Wiring

Update : January 2015

 Summary

1. Overview
2. External links
3. Connectors
4. Maintenance and training

Update : January 2015

 1.Overview
2. External links
3. Connectors
4. Maintenance and training

Update : January 2015

Overview

Update : January 2015

Overview

Update : January 2015

Overview

Update : January 2015

 1. Overview
2.External links
3. Connectors
4. Maintenance and training

Update : January 2015

External links
 Master drawing :

Wiring
Card and
connector

Designation Sheet number

Update : January 2015

External links
 Standard : remote Starting Order

Update : January 2015

External links

 Standard : external ES

Update : January 2015

External links

 Standard : standby

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External links

 Options : Overload fault

Update : January 2015

External links

 Options : ATS

Update : January 2015

External links

 Options : retention tank

Update : January 2015

External links

 Options : Pack 3 relays

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External links

 Options : louvers

Update : January 2015

External links

 Options : water low level

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External links

 Options : oil

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External links

 Options : engine options

Update : January 2015

External links

 Options : fuel

Update : January 2015

 1. Overview
2. External links
3.Connectors
4. Maintenance and training

Update : January 2015

 Connectors
 Non isolated continuous voltage supply:

The voltage supply must be designed to support base card, the engine slave card
and any auxiliary module (4 inputs/6 outputs modules, voltage, synchronizing…)
Input range for DC voltage supply : 9 to 33 Vdc (Battery nominal voltage: 12Vdc or
24Vdc ).
Max. current input 5A dc.
5 modules 4 inputs/6 outputs max. linked to the base with CAN SOCOMEC
In case of battery problem, the voltage applied may be higher.
A protection against over voltage is provided.
Beware of the nominal voltage automatic detection when the battery is delivered at
zero-voltage (graduate voltage rise)
 Battery support :

Battery type: calculator battery like Telys with lithium CR2032

Battery life : 4 years if Telys is not supplied and 8 years almost continuously supplied
Telys (automatic genset).

Update : January 2015

Connectors
 Emergency Stop circuit:

The electrical connexions of the emergency stop circuit must be secured: no

accidental power up must buck the stop through immediate supply cancellation of
the actuators.
 Outputs:

The transistorized outputs are protected against overloads and short-circuits. All
outputs, except the specific ones, will be reconfigurable through P.C.
 Inputs:

All inputs, except the specific ones, will be reconfigurable through P.C.
 J5 Connector (Connection of protection conductor):

The connector is stamped: J5

Connector type: Fast-On 6.3 mm male terminal.
Ref. 0 volt of card.

Update : January 2015

 Connectors
 J1 : genset voltage measurement wiring
Connector type : MOLEX 5 Pts

Voltages coming from alternator. Non isolated inputs

Voltage inputs : 3 phases + neutral + earth
50 / 60Hz Frequencies and transient phases (Genset start/stop)
Inputs dynamic : from 50VAC to 289VAC nominal Ph/N , 500Vac between Ph/Ph.
Phase to neutral voltage measurement (V) and phase to phase voltage measurement (U).
True RMS voltages measurement Ph/N and Ph/Ph voltage AC
Frequency measurement on phase 1
Frequency measurement if V1>8.4VAC (Ph/N Voltage) for over speed information.

Accuracy on voltage measurements :

+/- 0,5% from 150VAC to 289VAC ( + 20% V nominal maxi ) (Neutral Phase)
+/- 1VAC from 50VAC to 150VAC (Neutral Phase)
Frequency accuracy :
+/- 0.1Hz if V1>50VAC
Immunity to harmonics 2,3,5,7… Immunity to deforming load (UPS)

Update : January 2015

 Connectors
 J1 : genset voltage measurement wiring

Pin N° Désignation Electrical characteristics Type

1 Genset voltage Phase 3 500 Vac 1 Amp Max. Input voltage

2 Genset voltage Phase 2 500 Vac 1 Amp Max. Input voltage

3 Genset voltage Phase 1 500 Vac 1 Amp Max. Input voltage

4 Genset Neutral voltage 1 A MAxi Input voltage

5 Ground 1A Input voltage

Update : January 2015

Connectors

 J1M : Genset intensity measurement

Connector type : AMP MATE N LOCK 4 Pts

Inputs of three-phases non isolated current on shunt I1, I2 and I3

50 / 60 Hz frequency and tolerance, the same as Voltages
Neutral current measurement through software calculation . Measurement True
RMS AC
Nominal current : In= 5A . Maximum measured current : 6A
Measurement range : from 100mA to 6A
Current dynamics : Up to 4500A with external CT.
Measurement accuracy of phase currents :
+/- 1% from 0.4 to 1.2 In
+/- 20mA from 0.1 to 0.4 In
Neutral current precision :
+ /- 3% from 0.2 to 1.2 In
Power measurement accuracy : Class 2

