ENGINE CONTROL MC3 ELECTRONIC MODULE FOR AUTOMATIC AND MANUAL CONTROL OF GENERATOR SETS MANUAL FOR: INSTALLATION OPERATION MAINTENANCE

Transcription

1 ENGINE CONTROL MC3 ELECTRONIC MODULE FOR AUTOMATIC AND MANUAL CONTROL OF GENERATOR SETS MANUAL FOR: INSTALLATION OPERATION MAINTENANCE A.E.Z. S.r.l. Tel. +39(051) Via Chiesaccia,13 Fax +39(051) Calcara (BO) Filename File Rev. Rev. Date Lang. page MC3-MU-ING-04C /05/2009 ENG Page 1 of 58 (4).doc

2 CONTENTS 1.0 USER MANUAL INTRODUCTION PURPOSE OPERATING PRINCIPLE OPERATION COMBINED WITH ATS FOR MAINS POWER OUTAGES VIEW OF THE MC3 MODULE FUNCTIONAL DESCRIPTION OF CONTROL PANEL COMPONENTS COMPONENTS DESCRIPTION DESCRIPTION OF THE VARIOUS MEASUREMENTS CONTROLS AND OPERATING MODES AUTOMATIC MODE (AUT) OFF MAN STOPPING WITH THE STOP BUTTON ON THE ELECTRONIC BOARD EMERGENCY STOP FUEL PUMP CONTROL (if present) ACTIONS IN THE CASE OF GENERATOR SET BREAKDOWN MISCELLANEOUS CONTROLS LED TEST ALARM MUTING (ACK) FUNCTIONS RESET RESIDUAL CURRENT PROTECTION TEST (if active) SPECIAL FUNCTIONS GE CUT-OUT SERVICE REQUEST REMOTE CONTROL AUTOMATIC TEST SIMPLE MAINTENANCE TASKS ELECTRICAL MAINTENANCE Overload fault MECHANICAL MAINTENANCE How to restore the fuel circuit PERIODIC CHECKS... 5 AUTOMATIC INSTALLATION MANUAL CONTROL PANEL CONSTRUCTION EXTERNAL COMPOSITION INTERNAL COMPOSITION OPERATION MEASUREMENTS DETAILED OPERATING DESCRIPTION AUTOMATIC MODE «AUT» «OFF» MODE MANUAL COMMAND FUNCTIONS «MAN» MANUAL STOPPING GENERATOR PARAMETER MEASUREMENTS THREE-PHASE / SINGLE-PHASE GENERATOR SENSOR CT CONNECTIONS... 5 MC3-MU-ING-04C (4).doc /05/2009 ENG Page 2 of 58

3 2.4.4 ELECTRONIC PROTECTION AGAINST OVERLOADS (51) AND SHORT-CIRCUITS (50) OF THE GENERATOR RESIDUAL CURRENT OR GROUND FAULT PROTECTION (TRIP) OPERATING PRINCIPLE PROGRAMMING INPUTS AND COMMANDS CC 12 AND 24V POWER CIRCUITS STARTED ENGINE DETECTION REMOTE CONTROLS EMERGENCY STOPPING (18) (NC) EJP FUNCTION (21) ON / OFF START / STOP FUNCTION (20) LOCK FUNCTION (19) FORCED START OR FIRE SAFETY DEVICE (19) UNI 9490 NFPA NFS DIGITAL INPUTS AND PROTECTIONS PROGRAMMABLE ENGINE PROTECTION DIGITAL INPUTS MEASUREMENT ANALOG INPUTS ENGINE PARAMETER MEASUREMENT ANALOG INPUTS (pressure, temperature, level) READING PRECISION OIL PRESSURE (38) ENGINE TEMPERATURE (16) FUEL LEVEL (15) FUEL PUMP COMMAND MISCELLANEOUS FUNCTIONS AND AUXILIARY EQUIPMENT COMMAND RELAYS AND OUTPUTS ENGINE PREHEATING GLOW PLUGS PRE-HEATING (output 31) DOUBLE BATTERY (output 31) UNI 9490 NFPA NFS ALARMS LOG BACK FEED PROTECTION (32) WEEKLY CLOCK SETUP 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 NOTE ON PROGRAMMING SELFPROGRAMMING TECHNICAL CHARACTERISTICS WIRING DIAGRAM Connections layout MC3 module dimensions INSTALLATION POSITIONING EARTH CONNECTIONS (PE)...5 MC3-MU-ING-04C (4).doc /05/2009 ENG Page 3 of 58

4 POWER CONNECTIONS CONNECTIONS TO THE BATTERY STARTING AND STOPPING STOPPING WITH SOLENOID VALVE ENGINE MONITORING PROBES ELECTRICAL STRENGTH TEST SERVICE PROCEDURES COMMISSIONING PROCEDURE BATTERY REPLACEMENT PROCEDURE MC3 BOARD REPLACEMENT PROCEDURE OPTIONAL EXPANSIONS AND REMOTE CONTROL REMOTE SIGNALS - INTERNET - INTRANET - ETHERNET REMOTE CONTROL REMOTE CONTROL AND MODEM MODBUS REGISTERS MAP AVAILABLE REGISTERS HOLD AVAILABLE REGISTERS INPUT AVAILABLE REGISTERS INPUT (LOG) AVAILABLE COILS AVAILABLE INPUT STATUSES SLAVE ID REPORT CAN BUS CONFIGURATION MAIN PAGE MEASUREMENT DYNAMICS PAGE ACTIVE FAULT DYNAMICS PAGE ALARMS MANAGEMENT COMMMANDS TRANSMITTED TO THE ENGINE CONTROL UNIT REMOTE CONTROL AND CANBUS MAINTENANCE ROUTINE MAINTENANCE ELECTRICAL MAINTENANCE EFFICIENCY TEST ENGINE SAFETY DEVICES GENERATOR SAFETY DEVICES OVERLOAD SAFETY DEVICE TROUBLESHOOTING...5 The data given in this document are subject to possible variations due to technical updates to the design project. MC3-MU-ING-04C (4).doc /05/2009 ENG Page 4 of 58

