control unit for generating set type cam-684 · - cosphimeter per phase - partial hour-meter -...

ELCOS- Parma- Italy - GB - CAM -684 1Valid for firmware revisions higher than or equal to 1.24

CONTROL UNIT FOR GENERATING SETTYPE CAM-684

Made for the preparation of automatic emergency intervention switchboards.This controls and commands the genset unit. It commands the mains and generator contactors tosupply the user.

MAI

NS

GEN

ERAT

OR

INST

RU

CTI

ON

AN

D U

SE M

ANU

ALIt is equipped with display to showthe INSTRUMENTS:- three mains voltmeters- three generator voltmeters- delta voltages phase/phase- star voltages- three mains/generator ammeters- frequency meter- wattmeter total and per phase- varmeter “- voltammeter “- kilowatt-hour- cosphimeter per phase- partial hour-meter- total hour-meter- starting counter- starting failure counter- tachometer- battery voltmeter- battery charger current

(with battery charger type CBS)- fuel level gauge- water oil thermometer- oil pressure gauge

• Automatic supervision of faults with messages on the display• Texts in 6 languages: Italian, English, French, German, Spanish and Portuguese• Information on 4 programmable preventive maintenance operations with display of the hours

remaining before the maintenance work is due• Remote controls (starting, stop and test)• EJP function• Preheating glow plugs management• Management of refuelling of working tank from storage tank• Clock to program starting or stopping the generating set• Generator start/stop on request for power• Possibility of starting the generating set in case of low battery-charge• Programmable weekly selftest.• Available inputs for fully programmable anomalies (times, polarities, stopping possibility and message

about the anomaly)• Three-phase voltmetric control, voltage failure, undervoltage, overvoltage, asymmetryc voltage and

not correct phase sequence of the mains and of the generator.• Anomaly historical log (including data from the last 50 occurred anomalies)• Displaying of the most serious faults with both led and messages on the display• Possibility of password protected programming.

• CAN Bus Connection (SAE J1939)• Serial ports RS232 and RS485• Connection with a remote panel (Type PRE-685) to display the instruments and errors managed

by the CAM-684• GSM Modem (to be mounted externally), possibility of displaying the control unit instruments with a

mobile phone, operating the starting and stopping and notifying with an SMS message when the generating set is in alarm state• MODBus protocol through port RS232, RS485 and the serial port via USB• Remote operation with personal computer (on request):

- reading of the instruments shown on the display of the control unit- anomaly historical record- displaying of anomalies and operating status of the generating set.- start stop controls

MODES OF COMMUNICATION OF CAM-684

®PARMA ITALY

E-mail: [email protected] - HTTP://www.elcos.it Fax +39 0521/270218Tel. +39 0521/772021

ELCOS- Parma- Italy - GB - CAM -6842 Valid for firmware revisions higher than or equal to 1.24

TECHNICAL DATA Supply by battery 12 Vdc 24 Vdc Supply voltage 8 ÷ 32V Selfconsumption with stopped engine and pressed emergency button

350 mA 12V 180 mA 24V

Suitable for three-phase generators having the following voltage range:

80 ÷ 430Vac ±10%; frequency 50 ÷ 60Hz

Dielectric withstand voltage between battery powered circuits and mains/group powered circuits

3750 Vac 50Hz 1 sec

Voltage sag in power line from battery

65msec

0V

10V

Rated insulation voltage: • Terminal board at mains voltage

600V

• Terminal board at genset voltage 600V • Terminal board at battery voltage 32V Capacity of contact for control of the genset contactor 250V 3A (AC1) Max load on the outputs 15 (starting) 0,25A,

17 (stop) 1,5A, 19 (key) 0,25A, 6 (glow plugs) 0,25A 70 (general alarm) 0,25A

Degree of rear protection IP 20 Degree of front protection IP 64 Temperature range - 20 ÷ + 60°C W eight 1120g Dimensions with terminals disconnected (LxHxP)mm 290x200x62 Hole mm 274x185 Tachometer 5 digits Instruments accuracy: oil pressure gauge, water thermometer, fuel level

±2%

Mains/generator voltmeter Max 570V accuracy ±1% field of measurement 50 ÷ 570Vac

Rated current of the ammeters 5 A ac Ammeter Max 4800A, accuracy ±1%

field of measurement 0,02 (20mA) ÷ 6A Frequency meter: 0-85 Hz, accuracy ±0,1 Hz

frequency field 45 ÷ 85Hz Precision of the wattmeter, varmeter, voltammeter, kilowatt-hour and cosphimeter

±2%

Tachometer Max 4000 RPM accuracy ± 10 RPM Serial output parameters 9600 baud, 8 bit data, 1 bit stop; even parity Rechargeable batteries (excluded from supply) 1,2V Type AAA

