electronic module for automatic and manual...

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MC3-MU-ING-04C (4).doc

1.2 08/05/2009 ENG Page 1 of 58

ENGINE CONTROL MC3

ELECTRONIC MODULE FOR AUTOMATIC AND MANUAL

CONTROL OF GENERATOR SETS

MANUAL FOR: • INSTALLATION • OPERATION • MAINTENANCE

Filename REV. File Rev. Date LANGUAGE PAGE MC3-MU-ING-04C (4).doc 1.2 08/05/2009 ENG Page 2 of 58

CONTENTS

1.0 USER MANUAL ......................................................................................................5 1.1 INTRODUCTION.....................................................................................................5

1.2 PURPOSE...............................................................................................................5

1.3 OPERATING PRINCIPLE.......................................................................................5 1.3.2 OPERATION COMBINED WITH ATS FOR MAINS POWER OUTAGES.......................................... 5

1.4 VIEW OF THE “MC3” MODULE ............................................................................5

1.5 FUNCTIONAL DESCRIPTION OF CONTROL PANEL COMPONENTS....................5 1.5.1 COMPONENTS DESCRIPTION ......................................................................................................... 5 1.5.2 DESCRIPTION OF THE VARIOUS MEASUREMENTS..................................................................... 5

1.6 CONTROLS AND OPERATING MODES .................................................................5 1.6.1 AUTOMATIC MODE (AUT)................................................................................................................. 5 1.6.2 OFF...................................................................................................................................................... 5 1.6.3 MAN..................................................................................................................................................... 5 1.6.4 STOPPING WITH THE STOP BUTTON ON THE ELECTRONIC BOARD........................................ 5 1.6.5 EMERGENCY STOP........................................................................................................................... 5 1.6.6 FUEL PUMP CONTROL (if present) ................................................................................................... 5 1.6.7 ACTIONS IN THE CASE OF GENERATOR SET BREAKDOWN ...................................................... 5

1.7 MISCELLANEOUS CONTROLS .............................................................................5 1.7.1 LED TEST ........................................................................................................................................... 5 1.7.2 ALARM MUTING (ACK) ...................................................................................................................... 5 1.7.3 FUNCTIONS RESET........................................................................................................................... 5 1.7.4 RESIDUAL CURRENT PROTECTION TEST (if active) ..................................................................... 5

1.8 SPECIAL FUNCTIONS...........................................................................................5 1.8.1 GE CUT-OUT ...................................................................................................................................... 5 1.8.2 SERVICE REQUEST .......................................................................................................................... 5 1.8.3 REMOTE CONTROL........................................................................................................................... 5 1.8.4 AUTOMATIC TEST ............................................................................................................................. 5

1.9 SIMPLE MAINTENANCE TASKS.........................................................................5 1.9.1. ELECTRICAL MAINTENANCE.......................................................................................................... 5 1.9.1.1 Overload fault ................................................................................................................................... 5 1.9.2. MECHANICAL MAINTENANCE......................................................................................................... 5 1.9.2.1 How to restore the fuel circuit........................................................................................................... 5 1.9.3. PERIODIC CHECKS .......................................................................................................................... 5

AUTOMATIC .................................................................................................................................... 5 2.0 INSTALLATION MANUAL ......................................................................................5 2.1 CONTROL PANEL CONSTRUCTION .....................................................................5

2.1.1 EXTERNAL COMPOSITION............................................................................................................... 5 2.1.2 INTERNAL COMPOSITION ................................................................................................................ 5

2.2 OPERATION..........................................................................................................5 2.2.1 MEASUREMENTS .............................................................................................................................. 5

2.3 DETAILED OPERATING DESCRIPTION ................................................................5 2.3.1 AUTOMATIC MODE «AUT» ............................................................................................................... 5 2.3.2 «OFF» MODE...................................................................................................................................... 5 2.3.3 MANUAL COMMAND FUNCTIONS « MAN » .................................................................................... 5 2.3.4 MANUAL STOPPING.......................................................................................................................... 5

2.4 GENERATOR PARAMETER MEASUREMENTS......................................................5 2.4.1 THREE-PHASE / SINGLE-PHASE GENERATOR SENSOR............................................................. 5 2.4.3 CT CONNECTIONS ............................................................................................................................ 5


2.4.4 ELECTRONIC PROTECTION AGAINST OVERLOADS (51) AND SHORT-CIRCUITS (50) OF THE GENERATOR................................................................................................................................................5 2.4.5 RESIDUAL CURRENT OR GROUND FAULT PROTECTION (TRIP) ...............................................5 2.4.6 OPERATING PRINCIPLE ...................................................................................................................5 2.4.7 PROGRAMMING .................................................................................................................................5

2.5 INPUTS AND COMMANDS .................................................................................... 5 2.5.1 CC 12 AND 24V POWER CIRCUITS .................................................................................................5 2.5.2 STARTED ENGINE DETECTION........................................................................................................5 2.5.3 REMOTE CONTROLS.........................................................................................................................5 2.5.3.1 EMERGENCY STOPPING (18) (NC) ...............................................................................................5 2.5.3.2 EJP FUNCTION (21).........................................................................................................................5 2.5.3.3 ON / OFF START / STOP FUNCTION (20).....................................................................................5 2.5.3.4 LOCK FUNCTION (19) .....................................................................................................................5 2.5.3.5 FORCED START OR FIRE SAFETY DEVICE (19) UNI 9490 NFPA NFS61.940 ..................5 2.5.4. DIGITAL INPUTS AND PROTECTIONS ............................................................................................5 2.5.4.1 PROGRAMMABLE ENGINE PROTECTION DIGITAL INPUTS ......................................................5 2.5.5. MEASUREMENT ANALOG INPUTS..................................................................................................5 2.5.5.1 ENGINE PARAMETER MEASUREMENT ANALOG INPUTS (pressure, temperature, level) .........5 2.5.5.2 READING PRECISION .....................................................................................................................5 2.5.6 OIL PRESSURE (38) ...........................................................................................................................5 2.5.7 ENGINE TEMPERATURE (16)............................................................................................................5 2.5.8 FUEL LEVEL (15).................................................................................................................................5 2.5.9 FUEL PUMP COMMAND.....................................................................................................................5

2.6 MISCELLANEOUS FUNCTIONS AND AUXILIARY EQUIPMENT .......................... 5 2.6.1 COMMAND RELAYS AND OUTPUTS ................................................................................................5 2.6.2 ENGINE PREHEATING .......................................................................................................................5 2.6.3 GLOW PLUGS PRE-HEATING (output 31) .........................................................................................5 2.6.4 DOUBLE BATTERY (output 31) UNI 9490 NFPA NFS61.940 ...................................................5 2.6.5 ALARMS LOG ......................................................................................................................................5 2.6.6 BACK FEED PROTECTION (32).........................................................................................................5 2.6.7 WEEKLY CLOCK.................................................................................................................................5 2.7 SETUP.....................................................................................................................................................5 2.7.1 MENU LIST ..........................................................................................................................................5

M2 - Times ....................................................................................................................... 5

M3 - Settings..................................................................................................................... 5

M4 - Clock........................................................................................................................ 5

M5 – Serial line .................................................................................................................. 5

M6 – Residual current device .................................................................................................. 5

M7 - Tuning ...................................................................................................................... 5

M8 - Can Bus .................................................................................................................... 5

M9 – Defaults .................................................................................................................... 5 2.7.2 NOTE ON PROGRAMMING.............................................................................................................5 2.7.3 SELFPROGRAMMING ..................................................................................................................5

2.8 TECHNICAL CHARACTERISTICS ......................................................................... 5

2.9 WIRING DIAGRAM ................................................................................................ 5

2.10 Connections layout ............................................................................................ 5

2.11 MC3 module dimensions .................................................................................... 5

2.12 INSTALLATION................................................................................................... 5 2.12.1 POSITIONING....................................................................................................................................5 2.12.2. EARTH CONNECTIONS (PE) ..........................................................................................................5


2.12.3 POWER CONNECTIONS ................................................................................................................. 5 2.12.4. CONNECTIONS TO THE BATTERY............................................................................................... 5 2.12.5 STARTING AND STOPPING............................................................................................................ 5 2.12.6 STOPPING WITH SOLENOID VALVE ............................................................................................. 5 2.12.7 ENGINE MONITORING PROBES .................................................................................................... 5 2.12.8 ELECTRICAL STRENGTH TEST ..................................................................................................... 5

2.13 SERVICE PROCEDURES ......................................................................................5 2.13.1 COMMISSIONING PROCEDURE .................................................................................................... 5 2.13.2 BATTERY REPLACEMENT PROCEDURE...................................................................................... 5 2.13.3 MC3 BOARD REPLACEMENT PROCEDURE................................................................................. 5

2.14. OPTIONAL EXPANSIONS AND REMOTE CONTROL...........................................5 2.14.1. REMOTE SIGNALS - INTERNET - INTRANET - ETHERNET ........................................................ 5 2.14.2. REMOTE CONTROL........................................................................................................................ 5 2.14.3. REMOTE CONTROL AND MODEM................................................................................................ 5