5 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 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. Fig. 1 START/STOP QGE LOAD CB G M 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. MC3-MU-ING-04C (4).doc /05/2009 ENG Page 5 of 58

6 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. QGE R ATS START / STOP COMMAND CR CG LOAD USER CB CO G M R Mains QGE Control panel CR Mains contactor GM Generator set (generator + MC3 Electronic control board CG Generator set engine board) contactor CB Generator set breaker switch CO Trip coil 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. MC3-MU-ING-04C (4).doc /05/2009 ENG Page 6 of 58

7 1.4 VIEW OF THE MC3 MODULE Functional description of the panel blocks. 5. ACK alarm mute Fuel pump manual command. Engine preheating or glow plugs 1. CONTROL KEY Automatic mode. (AUT) Manual mode. (MAN) 3. Numerical and graphic display for presentation of all measurements and graphic description of alarm type 4. MODE buttons to select parameters and Reset button to restore functions or reset alarms. 2. Manual start and stop buttons. 1.5 FUNCTIONAL DESCRIPTION OF CONTROL PANEL COMPONENTS 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. MC3-MU-ING-04C (4).doc /05/2009 ENG Page 7 of 58

8 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 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 MC3-MU-ING-04C (4).doc /05/2009 ENG Page 8 of 58

9 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 MC3-MU-ING-04C (4).doc /05/2009 ENG Page 9 of 58

10 Two operating modes can be selected: 1.6 CONTROLS AND OPERATING MODES 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 OFF Supply to the electrical circuits is suspended and the generator set is disconnected. (Used for maintenance) 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 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 EMERGENCY STOP When pressed, the red mushroom head pushbutton stops the generator immediately, opening the generator contactor (CB) instantly and blocking the generator set 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 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). MC3-MU-ING-04C (4).doc /05/2009 ENG Page 10 of 58

11 1.7 MISCELLANEOUS CONTROLS LED TEST This routine is performed automatically whenever the module is powered on ALARM MUTING (ACK) When an alarm is active, the red alarm LED blinks and the siren sounds. Pressing the ACK key mutes the siren 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 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: 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 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 M REMOTE CONTROL The generator set can remote controlled by using remote communication (PC, modem or GSM) with automatic activation 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. MC3-MU-ING-04C (4).doc /05/2009 ENG Page 11 of 58

12 1.9 SIMPLE MAINTENANCE TASKS USER SAFETY PROCEDURE WARNING! It is strictly prohibited to work on live electrical parts 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 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 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 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) 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: 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 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. MC3-MU-ING-04C (4).doc /05/2009 ENG Page 12 of 58

13 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. MC3-MU-ING-04C (4).doc /05/2009 ENG Page 13 of 58

14 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 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 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 INTERNAL COMPOSITION 1. Numbered cables routed in PVC trunking; 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 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. MC3-MU-ING-04C (4).doc /05/2009 ENG Page 14 of 58

15 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 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 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 MC3-MU-ING-04C (4).doc /05/2009 ENG Page 15 of 58

16 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 Emergency pushbutton pressed LCD A SI 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 «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 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 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 MANUAL STOPPING The stop button may be disabled in automatic. MC3-MU-ING-04C (4).doc /05/2009 ENG Page 16 of 58

17 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 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 (*) Working voltages V ac with direct connection Working voltages with VT /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 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 V ca (*) FUNCTIONS Generator connections GEN X L1 Y L2 Z L3 N L4 MC THREE-PHASE CONNECTION WITH NEUTRAL TO GROUND TNC OR TNS R GEN X L1 Y L2 Z L3 N L4 MC THREE-PHASE CONNECTION WITH NEUTRAL ISOLATED FROM GROUND IT GEN X L1 Y L2 Z L3 MC GEN X L1 N L4 MC THREE-PHASE CONN. WITHOUT NEUTRAL SINGLE-PHASE CONNECTION MC3-MU-ING-04C (4).doc /05/2009 ENG Page 17 of 58

18 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 mm CONSUMPTION VA 0.41 VA VA VA VA 0,1Ω 5W x CT /5A M C CT CONNECTIONS CT PHASE R-L CT PHASE S-L CT PHASE T-L 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 TRIP CURVE T s Tp L Tp = programmed overload delay ( ) I1 = GE rated current ( A) I3 = I1 x3 short circuit current (Off A) 2 fixed delay 2 I 0 I 1 I 2 I 3 I 4 I 5 I 6 I A 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. MC3-MU-ING-04C (4).doc /05/2009 ENG Page 18 of 58