S U M M A R Y S u m m a ry – T e c h n ic a l d a ta - H is to ry o f re v is io n s P a g e 2 B r ie f in s tru c t io n s – In s tru m e n ts – M o d e s o f c o m m u n ic a tio n o f th e c o n tro l u n it “ 3

O p e ra tio n : F u n c tio n s s e le c tio n – M a n u a l – A u to m a tic – T e s t – O ff – G lo w p lu g s p re h e a t in g – S ta r t in g – S ta r tin g F a ilu re

“ 4

O p e ra tio n : D e te c t io n o f ru n n in g e n g in e – S to p – G e n e ra to r s e t p ro te c t io n d e v ic e s – G e n e ra l a la rm – P re v e n tiv e m a in te n a n c e – E m e rg e n c y s to p – S to p p in g fa ilu re – G e n e ra to r s e t s ta r tin g w ith lo w c h a rg e o f th e b a tte ry - S ta r t in g o n re q u e s t fo r p o w e r – C lo c k

“ 5

W ir in g d ia g ra m “ 6 -7 M e s s a g e s a n d in s tru m e n ts – A n o m a ly m e s s a g e s – C A N B u s in s tru m e n ts – C u m u la t iv e a la rm s “ 8

S ta r t u p , s to p a n d te s t c a l l re m o te c o n tro ls a n d E J P fu n c t io n s – M a in s g e n e ra to r v o ltm e tr ic re la y s “ 9

U s e r p ro g ra m m in g “ 1 0

N o tic e s “ 1 1

B a tte ry c h a rg e r – O rd e r in g d a ta – A c c e s s o r ie s s u p p lie d -D e c la ra t io n C E “ 1 2

HISTORY OF REVISIONSDate Description Page

VM . motor management inserted 3-5-9-20programming manual

4-1210-13-20

programming manual

Password management inserted.Minimum temperature read by the transmitter brought to 0°C.Disconnected temperature and pressure transmitter fault management removed.Stop time extended to 120 seconds.New Scania motor management inserted.

Level of theREVISION

Cummins .motor management insertedThe over-temperature error is delayed by the thermostat by 5 seconds.

GSM stop function enabled.

1.24 MODBus protocol through port RS232, RS485 and the serial port via USBFebruary 2014


With the running

engine the

generator set

instruments are

shown. In the

event of a fault,

instead of the

measurement,

the display

shows the

message of

the occurred

fault.

INSTRUMENTS

BRIEF INSTRUCTIONS

" " " "

With battery charger type CBS

• THREE MAINS AND GEN- ERATOR VOLTMETERS up to 570V

• THREE MAINS/ 30/5, 40/5, GENERATOR 80/5, 100/5, 150/5, 200/5, 250/5, 300/5, 600/5, 800/5, 1000/5, AMMETERS 1200/5, 1500/5, 2000/5, 2500/5, 3000/5, 4000/5.

• FREQUENCY METER greater than 30 V~.• WATTMETER (Total and per phase) • VARMETER • VOLTAMMETER

• COSPHIMETER (Per phase)

• 65535.• FAILURE COUNTER 9999• 8500 rpm.• • BATTERY CHARGER CURRENT

For three-phase voltages and nominal value ~.• DELTA VOLTAGES PHASE/PHASE• STAR VOLTAGES

Compatible with the amperemetric transformer type 50/5, 60/5, 400/5, 500/5,

Maximum reading of 4000A or 110% of the full-scale current of the chosen transformer.From 0Hz to 85Hz for alternating voltages with amplitude

• KILOWATT-HOUR (Total)

• PARTIAL HOUR-METER With four digits and a maximum reading of 9999 (hours and minutes). (The hours indicated are zeroset the next time the genset is started up.)

• TOTAL HOUR-METER Displays five digits and a maximum reading of 59999 (hours and minutes). STARTING COUNTER Displays the number of occurred startings up toSTARTING

Displays the number of failure startings up toTACHOMETER Displays the number of engine revs up toBATTERY VOLTMETER

• FUEL LEVEL GAUGE Displays the percentage of fuel present in the tank

• WATER OR OIL THERMOMETER Displays the water and oil temperature of the engine up to 140°C• OIL PRESSURE GAUGE Displays the oil pressure of the engine up to 9 bar

C

MODEM

ENGINEEquipped with control unitfor the electronic control ofthe injection system

10m max500m maxRS232/

RS485RS232/RS485

MODEM GSMELCOS

CAN Bus

RS232

RS485

I/0 EXTENSION

REMOTE PANEL

I/0 EXTENSION

MOD BUS

" " MASTER

" " MOD BUS


ENABLED WITH CONTROL UNIT IN AUTOMATIC MODE (For programming see page 10)after a pause of 3 seconds, the engine starts and continues to run for the WEEKLY TEST TIME (programmed to 3 minutes).This test will be repeated automatically every week on the exact day and at the hour to which it has been programmed. During the automatic test cycle, WEEKLY AUTOMATIC TEST is shown on the display.

