Pramac Generator Ac01 MT Gb4 Newoptimizada
Pramac Generator Ac01 MT Gb4 Newoptimizada
Pramac Generator Ac01 MT Gb4 Newoptimizada
MANUAL OF:
• INSTALLATION
USE
• MAINTENANCE
INDEX
N.B.: THE INFORMATION CONTAINED IN THIS DOCUMENT MAY BE CHANGED DUE TO TECHNICAL IMPROVEMENTS
WITHOUT NOTICE
1.1 PURPOSE
The manual has been prepared specifically for the user of the generator unit.
Information required for the following is provided:
1. to learn the operational principle of the unit;
2. to interpret the indications given on the electronic control panel;
3. to control it for the various operational requirements;
4. to perform the basic checks required to ensure the efficiency of the generator itself.
Technical or adjustment matters are not dealt with as these involve the installation engineer when setting up
the system.
QGE
AC01
R
G M
CR CG
Fig. 1
UTILITY
Supposing that the mains R is within the normal limits, the CR mains contact maker is closed therefore the
utility is powered from the mains. The AC01 module controls the R mains and if there should be a drop in
voltage, a phase should be missing or the phases should be dissymmetrical, the control panel:
1. opens the CR mains contact maker;
2. starts the G-M generator unit, which when the established operating conditions are reached, the AC01
module closes the CG contact maker that then powers the utility from the generator unit G;
NOTE: When running, the M motor and G generator are safeguarded against possible anomalies, which if
encountered, cause the generator to stop immediately and the cause for the alarm is saved and displayed (i.e.
low oil pressure, overload and so on);
3. When the R mains is restored within the normal limits, the AC01 after an adjustable delay, opens the
contact maker of the CG generator and one second later closes the CR contact maker, thus powering the
utility from the mains again;
4. The generator continues to run for at least another minute to cool down after which it stops automatically;
NOTE: Even when the generator is stopped, some safety devices relating to the fuel and water level are
enabled and if an anomaly is detected an alarm status is triggered. The switching of the mains/generator is
also constantly controlled and if there should be an overload on the mains contact maker an alarm buzzer is
triggered.
To ensure the perfect efficiency of the generator a battery charger automatically holds the battery perfectly
efficient. An automatic fuel filling system constantly keeps the correct level in the daily tank. A pre-heating
system maintains the motor at the ideal temperature so that it is ready to start whenever necessary.
RETE V12 389 When the mains are connected these readings are automatically displayed that indicate
HZ 50.0 I1 22 the mains voltage and frequency. The current on the phase 1 is displayed if the CT are
connected and reseted on the load.
RETE V12 V23 V13
389 388 394 The three line voltages between one phase and another are displayed for the detailed
control of the mains…
RETE V1N V2N V3N It indicates the three star voltages between phase and neutral
224 221 224
The three currents of phase enable to verify the situation about the load on the single
RETE I1 32 phase of the mains. This page is displayed if the CT are connected and reseted on the
I2 33 I3 31 load.
The powers indicate the state and the load type on the mains:
RETE 0KVAr KVA=kilovoltampere=apparent power; KW=kilowatt=real power; KVAr=kilovar=reactive
7KVA 7KW power. This page is displayed if the CT are connected and reseted on the load.
Cosfì= power factor = phase displacement angle between voltage and current, with
RETE COS. L 1.00 the normal load it indicates L 0,xx, if with capacitive load it indicates C 0,xx. This page
FREQ 50.0HZ is displayed if the CT are connected and reseted on the load
When the gen-set is running the gen-set voltage, the frequency and the current on the
GEN. V12 389 phase 1 are displayed.
HZ 50.1 I1 32
It indicates the three starry voltages between phase and neutral of the gen-set.
GEN. V1N V2N V3N
222 221 221
The three current of phase allow to verify the state of the load on the single phase of
GEN. I1 32 the gen-set.
I2 0 I3 0
The powers indicate the state and the type of load on the gen-set:
GEN. 0KVAr KVA = kilovoltampere = apparent power; KW = kilowatt = real power;
7KVA 7KW KVAr = kilovar = reactive power.
Cosfì= power factor = phase displacement angle between voltage and current, with the
normal load it indicates L 0,xx, if with capacitive load it indicates C 0,xx. (ATTENTION!
GEN. COS. L 1.00 In this last case it means that the automatic rephasing is inserted
FREQ 50.0HZ of the plant, that during the operation of the gen-set Has absolutely to be
disconnected: DANGEROUS CONDITION)
GEN. The kilowatthour indicates the supplied power from the gen-set.
KWh 13953
The voltage of the battery and the current of load are brought in case of present mains,
BATTERY CHARGER firm group and of inferior tide to 2 A. La tension doesn't have to overcome the 13,5 Vs in case
27.2V 1.4A of 12Vdc batteries and the 27V for the 24Vdc batteries; when the group is running the voltage
are superior since conditioned by the generator battery charger.
1500RPM LC 92% RPM: motor revolutions. LC: percentage of the fuel in the tank.
PO 4.4bar TM 83°C PO: oil pressure. TM: motor temperature.
Attention! LC, PO, TM are displayed only if the the respective probes are connected
CONTAORE
Hour counter totalizator: the value remains memorized even if the battery is not
4 h 7m 40S
connected.
IN 123456789ABCD
00111111111101 State of the inputs: it is displayed by the technicians in phase of test of the plant.
OUT 123456789ABC
01010000 State of the outputs: it is displayed by the technicians in phase of test of the plant.
MON 18:02:05
Weekly clock: every time is reseted that the battery is interrupted, and it serves for the
operation of the automatic test, of the automatic block and of the reserve gen-sets.
