automatic board for emergency gen-sets

FILE VER DATE LAN. PAGE TECGCEGBA0.doc LVI/02 23/04/2004 ENG 1 OF 16

GCE

AUTOMATIC BOARD FOR EMERGENCY GEN-SETS

MANUAL: • INSTALLATION • USE • MAINTENANCE


CONTENTS DESCRIPTION Page

GENERAL 3

CONSTRUCTION 3

AUTOMATIC OPERATION 4

MANUAL OPERATION 5

COMMANDS AND SIGNALINGS 5

PROTECTIONS 5

ADJUSTMENTS 6

VARIOUS FUNCTIONS 7

PREARRANGEMENTS 8

REMOTE CONTROL 8

EMERGENCY 8

INSTALLATION 9

PRE-START CHECKS 10

ELECTRICAL MAINTENANCE 10

MECHANICAL MAINTENANCE 11

TROUBLESHOOTING 11

BLOCK DIAGRAMS

OPERATIVE STANDARDS 13


GENERAL

The GCE control board starts automatically the electric emergency power generating unit (with petrol or diesel engine and 12 V or 24 V battery) as soon as the power supply from mains is disconnected, so as to allow the emergency unit after an adjustable period of time -- which is necessary for the engine to reach the working speed -- to supply power to the consumer. As soon as the power supply is connected again from mains -- after a preset delay -- the control board transfers the electric load to the mains and stops the emergency unit after an appropriate loadless cooling phase. During its functioning, the emergency unit is protected against possible anomalies which make the warning light and horn start. When the mains are connected, the automatic battery charger holds the batteries ready to start and a pre-heating device keeps the engine to the appropriate temperature for a quick start so that the emergency unit is ready to supply power. In addition, the above mentioned control board is prearranged for external safety controls and signalings and for the remote control of the following functions: • power supply from mains or emergency unit; • general alarm state; • blocked engine control; • forced start control with power supply; • automatic operation control ; • automatic test. Besides, the control board is prearranged for the connection of a remote control device by means of a appropriate interface card.

CONSTRUCTION

The whole construction complies with the European standards EN 60439-1 The control board is inside a cubicle made of sheet metal which has been subjected to an appropriate surface treatment. The cubicle is painted with standard siliceous grey epoxy powder (RAL 7032) which is resistant to severe environmental conditions. EXTERNAL FRAME It is made up of a metallic cabinet with a door where it is installed the control panel. The control panel is 3 cm. embedded to the door surface so as to avoid any damage during its transportation and to protect the controls against accidental shocks. The control panel is equipped with: • voltmeter; • frequency meter; • amperometer; • working hour counter; • GCE-F electronic card with the control and management logic of the emergency unit; • plate with operating instructions; • safety plate. INTERNAL COMPONENTS • numbered wired located inside a PVC duct; • fuses with sectionizable fuse carrier; • battery charger transformer; • battery charge bridge rectifier; • automatic protection switch for the generator (if provided); • switching by means of four-pole contactors whose capacity is suitable for the emergency unit power. These

contactors are interlocked mechanically and electrically; • generator protection thermal relay (if provided); • amperometric transformers to measure the current (if provided); • terminals for generator and mains inputs, for power consumer outputs and auxiliary connections; • safety, testing, fuse gauge and terminal board plates.


USE INSTRUCTIONS FOR USE All the controls are performed by the programming selector switch which is placed on the right side of the control panel. The following functions can be selected:

1. automatic test (AUTOMATIC TEST) 2. automatic running (AUTOMATIC RUNNING) 3. blocked engine (BLOCKED ENGINE) 4. manual mains (MANUAL MAINS) 5. manual start (MANUAL START) 6. manual emergency unit (MANUAL GEN-SET)

AUTOMATIC OPERATION

1 AUTOMATIC TEST

It starts the emergency unit automatically without disconnecting the mains so as to check its correct functioning. A TIMER card is available on request so as to perform the test automatically at regular intervals, which can be selected for two days or a week by means of jumper J which is located on the card. The start of the test can be performed by pressing the push button located on the TIMER card. When the test is complete the unit stops automatically. During this test if a mains failure occurs, the control board will switch from mains to emergency unit.

