03 03 01

Model MEC 2

MICROPROCESSOR ENGINE/GENERATOR CONTROLLER

Microprocessor-based circuitry provides ultimate reliability and versatility Standard features meet or exceed requirements as defined by NFPA 110 Level 1 and CSA C282 Backlit LCD display screen with alpha-numeric readout for display and programming Digital 3-phase voltage, 3-phase current and frequency metering for generator output 16 alarm/shutdown fault circuits utilizing analog and digital inputs Alarm/shutdown indications are displayed in plain English language Auto mains failure (AMF) functionality Optional expansion output module for individual fault output contacts Password protected programming levels Self diagnostic features continuously verify processing, I/O and memory circuits Superior EMI/RFI noise immunity and surge performance features as per IEEE C62.41 Certified to UL #508 and CSA 22.2 #14 Industrial Control Equipment Standards Quality Assurance System ISO 9001
EAP 110 Remote Annunciator With Data Communication Link

NEW

GENERAL DESCRIPTION
The MEC 2 Microprocessor-based Engine/Generator Controller utilizes the latest advancements in microprocessor technology, printed circuit board assembly techniques and software development. The eighth generation of engine controllers reflects over 25 years of engine controller design experience, including a decade utilizing microprocessors. The result is an automatic engine/generator controller of superior design, providing a comprehensive array of operational, protection and display features. All functions of the MEC 2 are fully configurable from the front panel keypad, and are password protected. The LCD display screen prompts are in plain English, providing a user-friendly operator interface with many display options available. The microprocessor design provides high accuracy for all voltage monitoring, current monitoring and timing functions as well as providing many standard features.
ISO 9001-2000

3815 Oregon Street Oshkosh, WI 54902 1-800-872-7697 Phone (920) 236-4200 Fax (920) 236-4219 www.baldor.com 909 Perkins Drive Mukwonago, WI 53149 Phone (262) 363-1555 Fax (262) 363-1556 www.baldor.com

STANDARD FEATURES
Alpha-Numeric Readout: Display and Programming Digital AC Metering: 3 phase voltage (Phase to Phase and Phase to Neutral), 3 phase current, kVA, frequency Digital Engine Gauge Display: Oil Pressure, Engine Temperature, Hourmeter, Tachometer, DC Voltage 16 Standard Fault Circuits:
SHUTDOWNS Undervoltage Underfrequency High Engine Temperature Low Oil Pressure Overspeed Loss of Speed Signal Overcrank ALARMS Weak Battery Low Battery Voltage High Battery Voltage Battery Charger Input Fail Low Engine Temperature High Engine Temperature Low Oil Pressure Low Fuel Level Switch Not in Auto

Timers: Control Switches: Emergency Stop: LCD Display Menus:

LED Indicators: AMF (Auto Mains Failure): Diagnostic LED Indicators: Audible Alarm Horn: Run & Crank Output Contacts: 4 Programmable Outputs: Provision for Remote Contact Inputs: Expansion Port: Engine Senders:

Engine Start, Cooldown, Oil Bypass, Overcrank, Cycle crank Run/Off/Auto/Load Test, Horn Silence, Lamp Test, Fault Reset Faceplate mounted push-button and provision for remote contact input AC metering, timer countdown functions, alarm/shutdown indication, engine parameters Switch position (run, off, auto, load test), Common alarm, Common shutdown, Ready, Speed signal, Emergency stop, Mode of operation Control outputs and timers to control external transfer mechanism (refer to manual) Watchdog (CPU running), run output energized, crank output energized, remote start signal initiated, common fail output energized Programmable continuous or auto silence feature (10A/240Vac, 8A/24Vdc, Form A) (10A/240Vac, 8A/24Vdc, Form C): User configured function (refer to programming functions available) Emergency stop, Remote reset Provision for addition of Expansion Port Module (Refer to Options) Oil pressure (1/8" NPT), Temperature (1/4" NPT) supplied loose for engine mounting

Standard features meet or exceed requirements as defined by NFPA 110 Level 1 & CSA C282. Requires customer-supplied sensing contact. Generator supply must utilize a solidly grounded neutral system for standard panel connections. High Engine Temperature and Low Oil Pressure shutdowns are factory programmed to utilize both digital contact and analog sender inputs.