MAINTENANCE 2 It indicates how much hours miss to the request of maintenance 2. Among parenthesis the
TRA 794h ( 1000) interval of maintenance. This page is only visualized if the application of maintenance is
activated.
Nome Cliente Advertising page brings name and telephone number of the producer or the technician.
Numero telefono This page is only visualized if it is compiled in the settings
The led WAIT/PROG indicates an elaboration in progress from the microcontroller: to the
end of the flashing the result of the elaboration it will be had. Es.: when the led is turned on, on the pylon of the
mains it means that the mains has reentered in the normal values; the switching gen-set-mains CG/CR is had
only after a certain delay, during which the led WAIT/PROG flashes.
The AC01 is provided with automatic command of the pomp of restocking gas-oil: when the led is turned
and the button serves to the manual command.
The button of starting motor (START) is trained only when the switch is in pos. MANUAL START. The
command is directed and to motor in running it is necessary to leave the button.The led indicates that the
command of starting is in progress.
The button of arrest (Stop), always trained, it has to be pressed up to the suit arrest of the motor. The led
indicates that the command of arrest is in progress.
The operational modes that can be selected with the programming switch are six, namely:
1.5.1 Automatic test: This starts to test the generator without disconnecting the mains power supply from the utility. When the
switch is turned back to automatic mode the generator stops following a delay of roughly one minute (it is used for periodic
tests or to check the running efficiency following maintenance).
1.5.2 Automatic mode; if there should be a failure in the mains the circuit board responds by opening the mains contact maker. If
the generator fails to start another 4 starting attempts are made. 10 seconds after it has started the generator powers the
utility. While running the generator and motor are constantly controlled and a possible anomaly is immediately displayed
(examples: fuel reserve, water level, overload, min. voltage etc.) and the relative stopping cycle is triggered. Once the mains is
re-connected, following the set time, the utility is switched back to the mains and the generator is stopped following a delay of
roughly one minute to allow it to cool down (this is the normal operational situation ).
1.5.3 Lock: this sets the generator in a locked status. It completely disables every possibility of starting while the mains power the
utility. This mode is used to work on the system in complete safety, being certain that the generator will not start even if the
mains should be disconnected ( it is used during maintenance).
1.5.4 Manual mains: this enables the forces the power supply from the mains even if the command and control electronics are
faulty (it is used when the generator is left inoperative).
1.5.5 Manual starting: this enables the generator to be started manually using the start push button. The control is direct without
the involvement of electronic components. It ensures the operation of the generator even when the electronics are faulty (it is
used for the manual emergency controls or for maintenance purposes).
WARNING
When the programming switch is in this position all the utility circuits of the generator are powered such as the solenoid
valves, electronic rpm regulators etc. If the switch is forgotten in this position with the generator stopped the starting battery
would run flat very quickly.
1.5.6 Manual generator: this enables the forced power supply from the generator (it is available for manual procedures or in
the case of problems with the automatic functions).
STOP
This is enabled whatever the situation.
It is to be held down until the motor stops completely
EMERGENCY STOP
If pressed, the red mushroom push button in the middle of the door stops the generator immediately, instantaneously opening the
contact maker of the generator (CG) thus locking it.
To release the emergency status set the programming switch in Lock position and then turn the emergency push button and pull up.
WAIT/PROG
A newly conceived and remarkably useful LED has been fitted on the AC01 module to assist the operator, namely the WAIT/PROG
LED. This LED flashes each time the timer is triggered informing the operator what is happening even over a lengthy timer period.
All LEDs are provided with a general description that make the control panel easily comprehensible.
SUMMARY
The unit is normally programmed in AUTOMATIC mode.
When any jobs are to be performed on the generator it is to be set in the LOCKED status.
If the generator is not to start even if the mains is disconnected it is to be set in the MANUAL MAINS status. The reason for this is that if,
while the generator is not working, there should be a failure in the electronics, the power supply from the mains would be ensured in any
case.
1.6 PROGRAMMING
If the electronic module should be disconnected from the power supply, the established weekly timer programming is deleted,
consequently all the functions foreseen for the internal timer would fail to work at the time and on the day programmed therefore the
weekly timer is to be re-programmed.
Access the page below to re-program it.
Press ENTER, the day flashes. Using the +/- keys modify the day and press
ENTER to confirm. The time flashes. Using the +/- keys modify the time and
confirm with ENTER. The same goes for the minutes and seconds.
You cannot change page until programming is complete.
ALARM SILENCING
With the state of alarm the red led of alarm on the motor flashes and the sonorous is active alarm. Pressing once the SILENT button the
acoustic alarm is interrupted, the red led on the motor remains turned on to fixed light
FUNCTIONS RESET
Pressing the RESET button two times the conditions of alarm are annulled, all the functions are restored and the red led on the motor is
turned off.
The AC01 is set up for special operating functions, such as: automatic testing or cut-out, routine
maintenance, remote control, etc. GEN OPERATION
When these are active, a page comes up on the display when they are activated, indicating which CUT-OUT
function is active.
There are functions that affect how the unit operates and that require direct intervention to allow the unit to be used:
GE CUT-OUT
The cut-out function is mainly used when the unit is run in a built-up area, and emergency standby is not required outside of working
hours. During the cut-out hours, if the mains power supply fails the unit does not react, and should it be necessary to start up the unit
during this time, this can only be done manually.