2 AUTOMATIC RUNNING

It carries out all the preset automatic functions, i.e.: • immediate automatic start when the mains are disconnected. • Adjustable number of start attempts (from 2 to 10 approx.), with adjustable length of time (from 2 to 7

second approx.), alternated by pauses of the same duration. The start attempts will be interrupted as soon as the engine starts. The started engine detection can be performed only on the generator or on the dynamo too: this choice can be made by setting C.M.A. jumper (Engine Started Control) which is located on GCE card, in GEN or GEN+DIN position.

• Alarm horn and warning light (red LED with barred symbol of the rotating engine). If the start attempts are not successful, a positive signal is delivered to terminal 9. The signal can be used to convey the remote signal by means of a LED, a buzzer or a restart relay.

• Delay of power supply from generator (adjustable from 6 to 60 seconds approx.) so as to permit the generator parameters to reach the appropriate values and the engine to warm up. During this phase, the relating protections are disconnected. When the delay time is over, the control board switches from mains to emergency unit. The yellow CR LED turns off and the CG LED turns on.

• During the functioning the following protections are activated: a) low oil pressure b) dynamo failure c) high engine temperature d) low fuel e) no starting f) thermal relay When these protections are activated the relating LED, the horn and the warning light -- which can be

remotely controlled through the positive output on terminal 9 -- turn on and the emergency unit stops immediately.

• When the electric current from mains is connected -- detected by the mains sensor, when the mains voltage is 75% higher than the rated value -- the switching from emergency unit to mains is performed after a delay of 40 sec., in order to stabilize the mains. CG LED turns off and CR LED turns on.

• Loadless running of the emergency unit for 45 seconds in order to cool before the automatic stop. If the stop mode EM has been selected on STOP TIME jumper (relay energized during the stop), the relating relay will be energized for about 15 seconds after the reception of blocked engine signal.

• Prearrangement for a new cycle.

3 LOCKED ENGINE

• It releases the alarm states. The emergency unit cannot be started by the control board, even if the power supply from mains is interrupted. This function can be used during the maintenance.


MANUAL OPERATION 4 MANUAL MAIN

t turns on the mains contactor and supplies electric power from mains permanently. All the automatic functions will be disconnected. 5 MANUAL START t enables the START button, which is disabled in all the other functions.

After the manual start, before transferring the supply of power to the emergency unit by starting the MANUAL GEN-SET function, wait until the emergency unit is running properly, namely: the motor oil has reached the right pressure and the generator has stabilized the output voltage value. 6 MANUAL GEN-SET The supply of power is transferred to the emergency unit switching from MANUAL START to MANUAL GEN-SET.

COMMANDS AND SIGNALINGS

CONTROLS Besides the programming selector switch, the GCE board is equipped with two push buttons. The START button controls the manual start and is enabled only in the MANUAL START function and the STOP button controls the manual and complete stop of the emergency unit.

INSTRUMENTS Generator amperometer for the current of one generator phase, scale: 120% In, class: 1,5, dimensions: 72x72mm. Voltmeter for measuring the generator line voltage, scale: 500v fs, class: 1,5, dimensions: 72 x 72 mm. Frequency meter with pointer for measuring the generator frequency, scale: 45/65 Hz, class: 0,5, dimensions: 72 x 72 mm. Generator working hour counter: it indicates the generator total working time; dimensions: 55x55mm. SIGNALINGS The GCE board is equipped with a horn for the alarm signaling and with LEDs indicating the system state:

• Mains connected: the mains connection is signalled by the yellow LED located on the tower symbol. • Mains contactor: the yellow CR LED turns on when the mains contactor is closed, namely: when the

equipment is supplied by the public electric network. • Generator contactor: the yellow CG LED turns on when the generator contactor is closed, namely: when

the equipment is supplied by the emergency unit.