Press key

STOPPING OF ENGINE DURING THE TEST

WEEKLY TEST STOP:The weekly test is stopped when an anomaly is displayed on the display

The function selectedwith the key is shown bythe associated warning light.

The control unit commands are enabledStarting with key stopping with key (it is obtained by pressing once the key

.).

MANUAL

OPERATIONFUNCTIONS SELECTION

STOPSTART

When key is pressed until Led comes onThe engine cannot be started in any way and, if running, the engine is stopped without carrying out engine cooling

..

OFF

- .- .

In with key (it is obtained by pressing once the key)In it is activated automatically before starting

The preheating action time can be adjusted, the preheating action stops before startup start. The factory preheating command is inhibited as it has been programmed to zero seconds.

manualautomatic

GLOW PLUGS PREHEATING

PROTECTIONSThe generator set protection function in manual mode can be programmed in two ways:· Display only of the fault that has intervened WITHOUT STOPPING the engine. The faults overfrequency, overspeed and emergency of the generator are programmed with stopping of the engine. It cannot be programmed without stopping of the engine.· Display of the fault that has intervened WITH ENGINE STOPPING. (The control unit is programmed in this way).

START

TEST

WEEKLY AUTOMATIC TEST

When a fault occurs on the mains, (detected by the internal voltmetric relay, or by the external call), once the ime have elapsed, the control unit commands the opening of the mains

contactor, and starts the generator set.With engine running and generator voltage normal and once the GENERATOR TO POWER USERS CONNECTION DELAY has elapsed, the generator contactor closes. While it is running the generator set is protected from possible faults.When the mains voltage is restored and the MAINS ACCEPTANCE time has elapsed, the control unit commands the opening of the generator contactor, after the GENERATOR-MAINS INTERLOCK time the mains contactor closes The COOLING TIME allows and facilitates subsequent cooling of the engine before stopping it.

tSTARTUP DELAY AFTER MAINS FAULT

AUTOMATIC

On pressing key , we obtain the engine startup cycle as in automatic, and the power users remain supplied by the mains. If a mains fault occurs during the test, the control unit remains in test mode, positions itself as in automatic operation and commands the closing of the generator contactor.

STOP

CONTROL FOR MAINS/GENERATOR CONTACTORS

It is left to the keys By pressing on the keys, the load is switched from the mains to the generator and vice versa.

STARTING

- .

. Engine start-up is stopped if the starter pinion does not couple with the flywheel ring gear. After the first missedcoupling, the starter motor makes five more attempts. When coupling is missed for the sixth time, the starter motor continues running for 5 seconds.

.

In mode or if a mains anomaly is detected by the internal voltmetric relay, or an external call, and after

To make starting easier, a special circuit establishes a series of programmable startups (programmed to 4STARTUPS); the number of startups, the length of the pause time and the startup time can be programmed

If the whole series of attempts is unable to start the engine, at the end of this cycle STARTING FAILUREis shown on the display and the stop signal is activated

automaticthe STARTUP DELAY AFTER MAINS FAULT time has elapsed

START-UP WITH PINION CONTROL ENGAGED

STARTING FAILURE

- In mode with key , in Test and with the remote control, it comes on immediately after the PREHEATING TIME.

manual START


OPERATION

GENERATOR SET STARTING WITH LOW BATTERY CHARGE(with control unit in automatic mode)

STARTS OR STOPS the generator set depending on the voltage measured on the battery terminalsBefore starting automatically, the generator set activates the intermittent general alarm for 8 seconds, followed by a pause of 3 seconds.

12.

When the voltage measured on the battery is lower than the minimum threshold, THE ENGINE STARTS. When the voltage exceeds the maximum threshold after the intervention delay, THE ENGINE STOPS. To change the programming of the thresholds and of the delay see the basic table of the TECHNICAL PROGRAMMING OPERATIONS manual on page

The intervention of the fault is displayed; it can cause the engine to be stopped and activates the general alarm see BASIC TABLE at pages 10-11 of the TECHNICAL PROGRAMMING manual.

When the engine is running the generator set instruments are shown.When there is a fault, instead of the reading, the display shows the intervened fault message, and the associated yellow LED flashes.

FAULT DISPLAY

FAULT RESET

It is possible to access the reading of the measurements and at the same time to silencing the general alarm,by pressing key for 1 second.

The display will resume showing the previous fault 20 seconds after the last pressing of the key.

On pressing the key , the protection devices and all the locked functions are reactivated.

HOW TO SEE THE INSTRUMENT READINGS AGAIN

GENERATOR SET PROTECTION DEVICES AND USER

GENERAL ALARMThis is produced by mounting an acoustic signal, linked to the appropriate terminalIt can be arranged so that it is activated continually or for a set timeWhen key is pressed the general alarm is silenced.

..