SERVICE REQUEST
This does not change the operating status, but raises an acoustic alarm to mark the set time, and a message reading SERVICE appears
on the display ALARM MAINTENACE 1 or ALARM MAINTENANCE 2, pressing RESET the function is restored.
REMOTE CONTROL
The unit can run under remote control by using remote communication (PC or modem or GSM), and this can be activated automatically.
WARNING
It is strictly prohibited for anyone to touch powered parts.
Overload fault
This may cause the unit’s trip switch to open (lever in central “TRIPPED” position). This must be reset by
pushing the lever down to the OFF position and then returning it to the ON position. Where switches have been
installed inside the electrical board, follow the ELECTRICAL MAINTENANCE procedure before opening the
board.
SUMMARY:
On a periodic basis check the electrolytic level of the clear batteries. Touch the motor to feel if it is warm (if equipped with pre-
heating system) and execute an automatic test.
The control panel is entirely manufactured in compliance with the following European standards:
ANS low voltage electrical control panels EN 60439-1
EMC electromagnetic compatibility directive 89/336/EEC
Each control panel or device is completely tested and supplied with test certificate, declaration of conformity and EC marking in
compliance with 626 safety standards.
The control panel is manufactured in a steel sheet cabinet, 15-20/10 that is skilfully treated and painted with standard grey silicon epoxy
powder, Ral 7032, and has a standard protection rating of IP 42.
EXTERNAL COMPOSITION
The control panel consists of the following:
1. AC01 electronic circuit board that houses the control logic, control and reading of the operational parameters of the generator;
2. Emergency stop mushroom push button (optional) ;
3. Nameplate with operational standards;
4. Nameplate with safety instructions.
INTERNAL COMPOSITION
1. numbered cables placed within PVC sheathing;
2. 10 x 38 fuses with disconnectable fuse boxes;
3. battery charger transformer of adequate capacity;
4. automatic generator protection switch (if provided);
5. switch with tetrapolar contact makers of adequate capacity for the power of the unit, interlocked mechanically and electrically and
scaled in AC1 in compliance with standard ISO DIS 8528-4 ;
6. three amperometric transformers for measuring the generator and mains current;
7. terminal for the mains and generator inputs, the utility output and any auxiliary connections;
8. safety fuse gauges and connection terminals nameplate.
Switching is controlled directly by CG and CR relays built in the MP-AC01 module, which directly command switching via unpowered
contacts.
IMPORTANT
The CG and CR command contacts are normally closed to allow the command circuits, in the case of
certain anomalies, to force the mains contact maker to close. For example by disconnecting the battery
and also the power supply to the battery charger transformer the mains contact maker is forced to close.
READINGS
All readings are shown on the display on two lines of 16 alphanumerical characters.
All the reading pages are controlled using the +/- push buttons, which run in both directions.
The reading pages available are the following:
• mains status, volts, hertz and amperes of phase 1
• R, S, T line mains voltage.
• RN, SN TN mains star voltage.
• Current on the three phases mains;
• KVA, KW, KWAr mains powers;
• Power factor, cosfì HZ mains;
• Generator status, volts, hertz and amperes of phase 1
• X, Y, Z line generator voltage.
• XN, YN, ZN generator star voltage;
• Current on the three phases gen-set;
• KVA, KW, KWAr gen-set powers;
• Kilowatthour gen-set;
• Power factor, cosfì, HZ;
• Differential trip switch, programmed current, dispersion current and programmed time;
• Battery, voltage and charging current;
• Status of the inputs;
• Status of the output;
• Start counter;
• Weekly timer for programming the automatic test.
• Operation active, automatic test, forced start, pilot GE, cut-out, etc.;
• Supplier’s name and telephone number;
• Maintenance, with programmed hours and working hours remaining before service.
If an alarm is triggered it will be shown on the display. For example a low oil pressure, fuel reserve, high battery voltage alarm, etc.
All operational modes are controlled by the AC01 control panel equipped with a programming switch to select the following functions:
1. TEST
2. AUTOMATIC MODE
3. LOCK MODE
4. POWER SUPPLY FROM MAINS.
5. MANUAL START.
6. POWER SUPPLY FROM GENERATOR.
1 TEST
1.A. it performs all the automatic functions with the exception of the switching function.
1.B. it tests the efficiency of the whole system without disconnecting the mains power supply
to the utility.
1.C. all safety devices are enabled while the test is running.
1.D. if the mains should be disconnected while the test is running the generator starts immediately .
1.E. the test ends automatically when the mains power supply is restored or following a programmed external command.
2 AUTOMATIC MODE
2.A. A special three-phase voltage relay is capable of working at a voltage of 8Kv to safeguard the mains against:
• sagging of over -20% of the rated voltage (this can be modified);
• excessive rise in the rated voltage of over +15% (this can be modified);
• missing phase;
• incorrect angle between the phases (phase displacement).
2.B. If one of the above-mentioned anomalies should occur the CR mains contact maker is immediately opened to safeguard its
integrity also in the case of excessive voltage sagging.
2.C. When the mains is disconnected a starting delay timer is triggered (programmable time). It makes the system insensitive to
brief mains disconnections. A buzzer will sound in this case.
FILE VER LAST ISSUE LANG. PAGE
AC01-MT-GB4 NEW jjg/02 05/03/2003 ENG Page 14 of 56
2.D. Following the STARTING DELAY phase 4 starting cycles of 5 seconds each start, split up by pauses of 5 seconds (these may
be programmed).
2.E. At the end of the start cycles if the gen-set has not started, there is the FAILED START signalling, if the gen-set starts but it
doesn’t reach the speed values, after 120” there will be the min voltage or frequency alarm.