OPTIONAL FEATURES
VFD PM EXP Vacuum flourescent display for extended low temperature operation (-40C) Additional Product Manual (One manual is included with each unit shipped)

16 point relay expansion module for individual fault output contacts on MEC 2. Relay contacts are configurable (normally open or closed) and are rated 0.5A 120Vac, 1.0A 30Vdc resistive (maximum) EAP 110 Remote annunciator with data communication link. 20 light annunciator for NFPA 110 (Level 1) & CSA282-00 fault

3815 Oregon Street Oshkosh, WI 54902 1-800-872-7697 Phone (920) 236-4200 Fax (920) 236-4219 www.baldor.com 909 Perkins Drive Mukwonago, WI 53149 Phone (262) 363-1555 Fax (262) 363-1556 www.baldor.com

PROGRAMMING
All of the following items are field programmable using the front panel keypad and LCD display. A password code restricts access. General Programming System voltage (120 - 15000 volts) System Frequency (50/60Hz) System Phases (single or 3 phase) Voltage sensing ratio (1 - 208) Current sensing ratio (1 - 999) Engine Temperature units (deg. F / C) Oil Pressure units ( PSI / KPA) Engine start delay (0 - 999 sec.) Crank time (0 - 99 sec.) Rest time (0 - 99 sec) Starter re-engage cycle time (0 - 99 sec.) Number of crank attempts (0 - 99) Oil Bypass delay (0 - 99 sec) Cooldown time (0 - 99 min.) Number of flywheel teeth (0-999 teeth) Nominal engine speed (0-4000 RPM) Crank disconnect set point (0 - 100%) Overspeed set point (100 - 150%) Run output fail safe activated (yes/no) Loss of speed signal (alarm/shutdown) Common fail output for not in auto (yes/no) Programmable output Display menu time-out (60 - 999 sec) Digital/Analog Fault Input Programming (For Each Circuit) Fault label description (choose from list) Level set point (analog fault) Shutdown or alarm Latched or non-latched alarm Remote reset (yes/no) Always active or after bypass delay Transient delay (0 - 99 sec.) Fault contact open/close to fail (digital fault) Programmable Output Contact Functions Energize to stop Switch not in auto alarm Preheat Ready alarm status Engine run alarm status Air flap Transfer switch load test Oil Bypass Delay Expired Common alarm Common fail Ready to load Analog Calibration Programming Analog zero Analog span

SPECIFICATIONS
Power supply: 10 to 30Vdc, negative ground Power consumption: 5 watts (max.) Operating temperature: -15C to +50C Storage temperature: -20C to +70C Environmental (Faceplate): NEMA 1 Humidity: 5 to 95% non-condensing Vibration: 4g, 5-250Hz Dimensions: 10.75W x 6.75H x 2.0D Engine Gauge Display Accuracy: AC Metering Accuracy: 1.0%, @ 25C Volts, Amps Analog Oil Pressure Measurement: 2.0% @ 25C KVA Range: 15 PSI 150 PSI (maximum) Operating range: 15 59 PSI = 6 PSI Pressure Accuracy: Operating range: 60 75 PSI = 2 PSI Operating range: 76 150 PSI = 7 PSI Analog Engine Temperature Measurement: Range: 0 200C (maximum) Temperature Accuracy: Operating range: 0 30C = 8C Operating range: 30 100C = 2C Operating range: 100 200C = 8C Inputs: Engine speed sensing 100 - 10,000Hz, 3.0 - 20Vac, rms AC Voltage 120 - 600Vac (nominal), 0.1VA, 3 phase, 50/60Hz AC Current 0 - 5Aac (nominal), 1.5VA, 3 phase Dedicated Senders (supplied loose) Engine Parameters Digital Fault Contacts Open or Close to DC Negative Output Contacts: Run, Crank 10A/240Vac, 8A/24Vdc resistive, (3A inductive, 0.4pf) Form A Programmable 10A/240Vac, 8A/24Vdc resistive, (3A inductive, 0.4pf) Form C 3815 Oregon Street Oshkosh, WI 54902 1-800-872-7697 Phone (920) 236-4200 Fax (920) 236-4219 www.baldor.com 909 Perkins Drive Mukwonago, WI 53149 Phone (262) 363-1555 Fax (262) 363-1556 www.baldor.com