2.15. MODBUS REGISTERS MAP.................................................................................5 2.15.1. AVAILABLE REGISTERS HOLD ..................................................................................................... 5

2.15.2. AVAILABLE REGISTERS INPUT .................................................................................................... 5

2.15.3. AVAILABLE REGISTERS INPUT (LOG) ......................................................................................... 5

2.15.4. AVAILABLE COILS .......................................................................................................................... 5

2.15.5. AVAILABLE INPUT STATUSES ...................................................................................................... 5

2.15.6. SLAVE ID REPORT ......................................................................................................................... 5

2.16 - CAN BUS............................................................................................................5 2.16.1. CONFIGURATION ........................................................................................................................... 5

2.16.2. MAIN PAGE...................................................................................................................................... 5

2.16.3. MEASUREMENT DYNAMICS PAGE .............................................................................................. 5

2.16.4. ACTIVE FAULT DYNAMICS PAGE................................................................................................. 5

2.16.5. ALARMS MANAGEMENT................................................................................................................ 5

2.16.6. COMMMANDS TRANSMITTED TO THE ENGINE CONTROL UNIT ............................................. 5

2.16.7. REMOTE CONTROL AND CANBUS............................................................................................... 5

3.0 MAINTENANCE......................................................................................................5 3.1 ROUTINE MAINTENANCE .................................................................................................................... 5 3.2 ELECTRICAL MAINTENANCE .............................................................................................................. 5 3.3 EFFICIENCY TEST................................................................................................................................ 5 3.3 ENGINE SAFETY DEVICES.................................................................................................................. 5 3.4 GENERATOR SAFETY DEVICES......................................................................................................... 5 3.5 OVERLOAD SAFETY DEVICE 51 ......................................................................................................... 5

4.0 TROUBLESHOOTING.............................................................................................5

The data given in this document are subject to possible variations due to technical updates to the design project.


1.0 USER MANUAL

1.1 INTRODUCTION We congratulate you for having purchased ENGINECONTROL 3 (MC3) for the management of your generator set. As you use your new control system you will gradually become familiar with its performance and the extensive range of possible applications available. This electronic microprocessor module provides comprehensive control of a generator set and is also prearranged for direct serial communication with a PC or, with the addition of a GSM modem: you will be able to control and monitor the operation of your generator set from a remote location, irrespective of the distance. Model MC3 is equipped with complete digital instrumentation that allows full monitoring of all engine, generator, pump, or compressor parameters. The USER MANUAL has been prepared to provide a clear and simple guide to help you use the unit rapidly, in complete safety, and exploiting all it to its full potential.

1.2 PURPOSE All information required for the management of generator sets is supplied in this manual:

1. Introduction to the unit’s principle of operation; 2. Interpretation of electronic panel signals; 3. Management of the electronic control board in all operational situations; 4. Execution of the basic checks required to ensure lasting efficiency of your generator set.

Technical details and set-up information are not covered, since these are the specific responsibility of the installation engineer at the time of system commissioning.

1.3 OPERATING PRINCIPLE 1.3.1 HOW THE "ENGINECONTROL 3" GENERATOR CONTROL SYSTEM WORKS

The system's components are represented in fig.1 and include: generator set GM and control panel QGE, which incorporates generator set contactor CG and control module MC3.

Model MC3 operates the generator set manually or automatically by means of an external START / STOP command. During operation, all generator set electrical and mechanical parameters are displayed and all safety devices against overloads, short circuits, and earth faults are active. If a fault occurs, breaker CB is opened by trip CO, causing the load to be disconnected.

Fig. 1

M G

LOAD

CB

QGE

START/STOP


If the MC3 is set to Manual mode, breaker CB also opens when the STOP command is transmitted, while in Automatic mode breaker CB opens only in the case of an overload, short circuit, or earth fault. When combined with an Automatic Transfer Switch with mains sensor, MC3 becomes a complete system for the management of mains power outages, as shown in Fig 2.

R Mains QGE Control panel CR Mains contactor GM Generator set (generator +

engine board) MC3 Electronic control board CG Generator set

contactor CB Generator set breaker switch CO Trip coil

1.3.2 OPERATION COMBINED WITH ATS FOR MAINS POWER OUTAGES If we assume mains R is within normal limits: contactor CR is closed and the user is powered by the mains. The ATS module monitors mains R and in the event of an anomaly due to a voltage drop, phase loss or asymmetry between phases, it reacts as follows: 1. opens mains contactor CR; 2. enables MC3 to start the generator set; when the generator set is running at operating speed, it closes

contactor CG and feeds the user service from generator G; N.B.: During operation engine M and generator G are monitored to detect possible anomalies that would cause immediate shut down of the generator set with the consequent saving and display of the cause of the relative alarm (e.g. low oil pressure, overload, etc). 3. When mains R returns to within normal limits, after an adjustable delay interval the ATS module opens

generator set contactor CG and, afer one second, closes contactor CR thereby feeding the user service from the mains power line R;

4. The generator set continues to run for at least one more minute to cool down after which it stops automatically.

CR CG

USER

R ATS

M G

LOAD CB

QGE

START / STOPCOMMAND

CO


1.4 VIEW OF THE “MC3” MODULE Functional description of the panel blocks.

1.5 FUNCTIONAL DESCRIPTION OF CONTROL PANEL COMPONENTS 1.5.1 COMPONENTS DESCRIPTION

1. Key for activating and selecting the operating mode.

AUT: generator set starts automatically in response to an external command.

ZERO: generator set is completely deactivated – no power draw from the power supply battery.

MAN: the START and STOP commands are activated manually.

1. CONTROL KEY Automatic mode. (AUT) Manual mode. (MAN)

4. MODE buttons to select parameters and Reset button to restore functions or reset alarms.

5. ACK alarm mute Fuel pump manual command. Engine preheating or glow plugs

2. Manual start and stop buttons.

3. Numerical and graphic display for presentation of all measurements and graphic description of alarm type


2. 3x4 digit numerical display with 40 graphic symbols; 3. START and STOP manual control buttons; 4. MODE buttons for selecting the measurement page, alarms RESET button; 5. ACK alarm acknowledging and silencing button, fuel pump manual command, and ON/OFF button for

engine preheating. 1.5.2 DESCRIPTION OF THE VARIOUS MEASUREMENTS The following data are shown while the generator is running:

• the three phase to phase voltages and the three star voltages between phase and neutral; • the three phase currents • KVA power values = kilovolt-ampere = apparent power; KW = kilowatt = real power; • KVAr = kilovar = reactive power. • Cosfì = power factor = phase displacement angle between voltage and current • KWh = kilowatt-hour = total energy supplied by the generator. • battery voltage • RPM = engine revolutions. • LC = percentage of fuel in the tank. • PO: oil pressure. • TM: engine temperature. • Totalizer hour counter • Successful and failed engine starts counter • Weekly clock: the clock will run independently for 60 hours if disconnected from the battery, and it is

used for automatic testing, automatic blocking and emergency power generating units. • Residual current protection: trips when the earth leakage current exceeds the set values (visible on

line 3 of the residual current device page). Unit MC3 is equipped with automatic control of the diesel-refuelling pump: when running, the LED is illuminated and the button is used for direct manual control. Speed + changes parameter values during programming The engine START button is enabled only when the selector is set to MAN. The command is AUTOMATIC so there is no need to keep pressing the START button. The LED indicates that the start command is in progress. The STOP button, which is disabled in automatic mode, stops the engine when pressed. The LED indicates that the stop command is in progress. Pressing the ACK button acknowledges the alarm, deactivates the siren, and causes the LED to stop flashing and illuminate steadily. Pressing this button activates the clock in pumpset mode. RESET eliminates alarm status and restores functions. ENTER confirms a selection or saves data during programming. Controls preheating or the glow plug. The LED switches off when programmed preheating time ends. Speed - changes parameter values during programming Selects the measurement page or the programming parameter on the display


Graphic symbols used on the display.

Generator Voltage phase 1,2,3 V1, V2, V3 Low oil pressure

Generator Current phase 1, 2, 3, A1, A2, A3 Engine High Temperature

Generator Frequency Hz Battery Charging Alternator

Apparent power KVA Low Fuel Level

Real power KW Timing ON OFF

Reactive power KVAR General alarm

Power factor COSFI' Failed Starting

Maximum Threshold Exceeded MAX Overspeed or Engine Revs

Minimum Threshold Exceeded MIN Battery 1 or 2, battery voltage

Free alarm 1 ALARM 1 Water or Oil Level

Free alarm 2 ALARM 2 Clock

Automatic start command COMMAND Override

Programming MEMORY Lock

Serial communication on REMOTE Maintenance

Drive unit MASTER EMERGENCY

Hour counter totalizer TH Water pressure BAR Each measurement is associated with a symbol or measurement unit. For example:

oil pressure value 3.5 is combined with the low pressure symbol.

