DE-4000 System Installation Instructions

The input channels contain overvoltage protection that helps prevent damage from inadvertent field mis-wires. They also contain channel to channel isolation to prevent one mis-wired channel from affecting other channels.

For analog sensors that require a +5 volt source, the Terminal Module can supply up to eight +5V sources of current up to 100mA each.

Please refer to figure 8 for Terminal Module Input Sensor wiring diagrams

N/O and N/C DISCRETE INPUTS

The Terminal Board inputs can accept standard normally-open and normally-closed dry contacts. The wetting current for sensor detection is supplied internally by the Terminal Module.

● For a normally-open sensor input, turn on switches 1 & 2 (or turn on switch 2 and place a shunt jumper between INx+ and INx-), connect the wire from the sensor to the INx+ input. The other wire from the N/O sensor is grounded to cause a fault.

● For a normally-closed sensor input, connect one wire from the sensor to INx+, the other on INx-. The sensor is closed for normal operation and opens upon a fault

Each Terminal Module can accept industry-standard type J or K thermocouples on inputs 01–32. Automatic cold junction compensation and linearity correction are built-in. The units can be configured for °F, °C, or °K. Both high and low setpoints are associated with each channel. The system can read type J thermocouples between -76°F and +1382°F (-60°C and +750°C) and type K thermocouples between -76°F and +1472°F (-60°C and +800°C). For both J and K type thermocouples the red insulation color is (-), the other color is the (+).

The pressure transducers, Altronic P/N 691201-x and P/N 691204-x, are packaged in a rugged sealed case with an NPT pressure port, a corrosion resistant media cavity, and a Packard Electric Metri-Pack connector. The ranges available are 0-100, 300, 500, 1000, 2000, and 5000 PSIG for the 691201-x series and 0-50,100, 300, 500 PSIA for the 691204-x series, all of which have an overload rating of 1.5 times full scale without damage. The three wires from the transducer are: +5 volt excitation, +0.5 to 4.5 volt output, and minus return. These three wires connect directly to the Terminal Module using cable assembly P/N 693008-x.

Typical speed signals can come from magnetic pickups or Hall effect pickups monitoring the engine flywheel or other rotating gears. The monitored gear can be of some ratio to the speed of interest (the speed configuration page is used to select a ratio of gear teeth to speed of interest). The frequency range of the speed input is 0 to 100KHz. Nominal input voltage levels are 5 to 24 volts. Each speed input is protected from mis-wires of up to 200 volts max.

The RPMx- terminals are common to DC-. Connect the speed input to the terminals marked RPMx+ and RPMx-. Altronic magnetic pickups or Hall effect pickups are typical sources for RPM measurement.

● MAGNETIC PICKUP — Connect the two wires from the 691118 series or similar magnetic pickup to the Module at terminals RPMx+ and RPMx- using cable assembly 693104 series.

● HALL EFFECT PICKUP — Connect the three wires from the 791050 series Hall effect pickup to the module at terminals RPMx+, RPMx-, and a +5 volt source using cable assembly 593050 series. Connect pickup cable wire B to a +5V supply, wire A to terminal RPMx+ (plus), and wire C to terminal RPMx- (minus). In addition, a 10,000-ohm pull-up resistor must be placed across the +5V supply to GT of the monitor. Refer to the wiring diagrams for hookup details.

Connect terminal AOx+ terminal to the plus (+) input, and the AOx- terminal to the (-) input of the device being controlled.

Each Terminal Module provides eight discrete outputs. DO1 through DO8 are fault protected, ground isolated, solid state switches that turn on from DOx+ to DOx-. Each discrete output is rated at 60V, 2A max. They are solid state smart switches with diagnostics (over current, over temp protection) and can be wired for high- or low-side operation. Dual LED indicators, one for each output, green indicates the output is energized, red indicates a fault condition. If an overload occurs, the red LED will illuminate indicating a fault condition. When the fault condition is removed, the switch will return to its normal operating condition.

Mount the temperature transducer in a thermowell on the engine or machine. The actual sensor is located at the bottom of the transducer body. To ensure accuracy, the tip of the probe should be surrounded by the measured media.

The Controller Module is the hub of the system. Ethernet cables connect the Controller Module to the other modules via standard industrial-type CAT5e Ethernet patch cables. The required Ethernet cable is terminated with a RJ45 connector on each end. Industrial Ethernet Cable assemblies are available from Altronic, reference part numbers 693221-x, “x” represents the length. Ethernet Cable assemblies, terminated both end with RJ45 jacks.
● 693221-1 Ethernet Cable, CAT5 0.3m (12”)
● 693221-2 Ethernet Cable, CAT5 1.0m (39“)
● 693221-3 Ethernet Cable, CAT5 2m (79”)
Available Ethernet ports are as follows:
● 5 – Ethernet ports reserved to connect to up to 5 Terminal Modules
● 1 – Ethernet port reserved to connect to the HMI Display
● 1 – Ethernet port reserved to connect to an outside network

Normally-open sensors most often use the engine ground as the minus return path. For normally-open sensors to operate properly, engine ground, panel ground, and power supply minus MUST be at the same potential as PWR- and GND wires on the Terminal Module.