19 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 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 Adaptable to toroids with /1 windings and with test coil. Reset using the RESET pushbutton enabled with current leakage less than 50% IΔn 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 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. FIG. A MC GEN X L1 Y L2 Z L3 N TOROID THREE-PHASE CONNECTION WITH NEUTRAL TO GROUND TNC OR TNS TOROID WITH TEST WINDING PE L O A D MEASUREMENT FIG. B GEN MC X L1 Y L2 Z L3 N PE THREE-PHASE CONNECTION WITH NEUTRAL TO GROUND TNC OR TNS TOROID WITHOUT TEST WINDING L O A D MEASUREMENT TEST 35 Adaptable to toroids with 500/1-750/1-1000/1 winding ratio TEST 10Kohm 0.5W PROGRAMMING 1. On menu M6, program the toroid's winding ratio in F /1. Program the trip current in F2 and the trip delay in F3. MC3-MU-ING-04C (4).doc /05/2009 ENG Page 19 of 58

20 2.5 INPUTS AND COMMANDS 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 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. Generator Voltage = > 81 Hz Start Crank 0 10 Programming M3 S17 settings started engine minimum frequency O Off Once the set frequency is reached: - 9Hz for 3000 rpm - 18Hz for 1500 rpm the starting command is interrupted REMOTE CONTROLS The following remote controls may be configured using inputs : 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. CON FUNCTION SETUP TIMES N 18 EMERGENCY STOPPING 19 FORCED START, NO STOP M3 S21 19 LOCK M3 S21 20 START/STOP COMMAND 21 EJP "FRANCIA" M2 T EMERG NO STOP ON/OFF EJP Batt 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 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 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. MC3-MU-ING-04C (4).doc /05/2009 ENG Page 20 of 58

21 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 FORCED START OR FIRE SAFETY DEVICE (19) UNI 9490 NFPA NFS 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 DIGITAL INPUTS AND PROTECTIONS 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 NC 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 15 - Batt NO MEASUREMENT ANALOG INPUTS 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 V ANALOG 0-10V ANALOG FUEL LEVEL WATER TEMP. OIL PRESS. VEGLIA OR VDO CONFIGURABLE ANALOG INPUTS ANALOG INPUTS CONFIGURED TO 0-10V MC3-MU-ING-04C (4).doc /05/2009 ENG Page 21 of 58

22 VDO pressure transmitted plus 0-8 bar alarm contact Thermistor (variable resistance) + VDO thermostat (NO contact) for instrument and indicator 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 OIL PRESSURE (38) 2 - Batt OP OM WT 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. BAR 8 OIL PRESSURE 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). O.5 MINIMUM PRESSURE ENGINE TEMPERATURE (16) Measurement is performed for Veglia and VDO engine temperature transducers up to 150 C. ENGINE TEMPERATURE 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. C PRE-ALARM PREHEAT. OFF PREHEAT. ON MINIMUM TEMP. (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. MC3-MU-ING-04C (4).doc /05/2009 ENG Page 22 of 58

23 2.5.8 FUEL LEVEL (15) Fuel level is measured by 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. % FUEL LEVEL OFF FUEL PUMP ON FUEL PUMP FUEL RESERVE 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. Position level transducer outside tank, simulate operation and adapt to tank. RECOVERY IN STORAGE TANK Position variable resistor on rod, in the centre of the level excursion range Max 100% 80% PUMP OFF R 40% PUMP ON Min 10% ALARM 0% MC3-MU-ING-04C (4).doc /05/2009 ENG Page 23 of 58

24 2.6 MISCELLANEOUS FUNCTIONS AND AUXILIARY EQUIPMENT 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. 30 A 30 A 30A 200mA 200mA 200mA 14 + Batt 17 Start 18 Stop 16 15/54 Fuel P. 29 Alarm 30 Preheating 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 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) 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. START COMMAND. GPLUG PREHEAT 31 STARTING DOUBLE BATTERY (output 31) UNI 9490 NFPA NFS 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. START OUT 31 BATT. 1 BATT. 2 M m R R 7 15/54 RB1 RB RB BATT. 1 RB2 BATT. 2 + B See alternative functional diagram in applications NOTE: To conform to fire safety standards, "FORCED RUNNING" may be required (see M3 S21) 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. MC3-MU-ING-04C (4).doc /05/2009 ENG Page 24 of 58

25 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 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. StOr HiSt 1 COSFì POS C+ L+ ACTIVE POWER COSFì NEG L - C - BACK FEED POWER 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 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. Day of the week in programming Press ENTER to confirm the value and go to the next one MON Number shows N of daily starts from 1 to 8 are changed using +/- buttons Use the MODE buttons to change the hours MC3-MU-ING-04C (4).doc /05/2009 ENG Page 25 of 58

26 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 MENU LIST M1 - Adjustments M1 ADJUSTMENTS Permitted values Default Permitted buttons R0 Generator type 3:TWO PHASE, 2:SINGLE PHASE, 1:THREE PHASE, THR.PH+N UP, DOWN 0:THR.PH+N R1 Generator voltage (V) UP, DOWN,+,- R2 VT ratio UP, DOWN,+,- R3 Generator Frequency (Hz) 0:50, 1:60 50 UP, DOWN 0: 10, 1:15, 2:20, 3:25, 4: 40, 5: 50, 6:60, 7:80, 8:100, 9: 150, 10: 200, R4 CT ratio 11: 250, 12:300, 13: 400, : 500, 15:600, 16: 800, --5 UP, DOWN 17:1000, 18:1200, 19:1500, 20: 2000, 21: 3000 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 MC3-MU-ING-04C (4).doc /05/2009 ENG Page 26 of 58

