicates that the +10VDC transducer reference source is nominal.

FAULT - Indicates when the transducer current is too low (open) or too high (shorted).

Getting Data Locally (With the Custom Software Package)

1) Install the Software from provided CD: The Custom Software Package is a Windows based(Win95/98 & Win2000) software suite of programs supplied with each PR4001 data recorder. Itconsists of a Download module, a Pressure Plot module and an Alarm Display module. It is suppliedon CDRom and is self extracting. Install the package by inserting the CDRom into the CDRom drive.If the installation program does not start automatically after a few seconds, start the installationprogram by selecting or double clicking on the "setup.exe" file which is in the root main) directory onthe CDRom disk. Then follow the installation prompts.

2) Connecting the Controller to the Computer: Connect the black custom cable to controller as shownabove, then connect the RS232 the black custom cable to the adapter. Now connect the adapter to thelaptop.


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Getting Data Locally - Continued

3) Getting Data on the Computer: When the computer is connected to the controller, open theDownload program (installed in step 1). You should see the following:

4) Setting Up Connection: Use theOptions Direct Connect AutoSelectedto properly set up theconnection.


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5) Connecting: Click the Connect button as shown below. Press OK when asked to try connecting toa Port.

6) Obtaining Data: After the program is done scanning the Port and connecting, you should see thescreen below. Click on the Pressure Data button and save the data to your desired folder. Next, clickthe Alarm Data button, and save the data to your desired folder. After you complete this step you canterminate the Download program.


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7) Reading the Data: To see the data, open two separate programs: Pressure and Alarm. Open thefiles you saved from the Download program in the respective program (Pressure data in thePressure program, Alarm data in the Alarm program).

8) Visualizing the Data: You will now see the data graphed out side by side. The programs interact witheach other, so when you mouse over a certain point in the Fire Pump Pressure Chart (shown below -right) it is reflected in the Fire Pump Alarm Panel (shown below left).

NOTE:Getting data remotely - To get data from the PR4001N over the dial-up phone lines (with option M), callup the PR4001N over the telephone line using a "Hayes" compatible smart modem. (Set the serial portfor 9600 baud, 8-bit, no parity one stop bit and XON/XOFF on.) Once connected, follow the directionsfrom the custom software package.


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SYSTEM COMMANDS AND ERROR CODES

PR4001 HELP MENU INDEX (H0)Section No. DESCRIPTION

H0 MAIN INDEXH1 CONTROL CODESH2 ERROR CODES

H3 TIME & DATE ENTRYH4 ALARM NAME ENTRYH5 PASSWORD ENTRY (used with modem)

(H1) CONTROL CODES USEDC0 Hardware reset (same as power up reset)C1 Software resetC6 Send alarm data buffer

Add ",MM/DD/YY" for starting dateC7 Send pressure data buffer

Add ",MM/DD/YY" for starting date

C8 Send current pressureC51 Request current alarm status

(H2) ERROR CODES USEDE1 Undefined message headerE2 Undefined message typeE3 Undefined message dataE10 Security breech attemptedE11 Data buffer empty (see C6/C7)E12 Start date not found (see C6/C7)E25 REMOTE "DIGSTK" overflow

E26 REMOTE "DATSTK" overflow

(H3) TIME & DATE ENTRYType "T=" followed by the day numberfollowed by month/date/year hour:min:secin 2-digit numeric form then .Set time in 24-hr format. To check type"T" then .

EXAMPLE: Type "T=07 10/19/96 16:04:00". This enters Sunday, October 19, 1996

at 4:04:00 in the afternoon.


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- 39 -Master Control Systems, Inc._______________________________________________________________Lake Bluff, IllinoisDEC Issue 02-v02 2009.08.3

SYSTEM COMMANDS AND ERROR CODES -- continued

(H4) ALARM NAME ENTRYTo change alarm names, determine the addressfrom the table below and type "M" followed by the4-digit address, followed by "T", followed by 18

ASCII characters or numbers.

Exeample: To change No. 1 to "Pump Running",type "M1012=TPUMP RUNNING ", followed by return>.To read back, type "M1012,18T", .

ALM ADDR ALM ADDR ALM ADDR ALM ADDR1 1012 9 10A2 17 1132 25 11C22 1024 10 10B4 18 1144 26 11D43 1036 11 10C6 19 1156 27 11E64 1048 12 10D8 20 1168 28 11F85 105A 13 10EA 21 117A 29 120A

6 106C 14 10FC 22 118C 30 121C7 107E 15 110E 23 119E 31 122E8 1090 16 1120 24 11B0 32 1240

(H5) PASSWORD ENTRYType "P=" followed by 4 to 16 ASCIIcharacters followed by . To check ,type "P" .EXAMPLE: Type "P=MASTER" to enter thepassword "MASTER".