DO NOT ground this device directly to the ignition system common coil ground.

All unused input channels on the DE-4000 Terminal Module must be shunted to avoid unwanted noise from entering the system.

All unused inputs on the Terminal Module must be shunted with either switch position 1 or have a shunt jumper in place. Each input has a 4-position mechanical switch located on the Terminal Module that must be switched to the proper position for the sensor type being used.

Please note that Commencing with serial number 2300 and above (also identified as 691760 R1), a hardware change was made to the DE-4000 Terminal Module. Switch position 1 on the 4-position channel configuration switch when set to “on” shunts the input. For ease of wiring, switch position 1 can be used in place of a shunt jumper when an input is not used or is set for a normally open or 4-20mA input.

• Unused Input – Switch Position 1 ON, 2, 3, 4 OFF
• Normally Open Input – Switch Position 1 & 2 ON, 3 & 4 OFF
• Normally Closed – Switch Position 2 ON, 1, 3, 4 OFF
• 4-20 mA Input – Switch Position 1 & 3 ON, 2 & 4 OFF
• Thermocouple Input – Switch Position 1, 2, 3, 4 OFF
• Analog, DEG1, 2, & 3 Input – Switch Position 4 ON, 1, 2, 3 OFF

See also input sensor wiring diagram figure 11 below.

● Normally-closed (N/C) sensor switches are wired with one wire to the (INx+) terminal and the other to the (IN-) terminal of the respective sensor number. Note that the shunt jumper must be removed.

Use a wire size between 16 AWG (max.) and 24 AWG (min.) to connect the sensor switches to the terminal strip connector. Strip the insulation back 3/8“; twist the exposed wires tightly together. Insert the exposed wire completely into the terminal strip. For wires that are fine and flexible, crimp on a ferrule. Wires running to sensor switches must be in good condition or replaced with new wires. When running wires, take care not to damage the insulation and take precautions against later damage from vibration, abrasion, or liquids in conduits. An explosion-proof conduit is not required, however, wires should be protected from damage by running them in a protective conduit or in sheaths where appropriate. In addition, it is essential that the following practices be adhered to:

A. Never run sensor wires in the same conduit with ignition wiring or other high energy wiring such as the AC line power.

B. Keep secondary wires to spark plugs and other high voltage wiring at least eight inches (200mm) away from sensor and sensor wiring.

C. Sensor switches may be connected to any passive device using contacts such as standard switch gauges, pressure or level switches.
DO NOT connect sensor leads to any voltage producing element.

D. In the case of a field conversion, where sensors have previously been used with Murphy tattletales, it is recommended that the sensors be checked frequently when the DE System is first put into use. Sensor contacts may be burned or pitted from past exposure to ignition system primary voltage. It is advisable to replace such sensors.

E. If it becomes necessary to check sensor switch to panel wiring with an ohmmeter or other checker, first DISCONNECT the plug-in terminal strips from the Terminal Module. Applying voltage to the DE-4000 System through the sensor leads may damage the device. The area should be tested as non-hazardous before such testing commences.

For each analog monitored point, inputs 01–32 on each Terminal Module, select a transducer, either an Altronic pressure or temperature transducer listed above, or one that outputs a signal in the range of 0 to 5 VDC or 0 to 25 mA. Mount as described above. Use cable assembly 693008-x or similar to wire transducer to the Terminal Module. The Terminal Module provides eight each connector terminals to power the Altronic transducers. Max combined current is 400 mA. See wiring diagrams. If the 5 volt sensor supply exits the panel, it must be fused with a 0.5 ampere fuse. If 24VDC powered sensors are used, the 24 volt supply to them must be fused appropriately. Take care not to damage the insulation when installing and take precautions against later damage from vibration, abrasion, or liquids in conduits. In addition, it is essential that the following practices be adhered to:

A. Never run sensor wires in the same conduit with ignition wiring or other high energy wiring such as AC line power.

B. Keep secondary wires to spark plugs and other high voltage wiring at least eight inches (200mm) away from sensor and sensor wiring.

Grounded or ungrounded type J or K thermocouples may be used. Use thermocouple extension wire of the same type as the thermocouple probe to connect to the terminal module. Use stranded thermocouple wire having a moisture-resistant insulation such as PVC. For higher ambient temperatures, Teflon or B-fiber insulated thermocouple wire is recommended. To ensure that an accurate signal is transmitted to the device, avoid any added junctions, splices and contact with other metals. On unused channels, leave the shunt jumper supplied with the system in place. Take care not to damage the insulation when installing and take precautions against later damage from vibration, abrasion, or liquids in conduits. In addition, it is essential that the following practices be adhered to:

A. Never run sensor wires in the same conduit with ignition wiring or other high energy wiring such as AC line power.

B. Keep secondary wires to spark plugs and other high voltage wiring at least eight inches (200mm) away from sensor and sensor wiring.