• Battery: the green BATT LED turns on when the current for the control board is supplied by the battery. • Battery Charger: the red CB LED signals the electric current transfer from battery charger to battery (max

electric current: 4A). The flashing light indicates that the battery is charged completely and the trickle charge is in progress to compensate for consumption and self discharge, whereas the steady light signals that the battery is being charged completely.

• A low voltage steady light turns on when the battery is getting worn.

PROTECTIONS

The generator is protected by the devices listed hereunder. If one of these devices is activated a LED, horn and warning light turn on, the generator contactor opens and the emergency unit stops immediately. Thermal relay activated: the red RT LED signals the activation of the overload or short circuit protection. Low oil pressure: the red LED, beside the oil cruet symbol, signals a low oil pressure. Dynamo: the battery charger dynamo malfunctioning (belt breaking) is signalled by the red LED which is beside the ringed G symbol. High engine temperature: the engine overheating is signalled by the red LED which is beside the thermometer symbol. Low fuel: the red LED, which is beside the fuel pump symbol, indicates the low fuel. Missed start: the red LED, which is beside the barred engine symbol, indicates that the starting attempts have failed and the emergency unit cannot supply power. General alarm: the red LED, which is beside the horn symbol, and the horn indicates the activation of an alarm or a protection device and the engine is stopped immediately.


ADJUSTMENTS The electronic card of the control board is equipped with adjustment trimmers and selecting jumpers: TRIMMERS (see drawing 1):

N.AVV. (number of starting attempts): the number of starting attempts --between 2 and 10 approx. -- can be adjusted by means of N.AVV. trimmer. Adjust to 4 the number of starting attempts for diesel engines. For petrol engines choose the maximum number of starting attempts. If all of these attempts fail, the missed starting alarm is turned on. T.AVV. (starting control duration): T. AVV. trimmer adjusts the starting control duration between 2" and 7" approx. For petrol engines choose a value near the minimum starting control duration and for diesel engines a value between 5"/6". RIT.GE. (generator delay): after the start of the emergency unit and before the switching command is sent to the generator a delay between 6 and 60 seconds allows the unit to reach the appropriate running speed. The delay can be adjusted by means of RIT.GE. trimmer. Set a long delay time if the unit works in a cold environment. CAR.BATT. (battery charge voltage): . The battery charge voltage can be adjusted by means of CAR.BATT. trimmer. The max. value is 13/13.5 V. Perform the adjustment when the battery is completely charged, namely: when CB LED is flashing. JUMPERS:

• The STOP TIME jumper (see diagram 2.a) is used to select the stop device type. Place J1 on EV to select the solenoid valve or the electronic speed governor (the engine is not running, the relay is energized: connect the solenoid valve to terminal 5) and on EM to select the stop electromagnet (relay energized during the stop: connect the electromagnet to terminal 4).

• C.M.A. jumper (see diagram 2.b) which is on GCE card is used to select the type of control of the running engine. Choose GEN to control the generator only, and GEN+DIN to control both generator and dynamo.

Drawing 1

STOP TIME

SOLENOID VALVE STOP (connect to faston 14 NC stop)

ELECTROMAGNET STOP

(connect to faston 13NO stop)

GCE-F CARD

GENERATOR CONTROL

GENERATOR + DYNAMOCONTROL

GCE-F CARD


• J jumper (see diagram 2.c) which is on TIMER card for the automatic test (can be mounted on GCE-F card on request), is used to select the time between the subsequent tests. Choose position 2 for a test every 2 days and position 7 for a test every 7 days.

• The test time can be set by pressing the push button on TIMER card.

VARIOUS FUNCTIONS

BATTERY CHARGER: An automatic battery charger hold the battery charged and carries out a complete charge with a max. 4A electric current. The choice of the battery voltage is made by means of V.BATT. jumper which is on GCE-F card. Choose position 12 for a 12 V. battery and position 24 for a 24 V. battery

• As soon as the battery reaches the preset charge value, the electric current is automatically reduced until reaching

the value which is suitable to compensate the battery consumption and the self discharge. This system limits the electrolyte consumption and increases the battery life.

