Manual of the central unit of the

engine ATS-25

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Introduction
ATS 25 is a monitoring and control tool for Mechanical Diesel Perkins, JCB and Kohler engines. It has
an LCD graphic display of 128x64 pixel with amber backlit, used to display the engine revolutions
(RPM) and the value of the engine counter. It also has 6 light indicators for quick review of the state
of the main parameters of the engine.

The parameters monitored by the tool for the alarms reporting are as follows:

 Engine oil pressure

 Voltage of the charging alternator (D+)
 Engine water temperature
 Fuel air filter
 Battery voltage
 Engine revolutions (W)

This tool allows you monitoring the Power Pack engine by the appropriate 10-pole connector on the
engine frame and on the control unit bottom. On the control panel, there is a engine ignition key
and a buzzer for alarm reporting.

Inside the Power Pack, there is a plastic box where there are engine control relays and protection
fuses. Each fuse has an associated LED that lights up when the fuse is blown.

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 1. Technical Specifications

GENERAL DATA
External dimensions See mechanical dimensions
Weight ≈ 1530 g
Electronic protection degree IP66
Protection degree of the terminal boards IP66
Working temperature -10 – 60 °C
Power supply 12 – 24 Vdc
Fixed consumption ≈ 122 mA + pre-excitation of the alternator
Display 128x64 graphic LCD with amber backlight
Buzzer 90 dB at 30 cm
Keys for the interface with the device 2
DIGITAL INPUTS
Inputs no. 3
Input type Negative
ALTERNATOR INPUT/OUTPUT
Alternator (D+) Direct voltage measurement (0-35 Vdc)
+ pre-excitation at 150 mA
Engine revolutions (W) Measurement of the pulses generated by the
alternator
10Hz – 4kHz
OUTPUTS OF RELAYS
Outputs no. 3
Outputs type Relay output
Contacts rate 2 A for the external relays control
RELAYS BOX
Outputs no. 3
Outputs type Relay output
Capacity of the relay contacts Plugs 70 A
Capacity of the relay contacts Starter motor 40 A
Capacity of the relay contacts of the solenoid 30 A
valve

Release Manual 1.2

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2. Pinout
2.1. Pinout of the 10-pole connector for the connection of the control unit and
the engine 10-pole connector

A. Battery positive locked (15) returning on the system

B. Starter motor (50)
C. Contact of the air filter sensor (-)
D. Plugs control
E. Alternator W out for engine revolutions
F. Contact of the oil pressure sensor (-)
G. Contact of the engine temperature sensor (-)
H. Alternator D+ out (connect to a pre-excitation resistor of 50Ohm)
I. Battery positive (30)
J. Battery negative

2.2 Pinout of the 24-pole connector of the square tool ATS-25

24-pole connector
1A. Output PNP 1
1B. Output PNP 2
1C. Output PNP 3
2A. Digital inputs 8
2B. Digital inputs 7
2C. Clean contact NC
3A. Digital inputs 6
3B. Digital inputs 5
3C. Clean contact NO
4A. Digital inputs 4
4B. Analog input 3
4C. Common clean contact
5A. Digital input 3
5B. Digital input 2
5C. CANBUS (H)

6A, Input of the battery charger alternator (D+) 8A. Positive

6B. Digital input 1 8B. Negative
6C. CANBUS (L) 8C. Negative
7A. Analog input 2
7B. Analog input 1
7C. Revolutions input (W)

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2.3 Pinout of the 24-pole connector of the relays box

24-pole connector

1A. Battery positive on fuse F3

1B. Battery negative
1C. Battery negative
2A. Battery positive on fuse F3
2B. Battery negative
2C. Alternator W
3A. Alternator D+
3B. Battery negative
3C. Temperature sensor of the engine water
4A. Alternator D+
4B. Battery negative
4C. Air filter sensor
5A. Positive locked
5B. Battery negative
5C. Oil pressure sensor
6A. Positive locked
6B. Battery negative
6C. Battery negative
7A. Positive locked
7B. Positive locked
7C. Positive locked
8A. Cable for emergency mushroom switch
8B. Cable for emergency mushroom switch
8C. Output for fuel pump or release
electromagnet

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3. Connection Diagrams
3.1 Connection diagram of the control unit

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3.2 Connection diagram of the 1144PTA Perkins engine