27 M2 - Times M2 TIMES Permitted values Default Permitted buttons T1 Start up delay (sec) UP, DOWN,+,- T2 Engine cooling stop delay (sec) UP, DOWN,+,- T3 Stop time (sec) UP, DOWN,+,- T4 Start and pause time (sec) UP, DOWN,+,- T5 Max. engine start attempts UP, DOWN,+,- T6 Overload alarm delay (sec) UP, DOWN,+,- T7 Glow plugs pre-heating time (sec.) UP, DOWN,+,- T8 Ready to supply generator output delay (sec) UP, DOWN,+,- T9 EJP delay (min) 1 90 minutes 0 = OFF 2 UP, DOWN,+,- T10 Request for maintenance intervention (hours) =OFF OFF UP, DOWN,+,- T11 Request for maintenance intervention2 (hours) =OFF OFF UP, DOWN,+,- T12 Alarms from gen. ready activation delay (sec) UP, DOWN,+,- T13 Maximum standby for alarms activation after engine started detection (sec) UP, DOWN,+,- M3 - Settings M3 SETTINGS Permitted values Default Permitted buttons S1 Generator max. % voltage UP, DOWN,+,- S2 Generator min. % voltage =OFF 20 UP, DOWN,+,- S3 Generator max. current (A) (if lower than S4) 0=OFF 120 UP, DOWN,+,- S4 Short-circuit current (A) =OFF 300 UP, DOWN,+,- S5 Generator max. frequency % =OFF 15% UP, DOWN,+,- S6 Generator min. frequency % =OFF 8% UP, DOWN,+,- S7 Max. water temperature ( C) = OFF 125 UP, DOWN,+,- S8 Min. water temperature ( C) UP, DOWN,+,- S9 Engine preheating max. temp. ( C) UP, DOWN,+,- S10 Engine preheating min. temp. ( C) UP, DOWN,+,- S11 Minimum oil pressure (bar) 0.4=OFF UP, DOWN,+,- S12 Pump fuel level % ON % UP, DOWN,+,- S13 Pump fuel level % OFF % UP, DOWN,+,- S14 Fuel reserve level % % UP, DOWN,+,- S15 Battery max. voltage % % UP, DOWN,+,- S16 Battery min. voltage % % UP, DOWN,+,- S17 Engine started generator min. frequency (Hz) UP, DOWN,+,- MC3-MU-ING-04C (4).doc /05/2009 ENG Page 27 of 58

28 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 = 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 O1 O2 O3 LUN1 LUN2 LUN3 LUN4 LUN5 LUN6 LUN7 LUN8 MAR1 MAR2 MAR3 MAR4 MAR5 MAR6 CLOCK Permitted values Default Permitted buttons O1 Date, month (2 nd line) Day(1 31), Month(1 12) UP, DOWN,+,- O1 Year (3 rd line) UP, DOWN,+,- O2 Day of week Sunday, Monday,, Saturday O3 Current time First start hour Monday (2 nd line) First stop hour Monday (3rd line) Second start hour Monday (2nd line) Second stop hour Monday (3rd line) Third start hour Monday (2nd line) Third stop hour Monday (3rd line) Fourth start hour Monday (2nd line) Fourth stop hour Monday (3rd line) Fifth start hour Monday (2nd line) Fifth stop hour Monday (3rd line) Sixth start hour Monday (2nd line) Sixth stop hour Monday (3rd line) Seventh start hour Monday (2nd line) Seventh stop hour Monday (3rd line) Eighth start hour Monday (2nd line) Eighth stop hour Monday (3rd line) First start hour Tuesday (2nd line) First stop hour Tuesday (3rd line) Second start hour Tuesday (2nd line) Second stop hour Tuesday (3rd line) Third start hour Tuesday (2nd line) Third stop hour Tuesday (3rd line) Fourth start hour Tuesday (2nd line) Fourth stop hour Tuesday (3rd line) Fifth start hour Tuesday (2nd line) Fifth stop hour Tuesday (3rd line) Sixth start hour Tuesday (2nd line) Sixth stop hour Tuesday (3rd line) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) MC3-MU-ING-04C (4).doc /05/2009 ENG Page 28 of 58