Caution ! The battery charger is not suitable to charge flat batteries. SWITCHING DEVICE: it is made up of two contactors which are interlocked mechanically and electrically. The capacity of the contactors complies with the values recommended by the manufacturer for line contactors. PREHEATING: a 220 V. single-phase system -- which is automatically controlled by the thermostat -- performs the engine pre-heating.

BATTERY VOLTS

12 V BATTERY 24 V BATTERY

GCE-F CARD

JUMPER

TEST EVERY 2 DAYS

TEST EVERY 7 DAYS

TIMER CARD


PREARRANGEMENTS CCD: • the control board is prearranged for the CCD remote control and command. The remote control sets the automatic

operation, controls the forced starting (sending a - battery signal to the control board), or blocks the engine (sending a +battery signal).

• This prearrangement can be used to make the control board suitable to particular uses, such as: the control of a discharge pump. In this case, when a power failure occurs the emergency unit is connected only if the float signals a high level in the tank (open float contact).

REMOTE CONTROL: The GCE control board is equipped with a connector for the connection to a card with relays whose loadless change-over contacts are connected to the terminal board. The following state and control signalings are transmitted:

1. blocked engine 2. automatic test 3. out-of-service due to emergency 4. automatic operation 5. mains connected 6. power supplied from mains 7. emergency unit connected 8. power supplied from emergency unit 9. general alarm 10. stop signaling 11. alarm due to low fuel 12. alarm due to low oil pressure 13. alarm due to high engine temperature 14. alarm due to battery charger generator failure 15. alarm due to thermal relay overload 16. forced start with power supply (aut.) 17. forced engine stop or blocking (aut.) 18. automatic operation control

TPA : The GCE control board is prearranged for the installation of TPA timer for an automatic test performed every 2 or 7 days. ELECTRIC ENERGY REQUIREMENT (RICHEN): The remote control connector can be used alternatively for the insertion of a card which controls the functioning of the emergency unit according to the electric energy required by the consumer. The commutation from mains to emergency unit is performed when the mains supply a lower power than needed (power requirement) or when the consumer requires electric energy, but the power supply from mains is interrupted (electric energy requirement; for instance: when the thermostat contact of a refrigerator or the switch contact of an electric machine closes). The functioning concept is as follows: Power requirement A TA device measures the electric current consumed by the power consumer. When the quantity of the consumed current is higher then the set value (which can be adjusted by means of a suitable trimmer and which depends on the max. power supplied by the public network) RICHEN starts the emergency unit which replace the mains. When the electric current consumption reaches the minimum adjustable value (which is lower than the operation value) the quick switching from emergency unit to mains is performed and, after the preset cooling phase, the engine is stopped. Electric energy requirement This kind of functioning is useful when the power supply from mains is interrupted. An impedance sensor detects a connection of a load on the generator line (with the possibility of disconnecting special loads such as: loadless transformers, bells, etc...) and starts the emergency unit only when this load is present. As soon as the load is disconnected, the emergency unit stops immediately.

EMERGENCY: A emergency push button can be used to stop the emergency unit. When this push button is pressed the emergency unit stops immediately. The mains and emergency unit remote control switches open.

ALARM SIGNALING: The terminal 9 of GCE card provides a positive output during the alarm state. This output has a max. capacity of 250 mA and can be used to control a LED, a buzzer or a restarting relay.


INSTALLATION POSITIONING The control board must have a system of protection (IP) suitable to the environment where it is installed: IP 40 (normal supply): for control boards installed inside rooms. IP 55: for control boards subjected to water jets or rain. The distance between the control board and the emergency unit shall not exceed 20 m, because possible lightnings which may strike the public mains cause a very high voltage inside the control board.

Please, contact our technical office if it is not possible to install the control board to a distance shorter than 20 m. from the emergency unit. CONNECTIONS: NOTE:

In order to make the installation easier, wiring diagrams and tables with the recommended dimensions of the line and auxiliary leads are supplied. We remind you that all the equipment and lines must be protected against short circuits and current overloads, and all the prevention measures must be taken against accidental direct contacts (see IEC 64-8/4 standards). For this reason an automatic switch -- with a suitable capacity -- must be installed on the beginning of the mains incoming cable and a differential switch on the power consumer line. For further information, please, contact your dealer or our technical office.