Update : January 2015

 Connectors

 J1M : Genset intensity measurement

Pin N° Designation Electrical Characteristics Type

1 Genset current Phase 1 6 Amp Max Current input

2 Genset current Phase 2 6 Amp Max Current input

3 Genset current Phase 3 6 Amp Max Current input

4 Common connexion from the 3 CT’s 6A Max Current input

Update : January 2015

 Connectors
 J3M : Oil Pressure/ Water T°/ Fuel Level
Connector type: AMP MATE N LOCK 3 Pts

Pin 1 Oil pressure (Sensor VDO ou DATCON )

Measurement dynamics : from 10 to 240 OhmsM
Measurement precision : +/- 7 Ohms from 100 to 240 Ohms +/- 4 Ohms fom 10 to
100 Ohms taking the battery minus of the card as reference
Maximum current supplied for detection : between 0 and 15mA
Protected against Magnetic Field interferences and overvoltage

Pin, 2 Water temperature input (sensor VDO or DATCON)

Measurement dynamics : from 22 to 445 Ohms
Measurement accuracy : +/- 10 Ohms from 200 to 445 Ohms +/- 7 Ohms from 100
to 200 Ohms
+/- 4 ohms de 20 à 100 Ohms taking as a reference, the battery minus for the card.
Maximum current supplied for the detection : between 0 and 15mA.
Protected against Magnetic Field interferences and overvoltage

Update : January 2015

 Connectors
 J3M : Oil Pressure/ Water T°/ Fuel Level

Pin 3 Fuel daily tank level input (Jaegger or Rochester sensor or VDO)
Measurement dynamics : from 0 to 350 Ohms
Measurement accuracy : +/- 7 Ohms from 100 to 350 Ohms +/- 4 Ohms from 0 to
100 Ohms , taking as a reference the battery minus for the card.
Maximum curent supplied for detection : between 0 and15mA.
Protected against Magnetic Field interferences and overvoltage

Update : January 2015

 Connectors
 J3M : Oil Pressure/ Water T°/ Fuel Level

Pin N° Désignation Caractéristiques Type

électriques
1 Oil Pressure Indicator 5 Vdc / 15mAmps Max Analog input N°3
See above

2 Water Temperature indicator 5 Vdc / 15mAmps Max Analog input N°4

See above

3 Fuel Level indicator 5 Vdc / 15mAmps Max Analog input N°5

See above

Update : January 2015

 Connectors

 J8 – J9 : Panel Emergency Stop

The connector is stamped AU. It allows to connect the panel emergency stop.
Wiring: Wires welded on card, screwed on the emergency stop.
The wires are stamped (different marks than J10 - J11)

Marks Désignation Caractéristiques Type

J8 Emergency stop input V max: 33V Logical input N°15
300mAmps
Plugged on J18 connector

J9 Emergency stop output V max: 33V Logical input N°15

300mAmps
Plugged on J16 connector

Update : January 2015

 Connectors

 J10 – J11 : ON/OFF Switch

The connector is marked KEY : it allows to connect the front fitted key switch.
Wiring : removable on card or switch side ( if removable on card side, with
4.8 mm fast on).
The wires are stamped (different marks than J8 – J9)

Mark Designation Characteristics

J10 Switch input +Vdc 5 Amps dc MAX *

J11 Switch output 5 Amps dc MAX *

Update : January 2015

 Connectors

 J12 – J13 : Fuse Support

The connector is stamped FUSE.