29 MAR7 MAR8 MER1 MER2 MER3 MER4 MER5 MER6 MER7 MER8 GIO1 GIO2 GIO3 GIO4 GIO5 GIO6 GIO7 GIO8 VEN1 VEN2 VEN3 VEN4 VEN5 VEN6 VEN7 VEN8 SAB1 SAB2 Seventh start hour Tuesday (2nd line) Seventh stop hour Tuesday (3rd line) Eighth start hour Tuesday (2nd line) Eighth stop hour Tuesday (3rd line) First start hour Wednesday (2nd line) First stop hour Wednesday (3rd line) Second start hour Wednesday (2nd line) Second stop hour Wednesday (3rd line) Third start hour Wednesday (2nd line) Third stop hour Wednesday (3rd line) Fourth start hour Wednesday (2nd line) Fourth stop hour Wednesday (3rd line) Fifth start hour Wednesday (2nd line) Fifth stop hour Wednesday (3rd line) Sixth start hour Wednesday (2nd line) Sixth stop hour Wednesday (3rd line) Seventh start hour Wednesday (2nd line) Seventh stop hour Wednesday (3rd line) Eighth start hour Wednesday (2nd line) Eighth stop hour Wednesday (3rd line) First start hour Thursday (2nd line) First stop hour Thursday (3rd line) Second start hour Thursday (2nd line) Second stop hour Thursday (3rd line) Third start hour Thursday (2nd line) Third stop hour Thursday (3rd line) Fourth start hour Thursday (2nd line) Fourth stop hour Thursday (3rd line) Fifth start hour Thursday (2nd line) Fifth stop hour Thursday (3rd line) Sixth start hour Thursday (2nd line) Sixth stop hour Thursday (3rd line) Seventh start hour Thursday (2nd line) Seventh stop hour Thursday (3rd line) Eighth start hour Thursday (2nd line) Eighth stop hour Thursday (3rd line) First start hour Friday (2nd line) First stop hour Friday (3rd line) Second start hour Friday (2nd line) Second stop hour Friday (3rd line) Third start hour Friday (2nd line) Third stop hour Friday (3rd line) Fourth start hour Friday (2nd line) Fourth stop hour Friday (3rd line) Fifth start hour Friday (2nd line) Fifth stop hour Friday (3rd line) Sixth start hour Friday (2nd line) Sixth stop hour Friday (3rd line) Seventh start hour Friday (2nd line) Seventh stop hour Friday (3rd line) Eighth start hour Friday (2nd line) Eighth stop hour Friday (3rd line) First start hour Saturday (2nd line) First stop hour Saturday (3rd line) Second start hour Saturday (2nd line) Second stop hour Saturday (3rd line) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) MC3-MU-ING-04C (4).doc /05/2009 ENG Page 29 of 58

30 SAB3 SAB4 SAB5 SAB6 SAB7 SAB8 DOM1 DOM2 DOM3 DOM4 DOM5 DOM6 DOM7 DOM8 O4 Third start hour Saturday (2nd line) Third stop hour Saturday (3rd line) Fourth start hour Saturday (2nd line) Fourth stop hour Saturday (3rd line) Fifth start hour Saturday (2nd line) Fifth stop hour Saturday (3rd line) Sixth start hour Saturday (2nd line) Sixth stop hour Saturday (3rd line) Seventh start hour Saturday (2nd line) Seventh stop hour Saturday (3rd line) Eighth start hour Saturday (2nd line) Eighth stop hour Saturday (3rd line) First start hour Sunday (2nd line) First stop hour Sunday (3rd line) Second start hour Sunday (2nd line) Second stop hour Sunday (3rd line) Third start hour Sunday (2nd line) Third stop hour Sunday (3rd line) Fourth start hour Sunday (2nd line) Fourth stop hour Sunday (3rd line) Fifth start hour Sunday (2nd line) Fifth stop hour Sunday (3rd line) Sixth start hour Sunday (2nd line) Sixth stop hour Sunday (3rd line) Seventh start hour Sunday (2nd line) Seventh stop hour Sunday (3rd line) Eighth start hour Sunday (2nd line) Eighth stop hour Sunday (3rd line) Test day (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) (0 59) Sunday, Monday,, Saturday O5 Test execution interval weeks O6 Test starting Hours (2 nd line) Test ending Hours (3 rd line) (0 59) M5 Serial line M5 SERIAL LINE Permitted values Default Permitted buttons C1 Device ID UP, DOWN,+,- C2 Generator set ID UP, DOWN,+,- C3 Baud rate 600,1200,2400, 4800, 9600, 14400, 19200, UP, DOWN C4 Modem OFF,ON OFF UP, DOWN PIN Card PIN SPACE, 0 9 SPACE UP, DOWN:cursor+,-: value csms1 nsms1 csms2 csms1 telephone number (2 nd line) csms1 telephone number (3rd line) nsms1 telephone number (2nd line) nsms1 telephone number (3rd line) csms2 telephone number (2nd line) csms2 telephone number (3rd line) SPACE, 0 9 SPACE, 0 9 SPACE, 0 9 SPACE SPACE SPACE UP, DOWN:cursor+,-: value UP, DOWN:cursor+,-: value UP, DOWN:cursor+,-: value MC3-MU-ING-04C (4).doc /05/2009 ENG Page 30 of 58

31 nsms2 cpc1 npc1 cpc2 npc2 nsms2 telephone number (2nd line) nsms2 telephone number (3rd line) cpc1 telephone number (2nd line) cpc1 telephone number (3rd line) npc1 telephone number (2nd line) npc1 telephone number (3rd line) cpc2 telephone number (2nd line) cpc2 telephone number (3rd line) npc2 telephone number (2nd line) npc2 telephone number (3rd line) SPACE, 0 9 SPACE, 0 9 SPACE, 0 9 SPACE, 0 9 SPACE, 0 9 SPACE SPACE SPACE SPACE SPACE UP, DOWN:cursor+,-: value UP, DOWN:cursor+,-: value UP, DOWN:cursor+,-: value UP, DOWN:cursor+,-: value UP, DOWN:cursor+,-: value M6 Residual current device M6 RESIDUAL CURRENT DEVICE Permitted values Default Permitted buttons F1 Toroid selection. 500, 600, 700, UP, DOWN F2 Tripping threshold (ma) 0:OFF, step 10 OFF UP, DOWN,+,- F3 Tripping time (sec) step UP, DOWN,+,- M7 - Tuning M7 TUNING Permitted values Default Permitted buttons N1 Voltage calibration coefficient L1N UP, DOWN,+,- N2 Voltage calibration coefficient L2N UP, DOWN,+,- N3 Voltage calibration coefficient L3N UP, DOWN,+,- N4 Voltage calibration coefficient L UP, DOWN,+,- N5 Voltage calibration coefficient L UP, DOWN,+,- N6 Voltage calibration coefficient L UP, DOWN,+,- N7 Current calibration coefficient L UP, DOWN,+,- N8 Current calibration coefficient L UP, DOWN,+,- N9 Current calibration coefficient L UP, DOWN,+,- N10 Battery calibration coefficient UP, DOWN,+,- N11 Differential calibration coefficient UP, DOWN,+,- N12 KWh reset ENTER 5 sec for CLEAR - ENTER N13 Hour counter reset ENTER 5 sec for CLEAR - ENTER N14 TUNING default parameters ENTER 5 sec for CLEAR - ENTER M8 - Can Bus M8 CB1 CANBUS Permitted values Default Permitted buttons OFF, Volv EDC3, Engine type selection Volv EDC4, Ivec, Deut, OFF UP, DOWN, SAE J1939 MC3-MU-ING-04C (4).doc /05/2009 ENG Page 31 of 58