PREVENTIVE MAINTENANCEWhen preventive maintenance operations need to be carried out, the yellow LED flashes while the number of the intervened maintenance appearsThe timing for the maintenance operations and the procedure for zeroing the time up maintenance indication can be programmed by the manufacturer of the generator set unit

.

.EMERGENCY STOP

The emergency stop can be activated in all working conditions, by mounting one or more click down push-button. The stop is immediate (without engine cooling), does enable the general alarm and EMERGENCY STOP is shown on the display.

STOPPING FAILEDThis intervenes if the running engine signal is detected 120 seconds after the stop command. STOPPING FAILURE will be read on the display.

Do not use the emergency button combined with a stopping system that is not energized in run mode.

DETECTION OF RUNNING ENGINEIt is obtained by detecting generator frequency and residual voltage or by detecting battery charger alternator (permanent magnets or pre-excitation) voltage and frequency. It is also possible to use a pick-up device in place of the alternator. In case of engine equipped with electronic injection controller (CAN Bus) it is not necessary any pick-up and the alternator is used only to detect belt breakage.When the running engine signal has been detected the unit disconnects the starter and switches on the led .

STOP- ).- .- .

:• w

•.

In mode using key (it is obtained by pressing once the keyIn mode when the protection systems and the remote controls interveneIn mode when the mains power returns, or when the protection systems or remote controls intervene

Stopping can occur in two waysith the solenoid deactivated while the engine is running and activated when stopped. This condition is maintained

during the STOP TIME after the engine stopped detection.

manualTestAutomatic

with solenoid or electro-valve activated while the engine is running and deactivated when stopped, remaining in this condition even when the engine is stationary

STOP

This starts or stops the generator set according to the power detected by the control unit.A general alarm triggers for 8 seconds followed by a 3-second pause before automatic start-up of the generator set.As soon as the power value of the power user is above the programmed threshold during the entire engagement delay, the control unit starts the generator set and controls opening of the network contactor. With engine running the generator contactor closes when the generator voltage is regular and the generator engagement delay to the power user has elapsed. As soon as the power value of the power user is below the programmed threshold during the entire engagement delay, the control unit opens the generator contactor, after the generator mains interlock time the mains contactor closes. The cooling time allows for and facilitates cooling of the engine before it is stopped.

STARTING ON REQUEST FOR POWER

CLOCKThe TIMER permits to programme the operation or the block of the generator set AUT

Operation obtained as during mains failure

Stops starting or running of generator set.

. In operation.STARTING

.STOP


TWISTEDCABLES

MAGNETICTRANSDUCER

EMERGENCYPUSH-BUTTON

30 85

87 86PREHEATING

30 85

86STOP

79

80

87

525150334 17154A21 6 313019

+ SUP

PLY

CO

NN

EC

T IF

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E

PRE

HE

ATIN

G O

F G

LOW

PLU

GS

STAR

TUP

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ITH

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TAR

TIN

G O

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UN

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GD

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ITH

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FF

OUTPUTS (+)0,25A MAX

FUEL

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OR

5

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ER

ATO

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ER

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ANSM

ITTE

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OIL

PR

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RE

TR

AN

SM

ITTE

R

63

585756

RS485+

RS485-GND

37 39

FUEL

LEV

EL

FLO

AT (

leve

l in

dica

tor w

ith c

onta

ct)M

AX

. SA

FETY

LE

VE

L

CA

LL

TEST

Or E

JP s

tarti

ng

STO

P

REMOTECONTROLSWITH CONTROLUNIT INAUTOMATIC10m MAX

+ -

30

STARTING

Connect to the terminal of the braid

PERMANENT MAGNETALTERNATOR

PRE-EXCITATIONALTER-NATOR

REGULATOR

CLB+

+

G

D+B+

R

RG

YELLOW REDYELLOW

NEVER INSTALL THE EMERGENCY PUSHBUTTON LINKED TO ASTOP SYSTEM WHICH ISNOT ENERGIZED WHENTHE UNIT IS RUNNING

YOUR ELECTRICAL TECHNICIAN CAN ASK US ANYTHING ABOUT THIS PRODUCT BY TELEPHONING ONE OF OUR TECHNICIANS

CONTACTOR CONTROL

MAI

NS

CO

NTA

CTO

R A

UX

ILIA

RY

CO

NTA

CT

GE

NE

RAT

OR

CO

NTA

CTO

R A

UX

ILIA

RY

CO

NTA

CT

2221

13

in th

e Te

chni

cal P

rogr

amm

ing

Man

ual)

(see

pag

e

WIRING

3632

75

76 L1

77 L2

78 L3

64

65

66

848586

FOR THE CONNECTIONOF A SINGLE AMMETERUSE TERMINALS 75-77

GENERATORMAINS

AMMETERS

DETECTIONOF RUNNING ENGINE

AND TACHOMETER

DETECTIONOF RUNNING ENGINE

AND TACHOMETER DETECTION OF RUNNING ENG- INE AND CHARGING ALTERNA- TOR PRE-EXCITATION (WITH- OUT THIS CONNECTION THE AL- TERNATOR DOES NOT CHARGE)

