EMS350

Zendine Private Limited

Engine Controller

EMS28

User Manual

Revision 1.0

The information contained in this manual is copyright,

and is not to be reproduced without the written authority
of Zendine ©2002

EMS28V1. Doc revision V1.5 1 20/10/02

Zendine Private Limited Tel: +65-65840112 Fax: +64-67660579 email: mail@zendine.com

 EMS28 Auto Start Module For Diesel Engines
User Guide

1. Features
• Operates with energise to run or energise to stop fuel solenoids.
• Simple switch closure initiates the starting sequence.
• Manual starting and stopping available from front panel.
• Monitors oil pressure or level and provides shutdown protection.
• Monitors engine temperature and provides shutdown protection.
• Monitors engine speed and provides optional shutdown protection.
• Maintains Engine Running Hours.
• Fully sequenced starting and stopping with retries.
• Displays starting and running sequence on display.
• Run output activates on successful engine start.
• Alarm output in the event of abnormal operation.
• Speed detection directly from Generator, MPU or Alternator output.
• External shutdown for EM stop or pump protection
• Screwles s front mounting

I 0

2. Typical applications include:

• Portable gensets
• Diesel pump sets
• Diesel air compressors
• Agricultural and Industrial machinery

Feature Specification
Overall Dimensions 110 x 100 x 60mm
Mounting Hole 96 x 96 mm
IP rating IP66 front, IP55 rear
Supply Voltage 6 V to 32V DC
Nominal 12V or 24V Automotive
Supply Current Standby 40ma @27.2 Volts, 20ma @13.6 Volts
Running 20ma @27.2 Volts, 20ma @13.6 Volts
Speed Input Sensitivity 1-270 Volts Pk
Input reference 0 volts common

EMS28V1. Doc revision V1.5 2 20/10/02

 Input Frequency Range 10Hz – 5KHz
Speed Sensing Options 50/60Hz AC, MPU, Magneto or alternator
Speed Display Options RPM/Hz
Displayed frequency range 0 – 9999 RPM
0 – 99.9 Hz
Engine Hours 0 – 99999.9 Hours
Oil pressure sensor type Switch close on fault
Resistive 10 to 180 Ohms (VDO/Datcon)
Resistive 0 to 90 Ohms (Pricol/Datcon)
Oil Pressure range 500, 700, 1000 KPa
Engine Temperature sensor type Switch close on fault
Resistive (NTC)
Engine Temperature range 120ºC, 150ºC, 200ºC
Battery Volts measurement 6 to 32 Volts
Alarm output Open drain current limited 300mA
Fuel output Open drain current limited 300mA
Crank output Open drain current limited 300mA
Running output Open drain current limited 300mA
Set-up and Adjustment All features may be adjusted using set-up buttons and LCD
menu.
Terminations Screwless connections on rear.

3. Set-up
The EMS28 is set-up using the buttons on the front panel.
Set-up is initiated by holding down the Item button (the alarm icon) for 10 seconds when the unit is in the
“Ready” mode. When the EMS28 is in the set-up mode, each set-up items can be selected by pressing the
Item button.

When in set-up mode, the start and stop buttons change their functionality as follows:

Start Button “I” Value Down

Stop Button “0” Value Up

Values can be changed using the Value Up and Value Down buttons.
Items displayed are as follows:

Display Item Selections Default Comment

OSEL Oil System 0 : Oil Level Used to select oil level instead of
Select Sensing 1 pressure. If Oil Pressure Sensing is
1 : Oil Pressure selected, then OSEN (below) must
Sensing be set to 0, Close on Fault
OSEN Oil Sensor 0 : Switch: Close See note above
Type on Fault
1 : Sender: 0 – 90 2
Ohm
2 : Sender: 10 –
180 Ohm
OFSD Oil Fu ll Scale 0 :500 KPa 0
1 : 750 KPa
2 : 1000 KPa
OALM Oil Alarm 50 – 300 KPa inc 70 KPa
Setpoint 10