CABLE DIMENSIONING TABLE

EN 60439-1 - TABLE A1

VALUES FOR ONE LEAD ONLY

FLEXIBLE LEADS

SWITCHING IN AMPERES (ITH) NUMBERS OF LEADS MIN. SECTION

IN sq.mm.

MAX. SECTION

IN sq.mm.

25A 1 2,5 6

40A 1 6 10

60A 1 10 16

90A 1 25 35

110A 1 25 35

125A 1 35 70

160A 1 50 70

200A 1 70 90

260A 1 95 120

350A 1 150 185

400A 1 185 240

500A 2 95 120

630A 2 120 150

800A 2 240

During the auxiliary circuit connection, pay particular attention to the right connection of the battery poles.

QGE

MAX 20m.

CONTROL BOARD

EMERGENCY UNIT


Caution! The direct earthing to the battery negative pole is recommended. Installation:

• place the programming switch to position: “LOCKED ENGINE”. • Connect the engine and generator auxiliary cables (controls and signalings) according to the wiring diagram. • Connect the timer card on GCE-F card, by means of the appropriate spacers. • Through the appropriate jumpers, select the battery voltage (12 V. or 24 V.), the stop type (solenoid valve or

electromagnet) and the type of running engine detection (generator voltage or generator + dynamo), according to the technical features of the emergency unit.

• Connect the battery paying attention to the right polarity. • Connect the incoming cables of the generator, mains and power consumer to the power terminals according to the

wiring diagrams supplied together with the control board.

PRE-START CHECKS:

When the installation is complete, it is possible to check the correct functioning of the control board by carrying out the following operations: 1. place the programming switch to MANUAL START. 2. Press the START button and, subsequently, the STOP button and check if the engine is running properly (without

starting the emergency unit). 3. Check the correct functioning of the probes and signalings of the low fuel, low oil pressure, high engine temperature

by disconnecting the lead from the probes and connecting it to earth temporarily. Then check if the signaling on the control board is correct.

4. Visually check the power connections between generator and control board, because if the C.M.A. jumper is set to GEN, the card detects the “running engine” state by means of the generator voltage and if there is no possibility to detect this voltage (because there is no power connection or because a disconnecting device is open along the line) the starter is not turned off when the engine is running.

5. Place the switch to MANUAL START. Press the start switch until the engine is running. 6. Wait 20/30 seconds and switch to MANUAL GEN-SET. 7. Check the direction of rotation of the motors used (invert the connection of two wires if it is opposite to the normal

direction). 8. Stop. 9. Place the switch to MANUAL MAIN. 10. After, at least, 15/20 seconds, supply the control board with power from mains and check again the direction of

rotation of the motors used (invert the connection of two wires if it is opposite to the normal direction). 11. Place the switch to AUTOMATIC RUNNING. Disconnect the mains and check the starting, power supply and

protection functions of the emergency unit. When the mains are connected again a delay will occur before the switching from emergency unit to mains takes place, and a further delay will occur so as to allow the engine to cool down.

MAINTENANCE The control board is designed to operate without any need for maintenance. However, the following checks shall be performed: every 30-60 days battery electrolyte level every 30 days oil, fuel and water level every 30 days engine preheating temperature (if present) every 30 days automatic test of the unit


ELECTRIC MAINTENANCE

CAUTION ! The control board is supplied with power either from mains or emergency unit, therefore, before carrying out the maintenance, disconnect the mains and stop the emergency unit by placing the programming switch to “LOCKED ENGINE”. REPLACEMENT OF GCE-F ELECTRONIC CARD Disconnect the battery, open all the fuses, remove and replace the electronic card. Note the settings and the ratings of the replaced card and set the new card to these values. Restore the functioning following the procedure described on chapters INSTALLATION and USE. BATTERY REPLACEMENT OR INTERRUPTION