DE

TEC

TION

OF

RU

NN

ING

EN

GIN

EW

HEN TERMINALS 63 AND 64 ARE CONNECTED, TERMINAL 65M

UST NOT BE CONNECTEDCOMMUNICATION PORT RS485

FOR DETEC-TION OF RUN-NING ENGINEWITH PRE-EXCITATIONALTERNATORTHISCONNECTIONIS SUFFICIENT

FU134A

Mai

ns d

etec

tion

on p

age

5in

the

Tech

nica

l

STA

RTU

P O

r EJP

sw

itchi

ng c

onse

nt

WAT

ER

OR

OIL

HEA

TER

TH

ERM

OS

TATI

C S

WIT

CH

FAU

LT IN

DIC

ATIN

G

RA

DIA

TOR

CO

OLA

NT

LEVE

L PR

OB

E

W

IF THEINDICATOR (WITHCONTACT) IS NOTUSED, CONNECT THE TERMINAL (36)TO GROUND

RELAY

KM-R KM-G

CONNECT DIRECT-LY TO THE ( )BATTERYTERMINAL

RELAY

RELAY

FU1

4A

Fuse 1A

The blownfuse doesnot stop theengine fromstarting

2,5 mm min50m MAX

50

See remotecontrols onpage 9

COMMUNICATIONPORTUSB

NO

T U

SED

ON PAGE 7OF THE TECHNICAL PROGRAM-MING MANUAL.

SEE

NECESS-ARY PRO- GRAMMING

INST

RU

MEN

T SU

PPLY

(

)

Prog

ram

min

g M

anua

l

CONTACT CAPACITY3A 275VAC MAX

FUELPUMP

EM

ER

GE

NC

YP

US

HB

UTT

ON

IS

NO

T FI

TTE

D

(1,5

A m

ax)

CAM-684

21


87 86PREHEATING

STOP

63

585756

RS485+

RS485-

REMOTECONTROLSWITH CONTROL

30

STARTING

Connect to thePERMANENT MAGNET

EVER INSTALL THE EMERGENCY PUSH

YOUR ELECTRICAL TECHNICIAN CAN ASK US ANYTHING ABOUT

3632

IF THE

RELAY

KM-R KM-G

CONNECT DIRECT-LY TO THE ( )

RELAY

RELAY

Fusenot stop the

2,5 mm min

50

See remote

FLAT

CA

BLE

U N

1 2

75 76

FU12

10

A

AUTOMATIC

TYPE CBS-030 CBS-060

BATTERYCHARGER

FU7 1A

FU8 1A

74

72

73

71

GENERATOR

MAINS

CONTACTORSCONTROL:

CONTACTSCAPACITY MAX3A 275VAC

FU6 1A

FU9 1A

FU5 1A

CONNECT THE TERMINALS95N 97V FOR SINGLE-PHASE DETECTION

97

98

96

95

THREE-PHASE DETECTIONOF RUNNING ENGINE MAX 475VAC 50÷60Hz

CONNECT THE TERMINALSFOR SINGLE-

PHASE DETECTION 90N 92V

92

93

91

90

THREE-PHASE DETECTION OF MAINS

MAX 475VAC50÷60Hz

CO

MM

UN

ICAT

ION

POR

T:• • A

MM

ETE

R• V

OLT

ME

TER

BAT

TER

Y C

HAR

GE

R S

TATU

S

CONSULT STANDARDS CEI 44-5 (EN 60204) FOR INFORMATION CONCERNING PROTECTION AGAINST OVERLOAD CURRENTS IN THE ELECTRICAL EQUIPMENT USING BATTERY VOLTAGE

STAR

TER

MOTO

R PI

NION

.NO

T CO

UPLE

D

70

OUTP

UT (+

)0,2

5A M

AX 10

0m M

AXGE

NERA

L ALA

RM

69

COMMUNICA-TION PORT

RS 232

FU14 2A

B.M.KM-R

TA1

TA2

TA3

FUELFLOAT

If only one levelindicator (float)with severalcontacts is usedASK FOR ASEPARATEDIAGRAM

GENER-ATOROVER-LOADSWITCH

OIL PRESS-URETRANS-MITTER

TEMPER-ATURETRANS-MITTER

THERMO-STATICSWITCH

OIL URESWITCH

PRESS-

GENERALALARM

FU2 4A

FU3 4A

KM-P

FUEL LOADING SAFETYSOLENOID VALVE

FUELPUMPTHER.

KM-G

SCREWELECTRODES

RODELECTRODE

COOLANT LEVEL PROBEFOR RADIATORS WITH

PLASTIC EXPANSION TANKFOR RADIATORS WITH

METAL EXPANSION TANK

- 4.