The same is true for engine temperature 69

Whereas low fuel level is not active NONE Combinations of symbols are also used to indicate the type of measurement or anomaly. For example, if a maximum voltage alarm occurs the V1+MAX, V2+MAX, or V3+MAX symbols are used. With overspeed, HZ + MAX is used If the EMERGENCY button is pressed, the following symbol will be shown: When the low fuel alarm trips, the siren sounds and the following symbol is displayed


1.6 CONTROLS AND OPERATING MODES Two operating modes can be selected: 1.6.1 AUTOMATIC MODE (AUT) The generator set is started when the command is given and a permissive signal allows the generator to supply the user. During operation the generator and engine are constantly monitored and any faults are displayed immediately (e.g.: low fuel level, low coolant level, overload, min. voltage, etc.) and the relative stopping cycle is triggered. When the stop command is given, the permissive for power feeding to the load is removed and the generator set is stopped after a delay of approximately one minute in order to allow the dissipation of excess heat. 1.6.2 OFF Supply to the electrical circuits is suspended and the generator set is disconnected. (Used for maintenance). 1.6.3 MAN Permits manual control of the generator set using the START and STOP buttons. After the generator set has started, the system waits for arrival at operating speed before closing the switch to supplying the load. During the stopping phase, first the load is disconnected by opening the contactor and after approximately one minute the generator set is stopped.

WARNING! With the programming key in "MAN", the unit's control circuits such as the solenoid valves, electronic

speed governors, etc., are supplied by output 15/54, which is activated only after the START button has been pressed.

1.6.4 STOPPING WITH THE STOP BUTTON ON THE ELECTRONIC BOARD When the stop button is pressed the engine is stopped. This function can be disable din automatic mode by means of the specific jumper located on the rear of the board. 1.6.5 EMERGENCY STOP When pressed, the red mushroom head pushbutton stops the generator immediately, opening the generator contactor (CB) instantly and blocking the generator set. 1.6.6 FUEL PUMP CONTROL (if present) The MC3 module is equipped with electronic fuel level control and performs automatic control of the fuel pump in order to ensure that the tank is full on a day to day basis. A button permits direct control of the pump, forcing automatic filling until the set level has been reached. 1.6.7 ACTIONS IN THE CASE OF GENERATOR SET BREAKDOWN When an alarm condition occurs, the relative alarm will be shown on the display. In the presence of malfunctions, press the ACK button once to mute the siren, check the cause of stopping and then press the RESET button to restore all functions. Causes and the solutions differ depending on the type of anomaly: 1. Electrical anomalies due to min./ max. voltage and frequency: if the anomaly persists after the RESET

button has been pressed, request technical assistance;

2. Anomaly due to low oil pressure, high engine temperature, low water or oil level, low fuel level etc.; check the relative levels (water, oil, fuel), top-up if necessary, then reset;

3. Battery charging alternator fault: call technical assistance;

4. Alarm due to active local or remote emergency stop status: set the key to the "OFF" position. Twist and pull the emergency pushbutton that was pressed and then reset;

5. Alarm due to failed starting: try starting with manual control and inform the supplier;

6. Generator overload protection switch tripped: this switch must be reset manually by a qualified engineer (see simple maintenance tasks section).


1.7 MISCELLANEOUS CONTROLS 1.7.1 LED TEST This routine is performed automatically whenever the module is powered on. 1.7.2 ALARM MUTING (ACK) When an alarm is active, the red alarm LED blinks and the siren sounds. Pressing the ACK key mutes the siren. 1.7.3 FUNCTIONS RESET When the RESET key is pressed the alarm conditions are cancelled, all functions are reset, and the red alarm LED is turned off. 1.7.4 RESIDUAL CURRENT PROTECTION TEST (if active) Open the "diff" page on the display and press RESET for 3 seconds. The TRIP switch must act, opening the generator contactor (CB) and disconnecting the load.

1.8 SPECIAL FUNCTIONS The MC3 module features a series of special operating functions: automatic testing or cut-out, routine maintenance, remote control, etc. If these are active, when they start an icon appears on the display and the function in progress is shown. There are functions that affect how the unit operates and that require direct intervention to allow the unit to be used:

1.8.1 GE CUT-OUT The cut-out function is mainly used when the unit is run in a built-up area, and emergency standby operation 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. 1.8.2 SERVICE REQUEST The MC3 has an hour counter to schedule maintenance, oil changes, filter changes, etc. When the hour counter trips to alert the operator of a scheduled requirement, this does not affect operation of the system; the siren sounds for the programmed time and the MAINTENANCE1 icon appears on the display. Press RESET to clear the message from the display. 2 service intervals can be configured using the T10 and T11 fields of menu M2.

1.8.3 REMOTE CONTROL The generator set can remote controlled by using “remote” communication (PC, modem or GSM) with automatic activation. 1.8.4 AUTOMATIC TEST The control board can be configured so that it performs a timer controlled automatic test of configurable duration. Use fields O4 and O5 fields in menu M4 to select the day of the week for the test and the start and end times of the test. The clock must be set correctly to enable this function.


1.9 SIMPLE MAINTENANCE TASKS

USER SAFETY PROCEDURE

WARNING! It is strictly prohibited to work on live electrical parts.

1.9.1. ELECTRICAL MAINTENANCE All jobs must be performed by skilled personnel. The control module panel is equipped with all command, control and reset functions. Proceed as follows to access the devices inside the control panel:

1. Set the programming switch to OFF. 2. Check to ensure that the generator set has come to a complete standstill. 3. Disconnect the mains line feeding the control panel and open the main disconnect switch upline from

the system. 4. Open the control panel and check for any anomalies in the:

• fuses; • automatic switches;

Once maintenance has been completed repeat the procedure in reverse sequence in order to prepare the unit for operation. 1.9.1.1 Overload fault This may cause the generator set breaker to open (lever in central "TRIP" position). Reset the circuit breaker by pushing the lever down to the OFF position and then returning it to the ON position. In the case of circuit breakers installed inside the electrical panel, follow the ELECTRICAL MAINTENANCE procedure before opening the panel. 1.9.2. MECHANICAL MAINTENANCE If the generator should fail to start due to an anomaly in the fuel circuit in emergency power conditions, the following tips may prove useful. 1.9.2.1 How to restore the fuel circuit

1. Set the selector to (MAN) and press the START button briefly without starting the generator set: this serves to activate output 15/54 output, which supplies power to the fuel cut-off solenoid valve.

2. Once you have filled up with fuel, operate the hand pump located on the engine until the circuit has been refilled – this condition is achieved when the level of resistance of the pump hand lever increases.

3. Start in manual mode (starting attempts should be restricted to 10 seconds each with a pause of 15 seconds between successive attempts to allow the battery to recover).

4. 1.9.3. PERIODIC CHECKS To keep your generator set in good working order some periodic checks must be carried out together with those scheduled by the engine manufacturer and by the installation engineer: 1. 2. check the battery electrolytic level every 15 days after installation and request technical assistance if the

level seems to drop excessively. Following the initial period check every 30 - 60 days 3. In generator sets equipped with engine preheating, check to ensure that the engine is warm at the time of

the batteries electrolyte level check. If the engine is cold, request technical service. (WARNING ! A cold engine in low ambient temperature conditions may be difficult to start and may not deliver the required power output once it is running)

4. If the generator is rarely started in response to mains power outages, perform an automatic start test once a month for at least 2 minutes.

5. If new electrical users are installed in the system powered by the generator, request technical assistance to check the suitability of the CG/CG mains/generator transfer switching to the new load.

6.

SUMMARY: Periodically check the electrolyte level in transparent sided cranking batteries. Touch the engine to feel if it is warm (if equipped with pre-heating system) Periodically carry out a manual or automatic test.


OPERATING PRESCRIPTIONS The key selects the unit's operating mode. AUTOMATIC Generator set starts automatically in response to power loss command and feeds power to the users. Generator set stops when external enable signal is removed. OFF Generator set is disconnected. All ancillary equipment, engine preheating, and fuel pump are deactivated. Safety condition for maintenance MANUAL The controls are manual, but operations are controlled electronically. All the installed electrical and mechanical protections are active during operation. The buttons do not affect the operating mode established by the key. Only the STOP button is continuously enabled in manual mode. The Stop but ton may be excluded in automatic mode. Mode buttons for selecting display readings: these buttons are used to select the required display page and to program the weekly clock. The ACK button mutes the siren and sets the alarm LED to steadily illuminated. RESET/ENTER button: resets the functions and eliminates alarm status (RESET), or confirms data during programming (ENTER). LED TEST Automatic every time the MC3 is powered, with display of graphic symbols and software update number. RESIDUAL CURRENT TEST: go to the residual current parameters page and press RESET for a few seconds. The residual current device will trip, the message “diff” will flash on the display and the circuit breaker will be opened. EMERGENCY STOP When this pushbutton is pressed the generator set stops immediately, the generator circuit breaker or contactor opens, and the unit is locked. To deactivate emergency status, release the emergency button and reset the MC3 module. FUEL PUMP COMMAND (if present) Permits direct control of the pump with maximum safety level protection only. PREHEATING COMMAND In automatic mode the command is excluded. The cycle is activated automatically at every start-up. In manual mode preheating should be activated when the engine is cold. The cycle is automatic for the programmed time interval and is accompanied by illumination of the relative LED. The LED switches off when the programmed preheating time has elapsed. START COMMAND The start command is inhibited in automatic mode. The start cycle is completely automatic. In manual mode, the start command remains active for as long as the button is pressed (limited by programmable maximum activation time). When the engine starts the START button is deactivated. STOP COMMAND The Stop command can be inhibited in automatic mode. If it is active, pressing Stop opens the generator set circuit breaker, stops the GE, and sets it to LOCKED status. The Stop command is always active in manual mode – when pressed it opens the generator set circuit breaker and stops the GE. STOP PROCEDURE IN MANUAL MODE To avoid engine overheating, the generator set circuit breaker must be opened before stopping in order to allow the engine to dissipate excess heat; allow the engine to run in no load conditions for about one minute and then stop. With the engine stopped set the key to zero to avoid power draw from the battery.