2.F. With the motor running at a steady state the voltage output by the generator is read. When this is within the established
parameters the generator delay timer is triggered (this may be adjusted from 1 sec. to 30 min. approx.). At the end of this
timing the generator (CG) contact maker is closed on.
2.G. By means of a normal VDO probe for reading the motor temperature the minimum temperature beyond which the load output
is enabled can be programmed. This is to prevent operating at a low temperature in the case of the failure or failed pre-heating
of the motor.
2.H. While the generator is running two pre-alarm safety devices are enabled, oil pressure and motor temperature. When these trip
a buzzer sounds. The following safety devices and indications, when tripped, are displayed and trigger the programmable
functions described:
No. DESCRIPTION ON DISPLAY LED COLOUR BUZZER IMMED. STOP DELAYED
STOP
MOTOR
1 Failed starting A
2 Failed stoppage A
3 Low oil level A
4 Low oil pressure A YES
5 Minimum oil pressure (pre-alarm) A
6 High oil temperature A SR
7 Low water level A
8 Very high water temperature A YES
9 High water temperature (pre-alarm)
10 Battery charger generator A YES
11 Lack fuel A
12 Low fuel level (pre-alarm) A
13 Starting R
14 Stoppage R
15 Fuel pump running (ON) V
16 Minimum temperature A
BATTERY
17 Battery connected V
18 Excessive battery voltage A
19 Low battery voltage A
20 Battery charging V
21
GENERATOR
22 Excessive voltage (59) A YES
23 Low voltage (27) A SR
24 Overload (51) A SR
25 Short-circuit (50) A SR
26 Maximum frequency (81) A YES
27 Minimum frequency (81) A SR
28 Phase sequence A
29 Inverted power A SR
30 Generator connected G
30 Generator contact maker closed (ON) G
32 Differential trip switch (earthing fault) A SR
33
MAINS
34 Mains connected V
35 Excessive voltage (59) V OFF
36 Low voltage (27) displacement V OFF
37 Overload (51) A SR
38 Phase sequence A
39 Mains contact maker closed G
VARIOUS
40 Emergency push button pressed A YES
41 CR mains contact maker anomaly G A
42 CG generator contact maker anomaly G A
3 LOCKED STATUS
3.A. It immediately stops the generator if this is running.
3.B. It disconnects the power supply from all starting circuits.
3.C. it ensures safety throughout maintenance.
It deactivates the fuel pump and the preheating in order to there is not any components in voltage during the maintenance.
WARNING if, after having powered the control panel the battery LED should fail to light up, check the POLARITY OF
THE BATTERY before operating any commands. Possible connection errors could cause electronic anomalies in the MP02
module if commands are operated with the poles inverted.
3 4 3 4
On the selected voltage, the AC01 is automatically shaped for the alarm
voltages for min battery voltage, contemporarily also the battery charger is
shaped.
12 Volt 24 Volt
= > 7V Krank
51 81 - 9Hz for 3000 rpms
voltage
PROGRAMMING
To set the value of max current of charge on the power of the installed transformer
CHARGE DIAGRAM FOR PLUMB BATTERIES
V/elem Max charge voltage limit
2,42Ve
Discharged battery
1,9Ve
1,8Ve Alarm min voltage for discharged battery
Corr. A
I max Charge max of programmed current
µP Battery
22 CONTROL 12 or 24V
II° 17/29V
2-B
Shunt
JUMPER
9 11 9 11
Modifying the jumpers placet on the electronic unit of
the power module, the AC01 can to work with posive
inputs.
2.6.2 ANALOGUE MOTOR PARAMETER READING INPUTS (PRESSURE, TEMPERATURE AND FUEL
LEVEL)
The three inputs 15-16-17 used to read the pressure, temperature and fuel level can be configured using the SW2 switch (on the MP02
unit) for motors type MTU that output 0-10V for the above-mentioned readings.
JUMPER INPUT
When SW2 is configured to “ON”, normal motor probes (transducers) of a VDO or VEGLIA type can be used (which can be configured
from the Misc. Settings Menu). Since they are not linear, the working fields available are restricted by the limits of the transducers.
Where the probe is not installed, no indication will appear on the display automatically.
When individually configured as “OFF” the three inputs operate at between 0 and 10V, and are connected directly to the MTU motors
and others of the same concept for taking motor measurements. The reading scale can be changed from the Measurements Menu.
15 16 17 16 17
0-10V 0-10V
ANAL. ANAL.
2 - Batt OP OM WT ET
PROGRAMMING
From the Menu various settings, to select for 17 analogic input the kind of transducer
Veglia, VDO or MTU.
1,0 PREALARM
If the transducer is 10 bar, to correct the reading value from the Menu measures.
O,5 MIN PRESSURE
ATTENTION! NOT CHANGE THE VALUE OF ZERO WHEN THE MOTOR IS RUNNING
To align eventually the zero reading, to go to page “REG. ZERO PO” and with the stopped
engine (0 pressure) to push ENTER. The transducer reading in that instant will be as zero.
(1) If you wish to set the high temperature pre-alarm, bear in mind that the value indicated
is affected by the wiring and a tolerance in the transducers that may be as much as 7°C. The temperature must therefore be set using
the measurements menu, and checked using a thermometer.
The setting entered must take the level at which the maximum temperature thermostat intervenes into account, as this causes the unit to
stop (WT11). The pre-alarm temperature must be set at least 3°C lower than the thermostat.