X1: Female 24-pole connector FCI

X2: Deutsch connector for oil sensor
X4: Insulated terminals for external plug
X5-1: Ferrules with emergency mushroom switch
X5-2: TE Connect connector for the fuel pump
X8: Deutsch connector for temperature sensor
X13: Female fastom for air filter sensor
X10: Eyelet dia. 8mm for Alternator D+
X7: Eyelet dia. 8mm for Alternator W
X9: Female fastom for battery positive
X15: Deutsch connector for magnetic release

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3.3 Connection diagram of the 441P3, 415P4 422P 422PT Perkins engine

X1: Female 24-pole connector FCI

X2: Deutsch connector for oil sensor
X4: Insulated terminals for external plug
X5-1: Ferrules with emergency mushroom switch
X5-2: TE Connect connector for the fuel pump
X8: Deutsch connector for temperature sensor
X13: Female fastom for air filter sensor
X10: Eyelet dia. 8mm for Alternator D+
X7: Eyelet dia. 8mm for Alternator W
X16: Faston with T-shaped insulator for Dynamo

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4. Mechanical dimensions
4.1 Mechanical dimensions of the ATS-25 tool

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4.2 Mechanical dimensions of the entire box

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4.3 Mechanical dimensions of the relays box

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5. Functional description

LCD L3

L2 L4

L1 L5

P1 P2

L6

5.1 GENERAL INFORMATION ON THE EQUIPMENT

ITEM TYPE DESCRIPTION
LCD LDC 128X46 Graphic display with amber backlight for the display
of data on the device
P1 KEY 1 Increase key, ESC key when held down
P2 KEY 2 Decrease key, ESC key when held down
L1 OIL LED Low oil pressure (digital input)
L2 BATTERY LED Low alternator voltage
L3 TEMPERATURE LED High water temperature (digital input)
L4 AIR FILTER LED Air filter clogged (digital input)
L5 ALARM LED Alarm ON
L6 PLUGS LED Plugs enabled

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5.2 HOMEPLAGE

Figure 1: homepage of ATS-25

ATS-25 is a tool allowing you to display the engine parameters. Once powered, the tool displays the
initial logo for a few seconds. Then it's displayed the main screen as shown in Figure 1.

The parameters displayed are as follows:

- Engine revolutions (RPM) is displayed both numerically and in graphic mode

- Hour meter: it is shown in the top right next to the hourglass symbol and indicates the
operating hours of the engine.

If in the advanced menu you set the  “Engine setup” sheet  “Startup thresholds” menu  “6-RPM
ENABLED” parameters to OFF, the parameters displayed are as follows:

- Hour meter: it is shown in the centre next to the hourglass symbol and indicates the
operating hours of the engine (Figure 2).

Figure 2: homepage of ATS-25 version without RPM

ATS-25 detects when the engine is running to identify the alarms ocurring when the engine is ON
and to update the engine hours counter.
The detection parameters of the running engine are as follows:
- Engine rpm above the threshold set
- Alternator voltage above the threshold set
- Pressure gauge of the engine oil open for mechanical engines with digital sensors

The presence of only one of these parameters above the thresholds set identifies that the engine is
running.
ATS-25 monitors several parameters to detect any anomalies in the engine and turn it off if necessary
not to damage the engine itself.

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The parameters controlled are as follows:

- High temperature of the engine water

- Low pressure of the engine oil
- Low voltage of the alternator of the battery charger
- High engine rpm
- High battery voltage
- Low battery voltage
- Air filter clogged
To properly set the tool, there is a programming menu that is structured in several pages.

5.3 PROGRAMMING MENU

5.3.1 BASIC MENU

To access the menu, you have to press P1 and P2 for 5 seconds at the same time. The tool will display
three figures showing"000".

Pressing P1, you access the basic menu where you can change some options of the tool, but you
cannot change the machine setup. The display is shown as in Figure 3.

Figure 3: page of the basic menu of ATS-25

To confirm the menu page, hold down P2 for 5 seconds. Then, you can select the first icon. Pressing
P2, you move in the menu by selecting one by one the various icons of the parameters, while
pressing P1 you recede in the menu by selecting them in the opposite direction.

After selecting the desired parameter to enter the edit page, hold down P2 for 5 seconds.

This menu allows you setting the following options:

Display contrast: accessing this parameter, you can choose a number that identifies the
contrast of the LCD, which is useful to increase the contrast in the case that the display
proves very clear in the event of low temperatures at which the tool is subjected.