HAVING MADE THE CONNECTIONS, THE CONTROL UNIT IS IN OFF MODE. TO SELECT OTHER OPERATING MODES, SEE PAGE

CABLES FOR CONNECTION OF THE AMMETERIC TRANSFORMERS

LENGTH m SECTION mm2

25

8

1,52,54

W1V1U1N1

X-MAINS 400V

N2U2V2W2

X-USER 400V

U4V4W4

FUE

LPU

MP

FU12

FU13

FU14

V5N53940

(1)

(2)

WATER OR OILHEATER

(1) WORKING THERMO-STATIC SWITCH(2) INDICATINGTHERMOSTATICSWITCH.

IF THE FUNCTION LOWCOOLING LIQUID LEVELIS NOT USED, CONNECTTERMINAL 50 TO GROUND

FU10 10A

FU11 10A

KM-P

FU4 1A

GE

NE

RAT

OR

INP

UT

DIAGRAM

KM-P

8786

3085

RELAY

CAN Bus

CAN H

CANL

KM-R

KM-G

KM-G

KM-R

W

VU

N

W

VU

N

CONN

ECT

USIN

G TW

ISTE

DOR

SHI

ELDE

D CA

BLES

MAX

10m

LONG

.

TERMINATION RESISTANCE (120 Ohm)Check in the control unit manual (ECM/ECU)if the resistance must be inserted (engineside) between the CAN-H and CAN-L wires(CAN Bus J1939)


MESSAGES AND INSTRUMENTSSent (SAE J1939 protocol Bus) from the engine equipped with control unit for electronic control of the injection system.All the messages or instruments displayed on the display regarding the injection control unit and the CAN Bus, are identified by the presence of the characters at bottom right.

ANOMALY MESSAGESThe anomaly messages managed by the injection control unit are indicated on the display. SPN...............................

FMI.........ANOMALYCAN BusANOMALY

Problems with connection to theCAN Bus

CAN Bus INSTRUMENTSThese are read by the injection control unit and shown on the display when the engine is running.

SOME MAKES OF ENGINE DO NOT PROVIDE FOR THE DISPLAY OF ALL THE LISTED INSTRUMENTS

All anomalies regarding these instruments are managed by the injection control unit.

CUMULATIVE ALARMSLED (red) STEADY LIGHT: anomaly managed by the injection control unit the engine . will cause to stop

LED (yellow) STEADY LIGHT: anomaly managed by the injection control unit the engine will NOT cause to stop. LED (red) FLASHING LIGHT: anomaly managed by the control unit CAM-684 the engine .will cause to stop .

LED (yellow) FLASHING LIGHT: anomaly managed by the control unit CAM-684 the engine LEDS OFF ALL OK.

will NOT cause to stop.

INSTRUMENTS DESCRIPTIONUNIT OFMEASURE-MENT

TACHOMETER Displays the number of engine revolutions rpmOIL PRESSUREGAUGE

Displays the pressure of the engine oil bar kPaTHERMOMETER Displays the engine water or oil temperature °C °FUSEDFUEL

Amount of fuel consumed by the engine per unit of time(l/h)

l/hFUELTEMPERATURE

Temperature of the fuel from the inlet of the injectors °C °FTURBO-CHARGERTEMPERATURE

Temperature of turbocharger lubricant °C °F

OILTEMPERATURE

Temperature of the engine lubricant oil °C °FINTERCOOLERTEMPERATURE

Temperature of intercooler liquid after the turbocharger °C °FINTAKETEMPERATURE

Temperature of the pre-combustion air °C °FCOOLANT LEVEL Level of the coolant expressed in % %FUELPRESSURE

Pressure of the fuel between the supply pump and theinjection pump

bar kPaCOOLANTPRESSURE

Pressure of the liquid in the cooling system bar kPaENGINETORQUE

Torque percentage at engine outlet NmENGINE POWER Power developed by the engine kW


REMOTE CONTROLS START, STOP, TEST AND EJP FUNCTIONS ENABLED WITH CONTROL UNIT IN AUTOMATIC AND IN TEST MODE

CALL

On closing the call contact operation is as with mains fault.

ENABLED WITH CONTROL UNIT IN AUTOMATIC

STARTING

When the start up contact (see page 6) is closed REMOTE STARTING is shown on the display. After the REMOTE STARTUP DELAY time (programmed to 1 sec.) has elapsed, the start up begins, the general alarm is activated intermittently (for 8 seconds), then the general alarm is deactivated and after a pause of 3 seconds the start up cycle begins and operation is as with mains fault. When the startup contact is opened operation is as with mains return.

TEST When the test contact is closed (see page 8) REMOTE TEST is shown on the display. The general alarm is activated intermittently (for 8 seconds). When the general alarm is deactivated, after a pause of 3 seconds the start up cycle begins. If there is a mains fault during the test, the control unit remains in test mode and, as in automatic, commands the closing of the generator contactor that will reopen when the mains returns. When the test contact is opened operation is as with mains return. If the automatic test is in progress the engine continues to run until the end of the automatic test.