Connection Diagram

GRD

12/24 Vdc BATTERY + 10A

B+ B-

VA VB VC CRANK 1 VN IA

1A 1A 1A

VA VB VC N

7 GRD 4 CRANK PILOT RELAY 4 RUN CIRCUIT 4 SPEED SENSING MAGNETIC PICKUP 4 OIL PRESSURE SENDER 4 ENGINE TEMPERATURE SENDER REMOTE EMERGENCY STOP (CLOSE TO INITIATE) REMOTE FAULT RESET (CLOSE TO INITIATE) REMOTE START CONTACT 4 2 DIGITAL FAULT INPUT CONTACTS #1 TO #4
GRD

23 24 18

CR
RUN CIRCUIT

GENERATOR OUTPUT VOLTAGE 120Vac TO 600Vac 3 PHASE OR SINGLE PHASE 3 (DELETE PHASE VC FOR SINGLE PHASE SYSTEMS) GENERATOR OUTPUT CURRENT SENSING TRANSFORMERS 5Aac SECONDARY (DELETE PHASE C FOR SINGLE PHASE SYSTEMS)

(FUEL SOL., GOV.)

19 MP1 MP2 37 38 13 14 15 16 17 1 2 3 4

RUN 1

OA IB OB

MEC 2

IC OC IN GRD

22 1 21 20 34 1 35 36 31 1 32 33 28 1 29 30 PROGRAMMABLE CONTACT # 1 PROGRAMMABLE CONTACT # 2 PROGRAMMABLE CONTACT # 3 PROGRAMMABLE CONTACT # 4

NOTES: 1 2 3 CONTACTS RATED MAXIMUM 10A/240Vac, 8A/24Vdc RESISTIVE LOGIC IS SOFTWARE PROGRAMMABLE FOR OPEN OR CLOSE ON FAIL GENERATOR SUPPLY MUST UTILIZE A SOLIDLY GROUNDED NEUTRAL SYSTEMREFER TO INSTRUCTION MANUAL FOR ALTERNATE CONNECTIONS

4 5

ENGINE MOUNTED COMPONENTS "GRD" CONNECTION TO BE MADE TO COMMON CHASSIS/ENCLOSURE GROUND BOND SYSTEM

NOTE: Specifications subject to change without notice. REV 2 03/03/01

3815 Oregon Street Oshkosh, WI 54902 1-800-872-7697 Phone (920) 236-4200 Fax (920) 236-4219 www.baldor.com 909 Perkins Drive Mukwonago, WI 53149 Phone (262) 363-1555 Fax (262) 363-1556 www.baldor.com

STANDARD FEATURES
Digital AC Metering: 3 phase voltage 4 , 3 phase voltage, 3 phase current, KVA, frequency Digital Engine Gauge Display: Oil pressure, Engine temperature, Battery Voltage, Hourmeter, Tachometer 28 Standard Fault Circuits:
* * * * * * * Shutdowns Overcrank Overspeed Loss of Speed Signal Low Oil Pressure 2 High Engine Temperature Emergency Stop Overvoltage * * * * * * * Alarms Switch Not in Auto Low Fuel Level 2 Low Engine Temperature Low Oil Pressure Pre-Alarm High Engine Temp. Pre-Alarm Undervoltage Overcurrent (definite time) * * * * * * * Low Battery Voltage High Battery Voltage Weak Battery Battery Charger Input Fail Underfrequency Overfrequency Spare fault inputs (qty 8)

Engine Start, Cooldown, Oil Bypass, Overcrank, Cycle crank Run/Off/Auto/Load Test, Horn Silence, Lamp Test, Fault Reset Faceplate mounted push-button and provision for remote contact input AC metering, timer countdown functions, alarm/shutdown indication, engine parameters LED Indicators: Switch position (run, off, auto, load test), Common alarm, Common shutdown, Ready, Speed signal, Emergency stop Diagnostic LED Indicators: Watchdog (CPU running), run output energized, crank output energized, remote start signal initiated, common fail output energized Audible Alarm Horn: Programmable continuous or auto silence feature Run & Crank Output Contacts: (10A/240Vac, 8A/24Vdc, Form A) Common Fail Output Contact: (10A/240Vac, 8A/24Vdc, Form C) 4 Programmable Output Contacts: (10A/240Vac, 8A/24Vdc, Form C): User configured function (refer to programming functions available) Engine Senders: Oil pressure (1/8" NPT), Temperature (1/4" NPT) supplied loose for engine mounting Future Remote Communication Capability: Every standard MEC 20 controller can be field upgraded. Consult factory for additional information. 1 Standard features meet or exceed requirements as defined by NFPA 110 Level 1 & CSA C282. 2 Requires customer-supplied sensing contact. For CSA C282 applications, Battery Charger Input Fail alarm is reconfigurable as Low Coolant Level Shutdown. 3
4