EMS28V1. Doc revision V1.5 3 20/10/02

 TSEN Temperature 0 : Switch: Close
Sensor Type on Fault 1
1 : Sender: 120ºC
2 : Sender: 150ºC
3 : Sender: 180ºC
TSET Temperature 0 – 200ºC inc 1 98ºC
Alarm Setpoint
DREV Display Rev 0 : RPM 0 If Hz is selected then CREV,
1 : Hz UREV, SREV and OREV will no
longer have sensible default values
and will need to be reprogrammed.
CREV Crank 0 – 1000 RPM 300 RPM
Disconnect inc 5
Speed
UREV Under rev 0 to 6000 RPM 0
Alarm Setpoint inc 5
SREV Calibration 500 – 6000 RPM 1500 This is the setpoint used to calibrate
Setpoint Speed inc 5 the engine.
OREV Over rev 0 - 6000 RPM inc 1650
Alarm Setpoint 5
FUEL Fuel Solenoid 0 : Energise to 0
Type run
1 : Energise to
stop
CHGV Charging 10 – 28 Volts inc 13.1
Voltage 0.1 Volts
CTRY Crank Retries 1 - 5 inc 1 3
BOSM Black Out 0 – Seconds 0
Delay Units 1 – Minutes
BOTM Black Out 0 – 240 seconds 3 Prevents unnecessary starts during
delay time inc 1 short power outages. Units can be
seconds or minutes (see previous
item)
CATM Crank Active 5 – 50 seconds 15
Time inc 1
CPTM Crank Pause 5 - 50 seconds 5
Time inc 1
TRTM Trip Time 0 – 120 seconds 0 If trip time is zero, trip input is used
inc 1 as an immediate stop. Otherwise it
is a delayed stop.
RUTM Run Up Time 2 – 60 seconds 5 Only HIREV is monitored at this
inc 1 time. Oil pressure, OREV and
UREV are not monitored
WUTM Warm Up 2 – 60 seconds 5 OIL, OREV and UREV are
Time inc 1 monitored. Run output is off. Run
output is turned on at completion of
Warm up time
ROTM Run On Time 0 – 60 Minutes 1 Minute Prevents premature stopping when
inc 1 mains has not fully restored
CDTM Cool Down 0 – 60 Minutes 1 Minute Run output is off
Time inc 1
SHTM Stop Hold 10 – 180 seconds 10 Limits maximum on time for
Time inc 1 Seconds energise to stop solenoids
SRTM Stop Rest Time 3 – 60 seconds 4 Prevents engine restarting when
inc 1 Seconds RPM and Oil indicate zero but
engine is still rotating.
EXIT Exit Set up 1 – Exit 0
EMS28V1. Doc revision V1.5 4 20/10/02
 When the EMS28 configured to display RPM is first connected to an engine or if the speed sensor on
the engine is changed, the speed input must be calibrated.

If a previously calibrated engine requires recalibration, the DREV setting must be toggled from its
current value to the alternative value and back again to reset the calibration constants. This action
resets the calibration coefficients to zero.

If the EMS28 is set to monitor Hz, then calibration is not required. Note however that the engine speed
signal must be directly derived from the AC alternator. Note also that settings such as CREV, OREV
and UREV must be set correctly.
An uncalibrated engine will not respond to an auto start command.

4. Calibration
To calibrate the engine
Manually start the engine using the start button. If the EMS28 is in an uncalibrated state, the start
button must be held in during the Fuel On and Crank Sequence until the engine fires and runs.
Removing the start signal before this time will terminate the starting sequence. Once the engine fires,
release the start button to disengage the crank solenoid. The display shows “CAL RUN”
Once the engine is running, adjust the engine speed to the speed set point value (SREV) previously
entered.
Press and hold the Item button (Alarm Icon).
After 5 seconds the EMS28 Display shows “CAL MODE” followed by the engine speed set point.
This display remains until the calibration cycle is complete and the unit reverts to the normal running
display.
Release the item button. At this point the engine will be calibrated and will be ready to operate when
restarted.
If the Autostart input is activated when the EMS28 exits from the calibration sequence, the unit will
display an AUTOLOCK alarm. This can be cleared by pressing the manual start button, (whereupon
the unit will perform a normal auto start sequence) or by removing the auto start condition (by
deactivating the auto start switch).
To stop the engine
Stop the engine by pressing the Stop button.