STOP When the stop contact is closed, REMOTE STOP is shown on the display. The control unit does not allow any startup operation, and if the generator set is running, it is stopped. The intervention of the remote control is shown on the display.

EJP FUNCTION Choose EJP function (see TECHNICAL PROGRAMMING manual on page 18). When the START UP contact, connected to terminal 31, closes, EJP STARTUP is seen on the display. After the EJP STARTUP DELAY time (programmed to 25 min.) has elapsed , the start up procedure begins. When the switching contact (terminal 32) closes, EJP SWITCHING CONSENT is seen on the display and the operation is as when there is a mains fault. When the two EJP contacts are opened functioning is as when the mains power returns.

VOLTMETRIC MAINS AND GENERATOR RELAYS INSIDE THE CONTROL UNIT

These check the mains and generator set voltage. They intervene in the event of: voltage failure, undervoltage, overvoltage, asymmetrical voltage and incorrect phase sequence

MAINS RELAY When voltage has been detected on the three phases, with a value within the preset limits, after the MAINS ACCEPTANCE delay (programmed to 100 sec.) the generator set stops (for the starting and stopping procedures see automatic operation on page 4).

GENERATOR RELAY When a voltage value is detected on the three phases of the operating generator set within the expected range, the generator contactor closes after the delay (setpoint equal to 7 seconds) for “GENERATOR TO POWER USERS CONNECTION”. When the voltage value detected is inferior or superior to the normally expected range, the generator contactor is de-energised.


STARTING CONSENT. Operation obtained as during automatic mode.

Programming of telephone numbers of the users to inform when alarm.Refer to “Sending SMS messages” in the Modem Manual

the generator set is in

ADJUST THE CALENDAR CLOCK. The TIMER permits to programme the operation or the block of the generating set.

WEEKLY AUTOMATIC TEST. When WEEKLY AUTOMATIC TEST ENGAGED programming is finished, withcontrol unit in automatic mode, the generator set executes the test cycle.

12:15

TO 15:20

FROM

333

333123456

12:15

TO 15:20

FROMDAILY STARTTIMER

WEEKLY AUTOMATICTEST

Decreases

Decreases

Increases

Increases

Press and wait forPROGRAMMED to be written



Press when the arrow is nextto the time to be corrected

Press to write number

Press to choose

USER PROGRAMMING

STOP

Press to

exit theprogramming

Press to select: PROGRAMMINGOPERATIONS

USERPROGRAMMING

LANGUAGE CHOICE

WEEKLY AUTOMATICTEST

DAILY STOPTIMER

DAILY STARTTIMER

PRESS TO DISPLAY THEREQUIRED PROGRAMMING

Decreases

LANGUAGE CHOICE. The language set up in the factory is ITALIAN the languages that can be selected areSPANISH

, : ENGLISH - FRENCH - GERMAN - - PORTOGUESE.

LANGUAGE CHOICE

Press and wait forPROGRAMMED to be writtenPress to select

Press to display

EXCLU

ENGAGED

EXCLUFactory setting

Press to display

STOP

STOP

Press to display

STOP

ACCESS TO PROGRAMMING MODE

( ) led off

CALENDAR CLOCK ADJUSTMENT

ADJUSTMENT IS RECOMMENDED.The time and date are used when the anomalylog events are displayed.

CALENDAR CLOCK ADJUSTMENT

ADJUSTMENTDAY MONTH YEAR

HOUR MINUTES

Press for 2 secondsuntil the number requiring editing flashes

If the power is cut off, adjustment of thecalendar clock must be repeated. Installation of tworechargeable batteries in the control unit shall preventa new setup.WARNING: USE RECHARGEABLE BATTERIES ONLY. Non-rechargeable batteries may damage the control unit.

STOP

Movesthe cursor

Increases

TELEPHONE 1

TELEPHONE 3

TELEPHONE 2

STOP. Stops starting or running of generator set. 23:00

TO 07:30

FROM

23:00

TO 07:30

FROMDAILY STOPTIMER Decreases Increases


Press when the arrow is nextto the time to be corrected.

STOP

Press to display

exam

ple

exam

ple

exam

ple No. user

No. mobile phone

Press to move the cursor

cursor

- - 2 3Or

TELEPHONE 1

TELEPHONE 1

TELEPHONE 1

LANGUAGE CHOICEENGLISH

TEST

CancelsC


NOTICES Used only to check and command a genset unit. It commands the mains and generator contactors to supply the user. It has been designed to be installed only inside on an electrical panel as a single unit and so that it can be connected to other components (contactors, fuses, thermo-magnetic switches, etc.) which the installer will have available to complete the plant.