It allows to connect the front fitted fuse support. Welded wires on fuse support,
connected through 4.8 mm FAST-ON sockets on card.
The wires are stamped (different stamps than J8- J9 and J10 – J11)

Marks Designation Connector type

J12 Fuse support input +Vdc Different of J8-J9 and J10-J11

J13 Fuse support output Different of J8-J9 and J10-J11

Update : January 2015

 Connectors

 J14 : Auto Pack Option

Connector type : AMP MATE N LOCK 5 Pts

The external starting ordered input is activated through a dry contact which can
be located at a maximum 200 m distance.
The external starting order is protected against overvoltage's and misconnection
(230 volts during two minutes at least).
A fault appears on the TELYS screen in case of misconnection.
The card grounding (J5 connector) must be carried out close to the starting
external order input, so that, in case of short-circuit (230Vac on this output), the
current would not cross the whole card.

Update : January 2015

Connectors

 J14 : Auto Pack Option

Pin N° Designation Electrical characteristics Type

1 Battery charger +Vdc 33 Vdc Max 5 Amps Voltage input

Note : connected before the fuse

2 External starting order 0 Vdc Logical input N°1

GND

3 External starting order 5 Vdc Logical input N°1

4 Battery charger 0Vdc 0 Vdc Voltage input

5 Pre-heating control I max: 300mAmps under Vmin = Logical output N°1

Vbattery – 2V (same as TELYS)

Update : January 2015

 Connectors
 J15: Remote Pack Option Pin Designation Electrical Type
N° characteristics

Connector type : 1 Not used NC

AMP MATE N LOCK 9 Pts

2 Genset ready to load I max: 300mAmps Logical output N°2
under Vmin = Vbattery
– 2V Same as Nexys

3 General fault I max: 300mAmps Logical output N°3

under Vmin = Vbattery
– 2V same as Nexys

4 Alarrm/Fault Low fuel level I max: 300mAmps Logical output N°4

under Vmin = Vbattery
– 2V same as Nexys

5 0Vdc Logical output

6 0Vdc Logical output

7 9 to 33Vdc (after fuse and 5A Logical output

key switch)
8 9 to 33Vdc (after fuse and 5A Logical output
key switch)
9 Insulation monitoring device Logical input N°2
or differential relay

Update : January 2015

 Connectors

 J16 WIRING: External Emergency Stop

Connector type : AMP MATE N LOCK 2 Pts

Pin N° Designation Electrical characteristics Type

1 External emergency V max: 33V Logical input

stop 300 mAmps connected on J8 N°16

2 External emergency V max: 33V Logical input

stop 300 mAmps connected to the transitor N°16

Update : January 2015

 Connectors
J17 : Engine Parameters
Full range cards only

Connector type : AMP MATE N LOCK 12 Pts.

Characteristics of the charge alternator excitation output :

Resistance automatic order for the charge alternator excitation, according to
the genset battery voltage (12 or 24 V).
Input of the charge alternator information on microprocessor level; input use to
switch of the starter in hard way, as soon as the charge alternator voltage rises.
In case of fault, an information is displayed on the TELYS.
The output voltage value is measured in a hard way, in order to switch of the
starter as soon as the voltage exceeds a certain level (6V +/-30 %).
An information is also sent to the microprocessor, in order to know the charge
alternator statement.
It’s possible to monitor the starter (pin 11), even if this output is not grounded
or if a problem occurs on the charge alternator (input in the air, not connected).

Update : January 2015

 Connectors
Pin N° Designation Electrical characteristics Type
J17 :
1 Water Pre-heating Thermostat Micro input Logical input N°8

2 Battery voltage +33Vdc MAX 5 Amps Voltage input

3 Battery voltage 0Vdc 5 Amps Voltage input

4 Oil pressure fault Logical input N°9

5 Water temperature fault Logical input N°10

6 Low water level fault or Logical input N°11

overload/short circuit (NEXYS)

7 Charge alternator excitation 33 Vdc Max 300 mAmps Voltage input/output

8 Water pre-heating thermostat Logical input N°8

9 Alarm/Fault low fuel level Logical input N°12

10 Solenoid valve control 33 Vdc Max 300 mAmps Logical output N°8

11 Starter control 33 Vdc Max 300 mAmps Logical output N°9

12 Air pre-heating control 33 Vdc Max 300 mAmps Logical output N°10

Update : January 2015

Connectors

 J18 WIRING : Vdc Supply – Engine Stop Output

Connector type : AMP MATE N LOCK 6 Pts

Pin N° Designation Electrical characteristics Type

1 Stop engine V max: 33V Logical output N°11

300 mAmps connected on J8

2 Stop engine V max: 33V Logical output N°11

NC 27 Amps during 200sec 10 Amps NC
continuous

3 NC NC NC

4 NC NC NC

5 9 à 33Vdc V max: 33Vdc Voltage input

(before fuse and 5 Amps
key switch)

6 0v ground Connection to 0V battery Voltage input

Update : January 2015

 Connectors
 J20 : Configurable Inputs
Connector type : AMP 4.2mm PE serial connector system 4 Pts
2 logical inputs on 2 wires.
Input as dry contact ; one terminal of each input is connected to the card, the
second terminal is connected to the genset framework (- battery).