Lighting time of the display: accessing this parameter, you select the seconds of the
switching time of the backlight of the display from when you no longer hold down the keys.
If selected to 0, the backlight turns off.

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 Exit time from the main menu: accessing this parameter, you select the minutes of exit
from the menu to display the homepage since you no longer hold down the keys. If selected
to 0, this function is disabled.

Language: accessing this parameter, you select the language for the non-symbolic menu
items of the advanced menu. The selectable languages are Italian, English and French.

Alarm history: accessing this parameter, it's displayed a list of the last 10 alarms detected
with the relevant indication of the work hours. You can scroll through the list with the P1
and P2 keys. If held down for 5 seconds, P2 resets them but only if you enter through the advanced
menu.

Information and assistance: accessing this page, the information of the Technical Assistance
Center will be displayed. It's also shown the software version programmed.

On every page you can change the parameter with the P1 and P2 keys. You can confirm the change
of the parameter by holding down P2 for 5 seconds, while it is possible to return without saving the
change by holding down P1 for 5 seconds.

To return to the homepage, hold down P1 and P2 for 5 seconds from anywhere on the menu.

5.3.2 ADVANCED MENU

To access the menu, you have to press P1 and P2 for 5 seconds at the same time. The tool will display
three figures showing"000".
Pressing P2, you increase the number shown. Then pressing P1, you can move the position of the
selection of the highlighted digit. By entering the code "135", you access the advanced menu where
you can change all the parameters of the tool. The display appears as in Figure 4.

Figure 4: page allowing you to manage the general setup in the advanced
menu of ATS-25
To scroll through the three sheets, hold down P1 and P2. Confirm the menu page and hold down P2
for 5 seconds. Then, you can select the first icon. Pressing P2, you move in the menu by selecting
one by one the various icons of the parameters, while pressing P1 you recede in the menu by
selecting them in the opposite direction. To return to the selection of the sheets, hold down P1 for
5 seconds. As with the basic menu, after selecting the desired parameter to enter the edit page, hold
down P2 for 5 seconds.

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The menu structure is shown in Figure 5

Main page

General Engine Adjustment

setup setup setup

Figure 5: Structure of the advance menu of ATS-25

GENERAL SETUP
The general setup is described in Section 5.3.1. of the basic menu, with the only exception of the
"alarm history" parameter. selecting the parameter, you can erase all the history holding down P2
for 5 seconds.

ENGINE SETUP

Figure 6: page allowing you to setup the engine in the advanced menu of
ATS-25
Startup thresholds: accessing this menu, it's display the list showing all the startup
parameters:
 1-LIM-HIGH RPM: Value expressed in RPM above which it's reported the high
revolutions alarm.
 2-OIL THRESHOLD: Values in bars above which the engine oil pressure shows that
the engine is running (not used to control the mechanical engines)
 3-THRESHOLD D+ ON: Value expressed in Volts above which the battery charge
voltage shows that the engine is running.
 4-RPM THRESHOLD: Value expressed in RPM above which the engine revolutions

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 shows that the engine is running.
 5-PREH. TIME: Value expressed in seconds of the pre-heating time of the engine
with plugs.
 6-RPM ENABLED: Value for RPM enabling on the homepage. If set to OFF on the
homepage, it's displayed only the engine hours meter.

Battery alarm: accessing this menu, it's displayed the list showing the various
parameters of the battery:
 1-ALARM D+: Value expressed in Volts above which the charge voltage indicates
the presence of a fault alarms of the battery charger alternator
 2-L-Vdc-BAT: Value expressed in Volts above which the battery voltage reports the
alarm.
 3-H-Vdc-BAT: Value expressed in Volts above which the battery voltage reports the
alarm.

Value of the Service maintenance: Accessing this menu, you can set the decremental
hours counter for the next service; to report the alarm upon timeout, you need to turn
on the alarm.

Threshold of the engine oil pressure: accessing this menu, you can set the alarm
threshold for the engine oil pressure (not used for the control of the mechanical
engines).

Threshold of the engine temperature: accessing this menu, you can set the alarm
threshold for the engine water temperature (not used for the control of the mechanical
engines).

Menu to set the alarms: accessing this menu, it's displayed the list of the alarms that
can be enabled from the control unit. The table below summarized the different alarms
present.