32 M9 Defaults All configurations are returned to their default value by holding down the reset button for 10 seconds. * With the exception of M7 Tuning menu parameters, for which see page N NOTE ON PROGRAMMING With reference to table M3, the current settings (S3 and S4) are co-dependant: input of either of the two parameters affects the value of the other one. E.g.: if we set short circuit current (S4) of 250A, the board will not accept Max GE current values (S3) greater than 250A. The same is true for parameters S7 and S8 concerning water temperature: also these values are reciprocally co-dependant SELFPROGRAMMING To restore the original factory setup, go to M9 DEFAULT and press ENTER until the first setup page is displayed (approximately 10 seconds); at this point all the default factory values will be restored. Restoring defaults resets all values except those relating to TUNING (table M7). These parameters are managed in a separate dedicated page (table M7 N14). MC3-MU-ING-04C (4).doc /05/2009 ENG Page 32 of 58

33 2.8 TECHNICAL CHARACTERISTICS Protection rating of front panel : IP 44 Non-scratch front panel with descriptive graphics LEXAN GE l1-l2-l3-lsolated generator voltage input => 2.5KV Generator ac voltage: 0 / 600VAC Frequency : 50 / 60Hz Generator current 15 to 3,000 / 5 A dc voltage: 12V or 24V +/- 30% Max. input current: 0.6 A Min. input current : 0.35 A Reverse polarity protection Built-in Working temperature From -20 to +60 C Relative humidity 90% non-condensing Resistance to vibration 40 mm/sec Pollution rating 1 Start/stop relay capacity 30 A 30V dc. 15/54 services power supply relay capacity 30 A 30V dc. Output control transistors capacity 0.3 A 1st engine started detection via ac gener. 2nd engine started detection via oil pressure 17 Hz for 1500 rev gener. from 0.5 to 1 bar delayed by 3 secs. Battery protection, functions < V 27 and >V 59 Generator protection, functions Protection against overload and short-circuit Direct voltage reading on generator Approx. 80 / 500V Three-phase Generator voltage reading by VT.../ 100v / 100V Engine pre-alarms MIN. PRESS. HIGH TEMP. Dimensions of mc3 unit H 145 L 216 P 35 Weight of unit 670 g Conformity with MC3 module norms EN 60255/6/21 EN EN (Att.B) EN / N.B.: Technical characteristics are subject to modifications without notice following technical improvements. (*) FUNCTIONS 27 Minimum voltage 59 Maximum voltage 60 Voltage asymmetry 81 Protection for minimum and maximum frequency 47 Phase sequence 50 Instantaneous or short-circuit current 51 Maximum current with programmable delay 87N/64S Residual current trip switch (ground fault) 32 Inverse power MC3-MU-ING-04C (4).doc /05/2009 ENG Page 33 of 58

34 2.9 WIRING DIAGRAM 0.1 S2 P FUEL - 15/54 CRANK STOP AUTOMATIC (OUT) ALARM PRE-HEATING FUEL PUMP DYNAMO LOW OIL PRESSURE HIGH WATER TEMP. FUEL RESERVE WATER LEVEL AVAILABLE ALARM AVAILABLE ALARM EJP / TEST STARTING / STOP COMMAND OVERRIDE EMERGENCY STOP OIL PRESSURE MOTOR TEMPERATURE FUEL LEVEL G FUEL BATTERY L1 L2 L3 LOAD LINE RS 485 IS03 INTERFACE RS 232 CB RJ 12 +B D F 39 6A 40 GEN-SET CIRCUIT BREAKER TRIP TEST OUT 15/54 30A 30A 30A 0.5A EV K S RPR STOP CT3.../5A CT2.../5A CT1.../5A F F F GENERATOR 34 MEASURE S1 P1 S2 S1 P2 P1 S2 P2 S1 P1 CWTR REMOTE CONTROL WITH CONVEYED WAVES TRANSMITTER CS05 1 UP TO 24 SIGNALS CAN BUS CAN1 CAN BUS J1939 CAN BUS CONNECTOR RJ 45 BA L1 L2 L3 N GEN-SET VOLTAGE MC3 ALARMS INPUT COMMANDS INPUT LEVELS D OP MT RES WL EJP CCD DISP. ES OM ET FL P T LOP HWT RC BLA RPC EPB OP MT FL OIL MOTOR GROUND MC3-MU-ING-04C (4).doc /05/2009 ENG Page 34 of 58