Timers: Control Switches: Emergency Stop: LCD Display Menus:

Generator supply must utilize a solidly grounded neutral system for standard panel connections.

OPTIONAL FEATURES
COM CIM EXP MEC 20 remote communication port (RS422). Can be used in conjunction with external Communication Interface Module (CIM module not included). Communication Interface Module with internal 14.4Kbaud modem, RS232/422/485 ports and Modbus protocol. One CIM module provides communication interface for up to ten MEC 20 controllers with COM per system. 16 point relay expansion module for individual fault output contacts on MEC 20. Specify number of expansion modules required (one module required for standard fault circuits, two modules required for standard and optional fault circuits). Relay contacts are configurable (normally open or closed) and are rated 0.5A 120Vac, 1.0A 30Vdc resistive (maximum) Vacuum flourescent display for extended low temperature operation (-40C) Custom programming of features (provides up to 6 custom fault labels) Additional Product Manual (One manual is included with each unit shipped)

VFD PRG PM

3815 Oregon Street Oshkosh, WI 54902 1-800-872-7697 Phone (920) 236-4200 Fax (920) 236-4219 www.baldor.com 909 Perkins Drive Mukwonago, WI 53149 Phone (262) 363-1555 Fax (262) 363-1556 www.baldor.com

PROGRAMMING
All of the following items are field programmable using the front panel keypad and LCD display. A password code restricts access. General Programming Digital/Analog Fault Input Programming (For Each Circuit) Node Address (1 - 255) Fault label description (choose from list) System voltage (120 - 15000 volts) Level set point (analog fault) System Frequency (50/60Hz) Shutdown or alarm System Phases (single or 3 phase) Latched or non-latched alarm Voltage sensing ratio (1 - 208) Remote reset (yes/no) Current sensing ratio (1 - 999) Always active or after bypass delay Engine Temperature units (deg. F / C) Transient delay (0 - 99 sec.) Oil Pressure units ( PSI / KPA) Fault contact open/close to fail (digital fault) Engine start delay (0 - 999 sec.) Crank time (0 - 99 sec.) Programmable Output Contact Functions Rest time (0 - 99 sec) (select only one function per output used) Starter re-engage cycle time (0 - 99 sec.) Energize to stop Number of crank attempts (0 - 99) Idle control Oil Bypass delay (0 - 99 sec) Pre-lube/post-lube/cycle-lube control Cooldown time (0 - 99 min.) Switch not in auto alarm Number of flywheel teeth (0-999 teeth) Overcurrent Nominal engine speed (0-4000 RPM) Preheat Crank disconnect set point (0 - 100%) Ready alarm status Overspeed set point (100 - 150%) Engine run alarm status Run output fail safe activated (yes/no) Air flap Loss of speed signal (alarm/shutdown) Transfer switch load test Remote Start signal (open or close to run) Oil Bypass Delay Expired Common fail output for not in auto (yes/no) Common alarm Programmable output #1, 2, 3, 4, 5, 61 Common fail Post lube duration (0 - 999 min.) Ready to load Cycle lube interval (1- 9999 min.) Cycle lube duration (0 - 999 min.) Analog Calibration Programming Horn duration (0 = continuous, 1- 999 sec) Analog zero Display menu time-out (60 - 999 sec) Analog span
1

Programmable outputs #5 & #6 are available only with option EXP

SPECIFICATIONS
Power supply: 10 to 30Vdc, negative ground Operating temperature: -15C to +50C Environmental (Faceplate): NEMA 12 Vibration: 4g, 5-250Hz Engine Gauge Display Accuracy: 1.0% @ 25 C (plus sender accuracy 5.0%) Inputs: Engine speed sensing AC Voltage AC Current Engine Parameters Digital Fault Contacts Output Contacts: Run, Crank Programmable, Common Fail Power consumption: 5 watts (max.) Storage temperature: -20C to +70C Humidity: 5 to 95% non-condensing Dimensions: 10.75W x 6.75H x 2.0D AC Metering Accuracy: 1.0%, @ 25C Volts, Amps 2% @ 25C KVA