5. Automatic Operation
To start engine using the auto start input

Close the autostart switch. The EMS28 display shows “BLACKOUT” for the blackout delay (BOTM).
The EMS28 displays “FUEL ON”.
The engine cranks for Crank Active Time (CATM) or until engine starts. Display shows
“CRANKING”. If the engine does not start before the crank active time (CATM), the crank is
released. The display shows “RESTING”. The rest time is the crank rest time (CRPT)
When the engine starts, the display shows “RUN UP” for the Run up time (RUTM). Only HIREV and
loss of Tacho is checked during run up.
At the end of run up, the display shows “WARM UP” for the Warm Up time (WUTM). Oil pressure
(OALM), and over rev (OREV) are checked (if selected in the setup routine).
The run output is energised on completion of the Warm up time. The display shows “AUTO RUN”
Retries occur as selected (CTRY) if engine does not start. A fail to start alarm occurs (RUN FAIL)
if the engine does not start.
To stop engine
Open the autostart switch. The EMS28 displays “RUN ON”. The engine runs for Run On Time
(ROTM).
After run on, the engine cools down for cool down time (CDTM). The run output is cleared and display
shows “COOL DOWN”
After cool down, if energise to stop fuel systems is selected, the fuel solenoid is energised for the Stop
Hold Time (SHTM) or until the engine stops.
If the engine does not stop the STOP FAIL alarm is displayed.
When oil pressure decays and tachometer indicates zero speed, after the Stop Rest Time (SRTM), the
EMS28 displays READY.

EMS28V1. Doc revision V1.5 5 20/10/02

6. Manual Operation
To start engine manually
Push the start button (I) briefly. The engine will perform the starting sequence in a similar manner to
the auto sequence above.
When running, the display shows “MAN RUN”
To stop the engine manually
Push the stop button (0) briefly. The engine will perform the stopping sequence as above.

7. Viewing static parameters

View engine static parameters by holding in the stop button (0) for 5 seconds when the controller is in the
ready mode. The controller displays the following parameters in sequence:
Engine RPM
Oil Pressure
Engine Temperature
Battery Volts
Engine Hours
Alarm Status
Autostart Status
If the stop button is released at any value, the display continues to show that value until the start button is
pressed again. The controller displays Ready at the end of the sequence.
Note that the above values are not dynamic but are a simple snapshot of the states when the function is
selected.

8. Trouble shooting
The EMS28 displays the following messages when an alarm occurs. These alarms shut down the engine,
set the alarm output and show the alarm indicator.

Message Cause
LOW OIL Oil pressure has not reached the Oil Alarm set point (OALM) at the end of
the run up time (RUTM) or has dropped below this value when the engine is
running.
HIGHTEMP Engine temperature has exceeded the high temperature set point TALM
UNDERREV Engine speed has dropped below the under rev speed set point (UREV)
OVER REV Engine speed has exceeded over rev speed set point (OREV)
HIGH REV Engine has exceeded saf e operating speed
LOST RPM Engine has lost tacho signals while running
TRIPSTOP The external shut down input has stopped the engine

The following warning messages indicate potential problems.

Message Cause
CHG WARN Battery volts have dropped below the minimum charge voltage when engine
is running (CHGV). This indicates a probable charging fault or broken belt.
This warning restores when the battery voltage climbs above the charge
voltage setpoint (CHGV)
AUTOLOCK The engine has been stopped when running in auto and with the auto start
input still on. This warning also occurs when engine alarms are reset and an
auto start is present. This condition is cleared by removing the autostart
input. Alternatively the start button can be pressed whereupon the engine
will carry out a normal autostart sequence.
TRIPLOCK The trip input is preventing the engine to start. The trip input must be
deactivated followed by pressing the stop button to clear the condition.

EMS28V1. Doc revision V1.5 6 20/10/02

9. Installation diagram

Speed

Alarm

Run
BAT+

Trip

Temp

Autostart
Oil

Fuel
Crank
BAT-

MPU

Speed Sense Options

Charging Alternator/Magneto

2 Amp 230V - 50/60Hz

Bat+ Alarm Fuel Crank Run Speed

Bat- Trip Oil Temp Autostart

Outputs are rated at 300ma DC

Interposing relays are required
between controller and actuator

Engine Block

EMS28V1. Doc revision V1.5 7 20/10/02