Pin N° Designation Electrical characteristics Type

1 Configurable input 1 ( + ) ( + ) Non Isolated Logical input N°3

2 Configurable input 11 ( - ) ( - ) Non Isolated Logical input N°3

3 Configurable input 21 ( + ) ( + ) Non Isolated Logical input N°4

4 Configurable input 21 ( - ) ( - ) Non Isolated Logical input N°4

Update : January 2015

 Connectors

 J21 : Configurable Output

Connector type : Fast-on 4.8mm located opposite to J27

Pin N° Designation Rlectrical characteristics Type

1 Configurable output 1 (+ ) I max 300 mAmps under Logical output N°5

Vmin = Vbattery – 2V

Update : January 2015

 Connectors
 Plug J22 : MX COIL Output

Connector type : AMP Mini Universal MATE N LOCK 2 Pts

Relay location on the voltage/speed adjustment card.

Pin N° Designation Electrical characteristics Type

1 MX coil 9ADC Vmax :250Vac Logical output N°6

2 MX coil 9ADC Vmax :250Vac Logical output N°6

Update : January 2015

 Connectors

 J23 WIRING : Engine Options

Connector type : AMP MATE N LOCK 2x3 Pts

Electrical characteristics pin 1 :

Analog input D.T. fuel level Jaegger / Rochester / VDO sensor: input on single
wire.
Dynamic measurement : from 0 to 350 Ohms .
Measurment accuracy : +/- 7 Ohms from 100 to 350 Ohms, +/- 4 Ohms de 0 à
100
taking (-) battery of the card as reference
Maximum current supplied for detection: between 0 and 15 mAmps.
Protected against magnetic field interference (CEM) and overvoltage.

Electrical characteristics pins 3 and 4 :

Analog input battery ammeter . Reaction time : 500 ms max.
Accuracy : 2% min . Acceptable overload : 20% min.

Update : January 2015

 Connectors

 J23 WIRING : Engine Options

Pin N° Designation Electrical characteristics Type

1 Fuel level indication See here under Analog input N°1

2 Low fuel level anomaly Logical input N°5

3 Battery ammeter indication 0/100mV + charge alternator Logical input N°2

4 Battery ammeter indication 0/100mV + Battery Logical input N°2

5 Water pre-heating thermostat + Analog input N°6

6 Water pre-heating thermostat 0V dc Logical input N°6

Update : January 2015

 Connectors

 J24 : Overload/Short-circuit Input

Connector type : AMP 4.2mm PE serial connector system 2 Pts

Pin N° Designation Electrical Type

characteristics
1 Overload/Short-circuit + Logical input N°7

2 Overload/Short-circuit 0Vdc Logical input N°7

Update : January 2015

 Connectors

 J25 : Oil Temperature Indication & Fault

Connector type : AMP Mini Universal MATE N LOCK 3 Pts

Electrical characteristics Pin 1 (Same as Telys oil T° sensor )

Measurement dynamics : from 22 to 565 Ohms
Measurement accuracy : +/- 10 Ohms from 200 to 565 Ohms,
+/- 7 Ohms from 100 to 200 Ohms, +/- 4 ohms from 20 to 100 Ohms
Taking as reference (-) battery of base module.
Maximum current supplied for detection : between 0 and 15 mAmps.
Protected against magnetic field interferences (CEM) and overvoltage.

Pin N° Designation Electrical characteristics Type

1 Oil temperature indication See here under Analog input N°6

2 Oil temperature defect Logical input N°13

3 NC NC

Update : January 2015

 Connectors
 J26 :Engine Can Bus
5 4 3 2 1

Connector type : Sub D 9 female 9 8 7 6

Filtered and protected against magnetic fields overvoltage (CEM).

Port according to CAN J1939 and CAN Open
End line resistance 120 ohms integrated on the base card.