CAUTION ! Set the control board to BLOCKED ENGINE and disconnect fuse F8. CHECK OF SWITCHING DEVICE DIMENSIONING If some modification are made to the operating system, check the dimensioning of the mains/emergency unit switching device. AUXILIARY FUSES CAPACITY 10 x 38 type FUSES F1: + Battery 16 A F2: generator X wire 2/4 A F3: generator Y wire 2 A F4: mains S wire 2/4 A F5: mains T wire 2 A F6: preheating 6 A F7: preheating 6 A F8: battery charger 2 A

MECHANICAL MAINTENANCE

Set the emergency unit to “blocked engine” and disconnect the engine preheating F6 an F7 fuses and the battery charger F8 fuse.

TECHNICAL SPECIFICATIONS

SYSTEM OF PROTECTION: IP 40 AC VOLTAGE: 230V/400V FREQUENCY: 50 Hz/60Hz DC VOLTAGE 12V/24V MAX. CURRENT CONSUMED: 700mA MIN. CURRENT CONSUMED: 200mA N.B.: the technical specifications can be modified, without any prior notice, because of technical improvements.


TROUBLESHOOTING

All the control boards are marked by an order number which is written on the test plate, inside the control board. All the control board technical and constructive data are referred to the order number. Therefore, this number must be stated if any spare parts or technical service are needed. Besides the following data must be specified:

1. type of electronic card (indicated on the front of the board) 2. battery voltage (12 o 24V) 3. mains voltage (230 o 400V) 4. emergency unit power (KVA) 5. frequency (50-60 Hz) 6. signalings on GCE module when failures occur. 7. operation mode (AUT. o MAN); 8. particular failure conditions during any possible maintenance or various circumstances such as: thunderstorms,

etc.

FAULT CAUSE REMEDY

1. THE EMERGENCY UNIT STARTS AUTOMATICALLY EVEN WHEN THE MAINS ARE CONNECTED

FUSE BREAKING OF THE BATTERY CHARGER

• Replace F fuse. • Perform the automatic test of the unit for 30

minutes approx. as to permit a quick recharge by means of the battery charger alternator.

2. THE START RUNS BUT THE ENGINE IS NOT FED.

LACK OF FUEL AIR IN THE FEEDING CIRCUIT

• Refuel the emergency unit.

3. NO STARTING LOW TEMPERATURE • Check the preheating efficiency. • Connect the additional diesel oil device.

4. STARTING BY FITS AND START

FLAT BATTERY

BATTERY CONNECTION BREAK

• Recharge the battery. • Check the battery terminals and remove any

oxidation. • Replace the battery with another one whose

capacity is higher. • Restore the connection. • Replace the electronic card.

5. THE GENERATOR CONTACTOR DOES NOT TURN ON

F4 FUSE BREAK

THE GENERATOR DOES NOT SUPPLY ELECTRIC POWER

THE CARD IS FAULTY

• Replace F4 . • Check the fuse located on the excitation

device. • Follow the manufacturer’s instructions. • Replace the electronic card.

6. STOP OF THE ENGINE DUE TO AN ALARM

OVERLOAD

NO STARTING LOW OIL PRESSURE HIGH ENGINE TEMPERATURE

• Reset the thermal relay by pressing the red push button.

• See the same remedy for fault Nr. 2. • Add oil until the appropriate level is reached • Replace the pressure-switch. • Add water until the appropriate level is

reached. • Clean the radiator. • Reduce the load. • Replace the thermostat.


7. WHEN THE ALARM IS ON THE ENGINE DOES NOT STOP

STOP DEVICE

FAULTY CARD

• Replace the electromagnet. • Set up the tension rod length. • Replace the restart relay. • Replace the electronic card.

8. THE MAINS CONTACTOR DOES NOT TURN ON.

F2 FUSE BREAK CONTACTOR COIL BREAK FAULTY CARD

• Replace the fuse. • Replace the coil. • Replace the card.

THE TECHNICAL SPECIFICATIONS CAN BE MODIFIED, WITHOUT ANY PRIOR NOTICE, BECAUSE OF TECHNICAL

IMPROVEMENTS.

automatic board for emergency gen-sets

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