PROGRAMMING %
From the menu various setting, to select for the analogic input 15, the kind of
transducer Veglia or VDO. 80 OFF FUEL PUMP
The failed installation of the level probe or the circuit breakage automatically excludes the operation of the pump and display indication.
When the level probe is being installed the real upward and downward excursion of the level rod must be taken into account.
R
Remove excess length on 40% START PUMP
the rod beyond the
resistance to facilitate
putting it into the tank.
Min
10% ALARM
0%
When the software is used to configure the sensor, in biphase, the control is activated only on connections L1 - L2.
Mains control Biphase
Use voltage 100 – 600 V ca
Min adjustable voltage (OFF) 60 - 400V (27)
Max adjustable voltage 110 – 600V (OFF) (59)
Intervention differential voltage 30V on MIN – 15V on MAX
When the software is used to configure the sensor, in single phase, the controls on connections L1 – L4 are activated.
Network control Single phase
Voltages used 70 – 340 V ac
Adjustable minimum voltage 70 - 280V (27)
Adjustable maximum voltage 110 – 300V (59)
Intervention voltage differential 20V on MIN – 10V on MAX
Bringing the MIN V GEN, MIN HZ, MAX V and MAX HZ values over the programmed maximum, the OFF function can be
activated to deactivate the control.
(*) FUNCTIONS
27 Min voltage
59 Max voltage
60 Dissymmetry
81 Protection for min/max frequency
47 Sequence phases
50 Instant current or short-circuit
51 Max current with programmable delay
87G Protection differential of breakdown to earth
32 Protection by energy's inverse or directional power protection
0V
T
Network connections
MP AC01 MP AC01 MP AC01
MP AC01 N ÷ L4 M N : L4
N +L4 M 47 M 47 47
M 47 R÷L1 R ÷ L1 A R ÷ L1
R ÷L1 A 48 A 48 48
A 48 S ÷L2 I I
I S ÷L2 I 59 59 59
59 N T ÷L3 N N
N T ÷L3 50 50 S
50
50 S S
S
THREE-PHASE CONN. BIPHASE CONN. SINGLE-PHASE CONN.
THREE-PHASE CONN. WITHOUT NEUTRAL
WITH NEUTRAL
Generator connections
GEN GEN MP AC01 GEN MP AC01
MP AC01 X ÷ L1
X ÷ L1 52 X ÷ L1
52 Y ÷ L2 52
Y ÷ L2 53 Y ÷ L2
53 Z ÷ L3 53
Z ÷ L3 54 Z ÷ L3
54 N ÷ L4 54
N ÷ L4 51 N ÷ L4
51 51
R R
THREE-PHASE WITH INSULATED THREE-PHASE CONN. WITH
THREE-PHASE WITH NEUTRAL
NEUTRAL FROM EARTH IT
TO EARTH TNC OR TNS NEUTRAL AND IT INSULATED
CONNECTIONS CT
CT PHASE R-L1 33 – 36 CT PHASE S-L2 34 – 36 CT PHASE T-L3 35 – 36
The AC01 is provided for managing generator units that operate automatically or manually, with or without mains power supply/generator
switching over. The circuit in which the CTs are installed and the readings shown on the display vary depending on their application. For
example:
Isolated generator without mains power supply generator Emergency generator backing up the mains power
switching, or with separate switching. supply, with mains power supply generator switching.
The CTs only read the generator current. The CTs read the mains power supply and generator
currents.
MAINS
G G
AC01
AC01
CG CR
3xCT
3xCT
100/2000 A/5
100/2000 A/5
All the generator’s electrical readings are displayed, Volt, Hz, All the generator’s electrical readings are shown, Volt, Hz,
Amp, Kw, Kva, Kvar, Power factor. Amp, Kw, Kva, Kvar, Power factor. The same readings are
When the mains power supply is connected voltages and carried out on the power supply when the Mains power
frequencies are displayed. supply connector (conn 25) is closed. This Connector also
The generator’s electronic trip switch is active to protect it activates the electronic cut-out for overloading on the mains
against overloading and short-circuits. power supply contactor (CR).
The type of operation is selected on the basis of the positioning of the current transformers (CT), via “misc. settings” by selecting:
1. for units without switching (CT ON GENERATOR );
2. for units with switching (CT ON SWITCHING ).
ELECTRONIC PROTECTION AGAINST OVERLOADS (51) AND SHORT-CIRCUITS (50) OF THE GENERATOR
The generators are supplied with their power expressed in KVA because the effective capacity limitation on the generator is given by the
Amps on the coils. Thus in order to effectively protect a generator the amps must be controlled.
Overloads 51:
If the rated current of the generator is exceeded following a set timing the generator contact maker is opened (at the same time the TRIP
40 and 41 contact is activated), the overload alarm is triggered and the generator is stopped following the motor cooling phase
(DEFAULT). (IT CAN BE EXCLUDED REGULATING THE THRESHOLD TO ZERO)
Short-circuit 50:
It trips immediately when the load current exceeds of 2 sec. the parameter set . The generator is stopped in the same way as in the
case of overloads. (IT CAN BE EXCLUDED REGULATING THE THRESHOLD TO ZERO)
These are active when the Generator Current contact is closed at 25.
Set under threshold and time settings.
WARNING measuring TAs are provided for the 50 function, to protect against shortcircuits, that are able to provide three times the
nominal current (5x3 = 15 A) in linear mode without reaching saturation.