35 2.10 Connections layout MC3-MU-ING-04C (4).doc /05/2009 ENG Page 35 of 58

36 FRONT SIDE (DISPLAY SIDE) AUTOMATIC (OUT) OUT # MC3-MU-ING-04C (4).doc /05/2009 ENG Page 36 of 58

37 2.11 MC3 module dimensions Front view 216 mm 145 mm OPENING mm 164 mm 200 mm 4 Pivot 4mm Side view 2,5m m mm 30 mm Key 3 mm IS03 RS232 - RS485 OPTIONAL MC3-MU-ING-04C (4).doc /05/2009 ENG Page 37 of 58

38 2.12 INSTALLATION 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 EARTH CONNECTIONS (PE) WARNING!! To ensure system reliability all components must be connected to earth. CNTR. PANEL QGE FUEL STORAGE TANK DAILY FUEL TANK GENERATOR SET EARTH ADDITIONAL COMPONENTS POWER CONNECTIONS To facilitate installation, wiring diagrams and indicative tables for sizing the line and user conductors are supplied. Bear in mind that all devices and lines must be protected against short-circuits and overloads by law and that for reasons of safety all prevention measures against accidental direct contacts must be taken (see IEC 64-8/4 standard) therefore an automatic switch of adequate capacity is to be installed at the beginning of the mains inlet cable (and selectivity) and a residual current device on the user line. EN TABLE A1 VALUES FOR SINGLE CONDUCTOR AMPERE Ith NUMBER OF CONDUCTORS MIN. CROSS SECTION IN sq mm MAX. CROSS SECTION IN sq mm 25A 1 2,5 6 40A A A A A A A A A A A A A A A A A For further information contact a reliable installation engineer or our engineering department. MC3-MU-ING-04C (4).doc /05/2009 ENG Page 38 of 58

39 CONNECTIONS TO THE BATTERY To supply power to the MC3 power module, we advise connecting directly to the battery cables that are connected to the starter motor. Experience shows that the use of engine grounds to connect up the -B often gives rise to operating problems. Batt. +/- leads recommended min. cross section: 6 sq mm 6 mm MC BATT STARTING AND STOPPING Devices with current output of up to 30 A may be controlled directly. Use terminal no.12 to control energised electromagnets during stopping. Fig. : 3 START 17 30A max STOP 12 - BATT. 50 STARTER MOTOR INJECTION PUMP Operation : with the stopping command the electromagnet is energised and stops the engine. To detect actual engine stopping closure of the oil pressure switch is controlled, which after 20 seconds from when it closed automatically disables the electromagnet thus avoiding the need for settings and adjustments STOPPING WITH SOLENOID VALVE Stopping with SOLENOID VALVE normally energised while the generator is running and while the generator set auxiliary services 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 stop command is received, A max 16 OTHER ENGINE SERVICES EV ELECTRONIC GOVERNOR - Batt MC3-MU-ING-04C (4).doc /05/2009 ENG Page 39 of 58

40 ENGINE MONITORING PROBES These probes detect the operational status of the engine. Safety and protection of the good condition of the engine rely on the efficiency of these probes. They are of two types: Contact type to command alarm status, such as low oil pressure, high engine temperature, low fuel level etc.; Type with variable resistance according to reading, to control instruments such as thermometers, gauges, levels etc. PROBE TYPE MARK OHM VALUE TRIPPING THRESHOLD ENGINE OIL PRESSURE SWITCH N.C. CONTACT ZERO OHM 0.5 Bar WATER THERMOSTAT N.O. CONTACT V D O OHM INFINITE 93 C WATER OIL THERMOSTAT N.O. CONTACT V D O OHM INFINITE 120 C AIR OIL PRESS. TRANSDUCER VARIABLE Adjustable pre-alarm RESISTANCE VDO OHM threshold TEMP. TRANSDUCER VARIABLE RESISTANCE VDO OHM LEVEL TRANSDUCER RESISTANCE VEGLIA Ohm Adjustable pre-alarm threshold Adjustable alarm, prealarm, pump control thresholds CONTACT PROBES VARIABLE RESISTANCE PROBES TERMOSTAT PRESSURE SWITCH TRANSDUCER NORMALLY NORMALLY OPEN P CLOSED T? P = PRESSURE T = TEMPERATURE L = LEVEL ENGINE GROUND ELECTRICAL STRENGTH TEST The control panels that are subject to the electrical strength test are to be prepared bearing in mind that the only connection point with the electronic logic is established by the generator's three-phase sensor to which a divider is connected that is made up of three 500 Kohm resistors for high voltage, for phase and connected to earth. Therefore the foregoing R - S - T - N inputs must be disconnected. MC3-MU-ING-04C (4).doc /05/2009 ENG Page 40 of 58