IDENTIFICATION NUMBER ALARM DESCRIPTION

1 Alarm related to the low Digital pressure gauge enabled for mechanical
pressure of the engine engines with digital sensor. It shows the low oil
oil pressure. Check that the oil level is correct.
2 Alarm related to the Digital thermostat enabled for mechanical engines
high temperature of the with digital sensor. It shows the high temperature of
cooling water of the the engine. Check the level of the coolant.
engine
3 Alarm related to the low Voltage of the battery under the thresold set. The
voltage of the battery battery voltage is low so you need to charge the
battery or replace it when necessary.

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 IDENTIFICATION NUMBER ALARM DESCRIPTION
4 Alarm related to the Battery voltage above the threshold set. Check that
high voltage of the the battery and the electric systems are ol.
battery
5 Alarm related to the low Voltage of the alternator of the battery charges
voltage of the alternator under the threshold set. It may be a problem with
of the battery charger the alternator belt, the alternator or the battery.
6 Alarm related to the Value of the engine revolutions above the threshold
high revolutions of the set. The engine accelerate more than the maximum
engine value allowed. You must adjust the limit switch of
the accelerator.
7 Air filter alarm Air filter clogged. Clean the air filter or replace it
before starting the engine.
8 Alarm related to the The value of the maintenance counter was zeroed;
maintenance time reporting on the expiration of the routine
maintenance on the engine. Carry out
maintenance.

P1 and P2 keys allow you scrolling between the list of alarms; once highlighted the alarm desired,
you can access its settings by pressing and holding down P2 for 5 seconds. For each alarm, you can
set it through the following parameters:
 ACTIVATION: parameter to enable the alarm. OFF to disable the alarm, ON to activate the
alarm when you turn the control unit and RUN to activate the alarm only when the engine is
running.
 RETENTIVE: Parameter related to the permanence of the alarm on the display. OFF to make
sure that, upon the restoration of the alarm condition, the alarm reporting disappears from
the display and ON in order to ensure that the alarm reporting remains even if the condition
has been restored.
 STOP: Parameter to stop the engine if the alarm is ON. ON to stop the engine, OFF only for
signaling without stopping the engine. For the mechanical engines, the automatic switching
offf is not allowed.
 DELAY: Parameter in seconds to enter an alarm activation delay given the event report of the
sensor.
 REPORTING: Parameter enabling the reporting of the alarm on the display; ON to show the
alarm on the display, OFF to hide it. With this parameter, the engine stop and the recording
of the event list work equally.
Below is a summary table of the various parameters for each alarm in its default configuration.

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ENGINE ACTIVATION RETENTIVE DELAY STOP REPORTING
Alarm related to the low
pressure of the engine
oil RUN YES 0 NO YES
Alarm related to the high
temperature of the
cooling water of the
engine ON YES 0 NO YES
Alarm related to the low
voltage of the battery ON NO 10 NO YES
Alarm related to the high
voltage of the battery ON YES 10 NO YES
Alarm related to the low
voltage of the alternator
of the battery charger RUN YES 10 NO YES
Alarm related to the high
revolutions of the engine RUN YES 5 NO YES
Air filter alarm RUN YES 5 NO YES
Alarm related to the
maintenance time OFF NO 0 NO YES

P1 and P2 keys allow you selecting the parameter to be changed. Holding down P2 for 5 seconds,
you access the parameter change phase. You can confirm by by holding down P2 for 5 seconds or
you can exit without changing the parameter by pressing P1 for 5 seconds. You can exist from the
alarm menu by holding down P1 for 5 seconds.

ADJUSTMENT SETUP

Figure 6: page allowing you to setup the adjustment in the advanced menuof
ATS-25
Adjusting the engine revolutions: accessing this menu, you access the parameter for
the adjustment of the engine revolutions. Start the engine and enter the RPM value on

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the display. Then, press PS for 5 seconds to confirm the adjustment. Section 6 described in detail the
procedure allowing you to perform the adjustment.