OPERATING PRINCIPLE
The AC01 uses a toroidal transformer on the load power supply line (fig. B) to constantly monitor the sum of the supply and return
currents. When the difference exceeds the set value, this indicates that part of the current is dispersed to earth, and after the relevant
delay the load is deactivated via commands 41 and 42.
This function is available from AC01MP modules rel. 6.0 or superiors.
Connections
Fig. A shows the 67G earthed fault protection commonly used in generators, since in addition to protect the unit against direct contacts, it
also detects leakage to earth from the generator’s coils. The insulation between the neutral (N) and the earth (PE) must be checked on
setting the unit up, as any link between the two would by-pass the differential trip switch.
EMERGENCY DEVICE
Pre-arrangement for the external emergency command enabled in all operational modes with immediate stoppage of the motor, opening
of the generator contact maker and triggering of the alarm.
The emergency device not only controls the control software of the circuit board but is also equipped with an electro-mechanical circuit
that totally ensures the stoppage of the unit and the opening of the generator contact maker.
WARNING
The command is double, the NO contact of the emergency push button is required to ensure the immediate opening of the
generator contact maker even in the case of an anomaly in the electronics. In fact to ensure the emergency power supply even
in extreme cases the contact that commands the mains and generator contact makers (CG-CR) is normally closed (NC),
therefore if the contact maker is to be opened, the command relay must be powered. The motor stoppage on the other hand is
ensured by the NC contact (positive safety), which disconnects the power supply from the motor even if the circuit is
disconnected or in the case of an anomaly in the electronics (as per standard).
+ BATT AC
RCG
PAE
CG
- BATT AC
OPERATING STATUS
A page on the display has been set aside to show the unit’s status, to facilitate use of the FUNZIONAMENTO
generator. This page shows all status indications such as: automatic test, cut-out, forced GRUPPO BLOCCATO
starting, remote controlled, pilot generator, standby generator, clock to be set, etc.
These status indications allow the operator to know the status of the unit, and what to do. For example:
a) clock to be set = the battery has been disconnected and the clock must be reset as some operations need to use the clock;
b) cut-out = Stop command, the generator cannot react automatically and can only be controlled manually;
c) forced start = the generator is controlled by forced power supply, and can only be operated manually.
CUSTOMISATION
This page can only be seen if programmed. It has two lines, the first can be used to enter a name AEZ BOLOGNA ITALIA
of up to 16 characters, and the second for a telephone number of up to 16 digits. 0039 051 739099
During the starting up phase a number of outputs may be in an abnormal condition. To identify these the status of all the inputs and
outputs are indicated on the display.
When a number of alarms are raised at the same time, these are shown on the display. Even after pushing RESET repeatedly it is
difficult to define all the alarms raised.
The correspondence table is used to identify all alarms raised and reset.
INPUT
Correspondence table, when the input or output is on “1”, this means that it is active (ON).
OUTPUT
Activate or deactivate this function and enter the cut-out time CUT-OUT ON/OFF 00:00
If ON is active, select the days of the week (MTWTFSS) and the time the cut-out is to end - OFF 00:00
When the unit is working without the mains power supply, the cut-out function determines the times at which the generator is stopped.
Outside of these hours the unit is placed in automatic mode.
Example: it needs to program that a gen-set works every working days from 7 to 21 and the remaining hours it has to be
stopped
I I
BLOCK OFF 7:00 BLOCK ON 21:00
The following remote commands and controls are available in the terminal board that can be configured on inputs 18-20:
1. Remote locking command to assure that the unit is not started when there is no mains power supply (overnight locking
and week-end shutdown for offices etc.).
2. Remote automatic test command (TEST) to remotely start the generator.
3. EJP function command (Programmable).
4. Remote starting command with forced output even in the presence of the mains power supply (SCR).
5. Stand-by generator operation command used to program the two units that run alternately for a set amount of time.
M-02
CONN FUNCTION PROG PROG 18 20
1 2
18-20 EJP FRANCE SPECIAL TIMES
SETTING 0-25’
EJP 2
FORCED START
20 SCR forced start with supply. SPECIAL 1
SETTING
SCR
18-20 RES two generators SPECIAL BLOCK
(one on standby) SETTING EJP1
2 GEN CHANGE TEST
RES + Batt.
20 Forced stop - BATTERY SCR
The TEST, BLC AND SCR functions are active simultaneously (standard configuration). When the EJP or RES functions are
activated, all the other functions are deactivated.
1 18 8 20 1 18 8 20
ON = STOP
OFF = START
D1 40A D2 40A
+ BATT 1 - + BATT 2 -
WARNING to protect the transistor from overloading a 1A diode must be fitted in parallel with the contactor’s coil, as shown
in the layout.
2.11.1. PROGRAMMING
MISC. SETTINGS (OUTPUT 28 ) TIME SETTINGS
MOTOR PRE-HEATING THRESHOLD SETTING
200mA
GLOW PLUG PRE-HEATING GLOW PLUG 10 – 120”
STARTER STARTER 0 – 10” 28
EV. GAS EV. GAS 0 – 10”
RESET RESET 2 – 10”
DOUBLE STARTING
COMAND STOP
2.11.7. DOUBLE STARTING (out 28) UNI 9490 NFPA NFS61.940 START
This allows an automatic switch over to a second starter battery.