41 2.13 SERVICE PROCEDURES COMMISSIONING PROCEDURE Before proceeding with the functional test : 1. Isolate the BATTERY fuses. 2. Check connection of the oil pressure switch. 3. Once installation is complete, check correctness by performing the procedures advised below: 1. Set the programming key to zero; 2. Select the battery voltage using the jumpers located on the left side of the terminal board. 3. Close the fuses; 4. Check that the Battery LED comes on. If not, the polarity (+/-) on the battery may be incorrect and need to be reversed, or the power supply may not be on. WARNING! Do not carry out commands. Incorrect connection could cause damage in spite of the polarity inversion protection; 5. Programme the MC3 on the basis of the working data and generator characteristics: Set switch no.4 to programming ON and follow the setup procedures. Program the operational voltage and the frequency if different from the standard 400V 50Hz. CT ratio.../ 5 Overload current, enter the rated current output of the generator plus 5%. Short-circuit current, enter the overload current multiplied by 3. If required, activate the special functions. Return switch N 4 to "OFF". 6. Set the programming key to MAN; 7. Since the protection devices are also active in Manual mode, check the probes for fuel reserve, engine temperature, etc. against the respective indications by disconnecting the relative signal wires and connecting them temporarily to ground and checking that the message displayed is correct. 8. Once the alarm check has been completed (in case of faults, see the input/output heading), press the START and STOP button quickly, and check the engine for the correct reaction and the power supply to the solenoid valve and actuator (it is not necessary to start the unit). 9. Visually check the power connections between the generator and the panel, making sure that the board detects "engine started" status via the generator voltage. If this voltage cannot be detected (due to an incorrect power connection or an open switch along the power supply line), the starter motor must remain active for three seconds after the engine has started. 10. Activate the start button until the engine starts. 11. Wait 20-30" so that the oil starts to circulate, or the time necessary for minimum preheating of the engine. Now turn on the unit's breaker to supply the load. 12. Check the rotation direction of any connected electric motors (invert two phases if incorrect). 13. Carry out alarm simulations on the probes in order to check the efficiency of the wiring. If the switch is equipped with an open command, each alarm will be opened. 14. Reset and restart after each stopping. 15. Manually command stopping at the end of the test. 16. Set the key to AUT and close the contact between terminals 20 and 15. Automatic start-up will take place. 17. When the contact is opened again the engine stops after a delay of approximately one minute. 18. During Automatic operation, the switch only opens automatically in the presence of an overload, short circuit, ground fault, and an emergency, anomalies that normally require manually resetting of the switch. The other anomalies cause stopping without opening of the switch and may be reset using an external command BATTERY REPLACEMENT PROCEDURE Set the programming key to zero; Isolate the BATTERY fuses. Install a new battery, reconnect the fuses and reset the operating program. WARNING! Never touch the battery connections or loosen the leads while the generator is running because when the battery is disconnected with the engine running the battery charge alternator will deliver between 50 and 150 Volts (can cause irreversible damage to electronic components). MC3-MU-ING-04C (4).doc /05/2009 ENG Page 41 of 58

42 MC3 BOARD REPLACEMENT PROCEDURE Isolate the BATTERY fuses. Replace the MC3. Copy the programming of the SW1 and of the JUMPERS situated on the replaced MC3. Close the battery F1 fuse. Program the operational voltage and the frequency if different to the standard 400V 50Hz. CT ratio.../ 5 Overload current, enter the rated generator output current plus 5%. Short-circuit current, enter the overload current multiplied by 3. Compare the remaining values with the test board. The settings of the type of measurement CT, the overload and short-circuit current are crucial. Re-connect all fuses and check operation. WARNING! It is strictly prohibited to work on live components. MC3-MU-ING-04C (4).doc /05/2009 ENG Page 42 of 58

43 2.14. OPTIONAL EXPANSIONS AND REMOTE CONTROL REMOTE SIGNALS - INTERNET - INTRANET - ETHERNET The serial output is connected to an interface board that has an independent microprocessor that allows special functions to be installed to suit the customer's specifications. The following functions are envisaged: 1. Control of three eight-relay modules, providing a total of 24 remote signals with free contacts. This also allows a single module to be connected for the remote signals required. 2. The same interface board has outputs that can be configured for connecting to the Internet, local intranets or Ethernet networks, as well as other connections upon request. INTERFACE FOR REMOTE SIGNALS, INTERNET, INTRANET ETC. THREE CONFIGURABLE 8-REMOTE SIGNAL MODULES REMOTE CONTROL Upon request an IS03 serial board can be provided. This is to be fitted to the module and has two serial RS232C and RS485 ports. The RS485 port communicates using a standard MODBUS RTU protocol that can communicate via networks and with PLCs. The RS232C serial port is used to interface with PCs, GSMs and Modems for remote control. It allows the switching status to be monitored, as well as all the parameters (voltage, frequency, current, etc.) and all the alarms. It is also possible to control the following functions - Automatic, Automatic Test, Stop, Forced start with generator supply, and Reset. Each message is recorded in a history document, and up to 60,000 units can be managed, each unit having an individual board. Each unit can address the alarm status to a Server PC and another two numbers for local service centres. The server can transmit SMS or fax messages to local service technicians. The control software is only supplied with boards fitted with serial ports. RS m RS 232C RS 485 / RS 232C CONVERTER RS 232C MODEM OR GSM MC3-MU-ING-04C (4).doc /05/2009 ENG Page 43 of 58

44 Serial communication allows monitoring of all generator set parameters and commands General plant situation monitor REMOTE CONTROL AND MODEM Considering the MC3 module equipped with software release 6.0, the remote control user connector is on the left side of the board (viewed from front), near the dip-switch that enables settings and languages and the trimmer that regulates brightness of the LCD display. The IS03 serial interface unit for serial communication must be set to work with two different types of serial connection: RS232 and RS485. The board also features a green LED and a red LED corresponding, respectively, to transmission functions (TX) and reception functions (RX). The LEDs flash during operation. The following figure shows an external view of the IS03 board. The jumper, opportunely connected, serves to close the RS485 serial line, connecting terminal resistance R to close the line. MC3-MU-ING-04C (4).doc /05/2009 ENG Page 44 of 58