Each Terminal Module provides eight discrete outputs, DO1 through DO8. These switches are fault protected, ground isolated, solid-state switches that turn on from DOx+ to DOx-. Each discrete output is rated at 60V, 2A max. These outputs can be wired as high-side or low-side switches. For wiring examples, refer to Figure 10.

Typical speed signals can come from magnetic pickups or Hall effect pickups monitoring the engine flywheel or other rotating gears. Each speed input is protected from mis-wires of up to 200 volts max.

The RPMx- terminals are common to DC-. Connect the speed input to the terminals marked RPMx+ and RPMx-. Altronic magnetic pickups or Hall effect pickups are typical sources for RPM measurement.

● MAGNETIC PICKUP – Connect the two wires from the 691118 series or similar magnetic pickup to the module at terminals RPMx+ and RPMx- using cable assembly 693104 series.

● HALL EFFECT PICKUP – Connect the three wires from the 791050 series Hall effect pickup to the module at terminals RPMx+, RPMx-, and a +5 volt source using cable assembly 593050 series. Connect pickup cable wire B to a +5V supply, wire A to terminal RPMx+ (plus), and wire C to terminal RPMx- (minus). In addition, a 10,000-ohm pull-up resistor must be placed across the +5V supply to GT of the monitor. Refer to the wiring diagrams for hookup details.

● STOP (+) to STOP (terminal 7)
● RESET (+) to RESET (terminal 8)
● START (+) to START (terminal 9)
● STOP (-) to MINUS(-) (terminal 10)

The STOP, RESET, and START inputs on the Controller Module can also be connected to normally-open, momentary panel-mounted dry contact switches. Please note that these inputs are internally pulled high to 3.3VDC and are activated when switched to (-).

DS01 – FUEL SHUTOFF: Typical use of Output 1 on the Controller Module is for fuel shutoff. Output 1 can be used to control a 12-24 volt fuel valve either as energized to run or pulsed to shut off.

DO NOT attempt to control a C.D.-powered fuel valve directly with any of the DSOx output switches. The C.D. ignition system exceeds the max operating voltage of the output switch. An interposing relay and a Murphy Panel Board Adapter must be used when the Fuel Valve is a C.D. ignition-type Murphy Fuel Valve.

DS02 – IGNITION SHUTDOWN: Typical use of Output 2 on the Controller Module is for Ignition Shutdown. Output 2 can be used in conjunction with the low voltage shutdown on most Altronic ignition systems. In addition DSO2 can be used to control the source power to the ignition system using a Power Management Module.

DO NOT attempt to directly ground-out (stop) a C.D. ignition system with output DSO2. The C.D. ignition system shutdown lead exceeds the max operating voltage of output switch DSO2. An interposing relay with high current contacts must be used when grounding the shutdown lead on a C.D. ignition system.

DO NOT connect directly to the ignition system common coil ground.

DS03 – CRANK DISCONNECT: Typical use of Output 3 on the Controller Module is for crank disconnect. When auto start is configured, digital output 3 is used for crank disconnect. If the voltage or current requirement of the crank disconnect solenoid is greater than 52VDC or 1.2 amp, wire DS03 to a pilot duty relay.

DSO4 – PRELUBE/POST LUBE: Typical use of Output 4 on the Controller Module is for prelube/post lube. If the voltage or current requirement of the prelube/post lube solenoid is greater than 52VDC or 1.2 amp, wire DS04 to a pilot duty relay.

There are two RS-485 communication ports available on the Controller Module:

RS485 1 port is used for Modbus slave data

RS485 2 is used for Modbus master data.

The DE-4000 System can communicate to other instruments, PC’s or PLC’s via the two serial RS-485 communication wires. Use a two-conductor shielded cable of fine gauge stranded wire and connect the wires to the terminals marked RS-485A, RS-485B, and shield. Make the following connections to the other communication device A to A(-) and B to B(+). If required, connect the shield wire to the master device only.

The CAN port on the Terminal Module is marked CANH, and CANL.

32-Bit Registers are sent out on Node Address 200

Default 32-bit registers

HAZARDOUS AREA OPERATION

General

Power

WARNINGS

IP54

Inputs

WiFi Antenna

Coaxial cable leaving the system enclosure shall be routed in conduit or be protected by another approved Division 2 wiring method. The antenna itself shall be located in a non-hazardous area, or shall not have exposed bare metal elements.

CONNECTING VIA ETHERNET TO CONFIGURE THE DE-4000

General

 List of Figures

System Diagram and General Hookup

Power Distribution and Hardware Safety Diagram

System Configuration Connection, Controller Module

HMI Display Module, Dimensions and Specifications

Controller Module, Dimensions

Wiring Diagram – Terminal Current Loop Outputs

Wiring Diagram – Terminal, RPM Inputs

NOTE: EITHER RPM INPUT CAN ACCEPT A MAGNETIC OR HALL EFFECT PICKUP.