Warning: Components carrying dangerous voltage levels Only assigned and suitably trained personnel are allowed access to the control unit. No maintenance operations are permitted unless the plant is disconnected from the mains and the battery. As an additional safety measure, the plant phases should be short-circuited and earthed. Not withstanding the above, only assigned and trained personnel can perform the following

operations with the plant on: - make a visual inspection of the control unit, the connections and their markings; - measure the voltage and/or current values; - programming of the functions. These interventions, however, must be performed using equipment which ensures appropriate levels of electrical protection.

Warning: Adhere closely to the following advice

- When making connections always follow the instructions and the Wiring Diagram on pages 6-7. - Any interventions on the unit must be performed with the motor stationary and terminal 50 of the starting motor disconnected. - Check that the consumption of the connected equipment are compatible with the described technical characteristics. - Install in such a way that there is always adequate heat disposal. - Always install under other equipment which produces or spreads heat. - Handle and connect without mechanically stressing the electronic board. - Make sure that no copper conductor cuttings or other waste material fall inside the control panel. - Never disconnect the terminals of the battery with running engine. - Never use a battery charger for the emergency start-up; the control unit could be damaged. - In order to safeguard people and equipment, before connecting an external battery charger, disconnect the electrical system terminals from the battery poles. THIS CONTROL UNIT IS NOT SUITABLE FOR OPERATING IN THE FOLLOWING CONDITIONS: - Where the environmental temperature is outside the limits indicated in the technical data. - Where the air pressure and temperature variations are so rapid as to produce exceptional condensation. - Where there are high levels of pollution caused by dust, smoke, vapour, salts and corrosive or radioactive particles. - Where there are high levels or heat from radiation caused by the sun, ovens or the like. - Where attacks from mould or small animals are possible. - Where there is the risk of fire or explosions. - Where the control panel can receive strong vibrations or knocks. - Where the control panel is protected by barriers or casing with protection level less than IP40. ELECTROMAGNETIC COMPATIBILITY This control unit functions correctly only if inserted in plants which conform with the CE marking standards; it meets the exemption requirements of the standard EN61326-1 but it cannot be excluded that malfunctions could occur in extreme cases due to particular situations. The installer has the task of checking that the disturbance levels are within the requirements of the standards. CONDUCTION AND MAINTENANCE The following maintenance operations should be performed every week: - check that the indicators function; - check the condition of the batteries; - check that the conductors are tight, check the condition of the terminals. UNLESS WE MAKE A WRITTEN DECLARATION STATING THE CONTRARY, THIS CONTROL UNIT IS NOT SUITABLE FOR USE AS A CRITICAL COMPONENT IN EQUIPMENT OR PLANTS RESPONSIBLE FOR KEEPING PERSONS OR OTHER LIVING BEINGS ALIVE.

YOUR ELECTRICAL TECHNICIAN CAN ASK ANY QUESTIONS ABOUT THIS CONTROL UNIT BY TELEPHONING OUR TECHNICIAN


ELCOS s.r.l. assumes full responsability for declaring that the control unit:

type CAM-684installed and used in the ways and for the purposes described in theinstruction and use manual, is in conformity with the following directives:- 2006/95/CE related to the electrical materials destined to be used

within certain voltages limits- 2004/108/CE related to the electromagnetic compatibility and that repeals

the directive 89/336/CEE- 2011/65/UE on the restriction of the use of certain hazardous substances in

electrical and electronic equipment,because it is built and functions in accordance with the harmonized Standards:EN61010-1, EN61326-1, EN61326/A1, EN61000-4-2,EN61000-4-3,EN61000-4-4, EN61000-4-5, EN61000-4-6, EN60529.

CONFORMITY DECLARATION

BATTERY CHARGERWe recommend fitting the plant with battery chargers

compliant with DIN41773 standards.

BATTERY CHARGER OPERATIONTHREE CHARGING LEVELS

- RAPID WITH CURRENT CONTROL- INTERMEDIATE- MAINTENANCE

WITH VOLTAGE CONTROL} WHEN THE BATTERY CHARGER IS CONNECTED TO THE CAM-684 CONTROL UNIT, THE DISPLAY SHOWS THE FOLLOWING:

• CHARGING CURRENT• BATTERY VOLTAGEANOMALIES

• DETACHMENT OF BATTERY CABLES (with engine stopped)• SHORT CIRCUITING OF BATTERY CABLES

ORDERING DATA

ACCESSORIES SUPPLIED

Type CodeCAM-684 00242283

Type CodeKIT MU CAM-684 40804469

ACCESSORIES ON REQUESTType CodeTHE REMOTE PANEL Type PRE-685 00242282(Displays the instruments and errorsmanaged by the CAM-684)

®

E-mail: [email protected] - HTTP://www.elcos.it

Strada Naviglio Alto, 24/aI 43122 PARMA ITALIA

S.r.l.

Fax +39 0521/270218Tel. +39 0521/772021 Margini Enzo

Parma,10/09/2012President

control unit for generating set type cam-684 · - cosphimeter per phase - partial hour-meter -...

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