OUT 28
The number of starts set under time settings is spread over the two batteries alternately. If,
at the end of the cycles, the motor has not started, an alarm is raised for no start having
occurred. BATT. 1 BATT. 2
7 15/54
AC01
200mA
+B
28 R RB1 RB2
To see other
functional scheme
in the applications
RB1 RB2 BATT. 1 BATT. 2
R
Note: for the adjustment to the rules of safety fireproof, the “FORCED RUNNING” can be required, to see 2.10.5
GEN SET
+ BATT 1 -
TO PRESS FOR 8”
J2 = CLOSE CG BY MANUAL
COMMAND = ON
J2 = CLOSE CG BY MICRO = OFF
SW1
ON OFF LED
BRIGHTNES
J1 = STOP ALWAYS ENABLED =
ON
J1 = STOP ENABLED ON IN
MANUAL MODE = OFF
SW PROGRAMMING SWITCH
Six languages can be selected and programming can be activated, using four switches.
2.12.1 SETTINGS
To gain access to the SW1
function programming page, turn switch no. 4 of the SW1 switch ON, situated at the side of the AC01 unit.
All the parameters indicated on the display can be modified, both the value indicated (i.e. 380V can be changed to 395 or 378 or any
other value) and the ZERO of the same parameter.
Once access has been gained to the programming function the messages that appear on the display will guide you through the
possibilities offered by the program that is in continuous development, surely you will find on the module more options of programming
in comparison to those brought on the manual.
All conditions can be worked on, even while the unit is running.
To gain access to the programming function, after having set the switch ON, use the +/- push buttons to select the
block required.
To help you find the block the fields that may be programmed have been split up into four blocks:
1. Parameters;
2. time settings;
3. thresholds;
4. various settings.
5. remote control
Once the block concerned has been selected, press ENTER to display all the fields that may be modified. Use the
+/- push buttons to find the field to be modified and once found, press ENTER again and using the +/- keys modify the value and confirm
with ENTER.
TIME PARAMETER THRESHOLD VARIOUS SETTINGS REMOTE CONTROL
SETTING SETTING SETTING SETTINGS
Access is gained to the Access is gained to the Access is gained to the Access is gained to the The type of remote
time settings to be parameter fields to be threshold settings at various alarms and the control can be
modified. modified. which alarms are tripped special applications. programmed on a PC –
Start delay V - A - Hz - W - °C - Min – max, volt, hz, MODEM or GSM as
Stop delay amper, ecc. well as the necessary
Etc. parameters
2.12.4 THRESHOLDS
The AC01MP unit is connected by means of FASTON 6,3 mm type terminal board.
BASIC
MP-02 +BATTERY
F
16A WIRE 3 AND 4
START
1 2 3 4 5 6 7 8 PR20 PR
RS232C,485 LO9 10 11
HIG 12 13 14 15 16 17 18 19 26 27 28
STA ST ALA HIG FU WA FU EJP EM OD EHPR
W H H EL TE EL ER EH
RT OP RM - UC EAT
OIL WA OIL RE R LEV GE EAT
TES TIO ING
PR TE TE SE LEV EL T NC N- . ING
ES R
25 POLES MP. RV EL Y AU CA.
SU TE E OIL
TO ND.
RE MP. MA -
TIC- STA
LO RT
F PAE CK
RS232C,485 LOP HWT HOT FR LWL FL OP ER
P T T
FLM
P
GCM-02 BA D+
TT RA RS EV RALL G T
WT
CPC R
ER
D-
Y +B
MOTOR GROUND
OIL
CONNECTION DIAGRAM
FILE VER LAST ISSUE LANG. PAGE
AC01-MT-GB4 NEW jjg/02 05/03/2003 ENG Page 41 of 56
2.14.2 CONNECTIONS ON THE MP02 POWER UNIT
This entails 6.3 mm. 54 terminals and a 25 poles connector for connections between the GC AC01 module and the MP02.
The faston connections used for isolated terminals can take conductors of up to 6 mm2.
The wiring of the terminal board that is also illustrated on the safety guard respects the numbering indicated in the table below:
Note:
The technical characteristics are subject to modifications without notice following technical
improvements.
216
200
HOLE
117
127
105
Ø2
0
26 26
4 HOLES Ø 4 mm
287 92
28 200 28
10
167
207
90
10
4 FORI Ø 5 67
4 HOLES Ø 5
To allow an immediate interpretation of the commutator of switching, a pocket has been foreseen, in which a nameplate is inserted with
the writings in the wanted language.
RS 232C
RS 485 100-1000m
CONVERTER
RS 485 / RS 232C
RS 232C
MODEM OR
GSM
The IS-03 serial interface unit for the serial communication has to be set to work in two different way of serial connection: RS232 and RS485.
On this unit there are also a green led and another red, the green is the transmission function (TX) and the red is the receipt, flashing during
the operation.
In the following figure is brought the external view of the IS03 unit.
The jumper, opportunely connected, enables the closing of the line of the RS485 serial, inserting the resistance R which closes the line.
For the connection from the ISO3 to PC by RS232 interface, it needs a wire null-modem (standard for PC); his configuration is the following:
5 1
5
6
CONNECTOR IS03 2 2 CONNECTOR PC
7
3 3
8
4
9
A B A B A B
COMMUNICATION PROTOCOL
The standard MODBUS RTU is particular type of protocol, suitable to communicate on a RS485 serial up to max speed of 256 Kb/s.
The speed used as standard is however that of 9600 Kb/s. At the end of the manual, in the appendixes section, there are the modbus mapper,
they cab be used on serial mains controlled from PLC etc.
N.B. being the IS03 an interface from the intelligent technology needs to do so that during the lighting this is
already connected to the unit because it happens a particular control of handshake that the serial trains to
the functioning After all to the manual, in the appendixes section, there are the mappers
If after the lighting the TX green led is again turned, press reset for to repeat the handshake with the IS03.