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-40-Master Control Systems, Inc._____________________________________________________________Lake Bluff, IllinoisDEC Issue 02-v02 2009.08.3

CUSTOMIZING THE RECORDER

The operating system allows the user to read all memory addresses and to write to both volatile and non-volatile memory. This capability allows the user to change many factory defaults. To customize yoursystem, refer to the above help sections H3 thru H5. In addition to these changes, the following systemconstants can be modified.

Constant Location Description (all $values are hexidecimal)Almpts 1400 Number of active alarms (hexadecimal). The default reset does not

change this value.

Clkcal 1403 Calibration value for the real time clock. Maximum value is 5 bitswide with the sixth bit indicating positive or negative calibration. Avalue of $00 indicates no calibration. A value of $01 indicates onecount negative and a value of $21 indicates one count positive. Themaximum positive count is $3F and maximum negative count is $1F.Each count adds or subtracts 0.176 seconds per day. The default resetdoes not change this value.

Daylit 1404 Daylight saving time change flag. Set to 1 for active. When set,automatically changes the time ahead one hour at 2:00 on the firstSunday in April and back one hour at 2:00 on the last Sunday inOctober. The default reset does not change this value. Note that thismay be set from the front panel,

see "Start-up Procedure" item 5.

Ctl 1409 Tells the ACIA what the baud rate of the system will be. The newspeed takes effect upon initialization. $16 equals 300 baud, $18 equals1200 baud, $1A equals 2400 baud and $1E equals 9600. The default

reset value is $1E.

Pagflg 140A When this flag is set to a '01' and a valid phone number is entered, thesystem will automatically place a phone call anytime an alarm inputchanges state. This is used with the DataMaster option supplied byMCS. Contact The factory for more information.

Thresh 140D Defines the threshold in PSI when data is stored into permanentmemory. The default reset value is 5. In this case, when the lastmeasured pressure is either 5 PSI greater or less than the last savedvalue, a new value is saved.

Prdy 1412 Data transmit time delay. Adds a delay to each lineof Alarm/Pressure data that is sent. Factory default resetsetting is $03 (20-30 ms).

Hrck 1426 This is used with the Pagflg above to set the daily phone line test time.Setting this to '24' will disable the daily test.


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CUSTOMIZING THE RECORDER Continued

Constant Location Description (all $values are hexidecimal)Minck 1427 Same as Hrck.

Secck 1428 Same as Hrck.

Nonc 1462-1469 If Swpflg is a 0, then the bits in the 4 odd bytes (even bytes not used)determines if the input contacts alarm on NO (close to alarm) or NC(open to alarm) contacts. A 1 in the appropriate bit indicates NC and a0 indicates NO. The default reset does not change this value.

Swpflg 146A Swaps input data byte end to end (Factory Set). The default reset doesnot change this value.

Rlyset 146B Activates Run, Fail, Trbl and Aux output relays. A 1 indicates that therelay drivers are active and follow the appropriate relay masks. Thedefault reset does not change this value.

Run 146D-1473 Run relay mask. Uses only even addresses. The Alarm byte turns onthe run relay if bits from the Alarm byte match those of the relay mask.For example, if the Run relay mask for address $146A =$01, the Runrelay will operate when bit 0 of Alarm byte 61 is set to a 1. $146Ccorresponds with Alarm byte 62, $146E corresponds with Alarm byte63 and $1470 corresponds with Alarm byte 64. The default reset doesnot change this value.

Fail 1474-147B Failure relay mask. Operates like the Run relay mask.

Trbl 147C-1483 Trouble relay mask. Operates like the Run relay mask.

Aux 1484-148B Auxiliary relay mask. Operates like the Run relay mask.


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SEQUENCE OF OPERATION

General: The PR4001N Paperless Pressure Recorderreads pressure signals from a pressure transducerand stores significant values in non-volatile computer memory for later down-loading to either a lap-topcomputer or to a phone modem. It reads the transducer frequently but only stores data which haschanged significantly from the last stored data. It consists of two main elements. Namely:

1) PR4001N Display Back Box. Door mounted, this unit contains the RS-232 serial port connector,serial port & system monitor LED's, pressure transducer connector, Pressure display, and miscellaneouscable connectors. It also contains a PR-PWR Switch, LED and Power supply board, PR-CPU MainComputer board and the PR-AIF Alarm Interface board.

3) Pressure transducer. This is a solid state strain gage type transducer which is powered by the PR-PWR board.

PR4001N systems having option "P" (power supply for use outside of a Fire Pump Controller) aresupplied in separate enclosures and also contain:

a) Model MBC6M Dual Rate Automatic Mode Switching battery charger.

b) 24 Vdc Battery bank.

c) Optional Alarm Output relay modules, typically for:- Pump Running- Pump Failure- System Trouble -or- Pumproom Trouble

Local Power Supplies: Units installed into controllers derive power from the controller. The systemmay be powered from 12Vdc or 24Vdc power or may be powered from various AC power sources (with

auxiliary stepdown transformer). The PR-PWR board converts the various input power to +5 Vdc logicpo

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