2.0 2.0 INSTALLATION MANUAL

2.1 CONTROL PANEL CONSTRUCTION The control panel is manufactured in compliance with the following European standards: ANS low voltage electrical control panels EN 60439-1 Electromagnetic compatibility directive 89/336/EEC Each control panel or device is completely tested and accompanied by a test certificate, declaration of conformity and CE marking in compliance with the safety regulations set down in Italian Law 626. The control panel is composed of a 15-20/10 gauge steel sheet cabinet with surface treatment and Ral 7032 silica grey epoxy powder coating. The cabinet protection rating is IP 42. 2.1.1 EXTERNAL COMPOSITION The control panel incorporates: 1. MC3 electronic circuit board containing the control logic for management, monitoring and display of

generator set operational parameters; 2. Mushroom head emergency stop pushbutton; 3. Nameplate with operating prescriptions; 4. Nameplate with safety instructions. 2.1.2 INTERNAL COMPOSITION 1. Numbered cables routed in PVC trunking; 2. 10 x 38 fuses with disconnectable fuseholders; 3. Generator protection breaker switch (if envisaged); 4. Three current transformers for generator and mains current measurements; 5. Terminal for mains and generator inputs, used output and auxiliary connections; 6. Nameplates for safety, fuse ratings and connection terminal assignments.

2.2 OPERATION 2.2.1 MEASUREMENTS All measurements are shown on three 4-character displays. All measurement pages are controlled using the MODE buttons, which serve to scroll the pages in both directions. The measurement pages available are as follows: • Generator status, volts, hertz and amperes of phase 1 • Generator X, Y, Z phase voltage. • XN, YN ZN generator star voltage. • Current values on the three generator phases; • Generator power values, KVA, KW, KVAr; • Generator kilowatt-hours • Power factor, cosfì, generator HZ; • Residual current device, programmed current, leakage current and programmed time; • Battery, charge voltage • Weekly timer for automatic test programming. • Maintenance, with programmed hours and duty hours remaining before service. The presence of an alarm condition is shown on the display by means of icons.


2.3 DETAILED OPERATING DESCRIPTION The control unit has two operating modes selected by means of a keyswitch: 1. AUTOMATIC 2. OFF 3. MANUAL START 2.3.1 AUTOMATIC MODE «AUT» Automatic use of the GE refers to operation in conjunction with an automatic transfer switch unit (ATS) for mains power emergency backup service, by means of a clock, or with remote control.

1. The start command (terminal 20 ON) triggers a series of four start cycles each of 5 seconds in duration alternating with 5-second pauses (programmable). If the engine is equipped with glow plugs, they can be controlled by a programmable command.

2. If the engine has not started when the start cycles have finished, the STARTUP FAILED warning will trip. If engine starts but fails to reach operating speed, a minimum voltage or minimum frequency alarm will trip after a configurable time interval.

3. During start-up the safety devices against overspeed and overvoltage are active. The GE is stopped immediately if the preset limits are exceeded for 1.5".

4. When the engine reaches operating speed, the voltage and frequency supplied by the generator are read. When these are within the established parameters, the engine protections are activated after a programmable time.

5. By means of a normal VDO or VEGLIA probe for engine temperature detection, the minimum temperature above which the load output is enabled can be programmed. This is to prevent low temperature operation in the case of a fault or if engine preheating should fail. This function may be used on systems equipped with an ATS.

6. While the generator is running three pre-alarm safety devices are enabled: oil pressure, engine temperature and fuel level. When these alarms trip an audible alarm is sounded, while tripping of the following protections generates a display message and the functions described below:

N° DESCRIPTION LED

COLOUR/ FNCT:

AUDIBLE ALARM

IMMED. STOP

DELAYED STOP

ENGINE PROTECTIONS 1 Failed starting LCD A SI 2 Low oil pressure LCD A SI 3 Minimum oil pressure (pre-alarm) LCD A 4 Low water level LCD A SR 5 Very high water temperature LCD A SI 6 High water temperature (pre-alarm) LCD A 7 Battery charge alternator LCD A SI 8 No fuel LCD A SR 9 Low fuel level (pre-alarm) LCD A

10 11

WARNINGS 12 General alarm R A 13 Fuel pump active (ON) V 14 Engine/glow plugs preheating V 15 Start ON R 16 Stop ON R 17 Automatic ON V 18

BATTERY 19 Low battery voltage LCD A 20 Excessive battery voltage LCD A 21

GENERATOR 22 Overvoltage (59) LCD A SI


23 Undervoltage (27) LCD A SR 24 Overload (51) LCD A SR 25 Short-circuit (50) LCD A SR 26 Maximum frequency (81) LCD A SI 27 Minimum frequency (81) LCD A SR 28 Residual current device (ground fault) LCD A SR 29 30 31 Emergency pushbutton pressed LCD A SI 32 33

7. When an alarm is triggered and the generator is stopped, the following occurs:

• Activation of the respective alarm icon on the display. • Immediate disconnection of the load by means of the unit contactor on the ATS. • Activation of immediate stopping (SI) or delayed stopping (SR) stopping after the engine cooling phase (If stopping is enabled). • The siren is activated and the flashing red ACK LED comes on. • Saving of the cause of the alarm. • Stopped status until reset. The first time the ACK button is pressed the siren is silenced and the alarm is acknowledged. To reset the functions and eliminate stopping because of the alarm, press the RESET button again. The red LED alarm turns off.

8. When short circuits and overloads occur or the residual current device trips (ground fault), the CB generator set circuit breaker is opened and, after the engine cooling phase, stopping takes place.

9. When the START command is given, the engine cooling phase begins and lasts approximately 1' (PROG), after which stopping is activated.

10. If the engine does not stop after a 30 to 250" programmed time the alarm status intervenes and a failure to stop signal is activated. All the functions are blocked until manual reset.

11. Pre-arrangement for a new cycle 2.3.2 «OFF» MODE 1. Excludes power to all circuits. 2. Guarantees safety during maintenance operations. 3. Deactivates the fuel pump and preheating so that none of the components are powered during

maintenance. 2.3.3 MANUAL COMMAND FUNCTIONS « MAN » Manual use of the GE is intended as isolated and the operator directly controls the GE. It enables the start button and when the command is given, relay 15/54 is simultaneously activated, which provides power to all of the unit's ancillary equipment (solenoid valves, actuator, etc.). During operation all of the engine and generator protections are active, as stated in points 1.6 - 1.7. Whenever an alarm occurs, the open command is sent to the CB unit's switch (which will need to be manually reset) in order to prevent stopping of the GE with the load connected. 2.3.4 MANUAL STOPPING The stop button may be disabled in automatic.


2.4 GENERATOR PARAMETER MEASUREMENTS The voltmeter measurements indicate the root mean square value (RMS) and feature precision of 1% with deviation of +/- 5.5 V with temperatures between -20 and +70°C. 2.4.1 THREE-PHASE / SINGLE-PHASE GENERATOR SENSOR The generator sensor is sensitive to the maximum and minimum voltage on each phase, and to the sequence of the three phases. It can work within a range of 100 to 500 V in direct connection and via a VT from 600 to 9,000/100V. The three phase mains sensor is made with three 500K OHM resistance dividers with high insulation voltage capable of withstanding any excessive voltages of up to 5KV for 1 second. It is sensitive to the minimum and maximum voltage on each phase and to the phase displacement angle of the three phases. All parameters can be modified. Main characteristics: Generator control Three-phase Functions 27 – 59 – 60 – 81 – 47(*) Working voltages 100 - 500 V ac with direct connection Working voltages with VT 600 – 9000/100V Minimum adjustable voltage -10 (30% Vn (27) Maximum adjustable voltage +10 (30% Vn (59) Insulation voltage on L1 – L2 – L3 – L4 => 5 KV for 1s Working frequency 50-60 Hz Minimum frequency -10 (30% HZn (81) Maximum frequency +10 (30% HZn (81) When the software is used to configure the sensor, in single phase, the control on connections L1 - L4 is activated. Generator control Single phase Working voltage 70 - 340 V ca (*) FUNCTIONS Generator connections