IMPORTANT!!! If it has a modem also trained to the operation GSM it is of fundamental importance to remember also to insert before the
start the SIM card opportunely trained to the traffic data, a standard SIM (not trained to the data communication) it allows only the
communication by SMS.
As first operation to feed the modem inside the GCM-02 unit.
In the case of modem GSM needs immediately to insert the number of the PIN of the telephone SIM and subsequently to set in the field of the
"serial regulations", they cab be activated elevating the switch 4, the telephone numbers of reference (two normal and two trained for the sms)
to which it has to correspond a computer with our software. In case of signallings of alarms before they are contacted the numbers
corresponding to the sms and subsequently those with the normal numbers.
It is important for a correct control, to insert gen-set identification number to make possible the controls and the modifications by the remote
control use.
The address modbus in standard conditions has to be set to 1; after set the modem that you want use and opportunely connected to the unit.
The U.S. Robotics modem works as a normal modem of telephone line and it is not trained to the function GSM. So, the communication speed
is usually set to 9600 Kb/s also if U.S. Robotics could work up to 57600 Kb/s.
When it operates with modem trained also to the use of the function GSM in the case in which the PIN of the SIM inserted resulted wrong the
signaling it would appear on the display "Alarm SIM PIN". In this case to come into the range of the serial regulations and to check the correct
insertion of the code and eventually to modify it. In the case the code for PUK is asked, due to the wrong digitation for three consecutive times
of the code PIN, to remove from the modem the card SIM and to handle the insertion of the code PUK through a normal cellular GSM.
When a modem is used also for to the functions GSM if you are in the functionings screening (that usually active) where the hour and tha day
are visualized you can also verify the field (signal radio) present. When the field results to be of smaller value than -91 dBs the communication
could result not perfect.
It is obviously possible to check the gen-set through a personal computer with the projected software adequately to the functions of the GCM-
02. It is possible in fact, once connected to the interested group, to command to distance the STOP, the START or the AUTOMATIC TEST of
the same group. In this case on the display of the GCM-02 following information are visualized respectively:
• START FROM SERIAL COMMAND
• STOP FROM SERIAL COMMAND
• AUTOMATIC TEST FROM SERIAL COMMAND
After 250" of absence of serial communication every command sent from PC is annulled and the AC01 it takes back the normal operation.
MAX 200m
2.18.1 POSITIONING
The control panel must have a protection rating (IP) suitable for the area in which it will be installed:
IP 42 (normal supply) for closed areas;
IP 55 in the case of possible splashing of water or for control panels exposed to rain.
WARNING !!!
It is advisable not to install the control panel further away than 20 meters from the generator.
QGE
CONTROL PANEL GENERATOR
MAX 20 m
This requirement is due to the excessive currents caused by lightening that hits the public mains causing the voltage inside the control panel to
rise excessively if the connection line exceeds 20 meters.
If there is no other choice than installing the control panel further away than 20 meters, our engineering
department can provide you with various technical solutions.
WARNING !!
To ensure the reliability of the system all of its components must be connected to earth.
CONTROL PANEL
DAILY FUEL TANK
FUEL TANK
QGE
GENERATOR
EARTH
OTHER COMPONENTS
START STOP
Fig. : 3
5 6
30A max
50
INJECTION PUMP
STARTING MOTOR
- BATT.
Operation : with the stopping command the electromagnet is energised and stops the motor. To establish the
stoppage of the motor the closure of the oil pressure switch is controlled, which after 20 seconds from when it closed
automatically disables the electromagnet thus avoiding settings and adjustments.
Stoppage with SOLENOID VALVE normally energised while the generator is running and while the utilities of
the unit are powered.
Connection 7 is defined 15/54, it emits the +B with a maximum current of 16A as the GE starting is commanded to stop
when the stoppage command is received,
15-54 7
OTHER MOTOR UTILITIES
16A max
ELECTRONIC
EV RPM
REGULATOR
P P = PRESSURE
T ? T = TEMPERATURE
NO NC L = LEVEL
MOTOR MASS
2.18.8 ELECTRICAL STRENGTH TEST
The control panels that are subject to the electrical strength test are to be prepared baring in mind that the only connection point with the
electronic logic is established by the MAINS sensor (inputs 50 – 49- 48) to which a divider is connected that is made up of 3 500 K ohm
resistors for high voltage, for phase and connected to earth.
Therefore the R - S – T - N inputs are to be disconnected.
WARNING the wiring to the terminal contactors may introduce residual voltages into the AC01, which may generate a value for a current
that does not exist. To eliminate this go into the measurements menu, zero the current and press Reset. The AC01 starts self-programming. This
operation must be carried out without current in the power circuits. Where this charge cannot be eliminated, short circuit the wires to the Terminal
Contactors.
WARNING! It is absolutely prohibited to touch any parts while they are powered.
WARNING the wiring to the terminal contactors may introduce residual voltages into the AC01, which may generate a value for a current
that does not exist. To eliminate this go into the measurements menu, zero the current and press Reset. The AC01 starts self-programming. This
operation must be carried out without current in the power circuits. Where this charge cannot be eliminated, short circuit the wires to the Terminal
Contactors.
WARNING !
The control panel is powered by the mains and by the generator. Before accessing it for maintenance purposes disconnect the mains and stop the
generator by setting the programming switch on “LOCKED”
TROUBLE SHOOTING
Alarm status triggered immediately
Failed generator output
Brief and rapid starting
Failed starting alarm
Nothing is working
Failed stoppage
Battery LED off
Attempt to start
Failed starting