100 - 10,000Hz, 3.0 - 20Vac, rms 120 - 600Vac (nominal), 0.1VA, 3 phase, 50/60Hz 0 - 5Aac (nominal), 1.5VA, 3 phase Dedicated Senders (supplied loose) Open or Close to DC Negative 10A/240Vac, 8A/24Vdc resistive, (3A inductive, 0.4pf) Form A 10A/240Vac, 8A/24Vdc resistive, (3A inductive, 0.4pf) Form C

3815 Oregon Street Oshkosh, WI 54902 1-800-872-7697 Phone (920) 236-4200 Fax (920) 236-4219 www.baldor.com 909 Perkins Drive Mukwonago, WI 53149 Phone (262) 363-1555 Fax (262) 363-1556 www.baldor.com

Connection Diagram

GRD

12/24 VDC BATTERY +

10A

B+ B-

VA VB VC
CRANK 1

1A 1A 1A

VA VB VC N

7 GRD 6 CRANK PILOT RELAY 6 RUN CIRCUIT 6 SPEED SENSING MAGNETIC PICKUP 6 OIL PRESSURE SENDER 6 ENGINE TEMPERATURE SENDER REMOTE EMERGENCY STOP (CLOSE TO INITIATE) REMOTE FAULT RESET (CLOSE TO INITIATE) 2 REMOTE START CONTACT 6 3 DIGITAL FAULT INPUT CONTACTS #1 TO #12
GRD

23 24 18

CR
RUN CIRCUIT
(FUEL SOL., GOV.)

VN 1A 1B

GENERATOR OUTPUT VOLTAGE 120Vac TO 600Vac 3 PHASE OR SINGLE PHASE 4 (DELETE PHASE VC FOR SINGLE PHASE SYSTEMS) 5 GENERATOR OUTPUT CURRENT SENSING TRANSFORMERS 5Aac SECONDARY (DELETE PHASE C FOR SINGLE PHASE SYSTEMS)

19 MP1 MP2 37 38 13 14 15 16 17 1 2 3 4 5 6 7 8 9 10 11 12

RUN 1

MEC 20

1C 1N 25 GRD

26 27 28

COMMON FAIL CONTACT (OPERATES ON AN ALARM OR SHUTDOWN CONDITION)

29 30 31

PROGRAMMABLE CONTACT #1

32 33 34

PROGRAMMABLE CONTACT #2

35 36 22

PROGRAMMABLE CONTACT #3

21 20

PROGRAMMABLE CONTACT #4

NOTES: 1 CONTACTS RATED MAXIMUM 10A/240Vac, 8A/24Vdc RESISTIVE 2 CONTACT TO CLOSE TO INITIATE STARTING 3 4 LOGIC IS SOFTWARE PROGRAMMABLE FOR OPEN OR CLOSE ON FAIL GENERATOR SUPPLY MUST UTILIZE A SOLIDLY GROUNDED NEUTRAL SYSTEMREFER TO INSTRUCTION MANUAL FOR ALTERNATE CONNECTIONS

5 6 7

NEUTRAL CONNECTION IS REQUIRED FOR SINGLE PHASE SYSTEMS ONLY ENGINE MOUNTED COMPONENTS "GRD" CONNECTION TO BE MADE TO COMMON CHASSIS/ENCLOSURE GROUND BOND SYSTEM

NOTE: Specifications subject to change without notice. REV 4 01/07/15

3815 Oregon Street Oshkosh, WI 54902 1-800-872-7697 Phone (920) 236-4200 Fax (920) 236-4219 www.baldor.com 909 Perkins Drive Mukwonago, WI 53149 Phone (262) 363-1555 Fax (262) 363-1556 www.baldor.com

00 11 01

THS 2000 Software with CIM Module

REMOTE COMMUNICATION SYSTEM MICROPROCESSOR ENGINE/GENERATOR CONTROLLER

Typical Remote Communication System

GENERAL DESCRIPTION
The Remote Communication System provides remote monitoring and control of microprocessor-based controllers as used in the power generation industry. The Communication Interface Module (CIM) is a hardware interface device which allows two way data transfer between microprocessor-based controllers (such as models MEC 20 or TSC 800) and a remote monitoring/controlling system. Utilizing Modbus protocol, the CIM can be integrated with building management systems, programmable logic controllers (PLCs) or used with a stand alone personal computer (PC). For remote monitoring and control applications utilizing a stand alone PC, model THS 2000 Host Software which operates on standard IBM compatible PCs. THS 2000 is a user friendly, Windows-based software program with pre-configured graphic screens showing operational status and analog data of connected controllers.