X ÷ L1 Y ÷ L2 Z ÷ L3 N ÷ L4

GEN MC3 1 3 5 7

THREE-PHASE CONNECTION WITH NEUTRAL TO GROUND TNC OR TNS

X ÷ L1 Y ÷ L2 Z ÷ L3 N ÷ L4

GEN MC3 1 3 5 7

THREE-PHASE CONNECTION WITH NEUTRAL ISOLATED FROM GROUND IT

R

X ÷ L1 N ÷ L4

GEN MC3 1 3 5 7

SINGLE-PHASE CONNECTION

X ÷ L1 Y ÷ L2 Z ÷ L3

GEN

THREE-PHASE CONN. WITHOUT NEUTRAL

MC3 1 3 5 7


2.4.2 CURRENT MEASUREMENTS The three current measurements for CT .../5A are class 0.5 up to 1000 A, class 1 from 1000 to 2000 A and 1.5 class from 2000 to 3000 A. The ammeter circuits are made up of three 0.1Ω 5W resistances, with a dissipation of 2.5W at maximum current (5 A). They can work at a constant overload of 20% 6 A, and have a short-circuit protection of 15 A for 3" or 20 A for 2". To ensure protection against overloading and short-circuits the CTs used must have a minimum power of => 4VA. Where the CTs also power other equipment, this power is increased to suit the power these require plus losses in the wires. Consumption table in VA per metre of wire. SECTION mm2 1.5 2.5 4 6 CONSUMPTION VA

0.685 VA 0.41 VA 0.254 VA 0.169 VA

2.4.3 CT CONNECTIONS CT PHASE R-L1 8 ÷ 11 CT PHASE S-L2 8 ÷ 10 CT PHASE T-L3 8 ÷ 9

2.4.4 ELECTRONIC PROTECTION AGAINST OVERLOADS (51) AND SHORT-CIRCUITS (50) OF THE GENERATOR The generators are supplied with power expressed in KVA since the actual load limit of the generator is determined by the amperes permitted on the windings. Overloads (51): If the rated current of the generator is exceeded following a set timing the generator contactor is opened (at the same time the TRIP 39 and 40 contact is activated), the overload alarm is triggered and the generator is stopped following the engine cooling phase

Short-circuit 50: 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. M2 and M3 programming.

WARNING measuring current transformers are provided for short circuit protection function 50; the transformers are able to deliver three times the rated current (5x3 = 15 A) in a linear mode

without reaching saturation.

11 10 9 8

0,1Ω 5W

M C 3

3 x CT 15 ÷ 3000/5A

T s Tp 2 0

I 1 I 2 I 3 I 4 I 5 I 6 I A

TRIP CURVE

Tp = programmed overload delay (15 – 255”) I1 = GE rated current (10 – 3000 A) I3 = I1 x3 short circuit current (Off – 16320 A) 2” fixed delay

L

I


2.4.5 RESIDUAL CURRENT OR GROUND FAULT PROTECTION (TRIP) Checks ground leakage currents. It closes the TRIP contact between connections 39 and 40. The contact is NO. If the set current is exceeded by 50% during operation, "diff" starts to flash rapidly. The switch is opened if the set threshold is exceeded. The leakage current, the programmed currents, and the programmed delay are shown on the display. The residual current device is equipped with a test coil that is activated with the DIFFERENTIAL TEST, which is carried out, by going to the "diff" display page and pressing RESET for 3". This will cause the relay to permanently intervene on connections 39 and 40 until the RESET command is given. Technical characteristics:

• Sensitive to waveforms type sinusoidal, choked sinusoidal, pulse and pulse with continuous component up to 6mA.

• Operating frequency 47 - 63 Hz. • Tripping current IΔn programmable from 0.05 to 5 A. • Tripping time programmable from 0.1 to 5 seconds. • Instantaneous tripping within 60 milliseconds. • Negative safety (NO) modifying the output contact 39 -40. • Adaptable to toroids with 500 - 750 - 1000/1 windings and with test coil. • Reset using the RESET pushbutton enabled with current leakage less than 50% IΔn.

2.4.6 OPERATING PRINCIPLE The MC3 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 leaking to ground, and after the relevant delay the load is deactivated via contact 40-41. 2.4.6.1 CONNECTIONS Fig. A shows the 87G 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 windings. The insulation between the neutral (N) and the earth (PE) must be checked on setting the unit up, as any connection between the two would by-pass the residual current trip switch. Fig. B shows the 67N residual current device commonly used.

Adaptable to toroids with 500/1 - 750/1 - 1000/1 winding ratio 2.4.7 PROGRAMMING

1. On menu M6, program the toroid's winding ratio in F1 500-700-1000/1. Program the trip current in F2 and the trip delay in F3.

X ÷ L1 Y ÷ L2 Z ÷ L3 N PE

GEN LOAD


FIG. B MC3 32÷35

X ÷ L1 Y ÷ L2 Z ÷ L3 N

GEN LOAD


FIG. A

MC3 32÷35

PE TOROID

MEASUREMENT TEST 10Kohm 0.5W

32 33 34 35

TOROID WITH TEST WINDING

MEASUREMENT TEST

32 33 34 35

TOROID WITHOUT TEST WINDING


2.5 INPUTS AND COMMANDS 2.5.1 CC 12 AND 24V POWER CIRCUITS The MC3 is foreseen for operation at 12 and 24V. A jumper on the left side of connector CN3 permits configuration. The MC3 is supplied configured for 24V. 2.5.2 STARTED ENGINE DETECTION No external signal is required. The control is carried out on the generator's frequency. During start-up, the first signal of engine start-up occurs when 540 rpm corresponding to programmable 18Hz have been reached. If the generator's voltage (at least 7V) is not present because of a failure, start-up is interrupted definitively by the second safety control caused by the pressurized oil, which activates a delay of 3" that interrupts start-up. Programming M3 S17 settings started engine minimum frequency 2.5.3 REMOTE CONTROLS The following remote controls may be configured using inputs 18-19-20-21:

1. Remote lock command, so that start-up may not occur even with the start/ON control 2. Command with EJP function. Commands start-up after the programmed time. 3. Remote start or stop control 4. Forced start command even with alarm. Manual stopping only.

CONN

FUNCTION SETUP TIMES

18 EMERGENCY STOPPING 19 FORCED START, NO STOP M3 S21 19 LOCK M3 S21 20 START/STOP COMMAND 21 EJP "FRANCIA" M2 T9 0 ÷ 90’

2.5.3.1 EMERGENCY STOPPING (18) (NC) An external emergency command, active under all conditions with immediate stopping of the engine, opening of the unit contact maker, and activation of the alarm. An active emergency command is indicated by the icon. 2.5.3.2 EJP FUNCTION (21) The special EJP function is present on French government systems only. When the EJP is activated, the unit starts after the programmed time (M2 T9). With the EJP2 command, switching immediately occurs from the mains to the unit. This is controlled by the ATS on the switchboard. 2.5.3.3 ON / OFF START / STOP FUNCTION (20) The contact on input 20 is active only when the MC3 is in "AUT". When the ON / START contact is closed, the engine start-up command is given with consequent forced supply by the unit. When the OFF / STOP contact is opened, the CG contact maker is opened (if present) and the unit is stopped after the cooling time. The closed ON contact is indicated by the "COMMAND" icon.

19 EMERG NO STOP ON/OFF EJP1

- Batt.

20 21 18

81 Hz

51 52

Gen

erat

orV

olta

ge

Start Crank

0 10

Once the set frequency is reached: - 9Hz for 3000 rpm - 18Hz for 1500 rpm

the starting command is interrupted.

O

Off

= >


2.5.3.4 LOCK FUNCTION (19) The closed contact on 19 places the board in a forced lock status. This function is especially useful for locking the GE at night or during the weekend. When the lock command is active, the lock icon is shown. Under this condition, the unit may operate only with direct manual commands. 2.5.3.5 FORCED START OR FIRE SAFETY DEVICE (19) UNI 9490 NFPA NFS61.940 This forces supply and prevents stopping by all alarms. Stopping may only be carried out manually. Automatic stopping takes place with 20. If a condition of extreme safety occurs during operation in which energy is fundamental, forced start 19 is activated which prevents all types of anomalies from stopping the GE. By removing the command from 19, the normal automatic stopping functions are activated. Programming in M3 S21 override 2.5.4. DIGITAL INPUTS AND PROTECTIONS 2.5.4.1 PROGRAMMABLE ENGINE PROTECTION DIGITAL INPUTS Some new concept engines are equipped with positive outputs for indicating Low Oil Pressure and High Engine Temperature anomalies. The MC3 is able to communicate with these engines in two ways: Via software or configuration of SW1 located on the upper part of the guard. The SW configurations for the digital inputs are as follows: 1. Engine temperature, programmable contact NO, NC - 26 prg M1 R13 2. Low water level, programmable contact NO, NC - 24 prg M1 R13 3. Fuel reserve, programmable contact NO, NC - 25 prg M1 R14 4. Low oil pressure, NC programmable Active/Excluded for engines without a pressure

switch - 27 prg M1 R15 5. Battery charger generator, programmable Active/Excluded - 28 prg M1 R16 6. Fuel reserve, alarm only or alarm with stopping - 25 prg M1 R17 7. Alarm 1, contact NO 8. Alarm 2, contact NO 2.5.5. MEASUREMENT ANALOG INPUTS

2.5.5.1 ENGINE PARAMETER MEASUREMENT ANALOG INPUTS (pressure, temperature, level) The three 36, 37, 38 inputs for measuring the fuel pressure, temperature, and level may be programmed using the SW switch for MTU engines that supply 0-10V or for Veglia / VDO transducers.