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6. Adjusting the engine revolutions
- Switch on the control unit
- Start the engine
- Accelerate the engine until it reaches a stable value (i.e. 1000, 1050, 1100, 1150, 1200)
- Access the advanced menu and press the following keys

 Press P1 and P2 at the same time (the display shows “000”)

 Press P2 once (the display shows “100”)
 Press P1
 Press P2 three times (the display shows “130”)
 Press P1
 Press P2 five times (the display shows “135”)
 Press P1

- Press P2 twice in the advanced menu and select the third sheet
- Press and hold P2 to access the sheet icons
- Press and hold P2 to access the adjustment page

Figure 7: page allowing you adjusting ATS-25

- Select the revolutions value of the engine with P1 or P2 arrows
- Press and hold P2 to confirm the adjustment and go back to the menu
- Press P1 and P2 at the same time to go back to the homepage

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7. Relay Box
Together with the wiring is installed a relay box, and inside of it there
are the three realys which make the engine run.

- Relay for the starter consent

- Relay for glow plugs command

Inside the box there are 5 protection fuses:

Fuse starter (F1, type ATO, 15A)

- Fuse Glow Plugs (F2, type MAXI, 40A)
- Fuse for Starter Consent (F3, type ATO, 15A)
- Fuse board Screen Protection (F4, type ATO, 15A)
- Fuse predisposition external socket (F5, type ATO, 15A)
For each fuse there is a signal LED for “broken fuse” to indicate to
indicate quickly if the fuse needs to be changed.

Inside the Relay Box there is a 5 SWITCH DIP switches for the automatic operation of the timing of
the plugs. The configuration in the OFF position switches off the automatic timer activation of the
glow plugs, allowing the management of this relay by an external control on
the 10-pin connector. In this mode you can set the activation time from the
ATS-25 Controller by using also the visualization of the respecting indicator
light L6. For any other operation without the use of the controller ATS-25, you can set an activation
time of the glow plugs relay automatically by properly setting the value in the following table.

SW1 SW2 SW3 SW4 SW5 Description

OFF OFF OFF OFF OFF Automatic activation function disabled, the command is run
by the 10-pin connector and therefore by the ATS-25
controller
ON OFF OFF OFF OFF Automatic activation time 1 second
OFF ON OFF OFF OFF Automatic activation time 2 seconds
ON ON OFF OFF OFF Automatic activation time 3 seconds
OFF OFF ON OFF OFF Automatic activation time 4 seconds
ON OFF ON OFF OFF Automatic activation time 5 seconds
OFF ON ON OFF OFF Automatic activation time 6 seconds
ON ON ON OFF OFF Automatic activation time 7 seconds
OFF OFF OFF ON OFF Automatic activation time 8 seconds
ON OFF OFF ON OFF Automatic activation time 9 seconds
OFF ON OFF ON OFF Automatic activation time 10 seconds
ON ON OFF ON OFF Automatic activation time 11 seconds
OFF OFF ON ON OFF Automatic activation time 12 seconds
ON OFF ON ON OFF Automatic activation time 13 seconds
OFF ON ON ON OFF Automatic activation time 14 seconds

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SW1 SW2 SW3 SW4 SW5 Description
ON ON ON ON OFF Automatic activation time 15 seconds
OFF OFF OFF OFF ON Automatic activation time 16 seconds
ON OFF OFF OFF ON Automatic activation time 17 seconds
OFF ON OFF OFF ON Automatic activation time 18 seconds
ON ON OFF OFF ON Automatic activation time 19 seconds
OFF OFF ON OFF ON Automatic activation time 20 seconds
ON OFF ON OFF ON Automatic activation time 21 seconds
OFF ON ON OFF ON Automatic activation time 22 seconds
ON ON ON OFF ON Automatic activation time 23 seconds
OFF OFF OFF ON ON Automatic activation time 24 seconds
ON OFF OFF ON ON Automatic activation time 25 seconds
OFF ON OFF ON ON Automatic activation time 26 seconds
ON ON OFF ON ON Automatic activation time 27 seconds
OFF OFF ON ON ON Automatic activation time 28 seconds
ON OFF ON ON ON Automatic activation time 29 seconds
OFF ON ON ON ON Automatic activation time 30 seconds
ON ON ON ON ON Automatic activation time 31 seconds

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8. TABLE RESERVED FOR ASSISTANCE AND ENGINE
INSPECTIONS
Service center:
NAME:

TELEPHONE:

ENGINE MODEL:

SERIAL NUMBER OF THE ENGINE:

Date: Engine time: Description:

Via Majorana, 7 – 48022 Lugo (RA), ITALY

Tel.: +3905459011
Fax: +390545901101
Email: [email protected]
Website: www.geminiani.com

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