Pin N° Designation Electrical characteristics

1 CANH 5Vdc
2 NC
3 NC
4 NC
5 NC + Alim NC V A to be settled / 1A
6 CANL 5 Vdc
7 NC
8 NC
9 Ground 0V / 1A

Update : January 2015

 Connectors
 J27: Tank Leakage

Connector type : 4.8 mm Fast-on terminal located opposite to J21

Pin N° Designation Electrical characteristics Type

1 Tank leakage Logical input N°15

Update : January 2015

 Connectors

 J28 : USB Host Port

Non isolated input.

Connector type : USB female standard Host.

Standard Port according to PC USB effective standards.

USB Standard compatible V1 and V2.

Update : January 2015

 Connectors
 J29 : Socomec Can Bus for Logical I/O card option

Connector type : RJ45 8 wires.

Can connection on 2 wires + Supply.

Non isolated input.
Filtered and protected against magnetic field overvoltage (CEM)
RJ45 standard cables use (5E Class straight cable)
Maximum lenght : 200 meters (INS)

Update : January 2015

 Connectors

 J30 : Ethernet Port

Connector : RJ45 8 wires

Non isolated input.

Filtered and protected against magnetic field overvoltage (CEM).
RJ45 standard cable use (5E Class straight cable)
The connector is stamped as on the PC: J30
A connection mistake between the Socomec CAN port and the Ethernet port
does’nt damage any equipement (Telys side and network side).
This Port allows a connection to the integrated software or an access to the
Modbus table.
TCP IP Modbus frame format will be integrated.

Update : January 2015

 Connectors
 J31 : RS 485 Port
Connector : Pluggable screw terminal.

Non isolated input.

The loop has to be closed at each end.
Filtered and protected against magnetic field overvoltage (CEM).
Configuration switch of the end line resistance (120 ohms) located close to the
base card, stamped R31.
Max. speed communication of this port is 38400 bauds.
Port in accordance with the RS485 standards.
This communication port will accept the MTU Modbus.
Pin N° Designation Electrical characteristics Mark on the male Sub D9 485/232
connector
1 L0 0 Vdc 0 Vdc 5

2 L1 5 Vdc A+ 7

3 L2 5 Vdc B- 2

Update : January 2015

 Connectors
 J33 B: HZ/U Adjustment Card connection

• 1 + 35v
• 2 - ground
• 3
• 4
• 5 Ana. output 10V1
• 6 Ana output 10V2
• 7 Log. output 6
• 8 +3V3
• 9 +5V3
• 10 - ground

Update : January 2015

 Connectors
J34 : Speed Adjustment

Pin 1: Shielded connection.

Pin 2: Reference of genset speed control output Input +/-10Vdc, 10 KOhms
impedance. Not connected for internal reference. Used when some speed regulators
supply a reference voltage.
Pin 3: Engine speed control isolated output (setting) +/-10Vdc impedance 50
Ohms, min. resolution 2mV/bit.
It will be possibleto adjust the gain with the Digital/Analog converter output.
Minimum input impedance of the speed regulators: 1 Kohm.

Pin Designation Electrical characteristics Mark Capacity Type

N°
1 Ground GND 1.5mm²
Speed adjustment Analog output
2 Input reference 212 1.5mm²
output SAH1
3 Speed adjustment output 213 1.5mm²

Update : January 2015

 Connectors

J35 : Voltage Ajustement

Pin 2-3 : Genset voltage control isolated output (instruction),

+/-3Vdc impedance 50 Ohms, resolution minimum 2mV/bit
It will be possible to adjust the gain at the Digital/Analog converter output.
Min. input impédance of the voltage regulator 1kOhm.

Pin Designation Electrical characteristics Mark Capacity Type

N°
1 Ground GND 1.5mm²
2 Voltage adjustment Voltage adjustment output + 214 1.5mm² Analog output
3 output Voltage adjustment output - 215 1.5mm² SAH2

4 NC

Update : January 2015

 1. Overview
2. External links
3. Connectors
4.Maintenance and
training

Update : January 2015

 Maintenance and training

 Case :

Update : January 2015

 Maintenance and training

 Case :

Update : January 2015

 Maintenance and training

 Tools :

Update : January 2015

 Maintenance and training

 Tools :

Update : January 2015

 Maintenance and training

 Tools :

Update : January 2015

 Maintenance and training

 Tools :

Update : January 2015

 Thank you for your attention !

Update : January 2015