SW Switch 1 ON = standard VDO Veglia 2 OFF = standard VDO Veglia 3 NOT ACTIVE 4 ON = programming OFF = operation

By configuring SW1 ON and SW2 OFF, inputs 37 and 38 are enabled for operation with Veglia and VDO transducers. By configuring SW1 OFF and SW2 ON, inputs 37 and 38 are set up for operation with 0 to 10V and may be connected directly to MTU engines and other types that have the same engine measurement concept. To complete programming, the control SW must be activated in M1. R9 determines selection of standard/MTU transducers. Select MTU to set temperature and oil pressure inputs as MTU inputs. Select STANDARD to choose the transducer type (VDO or VEGLIA). If a probe is not installed, the display indication is automatically inhibited.

NC NO

15 - Batt

36 37 38

FUEL LEVEL WATER TEMP. OIL PRESS. VEGLIA OR VDO CONFIGURABLE ANALOG INPUTS

37 38

0-10V ANALOG

0-10V ANALOG

ANALOG INPUTS CONFIGURED TO 0-10V


O.5

MINIMUM PRESSURE

8 BAR

OIL PRESSURE

150

50

40

20

PRE-ALARM

PREHEAT. OFF

PREHEAT. ON

MINIMUM TEMP.

ENGINE TEMPERATURE

°C

2.5.5.2 READING PRECISION The transducers used on engines can have tolerances of more than 10%. Furthermore, when they are connected to ground (and not via completely isolated terminals), the total measured resistance is influenced by the current on the battery's negative pole. They may therefore be used only as approximate indicators of the measurement and may be configured for pre-alarms that do not affect operation.

2.5.6 OIL PRESSURE (38) Measurement is envisaged for 8-bar transducers. Different values may be adapted from measurement menu M1. The siren may be activated for minimum oil pressure and must be programmed 0.5 bar above the trip value of the oil pressure switch. PROGRAMMING In M1, select Veglia, VDO or MTU transducer for analog input 38. In M3 S11, set the pre-alarm threshold. ATTENTION! DO NOT EDIT THE ZERO VALUE WHILE THE ENGINE IS RUNNING. To align the zero reading, go to M1 “REG. ZERO PO” while the engine is stopped (pressure at 0). 2.5.7 ENGINE TEMPERATURE (16) Measurement is performed for Veglia and VDO engine temperature transducers up to 150°C. When a transducer is present, the following may be activated and programmed:

1. Pre-alarm high temperature, normally programmed at full scale 150°C (1);

2. Preheating command (activate output 28 = preheating in misc. settings). Two levels are set: Activation ON and stop OFF;

3. Minimum temperature (M3 S8) With the engine temperature below the set value, the CB command is deactivated (programmable on fuel pump 29 or on preheating 31), allowing no-load engine warm-up until the minimum temperature is exceeded.

(1) If the high temperature pre-alarm must be programmed, note that the indicated value depends on the wiring and transducer tolerance of up to 7°C. The temperature must therefore be calibrated on M1 R8 and checked with a reference thermometer. The calibration value to be programmed must consider the trip value of the maximum temperature thermostat, which commands stopping (26), and the pre-alarm value must be calibrated at least 3°C below the thermostat.

9 17 11 16

VDO pressure transmitted plus 0-8 bar alarm contact

Thermistor (variable resistance) + VDO thermostat (NO contact) for instrument and indicator

2 - Batt OP OM WT


2.5.8 FUEL LEVEL (15) Fuel level is measured by 0-200 Ohm Veglia or VDO level transducers. When a transducer is present, the following may be activated and programmed:

1. Fuel reserve alarm, normally programmed at 10%; 2. Pump activation level 3. Pump stop level

PROGRAMMING On menu M1, select Veglia or VDO transducer for analog input 36. 2.5.9 FUEL PUMP COMMAND The MC3 module is prearranged to control a fuel pump for automatic daily fuel tank filling. The following levels are electronically defined using the fuel level probe (VDO or VEGLIA) that controls the digital fuel tank level gauge:

DESCRIPTION INDICATION FUNCTIONS LEVEL % Pump stop Pump OFF LED Pump OFF 80% Pump start Pump ON LED Pump start 40% Fuel reserve Display Siren 10%

The trip thresholds are programmable. If the level probe is not installed (or if the probe circuit is open), pump operation and the displayed percentage value are automatically inhibited. During level probe installation take account of the effective range of the level rod’s upward and downward movement.

80

40

10

OFF FUEL PUMP

ON FUEL PUMP

FUEL RESERVE

FUEL LEVEL

%

Max

Min

R

Position variable resistor on rod, in the centre of the level excursion range

Position level transducer outside tank, simulate operation and adapt to tank. RECOVERY IN

STORAGE TANK

100% 80% PUMP OFF 40% PUMP ON 10% ALARM 0%


START COMMAND.

STARTING

GPLUG PREHEAT 31

START

OUT 31

BATT. 1 BATT. 2

2.6 MISCELLANEOUS FUNCTIONS AND AUXILIARY EQUIPMENT

2.6.1 COMMAND RELAYS AND OUTPUTS Three 30A relays control starting and stopping and the 15/54 ancillary equipment. An additional relay, 39-40, rated 5A 250V≈, is used to control opening of the generator set circuit breaker in the event of residual current device trips or overloads.

2.6.2 ENGINE PREHEATING An input is provided for the engine preheating system. The MC3 is equipped with a transistorised command that controls a DC contactor which automatically deactivates preheating when the system is running or above the programmed maximum temperature (Off) and automatically activates it when the engine temperature is below the minimum value (On). This operation is active only when the temperature transducer is connected to terminal 31. 2.6.3 GLOW PLUGS PRE-HEATING (output 31) This output is controlled by the software and if programmed to pre-heat the glow plugs, each time it is triggered the pre-heating cycle is enabled before each starting cycle. Programming on M3 S18. 2.6.4 DOUBLE BATTERY (output 31) UNI 9490 NFPA NFS61.940 Commands automatic transition to a second cranking battery. The number of starts programmed on M2 T5 is distributed alternately on the two batteries. If the engine has not started . at the end of the cycles, a failed starting alarm is generated. To switch between Battery1 and Battery2, press the orange BATT button. The active battery is indicated by the relative icon. NOTE: To conform to fire safety standards, "FORCED RUNNING" may be required (see M3 S21). 2.6.5 ALARMS LOG This records all the parameters (measurements and alarms) present when an alarm is generated, and allows the last 8 alarms to be displayed consecutively.

31

- B

The contactor controls the preheating system PROGRAMMING Preheating control (activate out 31 = PGLO in setting S18, temperature ON in S10 and temperature OFF in S9)

14 + Batt 17 Start 18 Stop 16 15/54 Fuel P. 29 Alarm 30 Preheating 31

30 A 30 A 30A

200mA 200mA 200mA

28

200m

R

M02

RB RB BATT. 1

BATT. 2

+ B RB1 RB2 R

7 15/54

See alternative functional diagram in applications


StOr HiSt 1

Active only when the key is set to MAN. Displayed by simultaneously pressing the (-) button and the (RESET) button for 5". The alarms log display page appears. Select the log record number to be checked using MODE. Press ENTER and using the MODE buttons, scroll down the pages to view the operation parameters and cause of the alarm. To change the alarms log record, press ENTER and repeat the previous point. To exit, return to the alarms log records page and set the key to the zero position. 2.6.6 BACK FEED PROTECTION (32) When using the MC3 with units designed for parallel operation, protection against POWER BACK FEED (relay 32 function) can be activated. Power back feed protection comes into operation if the generator absorbs power rather than supplying it. Detection of power back feed is achieved by a mathematical calculation of the power factor, and reverse current occurs in the generator only when the power factor is L - or C . Calibration. Go to the M3 settings and calibrate back feed parameter S19 at -10% of the nominal power. Intervention is delayed 5". Intervention disconnects the load and stops the GE after the engine cooling stage. 2.6.7 WEEKLY CLOCK Permits automatic control of starts and stops programmed for the seven days of the week. Eight starts/stops may be programmed for each day with different schedules for each day of the week. The following can be programmed in Setup M4: 1. In O1, Day, Month, and Year 2. In O2, the day of the week 3. In O3, the current time and the ON/OFF times day per day for the entire week.