ADVANCED FEATURES
Automatic callout from a generator site to a remote monitoring PC when a generator system or transfer switch activity occurs, such as a fault or status change. Up to three phone numbers can be programmed using 32 digit numbers to support pager use. Remote communication via telephone system (with modems) or a direct connected serial communication link using RS-232, -422 or -485 transmission types. The THS 2000 program is designed for use with standard Windows 95/Windows 98, Windows NT and Windows 2000 operating systems. One CIM module can control and monitor up to ten controllers at a generator site using a single telephone line or direct connected serial link. Direct connect configuration for applications not requiring Modbus protocol, auto-callout and the need to communicate to multiple controllers. Communication system parameters are configured in software using the THS 2000 program. A three level password protected security system is provided to prevent unauthorized user access to a generator system.
ISO 9001-2000

DEVELOPMENT ASSISTANCE PROVIDED BY THE SCIENCE COUNCIL OF BC

3815 Oregon Street Oshkosh, WI 54902 1-800-872-7697 Phone (920) 236-4200 Fax (920) 236-4219 www.baldor.com 909 Perkins Drive Mukwonago, WI 53149 Phone (262) 363-1555 Fax (262) 363-1556 www.baldor.com

Generator Control Panel

Specications
Type: Solid State Size: Height 12.00 in. 305 mm Width 18.00 in. 508 mm Depth 10.00 in. 305 mm Weight: 30 lbs. (13.5 kg) Power Supply: 12 or 24 VDC Panel Specications: Operates at 50 or 60 Hertz. Removable top cover allows easy access to wiring. NEMA 1 type enclosure, shock mounted. AC meters comply with ANSI C39.1 and IP H2. Engine instruments meet SAE standard specications. Protection circuit breaker protects 12 or 24 volt engine, control wiring and components from overloads. Three AC line fuses for meter protection. Auto-Start Specications: Solid state LED indicators for long life. Plug in auto-start/overspeed for ease of service. CMOS logic and FET output transistors used to provide long life, reliability and no maintenance. LED lights on circuit board indicate engine status, such as cranking, running, auto start ready, etc.

Standard Design Features

Engine Instrument Section Engine Gauges Include: Engine oil pressure Engine coolant temperature Battery voltage Running time meter Engine gauges are 12 or 24 volt DC electric type, 2 1/8 (54 mm), 5% accuracy. Engine gauges indicate both English and Metric units and include international symbols. Includes manual engine start control switch. Includes a minimum of three alarm lights for the following fault conditions: Overspeed Low oil pressure High coolant temperature Generator Control Section AC Meters Include: AC Voltmeter AC Ammeter AC Frequency Meter Meters are 3.5 inch (89) mm, 2% accuracy. Includes ammeter/voltmeter selector switch for monitoring line voltage and current in each phase. Three tape wound current transformers included.

3815 Oregon Street Oshkosh, WI 54902 1-800-872-7697 Phone (920) 236-4200 Fax (920) 236-4219 www.baldor.com 909 Perkins Drive Mukwonago, WI 53149 Phone (262) 363-1555 Fax (262) 363-1556 www.baldor.com

3815 Oregon Street Oshkosh, WI 54902 1-800-872-7697 Phone (920) 236-4200 Fax (920) 236-4219 909 Perkins Drive Mukwonago, WI 53149 Phone (262) 363-1555 Fax (262) 363-1556 World Headquarters Baldor Electric Company P.O. Box 2400 Fort Smith, AR 72902-2400 U.S.A. Phone (479) 646-4711 Fax (479) 648-5792 International Fax (479) 648-5895 www.baldor.com

Baldor Electric Company FM2493CP

Printed in the U.S.A. 5/05 FARR 5000