C+ L+ L - C -

COSFì POS

COSFì NEG

ACTIVE POWER

BACK FEED POWER

MON8 07.00 20.15

Minutes are changed using +/- buttons

Number shows N° of daily starts from 1 to 8

Day of the week in programming

Use the MODE buttons to change the hours

Press ENTER to confirm the value and go to the next one


2.7 SETUP SETUP (machine data configuration) may be accessed at any time, even while the unit is running, by activating SW 4 ON or holding down the ACK-RESET-PAGE UP buttons for approx. 8 seconds. To quit programming set SW 4 to OFF or press the same buttons for 8 seconds. It is also possible to access the calibration fields relative to times (M2), timed starts (M4) and differential (M6) by pressing the FUEL PUMP (+) and PREHEATING (-) buttons for 8 seconds. Once programming is terminated, quit the calibration function by pressing the same combination of buttons for 8 seconds.

Warning! Do not exit the setup routine before finishing the current programming. Wait for the generator electrical parameters page to be displayed before switching the board off. The menus and respective entry fields are illustrated below. 2.7.1 MENU LIST M1 - Adjustments

M1 ADJUSTMENTS Permitted values Default Permitted buttons

R0 Generator type 3:TWO PHASE,

2:SINGLE PHASE, 1:THREE PHASE,

0:THR.PH+N THR.PH+N UP, DOWN

R1 Generator voltage (V) 100 ÷ 550 400 UP, DOWN,+,- R2 VT ratio 100 ÷ 9000 100 UP, DOWN,+,- R3 Generator Frequency (Hz) 0:50, 1:60 50 UP, DOWN

R4 CT ratio

0: 10, 1:15, 2:20, 3:25, 4: 40, 5: 50, 6:60, 7:80,

8:100, 9: 150, 10: 200, 11: 250, 12:300, 13: 400, 14: 500, 15:600, 16: 800,

17:1000, 18:1200, 19:1500, 20: 2000, 21:

3000

100 --5 UP, DOWN

R5 ZERO fuel level UP, DOWN R6 FULL fuel level UP, DOWN R7 ZERO oil pressure (bar) UP, DOWN R8 ZERO water temperature (°C) UP, DOWN

R10 Temperature transducers selection 0:Veglia1, 1: Veglia2 , 2:Vdo1, 3:Vdo2, 4: Vdo3 Vdo1 UP, DOWN

R11 Pressure transducers selection 0:Veglia, 1:VDO Vdo UP, DOWN R12 Fuel level transducers selection 0:Veglia, 1:VDO Vdo UP, DOWN R13 High temperature input polarity 0:NO, 1:NC No UP, DOWN R14 Low water level input polarity 0:NO, 1:NC No UP, DOWN R15 Fuel reserve input polarity 0:NO, 1:NC No UP, DOWN R16 BPO input inhibited 0:Exc, 1:Inc Inc UP, DOWN R17 Dynamo input inhibited 0:Exc, 1:Inc Inc UP, DOWN R18 Low fuel stop enabled 0:OFF, 1:ON OFF UP, DOWN


M2 - Times M2

TIMES Permitted values Default Permitted buttons T1 Start up delay (sec) 0 ÷ 255 2 UP, DOWN,+,- T2 Engine cooling stop delay (sec) 10 ÷ 255 60 UP, DOWN,+,- T3 Stop time (sec) 1 ÷ 60 20 UP, DOWN,+,- T4 Start and pause time (sec) 3 ÷ 15 5 UP, DOWN,+,- T5 Max. engine start attempts 2 ÷ 10 4 UP, DOWN,+,- T6 Overload alarm delay (sec) 15 ÷ 255 60 UP, DOWN,+,- T7 Glow plugs pre-heating time (sec.) 0 ÷ 255 10 UP, DOWN,+,- T8 ‘Ready to supply’ generator output delay (sec) 0 ÷ 255 5 UP, DOWN,+,-

T9 EJP delay (min) 1 ÷ 90 minutes 0 = OFF 2 UP, DOWN,+,-

T10 Request for maintenance intervention (hours) 200 ÷ 5000 199=OFF OFF UP, DOWN,+,-

T11 Request for maintenance intervention2 (hours) 200 ÷ 5000 199=OFF OFF UP, DOWN,+,-

T12 Alarms from gen. ready activation delay (sec) 5 ÷ 30 10 UP, DOWN,+,-

T13 Maximum standby for alarms activation after engine started detection (sec) 60 ÷ 255 120 UP, DOWN,+,-

M3 - Settings M3

SETTINGS Permitted values Default Permitted buttons S1 Generator max. % voltage 10 ÷ 30 10 UP, DOWN,+,-

S2 Generator min. % voltage 10 ÷ 39 40=OFF 20 UP, DOWN,+,-

S3 Generator max. current (A) 1 ÷ 4000 (if lower than S4) 0=OFF 120 UP, DOWN,+,-

S4 Short-circuit current (A) 1 ÷ 9000 0=OFF 300 UP, DOWN,+,-

S5 Generator max. frequency % 10 ÷ 30 31=OFF 15% UP, DOWN,+,-

S6 Generator min. frequency % 8 ÷ 39 40=OFF 8% UP, DOWN,+,-

S7 Max. water temperature (°C) 1 ÷ 125 0 = OFF 125 UP, DOWN,+,-

S8 Min. water temperature (°C) 0 ÷ 70 20 UP, DOWN,+,- S9 Engine preheating max. temp. (°C) 50 ÷ 100 50 UP, DOWN,+,- S10 Engine preheating min. temp. (°C) 20 ÷ 50 30 UP, DOWN,+,- S11 Minimum oil pressure (bar) 0.4=OFF 0.5 ÷ 3.0 1.5 UP, DOWN,+,- S12 Pump fuel level % ON 0 ÷ 30 30% UP, DOWN,+,- S13 Pump fuel level % OFF 80 ÷ 100 80% UP, DOWN,+,- S14 Fuel reserve level % 0 ÷ 10 10% UP, DOWN,+,- S15 Battery max. voltage % 10 ÷ 30 30% UP, DOWN,+,- S16 Battery min. voltage % 10 ÷ 30 30% UP, DOWN,+,- S17 Engine started generator min. frequency (Hz) 6 ÷ 25 18 UP, DOWN,+,-


S18 Preheating output operating mode

0:Glow plugs heat.(Prgl), 1:Engine preheating

(Pren),

2:Second battery selection (2STR)

Prgl UP, DOWN

S19 Back feed threshold (KW) 1 ÷ 6000 < 1 = OFF OFF UP, DOWN,+,-

S20 CG output 0:OFF, 1:CG OFF UP, DOWN S21 Operating mode 0:Norm, 1:Forc, 2:Over Norm UP, DOWN S22 Times style 0:EU, 1:non-EU Eu UP, DOWN

M4 - Clock M4

CLOCK Permitted values Default Permitted buttons O1 O1 – Date, month (2nd line) Day(1 ÷ 31), Month(1 ÷ 12) UP, DOWN,+,-

O1 – Year (3rd line) 2000 ÷ 2127 UP, DOWN,+,-

O2 O2 – Day of week Sunday, Monday, …, Saturday UP, DOWN,Hours+,-

Minutes

O3 O3 – Current time Hours (0 ÷ 24) Minutes (0 ÷ 59) UP, DOWN,Hours+,-

Minutes

LUN1 First start hour Monday (2nd line)

First stop hour Monday (3rd line) Hours (0 ÷ 24)

Minutes (0 ÷ 59) UP, DOWN,Hours+,-

Minutes

LUN2 Second start hour Monday (2nd line) Second stop hour Monday (3rd line) Hours (0 ÷ 24)


Minutes

LUN3 Third start hour Monday (2nd line) Third stop hour Monday (3rd line) Hours (0 ÷ 24)


Minutes

LUN4 Fourth start hour Monday (2nd line) Fourth stop hour Monday (3rd line) Hours (0 ÷ 24)


Minutes

LUN5 Fifth start hour Monday (2nd line) Fifth stop hour Monday (3rd line) Hours (0 ÷ 24)


Minutes

LUN6 Sixth start hour Monday (2nd line) Sixth stop hour Monday (3rd line) Hours (0 ÷ 24)


Minutes

LUN7 Seventh start hour Monday (2nd line) Seventh stop hour Monday (3rd line) Hours (0 ÷ 24)


Minutes

LUN8 Eighth start hour Monday (2nd line) Eighth stop hour Monday (3rd line) Hours (0 ÷ 24)


Minutes

MAR1 First start hour Tuesday (2nd line) First stop hour Tuesday (3rd line) Hours (0 ÷ 24)


Minutes

MAR2 Second start hour Tuesday (2nd line) Second stop hour Tuesday (3rd line) Hours (0 ÷ 24)


Minutes

MAR3 Third start hour Tuesday (2nd line) Third stop hour Tuesday (3rd line) Hours (0 ÷ 24)


Minutes

MAR4 Fourth start hour Tuesday (2nd line) Fourth stop hour Tuesday (3rd line) Hours (0 ÷ 24)


Minutes

MAR5 Fifth start hour Tuesday (2nd line) Fifth stop hour Tuesday (3rd line) Hours (0 ÷ 24)


Minutes

MAR6 Sixth start hour Tuesday (2nd line) Sixth stop hour Tuesday (3rd line) Hours (0 ÷ 24)


Minutes


MAR7 Seventh start hour Tuesday (2nd line) Seventh stop hour Tuesday (3rd line) Hours (0 ÷ 24)


Minutes

MAR8 Eighth start hour Tuesday (2nd line) Eighth stop hour Tuesday (3rd line) Hours (0 ÷ 24)


Minutes

MER1 First start hour Wednesday (2nd line) First stop hour Wednesday (3rd line) Hours (0 ÷ 24)


Minutes

MER2 Second start hour Wednesday (2nd line) Second stop hour Wednesday (3rd line) Hours (0 ÷ 24)


Minutes

MER3 Third start hour Wednesday (2nd line) Third stop hour Wednesday (3rd line) Hours (0 ÷ 24)


Minutes

MER4 Fourth start hour Wednesday (2nd line) Fourth stop hour Wednesday (3rd line) Hours (0 ÷ 24)


Minutes

MER5 Fifth start hour Wednesday (2nd line) Fifth stop hour Wednesday (3rd line) Hours (0 ÷ 24)


Minutes

MER6 Sixth start hour Wednesday (2nd line) Sixth stop hour Wednesday (3rd line) Hours (0 ÷ 24)


Minutes

MER7 Seventh start hour Wednesday (2nd line) Seventh stop hour Wednesday (3rd line) Hours (0 ÷ 24)


Minutes

MER8 Eighth start hour Wednesday (2nd line) Eighth stop hour Wednesday (3rd line) Hours (0 ÷ 24)


Minutes

GIO1 First start hour Thursday (2nd line) First stop hour Thursday (3rd line) Hours (0 ÷ 24)


Minutes

GIO2 Second start hour Thursday (2nd line) Second stop hour Thursday (3rd line) Hours (0 ÷ 24)


Minutes

GIO3 Third start hour Thursday (2nd line) Third stop hour Thursday (3rd line) Hours (0 ÷ 24)


Minutes

GIO4 Fourth start hour Thursday (2nd line) Fourth stop hour Thursday (3rd line) Hours (0 ÷ 24)


Minutes

GIO5 Fifth start hour Thursday (2nd line) Fifth stop hour Thursday (3rd line) Hours (0 ÷ 24)


Minutes

GIO6 Sixth start hour Thursday (2nd line) Sixth stop hour Thursday (3rd line) Hours (0 ÷ 24)


Minutes

GIO7 Seventh start hour Thursday (2nd line) Seventh stop hour Thursday (3rd line) Hours (0 ÷ 24)


Minutes

GIO8 Eighth start hour Thursday (2nd line) Eighth stop hour Thursday (3rd line) Hours (0 ÷ 24)


Minutes

VEN1 First start hour Friday (2nd line) First stop hour Friday (3rd line) Hours (0 ÷ 24)


Minutes

VEN2 Second start hour Friday (2nd line) Second stop hour Friday (3rd line) Hours (0 ÷ 24)


Minutes

VEN3 Third start hour Friday (2nd line) Third stop hour Friday (3rd line) Hours (0 ÷ 24)


Minutes

VEN4 Fourth start hour Friday (2nd line) Fourth stop hour Friday (3rd line) Hours (0 ÷ 24)


Minutes

VEN5 Fifth start hour Friday (2nd line) Fifth stop hour Friday (3rd line) Hours (0 ÷ 24)


Minutes

VEN6 Sixth start hour Friday (2nd line) Sixth stop hour Friday (3rd line) Hours (0 ÷ 24)


Minutes

VEN7 Seventh start hour Friday (2nd line) Seventh stop hour Friday (3rd line) Hours (0 ÷ 24)


Minutes

VEN8 Eighth start hour Friday (2nd line) Eighth stop hour Friday (3rd line) Hours (0 ÷ 24)


Minutes

SAB1 First start hour Saturday (2nd line) First stop hour Saturday (3rd line) Hours (0 ÷ 24)


Minutes

SAB2 Second start hour Saturday (2nd line) Second stop hour Saturday (3rd line) Hours (0 ÷ 24)


Minutes


SAB3 Third start hour Saturday (2nd line) Third stop hour Saturday (3rd line) Hours (0 ÷ 24)


Minutes

SAB4 Fourth start hour Saturday (2nd line) Fourth stop hour Saturday (3rd line) Hours (0 ÷ 24)


Minutes

SAB5 Fifth start hour Saturday (2nd line) Fifth stop hour Saturday (3rd line) Hours (0 ÷ 24)


Minutes

SAB6 Sixth start hour Saturday (2nd line) Sixth stop hour Saturday (3rd line) Hours (0 ÷ 24)


Minutes

SAB7 Seventh start hour Saturday (2nd line) Seventh stop hour Saturday (3rd line) Hours (0 ÷ 24)


Minutes

SAB8 Eighth start hour Saturday (2nd line) Eighth stop hour Saturday (3rd line) Hours (0 ÷ 24)


Minutes

DOM1 First start hour Sunday (2nd line) First stop hour Sunday (3rd line) Hours (0 ÷ 24)


Minutes

DOM2 Second start hour Sunday (2nd line) Second stop hour Sunday (3rd line) Hours (0 ÷ 24)


Minutes

DOM3 Third start hour Sunday (2nd line) Third stop hour Sunday (3rd line) Hours (0 ÷ 24)


Minutes

DOM4 Fourth start hour Sunday (2nd line) Fourth stop hour Sunday (3rd line) Hours (0 ÷ 24)


Minutes

DOM5 Fifth start hour Sunday (2nd line) Fifth stop hour Sunday (3rd line) Hours (0 ÷ 24)


Minutes

DOM6 Sixth start hour Sunday (2nd line) Sixth stop hour Sunday (3rd line) Hours (0 ÷ 24)


Minutes

DOM7 Seventh start hour Sunday (2nd line) Seventh stop hour Sunday (3rd line) Hours (0 ÷ 24)


Minutes

DOM8 Eighth start hour Sunday (2nd line) Eighth stop hour Sunday (3rd line) Hours (0 ÷ 24)


Minutes

O4 Test day Sunday, Monday, …, Saturday UP, DOWN,Hours+,-

Minutes

O5 Test execution interval weeks 0 ÷ 99 0 UP, DOWN,Hours+,-Minutes

O6 Test starting Hours (2nd line)

Test ending Hours (3rd line) Hours (0 ÷ 24)


Minutes

M5 – Serial line M5

SERIAL LINE Permitted values Default Permitted buttons C1 Device ID 1 ÷ 250 1 UP, DOWN,+,- C2 Generator set ID 1 ÷ 9999 1 UP, DOWN,+,-

C3 Baud rate 600,1200,2400, 4800, 9600, 14400, 19200,

38400 9600 UP, DOWN

C4 Modem OFF,ON OFF UP, DOWN

PIN Card PIN SPACE , 0 ÷ 9 SPACE UP, DOWN:cursor+,-:

value

cSMS1 cSMS1 telephone number (2nd line)

cSMS1 telephone number (3rd line) SPACE , 0 ÷ 9 SPACE UP, DOWN:cursor+,-:

value

nSMS1 nSMS1 telephone number (2nd line) nSMS1 telephone number (3rd line) SPACE , 0 ÷ 9 SPACE UP, DOWN:cursor+,-:

value

cSMS2 cSMS2 telephone number (2nd line) cSMS2 telephone number (3rd line) SPACE , 0 ÷ 9 SPACE UP, DOWN:cursor+,-:

value


nSMS2 nSMS2 telephone number (2nd line) nSMS2 telephone number (3rd line) SPACE , 0 ÷ 9 SPACE UP, DOWN:cursor+,-:

value

cPC1 cPC1 telephone number (2nd line) cPC1 telephone number (3rd line) SPACE , 0 ÷ 9 SPACE UP, DOWN:cursor+,-:

value

nPC1 nPC1 telephone number (2nd line) nPC1 telephone number (3rd line) SPACE , 0 ÷ 9 SPACE UP, DOWN:cursor+,-:

value

cPC2 cPC2 telephone number (2nd line) cPC2 telephone number (3rd line) SPACE , 0 ÷ 9 SPACE UP, DOWN:cursor+,-:

value

nPC2 nPC2 telephone number (2nd line) nPC2 telephone number (3rd line) SPACE , 0 ÷ 9 SPACE UP, DOWN:cursor+,-:

value

M6 – Residual current device M6

RESIDUAL CURRENT DEVICE Permitted values Default Permitted buttons F1 Toroid selection. 500, 600, 700, 1000 500 UP, DOWN

F2 Tripping threshold (mA) 0:OFF, 30 ÷ 3000 step 10 OFF UP, DOWN,+,-

F3 Tripping time (sec) 0.1 ÷ 5.0 step 0.1 1.0 UP, DOWN,+,-

M7 - Tuning M7

TUNING Permitted values Default Permitted buttons N1

electronic module for automatic and manual...

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